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เอกสารสิทธิบัตรเพื่อการวิจัยและพัฒนา (สสวพ) สกว

สถาบันค้นคว้าและพัฒนาผลิตภัณฑ์อาหาร

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1.

AU4602401 - 12/13/2001

GERMINATED BROWN RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=AU4602401

Inventor(s): AOTO HIROMICHI (--); ISHIWATA KENICHI (--); TSUCHIYA KEIKO (--);

SOMEYA SACHIKO (--); TERAMOTO SACHIYUKI (--); KISE MITSUO (--); MIZUKUCHI AYA

(--); SHINMURA HIROTO (--); SUGINO TOMOMI (--)

Applicant(s): FANCL CORP (--)

IP Class 4 Digits: A23L

IP Class: A23L1/10; A23L1/172

E Class: A23L1/182; A23L1/185

Application Number: AU20010046024D (20010517)

Priority Number: JP20000173795 (20000609); JP20000279469 (20000914); JP20000366465

(20001201)

Family: AU4602401

Equivalent:

Abstract:

US6630193; US2002031596; JP2002159269; CA2346582; CN1218663C

Abstract not available for AU4602401

Abstract of corresponding document: US2002031596

The invention relates to germinated brown rice which can be easily and deliciously boiled even by a household rice cooker without impairing its original nutritive value, and has excellent mouth feel and shelf stability. The germinated brown rice can be provided by subjecting germinated brown rice to a heat-moisture treatment and drying the treated germinated brown rice to a water content of 10 to 18% by mass and a degree of gelatinization of 5 to 50%.Description:

Description of corresponding document: US2002031596

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to germinated brown rice which can be easily boiled by a household rice cooker and is high in shelf-life stability. The present invention also relates to a process for treating brown rice, by which occurrence of cracked rice kernel or broken rice after drying is reduced.

[0003] 2. Description of the Background Art

[0004] Germinated brown rice is evaluated as functional food because it is good in digestion and uptake and contains nutrient components such as [gamma]-aminobutyric acid and ferulic acid in plenty compared with ordinary brown rice. However, cooked germinated brown rice is rough in mouth feel and unpleasant in flavor though the germinated brown rice may be cooked by an ordinary household rice cooker. Germinated brown rice subjected to, for example, steaming for at least 20 minutes, cooling, packaging as it is and heat sterilization, in order to facilitate boiling is broken or cracked in rice kernel because it contains water in plenty and moreover has been subjected to the heat treatment twice. Therefore, such germinated brown rice involves such problems that its appearance after boiling

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is impaired, it gives stink of bran and sticky feel upon eating and the cooked brown rice becomes quickly hard in mouth feel when it cools. So the use of the germinated brown rice is not always popular. In order to improve its mouth feel, it is possible to apply a process of cooking brown rice by an existing pressure rice cooker, which is performed as a method of cooking the brown rice, to the germinated brown rice. However, such a process involves a demerit of destroying rich nutrients of the germinated brown rice, such as vitamin B.

[0005] The germinated brown rice itself absorbs water in plenty in a germination process thereof, and so its shelf-life stability becomes poor and a problem arises from the viewpoint of distribution.

Therefore, it has been necessary to cope with such a problem by, for example, vacuum packaging a small amount of heat-treated germinated brown rice, such as an amount of one meal, and further heat sterilizing it. When the germinated brown rice is vacuum packaged, however, a problem of handling arises when it is used in processed food of the germinated brown rice or for business purpose.

Therefore, such treated germinated brown rice involves a problem that it is lacking in general-purpose properties from the viewpoints of processability and distribution property.

[0006] It is considered to dry germinated brown rice as a means for enhancing the shelf-life stability and distribution property of the germinated brown rice. However, the germinated brown rice, in which water has been contained in plenty in the germination process, involves a problem that cracking or breaking of rice kernel is often caused and its yield after the drying is lowered. On the other hand, it is also conducted to slow the drying speed to prevent the occurrence of cracked rice kernel and broken rice. However, it takes a considerably long time to dry the germinated brown rice to an ideal water content for improving shelf-life stability. There has thus been a demand for an effective means for industrially drying germinated brown rice.

SUMMARY OF THE INVENTION

[0007] It is a first object of the present invention to provide germinated brown rice which can be easily and deliciously cooked even by a household rice cooker without impairing its original nutritive value, and at the same time, is not accompanied by marked deterioration of mouth feel even when cooked germinated brown rice cools and moreover has excellent shelf-life stability.

[0008] A second object of the present invention is to provide germinated brown rice which can be cooked easily and has excellent shelf-life stability and is reduced in occurrence of cracked rice kernel or broken rice.

[0009] The present inventors have carried out an extensive investigation. As a result, it has been found that the first object can be achieved by controlling the water content, degree of gelatinization and preferably water absorption upon immersion in water of germinated brown rice. It has also been found that the second object can be achieved by controlling the water content and degree of gelatinization of germinated brown rice by subjecting the germinated brown rice to a steaming treatment or heatmoisture treatment and drying the treated germinated brown rice.

[0010] According to the present invention, there is thus provided germinated brown rice the water content of which is 10 to 18% by mass and the degree of gelatinization of which is 5 to 50%.

[0011] The germinated brown rice according to the present invention may preferably have a water absorption rate of 110 to 140% upon immersion in water.

[0012] According to the present invention, there is also provided germinated brown rice obtained by subjecting germinated brown rice to a heat-moisture treatment and drying the treated germinated brown rice to a water content of 10 to 18% by mass and a degree of gelatinization of 5 to 50%.

[0013] According to the present invention, there is further provided a process for treating germinated brown rice, which comprises removing water attached to the surface of the germinated brown rice to an extent that the germinated brown rice becomes an almost single kernel state, subjecting the germinated brown rice of the almost single kernel state to a heat-moisture treatment and then drying the treated germinated brown rice to a water content of 10 to 18% by mass and a degree of gelatinization of 5 to

50%.

[0014] According to the present invention, there can be provided germinated brown rice which can be cooked easily and has excellent mouth feel and shelf-life stability. According to the present invention, there can also be provided a treating method of germinated brown rice which can be cooked easily and has excellent shelf-life stability and is reduced in occurrence of cracked rice kernel or broken rice.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The water content in the germinated brown rice as referred to in the present invention may be generally 10 to 18% by mass, preferably 12 to 18% by mass, more preferably 13 to 16% by mass. If the water content is lower than 10% by mass, each kernel of such germinated brown rice tends to cause

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cracking or breaking, and so such germinated brown rice involves a problem that the taste of cooked germinated brown rice is impaired. If the water content exceeds 18% by mass on the other hand, mold, bacteria and the like are easy to gather, and so a problem arises from the viewpoint of shelf-life stability.

[0016] The degree of gelatinization as referred to in the present invention means a value determined in accordance with the [beta]-amylase.pllulanase method (BAP method). The BAP method is an excellent method for distinguishing gelatinized starch from raw starch or retrograded starch. The degree of gelatinization of the germinated brown rice according to the present invention may be 5 to 50%, preferably 5 to 30%, more preferably 10 to 20%. If the degree of gelatinization of the germinated brown rice is lower than 5%, such germinated brown rice involves problems that it is rough in mouth feel when boiled together with polished rice and that an incidence of cracked rice kernel or broken rice becomes high upon its drying. If the degree of gelatinization exceeds 50% on the other hand, blocking among rice kernels occurs, and so handling in the drying process becomes hard, and drying efficiency also becomes poor. In addition, when the germinated brown rice is blended with polished rice to boil the blend, only the germinated brown rice becomes too soft, and so balance of mouth feel after the cooking becomes poor.

[0017] The degree of gelatinization can be controlled to the desired value by, for example, suitably adjusting conditions of the heat-moisture treatment and drying in the production of the germinated brown rice. For example, when drying speed is made mild like solar drying to subject the germinated brown rice to no heat treatment, the degree of gelatinization amounts to about 5 to 15%. When the germinated brown rice is steamed at 98[deg.] C. for about 5 to 20 minutes, or heated and dried at

60[deg.] C. for about 40 minutes or at 80[deg.] C. for about 25 minutes, the degree of gelatinization amounts to about 10 to 50%.

[0018] The water absorption upon immersion in water as referred to in the present invention is found by using water of 25[deg.] C., immersing a germinated brown rice sample at room temperature for 30 minutes in water and dividing the weight of the germinated brown rice sample after immersion by the weight of the germinated brown rice sample before the immersion and is expressed by %. In the present invention, the water absorption rate upon immersion is preferably 110 to 140%, more preferably 112 to 138%. If the water absorption rate is lower than 110%, the boiled germinated brown rice is half-done, and rice kernels after cooled become hard and have a dry mouth feel. If the water absorption rate exceeds 140% on the other hand, such germinated brown rice looses its shape when it is cooked, and the germinated brown rice tends to have a sticky feel. Therefore, not only a mouth feel, but also its appearance is spoiled. The water absorption upon immersion is also related to the water content in the germinated brown rice. Germinated brown rice having low water content is high in water absorption, and germinated brown rice having high water content is low in water absorption. However, the water absorption upon immersion is greatly affected by not only water content, but also peeling off and damage of the surface of germinated brown rice. Accordingly, the water absorption rate can be controlled by controlling the water content and conducting peeling. The more the surface of germinated brown rice is peeled, the more its water absorption rate is made high.

[0019] The water content, degree of gelatinization and water absorption upon immersion can be controlled to respective desired values by determining conditions of peeling, heat-moisture treatment and drying by conducting experiments properly.

[0020] The germinated brown rice according to the present invention can be prepared in accordance with, for example, the following process.

[0021] Brown rice is immersed in a germination tank (tank for germination) as it is or after a part of the brown rice is peeled off by a rice whitening machine, rice washer or the like to cause peeling off and damage of its surface, and the thus-obtained brown rice is washed 2 to 4 times with water and then dewatered. The peeling may be conducted after the immersion. The brown rice may be peeled to preferably 95 to 99.8% by mass, more preferably 97 to 99% by mass. By such a treatment, foreign matter and microorganisms attached to the surface of the raw brown rice can be removed, and the amount of water required of rice washing can also be reduced. As described above, the degree of peeling affects the water absorption upon immersion and percentage germination. Therefore, the degree of the peeling can preferably be determined taking this point into consideration. The water used in the rice washing may be any of tap water, distilled water, well water, acid water, electrolytic brine, water in which ozone has been dissolved, etc. so far as it is water usable for food.

[0022] With respect to conditions of immersion in the germination tank, there is a method that the brown rice is immersed in warm water of generally 20 to 50[deg.] C. until the brown rice is germinated, or immersed for, for example, about 3 to 5 hours, dewatering is conducted thereafter, and water spraying is intermittently conducted to germinate the brown rice for the predetermined period of

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time under high-humidity conditions. As examples of the warm water used, may be mentioned the water described in the rice washing process, and any water may be used so far as it is water usable for food.

[0023] The germination may be conducted to a state that a swelling, protuberance or plumule of about

0.5 to 2.0 mm from an embryo can be recognized. After the germination, the germinated brown rice is subjected to a heat treatment in order to stop germination. In order to stop germination, the germinated brown rice may be steamed, or treated at a proper temperature or dried by a suitable method such as the use of hot air or microwaves or cooling.

[0024] The germinated brown rice is discharged from the germination tank to transfer it to the next drying process. Before drying, it is preferred that water attached to the germinated brown rice be removed to an extent that the germinated brown rice becomes an almost single kernel state, and the germinated brown rice be subjected to a heat-moisture treatment and then dried. The single kernel state means a state that most of kernels of the germinated brown rice are not bonded to one another with water attached to the surfaces thereof. By this state, handling upon the heat-moisture treatment and drying process is conducted with ease, and so attachment of kernels to one another or a wall surface of an apparatus, unevenness of degree of gelatinization and drying irregularity can be prevented, and drying efficiency can also be improved. The removal of water attached to the surfaces can be conducted by, for example, putting the germinated brown rice discharged on a draining conveyer. At this time, the water attached to the surfaces can be efficiently removed by vibrating the conveyer or conducting ventilation. It is more preferred that agitation be conducted by a rotating blade having a agitating function, screw or the like as needed.

[0025] Specifically, the heat-moisture treatment is a process in which a subject is heated by using, as a heating medium, saturated steam or hot water in a high-humidity atmosphere, for example, an atmosphere of at least 60% humidity. In this case, either a heating method in which the subject to be heated is brought into direct contact with the heating medium or a heating method in which the subject is brought into indirect contact with the heating medium like an indirect heating system, for example, in an atmosphere of at least 60% humidity may be performed. With respect to specific conditions, the treatment may be conducted, for example, at a steam temperature of 98 to 180[deg.] C. for 3 seconds to

30 minutes. If the steam temperature is lower than 98[deg.] C., the time required for the desired gelatinization is elongated. Therefore, such a low steam temperature is not very preferable when industrial mass production is performed. If the steam temperature exceeds 180[deg.] C. on the other hand, a problem that the gelatinization is allowed to too progress is caused, and so the immersion time is limited, and the mouth feed of boiled germinated brown rice is deteriorated when the immersion is conducted for a long period of time. If the treatment time is shorter than 3 seconds, irregularities may occur on the degree of gelatinization of rice kernels, and the control in the practical process is also difficult. If the treatment time exceeds 30 minutes on the other hand, the gelatinization of the germinated brown rice is allowed to too progress, and the swelling of rice kernels occurs. Therefore, kernels of the resulting germinated brown rice are easy to be collapsed when the germinated brown rice is blended with polished rice and immersed for a long period of time.

[0026] A steaming treatment of rice, which is used in boiled rice production, fermentation industry and the like, may be mentioned as an example of another method than the above-described method.

Specifically, for example, brown rice subjected to the germinating treatment is treated with steam for 3 seconds to 30 minutes, preferably 10 seconds to 30 minutes under conditions of 0.1 to 7.0 kg/cm>;2;, preferably 0.1 to 2.0 kg/cm>;2;. If the steam pressure is lower than 0.1 kg/cm the preventive effect on the occurrence of cracked rice kernel or broken rice is lessened. The same shall apply to the treatment time shorter than 3 seconds. If the treatment time is too long on the other hand, the gelatinization is allowed to too progress, and so the resulting germinated brown rice tends to deteriorate the mouth feel when boiled together with polished rice, easily cause blocking between kernels and deteriorate handling in the drying process. On the other hand, even if the steam pressure exceeds 7.0 kg/cm>;2;, the preventive effect on the occurrence of cracked rice kernel or broken rice is achieved. However, too high pressure involves a problem of safety.

[0027] The drying may be conducted by any of convective (hot air) drying method, radiation drying method, indirect drying method, evenly heating method by electromagnetic waves or the like, vacuum drying method, lyophilization method, etc.

[0028] When tempering is conducted before the desired water content is reached in the drying process, beautiful finish can be achieved, and the occurrence of broken rice can be reduced to a greater extent.

[0029] When the raw brown rice is peeled in advance, the drying time can be shortened, and it is possible to soften hard pericarp and lessen emission of offensive smell. When a part of surface of the

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germinated brown rice is whitened to peel off or damage it, it is also possible to more soften hard epidermis and lessen emission of offensive smell.

[0030] The germinated brown rice according to the present invention may be used for food by boiling it either singly or in combination with brown rice or polished rice, or as a raw material of rice confectionery such as rice crackers, and processed foods such as bread and behon. As needed, intensification of nutrition may be conducted with functional components such as vitamins, minerals,

[gamma]-orizanol, tocotrienol and ferulic acid by a proper treatment such as water absorption by immersion or coating.

[0031] The present invention will hereinafter be described in detail by the following Examples.

EXAMPLE 1

[0032] Raw brown rice (Hinohikari, trade name; from Kagawa) was washed by a rice washer and immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated.

Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 2 minutes and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice.

EXAMPLE 2

[0033] Raw brown rice (Koshihikari, trade name; from Nagano) was washed by a rice washer and immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated.

Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 20 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice.

EXAMPLE 3

[0034] Raw brown rice (Koshihikari, trade name; from Niigate) milled so as to give a milling yield of

98.5% was immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 2 minutes and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice.

EXAMPLE 4

[0035] Raw brown rice (Akitakomachi, trade name; from Akita) milled so as to give a milling yield of

99.9% was washed by a rice washer and immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice.

COMPARATIVE EXAMPLE 1

[0036] Raw brown rice was treated in the same manner as in Example 1 except that the water content of germinated brown rice after the fluidized bed drying was controlled to 18.7% by mass to obtain germinated brown rice.



Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 20 minutes and cooled to obtain germinated brown rice having a water content of 36.9% by mass.



Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 20 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 45 minutes to obtain germinated brown rice the water content of which was controlled to 9.5% by mass.


[0039] Raw brown rice (Hinohikari, trade name; from Kagawa) milled so as to give a milling yield of

94% was immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 30 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice the water content of which was controlled to 14% by mass.

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EXAMPLE 5

[0040] Raw brown rice (Koshihikari, trade name; from Nagano) milled so as to give a milling yield of

94% was washed by a rice washer and immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at

98[deg.] C. for 20 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 40 minutes to obtain germinated brown rice the water content of which was controlled to 10% by mass.

EXAMPLE 6


Thereafter, the thus-treated brown rice was subjected to fluidized bed drying at 80[deg.] C. for 13 minutes to obtain germinated brown rice the water content of which was controlled to 18% by mass.

[0042] The water contents, water absorption upon immersion in water, degree of gelatinization and fatty acid content of the germinated brown rices obtained in Examples 1 to 6 and Comparative

Examples 1 to 4, and the results of a panel test (mouth feel: roughness, glutinousness, odor) and a shelf-life stability test are shown collectively in Table 1. High fatty acid content causes offensive smell and deterioration of the taste. Incidentally, the water absorption upon immersion in water was found by immersing 50 g of each sample of the germinated brown rices obtained in Examples 1 to 6 and

Comparative Examples 1 to 4 at room temperature for 30 minutes in 100 ml of water of 25[deg.] C. and dividing the weight of the sample after immersion by the weight of the sample before the immersion and was expressed by %. The degree of gelatinization was determined by using a germinated brown rice sample after 1 week from the production of the germinated brown rice as a subject in accordance with the [beta]-amylase.pllulanase method (BAP method). The water content and fatty acid content were analyzed by a method using near infrared rays.

[0043] The shelf-life stability was evaluated by heat sterilizing a sample, placing the sample into a polyvinylchloride bag with a zipper and leaving the sample to stand for 1 month. Whether the appearance of the sample was changed or not and offensive smell was emitted or not was confirmed, and the sample was ranked as where no problem arose (good), or * where a problem arose.

[0044] The panel test was conducted by having 9 panelists (20 to 50 years of old) eat a boiled germinated brown rice sample right after the boiling and a cooled sample. The evaluation was made in the following manner. Each sample of the germinated brown rices obtained in Examples 1 to 6 and

Comparative Examples 1 to 4 was cooked by an electric rice cooker in immersion time of 30 minutes with water 1.5 times as much as the sample added thereto.

>;tb;>;sep;>;sep;TABLE 1

>;tb;>;sep;>;sep;>;sep;Degree of>;sep;Water absorption>;sep;>;sep;>;sep;

>;tb;>;sep;>;sep;Water content>;sep;gelatini->;sep;upon immersion>;sep;Fatty acid>;sep;Shelf stability (room

>;tb;>;sep;>;sep;(% by mass)>;sep;zation>;sep;in water (%)>;sep;content>;sep;temperature, 1 month)>;sep;Organoleptic test

>;tb;>;sep;Ex. 1>;sep;16.3>;sep;12.7>;sep;124.6>;sep;27>;sep;- (Neither gathered>;sep;

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;offensive smell)

>;tb;>;sep;Ex. 2>;sep;13.3>;sep;22.8>;sep;118.3>;sep;27>;sep;- (Neither gathered>;sep;- (Rice kernel had

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;no puffy feel)


>;tb;>;sep;Ex. 3>;sep;15.4>;sep;13.5>;sep;136.2>;sep;17>;sep;- (Neither gathered>;sep;

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted


>;tb;>;sep;Ex. 4>;sep;15.0>;sep;14.0>;sep;113.7>;sep;15>;sep;- (Neither gathered>;sep;[Delta]

(Mouth feel after

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;cooled was rough>;sep;>;sep;>;sep;offensive smell

>;tb;>;sep;Comp.>;sep;18.7>;sep;14.2>;sep;125.5>;sep;29>;sep;X (Emitted>;sep;-

>;tb;>;sep;Ex. 1>;sep;>;sep;>;sep;>;sep;>;sep;fermentation odor)

>;tb;>;sep;Comp.>;sep;36.9>;sep;24.3>;sep;108>;sep;79>;sep;X (Gathered mold>;sep;X (Kernels collapsed

>;tb;>;sep;Ex. 2>;sep;>;sep;>;sep;>;sep;>;sep;after 3 days, and>;sep;and had sticky feel.

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>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;emitted offensive>;sep;Had dry mouth feel

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;smell)>;sep;after cooled, and

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;emitted sugary odor)

>;tb;>;sep;Comp.>;sep;9.5>;sep;25.2>;sep;145>;sep;6>;sep;- (Neither gathered>;sep;X (Kernels collapsed

>;tb;>;sep;Ex. 3>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;and had sticky feel.

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;foreign odor)>;sep;Liable to become

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;hard after cooled)

>;tb;>;sep;Comp.>;sep;14.2>;sep;51>;sep;120.6>;sep;15>;sep;- (Neither gathered>;sep;X (Kernels has no

>;tb;>;sep;Ex. 4>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;grain feel and gave

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;offensive smell)>;sep;no eaten feel. Had

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;sticky feel)

>;tb;>;sep;Ex. 5>;sep;10>;sep;29>;sep;143>;sep;9>;sep;- (Neither gathered>;sep;[Delta] (Kernels has no

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;grain feel and gave

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;offensive smell)>;sep;no eaten feel. Had

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;sticky feel)

>;tb;>;sep;Ex. 6>;sep;18>;sep;11.2>;sep;108>;sep;22>;sep;- (Neither gathered>;sep;[Delta] (Hard in kernels,

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;mold nor emitted>;sep;and poor in mouth

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;>;sep;offensive smell)>;sep;feel after cooled)

>;tb;>;sep; : Very delicious;

>;tb;>;sep;- : Delicious;

>;tb;>;sep;[Delta] : Rather delicious.

>;tb;>;sep;X : Unpalatable.

EXAMPLE 7

[0045] Raw brown rice (Hinohikari, trade name; from Kagawa) was immersed for 16 hours in hot water of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at 98[deg.]

C. for 3 minutes, immediately subjected to fluidized bed drying at 100[deg.] C. for 20 minutes, and then cooled for 20 minutes by ventilation to obtain germinated brown rice the water content of which was controlled to 17% by mass.

EXAMPLE 8

[0046] Raw brown rice (Koshihikari, trade name; from Kagawa) was immersed for 5 hours in hot water of 30[deg.] C., dewatered and then left at rest at room temperature for 10 hours to be germinated.

Thereafter, the thus-treated brown rice was steamed at 120[deg.] C. for 3 minutes in a ribbon agitated dryer (indirect drying type), and then subjected to fluidized bed drying at 100[deg.] C. for 20 minutes to obtain germinated brown rice the water content of which was controlled to 16% by mass.

EXAMPLE 9

[0047] Raw brown rice (Koshihikari, trade name; from Nagano) was immersed for 24 hours in hot water of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at 98[deg.]

C. for 5 minutes, and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice the water content of which was controlled to 15% by mass.

EXAMPLE 10

[0048] Raw brown rice (Akitakomachi, trade name; from Akita) was immersed for 24 hours in hot water of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was treated with superheated steam of 170[deg.] C. for 90 seconds, and then dried for 2 hours by ventilation to obtain germinated brown rice the water content of which was controlled to 15% by mass.

EXAMPLE 11


C. for 30 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice the water content of which was controlled to 14% by mass.

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C. for 3 minutes, immediately subjected to fluidized bed drying at 100[deg.] C. for 20 minutes, and then cooled for 20 minutes by ventilation to obtain germinated brown rice the water content of which was controlled to 20% by mass.


[0051] Raw brown rice (Koshihikari, trade name; from Kagawa) was washed by a rice washer and immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated.

Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 20 minutes and cooled to obtain germinated brown rice the water content of which was controlled to 37% by mass.



Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 20 minutes, cooled and then subjected to fluidized bed drying at 80[deg.] C. for 20 minutes to obtain germinated brown rice the water content of which was controlled to 9.5% by mass.


[0053] Raw brown rice (Akitakomachi, trade name; from Akita) was immersed for 24 hours in water controlled to a constant temperature of 30[deg.] C. to be germinated. Thereafter, the thus-treated brown rice was steamed at 98[deg.] C. for 40 minutes, cooled and then subjected to fluidized bed drying at

80[deg.] C. for 30 minutes to obtain germinated brown rice the water content of which was controlled to 10% by mass.

[0054] The water contents and degree of gelatinization of the germinated brown rices obtained in

Examples 7 to 11 and Comparative Examples 5 to 8, and the results of an panel test (mouth feel: roughness, glutinousness, smell) and a shelf-life stability test are shown collectively in Table 2. The degree of gelatinization was determined by using a germinated brown rice sample after 1 week from the production of the germinated brown rice as a subject in accordance with the [beta]amylase.pllulanase method (BAP method). The water content was analyzed by a method using near infrared rays.

[0055] The shelf-life stability was evaluated by heat sterilizing a sample, placing the sample into a polyvinylchloride bag with a zipper and leaving the sample to stand for 1 month. Whether the appearance of the sample was changed or not and offensive smell was emitted or not was confirmed, and the sample was ranked as where no problem arose (good), or * where a problem arose.

[0056] The panel test was conducted by blending each of the germinated brown rice samples with milled rice (Koshihikari, trade name; from Kagawa) in a proportion of 1 to 1 and cooking the resultant blend by an electric rice cooker in immersion time of 30 minutes with water 1.5 times as much as the sample added thereto. The evaluation was made by having 9 panelists (20 to 50 years of old) eat the cooked blend sample right after the boiling to rank the sample in accordance with the following standard:

[0057] : Very delicious;

[0058] : Delicious;

[0059] [Delta]: Rather delicious.

[0060] *: Unpalatable. The finish of each germinated brown rice sample after the drying was visually tested to rank it in accordance with the following standard:


>;tb;>;sep;>;sep;>;sep;Degree of>;sep;>;sep;>;sep;

>;tb;>;sep;>;sep;Water Content>;sep;gelatini->;sep;Organoleptic>;sep;Shelf stability (room

>;tb;>;sep;>;sep;(% by mass)>;sep;zation>;sep;test>;sep;temperature, 1 month)>;sep;Finish after drying

>;tb;>;sep;Ex. 7>;sep;17>;sep;22.3>;sep; >;sep;- (Neither gathered mold nor>;sep;

>;tb;>;sep;>;sep;>;sep;>;sep;>;sep;emitted offensive smell)

>;tb;>;sep;Ex. 8>;sep;16>;sep;14.4>;sep; >;sep;- (Neither gathered mold nor>;sep;


>;tb;>;sep;Ex. 9>;sep;15>;sep;11.5>;sep;->;sep;- (Neither gathered mold nor>;sep;


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>;tb;>;sep;Ex. 10>;sep;15>;sep;34.2>;sep;[Delta]>;sep;- (Neither gathered mold nor>;sep;


>;tb;>;sep;Ex. 11>;sep;14>;sep;42.6>;sep;->;sep;- (Neither gathered mold nor>;sep;


>;tb;>;sep;Comp.>;sep;20>;sep;13>;sep;X>;sep;X (Gathered mold)>;sep;X

>;tb;>;sep;Ex. 5

>;tb;>;sep;Comp.>;sep;37>;sep;22.8>;sep; >;sep;-(Gathered mold and emitted>;sep;

>;tb;>;sep;Ex. 6>;sep;>;sep;>;sep;>;sep;offensive smell)

>;tb;>;sep;Comp.>;sep;9.5>;sep;24>;sep;->;sep;-(Neither gathered mold nor>;sep;X

>;tb;>;sep;Ex. 7>;sep;>;sep;>;sep;>;sep;emitted offensive smell)

>;tb;>;sep;Comp.>;sep;10>;sep;50.6>;sep;X>;sep;-(Neither gathered mold nor>;sep;-

>;tb;>;sep;Ex. 8>;sep;>;sep;>;sep;>;sep;emitted offensive smell)

>;tb;>;sep; : The incidence of broken rice was within 10%, and the kernels thereof had high transparency and were glossy;

>;tb;>;sep;- : The incidence of broken rice was within 20%, and the kernels thereof had high transparency;

>;tb;>;sep;[Delta] : The incidence of broken rice was conspicuous, and the kernels thereof were whitish;

>;tb;>;sep;X : The incidence of broken rice was very conspicuous, and the kernels thereof were whitish.Data supplied from the esp@cenet database - Worldwide Claims:

Claims of corresponding document: US2002031596

What is claimed is:

1. Germinated brown rice the water content of which is 10 to 18% by mass and the degree of gelatinization of which is 5 to 50%.

2. Germinated brown rice obtained by subjecting germinated brown rice to a heat-moisture treatment and drying the treated germinated brown rice to a water content of 10 to 18% by mass and a degree of gelatinization of 5 to 50%.

3. The germinated brown rice according to claim 1 or 2, wherein the water content is 12 to 18% by mass.

4. The germinated brown rice according to claim 1 or 2, wherein the water content is 13 to 16% by mass.

5. The germinated brown rice according to claim 1 or 2, wherein the degree of gelatinization is 5 to

30%.

6. The germinated brown rice according to claim 1 or 2, wherein the degree of gelatinization is 10 to

20%.

7. The germinated brown rice according to claim 1, which has a water absorption rate of 110 to 140% upon immersion in water.

8. The germinated brown rice according to claim 1, which has a water absorption rate of 112 to 138% upon immersion in water.

9. A process for treating germinated brown rice, which comprises removing water attached to the surface of the germinated brown rice to an extent that the germinated brown rice becomes an almost single kernel state, subjecting the germinated brown rice of the almost single kernel state to a heatmoisture treatment and then drying the treated germinated brown rice to a water content of 10 to 18% by mass and a degree of gelatinization of 5 to 50%.

10. The process according to claim 9, wherein the heat-moisture treatment is a steaming treatment.

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11. The process according to claim 10, wherein the steaming treatment is conducted under conditions of a steam pressure of 0.1 to 7 kg/cm>;2 ;and treatment time of 3 seconds to 30 minutes.

12. A processed food obtained by using the germinated brown rice according to any one of claims 1 to

8 as a raw material.Data supplied from the esp@cenet database - Worldwide

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2.

AU6876494 - 2/9/1995

HIGHLY WATER ABSORBED RICE AND METHOD OF PRODUCING THE

SAME, ULTRA-HIGHLY WATER ABSORBED RICE AND A VARIETY OF

RICE PRODUCTS UTILIZING THE SAME


Inventor(s): ISHIDA YUKIO (--); FUKUBA HIROYASU (--)

Applicant(s): ISHIDA YUKIO (--); JAPAN ENERGY CORP (--)


IP Class: A23L1/10; A23L1/168; A23L1/01

E Class: A23L1/182


Priority Number: JP19930204473 (19930728); JP19940184129 (19940714)

Family: AU6876494

Equivalent: EP0636320; US5500242; JP7087906

Abstract:


Abstract of corresponding document: EP0636320

The present invention relates to highly water absorbed rice produced by a process comprising a first step of turning immersed rice into water absorbed rice at a water content of 42 to 72 parts by weight to

100 parts by weight of rice by using hot water no less than 65 DEG C and/or steam or pressurized steam, a second step of immersing the resulting water absorbed rice into cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to generate water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of charging the water absorbed rice into warm water at 25 to 60 DEG C, preferably 30 to 55 DEG C to adjust the water content to 75 to 110 parts by weight of water to 100 parts by weight of raw rice. In accordance with the present invention, the generation of turbidity due to micro-particles of starch can be successfully reduced by immediately immersing the rice from the first step into cold water at a temperature of 0 to 25 DEG C, preferably 5 to 15 DEG C at the second step while the rice maintains the heating temperature of the first step.Description:

Description of corresponding document: EP0636320

Detailed Description of the Invention

Industrial Field of Utilization

The present invention is to provide rice pretreated with a water absorption process. The highly water absorbed rice or the ultra-highly water absorbed rice, in accordance with the present invention, can

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produce delicious boiled rice through simple heating at home, super markets, Japanese food restaurants and other restaurants.

Prior Art and Problems

In accordance with the present invention, it has been found that the process of producing highly water absorbed rice proposed previously (PCT/JP93/00134) has one drawback.

The previous process of producing the highly water absorbed rice comprises a first step of making 100 parts by weight of rice absorb 45 to 100 parts by weight of water, charging the rice into warm water at a temperature above 25 DEG C, and subjecting the rice to any one of processes including refrigeration, freezing, freezing after refrigeration and refrigeration after freezing, and a second step of further making the rice absorb water to adjust the total water absorption level to a ratio of 72 to 130 parts by weight of water to 100 parts by weight of rice. When the rice is immersed in warm water above 25

DEG C, micro-particles of starch disperse into the water, rapidly turning the water turbid. Thus, fresh warm water above 25 DEG C has to be charged therein to exchange the water, so as to prevent the starch particles from adhering to rice surfaces and reducing water absorption.Additionally it was found that the productivity of the highly water absorbed rice was reduced.

Means for Solving the Problems

In accordance with the present invention, the generation of the turbidity due to micro-particles of starch can be successfully reduced by immediately immersing the rice into cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C at the second step of the process of producing highly water absorbed rice while maintaining the heating temperature of the first step. The process of producing highly water absorbed rice or/and ultra-highly water absorbed rice can be made into a continuous through process, which enables almost no reduction of the productivity of such rice. The above advantages bring about the marked improvement in the industrial productivity together with the reduction in construction costs and running costs.

The present invention essentially relates to highly water absorbed rice produced by a process comprising a first step of turning immersed rice into water absorbed rice at a water content of 42 to 72 parts by weight to 100 parts by weight of raw rice by using hot water no less than 65 DEG C and/or steam or pressurized steam, a second step of immersing the resulting rice into cold water at 0 to 25

DEG C, preferably 5 to 15 DEG C while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to prepare water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of charging the water absorbed rice into warm water at 25 to 60 DEG C, preferably 30 to 55 DEG C to adjust the water content to 75 to 110 parts by weight of water to 100 parts by weight of raw rice.

The highly water absorbed rice of the present invention is produced by a process comprising a first step of preheating immersed rice in water at about 50 DEG C for about 3 minutes if necessary and heating the rice by using hot water no less than 65 DEG C and/or steam or pressurized steam for about 20 seconds to 45 minutes to prepare water absorbed rice at a water content of 42 to 72 parts by weight to

100 parts by weight of rice, a second step of immersing the resulting water absorbed rice into cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to prepare water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of charging the water absorbed rice into warm water at 25 to 60 DEG C, preferably 30 to 55 DEG C for about 10 minutes to 60 minutes to adjust the water content to 75 to 110 parts by weight of water to 100 parts by weight of raw rice.

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If necessary, the highly water absorbed rice of the present invention is frozen or/and refrigerated as it is or after a variety of seasoning broth is absorbed therein at the final step. The resulting rice is stored, and can be put on market as a rice product for steamed rice and the like.

Also, by immersing the highly water absorbed rice of the present invention into cold water at 0 to 25

DEG C, preferably 5 to 15 DEG C for 5 to 60 minutes, preferably 5 to 40 minutes while the rice maintains the temperature at the third step absorption (25 to 60 DEG C, preferably 30 to 55 DEG C) to adjust the water content to 90 to 120 parts by weight to 100 parts by weight of raw rice and subsequently immersing the resulting rice in warm water or a variety of seasoning broth at 25 to 60

DEG C, preferably 30 to 55 DEG C for about 5 to 50 minutes, the rice can be prepared into ultra-highly water absorbed rice at a water content of 105 to 135 parts by weight of water to 100 parts by weight of raw rice.

After appropriately freezing or/and refrigerating the highly water absorbed rice of the present invention for storage, the resulting rice is immersed in water, warm water and/or soup, sauce, soup stock, vinegar, seasoning broth and the like (in the case of freezing, this process also works as thawing process) at 5 to 40 DEG C, preferably 10 to 35 DEG C, to prepare the rice into ultra-highly water absorbed rice at a water content of 105 to 135 parts by weight to 100 parts by weight of raw rice.

The ultra-highly water absorbed rice of the present invention can be marketed as rice products for heating with a microwave oven, as it is or after the ultra-highly water absorbed rice is frozen or/and refrigerated.

The highly water absorbed rice and the ultra-highly water absorbed rice, in accordance with the present invention, can be stored through a process of refrigerating, freezing, inactive gas charging, deoxygen process or the combined process of them, and then, the resulting rice can be marketed as rice products or is used as a raw material for variations of boiled rice.

The highly water absorbed rice, ultra-highly water absorbed rice and rice products of the present invention can be charged and molded in a mold under pressure as it is, and/or they are heated in warm water or steam for tentative molding. Then, they are once drawn out therefrom and transferred into another mold and/or a molding frame or, a laminated bag and the like, followed by heating with warm water, steam, pressurized steam, an autoclave, direct flame, a microwave oven, and the like.

Subsequently, the molded rice products can be taken out from the molding frame or the mold.

For molding rice products, the rice is charged into a mold which is then heated with warm water, steam, pressurized steam, an autoclave, direct flame, a microwave oven. In that case, by utilizing the gelatinizing or/and water absorbing and expanding power of water absorbed rice during tentative molding or water absorbed rice during molding process, the rice is molded to prepare molded boiled rice. Furthermore, for storage after molding, the rice is frozen as it is in the mold or after taking out from the mold.

In accordance with the present invention, the process of producing highly water absorbed rice is significant, comprising a first step of preheating immersed rice in water around 50 DEG C if necessary and thereafter turning the rice into water absorbed rice at a water content of 42 to 72 parts by weight of water to 100 parts by weight of raw rice by using hot water no less than 65 DEG C, and/or steam or pressurized steam, a second step of cooling the rice in a forcing-in manner by immersing the rice in cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C for water absorption while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to prepare water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of subsequent recharging the water absorbed rice into warm water at 25 to 60 DEG C, preferably 30 to 55

DEG C to prepare highly water absorbed rice at a water content of 75 to 110 parts by weight of water to 100 parts by weight of raw rice. Such process of producing water absorbed rice has never been done conventionally.

Furthermore, since the highly water absorbed rice and the ultra-highly water absorbed rice with a higher water absorption level produced from the highly water absorbed rice, in accordance with the present invention, are processed in the order of heating, cooling and heating, the process prevents

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turbidity of warm water and water, and sticky surface of rice. Therefore, the rices are suitable for a large-scale boiled rice process at larger facilities, which production line works extremely efficient.

Thus, the process promises economical large-scale production of a variety of delicious boiled rice products.

Also, the highly water absorbed rice of the present invention is suitable as a raw material for pilaf, rizzotte, fried rice, seasoned rice, cha-meshi (cooked with soy sauce and seasoning broth), boiled rice cooked in a ceramic pot, and the like. Furthermore, the ultra-highly water absorbed rice of the present invention is suitable as a raw material of boiled rice to be cooked in a ceramic pot, boiled rice mixed with meat and other ingredients, rice gruel and the like, all of which should be cooked in a microwave oven.

Also, the boiled rice product for steamed rice in accordance with the present invention can be turned into delicious boiled rice by steaming the product at home, lunch center, and fast food stores for a short time.

The ultra-highly water absorbed rice and molded boiled rice in accordance with the present invention can be turned into delicious boiled rice when the rices are heated in a microwave oven as they are.

Also, when the ultra-highly water absorbed rice is charged into its two-fold volume of water and then heated in a microwave oven, the rice is made into delicious rice gruel.

PREFERRED EMBODIMENTS OF THE INVENTION

Examples of the present invention will now be explained hereinbelow.

Example 1

Rice was washed and then immersed in water for 2 hours prior to preheating at 50 DEG C for 3 minutes. Then, the rice was immersed in hot water at 96 DEG C under heating for 55 seconds, which corresponds to the completion of a first-step water absorption. At the first-step water absorption, the water absorption level was 55 parts by weight to 100 parts by weight of raw rice, and the temperature of the rice was 95 DEG C.

Then, the water absorbed rice at a temperature of 95 DEG C from the first step was charged into water at 10 DEG C as it was, for the process of immersion for 25 minutes, which corresponds to the completion of a second-step water absorption. The water at 10 DEG C was cooled under circulation, to maintain the water temperature of 10 DEG C.

The resulting water absorbed rice was at the total water absorption level of 70 parts by weight to 100 parts by weight of raw rice.

The resulting water absorbed rice was immersed in warm water at 45 DEG C for 25 minutes, to produce highly water absorbed rice at the total water absorption level of 100 parts by weight to 100 parts by weight of raw rice.

Example 2

The highly water absorbed rice produced in Example 1 was divided and refrigerated in one-meal portions, which were rice products for steamed rice as they were.

Example 3

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While the highly water absorbed rice obtained in example 1 still maintained the temperature of 45 DEG

C, the rice was immersed in cold water at 10 DEG C for 20 minutes, to produce water absorbed rice of the total water absorption level of 107 parts by weight to 100 parts by weight of raw rice.

Subsequently, the water absorbed rice was immersed in warm water at 40 DEG C for 20 minutes, to produce ultra-highly water absorbed rice of the total water absorption level of 115 parts by weight to

100 parts by weight of raw rice.

The resulting ultra-highly water absorbed rice was divided and frozen in one-meal portions, which were rice products for heating with a microwave oven.

Example 4

The highly water absorbed rice obtained in Example 1 was stored under freezing for 10 days, and then the frozen rice was immersed in water at 15 DEG C for 30 minutes, to produce ultra-highly water absorbed rice of the total water absorption level of 115 parts by weight to 100 parts by weight of raw rice.

Example 5

The highly water absorbed rice obtained in Example 1 was charged into a mold of a continuous boxtype rice ball production apparatus of a boiled fish paste-plate size, at a level of seven/tenth the capacity of the mold, on which were placed cooked ingredients comprising seasoned chicken and vegetables. Over the ingredients was then charged the highly water absorbed rice, followed by closing the mold with a lid in a forcing-in manner and placing continuously the mold in a steaming tank, which was subsequently heated with steam at 105 DEG C for 5 minutes, to tentatively mold a stick-type rice ball.

Loosing the lid so as to release the pressure while keeping the state as it was, the mold was put into a steaming tank, followed by heating with steam at 105 DEG C for 20 minutes, to produce a stick-type rice ball.

Taking out the ball from the mold, the highly water absorbed rice gelatinized in the mold was firmly molded under the pressure from the water absorption and expansion of the water absorbed rice, which did not readily break down. Even if the rice ball was picked up with hands while hot, the ball did not lose its shape. If the mold has thin plates with a higher heat conductivity, the rice can be steamed and/or heated for about 15 minutes while the lid is left as it is in the forcing-in manner, to gelatinize starch of the rice to produce a firmly molded rice ball.

Example 6

The highly water absorbed rice obtained in Example 1 was charged into a mold of a continuous boxtype apparatus for producing boiled rice in a plate form, at a level of eight/tenth the capacity of the mold, followed by closing the mold with a lid and placing continuously the mold in a steaming tank, which was subsequently heated with steam at 105 DEG C for 5 minutes prior to taking out the rice and molding the rice in the plate-form. The boiled rice molded in the plate form was then covered with bread crumb for frying. When various ingredients were mounted on the rice in the fried form, the rice was crispy and tasted very delicious, which was a very interesting and unconventional boiled rice product with very stylish touch.

Example 7

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The rice products of Example 2 under refrigeration were charged into a mixture of garlic and onion preliminarily fried, followed by addition of and light frying together with chicken, green pepper, carrot, small shrimp, and asari (Claudiconcha; a Japanese species of shellfish). Subsequently, soup colored with saffron and stewed tomato cooked in water were poured therein, followed by seasoning with salt and pepper and heating for 5 to 6 minutes prior to steaming for several minutes, to produce delicious paelia.

Example 8

One hundred grams of the ultra-highly water absorbed rice obtained in Example 3 was charged in 200 g water and cooked as it was in a microwave oven (500 W) for 3 minutes, to produce delicious rice gruel with the shape of its rice grain still kept.

Example 9

Rice was washed and then immersed in water for 2 hours prior to preheating at 55 DEG C for 3 minutes. Then, the rice was immersed in hot water at 86 DEG C under heating for 4.5 minutes, which corresponds to the completion of a first-step water absorption. At the first-step water absorption, the total water absorption level was 58 parts by weight to 100 parts by weight of raw rice, and the temperature of the rice was 85 DEG C.

Then, the water absorbed rice at the temperature of 85 DEG C from the first step was charged into water at 15 DEG C as it was, for the process of immersion for 20 minutes, which corresponds to the completion of a second-step water absorption. The water at 15 DEG C was cooled under circulation, to maintain the water temperature of 15 DEG C.

The resulting water absorbed rice was at the total water absorption level of 75 parts by weight to 100 parts by weight of raw rice.

The resulting water absorbed rice was immersed in warm water at 55 DEG C for 25 minutes, to produce highly water absorbed rice at the total water absorption level of 108 parts by weight to 100 parts by weight of raw rice.

Example 10

The highly water absorbed rice produced in Example 9 was divided and refrigerated in one-meal portions, which were rice products for steamed rice as they were.

Example 11

While the highly water absorbed rice obtained in Example 9 was in the state where the temperature above 50 DEG C was still maintained, the rice was immersed in cold water at 15 DEG C for 10 minutes, to produce water absorbed rice of the total water absorption level of 113 parts by weight to

100 parts by weight of raw rice.

Subsequently, the water absorbed rice was immersed in warm water at 40 DEG C for 10 minutes, to produce water absorbed rice of the total water absorption level of 120 parts by weight to 100 parts by weight of raw rice.

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The resulting ultra-highly water absorbed rice was divided in one-meal portions, which were rice products for heating with a microwave oven.

Example 12

The highly water absorbed rice obtained in Example 9 was poured into a mold of a continuous boxtype rice ball production apparatus of a boiled fish paste-plate size, at a level of seven/tenth the capacity of the mold, on which were placed cooked ingredients comprising seasoned chicken and vegetables. Over the ingredients was then charged the highly water absorbed rice, followed by closing the mold with a lid in a forcing-in manner and placing continuously the mold in a steaming tank, which was subsequently heated with steam at 105 DEG C for 5 minutes, to tentatively mold a stick-type rice ball.

Loosing the lid so as to release the pressure while keeping the state as it was, the mold was put into a steaming tank, followed by heating with steam at 105 DEG C for 10 minutes, to produce a stick-type rice ball.

Taking out the ball from the mold, the highly water absorbed rice gelatinized in the mold was firmly molded under the pressure from the water absorption and expansion of the water absorbed rice of itself, which did not readily break down. Even if the rice ball was picked up with hands while hot, the ball did not lose its shape.

OPERATION OF THE INVENTION

In accordance with the present invention, the generation of turbidity due to micro-particles of starch can be successfully reduced by immediately immersing the rice from the first step into cold water at a temperature of 0 to 25 DEG C, preferably 5 to 15 DEG C at the second step, while the rice maintains the heating temperature of the first step.Data supplied from the esp@cenet database - Worldwide

Claims:

Claims of corresponding document: EP0636320

1. Highly water absorbed rice produced by a process comprising a first step of turning immersed rice into water absorbed rice at a water content of 42 to 72 parts by weight to 100 parts by weight of raw rice by using hot water no less than 65 DEG C and/or steam or pressurized steam, a second step of immersing the resulting rice into cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to prepare water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of charging the water absorbed rice into warm water and/or sauce, soup, soup stock, vinegar, seasoning broth and the like at 25 to 60 DEG C, preferably 30 to 55 DEG C to adjust the water content to 75 to

110 parts by weight of water to 100 parts by weight of raw rice.

2. A method of producing highly water absorbed rice comprising a first step of turning immersed rice into water absorbed rice at a water content of 42 to 72 parts by weight to 100 parts by weight of raw rice by heating the immersed rice with hot water no less than 65 DEG C and/or steam or pressurized steam for about 20 seconds to 45 minutes, a second step of immersing the resulting rice into cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C for about 10 to 60 minutes while the rice is in the state where the temperature of the rice is nearly maintained at the temperature of the hot water, and/or steam and the like for use in the above heating of the rice, to generate water absorbed rice at a water content of 50 to 85 parts by weight of water to 100 parts by weight of raw rice, and a third step of charging the water absorbed rice into warm water and/or sauce, soup, soup stock, vinegar, seasoning broth and the like at 25 to 60 DEG C, preferably 30 to 55 DEG C for about 10 to 60 minutes to adjust the water content to 75 to 110 parts by weight of water to 100 parts by weight of raw rice.

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3. Rice products of the highly water absorbed rice according to claim 1, as it is or/and after freezing or/and under refrigeration.

4.Ultra-highly water absorbed rice produced by immersing the highly water absorbed rice according to claim 1 in cold water at 0 to 25 DEG C, preferably 5 to 15 DEG C while the rice maintains the temperature at the third step absorption to adjust the water content to 90 to 120 parts by weight to 100 parts by weight of raw rice, and immersing the resulting rice in warm water and/or soup, sauce, soup stock, vinegar, seasoning broth and the like at 25 to 60 DEG C, preferably 25 to 55 DEG C, to adjust the water content to 105 to 135 parts by weight to 100 parts by weight of raw rice.

5.Ultra-highly water absorbed rice produced by freezing or/and refrigerating the highly water absorbed rice according to claim 1 and immersing the resulting rice in water, warm water and/or soup, sauce, soup stock, vinegar, seasoning broth and the like at 5 to 40 DEG C, preferably 10 to 30 DEG C, to adjust the water content to 105 to 135 parts by weight to 100 parts by weight of raw rice.

6. Rice products for heating with a microwave oven and the like of the ultra-highly water absorbed rice according to claim 4 or 5, as it is or after freezing or/and under refrigeration.

7. Rice products produced by treating the highly water absorbed rice according to claim 1 or the ultrahighly water absorbed rice according to claim 4 or 5 with a process of inactive gas charging and/or deoxygen process and storing the resulting rice as it is or under refrigeration and/or after freezing.

8.Molded rice products produced by charging and molding the highly water absorbed rice or ultrahighly water absorbed rice claimed in claim 1 or 4 or 5 in a mold under pressure as it is, and/or heating the rice with warm water or steam for tentative molding under pressure, leaving the resulting rice therein as it is or/and once drawing out the rice therefrom and transferring the rice into another mold or/and or a molding frame, a laminated bag and the like, followed by heating with warm water, steam, pressurized steam, an autoclave, direct flame, a microwave oven, and the like and subsequently taking out the molded boiled rice from the molding frame or the mold.

9.Molded rice products produced by molding the highly water absorbed rice or ultra-highly water absorbed rice according to claim 1 or 4 or 5 without molds or molding the rice in a mold and taking out the rice from the mold, and subsequently storing the rice as it is or after freezing and/or under refrigeration.

10. Molded rice products produced by charging and heating rice in a mold with warm water, steam, pressurized steam, an autoclave, direct flame, a microwave oven, and the like for the molding of a molded boiled rice according to claim 8, wherein utilization is made of the pressure from the gelatinization or/and water absorption and expansion of the water absorbed rice during tentative molding and/or of the water absorbed rice during molding.

11. Rice products produced by processing or/and processing under heating the highly water absorbed rice or ultra-highly water absorbed rice according to claim 1, 3, 4, 5, 6, 8, or 9, as it is or together with other food materials.Data supplied from the esp@cenet database - Worldwide

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3.

AU6929274 - 11/27/1975

MANUFACTURE OF RICE


Inventor(s): MINAMI JUNICHI (--); SAWADA MAKOTO (--); ANDO MOMOFUKU (--);

TAKATSU MITSUMUNE (--); OHNISHI FUMIO (--)

Applicant(s): ANDO M (--)


IP Class: A23L1/10

E Class: A23L1/182C


Priority Number: AU19740069292 (19740523)

Family: AU6929274

Equivalent: AU489578

Abstract:


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4.

BE1000917 - 5/16/1989

PREPARING FROZEN ARANGINI

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=BE1000917

Applicant(s): DAGOBERTI DOMENICO (--); ALESSI MARIA (--)


IP Class: A23L

E Class: A23L1/182C; A23L1/164C

Application Number: BE19870001077 (19870923)

Priority Number: BE19870001077 (19870923)

Family: BE1000917

Abstract:

Abstract of BE1000917

The food is prepd. by boiling rice in salted water, straining and leaving to cool. The sauce is prepd. by frying an onion and adding minced meat and pouring on tomato juice when browned. This is brought to the boil, then salt, pepper, basil, the peas, fried mushrooms are added and left to simmer for 3 hrs.

Meanwhile the cheese is cut into half c.m. cubes. The tomato sauce is strained to recover the ingredients which are used to stuff the rice bowl. When the rice is ready, egg yokes are incorporated and it is all seasoned with nut-meg, grated cheese, salt and pepper. The egg whites are beaten with a pinch of salt, while bread crumbs are prepd. A rice bowl is formed with the meat, mushrooms and cheese inside. The 'arangina' is put into egg white and is rolled in the bread crumbs to finish. This is then deep-frozen and is browned by frying to 10 mins. for use.Description:

BE1000917 : No description available

Data supplied from the esp@cenet database - Worldwide

21/2197

5.

BE1000927 - 5/16/1989

RICE BASED FOODSTUFFS PREPN. APPTS


Applicant(s): B A HERTO B V (--)

IP Class 4 Digits: A23P

IP Class: A23P

E Class: A23L1/18C2



Family: BE1000927

Abstract:


Process is for prepn. of a grain based foodstuff and has the base material, i.e. principally comprising grain baked between two shaping parts or stamps, under pressure. The shaping parts are moved away from each other by being subjected to an expansion. The obtd. end prod. is removed and is maintained in the condition assumed at the end of expansion. The base material is provided when the shaping parts are in their expanded position. The shaping parts are held at a distance equal to or smaller than the expanded position during the complete prepn. or prodn. cycle.Description:

BE1000927 : No description available

Data supplied from the esp@cenet database - Worldwide Claims:

BE1000927 : No claims available


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6.

BE1004955 - 3/2/1993

METHOD FOR FINISHING PATE AND THE PATE OBTAINED BY THIS

METHOD


Applicant(s): SANPAREIL NV (--)


IP Class: A23L1/317

E Class: A23L1/317A



Family: BE1004955

Abstract:


Method for finishing pate, in accordance to this method a garnish (4) isplaced on the pate (1) and this is covered with a transparent edibleprotective layer (5), specifically that a rice paper leaf with an edible inkdesign is used as a garnish (4), this paper leaf (4) is affixed to the pate(1) using a fat substrate (3)

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7.

CA1028194 - 3/21/1978

DEHYDRATED RICE PRODUCT AND PROCESS

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=CA1028194

Inventor(s): DOLAN FRANCIS H (--); DAY PETER W (--)

Applicant(s): GEN FOODS LTD (--)

E Class: A23L1/168

Application Number: CA19740209517 (19740919)

Priority Number: CA19740209517 (19740919)

Family: CA1028194

Equivalent: JP51073158

Abstract:

Abstract not available for CA1028194

24/2197

8.

CA1066942 - 11/27/1979

PROCESS FOR MANUFACTURE OF FAST COOKING RICE


Inventor(s):

MAKOTO (--)

KAMADA HIDEMOTO (--); MIURA CHIAKI (--); KANO ETSUO (--); UTENA

Applicant(s): CALPIS FOOD IND CO LTD (--)


IP Class: A23L1/00

E Class: A23L1/182; A23L1/18C2; A23L1/18F



Family: CA1066942

Equivalent: GB1519418; FR2317884; DE2632121; IT1065072

Abstract:

Abstract of CA1066942

Title of the Invention: PROCESS FOR MANUFACTURE OF FAST COOKING RICE Fast cooking rice which readily reconstitutes itself into cooked rice is manufactured by a process which comprises causing a specified thickener to be diffused from the surface to the inside center of rice grains puffed in advance to a high degree and subsequently subjecting the treated puffed rice grains to drying and shrinking treatments.Description:

Description of corresponding document: GB1519418

(54) PROCESS FOR MANUFACTURE OF FAST

COOKING RICE

(71) We, CALPIS SHOKUHIN

KOGYO KABUSHIKI KAISHA, a Japanese body corporate, of203, Ebisunishi, 2-chome, Shibuyaku, Tokyo, Japan, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:-

The present invention is concerned with a process for the manufacture of fast cooking rice.

The cooked rice which is a staple food in the countries of Eastern Asia is so-called "steamed and boiled rice". It is cooked by a time-consuming procedure which comprises the steps of first washing raw rice (which means hulled rice in this specification and claims) with water, allowing the washed rice to absorb water and thereafter steaming and boiling the water-impregnated rice for a long time.

Ample impregnation with water and appropriate extents of boiling and steaming are required for preparing cooked rice of soft texture and agreeable resistance to the teeth on biting. The necessity for rigid control of these conditions prevents a quick cooking procedure. The fact that this cooking consumes much time also constitutes a disadvantage.

Another typical example of cooked rice is pilaf. This is prepared by frying washed rice with oil and then the fried rice is steamed and boiled in the presence of added water. It has a disadvantage that the

25/2197

texture is generally hard, although this disadvantage can be overcome by continuing the treatment of steaming and boiling for a relatively long time.

Nevertheless, it still has a drawback that the cooking consumes much time.

In view of this state of affairs, a need has been felt for development of a fast cooking rice which readily provides cooked rice of the class described above.

So-called "gelatinized rice" has been regarded as a kind of fast cooking rice. This is usually prepared by subjecting the rice to the ordinary treatment of steaming and boiling to gelatinize the rice starch and thereafter drying the starch-gelatinized rice. By mere addition of hot water of a temperature of about80"C or over, however, the fast cooking rice prepared as described above fails to reconstitute itself into cooked rice of the desired texture. It is not converted into desirable cooked rice unless it is boiled for several minutes. Such time-consuming treatment does not fit the requirements of fast cooking rice for which instantaneous reconstitution is desired.

A method which produces cooked rice by mere addition of hot water has been disclosed in Japanese

Patent Publication

No. 5729/1959. The method disclosed therein comprises first steaming and boiling the raw rice to a mild extent which is enough to pregelatinize the surface layer of the rice grains, then causing the steamed and boiled rice to absorb a paste such as dextrin or sodium carboxymethylcellulose, subjecting the treated rice to a regular steaming and boiling treatment to gelatinize completely the rice grains and finally drying the gelatinized rice.The fast cooking rice which is obtained by this method has a disadvantage that, when hot water is added immediately before its consumption, the reconstitution takes much time or the reconstituted rice has rather hard texture possibly because the rice, in the final drying treatment, suffers partial reversion of the gelatinized rice starch. Furthermore, the process of manufacture is complicated.

Studies have been continued with a view to producing a fast cooking rice which can be reconstituted into as exact an equivalent of regular boiled and steamed rice as practicable. For example, there is a method which utilizes puffed rice, in consideration of the fact that gelatinized rice is obtained by puffing (expanding) rice grains. If puffed rice is used as a fast cooking rice, it is quickly softened in the presence of hot water added prior to its consumption.

Nevertheless, it has a disadvantage that the hot water deprives the rice grains of their shape and renders them very different from regular boiled and steamed rice in taste, texture and viscoelasticity. Japanese

Patent

Publication No. 27700/1971 discloses a method which comprises the steps of first expanding raw rice to a slight extent, then immersing the puffed rice in water to increase the water content thereof, subsequently gelatinizing the puffed rice of increased water content, thereafter drying the gelatinized rice until the water content thereof decreases to prescribed level and finally re-expanding the dried rice.

The fast cooking rice produced by this method, however, suffers from undesirable spongy texture and poor resistance to the teeth on biting. It has the further disadvantages that the process for manufacture is complicated and the yield is consequently low.

As described above, there have been conceived methods for the manufacture of fast cooking rice which combine the treatment of expanding with other treatments. These conventional methods, however, are complicated from the operational point of view because the water content of rice grains must be rigidly regulated in the course of the treatments and consequently because the rigid regulation of water content calls for additional treatments, and so on. Methods which involve use of oil and fat are not desirable because the oil and fat incorporated into the rice grains degrade the taste and suffer oxidation to the extent of heavily impairing the quality of the fast cooking rice. Also the removal of excess oil and fat in the course of manufacture demands much time and labor.

According to the present invention there is provided a process for the manufacture of fast cooking rice comprising expanding raw rice, as herein defined, into a puffed rice having a volume of 6 to 16 times the volume of raw rice, adding to the puffed rice an aqueous solution of a thickener, or when using a thickener which forms a gel in the presence of a metal ion, an aqueous solution of the thickener and an aqueous solution of the metal ion, and thereafter drying and shrinking the treated puffed rice.

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When the thickener is one which forms a gel in the presence of a metal ion, the aqueous solution of the metal ion may be added before or after adding the aqueous solution of the thickener.

The first step is to prepare rice puffed to a high degree. The rice grains to be used in making the puffed rice may be of any of the numerous species available. For the purpose of this invention, the puffed rice grains obtained by any methods other than the method resorting to the treatment in heated oil and fat can be used. For example, the puffed rice obtained by first treating rice grains in a closed container kept at elevated temperatures under increased pressure and releasing the rice grains into the atmosphere, those puffed by means of heated air, those puffed by having rice grains heated with highfrequency waves and those puffed by having rice grains roasted in conjunction with heated grains such as of common salt, fine sand, ceramic, or those puffed by some other similar puffing methods are all usable for this invention.The degree of puffing used in the present invention is from 6 to 16 times, preferably from 9 to 12 times, but preferably from 10 to 12 times in case of using a thickener to be gelled by metal ions (to be described later), as large in volume (hereinafter the degrees of puffing will be expressed in terms of "volume") as the raw rice grains. The degree of puffing of the range 6 to1-6 times are used in the instantspeeilication and claims represents an average of each rice grain because the size and quality of each rice grain vary. For example, "6 times" includes the degree of puffing of a little bit smaller and also larger than 6 times.

Then there follows the step of adding a thickener to the puffed rice grains. The term "thickener" as used in the instant specification and also in claims includes to polysaccharides of plant origins, derivatives thereof, polysaccharides produced by microorganisms, and some synthetic polymerized substances. The thickener to be used for the present invention will be described in more detail herein below.

There are polysaccharides derived from marine plants: Agar, carrageenin, alginate, alginic acid and furcellaran belong to this class.

There are gums originating in plant seeds: Locust bean gum, guar gum, tamarind gum, psyllium seed gum, quince seed gum and gaz belong to this class.

There is karaya gum obtained from plant exudate.

There is pectin which is derived from fruits.

Besides, glucomannan which is contained in Amorphophallus Konjac in a large amount is also usable.

There are artificially produced thickeners: Propylene glycol alginate, low methyl ester pectin, sodium polyacrylate and cellulose derivatives such as a carboxylmethylcellulose salt, methylcellulose, hydroxymethylcellulose, methylethyl

cellulose and hydroxypropylcellulose

belong to this class.

There are microorganically produced thickeners: Xanthan gum, cardrun, scleroglucan, succinoglucan and pullulan belong to this class.

To be more specific, by using a specific thickener selected from the thickeners enumerated above, there can be manufactured a fast cooking rice which produces cooked rice of more excellent texture after several minutes of standing with added hot water of a temperature of not less than about80"C.

The fast cooking rice obtained with such a thickener, of course, is suitable for preparation of pilaf and other cooked rice.

Of the specifically selected thickeners, agar, carrageenin, propylene glycol alginate, carboxymethylcellulose salt, methylcellulose and glucomannan produce a thickening effect without the activating effect of a metal ion.

Others of the selectedthickeners, are gelled in the presence of metal ions.

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Although these thickeners do not have a

noticeable thickening effect when they are used without the presence of metal ions they manifest a conspicuous effect once they are gelled and consequently allowed to produce a fast cooking rice of all the more excellent quality. Where there is used a thickener capable of being gelled by metal ions, therefore, the process for manufacture of fast cooking rice is desired to incorporate an extra step for the formation of gel.

This formation of gel is accomplished by first adding the thickener to the puffed rice and subsequently adding thereto a metal ion capable of inducing gelation of said thickener or conversely by first adding said metal ion to the puffed rice and subsequently adding thereto the thickener.

The thickeners of this class are alginic acid, alginates, calcium-sensitive carrageenin, potassiumsensitive carrageenin and low methyl ester pectin.

In the present invention, the various thickeners described above can be used in the form of mixtures of varying combinations.

Now, the method by which the thickener is added to the puffed rice will be described. This addition is accomplished by causing the thickener to penetrate into the puffed rice by employing the thickener in the form of an aqueous solution. For example, the addition is effectively carried out by immersing the puffed rice in an aqueous solution containing the thickener or by spraying or sprinkling said aqueous solution on the puffed rice. The advantage of this method is the fact that the individual rice grains can be uniformly treated throughout from the surface to the center.

In contrast, the method of addition which uses the powdered thickener in its unaltered form fails to attain the object of this invention because the thickener cannot uniformly penetrate into the interior texture of rice grains.

It is true of the method for the addition of metal ion, too. The most advantageous method is to use an aqueous solution containing the metal ion.

Various conditions of treatment such as concentration of the aqueous solution of thickener and temperature will be described. It is natural that the conditions are variable to some extent because the thickeners themselves have properties different from one another. It is generally desirable, however, to avoid increasing the viscosity of the aqueous solution. If the viscosity of the aqueous solution is high, there is a risk that the treatment aimed at is obtained only on the surface of puffed rice and not sufficiently inside the rice grains and, the individual rice grains tend to conglomerate into lumps. The increase in viscosity further renders the handling of the aqueous solution itself more difficult.

Moreover, after the treatment for the addition of thickener, required removal of the excess aqueous solution adhering to the puffed rice cannot be fulfilled satisfactorily.

The high viscosity also raises a difficulty in immersing the puffed rice having a low specific gravity in the aqueous solution.

The conditions of the treatment involving use of thickeners which belong to the class consisting of gums of plant origin, polysaccharides originating in marine plants and polysaccharides originating in animals and microorganisms and which therefore are free from formation of gel by metal ion will be described below. The ranges of concentration of aqueous solutions of these thickeners suitable for use in this invention are substantially similar for each thickener, and the other treatments such as the method of addition of thickeners can be carried out under similar conditions in each case. The description, therefore, will be given generally to cover all the thickeners.

The concentration of the thickener in the aqueous solution typically falls in the range of from 0.1 wlw percent to 1.0 w/w percent (hereinafter indicated invariably in percent by weight/weight),

preferably in the neighborhood of

0.5 percent. The range of concen

tration, however, is variable slightly from

28/2197

one thickener to another. In general, when the concentration is below 0.1 percent, the effect aimed at is not obtained satisfactorily. When it exceeds 1.0 percent, the viscosity of the aqueous solution becomes so high that the solution cannot be handled easily, the individual rice grains tends to adhere mutually to form lumps and the flavour of the final product is impaired.

The temperature of the aqueous solution is only required to be such as to permit thorough solution of the thickener. In the case of the aqueous solution of agar, for example a temperature higher than40"C is adequate. In the immersion of the puffed rice in the aqueous solution of a thickener, the duration of immersion can be decreased in proportion as the temperature of the solution is increased. In the use of0.4% aqueous solution of agar, for example, the immersion given for ten seconds at 650C or for one minute at 400C will suffice for the purpose. Where the addition is effected by spraying or sprinking, the treated rice is, as a matter of course, desired to be left to stand at rest for a while to ensure uniform and thorough penetration of the aqueous solution into the individual grains of puffed rice.No matter whether the addition is effected by immersion, spraying or sprinkling, the purpose of the treatment is attained insofar as the aqueous solution is thoroughly penetrated from the surface to the center of the puffed rice which has a porous texture.

Then, the conditions of treatment involving the use of thickeners to be gelled by metal ion and the conditions of said gelation will be described. This gelling treatment substantially comprises causing the thickener and the metal ion both in the form of aqueous solutions to be penetrated into the puffed rice in two steps. Since the present invention uses a rice puffed to a high degree of from 6 to 16 times the original volume and consequently possessed of a porous texture, the rice grains readily permit penetration of said thickener and metal ion. The two steps of addition may be effectively carried out in any desired order.

The addition of the thickener and that of the metal ion will be described in order.

The concentration of the aqueous solution of a thickener involving formation of gel by a metal ion is generally desired to fall in the range of from 0.2 to 3.0 percent.

This range is variable to some extent with the particular kinds of thickeners to be used. To attain the effect aimed at in a short time, a concentration below 0.2 percent is generally not sufficient. When the concentration exceeds 3.0 percent, the viscosity of the aqueous solution increases to an extent such that the solution will not permit ready penetration in the puffed rice nor easy handling, the individual rice grains tend to adhere mutually and the flavour of the final product is impaired. The temperature of the aqueous solution and the duration of immersion in this aqueous solution are not specifically limited by the present invention. The purpose of the immersion is amply attained when the immersion is given for a brief period of about 30 seconds at a temperature falling within the range extending from normal room temperature to900 C, for example.

Where the addition is effected by spraying or sprinkling, the treated rice is, as a matter of course, desired to be left to stand at rest for a while to ensure uniform and thorough penetration of the aqueous solution into the puffed rice. Consequently, the thickener is thoroughly penetrated from the surface to the center of the puffed rice having a porous texture. Then, the puffed rice treated above is subjected to the same treatment with an aqueous solution

containing a metal ion.

The expression "aqueous solution containing a metal ion" as used in the present invention refers to an aqueous solution containing free metal ions.

Examples of the aqueous solution satisfying

this definition include aqueous solutions

prepared by addition of metal salts,

solutions prepared by an ion-exchange

treatment, naturally occurring mineral

waters containing metal ions and natural

aqueous solutions which originate in

animals and plants. Of the various aqueous

solutions described above, the aqueous

29/2197

solutions prepared by addition of metal

salts will be described by way of

exemplification.

In the preparation of aqueous solutions containing metal salts, examples of the metal salts usable for this purpose include calcium

salts, potassium salts, magnesium salts and

other similar metal salts of carbonic acid,

hydrochloric acid, sulfuric acid, phosphoric

acid, acetic acid, lactic acid, citric acid,

ascorbic acid, glycerophosphoric acid and

other similar acids.

In the solution containing a metal ion capable of reacting upon the thickener and consequently inducing gelation, the concentration of the metallic ion is only required to be such that the absolute amount of metallic ion present therein is enough to bring about the effect of gelation. Whether the combination of respective kind of the aqueous solutions containing the thickener and the metallic ion separately and the combination of their respective concentrations are proper or not for the purpose of this invention can be confirmed by mixing the two aqueous solutions in the absence of puffed rice and examining the resultant mixture to find the presence or absence of the ensuing reaction of gelation.

Thus the selection of a proper combination can easily be accomplished.The contact time between the thickener and the metallic ion has some bearing on the strength of gel to be consequently formed. For example, a strong gel is formed by allowing an ample contact time, so that the finally produced fast cooking rice provides enhanced teeth resistance when it is reconstituted with hot water and served for meal. Thus, the degree of resistance to the teeth can be controlled by suitably selecting the length of contact time for gelation. The kinds and concentrations of the aqueous solutions, the temperature, contact time and pH involved in the treatment can be suitably selected as are generally practiced in most treatments for gelation. Further and more specific information thereon is made apparent in several examples to be cited afterward.

The puffed rice to which the thickener or the gelled thickener has been incorporated as described above is now dried by an ordinary method. The drying may be carried out under normal atmospheric pressure or under vacuum, either in the absence or in the presence of heating.

During the drying, the individual grains of the puffed rice may be kept stationary or may be moved.

The method of drying, therefore, can suitably be selected by taking into due consideration the amount of puffed rice, the desired duration of drying time (reflecting readiness of handling), the desired quality of the fast cooking rice to be produced, etc. Where the drying is effected by application of heat, due attention should be paid to avoiding excessive heating which frequently results in occurrence of burnt rice emitting an objectionable odor.

Concrete examples of the drier well known for this purpose include a tunnel and band dryer, a chamber dryer, an infrared dryer, etc.

In consequence of the gradual vaporization of water, the puffed rice diminishes in volume eventually to approach the volume of raw rice while the incorporated thickener or gelled thickener is retained throughout from the surface to the center of individual rice grains. To obtain a fast cooking rice which gives a desirable texture when served for meal and yet is not so bulky as to impair the ease of handling, the process of drying and shrinking preferably continued until the volume of the treated puffed rice has decreased to a volume which is less than three times the volume of the raw rice.

To the aqueous solution of a thickener. to the aqueous solution of metal ion, to the puffed rice incorporating a thickener, or to the fast cooking rice which has undergone the treatment of drying, various seasoning agents, nutrition enriching agents, colorimproving agents, etc. may be suitably added and blended therewith. As a result, there can easily be produced a flavored fast cooking rice.

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As described in detail up to this point, this invention comprises the first step of puffing rice grains to a high degree for thereby gelatinizing rice starch, inducing cleavage of rice starch micelle, forming a porous texture in rice grains and causing a specific thickener in an unaltered form or a gelled form to be amply entrapped within the rice grains and the subsequent step of drying the treated puffed rice to the extent of allowing the rice grains to shrink to a prescribed volume. The fast cooking rice which is manufactured as described above enjoys high yields of production and high preservability and, upon reconstitution, converts itself into a cooked rice excelling in taste, texture and flavor.

Reconstitution of this fast cooking rice, for example, into ordinarily cooked rice can be obtained by adopting a method which is generally practiced in preparing fast cooking rices of this kind. To be specific, desired reconstitution into cooked rice can be accomplished by allowing this fast cooking rice to stand for one to two minutes in hot water heated in advance to about80"C or over and added in a volume roughly 1 to 1.5 times the volume of rice, then discarding an excess portion of said hot water and thereafter allowing the rice to be steamed for three to four minutes with the remaining heat. The fast cooking rice can be reconstituted into a soup containing rice grains by following the same procedures except for removal of excess hot water.The fast cooking rice produced by this invention can be also amply reconstituted into a cooked rice of good quality when it is left to stand in water of normal room temperature for about 30 minutes. When the fast cooking rice is reconstituted with milk instead of water of normal room temperature, the resultant cooked rice tastes good. For a user who feels like eating pilaf, a pilaf of mild texture can be obtained by heating the fast cooking rice of this invention such as in a frying pan in the presence of a small amount of oil and fat and a suitable amount of water.

Some specific embodiments of the present invention are described in the following Examples.

Example 1

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 9 times the original.

Two (2.0) Kg of this puffed rice was immersed for10--15 seconds in an0.4?o aqueous solution of agar-agar kept at 650C. It was immediately placed in an electric constant-temperature hot-air dryer at90"C and dried therein for 2.5 hours to produce 1.9 kg of fast cooking rice having a volume of about twice as large as that of the raw rice. This fast cooking rice was placed in a container provided with a lid. The same volume of hot water at 950C was poured into the container. The rice and the hot water in the container were left to stand for 90 seconds. Then, the excess hot water was discarded. Thereafter, the fast cooking rice was left to be steamed for three minutes with the remaining heat.

Consequently, there was obtained a cooked rice excellent in taste, texture and flavor.

Example 2

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 16 times as large.

Two (2.0) Kg of this puffed rice was sprayed with 5.3 kg of 0.3% aqueous solution of sodium carboxymethylcellulose at normal room temperature, then left to stand at normal room temperature for ten minutes, thereafter placed in a drying oven at 700C and dried therein for four hours to afford 2.0 kg of fast cooking rice having a volume about twice as large as the volume of raw rice.

A cooked rice of excellent quality was obtained by subjecting the fast cooking rice to the treatment of the same procedure as in Example I.

Example 3

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 9 times as large. One

(1.0) Kg of this puffed rice was sprayed with 2.5 kg ofl.0?/o aqueous solution of lambda carrageenin at44"C, then left to stand for ten minutes at normal room temperature, subsequently placed in a vacuum dryer, dried first at65"C under normal atmospheric pressure for one hour to vaporize the water and then at65"C under a vacuum of less than 10 mmHg for 3.5 hours. Thus there was obtained 0.98 kg of a fast cooking rice having a volume of about 1.7 times the volume of the raw rice. A cooked rice of excellent quality could be obtained by treating this fast cooking rice by the treatment of the same procedure as in

Example I.

Example 4

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A raw rice was expanded by use of heated air at 3000C into a puffed rice having a volume of 6 times as large. Three (3.0) Kg of this puffed rice was immersed in0.45 " aqueous solution of guar gum kept at65 C, then immediately placed in a drying oven at 900C and dried for three hours to afford 2.9 kg of a fast cooking rice having a volume of about 1.7 times as large as that of the raw rice. Two hundred

(200) g of this fast cooking rice was placed in a frying pan and heated in the presence of 600g of water and a small amount of salad oil added thereto. There was consequently obtained a cooked rice excellent in taste, texture and flavor.

Example 5

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 10 times as large. One and ahalf(l.5) kg of this puffed rice was immersed in a seasoning aqueous solution containing0.3 Ó of propylene glycol alginate,0.30o of sodium starch phosphate,O.S?b' of sodium chloride and a small proportion of seasoning agent.

After about 15 seconds of immersion in the solution, the puffed rice was immediately placed in a drying oven at 850C and dried therein for three hours to afford 1.4 kg of a fast cooking rice having a volume of about 1.9 times as large as that of the raw rice. A curry-flavoured cooked rice was obtained by cooking this fast cooking rice in the presence of curry powder and raisins added thereto by a procedure similar to that of

Example 4.

Example 6


(1.0) kg of this puffed rice was immersed in0.5or aqueous solution of low methyl ester pectin at normal room temperature for 60 seconds and then immersed again in0.5or aqueous solution of calcium chloride at 600C for 60 seconds.

The puffed rice thus treated was dried in a drying oven at 600C for four hours to afford 0.98 kg of a fast cooking rice having a volume of 2.4 times as large as that of the raw rice. A cooked rice of excellent quality was obtained by subjecting this fast cooking rice to a treatment similar to that of

Example 4.

Example 7


(1.00) Kg of this puffed rice was immersed in2.0To aqueous solution of calcium and potassiumsensitive carrageenin at 800C for 30 seconds, and then immersed again in an aqueous solution containingl.OOo of calcium lactate and1.0No of potassium monohydrogen phosphate at80"C for 60 seconds.

When the treated rice was dried for five hours under conditions of45"C+5"C and a vacuum of less than

10 mmHg, there was obtained 1.0 Kg of fast cooking rice having a volume of 1.6 times that of the raw rice. A cooked rice of excellent quality was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

Example 8


(1.0) Kg of this puffed rice was sprayed with 2.5 kg of 1.0% aqueous solution of calcium lactate at normal room temperature, then left to stand at normal room temperature for about ten minutes, and thereafter immersed in0.6 ó aqueous solution of sodium alginate at 400C for two minutes. When the treated rice was dried in a drying oven at80"C for three hours, there was consequently obtained 0.93 kg of fast cooking rice having a volume of 2.6 times as large as that of the raw rice.A flavored steeped rice of excellent taste was obtained by adding to this fast cooking rice small amounts of powdered sea weed and powdered green tea, a suitable amount of sodium chloride and a small amount of dried salmon flakes and allowing the resulting mixture to stand in hot water at 900C for three minutes.

Example 9


(1.0) Kg of this puffed rice was immersed in an aqueous solution of0-5 ,O sodium alginate and0.1 O,/o cardrun for 30 seconds, then immersed again in an aqueous solution containing3.0"/, of calcium

32/2197

lactate,3.0Go of chicken soup,0.5 Ó of sodium chloride and0.030 of seasoning agent at normal room temperature for 45 seconds, and thereafter dried in a drying oven at95"C for 2.5 hours. Consequently, there was obtained 0.97 kg of fast cooking rice having a volume of 2.7 times as large as that of the raw rice.A flavored cooked rice of excellent taste was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

WHAT WE CLAIM IS:

1. A process for the manufacture of fast cooking rice comprising expanding raw rice, as herein defined, into a puffed rice having a volume of 6 to 16 times the volume of raw rice, adding to the puffed rice an aqueous solution of a thickener, or when using a thickener which forms a gel in the presence of a metal ion, an aqueous solution of the thickener and an aqueous solution of the metal ion, and thereafter drying and shrinking the treated puffed rice.

2. A process according to claim 1, wherein the thickener is at least one of agar, carrageenin, propylene glycol alginate, glucomannan, methylcellulose or a carboxymethyl-cellulose salt.

3. A process according to claim 2, wherein the puffed rice has a volume of 9 to 12 times the volume of the raw rice.

4. A process according to claim 1 wherein a thickener which forms a gel in the presence of a metal ion is used, and the aqueous solution of the metal ion is added before or after adding the aqueous solution of the thickener.

5. A process according to claim 4, wherein the thickener is at least one of alginic acid, an alginate, calcium-sensitive carrageenin, potassium-sensitive carrageenin, and low methyl ester pectin.

6. A process according to claim 4 or 5, wherein the puffed rice has a volume of 10 to 12 times the raw rice.

7. A process according to any one of claims I to 6, wherein the drying and shrinking is continued until the volume of the treated puffed rice has decreased to a volume which is less than three times the volume of the raw rice.

8. A process for the manufacture of fast cooking rice, substantially as described in any one of the

Examples.

9. Fast cooking rice obtained by a process according to any one of claims I to 8.

**WARNING** end of DESC field may overlap start of CLMS **.Data supplied from the esp@cenet database - Worldwide Claims:

Claims of corresponding document: GB1519418

**WARNING** start of CLMS field may overlap end of DESC **.

When the treated rice was dried for five hours under conditions of45"C+5"C and a vacuum of less than

10 mmHg, there was obtained 1.0 Kg of fast cooking rice having a volume of 1.6 times that of the raw rice. A cooked rice of excellent quality was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

Example 8


(1.0) Kg of this puffed rice was sprayed with 2.5 kg of 1.0% aqueous solution of calcium lactate at normal room temperature, then left to stand at normal room temperature for about ten minutes, and thereafter immersed in0.6 ó aqueous solution of sodium alginate at 400C for two minutes. When the treated rice was dried in a drying oven at80"C for three hours, there was consequently obtained 0.93 kg of fast cooking rice having a volume of 2.6 times as large as that of the raw rice.A flavored steeped

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rice of excellent taste was obtained by adding to this fast cooking rice small amounts of powdered sea weed and powdered green tea, a suitable amount of sodium chloride and a small amount of dried salmon flakes and allowing the resulting mixture to stand in hot water at 900C for three minutes.

Example 9


(1.0) Kg of this puffed rice was immersed in an aqueous solution of0-5 ,O sodium alginate and0.1 O,/o cardrun for 30 seconds, then immersed again in an aqueous solution containing3.0"/, of calcium lactate,3.0Go of chicken soup,0.5 Ó of sodium chloride and0.030 of seasoning agent at normal room temperature for 45 seconds, and thereafter dried in a drying oven at95"C for 2.5 hours. Consequently, there was obtained 0.97 kg of fast cooking rice having a volume of 2.7 times as large as that of the raw rice.A flavored cooked rice of excellent taste was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

WHAT WE CLAIM IS:

1. A process for the manufacture of fast cooking rice comprising expanding raw rice, as herein defined, into a puffed rice having a volume of 6 to 16 times the volume of raw rice, adding to the puffed rice an aqueous solution of a thickener, or when using a thickener which forms a gel in the presence of a metal ion, an aqueous solution of the thickener and an aqueous solution of the metal ion, and thereafter drying and shrinking the treated puffed rice.

2. A process according to claim 1, wherein the thickener is at least one of agar, carrageenin, propylene glycol alginate, glucomannan, methylcellulose or a carboxymethyl-cellulose salt.

3. A process according to claim 2, wherein the puffed rice has a volume of 9 to 12 times the volume of the raw rice.

4. A process according to claim 1 wherein a thickener which forms a gel in the presence of a metal ion is used, and the aqueous solution of the metal ion is added before or after adding the aqueous solution of the thickener.

5. A process according to claim 4, wherein the thickener is at least one of alginic acid, an alginate, calcium-sensitive carrageenin, potassium-sensitive carrageenin, and low methyl ester pectin.

6. A process according to claim 4 or 5, wherein the puffed rice has a volume of 10 to 12 times the raw rice.

7. A process according to any one of claims I to 6, wherein the drying and shrinking is continued until the volume of the treated puffed rice has decreased to a volume which is less than three times the volume of the raw rice.

8. A process for the manufacture of fast cooking rice, substantially as described in any one of the

Examples.

9. Fast cooking rice obtained by a process according to any one of claims I to 8.Data supplied from the esp@cenet database - Worldwide

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9.

CA1075967 - 4/22/1980

CO-CRYSTALLIZATION OF DEXTROSE AND SUCROSE ON CEREAL

PRODUCTS


Inventor(s): EDWARDS LARRY W (--)

Applicant(s): CPC INTERNATIONAL INC (--)


IP Class: A23L1/164

E Class: A23L1/18F; A23L1/164B


Priority Number: US19770756931 (19770105)

Family: CA1075967

Equivalent:

Abstract:

US4101680


Larry W. Edwards D-3163 CO-CRYSTALLIZATION OF DEXTROSE AND SUCROSE ON

CEREAL PRODUCTS Dextrose and sucrose are co-crystallized onto the surface of breakfast cereal products; such as corn flakes, puffed wheat or puffed rice, by applying to the surface of said cereal product a powdered crystalline material comprising any of sucrose, dextrose or mixtures thereof, and coating the surface with a layer of a concentrated aqueous solution of dextrose and sucrose. The coated cereal product is then dried at a temperature below the browning temperature of the product. The resulting coated cereal product has a desirable frosted appearance.Description:



This invention relates to presweetened breakfast cereal products, and more in particular, to cereal products which have been coated with mixtures of sugars to produce a variety of presweetened cold breakfast cereal products for direct sale to the consumer. The sugar coated onto these cereal products have, at least in part, crystallized, thereby giving a consumer-pleasing frosted effect to the product.

Presweetened cold breakfast cereal products have been sold on the consumer market for many years.

Generally, the sugar material which was coated on the surface thereof was sucrose. However, during the past several years when the cost of sucrose has risen, interest has been shown in utilizing a substitute for sucrose; such as, corn syrup solids or dextrose which are generally lower in cost than sucrose. Unfortunately, however, the use of these materials produces presweetened cereals which tend to be hygroscopic, and where the sugar is not crystalline. Rather, these coatings tend to be hard, glassytype, transparent coatings which tend to become tacky upon storage. Recently, procedures have been developed in the art which enable these coatings to be applied in a form which is relatively nonhygroscopic.

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However, it has been found that the use of dextrose or dextrose-containing materials as the coating material on cereal products yields products which are insufficiently sweet for the consumer market. It is thus desirable to replace only a portion of the previously utilized sucrose with the dextrose or dextrose-containing material. Prior to this invention, it has not been possible to produce a coating on a breakfast cereal product wherein dextrose and sucrose are co-crystallized onto the surface of the cereal product. Through the utilization of the process of this invention it is, however, possible to form frosted crystalline coatings on these cereal products wherein at least a portion of the dextrose and sucrose are in the crystalline state.


An aqueous solution of dextrose and sucrose in a pre-determined ratio is formed at a solids concentration of about 80 to 85%, dry substance. This aqueous solution is maintained at a temperature above the saturation temperature of the sugars. A breakfast cereal product is substantially uniformly coated with seed crystals of dextrose, sucrose or a mixture thereof. The previously formed aqueous solution is then coated onto the surface of the cereal product in a substantially uniform manner. The coated cereal product is then dried with controlled heating to reduce the moisture content of the coating. The temperature should always remain below that which can cause browning of the cereal product. The drying is continued until a moisture content of not less than about 3% to about 4% remains in the coating. The coated cereal product is then sealed and stored. The coating gradually whitens due to the formation of crystals on the surface and the crystallization is generally complete after a period of about 2 to 3 days.

It is possible to introduce the seed material and sugar solution onto the surface of the cereal product either simultaneously or in either order, provided a uniform distribution of both materials is obtained.


This invention is useful to produce a wide variety of presweetened breakfast cereal products.

Generally, the process may be utilized to produce any frosted breakfast cereal product which has been conventionally been produced with a sucrose coating.

An aqueous solution of dextrose and sucrose is formed having a predetermined ratio of dextrose to sucrose. Generally, any commercial form of dextrose or sucrose may be used; e.g., the commercial granulated sucrose, anhydrous dextrose, dextrose monohydrate, liquid dextrose and high dextrose corn syrup, provided these corn syrups do not contain excessive levels of impurities, which levels could retard or prevent crystallization. The particular form of dextrose is not critical, as when placed in aqueous solution all are identical. It is, of course, necessary that the weight of water of hydration be taken in account.

The solution is formed in any conventional manner. Generally, it is most convenient to utilize as high a solids concentration as possible so that the subsequent drying step may be carried out as quickly as possible. Generally, the optimum value is the highest which may be conveniently handled; i.e., agitated, pumped, sprayed, etc. Based on these considerations, it has been found convenient to utilize solutions having from about 75% to about 88% total solids and preferably about 85%.

In practicing the process of this invention, any desired dextrose to sucrose ratio may be utilized. The selection of the ratio which is desired will depend upon the particular application, and the desired sweetness level of the final product. Thus, while crystallization of the sugar solution may be done at any values of the dextrose to sucrose ratio, the ultimate selection will be based upon the taste, hygroscopicity, and economic considerations dictated by the particular market for the final product.

Experimentally, satisfactory products have been prepared utilizing dextrose to sucrose ratios ranging from 85:15 to 25:75.

It is to be expected that the most satisfactory results may be obtained when utilizing ratios in which one sugar predominates. This is due to the fact that each of the sugars can function as an impurity retarding the crystallization of the other. Thus, when utilizing dextrose to sucrose ratios near 50:50, the rate of crystallization may be substantially slower than when utilizing other ratios of dextrose to sucrose; as at a 50:50 ratio each sugar can be considered to be a maximum impurity of the other.

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The aqueous sugar solution should be unsaturated with respect to both sugars; that is, not crystallize in the solution. Generally, convenient operating temperatures will vary from about 90 DEG to 100 DEG

C, but such is not critical.

The unsweetened breakfast cereal product is first treated by coating its surface with either a sucrose or dextrose powdered crystalline material. While certain sucrose to dextrose ratios may crystallize satisfactorily without seeding, and in particular those wherein sucrose is the predominant sugar, it is preferred that the surface of the cereal product be coated with these seed crystals. In general, the seed material may be sucrose, anhydrous dextrose or dextrose monohydrate interchangeably. However, where dextrose makes up at least about 65% of the total sugar in the solution, seeding with either anhydrous dextrose or dextrose monohydrate is superior to seeding with sucrose. Where less than about

65% of the total sugar is dextrose, the choice of seed crystal is immaterial.

The seeding is performed in any conventional manner which will uniformly coat the surface, such as by dusting or tumbling the dry cereal product with a quantity of finely comminuted seed material. The quantity of seed material utilized is not critical. An excess of seed material may be utilized if the excess can be removed from the system. Generally, the amount of seed material adhering to the surface will be about 1% to 2% based on weight of the cereal product when using corn flakes as the cereal product.

The sieve analyses of the seed materials used in the following example are set forth in Table I. These, however, are illustrative only.

>;tb; TABLE I

>;tb;______________________________________

>;tb;U.S. Standard

>;tb; Dextrose Anhydrous

>;tb;Sieve Monohydrate Dextrose Sucrose

>;tb;______________________________________

>;tb;+30 5.6 0 0

>;tb;-30 + 50 11.7 2.0 0

>;tb; -50 + 100 23.5 20.2 4.0

>;tb;-100 + 200 34.2 40.3 36.3

>;tb;-200 + 325 16.9 22.8 50.2

>;tb;-325 8.1 14.7 9.5

>;tb;______________________________________

The sugar solution is then applied in a thin, uniform coating onto the surface of the cereal product. It is convenient to spray the surface with the solution, but the mode of application is not crucial so long as the proper coating is obtained.

Another suitable method would be what is called the "random drip method" as described in U.S. Pat.

No. 3,959,498.

It has been found that the amount of coating material applied to the surface is preferably in the range of about 25% to about 45%, dry basis, based on weight of the cereal product. A most preferable amount is about 35%. These amounts, may, of course, be varied depending on the desired sweetness of the final product.

The moisture content of the applied sugar solution is then reduced. There are two important considerations here -- drying temperature and final moisture content of the coating.

With regard to the temperature at which the moisture content is reduced, it is important that the temperature not be sufficiently high to produce an unacceptable browning of the product which may happen in the presence of a reducing sugar. The particular drying temperature utilized is related to the drying time; i.e., higher temperatures may be used when the times are short. Commercially feasible conditions for drying would be a temperature of about 100 DEG to about 120 DEG C for about 30 minutes or less.

The moisture content of the coated material should be such that the crystallization if facilitated. In general, crystallization will be inhibited if the total moisture content is reduced below 3 to 4%. This is

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believed to be due to the fact that crystal growth occurs on the faces of the seed material. The rate of crystallization is in part controlled by the rate of diffusion in the coating solution. If overdrying occurs, the mobility of the dextrose and sucrose is reduced, and thus crystallization is impeded and a gloss tends to form. On the other hand, excess moisture is to be avoided, as any free water present can be absorbed by the cereal product causing it to become sodden. The optimum moisture content, therefore, is less than or equal to the amount required to hydrate the dextrose, but, in any event, not less than about 3 to 4%. Preferably, it is the lowest workable amount, such as, for example, 4-7%.

Any method of drying may be used. It is necessary that the drying apparatus be such that it can agitate the material during the drying operation to prevent agglomeration. Examples of such are a vertical turbo-dryer or an agitated belt dryer. On a laboratory scale, the material may be air-dried under ambient conditions.

It is to be understood that the dextrose and sucrose co-crystallize and are not believed to form mixed crystals. In addition, it is not to be expected that all of the sugars present will crystallize, but that a substantial portion will be crystalline, this portion being sufficient to impart the desirable frosted appearance.

The process and products of this invention are more specifically illustrated in the following nonlimiting example.

EXAMPLE

1. Preparation of Sugar Solution

The ingredients described below are heated under agitation to 90 DEG to 100 DEG C so as to completely dissolve the sugars:

>;tb;______________________________________

>;tb; Batch Number

>;tb; 1 2 3 4 5 6

>;tb;______________________________________

>;tb;Anhydrous dextrose, %

>;tb; 60.0@a)

>;tb; 20.0 74.5 56.2 65.5 23.5

>;tb;Sucrose, % 20.0@a)

>;tb; 57.4 10.5 28.1 18.8 61.2

>;tb;Distilled Water, %

>;tb; 20.0@a)

>;tb; 22.6 15.0 15.7 15.7 15.3

>;tb;Dextrose:Sucrose

>;tb; 75:25@a)

>;tb; 25.8: 87.6:

>;tb; 66.7:

>;tb; 77.7:

>;tb; 27.7:

>;tb; 74.2 12.4 33.3 22.3 72.3

>;tb;______________________________________

>;tb; @a) Calculated

Although anhydrous dextrose was used in all the above tests, there is little doubt that hydrate dextrose and liquid dextrose would also be satisfactory for solution make-up.

The solids concentration should be as high as can be transported, to minimize the drying required later; crystallization considerations limit the solids content to a maximum of about 96%. A value of 85% was selected for these tests as being the maximum which could be handled with the available equipment.

2. Preparation of Corn Flakes

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Special treatment of the corn flakes was required to determine the effect of seeding on crystallization of the sugar solutions described above. For these experiments, seeding was simulated by dusting the corn flakes with powdered, crystalline sugar (sucrose, anhydrous or hydrate dextrose). This dusting was accomplished by agitating a mixture of plain corn flakes and powdered sugar until the cereal surface was uniformly dusted, then sieving off excess sugar. The estimated seed concentration was 1.5% of the plain cereal weight. For each experiment plain corn flakes were used as an unseeded control.

The type of seed used in each of the tests is summarized as follows (U= unseeded; S= sucrose; D= dextrose; DH= hydrate dextrose):

>;tb;______________________________________

>;tb;Batch Seed

>;tb;No. Type

>;tb;______________________________________

>;tb;1 U, S

>;tb;2 U, S

>;tb;3 U, S

>;tb;4 U, S

>;tb;5 U, S, D, DH

>;tb;6 U, S, D

>;tb;______________________________________

3. Spray Application of Sugar Solution Onto Corn Flakes

For all tests, the sugar solutions were sprayed onto corn flakes by means of pneumatic atomizing nozzle (Spraying Systems Company: fluid nozzle #2850, air nozzle #64), where nitrogen was used as the atomizing gas. Sugar solution was delivered to the nozzle by pressurizing the solution-containing vessel to about 20 psig, thus forcing the solution out of the vessel through a dip tube immersed in the solution. The atomizing nitrogen pressure varied from 25-40 psig. The estimated applied sugar dosage was about 35% based on plain cereal weight. Any method by which a thin coating of sugar solution could be applied to the cereal surface would be satisfactory. In the above described configuration, vessel and atomization pressures were selected based on the characteristics of the available nozzle and convenience. Also, there is nothing significant in the use of nitrogen as the atomizaing gas; air would be as good.

To achieve a uniform distribution of sugar solution on the total cereal surface area, a commercial process would require some means of agitating the cereal during application. For these experiments, however, we were not concerned about obtaining a total coating, and no cereal agitation was used.

4. Drying the Coated Cereal flakes

Following the application of the sugar solution, the corn flakes were dried, then treated in a variety of ways to observe the effect of crystallization. Up to this point the procedures, as described previously, varied little from test to test. Because the drying operation appears to be critical to the degree of crystallization attained, this portion of the tests will be described on a test-to-test basis.

Batch 1: Dextrose:Sucrose 75:25 Unseeded, sucrose seeded

The unseeded and sucrose-seeded samples were split for drying at ambient conditions and at 71 DEG C for 45 minutes. All samples were left exposed to the atmosphere, where after a period of 2-3 days, light crystallization was observed on those samples which had been seeded. Subsequent dessication of all samples produced no visable change.


The unseeded and sucrose-seeded samples were split for drying at ambient conditions and at 60 DEG and 150 DEG C for 45 minutes. After the oven drying, all samples were left exposed to the atmosphere, where after 2 to 3 days, light crystallization was observed on all samples, seeded and unseeded, except those dried at 150 DEG C. In addition to showing no crystallization, the flakes dried at 150 DEG C turned dark brown.

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The unseeded and sucrose-seeded samples were split for drying at ambient conditions and at 60 DEG and 150 DEG C for 1 hour. All samples were left exposed to the atmosphere overnight. The next day, portions of each sample were: (1) dessicated; (2) bottled; or (3) placed in an oven at 60 DEG C for one hour. From the oven, separate samples were: (1) dessicated, (2) bottled, or (3) exposed to the atmosphere.

All corn flake samples which were initially dried at 150 DEG C turned dark brown, with no crystallization observed. All samples shich ended their treatment with dessication (except those dried at

150 DEG C) showed light crystallization. All samples (except those dried at 150 DEG C) which ended their treatment by exposure to the atmosphere showed moderate to heavy crystallization. Those samples which were bottled immediately following the second 60 DEG C treatment showed no crystallization and were very sticky.

When the immediately bottled samples failed to crystallize after about two weeks, they were opened and portions were removed and exposed to the atmosphere; the remaining portion of the samples were resealed. Those flakes exposed to the atmosphere began to crystallize after about 4 to 6 days; those remaining in the bottle did not cyrstallize.


The unseeded and sucrose-seeded samples were split for drying at ambient conditions and at 60 DEG C for one and two hours. After the drying period, all samples, except the seeded air-dried sample, were placed in dessication. The excepted sample was left exposed to the air. After 3 days, all samples were bottled. On inspection 18 days later, the only sample which had crystallized was the sample which had not been dessicated. At this point, portions from all samples were exposed to the atmosphere, with the remaining portion being immediately resealed. After an additional eight days, all samples left sealed showed no change. Those opened to the air all showed light to moderate crystallization, including those which had not been seeded.

Batch 5: Dextrose:Sucrose 75:25 Unseeded, sucrose, anhydrous and hydratedextrose seeded

The corn flakes seeded with hydrate dextrose were dried at 45 DEG, the remaining at 60 DEG C, for times from 20 to 240 minutes. After drying each sample was immediately sealed. The solids content of the coating solution was measured at each time of sampling. After 5 days, results indicated crystallization only on those samples seeded with anhydrous or hydrate dextrose. In addition, little or no crystallization was observed on those samples which were dried for longer than two hours, which corresponds to a coating solution content of 94 to 95%.

Batch 6: Dextrose:Sucrose 25:75 Unseeded, sucrose and anhydrous dextrose seeded

The three sets of coated corn flake samples, differing in seed type, were dried at 60 DEG C for times varying from 20 minutes to 18 hours. After drying each sample was immediately sealed. After 4 days, results indicated no crystallization on the unseeded samples; the sucrose and dextrose-seeded samples showed roughly equivalent degrees of crystallization.

While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, use or adaptions of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as fall within the scope of the invention.Data supplied from the esp@cenet database -

Worldwide

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10.

CA1088803 - 11/4/1980

PROCESS FOR PREPARING A PRE-COOKED FROZEN RICE PRODUCT


Inventor(s): KUNTZ JAMES T (--); MASON CHARLES R (--); WILLIAMS ROGER (--);

HENDRIX ALAN F (--)

Applicant(s): GEN FOODS CORP (--)


IP Class: A23L1/20

E Class: A23L1/182



Family: CA1088803

Equivalent: US4308295

Abstract:


A superior frozen rice product is produced by hydrating a parboiled rice, quick-cooling the hydrated rice followed by fast-freezing the cooled rice.Claims:


What is claimed is:

1. A process for preparing a pre-cooked frozen rice product which upon reheating possesses tolerance to preparation variations while still resulting in a reheated rice which exhibits distinct grains with a firm but tender texture, but without mushy, soft, sticky or gummy characteristics comprising: a. hydrating a parboiled rice to a moisture content of about 55% to 70%, the hydration being carried out at temperatures greater than about 150 DEG F; b. cooling said hydrated rice to a temperature between about 35 DEG F. and 95 DEG F. within about 30 minutes following hydration: and c. freezing said cooled rice to a temperature below about 20 DEG F. in a period of time less than about 30 minutes so as to avoid a significant amount of rupturing of the cells of the rice and wherein during freezing loss of more than 5% of the moisture content of the rice is avoided.

2. Process of claim 1 wherein the cooled rice is frozen in less than 10 minutes.

3. Process of claim 2 wherein the cooled rice is frozen to a temperature below about 10 DEG F.

4. Process of claim 2 wherein during cooling loss of more than 5% of the moisture content of the rice is avoided.

5. Process of claim 4 wherein the hydrated rice is cooled within about 10 minutes following hydration.

6. Process of claim 5 wherein the hydrated rice is cooled to a temperature between 40 DEG F. and 80

DEG F.

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7. Process of claim 6 wherein the parboiled rice is hydrated at temperatures between about 200 DEG F. and about 212 DEG F.

8. Process of claim 7 wherein the parboiled rice is hydrated to a moisture content of about 61% to 68%.

9. Process of claim 5 wherein the hydration is carried out in less than 60 minutes.

10. Process of claim 9 wherein the water used to hydrate the parboiled rice contains an effective amount of an ingredient which aids in the hydration of the rice.

11. Process of claim 5 wherein the starch of the parboiled rice is at least 90% gelatinized.

12. Process of claim 11 wherein the parboiled rice has been dried to a moisture content between about

7 and 13%.

13. Process of claim 5 further comprising adding frozen vegetables to the frozen rice.Data supplied from the esp@cenet database - Worldwide

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11.

CA1120775 - 3/30/1982

PROCESS FOR THE PREPARATION OF A HYDROLYSED PRODUCT FROM

WHOLE CORN, AND SUCH A PRODUCT


Inventor(s): CONRAD ERNST (--)

Applicant(s): LYCKEBY STAERKELSEFOERAEDLING (--)

IP Class 4 Digits: A23J

IP Class: A23J1/12

E Class: A21D13/02; A23C21/02; A23J3/34B4; A23J3/34C; A23L1/105B; C12C9/00; C12G3/02;

C13K1/06


Priority Number: SE19770011742 (19771018); SE19770012341 (19771101); SE19780008870

(19780822)

Family: CA1120775

Equivalent: US4282319; NL7810395; LU80380; JP54095760; GB2007960; FR2406665;

ES474311; DE2844896; CH644736; IT1101253; IE781984L; IE48036; GR64395

Abstract:

Abstract of CA1120775 of the disclosure The present invention relates to a process for the preparation of hydrolysed products from whole corn, and such derived products. The invention solves the problem of obtaining a protein and sugar containing product able to be filtrated whereby this is achieved by treating whole corn, as wheat, maize, rye, barley, oat, and rice, with a proteolytic enzyme to transform waterinsoluble proteins into watersoluble products, and further to treat the starch contents with an amylase free from other carbohydrate hydrolysing enzymes to form watersoluble starch products, as mono and disaccharides, removing the bran fraction and removing water to obtain a dry, semimoist, or liquid but concentrated derived product. The product is to be added as a sweltening agent in food products as bread, drinks, and cereal products, whereby the bran obtained can be used in bread as fiber additive.Description:


The present invention relates to a process for the preparation of a product and/or products from whole corn by means of enzymatic hydrolysis and such product and/or products.

It is known to use corn, preferably rice, maize, and wheat, (besides the common use as flour, grain, flakes and the like) for preparation of products from their main components, starch and proteins or to use them as such. Isolated starch is used in preparation of starch syrup or starch sugar by means of hydrolysis in acidic environment and/or by means of enzymatic treatment. Water soluble proteins present were originally used in preparation of glue but have today, due to better refining methods to higher qualities also been used in food industry.

It is thus known from the Swiss Pat. No. 514.674 to produce a product to be used in beer preparation, whereby a starch containing material is mixed with water, pH is djusted in such a way that proteolytic enzymes present in the material is released and peptisation occurs, pH is further adjusted and a heat

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stable proteolytic enzyme is added to further hydrolyse the material. The material thus obtained is then further treated to give a partial amylolysis and then a complete amylolysis by means of an amylolytic enzyme.

However, a product prepared according to said patent will not contain all the proteins and/or proteolytic products present from the beginning. After filtration, to produce a clear filtrate, it will loose most of its proteins. Such a product in unfiltrated state cannot be used in the preparation of clear products as for example stilldrinks and carbonated soft drinks.

An object of the present invention is to obtain a process for the preparation of product and/or products from whole grain, whereby especially substantially all the essential, nutritionally important proteins of the grain are present in water soluble state substantially as peptides, preferably together with the watersoluble starch hydrolysis products. These water soluble ingredients may in some products also contain all or part of the water insoluble bran parts of the whole grain and starch not converted.

However, another object of the invention is to obtain a clean bran fraction, substantially free from starch.

It is understood that also other substances present in the grain as fats, minerals and vitamins are present in the end product/products.

Grain consists substantially of starch, but also about 10-12 percent of proteins.

Conventional isolation of starch from grain involves great technical problems mainly due to the tendency of proteins, bran, germs and starch granules of gluing together. In order to separate the different parts, manufacturers therefor generally have to use a lot of water. Water which later will carry small parts from the grain and causes increased tendency of growing recipients.

According to the present invention all proteins and starch ingredients are recovered as water soluble hydrolysis products whereby mentioned problems are eliminated. Fats, salts, vitamins and minerals are recovered as well, and as a "byproduct" a fibre rich and almost starch free bran is obtained which is very suitable to stimulate a normal gastro intestinal function.

In order to increase the proteinaceous value of the end product/products, as well as the improved taste derived from hydrolysed lactose another object of the present invention is to use an aqueous medium in the process, which medium consists of whey.

The present invention is based on the fundamental idea that instead of preparing the waterinsoluble protein and starch, these main components are subjected to a process in situ, i.e. when still present in the grain mass. It is understood that the grain has to be crushed in order to make the starch and proteins available to the aqueous solution in which the treatment is to be carried out. As the crushing of the grain is made only to open the grain to make the starch and proteins available the degree of crushing is of minor importance. One can thus crush or grind eg between rollers to coarse flakes and grains down to flour and to make it as wet or dry milling.

All types of grain may be used as heat, rye, barley, oat, maize, rice and the like, whereby however, wheat is preferred.

In dry milling the bran may be sieved off, whereby, however, as will be evident from below it may be preferred to let them be present during processing.

The treatment gives also a possibility of obtaining different end products. Thus one can recover the water solubilized proteins and the water insoluble starch fraction. One may also recover the watersolubilized starch fraction per se and then the bran and waterinsoluble protein fraction per se, which latter fraction then is made water soluble.

The process of the invention thus relates to the preparation of product totally enzymatically hydrolysed from whole grain whereby substantially all of the nutritionally important protein ingredients of the grain are present in water soluble state, and, possibly, substantially all of the starch of the grain is

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present in water soluble form in the form of degraded products of starch, as well as fats, salts, vitamins and minerals, whereby the invention is characterized in that one crushes the grains and in any order or simultaneously subjects the material thus crushed to

(a) on one hand an enzymatic treatment with a proteolytic enzyme for the transformation of water insoluble proteins to water soluble degraded products whereby the enzymatic treatment is carried out using an endopeptidase to give a protein hydrolysate containing 50-60% of peptides having at least 25 amino acid residues, 35-45% of peptides having 5-20 amino acid residues and 4-8% of peptides having up to 4 amino acid residues, the protein fraction being substantially recovered in the filtrate after clear filtration

(b) on the other hand an enzymatic treatment using a starch hydrolyzing enzyme for the transformation of water insoluble starch to water soluble degraded products of starch, preferably mono and disaccharides, the enzymatic treatment being carried out using a specific amylase substantially free from other carbohydrate hydrolysing enzymes

(c) and further separating off water insoluble bran ingredients and, if present, water insoluble starch components; and

(d) further, if desired, completely or partly evaporate the solution of products thus obtaining these in dry, semimoist, or liquid but concentrated form.

A preferred embodiment of the invention is characterized in that process step (a) is carried out prior to or simultaneously with process step (b).

Another preferred embodiment of the invention is characterized in that the process is carried out at a temperature below the gelatinization temperature of the grain used.

A further preferred embodiment of the invention is characterized in that process step (b) is carried out using an .alpha.-amylase and then and/or simultaneously using an amyloglucosidase.

Another preferred embodiment of the invention is characterized in that one uses amyloglucosidase at pH 4-4.5 to transformation of starch to glucose.

A further preferred embodiment of the invention is characterized in that one uses amyloglucosidase at pH 6 for the transformation of starch to mainly maltose.

A preferred embodiment of the invention is characterized in that one moreover adds an isomerase for the partial transformation of glucose formed to fructose.

Another preferred embodiment of the invention is characterized in that the water insoluble bran components are isolated in process step (c), which components, if desired, are washed, whereby the components contain at least 60% by weight of fibres, and at most 2% by weight of residual starch.

According to another aspect the invention comprises a grain product obtained in accordance with the process, whereby it is characterized in that the proteins are present as a protein hydrolysate enzymatically obtained by an endopeptidase, whereby 50-60% of the peptides present have more than

25 amino acid residues, 35-45% of the peptides have 5-20 amino acid residues and 4-8% of the peptides have up to 4 amino acid residues, which protein hydrolysate is water soluble and capable of being substantially recovered after clear filtration, that the starch is present as enzymatically present starch hydrolysate obtained by a specific amylas substantially free from other carbohydrate hydrolysing enzymes whereby the product is present as powder, syrup or liquid in unconcentrated or concentrated form.

According to another aspect the invention comprises a bran fraction, whereby it is characterized i.e. that it consists of the bran fraction isolated from an enzymatically hydrolyzed grain, which bran fraction contains at least 60% by weight of fibres, and at most 2% by weight of starch residues.

According to a further aspect of the invention the invention comprises food products containing a grain product obtained in accordance with the process and defined in process and product definitions herein.

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Process steps (a) and (b) above may be carried out simultaneously, if so desired, but may also be carried out separately, whereby the different fractions are recovered as separate products. The enzymes used are commercially available. The transformation of water insoluble protein to water soluble products is thereby carried out using an endopeptidase and the transformation of starch to water soluble oligosaccharides is carried out using amylases, preferably .alpha.-amylas, possibly together with amyloglucosidase, whereby a high content of glucose is obtained. However, as given above, if a certain pH is selected, pH 6, a high content of maltose is obtained which is preferred in certain cases to improve flavour. Isomerase may be used in another preferred embodiment to transform part of the glucose content to fructose, whereby a crystallization of the end product is inhibited. The starch may under certain circumstances be isolated as such.

Suitable enzymes are manufactured industrially and are marketed e.g. by Novo A/S, Copenhagen, and

Miles Kalichemi, BRD. Suitable proteolytic enzymes are "Neutrase" (Novo A/S) and "HT Proteolytic"

(Miles Kalichemi). .alpha.-amylases used are "BANL 120" (Novo A/S) and "Optiamyl-L" (Miles

Kalichemi). A suitable .beta.-amylase and maltose forming enzyme, respectively is e.g. "AMG 150"

(Novo A/S) and "Optidex-L" (Miles Kalichemi). A useful isomerase is e.g. "Optisweet P" (Miles

Kalichemi).

Malted grain may be used to carry out the transformation of a starch to water soluble derivatives. In this case the grains are malted as known per se in beer and liquor production. The malted grain is mixed with water, whereupon a proteolytic enzyme is added. After protein hydrolysis transformation to water soluble starch derivatives is carried out.

According to the invention one may thus obtain a product which, after transformation in situ, contains different nutritionally important components, possibly with or without the bran fraction. According to the invention it is also possible to obtain a product which substantially consists of water soluble proteins products whereby the water insoluble protein fraction is isolated and transformated per se.

Thus a bran fraction containing ;30% of protein is possible to obtain, as well as protein hydrolysate containing 80-90% of protein.

Such a protein hydrolysate may be mixed with bran and be used in the preparation of soups. Further a pure starch fraction can be obtained, and a pure fraction containing water soluble starch products thereof as glucose and oligosaccharides and a bran fraction, which products mixed or separately isolated are of food industrial interest.

It is evident from above that the main steps of the process are carried out in an aqueous solution or suspension. For economical reasons it is desirable to evaporate the product/products obtained to a suitable water amount for obtaining the product in dry, semimoist, or liquid bust concentrated form.

The removal of excess water can be carried out in any suitable manner as e.g. by roller drying, freeze drying, and lyophilisation or the like.

According to the further object of the present invention an economically preferable way for handling whey and its nutritionally valuable content is obtained. The invention thus concerns in a preferred embodiment the use of whey or concentrated whey as aqueous medium in the process of the invention.

In industrial preparation of cheese from milk considerable amounts of whey are obtained as biproduct.

The whey is then obtained as a low concentrated solution containing about 6.5% dry matter, (5% of lactose, 1% of proteins, and 0.5% of salts).

Whey has hitherto been used to a very small extent and its main use has been as a feed additive for animal feedstuffs especially for pigs. Depending on the high water content of the whey the kidneys are subject to great strain in connection with the excretion of large water amounts and for this reason whey can only be restrictedly used as feed stuff or feed stuff additive.

It has of course been tried to reduce the water content of whey but as evident the costs are too high to evaporate so large volumes as about 93.5%. One has thus been forced to let the whey being fed to the waste water off-flow. This gives however great environmental problems, and it is, today, no longer possible to let the whey go this way depending on environmental laws and similar directions.

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One may either use whey as such or a concentrate thereof, whereby only a minor part of the water of the whey has been evaporated. According to another prepared embodiment of the invention the lactose of the whey is transformed to glucose and galactose, which transformation may take place either separately prior to the addition of the whey to the grain or may be done enzymatically together with process steps (a) and/or (b).

The transformation of lactose to glucose and galactose is preferred as in some areas of the world a great part of the population unable to utilize lactose due to lack of enzyme lactase. This is especially pronounced in many developing countries. Too high amounts of lactose in the food may even create gastro intestinal disturbances in such groups of people which can not utilize lacto.

The transformation of lactose to glucose and galactose is carried out enzymatically using a suitable lactase as e.g. "Novo Lactase" sold by Novo Industry A/S, Copenhagen, Denmark.

In the preferred process using whey products are thus obtained which are still more enriched with regard to saccharides, proteins, and nutritionally important salts.

As mentioned above all the important components of the cereal raw materialare recovered in the end product/products. The final syrup, which can be filtrated through a standard filtration procedure can be used either directly as a nutrient or in combination with other nutrients in drinks, breakfast flakes, food for children. A syrup prepared is very suitable for bread baking purposes, as it is similar to flour with regard to its constituents. The baked products obtained are positively affected with regard to colour, taste and freshness.

The syrup can also be used in beer production

The invention will be described in the following examples showing embodiments thereof.

EXAMPLE 1

0.5 g of proteolytic enzyme "Neutrase" (Novo Ind.) were dissolved in 3 liters of water having a temperature of 50 DEG C. 1500 g of coarsely crushed wheat containing 15% of water and 12% of gluten protein (N.times.6.25) were suspended in the water. After one hour at 50 DEG C. all protein had been transformed into water soluble products thereof, preferably polypeptides, whereby 55% lof the peptides contained more than 25 amino acid residues, 41% of the peptides contained 5-20 amino acid residues, and 4% of the peptides contained 1-4 amino acid residues. Thereupon 0.1 g of .alpha.amylase "BANL 120" were added and the temperature was raised to 75 DEG C. The reaction mixture was kept at 75 DEG C. for 2 hrs, whereupon it was cooled to 60 DEG C. and 0.5 g of maltose forming enzyme "Fungamyl 1600" were added. The suspension was kept at 60 DEG C. for 12 hrs. At this time

60% of maltose had been formed. Depending on the use of the final product the suspension may be sterilized by heating to about 100 DEG C. or further heated. The suspension is then sieved and undissolved husk residues are washed with water. Said water is used in following, new reaction.

The bran components thus washed are dried and the solution is evaporated to the consistency of syrup or is dried alternatively, to a powder. Yield: 85% of syrup dry matter, including dry matter of the wash water; 15% of bran dry matter.

EXAMPLE 2

0.5 g of protease "Neutrase"

0.2 g of -amylase "BANL 120", and

0.2 g of amyloglucosidase "AMG 150" were added to 3 liters of water of 65 DEG C. The temperature was kept at 65 DEG C. and 1500 g of coarsely crushed wheat were introduced. After 2 hrs all protein and all starch had been transformed to watersoluble form. pH was decreased to 5.0 by the addition of citric acid g.s. and the temperature was kept at 60 DEG C. After 24 hrs 96% of all starch present had been converted to pure glucose. pH of the suspension was increased to 6.0 by adding sodium carbonate. The solid bran fraction was sieved off

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and washed with water, and dried. The wash water was fed to a new treatment. The solution obtained was used without further treatment in the preparation of still drinks. Yield: 90% sugar/protein dry matter, calculated on the starting material, 15% of bran dry matter.

The bran fraction, which contained about 20% of water, was used without further treatment for mixing with the syrup obtained after evaporation of the solution for baking purposes or form casted with syrup or mixed and dried to a powder. The product thus obtained contained all the valuable nutrients of the wheat grain and the bran fraction. The same product may be obtained by mixing the products obtained from each of the steps (a), (b) and (c).

The bran fraction was analysed and compared with other types of bran preparations.

In the table 1 below product A is a bran fraction according to Example 2 above, product B is a common wheat bran fraction obtained at an ordinary mill, product C is a rye bran fraction, and product D is the official US "AACC Certified Food Grade Wheat Bran RO7-3691". Values given as % of dry substance.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Carbohydrate chemical analysis of bran fractions

>;tb; A B C D

>;tb;______________________________________

>;tb; Extrationable

>;tb; using 80%

>;tb; ethanol 7.7 15.0 13.0 14.5

>;tb; Ash 6.1 -- -- 5.9

>;tb; Starch@(1)

>;tb; 1.1 21.3 37.0 20.0

>;tb; Cellulose@(2)

>;tb; 13.9 14.9 13.5 10.4

>;tb; Hemicellulose@(2)

>;tb; (neutral part)

>;tb; 37.1 28.9 23.7 23.7

>;tb;Fibers

>;tb; Hemicellulose@(3)

>;tb; (acidic part) +

>;tb; pectin 2.3 -- -- 1.5

>;tb; Lignin acc. to

>;tb; Klason 10.2 14.4 15.0 5.2

>;tb;Fiberanalysis acc. to Van

>;tb;Soest:

>;tb;NDF@(4) approximative

>;tb;cellulose + hemicellu-

>;tb;lose + lignin 74.2 -- -- 44.9

>;tb;ADF@(4) approximative

>;tb;cellulose + lignin

>;tb; 22.1 -- -- 12.2

>;tb;______________________________________

>;tb; @(1) Determined enzymatically

>;tb; @(2) Determined by gas liquid chromatography using an ethanol

>;tb; extracted, starch freed sample after total hydrolysis, the glucose value

>;tb; being used approximatively for calculating the values of cellulose and

>;tb; other values of neutral sugars being used for calculating of neutral

>;tb; hemicellulose

>;tb; @(3) Determined by decarboxylation

>;tb; @(4) Not determined freed from ashes.

EXAMPLE 3

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The preparation according to Example 2 was repeated with the exception that the transformation using amyloglucosidase was carried out at pH 6 instead of pH 5, whereby the starch was recovered as maltose instead of glucose.

EXAMPLE 4

0.5 g of the proteolytic enzyme "HT Proteolytic" and 0.1 g of the .alpha.-amylase "Optiamyl-L" were added to 3 liters of water of 65 DEG C. The suspension was kept at 65 DEG C. and 1.5 kg of maize were added. The maize was coarse crushed. After 3 hours all proteins and all starch has been transformed into soluble form. The temperature was raised to 80 DEG C. and was kept there for 2 hrs.

Then the solution was cooled to 60 DEG C. and pH was adjusted to 4.5 by addition of citric acid. 0.2 g of glucose forming amyloglucosidase "Optidex-L" were added. After 24 hrs 97% of the starch present had been transformed into pure glucose. Then pH was adjusted to 6.0 by addition of sodium carbonate and from pH 6.0 to pH 7.0 by addition of magnesium hydroxide. 2 g of fructose forming isomerase enzyme "Optisweet P" were added and the temperature was kept at 60 DEG C. for another 24 hrs while pH was automatically adjusted to pH 7.0 by adding sodium carbonate.

At this moment 40% of the original amount of glucose (97%) had been transformed into fructose.

Hereby a crystallisation was inhibited, when the solution after clear filtration was evaporated to a syrup. The bran parts sieved off were washed with water and dried. The wash water was returned. pH of the solution was adjusted to about 6 by adding a small amount of citric acid and was evaporated, as mentioned above, to a syrup. Yield: 90% of a water soluble proteinaceous syrup (dry matter); 15% of bran fraction (dry matter).

EXAMPLE 5

0.2 g of proteolytic enzyme "Neutrase" were added to 3 liters of water of 65 DEG C. To the water a mixture of 0.5 kg of malted and dried wheat and 1 kg of common wheat were added, the malted wheat and the wheat having been crushed together. The mixture of wheat contained 13% of water and 11.5% of protein (N.times.6.25) of dry substance. After 1 hr at 65 DEG C. the temperature was raised to 80

DEG C. and kept at 80 DEG C. for another hour. Then the solution was cooled at 60 DEG C. and 0.5 g of amyloglucosidase "AMG 150" (Novo A/S) were added. The mixture was kept at 60 DEG C. for another 12 hrs after when the sugar amount had raised to 66 dextrose equivalents. (66 DE). Then the bran fraction was separated off by sieving washed and dried, the wash water being fed in return. The solution was evaporated to a syrup. Yield: 83% proteinacous syrup (calculated on dry matter); 17 bran dry matter.

EXAMPLE 6

0.5 g of proteolytic enzyme "Neutrase" were added to 2.5 liters of water having a temperature of 22

DEG C. 1200 g of malted, crushed barley so called malt having 6% of water and 12% of proteins

(N.times.6.25) therein calculated on dry matter, were added. The mixture was allowed to stand for 12 hrs, after when all proteins had been hydrolysed into water soluble state. The mixture was then added to 0.5 liter of water of 65 DEG C. during 15 minutes and was kept at 65 DEG C. for another 2 hrs whereby 46 dextrose equivalents (46 DE) had been obtained. The bran fraction was sieved off, washed, and dried, the wash water being returned to a new process. The solution obtained was evaporated to a syrup. Yield: 82% proteinacous syrup (dry matter). 18% bran (dry matter).

EXAMPLE 7

0.5 g of proteolytic enzyme "Neutrase" were added to 4 liters of water of 55 DEG C. 1500 g of coarsely crushed wheat were added at 55 DEG C. which temperature was kept for 1 hr at which time all gluten protein had been solubilized. The reaction temperature was raised to 75 DEG C. while adding 0.5 g of

.alpha.-amylase "BANL 120". The reaction mixture was kept at 75 DEG C. for 6 hrs, whereby all starch had been solubilized (DE-value 38). The suspension was freed from solid components by sieving. The bran fraction was washed with water. The solution obtained was evaporated to dryness

(powder). Yield: 82% of protein-sugar (dry matter), 18% of bran (dry matter).

EXAMPLE 8

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0.2 g of .alpha.-amylase "BANL 120" were added to 4 liters of water of 75 DEG C. Into the solution at

75 DEG C. 1500 g of coarsely crushed wheat were introduced. The temperature was kept at 75 DEG C. for 6 hrs, whereby all starch had been converted into watersoluble products. The temperature was lowered to 55 DEG C. and 1 g of amyloglucosidase and 1.5 g of proteolytic enzyme "Neutrase" were added. After 6 hrs all the proteins had been transformed into watersoluble state and the sugar value had increased to a DE-value of 60. The bran fraction was sieved off and washed with water. Yield: 84% of syrup (dry matter; including wash water dry substance). 18% of bran (dry matter).

EXAMPLE 9

2 kg of crushed wheat (dry matter 87%) were added to 4 liters of water containing 3 g of proteolytic enzyme "Neutrase", and were treated therein for 4 hrs at 50 DEG C. The solubilized phase containing hydrolysed proteins was separated off by centrifuging and was recovered for, if so desired, a combination with pure starch. The solid phase left in the centrifuge together with the bran components was washed with water, about 2 liters, which was recovered for a new process cycle. The solid phase was suspended in 2 liters of water was allowed to pass through a fine meshed vibration sieve. The fine ground wheat starch and the water was allowed to pass, while one bran fraction was vibrated over the sieve and was recovered.

The starch suspension was introduced into a further centrifuge provided with a suitable filtration cloth.

The aqueous phase obtained (about 2 liters) was recovered and was used in a new process cycle.

The starch was either recovered as such or hydrolysed to a syrup or sugar as described in the foregoing examples. Yield:

1200 g of starch dry matter (68.5%)

200 g of protein dry matter (11.5%)

300 g of bran dry matter (20.0%)

EXAMPLE 10

4 kg of whey containing 6.5% dry matter were heated to 60 DEG C. and 0.5 g of proteolytic enzyme,

"Neutrase" (Novo A/S) were added 1.5 kg of coarsely crushed wheat were introduced. The temperature of the mixture was kept at 60 DEG C. for 1 hr when all water insoluble protein had become water soluble derivatives. Then 0.1 g of .alpha.-amylase "BANL 120" (Novo A/S) were added and the reaction temperature was raised to 75 DEG C., which was maintained for 6 hrs, when all starch had been converted into water soluble saccharides, DE-value 38.

The temperature was lowered to 60 DEG C. and 1.0 g of amyloglucosidase "AMG 150" was added.

The reaction temperature was kept at 60 DEG C. for another 12 hrs whereby a DE-value of 66 had been obtained.

The reaction mixture was heated to 100 DEG C. for sterilization and inactivation of the enzymes, whereupon the bran fraction was sieved off by centrifuging. The solution was evaporated to a syrup and the bran fraction was dried.

The product obtained had a dry matter content of 1460 g of which 260 g were dry matter derived from whey i.e. 18%.

EXAMPLE 11

4 kg of whey containing 6.5% dry matter were heated to 40 DEG C. 0.4 g of lactase enzyme (Novo

A/S) were added and the temperature was kept at 40 DEG C. for 6 hrs. At this time the lactose of the whey had been converted to equal amounts of glucose and galactose.

The temperature was raised to 60 DEG C. and 0.5 g of proteolytic enzyme, "Neutrase" (Novo A/S) were added. 1.5 kg of coarsely crushed wheat were introduced into the reaction mixture and the following treatment was continued in accordance with Example 10 above.

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EXAMPLE 12

4 kg of whey, (6.5% dry matter), were heated to 45 DEG C. 0.5 g of lactase, 0.5 g of protease,

"Neutrase", 0,1 g of .alpha.-amylase, "BANL 120", and 0.5 g of amyloglucosidase "AMG 150" (all from Novo A/S) were introduced therein.

1000 g of coarsely crushed wheat were introduced and the reaction temperature was kept at 45 DEG C. for 5 hrs, when the lactose had been converted to glucose and galactose, and water insoluble proteins of the wheat had been converted into water soluble products.

The temperature was raised to 70 DEG C. and kept there for another 5 hrs, when all water insoluble starch had been converted into water soluble saccharides having a DE-value of 50.

The bran fraction was separated off by centrifuging, and the solution was evaporated to a syrup. The end product contained 25% of dry matter derived from whey.

EXAMPLE 13

4 kg of concentrated whey (13% dry matter) were heated to 65 DEG C. 0.5 g of proteolytic enzyme,

"Neutrase" 0.1 g of -amylase "BANL 120" and 0.5 g of amyloglucosidase "AMG 150" (all from Novo

A/S) were added.

The temperature was kept at 65 DEG C. for 12 hrs, when water insoluble protein and starch had been converted into water soluble products. The solution had a DE-value of 6.5. The bran fraction was separated off, and the solution was concentrated to a syrup, 30% of the dry matter of the syrup derived from whey.

EXAMPLE 14

4 liters of concentrated whey (20% dry matter) were kept at ambient temperature (20 DEG C.). 1 g of proteolytic enzyme "Neutrase" (Novo A/S) and 1.1 kg of crushed barley were added.

The mixture was stirred for 4 hrs when all protein had been dissolved.

Then 0.2 g of .alpha.-amylase "BANL 120" (Novo A/S) were added, and the temperature was raised to

75 DEG C. and kept at 75 DEG C. for another 4 hrs. After said 4 hrs all starch had been converted to water soluble sugar derivatives, and a DE-value of 40 was determined. The reaction mixture was sterilized at 100 DEG C. and the bran fraction was separated off.

The solution was dried to a powder. 50% of the dry matter obtained derived from whey.

EXAMPLE 15

Wheat bread having separate bran.

A wheat bread was prepared from

1000 g of water

25 g of salt

300 g of wheat syrup (DE value 65, 80% dry substance, pH 6.2) prepared acc. to Example 2.

50 g of yeast

200 g of bran obtained acc. to Example 2

1000 g of wheat flour.

The ingredients are mixed together, fermented, and baked in owen in conventional way.

The bread obtained contains 124 g of protein, whereby 100 g derives from the wheat flour. Increase about 25%.

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If the wheat flour in a normal bread is replaced by whole wheat flour such a bread will contain 150 g of bran, compared with a bread above which contains 200 g of bran. A normal bread will thereby become more "heavy" and not so porous as a bread above.

EXAMPLE 16

A milkshake was prepared from

1200 g of wheat syrup (DE-value 70, 20% dry substance, protein 11%) acc. to Example 2.

400 g milk from whole milk powder 20% dry substance.

0.1 ml of vanilla essence

The components are mixed and pH is adjusted to 6.2 using sodium bicarbonate and sterilized. The end product may be diluted with equal part of water prior to use.

EXAMPLE 17

A milkshake with cocoa flavor was prepared: 1200 g of wheat syrup acc. to Example 2 (17% dry substance) were boiled together with 15 g of cocoa powder and is then adjusted to 17% dry substance by adding water. 400 g of milk having 17% dry substance from whole milk powder are added. pH is adjusted to 6.8 using sodium bicarbonate and is sterilized. The final product is consumed in the end form.

EXAMPLE 18

A milkshake with coffee flavour was prepared:

In 1200 g of wheat syrup acc. to example 2 (13% dry substance) 7.5 g of freeze dried coffee (Nescafe,

Nestle) are dissolved. Then 400 g of whole milk (13% dry substance) are added and pH is adjusted to

6.8 using sodium bicarbonate. The solution is sterilized and consumed as such.

EXAMPLE 19

A drink with taste of beer is prepared from :

750 ml of wheat syrup (DE-value 67, 36% dry substance) acc. to example 3.

8.5 ml of hopextract (Flavoring 010977)

5.5 g of citric acid

3 g of sodium bicarbonate.

The ingredients are mixed. 70 ml thereof are diluted to 330 ml using water. Dry substance 7.5%. pH

4.1. This drink can, if desired, be brewed in a conventional way by adding common yeastculture.

EXAMPLE 20

A soft drink was prepared from:

1750 ml of wheat syrup acc. to example 2 (DE-value 67, 52% dry substance)

0.5 ml of lemon flavour (Flavoring 061271)

10 ml of grape extract (Flavoring 140278)

7 ml of mango essence

20 g of citric acid

15 g of Na-benzoate.

The ingredients are mixed and diluted to 2.500 ml using water, which gives a dry matter content of

35%, pH 4.4. The solution is filtered to clearness. 80 ml of the solution are diluted to 330 ml using carbonated water or ordinary water. It should be understood that any other flavour than in this example as cola, coffee, pear, banana etc. may be used.

EXAMPLE 21

"Fruit juice" containing protein, maltose and dextrose was prepared from:

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>;tb;______________________________________

>;tb;100 g of wheat syrup (DE 70, 42% dry substance) acc. to Ex. 2.

>;tb; 90 g of conc apple juice. (47% dry substance).

>;tb;190 g juice (44% dry substance).

>;tb;______________________________________

1.5 g of citric acid and 1 g of Na-benzoate are added. 95 g of the solution are diluted to 320 ml using water. Dry substance 13%.

In Example 21 above apple juice has been used. It should be understood that any other juice as orange, grapefruit, lemon, lime and the like juices may be used.

EXAMPLE 22

Breakfast Cereal product containing wheat syrup and bran prepared from

1000 g wheat bran made acc. to Ex. 2

250 g wheat syrup acc. to Ex. 2

10 g salt

The ingredients are mixed and the mix is dried and eventually roasted.

In the examples above, especially examples 15-18 it is evident that a syrup according to any of examples 10-14 prepared one way or the other can be used for preparation of the products.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A process for preparing in situ, enzymatically hydrolyzed protein and starch products from whole grain, comprising crushing said grain and thereafter subjecting the crushed grain to a treatment which consists essentially of both the following steps: (a) subjecting said grain to an enzymatic treatment in an aqueous medium with an endopeptidase so as to transform substantially all water-insoluble proteins present in the grain to water-soluble protein products, which thereafter are filtered and recovered from the crushed grain as a clear filtrate containing protein products containing about 50 to 60% peptides having at least 25 amino acid residues, 35 to 45% peptides having between about 5 to 20 amino acid residues and 4-8% peptides having up to 4 amino acid residues and subjecting the remaining crushed grain to (b) an enzymatic treatment in an aqueous medium with at least one starch hydrolyzing enzyme so as to transform substantially all of the water-insoluble starch fraction in the grain to water-soluble, degraded products of starch, and wherein the starch hydrolyzing enzyme is amylase substantially free from other carbohydrate hydrolyzing enzymes.

2. A process according to claim 1 wherein upon completion of process steps (a) and (b) any remaining water-insoluble husk components of said grain such as bran and water-insoluble starch components are separated.

3. A process according to claim 1, wherein the water-soluble protein products and water-soluble degraded products of starch are obtained in a dry, semimoist or liquid concentrated form by completely or partly removing any water associated with said products.

4. A process according to claim 1, wherein the water-soluble degraded products of starch obtained in step (b) are mono and disaccharides.

5. A process for preparing in situ enzymatically hydrolyzed protein and starch products from whole grain, comprising crushing said grain and thereafter subjecting the crushed grain to a treatment which consists essentially of both the following steps: (a) subjecting said grain to an enzymatic treatment in an aqueous medium with an endopeptidase so as to transform substantially all water-insoluble proteins present in the grain to water-soluble protein products, which thereafter are filtered and recovered from the crushed grain as a clear filtrate containing protein products containing about 50 to 60% peptides

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having at least 25 amino acid residues, 35 to 45% peptides having between about 5 to 20 amino acid residues and 4-8% peptides having up to 4 amino acid residues and subjecting the remaining crushed grain to (b) an enzymatic treatment in an aqueous medium with .alpha.-amylase followed sequentially by an amyloglucosidase both enzymes substantially free from other carbohydrate hydrolyzing enzymes so as to transform substantially all the water-insoluble starch fraction in the grain to water-soluble, degraded products of starch.

6. A process according to claim 5, wherein the enzymatic treatment in step (b) is carried out in an aqueous medium with .alpha.-amylase followed simultaneously by an amyloglucosidase, both enzymes substantially free from other carbohydrate hydrolyzing enzymes so as to transform substantially all of the water-insoluble starch fractions in the grain to water-soluble, degraded products of starch.

7. A process according to claim 5, wherein the amyloglucosidase is at a pH of between 4 to 4.5, so as to transform substantially all the water-insoluble starch fractions in the grain to glucose.

8. A process according to claim 7, wherein the glucose is treated with isomerase to transform the glucose to fructose.

9. A process for preparing in situ, enzymatically hydrolyzed protein and starch products from whole grain, comprising crushing said grain and thereafter subjecting the crushed grain to a treatment which consists essentially of both the following steps: (a) subjecting said grain to an enzymatic treatment in an aqueous medium containing whey with an endopeptidase so as to transform substantially all waterinsoluble proteins present in the grain to water-soluble protein products, which thereafter are filtered and recovered from the crushed grain as a clear filtrate containing protein products containing about 50 to 60% peptides having at least 25 amino acid residues, 35 to 45% peptides having between about 5 to

20 amino acid residues and 4-8% peptides having up to 4 amino acid residues and subjecting the remaining crushed grain to (b) an enzymatic treatment in an aqueous medium containing whey with at least one starch hydrolyzing enzyme so as to transform substantially all of the water-insoluble starch fraction in the grain to water-soluble, degraded products of starch, and wherein the starch hydrolyzing enzyme is amylase substantially free from other carbohydrate hydrolyzing enzymes.

10. A process according to claim 9, wherein the grain is subjected in step (a) to an enzymatic treatment in an aqueous medium containing whey with an endopeptidase and a suitable lactase so as to simultaneously transform the whey's lactose to gluclose and galactose and to transform substantially all water-insoluble proteins present in the grain to water-soluble protein products.

11. A process according to claim 2 wherein said husk component, after washing, contain at least about

60% by weight of fibers and no more than about 2% by weight of residual starch.

12. A process according to claim 5, wherein the amyloglucosidase is at a pH of 6, so as to transform substantially all the water-insoluble starch fractions in the grain to maltose.

13. A process for preparing in situ, an enzymatically hydrolyzed protein and starch product from whole grain, which thereafter may be recovered as a clear liquid, consisting essentially of crushing the grain and thereafter subjecting the crushed grain to simultaneous enzymatic treatment in an aqueous medium with an endopeptidase and at least one starch hydrolyzing enzyme which is amylase, substantially free from other carbohydrate hyrolyzed enzymes, so as to transform substantially all of the water-insoluble proteins and starch present in the grain to a water-soluble protein and degraded starch product, said water-soluble protein and degraded starch product containing about 50-60% peptides having at least 25 amino acid residues, 35-45% peptides having between 5-20 amino acid residues and 4 to 8% peptides having up to 4 amino acid residues.Data supplied from the esp@cenet database - Worldwide

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12.

CA1194359 - 10/1/1985

METHOD OF PROCESSING RICE WITH CHAFFS ATTACHED THERETO AND

UNMILLED RICE AND THE PROCESSED RICE OBTAINED THEREBY


Inventor(s): HASHIMOTO MOTOICHI (--)

Applicant(s): HASHIMOTO MOTOICHI (--)

IP Class 4 Digits: A23L; A23P

IP Class: A23L1/10; A23L1/182; A23P1/00

E Class: A23L1/182; A23L1/10H2


Priority Number: JP19820191924 (19821102)

Family: CA1194359

Equivalent: US4497839; JP59082059; GB2129277; FR2535174; ES8406856; DE3339484;

BE898130; IT1169633

Abstract:


The invention is relative to a method of processing unmilled unsprouted rice with chaffs according to which the rice is immersed in water for a predetermined time, the rice is then freed of water affixed thereto and roasted in a kiln for a predetermined time at a predetermined temperature, the rice thus roasted is steamed, pressured by rolls and freed of peeled-off chaffs, and the processed rice obtained by the method.Description:


FIELD OF THE INVENTION

This invention relates to processed food prepared from unmilled rice with chaff attached thereto. More particularly, it relates to a method of processing unmilled rice with chaff about to be sprouted and the processed rice obtained by the method that may be served to the aged, infants and invalids and stored for long periods of time for emergency use, such as after an earthquake or typhoon.


Unmilled rice, while appraised highly because of its excellent nutritive value, is not necessarily welcomed by the consuming public because of processing and storage difficulties.

In light of this, research has been done on effective processing of the unmilled rice. For example, the

Japanese Laid-open Patent Publication No. 48357/1980 discloses a method for producing keepable food from unmilled rice, according to which unmatured rice with chaffs swollen with water is dehydrated, then fried in a rotary kiln at a temperature at which the rice chaff is burst open, and pressured between a pair of rolls, while the peeled-off chaffs are removed. On the other hand, the

Japanese Laid-Open Patent Publication No. 118361/1980 discloses a method of producing precooked

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food according to which unmilled rice swollen with water is alpharized by roasting and the peeled-off chaffs are removed.

In the former method, since the chaffs are removed at an earlier processing step, the layer of rice bran containing rice germ, rice germ milk or fat, protein, inorganic matter and vitamins tends to be discarded. Thus it is not possible to completely hold the nutrients of the unmilled rice in the processed food.

In the latter method, the rice is fried and hence can be preserved for a certain time. However, the processed rice needs to be cooked again before service because it is relatively hard and therefore is not necessarily suited as emergency food.

While there are other types of the precooked keepable rice food, these are not generally preferred because they contain chemicals and food additives if they are to be preserved for prolonged time.

These types of processed rice food are not entirely satisfactory because some do not come up to the taste of many, while others are unsuitable for prolonged storage, elevated in costs because of chemicals or food additives, or lack mineral nutrients.

BRIEF DESCRIPTION OF THE INVENTION

This invention has been completed in view of the aforementioned deficiency of the prior art and with a view to providing emergency food or staple food for the aged, invalids or infants. It comprises a method of processing rice, i.e. brown rice with chaffs and unmilled rice according to which unmilled rice with chaffs about to be sprouted is immersed in water for a predetermined time, freed of water attached thereto, roasted in a kiln for a predetermined time and at a predetermined temperature, steamed and aged, pressured by rolls and then freed of peeled-off chaffs. The invention also includes the processed rice food obtained by the method.

DETAILED DESCRIPTION OF THE INVENTION

The term "unmilled rice with chaffs" is used herein to denote rice as cropped and threshed, that is, cropped rice from which ears have been removed.

In the method of the present invention, unmilled rice with chaffs which is about to be sprouted, is used as starting material. The rice grains at this stage have the greatest nutrient value because of the continued supply of the nutrients from the rice plants to the grains until the time of cropping.

The unmilled rice with chaffs at this stage consists roughly of rice hull, germ and germ milk, the germ containing vitamins, protein, fats and minerals and the germ milk containing starch.

These nutrients in the germ tend to peel off upon removal of the chaffs on account of physical stress caused during threshing and subsequent contact of rice grains with one another. For instance, fat contents in unmilled rice with chaffs may fall to 1.7 percent from 3 percent for unmilled rice with chaffs.

The nutrients (g/100 g) contained in unmilled rice per se and those in polished rice obtained upon milling are shown in the Table below.

>;tb;______________________________________

>;tb; Protein

>;tb; Fat Glucide Vitamin B1

>;tb;______________________________________

>;tb;Unmilled Rice

>;tb; 7.4 3.0 71.8 0.54

>;tb;Polished Rice

>;tb; 6.8 1.3 75.5 0.12

>;tb;______________________________________

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It is therefore apparent that the chaffs are preferably removed at the latest possible stage of processing of unmilled rice.

In view of the foregoing, unmilled rice with chaffs is immersed in water for e.g. 24 to 72 hours as a preliminary step, after which the rice is dehydrated for 12 to 24 hours and transferred to a kiln for roasting. It is preferred that water contents of approximately 25 to 40 percent in unmilled rice with chaffs be adjusted to 13 to 18 percent by the roasting process, because the rice may otherwise be collapsed in shape in the subsequent processing.

Roasting is continued for 15 to 20 minutes at a temperature of approximately 100 DEG to 140 DEG C.

The purpose of this roasting step is to get about one half (about 30 to 50 percent) of unmilled rice starch alpharized and to promote transmutation of the rice hull for steam to be absorbed more easily into rice grains.

The unmilled rice with chaffs thus roasted is steamed and flattened in shape by pressuring between a roll pair made of steel. This pressuring is carried out under heat. If unmilled rice without chaffs were subjected to such pressuring, mineral contents in unmilled rice would be lost.

The rice is flattened to minimize cooking, and to promote digestion. The processed rice may be supplied in any desired thickness according to its intended use.

After pressuring, the chaffs are ultimately removed from the rice. The chaffs may be removed easily because they are already split in the preceding pressuring step and the water contents in the chaffs are lowered (about 12 to 15 percent). For instance, unmilled rice with chaffs is dropped into air from a supply chute and separated from the chaffs under the effect of an air current. Alternatively, any suitable device may be used for separating the chaffs from the unmilled rice and automatically transferring only the rice into a storage tank.

The unmilled rice thus processed in accordance with the present invention may be adapted as food for the aged, invalids or infants, emergency food of cooking material as for instance in adjusting the density of consome soup or as relish or seasoning for meat dish.

For better understanding of the present invention, reference is now made to a preferred embodiment of the invention which is intended for illustration only and is not intended for limiting the scope of the invention.

EXAMPLE

Fresh unmilled rice with chaffs attached thereto was immersed for 36 hours in water maintained at room temperature (20 DEG to 25 DEG C.). This rice was dried in shade as it was dehydrated gradually for 12 hours. About 30 kgs of this starting rice thus swollen with water were then taken in a kiln-type roaster a little less than 1 m in diameter and about 1 m in length and roasted. The roasted rice thus obtained was aged in the tower for 20 minutes at 100 DEG to 120 DEG C. by high-pressure steam supplied from a lower steam inlet of the tower. The rice thus aged was taken out gradually from the lower part of the tower and supplied to a pair of rolls (each 30 cm in diameter and 120 cm in length) for pressuring.

The temperatures to which the rice was subjected during roasting are shown below. The ultimate water contents of the rice were in the range of from 13 to 18 percent.

>;tb;______________________________________

>;tb;initial 150 to 170 DEG C.

>;tb;after 2 minutes 100 to 120 DEG C.

>;tb;after 3 minutes 90 to 120 DEG C.

>;tb;after 7 minutes "




>;tb;______________________________________

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After pressuring, it was found that chaffs were peeled off from the rice grains almost completely. Thus, these chaffs were blown off and removed upon operation of a fan and the rice was allowed to descend in a collecting zone.

Upon analysis, the rice was found to have the following characteristics,

>;tb;______________________________________

>;tb; cooked cooked

>;tb; unmilled well milled

>;tb; Inventive

>;tb; rice rice

>;tb;______________________________________

>;tb;moisture % 15.4 63.0 65.0

>;tb;(atmospheric desiccation)

>;tb;protein (factor, 5.95) %

>;tb; 6.6 3.3 2.6

>;tb;lipid (acidolysis) %

>;tb; 1.6 1.3 0.5

>;tb;glucide % 75.3 31.4 31.7

>;tb;fiber % 0.3 0.4 0.1

>;tb;ash % 0.8 0.6 0.1

>;tb;energy per 100 g*

>;tb; 339@Kcal

>;tb; 153@Kcal

>;tb; 148@Kcal

>;tb;phosphorous,** mg

>;tb; 178 130 30

>;tb;calcium**, mg 10.2 4 2

>;tb;iron**, mg 3.96 0.5 0.1

>;tb;natrium**, mg 2.11 2 2

>;tb;vitamin B1 **

>;tb; 0.18 0.16 0.03

>;tb;vitamin B2 **

>;tb; 0.01 0.02 0.01

>;tb;degree % 98.6 -- --

>;tb;______________________________________

>;tb; *The factors of 3.41, 5.39 and 4.07 were used for protein, lipid and

>;tb; carbohydrate (glucide plus fiber), respectively.

>;tb; **mg/100 g

It is seen from above that the unmilled rice processed in accordance with the present invention (with

.alpha.-degree nearly equal to 100 percent) can be stored for prolonged time and thus used conveniently as kept or portable food. Moreover, as shown in the Example above, the glucide contents in the hull are retained in the processed rice because the unmilled rice with chaffs is pressured by rolls so that the high nutritive value is retained in the rice.

In using the inventive rice as food, a small amount of water is added to the rice. If desired, the rice may be heated with water to a rice gruel. When used as emergency food, the rice gruel may be completed in several minutes upon pouring a suitable amount of hot water to the rice. Thus the processed rice of the present invention is extremely useful as instant food in hospitals or asylum for aged for improving the diet of the aged or patients.Data supplied from the esp@cenet database - Worldwide

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13.

CA1237331 - 5/31/1988

SMOOTH, THICK, STABILIZED SAUCE AND GRAVY COMPOSITIONS

CONTAINING COMBINATIONS OF RICE STARCH AND CAROB-BEAN

FLOUR, METHOD FOR PREPARATION THEREOF AND PROCESS FOR

PREPARING CONVENIENCE FOOD PRODUCTS UTILIZING SAME


Inventor(s): FONTENEAU JEAN L (--); GERMON JEAN P (--)

Applicant(s): FLEURY MICHON (--)


IP Class: A23L1/31; A23L1/195; A23L1/39

E Class: A23L1/0526; A23L1/31K; A23L1/39



Family: CA1237331


Abstract:


Edible sauce and gravy compositions are formulated incorporating as an essential ingredient a combination of rice starch and carob-bean flour, to give the compositions desirable thickness, smoothness and stability characteristics. A method for preparing such compositions is disclosed. A process for preparing already-cooked, packaged, meat or fish-in-sauce type food products utilizing the formulated sauce and gravy compositions is also disclosed.Description:



This invention relates generally to tne formulation of novel sauce and gravy compositions. More particularly, this invention relates to such sauces and gravies derived from meat or fish stock or utilizing a wine and/or other liquid base and incorporating a novel combination of natural ingredients to impart the proper thickness, smoothness and stability. These sauces and gravies may be packaged separately and so vended for use by the consumer to embellish meat or fish dishes prepared in such manner as not to yield a sauce or gravy, such as grilled meats, or they may be used in the preparation of meat or fish-in-sauce or gravy precooked, packaged convenience food products in individual or multiple size portions which can be stored for long periods of time under refrigeration and which can be quickly and easily reheated for final serving. This invention also relates to a method for preparing such food products.


For many years, those skilled in the art of food preparation, particularly in the formulation of sauces and gravies, especially for use in packaged, convenience type, meat or fish-in-sauce or gravy food products, have sought to develop sauces and gravies possessing certain desirable properties. They have

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also sought to overcome or prevent the occurrence of certain specific problems arising in the preparation of and during the course of storage of products utilizing such compositions.

Such sauces and gravies desirably have the properties of thickness, smoothness, resistance to thermal shock and stability during storage. Resistance to thermal shock is evidenced by maintenance of consistency during variations in temperature which can range from hot to cold and back to hot during the course of preparation, storage and final serving. Stability is measured by the maintenance of aesthetic appeal and the non-occurrence of such phenomena as fat-cap formation and gel formation in the combined meat-in-sauce packaged food product during preparation or over long periods of time during the storage phase.

Customarily, modified starches, gelatin and gums such as carragheenin extract have been some of the ingredients used as thickening agents.

Thus, U.S. Pat. No. 3,598,614 discloses the use of a mixed starch, mixed starch plus gelatin or a mixture of agar and gelatin as a thickener for liquid soy sauce. The mixed starches, one of which must contain amylopectin and the other, both amylose and amylopectin, are typified by a mixture of

"glutinous" rice starch or "waxy" corn starch with tapioca, corn, potato or "common" rice starches.

Glutinous rice starch is also commonly known as "waxy" or "sweet" rice "flour". Where the starch mixture is used as the thickener, the final thickened soy sauce contains from about 3 to 15% by weight of the starch mixture which is made up from about 25 to 50% of the amylopectin-containing ingredient and from about 75 to 50% of the amylose/amylopectin-containing ingredient. Where the mixed starch is used as the thickener, it is thus evident that a high proportion of that mixture must be used to attain the desired degree of thickness to cause the thickened sauce of that invention to adhere to the food onto which it is applied and not run-off.

Similarly, U.S. Pat. No. 3,266,908 discloses a process for preparing concentrated poultry sauce or gravy compositions in which rice flour is used as a thickening agent. The products of that invention, however, contain a substantial percentage of actual poultry meat or poultry by-products and may be packaged in dry powder form for later reconstitution with water or milk, as a frozen semi-liquid or as canned gravies.

U.S. Pat. No. 3,681,094 requires the use of gelatin in the gravy mixture to give it a semi-rigid rubbery consistency necessary to support the solid phase food according to the packaging scheme of that invention.

The use of thickening agents alone, however, is not enough to achieve the unctuousness or smoothness characteristic of the sauces prepared by the great chefs. Moreover, the consistency of such sauces varies greatly with temperature. This lack of thermal stability and resistance to thermally induced shocks typically causes thermal decomposition or aesthetic changes which are an unfavorable factor from the perspective of consumer acceptability.

The food processing industry has also recognized the existence of other physical and chemical change producing conditions that may occur during the preparation and/or storage phases of such meat-ingravy type food products. Typically, the industry has sought to overcome such problems by the inclusion of various additives or preservatives in the product to minimize or prevent these changes from occurring.

Thus, for example, U.S. Pat. No. 3,843,815 discloses the use of an acid additive in a meat-in-gravy product to inhibit the formation of gelatin in the gravy during its preparation and to prevent subsequent gellification of the gravy in the container during storage. Gellification is caused by collagen in the food which has cooked out combining with moisture in the gravy.

Weak acids such as phosphoric, citric, succinic, tartaric, fumaric, adipic, acetic and lactic may be used to prevent the problem from occurring, but care must be taken to control the level of acid used to avoid significantly reducing the pH of the product, which, in turn, would produce other undesirable palatability and/or aesthetic side effects.

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Similarly, U.S. Pat. No. 3,836,685 discloses the use of a filler material incorporated with the meat portion of a packaged meat-in-gravy product to prevent migration of fat from the meat upon heating the contents, thereby avoiding the formation of a "fat-cap" or layer of fat at the surface of the contents upon cooling down after cooking.

In short, it can be said that the use of previously known thickening agents alone is insufficient to give the prepared sauces and gravies all the desired qualities and the use of specific additives to overcome various problems that occur in the preparation and storage of food products that incorporate such compositions is at best an expedient measure that often complicates matters by curing one problem but causing others.

The ideal sauce or gravy composition is one that achieves the desired results with the minimum of ingredients not essential to the gustatory aspects of the product. Moreover, it is preferable that such ingredients be "natural", as opposed to synthetic chemical additives.

We have discovered that novel mixtures of two such "natural" ingredients, namely, rice starch and carob-bean flour, when incorporated into sauce and gravy formulations, yield compositions of the highest quality possessing all the desirable gustatory and aesthetic characteristics and demonstrating none of the commonly experienced preparation and/or storage problems.

We have also developed a method for preparing food products utilizing these compositions. Until now, no one has been able to develop a simplified, integrated process for producing both the food and the sauce. Thus, although U.S. Pat. No. 3,597,228 discusses a process for preparing precooked poultry pieces which may be packaged in a reheatable container with any of various sauces, those sauces must either be prepared separately or obtained from another source, already premixed and ready for use, for inclusion in those product embodiments so requiring them. The cooking process disclosed in that invention, moreover, is a somewhat complicated two-step process involving both microwave and hotoil cooking steps. The second cooking step of that invention is required to give the cooked food the desired aesthetic qualities, especially a "browned" appearance such as results from conventional cooking methods and which is unattainable by microwave cooking alone.

Contrastingly, in the food preparation process of the present invention, we have been able to develop an integrated overall process wherein the novel sauce compositions of this invention can be prepared and utilized together with portions of cooked meat or fish to form convenient, reheatable packaged meat-or-fish-in-sauce products of the highest culinary quality. This process is advantageous in that it allows the simultaneous preparation of both food and sauce in separate but integrable steps, thereby increasing the efficiency of the operation and eliminating any dependence on outside sources of supply for the sauces. The efficiency of our process is further enhanced by the fact that the food cooking operation is simplified to a single step based on conventional cooking means, thus also resulting in products with desirable aesthetic appeal.


The sauces and gravies (hereinafter "sauces") formulated according to this invention incorporate as essential ingredients a combination of natural rice starch and carob-bean flour which we have discovered imparts to such sauces the desirable thickness, smoothness and resistance to thermal shock properties, without the need for gelatin or other thickening agents.

The "natural" rice starch used in this invention is prepared by grinding to a fine white powder hulled, de-germinated white rice. Such rice starch is contrasted to "glutinous" or "waxy" rice starches which are obtained after further processing of the rice.

The discovery that the use of combinations of natural rice starch and carob-bean flour in the formulation of sauce compositions leads to such sauces having desirable properties has made possible the preparation of meat or fish-in-sauce or gravy (hereinafter "meat-in-sauce") food products utilizing these sauces. Surprisingly, the use of these sauce compositions in such products prevents the occurrence of other problems that have been recognized in the development of such products, without the need for any other additives or special processing steps.

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The process for producing meat-in-sauce type precooked, packaged food products according to this invention surprisingly overcomes the preparation and storage problems known in the industry without the need for the inclusion of additives or preservatives in the product, as is customarily done. This is because the use of sauce compositions containing novel combinations of rice starch and carob-flour appears to prevent the occurrence of physical and chemical conditions that cause such problems.

Moreover, the use of such ingredient-containing sauces in the preparation of such food products enables the adoption of certain packaging sequencing steps heretofore found impracticable by other inventors because of the subsequent storage and/or reheating phase problems that resulted.

Thus, according to the food product preparation process of this invention, a packaged meat-in-sauce type food product can be prepared wherein the solid food phase may be placed into the container before addition of the sauce. This directly overcomes the perceived limitation as disclosed in U.S. Pat. No.

3,681,094.

In that invention it was found that preparation of a packaged food product in which the solid phase food is placed in the container first, followed by addition of the sauce or gravy thereto leads to an aesthetically unappealing product. The food products of that invention are not precooked but are cooked for final use only after packaging. It was there found that during cooking, the gravy remained on the top surface of the meat and tended to burn or boil away. The cooked-out juices from the meat were also observed to run to the bottom of the pan and did not mix sufficiently well with the rest of the gravy on top. Moreover, the existence of the gravy on top of the meat prevented it from browning during cooking. In that invention such problems were overcome by reversing the sequence of the packaging with the gravy being introduced into the container prior to the solid phase food. This, in turn, required, and the apparent novelty of that invention disclosed, the essential use of gelatin in the gravy to produce a relatively firm, gellified gravy layer on top of which the solid phase food could be supported.

The process of this invention does not have any such limitations in packaging nor does it require the use of gelatin. The sequence of packaging the food and sauce is not critical and can be performed in any order. This flexibility is a tremendous commercial advantage of this process.

The preferred embodiment of the process of preparing packaged meat-in-sauce products according to this invention incorporates a "food-then-sauce" packaging sequence, thus distinguishing it from the less flexible opposite sequence processes required by others. This flexibility is attributable primarily to the nature and composition of the sauces and gravies used and because of the precooking step utilized in our process. Thus, the difficulties earlier encountered by those practicing the art have been successfully overcome by us without the need to resort to using gelatin with its effects on the aesthetic and taste characteristics of the sauce and without the inconvenience in packaging occasioned by a need to allow the gravy or sauce phase to set to a semi-rigid, rubbery state before addition of the solid phase food.

We have not experienced any problems of sauce boiling away or burning in those instances where the sauce is added to the food since only relatively lower temperatures are required to reheat our product than would be necessary to fully cook the food as must be done in other processes where it is packaged raw or only partially cooked. Moreover, since the food is already cooked according to our invention, it is browned and thus possesses the aesthetic attributes of cooked versus raw food before packaging.

Finally, since the sauces of our invention are fully blended to their final consistency before packaging, including intermixing with the cooked-out juices of the food, and are capable of resisting changes in consistency due to thermal changes, there is no problem of inadequate or incomplete mixing of the sauce components in the container.

The food products produced according to the process of this invention and utilizing the novel combination of rice starch and carob bean flour as essential ingredients of the sauce part of the product, are ideally suited for use by large scale commercial and institutional organizations such as airlines, catering services, restaurants, hospitals and schools, where many meals must be compactly stored, quickly prepared and served with a minimum of effort and inconvenience on a frequent and recurring basis. Such products are, of course, equally well suited as a convenience food for use at home.

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The food products of this invention possess a number of desirable attributes, such as flexibility in terms of storage conditions, being refrigeratable for long periods of time while retaining the stability of their sauces; compactness and convenience of storage in easily shelved or stacked, sealed, combination container-serving trays; require no further direct handling or preparation of the food except for reheating in the container; speed and convenience in reheating with minimal time required because the foods are already cooked; and flexibility and variety in terms of menu offerings with a wide range of meat and fish in sauce or gravy entrees capable of being so prepared. A further advantage of the food products of this invention and an improvement over previously developed products is the aesthetic appeal of the final packaged product. The food is neatly and eye-appealingly arranged in the serving tray-container, and further, due to its precooked state, is already browned and possesses the visual characteristics of a fully prepared meal ready for serving. The plastic serving tray containers may be embellished with decorations to give the appearance of a serving plate thus further enhancing the consumer appeal of the product.

This contrasts sharply with the method of packaging and presentation of many previously developed meat-in-sauce type packaged food products, particularly those such as disclosed in U.S. Pat. No.

3,132,029 wherein the food is packaged in a flattened plastic pouch. While such products may possess the desirable feature of convenience they are usually only of a common variety and consumers tend to regard them as just that, convenience foods, with the result that often, at least subconsciously, they feel they are consuming a product inferior to a home-cooked or restaurant-prepared meal.

The aesthetic presentation of the food products of this invention, on the other hand, complements the wide variety of dishes, many exotic, which can be prepared according to our invention. We have prepared about 100 varieties of food dishes with their corresponding sauces according to our process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the relationship of sauce viscosity to pH at various carob bean flour levels.

FIG. 2 shows the time-sequence of steps in a method for the preparation of sauces according to this invention, as the steps occur in the sauce preparation vessel.

FIG. 3 shows the flow-sequence of steps in an integrated process for the preparation of packaged meatin-sauce convenience type food products.


During the course of testing various ingredients to develop sauces and gravies with the desired attributes of thickness and unctuousness, natural rice starch was observed to be the ingredient of choice as the primary thickening agent. Rice starch has the capability of absorbing large quantities of liquid, which property is directly responsible for its utility as a thickener. Moreover, rice starch has excellent emulsifying properties thereby making it especially useful in preparing sauces and gravies since that property enables it to physically interact with the fat used in the formulation thus producing a sauce or gravy of uniform consistency resistant to component separation. Through the preparation of various sauces and gravies with a wide range of pH values, rice starch was observed to be the only ingredient which did not undergo a change in properties with changing pH, especially in the acidic range.

Through the formulation and preparation of various sauces over a range of pH values it became possible to develop a correlation of the optimum weight percent of rice starch to be used in a given recipe as a function of pH. As acidity increases it becomes necessary to increase the amount of rice starch used.

Thus, for a red wine sauce with a pH of 6, rice starch optimally comprises 1.7 weight percent of the overall composition, while for a pork tongue sauce with a pH of 4.5, rice starch is optimally increased to 2.1 weight percent of the overall composition.

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Testing of ingredients to give the sauces the desired properties similarly revealed that carob-bean flour is the ingredient of choice to properly bind all the ingredients of the sauce together thereby giving them tremendous smoothness and consistency over a wide temperature range.

Our testing revealed the existence of a correlation between the viscosity of a sauce at a given pH and the weight percent of carob-bean flour optimally used for a given sauce recipe based on its pH. FIG. 1 shows the relationship of sauce visosity to pH at carob-bean flour levels of 0.5 and 0.88 weight percent of the total sauce composition. Of all ingredients and combinations thereof the use of rice starch and carob-bean flour in essential combination as disclosed in this invention was discovered to yield the most satisfactory sauces.

Finally, by testing sauce and gravy formulations using liquid ingredients, especially the cooked-out juices from meat or fish, having varying water hardness levels, it was observed that an inverse correlation between the viscosity of the final sauce and the hardness of the water existed. Thus, as water hardness increased, the viscosity of the composition decreased. Thus, softened water is preferably used in the preparation of sauces and gravies according to this invention.

The sauces of this invention are prepared according to a multi-step operation. FIG. 2 illustrates the time-sequence of processing steps in the method, as the steps occur in the sauce preparation vessel.

A quantity of solid fat such as lard or butter is first melted in a cooking vessel. Alternately, a fat such as heavy cream which is a liquid at room temperature may be used. Mixtures of fats may also be used.

The selection of the fat to be used is determined by the nature of the sauce to be prepared. The fat accounts for from 1.5 to 2.5 weight percent of the total sauce composition depending on the particular sauce being prepared.

Preparation of the sauce is preferably done in a "jacketed kettle" type cooking means consisting of a double-walled vessel forming an interior space for cooking and mixing the ingredients, surrounded on the sides and bottom by an exterior enclosed space into which a heating medium such as steam can be injected. Such a means is desirable because it permits good temperature control and helps prevent burning the delicate sauces as might occur were the sauces to be prepared in a vessel in direct contact with an open flame wherein poor temperature control and uneven heating could readily lead to "hot spots" in the vessel wall conducting too much heat to the contents. Alternate devices allowing careful control of the temperature may however also be employed and there is no limitation to the preparation of the sauces in such jacketed kettle type vessels.

The fat is heated to a temperature around 120 DEG C. Rice starch is then added to the hot fat so that the overall ratio of starch to fat is appproximately 50/50 by weight. The rice starch thus also accounts for from 1.5 to 2.5 weight percent of the total sauce composition depending on the particular sauce being prepared. The starch-fat mixture is cooked for several minutes, from 2 to 8 minutes and preferably from 3 to 5 minutes, still at around 120 DEG C.

At this point, the liquid phase cooking medium decanted from the separate cooking of meat or fish is added to the sauce base. This liquid is composed of either hot oil or water depending on the method of cooking the food (i.e. sauteing or boiling, respectively) and also contains the cook-out juices from the meat or fish and any optionally added bits of vegetables added for flavor. Alternatively, if the particular sauce being prepared does not call for meat or fish stock, or additionally if the recipe so calls for, other liquids, particularly wine, vinegar or juices extracted from vegetables such as mushrooms may be added to the sauce base. The total liquid phase materials added at this step account for from 70 to 90 weight percent of the total sauce composition depending on the sauce prepared. The temperature of the cooking ingredients is then reduced to around 100 DEG C.

During this phase of the sauce preparation, the rice starch expands due to the absorption of liquids from the above introduced liquid phase materials, thereby causing the sauce to thicken.

The mixture is brought to a boil, whereupon the remaining ingredients of the sauce composition, consisting of flavorings and spices and carob-bean flour, are added. Carob-bean flour accounts for from

0.3 to 1.0 weight percent of the total sauce composition depending on the sauce prepared. The flavorings and spices constitute the otherwise unaccounted for balance to bring the total of all the

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ingredients to 100 percent. The final mixture is then allowed to cook at a temperature ranging from 90

DEG C. to 100 DEG C., preferably from 95 DEG C. to 100 DEG C., for an additional period of time.

The total cooking time from the point of addition of the decanted liquid phase from the food cooking operation and/or other liquids, to addition of the remaining ingredients and completion of the cooking, ranges from 10 minutes to 30 minutes depending on the nature of the sauce being prepared.

After cooking is completed, the final sauce in the cooking vessel is energetically mixed, such as with an electric mixer for several minutes, ranging from 2 minutes to 5 minutes, depending on the type of sauce, to asssure homogenous mixing of all ingredients and even distribution of the carob-bean flour binder.

The finalized sauces, at around 80 DEG C., are pumped from the preparation vessel to sauce dosing machines and, where prepared as part of an integrated meat-in-sauce packaged convenience food product, as further described below, are utilized for the sauce dispensing operation, or alternately, the sauces may be separately packaged as for retail sale. Separately packaged sauce must be pasteurized according to the process step more fully described below.

Food products of this invention, utilizing sauces prepared as described above are produced according to a multi-step process as follows. FIG. 3 illustrates the flow-sequence of processing steps.

Raw solid food ingredients for the dish to be prepared, such as meat or fish and vegetables, are obtained in bulk in a fresh or frozen state. Preferably fresh raw materials are used to yield final food products of the highest culinary quality. Frozen raw materials may however also be used, and yield prepared dishes of acceptably high quality.

Where fresh raw materials are used, they are initially prepared by cleaning, washing, and, as appropriate, trimming of excess fat, deboning and removing of inedible or unwanted portions such as stems or leaves. Alternately, where frozen raw materials are used, initial preparation consists of thawing the ingredients.

The raw solid food ingredients, in condition for further processing, are then cut into smaller pieces or chunks for cooking. These smaller pieces are of uniform size and weight.

Cooking of the raw food is accomplished by conventional thermal methods, either by cooking in boiling water or by sauteing in hot oil. The pieces or chunks of meat or fish are placed in an appropriate cooking vessel containing either water or oil depending on the method of cooking to be used. Small pieces of vegetables such as onions and/or carrots may be added for additional flavor. The food is then cooked until the desired degree of "doneness" is achieved. Cooking by sauteing in hot oil is performed at a temperature around 180 DEG C. Cooking in boiling water is performed at a temperature around

100 DEG C. Cooking times, which depend on the method and the nature of the dish being prepared, range from 7 minutes to 2 hours.

After cooking has been completed, the cooked meat or fish is separated from the liquid phase. The remaining liquid phase consists of the water or oil cooking medium which now contains the cook-out juices from the meat or fish. The liquid also contains any optionally added vegetables. This liquid is utilized in the preparation of the sauces, as described above.

The cooked meat or fish, free from surrounding moisture, is transferred to containers, which also serve as a reheating dish and serving tray. We have found high-density polyethylene to be a material of choice for the fabrication of these containers although other heat-resistant plastics or other materials may be used. Based on measured "after-cooking" weights of the small pieces or chunks of meat or fish, the containers may be filled with a known weight of food to provide either individual or multiple serving portions. We have prepared both single-sized servings as well as containers with portions for serving 8, however this is not a limitation on the range of sizes that can be packed.

The solid food packed containers are then taken to a sauce dosing machine where sauce is added to the container. The sauce added to the containers is at a temperature around 80 DEG C. It is desirable that the sauce cover and flow around the food in the container, evenly distributing itself throughout.

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The sauce dosing machine is filled with the appropriate sauce for the dish being prepared as received from the sauce preparation vessel. The sauce dosing machine is of a type known in the food processing industry and readily commercially available. Such machines are designed to uniformly dispense a premeasured quantity of contents from a small diameter opening or spout upon the pressing of a button, release of a lever or some such action. These machines are also readily adaptable for use on an automated filling line.

Although we have found that in most instances the preferred sequence is to place the solid food portions in the containers first and add the measured amount of sauce thereto, the scope of the process of this invention, as mentioned above, is not limited to this procedure. Alternately, under certain circumstances it may be desirable to reverse the sequence and first dispense the sauce into the containers, followed by placement of the portions of meat or fish. The former method is preferable where the sauce is of low to medium viscosity, to avoid splattering of the sauce as might occur if the solid food were subsequently added. This prevents the creation of a messy, unaesthetic final package.

The alternate method is more suited to situations where a thick sauce of hign viscosity is used. Such sauces are more resistant to the impact of solid food subsequently being placed into the container and are less likely to splatter and create a messy package.

Final garnishing ingredients such as cooked bacon, cooked mushrooms and so forth may optionally be added at this point.

The food and sauce filled containers are then taken to a combined wrapping/sealing and air evacuation machine. The containers are placed in the chamber of the machine and are first covered with a plastic film. The film may be dispensed and cut from a continuous roll. The film is heat-sealed to the plastic container at around 150 DEG C.

We have found that a preferred material for the container covering is a bi-layered plastic film composed of an interiorly facing layer of polyamide bonded to an exteriorly facing layer of mediumdensity polyethylene. Such a film provides on ideal air and moisture barrier between the container contents and the environment.

The chamber of the machine is then closed and air is pumped from the containers via a small opening in the containers. The containers are evacuated at a lowered pressure in the chamber of from 400 to 600 millimeters of mercury. After the desired vacuum conditions are attained, the small openings in the containers are mechanically sealed to prevent air from being reintroduced into the containers. Creation of a vacuum in the containers helps retard oxidation and spoilage of the food during storage. The wrapping/sealing and air evacuation machine is of a type commonly used in the food processing industry. Such machines are readily-commercially available.

The sealed, hermetically-packed containers are then taken to a pasteurizing unit. The containers are there heated under carefully controlled conditions of temperature to sterilize the package and its contents. Any bacteria on the exterior of the package as well as any in the food which might cause spoilage of the food are thermally destroyed. The packages are pasteurized by immersion in a hot water bath. The bath temperature and duration of the pasteurizing step are carefully controlled. The conditions are also a function of the type of food being pasteurized. Conditions have been optimized for a wide range of food dishes. The range of hot water bath temperatures ranges from approximately

90 DEG C. to 106 DEG C. The corresponding temperatures attained in the food itself range from 80

DEG C. to 95 DEG C., respectively. The range of pasteurization times ranges from 30 minutes to 2 hours. These conditions are sufficiently stringent to destroy any bacteria without affecting the state of the food contents. It is important to ensure proper pasteurization to destroy any bacteria while avoiding too-high temperatures and too-long exposures which may overcook the already cooked food, and spoil its appearance and/or taste.

After pasteurization has been completed, the hot water bath in the unit is drained and replaced with a cool water bath to lower the temperature of the container packages as a preliminary refrigeration step.

The cool water bath, at about 15 DEG C. is maintained for about 30 to 45 minutes. The temperature of the food is reduced to about 30 DEG C.

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The cooled containers are then removed from the pasteurization unit and sent to a chilled room maintained at about 0 DEG C., for refrigerated storage. The product packages attain a temperature of around 4 DEG C. while in refrigerated storage.

The final product packages are distributed to the commercial or institutional user or retailer by refrigerated transport at a temperature not to exceed 7 DEG C.

The "shelf-life" of the final product from storage in the refrigerated room to final consumption is about

4 weeks for fish dishes and about 8 weeks for meat dishes.

The product packages may be reheated for ultimate serving by the commercial or institutional user or retail consumer either by immersion in boiling water, at 100 DEG C., or by microwave heating. The food may also be reheated in a conventional oven at less than 250 DEG C. This alternate method can be utilized with the food in the packaging tray, however, only if a non-plastic or sufficiently thermally resistant plastic container has been used. Food products packed in the standard high-density polyethylene containers may not be oven reheated.

Reheating times are a function of the method used and of the size of the portion. For a single size portion typical reheating times are 10 minutes for water-boiling and 3 minutes for microwave heating.

For an 8 portion package, reheating time is typically 30 minutes for water-boiling and 20 minutes for microwave heating.

The food product preparation process of this invention is readily adaptable to either a batch or a continuous process. A fully automated continuous processing scheme can easily be developed to produce large numbers of food product units such as is required by large-scale institutional users.

EXAMPLES

The following examples serve to illustrate several embodiments of the aspects of this invention. It is understood that the scope of the invention is, however, not limited to these examples.

EXAMPLE 1

Food and sauce for approximately 100 portions of Beef Bourguignon were prepared using the following ingredients in the amounts and percentages indicated.

Food Cooking

>;tb;______________________________________

>;tb;Beef (raw, in cubes of 54

>;tb; 17.000 kilograms

>;tb;grams each)

>;tb;Water 12.000 liters

>;tb;Red Wine 8.000 liters

>;tb;Tomato 0.275 kilograms

>;tb;______________________________________

The beef was browned in lard in a frying pan then cooked by simmering at the boiling point for two hours in the water and wine with the tomato.

After cooking, the meat was removed from the liquids and tomato. The liquids were decanted for use in the preparation of the sauce.

Sauce Preparation

Approximately 20 kilograms of sauce were prepared utilizing the lard and decanted liquids from the meat cooking.

>;tb;______________________________________

>;tb;Ingredient Weight Percent

>;tb;______________________________________

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>;tb;Lard 1.733

>;tb;Rice Starch 1.733

>;tb;Cooking Juices, Water and Red Wine

>;tb; 80.607

>;tb;Vegetables 4.210

>;tb;Flavorings and Spices 11.222

>;tb;Carob-Bean Flour 0.495

>;tb; 100.000

>;tb;______________________________________

The sauce was prepared according to the method of this invention as fully described in the specification.

Product Packaging

Individual size portions of a Beef Bourguignon meat-in-sauce food product were packaged as follows:

>;tb;______________________________________

>;tb;Cooked beef, 3 pieces


>;tb;Sauce 0.135 kilograms

>;tb;Bacon bits 0.010 kilograms

>;tb;Mushrooms 0.010 kilograms

>;tb;Total Net Weight of Food


>;tb;______________________________________

EURO BQ 26 containers were used to package the product. The packages were pasteurized at 106

DEG C. for 2 hours.

EXAMPLE 2

Food and sauce for approximately 100 portions of Stewed Chicken Bordelaise were prepared using the following ingredients in the amounts and percentages indicated.

Food Cooking

>;tb;______________________________________

>;tb;Chicken thighs and legs


>;tb;______________________________________

(approximately 190 grams each, cut in two pieces from de-boned chicken carcasses of appoximately 1 kilogram).

The chicken parts were browned with lard in a frying pan, then cooked in boiling water for 15 minutes.

The parts were then drained and cooked with the remainder of the chicken carcasses for one hour.

Sauce Preparation

Approximately 13 kilograms of sauce were prepared utilizing the lard and decanted liquids from the meat cooking.

>;tb;______________________________________

>;tb;Ingredient Weight Percent

>;tb;______________________________________

>;tb;Lard 1.602


>;tb;Cooking Juices 38.712

>;tb;Red Wine 38.712

>;tb;Vegetables 3.476

>;tb;Flavorings and Spices

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>;tb; 15.362

>;tb;Carob-Bean Flour 0.534

>;tb; 100.000

>;tb;______________________________________

The sauce was prepared according to the method of this invention as fully described in the specification.

Product Packaging

Individual size portions of a Stewed Chicken Bordelaise mean-in-sauce food product were packaged as follows:

>;tb;______________________________________

>;tb;Cooked chicken, 1 thigh piece


>;tb;and 1 leg piece

>;tb;Sauce 0.125 kilograms

>;tb;Bacon bits 0.200 kilograms

>;tb;Mushrooms 0.200 kilograms

>;tb;Total Net Weight of Food


>;tb;______________________________________

DYNO 522 containers were used to package the product.

The packages were pasteurized at 106 DEG C. for 1 hour.

EXAMPLE 3

Recipe for a Beurre Blanc (White Butter) Sauce not utilizing cook-out juices from separately cooked meat or fish.

Approximately 100 liters of sauce were prepared according to the following procedure using ingredients in the amounts specified.

Preparation of "Reduction"

>;tb;______________________________________

>;tb;Ingredients Amount (Liters)

>;tb;______________________________________

>;tb;White Wine 6.500

>;tb;Wine Vinegar 3.250

>;tb;Shallots (chopped to 6 mm pieces)

>;tb; 4.540

>;tb;Butter 1.760

>;tb; 16.050

>;tb;______________________________________

Cook entire mixture until reduced to 7.355 liters.

Sauce Composition

>;tb;______________________________________

>;tb;Ingredient Amount (Liters)

>;tb;______________________________________

>;tb;"Reduction" 7.355

>;tb;Butter (1st portion)

>;tb; 2.140


>;tb;Thick Fresh Cream

>;tb; 65.630

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>;tb;Water 12.540

>;tb;Butter (2nd portion)

>;tb; 9.460

>;tb;Carob-Bean Flour

>;tb; 0.360

>;tb;Table salt 0.940

>;tb;White pepper 0.130

>;tb; 99.855

>;tb;______________________________________

Preparation Procedure

(1) Lightly brown the shallots in butter; moisten with white vinegar and reduce.

(2) Drain shallots in strainer.

(3) Separately, make the rice starch/butter mixture combining the rice starch and first portion of butter for the sauce.

(4) Add the water, thickened fresh cream and liquid drained from the shallots.

(5) Add salt and pepper.

(6) Incorporate the second portion of butter for the sauce at a full boil and mix.

(7) Add carob flour while mixing.

(8) Add shallots, mixing with whip.

The sauce ws packed inindividual 0.240 kilogram portions using EURO BQ 26 containers and in multiple portions of 2.250 kilograms using DYNO 501 or MONO BPE 250 containers.

The packages were pasteurized at 90 DEG C. for 40 minutes.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A sauce or gravy composition comprising: a fat in an amount of about 1.5 to 2.5 weight percent; at least one liquid of water, oil, meat cook-out juice, fish cook-out juice, wine, vinegar, or vegetable juice in an amount of about 70 to 90 weight percent; rice starch in an mount of about 1.5 to 2.5 weight percent; carob-bean flour in an amount of about 0.3 to 1 weight percent; and at least one flavoring or spice in an amount of about 4 to 26.7 weight percent.

2. The sauce or gravy composition of claim 1 wherein the amounts of fat and rice starch are substantially equal.

3. The sauce or gravy composition of claim 1 wherein the fat is lard, butter, cream, or mixtures thereof.

4. A food product comprising at least one of cooked meat, fish, or vegetable portion and the sauce or gravy composition of claim 1.

5. A packaged food product which comprises the food product of claim 4 inside of a sealed package or sealed container.

6. A method for preparing a sauce or gravy composition which comprises: heating about 1.5 to 2.5 parts by weight of a fat to about 120 DEG C.; adding about 1.5 to 2.5 parts by weight of rice starch to the heated fat to form a first mixture; cooking the first mixture at 120 DEG C.; adding about 70 to 90 parts by weight of at least one liquid of water, oil, meat cook-out juice, fish cook-out juice, wine, vinegar or vegetable juice to the first mixture to form a second mixture; expanding the rice starch by contact with the liquid so as to thicken the second mixture; heating the thickened second mixture to boiling; adding about 0.3 to 1 part by weight carob-bean flour and about 4 to 26.7 parts by weight of at least one flavoring or spice to form a third mixture; cooking the third mixture for a sufficient time to obtain the desired sauce or gravy; and mixing the sauce or gravy to obtain a homogeneous composition.

7. The method of claim 6 wherein the fat and rice starch are present in equal amounts.

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8. The method of claim 6 wherein the first mixture is cooked for about 2 to 8 minutes.

9. The method of claim 6 wherein two or more of the liquids are added to the first mixture.

10. The method of claim 6 wherein the liquid includes a portion of the flavoring or spices; while the remainder of the flavoring or spices is added with the carob-bean flour to the boiling second mixture.

11. The method of claim 6 which further comprises reducing the temperature of the second mixture to about 100 DEG C. after adding the liquid.

12. The method of claim 6 wherein the total cooking time from the step where the liquid is added to the step where the desired sauce or gravy is obtained is about 10 to 30 minutes.

13. The method of claim 6 wherein the mixing of the sauce or gravy is accomplished by electric mixing means.

14. A sauce or gravy composition produced by the method of claim 6.

15. A food product comprising at least one of cooked meat, fish, or vegetable portion and the sauce or gravy composition of claim 14.


17. A method for preparing a food product which comprises preparing a food portion of at least one raw meat, fish or vegetable; cooking said food portion; and adding the sauce or gravy composition of claim 1.

18. A food product produced by the method of claim 17.

19. A packaged food product which comprises the food product of claim 18 inside of a sealed package of sealed container.

20. A method for preparing a food product which comprises preparing a food portion of at least one raw meat, fish or vegetable; cooking said food portion; preparing a sauce of gravy according to claim

6; and adding the sauce or gravy to the food portion.

21. A food product produced by the method of claim 20.


23. A method for preparing a packaged food product which comprises preparing a food product according to claim 17; placing a pre-measured quantity of the food product into a package or container; and sealing the package or container.

24. The method of claim 23 wherein the package or container comprises polyethylene.

25. A method for preparing a package food product which comprises: preparing at least one raw meat, fish or vegetable food ingredient by cleaning and then removing inedible or unwanted portions of the food ingredient; cutting the food ingredient to a predetermined size or sizes; cooking the food ingredient to the desired degree in a water or oil medium; decanting the water or oil medium to recover cook-out juices from the cooked food ingredient; preparing a sauce or gravy by: adding about 70 to 90 parts by weight of the cook out juices to a first mixture of about 1.5 to 2.5 parts by weight of a fat and about 1.5 to 2.5 parts by weight of rice starch after the first mixture is cooked at 120 DEG C. to form a second mixture; expanding the rice starch by contact with the liquid to thicken the second mixture; heating the thickened second mixture to boiling; adding about 0.3 to 1 part by weight carob-bean flour and about 4 to 26.7 parts by weight of at least one flavoring or spice to form a third mixture; cooking

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the third mixture for a sufficient time to obtain the desired sauce or gravy; and mixing the sauce or gravy to obtain a homogenous composition; placing predetermined weighed portions of the cooked food ingredient into a package or container; adding a predetermined quantity of the sauce or gravy to the container; sealing the package or container to form a sealed packaged food product; pasteurizing the product to destory any bacteria; and storing the cooled product under refrigerated conditions until subsequent reheating and serving.

26. The method of claim 25 wherein the food ingredients are obtained in a frozen state and are thawed before preparation.

27. The method of claim 25 wherein the food ingredient is cooked by sauteing in hot oil at about 180

DEG C., simmering in boiling water at about 100 DEG C., or combinations therefor.

28. The method of claim 25 wherein the food ingredient is cooked from between 7 minutes to 2 hours.

29. The method of claim 25 wherein the food ingredient is packaged in high-density polyethylene plastic containers covered by heat-sealing with a bi-layered plastic film comprising a layer of polyamide bonded to a layer of medium-density polyethylene; the polyamide side of the film facing the food ingredient.

30. The method of claim 25 wherein the packages or containers are hermetically sealed under vacuum of from 400 to 600 millimeters of mercury.

31. The method according to claim 25 wherein the pasteurization step comprises immersing the sealed packages or containers in a hot-water bath at a temperature ranging from 90 DEG C. to 106 DEG C. and for a time ranging from 30 minutes to 2 hours.

32. The method of claim 25 wherein the packaged products are stored underrefrigeration at a temperature of from 0 DEG C. to 7 DEG C. for a time ranging from 4 to 8 weeks.

33. The method of claim 25 wherein the packaged products are reheated by immersion in boiling water or by heating with microwaves.

34. The method of claim 25 wherein all processing steps are fully automated in a continuous production line.

35. A packaged food product produced by the method of claim 25.

36. A method for preparing a packaged food product which comprises: preparing at least one raw meat, fish or vegetable food ingredient by cleaning and then removing inedible or unwanted portions of the food ingredient; cutting the food ingredient to a predetermined size or sizes; cooking the food ingredient to the desired degree in a water or oil medium; decanting the water or oil medium to recover cook-out juices from the cooked food ingredient; preparing a sauce of gravy by: adding about 70 to 90 parts by weight of the cook out juices to a first mixture of about 1.5 to 2.5 parts by weight of a fat and about 1.5 to 2.5 parts by weight of rice starch after the first mixture is cooked at 120 DEG C. to form a second mixture; expanding the rice starch by contact with the liquid to thicken the second mixture; heating the thickened second mixture to boiling; adding about 0.3 to 1 part by weight carob-bean flour and about 4 to 26.7 parts by weight of at least one flavoring or spice to form a third mixture; cooking the third mixture for a sufficient time to obtain the desired sauce or gravy; and mixing the sauce or gravy to obtain a homogenous composition; adding a predetermined quantity of the sauce or gravy to the container; placing predetermined weighted portions of the cooked food ingredient into a package or container; sealing the package or container to form a sealed packaged food product; pasteurizing the product to destory any bacteria; and storing the cooled product under refrigerated conditions until subsequent reheating and serving.

37. A packaged food product produced by the method of claim 36.

38. A method for improving the thickness, smoothness and consistency of a sauce or gravy composition which comprises: adding rice starch to the composition in an amount sufficient to act as a

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primary thickening agent; and adding carob-bean flour to the composition in an amount sufficient to act as a binding agent; wherein the relative amounts of rice starch and carob-bean flour to provide a weight ratio of rice starch to carob-bean flour of between about 2.5:1 and about 5:1.

39. The method of claim 38 wherein the amount of rice starch is between about 1.5 and 2.5 weight percent of the overall composition and the amount of carob-bean flour is between about 0.3 and 1 weight percent of the overall composition.Data supplied from the esp@cenet database - Worldwide

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14.

CA2038770 - 10/4/1991

RICE PASTA


Inventor(s): HSU JAU Y (US); WEDRAL ELAINE R (US)

Applicant(s): NESTLE SA (CH)


IP Class: A23L1/16

E Class: A23L1/16; A23L1/16D



Family: AU633407

Equivalent: EP0450310; MX171794

Abstract:


Rice Pasta A process for the preparation of a rice pasta which comprises extruding or sheeting into a dough sheet a pasta mix comprising uncooked rice flour and precooked rice flour and having a maximum moisture content of 40%, followed by predrying and cutting into a pasta shape.

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15.

CA2098893 - 12/23/1993

OILY PREPARATION AND METHOD OF PRODUCTION THEREOF


Inventor(s): NIWA KOZO (JP); NIWA EMIYO (JP)

Applicant(s): NIWA EMIYO (JP)

IP Class 4 Digits: A61K; C12P

IP Class: C12P1/04; C12P21/00; A61K35/78; A61K37/02; A61K7/40

E Class: A23D9/00; A23L1/105; A23L1/172; A23L1/238; A23L1/30; A23L1/30B; A23L1/30C2;

A61K8/92C; A61K8/97; A61K8/99; A61K9/48H4; A61K35/78; A61K47/44; A61Q19/00;

A61Q19/02; C11B1/08



Family: CA2098893

Equivalent: NL9301083; JP6009421; ITTO930448; GB2268185; FR2692442; ES2049189;

DE4320526; CH686482; BE1006911; SE9302141; SE512781; NL193398C

Abstract:

Abstract not available for CA2098893Claims:

Claims of corresponding document: DE4320526

1. Ölpräparat, erhalten durch:

Erwärmen eines Getreiderohmaterials, welches Reiskeime und/oder Weizenkeime und Sojabohnen aufweist, auf eine Temperatur von nicht grösser als 100 DEG C;

Zubereiten eines feinen Pulvers aus dem erwärmten Material;

Zugabe von Koji zu dem pulverisierten Material und Aufziehen des pulverisierten Materials; und

Zugeben des so aufgezogenen Materials zu einem Ölgemisch, welches ein Pastenöl aufweist, welches man aus Sesam erhält, dass bei einer Temperatur erwärmt wurde, welche 100 DEG C nicht

überschreitet, und ein Öl aufweist, das man aus rohem Sesam erhält, wobei ein Verhältnis des

Ölgemisches zu einer Gesamtmenge des feinen Pulvers und des Ölgemisches 60 bis 95 Gew.-% ausmacht.

2. Ölpräparat nach Anspruch 1, welches ferner ein Getreiderohmaterial umfasst, welches Reiskeime und/oder Weizenkeime und Sojabohnen aufweist, welches zu feinem Pulver ohne Erwärmung und

Aufziehen verarbeitet ist.

3. Ölpräparat nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das erwärmte oder nichterwärmte

Getreiderohmaterial zusätzl zu Reiskeimen und/oder Weizenkeimen und Sojabohnen wenigstens eine

Substanz umfasst, die aus der Gruppe gewählt ist, welche Reiskleie, Hatomugi (Perlgraupen) oder

Weizen umfasst.

4. Ölpräparat nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass es zur oralen Verabreichung als eine Medizin oder als eine Gesundheitsnahrung eingekapselt ist.

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5. Verfahren zum Herstellen eines Ölpräparats, dadurch gekennzeichnet, dass das Getreiderohmaterial nach. Anspruch 1, 2 oder 3 mit Strahlen im fernen Infrarot erwärmt wird, welche eine Wellenlänge von

4 bis 14 mu m haben.

6. Verfahren zum Herstellen eines Ölpräparats, dadurch gekennzeichnet, dass das Getreiderohmaterial nach Anspruch 1, 2 oder 3 bei 20 bis 36 DEG C 2 bis 6 Tage nach der Wärmebehandlung aufgezogen wird.

7. Verfahren zum Herstellen eines Ölpräparats, dadurch gekennzeichnet, dass das feine Pulver nach

Anspruch 1, 2 oder 3 dem Ölgemisch zugegeben wird, und dass dann eine Ablagerungsbehandlung bei

20 bis 35 DEG C für 3 bis 30 Tage vorgenommen wird.Data supplied from the esp@cenet database -

Worldwide

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16.

CA2121034 - 7/8/1993

SEPARATION OF PHYTATE AND MANGANESE FROM PLANT PROTEIN

AND DIETARY FIBER USING ALUMINA


Inventor(s): MAZER TERRENCE B (US); NARDELLI CHRISTY A (US); HOGARTH

ARTHUR J C L (US); DAAB-KRZYKOWSKI ANDRE (US)

Applicant(s): ABBOTT LAB (US)

IP Class 4 Digits: A23L; A23J; C07F

IP Class: A23L1/20; A23J1/14; A23J3/00; C07F9/117; A23L1/305

E Class: A23J1/14; A23L1/211E; A23L1/308



Family: CA2121034

Equivalent: WO9312668; EP0617580; US5248765

Abstract:


2121034 9312668 PCTABS00024 A method for separating phytate and manganese from protein and dietary fiber involves treatment of an aqueous slurry of phytate-containing material at a low pH with insoluble alumina. In a batch treatment process the pH of the solution is increased, leaving phytate units attached to the alumina while freeing the protein and dietary fiber. In a column treatment process, the column containing alumina is rinsed, after the low pH treatment, with dilute acid and water to recover the protein and/or dietary fiber. This method may be employed either during the manufacture of protein and fiber isolates from flour or flakes, or for removing phytate from commercially available protein and fiber commodities. The spent alumina may be readily regenerated and reused. The method of separating manganese from rice protein using this same technology is also discussed.Description:



The present invention relates generally to a method of separating phytate and manganese from protein and dietary fiber and more particularly to a method of using alumina to separate phytate from protein and dietary fiber and to nutritional products containing the protein and dietary fiber isolated by said method.


It is desirable to remove manganese from rice protein because the inherent level of manganese in rice alone may be greater than the total desired in a nutritional product, such as a liquid nutritional formula for infants.

Phytic acid, also known as inositol hexaphosphate, is a myo-inositol molecule in which all the hydroxy groups have been replaced by phosphate groups as shown in FIG. 1. Phytic acid is the source of up to

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85% of the total phosphorus in many cereals and legumes. Phytate is the salts of phytic acid. Phytic acid is believed to reduce the bioavailability of essential minerals by forming complexes with them.

Also, it may influence the functional and nutritional value of proteins.

Aluminum is known to form complexes with phosphates. Classically, aluminum sulfate, commonly known as alum, has been used to remove inorganic phosphates in water purification processes.

Alumina (aluminum oxide, Al2 O3) is insoluble in water, practically insoluble in organic solvents, and only slightly soluble in aqueous alkaline solutions with the formation of hydroxides. The ability of the aluminum portion of the aluminum oxide to attach to the phosphate portion of phytate was the theoretical and practical basis for its initial experimental use in the reduction of phytate in proteins.

PRIOR ART

In a typical commercial process, soy proteins are extracted at slightly alkaline pH from defatted soy flake or defatted soy flour. The major protein fraction is then precipitated from the clarified extract by adjusting the pH to the isoelectric point of the proteins (pH 3.8 to 6.0). Inasmuch as the proteins are insoluble at this pH the protein curd can be separated from soluble sugars, salts, etc., by centrifugation.

To complete the purification, the protein curd is washed with water at least once at this isoelectric pH, then the protein is spray-dried either as is or after resuspension at neutral pH. Under such prior art conditions, a major portion of the phytate present in the soy flour will complex with the protein and will be present in the soy isolate. Commercial soy isolates typically have a phytate content of 2.0-2.5% and in some instances as much as 3% by weight.

The prior art contains many examples of methods of separating phytic acid, and phytates, from protein.

The desirability of an economical method of separating phytates from the more nutritional components of a food, such as maize, rice, sorghum, cowpea, soybean, cassava, coyam and yam is well established, see for example "Effect of Local Food Processing on Phytate Levels in Cassava, Cocoyam, Yam,

Maize, Sorghum, Rice, Cowpea, and Soybean", Marfo et al., Journal of Agriculture and Food

Chemistry, 38:1580-1585 (1990).

Bolley et al., U.S. Pat. No. 2,732,395, teaches a method for separating phytic acid from various oil seeds with an aqueous acid extraction at a pH near the isoelectric point of the protein (about 4.5). The phytic acid is partly dissolved at this pH and is recovered. The protein is recovered by solubilizing it at an alkaline pH, separating the insoluble portion, and precipitating the protein at a pH near the isoelectric point. The resulting protein fraction contained as much as 4% organic phosphorus, which is an indicator of a high phytate content.

"Studies on the Preparation of Soy Bean Protein Free from Phosphorus", McKinney et al., Journal of

Biological Chemistry 178:117-132 (1949), teaches that phytic acid dissociates from soy protein at pH values between 11.0 and 11.5 and forms a precipitate that may be removed by centrifugation.

Goodnight et al., U.S. Pat. No. 4,072,670, teaches that an alkali-stable complex is formed between protein and phytic acid in the acidic conditions used by Bolley et al. In an attempt to overcome this disadvantage, Goodnight et al. teaches precipitation of the phytate at pH values a little higher than those described by McKinney et al., i.e., pH values between 11.6 and 14. Phytate is then separated from the protein prior to protein precipitation at the protein isoelectric point of pH 4.5. One disadvantage of the Goodnight et al. process is that exposing proteins to such an extremely alkaline pH adversely affects the nutritive value of the protein. Also, there is a tendency to increase the undesirable formation of lysinoalanine. In addition, continuous centrifuges employed in industrial applications are unable to separate the very light phytate precipitate formed at such a high pH.

Goodnight et al., U.S. Pat. No. 4,088,795 teaches the removal of phytate by rendering the phytate insoluble at pH 10. This high of a pH is detrimental to protein. The insoluble protein is separated by centrifugation, then ultrafiltration. However; in the ultrafiltration step the protein is in the retentate.

Goodnight et al., U.S. Pat. No. 3,995,071 teaches basically the same method as U.S. Pat. No. 4,088,795 with additional heat treating steps, as well as a recipe for soy milk containing a protein isolate.

Goodnight et al., U.S. Pat. No. 4,091,120 teaches the ultrafiltration of a material containing soy protein which has already been extracted and centrifuged. During ultrafiltration the protein is collected in the

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retentate while carbohydrates and minerals are passed into the permeate. In this patent Goodnight et al., also teach formulations for nutritional products containing soy protein isolated by the process taught therein. deRham, UK Patent 1,574,110, teaches methods by which the phytic acid content of a soy protein isolate can be decreased to be in the range of 2% to 0.6%, when protein precipitation from neutral soy extract (extracted at pH 8.0) is performed at pH 5.7 instead of pH 4.5. When soy proteins are extracted at pH 2.5 and recovered at pH 4.5 the phytic acid content is reported to be 1.7%. By performing the precipitation at pH 5.5, the phytic acid content was reportedly decreased to 0.7%. The phytic acid concentration of the isolate could be decreased to 0.2% by extracting the protein at pH 11.5 and recovering it at pH 5.5. However, these methods suffer from various drawbacks, i.e. protein yield is decreased by as much as 20%, which renders them commercially impracticable.

"Phytate-Protein Interactions in Soybean Extracts and Low-Phytate Soy Protein Products", deRham et al, Journal of Food Science 44:596-600 (1979), teaches that calcium ions enhance the precipitation of soy protein at pH 11.5. Very low phytic acid concentrations could be achieved by extraction with 10%

NaCl, but these methods produced a protein isolate which is effectively unusable without desalting by dialysis or ultrafiltration. Moreover, the protein yield according to these methods is low.

"Association of Zinc with Soy Proteins as Affected by Heat and pH", Khan et al., Journal of Food

Science 55:263-266 (1990), at page 264 points out that one shortcoming of Goodnight et al. and deRham et al. is that unless most of the phytate is removed by centrifugation at pH 12.0 prior to acid precipitating the protein, isolated soy protein should be supplemented with zinc when it is the main source of zinc in the diet.

Puski et al., U.S. Pat. No. 4,697,004, teaches a soy protein preparation method in which proteins are extracted at a pH of 8 to 10 and at a temperature above 65 DEG C. The protein product contains less than about 0.3% phytic acid. Again, however, such high temperatures adversely affect the solubility and other functional properties of the proteins.

"Phytate Removal from Soy Protein Isolates Using Ion Exchange Processing Treatments", Brooks et al., Journal of Food Science 47:1280-1282 (1982), teaches a method for phytate removal from soy protein isolates using ion exchange treatments. A combination of cation and anion exchange processes is required for effective phytate removal. A dialysis step is used to remove other nonprotein components. This method, however, would be unacceptably complex and expensive for use on a commercial scale.

Enzymes, such as phytase, also have been used in the preparation of soy protein isolates. For example,

McCabe, U.S. Pat. No. 3,733,207, teaches the preparation of a soluble protein fraction having a decreased phytic acid content. Proteins are solubilized in alkaline conditions, and wheat phytase is added after lowering the pH to about 5. The protein fraction not precipitated at pH 4.5 is recovered.

The resulting protein, because of its solubility in acidic conditions, is suitable for carbonated beverages.

The enzyme treatment is long, however, requiring 24-36 hours. The phytic acid content of the protein is not reported in the patent.

Published PCT Application WO 90/08476 teaches a method of producing a phytate free, or low phytate, soy protein isolate using the enzyme phytase.

Iacobucci et al, U.S. Pat. No. 3,736,147, teaches a method of reducing phytate concentration in soy protein involving various chemical treatments in combination with ultrafiltration. The chemical treatments include hydrolysis of phytic acid by indigenous phytase at neutral pH, ultrafiltration in the presence of calcium ions at low pH, or the use of Ethylenediamine Tetraacetic Acid (EDTA) at high pH. The methods taught by Iacobucci et al. have several disadvantages. Soy globulins are known to dissociate into subunits and to be denatured at such low pH values. The use of calcium ions at low pH values requires an additional ultrafiltration step for salt removal. The high temperature (65 DEG C.) in the phytase method may decrease the solubility of the protein on either side of the isoelectric point. The lowest phosphorous content achieved is not less than 0.2%, which corresponds to 0.7% phytic acid.

The 4 methods employ very time-consuming 18-48 hour ultrafiltrations.

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Several publications, for example U.S. Pat. No. 3,728,327, contain descriptions of attempts to separate phytates from protein using ultrafiltration, but repeatedly the protein was captured in the retentate, so that either no separation was achieved or only a minor amount of separation was achieved. These separation processes were attempted not only with soybeans and soy milk, but also peanuts, cottonseed, and other vegetable sources of protein. "Ultrafiltration Studies of Foods: Part 1--The Removal of

Undesirable Components in Soymilk and the Effects on the Quality of the Spray-dried Powder", Ang et al., Food Chemistry, 20:183-189 (1986).

U.S. Pat. Nos. 4,212,799 and 4,375,431 teach the use of various forms of aluminum to bind or separate materials in protein containing substances. In each instance the aluminum is left as an ingredient of the resultant material. It is believed that intentionally adding bound or unbound aluminum to a food substance is highly undesirable because there is some evidence that the aluminum could cause health problems.

The prior art illustrates that considerable effort has been expended to develop methods to reduce the phytic acid content of soy protein. These methods, however, have suffered from various drawbacks, including inefficient phytic acid reduction, high cost, long treatment time requirements, unacceptable alterations of the treated protein, addition of aluminum to foodstuff, and incompatibility with commercial soy protein processing techniques and equipment. As a result, there continues to be a need for an improved method of producing phytate-free or low phytate isolates and concentrates of protein and dietary fiber which avoid these drawbacks.

The present invention comprises a novel and unobvious method through which low-phytate isolates and concentrates of plant protein and dietary fiber may be prepared. The invention further comprises low-phytate soy protein isolates and dietary fiber produced according to the methods and processes of the present invention and the products containing the protein isolate and dietary fiber so produced.


The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its structure and manner of operation, may best be understood by reference to the following detailed description, taken in accordance with the accompanying drawings in which:

FIG. 1 is a pictorial representation of the chemical structure of a phytic acid molecule;

FIG. 2 is a graph showing the effect of pH on the solubility of a soy protein isolate;

FIG. 3 is a graph showing the effect of pH on the phytate content of a soy protein isolate;

FIG. 4 is a graph showing the effect of pH on an acid alumina treatment of a soy protein isolate;

FIGS. 5, 6, 7, and 8 are graphs showing the effect of a two step pH alumina treatment on phytate reduction for a soy protein isolate;

FIG. 9 is a graph showing the effect of the alumina:protein ratio on phytate removal for a soy protein isolate;

FIG. 10 is a graph showing the effect of the alumina to protein ratio on phytate removal for a soy protein isolate for both conditioned and unconditioned alumina;

FIG. 11 is a graph showing the effect of a variety of conditioned aluminas on phytate reduction for a soy protein isolate; and

FIG. 12 is a graph showing the effect of using various materials to treat alumina on phytate removal from soy protein.

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When the term "phytate" is used herein and in the claims, it is understood to include salts of phytic acid or molecular complexes of phytic acid with other constituents of a food product. Phytic acid, the hexaorthomonophosphate ester of myo-inositol, occurs at fairly high levels in grains and oil seeds as the calcium magnesium salt, phytin. In soybean meal, roughly 70% of the total phosphorus is accounted for by phytin. Phytic acid will form complexes of phytate-mineral-protein and phytatemineral-dietary fiber during processing which has been shown to reduce the bioavailability of various minerals, such as zinc, magnesium, calcium, iron, etc. During the preparation of protein isolates according to conventional methods much of the phytic acid and phytates remain associated with the protein and dietary fiber in the form of complexes. Phytate removal from plant protein sources and dietary fiber is desirable because phytate phosphorous is not bioavailable as a nutritional entity to humans and it interferes with the absorption of nutritionally essential multivalent cations, such as calcium, iron and zinc. Therefore, it is desirable to eliminate or reduce the phytate content of protein and dietary fiber sources.

Numerous types of dietary fiber are currently available. Basically, dietary fiber passes through the small intestine undigested by enzymes and is a kind of natural and necessary laxative. As used herein and in the claims "dietary fiber" is understood to be all of the components of a food that are not broken down by enzymes in the human digestive tract to produce small molecular compounds which are then absorbed into the bloodstream. These components are mostly celluloses, hemicelluloses, pectin, gums, mucilages, lignin and lignin material varying in different plants according to type and age. These fibers differ significantly in their chemical composition and physical structure and subsequently their physiological function.

There is disclosed herein a method for separating phytate from flakes and flours which contain plant protein and dietary fiber which is: (a) effective--with up to 100% phytate removal; (b) quick--requiring less than 1 hour; and (c) very cost-effective--with a cost of pennies per pound of protein. Additionally, an excellent yield is achieved. For example, between 87% and 100% of the soy protein from soy flour is recovered using the method disclosed herein. The method disclosed herein has been demonstrated on soy and rice protein and dietary fiber, and can be used with commercial commodity proteins, or in otherwise conventional method5 of isolating proteins and/or dietary fibers from flour or flakes. There is also evidence that alumina may be helpful in trace metal reduction in proteins and other materials. For example, the removal of manganese from rice protein is another potential application for the method disclosed herein.

The method has been demonstrated utilizing a "batch treatment" and "column treatment" processes, but it is believed that a preferred embodiment will employ column technology.

According to one aspect of the invention disclosed herein a batch treatment method involves treating a slurry containing vegetable protein and/or dietary fiber with alumina at room temperature and at a low pH. The pH is then raised to solubilize the protein, and, in the case of a flour slurry, the dietary fiber is removed. The soluble protein is then precipitated by lowering the pH to the protein's isoelectric point

(4.5 for soy protein), and the protein can then be used as a "wet curd", or dried for later use.

According to a second aspect of the invention disclosed herein a column treatment method involves passing a continuous stream of a slurry (rather than a discrete amount in a container) through a column containing alumina. The slurry entering the column has a low pH the pH remains low throughout the process. After the stream has passed through the column, the alumina is treated with an acidic solution to flush protein from the column.

The alumina itself may be used repeatedly. There are few, if any, waste disposal problems associated with the alumina treatment process. Additionally, it is possible that myo-inositol, another commodity which is nutritionally significant, may be recovered from the alumina conditioning streams with a phytase enzyme treatment.

While any flour or protein isolate containing vegetable protein and/or dietary fiber may be used in the slurry, preferably the source of the vegetable protein is at least one plant selected from the group of plants consisting of maize, rice, sorghum, cowpeas, soybeans, cassava, coyam, peas, peanuts, oat,

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wheat, sunflowers, sesame, cotton, beans Jerusalem artichoke and yams. In the most preferred embodiments a flour comprising defatted soy flour or defatted soy flakes or a soy protein isolate is used in the slurry. As used herein and in the claims "defatted soy flour" is understood to mean both defatted soy flour and defatted soy flakes. In one preferred embodiment, the aqueous slurry comprises 1/2% to

30%, and most preferably 5% to 15%, by weight, of defatted soy flour. In another preferred embodiment, the aqueous slurry comprises 0.5% to 20%, most preferably 1% to 10%, by weight, of a soy protein isolate. As used herein and in the claims "aqueous slurry" is understood to mean a slurry comprising more than 50% water by weight. The fluid portion of the aqueous slurry may be selected from water, and aqueous saline or sulfated solutions. In a preferred embodiment using defatted soy flour or soy protein isolate the fluid is water.

The product, referred to as a protein isolate and/or dietary fiber, produced by the method which is disclosed herein has utility as an ingredient in a nutritional composition. A soy protein isolate produced by the above described process has utility as an ingredient in a nutritional product such as a non-dairy nutritional product for human infants.

The method employed for the determination of phytate in a vegetable flour, flakes, protein or dietary fiber is crucial to the accurate assessment of phytate reduction processes. No current published analytical method is sufficient to accomplish the desired quick, quantitative measurement of phytate in plant proteins and dietary fiber. Through the expenditure of a great deal of effort such a method has been developed. The procedure involves the extraction of phytate with hydrochloric or trichloroacetic acid, separation on a mixed-mode column using a sodium hydroxide gradient, and subsequent detection via suppressed conductivity.The terms "protein isolate having a low phytate content" and "dietary fiber having a low phytate content" as employed herein and in the claims are understood to mean a protein or dietary fiber product containing less than 1.0% by weight of phytate as determined by the analytical method set forth below which is hereinafter referred to as the "ion chromatographic procedure". The procedure comprises the following steps.

1. A sample of the material to be tested is weighed and extracted in 2.4% hydrochloric acid in a shaker bath for two hours. It is understood that sample weight is dependent upon the estimated concentration of phytate, i.e. the higher the estimated level of phytate the smaller the sample size should be.

2. The pH of the sample is adjusted to be greater than 8, followed by quantitative transfer and dilution to a specified volume. It is believed that persons of ordinary skill in the science of analytical chemistry will understand that the exact amount of dilution is dependent upon the estimated concentration of phytate in the sample.

3. The diluted sample is filtered through #2V Whatman filter paper and the filtrate is collected in a suitable container.

4. An aliquot of the filtrate is injected onto an OmniPacy.TM. mixed mode column, available from

Dionex Corporation, Sunnyvale, California, U.S.A. and separation is achieved utilizing a 200 mM sodium hydroxide gradient in the range of 28% to 75%, in the presence of 5% isopropyl alcohol at a flow rate of 1.0 ml per minute.

5. Detection of phytate in the sample is made via suppressed conductivity utilizing a Dionex anion micromembrane suppressor (AMMS). The micromembrane suppressor exchanges increasing sodium ions in the mobile phase with hydrogen cations from the regenerant (0.15% sulfuric acid), thereby suppressing the increasing background signal present due to the increasing sodium hydroxide concentration in the gradient. The detector then measures conductivity due to the structurally attached phosphate portion of the phytate structure.

6. The concentration of phytate in the sample is determined by comparison of chromatographic data of the sample with standards of known concentrations of phytate. For example, this analytical procedure has been successfully practiced using a Spectra Physics Model 4270 Integrator, but it is understood that any suitable equipment such as another integrating system or a chart recorder may be employed in this procedure.

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It is believed that a person of ordinary skill in the science of analytical chemistry will find it obvious to adjust sample sizes, dilutions, and so forth of materials which are to be compared, (including known concentrations), in order that the results may be plotted in an easily comparable range of values.

EXPERIMENT NUMBER 1

Initial work on phytate removal using alumina was conducted with simple phytate-in-water and phytate-in-hydrochloric acid solutions. Basic, neutral, and acidic alumina columns, (which are available from Alltech Associates, 2051 Waukegan Road, Deerfield, Illinois 60015) were wet down with deionized water and placed on a Vac-Elut.TM. vacuum manifold to allow the water to pass through. The Vac-Elut.TM. is available from Analytichem International, (Varian Sample Preparation

Products), European Technical Center Street, John's Innovative Center, Cowlegy Road, Cambridge

CB4 4WS, England. Solutions were made which contained approximately 100 ppm phytic acid in water and in 0.2% hydrochloric acid, and then 7 ml of each phytic acid type were pulled through each column one or two times using a vacuum. Eluants through the column were collected, and aliquots of each were injected into the Dionex System for phytate analysis. Samples of phytate which had not been passed through the alumina columns were also injected as "reference" solutions with which to compare the treated samples. The results of these experiments are set forth in Table I which shows that all three of the alumina types reduced the phytate level in 100 ppm phytate starting solutions. However, the most effective phytate reduction was seen using acidified phytate solutions or using the acidic alumina column with phytate in water. This indicated the necessity of acidic conditions, either with the alumina itself or with the phytate-containing solution. Results of this experiment supported the theory that alumina has utility for separating phytate from plant protein.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Through Through

>;tb; Column Once Column Twice

>;tb; Phytate Reduction

>;tb; Phytate Reduction

>;tb; Phytate Phytate Phytate Phytate

>;tb; In HCl In H2 O

>;tb; In HCl In H2 O

>;tb;______________________________________

>;tb;Acidic Alumina

>;tb; 99.2% 96.3% 100% 97.7%

>;tb;Basic Alumina

>;tb; 97.1% 12.3% 99.3% 21.7%

>;tb;Neutral Alumina

>;tb; 98.1% 49.4% 100% 71.6%

>;tb;______________________________________

PP1610 soy protein isolate was selected as the protein for further experimentation because of the widespread commercial use of this protein isolate in nutritional products for infants. PP1610 is a commercially available soy protein isolate product manufactured by Protein Technology International which is a division of Ralston Purina, 835 South 8th Street, St. Louis, Missouri 63012. (Protein

Technologies International has indicated that some time in 1991 the "trade name" of PP1610 will be changed to "SUPRO 1610"). It is believed that PP1610 is typical of commercially available soy protein isolates which are made by adjusting the pH of a soy flour slurry to about 9 in order to solubilize the protein; then centrifuging the slurry to separate a sludge of fiber and insoluble materials from a centrate containing the soluble protein; then adjusting the pH of the centrate to 4.5 to precipitate the protein; and then again centrifuging to get a sludge containing the protein. It is believed that PP1610 has had the pH adjusted to 7.0 to neutralize it.

EXPERIMENT NUMBER 2

Attempts were made to pass slurries having a variety of concentrations of the soy protein through the

Alltech alumina columns. The concentrations of soy protein in water which were used were: 0.75%,

1.25%, 2.5%, and 5% by weight. All percentages for slurries and solutions set forth herein and in the claims are by weight. Initial experiments with the soy protein slurry and alumina columns were

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disappointing. None of the slurries would pass through the columns because the alumina particles were too small and too densely packed. Additionally, the protein slurries were too viscous and contained too much insoluble material to effectively pass through the column. This problem could have been alleviated if alumina with a larger particle size had been available. Therefore a change was made in the experimental procedure and the alumina was added directly to the protein slurry in a batch process.

Alumina was removed from the Alltech columns and similar amounts of the alumina were added directly to the protein slurries, mixed well, and then samples were removed for phytate analysis. The results of this experiment are shown in Table 2 and indicate that good phytate reduction in the soy protein was achieved using this "batch treatment" procedure. However, the results of this experiment indicated that perhaps one of the limiting factors was the amount of alumina added. In this experiment each sample was treated with substantially the same amount of alumina. The treated samples were compared with untreated samples of each slurry to determine the amount of phytate reduction.

Although the relative amounts of phytate removed were similar in all slurry concentrations, the percentages removed were greater for weaker slurries since there was less protein, and thus less phytate, present initially.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;pH of Protein in Slurry

>;tb; % Phytate

>;tb;Slurry by weight Reduction

>;tb;______________________________________

>;tb;2.0 5% 0%

>;tb;4.0 5% 0%

>;tb;6.0 5% 65.2%

>;tb;8.0 5% 50.3%

>;tb;9.0 5% 6.01%

>;tb;9.0 2.5% 9.13%

>;tb;9.0 1.25% 20.4%

>;tb;9.0 0.75% 35.9%

>;tb;10.0 5% 52.3%

>;tb;______________________________________

It was observed throughout these early experiments that an unusually high amount of drift and relatively quick loss of sensitivity was seen in the ion chromatographic procedure after some of the alumina-treated samples had been injected. It was observed also that this phenomenon could be reversed by changing the 0.15% sulfuric acid regenerant, and periodically changing the AutoRegen anion cartridge on the regeneration module of the Dionex system. This effect may have been caused by the high aluminum content of the soy protein. No standard curve run was attempted, and "control" samples were run frequently to obtain a true idea of phytate content of experimental samples. Samples are therefore compared only to a "control" to determine phytate reduction, and results are not on a true

"concentration" basis. This comparison was used throughout these experiments, giving an approximate

"% reduction" in phytate levels.

Table 3 shows a comparison of the data produced by a computer-generated experimental design.

General trends in this data show that lower pH tends to be more effective in phytate removal.

Temperature, particle size, pH, aluminum:phytate ratio and protein slurry concentration were evaluated as variables. Time was not evaluated as a variable, as it was not believed that time significantly affected the phytate attachment to the alumina. Particle size had some effect, although this may have been partially due to alumina type (acid, basic, neutral). Temperature does not appear to affect phytate removal, but may have an effect on the aluminum content of the treated protein. The protein slurry concentration and aluminum:phytate ratio are significant only to the relative amounts of phytate present in each protein slurry.

>;tb; TABLE 3

>;tb;__________________________________________________________________________

>;tb;FACTORS RESULTS

>;tb; SURFACE RATIO OF

>;tb; SLURRY PHYTATE

>;tb; TEMP

>;tb; AREA ALUMINUM

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>;tb; CONCENTRATION

>;tb; CONCENTRATION

>;tb;RUN ( DEGC.)

>;tb; (m2 g)

>;tb; pH

>;tb; TO PHYTATE

>;tb; (% by weight)

>;tb; (% by weight)

>;tb;__________________________________________________________________________

>;tb; 1 35 350 7 72 5 2.07%

>;tb; 2 35 350 6 18 2.5 2.34%

>;tb; 3 35 350 3 72 3 0.20%

>;tb; 4 35 300 7 39 1 2.21%

>;tb; 5 35 350 3 6 5 N/D

>;tb; 6 35 250 4 39 3 1.38%

>;tb; 7 35 250 7 6 5 2.40%

>;tb; 8 35 350 5 39 1 0.23%

>;tb; 9 35 250 3 39 5 --

>;tb;10 35 350 7 6 5 2.04%

>;tb;11 35 250 7 6 1 2.68%

>;tb;12 35 250 7 72 3 1.63%

>;tb;13 35 250 3 6 1 0.16%

>;tb;14 50 300 7 24 3 1.64%

>;tb;15 50 250 3 39 1 0.05%

>;tb;16 50 250 5 6 5 0.90%

>;tb;17 50 300 5 72 5 0.50%

>;tb;18 50 350 3 6 1 N/D

>;tb;19 65 300 3 72 3 0.36%

>;tb;20 65 350 7 72 3 2.00%

>;tb;21 65 350 4 39 3 N/D

>;tb;22 65 250 3 72 5 0.88%

>;tb;23 65 250 7 72 5 1.91%

>;tb;24 65 300 7 39 5 --

>;tb;25 65 350 7 6 5 1.78%

>;tb;26 65 250 6 18 2.5 2.14%

>;tb;27 65 350 7 6 1 2.60%

>;tb;28 65 300 3 6 1 0.07%

>;tb;29 65 250 5 39 1 1.95%

>;tb;30 65 250 7 1 1 2.53%

>;tb;31 65 350 3 39 5 0.09%

>;tb;32 65 250 3 6 5 0.25%

>;tb;__________________________________________________________________________

EXPERIMENT NUMBER 3

The solubility of PP1610 soy protein at varying pHs was investigated. An experiment designed to determine the solubility of the PP1610 soy protein over a pH range from 1 to 12 proved to be invaluable. 1% slurries of soy protein were placed into beakers and adjusted to a pH between 1 and 12 with either hydrochloric acid or sodium hydroxide. Each slurry was then centrifuged, and the supernatant was decanted and tested for protein and phytate. Protein was determined using the Kjeldahl protein and analysis method. The Kjeldahl nitrogen/protein method is based on AOAC Method 955.04,

"Improved Kjeldahl Method for Nitrate-Free Samples". This method appears on p. 18 of the 15th edition of the AOAC official methods book. For the phytate determination, 40 g of 1% protein solution were weighed into a 125 ml Erlenmeyer flask, and 4 ml of 25% hydrochloric acid were added. The sample was extracted for two hours, and adjusted to a pH;8.5. Samples were then transferred to a 100 ml volumetric flask and brought to volume with water. Prior to injection into the chromatograph, samples were filtered through #2V Whatman filter paper. FIG. 2 is a solubility curve representing the protein concentration data collected during this experiment. FIG. 2 shows that the protein is slightly soluble from pH 1-3, very insoluble from pH 4-5, and exhibits increasing solubility with increasing pH

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above 5. Clearly, the protein is never completely soluble; even at pH 12, approximately 15% of the protein remains insoluble. FIG. 3 is a graph which illustrates the variation of the phytate concentration over this pH range. The phytate remains attached to protein over the extent of the curve.

EXPERIMENT NUMBER 4

It appeared that acid alumina, which had been treated with hydrochloric acid, would have the greatest capability to remove phytate, therefore in this experiment acid alumina was added to 1% slurries of

PP1610 at pH values of 6, 7, 8, 9, and 10. Samples of each of the slurries were treated with two grades of acid alumina (Alumina A Super 1 and Alumina A Act 1 from Universal Scientific). Phytate levels were determined for these samples. The evaluation of the effect of pH on acid alumina over a pH range of 6-10 is presented in FIG. 4 which shows that with an increase in pH of the protein solution, there was a decrease in the ability of the alumina to reduce phytate concentrations. Even at the low end of the pH range of the experiment (pH 6), phytate removal was only 30-35%, and this reduction was due to protein loss because of decreased protein solubility at lower pH.

Following a comparison of the results of protein solubility (FIG. 2) and phytate:alumina binding conditions (FIG. 4), it was concluded that a two-step pH process would be beneficial for both the removal of phytate and the recovery of protein. The theory behind a two-step pH alumina treatment for phytate removal from the protein is that the phytate:protein complex attached to the alumina at a low pH; (Phytate would probably be present as phytic acid at this low pH). When the pH was raised, the protein portion of the phytate:protein complex would solubilize, but the phytate would remain attached to the alumina.

EXPERIMENT NUMBER 5

The two step alumina treatment theory was tested with the protein solution treated with alumina at initial pH levels of 1-5, then raised to a pH of 8. Portions of 1% slurries of PP1610 soy protein were adjusted to initial pH values of 1.0, 2.0, 3.0, 4.0, and 5.0. A portion of the protein slurry at each pH was set aside for phytate testing. To the remaining slurry was added Alumina A Super I (Universal

Scientific) at an aluminum:phytate molar ratio of approximately 30:1. After allowing the alumina to react with the protein slurry, each protein solution was adjusted to a pH of 8.0 with sodium hydroxide.

Samples were then prepared for phytate and protein analyses. FIG. 5 shows the phytate reductions achieved in this experiment. Phytate was significantly reduced during this experiment, especially towards the lower end of the pH range. Protein loss at the secondary pH of 8, although less than in previous experiments, was still significant (24%-46%). This was to be expected, however, from the protein solubility curve (FIG. 2). Extrapolation using the protein solubility curve, suggested that a pH of 12 would offer the best solubility conditions; however, above pH 10, lysinoalanine is formed in the protein, and this would be a most undesirable impurity as it is believed to be nutritionally detrimental.

It was concluded from this experiment that the lower the initial pH the more effective the phytate removal.

EXPERIMENT NUMBER 6

The next experiment involving pH treatment of the protein with alumina at an initial pH of 1, then raising the secondary pH to 8.5-12.0 (two-step pH treatment) gave some very interesting results. With the successful removal of phytate and a good recovery of protein using the two-step pH process, a study of the protein redissolution step became necessary. 1% PP1610 soy protein was slurried, adjusted to a pH of 1.0 with hydrochloric acid, and split into two portions. One portion was treated by adding

Alumina A Super I portion (aluminum:phytate molar ratio approximately 30:1) and was allowed to mix well. Both the treated and untreated portions of the protein slurries were adjusted to pH secondary values of 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, and 12.0. Both the treated and untreated protein slurries were tested for phytate and protein content. FIG. 6 shows the effect of the alumina on phytate concentration across this range of secondary pH's. Clearly, the treatment is equally effective in phytate reduction from secondary pH's between 8.5 and 12. FIG. 7 shows the effect of alumina on the protein concentration across this pH range of secondary pH's, and compares the soluble protein in the treated and untreated slurries. The alumina does not obstruct protein recovery and, in fact, seems to improve protein solubility slightly above pH 10.5. FIG. 8 combines FIGS. 6 and 7, showing effective phytate removal across the range of pH's at which soy protein is soluble for efficiently practicing the invention.

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The experimental condition of choice, was, therefore, a secondary pH range between 9.2 and 9.6 to maximize protein solubility and minimize lysinoalanine formation.

EXPERIMENT NUMBER 7

Several different types of alumina from various vendors were evaluated for effectiveness in protein recovery and phytate removal. The vendors were Alcan Chemicals (Alcan) Division of Alcan

Aluminum Ltd., 4000 Development Dr. Box 250, Brookville, Ontario, Canada, BA Chemicals Ltd.,

(BA Chemicals) Division of British Alcan Aluminum, Chalfont Park, Gerrardo Cross,

Buckinghamshire, SL9 0QB Great Britain, and Universal Scientific Incorporated (Universal Scientific) of 2801 Bankers Industrial Drive, Atlanta, Georgia 30360. Zirconium was also tested because the adsorption of organic phosphates by zirconium dioxide (zirconium) and titanium dioxide (titania) has been discussed in the prior art. ("New Ceramic Titania: Selective Adsorbent for Organic Phosphates",

Hisashi et al., ANALYTICAL SCIENCES, Vol. 61 December 1990, pages 911-912) However, a source of titanium dioxide was not located and that material was not evaluated. Zirconium oxide which was approximately 93% pure was obtained from Zircoa, Inc. of 31501 Solon Road, Solon, Ohio 45139.

To evaluate their effectiveness in phytate removal similar quantities of AA100 (Alcan), AA101

(Alcan), Desisphere (Universal Scientific), AL2100 Scavenger (Universal Scientific), BACO AF220

(BA Chemicals), Alumina B Act I (Universal Scientific), Alumina Act II - III (Universal Scientific), and zirconium dioxide (AGRAIN) were added to individual 1% slurries of PP1610 soy protein. The percentage of protein recovered in comparison to an untreated control sample was determined by the

Kieldahl protein method. Table 4 shows that several different types of alumina from different vendors were found to be as effective as the Alumina A Super I (Universal Scientific) used previously, and protein recoveries were comparable for many. Clearly the source of alumina is not a point of major concern. Zirconia, by contrast, showed no major useful properties for phytate removal.

>;tb; TABLE 4

>;tb;______________________________________

>;tb; % Phytate % Protein

>;tb;Alumina Type Reduction Recovery

>;tb;______________________________________

>;tb;Alcan AA100 100% 88.2%

>;tb;Alcan AA101 100% 76.4%

>;tb;Universal Scientific Desisphere

>;tb; 42.9% 105%

>;tb;Universal Scientific AL2100

>;tb; 67.2% 103%

>;tb;BACO AF220 24.5% 106%

>;tb;Universal Scientific Alumina B ActI

>;tb; 100% 91.8%

>;tb;Universal Scientific Alumina N SuperI

>;tb; 100% 95.5%

>;tb;Universal Scientific Alumina ActII-III

>;tb; 100% 91.5%

>;tb;Zirconium Dioxide AGRAIN

>;tb; 0% 97.9%

>;tb;______________________________________

A disadvantage of treating commercially available soy protein isolates with alumina lies with protein resolubilization and the inability of any process to fully recover all of the protein in a soluble form. The batch treatment process used thus far consisted of the addition of alumina directly to the protein slurry, and then centrifugation to remove the alumina, with any insoluble protein being discarded with the alumina. This situation would not be true if a column-treatment apparatus was used. Column technology would require alumina particles considerably larger than the insoluble protein particles and the pores of the mesh bed support, thus allowing passage of the protein slurry. In either the column or the batch treatment processes, however, it would seem practical to treat the protein during its isolation from the soy flour/flakes.

The conventional process of soy protein isolate manufacture consists of adjusting the pH of a 10% soy flour slurry in water to 9.2-9.6, holding the pH for a period of approximately 45 minutes to dissolve the

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protein portion of the soy flour, and then centrifuging, at which time the fiber portion of the soy flour falls to the bottom. The liquid portion, containing the dissolved protein, is then removed and adjusted to a pH of approximately 4.5, the isoelectric point of the soy protein. The protein precipitate is centrifuged, resuspended in water to wash, and recentrifuged. The wet protein can then be spray dried, freeze dried or used as a wet curd.

Table 5 shows the results from experiments 8, 15 and 16 which are described below.

>;tb; TABLE 5

>;tb;__________________________________________________________________________

>;tb; Alumina SPI

>;tb; Alumina SPI

>;tb; Alumina SPI

>;tb; Alumina SPI

>;tb; Fibrim

>;tb; Alumina

>;tb; CNP Rice

>;tb; Alumina

>;tb;PP1610 CAN-1 CAN-2 CAN-3 CAN-4 300 Fiber Protein

>;tb; CNP

>;tb;__________________________________________________________________________

>;tb;Calcium

>;tb; 157 27.2 57.6 7.80 19.0 -- -- -- --

>;tb;Sodium

>;tb; 1033 2460 83.5 2.63 8.60 -- -- -- --

>;tb;Potassium

>;tb; 83.4 966 4224 1540 1584 -- -- -- --

>;tb;Magnesium

>;tb; 32.6 60.8 60.3 8.96 8.44 -- -- -- --

>;tb;Phosphorus

>;tb; 913 371 568 291 272 -- -- -- --

>;tb;Iron -- -- -- -- 3.26 -- -- -- --

>;tb;Zinc -- -- -- -- 1.18 -- -- -- --

>;tb;Copper

>;tb; -- -- -- -- 1.77 -- -- -- --

>;tb;Manganese

>;tb; -- -- -- -- 0.135 -- -- -- --

>;tb;Phytate

>;tb; 2.05% >;0.2% >;0.5% >;0.5% >;0.1% 1.06%

>;tb; 0.17% 0.02% 0.02%

>;tb;Yield -- 35.1% 22% 32.3% -- -- -- -- --

>;tb;Protein

>;tb; -- 76.4% 76.5% 87.0% 84.46% -- -- 54% 73%

>;tb;Ash -- -- 11.7% 3.62% 4.50% -- -- -- --

>;tb;Moisture

>;tb; -- -- 3.8% 5.12% 6.37% -- -- -- --

>;tb;Ca:P Ratio

>;tb; 0.172 0.073 0.101

>;tb; 0.026 0.070 -- -- -- --

>;tb;__________________________________________________________________________

EXPERIMENT NUMBER 8

This experiment was designed to couple the conventional method of isolating soy protein from soy flour with the alumina batch treatment process. The conventional process of protein manufacture from soy flour was adapted to include an alumina treatment in accordance with the present invention both on a bench scale and in a pilot plant. A 10% slurry of soy flour in water was adjusted to an initial pH of

1.0 with hydrochloric acid. The use of hydrochloric acid to lower the pH of the 10% soy flour slurry, would raise the chloride level of the resulting soy protein isolate. A final water rinse would reduce this chloride level. A portion of the soy flour slurry was removed for phytate testing "before alumina

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treatment". Alumina A Super I (Universal Scientific) was added to the remaining slurry and mixed well for approximately 8 minutes. The pH of the slurry was then adjusted to a secondary pH of 9.2-9.6 with sodium hydroxide, and this secondary pH was maintained (with the addition of sodium hydroxide) for

45 minutes. The use of potassium hydroxide in combination with sodium hydroxide is a way to control both the sodium and potassium content of the final soy protein; these could be reduced somewhat using a final water rinse. The slurry was then centrifuged at about 1700 rpm for 15 minutes. The supernatant was decanted and adjusted to a pH of 4.5 with hydrochloric acid. The protein precipitate, labeled

"CAN-1", was then freeze dried, weighed, and the total yield was calculated. This protein fraction was submitted for analytical characterization, the results of which are presented in Table 5.

This experiment was then repeated on a larger scale in a pilot plant environment. A 10% slurry containing approximately 20 pounds of soy flour was used to manufacture the soy isolate. Alcan

Activated Alumina AA101 was used because of limited availability in-house of Alumina A Super I.

Potassium hydroxide was used instead of sodium hydroxide for the pH adjustments because of the desirability of a low sodium content for the protein. All other aspects of the experiment remained identical to the previous bench scale experiment. This sample was labeled "CAN-2", and was submitted for relevant analyses, the results of which are presented in Table 5.

Table 5 data from CAN-1, the batch of soy protein made in the laboratory, and CAN-2, the soy protein manufactured on a larger scale in the pilot plant. Protein recovery in the CAN-2 batch was lower than the CAN-1 bench scale batch, largely because non-optimal alumina (Alcan AA101) had been used for the process. This lower protein recovery was consistent with previous findings from experiments using this alumina (Table 4). Also, since these protein isolates were not washed with water, mineral and ash levels were higher than might have otherwise been expected with commercial grade isolates.

>;tb; TABLE 7

>;tb;______________________________________

>;tb;Amino Acid Profile Comparison

>;tb;(g/100 g protein)

>;tb; Commercial

>;tb; Soy Proteins

>;tb; Alumina Soy Protein

>;tb;Amino Acid PP1610 PP750 CAN-4

>;tb;______________________________________

>;tb;Aspartic Acid

>;tb; 11.463 12.493 11.660

>;tb;*Threonine 3.712 4.266 3.821

>;tb;Serine 5.312 5.710 5.469

>;tb;Glutamic Acid

>;tb; 18.953 21.315 19.275

>;tb;Proline 5.156 5.704 5.367

>;tb;Glycine 4.037 4.445 4.215

>;tb;Alanine 4.134 4.563 4.125

>;tb;*Valine 4.027 4.566 4.374

>;tb;*Methionine

>;tb; 1.156 1.461 1.249

>;tb;*Isoleucine

>;tb; 4.029 4.733 4.368

>;tb;*Leucine 7.715 8.534 7.972

>;tb;Tyrosine 3.900 4.118 4.008

>;tb;*Phenylalanine

>;tb; 5.054 5.500 5.253

>;tb;Histidine 2.460 2.716 2.566

>;tb;*Lysine 6.033 6.454 5.900

>;tb;Arginine 7.439 8.075 7.350

>;tb;*Tryptophan

>;tb; 1.196 1.640 1.421

>;tb;Cystine 1.291 1.280 1.423

>;tb;______________________________________

>;tb; *Essential amino acids

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EXPERIMENT NUMBER 9

The object of this experiment was to determine the best aluminum-to-phytate molar ratio for effective phytate removal. Molar ratios from 3.5:1 to 550:1 aluminum:phytate were evaluated. Phytate determinations were then made on these samples. Table 6 shows an approximate conversion of molar ratios to weight-to-weight ratios.

In an industrial application the cost for this alumina treatment would be a primary concern, thus the accurate determination of alumina requirements per pound of protein for effective phytate reduction is important. The determination of these required ratios, alumina-to-protein (phytate), was made and is shown in FIG. 9. It is clear from FIG. 9 that a "sliding scale" of phytate removal could be achieved if desired. The experiment showed also that about 1.7 pounds of alumina would be required to remove

90% or more of the phytate from one pound of the commercially available soy protein isolate.

Discarding the alumina after a single use would be very costly, rendering the process unattractive from a cost standpoint. The regeneration process for the alumina which is disclosed below greatly improves cost effectiveness.

EXPERIMENT NUMBER 10

The results of the molar ratio alumina:phytate study, dictated that an alumina regeneration process would be necessary if the method disclosed herein is to be cost-effective. For this reason, the Alumina

A Activity I (Universal Scientific) was used to treat a quantity of PP1610. The "spent" alumina was then divided and samples were treated with one of the following: 1% sodium hydroxide, 10% sodium hydroxide, 1% sulfuric acid, 10% sulfuric acid, 20% sulfuric acid, 15% acetic acid, 5% hydrochloric acid, 10% hydrochloric acid, 20% hydrochloric acid, and a combination 2% sodium hydroxide/10% sulfuric acid. The treated alumina samples, as well as a "spent" alumina sample (no regeneration attempted) as a "control", were investigated using X-ray fluorescence spectroscopy to assess phosphorus attachment to the alumina. "Spent" alumina, which had been used to remove phytate from

PP1610 soy protein isolate was qualitatively compared with "conditioned" alumina sample of which had been variously treated. A comparison of the spent alumina with that which had been treated with hydrochloric acid showed only a minimal amount of the phosphorus had been removed from the alumina. Alumina which had been treated with acetic acid showed evidence of gel formation. Sodium hydroxide and sulfuric acid rinses seemed to show the most promise for removal of the phosphorus attached to the alumina, with increasing concentrations of sulfuric acid and sodium hydroxide having increasing removal effects. A combination of sodium hydroxide and sulfuric acid seemed to be the most effective in stripping the phytate/phosphorus from the alumina.


The next experiment was conducted to determine the necessity of adjusting the initial pH of the protein/flour slurry to 1.0 for alumina treatment. The alumina was soaked in pH 1.0 hydrochloric acid for about 10 minutes, rinsed, and then added to a 1% PP1610 slurry which had not been pH adjusted in any way. The slurry was mixed well for about ten minutes, the secondary pH was adjusted to 9.2-9.4 with potassium hydroxide, and the slurry was centrifuged at about 2700 RPM for five minutes. Phytate content was then determined in the supernatant. The alumina, which had been soaked in hydrochloric acid solution and added directly to a PP1610 protein slurry was, not effective in phytate removal.

Although the acid alumina did reduce the pH of the slurry from 6.7 to 4.6, the pH was not low enough to facilitate effective alumina:phytate attachment.


The effects of initial pH on the alumina-phytate reaction was the emphasis of the next experiment. The alumina was added to the 1% PP1610 slurry at initial pH values of 1.0, 1.5, 2.0, 3.0, 5.0, and "as is", and was allowed to mix well. The solutions were adjusted to secondary pH's of 9.2-9.4, mixed for forty five minutes, and then the slurries were centrifuged in graduated centrifuge tubes. Phytate content of the slurries was determined in the supernatants. The results of this experiment to determine the optimal initial pH indicated that a lower initial pH value of the protein slurry resulted in a greater reduction in

90/2197

phytate content. This parameter is clearly another which may be varied to control the amount of phytate reduction in the soy protein.


This experiment evaluated the effect of soaking the alumina in aluminum sulfate solution prior to addition of the alumina to a protein slurry. Varying amounts of alumina were soaked in 5% aluminum sulfate solution for approximately ten minutes. The aluminum sulfate solution was decanted, and the alumina washed with water. The alumina was added to a 1% PP1610 soy protein isolate slurry, the initial pH was adjusted to 1.5-1.7 with hydrochloric acid, and the slurry was mixed. The secondary pH of the protein slurry was then adjusted to 9.2-9.4 with potassium hydroxide, mixed well, then centrifuged. A determination of phytate was made in the usual fashion, and the phytate removal efficiency was observed to be greater than that of untreated alumina. It was unknown whether this improved attachment efficiency was because of the additional aluminum from the aluminum sulfate or the attached sulfate on the alumina surface. If the increased efficiency of the alumina was caused by the sulfate attachment, the proposed treatment of alumina with sodium hydroxide and sulfuric acid would accomplish the same sulfate attachment. "Conditioned alumina" which had been treated with sodium hydroxide and sulfuric acid was compared with "unconditioned alumina" to determine their relative effectiveness to remove phytate. FIG. 10 shows that the conditioning process improved efficiency of phytate removal by a factor of at least about 4. Although this was a significant improvement, it is unknown whether this is due to the sulfate or aluminum attachment, or a combination of both phenomena.


The effects of the "conditioning treatment" with sodium hydroxide and sulfuric acid on several alumina types were studied. Universal Scientific Alumina A Act II - III was compared with Alcoa Alumina available from ALCOA, 425 6th Avenue, Pittsburgh, Pennsylvania following treatment with 10% sodium hydroxide/10% sulfuric acid. The "conditioned" aluminas were added to 1% PP1610 in varying amounts at an initial pH of 1.0, mixed well, and then adjusted to a secondary pH 9.2-9.4 with potassium hydroxide. The solutions were centrifuged, and an analysis of phytate content was made.

This experiment was repeated with other "conditioned aluminas" such as AL2100 (Universal

Scientific) and Desisphere (Universal Scientific). The alumina treatment was also attempted using

"conditioned alumina" with no prior pH treatment of the protein slurry. The experiment using

"conditioned alumina" with no prior pH treatment of the protein slurry showed no phytate removal.

FIG. 11 shows that a number of aluminas were substantially equally effective at removing phytate, allowing a greater degree of freedom in choosing a preferred alumina for this process.

An X-ray fluorescence scan of "conditioned alumina" which had been used was compared with re-used

"conditioned alumina" and showed that phosphorus did reattach to the surface of both. This suggests that the alumina may be reused and reconditioned many times. It is speculated that reconditioning of spent alumina will yield a cost effective process. The useful lifetime of the alumina in the process using cycles of regenerating and reusing spent alumina has not been determined.

Conditioning (or re-conditioning) of the alumina with sodium hydroxide and sulfuric acid detaches the phytate/phytic acid/phosphorus from the alumina. It is possible that the rinse streams may be treated with phytase enzyme under the correct conditions to yield myo-inositol, another commodity which has nutritional value.


A bench scale batch of soy protein was again made from soy flour. A 10% soy flour slurry at an initial pH of 1.0 was treated with alumina which had been conditioned with 10% sodium hydroxide/10% sulfuric acid. The slurry mixed for approximately ten minutes before the secondary pH was adjusted to

9.2-9.6 with potassium hydroxide, and then was mixed for an additional forty five minutes. The slurry was centrifuged, the solution was decanted, and its pH was adjusted to 4.5 with hydrochloric acid. The protein was precipitated in the usual way and the liquid was decanted from the top. The protein was washed with water, centrifuged, and freeze dried. This sample was labeled "CAN-3" and subjected to a battery of analyses, the results of which are presented above in Table 5.

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Data from this batch of soy protein isolate made from soy flour ("CAN-3") looked very encouraging

(Table 5). Since this was the first alumina-treated soy protein isolate which had been washed prior to freeze-drying, mineral levels, and hence ash content, were significantly reduced over alumina-treated protein from earlier experiments. Protein isolate yield from the soy flour starting material was good at over 32% (over 91% of conventional process recovery). The Kjeldahl protein content at 87% was al so good. Aluminum was high for this batch, however, and it is conjectured that alumina fines may have carried over to the protein precipitate portion. This experiment demonstrated the use of the present invention to produce a protein isolate while simultaneously removing phytate.


In this experiment a bench scale batch of soy protein isolate was prepared using "conditioned" alumina

(Universal Scientific Alumina A Act II - III) to treat SOY flour. Hydrochloric acid and potassium hydroxide were used for the initial and secondary pH steps as described in Experiment Number 15, and the final protein precipitate was rinsed with water. Samples of the resulting protein, labeled "CAN-4" were subjected to a battery of analyses, the results of which are presented above in Table 5.

The analysis of CAN-4 confirmed a phytate-reduced soy protein isolate. Additionally, the Kjeldahl protein content of the isolate was good. Ash and chloride, as well as mineral content, were high, however, these may be reduced by a better final water rinse of the isolate. The amino acid profile of the alumina-treated soy protein isolate, as set forth in Table 7, was very similar to commercial soy protein.

>;tb; TABLE 6

>;tb;______________________________________

>;tb;Aluminum:Phytate Molar Ratio

>;tb; Alumina:Protein Weight Ratio

>;tb;______________________________________

>;tb; 3.5:1 0.01:1

>;tb; 9.0:1 0.03:1

>;tb; 18:1 0.07:1

>;tb; 36:1 0.13:1

>;tb; 90:1 0.33:1

>;tb;180:1 0.67:1

>;tb;275:1 1:1

>;tb;360:1 1.33:1

>;tb;450:1 1.67:1

>;tb;550:1 2:1

>;tb;______________________________________

It was then decided to determine the phytate content of the fiber isolated in this experiment. After the centrifugation step (after the pH has been adjusted to 9.2-9.4), the alumina resides at the bottom of the centrifuge tube, and the fiber is the layer directly above the alumina. The fiber was separated from the alumina (mostly by scraping), washed with water, and re-centrifuged. The fiber was then analyzed for its phytate content both as a wet sludge and a freeze dried material and compared with the phytate content of a commercial fiber, Fibrim 300.TM..

As shown above in Table 5 the commercial commodity Fibrim 300.TM. which is available from

Protein Technology International which is a division of Ralston Purina, contains approximately 1% phytate and the fiber produced using the alumina treatment process of soy flour contained less than

0.2% phytate. This represents a significant reduction in phytate content for fiber (;80% reduction), and a major advantage to the alumina treatment process of the present invention.


Samples of Remy rice protein flour which is available from AB Ingredients, 24 Spielman, Fairfield,

New Jersey 07004 U.S.A., which is the U.S.A. Representative of S. A. Remy Industries B-3018

Wijgmaal-Leuren-Belgium and CNP rice protein which is available from California Natural Products,

P.O. Box 1219, Lathrop, California 95330 U.S.A. were treated with alumina. The batch process, similar to that for soy protein isolate, consisted of the addition of alumina at a low initial pH (1.0) to a

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slurry, raising the pH of the slurry to a secondary pH of 9.2-9.5, centrifugation, decanting of the supernatant, and precipitation of the rice protein at a pH of 4.5. Samples of the precipitated soluble protein and insoluble materials were analyzed for protein, manganese and phytate content.

Treatment of rice proteins with alumina produced significant results. Although a large portion of the

Remy rice protein flour remained insoluble throughout the process, phytate was tested on both the soluble and insoluble components. The untreated REMY rice flour was found to contain approximately

2.2% phytate, while the alumina treated soluble portion contained approximately 0.7% phytate and the alumina treated insoluble component contained no detectable phytate. As the soluble portion of the rice protein flour was only about 3% of the total, this phytate reduction is equivalent to a 99% reduction in phytate in the total Remy rice protein flour. The CNP rice protein contained very little phytate initially

(>;0.25%), and the alumina treatment appeared to remove virtually all of the phytate that was present.

CNP rice protein, however, contains very little (if any) soluble protein. Because of the large amount of insoluble protein/fiber in these rice materials, it is believed that the use of column technology would be more practical.

The alumina treatment of the CNP rice protein was also found to remove manganese. Prior to alumina treatment, CNP rice protein was found to contain 7.62 mg/100 g manganese and have 54% protein (as determined by the Tecator kjeldahl method). After alumina treatment, the CNP rice protein contained

1.94 mg/100 g manganese with a 73% protein content. The removal of manganese from rice protein is considered to be very desirable for its use in nutritional products for infants, such as liquid formulas. It is postulated that the apparent increase in protein content of this rice protein source may be due to washing away of some of the excess minerals found in the raw commercial commodity.

Although data collected from the above experiments was from batch treatment with alumina, column technology is considered to be the preferred process. The most critical issues for column scaleup/applicability would be the size of the alumina particles and the porosity of the bed support. An alumina particle size which is greater than fiber or insoluble protein particle size, combined with a bed support with a pore size less than the particle size of the alumina but greater than the fiber or insoluble protein are critical parameters. The chemistry of alumina indicates that a wide range of aluminas will remove phytate, thus column technology could be used readily for the task.


The use of column technology for phytate removal from soy proteins was then attempted. A 2" by 24" column constructed of Lexan with a nylon screen and perforated Lexan support was made.

Approximately 900 grams of Desisphere (Universal Scientific) alumina was conditioned with 2% sodium hydroxide and 10% sulfuric acid and packed into the column. After rinsing the alumina with water until no alumina fines were visible in the eluant, one liter of a 5% slurry of PP1610 soy protein was passed through the column. The eluant was collected, and the alumina in the column was rinsed with approximately 250 ml of 25% hydrochloric acid. The acid was then recirculated through the column two more times. This eluant was also collected. A water rinse of 250 ml was then taken through the column twice and collected. Individual eluants as well as a combination of all these eluants were then analyzed for phytate content. The column was then rinsed with 250 ml IN potassium hydroxide twice. An aliquot of this rinse solution as well as all solutions combined were also tested for phytate content. Total solids were determined for selected samples to achieve a better estimation of actual phytate reduction.

Alumina treatment of PP1610 soy protein isolate using column technology was successful in the lab scale experiment. A reduction in the phytate level of greater than 90% was achieved using column alumina treatment. The process used for column treatment was slightly different from that used for batch treatment of the soy isolate, however. In the alumina batch treatment process, the protein must be separated from the alumina by centrifugation, which results in all insoluble material, including protein, being separated from that which is solubilized. This necessitates maximum resolubilization of the soy protein at a high secondary pH, (9.2-9.6). With an alumina column treatment process, the alumina:phytate contact is made, then the alumina is separated from the protein--both soluble and insoluble--by process design. Therefore, no increase in pH is necessary to resolubilize the protein. Acid and water rinses recover any material remaining in the column proper. The treated slurry can then be adjusted to a pH of approximately 4.5 to precipitate the protein. The protein isolate can be rinsed with

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water to lower mineral content and subsequently can be spray-dried or used as a wet curd. The mineral content of the protein isolate would be lower using this column treatment process than in the batch treatment process since less potassium hydroxide and less hydrochloric acid are used. Theoretically, the only protein loss should be from that protein which remains attached to the alumina via the phytate

(approximately the phytate content of the material). If it is desirable to recover this 1-3% of the protein, a 1N potassium hydroxide wash should resolubilize (recover) the protein while allowing the phytate to remain on the alumina. The potential drawback of this method may be increased lysinoalanine formation due to the momentary high pH of the potassium hydroxide solution.

Aluminum levels varied for all alumina-treated batches of soy protein. The increase in alumina can be explained in several ways: alumina fines, dissolved aluminum, etc. Alumina fines could be eliminated by process design--for example, washing them from the column by back-flushing. If the problem was dissolved aluminum, a filter which is commercially available from CUNO, Inc., could be used to scavenge it.


Conditioning of alumina using potassium and calcium sulfate instead of sulfuric acid was evaluated. As it was believed that the low pH of the sulfuric acid treatment may cause alumina particle degradation, the relatively neutral pH of a sulfate salt treatment may prove beneficial for stability of the alumina particle. Soy protein isolate was treated with varying levels of alumina which had been conditioned with sodium hydroxide and potassium sulfate for comparison with samples treated with sodium hydroxide and sulfuric acid-treated alumina. A sample was analyzed for calcium, phosphorus, and protein content and compared to an untreated "control" sample.

Results of trials using potassium sulfate-treated alumina for phytate removal from soy protein are presented in FIG. 12. This figure illustrates significant phytate removal from the starting material with minimal protein loss. This experiment proved the utility of alumina treated with a potassium sulfate solution for separating phytate from soy protein.


Additional trials were performed to determine the effects of the initial sodium hydroxide conditioning of alumina. Since other sulfate salts had shown effectiveness in previous experiments, eliminations of the alkaline rinse with sodium hydroxide would further lessen the harsh treatment of the alumina particle, minimizing its degradation. Alcoa Alumina F-200 and Selecto ABA-6000N were conditioned with, and without, a 2% sodium hydroxide rinse prior to potassium sulfate treatment. 1% PP1610 soy protein isolate slurries were then treated with both conditioned aluminas (with and without sodium hydroxide pretreatment), and with Alcoa Alumina F-200 and Selectro (Selecto, Inc. Atlanta, Ga.)

ABA-6000N which had been rinsed with water. Phytate determinations were made on all samples and were compared with an untreated control sample.

Table 8 shows the results of the use of sodium hydroxide in the alumina conditioning process for the removal of phytate from soy protein. As these aluminas had not previously been evaluated for phytate removal, alumina:protein ratios were not optimal, with only 55% to 65% phytate removed. (This reduction can be undoubtedly increased with increased alumina:protein ratios.) While these results indicate that a sodium hydroxide pretreatment prior to sulfate conditioning does improve the effectiveness of the Alcoa Alumina F-200 and Selecto ABA-6000N for phytate removal from soy protein, significant phytate reduction still occurs without the caustic alumina treatment.

>;tb; TABLE 8

>;tb;______________________________________

>;tb;Effect of Sodium Hydroxide in Alumina Conditioning

>;tb;Alumina Type/

>;tb; Sodium Hydroxide

>;tb; Phytate Removal

>;tb;Conditioned With

>;tb; Used in Conditioning

>;tb; from SPI

>;tb;______________________________________

94/2197

>;tb;Alcoa F-200/"as is"

>;tb; no 36.9%

>;tb;Alcoa F-200/K2 SO4

>;tb; no 55.7%

>;tb;Alcoa F-200/K2 SO4

>;tb; yes 64.6%

>;tb;Selecto ABA-6000N/

>;tb; no 30.1%

>;tb;"as is"


>;tb; no 54.9%

>;tb;K2 SO4


>;tb; yes 59.6%

>;tb;K2 SO4

>;tb;______________________________________

While certain representative embodiments and details have been described for the purpose of illustrating the invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A method of separating phytate from plant protein and dietary fiber comprising the steps of: (a) providing an aqueous slurry containing phytate and at least one material selected from the group consisting of plant protein and dietary fiber; (b) providing a column which contains particles of alumina, said column having at least one inlet and one outlet; (c) causing the slurry to pass through the column and contact the particles of alumina for a period of time, with the slurry for at least a portion of the contact period having a pH of not greater than about 6, such that during the contact period phytate bonds to the alumina; and (d) after the slurry has exited the column via said outlet adjusting the pH of the slurry to be greater than about 9.

2. A method of separating phytate from plant protein and dietary fiber according to claim 1 wherein the particles of alumina have been conditioned by exposing said particles to a solution containing a sulfate moiety.

3. A method of separating phytate from plant protein and dietary fiber according to claim 2 wherein the sulfate solution has a pH which is about 7.0.

4. A method of separating phytate from plant protein and dietary fiber according to claim 1 further comprising the step (e) of reconditioning the particles of alumina by exposing the particles to a sulfate solution following step (d) and thereafter repeating steps (a) through (d) using the reconditioned particles of alumina in step (b).

5. A low-phytate vegetable protein which is produced by the method of claim 1.




9. A low-phytate dietary fiber which is produced by the method of claim 1.


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13. A nutritional product containing a low-phytate vegetable protein produced by the method of claim

1.


2.


3.

16. A nutritional product containing a low-phytate dietary fiber produced by the method of claim 1.




20. A method of making a low-phytate plant protein isolate comprising the steps of: (a) isolating protein and phytate from a source of plant protein; (b) dispersing the protein and phytate isolated in step (a) in an aqueous slurry; (c) providing a column which contains particles of alumina said column having at least one inlet and one outlet; (d) causing the slurry containing the protein isolate to pass through the column and contact the particles of alumina for a period of time, with the slurry for at least a portion of the contact period having a pH of not greater than about 6, such that during the contact period phytate bonds to the alumina; and (e) after the slurry has exited the column via said outlet adjusting the pH of the slurry containing the protein isolate to be greater than about 9.

21. A method of making a low-phytate plant protein isolate according to claim 20 wherein the protein is from a source selected from the group consisting of soybeans and rice.

22. A low-phytate plant protein isolate which is produced by the method of either of claims 20-21.

23. A nutritional product containing a low-phytate plant protein isolate which is produced by the method of either of claims 20-22.

24. A method of making a low-phytate soy protein isolate comprising the steps of: (a) providing an aqueous slurry containing a soy protein isolate and phytate; (b) providing a column which contains particles of alumina, said column having at least one inlet and one outlet; (b) causing the slurry to pass through the column and contact the particles of alumina for a period of time, with the slurry for at least a portion of the contact period having a pH of not greater than about 6, such that during the contact period phytate bonds to the alumina; and (d) after the slurry has exited the column via said outlet adjusting the pH of the slurry to be greater than about 9.

25. A method of making a low-phytate soy protein isolate according to claim 24 wherein the particles of alumina have been conditioned by exposing said particles to a basic hydroxide solution and an sulfuric acid solution.

26. A method of making a low-phytate soy protein isolate according to claim 24 further comprising the step (e) of reconditioning the particles of alumina with a sulfate solution following step (d) and thereafter repeating steps (a) through (d) using the reconditioned particles of alumina in step (b).

27. A low-phytate soy protein isolate produced by the method of claim 24.



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30. A nutritional product containing a low-phytate soy protein isolate produced by the method according to claim 24.

31. A nutritional product containing low-phytate soy protein isolate produced by the method of claim

25.

32. A nutritional product containing a low-phytate soy protein isolate produced by the method of claim

26.

33. A nutritional product formulated for consumption by human infants which contains a low-phytate soy protein isolate produced by the method of claim 24.

34. A nutritional product formulated for consumption by human infants which contains a low-phytate soy protein isolate produced by the method of claim 25.

35. A nutritional product formulated for consumption by human infants which contains a low-phytate soy protein isolate produced by the method of claim 26.Data supplied from the esp@cenet database -

Worldwide

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17.

CA2122781 - 11/4/1995

RICE PORRIDGE PRODUCT AND METHOD OF MANUFACTURE


Inventor(s): HIRATA YOSHIHIRO (JP)

Applicant(s): HIRATA YOSHIHIRO (JP)


IP Class: A23L1/187

E Class: A23L1/182; A23L1/0532; A23L1/168B



Family: CA2122781

Abstract:


A rice porridge comprising rice, water and a gelatin agent is sealed in a container. The gelatin agent may for example be agar-agar. Due to the stickilless imparted by the gelatin agent, the taste and consistency of the rice porridge may be enjoyed even when the porridge is cold. This rice porridge product may be manufactured by heating the mixture of rice, water and gelatin agent either after or before sealing it in the container.

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18.

CA2179696 - 12/23/1996

COATED FOOD


Inventor(s): DE VRIES HIELKE T (NL); LAPRE JOHN A (NL); MCNABOLA WILLIAM T

(US); VEENSTRA JAN (NL)

Applicant(s): HERCULES INC (US)


IP Class: A23L1/10; A23L1/307; A23P1/08

E Class: A23L1/16; A23L1/164B; A23L1/182B; A23L1/00P4; A23L1/00P8B6; A23L1/0522;

A23L1/10M


Priority Number: EP19950109753 (19950622)

Family: CA2179696

Equivalent: EP0749697; JP9000172; FI962539; NO962628; AU713404

Abstract:


Provided is the use of a cation cross-linked polysaccharide coating for reducingthe glycemic response of a carbohydrate-containing food. The cation cross-linked polysaccharide coating may be formed from calcium cross-linked pectin or pectinate. The carbohydrate-containing food may be a rice grain, pasta shape, flour, starch or a piece of breakfast cereal. Such a coated food may be prepared by coating a cross-linkable polysaccharide on a hydratable carbohydrate-containing food core. The food core is then hydrated by cooking the coated food core in an aqueous solution of crosslinking cations which simultaneously cross-link the coating. The resulting foods can be used in the diets of individuals suffering from diabetes, hypoglycemia or glycogen storage disease. They also have the effect of suppressing appetite or assisting in the performance of sustained physical activity. The effect of coating the carbohydrate-containing food is slow down its rate of digestion in the small intestine. This in turn smooths out the release of glucose into the blood stream which otherwise would peak very sharply soon after the digestion of the food commences.

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19.

CN1034475 - 8/9/1989

BOILED RICE PROCESSED FOOD AND ITS MANUFACTURING METHOD

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=CN1034475

Inventor(s): ITOI YASUKI (JP)

Applicant(s): YASUAKI ITOI (JP)


IP Class: A23L1/10; A23P1/10

E Class: A23L1/164C; A23L1/00P8E

Application Number: CN19890100266 (19890113)


Family: CN1034475

Equivalent: GB2208784

Abstract:

Abstract not available for CN1034475

Abstract of corresponding document: GB2208784

A boiled rice processed food product is manufactured by packing at least one food article into the space formed between shaped plates of boiled rice, the boiled rice plates being made by applying heat thereto and moulding one or both into concave shape by the use of a liaisoning material. The space may be formed between one concave and one flat plate, or between two opposing concave plates. The product may be coated with egg before baking.Description:


BOILED RICE PROCESSED FOOD AND ITS MANUFACTURING METHOD


The present invention relates to boiled rice processed food and its manufacturing method.

The present applicant has previously proposed a boiled rice processed food and a method for manufacturing the same in the patent specifications Application Number Showa 60-9283/1985. In the above mentioned patent application, the boiled rice processed food is manufactured in a way that subsidiary articles of foods are placed within the boiled rice, and then a layer of egg is unitarily attached by baking it onto the entire external surface of the boiled rice.

The method for manufacturing the boiled rice processed food is described hereinafter.

A constant amount of boiled rice and condiments are put into the lower half of a heated molding tool, other subsidiary food articles are placed thereon, and again another amount of boiled rice is added onto the latter.

Then the subsidiary food articles and boiled rice are heated and molded in a space between the upper half and the lower half of the tool in order to make a molded plate of boiled rice.

Next, the molded boiled rice plate is taken out from the heated tool and a coat of previously seasoned egg solution is applied thereon.

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On the other hand, a small amount egg solution is also put into the lower half of the tool.

Furthermore, the molded boiled rice plate covered with the solution of egg is put into the lower half containing therein seasoned egg, and the heated tool is closed, and further the egg layer is unitarily attached by baking onto the external surface of the above-mentioned molded plate.

As mentioned above, conventional boiled rice processed food has a large number of merits since the boiled rice processed food is manufactured by covering the subsidiary diet articles with the boiled rice and by unitarily attaching the egg by baking it onto the molded rice plate consisting of boiled rice and the subsidiary food articles, the boiled rice processed food can be easily carried, and it can be preserved by freezing in the freezer. Above all, the added food articles can be eaten easily because they are cooked with the rice and not apt to fall out when eaten.

Moreover, the conventional boiled rice processed food has another merit, that, since the food can be manufactured only by the use of an exclusively used thermal molding machine, the cost of the facilities is low enough to provide the food at low competitive price. However, there still remain some problems to be solved as mentioned hereinafter.

Although the food can be eaten easily because the food articles aren't apt to fall out as mentioned above, since the subsidiary food articles are thermally molded together with the boiled rice, such food articles that can be easily effected by heat, for example, vegetables, pickles etc. can not be packed with the boiled rice. If those subsidiary food articles are forcibly wrapped with the boiled rice, those articles lose their flavor by the action of the heat.

Consequently, the sort of foods capable of being wrapped therein are limited, and this food cannot compare favorably with other available foods.

In the manufacturing process of the food, when the boiled rice and the subsidiary food articles are put into the lower half of the tool it is necessary to pay attention to the other articles so they won't fall out from the boiled rice. Therefore, the work of molding them becomes troublesome and the efficiency of the process is lessened.

There is no trouble in the case of employing larger food articles which are highly solidified such as hamburg steak.

However the manufacture of small crumbly food articles such as preserved food boiled down in soy sauce is especially troublesome and inefficient.


It is an object of the present invention to provide a boiled rice processed food which is manufactured by wrapping various sorts of food articles with the molded boiled rice so as not to allow the subsidiary food articles to fall out from the boiled rice body and therefore which can be eaten with ease.

It is another object of the present invention to provide a method for manufacturing the boiled rice processed food easily and effectively.

The invention includes a food article comprising at least one food item disposed in a closed container formed by moulded boiled rice parts.

In one embodiment of the invention, the container comprises two parts, each of which defines a respective open recess, the parts being fitted together such that each part closes the recess of the other part, and wherein the or each food item is disposed in the space defined by said recesses.

The abovementioned two parts comprise a pair of concave plates in this embodiment.

In another embodiment, the container comprises a first part which defines an open recess and a second part fitted to said first part to close said recess, and wherein the or each food item is disposed in said

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recess. In this other embodiment, the first part is a concave plate and the second part is a substantially flat plate.

Preferably each of the separately moulded container parts is moulded using a bonding material to bond the boiled rice together and by the application of heat.

The invention also includes a method of manufacturing a food article, comprising moulding boiled rice parts for forming a closed container by moulding boiled rice into the shape of such parts by the application of heat thereto and by the use of a bonding material, and thereafter putting at least one food item in said container and closing same.

In one embodiment the step of moulding said boiled rice parts for forming said closed container comprises moulding two said parts, each of which is shaped to define a recess, and wherein the parts are fitted together after the or each food item has been put in the recess of one part such that the other part closes that recess. Preferably each of the parts is moulded in the shape of a concave plate.

In another embodiment, the step of moulding said boiled rice parts for forming said closed container comprises moulding a first part in a shape which defines an open recess and a second part for closing said recess, and wherein the parts are fitted together after the or each food item has been put in the recess. Preferably the first part is moulded in the shape of a concave plate and the second part is moulded in the shape of a substantially flat plate.

The invention also includes processed food and methods of manufacturing the same as defined in the appended claims 14 - 17.

In order that the invention may be well understood, the abovementioned embodiments thereof, which are given by way of example only, will now be described in more detail with reference to the accompanying drawings.

Fig. 1 is a perspective view of the boiled rice processed food according to the prior art;

Fig. 2 is a cross-sectional view of Fig. 1;

Fig. 3 is an explanatory view for explaining a manufacturing process of boiled rice processed food according to the prior art;

Fig. 4 is a perspective view showing boiled rice processed food in an embodiment according to the present invention;

Fig. 5 is a cross-sectional view of Fig. 4;

Figs. 6 and 7 are explanatory views for explaining a manufacturing process for the boiled rice processed food according to another embodiment of the present invention and corresponding to the process shown in Figs. 6 and 7.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Fig.l and 2 are views showing the prior art of boiled rice processed food andFig.3 is a view showing the steps for manufacturing- the same. All of the technology is disclosed in the patent Application

Number Showa 60-9283/1985 proposed by the present applicant.

The above-mentioned boiled rice processed food F is manufactured in such a way that subsidiary articles of diet or subsidiary food articles 1 are placed within the boiled rice 2 and a layer of egg 3 is unitarily attached by baking it onto the entire external surface of the boiled rice 2.

The method for manufacturing the above mentioned boiled rice processed food is described hereinafter accompanying

Fig.3.

(1) As shown in Fig.3(a), a constant amount of boiled rice 2 with condiments are put into the lower half 4a of a heated molding tool 4, other subsidiary food articles 1 are placed thereon, and again another amount of boiled rice 2 is added onto the latter. Then the subsidiary food articles and boiled rice are heated and molded in a space between the upper half 4b and the lower half 4a of the tool in order to make a molded plate f of boiled rice as shown in Fig.3(b).

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(2) Next, the molded boiled rice plate f is taken out from the heated tool 4 and a coat of previously seasoned egg solution 5 is applied thereon as shown in Fig.3(c).

(3) On the other hand, a small amount egg solution 5 is also put into the lower half 4a of the tool as shown in

Fig.3(d).

(4) Furthermore, the molded boiled rice plate f covered with the solution of egg 5 is put into the lower half 4a containing therein seasoned egg 5, and the heated tool 4 is closed, and further the egg layer 3 is unitarily attached by baking onto the external surface of the above-mentioned molded plate f.

As mentioned above, conventional boiled rice processed food has a large number of merits since the boiled rice processed food is manufactured by covering the subsidiary diet articles 1 with the boiled rice 2 and by unitarily attaching the egg 5 by baking it onto the molded rice plate consisting of boiled rice and the other food articles, the boiled rice processed food can be easily carried, and it can be preserved by freezing in the freezer. Above all, the added food articles can be eaten easily because they are cooked with the rice and not apt to fall out when eaten.

Moreover, the conventional boiled rice processed food has another merit, that, since the food can be manufactured only by the use of an exclusively used thermal molding machine, the cost of the facilities is low enough to provide the food at low competitive price. However, there still remain some problems to be solved as mentioned hereinafter.

Although the food can be eaten easily because the food articles aren't apt to fall out as mentioned above, since the other food articles 1 are thermally molded together with the boiled rice 2, such food articles that can be easily effected by heat, for example, vegetables, pickles etc. can not be packed with the boiled rice 2. If those other food articles are forcibly wrapped with the boiled rice, those articles lose their flavorby the action of the heat.

Consequently, the sort of foods 1 capable of being wrapped therein are limited, and this food cannot compare favorably with other available foods.

In the manufacturing process of the food, when the boiled rice 2 and the other food articles 1 are put into the lower half 4a of the tool it is necessary to pay attention to the other articles so they won't fail out from the boiled rice 2. Therefore, the work of molding them becomes troublesome and the efficiency of the process is lessened.

There is no trouble in the case of employing larger food articles 1 which are highly solidified such as hamburg steak. However the manufacture of small crumbly food articles such as preserved food boiled down in soy sauce is especially troublesome and inefficient.

The present invention was made to solve such conventional problems, and to provide a boiled rice processed food which is manufactured by wrapping various sorts of food articles with the molded boiled rice so as not to allow the food articles to fall out from the boiled rice body and therefore which can be eaten with ease, and further, to provide a method for manufacturing the boiled rice processed food easily and effectively.

Figs.4 and 5 show the boiled rice processed foodF1 (see Fig.7(b)) of the first embodiment according to the present invention.

The boiled rice processed foodF1 has a construction which allows for putting other foods 13 into the space 12 formed between a pair of concave-shaped(in this embodiment, dish-shaped) molded boiled rice plates f2 superimposed one upon the other and- for covering the other food articles 13 with two molded boiled rice plates f2.

The same foodF1 is manufactured in the procedure described below.

(1) As shown in Fig.6(a), the lower half 14 of the thermally molding tool K is filled with a proper quantity of mixed boiled rice at the rate of eight (non-glutinous rice) to two (glutinous rice). The

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mixture of boiled rice is thermally molded in the upper 15 and the lower 14 halves of the molding tool in order to obtain a boiled rice plate fl of a concave-shape as shown in Fig.6(b).

(2) Next, the boiled rice platefl of a concave shape is temporarily taken out from the tool K and coated with a solution of seasoned soy sauce and further with a solution of egg (a liaisoning material) by means of spraying. The molded boiled rice plate is put into the molding tool again as shown in

Fig.6(c), and thermally molded as shown in

Fig.6(d). Fig.6(e) shows the molded boiled rice plate f2 formed in the shape of a concave plate obtained in such a way.

(3) Other food articles are put into the recessed portion of the molded boiled rice plate f2 of a concaveshape as shown in Fig.7(a), and further the other molded boiled rice plate f2 of concave-shape is put thereon so as to cover it as shown in Fig.7(b).In such a way, boiled rice processed foodfl can be produced.

Although a seasoned soy sauce is employed as seasoning in the above-mentioned embodiment, the other molded boiled rice plate f2 of a concave-shape is put thereon so as to cover it. In such a way, boiled rice processed foodF1 can be obtained. Moreover, although a seasoned soy sauce is employed as seasoning in the above-mentioned embodiment, all sorts of condiments can be used for the purpose of producing the flavoring of the molded boiled rice plate f2, as for example, other sauces such as catsup, salt, vinegar etc., and one seasoned by other condiments can be used. On the other hand, starch, rice powder, wheat flour, etc. can be used in addition to egg as a liaisoning material.

And further, in the above-mentioned embodiment, the preliminary concave-shaped boiled rice plate fl is taken out temporarily from the molding tool K and seasoned with soy sauce by the method of spraying. However, it's also possible to spray the condiments on the molded boiled rice plate as being left in the lower tool 14. Needless to mention, the condiments can also be applied when the rice being boiled. The liaisoning material can also be mixed with the rice prior to boiling.

Furthermore, the condiments may be added to the boiled rice as the occasion demands. On the other hand, the liaisoning material is absolutely necessary for maintaining the shape of the finally obtained product f2. The concave-shaped molded boiled rice f2 has the shape of a dish. The shape of the flat plane can be square (four-cornered). The molded boiled rice f2 can also be square (four-cornered). And further, the shape of the molded boiled rice f2 can be changed by bending the flat plane.

In the first embodiment, the boiled rice processed foodF1 constructed of a pair of molded boiled rice plates f2 of concave-shapes combined with each other and with other food articles covered in a space there-between has been described. As shown in Fig.9, the boiled rice processed food F2 of the second embodiment is constructed of a molded boiled rice plate f2 of a concave shape, another molded boiled rice plate f3 of a flat shape, which is made in a different way and combined with the former, and other food articles 16 wrapped in a space there-between.

The manufacturing procedure of the afore-mentioned flat-shaped rice plate is the same as that of the molded boiled rice plate f2 of a concave shape. A different molding tool is employed in accordance with the desired shape of the molded boiled rice. Furthermore, the manufacturing process for the boiled rice processed food F2 is the same as that for the boiled rice processed foodFl shown in Fig.7.

Consequently, in Figs.6 and 8 and in Figs.7 and 9, the same reference numeral is attached to the part corresponding to the other.(However, both of the other food articles 16 and the molded boiled rice plate f3 of a flat-shape are excluded.)

The explanation for the same reference numerals is omitted here.

As is apparent from the foregoing description, according to the present invention;

(1) Since the above-mentioned boiled rice processed food is manufactured by covering the other food articles in the space formed between a pair of molded boiled rice plates when both of them are superimposed one upon the other, the other food articles aren't apt to fall out at the time of eating.

Therefore said food is very easy to eat.

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(2) Since the molded boiled rice plates are thermally molded beforehand, and'thereafter the other food articles are wrapped with said plates1 heat isn't applied to the other food articles. For this reason, various kinds of food articles, in particular, articles not responding well to heat such as vegetables, pickles or the like can be covered with the molded boiled rice plates.

(3) It is not necessary to thermally mold the boiled rice together with the other food articles, that is, only the boiled rice may be that is, thermally molded into the required shape. Therefore the efficiency of the food manufacturing process is improved.Data supplied from the esp@cenet database -

Worldwide Claims:


CLAIMS:

1. A food article comprising at least one food item disposed in a closed container formed by moulded boiled rice parts.

2. A food article as claimed in claim 1, wherein said container comprises two parts, each of which defines a respective open recess, the parts being fitted together such that each part closes the recess of the other part, and wherein the or each food item is disposed in the space defined by said recesses.

3. A food article as claimed in claim 2, wherein said parts comprise a pair of concave plates.

4. A food article as claimed in claim 1, wherein said container comprises a first part which defines an open recess and a second part fitted to said first part to close said recess, and wherein the or each food item is disposed in said recess.

5. A food article as claimed in claim 4, wherein said first part is a concave plate and the second part is a substantially flat plate.

6. A food article as claimed in any one of the preceding claims, wherein each of said separately moulded container parts is moulded using a bonding material to bond the boiled rice together and by the application of heat.

7. A method of manufacturing a food article, comprising moulding boiled rice parts for forming a closed container by moulding boiled rice into the shape of such parts by the application of heat thereto and by the use of a bonding material, and thereafter putting at least one food item in said container and closing same.

8. A method as claimed in claim 7, wherein said step of moulding said boiled rice parts for forming said closed container comprises moulding two said parts, each of which is shaped to define a recess, and wherein the parts are fitted together after the or each food item has been put in the recess of one part such that the other part closes that recess.

9. A method as claimed in claim 8, wherein each of said parts is moulded in the shape of a concave plate.

10. A method as claimed in claim 7, wherein said step of moulding said boiled rice parts for forming said closed container comprises moulding a first part in a shape which defines an open recess and a second part for closing said recess, and wherein the parts are fitted together after the or each food item has been put in the recess.

11. A method as claimed in claim 10, wherein said front part is moulded in the shape of a concave plate and the second part is moulded in the shape of a substantially flat plate.

12. A food article substantially as hereinbefore described with reference to Figures 4 and 5 or 9(b) of the accompanying drawings.

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13. A method of manufacturing a food article substantially as hereinbefore described with reference to

Figures 6 and 7 or 8 and 9 of the accompanying drawings.

14. Boiled rice processed food, characterized in that said food is manufactured by packing other food articles into the space which is formed at the time of putting one of a pair of concave-shaped plates of boiled rice one upon the other, both of said boiled rice plates being made by applying heat thereto and molding into the shape of a concave plate by the use of a liaisoning material.

15. Boiled rice processed food, characterized in that said food is manufactured by packing other food articles into the space which is formed at the time of putting one of a pair of concave-shaped plates of boiled rice and a flat-shaped plate of boiled rice one upon the other, both of said boiled rice plates being made by applying heat thereto and molding into the shape of a concave plate and in the shape of a flat plate by the use of a liaisoning material.

16. The method for manufacturing said boiled rice food, characterized in that said method comprises a step for obtaining a concave-shaped boiled rice plate by applying heat thereto and molding it into the shape of a concave plate by the use of a liaisoning material, and another step for obtaining the boiled rice processed food by filling the recessed portion of said concave-shaped boiled rice plate with other food articles and covering it with another concave-shaped boiled rice plate.

17. The method for manufacturing said boiled rice processed food, characterized in that said method comprises a step for obtaining a concave-shaped boiled rice plate and a flat-shaped boiled rice plate by applying heat thereto and molding into the shape of a concave plate and into the shape of a flat plate by the use of liaisoning material and another step for obtaining boiled rice processed food by putting other food articles into the recessed portion of said concave-shaped boiled rice plate and covering it with said flat-shaped boiled rice plate.Data supplied from the esp@cenet database - Worldwide

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20.

DE19937973 - 2/15/2001

DEEP-FROZEN PASTA OR NOODLE PRODUCT IN CROQUETTE FORM FOR

DEEP-FRYING CONTAINS SAUCE OR RICE TOGETHER WITH MELTED

CHEESE AND IS EASILY PREPARED

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=DE19937973

Inventor(s): ZIMMER UWE (DE)

Applicant(s): ZIMMER VIOLETTA (DE); ZIMMER UWE (DE)

IP Class 4 Digits: A23B; A23L

IP Class: A23L1/162; A23L1/48; A23B9/10

E Class: A23L1/16D

Application Number: DE19991037973 (19990811)

Priority Number: DE19991037973 (19990811)

Family: DE19937973

Abstract:

Abstract of DE19937973

An especially deep-frozen product in croquette, disc or other form comprises a 1:1 (volume) mixture of pasta or noodles with either a Bechamel sauce or a Duchess product or a 1:1 (volume) combination of the pasta or noodles with a rice product, there also being present melted cheese in amount corresponding to one-quarter of the total volume of the pasta and Bechamel sauce or Duchess product.

An especially deep-frozen product in croquette, disc or other form comprises a 1:1 (volume) mixture of pasta or noodles with either a Bechamel sauce or a Duchess product or a 1:1 (volume) combination of the pasta or noodles with a rice product, there also being present melted cheese in amount corresponding to one-quarter of the total volume of the pasta and Bechamel sauce or Duchess product.

An Independent claim for preparation of the product.Description:

Description of DE19937973

Tiefkühlkost findet eine immer grössere Verbreitung, sowohl mengenmässig als auch in der

Produktpalette. Einen weiten Raum nehmen Produkte auf der Basis von Kartoffeln ein, sei als Chips,

Kroketten oder anderen Ausbildungen.

Wichtig hierbei ist, dass diese Produkte frittiert werden können, um sie schnell vom tiefgekühlten

Zustand in einen servier- und essfähigen Zustand überzuführen. Keinen besonderen Eingang in

Tiefkühlprodukte haben deshalb Nudeln gefunden, da diese durch das Einfrieren und spätere Auftauen ihren Biss verlieren. Sie sind nicht mehr "al dente". Nudelprodukte werden daher als Trockenprodukt vertrieben und müssen vor dem Verzehr gekocht werden.

Der vorliegenden Erfindung liegt die Aufgabe zugrunde, ein Tiefkühlprodukt herzustellen, dass einfach im Aufbau und vielfältig in seiner Verwendungsmöglichkeit ist. Das Produkt soll schmackhaft sein, leicht herstellbar und mit weitem Einsatzbereich.

Die Lösung der gestellten Aufgabe wird erreicht durch ein tiefgefrorenes Nudelprodukt in der Form von Kroketten, Scheiben oder dgl. als Mischung aus Nudeln mit Béchamel- Sosse im

Volumenverhältnis von etwa 1 zu 1 und geschmolzenen Käse in einer Menge von etwa einem Viertel

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des Gesamtvolumens aus Nudeln und Béchamel-Sosse. Ein solches Produkt ist tiefgefroren lange haltbar und ergibt in einer Fritteuse erhitzt eine schmackhafte Beilage zu vielen Gerichten.

Die Béchamel-Sosse kann mit Weisswein, Sahne, Kräutern, Salz, Pfeffer, Muskat allein oder in

Kombination angereichert sein, je nach gewünschter Geschmacksrichtung. Möglich sind auch weitere

Geschmacksingredenzien für Spezialitätengerichte.

Der verwendete Käse soll eine Schmelztemperatur von unter 70 DEG C haben, damit er eine gute

Durchmischung ergibt.

Möglich ist auch, das Nudelprodukt nicht nur als Beilage zu anderen Gerichten vorzusehen, sondern als eigenes selbständiges Gericht auszubilden, indem verschiedene Zugaben in geeigneten Mengen der

Mischung beigegeben werden. Als Zugaben kommen hier vor allem Schinken, Speck, Pilze, Lauch,

Gemüse, Sojasprossen allein oder in Kombination in Frage. Zu beachten ist hierbei, dass die Zugaben nicht zu stark wasserhaltig sind, was zu Spritzern beim Frittieren führen kann.

Es ist zweckmässig, wenn das Nudelprodukt mit einer Panierung überzogen ist. Übliche Panierungen können hier eingesetzt werden.

In Fortführung des Erfindungsgedankens wird ein Verfahren zur Herstellung eines tiefgefrorenen

Nudelproduktes vorgeschlagen, nach dem die Nudeln auf Biss gekocht, mit einer Béchamel-Sosse im

Volumenverhältnis 1 zu 1 warm miteinander vermischt werden und ein geriebener Käse in einer

Menge von etwa einem Viertel des Gesamtvolumens aus Nudeln und Béchamel-Sosse der warmen

Mischung unter Rühren beigegeben wird. Die so gebildete Masse wird zu Kroketten oder scheibenförmigen Stücken vereinzelt, die anschliessend paniert und tiefgefroren werden.

Verschiedene in der industriellen Fertigung bekannte Apparate können hier zum Einsatz gelangen. Bei geringeren Mengen ist es günstig, wenn die Masse auf einem Blech mit einem Rand von 2 bis 3 cm

Höhe ausgestrichen und in einem Tiefkühler abgekühlt wird, bis sie schneidfähig ist. Dann wird sie in einzelne Stücke vorbestimmter Form geschnitten, paniert und endgültig tiefgefroren.

Es versteht sich, dass die Mengenangaben nach oben und unten variieren können, ohne den

Erfindungsgedanken zu verlassen. Wichtig ist die Überführung eines gekochten Nudelproduktes in ein tiefgefrorenes Produkt, das in einer Fritteuse essfertig zubereitet werden kann.

Die Erfindung kann auch als Halbfertigprodukt vakuumverpackt werden. Die Lagerzeiten werden dann jedoch verringert.

Damit das Produkt leicht durch einfaches Erhitzen verzehrfertig ist, besteht auch die Möglichkeit, es vorzufrittieren.

Ausführungsbeispiel 1

2 kg Nudeln werden gekocht und mit einer parallel hergestellten, abgeschmeckten Béchamel-Sosse in einer Menge von 2,5 l warm miteinander vermischt. Der Mischung werden 1,2 kg geriebener Gouda beigegeben. Die Masse wird auf einem Blech ausgestrichen und mit einer Folie bedeckt in einen

Tiefkühler gestellt. Nachdem die Masse eine schneidfähige Konsistenz erreicht hat, wird sie in Stücke geschnitten, in Semmelbröseln paniert und dann tiefgefroren. Die Stücke werden als Kroketten anderen

Gerichten beigegeben, nachdem sie frittiert werden.

Ausführungsbeispiel 2

Der nach dem Beispiel 1 hergestellten Masse werden kleingeschnitten bzw. kleingehackt 300 Gramm aus Schinken, Speck und Lauch beigegeben. Die Masse wird zu Scheiben geschnitten, paniert und

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tiefgefroren. In einer Fritteuse wird ein schmackhaftes Gericht hergestellt.Data supplied from the esp@cenet database - Worldwide Claims:

Claims of DE19937973

1. Nudelprodukt, insbesondere tiefgefrorenes, in Kroketten- oder Scheibenform oder anderen

Ausformungen als Mischung aus Nudeln und Béchamel-Sosse oder Duchessemasse oder einer Bindung aus einem Reiserzeugnis im Volumenverhältnis von etwa 1 zu 1 und geschmolzenem Käse in einer

Menge von etwa einem Viertel des Gesamtvolumens aus Nudeln und Béchamel-Sosse oder

Duchessemesse.

2. Nudelprodukt nach Anspruch 1, dadurch gekennzeichnet, dass die Béchamel-Sosse mit Weisswein,

Sahne, Kräutern, Salz, Pfeffer, Muskat allein oder in Kombination und/oder anderen

Geschmacksingredenzien angereichert ist.

3. Nudelprodukt nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass ein Käse verwendet wird, der bei einer Temperatur unterhalb von 70 DEG C schmilzt.

4. Nudelprodukt nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass im Produkt Zugaben aus Schinken, Speck, Lauch, Pilzen, Gemüse, Soja- oder anderen Sprossen, Gewürzen, Kräutern allein oder in Kombination enthalten sind.

5. Nudelprodukt nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass das Nudelprodukt paniert ist.

6. Verfahren zur Herstellung eines tiefgefrorenen Nudelproduktes nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die Nudeln auf Biss gekocht, mit einer gesondert hergestellten

Béchamel-Sosse oder Duchessemasse oder einer Bindung aus einem Reiserzeugnis im

Volumenverhältnis von etwa 1 zu 1 warm miteinander vermischt werden und ein geriebener Käse in einer Menge von etwa einem Viertel des Gesamtvolumens aus Nudeln und Béchamel-Sosse der warmen Mischung unter Rühren beigegeben wird, die so gebildete Masse zu kroketten- oder scheibenförmigen Stücken vereinzelt wird und die Stücke paniert und tiefgefroren oder vakuumverpackt werden.

7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass die Masse auf ein Blech mit einem Rand von 2 bis 3 cm Höhe ausgestrichen und im Tiefkühler abgekühlt wird, bis sie schneidfähig ist, dann in einzelne Stücke vorbestimmter Form geschnitten, paniert und tiefgefroren wird.Data supplied from the esp@cenet database - Worldwide

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21.

DE2103405 - 8/17/1972

INSTANT RICE PREPN - BY BOILING, GRADUAL DRYING AND FRYING


E Class: A23L1/182C



Family: DE2103405

Abstract:


Instant fried rice is prepared by gradually drying boiled rice in hot air at 86 degrees F rising to 194 degrees F until the moisture content is 10 - 20 wt.% then frying for 10 - 20 secs in oil, such as a lard oil at 356 - 428 degrees F. For serving, the product requires boiling in water for as little as 3 mins. to obtain a quality comparable to that of boiled rice.Description:


"Verfahren zum Erzeugen von gebackenem

Reis zum Schnellkochen" Die Erfindung bezieht sich auf ein Verfahren zum Erzeugen von gebackenem Reis, der durch schnelles Kochen als Mahlzeit serviert werden kann.

Der durch bekannte Verfahren hergestellte gebackene Reis erfordert eine lange Kochzeit von über 15

Minuten, um den gleichen Zustand wie gekochter Reis zu erreichen, und der mit den bekannten

Verfahren hergestellte gekochte, gebackene Reis hat einen schlechteren Geschmack als gekochter Reis.

Entsprechend der vorliegenden Erfindung wurde ein neuer und verbesserter gebackener Reis erzeugt, welcher in etwa drei Minuten gekocht und als Mahlzeit serviert werden kann. Der nach der vorliegenden Erfindung hergestellte Reis hat einen ausgezeichneten Geschmack und ist in seiner

Qualität mit gekochtem Reis zu vergleichen.

Das Verfahren zum Erzeugen von gebackenem Reis entsprechend der Erfindung weist eine Reihe von

Verfahrensschritten auf,durch welche die Stärke des Rohreises in-Stärke mit ausreichender Quellung beim Kochen geändert wird. Dieser Reis wird dann durch Heissluft in der Weise getrocknet, dass die

Temperatur von 300 bis 900 C langsam fortschreitend'erhöht wird, um ein Platzen des Reises zu vermeiden.

Wenn die Trocknungstemperatur 600 C übersteigt, neigen viele der Teilchen des Reises zum Platzen und Brechen.

Da der Wassergehalt des getrockneten Reises die Ergebnisse des nächsten Verfahrensschrittes zum

Behandeln des Reises, z.B. durch dessen Backen und Kochen,beeinflusst, muss der gekochte Reis bei der Vorbehandlung (z.B. in der Stufe, in welcher die Stärke inX-Stärke umgewandelt wird) zur

Reduzierung des Wassergehalts auf 10 bis 20% getrocknet werden, um die besten Ergebnisse zu erzielen, wie sich aus der nachfolgenden Tabelleergibt worin einige experimentelle Beobachtungen in bezug auf das Quellverhältnis und den gekochten Zustand des Reises bei unterschiedlichen

Wassergehalten des getrockneten Reises aufgezeichnet sind:: Wassergehalt des Tatsächliches spezi-

Erscheinungsbild und Ge-getrockneten fisches Gewicht des schmack des Reises nach Reises in%

Reises nach der dem Kochen

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Backbehandlung 40 0,45 Oberfläche hat braune30 0,32 Flecken und der Kern des Reises ist noch hart zu essen 20o,i8 Oberfläche ist kremfarben 10 0,17 und ausreichende Quellung ohne harten Kern oder un- gewöhnlichen Geschmack

7 0,26 Oberfläche ist braun und der Kern ist noch hart zu essen Bemerkung 1: Die Backtemperatur betrug 2100 C während

15 Sekunden. Das tatsächliche spezifische Ge wicht von Rohreis ist 0,80.

Bemerkung 2: Das Kochverfahren besteht in einem 3-minütigen

Kochen von 120 g gebackenem Reis mit 180 Milli

Liter Wasser.

Die vorliegende Erfindung weist eine Backbehandlung nach dem Trocknungsvorgang auf, bei welcher

Behandlung der getrocknete Reis, der einen Wassergehalt von 10 bis 20 hat (gemessen am

Gesamtgewicht des Reises), 10 bis 20 Sekunden in51 oder Fett, welches von Pflanzen oder Tieren stammt, bei hohen Temperaturen von 180 bis 2200 C gebacken wird.

Bei den bekannten Verfahren ist versucht worden, Schnellkochreis durch Backen von gewaschenem

Rohreis zu erzeugen. Dieses Verfahren hat jedoch den Nachteil, dass der hierdurch erzeugte Reis eine unerwünschte braune Färbung hat und das Quellen des Reises sehr gering ist. Es ist bei den bekannten

Verfahren auch versucht worden, einen Schnellkochreis zu erzeugen, indem dieser zuerst gekocht und ohne zu trocknen 3 bis 5 Minuten lang bei 110 bis 1500 C gebacken wird. Der durch dieses Verfahren hergestellte Reis hat jedoch ebenfalls eine braune Farbe und ist auch nicht ausreichend gequollen. Als

Ergebnis der beiden vorbeschriebenen Verfahren ergibt sich, dass der damit hergestellte

Schnellkochreis während einer beträchtlichen Zeitspanne, z.B. über 15 Minuten lang, gekocht werden muss, damit dieser richtig gar wird und der Geschmack und natürlich die Farbe ist entsprechend schlechter.

Die vorliegende Erfindung vermeidet die vorgenannten Nachteile der bekannten Verfahren durch langsam fortschreitendes Trocknen von gekochtem Rohreis mit Heissluft in der Weise, dass der

Wassergehalt des Reises auf einen Wassergehalt zwischen etwa 10 bis20 ver mindert wird, und durch darauffolgendes Backen des getrockneten Reises bei einer Temperatur von 180 bis 2200 C inö1 während einer Dauer von 10 bis 20 Sekunden. ditemperatur tatsächliches Wassergehaltöl- oder Fettgehalt oc spezifisches im getrockne- in gebackenem Reis

Gewicht ten Reis in in # 150 0,54 8,32 8,2 160 0,42 5,01 9,5 170 0,35 3,83 12,3 180 0,21 2,78 16,5

190 0,20 2,071R,2 200 0,18 1,93 20,0 210 0,18 1,75 22,3 220 0,171,43 23,5 Bemerkung 1: Jede

Backbehandlung dauert 15 Sekunden. Der

Wassergehalt im getrockneten Reis beträgt 15,3%.

Wie aus vorstehender Tabelle ersichtlich, ist das Quellen des Reises nicht ausreichend, wenn die

Backtemperatur unter 1500 C liegt, und die gleichen Ergebnisse ungenügenden Quellens beim

Trocknen desOberflächenteiles des Reises allein werden bei 1500 C (Backtemperatur) erreicht und dies blieb gleich, selbst wenn die Backzeit auf 3 bis 5 Minuten verlängert wurde. Es ist ferner zu bemerken, dass mit erhöhter Backtemperatur dastatsäch- liche spezifische Gewicht des Reises erniedrigt wird, was bedeutet, dass das Quellen des Reises stärker wurde.Der Wassergehalt in dem getrockneten Reis wird kleiner durch Entwässern und derbl oder Fettgehalt in dem gebackenen Reis wird grösser, was bedeutet, dass der schliesslich erzeugte Schnellkochreis einen ausgezeichnetenGeschmack hat und in verhältnismässig kurzer Zeit gekocht werden kann.

Nach Durchführung des vorgenannten Verfahrens und der Behandlung ist der gebackene Reis für das

Schnellkochen fertig.

Wenn eine Mengeneinheit von 120 g des gebackenen Reises 3 Minuten lang mit 180 Milli-Liter

Wasser in einem Tiegel oder in einer Pfanne gekocht wird, so hat der dadurch hergestellte Reis einen ausgezeichneten Geschmack, ein glänzendes Aussehen und ein ausreichendes Quellen ohne harten

Kern in den Reisteilchen.

Die Erfindung wird durch die nachfolgenden, nicht einschränkenden Ausführungsbeispiele erläutert.

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Beispiel I 2kg Rohreis werden gewaschen und in Wasser getaucht sowie20 Minuten lang unter einem

Druck von 3kg/cm2 in einem Druck- kessel gekocht. Nach dem Kochen unter Druck wird der gekochte Reis langsam fortschreitend mit Hilfe einer Heisslufttrockenvorrichtung ,getrocknet in welcher die Lufttemperatur langsam fortschreitend von 300 C bis 900 C erhöht wird. Hieraus ergibt sich 1,5 kg getrockneter Reis mit einem Wassergehalt von15 bezogen auf das Gewicht des Reises.

Der getrocknete Reis wird weiterhin 15 Sekunden lang in geschmolzenem Schweinefett gebacken, das auf eine Temperatur von200 C erhitzt ist, und es werden 2,2 kg an gebackenem Reis mit optimaler

Entwässerung und Quellung für das Schnellkochen erzeugt. Der gebackene Reis zum Schnellkochen hat 0,2 des tatsächlichen spezifischen Gewichts,2,1% Wassergehalt und21,3N bl- oder Fettgehalt.

Wenn eine Mengeneinheit von 120 g des gebackenen Reises zum Schnellkochen 3 Minuten lang mit

180 Milli-Liter Wasser gekocht werden, so ist ein gekochter Reis, der ein ausgezeichnetes

Quellvermögen ohne harten Kern hat, fertig zur Mahlzeit.

Beispiel II 2 kg Rohreis werden gewaschen und in Wasser getaucht und es werden 0,5% eines

Glyzerin-Fett-Säure-Esters dem Rohreis zugefügt. Der Reis wird dann 20 Minuten lang unter einem

Druck von 2 kg/cm2 in einem Druckkessel gekocht. Nach dem Kochen unter Druck wird der gekochte

Reis langsam fortschreitend in heisser Luft getrocknet, in welcher die Temperatur von 300 C bis 900 C langsam fortschreitend angehoben wird. Hieraus ergeben sich 2,0 kg getrockneter Reis mit einem

Wassergehalt von12,8. Der getrocknete Reis wird weiterhin 10 Minuten lang in geschmolzenem

Rinderfett mit einer Temperatur von 2100 C gebacken. Auf diese Weise erhält man 2,4 kg gebackenen

Reis, welcher eine ausgezeichnete Entwässerung und Quelleigenschaften hat und zum Schnellkochen verwendet werden kann.

Der im vorstehend genannten Verfahren erhaltene gebackene Reis hat 0,18 seines tatsächlichen spezifischen Gewichts,1,8 Wassergehalt und 24,3%öl- oder Fettgehalt. Wenn der getrocknete Reis zum Schnellkochen in gleicher Weise wie im vorgenannten Beispiel I gekocht wird, so ist der gekochte

Reis, der eine ausreichende Quellung ohne harten Kern hat, fertig als Mahlzeit.Data supplied from the esp@cenet database - Worldwide Claims:


Patentansprüche

1. Verfahren zum Erzeugen von gebackenen Reis zum Schnell kochen, g e k e n n z e i c h n e t durch langsam fort schreitendes Trocknen von gekochtem Reis durch Erhitzen mit

Heissluft bei einer Temperatur zwischen300 C bis 900 C bis der Wassergehalt des Reises auf 10 bis

20% reduziert ist, durch Entwässern und Quellen des Reises, durch Backen des getrockneten Reises 10 bis 20 Sekunden lang in Fett, das auf eine Temperatur zwischen 180 bis 2200 C erhitzt ist, wodurch ein

Erzeugnis aus gebackenem Reis hergestellt wird, welches zum Verzehr innerhalb verhältnismässig kurzer Zeit zubereitet werden kann.

2. Verfahren nach Anspruch 1, dadurch g e k e n n z e i c h n e t , dass der Reis anfangs etwa 20

Minuten lang gekocht wird, ehe er langsam fortschreitend getrocknet wird.

3. Verfahren nach Anspruch 2, dadurchR e k e n n z e i c h n e t , dass der Reis anfangs unter einem

Druck von 2kg/cm2 gekocht wird.

4. Verfahren nach Anspruch 2, dadurch g e k e n n z e i c h n e t , dass der Reis anfangs unter einem

Druck von 3 kg/cm2 gekocht wird.Data supplied from the esp@cenet database - Worldwide

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22.

DE3131207 - 2/17/1983

PROCESS FOR PRODUCING FOODSTUFFS, IN PARTICULAR ANIMAL FEED


Inventor(s): BISMARCK FRIEDRICH VON (DE); HUSSMANN PETER DR (IT)

Applicant(s): MITTEX AG (LI)

IP Class 4 Digits: A23L; A23K; A23N

IP Class: A23L1/00; A23L1/20; A23K1/14; A23N17/00

E Class: A61K35/78; A23K1/12; A23K1/16M; A23L1/211C; C05F11/00



Family: DE3131207

Abstract:


A process for producing foodstuffs, in particular animal feed, from lignocellulosic starting materials, such as wheat straw, rice straw or maize straw, bagasse, elephant grass, sawdust and lupins is characterised in that the starting materials are placed in a ball mill and are very finely ground or intensively milled there with the addition of water and, possibly, acid or alkali. If the starting material contains bitter substances, these can be removed by a washing taking place after the processing in the ball mill. The product taken from the ball mill, and washed if necessary, can further be dried. The finished product is characterised by a high nutritional value and a good digestibility, in particular in the case of cattle.Claims:


Patentansprüche 1. Verfahren zur Herstellung von Nahrungsmitteln, insbesondere Tierfutter, aus lignocellulosehaltigen Ausgangsmaterialien, d a d u r c h g e k e n n z e i c h n e t, dass die

Ausgangsmaterialien in zerkleinerter Form in eine Kugelmühle gegeben und dort unter Zusatz von

Wasser bearbeitet werden.

2. Verfahren nach Anspruch 1, d a d u r c h g e k e n nzeichnet, dass auf einen Teil der

Ausgangsmaterialien zwei bis fünf Teile Wasser verwendet werden.

3.Verfahren nach Anspruch 1 oder Anspruch 2, d a d u r c h y e k e n n z e i c h ne t, dass die

Ausgangsmaterialien ferner unter Zusatz von Säure oder Lauge in der Kugelmühle bearbeitet werden.

4. Verfahren nach Anspruch 3, d a d u r c h g e k e n nz e i c h n e t, dass als Säure Schwefelsäure oder

Salzsäure und als Lauge Natronlauge verwendet wird.

5. Verfahren nach Anspruch 3 oder Anspruch 4, d a d u rc.h g e k e n n z e i c h n e t, dass 0,5 bis 1%

Säure oder Lauge, bezogen auf die Ausgangsmaterialien und das Wasser, verwendet werden.

6. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Ausgangsmaterialien Bitterstoffe enthalten, da d u r c h g e k e n n z e i c h n e t, dass das durch die Bearbeitung in der Kugelmühle erhaltene Produkt gewaschen wird, um die Bitterstoffe von ihm zu trennen.

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7. Verfahren nach Anspruch 6, d a d u r c h g e k e n nz e i c h n e t, dass die Waschung in einem

Flachhettfilterextraktor erfolgt, indem Wasser durch das Produkt hindurchgedrückt wird.

8. Verfahren nach einem der vorhergehenden Ansprüche, d ad u r c h g e k e n n z e i c h n e t, dass das

Produkt ggf. nach dem Waschen noch getrocknet wird.Data supplied from the esp@cenet database -

Worldwide

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23.

DE3336521 - 4/25/1985

RICE PUDDING DRY MIX, PREFERABLY FOR THE PRODUCTION OF

DESSERTS


Inventor(s): PANKRATZ MICHAEL ING GRAD (DE); KOCH GEB TEISMANN (DE);

BUEKER ULRIKE (DE)

Applicant(s): OETKER AUGUST DR FA (DE)


IP Class: A23L1/187; A23L1/34

E Class: A23C9/154D2; A23L1/164F; A23L1/187



Family: DE3336521

Abstract:


The present invention describes a rice pudding dry mix, preferably as a base for the simple and rapid preparation of rice pudding dishes, which dry mix is characterised in that it is composed of 20-50 parts by weight of carbohydrate sweetener, 18-30 parts by weight of thickener mixture and 20-80 parts by weight of special instant rice pudding. The rice pudding dry mix is further characterised in that a mixture of modified and native thickeners and a special instant rice pudding is dispersed in hot liquids, thickens and gives a ready-to-eat food on cooling.

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24.

DE3742261 - 6/22/1989

METHOD FOR REDUCING THE COOKING TIME OF BROWN RICE


Inventor(s): REIFENSTUEL GERD (DE)

Applicant(s): MUELLER S MUEHLE (DE)


IP Class: A23L1/182

E Class: A23L1/182



Family: DE3742261

Abstract:


The brown rice with its natural moisture content in the range of 10 to 15 % by weight is exposed in ambient air to the action of infrared radiation and, as a result, precooked.Description:


Die Erfindung betrifft ein Verfahren zum Reduzieren der Kochzeit von Naturreis. Naturreis bezeichnet entspelzten, jedoch ungeschälten und ungeschliffenen Reis. Er gewinnt wegen seines hohen Gehaltes an Naturstoffen und Ballaststoffen in zunehmendem Masse an Bedeutun für die menschliche

Ernährung.

Um die Kochzeit, die Reis als geniessbares Nahrungsmittel benötigt, zu reduzieren, sind verschiedene

Verfahren bekannt. Sie führen zu sogenanntem Schnellkochreis. Darunter versteht man auf besondere

Weise behandelten geschälten und geschliffenen Reis. Nach üblichem Verfahren hergestellter Reis benötigt zwanzig bis fünfunddreissig Minuten Kochzeit, bis er verzehrfähig ist. Schnellkochreis kann fünf bis fünfzehn Minuten, nachdem er ins kochende Wasser gebracht wurde serviert werden. Zur

Herstellung von Schnellkochreis wird der Reis eingeweicht (meist bei Zimmertemperatur). Er nimmt beim Einweichen etwa 30 Gew.-% Wasser auf. Er wird anschliessend acht bis zehn Minuten in kochendes Wasser gebracht. Dadurch erhöht sich der Wassergehalt auf 65 bis 70 Gew.-%.Nach

Entfernen des überschüssigen Wassers wird der Reis gekühlt, mit Wasser gewaschen und mit Heissluft auf einen Wassergehalt von 8 bis 14 Gew.-% getrocknet. Auch chemische Verfahren zur Herstellung von Schnellkochreis sind bekannt. Auch bei ihnen ist das Einweichen und Vorkochen ein wesentlicher

Verfahrensschritt. Häufig wird der Reis dabei in eine gesättigte Kochsalzlösung bei 80 DEG C eingelegt. Auch die Verwendung von Phosphaten und Polyphosphaten als Zusatzmittel wurde vorgeschlagen, jedoch werde chemische Verfahren heute in zunehmendem Masse für die Herstellung von Schnellkochreis abgelehnt.

Zu den bekannten Verfahren zur Vorbereitung von Reis gehört auch das sogenannte Parboiling-

Verfahren. Es führt zu sogenanntem parboiled Reis, und arbeitet mit drei Verfahrensstufen, nämlich

Einweichen des entspelzten Reises, Erhitzen mit Dampf, anschlies Trocknen. Um Gärung zu vermeiden, wird zum Einweichen heisses Wasser verwendet. Der eingeweichte Reis wird im

Autoklaven mit direktem Dampf erhitzt. Bei dieser Behandlung wandern Mineralstoffe und Vitamine aus den äusseren Kornschichten ins Innere des sogenannte Endosperms, wonach sich der Nährwert

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gegenüber unbehandeltem Reis beträchtlich verbessert. Der nährstoffangereicherte Reis wird nach der

Trocknung durch Heissluft wie üblich weiterverarbeitet.

All die vorstehend beschriebenen bekannten Massnahmen haben zur Entwicklung eines Verfahrens zur

Reduzierung der Kochzeit von Naturreis nichts beigetragen. Allerdings ist Naturreis, dessen Kochzeit auf bis zu 20 Minuten reduziert ist, auf dem Markt. Seine Herstellung ist im einzelnen nicht bekannt.

Die physikalischen und chemischen Eigenschaften seiner Reiskörner lassen den Schluss zu, dass ein

Vorkochen in Wasser, ähnlich wie bei der Herstellung von Schnellkochreis, sowie ein Quetschen zwischen Walzen stattfindet.

Im übrigen kennt man für das Rösten von Nüssen und anderen Samenkernen die Behandlung dieser mit infraroten Strahlen (vgl. Prospekt Maschinenfabrik G. W. Barth Ludwigsburg GmbH & Co. in 7140

Ludwigsburg, Ausgabe 86/3.Ho). Die Samenkerne werden geröstet, um bestimmte flüchtige, den

Geschmack beeinträchtigende Substanzen auszutragen, verschiedene Aroma- und Geschmacksstoffe zu entwickeln und zu verstärken oder um neue zu bilden. Das Rösten ist ein thermischer Prozess, dem eine Entfeuchtung der Samenkerne vorausgeht. Die Entfeuchtung ist im Gegensatz zum Rösten nicht mit einer chemischen Veränderung bestimmter Stoffe und auch nicht mit einer Veränderung des

Kerngefüges verbunden. Der Röstvorgang ist daher ein eindeutig definierter und verfahrenstechnisch verstellbarer Zustand.Ein Ziel des Röstens ist häufig auch die Lockerung der Samenschalen, so dass sie später leicht entfernt werden können. Durch Rösten mit infraroten Strahlen kann die Kochzeit von

Naturreis nicht reduziert werden. Der Naturreis wird durch einen Röstprozess eher ungeniessbar.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren anzugeben, mit dem Naturreis unter Verzicht auf Einweichen, Vorkochen und Quetschen auf einfache Weise in einen Schnellkoch-Naturreis umgewandelt werden kann - wobei gleichzeitig Nährstoffe aus der Schale in den Reiskern übergehen sollen.

Das erfindungsgemässe Verfahren zum Reduzieren der Kochzeit von Naturreis ist dadurch gekennzeichnet, dass der Naturreis mit seiner natürlichen Feuchte im Bereich von 10 bis 15 Gew.-% in

Umgebungsluft der Einwirkung von infraroten Strahlen ausgesetzt und dadurch vorgegart wird. Die

Einwirkung der infraroten Strahlen wird vor dem Beginn der Röstung, zumindest vor dem Beginn einer störenden Röstung, abgebrochen. Es versteht sich, dass die Behandlung mit den infraroten Strahlen zwar in Umgebungsluft, also nicht in einer besonderen Atmosphäre, jedoch im allgemeinen in einem besonderen Ofen, vorzugsweise in einem Trommelofen erfolgt (vgl. Prospekt Maschinenfa G. W.

Barth Ludwigsburg GmbH & Co. 1.c.).Nach bevorzugter Ausführungsform der Erfindung wird der

Naturreis mit seiner Feuchte, die enger als vorstehend angegeben eingestellt ist, der Einwirkung der infraroten Stahlen ausgesetzt, nämlich mit einer Feuchte von 12 bis 13 Gew.-%. Es empfiehlt sich, den

Naturreis durch die Einwirkung der infraroten Strahlen auf eine Temperatur auf etwa 140 DEG C zu erwärmen. Die Behandlungsdauer wird so gewählt, dass eine ausreichende Reduzierung der Kochzeit erreicht wird. Sie kann auf 15 Minuten und sogar weniger reduziert werden. In diesem Zusammenhang lehrt die Erfindung, dass der Naturreis maximal 8 bis 10 Minuten auf der Temperatur von 140 DEG C gehalten und danach an der Luft abgekühlt wird.

Die Erfindung beruht auf der überraschenden Tatsache, dass Naturreis durch eine Behandlung mit infraroten Stahlen, die ihn augenscheinlich nicht oder nur wenig verändern, so "vorgegart" werden kann, dass er, zum Zwecke der Nahrungszubereitung in kochendes Wasser gebracht, innerhalb 15

Minuten oder sogar weniger genussreif gart. Auch andere Garungszeiten, beispielsweise längere

Garungszeiten, lassen sich bei dem erfindungsgemässen Verfahren durch die Temperatur und die

Behandlungszeit einstellen. Allerdings muss Vorsorge getroffen wer dass ein Rösten der zu behandelnden Reiskörner vermieden wird. Es versteht sich, dass die Wellenlänge und die Intensität der

Infrarotstrahlen dem erfindungsgemässen Behandlungsprozess angepasst wird. In diesem

Zusammenhang empfiehlt es sich, zunächst das Absorptionsspektrum der zu behandelnden Reiskörner zu untersuchen und das Emissionsspektrum der Infrarotstrahler entsprechend abzustimmen.

Üblicherweise arbeitet man mit Wellenlängen im Bereich von unter 10 mu m.

Gegenstand der Erfindung ist mit anderen Worten die Anwendung des Verfahrens der Behandlung von

Samenkernen mit infraroten Strahlen auf die Behandlung von Naturreis zum Zwecke der Reduzierung der Kochzeit mit der Massgabe, dass der Naturreis bei der Behandlung eine Feuchtigkeit von 10 bis 15

Gew.-%, vorzugsweise etwa 12 bis 13 Gew.%, aufweist und praktisch ohne Rösten vorgegart wird. Das

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kann, wie bereits erwähnt, in Öfen und Anlagen erfolgen, wie sie in anderen Bereichen der Technik, auch der Nahrungsmitteltechnik, üblich sind, beispielsweise zum Rösten von Nüssen und anderen

Samenkernen.Data supplied from the esp@cenet database - Worldwide Claims:


1. Verfahren zum Reduzieren der Kochzeit von Naturreis, dadurch gekennzeichnet, dass der Naturreis mit seiner natürlichen Feuchte im Bereich von 10 bis 15 Gew.-% in Umgebungsluft der Einwirkung von infraroten Strahlen ausgesetzt und dadur vorgegart wird.

2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Naturreis mit einer Feuchte von 12 bis 13 Gew.-% der Einwirkung der infraroten Strahlen ausgesetzt wird.

3. Verfahren nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass der Naturreis durch die

Einwirkung der infraroten Strahlen auf eine Temperatur von etwa 140 DEG C erwärmt wird.

4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass der Naturreis maximal 8 bis 10 Minuten auf der Temperatur von etwa 140 DEG C gehalten und danach an der Luft abgekühlt wird.

5. Anwendung des Verfahrens der Behandlung von Samenkörnern mit infraroten Strahlen

auf die Behandlung von Naturreis zum Zwecke der Reduzierung der Kochzeit

mit der Massgabe, dass der Naturreis eine Feuchtigkeit von 10 bis 15 Gew.-%, vorzugsweise von etwa

12 bis 13 Gew.-%, aufweist und praktisch ohne Rösten durch die infraroten Strahlen vorgegart wird.Data supplied from the esp@cenet database - Worldwide

118/2197

25.

DE3937238 - 5/16/1991

PREPN. OF FOOD FOR HUMANS - FROM FISH PROTEIN CONCENTRATE

OBTD. FROM RESIDUES FROM FISH PROCESSING


Inventor(s): GREVE LILIA (DE)

Applicant(s): TECHNOLOGISCHES BERATUNGS UND (DE)

IP Class 4 Digits: A23L; A23J

IP Class: A23J3/04; A23L1/24; A23L1/326

E Class: A23J3/04; A23L1/326



Family: DE3937238

Abstract:


Fish protein concentrate (FPC) obtd. from the residues form fish processing e.g. filtering is used to prepare foods for human use as follows: fish chips are made by prepg. a dough contg. 710g of FPC (45-

55% water content) 100g of wheat flour, 80g of rice flour and 50g of salt, cutting the dough into strips, frying in hot fat, and sprinkling with 60g of a mixt. of seasonings. (ii) freeze-dried FPC is encapsulated in gelatine. (iii) an emulsion as replacement for mayonnaise in fish salads, is prepd. by beating 210g of

FPC with 500g of water, adding 200g of oil dropwise, and adding 40g of salt and 50g of a mixt. of seasonings. (iv) pieces which can be cut up, for frying or grilling are prepd. by forming the FPC pouring off the water, isolating the compsn. under 1kg pressure for 5 hr, pressing out further water under 20kg for up to 10h, washing, and storing the FPC compsn. in a bath contg. 10% of NaCl 80% of water, and 10% of fruit acid and seasonings. ADVANTAGE - Cheap fish residues, previously used only for fodder, are utilised for human consumption. The prods. have a high protein content.Description:


Das Produkt und den Namen "fish-chips"

Bei diesem Produkt handelt es sich um einen Gewürz-Snack, hergestellt unter der Verwendung von

Fischproteinkonzentrat, das aus dem Restanfall bei der Fischverarbeitung gewonnen wurde.

Neu an diesem Produkt ist a) die Herkunft des Rohmaterials aus Fischresten und b) die Rezeptur für den Snack.

Die Proteingewinnung erfolgte nach bewährten Methoden.

Zu a)

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Die Verwendung von Fischresten, die bisher nur für die Futtermittelherstellung verwendet wurden, ist eine kostengünstige und im weitesten Sinne umweltschonende Grundlage zur Herstellung von

Lebensmitteln.

Die Qualität und Reinheit des erhaltenen Fischproteinkonzentrats entsprechen denen eines

Eiweisskonzentrats aus z. B. Fischfilet.

Um die Qualität unseres Produktes zu vergleichen, ist in nachstehender Tabelle eine Auflistung der

Aminosäurenzusammensetzung unseres Fischproteinkonzentrats (FPC) gegenüber frischem Fischfilet, sowie auch den empfohlenen FAO Aminosäuren-Werten eines Proteins angefertigt.

Tabelle 1

Aminosäurezusammensetzung: Vergleichswerte

EMI2.1

Zu b)

Die von uns entwickelte Rezeptur für den als "fish-chip" bezeichneten Gewürz-Snack besteht aus folgenden Grundstoffen (100 g Teig):

>;tb;>;TABLE; Columns=2;

>;tb;-

>;tb;- Weizenmehl (Typ 405)>;SEP;-; 10 g

>;tb;- Reismehl>;SEP;-; 8 g

>;tb;- Kochsalz>;SEP;-; 5 g

>;tb;- Gewürzmischung>;SEP;-; 6 g

>;tb;>;/TABLE;

Die Haltbarkeit des Produktes ist sowohl in geschmacklicher, als auch in mikrobiologischer Hinsicht geprüft worden.

Die Nährwertanalyse wird zur Zeit durchgeführt.

Es ist davon auszugehen, dass dieser Snack durch seinen hohen Eiweissgehalt einen Beitrag zur gesunden Ernährung leistet, was ihn weiterhin von vergleichbaren Produkten erheblich unterscheiden würde.

Die Entwicklung der Verfahren zur Herstellung genussfähiger Produkte aus Fischresten gehört in den

Bereich der Lebensmitteltechnologie und Produktentwicklung.

Soweit dem Antragsteller bekannt, entspricht lediglich die Herstellung des Fischproteinkonzentrats dem Stand der Technik, wobei als Ausgangsprodukt Frischfisch verwendet wurde.

Die Verwendung von Fischresten und die Weiterverarbeitung des Proteinkonzentrats bis zur Eignung für den Verzehr sind nach de Wissen des Antragstellers neu.

Das Verfahren zur Herstellung des Fischproteinkonzentrats ist in folgender Literaturstelle nachzulesen:

"LWT-Report, Fish Protein Concentrate from Anchovies", Lebensm.-Wiss. u. Technol., 18, S. 374-378

(1985).

Die Entwicklung genussfähiger Produkte aus Fischabfällen, die bisher lediglich als Tierfutter verwendet wurden, ist von erheblicher Bedeutung, da sie einerseits einen Beitrag zur

"Rohstoffeinsparun im Sinne der Schonung des Fischbestandes liefert, andererseits den Aspekt gesundheitsbewusster Ernährung fördert.

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- Die Herstellung eines Snacks aus Proteinkonzentrat liefert einen erheblichen Beitrag zur gesunden

Ernährung.

- Die Verwendung eines Proteinkonzentrats als Lebensmittelgrundstoff ist - insbesondere im

Austausch gegen stark fetthaltige Phasen - ernährungsphysiologisch positiv zu bewerten.

- Die Herstellung einer Proteinkapsel zum Einnehmen soll der Gesundheitspflege dienen und könnte bei Export in Entwicklungsländer evtl. einen Beitrag zur Bekämpfung des Eiweissmangels leisten.

- Das Pressen von Laiben aus frischem Fischproteinkonzentrat vereinfacht Transport und Lagerung gegenüber Frischfisch erhebl und erlaubt eine vielfältige Verwendung in der Fischindustrie.Data supplied from the esp@cenet database - Worldwide Claims:


Die anzumeldenden Patentansprüche gelten verschiedenen "Verfahren zur Verwertung von

Fischproteinkonzentrat (FPC) aus aufbereiteten Resten der Fischverarbeitung für den menschlichen

Genuss". Unter "Resten der Fischverarbeitung" ist das "nach herkömmlichen Methoden nicht verwertbare, jedoch reine Rohmaterial aus Frischfisch", das z. B. rund 50% der Materialverluste beim

Filetieren ausmacht, zu verstehen. Alle hier angesprochenen Produkte zeichnen sich durch einen sehr hohen Eiweissgehalt aus.

Folgende Verfahren sollen geschützt werden:

1.Herstellung eines gewürzten Snacks, gekennzeichnet durch die Verwendung von zu Mehl getrocknetem Fischprotein. (Die Herstellung des Mehles erfolgt nach bekannten Methoden).

Rezeptur und Verfahren:

a) Fish-Chips

Rezeptur/1000 g Teig


>;tb;Fischproteinkonzentrat:>;CEL

>;tb;Weizenmehl Typ 405:>;SEP;100 g

>;tb;Reismehl:>;SEP;80 g

>;tb;Kochsalz:>;SEP;50 g

>;tb;Gewürzmischung:>;SEP;60 g

>;tb;>;/TABLE; Verfahren:

- Zutaten mischen (Gewürzmischung ausgenommen),

- Durchkneten, so lange, bis der Teig sehr geschmeidig wird,

- Teig in sehr feine Streifen schneiden,

- im heissen Fett fritieren,

- mit der Gewürzmischung bestreuen.

2.Herstellung von Proteinkapseln zum Einnehmen, die durch ihre Hauptkomponente

"Frischproteinkonzentrat" gekennzeichnet sind.


b) FPC-Kapsel

FPC (gefriergetrocknet) Verfahren:

FPC-Pulver wird in Gelatinehartkapseln gefüllt.

3. Herstellung von Emulsionen, gekennzeichnet durch den Hauptinhaltsstoff "Fischproteinkonzentrat", die zum Ersatz von Mayonnaise in Fischsalaten dienen.


c) Fisch-Emulsion/1000 g


>;tb;Fischproteinkonzentrat:>;SEP;210

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>;tb;Wasser:>;SEP;500 g

>;tb;Speiseöl:>;SEP;200 g

>;tb;Kochsalz:>;SEP;40 g

>;tb;Gewürzmischung:>;SEP;50 g

>;tb;>;/TABLE;Verfahren:

- FPC mit kaltem Wasser kräftig aufschlagen,

- Speiseöl tropfenweise unter ständigem Rühren zugeben,

- Kochsalz und Gewürzmischung zugeben.

4. Pressen von nicht getrocknetem Fischproteinkonzentrat zu schnittfesten Laiben, die - entsprechend portioniert - z. B. fritiert oder gebraten werden können.


d) FPC-Laibe FPC - 1000 g Einlegebad:


>;tb;NaCl>;SEP;10%

>;tb;Wasser>;SEP;80%

>;tb;Fruchtsäuremischung und Gewürze>;SEP;10%

>;tb;>;/TABLE;Verfahren:

- Das FPC wird nach unserer Methode gewonnen.

- Nach dem Absetzen wird das Wasser abgegossen.

- Die Masse wird schliesslich durch leichtes Abpressen (5 h/1 kg Pressgewicht) isoliert.

- Danach werden bis zu 10 h/20 kg Pressgewicht weiteres Wasser entzogen.

- Ein Waschvorgang schliesst sich an.

- Die erhaltenen FPC-Laibe werden in ein Einlegebad zur Haltbarmachung gelegt.Data supplied from the esp@cenet database - Worldwide

122/2197

26.

DE4009157 - 9/26/1991

PREPN. OF PARBOILED STARCHY FOODSTUFF USING SIMPLE UNIT -

USING WORM CONVEYOR TO HEAT TO REQUIRED TEMP. MAINTAINING

AT TEMP. IN INSULATED CONTAINER AND DRYING


Inventor(s): VORWERCK KARLDIETRICH DR ING (DE); BRANDT UWE DIPL ING (DE)

Applicant(s): BUEHLER GMBH (DE)

IP Class 4 Digits: A23L; B65D; G05D

IP Class: A23L1/182; B65D81/18; G05D23/19

E Class: A23L1/182; A23L1/10H2; A23B9/00



Family: DE4009157

Equivalent: JP4211338; IT1249044

Abstract:


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In prepn. of a parboiled starchy foodstuff, esp. rice for reducing cooking time by a final customer, the rice (possibly after initial softening) is brought to boiling temp., e.g. in a worm conveyor operating at atmos. pressure. The prod. is then transferred to an insulated container (9) to be held at the same temp. for a predetermined period. The container has a heating jacket providing sufficient heat merely to compensate for natural cooling losses, as measured by an immersed sensor (21) and processed by a control circuit (22). On completion of thermal treatment, rice is transferred to a multi-stage dryer (12) operated by counter-flowing warm air, and finally discharging the rice for packaging. ADVANTAGE -

Easily operated unit uses power economically.

124/2197

27.

DE4241872 - 6/17/1993

DE4241872


Inventor(s): SAKAI MITURU (JP)

Applicant(s): TANISAKE KK (JP)


IP Class: A23J3/14; A23J3/34

E Class: A23J3/34C; A23L1/214D; A23L1/105; A23L1/238; A23L1/015D; A23L1/015M;

A23L1/20F; A23L1/212E



Family: DE4241872

Equivalent: JP5161473; GB2262213; FR2684847

Abstract:


A supplementary foodstuff is prepared in steps: (a) preparing an aqueous substrate containing vegetable protein and vegetable lipid; (b) adding thereto lipase, proteinase and/or amylase; and (c) fermenting the aqueous substrate. Koji such as malted rice or malt can replace said lipase, proteinase and/or amylase.

The fermented products improve immunity and can promote health.Description:


Die Erfindung betrifft Ergänzungsnahrungsmittel (oder auch Zusätze zu Nahrungsmitteln).

Insbesondere betrifft die Erfindung Ergänzungsnahrungsmittel, die im Überschuss Nährstoffe wie

Saccharide, Vitamine sowie Sulfide der Aminosäuren und ungesättigte Fettsäuren enthalten, welche für eine ausgezeichnete Immunität sorgen.

Es befinden sich eine Vielzahl von Ergänzungsnahrungsmitteln auf dem Markt, die auf eine Erhaltung und/oder Förderung der Gesundheit gerichtet sind. Viele dieser Zusatznahrungsmittel enthalten verschiedene Nährstoffe wie Aminosäuren, Fettsäuren, Vitamine und Mineralien. Diese

Nahrungsmittel sorgen bei denjenigen, die sie zu sich nehmen, für bestimmte Wirkungen, wie beispielsweise die Blutdruckkontrolle durch Fettsäuren wie Linolinsäure und Vasodilatation durch

Aminosäuren.

Der Erfinder hat nach intensiven Studien bei der Fermentation von Substraten wie Reiskleie, Weizen und Sojabohnen die im Überschuss pflanzliches Protein und pflanzliches Lipid enthielten, festgestellt, dass die Sulfide der Aminosäuren und ungesättigte Fettsäuren in diesen Substraten für eine ausgezeichnete Immunität sorgen können, so dass beide für den menschlichen Körper sehr nützlich sind.

Gegenstand der Erfindung ist somit gemäss Anspruch 1 ein Ergänzungsnahrungsmittel, das ein fermentiertes Produkt, das durch Fermentierung eines wässrigen Substrates bei 30 DEG C bis 50 DEG

C über 8 bis 15 Stunden, das pflanzliches Protein und pflanzliches Lipid und mit einer Gesamtmenge von 0,01 bis 0,1 Gew.-% Lipase und Proteinase enthält, erhalten wurde.

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Gegenstand der Erfindung gemäss Anspruch 2 ist ein Ergänzungsnahrungsmittel, das ein fermentiertes

Produkt enthält, das erhal wurde durch Fermentierung eines wässrigen Substrates bei 30 DEG C bis 55

DEG C über 8 bis 15 Stunden, das pflanzliches Protein und pflanzliches Lipid und in einer

Gesamtmenge von 0,01 bis 0,1 Gew.-% Lipase, Proteinase und Amylase enthält.

Gegenstand der Erfindung gemäss Anspruch 3 ist ein Ergänzungsnahrungsmittel, das ein fermentiertes

Produkt enthält, das durch Fermentierung bei 40 DEG C bis 50 DEG C über 12 bis 15 Stunden eines wässrigen Substrates, enthaltend pflanzliches Protein und pflanzliches Lipid und 1 bis 3 Gew.-% Koyi

(oder auch Koji, eine Art der Hefe) erhalten wurde.

Das erfindungsgemässe Verfahren zur Herstellung des Ergänzungsnahrungsmittels ist in den

Ansprüchen 4 bis 8 näher angegeben.

Erfindungsgemäss zu verwendende Substrate sind irgendwelche, die pflanzliches Protein und pflanzliches Lipid enthalten, beispielsweise Reiskleie, Sake (Reiswein) Bodensatz oder Abfall,

Weizenkeimlinge, Weizenkleie, Buchweizen, Bauernhofhirse, Sojabohnen, Bohnenquark (Ausschuss),

Sojabohnenmilch, Adzuki-Bohnen, Sojabohnenmehl, Yams (Wurzel), Taros (Colocasia Antiquarum), gemahlener Tee, Honig, Sesam, Erdnüsse, Lotussamen, Ashitaba-Blätter, "Beefsteak"-Pflanzen (perilla frutescens crispa), Wakame (Seetang und Tang). Von diesen werden insbesondere Reiskleie, Sake-

Rückstand, Weizenkleie, gemahlener Kaffee, Weizenkeimlinge, Sesam, Bohnenquarkabfall,

Sojabohnen und Adzuki als Substrate für die vorliegende Erfindung bevorzugt, da diese Materialien in ausgeglichener Weise pflanzliches Protein und pflanzliches Lipid enthalten.

Ein derartiges Substrat wird unter Verwendung eines Enzyms fermentiert, das fähig ist, sowohl das pflanzliche Protein als auch das pflanzliche Lipid in dem Substrat zu zersetzen und/oder unter

Verwendung von Hefe. Dieses Enzym umfasst Lipase und Proteinase, oder Lipase, Proteinase und

Amylase. Bei der Hefe kann es sich um Koyi oder gemalzten Reis handeln, die Lipase, Proteinase,

Amylase und/oder andere verschiedene Arten von Enzymen erzeugen können.

Besonders bevorzugt wird eine alkalische Proteinase verwendet (pH 9 bis 13), die beispielsweise aus

Bacillus, Bacillus subtillus, Bacillus licheniformis, Bacillus alkalophilus, Bacillus cereus und Bacillus mycoides erhalten werden kann.

Eine bevorzugte Pufferlösung enthält Harnstoff, vorzugsweise 0,1 bis 1,0 Mol/l.

Wenn es sich bei der Alkaliproteinase beispielsweise um neutralisiertes angesäuertes Papain handelt, kann dieses mit einer Proteinase, die aus Aspergillus erhalten wurde, vermischt werden. Eine Gruppe schwacher Alkali-neutraler Proteinasen (beste Funktionalität bei pH 6 bis 8) die noch eine vernünftige

Stabilität bei pH 9 aufweisen kann (so zum Beispiel neutrale Proteinase Streptomyces griseus kann zusammen mit Alkaliproteinase eingesetzt werden. Eine solche Alkaliproteinase kann mit tierischer

Proteinase vermischt werden. Pankreasproteinase, die am besten bei einem pH-Wert von 8 bis 9 oder darunter arbeitet, kann verwendet werden, wie beispielsweise eine Proteinasezusammensetzung aus

Streptomyces griseus und einem Enzym aus Bacillus natto, Bacillus cereus oder Bacillus mycoides, einem Enzym aus Asp. Orizae, Rhiz. Chinensis oder Mucor.Pusillus und pflanzliche Proteinase, beispielsweise Papain, Ficin und Bromelain. Es ist sinnvoll, die pH-Werte bei den genannten Proteasen so einzustellen, dass diese bei ihrer grössten Aktivität eingesetzt werden. Es kann Harnstoff oder eine

Pufferlösung von beispielsweise Natriumhydrogencarbonat oder Kaliumdihydrogenphosphat hinzugegeben werden um den pH-Wert einzustellen.

Die Lipase kann sich aus verschiedenen Arten von Schimmel, Hefe, Bacillii, Körperflüssigkeiten oder

Enzymen aus inneren Organen, wie beispielsweise Pankreaslipase, Leberlipase,

Tuberkelbakterienlipase, FIB-Lipase (aus Rinderleber extrahierte Lipase; Fibrinolysin) und Hima-

Lipase, ableiten. Die in den Substraten enthaltenen Polysaccharide, insbesondere Disaccharide und

Trisaccharide, besitzen ausgezeichnete Immunisierungswirkungen und Amylase kann Saccharide zersetzen.

Es ist jedenfalls erforderlich, den pH-Wert betreffs der Lipase und Amylase einzustellen, um eine gute

Zersetzung zu erhalten. Es kann eine Pufferlösung aus Natriumhydrogencarbonat-Natriumcarbonat,

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Borax-Natriumhydroxid, Borax-Natriumcarbonat, Natriumdihydrogenphosphat-Natriumhydroxid und

Natriumdihydrogenphosphat-Natriumhydroxid eingesetzt werden. Es ist möglich, eine Vielzahl solcher

Pufferlösungen einzusetzen.

Die Menge des einzusetzenden Enzyms hängt von der Art des Enzyms und dessen Aktivität ab. Im allgemeinen wird ein Bereich von 0,01 bis 1,0 Gew.-% bevorzugt. Für gewöhnlich ist die Menge von

Lipase oder Amylase die Hälfte der Menge an Proteinase. Die Fermentationstemperatur ist nicht wesentlich für die vorliegende Erfindung. Diese hängt von der Eigenschaft des eingesetzten Enz ab, was die am besten geeignete Temperatur und den Bereich der Stabilität angeht. Die Temperatur liegt im allgemeinen im Bereich von 30 DEG C bis 55 DEG C. Die Fermentationsze beträgt üblicherweise 8 bis 15 Stunden. Es ist bevorzugt, vor jeder Fermentation das Substrat in einem Autoklaven zu sterilisieren.

Koyi, sowie gemalzter Reis oder Malz, das die Enzyme wie Lipase, Proteinase und Amylase in

Organismen produzieren kann, kann ebenfalls zur Fermentation eingesetzt werden. Die bevorzugten

Fermentationsbedingungen im Fall von Koyi sind 1 bis 3 Gew.-% Koyi, 40 DEG C bis 50 DEG C und

12 bis 15 Stunden. Wenn Koyi zur Zersetzung des Substrates eingesetzt wird, ist es nicht erforderlich, speziell hergestellte Pufferlösungen zu verwenden.

Eine nach der Anthon-Methode bestimmte Einheit wird verwendet, um die Aktivitäten der Enzyme zu bestimmen. Diese Einheit wird Proteinase-Einheit (Hämoglobin) U genannt. Diese Methode wird häufig zur Bestimmung der Aktivität von Endopeptidasen eingesetzt. Hierbei wird bspw.

Trichloressigsäure einer Fermentierungslös zugegeben, Protein entfernt, das noch nicht enzymatisch abgebaut wurde, und im Überstand die verbliebenen Peptide quantitativ analysiert. Üblicherweise werden Tyrosin und Tryptophan bestimmt. Durch Umsetzung der Aminosäuren mit einem farbbildenden Reagenz, wie z. B. Folin min s Phenolreagenz, zu einer gefärbten Substanz können diese colorimetrisch bei bspw. 280 nm leicht analysiert werden. Die Einheit 1 U entspricht der Menge an

Enzym, die ein Mikromol/min (bei 40 DEG C; 280 nm) Tyrosin aus Hämoglobin freigesetzt hat.

Fermentierte Produkte werden dadurch erhalten, dass Wasser dem Substrat zugegeben wird, dann die

Enzyme (Lipase, Proteinase und/oder Amylase) oder Koyi (gemalzter Reis und/oder Malz) dem wässrigen Substrat hinzugegeben werden und dann die Flüssigkeit fermentiert wird. Das Filtrat eines fermentierten Produktes, das durch Zugabe von Enzym oder Koyi zu einem wässrigen Substrat, welches pflanzliches Protein und pflanzliches Lipid enthielt, erhalten wurde, wurde mittels HPLC analysiert. Die Analyse wurde unter Verwendung eines Detektors (LC-9A, SHIMADZU

SEISAKUSHO Company, Ltd., Japan), einer Säulenanordnung (3 Meter lang) und dem Lösungsmittel

Acetonitril als Elutionsmittel unter den Bedingungen, dass die Säulentemperatur 30 DEG C und die

Flüssigkeitsdurchflussgeschwindigkeit 10 ml/min war, durchgeführt. Die folgenden Ergebnisse wurden erhalten.

Es bestätigte sich, dass das fermentierte Filtrat Fettsäuren enthielt, sowie Myristinsäure, Palmitinsäure,

Stearinsäure, Arachinsäure, Behensäure, Ligninsäure, Lignoceroinsäure, Dodekansäure,

Tetradekansäure, Tetradekandiensäure, Pentadekansäure, Hexadekansäure, Oleinsäure, Linolsäure,

Linolensäure, Eicosaensäure, Eicosadiensäure, Arachidonsäure, Eicosatriensäure, Dococensäure,

Ölsäure, und Docosahexansäure. Es wurde weiterhin festgestellt, dass das Filtrat darüberhinaus

Aminosäuren wie Leucin, Isoleucin, Lysin, Methionin, Cystein, Phenylallanin, Tyrosin, Threonin,

Tryptophan, Valin, Histidin, Arginin, Asparaginsäure, Alanin, Glutaminsäure, Glycin, Prolin und Serin enthielt. Es wurden darüberhinaus Saccharide, Asche, Calcium, Phosphor, Karotin, Vitamin B1,

Vitamin B2, Vitamin B6, Pantothensäure und Nukleinsäure in Filtrat festgestellt.

Wie aus der Analyse ersichtlich, enthält das erfindungsgemäss fermentierte Produkt vielerlei Arten von

Aminosäuren und Fettsäuren. Die Sulfide der Aminosäuren und der ungesättigten Fettsäure werden für wesentlich zur Aufrechterhaltung und Förderung der Immunität erachtet. Was ein fermentiertes

Produkte angeht, das aus einem wässrigen Substrat erhalten wird, dem Proteinase, Lipase und/oder

Amylase oder Koyi, so wie gemalzter Reis oder Malz, hinzugegeben wurde, werden die Saccharide in dem Substrat zersetzt und Polysaccharide, wie Disaccharide und Trisaccharide, erhalten, bei denen man ebenfalls davon ausgeht, dass sie die Immunität fördern.

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Ein Verfahren zur Herstellung eines erfindungsgemässen Ergänzungsnahrungsmittels wird im folgenden beschrieben. Es wird ein wässriges Substrat hergestellt, wobei pflanzliches Protein und pflanzliches Lipid hinzugegeben werden. Dann wird Enzym hinzugegeben. Zur Zersetzung des

Substrates wird Proteinase, Lipase und/oder Amylase und/oder Koyi, das eine Vielzahl von Enzymen in Organismen produzieren kann, verwendet. Die Enzyme können zusammen oder getrennt hinzugegeben werden. Andere Arten von Enzymen können ebenfalls eingesetzt werden. Die bevorzugte Fermentationstemperatur im Falle der Enzyme liegt zwischen 30 DEG C und 55 DEG C.

Die bevorzugte Fermentationszeit unter Bewegung des Substrats liegt zwischen 8 und 15 Stunden. Die pH-Werte sollten entsprechend den eingesetzten Enzymen eingestellt werden.Soweit Koyi eingesetzt wird, liegt die bevorzugte Fermentationstempera zwischen 40 DEG C und 50 DEG C. Die bevorzugte

Fermentationszeit liegt dann zwischen 12 und 15 Stunden unter Rühren. Die solcherlei erhaltenen fermentierten Produkte werden filtriert.

Das durch Filtration des fermentierten Produktes erhaltene Ergänzungsnahrungsmittel kann Säften,

Süsswaren, Sojasaucen usw. hinzugegeben werden.

Bevorzugte Ausgestaltungen der Erfindung

Ausgestaltung 1

Reiskleie wurde 30 Minuten durch heissen Dampf (150 DEG C bis 180 DEG C) in einem Autoklaven hitzebehandelt. Die hitzebehandelte Reiskleie wurde dann durch eine Presse ausgepresst bis der

Feuchtigkeitsgehalt 40 Gew.-% war. Aspergillus Orizae und Hanzenula Anorama wurden separat auf

MY Medien (Mischung von Polypepton, Hefeextrakt, Malzextrakt, Glukose und Wasser) kultiviert.

Buzillus subtillus wurde auf Bouillon-Medium kultiviert. Die ausgepresste Reiskleie (10 kg) wurde sterilisiert und die drei kultivierten Substanzen wurden damit vermischt. Die Mischung wurde bei 30

DEG C gerührt. Nachdem 8 Stunden vergangen waren, wurde die Temperatur auf 45 DEG C erhöht und es wurde für weitere 5 Stunden gerührt. Das so erhaltene fermentierte Produkt wurde filtriert und es wurden 300 g Filtrat erhalten. Das Filtrat wurde dann analysiert.Im folgenden wird das Ergebnis der

Analyse im einzelnen angegeben.


>;tb;Head Col 1: Komponenten

>;tb;Head Col 2: Gew.-%

>;tb;Wasser>;SEP;8,5

>;tb;Aminosäuren>;SEP;55,8

>;tb;Fettsäuren>;SEP;20,1

>;tb;Saccharide>;SEP;2,5

>;tb;Asche>;SEP;8,3

>;tb;Calcium>;SEP;2,3

>;tb;Phosphor>;SEP;2,2

>;tb;Karotin>;SEP;0,09

>;tb;Vitamin B1>;SEP;0,15



>;tb;Panthothensäure>;SEP;0,0058

>;tb;Nukleinsäure>;SEP;0,1160

>;tb;>;/TABLE;

Ausgestaltung 2

Es wurde Wasser Weizenkeimlingen (40 Gew.-%) hinzugegeben und das wässrige Substrat wurde dann in einen Autoklaven über 25 Minuten hitzebehandelt. Aspergillus Soja wurde auf MY-Medium kultiviert. Saccharomyces subtillus wurde auf einem Bouillon- Medium kultiviert. Zu der Mischung

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aus den zwei kultivierten Substanzen wurde Papain, gemalzter Reis, Nierenlipase und

Natriumhydrogencarbonat hinzugegeben und die sich ergebende Mischung wurde mit dem wässrigen

Substrat (10 kg) vermischt. Die gesamte Mischung wurde bei 45 DEG C über 10 Stunden gerührt. Das fermentierte Produkt wurde abfiltriert und es wurde 310 g Filtrat erhalten.Das Filtrat wurde analysiert und es ergaben sich dabei die folgenden Werte:


>;tb;Head Col 1: Komponenten

>;tb;Head Col 2: Gew.-%

>;tb;Saccharide>;SEP;2,0

>;tb;Aminosäuren>;SEP;65,5

>;tb;Fettsäuren>;SEP;25,5

>;tb;Asche>;SEP;12,3

>;tb;Karotin>;SEP;0,009




>;tb;Panthothensäure>;SEP;0,0038

>;tb;Nukleinsäure>;SEP;0,150

>;tb;>;/TABLE;

Immunitätstest

Die bei den Ausgestaltungen 1 und 2 erhaltenen Filtrate wurden mit 20 Mäusen untersucht, von denen

10 gesund waren wobei die anderen 10 an einer Erkältung litten. Diese wurden wiederum in zwei

Gruppen aufgeteilt, jeweils 10, wobei 5 in jeder Gruppe gesund waren. In jeder Gruppe wurden jeweils

2 gesunden und kranken Mäusen eine physiologische Kochsalzlösung (2 ml, zweimal täglich) verabreicht. Die anderen drei jeweils gesunden und kranken Mäuse in jeder Gruppe erhielten jeweils die Filtrate nach den Ausgestaltungen 1 und 2 (2 ml, zweimal täglich). Das folgende ist das Ergebnis nach 30 Tagen Beobachtung.

Gesunde Mäuse

Es wurde keine Abnormalität bei den 4 Mäusen in beiden Gruppen beobachtet, die lediglich physiologische Kochsalzlösung erhalten hatten.

Es wurde keinerlei Abnormalität bei den 6 Mäusen in den zwei Gruppen beobachtet, die die Filtrate verabreicht bekommen hatten.

Kranke Mäuse

In beiden Gruppen starben alle vier Mäuse, die lediglich eine physiologische Kochsalzlösung erhalten hatten innerhalb von 5 Tagen.

Alle 6 Mäuse in beiden Gruppen, die jeweils die Filtrate erhalten hatten, überlebten den 30 Tage andauernden Test. Somit wurde eine immunizierende Wirkung der Filtrate bestätigt.

Ausgestaltungen, die den praktischen Einsatz der Filtrate der erfindungsgemäss fermentierten Produkte ausmachen, werden im folgenden angegeben.

Ausgestaltung 3

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Voll ausgereifte Tomaten (1 kg) wurden mit einem Mixer zerstampft. Die zerstampfte Paste wurde in einen Liebig-Kühler gebracht, durch den 90 DEG C heisses Wasser liefen, so dass das oxidierende

Enzym in der Paste zerstört wurde. Die Paste wurde dann weiterbearbeitet und 7 g Salz und das nach der Ausgestaltung 1 erhaltene Filtrat (20 g) hinzugegeben. Die Mischung wurde üb Sekunden vermahlen. Die vermahlene Paste wurde dann vakuumbehandelt und bei 120 DEG C über zwei

Sekunden sterilisiert. Sodann wurde sie abgekühlt und daraus Tomatensaft erhalten.

Ausgestaltung 4

Es wurden Puderzucker (1 kg) und verdickter Malzsirup (500 g) mit dem Filtrat des nach der

Ausgestaltung 1 fermentierten Produktes (10 g) vermischt. Die Mischung wurde in einer

Aluminiumpfan auf 120 DEG C erhitzt. Der verdickte Sirup wurde tröpfchenweise in Alkohol bei

Temperaturen unter 0 DEG C gegeben und es wurden daraus Drops erhalten.

Ausgestaltung 5

Natürliches Kaugummigummimaterial (20 g) wurde in der Hitze geschmolzen und es wurden das

Filtrat der Ausgestaltung 1 (2 g) Calciumcarbonat (2 g), Pulverzucker (40 g), Fruchtzucker (20 g),

Malzsirup (15 g) und Aromen (1 g) hinzugegeben. Die Mischung wurde gut verknetet und flach ausgedrückt. Auf diese Weise wurde Kaugummi erhalten.

Ausgestaltung 6

Es wurden Reispulver (100 g) und Zucker (100 g) in einen Behälter gegeben. In den Behälter wurde tröpfchenweise Wasser (80 ml) gegeben. Die Bestandteile wurden dann vermischt und es wurde ein

Filtrat der Ausgestaltung 1 (10 g) hinzugegeben. Diese Mischung wurde gut durchgeknetet. Dann wurde diese verknetete Mischung in einem Dämpfer mit Dampf über 25 Minuten behandelt. Die gedämpfte Mischung wurde dann in einen Topf gegeben und es wurde etwas Salz hineingemischt. Die

Mischung wurde in kleinere Teile aufgeteilt, jeweils mit einem Gewicht von 5 g und daraus wurden

Knödel erhalten.

Die aufgezählten Ausgestaltungen zeigen nur wenige der vielen möglichen Wege, die erfindungsgemäss hergestellten fermentierten Produkte einzusetzen. Durch die Konsumierung dieser

Nahrungsmittel wird die Gesundheit besser aufrechterhalten und/oder gefördert.Data supplied from the esp@cenet database - Worldwide Claims:


1. Ergänzungsnahrungsmittel, erhältlich durch folgende Schritte:

a) Herstellung eines wässrigen Substrates enthaltend pflanzliches Protein und pflanzliches Lipid;

b) Zugabe von Lipase und Proteinase in einer Gesamtmenge von 0,01 bis 0,1 Gew.-% und

c) Fermentierung des wässrigen Substrates bei 30 DEG C bis 55 DEG C über 8 bis 15 Stunden.

2. Ergänzungsnahrungsmittel, erhältlich durch die folgenden Schritte:

a) Herstellung eines wässrigen Substrates enthaltend pflanzliches Protein und pflanzliches Lipid;

b) Zugabe von Lipase, Proteinase und Amylase in einer Gesamtmenge von 0,01 bis 0,1 Gew.-% und


3.Ergänzungsnahrungsmittel erhältlich durch folgende Schritte:

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a) Herstellung eines wässrigen Substrates, enthaltend pflanzliches Protein und pflanzliches Lipid;

b) Zugabe von Koyi in einer Menge von 1 bis 3 Gew.-% und


4. Verfahren zur Herstellung eines Ergänzungsnahrungsmittels, dadurch gekennzeichnet, dass

a) zunächst ein wässriges Substrat, enthaltend pflanzliches Protein und pflanzliches Lipid hergestellt wird;

b) eine enzymatisch aktive Substanz hinzugefügt wird, die aus der folgenden Aufstellung ausgewählt ist:

1. Lipase und Proteinase,

2. Lipase, Proteinase und Amylase und

3. Koyi

und

c) das wässrige Substrat fermentiert wird.

5. Verfahren gemäss Anspruch 4, dadurch gekennzeichnet, dass die Fermentation des wässrigen

Substrates bei 30 DEG C bis 55 DEG C über 8 bis 15 Stunden durchgeführt wird.

6. Verfahren gemäss Anspruch 5, dadurch gekennzeichnet, dass Lipase, Proteinase und gegebenenfalls

Amylase in einer Gesamtmenge von 0,01 bis 0,1 Gew.-% zugegeben werden.

7. Verfahren gemäss Anspruch 4, dadurch gekennzeichnet, dass das wässrige Substrat bei

Temperaturen von 40 DEG C bis 50 DEG C über 12 bis 15 Stunden fermentiert wird.

8. Verfahren gemäss Anspruch 7, dadurch gekennzeichnet, dass Koyi in einer Menge von 1 bis 3 Gew.-

% zugegeben wird.Data supplied from the esp@cenet database - Worldwide

131/2197

28.

DE4403371 - 1/26/1995

SUPPLEMENTARY FEED FOR PIGEONS


Inventor(s): SCHWEIZER HEINZ-DIETER (DE)

Applicant(s): SCHWEIZER HEINZ DIETER (DE)

IP Class 4 Digits: A23P; A23K; C01G

IP Class: A23P1/12; A23K1/14; A23K1/18; A23K1/175; C01G49/08

E Class: A23L1/212E; A23K1/14; A23K1/16C; A23K1/18L; A23L1/18B2



Family: DE4403371

Abstract:


The invention relates to a supplementary feed for pigeons which contains maize and carrots. According to the invention, the supplementary feed exists as approximately spherical croquettes produced by extrusion cooking. In addition to the main constituents maize and carrots, the croquettes also contain rice and iron(II, III) mixed oxide as colorant additive.Description:


Die Erfindung betrifft ein Beifutter für Tauben, welches Mais und Karotten enthält.

Im Rahmen der bekannten Massnahmen werden Tauben, die im Taubensport als Brieftauben eingesetzt werden, Futtermischungen verabreicht, die Körner, Pflanzenteile gegebenenfalls Kräuter und zerkleinertes Gemüse, jeweils in roher Form, enthalten. Die Nahrung gelangt über die Speiseröhre in den Kropf der Taube und wird dort vorverdaut. Die Vorverdauung umfasst einen Zeitraum von etwa fünf Stunden. Erst anschliessend setzt die eigentliche Verwertung der Nahrung ein. Im Frühjahr und

Herbst geben die Züchter oft karottenhaltiges Beifutter zur Entschlackung. Das Beifutter sollte leicht verdaulich sein und ohne Zugabe synthetischer Farbstoffe eine der frischen Karotte entsprechende natürliche Färbung besitzen.

Der Erfindung liegt die Aufgabe zugrunde, ein Beifutter mit den vorgenannten Eigenschaften anzugeben.

Zur Lösung dieser Aufgabe lehrt die Erfindung, dass das Beifutter als annähernd kugelförmige, durch

Kochextrusion hergestellte Kroketten vorliegt und dass die Kroketten neben den Hauptbestandteilen

Mais und Karotten auch Reis und Eisen(II, III)-Mischoxid als farbgebenden Zusatz enthalten. Die durch Kochextrusion hergestellten Karotten enthalten sämtliche Bestandteile in einem vorgegebenen, durch das Herstellungsverfahren steuerbaren Mischungsverhältnis. Die kugelförmigen Kroketten stellen eine artgerechte Abgabeform dar, die ein Vogel ohne Gefahr innerer Verletzungen aufnehmen und rasch verwerten kann. Die Extrudatkroketten zeichnen sich ferner durch eine grosse Porosität aus und besitzen eine grosse Aufnahmefähigkeit für Flüssigkeiten. Das ermöglicht dem Züchter, gezielt

Flüssigbestandteile hinzuzufügen, die der Vogel mit der festen Nahrung zusammen aufnimmt.Ohne

Zugabe von Reis und Eisen(II, III)-Mischoxid bleiben die Extrudatkroketten blass, und zwar auch bei hohem Karottenanteil. Die Kroketten haben nicht das Aussehen eines Gemüseproduktes. Die Zugabe

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eines Eisen(II, III)-Mischoxids allein führt ebenfalls nicht zu der gewünschten Färbung.

Überraschenderweise stellt sich eine naturnahe, frische Färbung der Kroketten ein, wenn diese Reis und Eisen(II, III)-Mischoxid in Kombination enthalten. Der Gehalt an Reis sollte mindestens 4 Gew.% betragen. Gute Ergebnisse werden erreicht mit 4 bis 10 Gew.% Reis und mindestens 0,05 Gew.%, vorzugsweise etwa 0,10 Gew.%, Eisen(II, III)-Mischoxid. Nach bevorzugter Ausführungsform der

Erfindung weisen die Kroketten

15 bis 20 Gew.% Karotten

4 Gew.% Reis

0,10 Gew.% Eisen(II, III)-Mischoxid,

Rest Mais

auf.

Das erfindungsgemässe Beifutter ist durch Kochextrusion herstellbar. Eine Futtermischung mit einer vorgegebenen, dem Bestimmungszweck angepassten Zusammensetzung wird in einem

Schneckenextruder unter Zugabe von Wasser und Wasserdampf bei gegenüber atmospärischem Druck mit erhöhtem Druck aufgekocht und als pastöser Strang extrudiert. Am Düsenaustritt bläht der Strang durch Wasserverdampfung auf. Stärke, die der Futtermischung vornehmlich in Form von Mais zugesetzt wird, verstärkt den Bläheffekt. Der aus dem Schneckenextruder austretende pastöse Strang wird in kleine Strangabschnitte portioniert, wobei der Schnitt unmittelbar an der Düse des

Schneckenextruders erfolgt. Der so geführte Schnitt in Verbindung mit dem vornehmlich durch den

Stärkegehalt steuerbaren Aufblähen des Stranges ergibt kugelförmig geformte Strangabschnitte, die nach Trocknung die erfindungsgemässen Extrudatkroketten bilden.

Ausführungsbeispiel

Beifutter für Tauben aus kochextrudierten Kroketten mit folgender Zusammensetzung:

77,90 Gew.% Mais

18,00 Gew.% Karotten

4,00 Gew.% Reis

0,10 Gew.% Eisen(II, III)-MischoxidData supplied from the esp@cenet database - Worldwide

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29.

DK191283 - 4/28/1983

QUICK COOKING RICE AND PROCESS FOR MAKING THE SAME

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=DK191283

Inventor(s): WEIBYE BJARNE (--)

Applicant(s): APOTHEKERNES LAB (NO)


IP Class: A23L

E Class: A23L1/182; A23B9/02F; A23B9/08; A23B7/005F; A23B7/02D; A23L1/212C; A23L1/216D

Application Number: DK19830001912 (19830428)

Priority Number: US19810298676 (19810902); WO1982NO00047 (19820902)

Family: CA1235600

Equivalent: WO8300802; US4385074; NL8220309; GB2115266; FR2513085; SE450807;

NL191140C; IT1152516; IE822137L; IE54047

Abstract:

Abstract of DK191283

In a method for the manufacture of a product, which can be prepared for eating in a short time, from a material such as rice or pieces of starchy vegetables by forming a layer of raw material 10 on a gaspermeable conveyor 16 and conveying the raw material through a processing chamber 30, in which the water content of the raw material is increased by treating with water, and the raw material is gelatinised by heat treatment, following which the product is finally dried to a moisture content of 5-15 per cent by weight, the raw material is processed in a number of successive stages, the raw material being alternately wetted by spraying with water and heated by means of steam at a temperature of between

135 and 160 degrees C, the alternate processing stages being repeated until the final temperature of the material is in the range 72 to 160 degrees C. As a result, rice or vegetables, which are processed by the method, will only have to be swelled from 3-5 minutes in hot but not boiling water as preparation for eating. The manufactured products have a high nutritional content, because during processing only very small amounts of starch and other nutrients are removed, which also reduces pollution of the drainage water. The invention also relates to an apparatus for performing the method.Description:



This invention relates to a continuous process for producing quick cooking (instant) rice which requires only about five minuts for swelling in hot, not necessarily boiling, water to be suitable for consumption, while retaining most of the nutritional value in the rice.

Standard milled white rice requires about 20 to 35 minutes of cooking in boiling water. In addition to the long cooking time required for the rice, the starch is sometimes not entirely gelatinized, or an undue number of the starch cells in the rice may burst to form a viscous, sticky, pasty cooked rice. For these reasons and others, the consumption of rice has been restricted for many years. Accordingly, considerable effort has been directed towards the production of quick cooking rice. Generally, quick cooking rice is rice that has been hydrated and/or gelatinized to various degrees and dried in such a manner to produce individual kernels.

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An excellent discussion of quick cooking rice is given in RICE CHEMISTRY AND TECHNOLOGY edited by D. F. Houston, published by the American Association of Cereal Chemists, Incorporated, St.

Paul, Minn., Chapter 15, Quick Cooking Rice, Robert L. Roberts, pages 381-399, the entire contents of which are incorporated by reference herein.

Generally most prior art methods of making quick cooking rice involve soaking the rice in water. For example, see U.S. Pat. Nos. 2,438,939; 2,733,147; 2,740,719; and 2,828,209. The soaking technique, however, is time consuming, involves a loss of valuable rice starch and produces a waste water pollution problem. Soaking involves the use of excess water which invariably leads to a dissolving of rice starch into the water which not only lowers the nutritional value of the rice (loss of carbohydrates and calories), but also results in the production of a starchy water effluent which must be disposed.

Another technique used in producing quick cooking rice is to fissure the rice and such method is disclosed in various patents including U.S. Pat. Nos. 3,157,514 and Norwegian Pat. No. 107,170. U.S.

Pat. No. 3,157,514 suffers from the fact that it specifically requires hydrated rice to be used as a raw starting material. Further, U.S. Pat. No. 3,157,514 involves the soaking technique and cooling the rice before drying (a very energy wasteful step). The rice product of U.S. Pat. No. 3,157,514 is not completely gelatinized and thus requires boiling to render the rice suitable for consumption. The rice produced by the method of Norwegian Pat. No. 107,170 is also not completely gelatinized and thus requires boiling in water before consumption.

Still another process to produce quick cooking rice is given in U.S. Pat. No. 2,937,946 which discloses the use of spraying with hot water to gelatinize the rice. This technique requires large amounts of hot water and is thus very energy consuming. Also, the process of U.S. Pat. No. 2,937,946 involves a great deal of time to achieve gelatinization.

DEFINITIONS

"Gelatinization" of rice as referred to herein concerns the condition of the rice after it has been treated at a certain temperature in a sufficient amount of moisture such that the starchy component of the rice is softened, structurally broken down and converted in such a manner that the rice swells in hot water.

"Completely gelatinized" as referred to herein concerns the condition of the rice when all the starchy material in the rice is completely softened and all of the starch content in the rice is converted. Rice that is completely gelatinized will generally not yield crispy fragments when cooked by soaking in hot water.

"Moisture content" of rice as referred to herein and expressed as a weight percentage is the weight percent of moisture with respect to the total weight of the dry rice plus the weight of moisture contained in the rice.

"Water" as referred to herein is water in the liquid phase and does not include water in the gaseous phase, i.e., steam.

"Dry steam" or "steam" as referred to herein is steam which does not contain any particles of moisture.

The dry steam or steam will experience a rise in temperature when exposed to an increase in heat.

"Wet steam" as referred to herein is steam which contains moisture.


There has now been discovered a process to prepare a quick cooking rice product in which most of the carbohydrate and nutritional value is retained and in which the rice kernels are generally whole grain and not broken. Depending on the nature of the rice utilized, the rice product made by this new process will have a starch content which is 15% to 20% higher than a corresponding rice product made by conventional batch processes. The rice prepared by this novel process can be cooked in about five minutes by swelling in hot water. The novel process of this invention is also economical, saves energy,

135/2197

saves time, and produces a minimum of starchy pollutant effluents. This process can also be conducted in a closed chamber, thus avoiding undue contamination of the area in which the rice is processed.

The continuous process of the present invention involves the spraying of rice with water and steam, such that the rice is completely gelatinized and attains a moisture content of between about 24 weight percent and about 78 weight percent with a resultant temperature for the gelatinized rice of between about 79 DEG C. and about 100 DEG C. The gelatinized rice is then dried to attain a final moisture content of between about 10 weight percent and about 14 weight percent, with the rice not being agitated to the extent where the rice forms a sticky mass.

The spraying of the rice can be accomplished by using alternate separate sprays of water and steam, or with wet steam.

For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.


FIG. 1 is a schematic diagram of an exemplary embodiment of an apparatus for conducting the continuous quick cooking rice process of the present invention.

FIG. 2 is a plot of treating time to obtain complete gelatinization of the rice as a function of the weight percentage of moisture in the rice.


The rice that can be used in the present process is dehulled rice. Non-limiting examples of rice that can be utilized in this process include white rice, brown rice, long grain rice, medium grain rice, short grain rice and parboiled rice.

Although untreated rice can be utilized in the process of this invention, i.e., ordinary dehulled unpreheated rice, it is preferable to use fissured (finely cracked) rice grains. Without wishing to be bound by any particular theory of operability, it is believed that fissuring or causing fine cracks in the rice causes liquid to penetrate the grains quickly. The preferred method of obtaining this fissuring is by preheating the rice. This preheating is preferentially done in a hot gas, for example, air, oxygen, nitrogen, etc. The extent of preheating to achieve fissuring depends on the rice quality, for example, its starch content. The appropriate amount of preheating to achieve fissuring is empirical and must be determined experimentally. Generally, the temperature of preheating is between about 110 DEG C. and about 150 DEG C., and preferentially, between about 130 DEG C. and about 140 DEG C. The duration of preheat is between about 10 minutes and about 15 minutes, and preferentially between about 11 minutes and about 13 minutes.

The rice, either untreated or preheated, is completely gelatinized and a certain predetermined moisture content is imparted thereto by intermittently spraying the rice with water and steam. If preheated rice is used, such rice is sprayed while it is still hot. A controlled amount of water and steam is utilized during spraying in order to attain a moisture content of between about 24 weight percent and about 78 weight percent with a resultant temperature for the completely gelatinized rice of between about 79 DEG C. and about 100 DEG C. It is preferred to achieve a moisture content of between about 52 weight percent and about 73 weight percent and more preferably to achieve a moisture content of between about 68 weight percent and about 71 weight percent. It is also preferred to attain a resultant temperature of the gelatinized rice of between about 87 DEG C. and about 95 DEG C., most preferably between about 90

DEG C. and about 93 DEG C.

The spraying of water and steam onto the rice can be performed using wet steam or with one or more cycles of sprays of water and steam (a cycle consists of one spray of water and one spray of steam) either alternately or simultaneously, with alternate spraying preferred. Each individual spray of water

136/2197

lasts between about 5 seconds and 40 seconds, preferably between about 10 seconds and 40 seconds.

The temperature of the water utilized is not crucial (it may be hot or cold) and can be ambient, for example, between about 10 DEG C. and 20 DEG C. Water such as tap water, distilled water, etc. can be utilized. Also, both hard and soft water can be employed. The number of cycles of sprays utilized may be between about 3 and 7. The actual number of cycles of sprays will depend upon the starch content of the rice. Italian rice, for example, has a starch content of between about 85 weight percent and about 87 weight percent and preferably is treated in 5 cycles. American rice, on the other hand, has a starch content of 87 weight percent to 90 weight percent and preferably is treated in 6 cycles or in 5 cycles with extended spraying and steaming.

The steam utilized will have a pressure of between about 3.8 kg/cm@2 and about 6 kg/cm@2, with a corresponding temperature of between about 135 DEG C. and about 160 DEG C. Each individual spray of steam lasts between about 0.5 minute and 4 minutes, preferably between about 1 minute and about 3 minutes.

A typical scheme for spraying water and steam is as follows: First, water is sprayed onto the rice for between about 10 seconds and about 30 seconds (such as about 15 seconds), followed by a steam spray for about 0.25 minute and about 3 minutes (such as about 2 minutes). This cycle for spraying water and steam onto the rice is repeated up to about 7 cycles, depending on the type of rice utilized, the duration of the sprays, the temperature of the sprays, etc. until the rice is substantially completely gelatinized.

The total contact time during the intermittent spraying of the rice with the steam and water is approximately between about 2 minutes and 26 minutes, preferably between about 2 minutes and 20 minutes, and more preferably between about 3 minutes and 17 minutes. It is preferred to carry out the spraying of the rice with water and steam wherein the rice is on a moving perforated bed or belt and the sprays can contact the rice from either above or below the rice, or both above and below the rice. It is preferred that a rice layer on the belt or bed be between about 3 millimeters and 10 millimeters, and more preferably between about 5 millimeters and 7 millimeters in depth. The spraying can be conducted in a closed chamber to avoid contamination.

The rice may also be sprayed by using alternate pulses of water, steam and heat. In this instance, the rice would be alternately sprayed with water and steam, then heated, then sprayed with water and steam, then heated, and so on for a number of cycles of water-steam spraying and heating.

Gelatinization may be carried out to completion while the rice is being sprayed. In rare instances, gelatinization may extend to completion to a small extent in a subsequent drying operation. However, it is preferred and contemplated that all of the gelatinization occur during spraying.

The total amount of moisture imparted to the rice depends on several variables including the nature of the rice, the pressure and temperature of the steam, the temperature of the water, the time of treatment

(contact time) and the weight and surface area of the rice being contacted. The time for obtaining complete gelatinization depends, among other variables, on the rice quality.

Steam treating time during spraying is dependent upon the depth of the rice layer being contacted. The less the depth, the less treating time required. It must be noted that during steaming, the depth may increase due to swelling. The temperature of the steam used in spraying can be between about 135

DEG C. and 160 DEG C.

After the spraying with water and steam, with the rice now being completely gelatinized and having a moisture content of between about 24 weight percent and 78 weight percent, such as approximately 70 weight percent, and at a temperature of between 79 DEG C. and about 100 DEG C., such as approximately 90 DEG C., the rice while still hot, is dried, such as by transferring the rice on a moving bed to a drying section. It is important that when the rice is handled between the spraying and drying steps that the rice not be stirred or agitated in order to prevent a sticky mass from being formed. During the drying step, the gelatinized rice is reduced to a final moisture content of between about 10 weight percent and about 14 weight percent.

It is preferred that the drying be carried out in two steps, a predryingstep in which the moisture content is reduced to between about 25 weight percent and about 35 weight percent and a final drying step in

137/2197

which the moisture content is reduced to between about 10 weight percent and about 14 weight percent.

Thus, a predrying section could be operated at a temperature between about 100 DEG C. and about 140

DEG C. with a duration of drying of between about 2 minutes and about 3 minutes. The final drying section could be operated at a temperature of between about 50 DEG C. and about 70 DEG C. and for a duration of drying of between about 20 minutes and about 30 minutes. Such drying can be carried out in any convenient manner such as in a drying tunnel. Methods to conduct this drying include the use of hot air, indirect heat exchangers (steam heat exchangers), microwaves, electric resistance heating, fired heaters, etc. During drying, case hardening of the rice grains must be prevented. After drying, the finished quick cooking rice is then ready to be sent for packing or storage.

Now referring to FIG. 1 in detail, unpreheated or preheated, fissured raw rice schematically represented by arrow 10, enters a raw rice hopper 11 and is deposited onto a perforated stainless steel conveyor belt

12. While moving on the conveyor belt, the rice is alternately contacted with water from sprayers 13 and steam from sprayers 14. Although FIG. 1 schematically illustrates the water and steam as contacting the rice from above the bed, the water and steam sprays may be located below and above the moving rice bed. After being contacted with water and steam, the rice then moves into a predryer 15.

After being predried, the rice is passed through a gelatinized rice hopper 16 into a drying tunnel 17.

Although not so illustrated, the drying tunnel may include several drying sections with each section heated by a source of heat, such as by an indirect heat exchanger 18. The last section of the drying tunnel 17 is a cooling section 19. The rice is discharged from the cooling section 19 at outlet 20. The finished quick cooking rice is then ready to be transported for packing and/or storage.

The present invention is very advantageous in that a superior quick cooking rice product is obtained by the novel process of this invention. The rice product so obtained does not require conventional cooking in boiling water to be suitable for consumption. The rice produced by this process requires only a few minutes swelling time in hot water before it can be served. Furthermore, the rice obtained by the present process is a richer product than that obtained by prior art processes in that most of the rice's fatty materials and starches are retained in the rice and not lost during processing. Also the rice product of this process has a very low percentage of unattractive broken grains.

As compared to prior art instant rice processes, the process of the present invention has the advantages of consuming less time, energy and labor. Also, this process is less polluting than conventional processes and more economical to operate.

The invention will now be described in greater detail by reference to the following specific, nonlimiting examples.

EXAMPLES 1-3

A layer of rice supported on a perforated steel bottom of an uninsulated chamber was contacted with wet steam. Such wet steam was sprayed through orifices located both above and beneath the rice bed.

After the rice was sprayed with wet steam, the rice was dried by predrying the hot material at 120 DEG

C. for 1-2 minutes. The rice was then gently turned and after-dried at 60 DEG-65 DEG C. for about 10-

30 minutes. To prevent formation of a sticky mass, excess water had to be quickly removed. To accomplish such drying, high velocity air at about 100 meters/minute was employed. Conditions for

Examples 1-3 are given in Table 1 hereinafter. The results for Examples 1-3 were good. In each example, the rice was completely gelatinized.

Determination of the water content of the finished dry rice product was accomplished by using a Sauter balance with an infrared lamp located above the balance pan in a manner well known to those skilled in the art. A 10 gram sample of the rice was measured on the balance and then the lamp was turned on for a period of about 10 minutes. After the 10 minute period, the sample was reweighed and the difference in weight represented the loss of water.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Amount of

>;tb; Rate of Moisture

>;tb;Area of Steam

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>;tb; Rice Utilized

>;tb; Water Mixed

>;tb; Total Temp. of

>;tb; Imparted To

>;tb;Ex.

>;tb; Treatment,

>;tb; Pressure, Amount,

>;tb; With The Steam,

>;tb; Duration of

>;tb; Channel,

>;tb; the Rice,

>;tb;No.

>;tb; m@2

>;tb; kg/cm@2

>;tb; Type kg liter/min.

>;tb; Steaming, min.

>;tb; DEGC.

>;tb; liters

>;tb;__________________________________________________________________________

>;tb; 3 min.

>;tb;1 0.19 5 rice*

>;tb; 0.8 0.25 4 92 1.0*

>;tb;2 0.19 5 parboiled

>;tb; 1.1 0.25 10 90 2.5**

>;tb; via top

>;tb;3 0.30 3.8 3 min.

>;tb; 1.2 orifice: 5

>;tb; 6 93 30**

>;tb; rice* via bottom

>;tb; orifice: 10

>;tb;__________________________________________________________________________

>;tb; *"3 min" or "10 min" rice referred to in this Table and elsewhere herein

>;tb; means rice that is heated so it requires 3 minutes (or 10 minutes) boilin

>;tb; time for consumption.

>;tb; **Not including some condensed water from the steam

EXAMPLES 4-15

A pilot apparatus similar in principle to the process equipment depicted in FIG. 1 was utilized in

Examples 4-15. In these Examples 4-15, separate sprays of water and steam were sprayed alternately and progressively from separate orifices onto the rice.

In Examples 5-9, the gelatinized rice before drying was found to have a moisture content of between about 65 and 70 weight percent. In Examples 10-12, the moisture content in the rice after gelatinization varied between 62% and 70%. In Examples 13-15, the moisture content in the rice after gelatinization varied between 63% and 70%. Gelatinization conditions for Examples 4-15 are given in Table 2 hereinafter. Table 3 hereinafter gives the predrying and afterdrying conditions and results for Examples

4-15.

In the last three examples, Examples 13-15, untreated rice was used as a starting material, i.e., ordinary, dehulled white rice which was not preheated. Examples 13-15 clearly show that the process of this invention also works well with this type of material, but the process time is longer and the loss of starchy material is greater.

The time for obtaining complete gelatinization, in fact, depends on the rice quality, among other variables. Referring to FIG. 2, which is a plot of treating time to achieve complete gelatinization as a function of the weight percentage of moisture in the rice, the time required from point A to point B and from point B to point C, providing a constant temperature of between about 90 DEG C. and about 93

DEG C. is maintained, can be stated as follows:

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>;tb;______________________________________

>;tb; A to B B to C

>;tb; (approximate time


>;tb;Rice quality in minutes) in minutes)

>;tb;______________________________________

>;tb;Untreated rice

>;tb; 11 2-3

>;tb;3 minute rice

>;tb; 3 1

>;tb;10 minute rice

>;tb; 6 1

>;tb;Parboiled rice

>;tb; 11 1

>;tb;______________________________________

If the treating time is extended beyond point C, the rice will be destroyed, thus losing its form and consistency.

The steam treating time is also dependent on the depth of the rice layer on the perforated bed. In the

Examples, the depth was 5 mm, which increased to 25 mm during the gelatinization process. This was due to the swelling of the rice grains.

Although rice of any quality may be used in the novel process of this invention, the best results were achieved by using 3 minute rice, since the steam quickly penetrated the outer layer and started the gelatinization in the interior of the rice grain. 3 minute rice also required the shortest steaming time.

The most chewy and temperature stable product, however, was obtained by using ordinary dehulled, white long grain rice which was not preheated.

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb; Water Sprays

>;tb; Total

>;tb;Area of Steam

>;tb; Rice Utilized

>;tb; Rate of water

>;tb; Duration of

>;tb; Duration of

>;tb;Example

>;tb; Treatment,


>;tb; Utilized,

>;tb; No. of

>;tb; Each Spray

>;tb; Spraying,

>;tb;No. m@2

>;tb; kg/cm@2

>;tb; Type kg liters/min.

>;tb; Sprays

>;tb; min. min.

>;tb;__________________________________________________________________________

>;tb; 4*

>;tb; 0.3 3.8 3 min. rice

>;tb; 3.0 5 5 1/2 21/2

>;tb; 5 0.3 4.0 3 min. rice

>;tb; 3.0 4.8 5 1/4 11/4

>;tb; 6 0.3 4.0 3 min. rcie

>;tb; 3.0 4.8 5 1/4 11/4

>;tb; 7 0.3 4.0 3 min. rice

>;tb; 3.0 4.8 5 1/4 11/4

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>;tb; 8 0.3 4.0 3 min. rice

>;tb; 3.0 4.8 5 1/4 11/4

>;tb; 9 0.3 4.0 3 min. rice

>;tb; 3.0 4.8 6 1/4 11/2

>;tb;10 0.3 4.0 10 min. rice

>;tb; 3.0 4.8 7 1/4 13/4

>;tb;11 0.3 4.0 10 min. rice

>;tb; 3.0 4.8 5 1/4 11/4

>;tb;12 0.3 4.0 10 min. rice

>;tb; 3.0 4.8 5 1/4 11/4

>;tb;13 0.3 4.0 untreated rice

>;tb; 3.0 4.8 6 1/4 11/2


>;tb; 3.0 4.8 6 1/4 11/2


>;tb; 3.0 4.8 6 1/4 11/2

>;tb;__________________________________________________________________________

>;tb; Steam Sprays

>;tb; Total

>;tb; Duration of

>;tb; Duration of

>;tb; Temp. of

>;tb; Example

>;tb; No. of

>;tb; Each Spray,

>;tb; Spraying,

>;tb; Channel

>;tb; No. Sprays

>;tb; min. min. DEGC.

>;tb; Gelatinization

>;tb;__________________________________________________________________________

>;tb; 4*

>;tb; 5 1 5 94 Not completely

>;tb; gelatinized,

>;tb; some crispy

>;tb; fragments

>;tb; 5 2 1 8 98-100

>;tb; Very Good

>;tb; 3 2

>;tb; 6 2 1 8 98-100

>;tb; Very Good

>;tb; 3 2

>;tb; 7 2 1 8 98-100

>;tb; Satisfactory

>;tb; 3 2

>;tb; 8 2 1 8 98-100

>;tb; Satisfactory

>;tb; 3 2**

>;tb; 9 2 1 10 98-100


>;tb; 4 2 seemed to go

>;tb; too far

>;tb; 10 2 1 12 98-100

>;tb; Good (5

>;tb; 5 2 sequences

>;tb; were not

>;tb; sufficient)

>;tb; 11 2 1.25 10 98- 100

>;tb; Satisfactory

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>;tb; 3 2.5

>;tb; 12 2 1.25 10 70-85

>;tb; Not satisfac-

>;tb; 3 2.5 tory - trouble

>;tb; with the steam

>;tb; 13 2 1.25 12.5 98-100

>;tb; Rice was hard

>;tb; 4 2.5 after 5

>;tb; sequences -

>;tb; gelatinization

>;tb; was satisfac-

>;tb; tory after an

>;tb; additional

>;tb; sequence

>;tb; 14 2 1.25 12.5 98-100

>;tb; Satisfactory

>;tb; 4 2.5

>;tb; 15 2 1.5 15 98-100

>;tb; Satisfactory

>;tb; 4 3

>;tb;__________________________________________________________________________

>;tb; *Amount of water added to the rice was 12.5 liters, not including some

>;tb; condensed water from the steam.

>;tb; **Rice was sprayed with cold water immediately after the last steaming

>;tb; cold water had no effect on gelatinization.

>;tb; TABLE 3

>;tb;__________________________________________________________________________

>;tb;Pre-Drying Conditions

>;tb; After Drying Conditions

>;tb; Air Air

>;tb;Ex.

>;tb; Velocity,

>;tb; Temp.,

>;tb; Duration,

>;tb; Velocity,

>;tb; Temp.

>;tb; Duration,

>;tb;No.

>;tb; m/min.

>;tb; DEGC.

>;tb; min. m/min.

>;tb; DEGC.

>;tb; min. Results

>;tb;__________________________________________________________________________

>;tb;4 125 114 4 90 55 21 Good results were obtained

>;tb;5 125 110 11/2 90 53 25 Case hardening had occurred and the

>;tb; grains had a hard

>;tb; shell with a soft kernel.

>;tb;6 125 100 21/2 90 55 25 The product was not perfectly dry.

>;tb;7 125 100 21/2 90 55 25 Very good. The rice agglomerates could

>;tb; be broken apart

>;tb; into separate grains very easily. A

>;tb; sample was pre-

>;tb; pared by swelling in hot water for 5

>;tb; minutes. The rice

>;tb; was well cooked and the consistency was

>;tb; nice and soft

>;tb; without any hard fragments in the

>;tb; grains.

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>;tb;8 125 100 3 90 70 25 Very good. Exactly the same result as in

>;tb; Example No. 7.

>;tb;9 125 110 3 90 70 25 The product was satisfactorily dried and

>;tb; the agglomer-

>;tb; ates were easily broken apart into

>;tb; separate grains. A

>;tb; sample which was prepared for eating by

>;tb; swelling in hot

>;tb; water was too soft. The gelatinization

>;tb; process had gone

>;tb; too far.

>;tb;10 125* 115 3 90 70 25 The product was not satisfactorily dried

>;tb; and the dry-

>;tb; ing had to continue for another 3

>;tb; minutes. Still, the

>;tb; product was not as dry as desired and it

>;tb; was almost

>;tb; completely impossible to break up the

>;tb; agglomerates.

>;tb;11 125 108 3 90 70 25 Very good. The rice agglomerates could

>;tb; easily be

>;tb; broken apart to single grains. A sample

>;tb; was prepared

>;tb; for eating by swelling in hot water for

>;tb; 5 minutes.

>;tb; The grains had a firm and nice

>;tb; consistency without any

>;tb; hard zones and were more chewy than that

>;tb; from "3 minute

>;tb; rice". This is the way this kind of rice

>;tb; should be.

>;tb;12 125 110 2 90 70 26 The product was satisfactorily dry but

>;tb; the grains had

>;tb; crispy zones because of unsatisfactory

>;tb; gelatinization.

>;tb;13 125 110 2 90 70 26 Although the product was not perfectly

>;tb; dry, the result

>;tb; was promising.

>;tb;14 125 120 2 90 70 30 The product was sufficiently dry and the

>;tb; rice agglomer-

>;tb; ates could easily be broken apart. A


>;tb; pared for eating by swelling the rice in

>;tb; hot water for

>;tb; 5 minutes. The grains had some crispy

>;tb; zones which in-

>;tb; dicated that the gelatinization process

>;tb; was not completed.

>;tb;15 125 108 2 90 70 30 The product was satisfactorily dry and

>;tb; the aggolomer-

>;tb; ates could quite easily be broken up. A

>;tb; sample was

>;tb; prepared for eating by swelling in hot

>;tb; water for 5

>;tb; minutes. The rice was firm and nice and

>;tb; probably still

>;tb; more chewy than that from the "10 minute

>;tb; rice". The

>;tb; result was very good.

143/2197

>;tb;__________________________________________________________________________

>;tb; *Rice was sprayed with water before drying

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.Data supplied from the esp@cenet database - Worldwide

144/2197

30.

EP0064224 - 11/10/1982

PREVENTION OF PUFFING DURING FRYING OF EXPANDED SNACK

PRODUCTS

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=EP0064224

Inventor(s): DAYLEY KYLE E (--); WILLARD MILES JAMISON (--)

Applicant(s): JAMISON WILLARD MILES (US)


IP Class: A23L1/164; A23L1/216

E Class: A23L1/164E; A23L1/214D; A23L1/217B; H05K7/20E

Application Number: EP19820103377 (19820421)


Family: CA1192076

Equivalent: JP57208952; EP0064224

Cited Document(s): US3656966; US3259503; US3800050

Abstract:

Abstract of EP0064224

A process for making fried expanded snack products includes preparing a moist dough principally from solids, such as corn or potato solids. Larger particle size dry food particles, such as wheat or rice particles, are included in the dough. The dough is then formed, such as by rollerforming, into a thin sheet, and dough pieces cut from the sheeted dough are fried in hot cooking oil to form a fried expanded snack. The larger food particles project through or are contained in the surface of each dough piece to cause steam to escape during frying, which greatly reduces "puffing", i.e., formation of undesired bubbles in the snack, during frying. By providing a sufficient number of larger particles with an average particle size at least about to the thickness of the dough piece (so that an appreciable number of particles can project through or be contained in the surface of the dough piece), formation of undesired large bubbles is significantly reduced. The size of the largest bubbles formed during frying is proportionately reduced as the amount of larger particles added to the dough is increased. Formation of bubbles larger than a maximum tolerable size can be controlled to within acceptable limits by adding particulates greater in particle size than the dough thickness and in an amount that results in at least one particle per unit surface area of the sheeted dough piece, where said untt surface area is the largest acceptable size (area) of any bubbles formed during frying.Claims:

Claims of EP0064224

WHAT IS CLAIMED IS:

1. In a process for producing a fried expanded snack from a dough prepared principally from dry solid ingredients selected from the group consisting of corn, potatoes, tapioca, amioca, wheat, rice, and mixtures thereof, an improved method for reducing puffing of a dough piece during frying, the improvement comprising the steps of:

145/2197

combining dry food particles with the principal dry solid ingredients to be contained in dough mixture, the dry food particles being larger in particle size than the average particle size of the principal dry solid ingredients;

forming a dough piece from the dough, the larger food particles being of a particle size at least similar to the thickness of the formed dough piece, said larger particles also projecting through or being contained in the surface of the dough piece; and

frying the dough piece in hot cooking oil to form an expanded fried snack product, the larger food particles providing a means of escape for moisture contained in the dough piece to reduce puffing of the snack product during frying, when compared with a similar snack product that does not contain said larger food particles.

2. The improvement according to claim 1, including forming the dough piece in thin sheet form of essentially uniform thickness.

3. The improvement according to claim 2, in which the dough piece is at least about 1.0 mm in thickness.

4. The improvement according to claim 3, in which the dough, at the time it is fried, has a moisture content of at least about 40%, by weight.

5. The improvement according to claim 4, in which a sufficient number of such larger food particles are contained in the dough piece that formation of bubbles greater in size than about 6 mm is substantially prevented in about 85% or more of the fried products made from the dough.

6. The improvement according to claim 1, in which the larger dry food particles are extraneously added to the dough ingredients.

7. A process for reducing puffing of a dough piece during frying, comprising the steps of:

forming a dough principally from relatively finer particle size dry solid ingredients selected from the group consisting of corn, potatoes, tapioca, amioca, wheat, rice, and mixtures thereof;

combining relatively larger particle size dry food particles with the principal dry solid ingredients to be contained in the dough;

forming a thin dough piece from the dough, the larger food particles having been mixed into the dough in an amount that will provide, on the average, at least one larger particle per each 36 mm2 of surface area of the formed dough piece, the larger food particles having a particle size at least about the thickness of the dough piece; and

frying the dough piece in hot cooking oil to form an expanded fried snack product.

8. The process according to claim 7, in which the dough has a moisture content at least about 40%, by weight.

9. The process according to claim 7, in which the dry larger food particles are extraneously added to the dough ingredients.

10. In a process for producing a fried expanded snack principally from a dough containing solid ingredients selected from the group consisting of corn, potatoes, tapioca, amioca, wheat, rice, and mixtures thereof, an improved method for reducing puffing of a dough piece having a thickness of about 1.0 to 1.2 mm, the improvement comprising the steps of:

combining dry food particles with the solid ingredients of the dough to disperse the food particles throughout the dough, the dry food particles having a particle size larger than the average particle size of the principal solid ingredients contained in the dough;

forming a thin dough piece with a thickness of about 1.0 to about 1.2 mm from the dough containing the larger food particles, the food particles having a particle size of at least about 0.8 mm; and

frying the dough piece in hot cooking oil to form an expanded fried snack product.

11. The improvement according to claim 10, in which the larger food particles are contained in the dough in an amount such that there is at least about one particle for about each 36 mm2 of surface area of the formed dough piece.

146/2197

12. The improvement according to claim 10, in which the dough has a moisture content of from at least about 40%, by weight.

13. The improvement according to claim 12, in which the principal solid ingredients in the dough have an average particle size of 0.5 mm or less.

14. A process for reducing puffing of a dough piece during drying, comprising the steps of:

forming a dough principally from solid ingredients selected from the group consisting of corn, potatoes, tapioca, amioca, wheat, rice, and mixtures thereof;

combining dry food particles with the principal solid ingredients to be contained in the dough, said dry food particles being of larger average particle size than the average particle size of the principal solid ingredients contained in the dough, sufficient water being combined with the principal solid ingredients and the larger dry food particles to form a dough with a moisture content of at least about 40%, by weight; ;

forming a thin dough piece at least about 1.0 mm in thickness from the dough, the larger food particles being of a particle size at least about the thickness of the formed dough piece and being in an amount sufficient to reduce puffing of the dough piece when fried in hot cooking oil, when compared with a similar dough piece that does not contain said larger food particles; and

frying the dough piece in hot cooking oil to form an expanded fried snack product essentially free of puffing.

15. The process according to claim 14 in which the larger particles are contained in the dough in an amount such that there is at least one particle for about each 36 mm2 of surface area of the dough piece.Data supplied from the esp@cenet database - Worldwide

147/2197

31.

EP0124891 - 11/14/1984

ANTIMUTAGENIC AGENT AND METHOD OF INACTIVATING THE

MUTAGENICITY OF FOODS AND BEVERAGES BY USING SAID AGENT


Inventor(s): SUWA YOSHIHIDE (--); KOBAYASHI TAKUMI (--); KIYOTA NORIKO (--);

YOSHIZUMI HAJIME (--)

Applicant(s): SUNTORY LTD (JP)

IP Class 4 Digits: A23L; A61K; A23F; C12G

IP Class: A23L1/172; A61K35/78; A23L1/34; A23F3/14; A23F5/14; A23F5/40; C12G3/00

E Class: A23L1/172; A23F3/14; A23F5/14; A23F5/40; A23L1/03D; C12G3/00



(19830708); JP19830124245 (19830708); JP19830160879 (19830901)

Family: EP0124891

Equivalent: EP0124891

Cited Document(s):

DE2043888; JP58020163

FR1182623; FR363969; US2676888; DE852938; GB191405001;

Abstract:


A method of reducing or eliminating the mutagenicity of foods and beverages by causing an antimutagenic substance to act on them is disclosed. The antimutagentic substance is selected from the group consisting of wheat germ, barley malt, soybean, powders thereof, rice bran and extracted fractions thereof. An antimutagenic agent for use in this method which contains one of these antimutagenic substances as the effective ingredient is also disclosed.

148/2197

32.

EP0129032 - 12/27/1984

A SAFE PREPARATION OF VITAMIN C


Inventor(s): SUWA YOSHIHIDE (--); KOBAYASHI TAKUMI (--); KIYOTA NORIKO (--);

YOSHIZUMI HAJIME (--)

Applicant(s): SUNTORY LTD (JP)

IP Class 4 Digits: A23L; A61K; A24B; C12H

IP Class: A61K35/78; A23L1/30; A24B15/30; A61K31/375; A61K37/50; C12H1/14

E Class: A61K35/78; A23F5/40; A23L1/302; A61K38/44



Family: EP0129032


Cited Document(s):

Abstract:

US2300439; FR999725; US2620275; JP55141177; JP54062357


A germ component selected from the group consisting of barley malt, wheat germ, soy bean germ, rice germ and extracts thereof reduces or completely inactinates the mutagenicity which is caused or enhanced by the combination of synthetic vitamin C and beverages, tobacco or cupreous ions. Catalase reduces or completely inactivates the mutagenicity and cytotoxicity caused or enhanced by said combination. Therefore, this mutagenicity and cytotoxicity may be reduced or inactivated by preparing a preparation of vitamin C comprising vitamin C and said germ component or catalase.Description:

Description of EP0129032

A SAFE PREPARATION OF VITAMIN C

This invention relates to a preparation of vitamin C combining vitamin C with a germ component or catalase[Catalase (hydrogen-peroxide: hydrogen-peroxide oxdoreductase, EC 1.11. 1.6)) to reduce or inactivate the mutagenicity of beverages or tobacco caused or enhanced by vitamin

C, or to reduce or inactivate the mutagenicity and cytotoxicity of beverages or tobacco coused of enhanced by vitamin C (also known as L-ascorbic acid).

Vitamin C has long been used as a soverign remedy against scurvy. It is also known to be efficacious against viral or bacteriogenous infections diseases such as common cold, influenze, virus pneumonia, hepatitic poliomyelitis, measles, mumps, chickenpox and tuberculosis.

Recently, vitamin C has been found to have the ability to check the growth of malignant tumors (H.

Kawasaki et al., Cancer Letters, Vol. 16, 57-63, 1982) or retard the formation of a nitroso compound

(S. S. Mirvish et al.,

Science, Vol. 177, 65-68, 1972). Therefore, vitamin C is considered to be an important substance for cancer prevention. Furthermore, the effectiveness of a large intake of vitamin C is being claimed by several authorities, among whom a Nobel laureate Dr. Linus Pauling is the most prestigious protagonist

(E. Cameron et al., Cancer Research,

149/2197

Vol. 39, 663-681, 1979). Today, a high intake of vitamin C in the form of pills or tablets is an everyday matter for an increasing number of people.

However, vitamin C has a strong reducing nature due to an endiol group in the molecule, and in addition to its useful physiological activities, vitamin C may cause deleterious reactions depending on the type of substances with which it is ingested into the body. As a matter of fact, in the presence of cupreous ions, vitamin C exhibits mutagenicity (H.F. Stich et al., Nature, Vol. 260, 722-724, 1976).

Incidentally it is presumed that the above mutagenicity is due to radicals such as monodehydroascorbic acid, superoxide amion radical( 2 ) and hydroxy radical( OH) but it has not yet been proved by experiments. Furthermore, vitamin C causes chromosome aberration in animal cells (H.F.

Stich et al., Fd. Cosmet. Toxicol., Vol. 18, 497-501, 1980), enhances the potency of a carcinogenmethylchslanthrene (S. Bamit, Cancer Letters, Vol. 11, 239-242, 1981) cr works as a cancer-inducing promoter (K.Imaida et al.,Proc. Jap.

Cancer Association,41th Ann.Meeting, p. 79, 1982).

It is already known that when vitamin C is dissolved in coffee, the mutagenicity of the resulting solution is at least 6 times as high as that of the coffee alone(. Suwa et al., Mutation Res., Vol. 102,

383-391, 1982). According to the studies of the present inventors, therutagenicitv of other beverages such as black tea and bourbon whiskey, as well as tobacco, when ingested together withvitamin C, is increased to a level that is several times as high as that of these beverages or tobacco per se. Since a large intake of vitamin C by an individual is not unusual these days, the development of a method for utilizing onl the meritorious effects of vitamin C withoutendanger In the human body will be an urgent matter for the protection of human health.

Since the dawn of its history, man hastake in vitamin C together with other nutrients that occur in nature, and it is quite exceptional in the evolution ofanirals that vitamin C alone is now ingested in high doses. It s unthinkable that the occurrence of increasedmutatenlcity due to vitamin C will not cause toxicity in human cells, and when vitamin C is ingested in the form ofvegetables and fruits, its deleterious effects are in mostllkellfood inhibited by some other of the components of vegetables or fruits. Based on this assumption, the present inventors made various studies to find substances that arecapable of reducing or completely eliminating the increase in mutagenicity due to vitamin C.

After elaborate screening, the present inventors found that barley malt, wheat germ, rice germ and soy bean germ, and extracts thereof (hereunder referred to as "germ components") have activities which suppress mutagenicity due to the present of vitamin C. Moreover the present inventors also found that catalase has remarkable effects to inactivate the mutagenicity and cytotoxicity caused or increased by the combination of vitamin C and beverages or tobacco.

Catalase has a molecular weight of from 220,000 to 250,000 and is an enzyme decomposing hydrogen peroxide as indicated in the following reaction:2H 202

EMI3.1

2H 20 + 2

Catalase also acts as a catalyst for oxidation of alcohols, formic acid etc. in the presece of hydrogen peroxide. Catalase is present in most organisms other than anaerobic bacteria and is recognized to be conducive to decomposition or detoxication of hydrogen peroxide endogenously produced in organism living in the aerobic environment.

Any catalases obtained from animal sources including cow and horse livers and erythrocytes; vegetable sources; and microorganisms such as Micrococcus lysodeikticus and

Aspergillus niger can be used in this invention.

Fig. 1 is a graph indicating the effects of vitamin C in enhancing the cytotoxicity of coffee and the efficacy of catalase in destroying such effects.

In the figure, the symbol indicates % survival of coffee per se (containing no additive), the symbol A indicates that of coffee to which vitamin C (0.1 mg/ml) was added and the symbolw means % survival of coffee to which vitamin C (0.1 mg/ml) and catalase (10 units/ml) were added.

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According to the experiments conducted by the present inventors, vitamin C increases the mutagenicity of coffee by about 6 fold. However, this increase can be suppressed almost completely by mixing vitamin C with a germ powder in an amount not less than five times as much as the vitamin C, or a germ extract powder in an amount not less than the amount of vitamin C. Further the mutagenicity of coffee per se is also almost completely suppressed. And if 5-25 units of catalase per 1 mg of vitamin

C is added, the mutagenicity increase caused by vitamin C can be almost completely suppressed.

Similarly, the increase in the mutagenicity of black tea, tobacco or straight bourbon whiskey due to vitamin C can be inhibited in the manner described above.

Consequently, mixing the germ component or catalase with vitamin C and making a preparation that is able to prevent the occurrence of mutagenicity and cytotoxicity owing to the reaction between vitamin

C and beverages or tobacco or cupreous ions, without sacrificing the desired activities of vitamin C, is entirely a new use of these substances.

Incidentally the term"combination1, or11corrining" used herein means any kind of pharmaceutical means able to attain the purposes of this invention, for example, blending of liquid, mixing by using a binder, kneading, combination observed in a multilayer tablet etc.

It will be obvious that a preparation ofvitamin C of this invention significantly useful for maintaining human health because the germ component and catalase per se are non-toxic and because the germ agents are rich in vitamins, proteins, essential lipid acids etc. and catalase is an enzyme necessary for protecting an organism against cell lesion by active oxygen.

The preparation of vitamin C of this invention can be used in dosage forms such as oral preparations,e.g., liquid, tables, powder, granules, etc. and the preparation can be used in foods as well as medicines. The preparation containing catalase can also be used in the formcf injection.

Substances from which originates themutagenicity occurring by the combination of vitamin C and beverages, non-alcoholic or alcoholic, or tobacco have not yet been analyzed. As mentioned above, according toman experiments vitamin C is oxidized to dehydroascorbic acid accompanying the free radicals. But this phenomenon has not yet been directly proved.

First of all, the present inventors investigated the solution of this problem by bringing into focus the reduction of mutagenicity. That is, considering that about80E of mutagens are carcinogens and also considering that mutagens attack and damage at least DNA constructing genes in cells, it is very important to eliminate or inactivate mutagens for the protection of human health.

The advantages of the present invention will become apparent by reading the following examples to which the invention is by no means limited.

Example I

Efficacy of Germ Components

I) Measuring the mutagenicity and antimutagenic activity (i) Method: The preincubation method shown in Sugimura

& Nagao, Chemical Mutagens, Vol. 6, 41, 1981 was used.

(ii) Microorganism: Histidine requiring Salmonella

typhimurium TA 100 (hereunder "S.TA 100)

was used.

(iii) Preparation of samples a) Instant coffee: instant coffee powder was disclosed in distilled water.

Predetermined amounts of the germ components were respectively suspended or dissolved in distilled water. Each solution was mixed with the aqueous coffee solution to make 100p1. b) Bourbon whiskey: Bourbon whiskey was evaporated to dryness under vacuum at a temperature below 400C in a rotary evaporator. The resulting solid product was dissolved in

DMSO. Predetermined amounts of the germ compounds were suspended or dissolved in distilled water.

Each solution was mixed with the DMSO solution of the concentrate to make100 p 1.

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c) Black tea: Black tea leaves (2.5 g) were brewed with 100 ml of boiling water. The extract was freezedried and the resulting solid matter was dissolved in distilled water to form a solution of a predetermined concentration.

Selected amounts of the germ components were suspended or dissolved in distilled water. Each solution was mixed with the aqueous solution of tea concentrate to make 100;1. d) When adding vitamin C to the samples (a)-(c), a solution of vitamin C in 25;1 of distilled water was mixed with each of said samples (25W1) so as to make the final concentration of vitamin C 0.5 mg/plate. After standing the mixture for 30 minutes at room temperature, it was mixed with the germ component as described hereinafter, suspended or dissolved in distilled water (501), to make 1001. e) The rice germ used was bran manufactured by Gosyo

Kabushiki Kaisha (a maker of dried foods in Kobe city, Japan.)

The wheat germ used was one commercially available under the trade mark "Riburon" (wheatgerm prepared by Nissin Seifun

Kabushiki Kaisha in Tokyo, Japan) or one manufactured by

Gosyo Kabushiki Kaisha. The barley malt used was one alightly germinated and the soy bean germ used was soy bean immersed in water.

(iv) Measurement of mutagenicity

To 100 ul of each of the samples prepared in (a) to (c), 500D1 of 100 mM sodium phosphate buffer

(pH 7.4) and 100D1 of a culture of S.TA 100 were added. Each of the mixtures was shaken for 20 minutes at37 CC, added to 2.5 ml of a soft agar solution and spread on aminimurn glucose agar plate which had been supplemented with 50-M per plate for causing severaldz ision After incubation at370C for 48 hours, the number of colonies on the plate was counted as revertants.

II) Results (i) Sanctivation of themutageniclty caused by

mixing vitamin C with coffee

The mutagenicity against S.TA 100 caused by mixing vitamin C with coffee was determIned.

The mutagenicity of coffee was increased by about 6 fold upon addition of vitamin C. To take coffee as an example, when coffee having a concentration usual to ordinary persons (i.e. 15 mg of coffee powder perm1 x 150 ml) is combined with one commercial vitamin pill (75mJ) the number of revertant colonies for 108 cells is theoretically 315,000. This value is almost equivalent to the mutagenicity caused by about 65 cigarettes.

On the other hand, various germ components almost completely inhibited the mutagenicity of the combination of vitamin C with coffee as shown in Table 1.

Table 1

S.TA 100 strain

Sample No. of revertants/plate

Coffee (mg/plate) 1.5 3.75 7.5 11.25

coffee (no additive) 12 26 105 244

coffee + vitamin C (vc) 125 190 596 1,575

coffee + vc +

barley malt powder ~

coffee +ve +

barley malt extract powder 0 5 4 0

coffee + vc +

wheat germ powder 0 21 19 14

coffee +ve It

wheat germ extract powder

coffee + vc + bran powder 21 23 23

coffee + vc+

bran extract powder 7 6 18

coffee + vc + 10 0 4 16

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soy bean extract powder

vitamin C: 500plate

barley malt powder, wheat germ powder,

bran powder: 3 mg/plate

barley malt extract powder, wheat germ extract

powder, bran extract powder, soy bean extract

powder: 1 mg/plate (ii) Inactivation of mutagenicity due to mixing vitamin C

with straight bourbon whiskey

As shown in Table 2 below, various germ components almost completely suppressed the mutagenicity for S.TA 100 caused by mixing vitamin C with straight bourbon whiskey.

Table 2

No. of revertants/plate

Sample bourbon whiskey

Sample (ml equivalent/plate)

0.5 1.0 2.5 5 bourbon whiskey(no additive) 63 101 379 883 bourbon whiskey +32i 480 1,052 1,799

vitamin C (vc) bourbon whiskey + vc + 0 19 30 112

barley malt powder bourbon whiskey + vc +

barley malt extract powder 13 22 44 86bourbon whiskey + vc 15 +

wheat germ extract powder 15 0 43 bourbon whiskey + vc + 50 39 103 179

bran extract powder

vitamin C: 500plate

barley malt powder: 3 mg/plate

barley malt extract powder, wheat germ extract

powder1 bran extract powder: 1 mg/plate (iii) Inactivation of mutagenicity due to mixing vitamin C

with black tea

Although the mutagenicity of black tea is weak in comparison with that of coffee or bourbon whiskey, it is increased upon addition ofvitamin C as shown in Table 3 below. The germ components also remarkably reduced the mutagenicity of black tea.

Table 3


Sample black tea (ml equivalent/plate)

0.1 0.25 0.5 1.0 black tea (no additive) 9 26 55 108 black tea + vitamin C (vc) 34 97 161 193 black tea

+ vc +

barley malt extract powder black tea + vc +

wheat germ powder 1 7 0 2 black tea + vc +

wheat germ extract powder black tea+ vc +

bran extract powder 0 0 15 28

vitamin C: 500pg/plate

wheat germ powder: 3 mg/plate

barley malt extract powder, wheat germn extract

powder, bran extract powder: 1 mg/plate

The term "ml equivalent" in Tables 2 and 3 means an amount in terms of volume (ml) of bourbon whiskey prior to evaporation in I) b) or black tea prior to lyophilization in I) c)

Example II

Efficacy of Catalase

I)Measuring mutagenicity and the antimutagenic effect (i) Method: See Example I.

(ii) Microorganism: See Example I.

(iii) Preparation of samples a) Instant coffee: Instant coffee powder was dissolved in distilled water.

Predetermined amounts of catalase were diluted with or dissolved in distilled water, and each solution was mixed with the previously prepared instant coffee solution to make 100 1. b) Bourbon whiskey: straight bourbon whiskey was evaporated to dryness under vacuum(400C) in a rotary evaporator.

The resulting solid material was dissolved in DMSO.

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Predetermined amounts of catalase were diluted with distilled water and each solution was mixed with the DMSO solution of alcoholic concentrate to make 100ul. c) Black tea: Black tea leaves (2.5 g) were drewed with 100 ml of boiling water, and the extract was freeze-dried.

The resulting solid material was dissolved in distilled water to give a selected concentration.

Predetermined amounts of catalase were diluted with distilled water, and each solution was mixed with the solution of tea concentrate to make 100ul. d) Tobacco tar: Cigarettes were smoked on a smoking machine, and the collected tobacco tar was dissolved inDSO.

Predetermined amounts of catalase were diluted with distilledwater, and 25 ~ l of each solution was mixed with 75 Li of the DMSO solutiono tobacco tar. As a control, a 25%DMSO solution of tobacco tar was use. e) Catalase: Anenzyme purified from calf liver and available from P-L Biochemicals, Inc. was used.

Its activity was 150,000 U/ml (20,000 U/mg). f) Addition of vitamin C: Whenrequires, vitamin C was dissolved in 25 1 of distilled water to give aconcentrate tion of 0.5mg/plate, and the solution was mixed with 50 1 each of the samples prepared ina) to d). Afterstanding at toom temperature for 30 minutes, each mixture was further combined with

25Ll of a suspension or solution of catalase in distilled water to make 100,i.

(iv)Measurement of mutagenicity: SeeExample I.

The percent inhibition of mutagenicity can be calculated by the following formula, if necessary:

Percent inhibition = (1 - Number of colonies in catalase

Percentinhibition = (1Number of colonies in untreated

containing plate x 100 (%)

plate (v) Measurement of cytotoxicity

Chinese hamster lungfibroblasts or CHL cells (5 x104) were transferred onto aVAMEM or MEM medium supplemented with vitamins, amino acids and10E tetal bovine serum, and incubation was made at 370C for 48 hours in 5% CO2 atmosphere. A flat-bottom tube having across-sectional area of

5.5cm was used as an incubator.

The medium was treated for 3 hours with 1 ml of VAMEM containing 10% fetal bovine serum with predetermined concentrations of coffee. After the treatment with coffee, the CHL cells were washed once with VAMEM and twice with a phosphate buffer (135mE1 NaCl, 2.7 mMKC1, 5.3 mM

Na2HPO4 and 1.45 mM KH2PO4). The cells were removed by treatment with trypsin, and 200 to 400 cells of them were transferred to petri dish (60mum) and incubated in 5 ml of VAMEM containing10E fetal bovine embryonic serum. The plating efficiency was checked on the 7th day of the incubation.

The percent survival of the cells was determined by the following formula:

Percent survival = Plating efficiency of treated cells

Plating efficiency of untreated cells

x 100 (%)

II) Results (i) Mutagenicity due to the mixing of vitamin C

The mutagenicity of each of instant coffee, black tea, straight bourbon whiskey and tobacco tar with respect to

S.TA 100 was increased by the mixing of vitamin C as shown in Table 4.

Table 4

S.TA 100; without S9 mix


Sample unmixed mixed with vitamin C

(0.5 mg/ml)

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instant coffee (150 ml) 43,543 315,000

black tea (150 ml) 16,500 60,750

straight bourton whiskey 5,802 22,404

(30 ml)

tobacco tar 4,800 15,360

The figures in the rightmost column are about 3 to 7 times as great as those in the center column. This value is almost equivalent to the mutagenicity caused by about 65 cigarettes as mentioned in Example

I. However, no increase occurred in the mutagenicity of black tea even when it was mixed with lemon juice having a vitamin C content equivalent to that of one commercial vitamin C pill.The above data suggests the following: the mutagenicity of a beverage or tobacco is increased if it is mixed with synthetic vitamin C alone, but as shown by the example of lemon juice, naturally occurring products that contain vitamin C seem to harbor a certain substance that interferes with the reaction causing the increased mutagenicity.

(ii) Inactivation of the mutagenicity due to the mixing

with vitamin C

As Table 5 shows, the advantages of catalase are not limited to its ability to reduce the increase in mutagenicity owing to the reaction between vitamin C and coffee, black tea, bourbon whiskey or tobacco; catalase is also effective in reducing or even eliminating the mutagenicity of coffee per se with respect toS.TA 100. For achieving this effect, it would be necessary to use catalase in an amount which is at least equivalent to 10 .

Table 5

S.TA 100; withoutS9 mix

Sample No. of revertants/plate

Catalase (U/plate)0 1 3 10 coffee 244 157 42 0 coffee + vitamin C 1,575 755 241 8 black tea 55 59 48

41 black tea + vitamin C 161 123 67 50 straight bourbonwhiskey (SB) 379 362 373 362

SB + vitamin C 1,052 778 425 354 tobacco tar(CSC) 36 39 43 34

CSC + vitamin C 115 90 72 41

The respective samples and vitamin C were used in the following amounts.

Coffee: 11.25 mg/plate

Black tea: 0.5 ml equivalent/plate

Straight bourbon whiskey: 2.5 ml equivalent/plate

Tobacco tar: 0.25 mg/plate

Vitamin C: 0.5 mg/plate (0.35 mg/plate for addition to

tobacco tar) (iii) Inactivation of the cytotoxicity due to the mixing

with vitamin C

According to the method shown in I) (V), untreated coffee, one sample containing vitamin C, and one sample having both vitamin C and catalase, were checked for their cytotoxicity against CHL cells. The results are shown in

Fig. 1, from which one can see that an appreciably high level of cytotoxicity occurred when vitamin C

(0.1 mg/ml) was added to coffee, but this could be completely prevented by further adding catalase (10

U/ml).

(iv) Formulations

Formulation 1

Components Amount

Ascorbic acid 2,000 mg

Lactose 6,000 mg

Corn starch 3,000 mg

Potato starch 150 mg

Catalase 20,000 U

Formulation 2

Ascorbic acid 127.5 g

Sodium ascorbate 127.5 g

Powdered sugar (sucrose) 615.0 g

Corn starch 120.0 g

Pigment (sunset yellow) 50 mg

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Catalase 2,000,000 U

For each formulation, the powder mix of the respective components was directly compressed into tablets. The catalase was a product of Nagase Sangyo K.K. which was commercially used as a food additive (1,000,000 U/g).

Magnesium stearate was used as a lubricant.Data supplied from the esp@cenet database - Worldwide

Claims:


Claims:

1. A preparation of vitamin C characterized by combining vitamin C with a component selected from the group consisting of catalase and a germ component selected from barley malt, wheat germ, rice germ, soy bean germ and extracts thereof.

2. The preparation according to Claim 1 wherein the component is barley malt or extract thereof.

3. The preparation according to Claim 1 wherein the component is wheat germ or extract thereof.

4. The preparation according to Claim I wherein the component is rice germ or extract thereof.

5. The preparation according to Claim 1 wherein the component is soy bean germ or extract thereof.

6. The preparation according to Claim1 wherein the component is catalase.

7. The preparation according to Claim 6 wherein the proportion of catalase is not less than 5 units per 1 mg of vitamin C.Data supplied from the esp@cenet database - Worldwide

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33.

EP0226375 - 6/24/1987

EXTRUDED QUICK-COOKING RICE-LIKE PRODUCT


Inventor(s): SCELIA RICHARD P (--); HEGEDUS ELIZABETH (--); GIACONE JOSEPH (--);

BRUINS HENDERIKUS B (--); BENJAMIN EARL J (--)

Applicant(s): GEN FOODS CORP (US)


IP Class: A23L1/182; A23L1/168

E Class: A23L1/168; A23L1/18B2



Family: EP0226375


Cited Document(s):

Abstract:

US4521436; US4325976; CA1028194


The present invention teaches the preparation of a quick-cooking rice-like product comprising: feeding ungelatinized rice flour into an extruder under conditions sufficient to substantially gelatinize the starch molecules and denature the protein, and drying the extrudate to form a rehydratable product.Description:


EXTRUDED QUICK-COOKING RICE-LIKE PRODUCT


The present invention is concerned with an extruded quick-cooking rice-like product. More particular, the present invention is concerned with a quick-cooking rice product made from extruding ungelatinized rice flour.

"Quick-cooking" food products are conventionally prepared by boiling in water or exposing the same to steam until a desired amount of moisture is absorbed by the product. The so-called "quick-cooking" varities of these products are typically prepared by pre-cooking to a predetermined moisture content and subsequently drying to a stable condition for sale.

Such products can then be recooked particularly rapidly because their pretreatment has rendered them more hydroscopic, such that they reabsorb moisture at a faster rate than during conventional cooking.

Several "quick-cooking" rice processes have been developed during the past decades. These include fabricating quick-cooking rice from broken grades of rice, products for specialized applications, minor modifications and multiple step treatments applied to previously known methods, microwave heating, and adoption of quick-cooking white rice processes to brown rice.

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For instance, U.S. Pat. No. 2,992,921 describes a process for rendering brown rice "quick-cooking" which comprises blowing hot air at a temperature of232.2 0C to315 0C (450 to 6000F) and a velocity of about 833.3 metres (2,500 feet) per minute through the brown rice for a period of 10 to 30 seconds and immediately thereafter cooling the rice with relatively cool air to prevent overcooking.

It was also indicated in the patent that the treated product was easy to cook. Also, U.S. Pat.

No. 3,157,514 describes another method wherein the rice is hydrated below the gelatinization temperature to a moisture content of between 25% and 40% followed by steaming at a temperature above about 550C, and finally completing the hydrating process by exposing the steamed rice to alternate steam and water treatments at a temperature below550C.

U.S. Pat. No. 4,133,898 discloses a process wherein rice is cooked by boiling in water for a predetermined length of time and subsequently drying in a centrifugal fluidizing bed dryer. If desired, the rice after cooking but before drying can be treated with water at an ambient temperature to prevent overcooking. U.S. Pat. No. 4,473,593 fluidizes the particular food product using a steam atmosphere as the fluidizing medium instead of water, claiming that fluidizing with steam minimizes sticking and clumping of the food product.

Several attempts have been made to reform rice by extrusion. For instance, U.S. Pat. No. 4,446,163 by

Galle et al. discloses the manufacture of rice or starch-based products from either broken rice or whole rice, which is first ground, then hydrated and extruded to form individual pieces. These individual pieces are then exposed to substantially saturated steam at super atmospheric pressure above about

3.447Wa (0.5 psig) in an autoclave for a time sufficient to gelatinize a major portion of said starch.

U.S.

Pat. No. 4,325,976 discloses a process for producing a reformed rice product by the cold extrusion of a dough formed from a composition comprising a mixture of pregelatinized and ungelatinized rice flour, sodium chloride, and fat in powdered form. The extrudate is sliced at the extruder face to obtain simulated rice grains. The simulated grains are then dried at an elevated temperature. The reformed rice product produced in this manner rehydrates in water in about three minutes thereby significantly reducing the time required to prepare a finished product. The drawback of the above reformed rice is its rapid rate of disintegration after rehydration.

U.S. Pat. No. 4,521,436 by Fulger discloses a

rehydratable rice product made from ungelatinized rice flour in a single step, without the addition of sodium chloride and powdered fats and through a cooking extruder. Fulger, however, discloses the use of an aerating agent to develop a porous structure

in the expanded product which facilitates rehydration and reduces the preparation time. This concept was also disclosed in U.S. Pat. No. 4,440,794 wherein an aerating agent was also used in the preparation of an instant rice pudding mix. These references specifically add aerating agents to develop more porous structure, making rehydration more facile.

The products upon rehydration disintegrate rapidly and have a mushy texture.

All of these prior art processes require large amounts of energy to accomplish the preparation of

"quick-cooking" food products. In the non-reform cases, either alternate heating and cooling cycles are utilized or excess moisture is added to the rice during the cooking process. Whereas, in the case of reformed products, additional ingredients are added to facilitate the extrusion process, and in some cases aerating agents or gas forming ingredients are added to facilitate expansion and aid rehydration.

None of the above products have a texture and shape similar to commodity rice particular in cases when the starting material is rice flour.

We have found that a hydrated "quick-cooking" product can be made from ungelatinized rice flour without the addition of sodium chloride, powdered fat, and an aerating agent, yet utilizing a cooker extruder.

The object of the present invention is, therefore, to provide a'1quick-cooking" reformed rice product.

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A further object of the present invention is to provide an extruded expanded rice product without the addition of gas forming ingredients and without gasifying a zone of the extruder.

A still further object of the invention is to provide a process which is straight forward and can utilize existing manufacturing equipment.

Other objects of the present invention will become more apparent from the following detailed description which set forth by way of illustration and example, certain embodiments of the present invention.


The present invention is concerned with a process for preparing a quick-cooking parboil ricelike product that absorbs its own volume in water in about 5 minutes and maintains its textural integrity for from 20 to 30 minutes without gasifying the extruder zone, and without the addition of a gas forming ingredients, fat or sodium chloride, comprising the-steps of: feeding a composition comprising rice flour, into an extruder; extruding said composition for a time and at a temperature and pressure effective to substantially gelatinize the starch fraction of the rice flour and denature the protein to produce an extrudate; and drying said extrudate to form a rehydratable rice-like product.

The present invention is also concerned with an extruded expanded quick-cooking parboil rice-like product that absorbs its own volume in water in about 5 minutes, and maintains it textural integrity for from 20 to 30 minutes comprising from 99 to 100% rice flour.

DETAILED DESCRIPTION

In the present invention a rice flour is extruded under conditions effective to gelatinize the starch fraction of said rice flour and to form extrudates.

The extrudates formed are dried and packaged. The product formed hydrates in 5 minutes, retains its textural integrity for extended periods of time, and has organoleptic qualities similar to cooked, parboiled rice products.

In preparing the rice-like product a composition comprising rice flour, an optional starch complexing agent and an optional gum is fed into an extruder. The rice flour is generally ungelatinized and may be of the long grain, medium grain, or short grain variety, or combination thereof. Generally the rice flour has a moisture content of 10%. When long grain rice is used a finish product having a firmer texture is produced, while medium grain produces a softer texture, similar to that which is characteristic of oriental rice. Short grain rice generally produces an even softer, sticky product similar to a rice-pudding type. Suitably, the rice flour is employed in amounts from 95 percent by weight to 100 percent by weight of the composition and preferably from 98 percent by weight to 99.5 percent by weight.

Optionally, a starch complexing agent may be added to the rice flour. This starch complexing agent complexes the starch during cooking and extruding, resulting in a less sticky and firmer product which is more resistant to overcooking. The amount of starch complexing agent added is generally from 0 to 5 percent by weight of the composition, and preferably from 0.5 to 2 percent by weight. Suitable starch complexing agents include, but are not limited to, glyceral monostearate, sodium staryl lactilate, or other suitable mono diglycerides and mixtures thereof.

Optionally, the rice flour may also contain an edible gum. The gum acts as a binding agent, which facilitates rehydration and maintains the shape of the rehydrated product. Suitable gums include xanthan gum, CMC, caragenen, alginetes and mixtures thereof. Depending on the formula, the gum may be employed in amounts of from 0 to 2% by weight of the composition and preferably in amounts of from 0 to 0.2% by weight.

The composition is then extruded for a time and at a temperature and pressure effective to substantially gelatinize the starch fraction of the rice flour and denature the protein to produce an extrudate.

The rice flour and water are first mixed and kneaded to prepare a homogenous dough. This kneading is carried out in a first stage or section of the extruder which has a temperature below the cooking range

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of the ingredients. The composition is fed into the extruder at a rate of 56.8 kg (125libs) per hour and water is fed into the first stage at a rate of about 104 to 150 cc/min. and preferably about 140 cc/min.

The kneaded dough then passes into the cooking section of the extruder.

In the cooking section of the extruder, the dough is subjected to extrusion temperatures effective to substantially gelatinize the starch molecules and denature the protein. Suitable extrusion temperatures

should range from between about 29.40C (850F) and 104.40C (2200F) depending on the barrel temperature of the particular cooking zone.For instance, in the first cooking zone the barrel temperature should range from about32.20C (SOUF) toabout43.30C (1100F) and preferably about 41.80C 0

(108OF); in the second and third cooking zones the barrel tempera-

ture should range fromabout 65.'0 (1500F) to about 79.40C(175OF)

and preferably about 73.90C(1650F); in the fourth cooking zone the barrel temperature should range from about

87.80C(190OF) to about 104.40C (2200F) and preferably about

94.10C(203OF);; and finally in the last zone which is a cooling

zone, the >;RTI tempeflture should range from about32.20C (900F) to

about40.50C (1050F) andpreferably about 36.30C(98OF). The above conditions are necessary to produce the products of the present invention, and any variation therefrom will affect the quality of the final product.

Suitable head pressures within the extruder

should rangebetween about 6205 kPa (900 psig) and 10,342 kPa

(1500 psig) and preferably about 8,963 kPa (1300 psig). Under

these temperatures and pressure conditions, the protein hydrates and denature into a matrix and the starch gelatinizes.

The length of time the composition remains in the extruder is dependent upon the temperature and pressure conditions etc., but generally will be within the range of 15 to 60 seconds and preferably within the range of 25 to 50 seconds. The screw speed will also affect the length of time the composition remains in the extruder. Suitable screw speed ranges from 225 to 300 RPM and preferably about 250 RPM.

The work done on the dough is estimated to be within the range of 0.398 (0.05) to 0.95PSU per kg

(0.12 kilowatt hour per pound) feed and preferably with the range of 0.55 (0.07) and 0.95M7 per kg

(0.12 kilowatt hour per pound) feed and more preferably about 0.79 MJ per kg (0.10 kilowatt hour per pound) feed.

These data are calculated by the amperage and voltage employed with the dough being run in the extruder less the amperage and voltage with the extruder running with water only. A single or twin screw extruder may be employed, with a twin screw extruder being preferred.

The temperature of the extrudate exiting the extruder may vary from about 87.80C(190OF) to about148.90C (3000F) and preferably from about93.3 C (2000F) to about126.60C (2600F).

The extrudate as it exists the extruder may also be sized into suitable dimensions depending upon the product desired such as, dimensions simulating a rice grain.

Sizing is preferably affected before drying but may be affected after drying. In the case of a rice product, the extrusion orifice is selected such that the extrudate is cut as it emerges from the orifice and sized to form individual rice particles. The product produced has a length ranging from 3 mm to 6 mm and a diameter of from 1.8 mm to 2.5 mm.

The extruded and cut particles have a moisture content of from about 15% to about 35% by weight percent, and preferably from about 20% to about 30%.

As the extrudate exits the extruder it expands.

The degree of expansion ranges from 15 to 25% and preferably about 20%.

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The extruded expanded product is dried utilizing conventional methods to form a product that rehydrates between 4 and 8 minutes and preferably in about 5 minutes. When rehydrated the finished product has a texture similar to cooked parboiled rice. Preferably, drying is effected in convection air at temperatures ranging from 65.5 (150) to104.40C (2200F).

In order to produce an extruded rice product with a texture similar to parboiled rice, ungelatinized long grain, medium grain or short grain rice flours were examined. A composition consisting of 100% ungelatinized long grain rice flour produces a suitable product. Products made with 100% ungelatinized medium grain rice flour produces a softer product, not typical of commercially available parboil rice. It should also be understood that combinations of ungelatinized long grain and medium grain rice flour were evaluated. The products produced were within acceptable range, but did not have as firm a texture as the commercially available parboiled rice.

An acceptable product according to the present invention can be produced by extruding ungelatinized long grain rice flour only, i.e. without the addition of a starch complexing agent and a gum. The product produced is negligably softer and rehydrates in the same time as when a starch complexing agent and a gum is added.

The following examples illustrate preferred embodiments of the invention.

EXAMPLE I

Ingredients

Rice Flour - Long Grain - 99.10%

Rice Flour - Medium Grain- - -

Xanthum Gum - .15%

Mono and Diglyceride - .75%

Raw materials were blended in a dry solids blender and fed to the inlet zone of the extruder as a dry premix. Dry premix was metered into the feed zone of the extruder at a rateof 56.8 kg/hr (125 Ibs/hr).

Simultaneously, water was metered to the same feed zone at a rate of 140 cc/min. The screw configuration of the extruder was designed to mix the water and dry material to form a dough. The dough was conveyed to a cooking zone where it was heated to

126.6 C (2600F) and the pressure was raised to 8,963 kPa (1300 psi).

The cooked dough was finally extruded through a die having eight slots each having dimensions measuring 1 mm x 4 mm. The speed of the screw during processing was 250 RPM. The temperature of the product as it exits from the extruder was 119.40C(249OF).

This material was cut by a rotating knife positioned on the die face to give particles resembling whole grain rice. The dimension of these particles was 2.5 mm x 6 mm. These particles fall onto a moving belt wherein room temperature air was drawn through to cool the product and remove some of the moisture.The particles travel on this belt for a period of 40 seconds wherein the moisture was reduced from 20% to 18% and the temperature reduced from

119.40C(249OF) to57.20C (136OF). The riceparticles were then transported to a continuous belt dryer where they were loaded to a bed depth of 0.63-1.26cm (1/4-1/2").i1e drycr temllera- ture in the first zone was set at76.60C (170OF) and the second zone was set at98.90C (210OF). The total drying time was 8 minutes.

The resulting product had a moisture of 8% and a density of 0.55 gm/cc. The final product was prepared by mixing equal volumes of boiling water and product and allowing same to rehydrate for five minutes. At the end of five minutes there was no excess water and the rice particles were fully rehydrated having texture and eating qualities similar to that of cooked parboiled rice.

EXAMPLE II

Ingredients

Rice Flour - Long Grain - 74.15%

Rice Flour - Medium Grain - 25%

Xanthum Gum - 0.10%

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Mono and Diglyceride - 0.75%

This combination of long grain and medium grain rice flour was processed under conditions according to Example I.

The resulting product rehydrated in 5 minutes and disintegrated in 20 minutes.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT IS CLAIMED IS:

1. A process for preparing a quick-cooking extruded expanded parboil rice-like product that absorbs its own volume in water in about 5 minutes and maintains its textural integrity for from 20 to 30 minutes without gasifying an extruder zone and without the addition of a gas forming ingredient, fat or sodium chloride, comprising the steps of:

(a) feeding a composition comprising rice

flour into an extruder;

(b) extruding the composition for a time

and at a temperature and pressure effective to

substantially gelatinize the starch fraction of

the rice flour and denature the protein to

produce an extrudate; and

(c) drying the extrudate to form a rehy

dratable rice product.

2. A process according to claim 1 wherein the rice flour is a member selected from a group comprising: ungelatinized long grain rice flour, ungelatinized medium grain rice flour.

3. A process according to claim 1 wherein the

amount of rice flour ranges from 95 to100t by weight.

4. A process according to either of claims 1 and

2 wherein the composition further comprises a starch

complexing agent.


starch complexing agent is a mono and diglyceride.


5 wherein the amount of starch complexing agent ranges

from 0 to5 by weight.

7. A process according to any one of claims 1 to

6 wherein the composition further comprises a gum.


gum is xanthan gum.


8 wherein the amount of gum ranges from O to5 by

weight.

10. A process according to any one ofcYa! 7I 9 wherein the composition is extruded for a time ranging from between 15 seconds and 60 seconds.

11. A process according to any one of claims 1 to 10 wherein the composition is extruded at a temperature ranging from between1OOC (500F) and 1210C(250OF).

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12. A process according to any one of claims 1 to 11 wherein the composition is extruded at a head pressure ranging from between 6205 kPa (900 psi) and 10342 kPa (1500 psi).

13. A process according to any one of claims 1 to 12 wherein the extrudate is sized prior to drying to form rice particles approximately the size of whole rice grain.

14. A process according to claim 13 wherein the composition is extruded through a circular die orifice having a diameter of 1.8 to 2.5 mm, and where the extruded composition is cut into length of from 3 to

6 mm.

15. A process according to any one of claims 1 to 14 further comprising injecting water into the extruder at a rate of 104 to 150 cc/minute.

16. A process according to claim 15 wherein the amount of water present in the extrudate ranges from between 15% to35 by weight of the extrudate before drying.

17. A process according to any one of claims 1 to 16 wherein the work done on the composition as it passes through the extruder ranges from 0.398 to 0.95 MJ per kg (0.05 to 0.12Kw hr./lb) feed.

18. A process according to claim 1 wherein the degree of expansion ranges from 15 to 25%.

19. An extruded expanded quick-cooling rice flour product in which the starch fraction is substantially gelatinised and the protein denatured comprising by weight 99 to 100% rice flour, 0 to 0.75% starch complexing agent and 0 to0.25 ó gum which product will absorb its own volume in water in about 5 minutes and maintain textural integrity for at least 20 minutes.

20. A composition according to claim 19 wherein the rice flour is selected from ungelatinized long grain rice flour, ungelatinized medium grain rice flour and combinations thereof.

21. A composition according to claim 20 wherein the rice flour is a combination of 75% ungelatinized long grain rice flour and 25% ungelatinized medium grain rice flour.

22. A composition according to any one of claims 19 to 21 wherein the starch complexing agent is a mono and diglyceride.

23. A composition according to any one of claims 19 to 22 wherein the gum is xanthan gum.Data supplied from the esp@cenet database - Worldwide

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34.

EP0319726 - 6/14/1989

POTABLE AQUEOUS EXTRACT CONTAINING THE ACTIVE SUBSTANCE

OF SPROUTED WHEAT AND/OR LEGUMES AND/OR OTHER GRAINS


Inventor(s): GOBEL ARMIN (--); HITZE WINFRIED PROF DR-ING (--)

Applicant(s): GEMUESESAFT GMBH (DE)


IP Class: A23L1/185; A23L1/308; A23L2/38

E Class: A23L1/185; A23L1/202; A23L2/38



Family: EP0319726

Equivalent: FI885699; EP0319726; NO885516; DE3741991

Cited Document(s): EP0199105; AU553881; DE1261741; FR1012425

Abstract:


The extract includes dextrins, maltose, glucose, minerals and vitamins, the remainder water, characterised in that it is obtainable by conversion, without leaving any residue, of germinated cereals and/or legumes and/or other grains, in which the total extract contains a naturally water-soluble extract fraction, an extract fraction, up to about 90% of the total extract, that has been made water-soluble, and a water-insoluble extract fraction, and that germinated cereals which may be used are the seven cereal types wheat and/or rye and/or barley and/or oats and/or maize and/or rice and/or millet.Description:


Trinkbarer wasserhaltiger Extrakt mit einem Gehalt an Wirk- und Wertstoffen des gekeimten Getreides und/oder von Leguminosen und/oder sonstiger körnerartiger Samen

Die vorliegende Erfindung betrifft einen trinkbaren wasserhaltigen Extrakt mit einem Gehalt an Wirk- und Wertstoffen des gekeimten Getreides und/oder von Leguminosen und/oder sonstiger körnerartiger

Samen einschliesslich Dextrinen, maltose, Glukose, Mineralstoffen und Vitaminen, Rest Wasser.

Nach einer bevorzugten Ausführungsform enthält der erfindungsgemäss trinkbare wasserhaltige

Extrakt aus gekeimtem Getreide ferner Fructose und/oder Saccharose und/oder Lactose und/oder

Galactose.

Bei den in dieser Anmeldung angegebenen Prozentangaben ist die Bezugsgrösse die Trockenmasse des wässrigen Extrakts.

In den letzten fünf Jahren hat sich der Konsument wieder verstärkt einer uralten Ernährungsbasis, nämlich dem Getreide und den hieraus hergestellten Produkten zugewandt. Gefragt sind hierbei in immer höherem Mass Lebensmittel aus Stärke aus gemahlenen Mühleprodukten sowie die Produkte,

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die direkt aus dem vollen Korn bestehen bzw. dieses beinhalten. Der hohe Ballaststoffgehalt, das pflanzliche Eiweiss, der Vitamin- und Mineralstoffkomplex des Vollgetreides, sind hier neben einer heute wesentlich verbesserten Verarbeitung der Vollkorn-Produkt-Palette zu schmackhaften

Erzeugnissen der Grund für das ständig steigende Interesse an diesen Produkten.

Neben diesem Haupttrend im Vollkornverzehr zeigt sich seit einigen Jahren auch ein sogenannter zusätzlicher Nebenverzehr-Trend; man versteht hierunter den Verzehr von frischem oder abgetrocknetem Keimgetreide und/oder Leguminosen bzw. den Verzehr von lediglich Leguminosen-

Keimen, beispielsweise von Soja-Sprossen und der insgesamt hieraus hergestellten Produkte.

Diese Produkte sind besonders gesund infolge der Tatsache dass Keimgetreide und Keim-Leguminosen im Keimprozess neue Vitamine synthetisieren und so eine Verdoppelung bis Verfünffachung ihres

Ausgangsvitamingehalts erreichen.

Dem erfindungsgemässen trinkbaren wasserhaltigen Extrakt aus gekeimtem Getreide liegt die

Erkenntnis zugrunde, dass die ernährungsphysiologischen Vorteile des Vollkorns mit denen des gekeimten Korns verbunden werden. Hierbei wird also sozusagen aus einem Vollkorn-Keimgetreide ein Vollkorn-Trunk gemacht und damit die ernährungsphysiologisch besonders wertvollen

Ausgangsprodukte in ein gut verzehrbares, leicht verdauliches, den Organismus nicht belastendes neues Verzehrprodukt überführt, ohne dass Verluste der wertgebenden Inhaltsstoffe stattfinden.

So gesund auch der Verzehr von festen Vollkornprodukten auch in gekeimter Form ist, so verlangen sie vom Verzehrenden doch eine sehr kräftige und intensive Kauarbeit und verlangen vom Organismus eine wesentlich erhöhte Verdauungsleistung, da sonst ein grosser Teil der wertvollen Inhaltsstoffe ungenutzt den Körper verlässt. Dieser Nachteil der festen Vollkornprodukte wird durch den erfindungsgemässen trinkbaren wasserhaltigen Extrakt aus gekeimtem Getreide überwunden, da dort die wertvollen Inhaltsstoffe vom Körper weitestgehend aufgenommen werden.

Grundsätzlich sind alle sieben Getreidearten zur Keimgetreide-Vollkorntrunk-Herstellung gemäss vorliegender Erfindung geeignet.

Gekeimter Hafer soll dabei nach der Keimung als ganzes Korn hydrothermisch mit Sattdampf behandelt werden, um die lipolytischen Enzyme zu inaktivieren.

Der erfindungsgemässe Vorschlag besteht darin, einen trinkbaren wasserhaltigen Extrakt der einganges genannten Gattung zu schaffen, der dadurch gekennzeichnet ist, dass er erhältlich ist durch rückstandsfreie Überführung von gekeimtem Getreide und/oder Leguminosen und/oder sonstiger körnerartiger Samen, wobei der Gesamtextrakt einen natürlicherweise wasserlöslichen Extraktanteil, einen wasserlöslich gemachten Extraktanteil, der bis zu etwa 90% vom Gesamtextrakt beträgt und einen wasserunlöslichen Extraktanteil enthält und als gekeimtes Getreide die sieben Getreidearten

Weizen und/oder Roggen und/oder Gerste und/oder Hafer und/oder Mais und/oder Reis und/oder Hirse einsetzbar sind.

Weitere bevorzugte Ausführungsformen sind in den Unteransprüchen dieser Anmeldung geoffenbart.

Verschiedenste Getreideausmischungen werden bei der Durchführung des Keimverfahrens möglichst einem speziellen Keimverfahren unterworfen, mit dem Ziel, hohe Vitaminausbeuten zu erhalten. Dazu ist ein spezielles Kornwassergehalt-, Temperatur- und Zeitprogramm erforderlich. So geschieht beispielsweise die Keimführung insbesondere im Temperaturbereich von 25 DEG C bis 30 DEG C und darüber. Bereits hierdurch unterscheidet sich das erfindungsgemässe Keimverfahren wesentlich von den üblichen Melzverfahren zur Herstellung für die Bierbereitung oder für die Herstellung sonstiger

Malzprodukte. Während man nämlich sonst bei allen üblichen Melzverfahren auf einen möglichst geringen Extraktverlust d.h.Zuckerverlust bedacht ist, da primär hohe Extraktausbeuten gefordert werden und somit ein möglichst geringer Atmungsschwund und ein geringer Schwund durch den später abfallenden Wurzelkeim gefordert wird, ist beim erfindungsgemässen Keimprozess der hohe

Vitamingehalt die wertgebende Hauptkomponente, wobei ein langer Wurzelkeim hier keinen Verlust bedeutet, da sowieso eine Verarbeitung mit dem ganzen Korn stattfindet.

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Bei der Durchführung des Maischverfahrens gemäss vorliegender Erfindung wird das gekeimte nassvermahlene Gesamtkorn in einem bezüglich Temperaturprogramm von der Bierherstellung abweichenden Maischverfahren enzymatisch aufgeschlossen undzwar mit dem Ziel, die Vitamine aus der Kornmatrix schonend freizusetzen und zu erhalten, sowie möglichst viel lösliche Ballast- und

Eiweissstoffe zu bekommen.

Das Wasser-, Rohstoff-Verhältnis wird dabei vorzugsweise so gewählt, dass im Endprodukt ein echt löslicher Extraktgehalt von ca. 11,0 g pro 100 ml bei entsprechend höherem Gesamtextrakt gewährleistet werden kann.

Zur Maischeaufbereitung zum Endprodukt erfindungsgemässer Keimgetreide-Vollkorn-Trunk oder

Keimgetreide-Trunk, wird die gesamte fertige Maische zunächst milchsauer vergoren und anschliessen für Vollkornprodukte rückstandsfrei zum Ensprodukt aufgearbeitet. Hierzu wird das Produkt mechanisch, beispielsweise mittels eines Spalthomogenisators und/oder enzymatisch homogenisiert.

Für den enzymatischen Nachaufschluss bringt man mittels Filter oder Dekanter die noch unlöslichen

Treberpartikel aus der milchsauren Maische ab und behandelt diesen Rückstand mit hemicellulytischen/cellulytischen Enzymen (z.B. mit Rohament PC, 0,2 g Enzym auf 100 g

Feuchttreber, bei 45 bis 50 DEG C für 1,5 Stunden), die in etwas partikelfreier milchsaurer Kornwürze

(pH 4,0 bis 3,7) vorgelöst dem Rückstand zwecks Mazeration zugegeben werden. Das pH-Optimum solcher Mazerationsenzyme liegt im pH-Bereich 3,0 bis 5,0 - bevorzugt um pH 4,0.

Der abgebaute Ansatz wird thermisch kurz inaktiviert (85 DEG C, 10 Minuten) anschliessend der

Kornwürze wieder zugemischt und das ganze Produkt durch Zusatz von Citruspektin (0,15 g bis 0,20 g pro 100 ml Endprodukt) stabilisert.

Das Produkt kann auf Flaschen abgefüllt und darin pasteurisiert werden. Es kann ferner die partikelfreie Kornwürze auch isoliert und mehr oder weniger nachgeklärt als Keimgetreidetrunk allein oder in Verbindung mit anderen Produkten eingesetzt werden.

Wie aus der weitere unter folgenden tabellarischen Zusammenstellung zu entnehmen ist, hat das als

Keimgetreide-Vollkorntrunk bezeichnete Produkt 1 noch die weiteren Vorteile:

Das Produkt enthält das gesamte pflanzliche Eiweiss und kann damit bis zu einem Drittel des durchschnittlichen Tages-Eiweiss-Bedarfs decken.

Ferner kann der Ballaststoffgehalt pro Liter bis zu ca. 14 g und rechnet man den Pektinstabilisator hinzu sogar bis zu ca. 15 g Ballaststoffe in gut trinkbarer Form betragen.

Hierzu sei bemerkt, dass der heutige tatsächliche Tages-Ballaststoff-Verzehr im Durchschnitt immer noch bei knapp 20 g pro Person und nicht etwa wie ärztlich empfohlen, bei etwa 30 g Tagesaufnahme pro Person liegt. Damit kann der erfindungsgemässe Keimgetreide-Vollkorntrunk auch zur optimalen

Ballaststoff-Versorgung beitragen, was insbesondere für Kranke und ältere Personen von grosser

Wichtigkeit ist.

Der Erfindungsgegenstand stellt ein alkoholfreies und kühlgetrunken erfrischendes und durstlöschendes sofort verdauliches und den Verdauungstrakt nicht belastendes höchst gesundes

Nahrungsmittel dar.

Der Erfindungsgegenstand, der in der Praxis als Keimgetreidetrunk bezeichnet wird, wird insbesondere aus biologisch angebautem Getreide undzwar aus gekeimtem Roggen, gekeimter Gerste und gekeimtem Hafer hergestellt, er ist naturtrüb, er ist milchsaure vergoren mit einem überwiegenden

Gehalt an L (+) -Milchsäure.

Der Erfindungsgegenstand ist auch als Alten- und Krankenkost hervorragend geeignet, da die

Inhaltsstoffe überwiegend sofort verdaulich sind und den Verdauungstrakt nicht belasten. Die in ihm enthaltenen Getreide-Ballaststoffe, auch in gelöster Form, sowie die Milchsäure, sind verdauungsanregend.

Der erfindungsgemässe Keimgetreidetrunk enthält den Vitamin B-Komplex des gekeimten Getreides, wobei die heutigen Haupt-Defizit-Vitamine B1, Folsäure, aber auch Vitamin B12 im Keimgetreide

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verstärkt vorhanden sind. Der Erfindungsgegenstand bietet alle löslichen Getreidemineralstoffe bei einem in der heutigen kochsalzreichen Ernährung sehr günstigen Natrium/Kalium-Verhältnis.

Für die Getreide-Rohstoffe insbesondere aus biologischem Anbau hat sich in der Ausmischung ein

Verhältnis von 55 % Roggen, 35 % Gerste und höchstens 10 % Hafer als besonders vorteilhaft herausgestellt.

Die Getreidekeimung wird in sogenannter "warmer Führung" durchgeführt.

Beim durchzuführenden Maischverfahren wird das gekeimte nassvermahlene Korn enzymatisch aufgeschlossen, wobei die Vitamine aus der Kornmatrix schonend Freigesetzt werden und ferner möglichst viel lösliche Ballaststoffe und Eiweissstoffe erhalten werden.

Es wird daher bei diesem Maischverfahren insbesondere bei 45 DEG C eingemaischt, auf die erste

Haltestufe hochgeheizt und unter langsamen Rühren der Maischansatz bei 48 DEG C bis 50 DEG C für 120 Minuten gehalten.

Danach wird der Maischansatz pro Minute um 1 DEG C (Aufheizzeit mindestens 20 Minuten, höchstens 30 Minuten) auf die Vollverzuckerungsstufe 70 bis 72 DEG C hochgeheizt und hier bis zur

Jodnormalität des Ansatzes gehalten.

Mit dem Verzuckerungsabschluss der Maische wird auf 75 DEG C langsam aufgeheizt, bei dieser

Enzymgrenztemperatur die Jodnormalität nochmals überprüft und danach rasch auf 80 bis 82 DEG C aufgeheizt, um bei dieser Temperatur zwecks Inaktivierung der korneigenen Enzyme 15 Minuten gehalten.

Sodann beginnt der eigentliche Läuterprozess, d.h. die Abtrennung wasserunlöslicher Treber von der

Kornwürze. Auf den Einsatz von L-Ascorbinsäure im Waschwasser wie auch im Einmaischwasser wird vorzugsweise verzichtet.

Das Wasser/ Grünmalz-Verhältnis ist vorzugsweise so zu wählen, dass auch nach Auswaschen der

Treber die für die Kontrollmessung geklärte Würze eine Spindelanzeige von mindestens 11,5 %

Stammwürze aufweist.

Nach einer bevorzugten Ausführungsform wird die auf Anstelltemperatur gekühlte Würze unmittelbar danach mit Milchsäure-Kultur geimpft. Je schneller nämlich der pH-Wert absinkt, um so mikrobiell sicherer wird das Endprodukt und um so stabiler werden die oxidationsempfindlichen Enzyme, wie beispielsweise Vitamin B1.

Sodann erfolgt der Abschluss der Milchsäuregärung; die jetzt milchsaure Ware wird trubstabil filtriert, die Filteranlagen nachgewaschen und mit dem Waschwasser/Zusatzwasser das Produkt auf vorzugsweise 11,0 g Extrakt pro 100 ml eingestellt. Diese erfindungsgemässe Produkt wird als

Grundtyp 1 bezeichnet. Es ist naturtrüb aber trubstabil. Es scheckt angenehm nach Getreide-und

Milchsäure und wirkt, kühl getrunken, erfrischend.

Nähere Einzelheiten dieses Produkts 1 sind in der weiter unten folgenden Tabelle (tabellarische

Zusammenstellung) aufgeführt.

Bei diesem erfindungsgemässen Keimgetreide-Volltrunk, genannten Produkt 1 wird die Maische rückstandslos zum Endprodukt aufgearbeitet ohne dass eine Filtration erfolgt.

Das in der Tabelle ebenfalls in den Einzelheiten erläuterte Produkt 2 stellt einen erfindungsgemässen

Keimgetreidetrunk dar, bei dem der unlösliche Treber herausgenommen, d.h. eine Filtration durchgeführt wurde.

Das in der Tabelle weiterhin in den Einzelheiten geoffenbarte Produkt 3 stellt eine beispielhafte

Ausführungsform des erfindungsgemässen Keimgetreidetrunks dar, bei dem sowohl die Herausnahme der unlöslichen Treber als auch eine Herausnahme des Kühltrubs stattgefunden hat, d.h. es wurden

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zwei Filtrationen durchgeführt. EMI9.1 EMI10.1 EMI11.1 EMI12.1 EMI13.1Data supplied from the esp@cenet database - Worldwide Claims:


1. Trinkbarer wasserhaltiger Extrakt mit einem Gehalt an Wirk- und Wertstoffen des gekeimten

Getreides und/oder von Leguminosen und/oder sonstiger körnerartiger Samen einschliesslich

Dextrinen, Maltose, Glukose, Mineralstoffen und Vitaminen, Rest Wasser,

dadurch gekennzeichnet,

dass der erhältlich ist durch rückstandsfreie Überführung von gekeimtem Getreide und/oder

Leguminosen und/oder sonstiger körnerartiger Samen, wobei der Gesamtextrakt einen natürlicherweise wasserlöslichen Extraktanteil, einen wasserlöslich gemachten Extraktanteil, der bis zu etwa 90% vom

Gesamtextrakt beträgt und einen wasserunlöslichen Extraktanteil enthält und als gekeimtes Getreide die sieben Getreidearten Weizen und/oder Roggen und/oder Gerste und/oder Hafer und/oder Mais und/oder Reis und/oder Hirse einsetzbar sind.

2.Trinkbarer wasserhaltiger Extrakt aus gekeimtem Getreide nach Anspruch 1,


dass er einem Gehalt an Fructose und/oder Saccharose und/oder Lactose und/oder Galactose aufweist.

3. Trinkbarer wasserhaltiger Extrakt aus gekeimten Getreide nach Anspruch 1 bis 2,


dass er aus 70 bis 85% verdaulicher Kohlenhydrate,nämlich 12 bis 18% Dextrinen, 45 bis 55%

Maltose, 10 bis 14% Glukose, 0,2 bis 0,8% Saccharose, bezogen auf die Trockenmasse, ferner aus 20 bis 50 mg Lactose und 150 bis 300 mg Galactose, bezogen auf 1 l Endprodukte Rest Wasser besteht.

(Prozentangaben = Gew.-%)

4.Verfahren zur rückstandsfreien Überführung von gekeimtem Getreide in einen trinkbaren wasserhaltigen Extrakt, dadurch gekennzeichnet,

dass man durch entsprechende Keimführung die Vitaminsynthese im keimenden Getreidekorn stark fördert und hierdurch insbesondere die B-Vitamine im fertigen Keimgetreide im Vergleich zum

Ausgangsprodukte, bezogen auf die gleiche Korntrockenmasse, je nach Vitamin signifikant erhöht vorliegen.

5. Verfahren nach Anspruch 4,


dass man das fertig gekeimte Getreide ohne Wärmenachbehandlung, mit Ausnahme vom Hafer, ungetrocknet mit den Wurzelkeimen, und damit ohne Substanzverlust in nassvermahlenem Zustand der

Einmaischung unterwirft.

6.Verfahren nach Anspruch 4 bis 5,


dass der Maischprozess temperatur- und zeitmässig dem Ensprodukt entsprechend geführt wird

a) der Eiweissabbau sowie die Gewinnung von mehr löslichen Ballaststoffen und damit auch die verstärkte Freisetzung von Vitaminen aus dem Zellverband während des Maischprozesses besonders stark begünstigt wird - so durch eine Temperaturführung bei 45 DEG bis 65 DEG C, bevorzugt um 50

DEG C, über eine Inkubationszeit von 1 bis 3 Std., bevorzugt um 2 Std. - und

b) im Maischprozess sowie im weiteren Herstellungsverfahren die Kochstufen - z.B. nach Abschluss der Stärkeverzuckerung - entfallen.



dass die enzymatisch abgebaute und auf Anstelltemperatur rückgeholte Getreidemaische mit Kultur-

Milchsäurebildnern versetzt wird, die ausschliesslich oder überwiegend L(+)-Milchsäure bilden und hierdurch den pH-Wert der Getreidemaische auf pH 4,0 bis 3,7, bevorzugt auf pH 3,8, absenken.

8. Verfahren nach Anspruch 4 bis 7,

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dass die noch gröberen, das "mouthfeeling" störenden Getreidepartikel, z.B. mittels Filter, oder

Separator, oder Dekanter aus der abgebauten, milchsauren Getreidemaische abgetrennt werden, diese

Partikel mechanisch, z.B. mittels Spalthomogenisator, und/oder enzymatisch, z.B. mittels

Mazerationsenzymen, aufgeschlossen werden und man diese -so notwendig nach thermischer

Behandlung- dem Ausgangsprodukt wieder zusetzt.



dass dieser Gesamtextrakt vorwiegend besteht aus:

60 bis 80 % verdaulichen Kohlenhydraten, nämlich bevorzugt aus 1 bis 20 % Maltodextrinen, 40 bis

50 % Maltose, 10 bis 14 % Glucose, dazu bis zu 2,5 % Fruktose, unter 1 % Saccharose, unter 0,5 %

Lactose und Galactose;

4 bis 15 % unverdaulichen Kohlenhydraten = Ballaststoffen;

2,5 % bis 3,5 % Säureanteil, wobei dieser Säureanteil zu 96 bis 98 % aus Milchsäure(n) und der Rest aus Citronensäure besteht;

8 bis 15 % Eiweiss;

1 bis 3 % Mineralstoffen;

dazu die Getreidevitamine, vorrangig der Vitamin B - Komplex mit bis zu 14 mg pro 100 g

Trockenmasse.

Alle Prozentangaben bezogen auf die Gesamtextrakt - Trockenmasse = 100 %.



dass dieser Gesamtextrakt in einer Menge bis 180 g, bevorzugt zwischen 100 g und 120 g, im Liter vorliegt.



dass der nach obigen Kriterien hergestellt und zusammengesetzte trinkbare Extrakt nicht nur in Form eines Flüssigproduktes zur Verfügung steht, sondern hieraus auch ein Trockenprodukt, z.B. durch

Sprühtrocknung, hergestellt wird.Data supplied from the esp@cenet database - Worldwide

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35.

EP0322996 - 7/5/1989

COOKED AND PACKAGED STARCHY FOODSTUFFS


Inventor(s): LEE YANIEN (--); MERRITT CARLETON GEORGE (--); GILLMORE STEPHEN

RUSSELL (--); DERMODY NANCY ELIZABETH (--)

Applicant(s): BORDEN INC (US)


IP Class: A23L1/182; A23L1/16; A23L3/34

E Class: A23L1/182; A23L1/16D; A23B7/10; A23B9/26; A23L3/10; A23L3/3463; B65B25/00A



Family: CA1321917

Equivalent: JP2002323; EP0322996

Cited Document(s):

EP0239656; JP61181350

US4659576; FR2130906; US4552772; EP0192354; US4495214;

Abstract:


Fully cooked, starchy foodstuffs, such as rice and pasta, are preserved against microbiological spoilage by treatment with a predetermined quantity of an edible acid. Packages of fully cooked starchy foodstuffs are provided which are shelf-stable for periods in excess of 6 months and are neutralized to a proper pH to avoid sourness. Ready-to-eat meals of neutralized acid preserved starchy foodstuffs are also provided. Edible alkaline neutralizing agents are used to balance the pH. Also provided are methods for producing shelf-stable packages of fully cooked, starchy foodstuffs wherein measured quantities of acid are introduced to fully cooked, starchy foodstuffs to inhibit microbiological growth.Claims:


1. A shelf-stable, fully cooked packaged meal comprising

(a) a primary sealed container which substantially isolates its contents from atmospheric oxygen, said contents being a preserved food composition comprised of

(i) a fully cooked starchy foodstuff selected from alimentary pastes, grains, starchy legumes and potatoes; and

(ii) an edible acid uniformly dispersed in said primary container with said foodstuff in a quantity sufficient to provide shelf-stability; and

(b) a secondary container which substantially isolates its contents from said preserved food composition, the contents within said secondary container comprising an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of said food stuff upon mixing therewith to a value in the range of about 5 to about 7;

wherein the pH of the starchy foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.

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2. A packaged meal according to claim 1, wherein the quantity of edible acid provides a pH for said starchy foodstuff in the range of from 3.5 to 4.6.

3.A packaged meal according to claim 1 or claim 2, wherein said foodstuff is selected from rice and alimentary pastes prepared from flours selected from semolina flour, durum wheat flour, corn flour, buckwheat flour, farina flour, rice flour, whole wheat flour, and mixtures thereof.

4. A packaged meal according to any one of claims 1 to 3, selected from acetic acid, citric acid, tartaric acid, propionic acid, hydrochloric acid, fumaric acid, adipic acid, benzoic acid, malic acid, phosphoric acid, lactic acid, sorbic acid and mixtures thereof.

5. A packaged meal according to claim 4, wherein the edible acid is selected from propionic acid and lactic acid.

6.A packaged meal according to any one of claims 1 to 5, wherein the preserved food composition additionally comprises an edible lubricant in an amount of less than 15% by weight, which edible lubricant is selected from unsaturated safflower oil, peanut oil, coconut oil, palm oil, sunflower oil, corn oil, olive oil and combinations thereof.

7. A packaged meal according to claim 6, wherein the edible lubricant is present in an amount of from

1 to 8% by weight based on the total weight of the preserved food composition.

8. A packaged meal according to any one of claims 1 to 7, wherein the edible alkaline neutralizing agent is selected from sodium bicarbonate, sodium carbonate, potassium bicarbonate and potassium carbonate.

9. A packaged meal according to claim 8, wherein the edible alkaline neutralizing agent is encapsulated in a dehydrated fat or a dehydrated oil.

10.A packaged meal according to any one of claims 1 to 9, wherein the primary sealed container is a pouch formed of a synthetic resin.

11. A packaged meal according to claim 1, comprising

(a) a polyester pouch which substantially isolates the contents from atmospheric oxygen, said contents being a preserved food composition comprised of

(i) a fully cooked starchy foodstuff selected from rice, alimentary pastes obtained from semolina flour and combinations thereof,

(ii) an edible acid uniformly dispersed in said polyester pouch selected from propionic acid, lactic acid and combinations thereof, in a quantity sufficient to provide a pH for said foodstuff having a value in the range of about 4.0 to 4.3, and

(iii) about 1% to 8% by weight vegetable oil, based on the total weight of the preserved food composition, uniformly dispersed in said polyester pouch,

(b) a secondary container which substantially isolates the contents from said preserved food composition, the contents of said secondary container comprising sodium bicarbonate encapsulated with an encapsulant selected from dehydrated fat, dehydrated oil and combinations of both in a quantity sufficient upon mixing therewith to increase the pH of said foodstuff to a value in the range of about 5 to 7;


12.A packaged meal according to any one of claims 1 to 11, wherein the contents of said secondary container additionally comprise seasonings selected from salt, dried chives, dried onions, dried bread crumbs, dehydrated cheese and combinations thereof.

13. A ready-to-eat meal comprising an admixture of::

(1) a shelf-stable, fully cooked, starchy foodstuff selected from alimentary pastes, grains, potatoes and combinations thereof, wherein said foodstuff is shelf-stabilized with an edible acid, and

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(2) an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to 7;


14. A ready-to-eat meal according to claim 13, wherein said foodstuff of component (1) has a pH with a value in the range of from 3.5 to 4.6 provided by said edible acid prior to admixture with component

(2).

15.A ready-to-eat meal according to claim 13 or claim 14, stabilized, fully cooked, starchy foodstuff is selected from rice, alimentary pastes obtained from semolina flour and combinations thereof.

16. A ready-to-eat meal according to anyone of claims 13 to 15, wherein said edible acid is selected from acetic acid, citric acid, tartaric acid, propionic acid, sorbic acid, hydrochloric acid, lactic acid, benzoic acid, fumaric acid, adipic acid, phosphoric acid, malic acid and combinations thereof.

17. A ready-to-eat meal according to any one of claims 13 to 16, wherein the edible alkaline neutralizing agent is selected from the group consisting of sodium bicarbonate, sodium carbonate, potassium bicarbonate and potassium carbonate and said alkaline neutralizing agent is encapsulated in dehydrated palm oil.

18. A ready-to-eat meal according to claim 13, comprising an admixture of:

(1) a shelf-stable, fully cooked, starchy foodstuff selected from rice, alimentary pastes obtained from semolina flour and combinations thereof, said foodstuff having a pH with a value in the range of about

3.5 to 4.6 provided by an acid selected from propionic acid, lactic acid and combinations thereof; and

(2) a quantity of sodium bicarbonate encapsulated in dehydrated palm oil in a quantity sufficient to increase the pH of said foodstuff to a value in the range of about 5 to 7 when admixed therewith;

wherein the pH of the starch foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.

19.A process for producing a packaged, shelf-stable, fully cooked, starchy foodstuff comprising

(1) a starchy foodstuff selected from grains, alimentary pastes and potatoes, (2) an edible acid and (3) an edible lubricant having a melting point below about 95 DEG F (about 35 DEG C), said process comprising the steps of:

(a) preparing said starchy foodstuff for packaging by:

(i) heating said foodstuff in boiling water and/or steam until fully cooked, the quantity of water and/or steam being sufficient to provide the desired moisture level within said foodstuff;

(ii) adding a quantity of an edible acid to the fully cooked, starchy foodstuff sufficient to provide shelfstability;

(iii) mixing the edible acid and fully cooked, starchy foodstuff to uniformly distribute the edible acid on the foodstuff; and

(iv) mixing an edible lubricant with the mixture of edible acid and starchy foodstuff in a quantity up to about 15% by weight, based on the weight of the starch foodstuff; and

(b) filling a container with the prepared starchy foodstuff, said container being resistant to wet heat at a temperature about 180 DEG F and comprised of a material which isolates the contents from atmospheric oxygen;

(c) sealing said container so as to exclude air from the prepared starchy foodstuff therein; and

(d) exposing the contents of said container to a pasteurization process or a sterilization process.

20.A process according to claim 19 wherein the quantity of edible acid added to the starchy foodstuff is sufficient to provide a pH in the range of about 3.5 to 4.6 when mixed therewith;


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21. A process according to claim 19 or claim 20, wherein the starchy foodstuff is an alimentary paste obtained from semolina flour and the heating step proceeds until a moisture level of about 75% to 85% by weight is obtained.

22. A process according to claim 19 or claim 20, wherein the starchy foodstuff is rice and the heating step proceeds until a moisture level of about 60% to 70% by weight moisture is obtained.

23.A process according to claim 19 or claim 20, wherein the starchy foodstuff is heated in excess boiling water and said process comprises an additional step of draining the excess water from the fully cooked, starchy foodstuff prior to the addition of edible acid.

24. A process according to any one of claims 19 to 23, wherein the edible acid is selected from acetic acid, citric acid, tartaric acid, sorbic acid, lactic acid, adipic acid, fumaric acid, benzoic acid, propionic acid, hydrochloric acid, malic acid, phosphoric acid and mixtures thereof.

25. A process according to any one of claims 19 to 24, wherein the edible lubricant is an oil selected from unsaturated safflower oil, peanut oil, coconut oil, corn oil, olive oil, palm oil and mixtures thereof.

26.A process according to any one of claims 19 to 25, lubricant is from 1% to 8% by weight based on the total weight of said fully cooked, starchy foodstuff.

27. A process according to any one of claims 19 to 26, wherein air is excluded from the sealed container by generating water vapour from the fully cooked, starchy foodstuff.

28.A process for producing a packaged, shelf-stable, fully cooked starchy foodstuff comprising (1) a starchy foodstuff selected from grains, alimentary pastes, potatoes and combinations thereof, (2) an edible acid and (3) an edible lubricant having a melting point below about 95 DEG F (about 35 DEG

C), said process comprising the steps of:

(a) preparing said starchy foodstuff for packaging by::

(i) heating said foodstuff in boiling water and/or steam until fully cooked, at a temperature sufficiently high to pasteurize said foodstuff, the quantity of water and/or steam being sufficient to provide the desired moisture level within said foodstuff;

(ii) maintaining the fully cooked, starchy foodstuff pasteurized until packaged;

(iii) adding a quantity of an edible acid to the starchy foodstuff sufficient to provide a pH in the range of about 3.5 to 4.6 when mixed therewith;

(iv) mixing the edible acid and said starchy foodstuff to uniformly distribute said edible acid on said starchy foodstuff; and

(v) mixing an edible lubricant with the mixture of edible acid and starchy foodstuff in a quantity up to about 15% by weight based on the weight of said starchy foodstuff; and

(b) filling an aseptic container with the prepared starchy foodstuff of step (a), said aseptic container being resistant to wet heat at a temperature of about 180 DEG F (82 DEG C) and above and comprised of a material which substantially isolates the contents from atmospheric oxygen;

(c) sealing said aseptic container so as to exclude air from the prepared starchy foodstuff;

and, optionally, exposing the contents of the sealed aseptic container to a pasteurization process;

wherein the pH of the starchy foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to from a puree and measuring the pH of the puree with a pH meter.

29.A process according to claim 28, comprising (1) a starchy foodstuff selected from rice, alimentary pastes obtained from semolina flour and combinations thereof, (2) an edible acid and (3) an edible lubricant, said process comprising the steps of:

(a) preparing a starchy foodstuff for packaging by:

(i) heating said foodstuff in excess boiling water until fully cooked to provide a moisture content of from 50% to 70% by weight for rice and a moisture content of from 75% to 85% by weight for alimentary pastes;

(ii) draining the excess boiling water from the fully cooked, starchy foodstuff;

(iii) maintaining the fully cooked, starchy foodstuff at a temperature above about 180 DEG F (82 DEG

C) until packaged;

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(iv) adding a quantity of an edible acid to the fully cooked, starchy foodstuff sufficient to provide it with a pH in the range of about 3.5 to 4.6; said edible acid being selected from propionic acid, lactic acid and combinations thereof;

(v) mixing the edible acid and fully cooked, starchy foodstuff for a period of about 1 to 3 minutes to uniformly distribute the edible acid; and

(vi) mixing an edible lubricant with the mixture of edible acid and starchy foodstuff, said edible lubricant being selected from corn oil and unsaturated safflower oil in a quantity of from 1% to 8% by weight based on the weight of starchy foodstuff; and

(b) filling a polyester pouch with the prepared starchy foodstuff of step (a), said polyester being resistant to wet heat at a temperature of about 180 DEG F (82 DEG C) and above and substantially resistant to permiation by atmospheric oxygen;

(c) sealing said polyester pouch while steam is generated from the prepared starchy foodstuff; and

(d) heating the contents of the sealed polyester pouch to a temperature in excess of about 180 DEG F

(82 DEG C)

wherein the pH of the starchy foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.Data supplied from the esp@cenet database -

Worldwide

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36.

EP0333858 - 9/27/1989

FOOD FOR CONTROLLING CALORIE INTAKE


Inventor(s):

ROOM A- (--)

OHTA ATSUTANE TERUMO KABUSHIKI (--); WATANABE HIROYUKI

Applicant(s): TERUMO CORP (JP)


IP Class: A23L1/307

E Class: A23L1/182; A23L1/308; A23L1/305D



Family: EP0333858

Equivalent: WO8802992; US5122379; EP0333858

Cited Document(s):

WO8603380; US4119734

EP0323510; EP0251925; US4585664; FR2317884; EP0176113;

Abstract:


Improved diet food for controlling calorie intake, has a reduced content of carbohydrate and contains low-calorie cereals, water-soluble edible fibres, and proteins in predetermined amts. corres. to an intended intake. The proteins are specified to have an isoelectric point in acid region. The amts. of the water-soluble edible fibres and the proteins are adjusted so that when an aq. soln. of this food comes into contact with a gastric juice the soln. become a gel. The weight ratio of the water-soluble edible fibres to the proteins is specified to be 1:0.5-1:8 (pref. 1:0.5-1:2). The weight ratio of the total amt. of the water-soluble edible fibres and the proteins to the amt. of the low-calorie cereals is specified to be

1:1-100. The low-claorie cereals are sugar-free cereals produced by removing sugar materials from boiled rice through extraction. Pref. water-soluble edible fibres are carrageenan and guar gum. An example of this diet food is rice gruel. The diet food can contain condiments such as soy sauce, bean paste, sodium glutamate.

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37.

EP0338239 - 10/25/1989

MICROWAVEABLE FOOD PRODUCTS AND METHODS FOR PRODUCING

THEM


Inventor(s): SHORT ALLEN T (--); WILKINSON RALEIGH J (--)

Applicant(s): SHORT MILLING CO J (US)

IP Class 4 Digits: A23L; A23P; A21D

IP Class: A23L1/18; A21D13/00; A23P1/14

E Class: A23L1/164; A23L1/18B



Family: EP0338239

Cited Document(s): US3966990; DE1692806; US4251551; US4409250

Abstract:

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A method for producing microwaveable half products comprising the steps of: forming a preliminary mixture comprising a starch-containing material, comprising corn flour, waxy maize corn flour, rice flour, wheat flour, potato flakes, or a mixture thereof, and added water adequate to bring the total moisture content of the mixture from about 30 to about 40 percent by weight; gelatinizing the starch content of the mixture to form a dough by subjecting the mixture to low shear agitation while heating; extruding the resulting dough through a shaped die and cutting to provide formed dough pieces; and drying the formed dough pieces to form half products having a moisture content of from about 9.5 to about 17 percent by weight under conditions which inhibit case hardening. The half products can be placed in a container to form a microwave package, which is in turn placed into the microwave oven.Description:


MICROWAVEABLE FOOD PRODUCTS AND METHODS FOR PRODUCING THEM

The present invention relates to microwaveable food products and methods for producing them. More particularly, the present invention relates to snack food products comprising puffable starch-containing half products, microwaveable packages comprising such half products in a microwaveable container, and to processes for the microwave puffing of such half products.

Background of the Invention

It has long been known that certain starch-containing materials will expand or puff under appropriate heating conditions. Such materials are puffed by causing trapped moisture to expand from the liquid state to the vapor phase. Rapid heating or rapid depressurizing are the methods commonly used to convert hard, dense starch-containing materials called "half products" into the puffed crisp snack pieces. The half products are prepared by gelatinizing the starch of the starch-containing material into a dough, extruding the dough through a shaping die, cutting the dough into pieces, and drying the dough to a predetermined moisture content.

Puffing can be carried out using well-known methods such as gun puffing, baking and deep-fat frying, with the latter method being especially popular for snack foods. Deep-fat frying, however, has disadvantages. The resulting puffed snacks typically have high fat levels rendering the snacks high in calories and limiting the shelf life, even when carefully packaged.

Microwave heating has also been used as a rapid heating/puffing method for various starch-containing materials. See, for example, Van Hulle et al. U.S. patents 4,409,250 and 4,251,551. Thus, with the increasing number of consumer microwave ovens in homes, it would be desirable if puffed snack products could be prepared at th consumer's convenience by microwave puffing of commercially prepared puffable half products.

While microwave methods could eliminate certain disadvantages inherent in deep-fat frying, microwave puffing is also not without certain disadvantages. Heretofore, half products subjected to microwave heating have not all successfully puffed. Doughs formulated primarily for puffing by other puffing methods have had particularly poor microwave puff success rates. Those half products which do not successfully puff can dry, harden and even char under microwave heating. Because even small numbers of unsuccessfully puffed half products can adversely affect overall product quality, high puff success rates are vital to consumer acceptance.

Thus, it would be desirable to provide a microwaveable half product which could be puffed using a conventional consumer microwave oven. It would also be desirable to provide a microwaveable package comprising half products within a microwaveable container, which package could be placed directly into a microwave oven. Accordingly, it is an object of the present invention to provide microwaveable half products, packages and methods for the preparation of puffed snack products using conventional consumer microwave ovens.

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Summary of the Invention

Surprisingly, we have discovered a method for producing microwaveable half products comprising the steps of forming a preliminary mixture comprising a starch-containing material, wherein the starchcontaining material comprises corn flour, waxy maize corn flour, rice flour, wheat flour, potato or a mixture thereof, and added water adequate to bring the total moisture content of the mixture to between about 30 to 40 percent by weight; gelatinizing the starch content of the mixture by subjecting the mixture to low shear agitation while heating the mixture at not more than 160 DEG C (320 DEG F); extruding the resulting dough through a shaping die and cutting the dough at the die to provide formed dough pieces; and drying the formed dough pieces to form half products having a moisture content of from about 9.5 to about 17 percent or more by weight under conditions which inhibit case hardening.

We have also discovered a microwaveable package comprising such half products enclosed in a microwaveable container.

We have also discovered a method of producing a puffed microwave food product comprising the steps of enclosing a quantity of microwaveable half product in a container and microwaving the half product and container until substantially all of the half products are puffed.

Brief Description of the Drawings

Fig. 1 is a flow diagram of one typical embodiment of a method for making a microwaveable half product; and

Fig. 2 is a perspective view of a typical half product shape which can be made according to the invention.


The method of this invention is dependant upon the use of a starch-containing material which, upon gelatinization under conditions of relatively low shear mixing and temperatures not exceeding about

160 DEG C (320 DEG F), advantageously not exceeding 155 DEG C (311 DEG F), will form a relatively uniform matrix. Exemplary of such starch-containing material are corn flour, waxy maize corn flour, rice flour, wheat flour and potato (generally in the form of granules or flakes). If corn flour is used, it is preferred that the flour be derived mainly from the horny endosperm of the corn kernel.

"Reduction flour" is a type of flour obtained in dry milling and is derived mainly from the horny endosperm of the corn kernel.The use of corn materials derived predominantly from the horny endosperm of the corn kernel is described fully in our co-pending U.S. application Serial No. 037,054, filed April 13, 1987, which is a continuation of our U.S. application Serial No. 836,704 filed March 6,

1986.

Surprisingly, we have found that the use of waxy maize corn flour can dramatically improve microwave puffing and provide an improved, tender texture. Waxy maize corn flour is made from whole ground waxy maize corn. Amounts ranging from about 25 percent to about 40 percent by weight have been found to provide good results, although from about 10-60 percent or more can be used.

However, we have found that 100 percent waxy maize corn flour does not provide a noticeable difference when compared to 100 percent reduction corn flour.

Likewise, a prepared starch material refined from waxy maize corn can also dramatically improve both puffing and texture. Only from about 5 percent by weight to about 25 percent bv weight is required although more can be used to improve puffing but will significantly increase the cost of the half product. Good results have been obtained using about 15 percent. It is believed that less of the prepared starch (as compared to the full waxy maize flour) is required because the prepared starch does not contain the waxy maize corn oils and bran found in the flour which likely inhibit puffing. One brand of

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waxy maize starch which provides good results is Amioca Powdered Refined from Waxy Corn BH

4332A 0017, produced by the National Starch & Chemical Corp., Bridgewater, New Jersey.

Starch from common (Dent) corn contains about 27 percent amylose and 72 percent amylopectin.

Waxy maize corn contains essentially 100 percent amylopectin. It is believed that the high amylopectin content of the starch may be responsible for the improved puffing and texture. The increased puffing may also be due to the starch structure itself. Waxy maize starch is a long, branch type starch that is more delicate and more elastic than dent starch.

The term "corn flour" as used in this application refers to flour obtained from Dent corn, and preferably the reduction flour obtained from such corn. The term "waxy maize corn flour" refers to flour from whole ground waxy maize corn.

Additional starch-containing materials such as pregelatinized tapioca starch can be added to the mixture used to form the half product. While expensive, tapioca starch can significantly aid the puffability of a half product, especially when the mixture used to form the half product contains an ingredient that inhibits puffing such as a full fat almond product.

Surprisingly, we have also discovered that adding hydrolyzed vegetable protein to the product markedly increases puffing. Amounts from about 1 percent to about 20 percent or more can be used, 5 percent having been found to provide good results. A hydrolyzed vegetable protein which has provided good results is HVP ST 21 powder sold by Beatrice Food Ingredients, Inc., Beloit, Wisconsin, and manufactured for Beatrice by HACO Ltd., Gumligen, Switzerland.

A variety of optional materials can also be added to the mixture which forms the half products of this invention. Such materials can render the half products and microwave-puffed snacks more nutritious and or aesthetically or organoleptically desirable. Such ingredients include additional starch materials, sucrose, various protein sources, shortening and common salt. A description of such optional materials is found in Van Hulle 4,409,250. Such optional ingredients can generally comprise up to a few percent by weight of the half product.

Likewise, other ingredients such as colors, dyes, flavors, flavored coatings, vitamins, preservatives, etc. may be added as minor components. For example, a monoglyceride coating can be applied to the half product to improve the texture and mouth feel of the product after microwaving, and to act as a carrier for flavoring. Of course, many possibilities for additives, and particularly flavoring additives and coatings, will be readily apparent to those skilled in the art.

It has been found that the addition of common salt enhances the microwave puffing of half products of this invention. While amounts of up to about 10 percent can be used, amounts greater than about 4 percent provide a puffed product which may be too salty for many consumers. Thus, the salt content should be kept a about 1-5 percent by weight of the half product.

Good results are obtained when rice flour is used as the predominant starch-containing material of the half product. Such half products have been found to provide the best results for uniform microwaving of corners, ends, or other discontinuities of the half product. From a processing standpoint, it is advantageous to add from about 5 to about 15 percent by weight, and preferably about 10 percent by weight of corn flour or corn meal when making either a wheat or a rice half product. While the addition of corn flour or corn meal improves processing, it does not appear to affect the microwaveability of the product.

Surprisingly, it has been found that raising the pH of the half product to greater than pH 6.5 (i.e., from about 6.5-12) by addition of basic ingredients such as calcium oxide, significantly increases expansion of microwaved half product. The addition of acidic ingredients does not appear to affect expansion of half products predominantly comprised of corn but does appear to enhance expansion of predominantly rice half products. For example, citric acid can be used to lower the pH to between 3 and 6.5.

Surprisingly, it has also been discovered that the moisture content of the half product is important to good microwave puffing results. While moisture contents as low as about 9.5 percent can be used, moisture contents of about 12 to about 17 percent or more should be used, with about 13 percent to

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about 14 percent providing good results. If percentages higher than 17 are used, the potential for microbial spoilage may have to be addressed, for example, by addition of anti-microbial agents. Such moisture contents are generally higher than those of half products intended for frying because frying half products with 12 percent moisture or more would generally cause blistering of the puffed product.

To produce a half product of this invention, the starch-containing material, such as dry milled reduction flour from yellow corn, is combined with sufficient water to bring the moisture content within the range of 30-40 percent by weight, and the mixture is delivered to a conventional single screw cooker extruder 1, Fig. 1, for processing to gelatinize the starch content of the corn material. The cooker extruder is operated to mix the material, under low shear conditions, into a uniform dough and subjects the mix to temperatures which increase from the input end of the extruder barrel toward the die, commencing at at least 55 DEG C (131 DEG F) adjacent the input and increasing, stepwise or progressively, to no more than 160 DEG C (320 DEG F) at the output end of the barrel, the precise temperatures depending upon the size and throughput rate of the cooker extruder. For best results, the barrel of cooker extruder 1 is divided into four equal zones each equipped with electrical resistance heaters. The following table gives operative temperature ranges for the four zones for a semiworks or pilot plant apparatus and for a full scale production plant. EMI8.1 Optimum temperatures for the four zones are 70 DEG C (158 DEG F), 85 DEG C (185 DEG F), 110 DEG C (230 DEG F) and 120 DEG C

(248 DEG F) for the semiworks scale apparatus and 125 DEG C (257 DEG F), 135 DEG C (275 DEG

F). 145 DEG C (293 DEG F) and 155 DEG C (311 DEG F) for a full scale apparatus with cooker extruder 1 having a screw diameter of 8 inches. Residence time of the mix in the barrel of cooker extruder 1 is in the range of 1-1.5 min. and the head pressure is sufficiently low to cause the dough to ooze from the die in the form of a relatively shapeless glob.Such operation of cooker extruder 1 achieves a uniform and substantially complete gelatinization of the starch and not only distributes the added water uniformly through the dough during the mixing operation but also causes at least a substantial part of the moisture to be entrapped in the tiny capillary-like cells of the starch matrix by the time the mix, now in the form of a uniform dough, is forced through the die orifice or orifices.

The dough emerging from the die of cooker extruder 1 is cut by rotary knife 2 into relatively small glob-like pieces 0.5-4 inches (1.3-10cm) long, each piece consisting of a uniform dough matrix in which the starch is up to 98 percent gelatinized, as measured by the Maltese Cross test, with the matrix having substantially the same total moisture content as did the corn material after the water was added.

Despite the relatively high moisture content, the dough pieces are individually coherent and can be handled and conveyed. After being cut off by knife 2, the dough pieces are delivered by air conveyor 3 to blender 4, typically a radial blade rotary blender, which subjects the dough pieces to a relatively gentle agitation in the presence of ambient air so as to reduce the moisture content at and near the surfaces of the pieces.The pieces are then delivered directly into the input end of a kneading and forming extruder 5. The dough pieces are treated in blender 4 for a period time such that the total moisture content of the pieces is reduced by 3-10 percent, bringing the moisture content down to the range of 25-37 percent by weight.

Extruder 5 is so designed as to have a first stage, which serves primarily to knead the dough pieces into one continuous mass, and a second stage, which is adjacent the die and serves to compact the dough mass just before it enters the die. The extruder is of the type in which both the screw and the barrel are water cooled, with the cooling water exit temperature being measured, and the operator observes the extruded material and adjusts the cooling water temperature to make the dough firmer or more pliable, as required to achieve adequate shaping and proper cutting of the extruded material. The die structure of extruder 5 includes a preliminary portion to divide the dough mass into a plurality of individual strands, and a die orifice for each strand, the orifices converting the strands into the desired crosssectional shape.Head pressure for extruder 5 is 1160-1855 p.s.i., advantageously 1400-1680 p.s.i. Upon emerging from the die orifices, the strands are cut into individual pieces by rotary knife 6. As they are cut off at the die orifices, the individual formed pieces are directed by an air stream through a confining shroud 7 into air conveyor 8 and delivered by that conveyor to the input hopper of a predryer 9.

Dryer 9 is of the endless belt type in full scale production apparatus and, for practical purposes, a static dryer is used in semiworks scale operations. When of the continuous belt type, the belts are of screen material and the drying atmosphere is directed upwardly through the layer of formed half product pieces supported by the belt. The drying atmosphere can be ambient air at 70-80 DEG C (158-176

DEG F). Residence time in the dryer is selected to effect removal of the surface moisture from the

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formed pieces before discharge from the dryer so that the formed pieces are then substantially nonsticky.The surface moisture of the formed pieces does not exceed 5 percent by weight and is usually less, so that the pieces as discharged from predryer 9 have a total moisture content of not less than 20 percent by weight, advantageously 20-24 percent, with substantially all of the moisture being uniformly distributed internally of the formed piece.

After discharge from dryer 9, the formed pieces are delivered by air conveyor 10 to a final dryer 11 by which the formed pieces are slowly dried, without case hardening, until the moisture content is in the range of about 9.5-17 percent, advantageously about 13-14 percent, by weight. For full scale production, dryer 11 advantageously includes several stages through which the formed pieces are carried by formainous endless conveyor belts, a drying atmosphere of controlled temperature and humidity being passed upwardly through the conveyor belts and the layers of formed pieces carried thereby.Excellent results are achieved when the dryer includes five successive stages, with the drying atmosphere being air at 47-50 DEG C (116-122 DEG F) and a relative humidity of 81 percent in the first stage; 51-54 DEG C (123-129 DEG F) and a relative humidity of 92 percent in the second stage;

50-54 DEG C (122-129 DEG F) and a relative humidity of 89 percent in the third stage, 47-51 DEG C

(116-123 DEG F) and a relative humidity of 84 percent in the fourth stage, and 42-47 DEG C (107-121

DEG F) and a relative humidity of 34 percent in the fifth stage. Residence times in the five stages can be equal, with a total residence time in the dryer of 5.5-7.5 hours. The above temperatures and residence times will yield a half product having about a 13-14 percent moisture content.Temperatures and residence times can be increased for lower moisture contents or decreased for higher moisture contents.

When a potato starch-containing material is used, it is advantageous to use a single stage or transfer screw in the single screw cooker extruder 1. The use of either such screw will transfer the material through the gelatinizer more quickly and at a lower shear, thereby preventing overcooking of the potato starch.

The shape of the half product plays an important part in its microwaveability. The best results have been obtained using half products of continuous shape wherein the product flows in a uniform pattern into the various connections where the product is formed. An example of this is the wagon wheel shown in Fig. 2. Another example of a continuous shape that microwaves well is the "onion ring" shape. Half products having discontinuities or protruding parts do not microwave as well because the discontinuity or protruding part often does not puff and/or becomes hard. For example, the corners on a square shaped product generally do not microwave very well. As mentioned above, a half product comprised predominantly of rice has been found to provide the best microwave puffing results when discontinuities such as ends, corners or protrusions are desired.

We have also found that the use of a microwaveable container which holds the half products while they are being microwaved can provide enhanced results. Good results have been obtained using a reclosable, microwaveable box into which a predetermined quantity of half product is placed. Good results have also been obtained using microwaveable bags, which are well known. Such bags appear to fall into one of two categories, i.e., those having "susceptor" plates which reflect microwave energy, and those that do not. Bags without susceptor plates have generally been found to work well because a susceptor plate can cause charring of the half product.However, consistently good results have been achieved using a bag produced by the Stone Container Company, Schaumburg, Illinois, having a four inch gusset and a 48 gauge susceptor plate with an 18-24 optical density containing 3.5 ounces (about

100 grams) of half product. Using that bag, even the corners of fish-shaped half products cooked completely with no hard spots.

It is believed that the enhanced results are due to the retention of heat or steam in the box or bag during microwave puffing. The use of a box, bag or other microwaveable container is further desirable because, similar to microwave popcorn products, prepackaging the microwaveable half product in a microwaveable container provides the consumer with a "microwaveable package" which can simply be inserted directly into the microwave oven. Thus, there is no need to use (and later clean) any housewares such as bowls.

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Good results have been obtained using a microwaveable box produced by James River Corporation,

Paperboard Packaging Group, Neenah, Wisconsin, constructed of 16/1000 inch paperboard polycoated on both sides.

The box is approximately 10.1 cm wide, 13.3 cm long, and 3.5 cm high. Approximately 30 grams of half product shaped substantially as that shown in Fig. 2 are used to form the microwaveable package, which can be microwaved as discussed below. However, other size boxes have worked equally well.

Generally, the boxes or bags will contain from about 20 to about 150 grams of half product.

The length of time required for microwave puffing depends on the type of microwave used because there are no uniform standards for microwaves. For example, using a microwaveable package comprising about 30 grams of half product in the above James River Corporation Box, the duration of times for microwave puffing can range from about 1 minute in one 700 watt microwave oven to about

2 minutes in a different 700 watt microwave oven (see Examples 2 and 3, below). As with all other microwave products for home use, the consumer will have to perform some initial experimentation to optimize microwave cooking times. Generally, however, the time required to puff about 30 grams of half product, with or without a container, will be from about 40 seconds to about 2 minutes.

It can also be advantageous to puff the half products of this invention using multiple exposures of microwave energy. Such practice is also quite commonly used by consumers. For example, half products (with or without a container) can be exposed to a first period of microwave energy, thereby providing at least partially microwaved half products. The half products can then be stirred, shaken or otherwise redistributed. If the half products are in a container such as a box, the box can be substantially inverted, shaken and replaced in the microwave. The at least partially microwaved half products can then be microwaved for an additional period of time.

As stated above, it has been found that approximately thirty grams of half product made in accordance with this invention when placed in the above James River Corporation box, require from about 1-2 minutes in different 700 watt microwave ovens. Good results have been achieved using a first period of microwave exposure of from about 30 seconds to about 80 seconds, and the additional time period being from about 15 seconds to about 40 seconds. The box is shaken and inverted in between the first and second microwave exposures.

The half products, microwaveable packages, and methods of this invention are illustrated by the following examples.

EXAMPLE 1

A half product of this invention can be made as follows: Cooker extruder 1 was a conventional single screw cooker extruder manufactured by Mapimpianti S.P.A. and having a 2 inch screw diameter, the barrel being equipped with four electrical resistance heaters for controlled heating of the four successive zones of the extruder, the extruder screw being conventionally designed for low shear operation, and the extruder being operated at such low head pressures that the head pressure was not measured. Such apparatus is of pilot plant or semiworks scale and is used in experimental runs for the sake of economy.

A dry milled reduction flour from yellow corn was used as the source of gelatinizable starch. The flour had an initial moisture content of 10.5 percent by weight and a fat content of 1.5 percent by weight.

The particle size distribution of the flour was such that only 4.3 percent by weight remained on a 60 mesh U.S. Standard Series screen and 35.6 percent by weight passed a 100 mesh screen. The mixture supplied to cooker extruder 1 consisted of 74.7 percent by weight corn reduction flour and 25.3 percent by weight added water. Cooker extruder 1 was operated at 70 DEG C (158 DEG F) in the first zone, 85

DEG C (195 DEG F) in the second zone, 110 DEG C (230 DEG F) in the third zone and and 120 DEG

C (248 DEG F) in the fourth zone. The screw was operated at 37 r.p.m. The die orifice was of circular transverse cross section and the dough emerged from the orifice more as an oozing glob than a shaped strand. Knife 2 was rotated at a speed such that all of the dough pieces obtained were in the size range of 0.5-4 inches (1.2-10 cm) in length. The dough pieces were air-conveyed to blender 4 and there

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agitated for 5 min., then delivered into the input end of forming extruder 5. Moisture content of the dough pieces as delivered to the forming extruder was approximately 25 percent by weight.

The extrusion orifices of the die of forming extruder 5 were shaped to provide each extruded strand with a diameter of 1.2 inches (3.1 cm) and the wagon wheel transverse cross section seen in Fig. 2.

Extruder 5 was operated with a screw temperature of 27 DEG C (80.6 DEG F), a barrel temperature of

40 DEG C (104 DEG F) and a head pressure within the range of 1400-1680 p.s.i. Knife 6 was rotated at a speed such that the formed pieces cut off by the knife had a thickness of approximately 0.05 inch

(1.25 mm). The shaped pieces thus obtained were air-conveyed to preliminary dryer 8, in this case a static dryer in which the pieces were shelf-supported rather than being conveyed and were subjected to flowing air as the drying atmosphere at 78 DEG C (172 DEG F) for 1.5 min to remove surface moisture and render the shaped pieces non-sticky.The shaped pieces were then air-conveyed to final dryer 10, in this case again a static dryer. The flowing drying atmosphere in dryer 10 was air 60 DEG C

(140 DEG F) and a relative humidity of 85 percent, residence time of the product in the dryer being 6 hours.

The half products thus produced were of substantially uniform size, shape and color, all being slightly cupped as seen in Fig. 2 and all having a very hard, slightly shiny external surface of uniform yellowish color described by some observers as golden and others are a yellowish tan. In 85 percent of all of the half products, the rim was essen tially circular, the remaining 15 percent having one rim portion extending between two adjacent "spokes" which curved slightly inwardly, the remainder of the rim being essentially circular. The half products were so uniform that the diameter of the "hub" openings did not vary by more than 0.1 inch (0.25 mm) and there was no discernible difference in either the width or the thickness of the "spokes" or the width or the thickness of the rim.The half products were sufficiently strong to support a total weight in excess of 3.6 lbs. (1.31 kg.) applied to the center of the half product when the half product had been placed concave side down on a supporting surface.

EXAMPLE 2

The procedure of Example 1 was repeated without material change except for substituting for the reduction corn flour a mixture comprising approximately 88 percent by weight of rice flour, 10 percent by weight of reduction corn flour and 2 percent by weight salt.

Approximately 30 grams of the resulting half product was placed in the above-described James River

Corporation box, and in turn placed into a Litton, Generation II, 700 watt home microwave oven. The product was microwaved at high power for a first time period of about 40 seconds. The box was inverted, shaken and microwaved for an additional 20 seconds at high power. Substantially all of the half product was uniformly puffed.

EXAMPLE 3

The procedure of Example 2 was repeated, but an Amana 700 watt microwave oven was used to microwave the half products. The times required to properly process the half products were almost doubled from those described in Example 2.

EXAMPLE 4

A rice-based wagon wheel produced in Example 2 was coated with a mixture comprising equal parts of a distilled acetylanted monoglyceride and a nacho cheese flavoring. (The half product was dipped in the mixture and allowed to sit overnight.) The product was then microwaved substantially as described in Example 2. The product microwaved extremely well and most of the flavoring stayed on the product. There was also a market improvement in the texture and mouth feel of the product.

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Examples 5-9 illustrate different half product compositions in accordance with this invention. Each half product produced had a moisture content of about 13-14 percent. Approximately 30 grams of each were placed in the above-identified James River Corporation box and microwaved substantially as described in Example 2. In each instance, all of the half products puffed and were edible.

EXAMPLE 5

The half product comprised 80 grams of reduction corn flour, 15 grams of the above-described Amioca

Powdered Refined Starch from Waxy Maize (National Starch & Chemical Corp.), and 5 grams of the above described HVP ST 21 hydrolyzed vegetable protein from Beatrice. The microwaved half product had very high expansion and the outer surface had a sheen.

EXAMPLE 6

The half product comprised 73 percent reduction corn flour, 25 percent waxy maize corn flour and 2 percent salt. The half product had good expansion when microwaved.

EXAMPLE 7

The half product comprised 58 percent reduction corn flour, 40 percent waxy maize corn flour and 2 percent salt. The half product had good expansion when microwaved.

EXAMPLE 8

The half product comprised 83 percent reduction corn flour, 15 percent rice flour and 2 percent salt.

The half product had good expansion and was crunchy.

EXAMPLE 9

The half product comprised 82 percent reduction corn flour, 15 percent of the above described Amioca waxy maize starch, 2 percent salt and 1 percent calcium oxide to raise the pH of the product to greater than 7. The half product had very high expansion.

EXAMPLE 10

Examples 5-9 were substantially repeated but with rice flour substituted for reduction corn flour. Good results were achieved.

While several advantageous embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


1. A method for producing microwaveable half products comprising the steps of

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forming a preliminary mixture comprising a starch-containing material, wherein the starch-containing material comprises corn flour, waxy maize corn flour, rice flour, wheat flour, potato, or a mixture thereof, and added water adequate to bring the total moisture content of the mixture to from about 30 to about 40 percent by weight;

gelatinizing the starch content of the mixture to form a dough by subjecting the mixture to low shear agitation while heating the mixture at not more than 160 DEG C (320 DEG F);

extruding the resulting dough through a shaping die and cutting the dough at the die to provide formed dough pieces; and

drying the formed dough pieces to form half products having a moisture content of from about 13.0 to about 17 percent by weight under conditions which inhibit case hardening.

2. The method according to claim 1, wherein the starch-containing material is predominantly rice flour.

3. The method according to claim 1, wherein the starch-containing material is predominantly wheat flour.

4. The method according to claim 1, wherein the starch-containing material is predominantly potato.

5. A microwaveable half product produced by the method of claim 1.

6.A method of producing a puffed microwaved food product comprising the steps of

enclosing microwaveable half products produced by the method of claim 1 in a microwaveable container capable of substantially retaining heat and steam, and

microwaving the half products and container until substantially all of the half products are puffed.

7. The method of claim 6, wherein the step of microwaving comprises multiple exposures of the half products and container to microwave energy.

8. The method of claim 7, wherein the step of microwaving comprises the steps of

microwaving the half products and container for a first period of time to provide at least partially microwaved half products,

physically moving the container or the at least partially microwaved half products to redistribute the at least partially microwaved half products, and

microwaving the partially microwaved half products for an additional period of time.

9. A microwaveable package comprising

a microwaveable container capable of substantially retaining steam and heat, and

a microwaveable half product produced in accordance with claim 1 enclosed in said container.Data supplied from the esp@cenet database - Worldwide

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38.

EP0350952 - 1/17/1990

LOW MANGANESE HIGH PROTEIN RICE FLOUR


Inventor(s): EUBER JOHN R (--); PUSKI GABOR (--); HARTMAN GRANT H JR (--)

Applicant(s): BRISTOL MYERS CO (US)


IP Class: A23L1/10; A23L1/105

E Class: A23L1/105B; A23L1/10M



Family: EP0350952

Equivalent: US4830861; MX164968; EP0350952

GB1442149; US3687687; JP57202258 Cited Document(s):

Abstract:


A method for preparing high protein rice flour (HPRF) containing low manganese is disclosed wherein essential steps comprise: blending rice flour and water at a pH of 3.4 to 4.6; separating the insoluble washed rice flour; resuspending the washed rice flour and adjusting the suspension to a pH and temperature within the operable range of an alpha-amylase enzyme; treating the suspension with an alpha-amylase enzyme for a sufficient time to hydrolyze the starch to 5 to 50 DE content; adjusting the treated mixture to a pH of 3.4 to 4.6; and then separating rice syrup from low manganese high protein rice flour. The high protein rice flour contains more than 16% protein, has a manganese content of 50 micrograms or less per gram of protein and is further treated with a proteolytic enzyme to provide a modified low manganese HPRF suitable for use in powdered infant formula.Description:


LOW MANGANESE HIGH PROTEIN RICE FLOUR


1. Field of the Invention

The present invention relates to rice-based food compositions and to their methods of preparation.

More particularly, the present invention relates to high protein rice flour (HPRF) nutritionally complete formulas and most particularly to infant formula. In its methods aspect, the present invention relates to methods for preparing high protein rice flour suitable for use in rice-based infant and adult nutritional formulas.

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2. Description of the Prior Art

Rice is a starchy food containing approximately 6-10% protein. Rice flour, as a raw material of nutritional value, constitutes an inexpensive by-product of rice milling obtained by grinding broken rice. Conventional milling practices produce rice flour composed largely of about 80% carbohydrate with about 7-9% protein material. However, the PER (protein efficiency ratio - ratio of weight gain of rats to protein consumed of a 10% protein diet) for rice is 2.18 which is almost equivalent to that of beef (2.30), a considerably more costly protein source. Because of the low concentration of protein in rice and the resulting bulk required to obtain a satisfactory protein intake, infants and children cannot eat a sufficient amount to meet their protein requirements.

Efforts to improve the protein quantity of rice involving selected breeding of new rice varieties have not met the protein content required by young children. Research directed to the production of rice flour with increased protein content has been conducted. Prior art within this general area includes the following papers.

Hansen, et al., Food Technology, 35 (No. 11), pages 38-42 (1981) developed a high protein rice flour

(25% protein content) by using the enzyme alpha-amylase to digest the starch material of milled broken rice thereby decreasing starch content resulting in increased protein content compared to the original rice flour. In the Hansen, et al. process, a 5% slurry of finely ground crude rice flour is first heated for

30 min. at 100>;o;C. to effect gelatinization, then partially digested by enzyme (alpha-amylase) treatment, centrifuged and the precipitated HPRF freeze-dried. Protein level of HPRF was reportedly increased three-fold over the starting material (approximately from about 8% to 25%). The supernatant is principally carbohydrate (98.3%).

Chen, et al., J. Sci. Food Agric. 35, 1128-1135 (1984) modified the Hansen et al. process to provide both HPRF and high-fructose rice syrup from broken rice. In the Chen, et al. process, a 20% slurry of the milled broken rice is mixed with calcium chloride (70 mg/kg rice), pH adjusted to 6.5 and digested

(liquified) with alpha-amylase optimally at 90>;o;C. for 90 min.; specifically with Termamyl 60L alpha-amylase obtained from NOVO Industri, A/S, Denmark. The liquified mixture is centrifuged and the precipitated HPRF dried. Protein content of the HPRF was similar to Hansen, et al. (approximately three times as high as the raw material). The supernatant is saccharified at 60>;o;C. with glucoamylase and then isomerized to fructose with glucose isomerase to provide a high-fructose rice syrup containing

50% glucose, 42% fructose and 3% maltose.

Chang, et al., Journal of Food Science, 51 (No. 2), pages 464-467 (1986) further modified the Hansen, et al. process to produce a rice flour with increased protein and calcium contents. According to Chang, et al., processing conditions for the production of HPRF concerned treating gelatinized rice flour slurry with calcium chloride and alpha-amylase 60>;o;C. for 90 min. The hydrolyzed starch is removed by centrifugation and the precipitated paste freeze dried to yield high protein rice flour with approximately

38% protein, a PER ratio of 2.17 and an amino acid composition similar to the rice flour of Hansen, et al.

It is evident that the prior art mentioned above describes a fundamental process for preparation of high protein rice flour (HPRF) wherein rice flour is gelatinized and enzymatically digested with carbohydrate-type enzymes commonly known as amylases. This treatment hydrolysis the starch to soluble saccharides of various molecular weights such as glucose, maltose, oligosaccharides, and dextrins from which the insoluble HPRF is separated, for example by centrifugation. Thus, by partial removal of the non-proteinaceous material, the processed rice flour contains less carbohydrate and the protein content is correspondingly enhanced.

High protein rice flour obtained as described in the prior art has not proved to be entirely satisfactory as a raw material for nutritional products. For instance, over 80% of rice protein consists of glutelin which is completely insoluble at pH's acceptable for infant formula. Infant formulas made with such protein do not form satisfactory dispersion, have a very grainy, gritty mouthfeel and tend to plug up the nipple.

Moreover, the HPRF prior art process does not address the problem of unacceptable manganese levels.

The manganese content of commercially available rice flour varies considerably with a typical content

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of about 150-260 micrograms (mcg) per gram protein.Table I below illustrates observed variations in manganese content of representative commercial rice flours containing about 8% protein.

>;tb;>;TABLE; Columns=2 Manganese Content of Commercial Rice Flours

>;tb;Head Col 1: Source

>;tb;Head Col 2: Manganese, mcg/g Protein

>;tb;Riceland Foods

>;a;

>;SEP;150 - 163

>;tb;

>;tb;California Rice Growers Association

>;b;

>;SEP;150 - 200

>;tb;Riviana Rice Flour

>;c;

>;SEP;150 - 250

>;tb;Coor's rice flour

>;d;

>;SEP;220 - 260

a. Stuttgart, AR

b. Sacramento, CA

c. Houston, Texas

d. ADM Milling, Rice Div., Weiner, AR

>;tb;>;/TABLE;

We have determined that using such rice flour as raw material in the conventional prior art process

(gelatinization and enzymatic digestion) results in a concomitant enrichment of manganese along with increased protein content. Apparently, the manganese associates with the protein and remains with the separated HPRF rather than the solubilized saccharides.

Manganese is considered an essential element in the mammalian diet. It is also known that only relatively small quantities are required by human infants. Human milk levels are generally below 32 micrograms per quart and pediatric nutritionists favor infant formula with relatively low manganese levels. The National Academy of Sciences-Food and Nutrition Board (NAS-FNB) has determined the

U.S. average daily intake and the estimated safe and adequate daily dietary intake as follows.


>;tb;Title: Dietary Intake

>;tb;Title: U.S. Avg.Daily Intake

>;tb;Infants>;SEP;10-300 mcg/day

>;tb;Children, 3-5 yrs.>;SEP;1,400 mcg/day

>;tb;Children, 10-13 yrs.>;SEP;2,180 mcg/day

>;tb;Adults>;SEP;2,500-9000 mcg/day Estimated Safe and Adequate Daily Dietary Intake

>;tb;Infants 0-6 months>;SEP;500-700 mcg/day

>;tb;Infants 6-12 months>;SEP;700-1000 mcg/day

>;tb;Children and Adolescents>;SEP;1,000-3,000 mcg/day

>;tb;Adults>;SEP;2,500-5,000 mcg/day

>;tb;>;/TABLE;

A quart of infant formula typically contains about 14-20 g protein. As previously mentioned, the HPRF of the prior art retains substantially all of the manganese found in rice flour raw material which has typical manganese levels of 150-260 micrograms per gram protein. Thus, the amount of manganese in a quart of rice protein based infant formula containing 14 and 20 grams protein is calculated as follows for particular levels of rice flour manganese content.

>;tb;>;TABLE; Columns=3 Manganese Per Quart Formula From Rice Flour (grams protein x mcg manganese per gram)

>;tb;Head Col 1: Mn Content of Rice Flour (mcg/g) Protein

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>;tb;Head Col 2 to 3:Micrograms Manganese per Quart

>;tb;SubHead Col 1:

>;tb;SubHead Col 2: 14g protein

>;tb;SubHead Col 3: 20g protein >;SEP;150>;SEP;2100>;SEP;3000

>;tb;>;SEP;260>;SEP;3640>;SEP;5200

>;tb;>;/TABLE; With the assumption that an infant's diet includes one quart of formula per day, rice flour as a source of protein can contain a maximum of about 50 mcg of manganese/g protein (estimated maximum safe and adequate daily dietary manganese intake of 700 mcg/day divided by 14 grams of protein). Since rice flours generally available contain considerably more than 50 mcg manganese/gram protein, they cannot be used to make HPRF suitable for infant formula.


It is an object of the present invention to provide a high protein rice flour (HPRF) with low levels of manganese relative to protein which can be used in infant nutritional formulas. The HPRF of the invention is characterized in that it has a protein content of greater than 16%, preferably 16 to 60% and a manganese content of 50 micrograms or less per gram protein. Preferred and practical operable ranges for the instant HPRF is 5 to 50 mcg manganese/gram protein with a typical production scale process of from 10 mcg/g protein to 30 mcg/g protein.

A second object is to improve the mouthfeel of the instant HPRF.

Another object is to provide a new and improved process for producing HPRF wherein low levels of manganese relative to protein are obtained.

A further object of the invention is to provide a nutritionally complete rice based infant powder formula having less than 700 micrograms of manganese per quart when reconstituted.

These objects, as well as others apparent from the specification, are achieved by the instant invention in accordance with the detailed description below.

Briefly, according to the invention, there is provided a process (herein Process A) for preparing high protein rice flour (HPRF) with substantially reduced manganese content from rice flour containing manganese which comprises the steps of:

(Aa) blending rice flour and water at a pH of 3.4 to 4.6,

(Ab) separating the insoluble washed rice flour of step (Aa);

(Ac) resuspending the washed rice flour of step (Ab) and adjusting the suspension to a pH and temperature within the operable range of an alpha-amylase enzyme;

(Ad) treating the pH and temperature adjusted suspension of step (Ac) with an alpha-amylase enzyme for a sufficient time to hydrolyze the starch to 5 to 50 DE content;

(Ae) adjusting the treated mixture of step (Ad) to pH of 3.4 to 4.6; and then

(Af) separating rice syrup from low manganese high protein rice flour.

Further in accordance with the invention, a process is provided for converting the low manganese high protein rice flour (HPRF) by enzymatic hydrolysis to provide a low manganese HPRF hydrolysate with dispersibility and mouthfeel characteristics suitable for liquid or powdered infant formula. The process comprises the steps of:

(a) adjusting a slurry of said low manganese HPRF to conditions optimum for protease enzyme;

(b) adding a proteolytic enzyme;

(c) stirring the mixture for a sufficient period to hydrolyze from 1 to 5% of the peptide bonds; and then

(d) heating the mixture to 70 DEG to 80 DEG C. to inactivate the proteolytic enzyme.

The hydrolysate can be partially concentrated by conventional means such as evaporation and then spray dried to provide a low manganese HPRF hydrolysate powder base which can be used in infant formulas.

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The process of the invention for preparing high protein rice flour (HPRF) with reduced manganese content is applicable to rice and in particular to whole kernel polished rice, rice grits and rice flour. In general, rice flour from about 90 to 120 mesh obtained by grinding broken rice constitutes preferred raw material as it is a by-product of rice milling, readily available, and relatively inexpensive.Detailed discussion of process steps follow and for purposes of the instant specification and claims, the following terms are defined.

High protein rice flour - processed rice flour having at least 16% protein.

Rice syrup - water soluble rice carbohydrate.

Low manganese HPRF - high protein rice flour containing 50 mcg or less manganese per gram protein.

High manganese HPRF - high protein rice flour containing more than 50 mcg of manganese per gram protein.

Modified low manganese HPRF - proteolytic treated low manganese HPRF containing 50 mcg or less manganese per gram protein with improved dispersibility and mouthfeel compared to low manganese

HPRF.

Blending rice flour and water at pH 3.4 to 4.6 and separating the insoluble washed rice flour -- steps

(Aa) and (Ab).

The initial step in Process A of the present invention involves washing rice flour containing more than

50 mcg manganese per gram protein. As previously mentioned, commercially available rice flour generally contains from 150-260 micrograms manganese per gram protein and the instant process is particularly suited to reducing manganese levels of the high protein rice flour obtained therefrom to levels of 50 microgram or less manganese per gram protein. This is conveniently carried out by continuous blending the rice flour and water with sufficient food-grade acid to maintain a pH in the range of 3.4 to 4.6. The method of washing (e.g., batch-wise or continuous) is not particularly critical as long as conditions provide thorough mixing. Both organic acids such as acetic, citric, and inorganic acids such as sulfuric, hydrochloric, nitric and phosphoric may be used for pH adjustment.

Sufficient water is used to provide a pumpable slurry. For example, a flour-water ratio (parts by weight) of about 1:3-20 is operable for commercial production with a flour-water ratio of 1:6-12 preferred and 1:9 most preferred. More dilute solutions can be employed if desired. For instance, three percent suspensions (flour-water ratio of about 1:33) of rice flour containing about 140 mcg/g protein of manganese adjusted to pH 3.5 with hydrochloric, nitric, sulfuric, acetic or citric acid stirred at ambient temperature for one hour and centrifuged provided rice flour with Mn levels of 15 mcg/g protein or less. Use of relatively large amounts of acid wash on a commercial scale is impractical and uneconomical because of the problems involved in handling and disposing the spent wash.In the above illustration, each pound of HPRF requires about 33 pounds of acid wash and on a tonage basis represents a major environmental consideration.

With reference to the pH range of 3.4 to 4.6 for blending the rice flour and water, a pH lower than about 3.4 tends to solubilize a significant amount of protein and use of pH higher than about 4.6 lessens the amount of manganese removed from the rice flour. The preferred blending step range is a pH of 3.8 to 4.2 wherein yields and low manganese levels are optimized.

Temperature at which the blending (washing) step is conducted is not particularly critical and the washing step is conveniently carried out at ambient temperature generally from about 10 to 30>;o;C., preferably at about 20-25>;o;C. Higher temperatures above 65-70 DEG C known to cause gelatinization of rice starch should be avoided because of excess water retention resulting from increased viscosity which significantly diminishes the amount of manganese removed.

Blending and separation (e.g., by centrifugation or other conventional means) of the washed rice flour is generally completed in from 10 minutes to 90 minutes but the length of the washing period has no

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appreciable effect on the degree of manganese removed and longer periods can be employed if desired for operating convenience.

Table 1 below sets out results obtained by washing 8% protein rice flour (1:9 flour-water ratio) containing 260 mcg manganese/g of protein at pH 3.5 for various times and temperatures indicating these variables have a relatively small effect on manganese removal.

>;tb;>;TABLE; Columns=4 Effect of Time and Temperature on Removal of Manganese from Rice

Flour by Acid Washing

>;tb;Head Col 1: Time (Min.)

>;tb;Head Col 2: Temperature ( DEG C)

>;tb;Head Col 3: mcg Mn/g Protein (washed flour)

>;tb;Head Col 4: Percent Mn Removed From Rice Flour >;SEP;0

>;a;

>;SEP;13>;SEP;63>;SEP;76

>;tb;>;SEP;15>;SEP;13>;SEP;70>;SEP;73

>;tb;>;SEP;30>;SEP;13>;SEP;59>;SEP;77

>;tb;>;SEP;60>;SEP;13>;SEP;59>;SEP;77

>;tb;>;SEP;120>;SEP;13>;SEP;65>;SEP;75

>;tb;>;SEP;15>;SEP;19>;SEP;68>;SEP;74

>;tb;>;SEP;15>;SEP;49>;SEP;60>;SEP;77

a. Immediately centrifuged following mixing.

>;tb;>;/TABLE;

The efficiency of manganese removal from rice flour by acid washing can be increased by the addition of relatively small amounts of calcium salts. Various calcium salts such as calcium chloride, monobasic calcium phosphate, dibasic calcium phosphate, tribasic calcium phosphate enhances manganese removal as shown in Table 2 below wherein results obtained by washing rice flour (1:9 flour-water ratio) containing 260 mcg/g protein manganese at pH 3.5 with calcium chloride are set forth.

>;tb;>;TABLE; Columns=3 Effect of Calcium Chloride on Manganese Removal During Acid Washing

>;tb;Head Col 1: Calcium chloride added (% of rice flour)

>;tb;Head Col 2: mcg Mn/g protein of acid washed flour

>;tb;Head Col 3: Percent Mn Removal >;SEP;0>;SEP;59>;SEP;77

>;tb;>;SEP;1>;SEP;49>;SEP;81

>;tb;>;SEP;2>;SEP;40>;SEP;85

>;tb;>;SEP;3>;SEP;34>;SEP;87

>;tb;>;/TABLE;

Thus, addition of calcium during acid washing of rice flour is another aspect of the instant process of the invention. In this regard, the step of blending rice flour and water at a pH of 3.4 to 4.6 is carried out by adding calcium salts to the rice flour at a concentration of 0.1 to 3.6% and preferably 0.3 to 1% calculated on the basis of calcium content.

Resuspending the washed rice flour, adjusting the suspension to a pH and temperature within the operable range of an alpha-amylase enzyme and treating with the enzyme to hydrolyze the starch -- steps (Ac) and (Ad)

Following acid washing, the resuspended washed rice flour is gelatinized and enzymatically hydrolyzed essentially as described by the aforementioned prior art to effect partial liquification of the rice starch for separation from the treated rice flour. In general, liquification (solubilization) is conventionally carried out by resuspending the washed rice flour in water providing a pumpable slurry with a solid content generally in the range from about 15-30%, preferably 20% by weight.The pH of the slurry is adjusted to within the operable range of the enzyme, generally about 5.5 to 9.0 and preferably to a pH of 6.2 to 7.0, with a base such as potassium hydroxide and relatively heat-stable alpha-amylase enzyme such as Termamyl (Novo Laboratories, Inc., Wilton, CT) or Takalite (Miles,

Inc., Elkhart, IN) added with the mixture subjected to elevated temperatures on the order of 75 to

100>;o;C. and preferably about 90>;o;C. with adequate mixing.

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As will be appreciated by those skilled in the art, different amylases may be used with appropriate process variations. For instance, with Termamyl or Takalite, about 0.3% enzyme is used based on the weight of unwashed rice flour. Higher enzyme levels allow shorter reaction time, or reverse.

Temperatures may vary from below room temperature to over 100 DEG C and the reaction time accordingly adjusted since the rate of enzyme activity varies with temperature. The length of amylase treatment is determined by the degree of starch hydrolysis required to achieve acceptable HPRF protein level.

Heating and stirring are continued until the enzymatic hydrolysis of the starch has proceeded to 5-50 dextrose equivalent (DE), preferably 20-35 DE and most preferably 24-30 DE syrup. DE is an index relating to ability to function as a reducing sugar. As such, it constitutes a measure of the total reducing power of the carbohydrate source expressed as anhydrous dextrose and calculated as a percent of the total solids. At 5-50 DE, the rice starch has been sufficiently hydrolyzed (i.e. liquified) to provide (on separating the mixture) rice flour (HPRF) with an increased protein level of 16% or above, preferably

16 to 60%, on a dry weight basis. Infant formula at protein level of 14 grams per quart can be made with HPRF protein content as low as 16% protein.At levels below 16% protein, complete infant formula are difficult to make because of the amount of flour required to provide the desired protein level. However, this does not preclude using the instant HPRF low Mn process to produce flour at levels of 10%-16% protein for use in infant food supplements which also require low manganese content.

Adjusting the enzyme treated reaction mixture to pH 3.4 to 4.6 and separating the HPRF from syrup -- steps (Ae) and (Af)

When the targeted DE content has been achieved, the amylase is inactivated by adding acid, preferably by adjusting the pH to about 3.4 to 4.6, and most preferably to pH 3.8, with temperature maintained at about 90 DEG C. Selection of the acid is not critical with food grade acids preferably employed.

Phosphoric acid is most preferred as it does not contribute off flavor and relatively small amounts are required compared to weaker acids such as acetic or citric. Following enzyme inactivation by pH adjustment, the solubilized (i.e. hydrolyzed) rice starch is separated from the insoluble HPRF by conventional means such as centrifugation, filtration, or decantation. If desired, the wet HPRF can be washed with water to remove additional rice syrup and manganese retained in the wet cake.Further the solubilized rice syrup fraction is useful in its own right and although it must be removed from the rice flour to provide the instant HPRF, it constitutes an economically valuable commodity as a food source.

For example, in the infant formula of the instant invention, an appropriate amount of rice carbohydrate can be added to the HPRF to provide required carbohydrate levels.

Aside from enzyme inactivation, adjustment to acid pH is critical with respect to further removal of manganese from HPRF. This additional reduction in manganese is necessary since if the Mn present in the washed rice flour exceeded a level of 35 to 50 mcg/g protein and was retained by the HPRF, the amount of Mn in finished infant formula would exceed desired levels. As previously mentioned, the maximum NAS-FNB Estimated Safe and Adequate Daily Dietary Intake of manganese for infants is

700 mcg/day. Assuming one quart of formula per day as average consumption, infant formulas should then have no more than 700 mcg manganese/qt.The following calculation establishes the maximum allowable and desired manganese levels in washed rice flour assuming no further removal during the separation of HPRF from syrup.

>;tb;>;TABLE; Columns=2 Maximum Allowable Manganese Levels in Washed Rice Flour (700 mcg/qt + grams protein)

>;tb;Head Col 1: Grams Protein

>;tb;Head Col 2: Manganese/g Protein >;SEP;14>;SEP;50 mcg

>;tb;>;SEP;20>;SEP;35 mcg

>;tb;>;/TABLE; It is evident that without further removal of manganese, washed rice flour having manganese levels of above 35-50 mcg/g protein cannot be used since the resulting infant formula would have unacceptable manganese levels.

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As previously mentioned, the acceptable upper manganese levels of rice flour is 50 mcg/g protein with less preferred. Lower levels cannot be obtained without extensive acid washing of the rice flour prior to enzyme treatment. This is not required in the instant process since by adjusting the mixture to a pH between 3.4-4.6 or preferably at pH 3.6-4.0 and more preferably 3.8 with a food grade acid prior to separation of HPRF from syrup, the manganese content of the HPRF is reduced. This pH adjustment is critical to providing HPRF having a manganese content of less than about 50 mcg per gram protein.The amount of manganese contributed by the HPRF to a quart of infant formula containing 14-20 grams protein is illustrated by the following calculation.

>;tb;>;TABLE; Columns=3 Manganese Provided by HPRF Per Quart Formula (grams protein/qt x mcg

Mn/g protein)

>;tb;Head Col 1: Mn Content of HPRF (mcg/g protein)

>;tb;Head Col 2 to 3: Micrograms Mn per quart at

>;tb;SubHead Col 1:

>;tb;SubHead Col 2: 14 g

>;tb;SubHead Col 3: 20 g >;SEP;50>;SEP;700>;SEP;1000

>;tb;>;SEP;40>;SEP;560>;SEP;800

>;tb;>;SEP;30>;SEP;420>;SEP;600

>;tb;>;SEP;20>;SEP;280>;SEP;400

>;tb;>;SEP;10>;SEP;140>;SEP;200

>;tb;>;SEP;5>;SEP;70>;SEP;100

>;tb;>;/TABLE;

As previously mentioned, maximum manganese levels provided by the instant low manganese HPRF are 700 mcg per quart formula. Thus, HPRF having a manganese content of about 50 mcg/g protein or less is required with a preferred level of no more than about 30. Preferred ranges in micrograms manganese per gram protein are 5 to 50 and 10 to 30. As will be appreciated by those skilled in the art, in the event the instant lower manganese HPRF does not provide sufficient manganese for the minimum recommended daily amount, appropriate amounts of manganese can be added to the formula.

The combined effect of adjusting the enzyme treated acid washed rice flour (1:9 rice flour-water) and rice syrup separation (1:4 washed rice flour-water) is shown in Table 3 below.

>;tb;>;TABLE; Columns=4 Manganese Content of High Protein Rice Flour (mcg Mn/g protein) Using

Various pH's for Acid Wash and Syrup Separation

>;tb;Head Col 1: Acid Wash pH

>;tb;Head Col 2 to 4: Rice Syrup Separation pH

>;tb;SubHead Col 1:

>;tb;SubHead Col 2: 5.5

>;tb;SubHead Col 3: 4.5

>;tb;SubHead Col 4: 3.5 >;SEP;4.5>;SEP;56.6>;SEP;18.2>;SEP;16.0

>;tb;>;SEP;4.0>;SEP;36.6>;SEP;17.9>;SEP;14.4

>;tb;>;SEP;3.5>;SEP;37.3>;SEP;16.1>;SEP;9.3

>;tb;>;/TABLE;

It is evident that the final Mn content of HPRF is dependent on the particular selection of both the pH of the acid wash and rice syrup separation. For example, acceptable manganese content can be obtained at separation of the rice syrup at 3.5 to 5.5 with acid wash at 3.5 to 4.0 but not at 4.5 acid wash.

According to the instant process, at the operable acid wash range pH 3.4 to 4.6, separation of rice syrup is preferably carried out at 3.4 to 4.6 following enzyme treatment.

Typical manganese levels for 1800 pound batches of 8% protein rice flour (originally assaying for 263 micrograms per gram protein) washed with 16,200 pounds of water at pH 3.5 and subsequently gelatinized and enzyme treated with separation of the HPRF and rice syrup at a pH of 3.5 are shown below in Table 4 below along with comparative manganese levels obtained with syrup separation at pH

6.0.

>;tb;>;TABLE; Columns=4 Manganese Content (mcg/g protein) of Acid Washed Flour and of HPRF

>;tb;Head Col 1: Batch

>;tb;Head Col 2: Acid Washed Flour

>;tb;Head Col 3 to 4:High Protein Rice Flour Separated from Rice Syrup at:

>;tb;SubHead Col 1:

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>;tb;SubHead Col 2:

>;tb;SubHead Col 3: pH 3.5

>;tb;SubHead Col 4: pH 6.0

>;tb;A>;SEP;53.6>;SEP;7.3

>;tb;B>;SEP;61.9>;SEP;9.5

>;tb;C>;SEP;61.9>;SEP;9.1

>;tb;D>;SEP;64.3>;SEP;9.8

>;tb;E>;SEP;64.3>;SEP;9.3

>;tb;F>;SEP;54.8>;SEP;9.3

>;tb;G>;SEP;61.9>;SEP;9.3

>;tb;H>;SEP;61.9>;SEP;10.5

>;tb;I>;SEP;56.0>;SEP;8.9

>;tb;J>;SEP;53.6>;SEP;8.0

>;tb;K>;SEP;69.0>;SEP;>;SEP;52.3

>;tb;L>;SEP;53.6>;SEP;>;SEP;53.6

>;tb;>;/TABLE;

The Mn content of HPRF is 11 mcg or less per gram HPRF when syrup separation is carried out at pH

3.5. Batch results vary to some extent according to centrifuge efficiency in separating the syrup. The results illustrate that satisfactory HPRF Mn levels can be obtained from acid washed rice flour when separation of the rice syrup is carried out at a pH of 3.5. As previously mentioned, below pH 3.4, the separated rice syrup contains significant amounts of solubilized rice protein thereby reducing the yield of low manganese HPRF.

Alternate process for preparing high protein rice flour (HPRF) with significantly reduced manganese content

In the process for preparing HPRF discussed above (Process A), manganese is removed at two stages.

The first stage involves washing rice flour at acid pH with substantial removal of manganese (about 70-

80%) with or without addition of calcium salts. Remaining manganese is concentrated in the HPRF obtained by enzymatic hydrolysis of the rice carbohydrate and, unless the rice flour manganese content has been reduced to 5 to 50 mcg/g protein or preferably 10 to 30 mcg/g protein by extensive washing, further separation of manganese is required. This is carried out at a second stage by separating the enzymatically hydrolyzed rice carbohydrate from HPRF under specific acid pH conditions.

In the instant alternate process (herein Process B) the rice flour is first enzymatically hydrolyzed, then separated from rice syrup at neutral pH and the high manganese HPRF finally washed at acid pH to remove manganese. Thus, in accordance with the instant invention, there is provided an alternate process for preparing high protein rice flour (HPRF) with substantially reduced manganese content from rice flour containing manganese which comprises the steps of:

(Ba) treating said rice flour with an alpha-amylase enzyme for a sufficient time to hydrolyze the starch to 5 to 50 DE content;

(Bb) separating high manganese HPRF from rice syrup at neutral pH;

(Bc) resuspending the high manganese HPRF in water at pH 3.4 to 4.6; and

(Bd) removing the acid wash water to provide low manganese high protein rice flour.

Steps (Ba) and (Bb) of Process B are conventional, essentially following the teachings of Hansen, et al., Chen, et al., and Chang, et al., supra. In practice, previously described conditions for carrying out the rice carbohydrate enzymatic hydrolysis of Process A are applicable and preferred. At step (Bb) there is relatively little separation of manganese from HPRF with only negligible levels of manganese present in the rice syrup. For example, 25% protein HPRF obtained from 8.5% protein rice flour with a manganese content of 165-175 mcg/g protein has a manganese level of about 168 mcg/g protein whereas the separated rice syrup contains only about 0.1 mcg/g solids.

As previously shown, the manganese content of rice flour varies considerably with levels ranging typically from 150 to 260 mcg/g protein. The HPRF in Step (Bb) will essentially contain the same

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manganese content as the original flour on a protein basis since there is no significant separation at neutral pH.

Also, as previously mentioned, a quart of formula typically contains from 14 to 20 g protein with desired maximum manganese level of less than 700 microgram per qt. Thus, in the above illustration, the HPRF from Step (Bb) provides from 2352 mcg to 3360 mcg of manganese per quart and cannot be used in infant formula.

Steps (Bc) and (Bd) are carried out under conditions described for the first stage of manganese removal in Process A, i.e. steps (Aa) and (Ab). After the step (Bb) rice syrup separation in Process B, the HPRF is resuspended in water to provide a pumpable slurry with an HPRF ratio (parts by weight) of about 1:3 to 16 preferred and a ratio of 1:9 most preferred and pH adjusted to 3.4 to 4.6 with food-grade acids

(e.g., phosphoric, hydrochloric, nitric, sulfuric, citric, acetic, and the like). The separated acid washed

HPRF has manganese levels similar to those found in Process A.

While Process B provides HPRF with significantly reduced manganese levels, there are several disadvantages inherent in the alternate process compared to Process A. The acid wash of HPRF produces a rice syrup with high manganese during step (Bd). This leads to greater problems in waste disposal of the spent acid wash containing the rice carbohydrate. In addition the yield of useful rice syrup is reduced.

High protein rice flour (HPRF) dispersibility and mouthfeel improvement (modified low manganese

HPRF)

Low manganese high protein rice flour obtained by Process A or B of the instant invention is suitable as a basic ingredient for non-liquid foodstuffs but further processing is required to provide characteristics appropriate for use in infant formula. In particular, protein dispersibility and mouthfeel must be improved. With respect to dispersibility, the grainy mouthfeel of infant formula using HPRF obtained according to the prior art primarily reflects HPRF protein insolubility at the pH of infant formula. Moreover, because of the grainy texture, the low manganese HPRF obtained according to

Process A or B cannot be easily given in an infant formula since feeding nipples tend to quickly plug up.

Modification of the low manganese HPRF protein to eliminate graininess and improve mouthfeel is carried out by treatment with a proteolytic enzyme. Complete solubilization of the HPRF protein is not necessary to improve dispersibility and mouthfeel and is to be avoided as extensive protease modification improves solubility but with development of an unpleasant bitter flavor.

There are a number of different proteases which can be used for this modification. These may include neutral bacterial proteases (e.g., Neutrase), alkaline bacterial proteases (e.g., Alcalase), fungal proteases, animal proteases (e.g., trypsin, pancreatin), or plant proteases (e.g., papain, ficin, bromelain).

For ease of processing, it is preferable to select a protease which has a pH optimum near neutral pH, relatively easy to inactivate, and commercially available at reasonable cost.

Preferably, the enzyme Neutrase (Novo, Inc., Wilton, CT) is used as it does not produce a bitter offflavor and is inactivated near pasteurization temperature. Thus, in accordance with the instant invention, there is provided a process for improving protein dispersibility and mouthfeel of low manganese high protein rice flour wherein said flour contains from 16 to 60% protein and 5 to 50 microgram manganese per gram protein which comprises the steps of:

(a) adjusting a slurry of said low manganese HPRF to pH 5.5 to 8 and temperature of 40 DEG to 60

DEG C.;

(b) adding a proteolytic enzyme;

(c) stirring the mixture for a sufficient period to hydrolyze from 1-5% of the peptide bonds; and then

(d) heating the mixture to inactivate the proteolytic enzyme.Preferred process conditions are:

Step (a) - slurry adjusted to pH 6.0 with base (e.g., potassium hydroxide) with temperature of 50

DEG C;

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Step (b) - adding the proteolytic enzyme at 0.5 to 2% and preferably a 1% concentration based on protein content of HPRF;

Step (c) - stir mixture 30 minutes;

Step (d) - heating the mixture to 70 DEG C to 80 DEG C for 10 minutes to inactivate the enzyme.

The above proteolytic processed high protein rice flour with reduced manganese can be spray dried by conventional means to provide a modified high protein rice flour containing 50 mcg or less manganese per gram protein with improved dispersability and mouthfeel as a powder base for an infant formula.

Alternatively, it can be incorporated into an infant formula base and then spray dried to provide powdered infant formula. Or, it can be incorporated into a shelf stable liquid formula.

As will be appreciated by those skilled in the art, numerous variations of the above process are possible. For example, longer reaction time allows use of lower enzyme concentration, lower temperature requires a longer reaction time, etc. The desired peptide hydrolysis of 1% to 5%

(preferably 2% to 3%) is determined by measuring the increase in free amino groups by a conventional primary amino group assay such as the method of Habeeb, Anal. Biochem. 14:328 (1966).

Comparative organoleptic testing of the mouthfeel of infant formula made with and without protease treatment was carried out. On a 5 to 1 scale where a score of 5 would mean a smooth mouthfeel and a score of 1 grainy, sandy, or mealy mouthfeel, product made without protease received a score of 2.

With protease treatment, the instant formula received a score of 4.

The proteolytic modified high protein rice flour (HPRF) with reduced manganese (Mn) of the instant invention can be used to prepare a complete infant formula that meets the nutritional requirements for infants as described by the infant Formula Act of 1980. (Public Law 96-359, Sept. 26, 1980). The term

"complete infant formula" means a food which purports to be or is represented for special dietary use solely as a food for infants by reason of its simulation of human milk or its suitability as a complete or partial substitute for human milk. The protein levels in complete infant formula vary from 1.8 to 4.5 g per 100 kcal. Since 640 kcal/qt is the average caloric content of human milk and infant formula and the range of protein in infant formula is 11.5 to 28.8 g per quart, then the protein caloric range is 7.2% to

18% of total calories.

In the instant formula, a protein range of 14 to 20 g of protein per quart is preferred with the protein source comprising modified low Mn HPRF containing 16-60% protein and 5 to 50 mcg Mn/g protein.

The protein levels found in low manganese HPRF may vary depending on the conditions used for starch hydrolysis and the efficiency of the separation process. For example, the more water retained in the HPRF the lower the protein content. The proteolytic modified low Mn HPRF contains manganese at levels less than 50 mcg per gram protein and the reconstituted product contains no more than 700 mcg Mn/qt (NAS-FNB).

In a typical formulation, the modified HPRF contains 44% protein and 10 mcg Mn/g protein. About

42.3 g of HPRF is needed to provide 18.6 g. of protein per quart. This modified HPRF with low Mn content thus provides 186 mcg Mn/qt which is about 15 to 25 times less Mn than a similar formula using HPRF prepared according to the prior art.

Optionally, the HPRF can be supplemented with the amino acids, lysine and threonine at levels of 2.75 and 6 g HPRF protein, respectively, to increase the PER from 70% casein without supplementation to

110% of casein with supplementation. The amino acid addition is not required but increases the nutritional value of the rice protein in the infant formula.

The carbohydrate portion of this infant formula may be any edible FDA approved carbohydrate that is readily digested by the infant. This carbohydrate may include lactose, sucrose, corn syrup solids, or rice syrup solids. Since the HPRF process produces a large quantity of by-product rice syrup solids that is easily digested by the infant, it is preferably used to adjust the carbohydrate levels to 28 to 63% of total calories required for a complete infant formula.

The lipid portion of the formula is made up of edible FDA approved oils or blends of oil which are generally recognized as appropriate for infant feeding. The total fat concentration of the infant formula is about 30 to 54% of calories and is usually made up of vegetable oils such as corn oil, soybean oil,

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coconut oil, or safflower oil. The lipid composition provides a fatty acid distribution similar to human milk and contains appropriate levels of linoleic acid, an essential fatty acid.

A powdered infant formula base is prepared by dispersing the modified HPRF in water together with rice syrup, minerals, and an oil blend. The mixture is heated to 75 DEG C and conventionally homogenized in a two stage piston-type homogenizer at 2500 and 500 psi pressure to develop a stable liquid emulsion. The concentrated liquid (at about 40% solids) is spray dried and then dry blended with the vitamin-amino acid premix and trace mineral premix to provide finished formula powder.

Generally, about 124-128 grams is used to make 1 qt of reconstituted product but the amount may be varied in accord with good nutritional practice.

The vitamin and mineral levels are similar to commercially marketed infant formulas and conform to the levels recommended by the Infant Formula Act of 1980.

Infant formula based on HPRF is unique because it contains no milk protein, no soy protein, no lactose, no sucrose, and no corn syrup solids. The instant formula provides levels of protein, carbohydrate, fat, vitamins, minerals, and trace elements based on recognized infant nutritional requirements and standards. Because of its unique composition, it can be used by infants with allergies to cow milk protein or soy protein, by infants with lactose or sucrose intolerance as well as by healthy, normal infants to provide desired growth and development in all children.

The following examples further illustrate the manner in which various aspects of the invention may be carried out.

Example 1

Manganese Removal From Rice Flour by Washing-pH and Dilution Effects

Eight percent protein rice flour (180 g, Riviana Foods, Inc., Houston, TX) containing 166 mcg manganese per gram protein was suspended in 420 grams distilled water at ambient temperature (about

22-25>;o;C.). The flour to water ratio employed has an effect on the amount of water soluble manganese retained by the washed flour with the amount of water soluble manganese remaining in the washed flour generally decreased by employing more water relative to flour. The pH of the suspension is 6.1. Five identical suspensions were prepared and adjusted to a pH of 3.5, 4.0, 4.5, 5.0 and 5.5 with

1N hydrochloric acid.

The flour suspensions were stirred for a period of 60 minutes and the flour collected by centrifugation using 2000 gravity (g)-minutes (min) (average). The supernatant was removed and a fraction of the flour pellet dried and analyzed for manganese using atomic absorption spectrometry. The remainder of the flour was then resuspended in distilled water to yield a flour to water ratio (parts by weight) of 3:7 and adjusted to test pH with 1N hydrochloric acid as required. The suspensions were then stirred for a

15 minute period and centrifuged as above. Samples of the collected flour were analyzed for manganese and the above rewash procedure repeated once again. There are no significant differences with respect to manganese removal between shorter or longer stirring times as long as thorough mixing is achieved.Findings are reported in Table 5 below.

>;tb;>;TABLE; Columns=4 Effect of pH on Washed Flour Manganese Content (microgram per gram protein)

>;tb;Head Col 1 AL=L: Wash pH

>;tb;Head Col 2 to 4: Number of Washes

>;tb;SubHead Col 1:

>;tb;SubHead Col 2: 1

>;tb;SubHead Col 3: 2

>;tb;SubHead Col 4: 3 >;SEP;"As is" (6.1)>;SEP;169>;SEP;159>;SEP;121

>;tb;>;SEP;5.5>;SEP;123>;SEP;55>;SEP;21

>;tb;>;SEP;5.0>;SEP;90>;SEP;40>;SEP;25

197/2197

>;tb;>;SEP;4.5>;SEP;54>;SEP;18>;SEP;13

>;tb;>;SEP;4.0>;SEP;64>;SEP;20>;SEP;11

>;tb;>;SEP;3.5>;SEP;56>;SEP;->;SEP;-

>;tb;>;/TABLE;

This study illustrates that manganese removal is dependent on the ratio of flour to water as reflected by the number of washes and is most effectively removed from rice flour at wash pH values of 3.5 to 5.5 with the amount of water soluble manganese retained by the washed flour decreasing as a higher ratio of water to flour is used. For example, at pH 4.0, 180 grams of flour was washed in a total of 1260 grams of water which represents an overall ratio (parts by weight) of 1 part flour to 7 parts water thereby providing "washed" rice flour with a manganese level of 11 microgram per gram protein.

Preferably, the flour is washed at a pH of 3.4-4.6 to reduce the manganese content to the desired level of less than 50 microgram per gram protein.

Example 2

Manganese Removal From Rice Flour By Washing - Temperature Effect

Aliquots of 8% protein rice flour (40 g, Riviana Foods, Inc., Houston, TX) containing 225 mcg manganese per gram protein were suspended in 360 grams distilled water at 10, 23, 30, 35 or 45>;o;C.

The pH was adjusted to 3.5 with 1N hydrochloric acid and the flour suspensions maintained at the designated temperatures for a 30 minute period with stirring. Suspensions were then centrifuged for

6000 g-min (average), the supernatant removed and the washed flour dried and analyzed for manganese using atomic absorption spectrometry. Findings are reported in Table 6 below.

>;tb;>;TABLE; Columns=2 Effect of Temperature on Washed Flour Manganese Content

>;tb;Head Col 1: Wash Temperatures ( DEG C)

>;tb;Head Col 2: Microgram per gram protein >;SEP;10>;SEP;58

>;tb;>;SEP;23>;SEP;56

>;tb;>;SEP;30>;SEP;60

>;tb;>;SEP;35>;SEP;59

>;tb;>;SEP;45>;SEP;55

>;tb;>;/TABLE;

This study indicates that the temperature of the extraction is not critical with respect to removal of manganese. Thus, temperatures below the point of gelatinization of the rice flour can be employed in the instant process with ambient temperature preferred from a convenience and operability standpoint.

Example 3

Manganese Removal From Rice Flour by Washing - Acidulant Effect

Three aliquots of 20 g of 8% protein rice flour (Riviana Foods, Inc., Houston, TX) containing 200 mcg manganese per gram protein were suspended in 180 grams of distilled water at ambient temperature.

The suspensions were adjusted to a pH of 3.5 with 1N hydrochloric acid, 1N citric acid, 1N phosphoric acid. After stirring for 30 minutes, the washed flour was collected by centrifugation for 6000 g-min

(average). The supernatant was removed and the washed flour dried and analyzed for manganese using atomic absorption spectrometry. Findings are reported in Table 7 below.

>;tb;>;TABLE; Columns=2 Effect of Acidulant on Flour Manganese Content

>;tb;Head Col 1: Acidulant

>;tb;Head Col 2: Microgram per gram protein

>;tb;Hydrochloric Acid>;SEP;51

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>;tb;Citric Acid>;SEP;53

>;tb;Phosphoric Acid>;SEP;48

>;tb;>;/TABLE;

This study demonstrates that both organic and inorganic acid can be employed as acidulants in the instant process without significantly affecting efficiency of the manganese extraction.

Example 4

Manganese Removal From Rice Flour by Washing - Particle Size Effect

Aliquots (20 g) of rice of varied particle size were washed with 180 grams water (rice:water ratio of

1:9). Samples consisted of (a) 100 mesh rice flour (Riviana Foods, Inc., Houston, TX), (b) rice grits

(Riviana Foods., Inc., Houston TX, 30 mesh) and (c) whole kernel rice (Coors Food Products., Weiner,

Arkansas). The same quantity of 1N hydrochloric acid was added to each sample to provide an adjusted pH of 3.5 +/- 0.5. The suspensions were stirred at room temperature for 2.5 hours with samples drawn at 15, 30, 60, 90, 120 and 150 minutes. The collected samples were centrifuged for 6000 g-min

(average), dried and analyzed for manganese using atomic absorption spectrometry.Findings are reported in Table 8 below with efficiency of the manganese removal calculated on a percent removed.

>;tb;>;TABLE; Columns=5 Effect of Rice Particle Size on Washed Flour Manganese Removal

>;tb;Head Col 1: Sample

>;tb;Head Col 2 to 5: Manganese Content and Percent Efficiency at Wash Time

>;tb;SubHead Col 1;:

>;tb;SubHead Col 2 to 3 RB=3: 15 min

>;tb;SubHead Col 4 to 5 RB=3: 30-150 min

>;a;

>;tb;

>;tb;SubHead Col 1:

>;tb;SubHead Col 2: mg/g protein

>;tb;SubHead Col 3: (efficiency)

>;tb;SubHead Col 4: mcg/g protein

>;tb;SubHead Col 5: (efficiency)

>;tb;Flour

>;b;

>;SEP;44>;SEP;(78%)>;SEP;35>;SEP;(82%)

>;tb;Grits

>;c;

>;SEP;23>;SEP;(78%)>;SEP;15>;SEP;(85%)

>;tb;Whole Kernel

>;d;

>;SEP;35>;SEP;(78%)>;SEP;29 >;SEP;(82%)

a. Determined by averaging Mn values obtained at 30 minute intervals

b. 100 Mesh - 195 mcg Mn/g protein

c. 30 Mesh - 104 mcg Mn/g protein

d.Polished rice (bran removed) - 159 mcg Mn/g protein

>;tb;>;/TABLE;

The results illustrate that particle size of rice raw material is not a significant controlling factor with respect to efficiency of reducing manganese by acid washing.

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Example 5

Manganese Removal From Rice Flour by Washing - Calcium Salt Effect

Aliquots (20 g) of 8% protein rice flour (Riviana Foods, Inc., Houston, TX) containing 213 microgram manganese per gram protein were suspended in 180 grams distilled water. A calcium salt selected from the group of calcium chloride, calcium phosphate monobasic, calcium phosphate dibasic and calcium phosphate tribasic was added to an aliquot to give a calcium to flour ratios ranging from 0.181 to 0.722 g calcium per 100 g flour and the rice flour-calcium salt suspensions stirred at ambient temperature for a period of five minutes. The pH of the suspensions were then adjusted to 3.5 with 1N phosphoric acid with stirring continued at ambient temperature for a period of 30 minutes. The flour was collected by centrifugation for 6000 g-min (average), the supernatent removed and the washed rice flour dried and analyzed using atomic absorption spectrometry.Findings are reported in Table 9 below.

>;tb;>;TABLE; Columns=3 Effect of Calcium Salts on Manganese Content of Washed Flour

>;tb;Head Col 1: Calcium Salt

>;tb;Head Col 2: g Calcium/100 g Flour

>;tb;Head Col 3: Flour Manganese Content (Microgram per gram protein)

>;tb;None>;SEP;--->;SEP;58

>;tb;Calcium Chloride>;SEP;0.722>;SEP;33

>;tb;Monobasic Calcium Phosphate>;SEP;0.181>;SEP;39




>;tb;Dibasic Calcium Phosphate>;SEP;0.361>;SEP;31

>;tb;Dibasic Calcium Phosphate>;SEP;0.722>;SEP;31

>;tb;Tribasic Calcium Phosphate>;SEP;0.361>;SEP;35

>;tb;Tribasic Calcium Phosphate>;SEP;0.722>;SEP;33

>;tb;>;/TABLE;

This study demonstrates that calcium chloride and calcium phosphate significantly enhances manganese removal from washed flour at acidic pH and a calcium salt to flour ratio of as little as 0.18 grams calcium per 100 grams flour.

Example 6

Low Manganese High Protein Rice Flour

Whole grain milled rice flour (150 parts by weight) having a protein content of 8 percent and a manganese content of about 200 microgram per gram protein and water (1350 parts by weight) were blended in a tank with high shear agitation with adjustment of pH to 3.8 with phosphoric acid. The pH adjusted slurry was then pumped to a Sharples P3400 Superdecanter (Sharples-Stokes Div., Pennwalt

Corp., Warminster, PA) centrifuge at 25 gallons per minute (GPM) flow rate. The protein containing residue from the centrifuge was resuspended in water, pumped to a second tank and sufficient water added to provide a slurry of 20% solids with adjustment to pH 6.2 with potassium hydroxide. After adjusting the pH, 0.58 parts by weight of amylase enzyme Takalite L-340 (Miles, Inc., Elkhart, IN) was added to the slurry.The slurry was then heated to 90 DEG C. by means of a scraped-surface heat exchanger and held for 20 minutes; pH adjusted to 3.8 with phosphoric acid and stirred at high temperature for an additional 10 minutes to inactivate the amylase enzyme. The slurry was centrifuged at 10-15 GPM flow rate to provide a high protein rice flour with substantially reduced manganese content of 9 microgram per gram protein, a protein content of about 44 percent and a carbohydrate content of 53 percent.

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Example 7

Alternate Process for Preparing High Protein Rice Flour (HPRF) With Significantly Reduced

Manganese Content

Rice flour (150 parts by weight, containing 8.0% protein and 250 microgram manganese per gram protein) is suspended in 600 parts by weight water at ambient temperature (about 22-25 DEG C.). After adjusting the pH to 6.2 with potassium hydroxide, 0.58 parts by weight of amylase enzyme Takalite L-

340 (Miles, Inc., Elkhart, IN) is added to the slurry. The slurry is then heated to 90 DEG C. by means of a scraped-surface heat exchanger and held for 20-30 minutes to hydrolyze the rice starch to 24 to 30

DE content and centrifuged. The high protein rice flour contains from 40 to 45% protein and about 227 microgram of manganese per gram protein and is resuspended in 1350 parts water with adjustment of pH to 3.5 to 4.5. Following mixing, the mixture is separated to provide low manganese high protein rice flour containing about 60% protein on a dry weight basis and about 10 micrograms of manganese per gram protein.

Example 8

Rice Syrup

The rice syrup supernatent from the centrifugal separation of low manganese high protein rice flour of

Example 6 had a DE of 24-30 and was concentrated from 22% solids to 60%, then spray dried to yield

100 parts by weight of rice syrup solids having a manganese content of 2-3 microgram per gram solids, a carbohydrate content of 98.3% and less than 1% protein.

Example 9

Low Manganese High Protein Rice Flour With Improved Dispersibility and Mouthfeel

The low manganese high protein rice flour of Example 6 was resuspended in water at 15-20% solids, pH of the rice protein slurry adjusted to pH 6.0 with potassium hydroxide and heated to 50 DEG C. A proteolytic enzyme, Neutrase 0.5L (Novo, Inc.), was added at a rate of 0.14 parts by weight (about 1% on protein basis) and stirred for 30 minutes. The rice protein slurry was heat treated at 75 DEG C. for

10 minutes to inactivate the proteolytic enzyme. The modified high protein rice flour with reduced manganese can be spray dried or incorporated into an infant formula base and then spray dried if desired. Approximately 25 lbs. of low manganese (9 mcg/g protein) high protein rice flour at 44% protein with improved dispersibility and mouthfeel was produced from 150 lbs. of the rice flour starting material used in Example 6.

Example 10

Preparation of Nutritional Powder Rice Formula

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The Example 9 modified low manganese high protein rice flour product (332.35 pounds) and 328.65 pounds of rice syrup solids (DE 30) are dispersed in 1434 pounds water at about 55>;o;C. A major mineral mix (total 29.2 pounds) is added to the dispersion followed by 266.1 pounds of an oil blend consisting of 55% corn oil and 45% coconut oil. The mixture is heated to 70-75>;o;C. for about 8 minutes and then homogenized in a two-stage homogenizer at pressures of 2500 and 500 psi. The homogenized material is spray dried to provide 980 g of solids containing about 2.5% water which is then dry-blended with 8.7 pounds of a vitamin-amino acid premix, 0.45 pounds trace mineral premix, and 10.85 pounds of rice syrup solids containing about 98-99% carbohydrate and 0.2 to 0.4% protein.

The major mineral premix contains the following substances.


>;tb;Head Col 1: Ingredient

>;tb;Head Col 2: Parts by weight

>;tb;Calcium carbonate>;SEP;13.3

>;tb;Potassium phosphate dibasic>;SEP;5.8

>;tb;Sodium citrate>;SEP;5.3

>;tb;magnesium phosphate dibasic>;SEP;3.6

>;tb;Sodium chloride>;SEP;0.9

>;tb;Potassium citrate>;SEP;0.4

>;tb;>;/TABLE;

The vitamin-amino acid premix contains the following substances per 100 parts by weight of dry material:




>;tb;Lysine HCl>;SEP;60.0549

>;tb;L-Threonine>;SEP;10.4960

>;tb;Sodium ascorbate>;SEP;8.0871

>;tb;Rice dextrins>;SEP;4.9781

>;tb;DL-Alpha tocopheryl acetate>;SEP;4.3829

>;tb;Taurine>;SEP;4.1548

>;tb;Inositol>;SEP;3.1535

>;tb;Vitamin D1, dry>;SEP;1.3682

>;tb;Vitamin A, 250A>;SEP;1.0234

>;tb;Niacinamide>;SEP;0.8399

>;tb;Biotin, 1% trituration>;SEP;0.5728

>;tb;Calcium pantothenate>;SEP;0.3654

>;tb;Vitamin B12>;SEP;0.2097

>;tb;Vitamin D3, 400D>;SEP;0.1190

>;tb;Riboflavin>;SEP;0.0634

>;tb;Thiamine hydrochloride>;SEP;0.0578

>;tb;Pyridoxine hydrochloride>;SEP;0.0510

>;tb;Folic acid>;SEP;0.0128

>;tb;Potassium iodide>;SEP;0.0093

>;tb;>;/TABLE;

The trace mineral premix contains the following substances per 100 parts by weight of dry material:




>;tb;Iron (Fe2SO4.7H2O)>;SEP;16.86

>;tb;Zinc sulfate>;SEP;9.94

>;tb;Cupric sulfate>;SEP;0.76

>;tb;>;/TABLE;

Example 11

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Reconstituted Rice Powder Formula

The rice formula powder product of Example 10 is reconstituted by dispersing 127.2 g to 1 quart volume in water to provide a ready-to-use rice based infant formula having the following typical composition:

>;tb;>;TABLE; Columns=4 Reconstituted Rice Formula

>;tb;Head Col 1: Composition

>;tb;Head Col 2: Quantity in 1 Qt. Formula

*

>;tb;Head Col 3: Manganese Content

>;tb;Head Col 4: Manganese mcg/Quart

>;tb;Rice protein concentrate (44% protein, 53% carb.)>;SEP;42.3 g >;SEP;9 mcg Mn/g protein>;SEP;167.5

>;tb;Rice syrup solids (0.3% protein, 98.3% carb.)>;SEP;43.2 g >;SEP;2.3 mcg Mn/g solids>;SEP;99.4

>;tb;Oils>;SEP;33.8 g>;SEP;0>;SEP;0

>;tb;Minerals>;SEP;3.7 g>;SEP;10 mcg Mn/g>;SEP;37

>;tb;Vitamins>;SEP;1.1 g>;SEP;0>;SEP;0

>;tb;>;SEP;Total Manganese>;SEP;>;SEP;273.9 mcg

*on a solids basis

>;tb;>;/TABLE;Data supplied from the esp@cenet database - Worldwide

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39.

EP0352971 - 1/31/1990

PROCESS FOR POPPING WILD RICE


Inventor(s): MACGREGOR WILD RICE CO (--)

Applicant(s): MACGREGOR WILD RICE CO (--)


IP Class: A23L1/18

E Class: A23L1/18C6



Family: CA1324731


GB2069812; US2696157; US2715579; US3411430; US1631145 Cited Document(s):

Abstract:


Disclosed is the process for popping wild rice to make a puffy snack food or breakfast cereal which has a nutty flavor. The process includes curing, roasting and parching the wild rice in roasting ovens, sorting the wild rice into differing lengths and widths so it will have uniformity prior to popping, heating the wild rice on a conveying means at a temperature between 500 - 800 DEG F, and immediately removing the popped product to avoid scorching the product and creating a bad taste.Description:


PROCESS FOR POPPING WILD RICE


This invention relates to a process for treating wild rice. More specifically, it relates to a process for popping wild rice to form a snack food or breakfast cereal exhibiting a tasty nutty flavor.

Wild rice is indigenous to North America and is grown only in limited geographic areas. Many consider wild rice to be a delicacy and exclusive restaurants serve it with pride in a variety of ways as a house specialty.

The potential of processing wild rice to serve it as a natural snack food, however, has never been fully exploited. This is primarily due to the difficulties of working with wild rice on a commercial scale.

While others, in the past, have tried to develop processes to pop wild rice on a commercial scale to make an acceptable snack food, the processes have not been proven acceptable because they tend to be very expensive, complex or yield a product which is not wholly satisfactory.

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For example, others have tried to pop wild rice using cooking oils. The residue of such oils left in the rice, however, contributed to undesirable flavors and additives. Various dry popping techniques are described in the following patents: U.S. Patent 3,845,701 which issued on November 5, 1974 to

Sachnik, U.S. Patent 1,631,145 which issued on June 7, 1927 to J. F. Nooman, U.S. Patent 508,125 which issued on November 7, 1893 to Jay White, U.S. Patent 1,201,510 which issued on October 17,

1916 to William Schuyler, U.S. Patent 1,266,448 which issued on May 14, 1918 to Hazime Fukuda, and U.S. Patent 3,411,430 which issued November 19, 1968 to W. C. Rockwell. However, "dry" popping techniques developed for use in conjunction with other grains have not proven to be satisfactory for popping wild rice on a commercial scale.

Many difficulties are inherent in attempting to pop wild rice on a commercial scale. The major problems encountered when attempting to use the processes and tools described in the above-listed patents center upon the fact that much higher temperatures are required for a shortened exposure time when popping wild rice than when popping other grains, such as corn or even white rice.

BRIEF DESCRIPTION OF THE INVENTION

As described in further detail below, the present invention is comprised of an inexpensive, noncomplex process for popping wild rice on a commercial scale to form a tasty, crisp, nutty product which can be used as a ready-to-eat snack food, a salad topping or a breakfast cereal. The popped wild rice can also be used in the cooking of soups, hot dishes or other entrees to improve their taste. What is truly exciting about the end product is that it is low in fat and sodium and has essentially no cholesterol. Further, the popped wild rice is high in protein and fiber and generally requires no additives or preservatives.

The subject invention relates to an improved process for producing popped wild rice on a commercial scale. It includes the steps of curing, roasting and parching the wild rice to reduce its moisture content.

Next, the rice is passed through a scarification drum to remove part of the outer shell or bran from the rice kernels. While, depending upon the quality of the raw product, this step may not be necessary, it has proven beneficial in enhancing the taste and texture of the final product.

Following the scarification step, the grains are sized into different lengths and widths so that the rice will have a desired uniformity prior to popping. The grains of uniform size are then deposited on a heated surface and their temperatures raised to a relatively high temperature in the range of 500-800

DEG F. Rapid heating of the moisture inside of the wild rice causes it to expand and pop the kernels.

The high temperature makes it imperative that the time the popped wild rice remain on the heated surface be short. This is vitally important to avoid scorching and the creation of a bad taste.After the wild rice is popped, it is then permitted to cool prior to packaging.

BRIEF DESCRIPTION OF THE DRAWING

Figure 1 is a flow diagram of the process comprising the preferred method of the present invention; and

Figure 2 discloses the apparatus used in the present invention to heat the wild rice grains to a very high temperature for a very short period of time.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred process for popping wild rice is illustrated in Figure 1 and is comprised of a plurality of steps. As indicated, it is first necessary to cure and parch the wild rice in roasting ovens. Harvested wild rice generally has a high moisture content. Not atypical is a moisture content in the range of 40% to 80% by weight. Successful popping of wild rice is possible when the moisture content of the rice is reduced by parching to a range of between 4-12% by weight.

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Next, the parched wild rice is examined to determine whether its kernels still contain an outer shell or bran. If this is the case, it is generally desirable to pass the wild rice through a scarification drum to remove part of the outer shell or bran from the kernels. After the wild rice has been passed through the scarification drum, it is then sized (graded) into batches each of uniform but different lengths and widths so that the wild rice will have a desired size uniformity prior to popping.

Once the grains have been divided into varying sizes, grains of a given uniform size are rapidly heated for a short duration to a very high temperature of between 500-800 DEG F so that they will pop. The popping occurs as a result of the rapid heating of the remaining moisture in the grain. The high temperatures recited makes it imperative that the time the popped kernels remain in communication with the heat surface be short. This is to avoid scorching of the popped wild rice and to prevent bad taste.

To obtain the required heating during a very short duration, we have found two techniques to be acceptable. The first is illustrated in Figure 1. The uniform grains of parched and optionally scarified wild rice are distributed from a hopper 1 onto the conveyer 2. The conveyer then moves the wild rice over or beneath a heat source 3 which is operative to raise the temperature of the grain to between 500

DEG F and 800 DEG F. The speed of the conveyer 2 is regulated so the wild rice remains in the heated area only for a time sufficient to allow it to pop, but not so long that the rice becomes scorched. Hence, a foul taste is not created. The popped wild rice is then referred along conveyer 2 to a cooling station 4.

Once cooled, the popped wild rice can be stored in a holding bin 5 for later packaging for distribution.

A second technique which has proven to be commercially suitable involves placing the wild rice grains of uniform size on a Syntron TM vibrating table. The vibrating table should be coated with a non-stick surface. The vibratory motion of the table will cause the wild rice grains to "march" across it so that the kernels will be subjected to a sufficient heat for just enough time so they will pop, but not so long that they will be scorched.

Aside from producing a nutritious snack food, the above described technique greatly reduces the amount of time needed to cook the wild rice when it is to be served as a side dish or as part of a hot dish. Typically, wild rice is cooked by boiling it in water for about one hour. However, if the wild rice is first popped using the above described technique, this cooking time is reduced to about five minutes.

Still another important advantage of the above described technique is found when preparing and packaging wild rice on a commercial scale. Cooking the wild rice for one hour in boiling water and then allowing it to dry prior to packaging removes the flavor from the wild rice. It leaves with the water. However, if the wild rice is treated as described above, then cooked for five to ten minutes, the distinct flavor of the wild rice is not lost. The finished product not only retains its taste, but has the desired texture and appearance.

While the specification discloses a process for the treatment of wild rice to cause it to pop, variations and modifications of this process may be made without departing from the scope of the novel concepts of the present invention. Accordingly, the present invention is limited solely by the scope of the appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


1. A Process for puffing wild rice comprises:

(a) curing and parching the wild rice in a roasting oven to reduce its moisture content to a level of 4% to 12% by weight;

(b) scarifying the wild rice to remove the outer shell and bran from the kernels of the wild rice;

(c) grouping the wild rice by length and width so as to achieve a uniform size in each group;

(d) depositing the groups of wild rice separately on a heating surface and exposing the wild rice in each group to heat the wild rice to 500 - 800 degrees fahrenheit so that the moisture in the wild rice expands, causing the wild rice to puff;

(e) removing the wild rice from the heating surface after it has popped to avoid scorching; and

(f) permitting the wild rice to cool.

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2. The method of Claim 1 wherein said heating surface is a conveyer and said heat is generated by an infrared energy source.

3. The method of Claim 1 wherein said heating surface is a vibrating table having a non-stick surface, said table being adapted to vibrate causing the grains to move across the table at a rate which permits the wild rice to pop, but prevents it from scorching.

4. The method of claim 1 further including the step of cooking the wild rice in boiling water for five to ten minutes.Data supplied from the esp@cenet database - Worldwide

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40.

EP0357320 - 3/7/1990

OBTAINING EDIBLE MATERIAL FROM FUNGUS-DIGESTED MEDIUM


Inventor(s): IKEDA HISAKAZU (--)

Applicant(s): IKEDA HISAKAZU (--)

IP Class 4 Digits: A23L; A23K; A01G; C12N

IP Class: A01G1/04; A23K1/00; A23L1/28; C12N1/22

E Class: A23K1/00C1; A23L1/28; C12N1/22



Family: EP0357320

Equivalent: US5028441; JP2065748; EP0357320

GB2074558; WO8000400; US4711787; DE3600892; JP63202356; Cited Document(s):

JP60149369

Abstract:


An edible material is produced from lignin-rich grassy material such as corncob, the husks of rice, barley or buck-wheat by cultivating mushrooms in a nutrient medium containing the grassy material to provide a digested medium and removing the specific odor from the digested medium by heating or fermenting.Description:


OBTAINING EDIBLE MATERIAL FROM FUNGUS-DIGESTED MEDIUM

This invention relates to an edible material obtained by processing a digested medium resulting from the cultivation of fungi. The material can be used as a food for animals and humans.

Main feed for domestic animals is cereals which are also food for humans. Grasses which can not be eaten by humans are generally used as feed for ruminants.

In order to reduce the cost of feed, husks such as rice husks and corncob are used partially as crude feed for ruminants, however, they have not been widely used because poor results are obtained and most of the husks are being disposed of.

Feeding tests have been conducted with a material obtained by decomposing, by the action of yeast, a waste medium resulting from the cultivation of mushrooms in a medium containing mainly sawdust.

However, the tests in most cases encountered large problems in continuous feeding. For example, in the case of feeding the above material to twenty cattle, very satisfactory growth was observed for 7 months, but, thereafter, the animals lost their appetites rapidly, exhibited robot-like actions by the stiffening of muscles and all of them died within one month.

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The reason is not yet known, but it seems that resins, tar and cyanic compounds originating from the sawdust were probably accumulated in the animal's body and the problem appeared when the accumulation had increased beyond some level.

In order to overcome the above problem, the present inventor has carried out research for many years for cultivating mushrooms employing grassy materials avoiding woody materials such as sawdust.

It has been found that good results are obtained when the digested medium obtained from the above cultivation is improved in taste by employing the medium in a small amount and adding thereto the lees of soybean sauce or apple juice, molasses or compound feed. However, when the ratio of the medium to the additives is increased, the feed declined in taste and poor results are obtained.

Furthermore, in the case of employing a digested medium obtained from the cultivation of mushrooms as a feed, a long period of time is required to accustom animals to the feed and the conversion of feed requires complicated procedures. The digested medium is not suitable for human food because of its odor.

It is an object of the present invention to solve these problems. According to this invention, there is provided an edible material which comprises a digested medium obtained by cultivating a non-toxic fungus in a medium containing finely cut grassy material which is rich in lignin together with nutrient sources, having the specific odor of the medium removed therefrom.

As the grassy material is rich in lignin, there may be exemplified, rice husks, barley jusks, corncob, bagasse, the husks of buck-wheat or soybean, and stems of leaves of Gramineae. These materials preferably are employed as a cut form having a volume density 0.15 to 0.66.

As the nutrient sources, it is preferable to employ materials such as rice bran, wheat bran, soybean-curd lees (residue left after pressing soybean milk out of boiled soybean). If desired, grain powder such as rice powder, wheat flour, or soybean powder may be employed.

When the nutrient sources are calculated as dry materials containing 10% of water, the ratio of the cut grassy material to the nutrient sources preferably is 3-4 : 2 by weight.

As the fungus to be cultured, any of edible mushroons which can be cultivated, such as Enokitake

(Flammulina veltipes), Hiratake (Pleurocus ostreatus), Bunashimeji (Hypsizygus marmoreus), Maitake

(Grifola frandose), Nameko (Pholiota nameko) and Shiitake (Lentinula edodes) may be employed.

The cultivation of mushrooms can be carried out by conventional methods employed in mushroom cultivation. For example, in the case of Enokitake, a medium is filled into bottles and sterilized by heating. Enokitake spores are inoculated on the medium and cultivated at 20 DEG C for 20 to 30 days.

The surface of the medium is then scraped to expose new surface. After allowing to stand at 10 DEG C for 8 to 10 days, the fruit bodies of Enokitake growing in banks 2-3 cm in height are wrapped with paper to prevent them from toppling over and, after further several days, matured fruit bodies are harvested.

In the case of other mushrooms, their cultivation may be carried out depending on the kind of mushroom by conventional or known methods or methods similar thereto.

During cultivation, hyphae grow in the medium and the ingredients of the medium are digested and decomposed with enzymes secreted from the hyphae.

In the present invention, mushrooms are cultivated to digest their culture mediums and the harvest of fruit bodies is only of subsidiary importance. Therefore, as long as the medium is digested, the harvest of the fruit bodies my be omitted and any non-toxic fungus may be cultured.

The digested medium thus obtained has a specific odor like a decayed fruit body of a mushroom, and the odor is removed in the present invention.

The removal of the odor can be carried out by heating the digested medium.

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The temperature of the heating is preferably not less than 70 DEG C and, if desired, a temperature around 100 DEG C or more may be employed.

Suitable time required for the heating depends on the heating temperature. For example, it is 1 to 2 hours at around 100 DEG C.

The digested medium is sterilized simultaneously with deodorization by heating and therefore, it can be preserved, and further it can be dried by heating to make a dried material.

The heating may be carried out directly by fire or indirectly by atmospheric or high pressure steam.

The removal of odor from the digested medium also can be carried out by fermenting the medium.

In the fermentation, the digested medium may be employed as it is or after sterilization by heating.

The fermentation is carried out by fermenting the medium after addition of a non-toxic microorganism.

As the microorganism, there may be exemplified, a yeast belonging to Torula, Saccharomyces,

Schizosaccharomyces, a fungus belonging to Aspergillus, Mucor and a bacteria such as a lactic-acid bacteria belonging to Lactobacillus, Streptococcus or Bacillus, and Bacillus natto. Among them, particularly preferable is a yeast for making Sake (Japanese rice wine), beer or bread, Aspergillus oryzae, a lactic-acid bacteria and Bacillus natto.

Each of these microorganisms can be employed alone or as a mixture thereof.

The fermentation is carried out generally at around 20 DEG C to 40 DEG C. When sufficient heat is generated by the fermentation, there is no need to apply external heat.

If the fermentation is carried out sufficiently, the specific odor of the digested medium is removed and, in most cases, an aroma results from the fermentation.

When the digested medium deodorized as above is given to domestic animals, it can be almost completely ingested with a very high ingestion rate. Accordingly, a large amount of crude protein and other nutrient sources contained in the medium are utilized effectively. Therefore, employing it as a concentrated nutrient, the healthy fattening of warm-blooded animals such as domestic animals can be achieved. It is also suitable as a feed for cold-blooded animals such as fish. Furthermore, it can be used as a food for humans, because it is rich in nutrients and its bad odor has been removed. Excellent results have been obtained in fattening tests of domestic animals.

The present food material can be employed, if desired, in combination with other feed, bait or food, depending on the animal to be fed.

The deodorized digested medium may be used as it is, however, from the view point of handling, it is generally preferable to preserve it in a dried form and it may be processed to powder or pellets of the dried material.

Hereinafter, the present invention is further explained in the form of examples.

Example 1

50 g of corncob, 40 g of rice husks and 30 g of the husks of buck-wheat were cut separately to 0.22 volume density and mixed together. To the mixture, 150 g of soybean-curd lees, 50 g of wheat bran and

10 g of rice bran were added as nutrient sources, and the water content of the mixture was adjusted to

63%. The adjusted mixture was filled into 800 ml bottles as culture medium whereon Hiratake was cultivated in conventional manner.

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The fruit bodies of Hiratake thus grown were harvested and the residual digested medium was dried by heating in a drying room.

In the drying room (which had been converted from a vinyl house for drying grass) room temperature was elevated to about 80 DEG C by direct irradiation of the sun. The digested medium was placed in nursery bed containers, spread in thin layers, and then the containers were placed on a draining board in the drying room, and heated by sun light in fine weather for 2 days.

The dried material thus obtained lost its bad odor and acquired an aroma like concentrated feed. The dried material was fed to pigs, sheep and cattle. The animals ate up the material willingly and there was no need to add other feed or tasty material.

Example 2

Each 20 kg of the digested material obtained in the same manner as in Example 1 was filled into vinyl bags. The filled bags were placed on shelves in an atmospheric steam sterilizer without being piled upon each other and heated for 2 hours by steam and then allowed to stand for 1 hour.

The heat-treated, digested medium thus obtained acquired an aroma like boiled rice, and, when it was fed to pigs, sheep and cattle, the animals ate it up willingly.

Example 3

150 kg of digested medium obtained in the same manner as in Example 1, 30 kg of molasses for feed (a feed product for cattle containing molasses; produced by Fuji Shiryo Co., Ltd.), 10 kg of rice bran and

6 kg of Vitakogen (a special feed containing lactic-acid bacteria, Bacillus subtilis, yeast, Aspergillus oryzae etc.; produced by Seiwa Sangyo Co., Ltd.) were mixed together, and the water content of the mixture was adjusted to 50%. Then the mixture was heaped on a floor and covered with a mat. It was summer and the temperature of the open air was 30 DEG C. After 1 hour, the mixture began to ferment and after 10 hours the temperature of the mixture rose to 45 DEG C and then gradually fell to 25 DEG

C after 20 hours.

The medium thus treated had a sweet and sour aroma and was filled in vinyl bags and stored.

Example 4

A digested medium was prepared in the same manner as in Example 1, except that 80 g of corncob, 40 g of rich husks, 200 g of soybean-curd lees and 50 g of wheat husks were employed and the water content is adjusted to 64%.

On the medium, a mushroom was cultivated as described in Example 1 to give a digested medium. To

200 kg of the digested medium, 100 kg of a compound feed for piglets (Meiji Highmax, produced by

Meiji Milk Products Co., Ltd., Toyko) and 5 kg of Biopremix (a preparation containing Bacillus natto, lactic-acid bacteria, yeast and Aspergillus oryzae; produced by Matsumoto Microbiology Research Co.,

Ltd., Matsumoto) were added and mixed together. 20 kg Portions of the mixture were filled into vinyl bags and subjected to fermentation. The atmospheric temperature was 27 DEG C. After 3 days, the fermented material was suitable for feeding to piglets, and after 7 days it acquired a very sweet and sour aroma and showed increased taste to piglets.

Example 5

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An experiment was carried out in the same manner as Example 4, except for employing yoghurt instead of Biopremix, to obtain results similar to Example 4.

In the above Examples 3 to 5, small amounts of nutrient sources for the fermentation are required, however, the bad odor of the digested medium was replaced by the aroma of the fermentation and the medium had a very increased ingestion ratio.Data supplied from the esp@cenet database - Worldwide

Claims:


1. A method for producing an edible material which comprises cultivating a non-toxic fungus in a nutrient medium containing finely cut lignin-rich grassy material, recovering the medium digested by the cultivation and then removing the specific odor of the digested medium by heating or fermenting the medium.

2. A method as claimed in Claim 1, wherein the grassy material is selected from rice husks, barley husks, corncob, bagasse, buck-wheat husks, soybean husks the stems or leaves of Gramineae, and mixtures thereof.

3. A process as claimed in Claim 1 or Claim 2, wherein the cut grassy material has a volume density of

0.15 to 0.66.

4. A process as claimed in any one of the preceding claims, wherein the nutrient medium contains also a nutrient source selected from rice bran, wheat bran, soybean-curd lees, rice powder, wheat flour, soybean powder and mixtures thereof.

5.A process as claimed in any one of the preceding claims, wherein the weight ratio of grassy material to nutrient sources is 3:2 to 4:2.

6. A process as claimed in any one of the preceding claims, wherein the non-toxic fungus is an edible mushroom.

7. A method as claimed in any one of the preceding claims, wherein said heating is carried out at a temperature not less than 70 DEG C.

8. A method as claimed in Claim 7, wherein said heating is carried out by steam at a temperature not less than 95 DEG C.

9. A method as claimed in any one of Claims 1 to 6, wherein said fermentation is carried out using a non-toxic microorganism selected from yeasts, fungi and bacteria.

10. A method as claimed in Claim 9, wherein the microorganism is a yeast, Lactobacillus, Aspergillus or Bacillus natto.

11. An edible material which comprises a digested medium obtained by cultivating a non-toxic fungus in a nutrient medium containing finely cut lignin-rich grassy material and having the specific odor of said digested medium removed therefrom by heating or fermenting the medium.Data supplied from the esp@cenet database - Worldwide

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41.

EP0371324 - 6/6/1990

AUTOMATIC AND CONTINUOUS RICE COOKING SYSTEM


Inventor(s): WATANABE KENJI (--)

Applicant(s): WATANABE KENJI (--)


IP Class: A23L1/182; A23L1/01

E Class: A23L1/10H2



Family: AU610047

Equivalent: US4934259; MX171469; JP2147023; BR8906032; EP0371324

Cited Document(s): WO8300802; US4338344; US4181072

Abstract:


An automatic and continuous rice cooking system comprises a horizontally arranged steam vessel (1) with an elongated steam jacket (2) having a semi-circular bottom housing a screw conveyer (3), and a steam tunnel passage (10) provided with a mesh conveyer (11) connected to the outlet port of the vessel at its terminal end via a duct (9).Description:


Automatic and Continuous Rice Cooking System

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The present invention relates to an automatic and continuous rice cooking system, and more particularly to a rice cooking system which comprises an elongated steam vessel provided with a screw conveyer therein and a passage to which steam is supplied, and which is characterized in that uncooked rice charged continuously at the inlet of the cooker is cooked and discharged out of the outlet of the system.

At caterers, hotels, and restaurants providing a large quantity of cooked rice at a time, or in businesses preparing secondary preservable products from cooked rice, a need for a system for cooking the rice continuously but without damaging the taste and the flavor is keenly felt.

A prior art system for continuously cooking the rice is disclosed, for example, in JPA Lay Open No.

19970/75. The system is structured to have a vertically inclined and elongated vessel in which a screw conveyer is provided. Water is retained at the bottom of said vessel, and by externally heating the water and by charging rinsed rice continuously inside the vessel at the bottom, the rice is cooked in the vessel at its bottom and then conveyed upward by means of the screw conveyer to be discharged from the vessel at the outlet provided at the upper end thereof.

Such elongated vessel with a screw conveyer is advantageous in that the material rice is steamed and cooked in a continuous process when it is conveyed from one end to the other end of the vessel.

However, because of the vessel being in an inclined position, it is a disadvantage of said device that during the so-called steaming process when the rice cooked at the bottom of the vessel is conveyed upward by means of the screw conveyer to the upper portion of the vessel where there is no cooking juice, the cooked rice is inevitably subjected to kneading by the screw conveyer and collects into a doughy lump like a rice cake. This makes it impossible to obtain cooked rice retaining discreate grain forms when discharged from the outlet at the upper end of the vessel.

The present invention was contrived to obviate such defects of the prior art system and is indicated in claim 1.

The cooking vessel provided with a screw conveyer according to the present invention is arranged in a horizontal position, and the "steaming process" in which the starch is released from each grain by steaming the material rice, the "gelatinization process" in which the released starch is gelatinized, and a portion of the "adsorption process" in which gelatinized starch is once again adsorbed into the grains are all carried out in the vessel. The remaining portion of said "adsorption" process and the "fixing process" in which the gelatinized starch adsorbed in the grains is fixed to coat the surface of each grain are conducted after the rice is discharged from the vessel and transported into a net conveyer where hot water vapor is sprayed on the rice grains.

As an additional means to carry out each of said processes, the present invention system may include a spiral rotary steam vessel comprising an elongated steam jacket with a semi-circular bottom which houses a screw conveyer with stirring vanes arranged in the axial direction and mounted on the shaft of the vessel, a passage forming a steam tunnel which is connected to the outlet of the vessel at its terminal end via a duct and which houses a net conveyer provided with plural nozzles for spraying water vapor both on the top and the bottom of the conveyer surfaces, a sump for cooking juice which is provided below said duct, and supply paths for supplying a portion of the cooking juice into the steam vessel at its mid portion and into the starting end of the conveyer in the steam tunnel.

In the present invention system of the above construction, a predetermined amount of rice is sequentially charged into the steam vessel wherein a predetermined amount of water is pooled. While the charged rice is gradually steamed and conveyed toward the terminal end of the vessel by the screw conveyer, the steaming process in which the starch is released from the rice and the gelatination process in which the released starch is gelatinized are conducted. The adsorption process in which the gelatinized starch is adsorbed in the rice once again is conducted in the vessel near the outlet.

The rice thus cooked is discharged onto the duct from the steam vessel outlet together with the cooking juice, dropped onto the starting end of the net conveyer housed in the conveyer passage in the form of a tunnel, and gradually conveyed toward the terminal end while being sprayed with hot water vapor both from the top and the bottom, during which time the remaining portion of said adsorption process and

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the fixing process in which the surface of the cooked rice gain is coated with the gelatinized starch are conducted.

The cooking juice discharged from the vessel outlet together with the cooked rice is retained in the sump provided below the duct. A portion of the cooking juice in the sump is sprayed onto the rice being conveyed from the end of the conveyer inside the tunnel passage, supplying gelatinized starch contained in the cooking juice onto the grain surface. The remaining portion of the cooking juice in the sump is returned to the vessel at its mid portion where the gelatination process shifts into the adsorption process, supplementing the cooking juice containing the gelatinized starch to ensure a sufficient supply of gelatinized starch during the adsorption process.

Other objects and advantages of this invention will become apparent when taken in conjunction with description herein below of an embodiment shown in the accompanying drawings.

Fig. 1 is a plan view to show the construction of an automatic and continuous rice cooking system according to the present invention;

Fig. 2 is a side view of the system shown in Fig. 1;

Fig. 3 is a sectional view of the vessel shown in Fig. 1 along the line III-III; and,

Fig. 4 is a sectional view of the tunnel passage shown in Fig. 1 along the line IV-IV to show the structure at its starting end.

An embodiment of the present invention system will now be explained referring to the accompanying drawings. Fig. 1 is a plan view and Fig. 2 a side view. The system as a whole includes an elongated steam vessel 1 which is a horizontally positioned steam jacket and houses a screw conveyer 3, a steam tunnel passage 10 which is connected to the steam vessel at its one end at the normal angle, and houses a horizontally positioned net conveyer 11.

The steam vessel 1 comprises an elongated steam jacket 2 with a double wall which has a semi-circular bottom (Fig. 3), and a cover 24 provided at the top of the jacket 2 which can be opened/closed. Said jacket 2 is supplied via a pipe 23 with hot water vapor as the heat source. As shown in Figs. 1 and 2, an inlet port 4 for the material rice is provided above the starting end 1a of the vessel 1. A predetermined amount each of washed rice and water is continuously supplied into the vessel 1 from said inlet port 4.

As the screw conveyer 3 transports the rice toward the terminal end 1b, the rice is sequentially heated and steamed by the hot water vapor supplied into the jacket 2.

A pair of stirring vanes 7 parallel to a shaft 6 of said screw conveyer 3 is provided at the outer periphery of a spiral vane 5, whereby the rice grains and water are conveyed toward the terminal end

1b of the vessel while being mixed. The steaming process in conducted in the portion A1 which takes up one third of the length of the vessel from the starting end 1a to release the starch from the rice.

Gelatilation of the starch released from the rice is conducted in the portion A2 which takes up one third of the length at the middle, and adsorption of the gelatinized starch by the rice takes place in the portion A3 in the final one third of the vessel length toward the terminal end 1b.Water charged into the steam vessel together with the rice at the inlet port 4 changes into the cooking juice containing the starch in the mid portion of the vessel 1 and a part of which is discharged out of the vessel into a duct 9 together with steamed rice gains which have not yet completely adsorbed the gelatinized starch.

The steamed rice discharged onto the duct 9 is further conveyed to the starting end 11a of a net conveyer 11 projecting from the steam tunnel passage 10 at the starting end 10a thereof. A laterally swinging comb 12 is provided at the bottom of the duct 9 so that the comb 12 reciprocating in lateral directions spreads uniformly onto the starting end 11a of the conveyer the steamed rice grains discharged from the outlet 8 of the vessel 1 into the duct 9.

The conveyer 11 inside the steam tunnel passage 10 is a very fine mesh of stainless steel and conveys the steamed rice from the duct 9 toward the terminal end 10b of the passage 10. A pipe 13 each which is connected to a vapor source (not shown) and which supplies hot water vapor is provided above and below said conveyer 11 with respect to the conveyer surface of the cooked rice grains in the longitudinal direction. Each vapor supply pipe 13 is provided with spray nozzles 14 facing the conveyer 11 to spray the rice grains with hot vapor and to maintain high temperature and humidity inside the tunnel passage 10.

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In the meantime, a sump 15 for retaining the cooking juice discharged from the outlet 8 of the vessel together with the cooked rice gains is provided below said duct 9 and the conveyer's starting end 11a.

The sump 15 is provided with a supply pipe 17 for supplying the cooking juice to a spray nozzle 18 provided above said conveyer's starting end 11a via a pump 16, and a supply pipe 19 for feeding the juice back into the vessel 1 at its mid portion.

The cooked rice grains transferred from the duct 9 onto the conveyer 11. in the passage 10 are separated from the cooking juice when dropped onto the conveyer's starting end 11a. Thus, the starch adhered on the surface of the rice grains alone is adsorbed in the rice grains in the subsequent steps.

However, as the cooking juice from the sump 15 is sprayed on the grain surface, extra supply of the gelatinized starch adheres on the grain surface. The cooked rice grains in this state are conveyed inside the tunnel passage 10, and a suitable amount of the gelatinized starch is adsorbed in the rice in the first half of the passage B1. In the latter half of the passage B2, an adequate fixing process is conducted to coat the rice grain surface with gelatinized starch.

On the other hand, a portion of said cooking juice is returned from the sump 15 to the vessel 1 at its mid poriton via a supply pipe 19, thereby making up the lack of the cooking juice which had been discharged together with the cooked rice from the outlet 8 and ensuring adequate adsorption of gelatinized starch in the final section of the vessel.

A second laterally swinging comb 20 similar to the first one is provided at the terminal end 11b of the conveyer in the tunnel passage 10. The rice grains cooked on the conveyer are tossed and loosened by the comb 20 and transferred into a receptacle 22 on a conveyer 21.

The steam vessel with a screw conveyer according to the present invention is positioned horizontally, and releasing of gelatinized starch from the rice by steaming and initial adsorption of the gelatinized starch is conducted in the vessel. The remaining portion of the adsorption and fixing process of the gelatinized starch are conducted while the cooked rice is being carried on the conveyer in the steam tunnel passage. Since the cooked rice which comes out of the outlet port of the vessel consists of discrete grains that have not yet completely adsorbed the cooking juice, the cooked rice in grains can be continuously transported out of the vessel by the screw conveyer with ease.

The cooked rice discharged from the vessel is separated once from its cooking juice, and the cooking juice is pooled in the sump before being injected on the rice grains from the upper starting end of the conveyer in the passage to supplement the gelatinized starch. This enables adequate fixing of the gelatinized starch and enables continuous and efficient cooking of the rice.Data supplied from the esp@cenet database - Worldwide Claims:


1. An automatic and continuous rice cooking system including an elongated steam vessel (1) housing a screw conveyer (3), characterized in that said steam vessel (1) is arranged horizontally, and that there is provided a horizontally arranged steam tunnel passage (10) housing a mesh conveyer (11) which is connected to an outlet port (8) of the steam vessel (1) at its terminal end.

2.The rice cooking system according to claim 1, wherein said steam vessel (1) further comprises a double walled steam jacket (2) having a semi-circular bottom and a cover (24) that can be opened/closed at the top of the jacket, an inlet (4) for charging the material rice provided above the starting end of the steam vessel (1), and an outlet (8) for discharging the rice provided on the terminal end of the vessel (1); said screw conveyer is housed inside the steam vessel (1) along the semi-circular bottom substantially over the entire length of the vessel, and a pair of mixing vanes (7) are provided on the outer periphery of a spiral vane (5) in parallel with the shaft of the conveyer.

3.The rice cooking system according to claim 1, wherein said steam tunnel passage (10) is connected to the outlet (8) of the vessel (1) at its terminal end via a duct (9) and houses a mesh conveyer (11), and wherein a sump (15) for receiving the cooking juice separated from the cooked rice is provided beneath the starting end of said mesh conveyer (11) which extends beneath said duct.

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4.The rice cooking system according to claim 1, wherein said steam tunnel passage (10) comprises: a conveyer (11) made of a very fine stainless steel mesh, and a tunnel (10) which envelopes the essential part of the conveyer;

a steam supply pipe (13) with nozzles for injecting steam on the cooked rice both from the top and the bottom of the conveyer surface is arranged inside the tunnel passage (10) along the length of the conveyer;

a nozzle (18), provided above the starting end of said conveyer (11) for spraying the cooking juice on the surface of the cooked rice being conveyed by said conveyer (11), the cooking juice being pooled in the sump (15) and containing gelatinized starch;

said sump (15) for the cooking juice being provided with a supply pipe (19) for returning and supplementing the juice to the steam vessel (1) at its mid portion.

5.The rice cooking system as claimed in claim 1, wherein a laterally swinging comb (12) is provided outside the duct (9) at the outlet of the steam vessel (1) at its terminal end for distributing and spreading the rice grains discharged from said duct onto the starting end of the conveyer (11) housed inside said steam tunnel passage (10).

6. The rice cooking system as claimed in claim 1, wherein a conveyer (21) with a receptacle (22) is provided at the terminal end of said conveyer (11) of the steam tunnel passage (10) for receiving the cooked rice.

7. The rice cooking system as claimed in claim 1 or 3, wherein a laterally swinging comb (20) is provided at the terminal end of said conveyer (11) in the steam tunnel passage for spreading and discharging the rice into the receptacle (22) on the conveyer (21).

8.The rice cooking system as claimed in claim 1, wherein said steam vessel (1) has a sufficient length so that the vessel includes a section (A1) within which the steaming process for releasing the starch from the rice is carried out while the material rice charged from the inlet at the starting end is transported toward the terminal end of the vessel by the screw conveyer (3) and a section (A2) within which the gelatination of the starch released from the steamed rice takes place, and a section (A3) where adsorption of the gelatinized starch by the rice grains takes place.

9. The rice cooking system as claimed in claim 1, wherein said steam tunnel passage (10) has a sufficient length so that the passage includes a system where said gelatinized starch is adsorbed by the rice grains as the cooking juice containing the gelatinized starch is sprayed on the rice grain surface at the starting end of said conveyer while the cooked rice is being conveyed by the conveyer, and a section where fixing process takes place in which the surface of the cooked rice grains is coated with said gelatinized starch under high temperature and high humidity as hot water vapor is sprayed.

10. The rice cooking system as claimed in claim 1, wherein said steam tunnel passage (10) is connected at a right angle to the outlet of the steam vessel (1) at its terminal end.Data supplied from the esp@cenet database - Worldwide

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42.

EP0379870 - 8/1/1990

PREPARATION OF QUICK COOKING RICE


Inventor(s): BAZ AFIF A (--); HSU JAU YANN (--); SCOVILLE EUGENE (--)

Applicant(s): NESTLE SA (CH)


IP Class: A23L1/182

E Class: A23L1/182



Family: EP0379870

Equivalent: MX171427; ES2019026; EP0379870

FR920013; GB494085; US4338344; FR2261715; US3694226; CH345232; Cited Document(s):

EP0306655

Abstract:


A quick-cooking rice product is prepared by first cooking raw rice at substantially atmospheric pressure in an amount of water at least sufficient to hydrate the rice to a moisture content of from about

60% to 75% by weight and at a temperature of about 90 DEG C to 100 DEG C for from about 1 min to

10 mins for hydrating the rice to a moisture content of from about 30% to 60% by weight. The watercooked rice then is steam pressure cooked in water with agitation at a pressure of from about 250 mm

Hg to about 2500 mm Hg above atmospheric pressure for from about 1 min to 50 mins for further hydrating and gelatinising the rice for obtaining a cooked rice which has a moisture content of from about 60% to 75% by weight and which is about 85% to 100% gelatinised. After steam pressure cooking, the pressure is gradually released for avoiding puffing the cooked rice. The cooked rice then is dried at a temperature from about 140 DEG C to 205 DEG C.

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43.

EP0405018 - 1/2/1991

PROCESS FOR PRECOOKING PARBOILED RICE


Inventor(s): SUMBATI PIERO JACQUES (IT); FERRERO FRANCO (IT)

Applicant(s): PANZANI PONTE LIEBIG S P A (IT)


IP Class: A23L1/182

E Class: A23L1/182


Priority Number: IT19890067541 (19890630)

Family: EP0405018

Equivalent: EP0405018; IT1233176

BE638846; GB794744; US3157514 Cited Document(s):

Abstract:


The rice to be treated is soaked in several phases, after which it is subjected to a thermal shock by indidrect air heating in a drying tunnel, which causes the instantaneous discharge of the soaking water from said grains and at the same time produces in the structure thereof (of the grains) a high porosity.Description:


PROCESS FOR PRECOOKING PARBOILED RICE

The present invention relates to a process for precooking rice, in particular parboiled rice, adapted to obtain a rice which after the treatment will cook in boiling water in a time not exceeding 5 minutes.

It is known that at present various systems for precooking rice have been experimented and developed which are adapted to obtain a rice which after the treatment will cook in a few minutes.

Said systems are substantially based on vigorous cooking of the rice in hot water or vapour, followed by a drying phase which in said systems has only the function of drying the product to make it packageable and bring the level of humidity within the limits prescribed by the law.

Now, by said systems a precooked rice is obtained which, when it is subsequently immersed into boiling water, will require at least 7 minutes, practically from 7 to 10 minutes, for cooking, as the above mentioned treatments are uncapable of obtaining more.

It is an object of the present invention to provide a process for precooking rice in such a manner that after the treatment the time of cooking in boiling water will effectively not exceed 5 minutes.

The aforementioned purpose, together with other characteristics and advantages, is achieved by the present process which is substantially based on the instantaneous discharge of the water by which the

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rice has been soaked in several phases, by a thermal shock so as to generate in the structure of the grains a high porosity.

More particularly, the present process is characterized by the following phases:

Introduction of the rice into the soaking vessels containing drinking water at a temperature of between

10 and 30 and preferably of between 15 and 25>;o; C for a time of between 1 and 5 and preferably of between 2 and 4 hours;

Transfer of said soaked rice into a continuously rotating boiler where it remains for a time of 2 to 6, preferably 3 to 5 minutes at a temperature of between 70 and 90>;o;C and preferably of between 75 and 85>;o;C;

Dropping of said rice on to a tunnel conveyor saturated with vapour at a temperature of between 60 and

100>;o;C and preferably of between 70 and 90>;o;C, where it remains for a time of from 4 to 12 and preferably of from 6 to 10 minutes;

Air and water cooling of the rice at the exit of said tunnel until it reaches a temperature of between 20 and 40>;o;C and preferably of between 25 and 35>;o;C;

After reaching this temperature the rice is introduced by means of an appropriate dosing mechanism into a drying tunnel having a temperature of between 160 and 200>;o;C and preferably of between 170 and 190>;o;C and indirect air heating by means of heat exchangers, where it undergoes a thermal shock which modifies its internal structure by making it more porous (and thus cookable in only 5 minutes);

Then the temperature of the tunnel decrease so that at the exit the rice will have a temperature of between 40 and 80 and preferably of between 50 and 70>;o;C, the dwell time in said drying tunnel being between 4 and 12 and preferably between 6 and 10 minutes and the level of residual humidity in the rice being less than 12%;

The rice thus treated reaches a temperature of about 30>;o;C by cooling naturally on a conveyor, this cooling being facilitated in the summer season by jets of cold air.

Some conditions of execution of the present process, which is believed to be sufficiently described hereinbefore, will now be described by way of a non-limiting example.

The introduction of the rice into the soaking vessels is generally effected by means of a conveyor belt.

Transfer of the soaked rice into the rotating boiler takes place by means of a continuous pickup device.

Dropping of the rice on to the tunnel conveyor saturated with vapour takes place by weight.

The rice is introduced into the drying tunnel, where it undergoes the thermal shock, by means of an appropriate dosing mechanism.

It is evident that the invention is not limited to the described embodiment and that numerous variations and further improvements may be made therein without thereby departing from the scope of the invention.Data supplied from the esp@cenet database - Worldwide Claims:


1. Process for precooking rice, in particular parboiled rice, characterized by the following phases:

Introduction of the rice into the soaking vessels containing drinking water at a temperature of between

10 and 30 and preferably of between 15 and 25>;o;C for a time of between 1 and 5 and preferably of between 2 and 4 hours;

Transfer of said soaked rice into a continuously rotating boiler where it remains for a time of 2 to 6, preferably 3 to 5 minutes at a temperature of between 70 and 90>;o;C and preferably of between 75 and 85>;o;C;

Dropping of said rice on to a tunnel conveyor saturated with vapour at a temperature of between 60 and 100>;o;C and preferably of between 70 and 90>;o;C, where it remains for a time of from 4 to 12 and preferably of from 6 to 10 minutes;;

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Air and water cooling of the rice at the exit of said tunnel until it reaches a temperature of between 20 and 40>;o;C and preferably of between 25 and 35>;o;C;

After reaching this temperature, the rice is introduced into a drying tunnel having a temperature of between 160 and 200>;o;C and preferably of between 170 and 190>;o;C and indirect air heating by means of heat exchangers, where it undergoes a thermal shock which modifies its internal structure by making it more porous (and thus cookable in only 5 minutes);

Then the temperatures of the tunnel decrease so that at the exit the rice will have a temperature of between 40 and 80 and preferably of between 50 and 70>;o;C, the dwell time in said drying tunnel being betwen 4 and 12 and preferably between 6 and 10 minutes and the level of residual humidity in th rice being less than 12%; ;

The rice thus treated reaches a temperature of about 30>;o;C by cooling naturally on a conveyor, this cooling being facilitated in the summer season by jets of cold air.

2. Process for precooking rice, in particular parboiled rice, according to claim 1, characterized in that the introduction of the rice into the soaking vessels is effected by means of a conveyor belt, the transfer of the soaked rice into the rotating boiler is made by a continuous pickup device, the dropping of the rice on to the tunnel conveyor saturated with vapour takes place by weight, and the introduction of the rice into the drying tunnel, where it undergoes the thermal shock, is carried out by an appropriate dosing mechanism.Data supplied from the esp@cenet database - Worldwide

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44.

EP0436481 - 7/10/1991

PROCESS FOR PREPARING 2-ACETYL-1-AZA-1-CYCLOALKENES USEFUL

AS FLAVOR COMPONENTS FOR BREAD AND RICE


Inventor(s):

PROF DR (BE)

DE KIMPE NORBERT DR IR (BE); STEVENS CHRIS (BE); SCHAMP NICEAS

Applicant(s): RIJKSUNIVERSITEIT GENT FACULTE (BE)

IP Class 4 Digits: A23L; C07D

IP Class: A23L1/226; C07D207/20; C07D211/70

E Class: A23L1/226H4; C07D207/20; C07D211/70



Family: EP0436481

Cited Document(s): US4522838; US3725425; US3620771

Abstract:


Straightforvard and inexpensive syntheses of 2-acetyl-1-aza-1-cycloalkenes usefull as bread and rice flavor components, i.e. 2-acetyl-1,4,5,6-tetrahydropyridine and 2-acetyl-1-pyrroline, respectively, comprise the following steps : oxidation of cyclic amines to cyclic imines; subsequent cyanation of cyclic amines to 2-cyano-1-azacycloalkanes ; oxidation of 2-cyano-1-azacycloalkanes to 2-cyano-1aza-1-cycloalkenes; synthesis of 2-acetyl-1-aza-1-cycloalkenes by a Grignard reaction. These syntheses give rise to the title compounds, free of side products, in a way easily amenable to industrial production.Description:


PROCESS FOR PREPARING 2-ACETYL-1-AZA-1-CYCLOALKENES USEFULL AS FLAVOR

COMPONENTS FOR BREAD AND RICE.

The present invention relates to a process for preparing 2-acetyl-1-aza-1-cycloalknes usefull as flavor components for bread and rice.

Flavor and aroma play a pronounced role in the food industry. Consumer demand has led the flavor manufacturers to create new and improved flavors. Numerous food products are being upgraded to

"value-added" products by the incorporation of flavorings with appropriate functional ingredients. In several food products, the natural inherent flavors of the food ingredients are not strong enough to deliver a good final product. This fact creates the need for an enhancer in order to boost the flavor or the foodstuff.

A variety of heterocyclic compounds are distributed in food flavors. These compounds originate from enzymatic reactions of several substrates ( e.g. polyphenols, lipids, and proteins ) and non-enzymatic browning reactions between alpha -amino acids and reducing sugars. The latter process is referred to as the Maillard reaction, which gaines in importance with increasing temperatures.

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During the Maillard reaction of L-proline and reducing sugars, more than one hundred proline-specific compounds are formed, depending on the reaction conditions and the sugars used [B. Helak, E.

Kersten, K. Spengler, R. Tressl, D. Rewicki, J. Agric. Food Chem., vol.37, 405 (1989); B. Helak, K.

Spengler, R. Tressl, D. Rewicki, J. Agric. Food Chem., 37, 400 (1989)]. Many of these compounds, such as 2-acetyl-1,4,5,6-tetrahydropyridine 3, display cracker-like odor characteristics. This compound has been identified in freshly baked bread [I.R. Hunter, M.K. Walden, J.R. Scherer, R.E. Lundin,

Cereal Chem., vol 46, 189 (1969)] and in the crust of freshly baked rye bread [P. Schieberle, W.

Grosch, Z. Lebensm. Unters. Forsch., vol 178, 479 (1984); P. Schieberle, W. Grosch, Z. Lebensm.

Unters. Forsch., vol 177, 173 (1983)].

Although 2-acetyl-1,4,5,6-tetrahydropyridine 3 is a rather labile compound, it is currently considered as the most significant bread flavor component. US-A-3620771 and US-A-3725425 disclose that 2-acetyl-

1,4,5,6-tetrahydropyridine 3 is available by synthesis in an unspecified yield via thermal condensation of proline with 1,3-dihydroxy-2-propanone in the presence of sodium bisulfite. An improved synthesis was published later, utilizing an expensive rhodium catalyst and a silver reagent [G. Büchi, H. Wüest,

J. Org. Chem., vol 36, 609 (1971)]. EMI2.1 2-Acetyl-1,4,5,6-tetrahydropyridine 3 has been stabilized as the bisulfite adduct and as the hydrochloride. Both derivatives were used as flavoring agents for bread and bakery products. It displays a characteristic and extremely strong cracker-like flavor.Only two syntheses of 2-acetyl-1,4,5,6-tetrahydropyridine have been disclosed in the literature (vide supra).

The second synthesis of 2-acetyl-1,4,5,6-tetrahydropyridine 3 entails a well-established procedure

(overall yield of 44% starting from the relatively expensive 2-acetylpyridine 1), but this synthesis is less attractive for industrial purposes because of the use of the extremely expensive rhodium catalyst and the use of an excess of very expensive silver salts [G. Büchi, H. Wüest, J. Org. Chem., vol.36, 609

(1971)].

The analogous 2-acetyl-1-pyrroline 6 has a similar potent cracker-like flavor and is considered as the most important flavor component of cooked rice. It has been identified and isolated from different varieties of cooked rice [R.G. Buttery, L.C. Ling, B.O. Juliano, Chem. Ind., 958 (1982); R.G. Buttery,

L.C. Ling, B.O. Juliano, J.G. Turnbaugh, J. Agric. Food Chem., vol.31, 823 (1983); R.G. Buttery, L.C.

Ling, T.R. Mon, J. Agric. Food Chem., vol.34, 112 (1986)] and the crust of wheat and rye bread [P.

Schieberle, W. Grosch, J. Agric. Food Chem., vol.35, 252 (1987); P. Schieberle, w. Grosch, Z.

Lebensm. Unters Forsch., vol. 180, 474 (1985)]. It is remarkable that 2-acetyl-1-pyrroline 6 has been found in pandam leaves (Pandanus amaryllifolius Roxb.)[R.G. Buttery, B.O. Juliano, L.C. Ling, Chem.

Ind., 478 (1983)].This fact explains that it has long been the practice in India and other parts of Asia to use leaves of Pandanus species in the cooking of common rices to impart a resemblance of the aroma of the more costly scented rice.

U.S. Pat. 4,522,838 discloses the sole known synthetic route to 2-acetyl-1-pyrroline.

The synthesis entails hydrogenation of 2-acetylpyrrole 4 with rhodium on alumina, followed by oxidation of the resulting aminoalcohol 5 by means of an excess of silver carbonate (absorbed on celite) in benzene. EMI4.1 2-Acetyl-1-pyrroline 6 has been used in flavoring foods, particularly in imparting a scented rice flavor to foods. The drawback of this synthesis of the rice flavor component 6 is the use of the very expensive reagents, the low overall yield of 10%, the use of toxic chemicals (e.g. benzene) and the virtually inaccessibility of the compound on a larger scale. Indeed, according to the patented procedure mentioned above, 2-acetyl-1-pyrroline 6 was isolated and purified by preparative gas chromatography, which entails at best subgram quantities.

It is clear from the above mentioned results that 2-acetyl-,4,5,6-tetrahydropyridine 3 and 2 acetyl 1 pyrroline 6 are the major contributors to the flavor of bread. Both compounds, having a pronounced cracker-like aroma, possess a great potential for use in bread, rice and bakery products in general. This pronounced potential especially originates from the extremely low odor threshold values, i.e. the minimum physical intensity detection where the subject is not required to identify the stimulus but just to detect the existence of the stimulus [R. Teranishi, R.G. Buttery, N. Schamp, Flavour Science and

Technology, Ed. M. Martens, G.A. Dalen, H. Russwurm, Jr., p. 515, J. Wiley and Sons, Ltd. (1987)].

The odor threshold values of 2-acetyl-1,4,5,6-tetrahydropyridine 3 and 2-acetyl-1-pyrroline 6 were established as 1.4 ppb and 0.1 ppb, respectively [R.Teranishi et al., Flavour Science and Technology, P.

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515, J. Wiley (1987)]. Because of these interesting flavor characteristics, both compounds are of major interest for the flavor industry.

The purpose of the present invention is to develop an attractive straightforward process for producing flavor components for bread and rice from very cheap basic chemicals.

The new process is characterized in that it comprises the following steps :

a) Synthesis of 2-cyano-1-azacycloalkanes by oxidation of cyclic amines to cyclic imines and subsequent cyanation in situ of the cyclic imines according to the following scheme : EMI6.1

b) Synthesis of 2-cyano-1-aza-1-cycloalkenes by oxidation of 2-cyano-1-azacycloalkanes. EMI6.2

c) Synthesis of 2-acetyl-1-aza-1-cycloalkenes by a Grignard reaction. EMI6.3 wherein n = 4 or 5

Hal = Cl, Br

R = CH3 or C2H5

Due to the ease of operation and the purity of the materials obtained, this synthesis can certainly be adapted for large scale preparations of these important cracker-like flavors.

This synthetic procedure utilizes cheap, basic chemicals and is easy to run. The end product is obtained free of side products.

In a first route, step 1 comprises direct cyanation in situ of the product obtained by oxidation of cyclic amines with t-butylhypohalite in ether at 0 DEG C during 30 minutes and subsequent reaction of the Nhalo cyclic amines with sodium methoxide in methanol according to the following scheme : EMI7.1

In an alternative route, step 1 comprises cyanation in situ of the product obtained by oxidation of cyclic amines by means of aqueous sodium peroxodisulfate under catalytic influence of silver nitrate.

A. Example 1 :

Synthesis of 2-Acetyl-1,4,5,6-tetrahydropyridine 3

A.1. Synthesis of 2-Cyanopiperidine 11

0.2 Mol of piperidine 7 in 130 ml dry ether was treated dropwise with 0.2 mol t-butylhypochlorite at 0

DEG C. Stirring was continued at this temperature for 30 minutes. Three fourth of the solvent was evaporated in vacuo (t DEG >;30 DEG C) and the residual product (N-chloropiperidine 8 in ether) was triturated with 0.26 mol of 2N sodium methoxide in methanol. In most cases, a vigorous reaction started after several minutes. After this vigorous reaction ceased or after an additional 20 minutes at room temperature, the mixture was stirred under reflux for 45 minutes. The precipitate was then filtered and washed with little dry methanol, after which the solvent was removed in vacuo. The residual lightyellow solid (tripiperideine 10) [G.P. Claxton, L. Allen, J.M. Grisar, Org.Synth., Vol 56, 118 (1977)] was directly treated with aqueous hydrogen cyanide, prepared from 0.4 mol potassium cyanide and 0.4 mol 4N HCl (hood!). If necessary, some additional HCl 12N was added dropwise in order to acidify the solution ( water bath cooling). The mixture was stirred at ambient temperature for 1 h. Sodium hydroxide pellets were added under cooling till alkaline. The aqueous phase was extracted three times with dichloromethane, the organic phases were dried (MgSO4) and evaporated in vacuo to leave a clear oil, which was distilled in vacuo to afford pure 2-cyanopiperidine 11 (65% yield), bp. 91-95 DEG C/12 mmHg [Lit. bp. 90-92 DEG C/12 mmHg; H. Böhme, H. Ellenberg, O.-E. Herboth, W. Lehners, Chem.

Ber., vol.92, 1608 (1959)]. EMI9.1

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A.2. Synthesis of 2-Cyano-3,4,5,6-tetrahydropyridine 13

A solution of 4.4 g (0.04 mol) of 2-cyanopiperidine 11 in 50 ml dry ether was treated with 4.34 g (0.04 mol) of t-butylhypochlorite at 0 DEG C. After stirring 1 h at this temperature, 4.04 g (0.04 mol) of triethylamine was added and stirring was continued during overnight. The precipitate was filtered, washed with dry ether, and evaporated without heating in vacuo. The remaining t-butanol was evacuated under high vacuum (0.05 mmHg) for 30 minutes. The remaining imidoyl cyanide 13 was obtained in quantitative yield and characterized by spectroscopic methods (>;1;H NMR, >;1;>;3;C

NMR, IR, MS). It was essential to avoid the use of elevated temperatures as otherwise tautomerism to the corresponding enamine occurred. This tautomerism seemed to have a negative influence on the elaboration of this compound in the next step.

A.3. Synthesis of 2-Acetyl-1,4,5,6-tetrahydropyridine 3

Freshly prepared 2-cyano-3,4,S,6-tetrahydropyridine 13 (0.04 mol), obtained as described above in quantitative yield, was dissolved in 20 ml dry ether and this solution was added dropwise to a vigorously stirred solution of freshly prepared methylmagnesium iodide in ether at -20 DEG C (the

Grignard reagent was prepared from 0.12 gramatom magnesium turnings and 0.12 mol methyl iodide in 120 ml ether under reflux for 1 hour). After complete addition of the imidoyl cyanide 13, stirring was continued for 1 hour. The supernatans was cautiously poured into a stirred and ice-cold aqueous ammonium chloride solution in an erlenmeyer. The viscous residue remaining in the reaction flask was triturated with the ice-cold mixture from the erlenmeyer. The clear organic and aqueous layers were stirred vigorously for 20 minutes at ambient temperature.The organic layer was isolated, and the aqueous phase twice extracted with ether. The combined ether extracts were dried (MgSO4) for 30 minutes. The drying agent was filtered and replaced for a fresh portion magnesium sulfate. After drying overnight at 5 DEG C, the drying agent was filtered and the solvent removed in vacuo without heating to afford 2.2 g light-yellow oil, which consisted of pure (purity sccue& 98%) 2-acetyl-1,4,5,6tetrahydropyridine 3 (GLC, >;1;H MMR, >;1;>;3;C NMR, IR, MS) (44% yield). Freshly prepared compound 3 occurred as a 4:1 mixture of the imino form and the enamino form (>;1;H NMR, CDCl3).

On standing, this ratio gradually changed to a ratio in favor of the enamino form (up to 1:2). The freshly prepared bread flavor compound 3 is rather labile in neat form and should therefore be kept in diluted solution (pentane, CH2Cl2, ...) at -20 DEG C (stable for years).Alternatively the stable hydrochloride salt can be prepared by reacting 3 with dry hydrogen chloride in ether [G. Büchi et al., J.

Org. Chem., vol.36, 609 (1971)]. This hydrochloride is stable for years as a free flowing powder kept at

-20 DEG C protected from moisture.

B. Example 2 :

Synthesis of 2-Acetyl-1-pyrroline 6

B.1. Synthesis of 2-Cyanopyrrolidine 16

Pyrrolidine 14 was oxidized by aqueous sodium peroxodisulfate to 1-pyrroline trimer 15 (70-78% yield) as described in the literature [K. Ogawa, Y. Nomura, Y. Takeuchi, S. Tomoda, J. Chem. Soc.

Perkin I, 3031 (1982)]. The crude trimer 15 was cyanated to 2-cyanopyrrolidine 16 in essentially the same way as described for compound 11 (see A.1.). 2-Cyanopyrrolidine 16 was obtained as a colorless oil, bp. 70-75 DEG C/14 mmHg (65% yield) [Lit. bp. 168-172 DEG C; R. Bonnett, V.M. Clark, A.

Giddey, A. Todd, J. Chem. Soc., 2087 (1959)].

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B.2. Synthesis of 2-Cyano-1-pyrroline 17

Imidoyl cyanide 17 was prepared in exactly the same way as described for imidoyl cyanide 13 (see

A.2). Compound 17 was obtained in 90-95% yield and used immediately in the next step, after complete characterization by means of >;1;H NMR, >;1;>;3;C NMR, IR and MS. EMI13.1

B.3. Synthesis of 2-Acetyl-1-pyrroline 6

The rice flavor compound 6 was prepared in exactly the same way as described in detail for the synthesis of the bread flavor component 3 (see A.3.). Compound 6 was obtained as a clear light-yellow oil (purity sccue& 96%) which darkened rapidly on standing at room temperature in neat form (yield

40%). Compound 6 was characterized by the usual spectrometric methods (>;1;H NMR,>;1;>;3;C

NMR, IR, MS). It should be stressed that, contrary to compound 3, the rice flavor component 6 exclusively occurs as the imine form. The compound is preferably kept in dilute solution (pentane, dichloromethane) at -20 DEG C. After an inital decantation from a small amount of dark viscous liquid

(one week at -20 DEG C), the clear solution is stable for several months at -20 DEG C (up to now, we observed a good stability over a period of two years).Data supplied from the esp@cenet database -

Worldwide Claims:


1. Process for preparing 2-acetyl-1-aza-1-cycloalkenes usefull as flavor components for bread and rice, characterized in that it comprises following steps :

a) Synthesis of 2-cyano-1-azacycloalkanes by oxidation of cyclic amines to cyclic imines and subsequent cyanation in situ of the cyclic imines according to the following scheme : EMI14.1

b) Synthesis of 2-cyano-1-aza-1-cycloalkenes by oxidation of 2-cyano-1-azacycloalkanes. EMI14.2

c) Synthesis of 2-acetyl-1-aza-1-cycloalkenes by a Grignard reaction. EMI15.1 wherein n = 4 or 5

Hal = Cl, Br

R = CH3 or C2H5

2. Process according claim 1, characterized in that it comprises direct cyanation in situ of the product obtained by oxidation of cyclic amines with t-butylhypohalite in ether at 0 DEG C during 30 minutes and subsequent reaction of the N-halo cyclic amines which are triturated with sodium methoxide in methanol according to the following scheme : EMI15.2

3. Process according claim 1 or 2, characterized in that it comprises cyanation in situ of the product obtained by oxidation of cyclic amines by means of aqueous sodium peroxodisulfate under addition of silver nitrate as catalyst.Data supplied from the esp@cenet database - Worldwide

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45.

EP0461350 - 12/18/1991

IMPROVED METHOD FOR RICE FOOD


Inventor(s): SUN XIUAI (CN)

Applicant(s): SUN XIUAI (CN)


IP Class: A23L1/182

E Class: A23L1/01B; A23L1/164C


Priority Number: CN19900104275 (19900612)

Family: AU633169

Equivalent: JP4229149; EP0461350; RU2012211

US3711295; US4166868; FR2614508; GB2184932 Cited Document(s):

Abstract:


This invention relates to an improved method for a fried food containing mainly of rice. The method comprises pretreating raw material in order to eliminate the impurities, skins, kernels and deteriorated component therein, steaming said raw material being added with certain amount of seasonings to make a ripened rice in ratio of said material to liquid being 1 : 1 - 1.5 by weight, then blending appropriate amount of bulking agent with said ripened rice, shaping and cuting said ripened rice into pieces, following frying at least twice in oil at different temperatures to produce a kind of food with chacteristic style which contains many kinds of nutritional components and it is fragrant , crisp , tasty and palatable .

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46.

EP0631727 - 1/4/1995

LIPASE INHIBITOR DERIVED FROM A DEFATTED RICE GERM


Inventor(s): TAKAHASHI HIDEHIKO (JP)

Applicant(s): YAKURIGAKU CHUO KENKYUSHO (JP)

IP Class 4 Digits: A23J; A23K; C11B

IP Class: A23J3/14; A23K1/18; C11B1/10; A23K1/16

E Class: A23L1/172; A23J3/14; A23K1/16G; A23K1/18N; C07K14/415; C11B1/10; C11B1/10C



Family: EP0631727

Equivalent: US5503831; JP7025779; EP0631727; CA2124763

DE4040874; EP0575846; JP4327536; JP1034264; JP1075430; JP4300839; Cited Document(s):

KR9203054; JP4279529

Abstract:


It is disclosed herein that; a defatted rice germ, which was obtained by defatting the rice germ with an organic solvent or through a super critical extraction method, is further water-extracted to obtain a

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crude product containing a lipase inhibitor, and thus-obtained crude product is further purified by conducting a dialysis, ultra filtration or the like to obtain a partially purified lipase-inhibitor preparation. The above rice term-resulting lipase inhibitor-containing crude product or its partially purified preparation is added to foods or pet feeds thereby allowing them to be remarkably excellent in anti-obesity effect as compared with prior art such as that derived from wheat germ or soybeans.Description:



Field of the Invention

The present invention relates to a crude lipase inhibitor-containing product, its purified preparations, anti-obesity foods and anti-obesity feeds for pets which are useful for preventing or treating obesity which induces so-called adult diseases such as cardiac disease, arteriosclerosis, diabetes and the like.

It is often becoming high obesity that people make a meal containing high fats and oils. In this connection, occurance rate of the above adult diseases are gradually increasing in parallel with obesity in degree. For treatment of such a trend, there should be a way to disturb digestion and absorption of fats and oils, in addition to improvement of diet to low fat and low oil Japanese type foods.

Description of the Prior Art

As an inhibitive substance of lipase, for example, Patent Kokai 4-300839 reports that serum albumin, beta -lactoglobulin or a certain kind of soy-bean protein or basic protein derived from wheat-germ will inhibit the action of lipase, thereby suppressing or inhibiting decomposition of emulsified lipids.

However, among the above mentioned materials, serum albumin, beta -lactoglobulin or a certain soybean protein does not exert such an action in the presence of bile acids.

On the contrary, there is reported that the basic protein derived from wheat germ suppresses or inhibits action of lipid-decomposition enzyme even in an emulsified system of lipids in the presence of sodium taurocholic acid which is a bile acid.


It is an object of the present invention to provide a crude product containing a lipase inhibitor derived from a defatted rice germ, and also a lipase-inhibitor preparation obtained by partially purifying said crude product. It is a further object of the present invention to provide anti-obesity foods and feeds having incorporated therein said crude lipase-inhibitor product or said preparation.

Referring to lipid-decomposition enzyme inhibitor materials, which are derived from rice germ in the present invention, a water-soluble protein (water-soluble extract) resulting from rice germ can be obtained by defatting the rice germ, which is followed by water-extraction. Said materials may exert inhibiting or suppressing effect on lipase in the presence of a bile acid and in a lipid-emulsified system.

The present inventor has found that in such a function and effect the present lipase inhibitor derived from rice germ is conspicuously remarkable, as compared with already known analogous materials resulting from wheat germ, soy bean, etc.


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Fig. 1 is the drawing showing in a semi-logarithmic graph a comparison between rice germ waterextract of the present invention and wheat germ water-extract of the prior art, in respect to lipaseinhibitor activity.

DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION

For better understanding of the present invention, the present invention will be specifically explained relying on the following examples but is not limited thereto. This means that any kind or state of waterextracts obtained from a defatted rice germ may be used as a lipid-decomposition enzyme inhibitor material.

Defatting method of rice germ

By using a super-critical carbon dioxide or n-hexane, oil-soluble fraction was separated (i.e. defatted) from rice germ, which was before hand applied with crushing or pressure as a pretreatment. The present inventor designated the thus-obtained lipase inhibitor derived from the defatted rice germ as

"Defattogen".

Example 1

(1) Defatting of rice germ with n-hexane

350.0 g of rice germ was crushed as a pretreatment, stirred in 3 liters of n-hexane at room temperature for 3 hrs., and then filtered. The filtrate was further stirred in 2 liters of n-hexane at room temperature for 1.5 hrs., and then filtered. The resulting residue was dried at 40>;o;C for 2 hrs., and thereafter dried in a desiccator under a reduced pressure for 10 hrs. to obtain a defatted substance with a yield of

65.4%. On the other hand, the total filtrate was concentrated under a reduced pressure to obtain an oil portion of rice germ oil with a yield of 21.3%.

(2) Defatting of rice germ by means of super critical carbon dioxide (SCE)

126.2 g of rice germ was separated into a defatted substance and an oil portion under such conditions as

350 kgf/cm>;2;/40>;o;C of extraction pressure, 60 kgf/cm>;2;/40>;o;C of separation pressure, 10 N liters/min. of CO2 flow-rate and 58 of extracting agent rate. As a result, the obtained defatted product was 91.38 g with yield of 72.4%, and the oil portion was 30.38 g with yield of 24.1%.

Preparation example of water-soluble protein derived from rice germ

The rice germ defatted by the above treatment method (1) or (2) was applied to (i) water-extraction to obtain a water-soluble fraction and then to step (ii) dialysis or step (iii) ultrafiltration, and further to freeze-drying to obtain powder containing a crude water-soluble protein. In order to conduct the dialysis of step (ii), a cellulose tube for use of dialysis (fractional molecular weight of 14,000)

(manufactured by VISKASE CO., LTD.) and in order to conduct ultra filtration of step (iii), a hollow filament-type ultrafiltration module (fractional molecular weight of 30,000) FB 02 (0.25 m>;2;) FUS

0382 (manufactured by Daicel K.K.) can be used respectively.

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Example 2

To 25.0 g of rice germ an amount of ten times of water was added. This was stirred at room temperature for 6 hrs. and then centrifuged in 3000 r.p.m. for 20 min. Its supernatant solution was lyophilized to obtain powder with yield of 30.8%. Protein content of the obtained powder was 27.0% in terms of albumin in accordance with Cu-Folin method.

As to the obtained lyophilized product of defatted rice germ water-extract, ion-exchange chromatography, gel-filtration chromatography and reversed phase chromatography were sequentially conducted to separate highly active components inhibiting a lipase into the three kinds of bands of 54

K, 38 K and 27.5 K. As the result of analysis of N-terminal amino acids sequence of each band, said three kinds of bands were all consistent with each other.

Said N-terminal amino acids sequence are shown as follows:

RDRRGEGSSEEED?GR

With reference to the existence of the three kinds of bands, the following presumption was made:

They are composed of the same polypeptide chain, but are different in manner of being modified with sacchrides.

They are different in the lengths of peptides on c-terminal side.

The above obtained sequence of amino acids is a novel sequence which has not been known yet since none conforming to any protein data base exists.

Example 3

Further, 120 ml of the above supernatant solution was applied to dialysis at room temperature for 4 hrs. with 3 liters of pure water/hr. of dialysis speed to concentrate to molecular weight of 14,000 or more.

As the result, powder having 49.5% of protein content was obtained with yield of 13.6%.

Example 4

To 250 g of rice germ, which was CES-defatted after having been pressed as a pretreatment, 20 times an amount of water was added and then stirred at room temperature for 6 hrs. Thereafter, it was centrifuged at 8000 r.p.m. for 20 min. and then, the resulting supernatant was concentrated by ultrafiltration to molecular weight of 30,000 or more. As a result of the similar treatment to the above, powder having protein content of 49.5% was obtained with yield of 10.5%.

Determination of inhibitory action to lipase activity by water-soluble protein

This determination was conducted by using lipase-determination reagent (manufactured by Boehringer

Manheim A.G.) and taking adsorbance at wave-length of 365 nm as an index. When an activity of lipase decomposing a lipid triolein is assumed to be 100, inhibition ratio(%) of a sample is indicated with how much the sample lowers the decomposition of a lipid triolein by lipase.

Example 5

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0.5 ml of aqueous sample in each concentration and 0.1 ml of a lipase solution (lipase: 0.044 U;

37>;o;C) were pre-incubated at 37>;o;C for 5 min. and 2.0 ml of

*) Final composition and concentration of the reaction solution:

triolein 0.30 mM, trisbuffer solution (pH 9.2) 26 mM, sodium deoxycholate 19 mM, calcium chloride

0.1 mM, colipase 3 mg/l.

*

) substrate solution (containing triolein) was added thereto. At 365 nm of wave-length, adsorbance of the resulting solution was determined after 4 min. and 14 min. to as certain the decrease of absorbance accompanying the substrate decomposition reaction by lipase.

As a specific example of lipase activity-inhibitory action by water-extract derived from rice germ, lipase activity inhibition ratio(%) of water-extract of sample defatted by super-critical carbon dioxide is shown in Table 1.

Table 1 shows that water-extracts derived from rice germ have an inhibitory action to lipase activity and that inhibitory ratio of lipase activity increases by exclusion of low molecular substances through dialysis, ultrafiltration etc., and also by elevation of protein content (%).

>;tb;>;TABLE; Id=Table 1 Columns=4 Lipase-activity inhibitory ratio of water extract of rice germ defatted by super critical carbon dioxide

>;tb;Head Col 1: Sample

>;tb;Head Col 2: Protein content (%)

>;tb;Head Col 3: Concentration of sample (%)

>;tb;Head Col 4:Lipase-activity inhibitory ratio (%)

>;tb;Blank>;SEP;0>;SEP;0>;SEP;0

>;tb;

>;tb;SubHead Col 1: [A]

>;tb;1) Water-extract>;SEP;27.0>;SEP;0.25>;SEP;56.5

>;tb;>;SEP;0.5>;SEP;98.3

>;tb;>;SEP;1.0>;SEP;101.0

>;tb;2) Dialysate of water-extract>;SEP;49.5>;SEP;0.25>;SEP;85.5

>;tb;>;SEP;0.5>;SEP;101.0

>;tb;>;SEP;1.0>;SEP;106.0

>;tb;

>;tb;SubHead Col 2: [B]

>;tb;1) Water-extract>;SEP;20.4>;SEP;0.25>;SEP;33.3

>;tb;>;SEP;0.5>;SEP;75.3

>;tb;>;SEP;1.0>;SEP;95.0

>;tb;2) Ultra-filtered product of water-extract>;SEP;35.6>;SEP;0.25>;SEP;74.7

>;tb;>;SEP;0.5>;SEP;96.3

>;tb;>;SEP;1.0>;SEP;101.0

Foot note)

[A]: Sample was crushed as pretreatment for defatting.

[B]: Sample was pressed as pretreatment for defatting.

>;tb;>;/TABLE;

Example 6

The following experiments were conducted to investigate properties of lipase inhibitor contained in a defatted rice germ. As the result, there were obtained data sufficient to suggest the fact that the entity of lipase inhibitor is a protein:

1) When water-extract of defatted rice germ was applied to a heat-treatment at 85>;o;C for 60 min., the lipase inhibitor was deactivated as much as about 30 - 35%.

2) When incubated at 37>;o;C for 4 hrs. together with Pronase E, the water-extract was almost all deactivated.

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Example 7

Activity in vivo of lipase inhibitor (Defattogen) contained in rice germ was investigated using rats.

That is, male Wistar rats were used. Control group (seven rats) was given a conventional breeding feed, and test group was given the feed, in which water extract of rice germ defatted by super critical extraction method was incorporated in an amount of 10% by weight.

The Wistar rats were allowed to freely take the feeds and water for the experimental period of two weeks.

Prior to the start of the experiment and after the completion thereof, determination of body weights and blood gathering of the test rats were conducted.

The experimental results were summarized in Table 2. As shown in Table 2, Defattogen has significantly controlled (P >; 0.1) the increase of body weight, and significantly reduced (P >; 0.1) blood sugar, HbAlc, plasma total cholesterol and triglyceride levels. EMI12.1

Example 8

Comparative experiment of lipase-inhibitor activities between water extracts of a defatted wheat germ and a defatted rice germ were conducted. As the result the latter was proved to be superior to the former in the points of yield and activity (unit/g).

Defatted germ was treated in such a manner that 10 g of each sample was extracted with 200 ml of a distilled water, centrifuged and then its supernatant was lyophilized.

>;tb;>;TABLE; Columns=3

>;tb;Yield:>;SEP;Wheat germ>;SEP;36.77%

>;tb;>;SEP;Rice germ>;SEP;40.66%

>;tb;>;/TABLE;

Lipase-inhibitor activity:

As shown in Fig. 1 (semi-logarithmic graph of extract concentration vs inhibitition ratio), the rice water-extract was 4.16 times the wheat water-extract, in respect to the activity (unit/g) at about 50% inhibition ratio.

It is disclosed herein that; a defatted rice germ, which was obtained by defatting the rice germ with an organic solvent or through a super critical extraction method, is further water-extracted to obtain a crude product containing a lipase inhibitor, and thus-obtained crude product is further purified by conducting a dialysis, ultra filtration or the like to obtain a partially purified lipase-inhibitor preparation.

The above rice term-resulting lipase inhibitor-containing crude product or its partially purified preparation is added to foods or pet feeds thereby allowing them to be remarkably excellent in antiobesity effect as compared with prior art such as that derived from wheat germ or soybeans.Data supplied from the esp@cenet database - Worldwide Claims:


1. A crude product containing a lipase inhibitor derived from a defatted rice germ, which has been defatted using an organic solvent or by means of an super-critical extraction, and then obtained by water-extraction.

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2. A lipase-inhibitor preparation which has been partially purified by means of a dialysis or an ultra filtration of the crude product claimed in Claim 1.

3. An anti-obesity food having incorporated therein the crude product defined in Claim 1 or the preparation defined in Claim 2.

4. An anti-obesity feed for pets such as dog, cat, etc. having incorporated therein the crude product defined in Claim 1 or the preparation defined in Claim 2.Data supplied from the esp@cenet database -

Worldwide

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47.

EP0648433 - 4/19/1995

ENHANCEMENT OF FOOD COATING TEXTURE VIA ADDITION OF

PROTEIN/ACID/REDUCING SUGAR SYSTEM


Inventor(s): NAYYAR DALIP KUMAR (US); COLEMAN EDWARD CHARLES (US);

MASON CHARLES ROBERT (US); BIRNEY SHARON ROSE (US)

Applicant(s): GEN FOODS INC (US)


IP Class: A23P1/08

E Class: A23L1/00P8B4; A23L1/176



Family: EP0648433


WO8806007; US4208442; GB2228662; WO9421143 Cited Document(s):

Abstract:


A coating composition for imparting a crisp, golden brown surface to foodstuffs cooked in a microwave or conventional oven in which the composition includes a protein/acid/reducing carbohydrate system. The coating composition of the present invention includes 0.5 to 10% by weight protein, 0.5 to 5.0% by weight food acid, 0.5 to 5.0% by weight reducing sugar and 55 to 97% by weight bulking agents. In a preferred embodiment, enhanced crispness and browning are obtained when the protein is dairy protein and the bulking agents include rice flour.Description:



The present invention is concerned with a coating composition for foods which produces a crisp coat when cooked. More particularly, the present invention is concerned with a coating composition which produces a crisp, golden-brown coating when applied to foodstuffs and cooked in a microwave or conventional oven.


Many foods such as poultry, meat, fish and vegetables are coated with a light coating of flour or bread crumbs which on frying in oil develops a characteristic crispy, brown-colored coating. However, the messiness involved with the preparation of fried foods, the ever present danger of spattering oil, and the unfavorable dietary aspects associated with fried foods have led to the development of coatings

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which attempt to impart a fried appearance to a foodstuff which is baked and with the appealing color, taste, and texture associated with fried foods.

U.S. Patent No. 3,586,512 by Mancuso et al. and U.S. Patent No. 3,843,827 by Lee et al. both prepare a baked comestible with a fried texture and appearance. The Mancuso et al. patent does this by providing a dye system which changes color during cooking, while the Lee et al. patent does this by providing a unique batter formulation and dry-mix coating. Other coatings have been developed for foodstuffs for the same purpose, i.e., to provide a baked food with a surface similar in appearance, color and texture to that of coated, deep, fat-fried foods, such as U.S. Patent No. 3,852,501 by Fazzina et al. However, these coatings rely on high levels of shortening to obtain the desired results.

In recent years, a number of products have been developed and marketed for coating foods prior to baking or frying. Their purpose is to produce the desirable crisp, browned coating. Such products have found considerable market acceptance, especially for the preparation of baked foods which resemble fried foods in appearance and crispness, but avoid the use of oil and other fats. These products work quite well in conventional ovens. However, when used in the recently developed microwave cooking appliances, the resulting product leaves much to be desired.

In conventional cooking, however, the surface temperature of the foodstuff far exceeds the internal temperature, which aids in the crisping and browning of the food. Since the heat energy in microwave is released internally within the food, the surface remains at a relatively even temperature with the interior. Therefore, in microwave cooking the high surface temperatures necessary to achieve browning, dehydration and crisping are never achieved since the internal moisture migrates to the food surface affecting crisping and browning on the surface of the foodstuff.

In an attempt to overcome these problems, the appliance manufacturers have resorted to including radiant browning elements within the microwave chamber. Food coating merchandisers often include brown coloring components in the coating mixes to artificially brown or golden color the food surface.

This, however, does not solve the problem of surface crispness.

A further attempt was disclosed in U.S. Patent No. 4,518,618 by Hsia wherein a food coating composition having an ability to produce crisp, brown coatings on food products cooked in microwave ovens was developed. In Hsia, the coating ingredients in combination with salts, such as potassium acetate, potassium chloride and potassium bicarbonate produced a crisp-brown coating.

U.S. Patent No. 4,529,607 by Lenchin discloses a batter composition for the preparation of batter coated prefried microwavable foodstuff. In Lenchin a batter mix containing an effective amount of amylase flour is cooked in hot fat or cooking oil, and subsequently cooked to completion by means of microwaving. It is important to note that the batter in Lenchin is coated onto raw chicken and baked.

The baked product is then frozen.

U.S. Patent 4,640,837 discloses a dry coating composition that includes soy protein concentrate. A bread crumb/oil blend is baked and then maltodextrin, pregelatinized starch and the soy protein concentrate are added, the composition results in a crisp golden-brown surface to foodstuffs cooked in a microwave.

The present invention is concerned with an improved food coating composition that will produce an enhanced crisp golden-brown texture to foodstuffs that are cooked in either a microwave or a conventional oven.


The present invention is concerned with a food coating composition for imparting an enhanced, crisp golden-brown texture to foodstuff which comprises: 1 to 15% by weight non-farinaceous protein, 0.5 to

5.0% by weight food grade acid, 0.5 to 5.0% by weight reducing sugar, 0.1 to 10% hydrocolloids (e.g., gums) and 55 to 97% by weight bulking agents. The protein and reducing carbohydrate in the presence of food acids react during cooking at high temperatures to provide a Maillard type reaction that

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produces browning. The resulting Maillard browning is superior to the browning produced by prior art coating compositions. The Maillard browning is achieved in both conventional and microwave ovens.

Enhanced crispness is also provided by including in the bulking agents 3 to 11% by weight flour.In a preferred embodiment of the invention the use of dairy proteins and rice flour results in an excellent browning and crispness upon baking in both microwaves and conventional ovens.


The present invention discloses a formulation of a farinaceous coating mix for baking comestibles in both a microwave or conventional oven, which comprises proteins, food acids, hydrocolloids, reducing sugars and bulking agents. The coating mix is applied on a wet food product such as poultry, meat, fish and vegetables and then cooked in a conventional oven or in a microwave oven using a susceptor bag.

A suitable susceptor bag is disclosed in U.S. Patent No. 5,227,599 to Mason, et al., which is hereby incorporated by reference. The combination of the protein, reducing carbohydrate and food grade acid produces a non-enzymatic Maillard type browning reaction during cooking. This reaction provides a coating texture having enhanced crispness and golden brown color.

The protein used in the present invention may come from one or more of added, non-farinaceous protein materials, such as dairy protein, soy protein, whey protein, sodium caseinate, gelatin, egg albumin, etc. and mixtures thereof. The levels of the protein in the coating composition should generally range from 0.5 to 10% by weight and preferably from 1 to 3% by weight of the total coating composition. The utilization of dairy proteins, which are proteins derived from milk, is a preferred embodiment of the present invention. The protein level is determined based on the actual protein content of the added protein materials.

The food acids used in the present invention are preferably anhydrous acids, and may include one or more of citric acid, lactic acid, adipic acid, malic acid, tartaric acid, fumaric acid, etc., and mixtures thereof. The level of the acid in the coating composition should generally range from 1 to 3% by weight and preferably from 1.7 to 2.3% by weight of the total coating composition.

Hydrolyzed starch solids may be employed as the source of reducing sugars in the present invention.

The hydrolyzed starch solids should have a Dextrose Equivalent (DE) within the range of 5-50. The hydrolyzed starch solids includes malto-dextrins, dextrins and corn syrup solids. Alternatively, a reducing sugar may be added directly. Monosaccharides, whether aldose or ketose, are reducing sugars.

Examples include glucose and fructose.

The reaction of the added protein and food grade acid with the reducing sugar during cooking produces what is known as a Maillard browning reaction. In this reaction, amino groups from the proteins react with the reducing sugars to eventually form brown uncharacterized polymers termed melanoidins. The amino groups combine with the carbonyl carbon of a reducing sugar to form a glucosyl amino compound. This initial reaction is followed by a rearrangement which yields a 1-amino-1-deoxy-2ketose, which in turn can undergo a complex series of reactions resulting in a multiplicity of organic compounds and ultimately the melanoidins.

The coating composition of the present invention may also contain gum, typically at a level of about

2.0 to 5.0% by weight of the coating composition. The gum may be a natural, modified or synthetic gum. For example, gum arabic, gum tragacanth, locust bean gum or cellulose derivatives such as methyl cellulose, carboxy methyl cellulose or microbial gum such as xanthan gum, all of the above gums are effective as an adhesive which enhance the texture of the coating. Other edible materials which enhance the cohesive properties of the composition may also be employed in combination with the above.

The coating composition of the present invention also includes a bulking agent component that preferably is comprised of 30 to 70% by weight bread crumbs and preferably 5 to 9% by weight flour, with the percentages being by weight of the composition. The bread crumbs may be of any formulation and may be processed by any means common in the art but preferably for optimum crispness Japanese bread crumbs are employed as a major portion of the bread crumb component. By Japanese bread

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crumbs, what is meant is that the bread crumbs consist of essentially wheat flour, yeast and salt and have an elongated porous and striated shape and structure. A typical particle size distribution for

Japanese bread crumbs is 5% on 8 mesh (U.S.), 40% on 14 mesh, 33% on 20 mesh and 22% thru 20 mesh (5% ; 2.36 mm, 40% ; 1.40 mm, 33% ; 850 mu m and 22% >; 850 mu m) .Bread crumb fines may constitute a minor portion of the bread component with a typical particle size distribution being

2% maximum on 14 mesh (U.S.), 30% maximum on 30 mesh and 10% maximum thru 100 mesh (2% maximum ; 1.40 mm, 30% maximum ; 600 mu m and 10% maximum >; 150 mu m). The bulking agent should also contain a flour as part of the dry coating composition such as rice, wheat, potato, corn, or tapioca flour. The flour is preferably a corn and/or a rice flour.

Studies have shown that coatings of the present invention formulated with rice flour have superior crispness due to the effect of the rice, protein/starch matrix on the water holding capacity of the system.

It has been determined that the use of rice achieves optimum crispness due in part to the lower water absorptivity of rice flour. Moreover because the protein fraction is key to controlling the water holding capacity of the coating matrix, it has been determined that dairy proteins have an optimum effect thereon which makes these proteins the preferred embodiment for delivering enhanced browning and crisping effects.

Residual ingredients may also be included in the coating composition and may include salt, spices, seasoning and color and are generally employed at a level of 1 to 20%, preferably 8 to 18%, by weight of the composition. Generally the residual ingredients employed in the coating composition comprise salt, lecithin, seasoning (e.g. pepper, garlic, paprika, sugar, onion powder, monosodium glutamate, etc.), coloring blends (e.g. FDC approved dyes, paprika, beet powder, annatto, tumeric, etc.) and minor amounts of other ingredients such as fats or oils (shortening).

The coating composition is applied to the foodstuff by first moistening the surface of the foodstuff and then coating the moistened foodstuff with the coating composition by any means common in the art.

Such common means includes, but is not limited to, applying the coating composition to the moistened foodstuff in a closed bag containing the composition, or simply covering the moistened foodstuff with the coating composition. After this coating step, the coated foodstuff is then placed in an oven and baked until done. If using a microwave oven, the foodstuff may be placed in a susceptor bag prior to baking and the bag containing the foodstuff is then placed in the microwave oven and cooked.

The following examples illustrate the invention. It should be understood, however, that these examples are merely meant to be illustrative and that the invention is not to be limited thereto.

EXAMPLE 1

A coating composition was prepared containing the following ingredients:


>;tb;Head Col 1: Ingredients

>;tb;Head Col 2: Percent by Weight

>;tb;Japanese Bread Crumbs>;SEP;47.253

>;tb;Rice Flour>;SEP;7.429

>;tb;Dextrin 10DE>;SEP;6.838

>;tb;Corn Syrup Solids (36 DE)>;SEP;5.954

>;tb;Salt>;SEP;5.359

>;tb;Bread Crumb Fines>;SEP;4.648

>;tb;Buttermilk Solids (34% protein)>;SEP;4.166

>;tb;Gum Arabic>;SEP;3.314

>;tb;Whey Solids (11.5% protein)>;SEP;2.857

>;tb;Onion Powder>;SEP;2.382

>;tb;Vegetable Oil>;SEP;2.305

>;tb;Garlic Powder>;SEP;1.904

>;tb;Lactic Acid>;SEP;1.447

>;tb;Paprika>;SEP;1.321

>;tb;Parsley Flakes>;SEP;.715

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>;tb;Black Pepper>;SEP;.595

>;tb;Citric Acid>;SEP;.595

>;tb;Milk Powder (26% protein)>;SEP;.474

>;tb;Buttermilk Flavor>;SEP;.237

>;tb;Beet Powder>;SEP;.207

>;tb;>;SEP;100.000

>;tb;>;/TABLE;

Four boneless chicken breasts (one pound) were dampened with water and coated by placing each chicken breast in a bag containing the coating composition and shaking until each breast was coated. 40 grams of coating was applied to the four chicken breasts. Each breast was then removed from the coating bag and placed in a baking pan and the pan placed in a conventional oven and cooked at 400

DEG F (204.4 DEG C) for 15 minutes. The resultant baked coated chicken had a very crisp golden brown coating. The crispy, brown coating had the texture and mouth feel characteristics as well as the appearance of fried chicken.

EXAMPLE 2

A coating composition was prepared containing the following ingredients:







>;tb;Salt, Mixing>;SEP;5.359


>;tb;Butter Milk Solids>;SEP;4.166


>;tb;Whey Solids>;SEP;2.857









>;tb;Milk Powder>;SEP;.474



>;tb;>;SEP;100.000

>;tb;>;/TABLE;

Four boneless chicken breasts (one pound) were dampened with water and coated by placing each chicken breast in a bag containing the coating composition and shaking until each breast was coated. 40 grams of coating was applied to the four chicken breasts. Each breast was then removed from the coating bag and placed in individual susceptor bags and the bags placed in a microwave oven (700 watts) and cooked at high power for 12 minutes. The resultant baked coated chicken had a very crisp golden brown coating. The crispy, brown coating had the texture and mouth feel characteristics as well as the appearance of fried chicken.

EXAMPLE 3

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Comparative Example

A coating composition without added protein was prepared containing the following ingredients:







>;tb;Corn Syrup Solids>;SEP;5.954

>;tb;Salt, Mixing>;SEP;5.359













>;tb;>;SEP;100.000

>;tb;>;/TABLE;


DEG F (204.4 DEG C) for 15 minutes. The resultant baked coated chicken had reduced crisping and browning as compared with the crispness and browning of the chicken cooked in EXAMPLE 1.

EXAMPLE 4

Comparative Example

A coating composition without added food acids was prepared containing the following ingredients:



>;tb;Head Col 2: Percent by Weight >;SEP;Japanese Bread Crumbs>;SEP;52.609

>;tb;>;SEP;Rice Flour>;SEP;7.429

>;tb;>;SEP;Dextrin 10DE>;SEP;6.838

>;tb;>;SEP;Corn Syrup Solids>;SEP;5.954

>;tb;>;SEP;Salt, Mixing>;SEP;5.359

>;tb;>;SEP;Bread Crumb Fines>;SEP;4.648

>;tb;>;SEP;Buttermilk Solids>;SEP;4.166

>;tb;>;SEP;Whey Solids>;SEP;2.857

>;tb;>;SEP;Onion Powder>;SEP;2.382

>;tb;>;SEP;Vegetable Oil>;SEP;2.305

>;tb;>;SEP;Garlic Powder>;SEP;1.904

>;tb;>;SEP;Paprika>;SEP;1.321

>;tb;>;SEP;Parsley Flakes>;SEP;.715

>;tb;>;SEP;Black Pepper>;SEP;.595

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>;tb;>;SEP;Milk Powder>;SEP;.474

>;tb;>;SEP;Buttermilk Flavor N/A>;SEP;.237

>;tb;>;SEP;Beet Powder>;SEP;.207

>;tb;>;SEP;>;SEP;100.000

>;tb;>;/TABLE;


DEG F (204.4 DEG C) for 15 minutes. The resultant baked coated chicken had reduced crisping and browning as compared with the crispness and browning of the chicken cooked in EXAMPLE 1.

The comparative studies as shown in EXAMPLES 3 and 4 were conducted on coating systems removing, respectively, the protein and the acid component versus the coating composition of the present invention. The results indicate enhanced crisping and browning is catalyzed by the acid/protein system of the present invention while cooking in a conventional or microwave oven. No such enhancement of the crispness and browning occurred when either the protein or the acid was not present in the composition.Data supplied from the esp@cenet database - Worldwide

Claims:


1. A food coating composition for imparting a crisp, golden brown texture to foodstuffs when backed comprising:

0.5 to 10% by weight non-farinaceous protein, 0.5 to 5.0% food grade acid, 0.5 to 5.0% by weight reducing sugar, and 55 to 97% by weight bulking agent.

2. A food coating composition according to claim 1, further comprising 0.1 to 10.0% by weight hydrocolloid.

3. A food coating composition according to claim 2, wherein the hydrocolloid is a natural, modified or synthetic gum.

4. A food coating composition according to claim 3, wherein the hydrocolloid is gum at a level of 2.0 to 5.0%.

5. A food coating composition according to any one of claims 1 to 4, wherein the protein is one of dairy protein, soy protein, sodium caseinate, egg albumin, gelatin or mixtures thereof.

6.A food coating composition according to claim 5, wherein the protein is dairy protein.

7. A food coating composition according to claim 6, wherein the dairy protein is milk powder, buttermilk solids, buttermilk powder, casein and its derivatives or a combination of two or more thereof.

8. A food coating composition according to any one of claims 1 to 7, wherein the acid is lactic acid, citric acid, malic acid, tartaric acid, fumaric acid, adipic acid or a combination of two or more thereof.

9. A food coating composition according to any one of claims 1 to 8, wherein the source of reducing sugar is hydrolyzed starch solids, having a DE of 5-50.

10. A food coating composition according to claim 9, wherein the hydrolyzed starch solids is corn syrup solids, dextrins, malto-dextrins or a combination of two or more thereof.

11.A food coating composition according to any one of claims 1 to 10, wherein the bulking agent includes 30 to 70% bread crumbs and 3 to 11% flour, the percentage being by weight of the composition.

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12. A food coating composition according to claim 11, wherein the flour is one of rice, wheat, potato, corn and tapioca.

13. A food coating composition according to claim 12, wherein the flour is rice flour.

14. A food coating composition according to any one of claims 1 to 13, further comprising flavor and color ingredients.

15. A food coating composition according to claim 14, wherein said flavor and color ingredients include salt, spices, seasoning and food dye.

16. A process for preparing a baked coated foodstuff with a crisp golden brown texture comprising moistening the foodstuff, coating the moistened foodstuff with a food coating composition according to any one of claims 1 to 15, and then baking the coated foodstuff.

17. A process according to claim 16, wherein the foodstuff is placed in a susceptor bag prior to baking and the foodstuff is then baked in a microwave oven.Data supplied from the esp@cenet database -

Worldwide

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48.

EP0649600 - 4/26/1995

CEREAL PRODUCT, USE THEREOF, AND PROCESS FOR PRODUCING THE

SAME


Inventor(s): TAKEBE MINORU (JP); ANDO YOSHIO (JP); KIKUSHIMA SUNAO

HISHIROKU CO L (JP)

Applicant(s): NICHIMO KK (JP)


IP Class: A23L1/10; A23L1/20

E Class: A23L1/105; A23L1/015M; A23K1/14; A23K1/00C1; A23L1/211M


Priority Number: WO1994JP00763 (19940511); JP19930109565 (19930511); JP19930254326

(19931012)

Family: EP0649600

Equivalent: WO9426127; US5853779; JP7023725; FI950135; EP0649600

Cited Document(s): FR2654585; EP0417481; GB2262213; JP1020090; XP002000317;

XP002000256; XP002000255

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Abstract:


Products obtained from cereal such as soybean, rice, wheat, corn and meals thereof and usable as food, animal feed and aquacultural feed. The production process comprises decomposing phytic acid contained in cereal. The products are superior in digestion efficiency to the conventional ones, and the process is superior in productivity to the conventional ones.Claims:


1. A product made from a grain as a starting material, said product characterized in that phytic acid contained in the grain is removed by conversion thereof into (a) form(s) readily absorbale in an animal body.

2. The product made from a grain as a starting material according to claim 1, wherein said phytic acid is removed by conversion thereof into inositol tetraphosphate, inositol triphosphate, inositol diphosphate, inositol monophosphate or inositol alone or a mixture thereof by liberating at least two phosphoric acid groups from phytic acid.

3. A product made from a grain as a starting material, said product characterized in that phytic acid contained in the grain is removed by conversion thereof into (a) form(s) readily absorbale in an animal body, and said product having activities of (a) phytic acid hydrolyzing enzyme(s).

4.A method for using a product made from a grain which comprises:

using the product made from a grain as a starting material according to claim 1 as a livestock feed.

5. A method for using a product made from a grain which comprises:


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6. A method for using a product made from a grain which comprises:


7. A process for preparing a product made from a grain which comprises:

inoculating a koji mold(starter) on, a grain to effect koji preparation, thereby removing phytic acid in said grain to form said product made from a grain.

8.The process for preparing a product made from a grain according to claim 7, wherein at least two phosphoric acid groups are liberated from phytic acid to form inositol tetraphosphate, inositol triphosphate, inositol diphosphate, inositol monophosphate or inositol alone or a mixture thereof, thereby removing said phytic acid.


inoculating a koji mold(starter) on a grain to effect koji preparation, thereby removing phytic acid in said grain and providing activities of (a) phytic acid hydrolyzing enzyme(s) to form said product made from a grain.

10.A process for preparing a product made from a grain which comprises:

inoculating a koji mold(starter) on a grain to effect koji preparation,

adding water to the resultant from the koji preparation treatment to hydrolyze a protein in the resultant in parallel with removal of phytic acid in said grain, thereby forming said product made from a grain.

11. The process for preparing a product made from a grain according to claim 10, wherein at least two phosphoric acid groups are liberated from phytic acid to form inositol tetraphosphate, inositol triphosphate, inositol diphosphate, inositol monophosphate or inositol alone or a mixture thereof, thereby removing said phytic acid.


inoculating a koji mold(starter) on a grain to effect koji preparation,

adding water to the resultant from the koji preparation to hydrolyze a protein in the resultant in parallel with removal of phytic acid in said grain and with providing activities of (a) phytic acid hydrolyzing enzyme(s), thereby forming said product made from a grain.Data supplied from the esp@cenet database - Worldwide

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49.

EP0671883 - 9/20/1995

METHOD FOR STABILIZING RICE BRAN AND RICE BRAN PRODUCTS


Inventor(s): HAMMOND NEAL A (US)

Applicant(s): BRAN TECH INC (US)

IP Class 4 Digits: A23L; A21D; C12P; C12N; C12C; A23G; A23C

IP Class: C12P21/00; A21D2/00; A21D8/02; A23L1/36; C12C7/00; C12C9/00; A23G1/02; C12N9/00;

C12N9/96; A23C9/12

E Class: A23L1/10E; A23C11/10; C12N9/99


Priority Number: WO1993US11025 (19931112); US19920975527 (19921112)

Family: EP0671883

Equivalent: WO9412038; US5292537; EP0671883; CA2149321

Cited Document(s): US3852504; GB1196623; WO9207474; GB186634; US5112964;

US4357323; XP002020038; XP002020402; JP62058950; XP002020037

Abstract:

Abstract not available for EP0671883


A process for stabilizing rice bran containing protein and a naturally occurring lipase enzyme that causes rancidity. The rice bran is treated with an antilipase enzyme, preferably a nonspecific protease of plant or fungal origin. Treatment with the antilipase enzyme stabilizes the rice bran against rancidity without denaturing the protein. Stabilized rice bran has food and industrial utility and can be processed by a sequence of steps including wet milling and microfiltration into a variety of other products also having food and industrial utility. In some instances depending on the product, it is not necessary to stabilize the rice bran before wet milling and microfiltration.Claims:


What is claimed:

1. A method for enzymatically stabilizing rice bran ground to a flour having a 40 mesh and smaller particle size, said rice bran containing protein and having a naturally occurring lipase enzyme that causes rancidity comprising: (a) selecting an antilipase enzyme which inactivates the naturally occurring lipase enzyme in the rice bran, said antilipase enzyme being a nonspecific protease; (b) mixing the rice bran with water and the antilipase enzyme, said antilipase enzyme being in an amount effective to substantially inactivate the lipase enzyme in a period of time that is dependent on the amount of water; and, (c) holding the mixture of rice bran, water and antilipase enzyme at a temperature below a temperature at which the antilipase enzyme is denatured while waiting the period of time for the inactivation to occur whereby a wet stabilized rice bran is produced without denaturing the protein.

2. The method of claim 1 wherein the water is present in a water to rice bran ratio of about 1:10 to about 5:1 by weight.

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3. The method of claim 1 wherein the mixture of rice bran, water and antilipase enzyme is held at a temperature from about 20 degrees to about 50 degrees C. during the waiting period for inactivation to occur.

4. The method of claim 1 wherein the antilipase enzyme is a nonspecific protease of plant, fungal, bacterial or animal origin.

5. The method of claim 1 wherein the antilipase enzyme is selected from the group consisting of papain, bromelin and fungal protease.

6. The method of claim 1 further comprising drying the wet stabilized rice bran to produce a dried stabilized rice bran.

7. A method for enzymatically stabilizing rice bran ground to a flour having a 40 mesh and smaller particle size, said rice bran containing protein and having a naturally occurring lipase enzyme that causes rancidity comprising: (a) selecting an antilipase enzyme which inactivates the naturally occurring lipase enzyme in the rice bran, said antilipase enzyme being a nonspecific protease or a nonspecific fungal protease; (b) mixing the rice bran with water in a ratio of about 1:10 to about 5:1 by weight and with the antilipase enzyme in an amount effective to substantially inactivate the lipase enzyme; (c) holding the mixture of rice bran, water and antilipase enzyme at a temperature from about

20 degrees C. to about 50 degrees C. while waiting the period of time for the inactivation to occur whereby a wet stabilized rice bran is produced without denaturing the protein.

8. The method of claim 7 further comprising drying the wet stabilized rice bran to produce a dried stabilized rice bran.Data supplied from the esp@cenet database - Worldwide

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50.

EP0679341 - 11/2/1995

METHOD FOR PREPARING DECORATED SNACK PRODUCTS AND

METHOD FOR PREPARING COLORED WAFER, OAT AND RICE FLAKES


Inventor(s): VISBEEN JOSEPH F M (NL); PLANTINGA WILLEM J (NL); ESSENS PAULUS

J M (NL); VAN AKEN PETRONELLA M M (NL); KREUNING JOHANNES (NL)

Applicant(s): LEE DE NV SARA (NL)


IP Class: A23L1/164; A23P1/08; A23L1/36; A23L1/176; A23L1/27

E Class: A23L1/164B; A23L1/36B2; A23L1/00P8B4; A23L1/176; A23L1/27


Priority Number: NL19940000536 (19940405)

Family: EP0679341

Equivalent: NL9400536

Cited Document(s): EP0542510; GB1437501; WO9115548; FR2248793; EP0226341;

JP57115146; JP59130156; JP59130148; JP59130152

Abstract:


The invention relates to a method for preparing decorated snack products which comprises the coating of a core with at least one layer of a dough material, followed by the heating thereof. In accordance with the invention, the dough material is provided with colored wafer flakes, colored oat flakes and/or colored rice flakes. In particular, the core that is at least partly coated with the at least one layer is sprinkled, before being heated, with the colored wafer flakes, colored oat flakes and/or colored rice flakes.Description:


The invention relates to a method for preparing decorated snack products which comprises the coating of a core with at least one layer of a dough material, followed by the heating thereof.

It is known to prepare many types of snack products on the basis of nuts and the like, with a coating being provided on the nuts when prepared. Such products consist of a core of, for instance, a peanut and a covering of one or more layers of dough. If desired, flavoring substances can further be provided in the dough, such as salt, herbs, flavors and the like.

The object of the invention is to provide a method of a new type of snack product having a more attractive appearance to the consumer.

The method according to the invention is based on the fact that the dough material is provided with colored wafer flakes, colored oat flakes and/or colored rice flakes. In this connection, by colored wafer flakes, colored oat flakes and/or colored rice flakes is meant colored wafer flakes and/or colored oat flakes and/or colored rice flakes. More in particular, prior to the heating thereof, the core that is at least

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partly coated with the at least one layer is sprinkled with colored wafer flakes, colored oat flakes and/or colored rice flakes.

In the past, attempts have been made to give coated nuts a colorful appearance by providing their outsides, prior to deep-frying, with colored herbs, vegetables or other colored natural products, for instance red or green pieces of paprika. It appears that due to this heat treatment, these parts color dark brown to black during deep-frying, causing the intended effect to be lost.

With the method according to the invention, a type of coated nuts and the like is obtained that could be referred to as decorated nibbling nuts. For instance, if a mixture of red and green flakes is used, coated nuts are formed whose outsides are apparently provided with pieces of red and green paprika. The colored wafer, oat and/or rice flakes have the property that they do not discolor, not even when subjected to a high temperature. Hence, the heat treatment which the snacks undergo when prepared has no negative influence on the appearance of the flakes.

A particularly great advantage of the method according to the invention is that for instance the colored wafer flakes are freely commercially available. Consequently, a manufacturer of snacks need not make any extra investments for the manufacture of such colored flakes. Accordingly, the further preparation of the snack can be carried out on existing equipment for producing snacks without the colored wafer, oat and/or rice flakes, as will be further explained hereinafter.

Colored wafer flakes are freely commercially available from Primus Ouwelfabriek B.V.

Rice flakes are rice grains that are crushed after steaming and subsequently dried.

Coating can take place in many ways.

In accordance with a particular aspect of the invention, the dough material is supplied to the core in the form of sprinkling flour, with the colored wafer flakes and/or colored rice flakes being supplied when the last 3-15 percent of the sprinkling flour is supplied.

In accordance with another variant of the method according to the invention, successively a first amount of sprinkling flour that forms the dough material is supplied to the core to be coated, and after the supply of sprinkling flour has stopped the colored wafer flakes and/or colored rice flakes are supplied, whereupon a final amount of sprinkling flour is subsequently supplied.

During the supply of the sprinkling flour, liquid is preferably supplied to produce a doughy substance readily capable of bonding to the core.

For this, a method can for instance successfully be used wherein the core is dredged in a dredging drum by effecting the contact between the core and the sprinkling flour in the rotating dredging drum. When the core is a peanut, it can be coated in husked as well as unhusked form.

In particular, the dough material comprises starch and flavoring and/or coloring substances. The dough material can further comprise modified starch. The flavoring and/or coloring substances can for instance be incorporated into the liquid that is added to the sprinkling flour. In this manner, a dough material of the desired color and flavor is for instance obtained during dredging or by means of another process suitable for that purpose.

The flavoring and/or coloring substances may for instance comprise sugar, salt, flavors and/or a spice extract.

In accordance with a possible method according to the invention, the flakes supplied are moist and may or may not have gum provided thereon. This variant can be used when the flakes are prepared directly before the snack is prepared.

Possible methods for preparing colored wafer and rice flakes will be discussed hereinafter. However, if colored wafer flakes are used, which are freely commercially available, these flakes will commonly not

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be moist when sprinkled on the surface of a core that is at least partly coated with dough material as discussed hereinabove.

Preferably, the coated core is heated by deep-frying it in fat. However, it is also possible to heat the coated core in an oven. This involves the coated core preferably being heated to a temperature ranging between 125 and 225 degrees centigrade.

The amount of flakes supplied, based on dry substance, is for instance equal to 0.5-2.5 percent by weight of the supplied amount of dough material. In particular, the amount of the supplied flakes and dough material together, based on dry substance, is equal to 60-140 percent by weight of the amount of cores to be coated.

In accordance with an attractive variant of the invention, the wafer flakes and/or rice flakes have mutually different colors. The wafer flakes and/or rice flakes have a largest diameter of for instance

0.2-5 mm, however preferably 2-3 mm.

A method for preparing colored rice, oat or wafer flakes that can be used in a method as described hereinabove is characterized in that the uncolored, i.e. natural flakes are introduced into an aqueous solution provided with coloring substance and are subsequently removed from the solution. The flakes have then been impregnated with the colored liquid and are moreover still moist.

If desired, these flakes can directly be used in a method for preparing decorated snacks as described hereinabove. However, it is also possible to dry the wafer, oat and/or rice flakes to enable them to be used for this method at a later time.

When the colored flakes are prepared, they are preferably mixed in a liquid for instance by stirring in the liquid.

Example

Approximately 40 kg of peanuts is introduced into a dredging drum. With this, 32 kg of sprinkling flour, consisting of 30 kg of starch and 2 kg of modified starch, is dredged with simultaneous addition of 25 kg of sprinkling liquid. When approximately 95 percent of the 32 kg of sprinkling flour has been added, 0.5 kg of colored wafer flakes is moreover added. In this example, the wafer flakes are added simultaneously with the last, approximately 5 percent, sprinkling flour to be added. The wafer flakes consist of a collection of red and green wafer flakes. The flakes have a largest diameter of 2-3 mm.

The sprinkling liquid comprises 2 kg of salt, 2 kg of sugar, 2 kg of flavors and 0.1 kg of coloring substances and 19 kg of water.

After dredging for some time, the resulting semi-finished product was deep-fried in deep-frying oil for

8 minutes at 160 degrees centigrade. The resulting finished product comprised a pretty surface in which red and green particles, resembling paprika or herbs, were embedded. The final product is composed of approximately 48 percent (by weight) peanuts, 35 percent starch, 10 percent vegetable oil, 1.5 percent sugar, 1.5 percent modified starch, 1.5 percent salt, 1.6 percent flavors, 0.3 percent spice extract and

0.6 percent colored wafer flakes.Data supplied from the esp@cenet database - Worldwide

Claims:


1. A method for preparing decorated snack products which comprises the coating of a core with at least one layer of a dough material, followed by the heating thereof, characterized in that the dough material is provided with colored wafer flakes, colored oat flakes and/or colored rice flakes.

2. A method according to claim 1, characterized in that prior to the heating thereof, the core that is at least partly coated with the at least one layer is sprinkled with the colored wafer flakes, colored oat flakes and/or colored rice flakes.

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3. A method according to claim 2, characterized in that the dough material is supplied to the core in the form of sprinkling flour, with the colored wafer flakes, colored oat flakes and/or colored rice flakes being supplied during the supply of the last 3-15 percent of the sprinkling flour.

4.A method according to claim 2, characterized in that successively a first amount of sprinkling flour, to form the dough material, is supplied to the core to be coated, and after the supply of the sprinkling flour has stopped the colored wafer flakes, colored oat flakes and/or colored rice flakes are supplied, whereupon a final amount of sprinkling flour is subsequently supplied.

5. A method according to claim 1, 2 or 3, characterized in that liquid is supplied during the supply of the sprinkling flour.

6. A method according to any one of the preceding claims, characterized in that the dough material comprises starch and flavoring and/or coloring substances.

7. A method according to claim 6, characterized in that the dough material further comprises modified starch.

8.A method according to claim 6 or 7, characterized in that the flavoring and/or coloring substances comprise sugar, salt, flavors and/or at least one spice extract.

9. A method according to any one of the preceding claims, characterized in that the flakes supplied are moist and have gum provided thereon.

10. A method according to any one of the preceding claims, characterized in that the coated core is heated by deep-frying it in fat.

11. A method according to any one of the preceding claims, characterized in that the coated core is heated to a temperature ranging between 125 and 225 degrees centigrade.

12. A method according to any one of the preceding claims, characterized in that the amount of flakes supplied, based on dry substance, is equal to 0.5-2.5 percent by weight of the supplied amount of dough material.

13.A method according to any one of the preceding claims, characterized in that the supplied amount of flakes and dough material together, based on dry substance, is equal to 60-140 percent by weight of the amount of cores to be coated.

14. A method according to any one of the preceding claims, characterized in that the wafer flakes, oat flakes and/or rice flakes have mutually different colors.

15. A method for preparing colored rice, oat or wafer flakes that can be used in the method according to any one of the preceding claims, characterized in that the uncolored flakes are introduced into an aqueous solution with or without gum and provided with coloring substance, and are subsequently removed from the solution.

16. A method according to claim 15, characterized in that the flakes, after having been removed from the colored aqueous solution, are dried.

17. A snack product obtainable by the use of the method according to any one of claims 1-14.

18. Colored rice flakes obtainable by the use of the method according to claim 15 or 16.

19. Colored wafer flakes obtainable by the use of the method according to claim 15 or 16.

20. Colored oat flakes obtainable by the use of the method according to claim 15 or 16.Data supplied from the esp@cenet database - Worldwide

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51.

EP0682880 - 11/22/1995

R-AMINOBUTYRIC ACID-ENRICHED FOOD MATERIAL AND METHOD FOR

PRODUCING R-AMINOBUTYRIC ACID


Inventor(s): SAIKUSA TAKAYO (JP); MORI YUTAKA (JP); HORINO TOSHIROH (JP)

Applicant(s): DIRECTOR GENERAL OF CHUGOKU NA (JP)


IP Class: A23L1/305

E Class: A23L1/172; A23L1/305A



Family: EP0682880

Equivalent: US5472730; JP7213252; EP0682880

Cited Document(s): GB1539756; US5215750; US4786647

Abstract:


Disclosed are gamma -aminobutyric acid-enriched food materials to be obtained by dipping at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs in water at a pH of from 2.5 to 7.5 and at 80 DEG C or lower. Also disclosed is a method for producing gamma -aminobutyric acid by extracting the gamma -aminobutyric acid-enriched food material with an acid followed by purifying the resulting extract by ion-exchanging chromatography. These products are useful as particular nutrient foods or additives to foods for patients suffering from hypertension.Description:


The present invention relates to a gamma -aminobutyric acid-enriched food material and a method for producing gamma -aminobutyric acid. More precisely, it relates to a gamma -aminobutyric acidenriched food material to be prepared by dipping at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs in water under pre-determined conditions so as to greatly increase the content of gamma -aminobutyric acid in the material due to the activity of the endogenous enzyme therein. It also relates to a method for producing gamma -aminobutyric acid by extracting the gamma -aminobutyric acid-enriched food material with an acid followed by purifying and concentrating the resulting extract by ion-exchanging chromatography.

gamma -Aminobutyric acid is a kind of amino acid that is produced by decarboxylation of glutamic acid in living organisms, and it is known that the acid plays an important role in the central nervous system as a neurotransmitter and, in addition, has a function to lower the blood pressure in animals including human beings.

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Recently, it has been found that the content of gamma -aminobutyric acid in tea leaves may be increased to 5 to 10 times by anaerobically treating raw tea leaves. At present, such tea having an increased content of gamma -aminobutyric acid has been commercially sold by various makers as

"Gabaron Tea" (trade name). "Gabaron Tea" has been proved to have an effect of curing hypertension by animal tests and has been utilized by persons suffering from hypertension as an easy means to cure hypertension without minding its side effect.

It is said necessary to perorally take a large amount of gamma -aminobutyric acid so as to lower the blood pressure in hypertension. For "Gabaron Tea", however, it is difficult to take a large amount of gamma -aminobutyric acid therefrom since the tea is diluted when extracted with hot water. This will be the reason why "Gabaron Tea" is considered ineffective against hypertension by some persons.

At present, gamma -aminobutyric acid is produced by fermentation, which, however, is not satisfactory in view of its cost. It is thus an object of the present invention to provide food materials from which a higher concentration of gamma -aminobutyric acid may be taken and to provide a method for producing a sale and low-priced gamma -aminobutyric acid.

This object could be achieved on the basis of the finding that a high concentration of glutamic acid which is a precursor of gamma -aminobutyric acid is contained in the surface layer parts of germs, rice grains and wheat grains and that the glutamic acid is rapidly converted into gamma -aminobutyric acid while dipped in water.

Specifically, the present invention provides a gamma -aminobutyric acid-enriched food material which is obtainable by dipping (holding) at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs in water at a pH of from 2.5 to 7.5 and at 80 DEG C or lower. It also provides a method for producing gamma aminobutyric acid by extracting the gamma -aminobutyric acid-enriched food material with an acid followed by purifying the resulting extract by ion-exchanging chromatography.

Fig. 1 is a graph showing the relationship between gamma -aminobutyric acid accumulated and the decrement in the glutamic acid content in the process of Example 1.

Fig. 2 is a graph showing gamma -aminobutyric acid accumulated in the process of Example 2.



Fig. 5 is a separation chart of gamma -aminobutyric acid by ion-exchanging chromatography in the process of Example 5.


Varieties of rice and wheat to be used in the present invention are not specifically defined, but preferred are those having a high proportion by weight of germs such as giant germ rice as well as those capable of producing a large amount of gamma -aminobutyric acid (e.g., rice of Hokkai No. 269, and wheat of Shirasagi-komugi).

Whole rice may be easily prepared by cleaning rice in an ordinary rice-cleaning mill (for example,

RMA-150 Model, made by Yanagisawa Seisaku-sho KK) to remove rice bran therefrom. Germs may be separated from whole rice by polishing it in a rice-polishing mill (for example, TM5 Model, made by Satake Seisaku-sho KK) followed by sieving the resulting albumen-derived rice powder and bran through a suitable sieve (of around 32-mesh) to separate germs therefrom.

On the other hand, germs of wheat and wheat bran containing germs may be obtained by milling wheat in a wheat mill (for example, Pullar Type Test Mill, made by Pullar Co.) to separate wheat bran (fine wheat bran, coarse wheat bran) therefrom. The thus-separated wheat bran (especially, fine wheat bran) is then sieved through a sieve of around 50-mesh or a finer sieve than that to be employed for obtaining

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germs of rice to further separate germs of wheat therefrom. As the wheat bran, preferred is fine wheat bran.

To prepare a gamma -aminobutyric acid-enriched food material, water having a pH of from 2.5 to 7.5, preferably from 3.0 to 7.0, more preferably from 5.5 to 6.0 is added to at least one material chosen from among the above-mentioned germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs, in an amount of from 2 to 10 times as large as the amount of the material, and shaken at 80 DEG C or lower, generally at a temperature of from 10 to 70 DEG C and at a shaking speed of from 50 to 150 strokes/min for a period of 20 minutes or more, generally from 20 minutes to 48 hours, preferably at a shaking speed of from 80 to 120 strokes/min for a period of from 1 to 48 hours, more preferably at 40 DEG C and at a shaking speed of 100 strokes/min for a period of from 4 to 48 hours. Acids may be used for adjusting the pH value of the water to be used, which may be either organic acids or inorganic acids. Preferred are organic acids such as acetic acid, citric acid and malic acid, and inorganic acids such as hydrochloric acid, sulfuric acid and phosphoric acid. Alkalis may also be used for the same purpose, which include, for example, sodium hydroxide, potassium hydroxide, calcium hydroxide, sodium carbonate and sodium phosphate.

By the treatment, the glutamate decarboxylase existing in germs acts on the glutamic acid therein to convert the acid into gamma -aminobutyric acid. During the treatment, the protease in germs, etc. also acts on proteins therein to decompose them into glutamic acid. Accordingly, the conversion of glutamic acid into gamma -aminobutyric acid is effected efficiently by the treatment.

Where Koshihikari rice, which is the most popular variety of rice to be boiled to eat, is subjected to the above-mentioned treatment, the gamma -aminobutyric acid content in its germs may be increased to about 400 mg/100 g. Considering the fact that the gamma -aminobutyric acid content in "Gabaron

Tea" is about 170 mg per 100 g of the dry leaves, gamma -aminobutyric acid can be accumulated in the germs of Koshihikari rice in an amount of 2 times or more than that in "Gabaron Tea" by the treatment.

Where gamma -aminobutyric acid is taken from "Gabaron Tea" or germs, "Gabaron Tea" shall be extracted and diluted with hot water and the thus-diluted extract is drunk while germs may directly be eaten as they are in whole rice or in food materials without being diluted. Accordingly, germs may be utilized as more effective gamma -aminobutyric acid sources.

To produce gamma -aminobutyric acid, an acid is added to at least one food material of germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs that have been treated by the above-mentioned dipping treatment to thereby extract the acid from the material.Concretely, an acid chosen from among inorganic acids such as hydrochloric acid, sulfuric acid and phosphoric acid and organic acids such as acetic acid, citric acid and malic acid is added to the material, by which the material is made acidic, preferably strongly acidic to have a pH of from 1 to 2, and thereafter the material is shaken at a temperature of from 0 to 70 DEG C preferably from 10 to 40

DEG C, and at a shaking speed of from 50 to 150 strokes/min for 5 minutes to 2 hours, preferably at a shaking speed of 100 strokes/min for one hour, to thereby extract gamma -aminobutyric acid from the material. Next, the resulting extract is subjected to solid-liquid separation, for example, by centrifugation (3000 rpm, 10 minutes) or filtration to recover the supernatant (liquid extract).

Next, the liquid extract is purified and concentrated by ion-exchanging chromatography. The ionexchanging chromatography may be conducted, for example, under the conditions shown in Table 1 below, thereby giving a pure gamma -aminobutyric acid. The thus-obtained gamma -aminobutyric acid is sweet and tasty and may be utilized as a food additive or seasoning. The amount of the acid to be used for this purpose may be determined according to the intended object. EMI6.1 EMI7.1

EMI8.1

According to the present invention that has been described in detail hereinabove, food materials containing a high concentration of gamma -aminobutyric acid and a high-purity gamma -aminobutyric acid are obtained from at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs, which have heretofore been utilized only as sources for edible oil, by simple operation. Such gamma -aminobutyric acid-enriched

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food materials and high-purity gamma -aminobutyric acid may be utilized as particular nutrient foods or additives to foods for patients suffering from hypertension.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.

The present invention will be explained in more detail by means of the following examples, which, however, are not intended to restrict the scope of the present invention.

EXAMPLE 1:

4 ml of distilled water were added to 0.2 g of germs derived from Koshihikari rice and shaken at 40

DEG C and at a shaking speed of 100 strokes/min, by which gamma -aminobutyric acid precipitated.

Precisely, as shown in Fig. 1, gamma -aminobutyric acid was accumulated rapidly with decrease of glutamic acid and reached 360 mg/100 g after 8 hours. Considering the fact that the gamma aminobutyric acid content in non-treated germs is about 25 mg/100 g, it is noted that the gamma aminobutyric acid content in the thus-treated germs increased to 14.4 times. After 20 minutes from the start of the treatment, the decrement in the glutamic acid content became small relative to the amount of the gamma -aminobutyric acid formed. From this, it is presumed that glutamic acid was supplemented by decomposition of proteins, etc. during the treatment.

EXAMPLE 2:

Germs of Koshihikari rice were treated at a temperature of from 30 to 70 DEG C in the same manner as in Example 1 to produce gamma -aminobutyric acid. The results are shown in Fig. 2, from which it is noted that 40 DEG C is the optimum treating temperature at which the amount of gamma aminobutyric acid produced was the highest and the producing speed was also the highest.

EXAMPLE 3:

Germs of Koshihikari rice were treated at a pH of from 3 to 8 in the same manner as in Example 1 to produce gamma -aminobutyric acid. The results are shown in Fig. 3, from which it is noted that the optimum pH range in producing gamma -aminobutyric acid by the treatment is from 5.5 to 6.0 whilst the amount of gamma -aminobutyric acid produced suddenly decreased under the alkaline condition.

EXAMPLE 4:

Germs derived from different 10 varieties of rice shown in Table 2 below were treated under the same conditions as those in Example 1 to produce gamma -aminobutyric acid. Table 2 shows the characteristics of rice used and the weight of germs in rice. The results are shown in Fig. 4, from which it is noted that the amount of gamma -aminobutyric acid formed greatly varied, depending on the variety of rice used. Briefly, Takanari rice did not almost produce the acid, while Hokkai No. 269 rice produced the acid in an amount of 2 times as large as that produced by Koshihikari rice.

>;tb;>;TABLE; Id=Table 2 Columns=3 Amount (by weight) of Germs in Rice

>;tb;Head Col 1: Variety of Rice

>;tb;Head Col 2: Characteristics

>;tb;Head Col 3: Amount of Germs (wt.%)

>;tb;1. Koshihikari>;SEP;Eating-quality rice>;SEP;3.5

>;tb;2. Aya>;SEP;Low-amylose rice>;SEP;3.5

>;tb;3.Takanari>;SEP;High-yield rice>;SEP;3.0

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>;tb;4. Ohchikara>;SEP;Giant-grain rice>;SEP;3.6

>;tb;5. Kitakaori>;SEP;Sweet-smelling rice>;SEP;2.7

>;tb;6. Chugoku No. 137>;SEP;Giant-germ rice>;SEP;10.3

>;tb;7. Hokkai No. 269>;SEP;Giant-germ rice>;SEP;9.0

>;tb;8. Chugoku-mochi No. 120>;SEP;For rice cake>;SEP;2.4

>;tb;9. Himenomochi>;SEP;For rice cake>;SEP;3.0

>;tb;10. Hoshiyutaka>;SEP;Long-grain>;SEP;4.3

>;tb;>;/TABLE;

It has been found that Hokkai No. 269 rice gave gamma -aminobutyric acid of 560 mg/100 g, after treated for 4 hours. The amount of the acid produced by Hok kai No. 269 rice is about 3 times as large as that produced by "Gabaron Tea". Hokkai No. 269 rice is giant-germ rice, having germs of nearly 3 times as large as those in ordinary rice, and it is the best as the raw material for producing gamma aminobutyric acid.

EXAMPLE 5:

Germs of Hokkai No. 269 rice were treated for 4 hours under the same conditions as those in Example

1 to produce a liquid containing gamma -aminobutyric ac. 1 N hydrochloric acid was added to the liquid in an amount of 1/5 of the liquid and shaken at a shaking speed of 100 strokes/min to extract gamma -aminobutyric acid therefrom at 30 DEG C for a time more than 5 minutes. Next, the resulting extrct was centrifuged for 10 minutes at 3000 rpm to remove the insoluble substances therefrom and then subjected to ion-exchanging chromatography under the same conditions as those shown in Table 1 above to separate gamma -aminobutyric acid therefrom. The results are shown in Fig. 5. Next, the thus-separated gamma -aminobutyric acid was collected, using a fraction collector. By the operation, obtained were 5.2 mg of gamma -aminobutyric acid from one g of germs of Hokkai No. 269 rice.

EXAMPLE 6:

8 ml of 1 M phosphate buffer (pH 5.5) were added to 0.5 g of fine wheat bran derived from Shirasagikomugi (a variety of wheat) and shaken at 40 DEG C at a shaking speed of 100 strokes/min, by which precipitated gamma -aminobutyric acid, as shown in Fig. 6. Precisely, gamma -aminobutyric acid began to precipitate after shaking the germs for 2 hours or more along with the buffer and reached 63.7 mg/100 g after 8 hours.Data supplied from the esp@cenet database - Worldwide

Claims:


1. A gamma -aminobutyric acid-enriched food material obtainable by dipping at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs in water at a pH of from 2.5 to 7.5 and at 80 DEG C or lower.

2. A method for producing gamma -aminobutyric acid, characterized by extracting a gamma aminobutyric acid-enriched food material, which is obtainable by dipping at least one material chosen from among germs of rice, rice bran containing germs, whole rice, germs of wheat and wheat bran containing germs in water at a pH of from 2.5 to 7.5 and at 80 DEG C or lower, with an acid followed by purifying the resulting extract by ion-exchanging chromatography.Data supplied from the esp@cenet database - Worldwide

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52.

EP0688507 - 12/27/1995

RICE GRAIN AND PROCESS FOR PREPARATION


Inventor(s): AREKION ISABELLE (FR); ESCLAUZE SYLVIE (FR); MINIER CHANTAL

(FR); MOUREAU JACQUES (FR)

Applicant(s): SICA FRANCE RIZ (FR)


IP Class: A23L1/10; A23L1/182

E Class: A23L1/182


Priority Number: FR19940007788 (19940624)

Family: EP0688507

Equivalent: FR2721480; EP0688507

Cited Document(s):

Abstract:

EP0352939; US5316783; GB2173986; BR9101467


Rice grain of which the X-ray diffraction diagram does not exhibit peaks of native starch at 2 theta =

9.9 degrees , 11.2 degrees , 15 degrees , 17 degrees , 18 degrees and 23.3 degrees , whereby after cooking 100g of the rice grains in 1l of water at 100 degrees C for 15 mins and cooling for 15 mins at ambient temp, the cooked and cooled grains of rice have (measured on a Chopin visco-elastograph) a firmness of less than 65 and an elastic recovery of less than 35.Description:


La présente invention se rapporte aux grains de riz et à leurs procédés de préparation.

Au brevet des Etats-Unis d'Amérique n DEG 5 130 153, on décrit un procédé d'étuvage du riz, qui consiste à traiter le riz par de l'eau à une température allant jusqu'à son point d'ébullition pour porter sa teneur en eau entre 17 et 28 % et à traiter par la vapeur le riz trempé à une température de 100 à 125

DEG C pour porter sa teneur en eau entre 19 et 30 %, à chauffer le riz traité à la vapeur en vase clos sous pression et en utilisant de la chaleur sèche à une température minimum qui dépend de la teneur en humidité, à réduire la pression sur le riz en 1 à 10 minutes à la pression atmosphérique de manière à faire s'évaporer l'eau du riz chauffé pour réduire sa température à 100 DEG C environ et sa teneur en eau à 17 à 24 % puis à sécher le riz.Grâce à cela, on obtiendrait un riz étuvé qui, lorsqu'il est cuit pendant 18 minutes environ dans de l'eau bouillante donc sensiblement pendant 2 minutes de moins qu'habituellement, est moins collant, plus fin et se présente sous forme de grain plus long et moins coloré que du riz étuvé classique cuit dans les mêmes conditions.

L'invention vise en revanche à obtenir des grains de riz qui, après 10 minutes de cuisson seulement, sont parfaitement comestibles, en ayant les mêmes qualités gustatives que du riz étuvé ayant subi une cuisson de 17 minutes environ.

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L'invention a donc pour objet un procédé de préparation de grains de riz qui consiste à mettre des grains de riz cargo en contact avec une quantité d'eau telle que les grains y soient complètement immergés pendant une durée suffisante pour que la teneur en eau des grains de riz hydratés atteignent un seuil minimum, à mettre ensuite les grains de riz hydratés dans une enceinte, à envoyer de la vapeur d'eau sous pression dans l'enceinte, de manière à porter la température dans l'enceinte à au moins 120

DEG C pendant 10 minutes et à obtenir des grains de riz traités à la vapeur, puis à mettre l'enceinte sous un vide d'au plus 0,2 bar absolu pendant un temps suffisant pour que la teneur en eau des grains de riz traités à la vapeur soit inférieure à 20 % en poids.Suivant l'invention

a) le seuil minimum de la teneur en eau des grains de riz hydratés est au moins de 30 % en poids, et

b) un stade de séchage sous vide d'au plus 0,6 bar absolu est intercalé entre la mise en contact avec l'eau et l'envoi de vapeur d'eau sous pression jusqu'à ce que les grains de riz n'ait plus de couche d'eau en surface.

La teneur de 30 % est absolument nécessaire pour obtenir la gélatinisation complète de l'amidon. Mais si cette teneur est obtenue, non pas par un simple stade de trempage sans élévation excessive de la température, mais par des traitements brutaux notamment à la vapeur, il se produit une modification des amidons du riz, en sorte que l'on n'obtient plus ultérieurement les mêmes qualités organoleptiques.Néanmoins, lorsque l'on se dispense de ces traitements brutaux à la vapeur qui avaient aussi pour rôle d'éliminer l'eau surperficielle des grains de riz issue des trempages, il faut prévoir, intermédiairement entre la mise en contact avec de l'eau et l'envoi de vapeur d'eau sous pression, un stade de séchage sous vide d'au plus 0,6 bar absolu pour que les grains de riz n'ait plus de couche d'eau en surface et pour qu'ainsi le traitement à la vapeur d'eau sous pression puisse s'effectuer correctement sans que le grain de riz ne gonfle trop et n'éclate.

Au US-A-5 316 783, on ne propose pas de traiter du riz par un stade de séchage sous vide. Le GB-A-2

173 986 propose un stade de séchage sous vide du riz, mais ce stade est effectué avant l'immersion dans de l'eau et est destiné à faciliter la pénétration ultérieure de l'eau dans les grains amylacées, alors que suivant l'invention le stade de séchage sous vide a lieu après le traitement à l'eau et est destiné à empêcher que les grains ne gonflent ou n'éclatent lors du traitement ultérieur à la vapeur d'eau.

Le premier stade du procédé selon l'invention consiste à mettre des grains de riz cargo en contact avec suffisamment d'eau pour que les grains y soient complètement immergés. La quantité d'eau en poids peut représenter de 2 à 10 fois celle des grains de riz.

La durée pour que la teneur en eau des grains de riz hydratés atteignent le seuil minimum de 30 % doit

être d'au moins 3 heures à la température ambiante, cette durée pouvant être écourtée lorsque la température de l'eau est plus haute, la température de l'eau ne pouvant toutefois pas dépasser 60 DEG C et de préférence 50 DEG C environ. Grâce à cette opération de trempage, on hydrate les grains de riz sans les gonfler.

Le deuxième stade du procédé suivant l'invention consiste à sécher sous vide d'au plus 0,6 bar absolu, les grains de riz ayant subi le traitement précédent de trempage. On préfère mettre sous vide de 0,2 bar absolu pendant au moins 30 minutes.

Le troisième stade du procédé suivant l'invention consiste à mettre les grains de riz dans une enceinte et

à envoyer de la vapeur d'eau sous pression dans l'enceinte, de manière à porter la température dans l'enceinte à au moins 120 DEG C pendant au moins 10 minutes. On peut envoyer notamment de la vapeur d'eau sous une pression de 1 bar dans l'enceinte. La température dans l'enceinte ne doit pas être inférieure à 120 DEG C mais si elle dépasse 120 DEG C, pour aller jusqu'à 150 DEG C, on peut diminuer la durée du traitement par la vapeur. A 120 DEG C, il faut en général au moins 10 minutes pour obtenir un traitement à la vapeur correct qui gélatinise complètement l'amidon au coeur des grains de riz.

On obtient ainsi après usinage, c'est-à-dire après avoir enlevé par abrasion les enveloppes périphériques, des grains de riz dont le diagramme de diffraction de rayons X ne comporte plus les pics de l'amidon natif pour 2 theta = 9,9 DEG ; 11,2 DEG ; 15 DEG ; 17 DEG ; 18 DEG et 23,3 DEG et qui sont caractérisés en ce qu'après cuisson de 100 g de grains de riz dans 1 litre d'eau à 100 DEG C

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pendant 10 minutes et refroidissement pendant 15 minutes à la température ambiante, les grains de riz cuits et refroidis ont, mesurés au viscoélastographe Chopin, une fermeté inférieure à 65 et une recouvrance élastique inférieure à 35, ce qui traduit leurs bonnes qualités gustatives. Ces grains de riz, bien que ne nécessitant qu'une cuisson de 10 minutes environ, ont des qualités gustatives comparables à celles de grains de riz étuvés classiques ayant subi une cuisson de 17 minutes environ.

Les diagrammes de diffraction sont obtenus avec un générateur de rayons X (marque Inel) opérant à

40 KV et 30 mA. L'échantillon est broyé puis scellé entre deux feuilles d'aluminium pour réaliser le spectre de diffraction de l'amidon.

Le viscoélastographe permet d'évaluer les caractéristiques visco-élastiques du riz cuit en traçant des courbes de déformation des grains en fonction du temps sous une force constante puis après suppression de la force. Il permet en particulier d'apprécier la fermeté et l'élasticité des grains de riz qui sont les critères principaux caractérisant la texture des riz étuvés. Pour la mesure au viscoélastographe

Chopin, 100g de grains de riz sont cuits dans un litre d'eau bouillante salée à 7g/litre. A la fin de la cuisson les grains sont égouttés pendant une minute sur un tamis d'ouverture 1,25 mm puis mis à refroidir pendant 15 minutes dans une boîte de Petri de 60 mn placée sur une plaque éponge humide et recouverte par une boîte de Petri de 80 mm de façon que cette dernière crée un joint étanche avec l'eau qui imbibe la plaque éponge.

3 grains ainsi refroidis sont ensuite placés sur le plateau du viscoélastographe pour la mesure.

Le cycle de mesure consiste à appliquer pendant 40 secondes une force de 700g puis à la retirer pendant les 20 secondes suivantes. On note l'épaisseur E des grains avant application de la force, l'épaisseur e1 après écrasement 40 secondes et l'épaisseur e2 après le relâchement de 20 secondes. A partir de ces valeurs, on calcule :

La fermeté F = 100. (e1/E)

La recouvrance élastique = 100((e2-e1)/(E-e1))

6 mesures sont effectuées sur la même cuisson pour calculer la moyenne et l'écart-type sur les 6 résultats obtenus ;

Il s'avère également que les grains de riz obtenus suivant l'invention sont moins colorés que les grains antérieurs susceptibles de cuire en 10 minutes. Leur couleur peut être définie par

L ; 62

a >; 3

b >; 18,5

La mesure de couleur des grains est réalisée à l'aide d'un chromamètre Minolta CR-200 et du système

1*a*b (L = variable de clarté, a = indice de rouge et b = indice de jaune). La mesure est effectuée sur

60 g de grains de riz placés dans la cellule de mesure. La mesure est réalisée sur 6 échantillons différents. On calcule ensuite la moyenne et l'écart type des mesures.

L'exemple suivant illustre l'invention.

5 tonnes de riz cargo long grain type B sont placés dans une cuve et recouverts avec de l'eau à 50 DEG

C. Le riz est laissé en contact avec l'eau pendant 5 heures. A la fin de cette période son humidité atteint

30,7%. Il est alors égoutté, transféré dans une enceinte rotative et mis sous vide de 0,3 bar absolu pendant 30 minutes.

Ce riz cargo trempé est ensuite chauffé par de la vapeur d'eau sous pression de 1 bar jusqu'à 125 DEG

C et maintenu à cette pression et cette température pendant 6 minutes.

Le riz cargo ainsi traité est ensuite séché sous vide de 0,2 bar absolu pendant 3 heures, son humidité redescend ainsi à 17,6%. Il est alors rapidement refroidi à l'air, usiné selon le procédé traditionnel et séché jusqu'à 12%, humidité requise pour sa conservation ;

Le riz ainsi traité, cuit pendant 10 minutes à l'eau bouillante et refroidi 15 minutes selon le protocole défini ci-dessus présente les caractéristiques de texture suivantes mesurées au viscoélastographe :

Fmoy = 62,5 - écart type sur 6 mesures = 2,8

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Rmoy = 29,3 - écart type sur 6 mesures = 3,8

Avant cuisson, sa couleur est définie par

Lmoy = 63,88 (écart type = 0,03)

amoy = 1,94 (écart type = 0,03)

bmoy = 18,25 (écart type = 0,04)

Comparaison avec un autre riz

Le riz étuvé "Uncle Ben's Riz long grain type B 10 mn de cuisson -codé par son n DEG de lot de fabrication 03.08.96C" cuit et refroidi dans les mêmes conditions que le riz cité en exemple donne les résultats suivants :

Fmoy = 72,1 - écart type sur 6 mesures = 1,1

Rmoy = 51,8 - écart type sur 6 mesures = 4,1

Avant cuisson, sa couleur est définie par

Lmoy = 59,19 (écart type = 0,03)

amoy = 4,24 (écart type = 0,06)

bmoy = 19,30 (écart type = 0,02)

Un jury d'expert en analyse sensorielle du riz distingue très aisément ces deux riz. Le riz suivant l'invention est moyennement ferme et élastique alors que le riz Uncle Ben's est considéré comme très ferme et très élastique.

Les couleurs des deux produits se différencient très facilement à l'oeil nu. Le riz suivant l'invention est jaune clair, le riz Uncle Ben's est jaune foncé.Data supplied from the esp@cenet database - Worldwide

Claims:


1. Grain de riz dont le diagramme de diffraction des rayons X ne comporte pas les pics de l'amidon natif pour 2 theta = 9,9 DEG ; 11,2 DEG ; 15 DEG ; 17 DEG ; 18 DEG et 23,3 DEG , caractérisé en ce qu'après cuisson de 100 g de grains de riz dans 1 litre d'eau à 100 DEG C pendant 15 minutes et refroidissement pendant 15 minutes à la température ambiante les grains de riz cuits et refroidis ont, mesurés au viscoélastographe Chopin, une fermeté inférieure à 65 et une recouvrance élastique inférieure à 35.

2. Grain suivant la revendication 1, caractérisé en ce que sa couleur évaluée au chromamètre Minolta

CR-200 dans le système L, a, b. L étant la variable de clarté, a l'indice de rouge et b l'indice de jaune est définie par

L ; 62

a >; 3

b >; 18,5

3.Procédé de préparation de grains de riz qui consiste à mettre des grains de riz Cargo en contact avec une quantité d'eau telle que les grains y soient complètement immergés pendant une durée suffisante pour que la teneur en eau des grains de riz hydratés atteignent un seuil minimum, à mettre les grains de riz hydratés dans une enceinte, à envoyer de la vapeur d'eau sous pression dans l'enceinte de manière à porter la température dans l'enceinte à au moins 120 DEG C pendant au moins 10 minutes, et à obtenir des grains de riz traités à la vapeur puis à mettre l'enceinte sous un vide d'au plus 0,2 bar absolu pendant un temps suffisant pour que la teneur en eau des grains de riz traités à la vapeur soit inférieure

à 20 % en poids, caractérisé en ce que

a) le seuil minimum de la teneur en eau des grains de riz hydratés est au moins de 30 % en poids, et

b) un stade de séchage sous vide d'au plus 0,6 bar absolu est intercalé entre la mise en contact avec de l'eau et l'envoi de vapeur d'eau sous pression jusqu'à ce que les grains de riz n'ait plus de couche d'eau en surface.

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4. Procédé suivant la revendication 3, caractérisé en ce qu'il consiste à envoyer de la vapeur d'eau sous pression dans l'enceinte de manière à porter la température dans la cuve à au moins 120 DEG C pendant 10 minutes.Data supplied from the esp@cenet database - Worldwide

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53.

EP0700642 - 3/13/1996

METHOD AND PLANT FOR THE CONTINUOUS BOILING OF RICE


Inventor(s): SCHROLL GUNNER (DK)

Applicant(s): DANRICE AS (DK)


IP Class: A23L1/10; A23L1/182

E Class: A23L1/182; A23L1/10H2


Priority Number: DK19940001034 (19940907)

Family: EP0700642

Equivalent: EP0700642; ES2176303T

US4702161; FR1547726; FR2416676; FR2674100; US4155293; Cited Document(s):

US4238997; US4787300

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Abstract:


By the automatic and continuous boiling of rice using a method and plant according to the invention, where the soaking takes place in water from the boiling zone, where the boiling takes place in water from the cooling, and where the salting takes place by means of a salt solution in a closed circuit, the consumption of water can be considerably reduced in comparison with hitherto-known methods and plants. The plant comprises a soaker (4) in the form of a drum (5) from which the heated and soaked rice is led into a blancher (14) with boiling zones (17, 18), cooling zones (19, 20), salting zone (21) and dripping-off zone (22). By boiling slowly and allowing the rice to absorb as much water as possible as late as possible, the plant can be made compact and the boiling can be effected in a rational manner, and the subsequent freezing is effected without risk of the formation of clumps. >;MATH;Description:


Background of the invention

The invention relates to a method for the automatic and continuous boiling of rice, and comprising a soaking of the rice which is hereafter heated to boiling by means of hot water, and subsequent cooling before possible salting of the rice, and also a plant for the execution of the method.

Boiled rice is used to a great extent as a semi-product for finished dishes such as mixed vegetables, paella, poultry dishes etc. The boiled rice is frozen and packed, after which it is transported to the places of use.

There are known methods and plants which can be used for such boiling.

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EP patent application no. 371,324 and US patent publication no. 4,873,917 both disclose apparatus for the continuous boiling of rice.

However, this known apparatus has a considerable water consumption and a correspondingly high consumption of energy.

The water consumption is due to the continuous supply of fresh water for both the boiling and the cooling, and the energy consumption is due to the constant heating of this water in the soaking and the boiling zones. This also results in a correspondingly large amount of waste water and herewith problems with the cleaning and disposal of same.

Advantages of the invention

According to the invention, by using a method whereby soaking is carried out in water from the boiling zone which is continuously fed to the rice in a counterflow, and where the boiling takes place by means of hot water which is continuously fed to the rice in a counterflow, and where the cooling is carried out by means of relatively cold water and air, and where the salting is carried out by using a salt solution in a closed circuit, in a surprisingly simple manner there is achieved an unknown low consumption of water in comparison with the water consumed with hitherto known methods. The soaking is thus carried out in counterflow with the water taken from the boiling, whereby a heating of the rice is achieved during the soaking, and the boiling is similarly effected in hot water which is supplied continuously in counterflow.By subsequently using the cooling water as boiling water, this is preheated. There is hereby achieved a hitherto-unknown low water consumption and energy consumption, and the amount of waste water is also extremely low in comparision with hitherto-known methods.

As disclosed in claim 2, by allowing the water to flow in such a manner that the raw water is supplied at the hottest end of the process, i.e. the discharge end, and preheating it by cooling the rice and using it for the boiling before it is used as soaking water, and at the same time to let the water recirculate to the greatest possible extent, a good operational economy is achieved.

As disclosed in claim 3, by removing the water from the soaking when the content of dry matter exceeds around 8%, the useful qualities of the water are utilized to the maximum, in that the rice can no longer absorb water.

Moreover, this waste water can be used as an advantageous animal fodder.

As disclosed in claim 4, by allowing the plant for the execution of the method to comprise rotating drums with internal vanes for the feeding of the rice, and leading the soaked and hot rice directly out on a conveyor in a blancher, the rice can be boiled possibly after having been coloured, cooled and salted in a continuous process, there is hereby achieved a compact plant which is suitable for continuous operation, where it is not necessary for the rice to be accumulated or stored in any way, but can remain on the conveyor.

As disclosed in claim 5, by leading the hot soaking water from jets and spraying the grains of rice along the inside of the drum and letting them drip the water when they pass a collection tank in the bottom, the most economical and uniform soaking of the rice is achieved.

As disclosed in claim 6, by pumping the water out of the tank or a vessel connected therewith when the content of dry matter gets too high, the water will be utilized to the optimum degree and the consumption of water and the energy will therefore be the lowest possible.

As disclosed in claim 7, by configuring one of the cooling zones as an air-cooled zone by sucking air up through the conveyor and the rice layer, a very effective cooling is achieved over a relatively short length of conveyor, which makes it possible for the plant to be of compact construction.

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As disclosed in claim 8, to effect the salting of the rice by using a concentrated salt solution in a closed circuit, said solution being sprayed out over the rice layer and being sifted through same and thereafter collected and re-circulated, a reliable control of the salt content and a uniformity in the finished rice is achieved.

As disclosed in claim 9, by allowing the rice to drain after being salted, its surface becomes suitable dry so that there is no tendency for the rice grains to stick together during the subsequent freezing and use.

Finally, it is expedient, as disclosed in claim 10, to lead the finish-boiled rice to a vibrating table where possible clumps are broken up, the result being a uniform and homogenous flow of rice which is suitable for freezing.

The drawing

An example embodiment of a plant for the execution of the method according to the invention wil now be described in more detail with reference to the drawing, where fig. 1 shows a principle drawing of a plant seen from above, fig. 2 shows a cross-section of the soaker seen in the direction II-II in fig. 1, fig. 3 shows a corresponding section through the blancher seen in the direction III-III in fig. 1, and fig. 4 shows a cross-section of the salting zone.

Description of the example embodiment

An example of an embodiment of a plant for the automatic and continuous boiling of rice and herewith related grain is shown in fig. 1-3.

The plant comprises a funnel 1 over which there can be suspended a not-shown sack of rice. The rice is fed from the bottom of the funnel 1 up to the soaker 4 by means of a worm conveyor 2 which opens out in an inlet 3 to the soaker.

This is provided with a drum 5 which is configured as a shroud having an inner side on which there are secured vanes 6 which extend in a spiral manner from the inlet end to the outlet end. By letting the pitch of the vanes extend in the direction of rotation of the drum, the rice will be fed forwards in the drum when this rotates.

As shown in fig. 2, soaking water is now applied to the rice in the drum 5, this water being stored in a tank 10 which is supplied with water from the blancher 14, which will be described later.

A pump 12 feeds the hot water to a nozzle pipe 8 which extends inside the drum 5. Distributed along the length of the pipe there are nozzles which spray water 7 on to the rice in the drum.

The drum 5 is constructed in such a manner that during its rotation the rice is moved in the direction of production, which in the drawing is towards the right, while the water 7 flows in the opposite direction in the whorl between the vanes 6. In the bottom of the drum there is arranged a not-shown sieve through which the water can be led out and thereafter fed into the preceding whorl in the direction of production. The water is hereby moved in counterflow to the rice.

The water is finally discharegd into a second tank 11. This is connected to the first tank 10 so that a supply of water can be effected from the second tank 11 in the event of the supply of water from the boiling zone in the blancher 14 not being sufficient.

When the content of solid matter in the water 7 in the tank 11 exceeds the maximum from which the rice can absorb water, which will be about 8% solid matter, a given amount of waste water 13 is

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pumped out to a not-shown collection tank or the like. Here it should be noted that the content of solid matter in this waste water makes it suitable, for example, for pig-food.

When the rice is being fed forwards, in the last whorls it will be conveyed without nozzle water 7, whereby it becomes suitable for the application of a possible dye solution such as a turmeric powder solution. The rotations of the drum 5 ensure that the dye is mixed evenly with the rice and is distributed uniformly on the grains.

Hereafter, the soaked and possibly dyed rice is fed directly on to a conveyor 15 in a blancher 14 as shown in figs. 1 and 3.

The blancher 14 comprises a first boiling zone 17, a second boiling zone 18, a first cooling zone 19, a second cooling zone 20, a third cooling zone 21 with salting zone and draining zone 22, all of which zones are past by the conveyor 15 before it passes over a turning roller 16 and extends forwards under the plant to the inlet end of the blancher.

The first boiling zone 17 is provided with an overflow for the boiling water to the tank 10, see fig. 2, so that it can be continuously replaced.

Hereafter, the rice is conveyed to the next boiling zone 18, after which follows the first cooling zone

19. This zone 19 is water-cooled, the result being that the water is preheated before it is led to the second boiling zone 18.

In the subsequent cooling zone 20, an air-cooling is effected by means of a fan which sucks out the air in the space over the rice on the conveyor 15.

This conveyor is preferably a chain-link conveyor which, as indicated in fig. 4, has through-going holes

25, so that air under the conveyor 15 will be sucked through the rice layer 24. The rice is hereby effectively cooled in the shortest possible time and herewith within an appropriately short conveyor movement.

After this follows the final, third water-cooled zone 21, where a simultaneous salting can be carried out by means of the equipment shown in fig. 4.

This comprises the supply of a concentrated salt solution via a pump 26 to a vessel 28 to which there is also supplied fresh water via a float valve 29. The salt solution 27 is pumped from this vessel 28 by means of a pump 30 to a nozzle 31, from where it is sprayed out over the rice 24. During the passage of the solution through the rice layer, the rice will absorb the applied amount of salt.

If, for example, a 1% salting of the finish-boiled rice is desired, and 1 ton of rice per hour passes through the salting zone, a salt solution corresponding to 10 kg. of salt per hour must be applied. Since the salt solution is applied only to the rice, this will be given the desired salting of 1%. It can hereby be ensured that a given degree of salting will be uniform.

The salt solution is recirculated and freshwater only is supplied when the level falls in the vessel 28, so that the concentration increases. There is hereby ensured a suitably uniform salt solution 27 for spraying out over the rice.

After the salting there extends a dripping-off zone 22 so that the surface water can drip off the rice which will then absorb the remaining surface water.

Finally, the finish-boiled, possibly dyed and salted rice is deposited on a transversely-extending vibration belt 32 where possible clumps are comminuted to loose rice.

From this belt 32, the rice is led to a conveyor 33 where it is given sufficient time, holding time, to absorb all the surface water, so that it is completely dry for the freezing. This can be effected in a commonly-known freezing plant 34, after which the frozen rice can be packed in a commonly-known manner.

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Description of the method

The dosing of the rice to the soaker 4 can take place by adjustment of the speed of rotation of the worm conveyor 2. Since this is steplessly variable, it can be set to provide a given dose.

The soaking takes place by giving the rice a retention time in the drum 5 of about 45 minutes. The pumping out of the water from the collection vessel 11 is effected when a given level in the tank is reached. The actual pumping out takes place at a predetermined volume, so that a given amount of the water containing the most solid matter is pumped out.

The water, which is fed to the blancher 14, is first led to a nozzle 23, see fig. 3, as rinsing water for the conveyor 15. It is hereby ensured that the conveyor belt is clean when it reaches the feeding end of the blancher 14.

The water is then led to the first cooling zone 19 where it is heated to 75-80 DEG C by the hot rice before being fed into the boiling zones 17 and 18, where thermal energy is supplied so that the water after the first boiling zone is around 95 DEG C.

The water has this temperature when it is fed to the soaker 4, see fig. 2, where before the water absorption a heating of the rice to around 60 DEG C takes place when the rice leaves the soaker.

During the operation of the plant, it is important to dimension and set the feeding rate of the conveyor in the individual zones so that the rice is boiled as slowly as possible. The individual grains of rice are hereby given a uniform water content.

The colouring takes place at a time when the rice is partly saturated with water in the soaker, which ensures a suitable absorption of colouring matter by the outside of the rice grains. The colouring is therafter boiled into the rice.

By allowing the rice to absorb and preheat the used water from the blancher, and to take up as much solid matter as possible from the water, a minimum loss of energy and solid matter is achieved.

Finally, it is advantageous that the rice becomes saturated with water at as late a time as possible, i.e. when the rice absorbs the last water in the dripping-off zone 22, whereby the plant can be dimensioned as compact and herewith as rationally as possible.Data supplied from the esp@cenet database -

Worldwide

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54.

EP0722669 - 7/24/1996

METHOD AND APPARATUS FOR THE CONTINUOUS PROCESSING OF RICE


Inventor(s): KENDALL JOHN H (US); MOHINDRA RANVIR B (US); RUTHERFORD

DUANE S (US); KANAMOTO SIGEHARU (JP); SATAKE SATORU (JP); KUMAMOTO

KATSUYUKI (JP)

Applicant(s): RIVIANA FOODS INC (US); SATAKE ENG CO LTD (JP)


IP Class: A23L1/10; A23L1/182

E Class: A23L1/182; A23L1/10H2; A23L1/01D; A47J27/16; F26B11/18B


Priority Number: EP19940927961 (19940829); US19930116032 (19930902); US19930116064

(19930902); US19930116114 (19930902); US19930116071 (19930902)

Family: EP0722669

Equivalent: EP1132031; EP0743497; EP0730837; EP0722669

Cited Document(s): US4571341; US4649055; GB903837; GB955636; GB1101821; FR975714;

GB668288; US2937946; GB990063; GB669900

Abstract:


A method and apparatus for processing food products to prepare the food product for packaging. The methods involve pre-steaming, pre-washing, steeping, steam cooking and then drying the food products. Chemical additives may be added to the food products during processing. The apparatus further includes a conveying means(38), steeping tanks(27) and a water re-circulating means(30). A dryer(32) including a rotating barrel adapted for agitation of the food products during cooking is present.

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55.

EP0745330 - 12/4/1996

ANTI-REGURGITATION INFANT FORMULA


Inventor(s): MARTINEZ SARAH B (US)

Applicant(s): SQUIBB BRISTOL MYERS CO (US)


IP Class: A23L1/0522

E Class: A23L1/30C2; A23L1/0522; A23L1/305D; A23L1/29F



Family: EP0745330

Equivalent: BR9602558; EP0745330; PL188275B; ES2094716T; DE69627867T;

DE69627867D; CZ291573

Cited Document(s):

SU1729404

US4140760; US3539358; US4428972; GB1220838; XP002010925;

Abstract:


Infant formula containing certain thickening agents useful for treating regurgitation. The thickening agent can be potato starch, waxy grain starch (e.g. waxy corn starch, waxy rice starch) or a mixture thereof.Claims:


1. An infant formula characterised in that it comprises a thickening agent which comprises potato starch, waxy grain starch, or a mixture thereof, in an amount effective to ameliorate regurgitation in infants.

2. The infant formula of Claim 1 characterised in that the effective amount of thickening agent is about

1.8 to 5 g per 100 calories of formula.

3. The infant formula of Claim 1 characterised in that the effective amount of thickening agent is 2 to about 4.7 g per 100 Calories of formula.

4. The infant formula of Claim 1 characterised in that the effective amount of thickening agent is about

2 to about 3 g per 100 Calories of formula.

5. The infant formula of any preceding claim characterised in that said thickening agent is waxy rice starch, waxy corn starch, potato starch, or a mixture thereof.

6.The infant formula of any preceding claim characterised in that said waxy rice starch or waxy corn starch comprises at least about 95% amylopectin by weight.

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7. The infant formula of any preceding claim characterised in that said waxy rice starch or waxy corn starch comprises at least about 98% amylopectin by weight.

8. The infant formula of Claim 1 wherein said thickening agent is waxy rice starch.

9. The infant formula of any preceding claim having a Brookfield viscosity of about 35 to about 150 cp.

10. The infant formula of any preceding claim, in a ready to use form, which does not separate into two phases or gel into a solid mass when stored overnight in the refrigerator.

11.The infant formula of any preceding claim comprising, per 100 Kcal of total formula, about 1.8 g to about 4.59 g protein, about 3.3 g to about 6 g lipid, and about 7 g to about 14 g carbohydrate.

12. The infant formula of any preceding claim further comprising vitamins and minerals.

13. The infant formula of any preceding claim which is nutritionally complete.

14. The infant formula of any preceding claim which is not hypercaloric.

15. The infant formula of any preceding claim which has a caloric density of not more than 20 Cal./fl. oz.

16. The infant formula of any preceding claim which has a caloric density of greater that 20 Cal./fl. oz. and not more than 24 Cal./fl. oz.

17. The infant formula of any preceding claim which is calorically balanced.

18.Use of waxy grain starch, or a mixture thereof, in the manufacture of an infant formula for use in the treatment of regurgitation in infants.

19. The use of Claim 18 characterised in that amount of thickening agent is about 2 to about 4.7 g per

100 calories of formula.

20. The use of Claim 18 characterised in that said thickening agent is waxy rice starch, waxy corn starch, potato starch, or a mixture thereof.

21. The use of Claim 18 characterised in that said thickening agent comprises waxy rice starch or waxy corn starch and said starch comprises at least about 98% amylopectin by weight.

22. The use of Claim 18 characterised in that said infant formula is in a form ready to use and does not separate into two phases nor gel into a solid mass when stored overnight in the refrigerator.

23. The use of Claim 18 characterised in that said infant formula comprises, per 100 Kcal of total formula, about 1.8 g to about 4.59 g protein, about 3.3 g to about 6 g lipid, and about 7 g to about 14 g carbohydrate, and further comprises vitamins and minerals.

24. The use of Claim 23 characterised in that said infant formula is nutritionally complete.

25. The use of Claim 18 characterised in that said infant formula is not hypercaloric.

26. The use of Claim 18 characterised in that infant formula has a caloric density of not more than 20

Cal./fl. oz.

27. The use of Claim 18 characterised in that said infant formula has a caloric density of greater than

20 Cal./fl. oz. and not more than 24 Cal./fl. oz.

28. The use of Claim 18 which is calorically balanced.Data supplied from the esp@cenet database -

Worldwide

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56.

EP1101413 - 5/23/2001

METHOD FOR PRODUCING AN ADDITIVE FOR BREAD AND ADDITIVE

FOR BREAD


Inventor(s): KOSHIISHI IKUO (JP)

Applicant(s): KOSHIISHI IKUO (JP)


IP Class: A23P1/08; A23L1/308

E Class: A23L1/16; A21D13/02; A23L1/308; A23L1/10E; A23K1/18N; A21D2/36


Priority Number: EP19990309188 (19991118); CA19992289986 (19991116); US19990448502

(19991124)

Family: EP1101413

Equivalent: US6509046; CA2289986; EP1101413

EP0835612; US5476678; US4568557; US4673578; JP1039953; Cited Document(s):

JP62236453; JP7008158

Abstract:


A method for producing an additive stuff for bread or the like and the additive stuff obtainable by said method. The method includes a water elimination process which eliminates the contained water of rice bran by roasting or drying it, and an oils-fats coating process, i.e., adding oils-fats to the dried rice bran and mixing them; such process covers the surface of the dried rice bran. Therefor, the smell and bitterness derived from the rice bran can be prevented. Moreover, even though the rice bran is used as an additive stuff for a loaf of bread, cracker (hard biscuit) or the like, cakes, cookies, a sort of noodles, a sort of pasta such as a spaghetti, ravioli or the like, foods for dogs and so forth, the rice bran does not spoil the taste of the manufactured product. Also, it can be used effectively and act on the human body with good effects by ingestion.Claims:


1. A method for producing an additive stuff for bread or the like comprising:

a water elimination process eliminates a contained water by roasting or drying an rice bran; and

an oils-fats coating process that adds an oils-fats to a dried rice bran that is eliminated water by said water elimination process and mixes therewith, the oils-fats coating process covering a surface of said dried rice bran.

2. The method for producing an additive stuff for bread or the like according to claim 1, wherein said water elimination process eliminates the contained water by roasting, drying or the like after a liquid seasoning including a raw sugar, a honey or the like is added into the rice bran.

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3. The method for producing an additive stuff for bread or the like according to claim 1, wherein said water elimination process eliminates the contained water by roasting, drying or the like after a little of powdered charcoal is added into the rice bran and a liquid seasoning including a raw sugar, a honey or the like is added into the rice bran

4. An additive stuff for bread or the like comprising:

a rice bran eliminated a contained water by roasting, drying or the like; and

an oil-fat coated a surface of a particle of said rice bran.

5. The additive stuff for bread or the like according to claim 4, wherein said rice bran eliminated the contained water is dried after a liquid seasoning including a raw sugar, honey or the like is mixed with said rice bran.

6. , The additive stuff for bread or the like according to claim 4, wherein said rice bran eliminated the contained water is dried after a powdered charcoal is added a little to said rice bran, and a liquid seasoning including a raw sugar, honey or the like is mixed with said rice bran.Data supplied from the esp@cenet database - Worldwide

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57.

EP1108366 - 6/20/2001

BOILED RICE CONTAINING TREHALOSE AND SOYBEAN

POLYSACCHARIDE


Inventor(s): IWAMOTO TADAHIKO (US)

Applicant(s): IWAMOTO TADAHIKO (US); IWAMOTO YUKIKO (US)


IP Class: A23L1/182

E Class: A23L1/182



Family: EP1108366

Equivalent: US6316042; JP2001178384

Cited Document(s): JP11285350; JP8168350; JP10150938; JP9163943; JP9107899;

XP002162607; JP2000166491

Abstract:


The invention relates to boiled rice foods containing soybean polysaccharides and trehalose. The texture of the boiled rice foods does not deteriorate when returned to an edible state by de-chilling or thawing following distribution in a chilled or frozen state, and are free from hygiene problems associated with de-chilling or thawing at room temperature.Description:



[0001] The present invention relates to boiled rice foods capable of being distributed at low temperatures. Specifically, the present invention relates to boiled rice foods having a texture which does not deteriorate following distribution and storage at low temperatures, and which are free from hygienic problems associated with warming or thawing at room temperature.

[0002] More specifically, the present invention relates to boiled rice foods having a texture which does not deteriorate when warmed or thawed following chilled or frozen distribution, and which are free from any hygienic problems associated with warming or thawing at room temperature. In the present invention, "chilled distribution" refers to distribution and storage in a temperature below about

5 DEG C and above a freezing point; "frozen distribution" refers to distribution and storage in a temperature range which enables freezing; while "de-chilling" refers to warming in a temperature below about 10 DEG C and above a freezing point.

[0003] Cooked boiled rice hardens over time. This phenomenon is also called deterioration of boiled rice. The degree of deterioration increases at lower temperatures. Such deterioration results from

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changes in intrinsic starch and it has been suggested that the mechanism involves recrystallization of starch which has been gelatinized and swollen under the influence of water and heat. In particular, the taste, texture and flavor of boiled rice all significantly deteriorate after distribution and storage at a temperatures sufficiently low to cause chilling or freezing.

[0004] In order to prevent the deterioration of boiled rice, attempts have been made which utilize methods such as increasing the amount of water added for cooking or adding enzymes such as alpha amylase, beta -amylase, glucoamylase and protease, starch such as pregelatinized starch and chemically modified starch, polysaccharides such as Duran gum and hyaluronic acid, sugars such as anhydrosugar, dextrin, glucose, fructose and cyclodextrin, sugar alcohols such as trehalose, maltitol, sorbitol and lactitol, or fatty acid esters such as sucrose fatty acid ester, polyglycerin fatty acid ester and glycerin fatty acid ester, and emulsifiers such as organic acid esters of monoglycerides. However, none of these methods achieve any significant improvement in taste or texture.

[0005] When boiled rice foods containing these additives are chilled or frozen for distribution, various methods are available to effect de-chilling or thawing, such as allowing the food to stand at room temperature for a period of time, warming at a relatively low temperature (de-chilling), or thawing by heating in a microwave oven. However, if foods are left to stand at room temperature for a period of time, a hygienic problem can arise. In addition, thawing by heating is not suitable for boiled rice foods such as sushi. If the microwave method is used for more suitable foods, hardening is likely to result, causing an undesirable taste, texture and flavor. The same problem exists with respect to dechilling. When boiled rice foods produced in a conventional method are subjected to de-chilling, such foods will suffer a deterioration in taste and texture.

[0006] As a countermeasure against such deterioration, a method of adding trehalose or trehalose plus sugar alcohol (e.g. JP-A 8-168350 and JP-A 9-163943) has been proposed. This method is said to enable foods to be returned to an edible state without heating following chilled or frozen storage and distribution. However, no improvement in taste and texture can be achieved using de-chilling, thus such foods should be thawed at room temperature. Thus, the problem of hygiene is not solved thereby.

Further, thawing at room temperature does not effect a satisfactory improvement in taste and texture.

[0007] The object of the present invention is to provide boiled rice foods the taste, texture and flavor of which do not deteriorate when returned to an edible state by hygienic de-chilling after being distributed in a chilled or frozen state.


[0008] As a result of intensive study to solve the object described above, the present inventor has found that by adding soybean polysaccharides and trehalose during cooking, deterioration in the quality of boiled rice foods with respect to taste, texture and flavor, caused by chilled distribution or frozen distribution, can be prevented to a far greater extent than that achieved by the conventional method. It has also been found that, as a method of returning boiled rice foods to an edible state, this technique can be applied to de-chilling or thawing at relatively low temperatures thus avoiding hygiene problems which arise at room temperature.

[0009] The present invention provides boiled rice foods containing soybean polysaccharides and trehalose. The boiled rice foods of the present invention can be obtained by cooking rice with addition of soybean polysaccharides and trehalose. The boiled rice foods of the present invention containing soybean polysaccharides and trehalose are advantageous in that deterioration in the quality of the rice foods with respect to taste and texture can be prevented when they are de-chilled following chilled or frozen distribution. Further, hygienic problem caused by thawing at room temperature can be avoided.

Thus, the boiled rice foods of the invention are much more suitable for low-temperature storage and distribution than the conventional products.


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[0010] As used herein, the term "soybean polysaccharides" refers to water-soluble polysaccharides, such as hemicellulose. Preferably, SOYAFIBE-S>;TM)>;Fuji Oil Co., Ltd.) may be used as a soybean polysaccharide. The soybean polysaccharides are added in an amount of 0.1 to 4% by weight, and trehalose is added in an amount of 0.1 to 4% by weight, preferably 0.5 to 3% by weight, more preferably 1 to 2.5% by weight, relative to the amount of raw rice. Soybean polysaccharides are believed to contribute to an increase of water absorbed in boiled rice, and trehalose is believed to have the effect of fixing water absorbed in boiled rice. It is currently believed that, by addition of these compounds, the amount of water absorbed in boiled rice is significantly increased and fixed therein, whereby a sufficient amount of absorbed water remains in boiled rice even upon de-chilling or thawing following chilled or frozen distribution, thus deterioration in taste, texture, flavor can be prevented.

[0011] In a preferred embodiment of the present invention, the improvement in taste, texture and flavor becomes even more pronounced when a food-grade enzyme is added. Selection of a suitable food-grade enzyme is not particularly limited so far as it can be used in boiled rice foods, and examples include alpha -amylase, beta -amylase, glucoamylase, pectinase, protease or papain. A wide variety of food-grade enzyme preparations containing a mixture of enzymes such as amylase, protease and papain are commercially available. For example, an enzyme preparation Miora>;TM; (Otsuka Pharmaceutical

Co., Ltd.) is suitable for use. These food-grade enzymes are added in an amount of 0.0001 to 1% by weight, preferably 0.0002 to 0.5% by weight, more preferably 0.0005 to 0.1% by weight relative to the amount of raw rice. It is believed that these food-grade enzymes facilitate the hydrolysis of cell walls, cell membranes and amyloplast membranes of rice albumen or starch particle-binding protein to promote gelatinization and swelling of starch particles, thus contributing to an increase in the amount of water incorporated into the cooked rice.

[0012] In accordance with the invention, the boiled rice foods containing soybean polysaccharides and trehalose exhibit a reduced deterioration in their texture. In addition, the amount of water incorporated is increased by adding a food-grade enzyme to improve water retention efficacy, thereby further improving taste, texture and flavor.

[0013] In another preferred embodiment, the boiled rice foods of the present invention may further contain edible acetic acid and edible fats and oils. Edible acetic acid is not particularly limited, and conventional vinegar is preferably used. Edible acetic acid may be added in an amount of 0.1 to 5% by weight, preferably 0.5 to 4% by weight, more preferably 1 to 3% by weight relative to raw rice. Edible fats and oils are not particularly limited, and conventionally used vegetable oils can be preferably used.

Edible fats and oils may be added in an amount of 0.1 to 5% by weight, preferably 0.5 to 4% by weight, more preferably 1 to 3% by weight relative to the amount of raw rice. Edible acetic acid is believed to act to soften cell walls of boiled rice, while edible fats and oils affect the shape retention of boiled rice grains. Accordingly, it is believed that addition of these ingredients helps providing a texture similar to that of fresh boiled rice.

[0014] The raw rice material used in the boiled rice foods of the present invention is not particularly limited, and any rice distributed on the market can be used. Preferably, rice with a low amylose content, specifically with an amylose content of 15% or less, preferably 10% or less can be used to provide boiled rice foods having a good taste and texture. The term "amylose content" herein used refers to an apparent amylose content determined by iodine affinity measurement or by iodine colorimetry, and is not necessarily coincident with true amylose content. This content is expressed on a dry weight basis.

[0015] For production of boiled rice foods of the present invention, the procedure of cooking itself is not particularly limited, and a usual method of producing cooked rice can be used. The method of adding soybean polysaccharides and trehalose is not particularly limited, and these ingredients may be added water followed by immersion and cooking of rise; or if water is changed between the steps of immersion and cooking, these ingredients may be added to water for cooking only. Alternatively, these ingredients may be added during or after the step of cooking. Similarly, the method of adding foodgrade enzymes, edible acetic acid and edible fats and oils is not particularly limited. Water used for immersion and cooking is not particularly limited, and for example, degassed water, electrical-field water or magnetic-field water can all be used, among which degassed water is particularly preferable.

Degassed water is water prepared by removing a dissolved gas by passing water along one side of a

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gas-permeable and liquid-impermeable membrane while maintaining the other side in vacuo; electricalfield water is water to which a high-pressure static voltage is applied; and magnetic-field water is water which has been passed through a magnetic field and an electrical field.

[0016] The amount of water used in cooking is preferably greater than that used in producing usual cooked rice. The amount of water relative to the amount of raw rice will vary depending on the boiled rice food, but may be in the range from 190 to 230% by weight, preferably 200 to 210% by weight for sushi rice, or from 160 to 190% by weight, preferably 170 to 185% by weight for non-sushi rice.

[0017] Preferable examples of boiled rice foods of the present invention include sushi distributed in a frozen state. In general, sushi materials, in particular fish and shellfish are easily heat-denatured upon heating and thawing. In contrast, frozen sushi prepared according to the present invention can be thawing at relatively low temperature so that sushi materials such as fish and shellfish are not denatured. Moreover, the problems of hygiene accompanying room-temperature thawing do not arise, and the same texture as exists just after production can be obtained at the time of eating. Frozen rice balls, pilafs, and boiled rice with assorted mixtures are also preferable examples. Such foods can be eaten after being subjected to thawing at relatively low temperatures, and as required, heated in a microwave oven.

Examples

[0018] The present invention is described in more detail by reference to the Examples below. Such examples, however, are not intended to limit the scope of the present invention.

Example 1

[0019] 400 g California rice was washed with water, and the water was drained off, then the rice was immersed in 830 cc degassed water (at a volume 2.08-times greater than that of the rice). 8 g (2 weight-

%) Soyafibe-S>;TM; (Fuji Oil Co., Ltd.) as soybean polysaccharides, 8 g (2 weight-%) trehalose, 1 g

(0.2 weight-%) Miora>;TM; (Otsuka Pharmaceutical Co., Ltd.) as a food-grade enzyme preparation, 8 cc (2 weight-%) vinegar, and 2 cc (0.5 weight-%) salad oil were added to the immersion water, and the rice was cooked in a household rice cooker. 105 cc (26 weight-%) sushi vinegar was added to the rice thus cooked. Thereafter, the rice was cooled at 35 DEG C in a cooling unit and formed into a shape usable for sushi. The sushi rice thus formed was frozen and stored at -20 DEG C. After storage for 24 hours, it was subjected to thawing at 4 DEG C for 24 hours and its qualities evaluated. The sushi rice had a taste and texture the same as that following production. Example 2

[0020] 400 g California rice was washed with water, and the water was drained off, then the rice was immersed in 720 cc degassed water (at a volume 1.8-times greater than that of the rice). 6 g (1.5 weight-%) Soyafibe-S>;TM; (Fuji Oil Co., Ltd.) as soybean polysaccharides, 8 g (2 weight-%) trehalose, 1 g (0.2 weight-%) Miora>;TM; (Otsuka Pharmaceutical Co., Ltd.) as a food-grade enzyme preparation, 8 cc (2 weight-%) vinegar, and 2 cc (0.5 weight-%) salad oil were added to the immersion water, and the rice was immersed therein for 1 hour and then cooked in a household rice cooker. The rice thus cooked was cooled at 35 DEG C in a vacuum cooling unit and formed into a rice ball. The rice ball was stored at 4 DEG C. After storage in this state for 48 hours, its qualities were evaluated.

The rice ball had a taste and texture the same as that after production. Comparative Example

[0021] Sushi boiled rice was produced, frozen and subjected to thawing in the same manner as in

Example 1, except that the soybean polysaccharides were not added. The resulting sushi rice was rigid and brittle and failed to retain its form, and was unpalatable.Data supplied from the esp@cenet database - Worldwide

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58.

EP1145647 - 10/17/2001

PROCESS FOR INDUSTRIAL PREPARATION OF VACUUM COOKED RICE


Inventor(s): HERNANDEZ CALLEJAS ANTONIO (ES); HERNANDEZ CALLEJAS FELIX

(ES); FRANCO BALIBREA ONOFRE (ES)

Applicant(s): ARROCERIAS HERBA S A (ES)


IP Class: A23L1/182

E Class: A23L1/182C


Priority Number: WO1999ES00408 (19991229); ES19990000028 (19990108)

Family: EP1145647

Equivalent: WO0040099; US6509053; ES2149125; EP1145647; DE69907272T; DE69907272D;

AU761409

Abstract:


Process for the industrial preparation of rice cooked under vacuum, according to which the rice is cleaned by decanting (1) by means of a shower with cold water, being carried out later on a scalding

(2) with hot water, after which a cooling (3) by means of a shower with refrigerated water takes place, with later draining and drying (4) with microfiltered air, carrying out afterwards the frying (5), pulverizing the rice with oil at high temperature, mixing it (6) next with the corresponding sauces and solids, to conclude with a packaging (7) under vacuum and after a maceration time, the cooking and sterilization (8) is carried out in revolving autoclave.Description:


[0001] In the traditional preparation of rice at home, water is put in a recipient and heated till the boiling point is reached. At that moment the rice is incorporated, maintaining the water with the rice in boiling state for a time ranging from twenty-five to thirty minutes. Once elapsed the cooking time the rice is strained and cooked rice is obtained.

[0002] The cooking gelatinizes the rice starch and increases the transfer of soluble compounds towards its interior; so that if the rice is cooked in a liquid different from water, such as sauces or broths, it takes the flavour of that means, giving rise to tasteful cooked dishes.

[0003] Different processes have been developed trying to obtain rice cooked in an industrial way, maintaining it in this state for a certain time later on, until it is used by the user, but so far a really satisfactory solution has not been found for the preparation of rice cooked under vacuum with meat, shellfish and/or fish sauces, as it would be necessary in the case of the preparation of a traditional dish such as paella.

[0004] Indeed, under the up to now well-known solutions, we find different options which are subsequently summarized:

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A. - THERMALLY TREATED RICE

[0005] Today the day, an industrial process is known in which the following ingredients take part: on the one hand rice, thermally treated and dehydrated previous to the process (i.e. vaporized rice) and on the other hand water. According to this process, the water is heated till a certain temperature and the previously treated and dehydrated rice is introduced for its rehydration and afterwards it is packed and thermally treated. This product has the main inconvenience that its texture is corklike and the rice grain does not absorb any flavour and, therefore, it is not advisable to use it in the preparation of culinary dishes which are more than simply rice cooked in water.

B. - RICE BLENDED WITH ACIDS AND OTHER AGENTS

[0006] Through the European Patent EP 0322996, a process is known in which the rice is maintained at a pH from five to seven, by mixing the rice with acids and neutralizing alkaline agents.

[0007] During the blending and packaging process, the product is maintained at about 82 DEG C

(aseptically packed).

[0008] The main inconveniences of this process are the fact of the incorporation itself of neutralizing acids and alkaline agents to achieve the conservation, and on the other hand the short life of the product obtained this way, since the maximum expiration time does not surpass 9 months from the preparation date on.

C. - HYDRATED RICE

[0009] Industrial processes are already known that start from previous rice hydration; so that this hydrating is carried out by putting the rice to soak or by moistening it. When the hydration is carried out by soaking, the cooking is usually done in cameras with pressureless vapour or in some cases by indirect heating. When the hydration is carried out by moistening, the cooking is done in continuous or discontinuous autoclaves with vapour under pressure. With this previous hydration process, the industrial preparation of cooked rice is known, to be frozen or canned afterwards.

[0010] In the European Patent EP 0736260 a previous rice hydrating process is described, in which peeled rice is started from, which is put to soak in water at a temperature between twenty and seventy degrees centigrade, being later on cooked by means of vapour under pressure and finally the rice is dried and dehydrated for its sale.

[0011] Also, in the "CDTI Notebooks of Nourishment Technology - April 1993", industrial processes to prepare cooked rice are described, always with a previous rice hydrating phase, either by soaking the rice in water or by moistening.

[0012] These processes which require a previous rice hydration have the inconvenience that the rice grain is filled with water during the soaking or moistening phase, which hinders greatly the later entrance of sauces or broths, which are to give the rice a characteristic flavour, so that the rice cooked by means of industrial processes with previous rice hydrating are not appreciated in culinary uses, since they do not allow the dish to get the appropriate cooking flavour.

[0013] Saving this inconvenience, a solution is already known which allows the production of cooked rice in an industrial way and without previous hydration of the rice, as we will see subsequently.

D. - RICE NOT HYDRATED PREVIOUSLY

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[0014] In the US patent number 4.986.995 a procedure for the production of cooked rice is described, starting from raw rice, without the need of its previous hydration.

[0015] According to this procedure, rice cooked in retort according to a process in which raw rice is introduced in a recipient with water and after having sealed this recipient the rice is cooked and at the same time sterilized raw inside the mentioned recipient.

[0016] This way, inside the mentioned recipient the gelatinization of the rice starch and the transfer of the soluble compounds to the interior takes place, so that if this cooking is done with sauces instead of with water, the flavour of these sauces penetrates inside the rice, improving this way its taste, as compared to the processes with previous hydration.

[0017] In the mentioned US Patent 4.986.995, it is indicated that in this process an inconvenience arises, residing in an unwished rice colouring. This colouring takes place as a result of a reaction of the oxygen with certain elements which are present in the rice or by decomposition of such elements. This phenomenon takes place when the rice is cooked at high temperatures (a hundred and twenty degrees centigrade and more), these temperatures are the ones employed in the industrial processes.

[0018] According to the aforementioned US Patent 4.986.995, a procedure is proposed by means of which cooked rice can be produced in retort without acquiring an unwished colour and without it losing any of the characteristics of its flavour. Therefore, the amount of oxygen inside the recipient that has to contain the rice is adjusted, using inert gas which when introduced in the recipient displaces the oxygen in the necessary amount so as to avoid that resulting unwished colouring. According to this procedure the amount of oxygen inside the recipient has to be from 4 to 12 ml per 100 gram of rice.

[0019] The mentioned procedure has in turn two main inconveniences, one of them the incorporation itself of inert gas inside the recipient with the rice to be cooked and on the other hand the fact that the recipient is not subjected to vacuum, since what is done is insuflating inert gas into the recipient to displace a certain amount of oxygen.

[0020] On the other hand, this procedure is valid for its use in the industrial preparation of rice cooked in water or even rice cooked in vegetable sauces and in similar products, but it is not valid for its use for rice cooked in meat, fish or shellfish sauces and, consequently such procedure would not be applicable for the preparation of rice for paella.

[0021] Indeed, according to the procedure described in US Patent 4.986.995, the conditions reached during the cooking are of about a hundred and twenty degrees centigrade for twenty minutes, which allows a Fo of between 5 and 6 to be reached. A Fo between 5 and 6 is acceptable for vegetables, but not for meat, fish, etc... What is more, even a Fo between 5 to 6 would not be admitted for tropical and similar countries.

[0022] With the procedure described in US Patent 4.986.995 it is not possible to reach a Fo value higher than 5 or 6, since when increasing the temperature and/or the cooking time, the rice does not resist it so and the final result is unacceptable rice.

[0023] According to the present invention, a process for the preparation of rice cooked in an industrial way is proposed, which discloses the following characteristics:

A previous hydration of the rice is not necessary.

There is no need to incorporate inert gas inside the recipient in which the rice is introduced for its cooking, so as to avoid its unwanted colouring.

A Fo between 8 and 16 is reached, which allows to lengthen the rice conservation time considerably once it is prepared and above all, it allows the preparation of rice cooked in meat, fish and/or shellfish sauces, even with the incorporation, next to the rice, of pieces of meat, fish, shellfish and vegetables, with a perfectly sterilized final product, as it has reached a Fo between 8 and 16.

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[0024] In accordance with the process object of the present invention, the rice is cleaned initially, eliminating its impurities by means of decanting the same through a current of cold water which cleans the rice without moisturizing it.

[0025] In a following phase the rice is scalded in water between seventy and seventy-five degrees centigrade (70 DEG - 75 DEG C).

[0026] After the scalding it is cooled by means of cold water and subsequently the rice is drained by means of microfiltering air for its stabilization and drying, being it fried later on; during this procedure the rice is pulverized with oil at high temperature, as for example two hundred and seventy-five degrees centigrade (275 DEG C), so that an external frying of the rice grains takes place, allowing to give these grains some appropriate conditions of resistance, looseness and swelling. The resistance acquired this way allows the rice to tolerate the necessary times and cooking temperatures to reach Fo values between eight and sixteen (8 and 16)

[0027] Once carried out the frying of the rice, a maceration phase follows, incorporating the sauces and solids in an aseptic atmosphere and leaving the whole to macerate, for the subsequent product packaging under vacuum and to go to a final sterilization phase in revolving autoclave.

[0028] This process brings about a series of advantages which are summarized in the following way:

With the scalding it is not necessary to use neutral gases, reaching the preparation of the grain to potentiate the final absorption of the flavours.

With the stabilizing with the help of microfiltered air the risk of contamination is eliminated, reaching a normalized working process that fulfils the most demanding hygienic-sanitary norms, so that the prepared culinary dishes are acceptable in any market, adding commercial value to the process.

With the frying at 275 DEG C the rice acquires a grain resistance for its cooking under vacuum and sterilization, reaching rice with a very nice texture and a longer conservation time, without any kind of damage to the grain for the absorption of the flavour humidity.

With the maceration it is possible to determine the flavours and the humidity that are wanted in each case so as to satisfy the consumers'likes.

With the cooking under vacuum and the quick cooling, a sterilization above 8 Fo is reached, allowing to lengthen the duration of the product between one and three years, without using additives, neither preservatives nor neutral gases.

With the sterilization in revolving autoclave and the cooling with the help of heat exchanger, temperatures can be used of up to a hundred and thirty-five degrees centigrade (135 DEG C), according to the recipients used for the rice packaging.

[0029] Figure 1 represents a block diagram of the sequence of the process object of the invention.

[0030] The invention refers to a process for the preparation of rice cooked in an industrial way, being able to obtain the rice with any type of flavour that is wanted and with the possibility of its conservation for a long time, up to between one and three years.

[0031] The process consists in an operative sequence that begins with a rice decanting phase (1) by means of a shower with cold water, being carried out this operation on a belt conveyor, with filter to recycle the water.

[0032] Once clean, the rice undergoes a scalding phase (2) which is carried out with water at a temperature between seventy and seventy-five degrees centigrade. With this operation it is avoided that the rice acquires an unwanted colouring, without the need to incorporate inert gases; as long as the mentioned scalding operation does not produce a previous rice hydration either.

[0033] Next a cooling phase (3) is carried out, which is done by means of a shower with refrigerated water with a cooling equipment.

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[0034] Then a draining phase (4) is carried out with the help of absolute filters, reaching microfiltered air which determines the stabilization and the drying of the rice, without any risk of contamination.

[0035] Subsequently a frying phase (5) is carried out, in which the rice is pulverized with oil at high temperature, of about two hundred and seventy-five degrees centigrade with which the frying of the external part of the rice grains is achieved, thanks to which these acquire a resistance which allows them to tolerate the necessary cooking time and temperatures to obtain Fo values between 8 (eight) and

16 (sixteen).

[0036] Next a dosage phase (6) is carried out, in which the rice is mixed with the sauces and solid ingredients, allowing the group to macerate.

[0037] Then a vacuum packaging phase (7) is carried out, allowing it again to macerate for a time between thirty and sixty minutes.

[0038] Lastly a cooking and sterilizing (8) phase is carried out in revolving autoclave, carrying out a sterilization higher than 8 Fo, with which a duration of the product is reached between one and three years, without the need to add preservatives nor to use cold atmosphere for the conservation.

[0039] The cooling is carried out in the revolving autoclave, incorporating a heat exchanger with which it is possible to cool it in a minimum time between five and fifteen minutes according to the kind of containers used.

[0040] Depending on the type of containers used, the treatment (8) in the autoclave is carried out with some variations of the temperature and of the Fo in the course of the time the operation lasts. Next some examples are indicated with the results obtained in both tests carried out with two different types of containers:


>;tb;Title: With glass jars having a metallic cover

>;tb;Beginning>;SEP;15,5 DEG C>;SEP;Fo = -----

>;tb;05 minutes>;SEP;41,3 DEG C>;SEP;Fo = -----


>;tb;15 minutes>;SEP;95,9 DEG C>;SEP;Fo = 0,004










>;tb;65 minutes>;SEP;84 DEG C>;SEP;Fo = 13,46





>;tb;>;/TABLE;


>;tb;Title: With PP/EVOX/PP dish provided with aluminium cover

>;tb;Beginning>;SEP;17,5 DEG C>;SEP;Fo = -----








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>;tb;>;/TABLE;

[0041] From these results, it can be seen that the sterilization degree begins from a temperature of about a hundred degrees centigrade (100 DEG C). On the other hand, at a certain moment the heating ceases and it begins to cool off but nevertheless the sterilization degree of the product continues to increase due to the internal temperature, until a sterilization point is reached,where it remains.

[0042] Here beyond some practical examples of the preparation of different quantities of rice are given, according to the process of the invention:

EXAMPLE 1


>;tb;

>;tb;Head Col 1: Decanting

>;tb;>;SEP;Weight of rice: 225 gr

>;tb;

>;tb;Head Col 2: Scalding


>;tb;>;SEP;External humidity: 100 %

>;tb;>;SEP;Internal humidity: 1 %

>;tb;>;SEP;Temperature: 70 DEG to 75 DEG C

>;tb;>;SEP;Time: 1 to 7 minutes

>;tb;

>;tb;Head Col 3: Cooling






>;tb;

>;tb;Head Col 4: Draining and drying






>;tb;

>;tb;Head Col 5: Frying


>;tb;>;SEP;Weight of oil: 18 gr

>;tb;>;SEP;Temperature: 275 DEG C

>;tb;>;SEP;Time: 1/2 to 2 minutes

>;tb;

>;tb;Head Col 6: Dosing



>;tb;>;SEP;Pilaff sauce: 50 gr

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>;tb;>;SEP;Curry sauce: 50 gr

>;tb;>;SEP;Negr sauce: 50 gr

>;tb;

>;tb;Head Col 7: Mixing and maceration


>;tb;

>;tb;Head Col 8: Vacuum packaging and second maceration


>;tb;>;/TABLE;

Cooking and sterilization in rotary autoclave

[0044] According to the kind or recipients used (see previously exposed results of the tests).

EXAMPLE 2


>;tb;



>;tb;







>;tb;







>;tb;







>;tb;






>;tb;




>;tb;>;SEP;Chicken sauce: 40 gr

>;tb;>;SEP;Three delights sauce: 40 gr

>;tb;>;SEP;Solid ingredients = variable quantities

>;tb;


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>;tb;



>;tb;>;/TABLE;



EXAMPLE 3


>;tb;



>;tb;




>;tb;>;SEP;Internal humidity: 30 - 35 %



>;tb;







>;tb;







>;tb;






>;tb;


>;tb;>;SEP;Weight of rice: 270 - 290 gr


>;tb;



>;tb;



>;tb;>;/TABLE;

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[0049] It is verified that in the examples 1 and 2 the external and internal humidity of the grain is 0 % in the DRAINING and DRYING, since in these cases with a SCALDING and COOLING it is only sought to prepare the rice grain so that later on it reaches the wanted texture and absorption when incorporating the corresponding sauces and solids.

[0050] In example 3, in which neither sauces nor solids are incorporated, if an external and internal humidity is determined in the grain, to get an incorporation of the rice into the stews which in one or two minutes absorb the flavours and the adequate degree of humidity and texture. In the same way it is nevertheless possible to elaborate other types of rice that acquire flavours, humidity and textures in other periods of time, for example between five and ten minutes, to be able to incorporate other types of ingredients, as in the case of paella.

[0051] Thanks to the FRYING and MACERATION the processed rice can resist very high temperatures and a processing time of eighty-five minutes or more, being able to achieve a very high sterilization degree (higher than 8 Fo =, with which a product of great quality is achieved which is excellent industrially and commercially, of which a great number of varieties can be obtained in combination with a multiplicity of different products.Data supplied from the esp@cenet database -

Worldwide Claims:


1. Process for the industrial preparation of rice cooked under vacuum, characterized because the rice under treatment is cleaned initially, eliminating its dirt by decanting by means of a shower with cold water, next carrying out a scalding of the rice with hot water, after which a cooling by means of a shower with refrigerated water is carried out, with later draining and drying by means of microfiltered air followed later on by a frying, by means of pulverization of the rice with oil at high temperature, mixing the rice afterwards with the sauces and solids that correspond, for the packaging of the whole under vacuum and, after a maceration phase, carrying out the cooking and the sterilization in revolving autoclave.

2. Process for the industrial preparation of rice cooked under vacuum, according to the first claim, characterized because the rice scalding is carried out with hot water between seventy and seventy-five degrees centigrade, obtaining the preparation of the rice grains to improve the final absorption of the flavours.

3. Process for the industrial preparation of rice cooked under vacuum, according to the first claim, characterized because the rice frying is carried out with oil at a temperature of about two hundred and seventy-five degrees centigrade, conferring the rice grains a resistance that allows them to tolerate long times and high cooking temperatures without deterioration.

4. Process for the industrial preparation of rice cooked under vacuum, according to the first claim, characterized because the cooking treatment and the sterilization are carried out with a progressive heating up to until temperatures that can reach a hundred and thirty-five degrees centigrade (135 DEG

C), with subsequent cooling with the help of heat exchange, getting a sterilization above 8 Fo.Data supplied from the esp@cenet database - Worldwide

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59.

FR2534456 - 4/20/1984

METHOD AND INSTALLATION FOR PRECOOKING CEREALS AND, MORE

PARTICULARLY, RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=FR2534456

Inventor(s): MOUREAU JACQUES (--); FEUILLET PIERRE (--); LAIGNELET BERNARD (--

); ALARY REMI (--)

Applicant(s): FRANCE RIZ (FR)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/10H2

Application Number: FR19820017385 (19821018)


Family: FR2534456

Abstract:

Abstract of FR2534456

Precooking of cereals. Installation for precooking cereals such as rice, of the type comprising means 8 for soaking the cereals, draining means 22, cooking means and drying means, characterised in that the cooking means comprise at least one fluidised-bed cooking apparatus 23.Claims:

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Claims of FR2534456

R E V E N D I C A T I O N S

1 - Procede de précuisson de céréales et plus particulièrement de riz naturel, riz étuvé, rizdécortique ou non décortiqué et du type dans lequel on fait tremper lesceréales puis on les égoutte, puis on les cuit, puis on les fait au moins en partie sécher, caractérisé en ce qu'il consiste à faire cuire lesdites céréales à l'air chaud.

2 - procédé de précuisson de céréales, selon la revendication1 , caracterise en ce qu'il consiste à faire tremper les cereales demaniée que l'hmidité de celles-ci soit supérieure à 33 %.

3 - Procédé de précuisson de céréales, selon la revendication 1, caractérisé en ce qu'il consiste faire cuire les céréales à l'air chaud à unetempérature'supérieure à1300C et durant un laps de tempscompris entre deux et quinzemin~utes.

40 - Installation pour la précuisson descereales, selon le procédé défini dans la revendication 1 et/ou l'une quelconque des revendications 2 et 3 et du type comprenant des moyens de trempage (8) des céréales, des moyens d'égouttage (22), des moyens de cuisson et des moyens, de séchage, caracterisée en ce que les moyens de cuisson comprennent au moins un appareil (23) de cuisson à litfluidisé.

5 - Installation de précuisson de céréales, selon la revendication 4, caractérisée en ce qu'elle comprend deux appareils à litfluidisé (23 et 35), le premier étant à une température supérieure à1300C, tandis que le second est à une température inférieure à1300C.

60 - Installation deprecuisson de céréales, selon les revendications 4 et 5, caractérisée en ce que le second appareil à litfluidisé (35) est agencé de manière à assurer le séchage, la durée de celui-ci étant inférieurea quarante cinq minutes.

7 - Installation deprècuisson de céréales, selon'la revendication 4, caractérisé en ce qu'elle comprend en amont des moyens de trempage (8), un distributeur à alvéoles.

80 -Installation (,eprecuisson dec-éréales, selon la revendication 4, caractérisée en ce que les moyens de trempage (8) sont constitues par deux vis d'Archimede(8,20) inclinées dans lesquelles circule, a contre courant, l'eau de trempage, le conduit (9) de chaque vis étant pourvu d'une double enveloppe

(13) dans laquelle circule de la vapeur.

9 - Installation deprécuisson de céréales, selon la revendication 4,caracterisee en ce qu en aval du second appareil (35) à litfluidisé, elle comporte un appareil de refroidissement (36).

10 - Installation de précuisson de céréales, selon la revendication 9,caracterisee en ce que l'appareil de refroidissement (36) est constitué d'une vis d'Archimède avec un conduit ajoure dans lequel circulent,entratnées par la vis (40), les céréales à refroidir depuis uneextremite (37) pourvue d' une entrée vers l'autre extrémité pourvue d'une sortie (38), et d'un ventilateur (45) soufflant de l'air froi-d à travers les ajours du conduit.

11 - Installation-de précuisson deceréales, selon les revendications 4 et 9, caractérisée en ce qu'elle comporte en aval de l'appareil de refroidissement un appareil émotteur (50).

12 - Installation de précuisson de céréales, selon la revendication 11, caractérisée en ce que l'appareil

émotteur (50) comprend une serie de plaques vibrantes (53, 54, 55) perforées inclinées et superposées, les perforations des plaques ayant des sections allant en diminuant depuis la plaque supérieure vers la plaque inférieure.

134 - Installation de précuisson deceréales, selon les revendications 4 et11, caractérisée en ce qu'elle comprend en aval de l'appareil émotteur, un appareil trieur (60).

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14" -- Installation- de précuisson de céreales, selon la revendication 13, caractérisée en ce que l'appareil trieur (60) comprend un cylindre rotatif horizontal dont la surface interne est pourvue d'alvéoles dont la dimension correspond à celle des grains à éliminer, une entrée (61) des grains à trier

à une extrémité du cylindre, une sortie (69) à l'autre extrémité, des moyens (63) pour étaler les grains en une nappe unciforme, une auge (64)situe axialement dans le cylindre et comprenant une vis transporteuse (65) pour acheminer les grains à éliminer tombés des alveoles dans l'auge (64) vers une goulotte (66) d'évacuation.

150 - Installation depré,cuisson decereales, selon la revendication 14, caractérisée en ce que l'auge

(64) comporte des moyens pour modifier sa position angulaire.

16 - Installation deprécuisson de céréales, selon les revendications 4 et 13,cractérisée en ce qu'elle comprend un appareil de calibrage (70) dispose en aval de l'appareil de triage.

17 - Installation deprécuisson de ceréales, selon la revendication 16, caractérisée en ce que l'appareil de calibrage (70) comprend un cylindre horizontal rotatif dont la paroi est ajourée, les ajours correspondant aux grains à eliminer, ledit cylindre (75) étant reliéa une extrémité à une goulotte (71) de chargement, tandis que l'autreextremite s' ouvre dans une goulotte (72) d'évacuation, et unebrosse

(77) étant prévue pour nettoyer les ajours.

180 - Installation de précuisson de céreales, selon la revendication 17, caractérisée en ce que l'appareil de calibrage (70) comporte une vis de transport (86) destinée 'à conduire les grainséliminés vers une goulotte d'évacuation (83).Data supplied from the esp@cenet database - Worldwide

288/2197

60.

FR2539591 - 7/27/1984

METHOD FOR THE CONTINUOUS DEEP-FREEZING (FAST-FREEZING) OF

FOOD PRODUCTS DIVIDED INTO GRAINS OR PARTICLES OF SMALL

DIMENSIONS, SUCH AS RICE, AND INSTALLATION FOR IMPLEMENTING

THE SAID METHOD


Applicant(s): MISTROT GUY (FR)


IP Class: A23L1/182; A23L3/36

E Class: A23L1/182; A23B9/10; A23L3/36D



Family: FR2539591

Abstract:


The present invention relates to a method for deep-freezing (fast-freezing) food products divided into grains or particles of small dimensions and to the installation for implementing the said method. The method according to the invention consists in hydrating a food product in the cold or hot state, in cooling it if it has undergone hot hydration and then in draining it, and is characterised essentially in that the said food product is subjected to a drying simultaneously with spreading and it immediately afterwards undergoes deep-freezing (fast-freezing); a division, fluidisation and agitation are performed at the deep-freezing (fast-freezing) temperature. Application: food industry.Description:

Description of FR2539591

Procédé pour la surgélation en continu de produits alimentaires divisés en grains ou particules de petites dimensions tels que le riz et installation pour la mise en oeuvre du dit procédé.

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La préparation de produits alimentaires tels que le riz necessite des temps de cuisson très longs et devant être minutés.

Ces différents facteurs rebutent souvent le consommateur -d'effectuer des plats à base de tels produits.

Afin de réduire les temps et les soins nécessaires à la préparation d'un tel produit, on surgèle ces produits et on obtient donc par simple réchauffement rapide un produit consommable immédiatement.

Mais la surgélation de produits alimentaires divisés de petite taille pose des problèmes principalement au niveau de leur séparation afin que les grains ou particules les constituant gardent leur individualité.

Le brevet françaisNO 2.324.243 de Monsieur GAYTE décrit un mode de préparation de riz surgelé.

Ce procédé utilise un riz pré-cuit ayant déjà donc fait l'objet d'un traitement.

Le riz pré-cuit est ensuite hydraté par cuisson pendant 10 mn et de manière très précise puisque l'absorption d'eau ne doit pas dépasser une limite bien définie.

Le riz est ensuite refroidi et égoutté plus placé dans une chambre de surgélation pendant 13 à 18 h.

Ce procédé n'est donc pas continu et nécessite pour la préparation du produit des temps très longs, ce qui grève la rentabilité d'un tel procédé qui de ce fait n'est pas valable au niveau industriel.

De plus la structure du riz est altérée par une décongélation effectuée pour la séparation des grains puis par une deuxième surgélation et de plus le produit est souvent exposé à la pollution au cours de ces différents transferts d'un lieu de traitement à un autre.

Afin d'éviter ces temps de préparation trop long qui diminuent la rentabilité de ce procédé,le brevet américainNO 4.042.717 de Monsieur

GAYTE donne un exemple de procédé de préparation en continu d'un tel produit alimentaire.

Selon ce procédé,après cuisson à l'eau chaude,égouttage et surgélation le riz traverse une zone dans laquelle il se réchauffe par diffusion de la chaleur contenue dans le noyau des grains vers la périphérie des dits grains puis il est versé dans une trémie.

Le réchauffement des grains est susceptible d'entraîner une décongélation partielle et une séparation des grains en rendant plus mous ceux-ci.

Mais lors du déversement dans la trémie le réchauffement se poursuit et donc les grains ont tendance à se recoller et à former une masse pâteuse.

La séparation par broyage qui est effectuée ultérieurement a donc tendance à laminer les grains de riz devenus tropmous.et/ou à les casser.

Ce procédé de préparation ne résoud donc en rien la séparation des grains de riz qui sont toujours exposés à la pollution dans la zone de réchauffement et qui sont broyés au cours de leur séparation sans pour autant retrouver obligatoirement leur individualité initiale.

Afin d'obvier à ces inconvénients,la présente invention propose un pro -cédé de préparation en continu et l'installation pour la mise en oeuvre du dit procédé, qui permet à un produit alimentaire d'être divisé sans que les grains ne soient cassés ou écrasés et sans qu'ils soient exposés à l'altération de leurs structures due à une décongélation suivied'une seconde surgélation et évitant les risques de pollution par un passage à l'air libre et des manipulations trop fréquentes.

A cet effet,le procédé selon l'invention pour la surgélation en continu de produits alimentaires divisés en grains ou particules de petites dimensions tels que le riz,consiste à hydrater indifféremment à chaud ou à froid leproduit,à le refroidir s'il a subit une hydratation à chaud,puis à l'égoutter et se caractérise essentiellement en ce que le produit alimentaire est soumis à un séchage simultanément à un épandage

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et qu'il subit immédiatement après une surgélation,une division,une fluidisation et une agitation effectuées à la températion de surgélation.

L'installation pour la mise en oeuvre du ce procédé comporte une sta

tion d'hydratation,une cuve de refroidissement, une station d'égoutta

ge,une tunnel de surgélation,un moyen de division du produit alimen

taire,une colonne de fluidisation suivie d'un bac de fluidisation de

grande longueur et des moyens de transport du produit entre les diffé

rentes stations de traitement, la dite installation se caractérise

essentiellement en ce que le moyen de transport du produit alimentaire

dans le tunnel de surgélation est en une matière permettant l'adhéren

ce du dit produit contre sa surface à basse température et qu'il com

porte à son extrémité intérieure au dit tunnel au moins un moyen de

séparation du produit alimentaire de sa surface afin que la séparation

s'effectue en un lieu précis.

Suivant une autre caractéristique au moins un moyen de division est

monté sous le dispositif de séparation du produit alimentaire de la

surface du moyen de transport dans le tunnel de surgélation.

Suivant encore une autre caractéristique de l'invention le moyen de

division est constitué d'un rouleau cylindrique rotatif autour de son

axe de révolution comportant sur sa surface des aiguilles alignées

suivant au moins une ligne génératrice du dit rouleau.

D'autres avantages et caractéristiques apparaîtront à la lecture de

la description et en se référant aux dessins annexés donnés à titre

d'exemples non limitatifs d'un mode de réalisation de l'invention en

lesquels - La figure 1 est une vue schématique de l'installation selonl'inven-

tion, - La figure 2 est une vue d'une forme préférentielle de réalisation du

moyen de division,

La présente invention concerne un procédé de surgélation en continu de

produits alimentaires divisés de petites dimensions et l'installation

pour la mise en oeuvre du dit procédé.

Le procédé selon l'invention consiste à hydrater indifféremment à

chaud ou à froid un produit alimentaire, à le refroidir s'il a subit

une hydratation à chaud,puis à l'égoutter et se caractérise essentiel lement en ce que le dit produit alimentaire est soumis à un séchage simultanément à un épandage et qu'il subit immédiatement après une surgélation,une division,une fluidisation et une agitation effectuées à la température de surgélation.

Le produit alimentaire lors du traitement traverse toutes les phases de la préparation sans qu'il n'y ait d'arrêt et à une vitesse réglablependant du type de produit alimentaire.

L'hydratation du ditproduit-alimentaire est effectuée à chaud ou à froid par passage à vitesse réglable selon le type d'hydratation dans de l'eau.

Le mode d'hydratation dépend du type de produit alimentaire à traiter.

Pour des produits nécessitant des temps d'absorption d'eau l-ongs,il va de soi que l'hydratation s'effectue de préférence à chaud.

De tels produits selon le procédé sont ensuite refroidis par passage dans de l'eau froide.

Après le refroidissement ou bien l'hydratation effectuée à froid, les produits sont égouttés et progressent simultanément dans une chambre de séchage à l'entrée de laquelle et dans laquelle ils sont soumis à un épandage.

Le séchage s'effectue de préférence à environ 200 C et à un taux d'humidité sensiblement égal à 70.

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Après être passés en continu dans la chambre de séchage, les produits alimentaires traversent un tunnel de surgélation.

La température de surgélation est comprise entre-20c C et-300 C et est préférentiellement de-30 C.

Dans l'enceinte du tunnel de surgélation et immédiatement après leur surgélation, les dits produits sont divisés sans cassure et sont fluidisés dans une colonne d'air aboutissant en un lit fluidisé de grande longueur.

La température à laquelle s'effectue la division est la même que la température de surgélation.

La température de l'air de fluidisation est également identique à la dite température de surgélation.

Ces températures sont équivalentes afin que les produits ne subissent pas de décongélation ni de réchauffement susceptible d'altérer leurs structures entre les opérations de surgélation, de division et defluidisation. La fluidisation permet la congélation à coeur.

La durée de maintien en lit fluidisé est réglée par la hauteur d'un trop plein réglable.

ïJne agitation du produit simultanée à la fluidisation permet la conservation de l'individualité des grains ou particules constituant les dits produits et évite leur entassement susceptible de provoquer leur réchauffement et donc un nouveau collage.

Il va de soi que les vitesses de passage des produits alimentaires dans les différentes stations de traitement peuvent être réglées et adaptées aux différents types de produits susceptibles de subir une surgélation suivant le procédé selon la présente invention.

L'installation pour la mise en oeuvre du dit procédé comporte une station d'hydratation 1 du produit alimentaire,un poste d'égouttage 2, un tunnel de surgélation 3, un moyen de division 4 du dit produit, une colonne d'air de fluidisation 5 suivie d'un lit de fluidisation de grande longueur et des moyens de transport du produit entre les différentes stations de traitement.

La dite installation se caractérise essentiellement en ce que le moyen de transport 6 du produit alimentaire dans le tunnel de -surgélation 3 est en une matière permettant l'adhérence du dit produit contre sa surface à basse température et qu'il comporte à son extrémité intérieure au dit tunnel au moins un moyen de séparation 7 du produit alimentaire de sa surface afin que la séparation s'effectue en un lieu précis.

La station d'hydratation 1 est -constituée par au moins une cuve 8 de grande longueur contenant de l'eau et est dotée d'un système de chauffage de l'eau de tout type connu par exemple par résistances

électriques.

Jne cuve 9 située après la ou les cuves 8 d'hydratation contient de l'eau froide pour le refroidissement du produit -alimentaire hydraté à chaud ou bien pour l'hydratation à froid du dit produit.

Ces cuves 8 et 9 sont de longueur suffisante pour que le produit alimentaire puisse être hydraté de manière satisfaisante.

Les vitesses de passage dans ces cuves sont donc réglées en fonction du produit à traiter et de la longueur des dites cuves.

Le produit alimentaire est transporté à partir d'un poste d'alimentation à travers les différentes cuves de la station d'hydratation par un moyen de transport constitué selon une forme préférentielle de réalisation d'un carrousel 30 doté de portions descendantes et ascendantes au niveau des cuves 8 et 9.

Des paniers 27 sont montés sur le dit carrousel et reçoivent le produit alimentaire.

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Il va de soi que les dits paniers sont formés de telle manière à laisser passer l'eau pour l'hydratation et/ou le refroidissement du produit qu'ils contiennent.

Le dit produit est ensuite déposé par les paniers 27 sur un poste d'égouttage 2 situé à l'extrémité d'un tapis sans fin 10 perforé entraîné par tous moyens connus de l'homme de l'art et qui amène le dit produit vers le tunnel de surgélation 3.

Le produit alimentaire est placé sur le moyen de transport 6 du tunnel de surgélation 3 en tombant du tapis sans fin 10 et est épandu sur le dit moyen de transport 6 sur une épaisseur de 5mm environ par des moyens qui seront décrits plus avant.

Le dit produit est donc au cours de son trajet surgelé et le moyen de transport 6 est porté simultanément

à une température assez basse et est constitué en une matière permettant l'adhérence du produit alimentaire contre sa surface.

A l'extrémité du moyen de transport 6 est situé un organe 7 permettant la séparation du produit alimentaire de la surface du dit moyen de transport.

Ainsi la séparation s'effectue en un lieu précis sur le moyen de transport.

Suivant une forme préférentielle de réalisation, le moyen de transport 6 est constitué par un tapis 11 sans fin en un matériau inoxydable souple tel qu'un alliage de nickel et de cuivre du type "Monel".

La constitution de ce tapis permet donc l'adhérence du produit alimen taire sur sa surface.

Le tapis 11 est tendu de toute manière connue par exemple entre deux rouleaux 12 et 13 d'entraînement.

Sous le rouleau- 13 est placé l'organe de séparation 7.

Celui-ci est de préférence constitué par un racleur 14 s'appuyant sur la surface du tapis 11 de manière à décoller le produit alimentaire du dit tapis et de position réglable.

Ce décollement s'effectue de préférence au retour du tapis 11 en arrière du rouleau 13 intérieur au tunnel de surgélation.

D'autre part le dit tunnel de surgélation 3 est doté d'un moyen de division.4 du produit alimentaire.

Ce moyen est monté sous le dispositif de séparation du produit alimentaire de la surface du tapis inoxydable 11.

Le produit alimentaire après son décollement du dit tapis 11 tombe sous forme de blocs et/ou de particules ou grains détachés dans le moyen de division 4.

Le dit moyen de division est doté d'éléments permettant la division du produit alimentaire et d'éléments permettant la -projection du dit produit dans la colonne de fluidisation 5 constitués selon une forme préférentielle de réalisation par des aiguilles 16 radiales alignées suivant au moins une génératrice d'un rouleau 15 cylindrique rotatif autour de son axe de révolution.

De préférence les aiguilles 16 sont disposées sur quatre génératrices régulièrement espacées.

Les dites aiguilles sont de préférence décalées d'une ligne à une autre d'environ 5 mm.

Le mouvement de rotation du rouleau 15 est obtenu par tous moyens connus.

Le dit rouleau est monté par exemple entre les deux parois du tunnel de surgélation dans des palliers de guidage.

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L'axe de révolution du dit rouleau 15 est parallèle à l'axe de rotation des rouleaux 12 et

13d'entrainement du tapis inoxydable 11.

Les blocs et/ou particules du produit alimentaire tombent sur le rouleau 15, sont détachés-en grains individuels sans cassure de ceux-ci et sont projetés par la vitesse de rotation du dit rouleau vers le haut et du côté opposé de l'endroit où se produit la séparation du produit alimentaire de la surface du tapis oxydable 11 de manière à ce que les grains ou particules soient bien pris dans la colonne de fluidisation

5.

A cet effet, une paroi 17 isole le rouleau 15 de la dite colonne d'air et dévie celle-ci du côté-où s'effectue la fluidisation.

La colonne de fluidisation présente la forme d'une enceinte close latéralement évasée vers le bas laissant échapperl'air vers le haut.

La dite colonne débouche vers le bas sur un bac de fluidisation 26 de forme allongée comprenant un caisson alimenté par plusieurs ventilateurs 18.

La dite colonne d'air est également doté d'un moyen d'agitation 19 du du produit alimentaire agissant dans l'épaisseur du lit fluidisé à l'endroit de la chute des grains.

Le bac de fluidisation est constitué par une grille 21 perforée sous lequel agissent les ventilateurs 18 qui permettent le maintien en suspension des grains ou particules d'un produit alimentaire et la formation d'un lit fluidisé d'épaisseur variable.

Le -moyen d'agitation 19 des grains placé au dessus de la grille 21 est de préférence constitué par un racleur 22 animé d'un mouvement alternatif horizontal obtenu par tout moyens connus de l'homme de l'art qui agit dans l'épaisseur du lit fluidisé du produit alimentaire et qui évite le tassement des grains ou particules susceptible de provoquer leur collage.

Le dit produit est évacué par un trop plein 23 à la sortie duquel il est ensaché.

Le trop plein 23 est de préférence constitué par une ouverture 24 dotée d'une porte 25 coulissante dont la position en hauteur est réglée selon le temps de maintien de fluidisation désiré.

Le produit alimentaire obtenu est donc-constitué par des grains ou par ticules séparés les uns des autres et surgelés sans que leur structure ait été altérée et sans avoir été cassés au cours de la division.

Le procédé de surgélation selon l'invention est d'autant plus rapide que le produit après avoir été

égoutté et avant d'être surgelé est séché dans une chambre de séchage 23.

Le produit est amené dans cette chambre par le tapis sans fin 10 à une extrémité duquel s'effectue l'égouttage et est soumis à un courant d'air à une température d'environ 200C à un taux d'humidité sensible ment égal à 7000.

Ce séchage permet de diminuer le temps de passage dans le tunnel de surgélation, et d'éliminer les excédents d'eau à la sortie du poste d'égouttage.

L'efficacité du séchage est accrue par un épandage du produit alimentaire dans la chambre de séchage.

Cet épandage est effectué par des moyens constitués par au moins une règle 28 réglable en hauteur disposée sur le parcours du tapis sans fin 10 dans la chambre de séchage afin que la couche du dit produit soit au plus comprise entre 5 et 10 millimètres.

Le procédé de surgélation an continu et l'installation pour la mise en oeuvre du dit procédé selonl'invention-permettent la préparation de produits alimentaires divisés en grains ou particules de petites dimensions en conservant l'individualité de ceux-ci sans que leurs structures soient altérées et sans qu'ils soient cassés ou écrasés et d'une manière très rapide.

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Il va de soi que la présente invention peut recevoir tous aménagements et toutes variantes dans le domaine des équivalents techniques sans pour autant sortir du cadre du présent brevet.Data supplied from the esp@cenet database - Worldwide Claims:


REVENDICATIONS

R1/ Procédé de surgélation en continu de produits alimentaires divisés

de petite taille consistant à hydrater à froid ou à chaud un pro

duit alimentaire, à le refroidir s'il a subit une hydratation à

chaud puis à l'égoutter, caractérisé en ce que le dit produit ali

mentaire est soumis à un séchage simultanément à un épandage et

qu'il subit immédiatement après une surgélation, une division, une fluidisation et une agitation effectuées à la température de sur

gélation.

R2/ Installation pour la mise en oeuvre du procédé selon la revendica

tion 1 comportant une station d'hydratation (1) du produit alimen

taire, un poste d'égouttage (2), un tunnel de surgélation (3), un

moyen de division (4) du dit produit, une colonne d'air de fluidi

sation (5) et des moyens de transport du produit entre et dans les

différentes stations de traitement caractérisée en ce que le moyen

de transport (6) du produit alimentaire dans le tunnel de surgéla

tion (3) est en une matière permettant l'adhérence du dit produit

contre sa surface à basse température et qu'il comporte à son

extrémité intérieure au dit tunnel au moins un moyen de séparation

(7) du produit alimentaire de sa surface afin que la séparation

s'effectue en un lieu précis.

R3/ Installation selon la revendication 2 caractérisée en ce que le

moyen de transport (6) constitué par un tapis sans fin (11) est en

une matière inoxydable souple.


moyen de séparation (7) est un racleur (14) s'appuyant sur la sur

face du tapis (11) en arrière du rouleau d'entraînement (13) et

de position réglable.


moyen de division (4) est monté sous le dispositif de séparation

du produit alimentaire de la surface du tapis (11) inoxydable.

R6/ Installation selon les revendications 2 et 5 caractérisée en ce

que le moyen de division (4) est doté d'éléments permettant la

division du produit alimentaire.

R7/ Installation selon les revendications 2 et 5 caractérisée en ce

que le moyen de division (4) est doté d'éléments permettant la

projection du produit alimentaire dans la colonne de fluidisation.

R8/ Installation selon les revendications 2, 5, 6,et 7 caractérisée en

ce que les éléments permettant la division du produit alimentaire

et les éléments permettant la projection du dit produit sont cons

titués par des aiguilles (16) radiales alignées suivant au moins

une génératrice d'un rouleau (15) cylindrique rotatif autour de

son axe de révolution.

R9/ Installation pour la mise en oeuvre du procédé selon la revendica

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tion 1 caractérisée en ce qu'elle comporte une chambre de séchage

(29) du produit alimentaire après le poste d'égouttage (2) et

qu'elle comporte des moyens d'épandage agissant dans la dite cham bre de séchage.

R10/ Installation selon la revendication 9 caractérisée en ce que les

moyens d'épandage sont constitués par au moins une règle (28) ré

glabre en hauteur disposée sur le parcours du produit alimentaire

dans la chambre de séchage (29).

R11/ Installation selon la revendication 2 caractérisée en ce que la

colonne d'air de fluidisation (5) comporte dans son fond au moins

un organe (19) pour l'agitation du produit alimentaire afin d'évi

ter le tassement du dit produit dans le fond de la colonne.

R12/ Installation selon la revendication 2 caractérisée en ce que la

colonne d'air de fluidisation débouche sur un bac de fluidisation

(26) de grande longueur fonctionnant en trop plein.


trop plein (23) par lequel s'effectue l'évacuation du produit ali

mentaire de la colonne d'air est à ouverture (24) réglable en hau

teur selon le temps de maintien en fluidisation désirée.Data supplied from the esp@cenet database -

Worldwide

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61.

FR2602957 - 2/26/1988

CULINARY PREPARATION OF THE COOKED DISH TYPE, METHOD FOR

PREPARING IT AND COOKING IT


Inventor(s): TORCATIS PHILIPPE (--); DAVENAS PHILIPPE (--)

Applicant(s): NOELLE ANCENIS COOP AGRICOLE (FR)


IP Class: A23L1/31; A23L1/48; A23L1/325

E Class: A23L1/31K; A23L1/325H; A23L1/31H; A23L1/48



Family: FR2602957

Abstract:


Culinary preparation of the cooked dish type, comprising a base piece of the meat or fish type, with which one or the other or both of the following components are arranged: an accompaniment of the vegetable, rice, pasta or mushroom type, and a sauce; it is characterised by its presentation in the form of a solid unit whose core consists of the base piece coated with the sauce or coated with the accompaniment by means of a binder consisting of the sauce. The method for cooking the preparation consists in dispersing the component or components coating the base piece by means of heat with the possible addition of water whose supplementary role is to contribute to the rehydration of the accompaniment and to give the desired quantity of sauce.Description:


La présente invention concerne une préparation culinaire du type plat cuisiné, ainsi que son procédé d'élaboration et de cuisson.

Le plat cuisiné, selon l'Encyclopédie de la

Charcuterie (Edition SOUSSANA 1982) est "une préparation à base de viande ou de poisson, accompagnée d'une sauce ou de légumes, susceptible de constituer le plat principal d'un repas et vendue prêteå etre consommée".

A la vue du consommateur, le plat cuisiné se présente classiquement sous des formes variées, en rapport bien souvent avec l'appellation traditionnelle du plat. On le trouve par exemple dans une seule boite de conserve, cas du cassoulet, renfermant une ou plusieurs parts ; ou dans deux boltes de conserve, l'une contenant la garniture, l'autre contenant la viande, cas du couscous ; on le trouve

également dans des sachets stériles simples ou doubles ou encore en portion de surgele.

Lorsqu'on achete un plat cuisiné, on est en présence d'un produit fini, preta etre consommé apres soit une simple mise en température dans un récipient ad hoc, soit une certaine cuisson.

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La présente invention a pour objet une nouvelle préparation culinaire du type plat cuisiné,c'est-a-dire susceptible de constituer le plat principal d'un repas pour une ou plusieurs personnes, et par rapprochement de la définition du plat cuisiné, vendue pretea etre consommée.

La préparation culinaire selon l'invention comprend les éléments habituels d'un plat cuisiné : viande ou poisson, avec sauce et/ou légumes ; elle se caractérise par sa présentation sous la forme d'une unité solide, dont le coeur est constitué de la piece de base (viande ou poisson), enrobe de la sauce, ou enrobée de l'accompagnement (légumes) au moyen d'un liant constitué par la sauce.

La piece de base est constituée d'un morceau de viande, avec ou sans os, d'un morceau de poisson ou de tous produits de la mer le plus souvent assimilés au poisson, enl'état reconstitués ou non. Cette pièce de base peut être utilisée à l'étant cru ou après avoir subi une pre-elaboration telle que operation de marinage ou saumurage, combinée ou non, ou des opérations telles que pré-cuisson, cuisson, dorage au four ou en friteuse. Cette pièce de base peut encore subir préalablement un pré-enrobage avec par exemple de l'amidon servanta fixer une aromatisation, ou encore avec une poudre aromatique de tomate par exemple, ou encore avec un gélifiant pulvérulent ou visqueux.

La pièce de base conditionne l'importance du plat et en particulier le nombre de parts quel'on peut lui attribuer ; c'est elle qui donne également la forme de-la préparation culinaire, telle qu'elle se présente aux yeux du consommateur.

L'accompagnement est constitué de produits adaptés à la pièce de base, tant au niveau de sa nature que de sa taille.

La gamme de produits utilisés est large et classique. Dans le cas de légumes, ceux-ci seront de préférence, mais non exclusivement, sous une forme deshydratée, en morceaux de petite taille. On utilisera également, selon le cas, un accompagnement constitué de pâtes, ou de champignons, ou encore un mélange de différents produits habituellement utilisés.

La pièce de base est enrobée de sauce et cette sauce est préparée avec un niveau de viscosité permettanta la fois sa fixation sur la pièce de base et la fixation de l'accompagnement.

La pièce de base est enrobée par tout moyen approprié, aspersion par exemple, d'une couche de sauce sur laquelle on va ensuite disperser l'accompagnement ; la sauce jouant le rôle de liant pour solidariser l'accompagnement à la pièce de base. On peut prévoir de disposer, autour de la pièce de base, plusieurs couches successives de sauce et d'accompagnement pour augmenter la quantité d'accompagnement sur une pièce de base déterminée.

Ainsi élaborée, la préparation culinaire selon l'invention se présente sous la forme d'une unité solide, laissant apparaître l'allure d'origine de la pièce de base côtelette, cuisse de poulet etc ...

Cette préparation culinaire s'apparente à première vue à un produit de type pané qui, lui aussi, forme une unité solide. Mais en fait, contrairement à ce type de produit, l'enrobage de la préparation culinaire selon l'invention, va se désolidariser de la pièce de base, lors de la cuisson par le consommateur. On réalise, au moment de la cuisson de la préparation culinaire, une dissociation des différents constituants de cette préparation alors que, dans un produit de type pané, l'enrobage est maintenu sur le produit, de telle sorte que, lors de la coupe du produit, on mange un morceau de ce dernier avec son enrobage.La dissociation des différents constituants de la préparation culinaire, s'effectue au cours de la cuisson ; elle peut être facilitée ou améliorée par un ajout d'eau, lors de cette opération de cuisson, lequel ajout va contribuer à la réhydratation de l'accompagnement et réaliser une dilution de la sauce.

La sauce de la préparation culinaire selon l'invention est donc constituée d'ingrédients dont le rôle primaire est de réaliser, à froid, la fixation de l'accompagnement sur la pièce de base et, à chaud, de se liquéfier en se diluant éventuellement dans l'eau de cuisson pour libérer l'accompagnement de la piece de base, et dont le rôle secondaire est de colorer et de mariner ladite pièce de base éventuellement, pendant le temps de stockage.

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La préparation culinaire selon l'invention peut être conditionnée et présentée sur une barquette enveloppée dans une protection transparente ou non, sur laquelle sera indiquée la dénomination du produit.

L'invention a trait également au procédé d'élaboration de cette préparation culinaire. Ce procédé consiste donc, dans un premier temps, à préparer les différents constituants du plat cuisiné, c'est-à-dire

à preparer la pièce de base, la sauce, l'accompagnement, puis, dans un deuxieme temps, à enrober laditepiece de base avec la sauce tout d'abord, puis, s'il y a lieu, avec l'accompagnement lié à la pièce de base par ladite sauce.

L'invention a trait encore au procédé de cuisson de cette préparation culinaire. Ce procédé consistant à réaliser une dispersion du ou des composants enrobant la piece de base par l'action de la chaleur et,

éventuellement par l'adjonction d'eau dont le rôle complémentaire est de donner la quantité voulue de sauce.

A titre d'exemple la préparation culinaire pour un plat cuisiné dénommé "poulet à l'indienne" serait la suivante. On prend une cuisse de poulet crue ou fritée quel'on enrobe avec une sauce composée de curry, huile, eau, protéines de lait, tomate en poudre, sel, poivre, puis on disperse tout autour un mélange de légumes composé de riz long étuvé coloré au safran, de légumes déshydratés en morceaux comprenant des tomates, poivrons verts, oignons.

Cette préparation est ensuite conditionnée de façon classique ; par exemple disposée sur une barquette pouvant contenir une ou plusieurs pièces, l'ensemble étant enveloppé d'une pellicule plastique transparente. Le plat cuisiné est disposé tel quel dans des vitrines réfrigérantes, à la vue du consommateur. Ce dernier obtient son "poulet à l'indienne" en disposant la ou les pièces dans une casserole par exemple, dans laquelle il ajoutera un ou deux verres d'eau selon le cas. Cette eau, après réduction, donnera la quantité de sauce souhaitée par le consommateur, nappant le poulet, et dans laquelle on retrouve l'accompagnement.Data supplied from the esp@cenet database - Worldwide

Claims:


- REVENDICATIONS

1.- Préparation culinaire du type plat cuisiné comprenant une pièce de base du genre viande ou poisson, avec laquelle sont disposésl'un ou l'autre ou les deux composants suivants : un accompagnement du genre légumes, riz, pâtes ou champignons, et une sauce, caractérisée en ce qu'elle se pressente sous la forme d'une unité solide, dont le coeur est constitué de la pièce de base enrobée de la sauce, ou enrobée de l'accompagnement au moyend'un liant constitué par la sauce.

2.- Préparation culinaire du type plat cuisiné, selon la revendication 1 caractérisée en ce que la sauce est constituée d'ingrédients dont le rôle essentiel est de réaliser, à froid, la fixation de l'accompagnement sur la piece de base et, de se liquéfier à chaud, en se diluant éventuellement dans l'eau de cuisson, pour libérer l'accompagnement de la pièce de base.

3.- Préparation culinaire du type plat cuisiné, selon la revendication 2, caractérisée en ce que la sauce est constituée d'ingrédients dont le rôle secondaire est de mariner et de colorer la pièce de base durant le temps de son stockage.

4.- Préparation culinaire du type plat cuisiné selon l'une des revendications 2 ou 3, caractérisée en ce qu'elle est constituée d'une pièce de base enrobée d'une ou plusieurs couches successives d'accompagnement fixées par une ou plusieurs couches successives de sauce.

5.- Procédé d'élaboration d'une préparation culinaire de plat cuisiné selon l'une des revendications 1 à

4, caractérisé en ce qu'il consiste

- à préparer une pièce de base

- à enrober ladite pièce de base avec la sauce tout d'abord, puis, s'il y a lieu, avec l'accompagnement lié

à la pièce de base par ladite sauce.

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6.- Procédé d'élaboration d'une préparation culinaire, selon la revendication 5, caractérisé en ce que la pièce de base est préparée avant enrobage, au moyen d'une opération de pre-enrobage ou de pré-

élaboration du type salaison, marinage, pré-cuisson, cuisson.

7.- Procédé de cuisson d'une préparation culinaire de plat cuisiné selon l'une des revendications 1 à 4, caractérisé en ce qu'il consiste à réaliser une dispersion du ou des composants enrobant la pièce de base par la chaleur avec adjonction éventuelle d'eau dont le rôle complémentaire est de contribuer à la réhydratation de l'accompagnement et de donner la quantité voulue de sauce.Data supplied from the esp@cenet database - Worldwide

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62.

FR2622404 - 5/5/1989

PULVERULENT COMPOSITION FOR THE PREPARATION OF FLANS


Inventor(s): GODIN DOMINIQUE (--)

Applicant(s): OMNIUM MONEGASQUE COMMERCE GL (MC)


IP Class: A23L1/187

E Class: A23L1/09D; A23L1/187



Family: FR2622404

Abstract:


New pulverulent composition intended for the preparation of flans, especially in industrial pastry, characterised in that it contains, in % by weight: Maltodextrin 18-32 Food lactose 13-30 Gelling agent

2-4 Modified rice starch 1-3 Fine salt 0.5 Caster sugar balance for 100 pDescription:


La présente invention concerne les compositions pulvérulentes destinées à la confection de produits de pâtisserie industrielle, notamment les flans, traditionnels ou modifiés pour en améliorer les qualités gustatives.

Ces compositions sont actuellement nombreuses et rencontrent un accueil favorable de la part des consommateurs.

Toutefois, il est apparu que leurs propriétés gustatives étaient encore susceptibles d'améliorations et/ou de modifications, tendant à satisfaire à la demande toujours croissante de variété et de nouveauté exprimée par le public.

La présente invention vise donc une nouvelle composition dont les qualités d'onctuosité, de souplesse, de légèreté et de texture sont améliorées par rapport aux compositions existantes.

La nouvelle composition est caractérisée en ce qu'elle comporte les ingrédients suivants, dans les proportions indiquées, en pourcentage pondéral

Maltodextrine 18 - 32

Lactose alimentaire 13 - 30

Gélifiant 2 - 4

Amidon de riz modifié 1 - 3

Sel fin 0,5

Sucre en poudre complément à 100

Un exemple de composition rentrant dans cet intervalle est la suivante

Maltodextrine 28

Lactose alimentaire 25

Sucre en poudre 41,5

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Amidon de riz modifié 2

FLANOGEN RS2 3

Sel fin 0,5

VitaminesCl,Bl,B2,B9 traces

Le FLANOGEN RS2 est un agent gélifiant d'origine naturelle à base de carraghenates et de galctomannane.

L'invention vise également le mode de préparation de cette composition, qui implique, pour assurer l'homogénéité de la composition, l'addition successive dans un ordre spécifique des constituants précités. Cet ordre consiste à ajouter les constituants par ordre décroissant de quantités, à savoir

En premier le sucre en poudre

puis la maltodextrine

puis le lactose alimentaire

puis les composants aromatisants

puis le gélifiant

puis l'amidon de riz

et enfin le sel fin.

Cette nouvelle formule confère au flan plus d'onctuosité, de légèreté et de souplesse, ainsi qu'une texture crémeuse très agréable.

A cette formule peuvent être adjoints des colorants, des arômes, des fruits lyophilisés en morceaux ou en flocons, des paillettes de noix de coco, des noisettes broyées, et analogues, conduisant à des produtis spécifiques, possédant des qualités gustatives excellentes dans des parfums très variés, tels que, par exemple

- flan praliné avec petits grains broyés de noisettes

- flan abricot-pêche avec ou sans adjonction de morceaux

de framboises lyophilisées

- flan noix de coco avec paillettes de coco

- flan citron avec ou sans morceaux de citrons

- flan orange avec ou sans morceaux d'oranges

- flan framboise avec ou sans morceaux de framboises

- flan fruits des bois avec ou sans morceaux de fruits

des bois ainsi que la gamme plus traditionnelle

- flan cacao

- flan pistache

- flan vanille naturelle

- flan pâtissier

- flan caramel

- flan café

- flan aux oeufsData supplied from the esp@cenet database - Worldwide Claims:


REVENDICATIONS 1. Nouvelle composition pulvérulente destinée à la préparation de flans, notamment dans la pâtisserie industrielle, caractérisée en ce qu'elle contient, en % en poids

Maltodextrine 18 - 32

Lactose alimentaire 13 - 30

Gélifiant 2 - 4

Amidon de riz modifié 1 - 3

Sel fin 0,5

Sucre en poudre complément à 100 2. Composition pulvérulente selon la revendication 1, caractérisée en ce qu'elle contient

Maltodextrine 28

Lactose alimentaire 25

Sucre en poudre 41,5

Amidon de riz modifié 2

FLANOGENRS2 3

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Sel fin 0,5 3. Composition selon l'une des revendications 1 et 2, caractérisée en ce qu'elle contient au surplus des colorants, des arômes, des morceaux de fruits lyophilisés, des paillettes de noix de coco, des noisettes broyées et analogues.

4. Flans réalisés à partir de compositions selon la revendication 3, et plus spécialement

- flan praliné avec petits grains broyés de noisettes

- flan abricot-pêche avec ou sans adjonction de morceaux

de framboises lyophilisées

- flan noix de coco avec ou sans adjonction de paillettes de coco

- flan citron avec ou sans morceaux de citrons

- flan orange avec ou sans morceaux d'oranges

- flan framboise avec ou sans morceaux de framboises

- flan fruits des bois avec ou sans morceaux de fruits

des bois

ainsi que la gamme plus traditionnelle

- flan cacao

- flan pistache

- flan vanille naturelle

- flan pâtissier

- flan caramel

- flan café

- flan aux oeufsData supplied from the esp@cenet database - Worldwide

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63.

FR2655820 - 6/21/1991

NUTRITIONAL COMPOSITION BASED ON CEREAL PRODUCTS FOR

HUMANS AND/OR ANIMALS


Inventor(s): HENRI AUBERT SERGE (--)

Applicant(s): AUBERT SERGE (FR)

IP Class 4 Digits: A23L; A23K

IP Class: A23L1/10; A23K1/14

E Class: A23L1/10M; A23L1/164F; A23K1/14



Family: FR2655820

Abstract:


Nutritional composition based on cereal products for humans and/or animals. It contains soft or hard wheat, white or yellow maize, oats, barley, and rice and, optionally, at least one of the following additional products: dried fruits chosen from walnut, hazelnut, sweet almond, sweet chestnut, cashew nut, groundnut, supplemented with rice and/or wheat bran, egg yolk, sodium chloride, olive oil, fruits and/or vegetables chosen from orange, lemon, grapefruit, apricot, cucumber, turnip, black radish, carrot, onion, beet, tomato, substances derived from mammals and/or fish chosen from bovine blood, beef, fish meal, especially salmon meal, the dry composition being supplemented with the waters separated from the market garden and fruit products subjected to freeze-drying. It may contain, in addition, an antioxidant and/or a preservative, as well as an antibiotic or a sulphamide.Description:


La présente invention concerne une composition nutritionnelle à base de produits céréaliers à but humain et/ou animalier.

La composition selon la présente invention renferme cinq céréales de base, à savoir : blé tendre ou dur, maïs blanc ou jaune, orge, avoins et riz. Cette composition renferme éventuellement en outre au moins un produitadditIonnel1 choisi enfonction de la déficien- ce organique, savoir : fruits secs choisis parmi noix, noisettes, amandes douces, chataignes, noix de cajou, cacahuètes, supplément de sons de riz et/ouae blé, jaunes d'oeuf, chlorure de sodium, huile d'olive, fruits et/ou légumes choisis parmi manges, poires, pommes, abricots, oranges, citrons, pamplemousses, concombres, navets, radis noir, carottes, oignons, betteraves, tomates, substances provenant de mammifères et/ou poissons choisis parmi sang de bovin, viande de boeuf1 farine de poisson, notamment saumon::

La plupart de ces produits sont soit rapés, soit microniséset/ou liophilisés et mélangés aux produits initiaux sous forme de liquides et supplémentés par les eaux de séparation des produits maraichers et fruitiers soumis àliophilîsation ta composition renferme en outre des additifs habituels à savoirantioxydant et conservateur

De plus, dans un but de traitement, la composition peut renfermer un antibiotique ou un sulfamide ou bien des extraits de racine ou d'herbe ayant les mêmes propriétés, pouvant engendrer le même résultat à utilisation d'ordre homéopatique.

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Tous les produits constituant les compositions alimentaires selon la présente invention, son rassemblés dans le tableau ci-après.

A partir des données du tableau, on pourra préparer les compositions suivantes, par diagrammes, qui s'établiront en poids de un kilogramme soit1O08 de produits et plus, ou en grammes, ou en dé-cilitres, soit des produits réduits pour lescéréales àl'état de farine ultra-pulvérisée au micron, soit à l'état de liquide pour les fruits et légumes, ou rapés

Pour les fruits secs, on utilisera de préférence une farine ultra-pulvérIsée1 soitnumide, à fort taux d'humidité, ainsi que pour les sons de blé et de riz, par exemple en rapant pour les farines diversesae poissons ou de viandes ou les apports sanguins de bovins.

Cette composition de produits précités peut s'établir de cettemaniere, de 1 gramme à1O00 grammes ouae 10 grammes à 1000 grammes, ou de 1 centilitre au litre ou dmcilitre, ou en milligramme deproduits precités en fonction de dégats corporels, morphologi- cues subis par leshumains1 soit en nourriture pour Les animaux.

A titre d'exemples illustratifs non limitatifs, on a préparé les compositions suivantes, basées à l'état brut de produit pur, s'éta blissant de l'ordre de1000 grammes à 10 grammes ou de 500 grammes à 0,50 gramme, soit en calcul d'équivalence, 1000 grammes égalant 100% et 500 grammes les 50% divisibles, pour ces deux pourcentages en dixième de tous produits

PRODUITS BRUTS : PRODUITS REDUITS A L'ETAT DE FARINE

100% EGAL :REDUITS AU MICRON

Blé dur Tendre :0,10:0,10:0,10:0,10:0,10:0,10:0,10:0,10:0,10:0,10:soit:100%:

Maïs :0,10: : : : : : : : : : :100%:

Orge :0,10: : : : : : : : : : :100%:

Avoine :0,10: : : : : : : : : : :100%:

Riz :0,10: : : : : : : : : : :100%:

Noïx décortiquée :0,10: : : : : : : : : : :100%:

Noisette décortiquée :0,10: : : : : : : : : : :100%:

Amande douce décortiquée :0,10: : : : : : : : : : :100%:

Chataigne décortiquée :0,10: : : : : : : : : : :100%:

Noix de cajou décortiquée :0,10: : : : : : : : : : :100%:

Son de riz :0,10: : : : : : : : : : :100%:

Son de blé :0,10: : : : : : : : : : :100%:

Jaune d'oeuf de poule : 1 per 1000 g de céréales : : : : : :100g:

Chlorure de Sodium :0010:0010: : :0010: :10g pour 1000 : : :100g:

Huile d'olive :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % :soit: 10%:

Orange :1 % : : : : : : : : : : : 10%:

Citron :1 % : : : : : : : : : : : 10%:

Pamolemousse :1 % : : : : : : : : : : : 10%:

Concombre :1 % : : : : : : : : : : : 10%:

Navet :1 % : : : : : : : : : : : 10%:

Radis noir :1 % : : : : : : : : : : : 10%:

Carotte :1 % : : : : : : : : : : : 10%:

Oignon :1 % : : : : : : : : : : : 10%:

Betterave :1 % : : : : : : : : : : : 10%:

Tomate :1 % : : : : : : : : : : : 10%:

Cahuète :1 % : " : " : " : " : " : " : " : " : " : : 10%: abricot :1 % : : : : : : : : : : : 10%:

Sang de Boeuf :10 %: : : : : : : : : : :100%:

Farine de poisson :10 %: : : : : : : : : : :100%:

Sang de Vache :10 %: : : : : : : : : : :100%:

Cellulose Végétale :0,10: : : : : : : : : : :100%:

Brisure de riz :2 % :2 % :2 % :2 % :2 % :2 % :2 % :2 % :2 % :2 % : : 20%:

Lait en poudre :10 %:10 %:10 %:10 %:10 %:10 %:10 %:10 %:10 %:10 %: :100%:

Mélasse de canne à sucre :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % :1 % : : 10%:

Viande de Boeuf :10 %: lyophilisé : : :10 %: 1000 g : : :100%:

Antibiotique :1 g :1 g :1 g :1 g :1 g :1 g :1 g :1 g :1 g : : : 9g:

Sulfamide :1 g :1 g :1 g :1 g :1 g :1 g :1 g :1 g : : : : 8g:

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Eau de séparation des produits : A VALEURS DE CAHQUE PRODUITS EAU SEPARES :

90%:maraichers et fruitiers

Saumons : ! KILOGRAMME LYOPHILISE

PRODUITS BRUTS : VALEURS DES PRODUITS DE 0 A 100 % 100% EGAL :BAREME A 10 %

A 100 % ET 0,5 % PAR PRODUITS

Blé dur Tendre :0,05:0,05:0,05:0,05:0,05:0,05:0,05:0,05:0,05:0,05:0,05:0,50:

Maïs :0,05: : : : : : : : : : :0,50:

Orge :0,05: : : : : : : : : : :0,50:

Avoine :0,05: : : : : : : : : : :0,50:

Riz :0,05: : : : : : : : : : :0,50:

Noix décortiquée :0,05: ; i i i : : : : :0,50%:

Noisette décortiquée :0,05: : : : : : : : : : :0,50:

Amande douce décortiquée :0,05: : : : : : : : : : :0,50:

Chataigne décortiquée :0,05: : : : : : : : : : :0,50:

Noix de cajou décortiquée :0,05: : : : : : : : : : :0,50:

Son de riz :0,05: : : : : : : : : : :0,50:

Son de blé :0,05: : : : : : : : : : :0,50:

Exemple de Préparation n 1, servant de base à toute Préparation

Pour une déficience organiqueimportante, on mélange : brisure de riz de blé dur ou tandre, maïs blanc ou jaune, orge, avoine, riz, cellulose et ce, par 100 g de chaque produit en farine ultra-pulvérisée au micron.

Exemple de Préparation n 2:

En partant de la Préparation de l'exemple n 1, en complémentarité, on ajoute des fruits secs, noix, noisettes, amandes douces, chataignes, noix de cajou, du son de riz, du son de blé, réduits à l'état de farine ultra-pulvérisée, en mouture et au micron,scit de 100 g a 1000 g et de 10% à 100% équivalent

à1000 9.

Exemple de Préparation n 3

La Préparation en plus du mélange de base comporte du aune d'oeuf de poule, du chlorure de sodium et de l'huile d'olive, a raison de 10 g parproduit


Au mélange de base on fait une adjonction de fruits, soit liquides, soit liophilisés, du type orange, citron, pamplemouse, abricot, de 10 g à 1000 g, soit de 1% à 100%.


On ajoute au mélange de base des légumes paraichers, liquides, rapé ou liophlisés, comportant concombre, navet, carotte, pignon, betterave, tomate, et l'eau de séparation des produits liophilisés, aux barèmes d'emploi de l'ordre de 100 g par produits précités faisant l'équivalence sur le tableau à 10% bruts et de 100 g à 1000 g, soit de 10% à 100% du barème.


Comportant soit des dérivés plasmatiques de bovins, procins, diverse farines de poissons, de viandes de boeuf, liophilisées et de saumon en poudre à la valeur de10O g à 1000 g, soit en pourcentage de 10%

à1008 équivalent à;000 g


Elle comporte du lait de vache en poudre, au taux de 100 g à 1000 g, pour une équivalence de 10% à

100% soit 1000 g.

Exemple de Préparation ne 8:

Rentrant en part de 100 g d'ajout de mélasses de canne à sucre, soi de 1% à 100%, soit pour 100 g de produits céréaliers, fruit secs, légumes, à part entière du kg initial. les compositions des exemples ne 1 à n 8 illustrent des Préparation: pour des cas de déficience organique. Plus la déficience est intense et plus il faudra préparer les produits à 100% de leur baseIllustre par le tableau.

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De même, ces compositions tiennent compte de la fragilité organique des sujets, soit en employant alors le 10% équivalent à 100 g de chacun des produits. Le mélanges est constitué pour une absorption de quatre prises/jour.

On utilise obligatoirement la masse céréalière formée de brisure, sons, fruits secs, fruits, légumes maraichers, conservateur, antioxidant ou antibiotique

Ces produits devront être concentrés en farineultra-pulvérsée microisée, mélangés à sec. selon la déficience et le pouvoir d'ingérence actuel du sujet, un pourcentage de liquides a valeur de10 cl de produits maraichers, sera ajouté au mélange total.

Il est important, pour garder les propriétés intéressantes de chaque produit, de les mélanger, sans aucune étape de chauffage et sans subir aucune préssurisation isobar.

A partir de 10 g par produit et selon l'âge, on utilise del g par produit ou dl de produit à l'état pur.


La Préparation renferme: blé, maïs, orge, avoine, riz en farine ultra-pulvérisée, contenant 50 g de chaque céréalesprécitées1 1009 ae lait en poudre et 50 g de sucre, ceux-ci sont mélangés puisdilué. avec le l'eau minérale, soit 400 cl d'eau.

Exemple de Préparationn0 10 :

On fait un dosage de céréales,blé, mais, orge, avoine riz en farineultra-pulvérisée, ainsi que des fruits secs en farine ; soit noix, noisette, amande, noix de cajou, chataigne Ces produits entreront en dosage de 50 gunltaire, ainsi qu'un ajout complémentaire de jus de fruit, de 30 g par fruits désignés ici ; abricot, orange, citron,poire, pamplemousse,mangue, soit au total ; fruits 200 g, fruits secs 250, céréales250 g, le tout étant diluer dans 100 c1 d'eau minérale.


Des céréales et des jus de légumes sont pris au dosage suivant céréales, blé, mais, orge, avoine, riz1 soit 50 g par produit

Ainsi pour les jus delégumes : concombre, navet, radis noir, carotte, oignon ,tomate, betterave, au taux de 20 cl chacun. On utilise pour les légumes 140 cl de liquide: 250 cl pour les céréales et on ajoute de l'eau minérale à raison de 100 cl sans chauffe, ni préssurisation isobar.


Caractérisée en ce qu'elle renferme - Blé 10 g, maïs 10 g, orge 10 g, avoine 10 g, riy 10 g: - Fruits secs: noix, noisette, amande, chataigne, noix de cajou,

à raison de 10 g chacunson de blé et riz 10g, fruits sous forme de jus de pomme, poire,

mangue, orange, citron, pamplemousse, 20 cl chacun.

- Légumes maraichers : concombre, navet, radis noir, carotte, oignon

betterave, tomate, réduits en jus, soit 20 cl de chaque.

Ces produits seront additionnés d'eau minérale soit 100 cl, sanscha fage ni préssurisation isobar

Exemple de Préparationn0 13+

A base de produits céréaliers et fruitiers, légumes, blé,mais, avoine riz, noix, noisette, amande, chataigne, son de riz, son de blé, orange, citron1 pamplemousse, abrieot, pomme, poire, mangue, concombre, navet, radis noir, carotte, oignon, tomate. Ces produits entreront en portions de l'ordre de

10 g par produIts précités, er seront réduits soit à l'état de farine, soit en jus, soit rapés ou réduits au micron.

La préparation de cet exemple peuten outre etre appliquée directement sur la peau en cosmétologie. Les produits la composant une fois malaxés,mélangés entreeux, seront apliqués soit sur le visage, soitsur tout le corps.

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Sous la même présentation, ces produits peuvent également être utilisés en cas de brulures chimiques, brulures occasionnées par le feu, brulures radioactives et mis sur le corps indirectement àl'aide d'un feuille de ouate decellulose formant séparation et sans chauffage


Fruits secs : noix, noisette1 amande douce, chataigne, noix de cajou, de l'ordre de 20 à 25 g par fruitse et avec un ajout de lait de vache entier, de l'ordre de100 ci et de 50 g de sucre roux de canne sans chauffage ni préssurisation isobar.


On part d'un dosage de son de riz et deblé1 ultra pulvérisés de 55 de chaque et l'homogéneité de son d'avoine

L'homogénéité du produit de cette composition permet des traitements épidermiologiques, virales ou retro virales, de déficience cellulaire par leurspropriétés inhibitrices au niveau stomacal.

Exemple de Préparation n 16: 40 g de jaune d'oeuf de poule, 35 g de sucre roux de canne, 50 g de noix en farine ultra-pulvérisée, 50 g de noisettes en farine ultra-pulvérisée, 50 g d'amande douce en farine ultra-pulvérisée, 100 g d'orge en farine ultra-pulvérisée,100 cl de jus de carotte. t'homogénéité du produit atteint, cette composition permet une absortion intestinale moyenne en cas de rupture vitaminique excessive et organique humaine sans tenir compte del'age du sujet.

Exemple de Préparation n0 17 :

Sonintéret est diététique, sur les problèmes humains, soit de transat intestinal,diverticulairev assimilation cellulaire,cardio-vasculai- re ou hypochloestérolémiante.

La composition présente un dosage de l'ordre de 20 g de barbe à mais ultra-pulvérisée, 50 g de son d'avoine, 100 g d'orge en farine ultra-pulvérisée, 10 g de farine de rizultra-pulvérisée, 20 cl de jus de citron, 50 cl de jus d'orange, 65 cl de jus de pamplemousse,

Cette composition alimentaire est utile lors de la perte massive de vitamines de l'appauvrissement nutritionnel spontané organique, sans subir de chauffage ni pression isobar.

Les compositions objet de la présente invention, sont modulées en fonction de leurs applications à l'ïre humain ou aux animaux.

Dans ce dernier cas, il s'agit d'animaux divers, marins et de faunes forestières.

En fonction du but à atteindre via à vis des animaux de cheptels, en nourrissage des oisons, marsoins, alvins, chiots, aquacultures, piscicultures, monicultures, volailles, galinacés, crustacés, pectinides, crevettes, thomidés, cétacés, valvicultures, salmonidés, gibiers d'eau, poissons plats, carangidés, truites, cerfs, biches, faunes forestières, sauvages et semi-sauvages, élevés en batterie, carnassiers.

Cette alimentation animalière serait préparée eninterconnection des produits soit seule oumélangée à l'ensemble en fonction del'age du cheptel , Soit en granulés de lmm àl cm.d'épaisseur, longueur del à

10 cm en mouture à faiblehumidité, ou à forte humidité, avec soit un degré de salinité de l'océan de la mer ou du

Continent, ceci évite la désagrégarion du granulé, ou fait à l'eau douce pour l'aquaculture, y compris des mélanges de cellulose de riz:

Fibres végétales, entrant dans un barème compris de 1 % à 100 % de la masse initiale des produits ou la division du 100 % ou alors la composition s'applique également : plancton, zooplancton, pisciculture, animaux marinsd'élevages.

Enfonction deia rentabilité recherchée de la maturation, le produit sera employé en granulés del mm, longueur 1 à 2 cm ; En emploi seul de chaque céréale, dans l'interconnection de 1 à 5 céréales, multiples, couplées ou triplées: Y compris des brisures de riz, de cellulose, de farine de poissons, sang de boeuf, sang de vache, prévus dans un barème de 108 à1C %, soit d'une division du 100 % ou du divisé par quatredu 100 %, l'unité de base étant le kg ou sadlvi- sion par deux ou quatre.

Pour la maturation sexuelle dessalmonidés, l'avoine entrera en part évidente, sur une augmentation du son de blé et de riz, en fonction de l'âge des alvins. Cette alimentation devra comporter dans son

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mélange alimentaire du mouture micronisée, un apport obligatoire d'antibiotique, en fonction de l'âge des naissins ou des alvins, en pourcentage de la préconisation des laboratoires vétérinaires Onév- te ainsi la diffusion d'antibiotique dans les piscines d'aquaculture ce qui permet un mailleur impact organique. L'apport complet des céréales, sel ouinterconnecté à deux ou trois composants selon lebu recherché,pourra renfermer un conservateur de type antioxygène, genre

E300 ou E211.

Lescon. positions pour les animaux de ferme et d'élevage comporteront obligatoirement, un tauxmassif de a son de blé ou de riz, s'établis- sant de l'ordre de 75 à 80 5, les autres produits céréaliers, finiro la marge restante des 100 %, ou feront une variation moindre, selon la climatique. Les antibiotiques devont être mis obligatoirement dans l'alimentation, en fonction des cheptels. Du chlorure de magnésium seranécessaire Pour l'absorption d'eau sera mise à part, dans le but d'une fixation des produits chez l'animal.Quant aux animaux de ferme, ces produits pourrount être employés dans une forme de granulametrie, selon l'âge des petits, soit en farine, ayant un taux d'humidification, leur permettant une déglutitio normale, augmentant de ce fait l'ingérence stomacal donnant au produit une capacité d'ingé- rence organique évidente, avec un accroissement de plus de 10 % d'un nourrissage normal. On fait uneIntroduction d'issues deblanchiment à raison du kg pour les bovins, ovins, porcins, galinacés, jeunes animaux. Ces produits seront employés àl'état de farine humidifiée ou presque liquide dans le cas d'animaux à gaver et en pré-gavage pour les oisons, oie, canards et ce, avant le temps des 90 jours de gavage, supprimant de ce fait, le gavage initial, pour ces animaux de cheptel.En particulier, les farines de maïs seront de l'ordre de départ de 50t et arriveront au maximum de 75 à 85% de farine de mais, avecoes rajouts cellulosiques de paddy et des sons de riz et des issues de blanchimentave des variantes mineures ou plus importante, selon le Pays. Le paddy devra tenterd'être réduit à l'état de farine, avec des moyens mécaniques.

Dans le casd'allaitement artificiel, pour les bovins, ovins, porcins, on ajoute au lait écrémé, un mélange comportant 258 debri- sures moulues de riz à raison de 55 g par litre. Une formule a base de brisure de riz donne d'excellent résultat pour les truies en gestation ou en nourride. Pour les porcelets elle devient aussi un anti diarrhéique.

Volaillers : Les brisures sontparticulièrement appréciées dans l'a-limentation des volailles an ferme ou en batterie, leur valeur alimentaire et leur teneur en hydrate de carbone, ne serontrelevées que mieux et, elle augmentent leur valeur protidique, lipidique, glucidique. En faisant un accroissement de ces valeurs par un apport obligatoire soit d'avoine, qui augmentent les pontes d'ceufs, ainsi que de l'orge qui est un régulateur intestinal, valabie pour tous animaux de ferme, élevages en batterie, etc...

our les richesses en phosphore, lipides, lysines, acides nucléiques les proteines salino-solubles, subdivisées en albumines et globuline les proteines solubles ou protaminées désignées le plus souvent par le terme de Zeine, et les proteines résiduelles ou glutélines. Parmi les minéraux apportés, il faut citer en particulier, le calcium, l'acide acorbique, les vitamines du groupe B et le carotène présent dans les parties colorées, vertes, jaunes, rouges, qui n'est pas anégliger.

Les céréales ayant un facteur limitant la lysine, sont choisis parm les légumineuses. Les acides aminés, le soufre, le tryptophane sontlimitant pour le maïs, les racines et tubercules qui sont pauvreser. protéines et ont un facteur limitant, pouvant tre la lysine, les balles, glumes de paddy et paille. Une telle composition constitue souvant une source d'alimentation du bétail en saisonseiche. Au poin de vue de l'alimentation du bétail, la paille de riz représente deux éléments essentiels, les matières azotées et la cellulose, et ce, er. fonction des animaux faisant un réglage de 20 a 30 % de la rationjournaliere, en fonction toujours de l'apport d'issue de blanchiment soit pour faire des craisses males, avantages très particulier pour les

Pays Asiatiques, lesquels recherchent des graisses semi-fluides et ce, en fonction des demandes et des pénuries alimentaires dansc--.

régions de climatalogie incertaine, et de la démographie incontrolable. Le nourrisage des animaux du point de vue qualité protidique de farines de blanchiment doit varié, tenant compte d'un apport de fari nes de céréales, telavoine, au vu de son caractèrephysice-chimi qvc, des fractions proteiques, soit en semouleultra-pulvérisée ou en granulométrie différentielle en emploi intercalaire journalier, en tenant

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compte du tableau du diagramme, de la variation, soit en farine ultra-pulvérisée en mouture, granulés ayant une variation de de 1micron a 10cmcde grosseur.

En outre, la possibilité mécanique pourrapermettre une alliance

de ces produits, les glumes de paddy et pailles, réduits pourront

être employés avec l'association des sons de riz et de blé, rédui

sant les coûts de nourissage des animaux de ferme, aquaculture, pisciculture, mariculture, augmentation de la faune marine, aqua

plancton, zooplancton, plytaplancton, macroplancton, d'une utili

sation à des pourcentages de variations entrant en part de 10 %

pour les animaux à poils.

En nourrissages pour les jeunes animaux, petits cheptels, oisons,

le pourcentage exprimé devra être compris de la façon suivants de

1 à 100 %, s'établi de 1 g de produit à 1000 g ou kg de produits

différentiels énoncés et dictés dans les autres pages.

Exemple dePréparation n0 18

Elle renferme un apport de maïs blanc ou jaune, de son de riz, de

son de blé, de cellulose végétale, brisure de riz, balle et glume

de paddy, lait de vache en poudre, dérivés sanguine d'abbattoirs,

poudre de farine de poissons et, apports mélangés de sulfamide.

Ces produits devront être préparés de la façon suivante, en partant

du kg pour les animaux de ferme, et toujours en association du kg,

et même jusqu'à la tonne, soit en mélangant artisanalement les pro

duits, soit mécaniquement, sous toutes formes possibles, caractéris

on ce que chacun des produits additionnels est inclu dans la compo

sition à raison de 1000 g par produits, ne devant subir aucune étape

de chauffe ou préssurisation isobar.

Exemple de compositioncéréalière et fruitière : Fruits secs, son

de riz ou de blé, légumes variés, racines de manioc, ainsi que des

alques telles des Nori, comportant 10 g de chaques produits précité:

dans le tableau de diagramme, ainsi que des produits de synthèse,

biosynthèse, de sèparation isotopique, anti-oxydant, conservateur,

antibiotique, sulfamide, et de produits résultant à des taux veri

ablesd'application homéopatique, soit humaine ou animalière.

Les compositions selon l'invention pourront être les pluspréparée

formulées et conditionnées dans les formes les plus diverses selon

le choix de leurs constituants, d'une part et, d'autre part, du do

maine d'application. A titre d'exemple on citera: rations, portions

batonnets, poudre, plaquettes,patte, pain, liquide.Data supplied from the esp@cenet database -

Worldwide Claims:


REVENDICATIONS

1/Composition nutritionnelle à base de produits céréaliers à but humain et/ou animalier, caractérisée en ce qu'elle renferme du blé tendre ou dur, du mais blanc ou jaune, de l'avoine, de l'orge et du riz et,

éventuellement, au moins un des produits additionnels suivants : fruits secs choisis parmi noix, noisette, amande douce, chataigne, noix de cajou, cacahuète, supplément de sons de riz et/ou de blé, jaune d'oeuf, chlorure de sodium, huile d'olive, fruits et/ou légumes choisis parmi orange, citron, pamplemousse, abricot, concombre, navet, radis noir, carotte, oignon, betterave, tomate, substances provenant de mammifères et/ou poissons choisis parmi sang de bovin, viande de boeuf, farine de poissons, notamment saumon, la composition sèche étant supplémentée par les eaux de séparation des produits maraichers et fruitiers soumis à liophilisation.

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2/Composition selon la revendicationl, caractérisée en ce qu'elle renferme en outre, un antioxydant et/ou un conservateur.

3/Composition selon la revendication 1 ou2, caractérisée en ce qu'elle renferme en outre un antibiotique ou un sulfamide.Data supplied from the esp@cenet database - Worldwide

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64.

FR2715804 - 8/11/1995

PIZZA-LIKE FOOD PROD. PREPN., MAINTAINING VITAMIN(S) AND

PROTEINS ON COOKING


Inventor(s): LAHOUCINE RAGOUB (--)

Applicant(s): RAGOUB LAHOUCINE (FR)

IP Class 4 Digits: A23P; A21D

IP Class: A23P1/08; A21D13/00

E Class: A23L1/00P8E; A23L1/325H; A21D2/36; A23L1/31H; A21D2/16D; A21D13/00D;

A23L1/315B



Family: FR2715804

Abstract:


Prodn. of food prods. having decorated topping on dough base, comprises (i) spreading the topping on the dough base; and (ii) decorating the prod. with the garnish. Dough comprises hard wheat flour and

(for 10 kg flour) 4000 ml water, 500 ml olive oil, 250 ml peanut oil, 120 ml rapeseed oil, 70 g salt, 10 g pepper, 10 g cayenne, 10 g nutmeg, 10 g saffron and 100 g yeast. The topping/garnish comprises e.g.

:(a) 40% minced poultry meat, 10% poultry meat strips (garnish) and 50% red onions, mushrooms, carrots, ginger, coriander leaves, corn flowers, vegetable and animal fat, chives, salt, pepper and 'conte rape' ; or (b) 40% (minced) fresh salmon fillets, 10% fresh salmon strips (garnish) and 50% red onions, eggs, creamed rice, fresh cream, cheese, Chanterelle (edible fungus), vegetable and animal fat, chives, chervil, nutmeg, cayenne, black pepper, sweet pimento, salt and paprika.Claims:


REVENDICATIONS 1. Procédé de préparation d'un produit alimentaire, à base de Volaille, ou

Saumon frais, ou Viande de grenouille, ou deux viandes (70 % veau/30% agneau), ou sept légumes, caractérisé en ce qu'ilcomprend a) la préparation d'une pâte, constituée de:

Farine de blé dur, avec, pour 10 kgs de farine:4 1 d'eau, 1/2 1 d'huilesolive, 1/4 1 huile arachide, 12 cl d'huile de colza, 70 9 de sel, 10 g de poivre, 10 g de piment de Cayenne, 10 g de noix de muscade,

10 g de safran, 100 g de levure boulangère. b) la préparation d'un appareila base de volaille constitué de: 40% de chair de volaille hachée 10 de chair de volaille en lamelles pour décoration incorporation de 50% d'ingrédients supplémentaires se composantde oignons rouges, champignons,carottes, gingembre, feuilles de coriendre, fleurs de mais, matières grasses végétales et animales, ciboulette, sel, poivre et contérapé. c) la préparation d'un appareil a base de saumon frais constitué de: 402 de filets de saumon frais 102 de filets de saumon en lamelles pour décoration incorporation de 50 % d'ingrédients supplémentaires se composant de: oignons rouges, oeufs, crème de riz, crème fraîche, fromage, girolles, matières grasses végétales et animales, ciboulette, cerfeuil,noix de muscade, piment de Cayenne, poivre noir, piment doux, sel et paprika.

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d) la préparation d'un appareil à base de viande de grenouille, constitué de 40% de chair de cuisse grenouille 10% de chair de cuisse de grenouille en lamelles pour décoration incorporation de 50 d'ingrédients supplémentaires se composantde oignons rouges, oeufs, crème de riz, crème fraiche, fromage, matières grasses végétales et animales, ciboulette,cerfeuil ; noix de muscade, piment de

Cayenne, poivre blanc, piment doux, sel et paprika. e) la préparation d'un appareil à base de deux viandes constituéde 40 % de mélange de viande (70 % veau & 30% agneau),

I'ensemble, mariné dans de l'huile d'olive

10% de ce mélange en lamelles pour décoration incorporation de 50% d'ingrédients supplémentaires se composantde oignons blancs, champignons de Paris, girolles, matières grasses animales et végétales, tomates, thym, laurier, fines herbes, ail, poudre de safran, poudre de paprika, poudre de gingembre, noix de muscade. f) la préparation d'un appareil à base de sept légumes, constitué de: 100% OIGNONS, CAROTTES,

CHOU FLEUR,CHAMPï6NONS,'POMMES DE

TERRE BROCOLI, et CELERI. pm : poireaux, fines herbes, ciboulette etc...

Assaisonnement : Noix de muscade, poudre de laurier, poudre de poivron rouge, grains de coriendre, grains de genièvre, oignons blancs. g) la disposition de l'appareil sur le fond de pâte de forme ronde, ovale, rectangulaire, triangulaire, ou, d'une manière générale sous n'importe quelle forme géométrique h) décoration avec la composante principale de l'appareil 2. Procédé de préparation, selon la revendication 1, caractérisé en ce que la Dâte est préparée comme suit

Incorporation de tous les ingrédients, au fur et à mesure, dans un mélangeur, spécialement adapté, dans l'ordre indiqué. On obtent, ainsi, une pâte épaisse, moelleuse, déposée dans une chambre froide

Après avoir subi une fermentation, de 24 h, dans une pièce à température constante de 10', la pâte est

étalée, en forme ronde, ovale, rectangulaire, triangulaire, ou, d'une manière générale sous n'importe quelle forme géométrique.

Cette pâte, subit une surgélation rapide 3. Procédé de préparation, selon la revendication 1, caractérisé en ce que l'appareil est préparé comme suit, s'il s'agit d'un appareil à base de volaille:

La viande est hachée dans un ROBOT COUPE, où la vitesse du couteau est régléea 1500 t/mn. On procédera à des arrêts fréquents de façon à bien homogénéiser le mélange, etl'on raclera les parois du

Hache viande. On continue cette opération pendant une durée suffisante, par exemple 5 à 7 minutes, pour l'obtention d'une pâte molle d'une couleur légèrement plus foncée qu'au départ. Mélangée ensuite dans un bac mélangeur préalablement refroidi sur un lit de glace pilée (le mélange devant s'effectuer continuellement au froid, afin de na pas rompre la chaine de froid) et additionnée de 12 cl de lait, afin de garder le maximum de protéines.

L'appareil, ainsi constitué, est mis au repos dans une chambre froide pendant1 heure. Pendant ce temps, les ingrédients sont hachés, les uns après les autres, afin d'obtenir une pâte épaisse, versée dans une casserole préchauffée, avec 20 cl d'huile d'olive et 250 g de beurre, jusqu'à température de 80'. Dès la cuisson de ces ingrédients, on incorpore le hachis de volaille, préalablement préparé au frais, en additionnant 1 1 de crème friche, montée en crème fouettée, par 10 kgs d'appareil (ceci afin d'avoir un appareil épais et onctueux.Cuisson à température de80' pendant 1 heure.Après la cuisson, on passe dans la cellule de refroidissement.

4. Procédé de préparation, selon la revendication 1, caractérisé en ce que l'appareil est préparé comme suit, s'il s'agit d'un appareil à base de saumon frais

Le saumon est haché dans un ROBOT COUPE, où la vitesse du couteau est réglée à 1500 t/mn.

Mélangé ensuite dans un bac mélangeur préalablement refroidi sur un lit de glace pilée (le mélange devant s'effectuer continuellement au froid), additionné de 12 cl de crème fraiche/kg, afin de garder le maximum de protéines.

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L'appareil, ainsi constitué, est mis au repos dans une chambre froide pendant 1 heure. Pendant ce temps, les ingrédients sont hachés, les uns après les autres, afin d'obtenir une pâte épaisse, versée dans une casserole préchauffée, avec 250 9 de beurre frais, jusqu'a température de80'. Dès la cuisson de ces ingrédients, on incorpore le hachis de saumon, préalablement préparé au frais, en additionnant 15 jaunes d'oeuf/litre decrème/10 kgs de saumon, 400 g de fleur de mais étant nécessaires pour la liaison de l'appareil. Cuisson à température de80-, pendant 1 heure. Après la cuisson, on passe dans la cellule de refroidissement.

5. Procédé de préparation, selon la revendication1, caractérisé en ce que l'appareil est préparé comme suit,s'il s'agit d'un appareil à base de viande de grenouille:

La chair de grenouille est hachée dans un ROBOT

COUPE, où la vitesse du couteau est réglée à 1500t/mn.

Mélangée ensuite dans un bac mélangeur préalablement refroidi sur un lit de glace pilée (le mélange devant s'effectuer continuellement au froid) additionnée de 12 cl de crème fraiche/kg, afin de garder le maximum de protéines.

L'appareil, ainsi constitué, est mis au repos dans une chambre froide pendant 1 heure. Pendant ce temps, les ingrédients sont hachés, les uns après les autres, afin d'obtenir une pâte épaisses versée dans une casserole préchauffée, avec 250 g de beurre frais, jusqu'à température de 80'. Dès la cuisson de ces ingrédients, on incorpore le hachis de grenouille, préalablement préparé au frais, en additionnant 15 jaunes d'oeuf/litre decrème/10 kgs de viande, 400 g de fleur de mais, étant nécessaires pour la liaison de l'appareil. Cuisson à température de80-, pendant 1 heure. Après la cuisson, on passe dans la cellule de refroidissement.

6. Procédé de préparation, selon la revendication1, caractérisé en ce que l'appareil est préparé comme suit,s'il s'agit d'un appareil à base de deux viandes:

Après 24h de marinade, à une température de3, La viande est hachée dans un ROBOT COUPE, où la vitesse du couteau est réglée à 1500 t/mn. Mélangée ensuite dans un bac mélangeur préalablement refroidi sur un lit de glace pilée (le mélange devant s'effectuer continuellement au froid) additionnée de

12 cl de fond de veau, pour garder son maximum de protéines. Le hachage doit s'effectuer pendant environ 5 mn, afin d'obtenir une pâte fine, bien ferme, avec couleur d'origine. On enlève cette pâte de viande hachée, quel'on dépose directement dans la casserole où les ingrédients sont déja pré-cuits, après avoir été hachés les uns après les autres, et sués dans 20 cl d'huile d'olive, pour obtenir une pâte

épaisse.

On mélange le tout, cuisson1 heure, à une température de100g. En fin de cuisson, on lie l'appareil avec 200 g de fleur de riz et 2 1 de fond de veau,

Contrôle de l'assaisonnement et passage en cellule de refroidissement.

7. Procédé de préparation, selon la revendication 1, caractérisé en ce que l'appareil est préparé comme suit,s'il s'agit d'un appareil à base de sept légumes:

Les légumes frais, sont épluches, lavés, blanchis à une température de 100', refroidis à l'eau froide,

égouttés.

On introduit tous les légumes dans un hache légumes.

Réglage de la vitesse du couteau à 1500 t/mn, pendant 7 minutes, pour obtenir une pâte très fine, avec une multicouleur de légumes frais.

On fait revenir ces légumes, dans une casserole en inox, préalablementchauffée (15 cl d'huile d'olive,

15 cl d'huile d'arachide, 5 1 de bouillon de volaille, pour 10 kgs de légumes).

Cuisson 1 heure. On stabilise l'appareil, avec 300 g de maizena, additionnée de2 1 de fond de volaille.

On termine la cuisson, 10 mn plus tard, pour la stérilisation de l'ensemble.

Contrôle de l'assaisonnement et passage en cellule de refroidissement.

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8. Produit alimentaire à base de volaille ou de saumon frais ou de viande de grenouille ou de 2 viandes

(70% veau , 30% d'agneau) ou sept légumes obtenus par le procédé selon les revendications 1 à 7 prises dans leur ensemble.Data supplied from the esp@cenet database - Worldwide

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65.

FR2724820 - 3/29/1996

FOOD COMPSN. BASED ON GRAINS, PREF. OR RICE


Inventor(s): BOCABEILLE GILLES (--); GAUDET PATRICE (--)

Applicant(s): SOREAL SA (FR)


IP Class: A23L1/10; A23L1/182; A23P1/02

E Class: A23L1/164C; A23L1/0532; A23L1/0562B



Family: FR2724820

Abstract:


A food compsn. comprises grains of food material agglomerated by a gel to form an agglomerate which breaks up after being subjected to elevated temp. and/or mechanical working. The grains are specifically of (pre)cooked cereal, esp. rice.Description:


COMPOSITION ALIMENTAIRE GRANULAIRE

ET PROCÉDÉ DE PRÉPARATION D'UNE TELLE COMPOSITION.

L'invention se rapporte au domaine général de l'agro-alimentaire. Elle concerne une composition alimentaire granulaire, ainsi qu'un procédé de préparation d'une telle composition.

Les compositions alimentaires granulaires et, en particulier, les compositions alimentaires de céréales, sont consommées, après cuisson, sous la forme de grains individualisés, séparés les uns des autres. Un consommateur ne peut donc concevoir, a priori, de manger de telles compositions sous une autre forme.

C'est le cas, notamment, du riz, dont la présentation en grains individualisés constitue une présentation

à laquelle nous sommes accoutumés depuis toujours.

Selon la présente invention, le demandeur s'est posé le problème d'une présentation différente des compositions précitées, en vue d'une préparation de nouvelles compositions alimentaires, dans lesquelles la nature granulaire ou particulaire est occultée par la composition elle-même. Cependant, le demandeur s'est attaché à faire en sorte que ces nouvelles compositions retrouvent leur nature d'origine, en grains individualisés, au moment de la consommation stricto sensu, c'est-à-dire au moment où le consommateur mange ladite composition.

En définitive, l'invention propose, de manière inattendue, la réalisation d'une composition alimentaire granulée qui constitue un état provisoire entre un état initial naturel en grains individualisés, et un état final, qui correspond sensiblement à l'état initial précité, et qui est destiné à la consommation.

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L'état provisoire permet, non seulement, de préparer de nouvelles compositions culinaires, mais aussi, notamment, de faciliter la préparation et de proposer de nouveaux mode de consommation.

Ce but, ainsi que d'autres quiapparaitront par la suite, sont atteints par l'agglomération des grains dans un gel de manière à former un agglomérat qui s'égrène sous l'effet de facteurs extérieurs liés à sa consommation.

Aussi, l'invention a pour objet une composition alimentaire granulaire, caractérisée en ce qu'elle comporte un gel, et en ce que des grains de ladite composition granulaire sont agglomérés par ledit gel de manière à former un agglomérat qui s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

Par ailleurs, l'invention a pour objet un procédé de préparation d'une composition alimentaire, caractérisé en ce qu'on mélange des grains avec une solution gélifiante, en vue d'obtenir un agglomérat instable après avoir subi une élévation de température et/ou une action mécanique.

La description qui va suivre, et qui ne comporte aucun caractère limitatif, permettra de mieux comprendre la manière dont l'invention peut être mise en pratique.

Elle est rédigée en référence à l'exemple d'une composition alimentaire dans laquelle les grains sont des grains de riz.

Toutefois, il est bien entendu que l'invention se rapporte, dans son sens le plus général, à une composition alimentaire granulaire et, plus particulièrement, à une composition alimentaire à base de particules végétales cuites ou précuites, de préférence, céréales, telles que, par exemple, le riz, la semoule de blé, les petits pois, le maïs, ou toute autre catégorie de grains naturels dont le diamètre moyen est compris entre 1 et 10 mm environ.

La composition de la présente invention comporte un gel qui constitue un réseau gélifié.

Ce réseau est avantageusement formé, d'une part, de longues chaînes polycycliques d'alginate liées entre elles par des liaisons covalentes et, d'autre part, de gélatine et de carraghénates. Toutefois, toute autre substance alimentaire gélifiante ou de ce type peut convenir. C'est le cas, par exemple, de la pectine, de la géllane ou de la gélose, ou alors, de certaines protéines telles que les lactoprotéines, les ovoprotéines et l'albumine.

Les grains de riz sont agglomérés par le gel, de manière à former un agglomérat

Cet agglomérat comporte environ 66 à 90 % en poids de grains et environ 10 à 33 % en poids de gel.

En pratique, pour le riz, on a 10 à 15% de gel.

Le gel est en partie absorbé par les grains de riz. L'autre partie reste cantonnée à la surface des grains de riz notamment aux points de contact entre ceux-ci qui constituent, en définitive, les points de fixation des éléments de l'agglomérat. Par suite, l'agglomérat peut présenter des interstices vides entre les grains.

D'une façon générale, la proportion de solution gélifiante dans la composition doit être minimale afin qu'elle soit facilement absorbée en surface des grains de céréales, qu'elle devienne alors invisible, et quel'on ne retrouve pas de résidu de gel lors de l'égrénage du produit aggloméré, après la cuisson.

L'agglomérat s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

On a donc une réversibilité d'un état transitoire aggloméré vers un état initial dissocié.

Le gel d'alginate est thermostable. Aussi, une cuisson de l'agglomérat à des températures comprises entre 60 et 2000C environ, ne suffit pas à rompre les liaisons covalentes qui relient les chaînes d'alginate.

L'agglomérat, bien que fragilisé, reste entier et conserve sa cohérence, et une action mécanique de faible intensité telle que, par exemple, la pression d'une fourchette ou d'une dent, suffit à briser ledit

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agglomérat, les grains se dissociant alors en retrouvant leur individualité initiale. Cette dissociation est facilitée par le fait que chaque grain de riz agit, au niveau des points de contact précités, à la manière d'un bras de levier.

D'autre part, le gel de gélatine et de carraghénate est thermosensible: les liaisons faibles qui relient les composés précités sont détruites à des températures de l'ordre de 350C. Aussi, une cuisson à une température supérieure à 350C fragilise1 'agglomérat.

Pour la préparation d'une composition selon l'invention, on choisit un riz étuvé. Ce riz est alors cuit, d'une manière traditionnelle, dans de l'eau portée à ébullition.

Par ailleurs, on prépare une solution gélifiante, ainsi qu'une solution calcique.

La solution gélifiante comporte, de préférence, deux agents gélifiants. Le premier est l'alginate de sodium et le second est formé par le couple carraghénate/gélatine. En outre, la solution gélifiante comporte du pyrophosphate dont la fonction est décrite ci-après.

La solution calcique comporte un sel de calcium tel que le sulfate de calcium et, éventuellement, un agent tensioactif tel que la xanthane qui permet de maintenir le sulfate de calcium en suspension.

On mélange alors le riz cuit, la solution gélifiante, et la solution calcique.

Le mélange est opéré, en général, dans les rapports suivants : céréales cuites/solution gélifiante : 66/33

à 90/10 (% en poids) et solution gélifiante/solution calcique : 95/5 à 80/20 (% en poids).

Pour ce mélange, les solutions gélifiantes et calciques sont préférentiellement acheminées vers un mélangeur classique à l'aide de pompes. Par contre, l'acheminement du riz cuit nécessite l'emploi d'une vis d'Archimède.I1 est ainsi particulièrement intéressant d'ajuster ledit mélangeur et la vis d'Archimède selon un même axe.

Dans un exemple, si les solutions de la présente invention ont la composition suivante

Solutiongélifiante

Eau QSP

Alginate1 2 %

Gélatine 2 à 10 %

Carraghénate 0,5 à 1 %

Pyrophosphate 0,1 à 0,3 %

Sel 0,5à1 %

Solution de calcium

Eau QSP

Sulfate de calcium 1 à 2 %

Xanthane 0,2 %, le mélange peut alors être effectué dans les proportions suivantes

Riz cuit : 85,00

Solution gélifiante : 13,50

Solution de calcium : 1,50, les pourcentages étant donnés en poids.

Une fois le mélange opéré, on coule le produit résultant, sans attendre, sur un tapis équipé d'un système de refroidissement rapide.

Le réseau gélifié s'établit, à la fois, par l'alginate réagissant avec les ions calcium et par la gélatine et les carraghénates qui, sous l'action du refroidissement rapide, emprisonnent les grains dans une trame gélifiante souple facilitant la manipulation du produit.

Cependant, le sulfate de calcium est peu soluble.

Aussi, quand on incorpore ledit sulfate, au dernier moment, à la solution d'alginate, les ions calcium ne réagissent pas immédiatement. C'est la raison pour laquelle il est, en pratique, possible de couler le mélange obtenu en vue de lui donner la forme voulue, par exemple, par moulage, ou alors de pousser

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ledit mélange en boyau. Pour ralentir encore la gélification, on ajoute du pyrophosphate de sodium qui chélate momentanément les ions calcium.

En conséquence, l'agglomérat est stable, aux basses températures, grâce à la présence des gels d'alginate et de carraghénate/gélatine, et aux températures usuelles de cuisson, grâce à la présence du gel d'alginate.

La réaction différée des ions calcium laisse le temps aux molécules gélifiantes hydratées d'être absorbées par les grains de riz.

L'agglomération peut être renforcée par un laminage du mélange lors de son dépôt sur le tapis. En effet, ledit l'agglomérat devient alors plus dense, plus résistant, plus manipulable et régulier. Ce laminage peut être réalisé par l'application d'un rouleau en tête de tapis sous lequel le mélange serait contraint de passer.

Après complet refroidissement du riz, on obtient un agglomérat quel'on peut manipuler, trancher et mettre en oeuvre avec une grande facilité dans des opérations industrielles, en vue d'obtenir, par exemple, des steaks de riz qui peuvent être utilisés tels quels, par le consommateur.I1 suffira alors à celui-ci de les faire cuire afin d'obtenir un plat cuisiné, simple d'emploi, ladite cuisson n'étant parfois qu'un simple réchauffage, le riz étant déjà cuit ou précuit.

L'agglomérat peut, par ailleurs, être découpé en plaques en vue de former des brochettes.

Bien entendu, il est possible de rajouter différents aliments au mélange obtenu et, en particulier, du fromage ou des tomates. Dans le cas du fromage, on aura un excédent de calcium et il faudra en tenir compte dans la gélification ultérieure. Dans le cas de la tomate, on aura une acidification qui solubilisera les ions calcium. La quantité de pyrophosphate sera alors avantageusement augmentée. Par ailleurs, la présente invention permet d'obtenir des plats tels que du riz cantonnais, des petits pois au jambon, du riz au curry, de la polenta au fromage. En fait, les compositions alimentaires issues du procédé offrent de nouvelles occasions de consommer des céréales (plat froid ou chaud), et de nouveaux modes de préparation (riz au barbecue, grillé, frit).On citera, par exemple, des galettes de riz cantonnais à grignoter, des petits cubes de riz arômatisés pour l'apéritif, des sandwiches dans lesquels le -riz formé remplace le pain.

La cuisson, qui dénature les liaisons faibles existant dans le réseau gélifié de carraghénate et gélatine et qui fragilise le réseau d'alginate, rend l'agglomérat susceptible de s'égrener à la moindre sollicitation mécanique. On retrouve, dans ce cas, la nature initiale en grains individualisés du plat. A ce sujet, l'obtention de la composition agglomérée thermosensible de l'invention constitue un résultat surprenant.

En effet, on aurait pu obtenir des blocs de gel et/ou des grains coupés si la cassure ne s'était pas effectuée aux points de contact entre les grains, et si le gel d'alginate n'avait pas été partiellement absorbé par le riz.

En définitive, suivant la taille et la nature des particules granulaires et en fonction de la composition de la solution gélifiante, on obtient, après cuisson, un produit qui va de1'égrené grain à grain jusqu'à la composition sécable à la fourchette, c'est-à-dire de totalement réversible à légèrement thermosensible.Data supplied from the esp@cenet database - Worldwide Claims:


REVENDICATIONS

1. Composition alimentaire granulaire, caractérisée en ce qu'elle comporte un gel, et en ce que des grains de ladite composition granulaire sont agglomérés par ledit gel de manière à former un agglomérat qui s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

2. Composition alimentaire selon la revendication 1, caractérisée en ce que les grains ont un diamètre moyen compris en 1 et 10 mm environ.

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3. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que les grains possèdent une surface perméable au gel afin quel'on ne retrouve pas de résidu de gel lors de l'égrénage du produit aggloméré.

4. Composition alimentaire selon l'une des revendications 1 ou 2, caractérisée en ce que les grains sont des céréales cuites ou précuites et, en particulier, des grains de riz.

5. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que le gel confère à ladite composition une thermostabilité aux températures usuelles de cuisson des compositions alimentaires et une résistance aux actions mécaniques aux basses températures.

6. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que le gel est formé d'alginates ayant réagi avec des ions calcium et/ou de gélatine et carraghénates.

7. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que ladite composition est formée d'environ 66 à 90 % en poids de grains et d'environ 33 à 10 % en poids de gel.

8. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce qu'elle comporte deux agents gélifiants, l'un thermosensible,1 'autre thermorésistant.

9. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce qu'on obtient après cuisson, un produit qui va del'égrené grain à grain à la composition sécable à la fourchette.

10. Procédé de préparation d'une composition alimentaire selon l'une des revendications précédentes, caractérisé en ce qu'on mélange des grains avec une solution gélifiante en vue d'obtenir un agglomérat instable après avoir subi une élévation de température et/ou une action mécanique.

11. Procédé de préparation d'une composition alimentaire selon la revendication 10, caractérisé en ce que on coule le mélange obtenu sur un élément dont la température est plus basse que la température du mélange.

12. Procédé selon l'une des revendications 10 ou 11, caractérisé en ce qu'on procède, ultérieurement au coulage, à un laminage du mélange.Data supplied from the esp@cenet database - Worldwide

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66.

FR2724821 - 3/29/1996

FOOD COMPSN. BASED ON GRAINS, PREF. OR RICE


Inventor(s): BOCABEILLE GILLES (--); GAUDET PATRICE (--)

Applicant(s): SOREAL SA (FR)


IP Class: A23L1/10; A23L1/182; A23P1/02

E Class: A23L1/164C; A23L1/0532; A23L1/0562B


Priority Number: FR19940011603 (19940928); FR19950002703 (19950308)

Family: FR2724821

Abstract:


A food compsn. comprises grains of food material agglomerated by a gel to form an agglomerate which breaks up after being subjected to elevated temp. and/or mechanical working. The grains are specifically of (pre)cooked cereal, esp. rice.Description:


COMPOSITION ALIMENTAIRE GRANULAIRE

ET PROCÉDÉ DE PRÉPARATION D'UNE TELLE COMPOSITION.

L'invention se rapporte au domaine général de l'agro-alimentaire. Elle concerne une composition alimentaire granulaire, ainsi qu'un procédé de préparation d'une telle composition.

Les compositions alimentaires granulaires et, en particulier, les compositions alimentaires de céréales, sont consommées, après cuisson, sous la forme de grains individualisés, séparés les uns des autres. Un consommateur ne peut donc concevoir, a priori, de manger de telles compositions sous une autre forme.

C'est le cas, notamment, du riz, dont la présentation en grains individualisés constitue une présentation a laquelle nous sommes accoutumés depuis toujours.

Selon la présente invention, le demandeur s'est posé le problème d'une présentation différente des compositions précitées, en vue d'une préparation de nouvelles compositions alimentaires, dans lesquelles la nature granulaire ou particulaire est occultée par la composition elle-même. Cependant, le demandeur s'est attaché à faire en sorte que ces nouvelles compositions retrouvent leur nature d'origine, en grains individualisés, au moment de la consommation stricto sensu, c'est-à-dire au moment où le consommateur mange ladite composition.

En définitive, l'invention propose, de maniere inattendue, la réalisation d'une composition alimentaire granulée qui constitue un état provisoire entre un état initial naturel en grains individualisés, et un état final, qui correspond sensiblement à l'état initial précité, et qui est destiné à la consommation.

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L'état provisoire permet, non seulement, de préparer de nouvelles compositions culinaires, mais aussi, notamment, de faciliter la préparation et de proposer de nouveaux mode de consommation.

Ce but, ainsi que d'autres qui apparaîtront par la suite, sont atteints par l'agglomération des grains dans un gel de manière à former un agglomérat qui s'égrène sous l'effet de facteurs extérieurs liés à sa consommation.

Aussi, l'invention a pour objet une composition alimentaire granulaire, caractérisée en ce qu'elle comporte un gel, et en ce que des grains de ladite composition granulaire sont agglomérés par ledit gel de manière à former un agglomérat qui s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

Par ailleurs, l'invention a pour objet un procédé de préparation d'une composition alimentaire, caractérisé en ce qu'on mélange des grains avec une solution gélifiante, en vue d'obtenir un agglomérat instable après avoir subi une élévation de température et/ou une action mécanique.

La description qui va suivre, et qui ne comporte aucun caractère limitatif, permettra de mieux comprendre la manière dont l'invention peut être mise en pratique.

Elle est rédigée en référence à l'exemple d'une composition alimentaire dans laquelle les grains sont des grains de riz.

Toutefois, il est bien entendu que l'invention se rapporte, dans son sens le plus général, à une composition alimentaire granulaire et, plus particulièrement, à une composition alimentaire à base de particules végétales cuites ou précuites, de préférence, céréales, telles que, par exemple, le riz, la semoule de blé, les petits pois, le maïs, ou toute autre catégorie de grains naturels dont le diamètre moyen est compris entre 1 et 10 mm environ.

La composition de la présente invention comporte un gel qui constitue un réseau gélifié.

Ce réseau est avantageusement formé, d'une part, de longues chaînes polycycliques d'alginate liées entre elles par des liaisons covalentes et, d'autre part, de gélatine et de carraghénates. Toutefois, toute autre substance alimentaire gélifiante ou de ce type peut convenir. C'est le cas, par exemple, de la pectine, de la géllane ou de la gélose, ou alors, de certaines protéines telles que les lactoprotéines, les ovoprotéines et l'albumine.

Les grains de riz sont agglomérés par le gel, de manière à former un agglomérat.

Cet agglomérat comporte environ 66 à 90 % en poids de grains et environ 10 à 33 % en poids de gel.

En pratique, pour le riz, on a 10 à 15% de gel.

Le gel est en partie absorbé par les grains de riz. L'autre partie reste cantonnée à la surface des grains de riz notamment aux points de contact entre ceux-ci qui constituent, en définitive, les points de fixation des éléments de l'agglomérat. Par suite, l'agglomérat peut présenter des interstices vides entre les grains.

D'une façon générale, la proportion de solution gélifiante dans la composition doit être minimale afin qu'elle soit facilement absorbée en surface des grains de céréales, qu'elle devienne alors invisible, et quel'on ne retrouve pas de résidu de gel lors de l'égrénage du produit aggloméré, après la cuisson.

L'agglomérat s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

On a donc une réversibilité d'un état transitoire aggloméré vers un état initial dissocié.

Le gel d'alginate est thermostable. Aussi, une cuisson de l'agglomérat à des températures comprises entre 60 et200"C environ, ne suffit pas à rompre les liaisons covalentes qui relient les chaînes d'alginate.

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L'agglomérat, bien que fragilisé, reste entier et conserve sa cohérence, et une action mécanique de faible intensité telle que, par exemple, la pression d'une fourchette ou d'une dent, suffit à briser ledit agglomérat, les grains se dissociant alors en retrouvant leur individualité initiale. Cette dissociation est facilitée par le fait que chaque grain de riz agit, au niveau des points de contact précités, à la manière d'un bras de levier.

D'autre part, le gel de gélatine et de carraghénate est thermosensible : les liaisons faibles qui relient les composés précités sont détruites à des températures de l'ordre de 350C. Aussi, une cuisson à une température supérieure à35"C fragilise1 'agglomérat.

Pour la préparation d'une composition selon l'invention, on choisit un riz étuvé. Ce riz est alors cuit, d'une manière traditionnelle, dans de l'eau portée à ébullition.

Par ailleurs, on prépare une solution gélifiante, ainsi qu'une solution calcique.

La solution gélifiante comporte, de préférence, deux agents gélifiants. Le premier est l'alginate de sodium et le second est formé par le couple carraghénate/gélatine. En outre, la solution gélifiante comporte du pyrophosphate dont la fonction est décrite ci-après.

La solution calcique comporte un sel de calcium tel que le sulfate de calcium et, éventuellement, un agent tensioactif tel que la xanthane qui permet de maintenir le sulfate de calcium en suspension.

On mélange alors le riz cuit, la solution gélifiante, et la solution calcique.

Le mélange est opéré, en général, dans les rapports suivants : céréales cuites/solution gélifiante : 66/33

à 90/10 (% en poids) et solution gélifiante/solution calcique : 95/5 à 80/20 (% en poids).

Pour ce mélange, les solutions gélifiantes et calciques sont préférentiellement acheminées vers un mélangeur classique à l'aide de pompes. Par contre, l'acheminement du riz cuit nécessite l'emploi d'une vis d'Archimède. Il est ainsi particulièrement intéressant d'ajuster ledit mélangeur et la vis d'Archimède selon un même axe.

Dans un exemple, si les solutions de la présente invention ont la composition suivante

Solutiongélifiante

Eau QSP

Alginate1 2 %

Gélatine 2 à 10 %

Carraghénate 0,5 à 1 %

Pyrophosphate 0,1 à 0,3 %

Sel 0,5 à 1 %

Solution de calcium

Eau QSP

Sulfate de calcium 1 à 2 %

Xanthane 0,2 %, le mélange peut alors être effectué dans les proportions suivantes

Riz cuit : 85,00

Solution gélifiante : 13,50

Solution de calcium : 1,50, les pourcentages étant donnés en poids.

Une fois le mélange opéré, on coule le produit résultant, sans attendre, sur un tapis équipéd'un système de refroidissement rapide.

Le réseau gélifié s'établit, à la fois, par l'alginate réagissant avec les ions calcium et par la gélatine et les carraghénates qui, sous l'action du refroidissement rapide, emprisonnent les grains dans une trame gélifiante souple facilitant la manipulation du produit.

Cependant, le sulfate de calcium est peu soluble.

Aussi, quand on incorpore ledit sulfate, au dernier moment, à la solution d'alginate, les ions calcium ne réagissent pas immédiatement. C'est la raison pour laquelle il est, en pratique, possible de couler le

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mélange obtenu en vue de lui donner la forme voulue, par exemple, par moulage, ou alors de pousser ledit mélange en boyau. Pour ralentir encore la gélification, on ajoute du pyrophosphate de sodium qui chélate momentanément les ions calcium.

En conséquence, l'agglomérat est stable, aux basses températures, grâce à la présence des gels d'alginate et de carraghénate/gélatine, et aux températures usuelles de cuisson, grâce à la présence du gel d'alginate.

La réaction différée des ions calcium laisse le temps aux molécules gélifiantes hydratées d'être absorbées par les grains de riz.

L'agglomération peut être renforcée par un laminage du mélange lors de son dépôt sur le tapis. En effet, ledit l'agglomérat devient alors plus dense, plus résistant, plus manipulable et régulier. Ce laminage peut être réalisé par l'application d'un rouleau en tête de tapis sous lequel le mélange serait contraint de passer.

Après complet refroidissement du riz, on obtient un agglomérat quel'on peut manipuler, trancher et mettre en oeuvre avec une grande facilité dans des opérations industrielles, en vue d'obtenir, par exemple, des steaks de riz qui peuvent être utilisés tels quels, par le consommateur. Il suffira alors à celui-ci de les faire cuire afin d'obtenir un plat cuisiné, simple d'emploi, ladite cuisson n'étant parfois qu'un simple réchauffage, le riz étant déjà cuit ou précuit.

L'agglomérat peut, par ailleurs, être découpé en plaques en vue de former des brochettes.

Dans une variante de réalisation de la composition alimentaire selon l'invention, la solution gélifiante, quel'on mélange avec le riz cuit à la manière et dans les proportions décrites ci-dessus, est sensiblement exempte de pyrophosphates.

On remplit alors directement des moules ajourés de forme choisie avec le mélange sans pyrophosphate. On applique ensuite des contraintes de pression en vue de tasser le mélange dans le moule et de réduire les espaces vides entre les grains, à l'aide, en particulier d'un rouleau ou d'une presse pneumatique.

C'est seulement après cette étape de remplissage quel'on provoque la réaction de gélification de l'alginate, soit par immersion du moule dans un bain de solution calcique, soit par passage de celui-ci sous un rideau continu de solution calcique comportant, dans un exemple, 3 % de lactate de calcium et

97 % d'eau. Cette réaction de gélification, induite par la mise en contact du mélange riz/solution gélifiante avec la solution calcique, est quasiment instantanée, du fait que le sel de calcium est très soluble et très réactif, et que le moule est ajouré en de multiples points. Il suffit alors de démouler et de laisser refroidir ladite composition pour obtenir un agglomérat selon l'invention, à la forme du moule.Par exemple, avec un moule rectangulaire, on obtient des plaques pour brochettes, avec un moule ovale, on obtient un steak et, avec un moule fantaisie,l'on peut obtenir un des ramequins de décoration pour assiettes.

Cette variante de réalisation, qui propose de provoquer la gélification de la solution gélifiante dans une

étape ultérieure au mélange de ladite solution gélifiante avec les grains et au moulage du mélane ainsi obtenu, présente donc l'avantage de ne pas nécessiter la présence de composés, tels que les pyrophosphates, retardant la gélification. La conduite industrielle du procédé est ainsi grandement facilitée etl'on économise par ailleurs les coûts inhérent à la présence des pyrophosphates. De surcroît, cette variante de réalisation conduit à la formation d'un agglomérat de qualité supérieure, la réaction de formation d'alginate de calcium n'étant en effet aucunement limitée ou gênée par la présence de sulfate de calcium et de pyrophosphates.

Bien entendu, il est possible de rajouter différents aliments au mélange obtenu et, en particulier, du fromage ou des tomates. Dans le cas du fromage, on aura un excédent de calcium et il faudra en tenir compte dans la gélification ultérieure. Dans le cas de la tomate, on aura une acidification qui solubilisera les ions calcium. La quantité de pyrophosphate sera alors avantageusement augmentée. Par ailleurs, la présente invention permet d'obtenir des plats tels que du riz cantonnais, des petits pois au jambon, du riz au curry, de la polenta au fromage. En fait, les compositions alimentaires issues du

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procédé offrent de nouvelles occasions de consommer des céréales (plat froid ou chaud), et de nouveaux modes de préparation (riz au barbecue, grillé, frit).On citera, par exemple, des galettes de riz cantonnais à grignoter, des petits cubes de riz aromatisés pour l'apéritif, des sandwiches dans lesquels le riz formé remplace le pain.

La cuisson, qui dénature les liaisons faibles existant dans le réseau gélifié de carraghénate et gélatine et qui fragilise le réseau d'alginate, rend l'agglomérat susceptible de s'égrener à la moindre sollicitation mécanique. On retrouve, dans ce cas, la nature initiale en grains individualisés du plat. A ce sujet, l'obtention de la composition agglomérée thermosensible de l'invention constitue un résultat surprenant.

En effet, on aurait pu obtenir des blocs de gel et/ou des grains coupés si la cassure ne s'était pas effectuée aux points de contact entre les grains, et si le gel d'alginate n'avait pas été partiellement absorbé par le riz.

En définitive, suivant la taille et la nature des particules granulaires et en fonction de la composition de la solution gélifiante, on obtient, après cuisson, un produit qui va de l'égréné grain à grain jusqu'à la composition sécable à la fourchette,c'est-à-dire de totalement réversible à légèrement thermosensible.Data supplied from the esp@cenet database - Worldwide Claims:


REVENDICATIONS

1. Composition alimentaire granulaire, caractérisée en ce qu'elle comporte un gel, et en ce que des grains de ladite composition granulaire sont agglomérés par ledit gel de manière à former un agglomérat qui s'égrène après avoir subi une élévation de la température et/ou une action mécanique.

2. Composition alimentaire selon la revendication 1, caractérisée en ce que les grains ont un diamètre moyen compris en 1 et 10 mm environ.

3. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que les grains possèdent une surface perméable au gel afin quel'on ne retrouve pas de résidu de gel lors deltegrenage du produit aggloméré.

4. Composition alimentaire selon l'une des revendications 1 ou 2, caractérisée en ce que les grains sont des céréales cuites ou précuites et, en particulier, des grains de riz.

5. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que le gel confère à ladite composition une thermostabilité aux températures usuelles de cuisson des compositions alimentaires et une résistance aux actions mécaniques aux basses températures.

6. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que le gel est formé d'alginates ayant réagi avec des ions calcium et/ou de gélatine et carraghénates.

7. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce que ladite composition est formée d'environ 66 à 90 % en poids de grains et d'environ 33 à 10 % en poids de gel.

8. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce qu'elle comporte deux agents gélifiants, l'un thermosensible,1 'autre thermorésistant.

9. Composition alimentaire selon l'une des revendications précédentes, caractérisée en ce qu'on obtient après cuisson, un produit qui va de l'égréné grain à grain à la composition sécable à la fourchette.

10. Procédé de préparation d'une composition alimentaire selon l'une des revendications précédentes, caractérisé en ce qu'on mélange des grains avec une solution gélifiante en vue d'obtenir un agglomérat instable après avoir subi une élévation de température et/ou une action mécanique.

11. Procédé selon la revendication 10, caractérisé en ce qu'on provoque la gélification de la solution gélifiante par mélange ou mise en contact d'une solution calcique avec les grains et ladite solution gélifiante.

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12. Procédé de préparation d'une composition alimentaire selon l'une des revendications 10 ou 11, caractérisé en ce que on coule le mélange obtenu sur un élément dont la température est plus basse que la température du mélange.

13. Procédé selon l'une des revendications 10 ou 11 ou 12, caractérisé en ce qu'on procède, ultérieurement au coulage, à un laminage du mélange.

14. Procédé selon la revendication 11, caractérisé en ce que la gélification de la solution gélifiante est provoquée dans une étape ultérieure au mélange de ladite solution gélifiante avec les grains et au moulage du mélange ainsi obtenu.Data supplied from the esp@cenet database - Worldwide

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67.

GB1010854 - 11/24/1965

PROCESS FOR THE PREPARATION OF PRECOOKED RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=GB1010854

Applicant(s): RIVER BRAND RICE MILLS INC (--)

E Class: A23L1/182

Application Number: GB19630000390 (19630103)

Priority Number: US19620164138 (19620103); US19620202073 (19620613)

Family: GB1010854

Abstract:

Abstract of GB1010854

1,010,854. Pre-cooked rice products. RIVER BRAND RICE MILLS Inc. Jan. 3, 1963 [Jan. 3, 1962;

June 13, 1962], No. 390/63. Heading A2Q. In preparing a pre-cooked rice product, grains of rice, e.g. white or brown raw rice or parboiled rice, are heated to a relatively high temperature, e.g. between 120 and 220 F. for raw rice, or between 200 and 225 F. for parboiled rice, then cooled to a lower temperature, e.g. between 60 and 100 F., and heated again to a relatively high temperature, e.g. between 120 and 230 F. for raw rice, or between 200 and 225 F. for parboiled rice, which heating- cooling-heating cycle may be repeated, to produce rifts, crevices, cracks and chinks in the grains thus making them highly permeable and absorptive to water and/or water vapour. The grains may be heated and cooled by hot and cold air and may be in the form of a bed, between 1 and 3 inches thick, on one or more, e.g. three, travelling conveyers. The bed may be quiescent or fluidized by the hot and cold air.

The grains are then cooked, e.g. at atmospheric pressure or at a pressure not exceeding this by more than 5 p.s.i., in hot water, e.g. at a temperature of 195 to 210 F., followed, if desired, by cooking in steam, until they are substantially completely gelatinized. The water-cooked grains may be cooled, i.e. quenched, in cold water or air before they are finally cooked in steam. The cooking water may be distilled water or water having a pH between 5 and 7. The cooked grains are then dried, continuously or in batches, by a hot gas, such as air or nitrogen, until they have a stable moisture content, e.g. between 6 and 11 per cent., by weight. The resulting dried, pre-cooked rice grains may be enriched with a vitamin and packed. The cooked rice grains may be dried by a hot gas in two stages, namely at a temperature between 250 and 350 F. for raw rice, or between 300 and 360 F. for parboiled rice, and then at a temperature between 210 and 280 F. The hot gas may be passed upwardly and downwardly through a bed of cooked grains. Additives, such as flavourings, seasonings and emulsifiers, may be sprayed on to the grains between the drying stages. The cooked rice grains may be cooled and washed in cold water, e.g. having a pH between 7 and 8, before they are dried. Brown rice grains, after having been heated, cooled and re-heated in the above-mentioned manner, may be soaked in tepid water before being cooked.Description:

Description of GB1010854

PATENT SPECIFICATION

NO DRAWINGS.

1,010,854 Date of Application andfiling Complete Specification:

Jan 3, 1963 No 390/63.

Application made in United States of America (No 164,138) on Jan 3, 1962.

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Application made in United States of America (No 202,073) on June 13, 1962.

Complete Specification Published: Nov 24, 1965.

Crown Copyright 1965.

index at Acceptane=:-A 2 Q( 3 A, 3 B, 13, 14 X 16 A, 16 D 16 X, 17).

In CL:-A 23 1 1/10.

CC-1 X Xfl T r 7-V 4 ZV Pt'YTC Ar TTAT' ERPPATA SPECIFICATION NO 1 010,854

Au IENEMENT T; O 1 Page 1, line 51 for tvaluble reai "valuable Page 2, line 98, for grain" read

"grains" Page 4, line 31, for "pressure" read "pressures" Page 4, line 107, for "lntlally" read "initially"

Page 5, line 126, after "er Sn 3 " insert For a clearer understanding of the invention, specific examples of he Invention are given below.

Page 7, line 76, for natmospneric" read "amnosphere" Page 8, line 127, for 1,25 Osh read 225 " THE

PATENT OFFICE, 17th October, 1 cg 6 D 75798/8 rice; or parboiled rice Raw milled or white rice is rice from which the husk and bran coating have both been removed.

Brown rice is raw rice from which the husk has been removed but in which the bran outer coating remains substantially intact Parboiled rice is created by soaking rough rice paddy (unhulled rice substantially as it comes from the field) in cold, warm, or hot water for a substantial period of time, until the rice grains have increased their moisture content, generally to at least above 20 %; draining the rice; and then steaming the rice, generally at superatmospheric pressure, for from 15 minutes to an hour or more.

The steaming opens the hulls and subselPrice The process of preparing parboiled rice is known and used in a number of Asian countries, such as, India, Burma, Malaya, and Ceylon, where it has apparently been practiced for thousands of years In these countries, the drying is usually accomplished by spreading the steamed rice grains in the sun rather than by artificial means.

Aside from differences in the drying means and cooking or steaming at superatmospheric pressure, the process of parboiling rice as practiced today is basically the same as that which has been used for many years under primitive conditions.

In addition to the advantage of transferring nutritive elements from the bran and I O 0 C:"'I II


1,010,854 NO DRAWINGS.

Date of Application and filing Complete Specification:

Jan 3, 1963 No 390/63.

Application made in United States of America (No 164,138) on Jan 3, 1962.

Application made in United States of America (No 202,073) on June 13, 1962.


C) Crown Copyright 1965.

Index at Acceptance:-A 2 Q( 3 A, 3 B, 13, 14 X, 16 A, 16 D, 16 X, 17).

Int CL:-A 23 1 1/10.

COMPLETE SPECIFICATION.

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Process for the Preparation of Precooked Rice.

We, RIVER BRAND R Ic E MILLS, INC, a Corporation organised under the laws of the State of

Delaware, United States of America, of 1702, Taylor Street, Houston, 10, Texas, United States of

America, (assignee of HARRY S AUTREY and LAWRENCE LYNN), do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a new and improved method for the preparation of an instant or precooked rice product, and more particularly to a method for creating a precooked rice or a precooked parboiled rice that can be rapidly rehydrated for serving and that upon rehydration has the natural flavour and texture of a good grade of regular cooked rice or cooked parboiled rice.

The method of this invention may be used to create a precooked rice product from any of three common types of rice, i e, raw milled polished rice or white rice; brown rice; or parboiled rice Raw milled or white rice is rice from which the husk and bran coating have both been removed.

Brown rice is raw rice from which the husk has been removed but in which the bran outer coating remains substantially intact Parboiled rice is created by soaking rough rice paddy (unhulled rice substantially as it comes from the field) in cold, warm, or hot water for a substantial period of time, until the rice grains have increased their moisture content, generally to at least above 20 %; draining the rice; and then steaming the rice, generally at superatmospheric pressure, for from 15 minutes to an hour or more.

The steaming opens the hulls and subselPrice quent to steaming the grains are dried and then milled.

Typical dry parboiled rice is somewhat discolored as compared with ordinary raw white rice The bran coating on rice grain is rich in nutritional elements including vitamins and minerals, and for this reason brown rice is generally considered more valuble nutritionally than white rice A major advantage of the parboiling process is that during the steaming step and especially when the steam is at superatmospheric pressure, nutritional elements in the bran coating, such as vitamins and minerals, tend to be driven into or to migrate into the rice grains During the actual parboiling or steaming step, the starch in the rice grains is substantially gelatinized, and since the rice grains are protected by the hull and the bran coating, they tend to retain their original shape After the grains have been thoroughly steamed, the hulls begin to separate from the kernels or grains At the end of the steaming, the kernels consist of a gelatinized elastic starch which becomes translucent and hard upon drying.

The process of preparing parboiled rice is known and used in a number of Asian countries, such as,

India, Burma, Malaya, and Ceylon, where it has apparently been practiced for thousands of years In these countries, the drying is usually accomplished by spreading the steamed rice grains in the sun rather than by artificial means.

Aside from differences in the drying means and cooking or steaming at superatmospheric pressure, the process of parboiling rice as practiced today is basically the same as that which has been used for many years under primitive conditions.

In addition to the advantage of transferring nutritive elements from the bran and IO Fo germ into the grain or endosperm, the parboiling process also provides the following advantages: parboiled rice keeps better both before and after cooking; parboiled rice is more resistant to insect infestation and any existing infestation is destroyed in the process; breakage in the milling step is substantially reduced and a higher yield of quality kernels is obtained; a distinctive flavor is imparted to the rice grains; this flavor being preferred by some users; and recipe tolerance is improved.

One disadvantage of parboiled rice as compared to raw white rice is that ordinary parboiled rice requires a longer kitchen cook time before it is ready for serving The time required for cooking regular raw white milled rice of the Bluebonnnet, Texas Patna, Rexoro, or similar varieties is about 15 minutes of residence in water at 212 'F, whereas the time required for cooking parboiled rice is customarily about 25 to 30 minutes at 212 'F Accordingly, the desirability of a process for preparing a precooked

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rice product of acceptable quality may be considered even greater for parboiled than for regular milled white rice.

Many attempts have been made to treat rice grains for instantization, with the object of producing economically with high acceptability and at high yields, precooked rice or precooked parboiled rice in the dehydrated state which, on rapid rehydration, will be as desirable in terms of appearance and organoleptic acceptability as a good grade of freshly cooked regular or parboiled rice.

Such prior art teachings, however, have left many shortcomings in flavor, rate of rehydration, degree of rehydration possible, dry or rehydrated appearance, color, mouth feel and structure, storageability, and the like In many instances the rehydrated final product is excessively bland, or lacking in natural flavor because of the damage to the flavor precursors or to the flavor itself inherent in the processing step.

In some instances of the prior art, the pretreatment of the raw material needed to permit a uniform cook irreversibly destroys the texture In other instances the ideal balance of desirable product attributes as compared to the economics of preparation remains to be deduced and practiced In still other instances where some quality is achieved, this achievement can be made with only extremely high capital cost facilities, and expensive processing as, for example, is characteristic of one process for preparing parboiled rice which comprises the steps of freezing the cooked parboiled rice followed by drying of the initially frozen rice cake at low temperatures for prolonged periods of time Compounding the problem of pretreatment, whether by heat or water, and the problem of precooking, is the problem of dehydration which must fix the structure, remove water sufficiently to satisfy stability requirements, and permit easy and rapid rehydration in the product 70 It has been found that a significant improvement over the prior art can be achieved by the process of this invention, which results in high yields of an instantized regular rice or parboiled rice product which 75 on rapid rehydration yields an end-product characterized by the natural flavor and grain individuality of a good grade of regular rice or parboiled rice, and precooked parboiled rice of this invention has resistance 80 to crumbling or falling apart in formulated recipe applications, such as, soups and casserole dishes, a characteristic particularly important to the institutional user of parboiled rice 85 Among the important and valuable results achieved by this invention are that it makes available to the manufacturer for sale and to the consumer for use, precooked rice products that save kitchen preparation 90 time and avoid recipe errors which might otherwise result in poor end-product characteristics.

According to the present invention, a process for preparing a precooked rice product 95 comprises thermally pretreating rice grains by exposing them alternately to elevated and lower temperatures, the grain being at least exposed first to an elevated or high temperature, then to a lower temperature, 100 and then for a second time to an elevated or high temperature, whereby the rice grains are rendered highly permeable and adsorptive to water and/or water vapour, cooking the grains with hot water and/or steam 105 until the grains are substantially completely gelatinised and rapidly drying the cooked grains to a stable moisture content with a heated inert gas i e a gas which is substantially inert with respect to the cooked grains, 110 e.g air.

The rice grains which are thermally pretreated may be raw or parboiled rice grains and may be exposed alternately to high and low temperatures in rapid succession, with 115 the first and last exposures preferably being to a high temperature.

In accordance with this invention, a new and improved process is provided for creating a precooked rice or precooked parboiled 120 rice produce that can be rapidly rehydrated to yield a highly palatable and desirable cooked rice having the natural flavor and texture of a good grade of regular cooked rice or parboiled cooked rice 125 As embodied in one preferred embodiment of this invention, the process may successfully employ as raw material, rice of long, medium, or short grain at its normal moisture content of 10 to 14 ,' The rice 130 1,010,854 temperature is maintained so that the total time in this operation is preferably about minutes, but may be from 3 to 7 minutes.

The rice is then moved onto the second conveyor, where it is quickly chilled by cool 70 air that may be from 60 to 1000 F, and is preferably 85 to 950 F for raw rice; and preferably 75 to 90 F, for parboiled rice.

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The rice is briefly retained at this temperature, for a combined residence time of from 75 3 to 10 minutes, preferably about 5 minutes.

The rice is then transferred to the third conveyor and is again heated as before in about 30 to 75 seconds to an elevated or high temperature equal to or preferably 80 slightly exceeding the temperature attained in the first stage of the heating cycle, which may be from 120 to 2300 F, is advantageously 140 to 1900 F, and is preferably 150 to 170 F for raw rice; and may be from 85 to 2250 F, and is preferably about 2100 F, for parboiled rice; but should always be below 2400 F The rice is then retained at the elevated temperature for a combined residence time of from 3 to 15 minutes, and 90 preferably about 5 minutes.

This procedure may be repeated using a number of cycles with the value of the temperature being dependent on the type and nature of raw materials, but for optimum 95 pretreatment with milled white rice, brown rice, or parboiled rice, of most common varieties, three cycles as described above in sequence is considered ideal insofar as further processing and final product quality are 100 concerned.

In the first elevated temperature step of the thermal cycling pretreatment, the raising of the temperature of the rice grains at a fairly high heat transfer rate during the 105 first 30 to 75 seconds causes a multiplicity of tiny rifts and crevices almost invisible to the naked eye, to form in the surface of the grains due partly to loss of stable moisture content upon heating The second pretreat 110 ment step, or the cooling step, because it follows the first heating step in rapid succession and is conducted at a fairly rapid heat transfer rate during the first few minutes, causes the rice grains to form compression

115 chinks and cracks as a result of the sudden downward shift in temperature Finally, the third pretreatment step, or the second heating step, also conducted at a fairly high heat transfer rate during the first 30 to 75 120 seconds, causes the grains to once more expand and causes additional moisture to be driven off; in so doing, -the compression chinks and cracks as well as the previously formed expansion rifts and crevices are in 125 duced to open and enlarge and some additional crevices are formed In this manner the rice grains are given a highly Dermeable and absorptive structure The results of the pretreatment are particularly pronounced 130 may be either milled white or brown The conditions following are illustrative of the processing of milled white rice, but it will be apparent to those skilled in the art that the sequence taught, with appropriate modifications and operating conditions, would be applicable also to brown rice.

As embodied in another preferred embodiment of this invention, this process may successfully employ as raw material parboiled rice of the long, medium, or short grain class at its normal moisture content of 10 to 14 % The conditions following are illustrative of the processing of parboiled rice made from the Bluebonnet variety but it will be apparent to those skilled in the art that the sequence taught with appropriate modifications in operating conditions, can be applied to parboiled rice prepared from other varieties and grain lengths.

Milled white rice, or parboiled rice, is first fed, preferably at a controlled weight rate of flow, to a pretreatment chamber including a conveyor, or preferably a multiplicity of conveyors arranged in series.

When a multiplicity of conveyors is used, minimum of three such conveyors is desirable A bed of rice reposes upon each conveyor and may be either turbulent i e.

fluidized by heating or cooling air or relatively quiescent.

The beds may be very close to each other, but practically speaking, not adjoining, or may be separated by short conveying devices For raw rice, the static thickness of the beds should be from 1 to 3 inches, preferably about 1 25 inches, and for parboiled rice, should be from 1/2 to 2-1/2 inches, preferably about 1 inch If a single bed is employed, as in batch processing, it is operated in sequence through steps simulating a multiplicity of beds.

In accordance with the invention, steps are provided for gentle thermal cycling of the rice grains to make them highly permeable and absorptive to water and water vapour and thus enable a rapid cook, rapid rehydration of the precooked product, and retention of flavor and uniformity of quality.

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In the thermal cycling portion of this invention as here embodied for raw rice, the feed material on the first conveyor is initially heated from its ambient temperature condition to an elevated temperature that may be from 120 to 2200 F, is advantageously to 1800 F, and preferably is 140 to 1600 F: and for parboiled rice, may be from to 2250 F, and is preferably about 2100 F Heated air is used as the heating medium, and if ambient air contains too much moisture, heated dehumidified air is used This heating to the elevated temperature is accomplished in from 30 to 75 seconds, preferably about 50 seconds, and the elevated 1,010,854 with parboiled rice which possesses a high permeable and absorptive structure after pretreatment, as compared to its original highly impermeable and vitreous surface which is characteristic of untreated parboiled rice.

The thermal cycling pretreatment step contributes significantly towards enabling a rapid cook, rapid dehydration, retention of flavor and uniformity of quality In its avoidance of extremes of temperature or prolonged exposure to high temperatures, it leads to the formation of very few broken grains and to extremely rapid processing after thermal cycling, thus reducing the time during which flavor or flavor precursors may be destroyed In these and other respects, thermal cycling is the major advance over prior teachings, which incorporate only heating, or only chilling, or only some simple non-timedependent combination of one cycle of each at either highly elevated or reduced temperatures.

Immediately, or shortly after thermal cycling, the rice is fed into a batch or continuous cooker for gelatinization At this time the moisture content of the rice grain is from 5 to 9 % and preferably about 6

5 %.

This cook may be carried out by water immersion in substantially boiling water at atmospheric pressure or at pressures up to psig, preferably the water is from 195 to 2100 F, and below 5 psig, by steaming, or by combinations of alternate immersion and steaming.

The duration of the cooking step for raw rice is from 9 to 13 minutes, and for parboiled rice and brown rice is from 18 to 25 minutes, preferably about 23 minutes At the end of the cooking step gelatinization will be substantially complete Upon completion of cooking the Gelatinization reaction should be abruptly terminated and the surface slightly case hardened by quenching An abundance of cold water is efficacious for such rapid quenching.

In accordance with the invention, at the completion of -the cooking an additional step may be advantageously included to firm the surface of the rice grains As here embodied, if immersion cooking is practiced, or a combination of alternate immersion and steaming, it may be desirable to terminate the cook with a very short period of atmospheric steaming, preferably of from 0.5 to 3 5 minutes in duration for raw rice, and from 1 to 5 minutes, preferably 2 to 4 minutes for parboiled rice, with or without an intermediate cold water or air quenching step before such steaming This steaming is advantageously conducted so as to firm the surface of the rice with little or no additional cooking, and this is evidenced by a negligible increase in moisture content during the steaming step Steaming substantially longer than this minimal time is not necessary and usually is to be avoided since this tends to destroy or carry off, as by steam distillation, the subtle and volatile flavor elements native to the rice grains 70 It has been found that an extremely white, dry, rehydrated rice will result from the use of distilled water or regular clean water adjusted if desired to a p H of from 5 to 7 in the cook and wash, when immersion 75 cooking or alternate immersion and steaming is used Such an extremely white rice may be attractive to and particularly desired by certain consumers Except for color, however, such a precooked rice exhibits 80 essentially the same physical and organoleptic properties as the product made without the use of distilled water or water in which the p H has not been adjusted.

The cooled and slightly case-hardened, 85 precooked rice with a moisture content of to 75 %, and preferably from 65 to 73 %, is then washed and drained in cold water both to intensify the casehardening and for removal of any surface slime and residue 90 of ruptured starch cells before surface draining for 4 to 10 minutes and transfer to the drying equipment.

The drying may be effected in either a batch or continuous manner, the moisture 95 beina most effectively removed by a stream of heated air or a stream of heated inert gas such as a nitrogen

Although a single temperature and air velocity may be used for a suitable time, for best results, the 100 drying sequence consists of two phases In the first phase the rice is exposed to a strong upward stream of heated air and raised to a bed temperature of from 250 to 350 F, preferably from 285 to 3350 F, 105

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for raw rice; and from 300 to 360 F, and preferably intially from 330 to 350 F, for parboiled rice, for a total heat application period of from 3 minutes to 10 minutes, and preferably about 6 minutes The time 110 temnerature relationship is a prime determinant of the amount of expansion or porosity which occurs in the final product.

The partially dried rice may then be withdrawn temporarily from the heating 115 medium, if desired to apply to the partially dried rice additives, such as flavorings, seasonings and emulsifiers by procedures such as spray coating, using a solution or dispersion of the additive to be used 120 In the second phase of the drying process, the partially dried rice kernels with essentially pre-set external size and structure are finally dried using heated air and a bed temperature of from 210 to 2800 F 125 prefershlv from 230 to 2700 F for raw rice; and preferably from 220 to 250 F for parboiled rice for a residence time of from 4 to 15 minutes, and preferably from 11 to 14 minutes for raw rice, and preferably 130 1,010,854 combined immersion and steaming, for about 12 minutes and at an average temperature of about 2030 F.

Upon completion of the cooking step, the rice is steamed for from 2 to 3 minutes It 70 is then quenched with cold water, washed and drained for about 5 minutes The water used throughout this quenching part of the process is preferably at a p H of about 7 to 8 75 The rice is then subjected to the first phase drying at a temperature of about 3250 F for about 6 to 7 minutes The second phase drying is then accomplished at about 275 F for about 13 miuntes Upon com 80 pletion of the drying the moisture content of the rice should be from 6 to 10 %, preferably at the lower end of this range The completion of the drying is followed by the usual screening and gentle working of the 85 grains

Ideally, the rice grains at a moisture content close to 6 % are then packaged with a suitable packaging material to retain this low moisture content.

The just described precooked rice product 90 can be rehydrated by immersion in cold water of volume equal to the rice which is brought to a boil with salt or butter added, if desired, and which, upon reaching a moderate rolling boil, is covered, removed 95 from the heat, and allowed to stand for from seconds to 2 minutes The rice is then ready for serving and is again extremely light fluffy rice with retention of natural flavor and texture and a high degree of grain 100 individuality.

The above-described basic process is easily adaptable to preparing a precooked brown rice product from brown rice To achieve the precooked brown rice product, 105 the pretreatment of this invention is administered at a slightly more elevated tempzraiure than is called for with raw milled white rice The brown rice should be cooked for from 15 to 25 minutes after the 110 thermal cycling pretreatment In other respects the process for brown rice does not differ from the basic process.

As an alternative to the above process for preparing precooked brown rice, after 115 the brown rice has been subjected to the thermal cycling pretreatment, a preliminary soaking may be used, of the order of 30 minutes im Pmersion in tenid water, e g at about 1500 F The soaking may take place 120 under sli-ht nressure, then the cooking time may be in the lower nqrt of the, nrescribed range, or about 15 minutes This process for nrenaring precooked brown rice yields a product having a density of about 0 4

125 gm/cm 3.

EXAMPLE I

Raw milled white rice of the Bluebonnet variety with a moisture content of 11 8 % was charged to a batch thermal cycling 130 from 5 to 10 minutes for parboiled rice.

This procedure permits the final drying of the rice grains to a moisture level of from 9 to 11 % by weight.

The dried rice is gently milled to break up large agglomerate clumps, prior to screening to separate

"unders" and "overs" cuts from the product stream The clumps or "overs" are further milled, as required, for size reduction, and further recovery of individual grains to be added to the main product stream prior to vitamin enrichment, if provided, and packaging.

The dried product of this invention, with a specific gravity of from 0 3 to 0 5 gm/cm 3 can be rehydrated rapidly upon standing in water which has been brought to a boil, the amount of water

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received and the stand time being dependent upon the raw material type and variety being used, and upon the specific conditions under which the unit processes described above are conducted.

With the precooked raw rice of this invention, using equal volumes of dried product and water, stand times from 2 to 5 minutes, yield an extremely white or light fluffy rice with retention of natural flavor and with a high degree of grain individuality With the precooked parboiled rice of this invention, using equal volumes of dried product and water, stand times from 3 to 5 minutes yield a light fluffy rice with retention of the natural flavor and high degree of grain individuality characteristic of parboiled rice, together with a high degree of resistance to crumbling or falling apart in recipe application typical of parboiled rice.

The precooked parboiled rice product can also be rehydrated by immersion in cold water of volume equal to the rice which is brought to a boil with salt or butter added, if desired, and which, upon reaching a moderate rolling boil, is covered, removed from the heat, and allowed to stand for from 3 to

5 minutes The rice is then ready for serving, and is again extremely light fluffy rice with retention of natural flavor and texture and a high degree of grain individuality, characteristic of parboiled rice.

With the following slight variations in the basic process described above, it is possible to produce a very rapidly rehydratable precooked white rice.

The same pretreatment as described above is used except that the thermal cycling temperatures will tend toward the upper part of the preferred ranges, e g, about 160 F for the first heating steo, about

850 F for the quick-chill or cooling step, and about F for the second heating stem Each of the steps should be about 5 minutes in duration.

Upon completion of the pretreatment, the rice is immersion cooked or cooked with 1,010,854

1,010,854 chamber to a bed depth of about 1 " It was brought to a temperature of 140 ' F in 30 seconds and maintained at that temperature by passage of heated air for 4 minutes and 30 seconds At the completion of that time, the moisture content was 10 %, and the rice was noted to have a number of heat-induced expansion rifts and crevices The rate of heat-transfer as measured by the bed temperature of the rice during the first 30 seconds of this heating step was about 57 BTU/lb /min. The rice was next air-cooled, reaching a

temperature of 980 F, in 3 minutes, and 880 F, in 5 minutes, at which time the moisture content was 9

%, and the rice was observed to have a number of chinks and cracks induced by the compression of rapid chilling The rate of heat transfer in this chilling step as measured by the bed temperature of the rice during the first minute of chilling was about 9 BTU/lb /min.

The temperature of the rice was next raised to 1640 F, in 3 minutes and maintained there for 2 minutes by preheated air; this reduced the moisture content to 6.0 % opening up the compression chinks and cracks and introducing some additional heat expansion rifts and crevices The rate of heat transfer as measured by the bed temperature of the rice during the first 30 seconds of this second heating step was about 56/BTU/lb /min.

The pretreated rice was then cooked in an excess of water at 2020 F for 12 minutes in a cooker equinned with a basket containing the rice, and the basket was raised and lowered to provide gentle aaitation This cook served to substantially gelatinize the starch in the rice and raised the moisture content to 70 %.

The basket was then raised above the surface of the cook water and the cook water drained from the rice for 2 minutes while the basket was immersed in steam.

The moisture content of the rice after steaming was 70 % or essentially the same as before steaming.

The pre-cooked rice was then reduced in temperature, using a water wash which, in addition to stopping the cook, served to clean the grains surface of ruptured starch cells A temperature of 90 F was reached after washing for 1 minute and a temperature of 66 WF was reached after another 3 minutes Washing was accomplished by rapidly pumping a mixture of water and rice into and out of a vessel containing 6 gallons of water per pound of rice After washing the rice was drained on a screen

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for 3 minutes, washed once more gently with water from a hose and drained for another 8 minutes The moisture content of the rice was then observed to be 74 %.

The drained rice was then dried from a 1 " thick bed in a two stage drying sequence.

First, preheated air was passed upwardly through the bed which was maintained at 260 'F for 6 minutes, with an air pressure drop of 0 6 " of water across the bed The 70 direction of air flow was then changed to a downward direction, and this required 2 minutes Finally, air was passed downwardly through the bed for 10 minutes with a 0 3 " pressure drop while the bed was 75 maintained at 2100 F

The moisture content of the rice was reduced by drying to about 10,'.

The processed rice was observed to have a specific gravity of 0 384 gm/cm 3 One 80 cup or 90 grams was rehydrated by the addition of one cup of 232 ml of water, which had been brought to a boil After standing 5 minutes, this yielded a rehydrated volume of 405 cubic centimeters of light 85 and fluffy rice with a highly palatable flavor and texture.

The heat-transfer rates in the above example should be considered illustrative rather than limiting 90

Heat-transfer rates particularly suitable for the process, whether applied to white milled rice, brown rice, or parboiled rice, as described herein and as measured by the bed temperature of the rice are from

40 95 BTU/lb Imin to 70 BTU/lb /min, and preferably from 50 BTU/lb /min to 62 BTU Jlb /min for the first 30 to 75 seconds of the first heating stem from 6 BTU/lb / min to 19 BTU/lb /min, and preferably

100 from 8 BTU/lb /min to 10 BTU/lb /min.

during the first minute of the chilling ste D; and from 40 BTU/lb /min to 70 BTU/lb / min, and preferably from 50 BTU/lb /min.

to 62 BTU/lb min for the first 30 to 75 105 seconds of the second heating step.

The heat-transfer rate for the first 30 seconds of the first or initial heating step has been pointed out above and should be high enough to cause rifts and crevices to 110 form in the surface of the rice grains; the heat-transfer rate for the first minute of the chilling step should be rapid enough to induce compression chinks and cracks to form in the rice grains, and the heat-transfer rate 115 for the first 30 seconds of the second heating ste D should be high enough to cause the rice grains to once more expand, to drive off add tional moisture, and to cause the previously formed expansion rifts and 120 crevices and compression chinks and cracks to open and enlarge and to cause the formation of some additional expansion crevices.

EXAMPLE II

Brown rice of the Bluebonnet variety with 125 a moisture content of 11 2 % was thermally cycled as in Example I to temperatures of 1850 F in 45 seconds and held there for 3 minutes and 15 seconds, to

1080 F in gelatinize the starch in the rice and raised the moisture content to 73 2 %.

The basket was then raised above the surface of the water and quenched to a temperature of 800 F, by passing water at 70 tap temperature through it for 2 minutes while draining the cook water out of the cooker.

The lid was then closed on the cooker and the rice was submitted to steam at 75 atmospheric pressure for 4 minutes at which time the moisture content was 72 0 %, or essentially unchanged.

The precooked rice was then reduced in temperature to 820 F, with a water quench 80 for 2 minutes which superficially cleaned the rice.

The precooked rice was then washed in a surplus of water at ambient temperature for 3 minutes after which the temperature 85 of the rice was lowered to 730 F, and the moisture content was 73 2 %

Washing was done by rapidly pumping a mixture of water and rice in and out of a vessel containing 6 gallons of water per pound of 90 rice After washing in the washer the rice was drained on a screen and again washed with a hose for 2 minutes The rice was then allowed to drain on the screen for from 6 to

7 minutes 95 The drained rice was then dried in a 1/2 inch thick bed in a two-stage drying sequence

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First preheated air at a static pressure of 0 65 " of water was passed up through the bed at a temperature of 3400 F, 100 in 5 minutes The direction of air flow was then reversed which required 2 5 minutes and air was blown down through the bed at a temperature of 2250 F, and a static pressure of 0 35 " of water for 7 minutes 1 o 5 The moisture content of the rice was reduced by drying to about 10 %.

The rice was observed to have a specific gravity of 0 39 gm/cm 3 One cup, or 90 grams, was rehydrated by the addition of 110 one cup or 232 ml of water, which had been brought to a boil, to yield after standing minutes a rehydrated volume of 385 cubic centimeters of light and fluffy looking rice with a highly palatable flavor and texture 115 and with the flavor, textural grain individuality and performance characteristics typical of a good grade of regular parboiled rice which has been properly cooked.Data supplied from the esp@cenet database - Worldwide Claims:

Claims of GB1010854

WHAT WE CLAIM IS: 120

1 A process for preparing a precooked rice product which comprises thermally pretreating rice grains by exposing them alternately to elevated and lower temperatures, the grains being at least exposed first to an 125 elevated or high temperature, then to a lower temperature, and then for a second time to an elevated or high temperature, whereby the rice grains are rendered highly 4 minutes, and to 1850 F in another 4 minutes and held there for 3 minutes The moisture content after this treatment was 7.2 % The rice was then precooked at 203 F, in water immersion using an excess of water for 19 minutes, and thereafter the rice was steamed for 2 minutes The moisture content after immersion cooking was 71 % and was substantially the same after steaming.

The rice was then quenched and washed with cool water for 4 minutes, drained for 3 minutes, briefly hose-washed and redrained for 6 minutes, and the moisture content was then 73 %.

The drained brown rice was dried initially for 6 minutes with air upflow at 2650 F, and a pressure drop of 0 65 " of water, then with air downwardly for 14 minutes at 2200 F, and a pressure drop of 0 30

" over the bed The dry precooked brown rice product was observed to have a specific gravity of about

0 4 and a moisture content of 11 % One cup or 94 grams rehydrated upon immersion and standing for 5 minutes in 232 ml of water which had been brought to a boil, to 350 ml of highly palatable brown rice with a flavor and texture equal to that of a well-prepared brown rice.

Alternatively, if an extra tender texture is desired, the dry product can be added to boiling water and therein simmered for 5 minutes.

EXAMPLE III Parboiled Texas Bluebonnet at a moisture content of 10 0 % was placed in a batch thermal cycling chamber to a bed depth of about 3/4 inch It was brought to a temperature of 2100 F, in

50 seconds and held there by passing heating air through it for 4 minutes and 10 seconds at which time the moisture content was lowered to 8 2 % and the rice was noted to have a multiplicity of very small heat-induced expansion rifts and crevices.

The parboiled rice was next air cooled, to a temperature of 1140 F, in 3 minutes and to 820 F, in five minutes, at which time the moisture content was 8 8 % and the rice was observed to have a multiplicity of very small chinks and cracks induced by the compression of rapid chilling.

The temperature of the rice was next raised to 2100 F, in five minutes by passing preheated air through the bed; this reduced the moisture content to 7 4 % opening up the compression chinks and cracks and introducing some additional heat-expansion rifts and crevices.

The pretreated rice was then cooked in an excess of water at 2100 F, for 23-1/2 minutes in a cooker equipped with a basket containing the rice, and the basket was raised and lowered to gently agitate this rice This cook served to substantially 1,010,854 permeable and absorptive to water and/or water vapour, cooking the grains with hot water and/or steam until the grains are substantially completely gelatinized, and rapidly drying the cooked grains to a stable moisture content with a heated inert gas.

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2 A process as claimed in claim 1 in which the rice grains are in the form of a bed when subjected to the thermal pretreatment, in which the heat-transfer rate as measured by the bed temperature of the rice during the first elevated or high temperature step is sufficiently high to cause rifts and crevices to form in the surface of the rice grains, in which the heat-transfer rate during the lower temperature step is sufficiently rapid to induce compression chinks and cracks to form in the rice grains, and in which the heat-transfer rate durin R the second elevated or high temperature step is sufficiently high to cause the previously formed exnansion rifts and crevices and compression chinks and cracks to open and enlarge and to cause the formation of additional expansion crevices.

3 A process as claimed in claim 2 in which the range of rates of heat transfer as measured by the bed temperature of the riee during portions of the nretreatment steps are as follows: from 40 BTU/lb /mm.

to 70 13 TIJ/lb min during the first 30 to 75 seconds of the first hieh temperature sten, from 6 IBTU/lb

/min, to 12 BTU/Ib /min.

during the first minute of the lower temperature step, and from 40 BTU/lb /min to 70 BTU/lb /min during the first 30 to 75 seconds of the second high temperature step.

4 A process as claimed in any one of the preceding claims in which the cooking of the rice grains is partially accomplished by immersing them in heated water, and in which the water has a p H adjusted to from to 7.

A process as claimed in any one of claims 1 to 3 in which the cooking of the rice grains is accomplished partially by immersing them in heated distilled water.

6 A process as claimed in any one of the preceding claims in which the rice grains are subjected to both the first and second high temperature exposures and the lower temperature exposure for a duration of about 5 minutes for each exposure.

7 A process as claimed in any of the preceding claims in which the cooking step comprises a treatment with hot water followed by a steaming step whereby the surface of the rice grains is firmed with substantially no additional cooking of the grain and without the driving off of flavor elements.

8 A process as claimed in any one of the preceding claims in which the rice grains are subjected to a quenching step upon completion of the cooking step.

9 A process as claimed in any one of the preceding claims in which the rice grains are washed in cold water and drained upon completion of the cooking step and prior to the drying step 70 A process as claimed in any one of the preceding claims in which the cooking of the rice grains is accomplished by alternate immersion in water at 1950 to 210 'F, and steaming 75 11 A process as claimed in any one of the preceding claims in which the rice before treatment is a raw milled white rice.

12 A process as claimed in any one of the preceding claims in which, for raw rice, 80 the first high temperature exposure is at a temperature of from 1200 to 220 'F, the lower temperature exposure is at a temperature of from 60 to 100 l F, and the second high temperature exposure is at a tempera 85 ture of from 1200 to 230 'F.

13 A process as claimed in any one of the nreceding claims in which for raw rice, the first high temperature exposure is at a temperature of from 1300 to 1800 F the low 90 temperature exposure is at a temperature of from 85 to 950 F, and the second high temperature exposure is at a temperature of from 140 to 190 'F.

14 A process as claimed in any one of 95 the preceding claims in which for raw milled rice, the cooking step has a duration of from 9 to 13 minutes.

A process as claimed in any one of the preceding claims in which for raw rice, 100 the cooking step is terminated with a short period of atmospheric steaming, the steaming having a duration of from 0 5 to 3

5 minutes.

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16 A -process as claimed in claim 15 105 which also includes an intermediate quenching step in which the grains are cooled in cold water or air before the terminal steaming step.

17 A process as claimed in any one of 110 the preceding claims in which for raw rice, the drying step is accomplished in two phases, the rice grains being subjected to heated gas at a temperature of from

2500 to 3500 F in the first stage, and the rice grains 115 being subjected to a temperature of from 210 ' to 280 'F in the second stage, with the second stage temperature always being substantially less than the first stage temperature 120 18 A process as claimed in any one of claims 1 to 10 in which the rice before treatment is a parboiled rice.

19 A process as claimed in claim 18 in which for parboiled rice, the first high 125 temperature exposure is at a temperature of from 2000 to 27 i O F, the lower temnerature exposure is at a temperature of from 600 to 1000 F, and the second high tempera1,010,854 of from 2100 to 280 'F in the second stage, with the second stage temperature always being substantially less than the first stage temperature.

23 A Process as claimed in any one of claims 1 to 10 in which the rice before treatment is a raw brown rice.

24 A process as claimed in any of claims 18 to 23 in which, for parboiled rice and brown rice, the cooking step has a duration of from 18 to 25 minutes.

A pre-cooked rice product whenever prepared by the process claimed in any one of the preceding claims.

26 A process for preparing a precooked rice product substantially as hereinbefore described with reference to the Examples.

W P THOMPSON & CO, 12 Church Street, Liverpool, 1, Chartered Patent Agents.

ture exposure is at a temperature of from 2000 to 2250 F.

A process as claimed in claim 19 in which the first high temperature exposure is at a temperature of substantially 210 'F, the lower temperature exposure is at a temperature of from 750 to 90 'F, and the second high temperature is at a temperature of substantially 210 'F.

21 A process as claimed in any one of claims 18 to 20 in which, for parboiled rice, the cooking step is terminated with a short period of atmospheric steaming, the steaming having a duration of from 1 to 5 minutes.

22 A process as claimed in any one ofclaims 18 to 21 in which, for parboiled rice, the drying step is accomplished in two phases, the rice grains being subjected to heated inert gas at a temperature of from

3000 to 360 'F in the first stage, and the rice grains being subjected to a temperature Abingdon: Printed for Her Majesty's Stationery Office, by Burgess & Son (Abingdon), Ltd -1965.

Published at The Patent Office, 25 Southampton Buildings, London, W C 2 from which copies may be obtained.

1,010,854Data supplied from the esp@cenet database - Worldwide

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68.

GB1012396 - 12/8/1965

IMPROVEMENTS IN OR RELATING TO DEXTROSE-CONTAINING

PRODUCTS


Applicant(s): HAROLD ELI BODE (--)

E Class: A23L1/105B; A21D2/18; A21D8/04B; C12P19/20


Priority Number: GB19630011457 (19630322)

Family: GB1012396

Abstract:


1,012,396. Glucose foods. H. E. BODE. March 22, 1963, No. 11457/63. Heading A2B. As a baking aid, a brewer's sugar or an ingredient of confectionery or ice-cream is used an amylaceous food in which the starch has been converted to glucose by an amyloglucosidase free from protease, lipase or transglucosidase. The amyloglucosidase may be derived by purifying an extract of Aspergillus niger mycelium. Examples of the foods converted are maize starch, ground maize and hominy and wheat flour, rice, tapioca, corn syrup malt syrup.Claims:


WHAT I CLAIM IS:

1 A process for the preparation of material containing dextrose from starch contained in crude amylaceous food or feed product containing protein and fat which comprises contacting the crude amylaceous food or feed product with amyloglucosidase which is substantially free from protease, lipase and transglucosidase.

2 A process as claimed in claim 1, wherein the amylaceous food or feed product is a vegetable foodstuff.

3 A process as claimed in claim 2 wherein the vegetable foodstuff is a cereal.

4 A process as claimed in any of claims 1 to 3 wherein sufficient invert sugar is added to the resulting material containing dextrose to prevent crystallisation of the dextrose.

A process as claimed in any of claims 1 to 4 wherein the crude amylaceous food or feed product is contacted with amyloglucosidase until the product comprises 95 % by weight of dextrose.

6 A process as claimed in claim 1 wherein the crude amylaceous food or feed product is nongelatinised bakery dough.

7 A process as claimed in claim 1 wherein the amyloglucosidase is added to an aqueous slurry of the crude amylaceous food or feed product.

8 A process as claimed in claim 1 which comprises forming an aqueous slurry from the crude amylaceous food or feed product, cooling the slurry to an amyloglucosidaseconverting temperature,

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contacting it with a substantially protase, lipase and transglucoPrinted for Her Majesty's Stationery

Office by the Courier Press, Leamington Spa, 1969.

Published by the Patent Office, 25 Southampton Buildings, London, W C 2, from which copies may be obtained.


340/2197

69.

GB1260047 - 1/12/1972

PROCESS FOR PREPARING A SNACK FOOD PRODUCT


E Class: A23L1/164E

Application Number: GBD1260047 (19691001)


Family: GB1260047


Abstract:


1,260,047. Snack food product. GENERAL FOODS CORP. 1 Oct., 1969 [7 Oct., 1968], No. 48355/69.

Heading A2B. A snack food product comprises popcorn in a dough matrix containing flours and starch.

The popcorn may be whole or comminuted and is preferably incorporated into a cooked dough. The flours may be a mixture of tapioca, corn, rice, oat and/or wheat flour. The starch may be potato, waxy maize, corn, rice and/or tapioca starch. The dough matrix may contain salt or other flavours. In a process of making the product, the dough matrix is formed and gelatinised, popcorn is incorporated in the dough and the resultant mixture is shaped (e.g. by extruding into sheets or ropes, rolling, cutting), cooled and dried. The dried product may be further shaped, roasted or cooked, e.g. in a fluidised bed or deep fat fryer, to puff it, and then coated e.g. with salt, spices or sauces.Claims:


WHAT WE CLAIM IS: -

1 A snack food product comprising popcorn in a dough matrix containing flours and starch.

2 A snack food product according to claim 1, in which the popcorn is comminuted and the dough matrix is cooked.

3 A snack food product according to claim 2, in which the ratio of popcorn to a cooked dough matrix is from 1 to 3 to 3 to 1, by weight.

4 A snack food product according to claim 3, in which the ratio of popcorn to a cooked dough base matrix is 2 to 1.

A snack food product according to any one of claims 1 to 4, in which the flours are tapioca flour and corn flour and the starch is potato starch.

6 A snack food product according to claim 5, in which the weight ratio of tapioca flour to corn flour to potato starch is 1 to 1 to 1.

7 A snack food product according to any one of claims 1 to 6, wherein said product 50 is a deep fat fried product.

8 A snack food product according to any one of claims 1 to 7, wherein the product is in chip form and popcorn is comminuted and is in a cooked dough matrix containing tapioca 55 flour, corn flour and potato starch, the ratio of popcorn to cooked dough matrix being 2 to 1, by weight.

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9 A snack food product substantially as hereinbefore described in the Examples 60 A process for preparing a snack food product which comprises making a dough mixture containing flours and starch, cooking said mixture to gelatinize the same, adding popcorn to said cooked dough mixture, 65 shaping and forming the popcorn-containing cooked dough mixture, cooling and drying said shaped and formed mixture to a moisture content of 8 to 12 % by weight.

11 A process according to claim 10, in 70 which shaping and forming are carried out by extruding and sheeting the popcorn-containing cooked dough mixture.

12 A process according to claim 10, in which shaping and forming are carried out 75 by extruding and slicing the popcorn-containing cooked dough mixture.

13 A process according to any one of claims 10 to 12, in which the popcorn is comminuted 80 14 A process according to any one of claims to 13, in which said shaped, dried mixture is deep fat fried.

A process for preparing a snack food product substantially as hereinbefore described 85 in the

Examples.

16 A snack food product when produced by the process according to any one of claims to 15.

STEVENS, HEWLETT & PERKINS, Chartered Patent Agents, Agents for the Applicants.

Printed for Her Majesty's Stationery Office by the Courier Press, Leamington Spa, 1972.

Published by the Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.

1,260,047 hiData supplied from the esp@cenet database - Worldwide

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70.

GB1261666 - 1/26/1972

FORTIFIED VEGETABLE PRODUCT


Inventor(s): HEUSDENS WILHELMUS (--); GUEVARA BALAGTAS FRANCISCO (--)

Applicant(s): RALSTON PURINA CO (US)


IP Class: A23L1/10

E Class: A23L1/01B; A23L1/164E; A23L1/217B; A23L1/00P8E; A23L1/216B



Family: GB1261666

Equivalent: US3692531; NL7010701; LU61365; FR2055568; DE2032753; BE753836

Abstract:


1,261,666. Protein food. RALSTON PUR- INA CO. 24 July, 1970 [24 July, 1969], No. 36148/70.

Heading A2B. A carbohydrate material is at least partly gelatinised, mixed with a heat settable oilseed protein material to form a substantially homogeneous mixture, containing 30-50% moisture, 15-20% protein, and 25-50% carbohydrate, and this mixture is then shaped. The product may be heated, for example by frying, to set the protein. Preferred carbohydrate sources include wheat, rice, milo, barley, and other corn, potatoes, tapioca, cellulosic vegetables such as carrot and beet, and fruit such as bananas, apples, and pears. The preferred protein materials are soy and sesame. Examples refer to the production of chips, puff shells, pie shells, and fried snack foods.Description:



NO DRAWINGS ( 21) Application No 36148/70 ( 22) Filed 24 July 1970 ( 31) Convention

Application No 844663 ( 32) Filed 24 July 1969 in ( 33) United States of America (US) ( 45) Complete

Specification published 26 Jan 1972 ( 51) International Classification A 23 j 3/00 A 2311/10 1/12 ( 52)

Index at acceptance A 2 B 1 B 1 E 1 J 1 L ( 72) Inventors WILHELMUS HEUSDENS and

BALAGTAS FRANCISCO GUEVARA ( 54) FORTIFIED VEGETABLE PRODUCT ( 71) We,

RALSTON PURINA COMPANY, a Body Corporate organised and existing under the laws of the

State of Missouri, United States of America, of 835, South Eighth Street, Saint Louis, Missouri 63199,

United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

The present invention relates to a carbohydrate material fortified with an oilseed protein.

Protein deficiency is a problem confronting a large proportion of the world's population, in particular, that portion of the population which is unable to purchase protein in its more expensive primary forms, such as milk, meat and fish Much of the world's protein deficiency could be met by less expensive

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protein sources than meat or fresh animal protein if an inexpensive secondary source of protein, such as vegetable protein, could be used.

We have now discovered a process for fortifying food products with protein from secondary sources, which process involves fortifying carbohydrate materials, such as a substantially gelatinized starch, with a substantially undenatured oilseed protein material.

Accordingly, the present invention consists in a process for preparing a food product which comprises wholly or partially gelatinizing a carbohydrate, preferably a high molecular weight carbohydrate, mixing a heat-settable oilseed protein material with the gelatinized carbohydrate to form a substantially homogeneous mixture containing from to 50 % 1 moisture, from 15 to 20 % protein and from 25 to 50

% carbohydrate and shaping the mixture to form said food product The product may then 'be heated to a temperature sufficient to set said protein, e.g by frying or otherwise.

The gelatinization of the carbohydrate source is preferably effected by cooking it at lPrice 25 pl a temperature of less than 1000 C Preferred carbohydrates are the polysaccharides, especially starch It is difficult to determine the degree of gelatinization of a starch, although an approximate estimate may be obtained by examining the starch under polarized light By this test, we prefer that more than 50 % of the starch particles should be gelatinized and preferably about 80 % are gelatinized.

The carbohydrate can be from a variety of sources, for example starch-containing materials such as grain and grain flours can be used Carbohydrate sources which are particularly useful in the process of the invention are: wheat; rice; milo; barley; other corn; potatoes; tapioca; cellulosic vegetables, such as carrots and beets; and fruit, such as bananas, apples and pears Green bananas are particularly useful due to their high starch content The source of carbohydrate used will normally be the dominant or most economical source in the particular locality in which the process of the invention is used.

The protein material used should be heatsettable and may sometimes be referred to as "undenatured" or "ungelled": it should still retain the capacity to set under the influence of heat and this means that it should have undergone substantially no irreversible changes to its structure The most useful protein materials are the vegetable protein and protein isolates from oilseeds, such as soy protein and sesame protein.

The food products are formed by mixing the protein material with the carbohydrate and working the material into a homogeneous mixture The carbohydrate may be in a cooked or an uncooked state, but if starch is used, it should be in a partially or wholly gelatinized condition The protein which is mixed with the carbohydrate should not, however, be heat gelled After the carbohydrate and the protein material are mixed, they are formed into the desired shape, for example a snack chip, and are heated to set the protein.

11) 1261666 1,261,666 The heat treatment gives the product its desirable taste and "mouthfeel" characteristics by fully gelatinizing the starch source, foi example by adding fat to the product or by cooking a crust on the surface of the product We have found that the combination of cooking and the high initial content of a protein which has not been heat-set adds unexpected desirable characteristics to the cooked product in addition to the nutritional benefit from the protein fortification The protein adds to the stability of the product on storage: products produced according to the method of this invention have an increased shelf life and they remain crisp and palatable for longer periods than do products which do not contain the protein fortification The exact mechanism by which this increased shelf life is obtained is not clear, however, we believe that the protein becomes resistant to moisture on being heatset and actually inhibits absorption of moisture by the food product.

By forming the food product at a temperature below the temperature at which the protein material will set or gell, preferably below 100 'C, a product is formed under conditions which allow the proteinfortified material to be readily worked The formed product can then be cooked to set the protein carbohydrate mixture The cooking toughens the protein and inhibits absorption of moisture by the product The cooking step also adds, crispness to the final product and reduces the moisture content The final moisture content of the cooked product will normally be about 6 % by weight.

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The cooking step can be performed mn a variety of ways: by conventional ovens; microwave ovens; or by frying We have found that deep-fat frying is particularly useful since it cooks the product quickly, reduces the moisture content and adds fat to the product The added fat improves the flavour of the cooked product A deep fried snack food produced by the method of this invention has a pleasing taste, a very crisp "mouthfeel" and a greatly enhanced shelf life Moreover, although it is desirable that the product should absorb some fat, a high content of absorbed fat will render a fried product undesirable since it will feel greasy in the mouth It has been found that the addition of protein to the product causes the product to absorb less fat than would be absorbed by an all starch product.

Food products can be produced by the method of this invention which are designed to be frozen and subsequently reconstituted by heat: examples of these are frozen pie shells or filled puff pastry The products will reconstitute rapidly to form a palatable cooked product: for example, puff pastry produced by this method will reconstitute in about 3 minutes, which is much quicker than the 20 minutes required by a conventional product.

The invention is further illustrated with reference to the following Examples.

EXAMPLE 1

Ground, frozen stew-cut potatoes were 70 cooked in a Brabender extruder cooker in two zones The first zone was at a temperature of 1000 C and the second zone was at a temperature of 801 C The cooked potatoes were extruded from the second zone at a tempera 75 ture of 800 C and with a moisture content of about 54 % by weight.

One hundred parts by weight of isolated soy protein and 200 parts by weight of water were added to

500 parts of the cooked potatoes 80 and mixed in a Brabender extruder fitted with a low pressure screw

The mixture was extruded (temperature between 80 to 100 GC) through a one inch ribbon die The ribbon was cut into 1 5 inch pieces and deep fried 85 in an oil bath at 1700 C The fried chips had a very crisp mouthfeel and a highly pleasing taste The chips had a final content of 6 % water, 20 fat, 20 ', protein, and 45 carbohydrate 90 EXAMPLE 2

A mixture prepared as described in Example 1 was formed into a puff shell product by cold extruding the material through a one inch diameter tube die The extruded 95 tube was filled with a cheese filling, cut into 2 inch lengths, and the lengths were closed at both ends The filled pieces were deep fried in an oil bath at 1700 C The cooked pieces had a pleasant taste and mouthfeel The puff 100 shells were very crisp The cooked pieces were frozen and were later prepared for consumption by heating in a 2050 C oven for three minutes.

EXAMPLE 3 105

A mixture prepared as described in Example 1 was cold extruded through a square die having 1/4 inch sides The extruded bars were cut into 2 inch lengths and deep fried in an oil bath at 1700 C The fried pieces had 110 a crisp texture and a pleasing taste The fried pieces could be frozen and reconstituted by heating in a 2050 C oven for about three minutes.

EXAMPLE 4 115

A mixture prepared as described in Example 1 was formed into a pie shell and frozen The frozen shell was prepared for use by heating in an oven at 2050 C for about ten minutes 120 EXAMPLE 5

Three hundred grams of all purpose wheat flour were extruded thriugh a Brabender extruder at a moisture content of 36 % at a temperature of 1400 C Seventy grams of iso 125 1,261,666 lated soy protein and 200 grams of canned pears (moisture content 85 to 90 % by weight) were ground and mixed in with the gelatinized flour The mix was cold extruded into 1/4 inch rods The rods were cut into

1 5 inch pieces and deep fried The deep fried pieces had a crisp, chewy texture and a pleasant fruit flavour The fried pieces were judged to be an exceptionally palatable snack food.

EXAMPLE 6

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Five hundred grams of rice flour were mixed with 100 grams of isolated soy protein and 500 grams of water The mix was worked to a homogeneous consistency and cold extruded into 1/4 inch diameter rods The rods were cut into 2 inch lengths and deep fried.

The fried pieces had a crisp mouthfeel and a pleasant taste The fried pieces were judged to be an exceptionally palatable snack food.Data supplied from the esp@cenet database - Worldwide

Claims:


WHAT WE CLAIM IS:-

1 A process for preparing a food product which comprises wholly or partially gelatinizing a carbohydrate, mixing a heat-settable oilseed protein material with the gelatinized carbohydrate to form a substantially homogeneous mixture containing from 30 to 50 % moisture, from 15 to 20 % protein and from 25 to 50 % carbohydrate and shaping the mixture to form said food product.

2 A process according to claim 1, in which said carbohydrate is a high molecular weight carbohydrate.

3 A process according to claim 2, in which said carbohydrate is starch.

4 A process according to claim 3, in which at least 50 % of said starch is gelatinized.

A process faccording to claim 3 or claim 4, in which said starch is in the form of potato.

6 A process according to any one of claims 1 to 5, in which said carbohydrate is gelatinized by heating at a temperature less than oc.

7 A process according to any one of the preceding claims, in which said protein material is soy protein.

8 A process according to any one of the preceding claims, in which said mixing is effected at a temperature below 1001 C.

9 A process according to any one of the preceding claims, in which said shaping is effected at a temperature below 1000 C.

A process according to any one of the preceding claims, in which said product is subsequently heated to a temperature sufficient to set said protein.

11 A process according to claim 1, substantially as hereinbefore described with reference to any one of the foregoing Examples.

12 A food product when prepared by a process according to any one of the preceding claims.

MARKS & CLERK, Chartered Patent Agents, 57 & 58 Lincoln's Inn Fields, London, WC 2 A 3 LS.

Agents for the applicant(s).

Printed for Her Majesty's Stationery Office, by the Courier Press, Leamington Spa, 1972.

Pu blished by The Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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71.

GB1262718 - 2/2/1972

METHOD AND APPARATUS FOR PRODUCING EXPANDED FOODSTUFFS


Applicant(s): KIKKOMAN SHOYU CO LTD (JP)


IP Class: A23L1/18

E Class: A23L1/00P14B; A23P1/14B



Family: GB1262718

Equivalent: US3754930; US3661071; DE1933393

Abstract:


1,262,718. Expanded foodstuffs. KIKKO- MAN SHOYU CO. Ltd. 30 June, 1969 [1 Oct., 1968], No.

32893/69. Headings A2B and A2Q. A continuous process for producing an expanded foodstuff comprises the steps of entraining the foodstuff in granular or powder form in a pressurised heated gas stream, for example superheated steam, thereby heating the foodstuff whilst it is in a dispersed and suspended state, and then discharging the thus heated material into a gaseous atmosphere maintained at a lower pressure. Foodstuffs exemplified are rice, wheat, and defatted soy bean. Also referred to are vegetables, fruit, fish, and shellfish Fig. 1 shows a suitable apparatus, the starting material being fed from hopper 1 into conduit 10 where it is entrained in superheated steam, separated at 11, and discharged into expansion tank 13.Description:



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DRAWINGS ATTACHED ( 21) Application No 32893/69, ( 22) Filed 30 June 1969 ( 31) Convention

Application No 70808 ( 32) Filed 1 Oct 1968 in ( 33) Japan (JA) ( 45) Complete Specification published 2 Feb 1972 ( 51) International Classification A 23 1 1/18 ( 52) Index at acceptance A 2 B i D l E 1 J A 2 Q 21 22 ( 54) METHOD AND APPARATUS FOR PRODUCING EXPANDED

FOODSTUFFS ( 71) We, KIKKOMAN S Ho Yu Co, LTD, a corporation organized under the laws of

Japan, of 339, Noda, Noda-shi, Japan, do hereby declare the invention, for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a method of and apparatus for continuously producing an expanded foodstuff

In particular but not exclusively, the invention is concerned with the expansion of materials (e g polished rice and glutinous rice) which are readily gelatinized by heat and therefore tend to adhere to and harden on the wall of the heating equipment in which they are heated or particles of which tend to agglomerate with each other, materials (e.g vegetables, fruits, fish and shellfish) which are sensitive to heat, materials -of uneven grain size (wide grain size distribution) and ordinary granular foodstuff materials.

An object of the invention is to heat a foodstuff material uniformly and to expand the same efficiently in a short period of time.

According to the invention a method of continuously producing an expanded foodstuff comprises entraining a granular or powdery foodstuff material or a mixture of two or more such materials in a pressurized, heated gas stream, e g pressurized super-heated steam at a pressure of 3-15 kg/cm 2 gauge and a temperature of 100-3001 C, in a dispersed and suspended condition thereby to transport said foodstuff material while heating the same by said heated gas, and then discharging the thus heated material into a gaseous atmosphere maintained at a lower pressure, thereby to expand said material.

In one hitherto known process -for producing an expanded foodstuff, the so-called indirect-heating method has been employed for heating the foodstuff material In this process the material is heated by charging it in a closed cylindrical pressure container or a socalled puffing gum which is heated externally by a gas burner or the like while being rotated With this method however, it is impossible uniformly to heat all particles of the material and the yield of the product is markedly lowered due to scorching or insufficient heating In addition, since the material particles are in contact with the wall and also with each other, the particles adhere to the wall of the container or to each other and harden in that state where the material has a particularly large amount of free water or the surface starch of the material is readily gelatinized, thus making it impossible to obtain a satisfactory result from the treatment.

In another method used for heating a material, the material is placed in the aforesaid container or a container in which there is provided means for mechanically stirring or transporting the material and heated therein by means of a heating medium, e g a pressurized heating gas, blown thereinto This method is superior to the preceding method in respect of heat transfer efficiency and thermal efficiency but still inevitably involves the above-mentioned trouble due to contact of the material particles with each other.

There has also been proposed a method (U.K patent specification No 1,099,253) which is the socalled fluidized bed heating method and in which a material is fed into a closed pressure container to form a fluidized bed on an apertured plate disposed in said container and heated in the fluidized state with a gaseous heating medium blown upwardly through the apertures in said apertured plate This method is far superior to the preceding two methods in respect of thermal efficiency and heat transfer efficiency and in that the material particles are heated in a dispersed condition, but is not adapted for use in the expansion of such a material which contains a relatively large amount of water providing for ready gelatinization of the starch thereof or which is sensitive to heat and ( 11) 1262718 1,262,718 consists of particles of uneven particle size.

The above-described problems possessed by the conventional methods and apparatus for expanding food stuffs have been solved easily by the method and apparatus according to the present invention.

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Namely, the present invention has the following advantages:

( 1) Since a gas stream is used as heating medium, the coefficient of heat-transfer between a material to be heated and the heating medium is extremely large (or the heattransfer speed is very high) and, therefore, a heat-expansion treatment can be accomplished in a very short period of time Practically speaking, an expansion treatment of the ordinary cereals can be accomplished only within 10 seconds when they are heated by a heating medium at a pressure of 5-15 kg/cm 2 G and a temperature of 200-

2500 C, as contrasted to a retention time of 1 minute or longer in case of the conventional expanding method and apparatus.

( 2) Since the material is intensely stirred and dispersed, not mechanically but by th W eddy flow of the gaseous heating medium, the particles of the material are brought into contact with the apparatus wall or with each other much less frequently during the period in which the material resides in the apparatus.

Therefore, a treatment of even such a material which has been agglomerated and hardened (into blocks) due to the free water or the surface starch of which is readily gelatinized by heat or which has a relatively large amount of free water (e g polished rice, vegetables, fruits) can be performed with ease.

( 3) The heating time can be varied freely by changing the flowing velocity of the gaseous heating medium With a constant velocity of a gas stream, the transport velocity of a given material is determined by the physical properties of said material, such as the particle size, water content and shape of the material Namely, even in case of a material with a wide particle size distribution, those particles which are relatively small in diameter and readily heated are entrained in the gas stream at a relatively high speed and heated in a shorter time, whilst those particles which are relatively large in diameter and take a relatively long time to be heated are entrained in the gas stream at a relatively low speed and heated for a longer time Thus, all the particles are heated uniformly and a uniform expanded food stuff can be obtained.

( 4) Powdery materials can be treated.

( 5) Since the pressure-receiving member is essentially a single tube, the structure of said member can be rendered resistive to pressure in a simple manner and further, since the apparatus involves no moving part for transporting a material, for a heating period, the operation, maintenance and control of the apparatus are simple.

( 6) Automatic control can be attained simply.

( 7) It is possible to transport a material over a long distance while heating the material 70 ( 8) Reheating and re-circulation of the heating medium are possible.

A preferred embodiment of the present invention will be described hereunder with reference to the accompanying drawings, par 75 ticularly to Fig 1 A material which has previously been subjected to a suitable pretreatment is continuously fed into a material supply hopper 1 The material in the supply hopper 1 is continuously dropped through a 80 chute 3 at a predetermined time interval by means of a rotary feeder 2, to be introduced into a solid substance displacing means 5 having forced discharge means 4 and located between closed containers maintained at dif 85 ferent pressures In this case, the displacing means 5 and the rotary feeder 2 are operatively correlated through a single chain in such a manner that the material is dropped from the rotary feeder when an inlet port 6 of the 90 displacing means is located just at the top of said displacing means.

Where use is made of a superheated steam, a high-pressure steam generated in a boiler 7 is heated in a superheater 8 and the result 95 ant superheated steam leaving the superheater 8 enters a mixer 9 and thence flows through a heating conduit 10.

On the other hand, the material displaced by the displacing means 5 under sealed con 100 dition is fed into the mixer 9 against the high pressure of the superheated steam and then entrained in the steam, flowing through the heating conduit 10, in a dispersed condition and transported in said heating conduit while 105 being subjected to a heat treatment In this case, the heating time (or retention time) of the

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material may optionally be changed by changing the length of the conduit 10 or the velocity of the steam flowing in said conduit 110 The material heated for a predetermined time in the heating conduit while being entrained in the flow of steam enters a cyclone 11, wherein it is separated from the steam and then abruptly discharged into an expansion 115 tank 13, maintained at the atmospheric pressure, by means of another displacing means 12 having the same construction as that of the aforesaid displacing means 5, whereby the material is expanded On the other hand, 120 the superheated steam leaving the cyclone 11 from the top thereof is led through a pressure regulating valve 14 to another station where it is used as a heat source (for example, for drying the expanded product or for pre 125 heating the material if such be necessary).

Alternatively, the used superheated steam is circulated by a compressor (not shown) for reuse The length of the heating conduit 10 can be determined by the time which is re 130 1,262,718 quired for heating the material to a temperature at which the material acquires an amount of heat sufficient for expansion, and the velocity at which the material moves in the conduit along with the superheated steam.

The mixer 9, the heating conduit 10 and the cyclone 11 are heated by the exhaust gases of the superheater 8, which gases are circulated through a heating jacket 15 and discharged therefrom through an exhaust port 16 under suction.

Referring to Fig 2 there is shown a mixer by which sticky materials, such as polished rice, are mixed in the superheated steam flow and which is used in place of the mixer 9 shown in Fig 1 The mixer has a material inlet port 31, a heating superheated steam inlet port 32 and another superheated steam inlet port 33 Interior of the material inlet port 31 is disposed a perforated inner cylinder having a large number of apertures 34 formed over the entire surface thereof The superheated steam admitted in the mixer through the inlet port 33 fills an annular space between the inner wall of the material inlet port

31 and the outer wall of the perforated inner cylinder 35, and sucked into the interior of said perforated inner cylinder through the apertures 34 formed therein.

Therefore, the material interior of the perforated inner cylinder 35 is blown radially inwardly of said inner cylinder by the steam jetting inwardly through the apertures 34 and thereby prevented from adhering to the inner surface of said inner cylinder 35 Occasionally, all the superheated steam required may be introduced into the mixer through the inlet port 33.

Now, examples of the expanding operation conducted by the present inventors using the apparatus of this invention will be illustrated hereinafter:

EXAMPLE 1

Material:

Heating medium:

Polished rice (with or without rice-bran) Bulk density Water content Superheated steam Pressure 1000 kg/M 3 14 5-15 % 6 kg/cm 2 G Temperature 250 O C.

(at heating conduit inlet) Temperature 200 'C.

(at heating conduit outlet) Steam velocity Material treating capacity (on a continuous basis):

Treatment time (retention time): m/sec.

1000 kg/hr.

6 sec.

Properties of the product:

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Water content Bulk density Conversion to cc starch 8 % kg/m 3 98 % 1,262,718 Wheat Superheated steam Treating capacity:

Treatment time:

Properties of product:

EXAMPLE 3

Material: Defatted soy bean Heating medium: Superheated steam Treating capacity (on a continuous basis):

Treatment time:

Properties of product:

Bulk density 780 kg/m 3 Water content 13 5 14 5 % Pressure 7 kg/cm 2 G Temperature 280 C.

(at heating conduit inlet) Temperature 220 C.

(at heating conduit outlet) Steam velocity 20 m/sec.

1000 kg/hr.

8 sec.

Water content 10 %l Bulk density 150 kg/mn 3 (Expansion ratio about 5 times) Conversion to a starch

99 % Bulk density 450 kg/m 3 Water content 9 5-10 5 % Particle size distribution 4 mesh or larger -68

5 % 4 -8 mesh 18 9 % f 8-32 mesh 12 6 % Pressure 5 kg/cm 2 G Temperature 250 C.

(at heating conduit inlet) Temperature 220 C.

(at heating conduit outlet) Steam velocity 18 m/sec.

500 kg/hr. sec.

Water content 4 % Note: The protein can be completely denatured) EXAMPLE 2

Material:

Heating medium:

1,262,718Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS: -

1 A method of continuously producing an expanded foodstuff comprising entraining a granular or powdery foodstuff material or a mixture of two or more such materials in a pressurized, heated gas stream in a dispersed and suspended condition thereby to transport said food stuff material while heating the same by said heated gas, and then discharging the thus heated material into a gaseous atmosphere maintained at a lower pressure.

2 The method claimed in claim 1, in which the heated gas stream is a stream of superheated steam.

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3 A method of continuously producing an expanded foodstuff substantially as herein described with reference to the accompanying drawings and any of the foregoing Examples.

4 An apparatus for continuously expanding a foodstuff comprising a conduit, means for producing a stream of a heated, pressurized gas flowing through the conduit at a desired velocity, a mixer in communication with said conduit for introducing the foodstuff material to be expanded into said conduit, means disposed downstream of said conduit in communication therewith for collecting said foodstuff material entrained in said heated pressurized gas stream while being heated thereby, and means for abruptly discharging the collected heated foodstuff material into a gaseous atmosphere at a lower pressure.

Apparatus for continuously producing an expanded foodstuff constructed and arranged substantially as herein described with reference to Figure 1, or Figure 1 as modified by Figure 2, of the accompanying drawings.

6 An expanded foodstuff when made by the method claimed in any of claims 1 to 3 or in the apparatus claimed in claim 4 or 5.

J Y & G W JOHNSON, Furnival House, 14-18, High Holborn, London, W C 1.

Chartered Patent Agents, Agents for the Applicants.


Published by the Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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72.

GB1265386 - 3/1/1972

GB1265386



IP Class: A23L1/00

E Class: A23L1/10B



Family: GB1265386

Equivalent: FR2004138; DE1913359

Abstract:


1,265,386. Enriching cereal grain. KYOWA HAKKO KOGYO K.K. 17 March, 1969 [18 March,

1968], No. 13986/69. Heading A2Q. A process of preparing cereal grains having an enriched amino acid content (e.g. rice, barley, wheat, rye, maize), comprises boiling the grains in an aqueous solution of one or more amino acids and/or salts thereof for a time sufficient to gelatinise at least part of the starch in the grains into the [alpha]-form and drying the boiled grains. The solution may comprise one or more of lysine, threanine, valine and salts (e.g. hydrochlorides and hydrobromides) thereof, methionine, sodium inosinate, sodium guanylate and sugar. The boiling may be done under pressure.Description:


(54)ENRICHME OiF CEREALGRMNS (71) We, KYOWA 1 HARKS I:OGYO

KABUSHIKI RAISHA, a Body Corporate ofJapan, of No. 4, 1-chome,Ohte-machi,

Chiyoda-ku, Tokyo-to, Japan, do hereby declare the invention, forwliid we pray that a patent may be granted to us, and the method bywhich it isbo be performed, to be particularly described in and by the followingstatement:

The present invention relates to a process for preparing cereal grains such as rice grains enriched with amino acids for example, lysine, threonine and valinewhich are water-soluble and which are stable in water wllen heated to100 C.

Enriched rice grains are widely used throughout south-east Asia as a foodstuff and it is well known that the shortage of essential aminoacids such as lysine and threonine is closely related to the nutritional problem amongr:ce-eating nations. Such essential amino acids have recently been produced more cheaply by fermentation procedures and it is proposed to utilize such amino acids by enriching rice grains with them in order to improve the balance of nutrients in the grain.

Although var;ous proposals have been made, for the preparation of enriched rice grains with various nutrients, with theexception of vitamin enrichment, such proposals have not been commercially successful. The required conditions forenriching rice grains with amino acids are significantly different from those conditionsreqmred when enriching rice grains with vitamins since substantially larger quantities of amino acids are required in order to obtain the desired results. It is therefore difficult to obtain optimum results by means of conventional enriching process since the operation is complicated and costs are high.

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Consequently, rice grains enriched with amino acids have never been produced on a commercially significant scale.

The method of enriching rice grains by coating the grains with amino acids is not advantageous because theenriching substances are readily dissolved in water when the rice grains are washed with water prior to boiling treatment.Although it is possible to utilize ricegrains that have been coatedvçlith amino acids by adding them to uncoated grains in an amount sufficient to enrich the total amount of rice grains before pre-treating the grains with water, this procedure is pointles since the same result could be obtained if the enriching agents were added to untreated grains beforeconsumption. However, enriched cereals can be obtained if the cereal grains are pretreated by heating them so as to gelatinize the starch present in the grains into thee-form and then soaking the pretreated grains in the enriching agent e.g. amino acids since the grains are then capable of absorbing considerable amounts of enriching agents.

This process hasrhe disadvantage that the pretreatment is complicated andexpensive owing to the fact that the grains must be dried twice. Moreover, the grains are liable to crack when subjected to the drying treatment.

The defects inherent in both the aforemenrioned processes can advantageously be overcome by employing the process of the present invention which utilizes the simultaneous treatment of the grains for thegelatiaza- tion of the starch into the a-form and for the absorption of one or more amino acids.

According to the present invention there is provided a process for preparing cereal grains having an enriched amino acid content whichcomprises boiling cereal grains in an aqueous solution of one or more amino acids and/or the water-soluble non-toxic salts thereof, for a period sufficient to gelatinize at least a part of the starch present in the grains into thete-form and drying the boiled grains.

In the present process the total amount of the amino acid(s) and/or the water-soluble non-toxic salt(s) thereof, dissolved in the water which is used fortreatment may be completely used for enriching the cereal grains, and furthermore the rate of loss of the enriching agents from the cereal grainsinto water can be surprisingly reduced when the grains are stood in water afterenrichment.

By the process of this invention, it is possible to obtain improved enriched cereals in a simple and advantageousway. In this manner, various amino acidsean be absorbed into the cereal grains e.g. amino acidswhich are soluble in water and stable under boiling conditions. It is also possible to incorporate various chemical and natural seasoning;with any of the desired amino acids.

Cereal grains suitable for use in the process of the present invention include r:ce,barley, wheat, rye and maize. To obtain the best advantage of the enriching treatment the grains should be in a semirefined or refined state prior to the treatment. As used herein the term"semi-refined" meansthe removal of the unedible external layers of the grain such as the husk, by grinding. The term "refined" as used herein means the removal of some edible external lavers and embryo in addition to the unedible layers.

Boiling can take place in variouscocven- tional ways,e.g. by using a rice boiler. The boiling temperature may be raised, if desired, to aboveIOOSC bv applying a suitable pressure of 0.5 to1Kg/cm. The boilingi.me is normally selected so as to effect substantially complete absorption of the amino acid(s) and/ or the water-soluble non-toxic salt(s) thereof, from the aqueous solution and it generally varies from 20 to 60 minutes.Usually, a fairlv concentrated aqueous solution of amino acid(s) and/or salts) thereofiS employed, e.g. from 5 to90-/) preferably from 15 to50 by weight of amino acids(s) and/or salt(s) thereof based on the water. The weight ratio of aqueous solution to grain may vary widely but is usually 0.5 to 5, and preferably 0.9 to 1.5.

After boiling, the grains may be dried in such a way so as to prevent the grains from cracking.

The used amino acids include amino acids which are soluble in water and stable at boiling temperatures. The aqueous solution may comprise lysine, threonine,valine or mixtures thereof, their water-soluble non-toxic salts, such as thehydroclilorides andhydrobromides, or mixtures of such salts.

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Other nutrients and seasoning agents which can be incorporated include methionine, sodium inosinate and sodium guanylate.

The invention will now be described with reference to the following Examples.

EXAMPLE 1.

Rice grains (market grade: 150g)were washed with water and were boiled in water (200 ml) containing L-lysine hydrochloride (50 g) using a conventional automatic rice boiler for a period of 30 minutes. The appearance of the cooked rice grains were similar to that of ordinarily cooked rice grains, but the boiled rice grains had a slightly basic odour. The cooked rice grains were then dried at a temperature of5e-600C by using a conventional ventilated dryer. The drying was performed in such manner as to prevent the adherence of rice grains to each other. Substantially, 200 grams of rice grains enriched with L-lysine hydrochloride were thus obtained.

The lysine content determined by the Warburg method using L-lysine decarboxylase was found to be28.6/ by weight based upon the grain. This value was almost identical with the amountwhich was calculated for complete utilization of the L-lys:ne hydrochloride present in the solution used. The rice grains obtained were allowed to stand in water (three times the volume of the rice grains) at room temperature, and the amount of the lysine eluted into the water was periodically measured to determine the elution of lysine by the water. The results are shown in the following table:

TABLE

Loss ofLysine

Hours Eluted lysine (mg)/rice (g) from Enriched rice (wt. /O)

1 87.9 32.3

2 97.5 41.3

4 101.8 43.2

From this table, it is apparent that the elution of the L-lysine used for the enrichment of cereal grain is not very great during ordinary washing in water prior to cooking.

EXAMPLE 2.

A similar treatment to that described in

Example 1 was carried out substituting threonine (40 g) for the L-lysine hydrochloride to obtain rice grains (substantially 190 g) enriched with threonine. The threoninecontent was determined to be 20.3

/O by weight based on the grain.

EXAMPLE 3.


Example 1 was carried out substituting for the L-lysine hydrochloride a mixture of 30 g of L-lysine hydrochloride and 20 g of Lthreonine. Enriched rice grains (substantially 200 g) were thus obtained.

The L-lysine and threonine contents of the rice were respectively 14.6 and 9.7% by weight based upon the grain.

EXAMPLE 4.

Refined barley grains (140 g) were treated with water (180 ml) containing L-valine (30 g) under the conditions described in Example 1 to obtain barley enriched with L-valine (substantially 170 g). The enriched barley grain had an L-valine content of 17.5% by weight based upon the grain.

The enriched grains produced as described above may be added to normal untreated grains to give an overall enriched composition.

Any suitable apparatus for boiling and drying cereal grains may be used in carrying out the process of the present invention.

WHAT WE CLAIMIS:

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1. A process for preparing cereal grains having an enriched amino acid content which comprises boiling cereal grains in an aqueous solution of one or more amino acids and/or the water-soluble nontoxic salts thereof, for a period sufficient to gelatinize at least a part of the starch present in the grains into thea-fonn and drying the boiled grains.

2. A process as claimed in claim 1, in which the cereal grains are rice grains.

3. A process as claimed in claim 2, in which the rice grains are semi-refined rice grains as hereinbefore defined.

4. A process as claimed in claim 1, in which the cereal grains are refined rice grains as hereinbefore defined.

5. A process as claimed in any one of the preceding claims in which the weight ratio of the aqueous solution to cereal grains undergoing treatment is 0.5: 5.0.

6. A process as claimed in claim 5, in which the weight ratio of the aqueous solution to grain is

0.9:1.5.

7. A process as claimed in any of the preceding claims in which drying is carried out in such a way so as to prevent the grain from cracking.

8. A process as claimed in any of the preceding claims in which the aqueous solution of amino acid(s) and/or the water-soluble non-toxic salt(s) thereof, contains from 5 to 90% by weight of amino acid(s) and/or salt(s) thereof based upon the weight of the water.

9. A process as claimed in claim 8, in which the aqueous solution of amino acid(s) and/or the watersoluble non-toxic salt(s) thereof, contains from 15 to50% by weight of amino acid(s) and/or salt(s) thereof based upon the weight of the water.

10. A process as claimed4n any of the preceding claims, in which the cereal grains are boiled for from

20 to 60 minutes.

11. A process as claimed in any of the preceding claims, in which the solution comprises an amino acid which is soluble in water and stable under boiling conditions.

12. A process as claimed in claim 11, in which the amino acid comprises lysine, threonine or valine, or a mixture thereof, or a water-soluble non-toxic salt thereof, or a mixture of such salts.

13. A process as claimed in any of claims 1 to 10 in which the aqueous solution further comprises sodium inosinate or sodium guanylate.

14. A process for preparing cereals having an enriched amino acid content according to claim 1 and substantially as hereinbefore described with reference to any of Examples 1 to 4.

15. Cereals having an enriched aminoadd content whenever prepared by a process according to any of the preceding claims.




EXAMPLE 3.

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Example 1 was carried out substituting for the L-lysine hydrochloride a mixture of 30 g of L-lysine hydrochloride and 20 g of Lthreonine. Enriched rice grains (substantially 200 g) were thus obtained.

The L-lysine and threonine contents of the rice were respectively 14.6 and 9.7% by weight based upon the grain.

EXAMPLE 4.

Refined barley grains (140 g) were treated with water (180 ml) containing L-valine (30 g) under the conditions described in Example 1 to obtain barley enriched with L-valine (substantially 170 g). The enriched barley grain had an L-valine content of 17.5% by weight based upon the grain.

The enriched grains produced as described above may be added to normal untreated grains to give an overall enriched composition.

Any suitable apparatus for boiling and drying cereal grains may be used in carrying out the process of the present invention.

WHAT WE CLAIMIS:

1. A process for preparing cereal grains having an enriched amino acid content which comprises boiling cereal grains in an aqueous solution of one or more amino acids and/or the water-soluble nontoxic salts thereof, for a period sufficient to gelatinize at least a part of the starch present in the grains into thea-fonn and drying the boiled grains.

2. A process as claimed in claim 1, in which the cereal grains are rice grains.

3. A process as claimed in claim 2, in which the rice grains are semi-refined rice grains as hereinbefore defined.

4. A process as claimed in claim 1, in which the cereal grains are refined rice grains as hereinbefore defined.

5. A process as claimed in any one of the preceding claims in which the weight ratio of the aqueous solution to cereal grains undergoing treatment is 0.5: 5.0.

6. A process as claimed in claim 5, in which the weight ratio of the aqueous solution to grain is

0.9:1.5.

7. A process as claimed in any of the preceding claims in which drying is carried out in such a way so as to prevent the grain from cracking.

8. A process as claimed in any of the preceding claims in which the aqueous solution of amino acid(s) and/or the water-soluble non-toxic salt(s) thereof, contains from 5 to 90% by weight of amino acid(s) and/or salt(s) thereof based upon the weight of the water.

9. A process as claimed in claim 8, in which the aqueous solution of amino acid(s) and/or the watersoluble non-toxic salt(s) thereof, contains from 15 to50% by weight of amino acid(s) and/or salt(s) thereof based upon the weight of the water.

10. A process as claimed4n any of the preceding claims, in which the cereal grains are boiled for from

20 to 60 minutes.

11. A process as claimed in any of the preceding claims, in which the solution comprises an amino acid which is soluble in water and stable under boiling conditions.

12. A process as claimed in claim 11, in which the amino acid comprises lysine, threonine or valine, or a mixture thereof, or a water-soluble non-toxic salt thereof, or a mixture of such salts.

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13. A process as claimed in any of claims 1 to 10 in which the aqueous solution further comprises sodium inosinate or sodium guanylate.

14. A process for preparing cereals having an enriched amino acid content according to claim 1 and substantially as hereinbefore described with reference to any of Examples 1 to 4.

15. Cereals having an enriched aminoadd content whenever prepared by a process according to any of the preceding claims.Data supplied from the esp@cenet database - Worldwide

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73.

GB1273998 - 5/10/1972

POTATO PRODUCTS AND PROCESS FOR MAKING SAME


Applicant(s): FRITO LAY INC (US)

E Class: A23L1/217B; A23L1/216B



Family: GB1273998

Equivalent: US3835222; GB1273999; DE1966693; DE1946129; SE7407307; SE371360

Abstract:


1,273,998. Potato product. FRITO-LAY Inc. 17 Sept., 1969 [18 Sept., 1968], No. 45925/69. Heading

A2B. Pieces of raw potato are heated sufficiently to gelatinise starch contained therein, the pieces are dried to a moisture content of 25- 60wt%, formed into a dough, shaped, and dried to a moisture content of 6-20 wt. %. The pieces may be blanched in water or steam at 180-220 F for 1-10 minutes. The reducing sugar content of the dough may be lowered by incorporating yeast and fermenting. Up to

40% of the potato solids in the dough may be replaced by for example rice flour. The product may be deep fat fried.Description:



( 11) 1273998 ( 21) ( 31) ( 33) NO DRAWINGS Application No 45925/69 ( 22) Filed 17 Sept 1969

Convention Application No 760736 ( 32) Filed 18 Sept 1968 in United States of America (US) ( 45)

Complete Specification published 10 May 1972 ( 51) International Classification A 23 L 1/12 ( 52)

Index at acceptance A 2 B 1 B 1 J ( 54) POTATO PRODUCTS AND PROCESS FOR MAKING

SAME ( 71) We, FRITO-LAY, INC, a corporation organised under the laws of the State of Delaware,

United States of America, of Frito-Lay Tower, Exchange Park, Dallas, Texas 75235, United States of

America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a potato product, and much particularly to a deep fat fried potato product, which is of a completely homogeneous nature This invention also relates to a process for making such products.

There are a great many disadvantages inherent in the methods presently employed in the processing of potatoes in the formation of commercial products such as potato crisps.

Many of these problems relate to the raw potato from which the product is made.

At the present time, potatoes are commonly cured by storing at temperatures of from 5075 "F for periods up to three months for the purpose of sugar removal This requires extensive storage facilities in which the temperature and humidity must be carefully controlled Potatoes so stored tend to sprout to a

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considerable extent This sprouting results in great economic loss due to shrinkage and the necessity for removing the sprouts prior to processing.

In the production of potato crisps according to conventional techniques, after the potatoes have been stored as previously described to lower the sugar level, they are peeled, sliced, and washed prior to frying Considerable loss of solids occurs during the slicing and washing operation due to the extremely large surface area of the crisps Commonly, this loss amounts to about 11 % of the total solids.

It is well known that natural potatoes vary greatly in their composition, such as sugar content, solids content, flavour, etc The extent of these variations are influenced by many factors such as the type of potatoes, l the season when harvested, the area where grown, their culture during the growing season, the length of time they are stored prior to use, etc These variations result in non-uniformity of products made from the potatoes For example, it is known that the rate of browning of a potato product during processing such as deep fat frying is influenced by the reducing sugar content of the potato Therefore, potato crisps made from one potato may be much darker in color than those made from another potato due to the difference in reducing sugar content between the different potatoes This correlation between the reducing sugar content of a potato and the extent of browning of crisps made from the potato imposes a series limitation on the selection of potatoes which may be used in crisp manufacture It has been reported in the literature that in most instances, acceptably colored crisps may be made from potatoes of less than O 2 % reducing sugars; but that crisps made from potatoes containing more than 0

25 % reducing sugar generally are too dark to be commercially acceptable.

Furthermore, the oil absorption rate of a potato product varies with the solids content of the potato

Generally, it has been found that for every 1 % by weight decrease in solids content of the raw potato, the amount by weight of oil which the potato product is capable of absorbing increases by about 1 1/2

% For example, when potato solids vary from 16 to 17 % by weight, the amount of oil which the potato product will absorb will vary from approximately 40 to 38 1/2 % by weight This results in potato crisps made from different potatoes having markedly different oil contents due to variances in solids content of the potatoes.

Moreover, individual potatoes are not of uniform composition For example, each potato contains a layer, a fraction of an inch below the surface of the potato, which completely encloses the inner portion of the potato This layer may be higher in reducing 1,273,998 sugar content than any of the rest of the potato and the portion of the potato which is enclosed by this layer may be of a higher reducing sugar content than the portion of the potato lying immediately below the surface.

Since the rate of browning on frying varies with the reducing sugar content, each potato crisp may therefore have at least three distinct areas of different degrees of browning.

Moreover, bruises result in localized areas of high reducing sugar concentrations Consequently, bruised areas will generally result in unsightly dark spots on the crisps when the crisps are fried Also, the inner portion of a natural potato has a lower solids content than does the outer portion Therefore a crisp sliced from a natural raw potato will, when fried, have areas of varying oil content due to the different rates of oil absorption in the areas of varying solids content.

The present invention provides a process of producing potato products of a completely homogeneous nature from fresh, raw potatoes which may be of widely divergent compositions and characteristics, which may be made at or near the areas where potatoes are grown, which may be shipped and/or stored over long periods of time, and which may be used to produce deep fat fried potato products, such as potato crisps.

The process of producing potato products according to this invention, comprises heating pieces of raw potatoes sufficiently to gelatinize starch contained therein, drying said pieces to a moisture content of from 25 to 60 % by weight, forming a dough from said pieces, and forming said dough into shaped bodies and drying said shaped bodies to a moisture content of from 6 to 200,l weight The potato shaped bodies or pellets thus formed may be immediately fried or may be shipped and/or stored for an indefinite period in moisture tight containers.

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According to the practice of this invention, potatoes of different varities, sizes and compositions may be used as starting materials.

Potatoes generally contain from about 70 to % by weight of moisture The raw potatoes are peeled and blemishes are graded out The potatoes are then sliced into smaller pieces and washed by techniques well known to the art.

The potato pieces are then heated sufficiently to gelatinize starch contained therein and to prevent enzymatic darkening This is preferably accomplished by blanching the pieces in hot water or with steam for a time sufficient to gel a substantial portion of the starch contained therein e g, at a temperature of from 180 to 212 F for from 1 to 10 minutes The potato pieces are then removed from the blanch water and rinsed with a water spray to cool them and to remove excess free starch from the surfaces thereof.

After rinsing, the potato pieces are dried in order to reduce the moisture content thereof to from 25 to

60 %, and, preferably from 35 to 45 % by weight The potato pieces may be dried at ambient temperatures, or, 70 preferably, by heating in an oven at a temperature of from 1750 to 2251 F.

The dried potato pieces are then formed into a dough This may be accomplished by grinding them in a food grinder which is 75 fitted with a grinding plate having hole sizes 1/4 inch or less in diameter.

If the raw potatoes which are used in the process of this invention have a reducing sugar content in excess of 0 2 % by weight, it is 80 preferred to treat the potatoes to lower the sugar content by fermenting the dough with yeast according to the process claimed in the specification of our copending application No.

42301/70 (Serial No 1273999) which has 85 been divided from this application This may be accomplished by adding from O 1 to 1 0 % by weight of yeast, based on the total solids content, to the dried potato pieces before they are ground into a dough The yeast may 90 be added to the potato pieces in the form of an aqueous slurry It is preferred that the potato pieces to which the yeast is added have a moisture content within the range of to 60 % by weight The yeast-treated 95 pieces are preferably formed into a dough at a temperature of from 80 to 115 'F The dough is then allowed to ferment at a temperature of from 75 to 100 l F for from 1 to 4 hours By controlling the reducing sugar 100 content of the dough, the extent of browning of the final product may also be controlled.

Since heat browning does not occur unless reducing sugars are present, browning may be controlled by removal of a portion of this 105 constituent If the reducing sugar content of the raw potatoes is below about 0 2 %, yeast treatment is not necessary.

Before the potato dough is formed into shaped bodies, it may be admixed with other 110 starch containing materials such as rice flour, tapioca, potato starch, potato flour, and wheat flour It is preferred that not more than 40 %,' by weight of the total solids in the dough be other starch containing material If other 115 starch containing material is mixed with the potato dough, the moisture content of the resultant dough should still be between 25 to % by weight, and preferably between 35 to 45 % by weight, before it is formed into 120 shaped bodies.

In forming the dough into shaped bodies, it is preferred to extrude the dough into a ribbon, to air dry the ribbon in order to case harden it so that the surfaces thereof are not 125 adherent, and then to cut the ribbon into shaped bodies A suitable extrusion apparatus is one which is capable of generating high pressures and elevated temperatures and which exerts a high degree of shear force ont 130 1,273,998 the dough It is preferred to employ an extruder fitted with a tapered auger which will raise the temperature of the dough to within the range of 175 to 215 'F when it emerges from the extrusion orifice.

The extruded ribbon, which preferably has a thickness of between 0 015 and 0 045 inch may be cut into shaped bodies by conventional means such as with a die While the process is being run in a continuous manner, it is preferred to recycle any excess dough from the ribbon to the extruder to be mixed with fresh dough.

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The shaped bodies are then dried to a moisture content of from 6 to 20 %, and preferably 8 to 16 % by weight This drying may be accomplished by placing them in a hot air oven which is heated to a temperature of from 120 to 140 'F for from 40 to 80 minutes.

The resultant dried potato pellets may be fried immediately or they may be shipped in moisture tight containers and/or stored for an indefinite period of time Thus, the pellets may be made at or near the area where the potatoes are grown and then shipped to other parts of the country for frying This results in considerable savings in transportation costs as compared to shipping raw potatoes since the pellets contain much less moisture than do raw potatoes.

Any conventional apparatus which is ordinarily used for deep fat frying may be employed to cook the potato products of this invention The frying may be accomplished by means of a batch operation, in which a batch of the pellets are charged directly into the cooker, agitated and then removed; or by means of a continuous frying process, in which the pellets are fed into one end of a cooker and are continuously removed from the other end.

The type and temperature of fat or oil used to cook the potato products are those conventionally used in deep fat frying potato crisps There may be used, for example, cottonseed oil, peanut oil, corn oil, soybean oil, coconut oil or mixtures thereof The temperature in the cooker generally varies between about 350 and 3950 F Frying time may vary between 12 and 60 seconds.

During the frying operation, the pellets expand considerably, lose moisture and take up oil The fried crisps are removed from the fryer, excess oil is shaken off and the crisps are then salted and packaged.

Crisps made in accordance with the practice of this invention have a moisture content below about 3 5

% by weight and an oil content of from about 30 % to 36 % by weight.

The products are characterized by uniformity of color, flavour, texture, oil content and size, both within each individual crisp and between all of the crisps They are crisp and have an elegant flavour

Moreover, they are sufficiently rigid to withstand breakage during packaging and shipping and during use with dips.

The following examples illustrate the best modes contemplated for carrying out this invention In these examples, all percentages are by weight unless otherwise specified.

EXAMPLE 1

Raw potatoes ( 100 lbs) having a moisture content of approximately 80 % and a reducing sugar content of less than 0 2 % are peeled, 75 trimmed to grade out blemishes and washed leaving about 94 lbs of potatoes The potatoes are then sliced into French cut shapes about 3 8 inch in thickness These slices are blanched by contracting them with steam in 80 a chamber maintained at atmospheric pressure for 2 1/3 minutes The steam is introduced to the chamber at a pressure of 15 p s i.

and the temperature in the chamber is thereby raised to 1980 F The blanched potato 85 slices are removed from the chamber, excess free starch is rinsed from the surfaces of the pieces and the pieces are cooled by a water spray Excess water is drained from the potato pieces and they are then passed 90 through a hot air drying oven The oven is operated at a temperature of about 200 'F.

and an air velocity of about 200 feet per minute The dried potato pieces have a moisture content of about 40 % and weigh 95 about 30 lbs The dried potato pieces are ground in a meat grinder fitted with a grinding plate having orifices 1/16 inch in diameter to produce a uniformly mixed potato dough This dough is fed into an extruder 100 fitted with a tapered auger In the extruder, the potato dough is subjected to a high degree of shear force The dough emerges from the extruder at a temperature of about 200 'F in a strip or ribbon 10 inches wide and about 105 0.020 to 0 025 inch in thickness The extruded ribon, which is in a uniform, amorphous form, is then cooled and the surface is air dried to case harden and render it nonsticky The ribbon is then cut by means of a 110 die into pellets which are dried to a moisture content of 12 % by passing them through a hot air dryer at a temperature of 130 'F for minutes The pellets are then fried by submerging them for about 13 to 15 seconds in 115 frying oil

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heated to a temperature of about 370 'F During frying, the pellets expand and form crisps having a crisp, friable texture, a golden color and good potato crisp flavor.

The fried crisps contain about 35 % oil The 120 crisps are then salted and packaged About 26 to 28 lbs of fried crisps are produced from the original 100 lbs of raw potatoes.

EXAMPLE 2

Raw potatoes ( 100 lbs) having a moisture content of about 80 % and a reducing sugar content of about 1 0 % are peeled, trimmed and sliced as described in Example 1 They 1,273,998 are then blanched by immersion in boiling water for 1 1/2 minutes and washed to remove free starch The potato pieces are then dried to a moisture content of about 52 5 % and a weight of about 38 lbs A yeast slurry is then blended with the dried potato pieces in an amount sufficient to give 0 3 % of yeast based on the total solids content of the mixture This requires 0 054 Ibs of active dry granulated yeast for the approximately 38 lbs.

of dried potatoes The yeast slurry is prepared by suspending the 0 054 lb of active dry granulated yeast in about 6 3 lbs of water The potato pieces having the yeast coated on the surfaces thereof are ground in a meat grinder fitted with a grinding plate having orifices 1/16 inch in diameter and having a cooling jacket to maintain a dough temperature of 960 F The resultant potato dough is allowed to ferment for 2 1/2 hours in a high humidity environment at a temperature of 850 F After fermentation, the dough is extruded into pieces 1/4 inch in diameter and 1 inch long These pieces are dried to a moisture content of 40 % and are fed into an extruder, extruded into a ribbon, cut into pellets, dried and the dried pellets fried as described in Example 1 The resultant crisps have good color and flavor By contrast, crisps made by conventional techniques from potatoes having the same sugar content as those used in this example have a very dark, burned appearance.

EXAMPLE 3

Example 1 is repeated except that before the 30 lbs of dried potato pieces having a moisture content of about 40 % are ground in a grinder, they are blended with 5 lbs of rice flour (containing a moisture content of 10 %) and 2 5 lbs of water This results in a dough comprising a solids content of 20 % rice solids and 80 % potato solids The yield of dried pellets having a moisture content of 12 % is about 25 5 lbs and the yield of fried crisps is between 32 to 36 lbs.

EXAMPLE 4

A fermented potato dough is prepared as described in Example 2 After fermentation, the potato dough is blended with 16 lbs of rice flour having a moisture content of 10 %.

The resultant dough contains approximately % rice solids and 70 % potato solids and has a moisture content of about 40 % This dough is then extruded into a ribbon, cut into pellets, dried, and the dried pellets fried as described in Example 1 The yield of dried pellets is about 37 lbs and the yield of fried crisps is about 49 lbs.Data supplied from the esp@cenet database - Worldwide

Claims:


WHAT WE CLAIM IS: -

1 A process for producing a potato product which comprises heating pieces of raw potatoes sufficiently to gelatinize starch contained therein, drying said pieces to a moisture content of from 25 to

60 % by weight, formt ing a dough from said pieces, forming said dough into shaped bodies and drying said shaped bodies to a moisture content of from 6 to 20 % by weight.

2 A process according to claim 1, wherein the potato pieces are blanched in water or steam at a temperature of from 1800 F to 212 'F for from 1 to 10 minutes.

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3 A process according to claim 1 or 2, wherein the pieces of raw potatoes are dried to a moisture content of from 35 to 45 % by weight.

4 A process according to claim 1, 2 or 3, wherein yeast is incorporated in the dough and the dough is allowed to ferment for a time sufficient to lower the reducing sugar content below 0 2 % by weight of original raw potatoes.

A process according to claim 1, 2, 3 or 4, wherein from 0 1 to 1 0 % by weight of yeast based on the total solids content is incorporated in the dough.

6 A process according to any preceding claim, wherein up to 14 % by weight of the potato solids content of said dough is replaced with another starch containing material.

7 A process according to claim 6, wherein the other starch containing material is rice flour.

8 A process according to any preceding claim, wherein the dough is extruded into a ribbon, the surfaces of said ribbon are air dried, and shaped bodies are cut from said ribbon.

9 A process according to any preceding claim, wherein the shaped bodies are dried to a moisture content of from 8 to 16 % by weight.

A process according to any preceding claim, wherein the shaped bodies are subsequently fried in deep fat.

11 A process of producing a fried potato product substantially as hereinbefore described with reference to Example 1.




1,273,998 A fried potato product made b-y the BARREN & WARREN, process claimed in any one of claims 10 to 16, Kensington Square, 14 London, W 8.

Chartered Patent Agents, Printed for Her Majesty's Stationery Office, by the Courier Press, Leamington

Spa, 1972.

Published by The Patent Office 25 Southampton Buildings, London, WC 2 A l AY, from which copies m ay be obtained.Data supplied from the esp@cenet database - Worldwide

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74.

GB1278735 - 6/21/1972

TEXTURED FOOD PRODUCTS


Applicant(s): CORPORATE FOODS (CA)

E Class: A23L1/217B; A23L1/164



Family: GB1278735

Equivalent: CA888648

Abstract:


1278735 Food product CORPORATE FOODS Ltd 20 March 1970 [21 March 1969] 13722/70

Headings A2B and A2D A process for the preparation of a crisp snack food comprises the steps of: (1) dispersing the foodstuff with suitable edible additives in water to form a fluid batter; (2) aerating the batter; (3) casting the aerated batter into a film; (4) drying the film to a moisture content of between 10 and 30% and (5) cooking the dried film rapidly to a final moisture content of between 1 and 10%. The cooking may be carried out by submerging in hot oil or toasting at 350 F. The foodstuff may comprise potato solids, rice solids, animal-derived solids, and soybean flour mixed with an edible colloid and starch.Description:


(54) TEXTURED FOOD PRODUCTS

(71) We, CORPORATE FOODS LIMITED, a Canadian Body Corporate, of 21, Vincent

Street, Toronto 9, Ontario, Canada, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention relates to a new process for the manufacture of food products with a controlled texture that may be crisp and friable or chewy. A particular feature of the invention is a method to produce crisp, ready to eat snack foods that may be prepared from a wide range of raw materials ranging from flours to fruit purees.

Although the process is suitable for the production of foods with a chewy texture, we are mainly concerned with friable foods.

Friable foods have little or no elasticity and break down readily into small, usually irregularly shaped particles during mastication. Examples of these friable foods are many breakfast cerals, baked products such as crackers and many snack foods such as potato chips.

There are many problems associated with the production of snack foods from the natural raw materials. For instance, the production of potato chips from sliced, raw potatoes is affected by the composition of the raw potato. Not all potatoes are suitable and great care is required in storing and socalled conditioning of these potatoes.

An important variable in the composition of the raw potato is reducing sugar content.

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The reaction of these sugars with amino acids will produce brown discolouration. In the past it was not possible to produce potato chips with acceptable colour from potatoes with a high sugar content of 5 or

6% by weight and dry these chips under milder conditions. Drying by means of micro-waves has become popular in the U.S. but capital and operating costs are high.

The problem is associated with the fact that in the process of cooking the potato slices in hot oil, the moisture content must be reduced from75-80% by weight to around2 by weight while at the same time an acceptable golden colour must be developed. To achieve both objectives in one operation is not always possible when raw material composition changes.

Many snacks and cereal products are made by rapidly decompressing the heated material.

This is done by the so-called gun puffing of cereals and also by extrusion puffing of for instance corn meal. Decompression results in sudden expansion of the product which creates a porous structure. The expansion is a secondary effect and can only be controlled within certain limits. The resulting air cells are often irregular in shape and large in size.

A number of efforts have been made to produce potato chips from dehydrated potatoes that are worked into a dough and shaped in the form of chips. These dough pieces are then usually dried and finally flash fried. This type of process offers only limited control over porosity and texture. The viscosity of the dough limits the choice of ingredients and control over structure is limited.

Because it is often not possible to produce tender crisp products from a dough, many published procedures call for the addition of shortening to the dough to reduce toughness.

However, the addition of a shortening affects the characteristics of the texture in a way that makes the finished product different from a conventional potato chip. The products will tend to have a texture similar to a cracker.

One method described by Rivoche in Canadian Patent 578,870 (U.S. Patent 2,791,508) makes use of an irreversible carrier gel. The method as described offers some control over structure but it depends largely on the gel structure to create the desired porosity in the finished product. The major disadvantage of the method as described is that dehydration takes place at high temperature, namely by cooking in oil Colour development and dehydration takes place in one step of the process and we have found that it is often im

possible to reduce moisture below 2% by weight and maintain a desired colour.

In the new process of the present inven tion, for example dehydrated or mashed potatoes can be used but instead of making this into a dough we make it into a batter that contains as much as85 by weight water and 15',' by weight solids. The viscosity of the batter will depend on the percentage of solids and the types of ingredients used. An advantage of the process is that because of the high moisture content of the batter there are no limitations on the ingredients that can be incorporated into it. It can be prepared from solid such as potato or rice solids or from starches such as tapioca or potato starch. It is also possible to include colloidal materials as alginates, carboxymethylcellulose or cellulose ether in a fully hydrated state and any number of inert materials such as cellulose powder or inorganic fillers can be used.The choice of ingredients depends on the flavour, and to some degree, the texture desired in the final product. The ratio of ingredients employed can also be varied to effect the final flavour and texture of the product and ingredient ratio will also be decided on the basis of cost.

According to the present invention there is provided a process for preparing a crisp snack food which comprises the steps of:

(a) dispersing the foodstuff with suitableedible additives in water to form a liquid batter;

(b) aerating the batter

(c) casting the aerated batter into a film

'd) drying the film to a moisture content between 10 and30 / by weight, and

(e) cooking the dried film rapidly to a final moisture content of between 1 and10or' by weight.

The films are dried to between 10 and300, by weight moisture in order to obtain a pliable product which can be handled without damage which at the same time possesses a low enough moisture content

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so as not toinhibit t the cooking, e.g., frying step. While the resulting uncooked foodstuff may be stored for long periods in an uncooked state, in order to convert it into a crisp ready to eat snack food the dried film is cooked rapidly to a final moisture content of between 1 and10'.t, by weight. This cooking step can be effected immediately bv submerging in hot oil or by toasting at350so.

The batter produced in step (a) should be fluid enough to allow processing. It can be deaerated or aerated in various mixers such as the Morton PressureWhisk (moron

Machine Co. Scotland) or the continuous'OAKES' (Registered Trade Mark) mixer, (T. E.Quakes

Corp.U.S.A.) and the number and size of the entrained air bubbles can be regulated. In this aeration step the fluidity of the batter therefore provides a second advantage over existing processes.

TheMarten PressureWhisk is an enclosednixer containingcr,e or more wire beaters, which rotate independently of one another, and rapidly whip the product to a foam. In contrast, the 'OAKES' mixer is a continuous unit, in which the product and air are pumped through a specially designed mixing bead, where aeration is effected. Both units claim a foamed product of extreme stability and uniform smooth texture.

A large number of factors affected the texture and eating quality of the finished product. Some of these factors are: Total volume of entrained air, average size and uniformity of air bubbles, thickness of cell walls, solids content of the liquid phase, composition of the liquid phase and the structure of the foam after drying. The difference between an open and a closed cell foam is primarily in the rate of oil absorption during frying, this in turn willaffcct the appearance of the product. An open cell foam structure will result in a higher oil content and a more translucent chip.

It will be apparent to anyone skilled in the art that the process provides wide latitudes for the adjustment of the above mentioned factors. Whipping agents such as egg or soy proteins and surfactants such as fatty esters can be incorporated to control foaming characteristics, and plasticizers such as sorbitol and propylene glycol can be used to change the brittleness of the solid phase in the finished product. In the process of whipping the batter, adjustments can be made in the whipping time, gas pressure and the energy input to create a wide range of specifications.

In one embodiment of the present invention, we have found that a satisfactory potato chip can be made when a batter containing potato and rice solids is whipped in a 'HOBART' (Registered Trade Mark) mixer using the wire whip. Whipping is continued until a foam density of .88 gms/cc to .89 gms/cc is reached. If this mixture is whipped to a density of .65gms/ce the walls of the foam tend to fracture during drying resulting in an open cell foam that after frying produces a very tender but rather translucent chip with a high oil content. Tenderness can be reduced by increasing the solids content of the batter and the translucency and oil content can be reduced by incorporating a colloidal material with good film-forming properties in the batter. This would result in more closed cells in the foam.

It should be understood these examples are only given to demonstrate the versatility of the process.

The scope of the invention is by no means limited to the examples given.

A third advantage is in forming the chips.

When a dough is used it must be sliced or extruded and then usually rolled. In our process a simple casting of the fluid mixture on a solid sheet which may be a continuous belt is sufficient and the thickness can be controlled as desired.

It has been found that casting can be accomplished successfully by using a casting knife with a beveled edge. Either the blade is pulled over a quantity of the batter on a flat sheet or a continuous steel belt is pulled past a casting box riding on the belt. The casting blade forms the front of the casting box and the gap between the belt and the blade, which has a beveled edge, is controlled with two micrometers. Casting thickness can be controlled easily in this manner.

The next step in the process is to dehydrate the batter to a moisture content of10 30% by weight. This dehydration can be accomplished by any of the known procedures and can be made continuous by the use of drum dryers. We have found the continuous belt drying manufactured by the American

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Machine and Foundry Company to be particularly suitable. This equipment is suitable for the drying of flour or starch compositions at high temperatures but can also be used to dry fruit or vegetable puree compositions at lower temperatures.

This equipment consists of a continuous steel belt riding over pulleys at both ends of the machine. A film of foamed material is applied to the belt from a casting box riding on top of the belt at the beginning of the machine. Heat is applied to the belt by a number of steamboxes wherein live steam condenses on the bottom of the belt. The result is fast uniform heat transfer and because heat is applied from the bottom no skin formation or case hardening will slow down the drying process The top of the belt is enclosed in chambers where air is circulated to remove moisture from the product. The temperature and velocity of this air can be controlled.

Towards the end of the dryer the product can be cooled and is then doctored off the belt as a continuous sheet. This equipment known as the Microflake dryer is in extensive commercial use in the production of tobacco sheets.

After die cutting the chips from the sheets, the final step of the process is a rapid cooking that may be accomplished by submersion in hot oil or by toasting in an oven.

If the chips are cooked or toasted (in the absence of oil they may be sprayed later with vegetable oil or shortening, or dipped in these materials). The regulation of the moisture content at the end of the dehydration step will result in proper development of colour in the final cooking step.

Higher moisture will require longer frying or cooking resulting in more colour development, hence, the regulation of the moisture content at the end of the dehydration step, will result in proper development of colour during the final cooking step. Frying time in oil of 3750F is 10 seconds for a potato chip formulation that contains25-30% by weight moisture after drying.

The food product may take the form of a film, produced by the process according to the invention which includes a continuous phase containing edible ingredients, from 1 to10% by weight water and a discontinuous phase consisting of small uniformly distributed air bubbles.

The advantages of the new process can be summarized by saying that we only accomplish one objective in each step of the process:

In the first step the batter is prepared. Ingredients are rehydrated and homogeneously mixed. If desired, heat can be applied to gelatinize starches. In this step we control viscosity.

In the second step the batter is aerated and a foam with the right characteristics is prepared.

In the third step the aerated batter is cast into a film.

In the fourth step the foam is dried to a certain moisture content.

In the fifth step the product is cooked in oil or toasted.

Each step can therefore be regulated independently as required and it becomes possible to adjust the process conditions and the material composition as necessary to produce both potato or corn chips and banana or apple chips.

Virtually any raw material is suitable for this process. Flours and starches have been mentioned already Meat or fish in combination with fillers such as flours or starches can be made into attractive and nutritious products that are suitable for eating as a snack or can become an ingredient in dishes such as dehydrated casseroles. The formula would in the latter case be adjusted to provide the desired texture after rehydration.

Soybean concentrates have been formulated into textured products and although these materials would normally result in very tough products, proper adjustment of the aeration can produce tender and friable products.

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A variation of the process is to omit the final cooking step. After dehydration the products are stable when the moisture content is low enough. They can be stored at ambient temperatures for extended periods. One product possibility in this class would be a bacon slice thatrequires no refrigeration and can be fried into its final crips texture in only 10 seconds. The bacon may be a natural composition or it could be made from a soybean composition with added flavours.

Another possibility is to produce dehydrated chips in a central plant and distribute these to institutional users or franchise holders. The chips would be fried or toasted and sprayed with vegetable oil (as previously described) for immediate consumption or fried and packaged for local distribution. The same procedure can be utilized when there is a fluctuating demand for the product. The dryer can operate continuously and dried chips can be stored until demand increases.

In this manner only the fryers and packaging equipment will have to be large enough to handle peak demands. This represents a distinct advantage over current procedures resulking in a more scheduled operation and lower production costs.

EXAMPLE:

Potato flour and rice flour are dispersed in water to give a composition that contains16.03?' potato flour,6.87 . rice flour and 77.1 water all by weight. The dispersionwas accomplished in a'COWLS"

(Registered

Trade Mark) Dissolver. This equipment manufactured by the Cowles Dissolver Co.

U S.A., consists of a vertically mounted motor and pulley transmission which drive a shaft at speeds of2500-5000 rpm. A specially designed saw tooth blade is attached to the end of the shaft, and through the use of shear erected by the blade rotating at high speeds,high-viscosity solid liquid mixtures can be homogenized.

The batter is aerated to a density of between .88 gms/cc and .S9 gms/ce in a 'HOBART' (Registered

Trade Mark) mixer using the wire whip. This equipment manufractured by the Hobart Manufacturing

Co. consists of a vertically mounted motor and gear transmission, which drive a shaft to which amixing attachment has been added.

The mixing attachment describes a planetary motion about a bowl fixed beneath the shaft and various mixing functions, such as blending or whipping, can be achieved at one of seven speeds.

The film was cast on the belt of an American Machine Foundry microflake dryer in a thickness of 60 mils and dried in about 4 min. to a moisture content of25 by weight.

Thefllr,l at this moisture content is pliable and can be handled easily. The film is die cut into oblong shapes of approsimately 11/2X2" and the pieces are cooked byimmersing them in oil at 3750F for 10 seconds.

WHAT WE CLAIMIS:-

1. A process for preparing a crisp snack food which comprises the steps of:

(a) dispersing the foodstuff with suitable edible additives in water to form a liquid batter;

(b) aerating the batter

(c) casting the aerated batter into a film

(d) drying the film to a moisture content between 10 and30 by weight1 and

(e) cooking the dried film rapidly to a final moisture content of between 1 and103: by weight.

2. A process as claimed in claim 1 wherein the cooking step (e) is effected by submerging the film in hot oil or by toasting it at350OF.

3. A food product when produced by the process claimed in claim 1 in the form of a filmwhich comprises a continuous phasecontaining edible ingredients, from 1 tolO, by weight water and a discontinuous phase consisting of small uniformly distributed air bubbles.

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4. A food product when produced by the process claimed in claim 1 or a food product as claimed in claim 3 wherein the edible ingredients comprise potato solids, rice solids and an edible colloid with good film-producingproIties

5 A food product when produced by the process claimed in claim 1 or a food product as claimed in claim 3 wherein the edible ingredients comprise solids of animal origin, one or more starches and an edible colloid with good film-forming properties.

6. A food product when produced by the process claimed in claim 1 or a food product as claimed in claim 3 wherein the edible ingredients comprise soyabean flour and an edible colloid with good filmforming properties.

7. A food product as claimed in any of claims 3 to 5 which is cooked by submerging in hot oil or by toasting at3500F.

8. A food product as claimed in any of claims 3 to 5 which is toasted at 3500F and has a vegetable oil or shortening applied to its surface.

9. A process for preparing a crisp snack food substantially as herein described with reference to the example.

**WARNING** end of DESC field may overlap start of CLMS **.Data supplied from the esp@cenet database - Worldwide

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75.

GB1278736 - 6/21/1972

SNACK PRODUCT AND PROCESS


Applicant(s): CORPORATE FOODS (CA)

E Class: A23L1/216B



Family: GB1278736

Equivalent: US3840673; CA927192

Abstract:


1278736 Potato product CORPORATE FOODS Ltd 19 April 1971 [10 March 1970] 24364/71 Heading

A2B An aqueous suspension of potato solids is heated with an alpha-amylase enzyme, which is then deactivated, whereby a mixture containing said solids, together with other ingredients, for example rice flour, has a reduced viscosity. In particular, a fluid batter containing about 30 wt. % potato flour and about 10 wt. % rice flour having a viscosity of about 100,000 cps at 80 C may be obtained. Such a mixture may be shaped and dried, and thereafter cooked for example by baking, toasting, or deep fat frying to give a crisp.Description:


PATENT SPECIFICATION ( 11

NO DRAWINGS ( 21) Application No 24364/71 ( 22) Filed 19 April 1971 ( 31) Convention

Application No 077009 ( 32) Filed 10 March 1970 in ( 33) Canada (CA) ( 45) Complete Specification published 21 June 1972 ( 51) International Classification A 23 L 1/12 ( 52) Index at acceptance A 2 B l

B 1 J ) 1278736 ( 54) SNACK PRODUCT AND PROCESS ( 71) We, CORPORATE FOODS

LIMITED, a Canadian body corporate of 21 Vincent Street, Toronto 9, Ontario, Canada, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be prepared, to be particularly described in and by the following statement: -

In our copending British Patent Application No 13722/70 (Serial No 1278735) entitled "Textured

Food Products", filed March 20, 1970, we have described a process for the production of crisp snacks

In the process described in our earlier application, potato flour and other starch additives are formed into a batter, cast into a film, dried and cooked.

The present invention is also concerned with the production of crisp snack foods In particular, it is concerned with the production of crisp snack foods having a lower oil content than normal Expressed in simple terms the present invention relates to a method that allows an increase in the solids content of a batter produced from potato flour by reducing the viscosity of the resulting suspension This is accomplished by reacting the hydrated flour for a short time with an c-amylase enzyme It is believed that the a-amylase enzyme dextrinizes at least part of the starch molecules and thus reduces the viscosity of the batter This process is suitable not only in the process described in our copending

British Patent Application No.

13722/70 (Serial No 1278735) but can also be used in other processes that utilizes potato solids as an ingredient in batters or doughs.

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For economic reasons it is advantageous to us commercially available potato solids and a suitable low cost material is sold as "potato flour" Potato flour is usually prepared by drying of a pre-cooked mashed potato on a drum dryer and it can be assumed that virtually all the starches in the potato are fully gelatinized either during the cooking or drying steps When this flour is rehydrated in a process to make potato snacks, a high viscosity develops almost lPrice 25 pl immediately This high viscosity limits the solids content in the dough or batter and results in increased drying time In the process of our copending British Patent Application No 13722/70 Serial No.

1278735), where we wish to produce a batter with enough fluidity to allow aeriation and casting, the high viscosity of the hydrated potato flour is especially troublesome.

With unmodified potato flour to which was added 33 1/3 %,/ rice flour it was found that the practical limit of the solids content was around 23 % A higher solids content would produce a viscosity that is not suitable for aeration and casting Drying of the cast film is carried out on a steel belt to a moisture content of about 30 % To produce one pound of the film containing 30 %, moisture it is necessary to remove 2 04 lb of water during the drying step By increasing the solids content of the batter of 35 % it is only necessary to evaporate 1 00 lb of water to produce one pound of film with 30 %, moisture remaining Drying requirements have been reduced by 50 % A further advantage of an increased solids content is the fact that it is possible to reduce the casting thickness while retaining the same amount of solids per square inch.

Thus it was found that whereas the batter with 23 '% solids should be cast at a thickness of 60 mils to produce a crisp with acceptable thickness and strength it is possible to reduce the casting thickness to around 40 mils when batter of 35 % solids is used Since drying rates relate to the square of the thickness, the reduction in thickness from 60 to 40 mnails would theoretically produce an increase in drying rate of 125 %.

It is clear from these calculations that an increase in solids content would reduce drying time very substantially and reduce processing costs by a factor of three or four.

Various processes in which enzymatic action has been used to modify starchcontaining products, such as potato products, are known Hence, Hilton in U S Patent No.

3,109,739 discloses a process in which 1,278,736 enzymatic oxidation is used for reducing the amount of reducing sugars in a mixture containing finely divided potato solids and liquid Similarly,

Singer in U S Patent No.

2,175,486 uses diastase enzymes to modify starch compositions to dextrins, and Wachman.

et al in U S Patent No 1,916,782 discloses a process for the dextrinizing of starch using a mineral acid and diastase enzymes Bode in U S Patent No 3,249,512 uses enzymes to convert starch to dextrose.

However, none of these inventors have solved the viscosity problem that exists in edible products when using a suspension containing a high concentration of potato solids in the manner adopted according to the present invention.

According to the present invention we have found that we can reduce the viscosity of a potato-water mixture by reacting the potato starches with an c:-ainm-lase enzyme for a short time Using this process, we have found that it is possible to reduce the viscosity so that a fluid batter can be produced containing as much as 40, solids comprising approximately 307 potato flour and 10 .

rice flour The resulting product does not have any unpleasant flavour and possesses a good potato flavour after cooking, e g by frying The enzymatic reaction produces a material which has good filmforming propzrties and improved drying rates This improvement in properties probably results from the formation of dextrins from the starch by the action of the enzyme.

Several times we have mentioned that the reaction time of the enzyme on the suspension of potato solids is "short" This is indeed a key feature of the invention because it was found that if the reaction is

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allowed to proceed too far, a completely unpalatable product results The off-flavour that can be described as chalky and astringent does not exhibit itself in the batter but becomes very unpleasant in the finished dry snack We have not explained this flavour development but the fact that it develops in the finished product rather than the batter would suggest that the compounds responsible must be dehydrated in order to give this taste sensation.

We have found that there is more than one procedure that can produce a product that is free from offflavours The concentration of the enzymes, the rate of the reaction as controlled by temperature and the total reaction times must be balanced in such a way that the reaction is terminated as soon as possible after the desired reduction in viscosi 3 ty is obtained With a relatively high concentration of enzsymes the reaction time is very short, when the concentration is reduced to 0 025 % 5 based on the concentration of solids, the reaction can be allowed to proceed as long as ten minutes.

After the enzyme has been allowed to react with the batter formed from the potato flour and water mixture, it can be deactivated quite simply by the action of heat It was found that the resulting product could be 70 cast on a flat surface and form a strong filmhn that can be stripped from the drying surface vwith ease The resulting film exhibits a structure with a uniform continuous surface, and due to the function of this continuous 75 uniform surface as an oil barrier, the product had a reduced absorption of oil during the subsequent frying by immersion in hot oil or shortening The unexpected results was a potato crisp that contained less than 20 %, 80 oil.

In other processes used to make snack products similar to potato crisps where dough containing potato solids is rolled, sliced or extruded it cannot be expected that a 85 continuous surface film is formed as is the case in the process of the present invention.

In our process where a mixture with a batter consistency is cast onto a flat surface and dried, a continuous surface film is formed 90 We believe that the treatment with an,ramylase enzyme results in the formation of dextrins and this improves the ability of the material to form these surface films.

Hence, according to the present invention 95 we provide a process for preparing a product suitable for cooking to produce a crisp snack food which comprises the steps of:(a) mixing a foodstuff containing potato solids with an c-amylase enzyme to form a premix 100 (b) dispersing this premix in water at a tenperature at which the enzyme has good activity, (c) heating the mixture until the enzyme is deactivated, 105 (d) shaping the resulting mixture to the described thickness, and (e) drying the shaped mixture to a moisture content so the dried shaped mixture will produce a golden colour when cooked

110 The product of the foregoing process when cooked rapidly by immersion in hot oil or shortening results in crisp with an oil cointent that is reduced by about 50 %, when compared to a conventional potato crisp 115 According to a preferred feature of the present invention, step (c) of the process described above is followed by an aeration step The objective of this step is to create a number of very small air bubbles in the 120 mixture Although this aeration is not essential and a crisp with good eating qualities can be made without its use, we have found that aeration improves drying rates and bv means of this step it is possible to more 125 accurately control the tenderness of the crisp.

Aeration alters the fragility of the product by creating thinner layers of solids in the product.

Potato crisps usually contain about 40 n, 130 1,278,736 oil and 60 % potato solids The calorie content of potato, crisps is about 600 cal/100 grams Because of the high calorie content there has been a considerable amount of interest in a crisp with a reduced calorie content If a potato crisp is fabricated from dry ingredients it becomes possible to replace some of the nutritional ingredients with nonnutritive ingredients such as edible cellulose or to replace starch with proteins by using for instance soy flour or soy isolates, if a high protein snack is required The oil content that accounts for the major part of the calorie content of a potato crisp must also be reduced.

According to processes previously described in the art some manipulation of the oil content of fabricated crisps is possible by adjusting the moisture content before frying and adjusting the frying conditions.

The process of the present invention produces crisps with an oil content that is reduced by at least 50

%' as has been indicated above.

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The reduced oil content is accomplished by a lower density which is probably caused by increased porosity in the interior of the crisp which in part is increased due to lower penetration of the oil or shortening used in the cooking step When the density of the product is compared with regular potato crisps we find that there is a reduction of at least % When the reduction in oil, the reduction in density and the addition of some nonnutritive additive is combined in our process, we have a suitable method by which to produce a crisp with a 50 %/, reduction in calories per serving if the serving is measured by volume rather than weight.

The present invention is further illustrated by the following Example:

EXAMPLE

1 A pre-mix was prepared by blending together the following dry ingredients:parts potato flour 25 parts rice flour 0.05 parts amylase enzyme (Rhozyme 33 lTrademarkl a fungal diastase as sold by

Rohm and Haas).

2 150 0 parts of water were heated to 80 WC.

3 The dry pre-mix from 1 was added to the hot water and because the pre-mix was at ambient temperature, the temperature of the mix dropped to the 60 VC range where the enzyme has good activity The addition of the pre-mix was regulated so that the viscosity of the mixture remained low enough to allow proper agitation In our experiments we found that the addition took three to four minutes.

4 After the addition of the pre-min was completed the viscosity of the mixture was about 100,000 cps and the temperature of the mix was raised to about 80 VC over a period of 10 minutes and this temperature was maintained for ten minutes to completely deactivate the enzyme.

The next step in our preferred process was to aerate the material The objective of this step is to create a number of very small air bubbles The aeration is not essential and a crisp with good eating qualities can be made without it but aeration improves drying rates and by means of aeration it is possible to control tenderness of the finished crisp Aeration alters the fragility of the product by creating thinner layers of solids in the product The density after aeration is about 9 grammes/cm 7.

6 The resulting aerated, hot suspension of fluid batter containing about 30 % by weight of potato flour and about 1 % by weight of rice flour from step 5 was then cast into a sheet with a thickness of about

40 mils.

The preferred method of casting and drying is to use a so-called Microflake dehydrator manufactured by the American Machine and Foundry Company Step 5 and 6 of -the process are described in more detail in our copending British Patent Application No.

13722/70 (Serial No 1278735) called "Textured Food Product", filed on March 20, 1970.

7 The resulting film was dried to a moistture content of about 30 % and flash-fried in oil (or shortening) at about 375 1 F for a period of 10-15 seconds Alternatively the film can be preserved by drying to lower moisture or by freezing and kept as a nonperishable semi-fabricated product It should be understood that the example describes a procedure that was found to produce a good product The invention is not limited by the procedure and conditions as described, nor is it necessarily limited to the formula used or to the commercial enzyme preparation mentioned.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS:-

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1 A process for preparing a crisp snack food from a mixture that consists in part of potato solids, the improvement which com 110 prises the step of treating an aqueous suspension of the potato solids for a short time with an alpha-amylase enzyme to reduce the viscosity of the mixture.

2 A process according to claim 1 which 115 comprises the steps of:

(a) mixing a foodstuff containing potato solids with an alpha-amylase enzyme to form a premix, (b) dispersing this premix in water at a tem 120 perature at which the enzyme has good activity, (c) heating the mixture until the enzyme is deactivated, (d) shaping the resulting mixture to the 125 desired thickness, and (e) drying the shaped mixture to a moisture 1,278,736 content so the dried, shaped mixture will produce a golden colour when cooked.

3 A process according to claim 2 where the dried and shaped material produced in step (e) is cooked rapidly by immersion in hot oil or shortening, of by baking or by toasting.

4 A process according to claim 2 or 3 where step (c) is followed by aeration of the mixture.

A process according to claim 2 where the consistency of the mixture at the end of the step (c) is fluid enough to allow pumping.

6 A process according to claim 2 where the dried and shaped material produced in step (e) is fried by immersion in hot oil or shortening for a period of about 10 to seconds.

7 A process according to claim 1 wherein the dried and shaped material produced in step (e) is baked or toasted to produce a cooked product having acceptable colour and crispness.

S A process according to claim 7 where vegetable oil or shortening is applied to the material by spraying or immersion.

9 A process according to claim 1 where the alpha-amylase enzyme is of fungal origin.

10 A process according to claim 2 where the viscosity of the mixture is about 100,000 cps at 80 WC.

11 A process as claimed in any of claims 1 to 10, carried out substantially as described in the Example herein.

12 A fluid batter containing about 30:', by weight of potato flour and about 10 ' by weight of rice flour and having a viscosity of about 100,000 cps at 80:C.

13 A partially dehydrated food product when prepared by the process as claimed in any of claims 2, 4,

5 or 10 consisting in part of potato solids and rice solids cooked by immersion in hot oil or shortening for a period of about 10 to 15 seconds wherein the surface consists of essentially continuous film that forms a barrier and reduces oil penetration into the product during submerged frying.

14 A food product as claimed in claim 13 that has an oil content of less than 20 V'. by weight.

A crisp ready to eat snack food product whenever prepared by the process of any of claims 6, 7 or S.

For the Applicants:

LLOYD WISE, BOULY & HAIG, Norman House, 105-109 Strand, London, W C 2.

Printed for Her Majesty's Stationery Office, by the Courier Press, Leamnington Spa, 1972.

Published by The Patent Office, 215 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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76.

GB1280436 - 7/5/1972

METHOD OF PRODUCING FRIED RICE FOR INSTANT COOKING


Inventor(s): TANAKA TATSURO (--); SATA YOSHITAKA (--)

Applicant(s): NISSIN SHOKUHIN KAISHA LTD (JP)

E Class: A23L1/182C



Family: GB1280436

Abstract:


1280436 Fried rice NISSIN SHOKUHIN KAISHA Ltd 4 Feb 1971 3952/71 Headings A2B A2E A method of producing fried rice for instant cooking comprises drying boiled rice by heating it with air the temperature of which is gradually increased from 86 to 194 F, until the water content of the rice is

10-20% by wt and dehydrating and swelling the dried rice by frying it for 10-20 seconds in oil (e.g. animal or vegetable oil) at 356 -428 F. The rice may be boiled under pressure in water containing a glyceryl fatty acid ester. The fried rice may be cooked ready for eating by boiling it in water for 3 minutes.

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77.

GB1280449 - 7/5/1972

SNACK PRODUCT


Applicant(s): GEN MILLS INC (US)


IP Class: A23L1/18

E Class: A23L1/164B; A23L1/18B2



Family: GB1280449


Abstract:


1280449 Puffed snack product GENERAL MILLS INC 29 Dec 1970 [29 Dec 1969] 61654/70 Heading

A2B A snack product resembling french fried onion rings comprises toasted rings of a puffed onion flavoured cereal product coated with an edible oil. The product may be coated with salt. A process for preparing the product may comprise (a) dry blending cereal flour and/or meal (e.g. corn grits and rice meal), onion flavour and sugar with or without a high protein flour or meal such as soy grits or peanut flour, and a colouring agent to form a premix, (b) mixing the premix with water to form a hydrated premix having a moisture content of 13-15% by wt, (c) tempering the hydrated premix for to 8 hours,

(d) extruding the premix at 950-1350 psig and at 255-310 F to form a tube of puffed cereal product

(e) cutting the tube into rings (f) toasting the rings e.g. to a moisture content of not more than 2% by wt (h) coating the rings with an edible oil (e.g. coconut oil) and if desired, then with salt. The expansion in step (d) may be 8-16 times the volume of material before extrusion.Claims:


WHAT WE CLAIM IS:

1 A snack food product resembling french friend onion rings which comprises toasted rings of a puffed onion flavoured cereal product coated with an edible oil.

2 A snack product as claimed in claim 1 prepared from a dry blended premix containing 90-95 , by weight of cereal grain flour and/or meal 4 75 to 5 75 l, by weight of onion flavouring and up to 5 %, by weight of sugar based upon the dry weight of the premix.

3 A snack product as claimed in claim 1 or claim 2 prepared from a hydrated premix containing from

13 to 15 %' by weight of water.

4 A snack product as claimed in any of the preceding claims wherein the toasted rings have a moisture content of not more than 20 ' by weight.

A snack product as claimed in any of the preceding claims wherein the edible oil comprises coconut oil.

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6 A snack product as claimed in any of the preceding claims including about 35 '5 ' by weight of edible oil.

7 A snack product as claimed in any of the preceding claims having salt applied to the surface thereof.

8 A snack product as claimed in claim 7 having about 2 5 %, by weight of salt applied to the surface thereof.

9 A snack food product resembling french fried onion rings substantially as herein described.

A snack food product resembling french fried onion rings substantially as herein described in either of the Examples.

11 A process for the production of a snack food product resembling french fried onion rings which comprises the steps of: a) dry blending 90 to 95,' by weight of cereal grain flour and/or meal, 4 75 to 5

75 ?' by weight of onion flavouring and up to 5 % by weight of sugar to form a premix; b) mixing the premi: with sufficient water to form a hydrated premix having a total moisture content of from 13 to 15

%, by weight, based on the weight of hydrated premix; c) tempering the resulting hydrated premix for a period of from to 8 hours; d) subjecting the tempered premix to a pressure of from 950 to 1350 pounds per square inch gauge and a temperature of from 255 to 310 F to form a plastic cereal mass; e) extruding and expanding the plastic cereal mass to form a tube of puffed cereal product; f) cutting the tube of puffed cereal product to form puffed rings; g) toasting the puffed rings; and h) coating the toasted rings with an edible oil.

12 A process as claimed in claim 11 wherein the meal comprises corn grits.

13 A process as claimed in claim 12 wherein the dry blended premix prepared in step (a) contains about 92 % by weight of corn grits.

14 A process as claimed in claim 12 or 115 claim 13 wherein the corn grits used in step (a) have a moisture content of not more than %' by weight.

A process as claimed in claim 14 wherein the moisture content of the corn grits is 120 from 7 to 9 % by weight.

16 A process as claimed in any of claims 11 to 15 wherein the flour or meal has a particle size such that all or nearly all passes through a U S No 20 Sieve and not more 125 than 6 % by weight passes through a U S.

No 40 Sieve.

17 A process as claimed in any of claims 1,280,449 11 to 16 wherein about 5-% by weight of onion flavoring is used in step (a).

18 A process as claimed in any of claims 11 to 17 wherein the onion flavoring used in step (a) is agglomerated onion powder.

19 A process as claimed in claim 18 wherein the onion flavoring has a particle size such that all or nearly all passes through a U S.

No 2 Sieve and not more than 10-, by weight passes through a U S No 100 Sieve.

A process as claimed in any of claims 11 to 19 wherein about 3, by weight of sugar is used in step (a).

21 A process as claimed in any of claims 11 to 20 modified in that the dry blended premix in step (a) includes a high protein flour or meal in place of part of the cereal flour or meal.

22 A process as claimed in claim 21 wherein up to 15 %' by weight of the cereal flour or meal is replaced by a high protein flour or meal.

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23 A process as claimed in claim 21 or claim 22 wherein the high protein flour or meal comprises soy grits or peanut flour.

24 A process as claimed in any of claims 11 to 23 wherein the blending in step (a) is effected using a ribbon mixer.

A process as claimed in any of claims 11 to 24 wherein the total moisture content of the hydrated premix produced in step (b) is from 13 5 to 14 % by weight based on the weight of the hydrated premix.

26 A process as claimed in any of claims 11 to 25 wherein the tempering in step (cc is effected for a period of from 1 to 2 hours.

27 A process as claimed in any of claims 11 to 26 wherein the pressure in step (d) is adjusted to from

1000 to 1300 pounds per square inch gauge.

28 A process as claimed in any of claims 11 to 27 wherein the temperature in step (d) is adjusted to from 280 to 300 F.

29 A process as claimed in any of claims 11 to 28 wherein step (d) and the extruding and expanding of step (e, are effected using a collet extruder.

A process as claimed in any of claims 11 to 29 wherein the plastic cereal mass is expanded by from 8 to 16 times its initial volume in step (e).

31 A process as claimed in claim 30 wherein the expansion is from 10 to 14 times its initial volume.

32 A process as claimed in any of claims 11 to 31 wherein the extruded tube produced in step (e) is substantially circular in crosssection.

33 A process as claimed in any of claims 60 11 to 32 wherein the extruded tube is cut into puffed dough rings having an axial length of about 1/4 inch.

34 A process as claimed in any of claims 11 to 33 wherein the toasting in step (g) is 65 effected until the rings are crisp.

A process as claimed in any of claims 11 to 34 wherein the toasting in step (g) is effected at a temperature of about 350 F.

36 A process as claimed in any of claims 70 11 to 35 wherein the toasting in step (g) is effected for a period and at a temperature whereby the toasted rings produced have a moisture content of not more than 2 ';, by weight 75 37 A process as claimed in any of claims 11 to 36 wherein the edible oil used in step (h) comprises coconut oil.

38 A process as claimed in any of claims 11 to 37 wherein the coating in step (h) is 80 effected at a temperature of about 120 F.

39 A process as claimed in any of claims 11 to 38 wherein the coating in step (h) is effected to provide a product containing about ",', by weight of edible oil 85 A process as claimed in any of claims l 1 to 39 wherein salt is applied on to the outside of the toasted rings produced in step (h I).

41 A process as claimed in claim 40 wherein about 2 5 '', by weight of salt is 90 applied.

42 A process as claimed in claim 11 or claim 21 for the production of a snack food product resembling french fried onion rings substantially as herein described 95 43 A process for the production of a snack food product resembling french fried onion rings substantially as herein described in either of the Examples.

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44 Snack food products resembling french 100 fried onion rings when produced by a process as claimed in any of claims 11 ito -3.

For the Applicants, FRANK B DEHN & CO, Chartered Patent Agents, Imperial House, 15/19,

Kingsway, London, WC 2 B 6 UZ.

Printed for Her Majesty's Stationery Office, by the Courier Press, Leamington Spa, 1972.


380/2197

78.

GB1284668 - 8/9/1972

A CONVERTING STARCH PRODUCT


Inventor(s): SZYMANSKI CHESTER D (--)

Applicant(s): NAT STARCH CHEM CORP (US)

IP Class 4 Digits: C08B

IP Class: C08B27/26

E Class: A23L1/0522B; C08B31/00; C08B31/04; D21H17/28



Family: GB1284668


Abstract:


1284668 Starch product NATIONAL STARCH & CHEMICAL CORP 11 Sept 1970 [14 Oct 1969]

43658/70 Heading C3U A converting starch product comprises a starch base admixed with 0À2% to

3À0%, based on the weight of the starch, of at least one of ascorbic acid, araboascorbic acid and dihydroxymaleic acid. The acid is preferably present in an amount of 0À4-3%, and the starch product may be dispersed in water in an amount of 2-30% by weight in forming a food product. The starch may be derived from corn, wheat, potato, tapioca, waxy maize, sago or rice. The starch product, after admixture of food products, may be pressure-cooked to 220-350 F. for 1-45 minutes, or, in the case of dihydroxymaleic acid, cooking at 185-212 F. for 20 to 30 minutes.Description:



( 11) 1284668 NO DRAWINGS ( 21) Application No 43658/70 ( 22) Filed 11 Sept 1970 ( 31)

Convention Application No 866 386 ( 32) Filed 14 Oct 1969 in ( 33) United States of America (US) (

45) Complete Specification published 9 Aug 1972 ( 51) International Classification CO 8 B 25102

27/00 ( 52) Index at acceptance C 3 U 12 B 1 A 3 2 A 1 2 AX 4 A 3 A ( 72) Inventor CHESTER D

SZYMANSKI ( 54) A CONVERTING STARCH PRODUCT ( 71) We, NATIONAL STARCH AND

CHEMICAL CORPORATION, a corporation organised under the Laws of the State of Delaware,

United States of America, of 750 Third Avenue, New York, New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a novel starch product, and to compositions containing the same.

The novel starch product of this invention is termed a "converting starch product" As used in this invention, the term "converting starch product" denotes a starch which has been admixed with a specified modifying agent in specified amounts so that when an aqueous dispersion of the starch

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product reaches its gelatinization temperature, it displays a normal, high viscosity, and when cooked at

"retort temperatures", the starch is converted, i e degraded, thereby reducing its molecular weight, as manifested by the substantially reduced viscosity of the resultant dispersion, as compared to a comparable dispersion of the identical starch which has not undergone treatment with the modifying agent.

The degradation or depolymerization of starch can be effected by means of a number of known methods which include treatment of starch with inorganic acids, or enzymes, or by exposing it to a combination of elevated temperatures and high shear action Thus, the treatment of dry starches with inorganic acids, such as hydrochloric or sulfuric acid, produces the so-called fluidity or thin-boiling starches, or, the acid conversion can be carried out on aqueous starch dispersions in the manner utilized for the production of syrups Ordinarily, relatively high concentrations of acid are needed in such conversion procedures in order to maintain the p H of the system at levels of 2 or below The conversion of starches by lPrice 25 pl means of enzymes is carried out by the treating of a dispersed starch system with hydrolyzing enzymes, for example, the alphaamylase preparations derived from

Bacillus subtilis While significant degradation is quickly attained in such starch systems, this method is economically unattractive because of the high cost of the required enzymes.

The conversion of starches by applying heat and high shear action is also carried out on aqueous starch dispersions, preferably in the presence of catalysts such as hydrogen peroxide and copper sulfate

In variations of the latter process, the starch may, if desired, be pretreated with an oxidizing agent in order to weaken the starch and hasten dispersion However, these thermal conversion procedures are relatively inefficient and time-consuming.

Thus, although it is seen that there are a number of procedures available for the conversion of starch, it is apparent that they all suffer from various disadvantages.

Furthermore, none of the conventional procedures results in dispersions which are characterized by their ability to provide a normally high viscosity product upon heating to the gelatinization temperature of the particular starch together with the ability to provide a much thinner product when the dispersion is heated to retort temperatures.

In accordance with the present invention there is provided a converting starch product, as hereinbefore defined, comprising a starch base which is intimately admixed with at least one modifying agent selected from ascorbic acid, araboascorbic acid and dihydroxymaleic acid, the modifying agent being present in a concentration of from 0 2 % to 3 0 % by weight, based on the weight of the starch base.

With certain of the converting starch products of this invention, temperatures which are commonly employed in cooking starch dispersions are sufficient: these temperatures being, of course, in all cases, higher than the normal gelatinization temperature of the starch As used in this in00 00 Z 1,284,668 vention, the term "retort temperatures" means temperatures of about 250 'F and pressures of about 15 psi.

The converting starch product of the present invention is characterized by a number of unusual and highly desirable features.

One such feature of this starch is that it may be stored in dry form, prior to use, for extended periods without any danger of its undergoing any premature degradation Thus, it is only upon cooking under the specified conditions that the desired degradation of the converting starch of this invention will take place.

Another feature of the converting starch product of this invention is that its conversion can be carried out at p H levels ranging from 3 to 9, with optimum results being attained at levels in the range of 5 5 to 6 5 The latter feature is particularly advantageous in using these converting starches for the commercial preparation of food products inasmuch as such foods are, ordinarily, retorted, i e pressure cooked, at approximately neutral p H levels.

It is to be noted that optimum conversions are attained with starch products which contain the selected modifying agent in the range of from 0 4 to 3 ' by weight, as based on the weight of the starch base.

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The starch base which may be used in preparing these converting starch products may be derived from any of the usual sources, including corn, wheat, potato, tapioca, waxy maize, sago and rice The degradation resulting from the use of the modifying agents of this invention will be most apparent in the so-called "heavy boiling" starches, such as corn starch, which contain a substantial proportion of amylose However, all types of starches can be used and are capable of being converted by means of the abovespecified modifying agents Mixtures of any desired starch bases may be also be utilized.

Moreover, the selected starch base mav be used in its original, raw, unmodified form, or it may first be treated in any desired manner, for example, by being crosslinked, esterified or etherified.

In order to prepare the converting starch products of this invention it is necessary only to admix an appropriate amount of the modifying agent, preferably in finely divided form, with the selected starch base.

The resulting homogeneous mixture may then immediately be put into the form of an aqueous dispersion or it may be stored in dry form for future use The conversion of degradation of these starches involves their dispersion in water, preferably in a concentration of from 2 to 30 %, by weight, and the subsequent cooking of the resulting dispersion All of the starch products of i this invention may be converted by the cooking of their aqueous dispersions at re l tort temperatures for a period of from

10 to 40 minutes While the use of retort temperatures has been found to be most practical and convenient, it is to be noted that the conversion of these starches may 70 adso be effected by the pressure-cooking of their dispersions to temperatures ranging from 220 to 350 'F for a period of from 1 to 45 minutes, since there is a time-temperature relationship which will be apparent to 75 those skilled in the art It is likewise to be noted that with the converting starches which are prepared using dihydroxylmaleic acid, a simple cooking procedure utilizing temperatures of from 185 to 212 'F for periods 80 of from 20 to 30 minutes is sufficient to effect their conversion.

The precise details of the above-described procedures for preparing these converting starches and their aqueous dispersions are 85 not particularly critical and other procedures which incorporate minor variations may, of course, be used For example, the modifying agent, instead of being mixed with the starch in dry form, may, if desired, be dis 90 solved directly in the water which is subsequently to be used in preparing the starch dispersion, thereby eliminating the need for pre-blending the modifying agent with the dry starch 95 The converting starches of the present invention are useful in the preparation of processed food systems in which application use is made of their ability to display a high viscosity upon their first being cooked 100 whereupon their viscosity will be significantly reduced subsequent to their being more fully cooked or exposed to elevated temperatures.

Among the food products which can profit from the presence of these starches are 105 soups, meat sauces, tomato sauce, gravies, baby foods, puddings, fruit sauces and fruit drinks.

In the commercial processing and canning of food products, for example, soups, gravies 110 and meat sauces, it is desirable to employ a highly viscous liquid vehicle, usually a starch dispersion, in order to eliminate or reduce the splashing which occurs during the can filling operation as well as to aid in 115 keeping the food solids in suspension Such high viscosities are, however, undesirable in the finished food product which is to be used by the consumer While conventional starches are often used as thickening agents 120 in such processed food systems, they do not offer any solution to the problem of providing a vehicle which first exhibits the high viscosity that is desirable during the processing and canning operations but which is 125 subsequently capable of exhibiting a substantiallv reduced viscosity so as to present a more appealing product to the ultimate consumer In contrast to conventional starches, however, dispersions of the converting 130 1,284,668 starches of this invention do possess such dual viscosity characteristics, and their use in the preparation of such food products permits the original thick or heavy viscosity of the liquid vehicle to be reduced merely by the retorting of the canned fool product in the conventional manner that is employed to effect the sterilization of the food product.

These converting starches are typically incorporated into food products either by combining the converting starch dispersion directly with the food base ingredients prior to canning, or, by admixing the converting starch with the food base ingredients during the initial cooking As an optional

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component, these converting starch slurries may also contain a conventional starch, for example, a crosslinked tapioca or waxy maize, which serves as a thickener The resulting slurry, i e the homogeneous blend of food base ingredients together with the converting starch product, either with or without the conventional starch thickener present therein, will initially display a high viscosity and is thereupon poured into cans or other containers The filled containers are subsequently retorted at temperatures of about 250 'F for a period of 20-30 minutes, thereby causing the viscosity of the slurry to undergo a substantial decrease In all cases, the starch-containing food products will have been placed into containers at a much higher viscosity level as compared to their final form subsequent to retorting.

The converting starch products of the present invention are also useful in the manufacture of paper wherein they can be used either as beater box sizes or calender sizes These converting starch products are particularly useful in situations wherein high starch solids content together with a low viscosity on the part of the resultant size are desired Thus, where sizes utilizing conventional starches are limited as to their starch solids content because of the resultant increased viscosity, sizes which incorporate the converting starch of the invention can contain a relatively higher concentration of starch solids while still maintaiing a low viscosity.

It is to be noted that while all of the modifying agents employed herein are monoor dicarboxylic acids, the mechaniscm involved in the degradion of the converting starch products of this invention is not dependent upon a simple acid conversion or hydrolysis as is evidenced by the neutral and slightly basic p H levels at which these starches may be converted Each of the modifying agents used herein displays an enediol structure, i e -C= =C-, and it is I I OH OH believed that it is the presence of this structure, surprisingly, which makes the conver sion reaction possible Thus, when a large number of related acids, for example, citric acid, lactic acid, gluconic acid, and 2-keto gluconic acid, none of which contained an ene-diol structure, were tested in order to determine their degradative action on starch, it was found that all of these acids were completely ineffective The possibility that ascorbic acid which exists as a lactone was undergoing hydrolysis to free the acid group was likewise considered

Glucuronolactone was thereupon used in the test systems and also found to be without effect It can be seen, therefore, that the conversions which take place with the converting starches of this invention do not result solely from the presence of carboxyl groups on the specified modifying agents.

The invention is further illustrated by the following examples in which all parts given are by weight unless otherwise noted.

EXAMPLE I 85

This example illustrates the preparation of a typical converting starch product of this invention as well as the viscosity characteristics of the aqueous dispersions derived therefrom 90 A total of 996 parts of a waxy maize starch was thoroughly blended with 4 parts of finely divided ascorbic acid until the mixture was homogeneous An aqueous dispersion of the thus prepared converting starch product, 95 comprising 6 parts of the starch-ascorbic acid mixture and 94 parts of water, was cooked for a period of

15 minutes at about 'F, displaying an expected high viscosity, whereupon the dispersion was retorted at

100 250 'F for a period of 40 minutes A control comprising an aqueous dispersion containing 6 %, by weight, of the waxy maize starch which, in this case, was devoid of any ascorbic acid, was also prepared and cooked 105 for a period of 15 minutes at about 2001 F.

and likewise displayed a comparable high viscosity The dispersion was then retorted at 250 'F for a period of 40 minutes Subsequent to the retorting period, each disper 110 sion was cooled to about 1670

F and its viscosity was determined using a Brookfield

RVF Viscometer employing a #2 spindle at rpm It was found that the dispersion of the converting starch had a viscosity of 77 115 cps while the control had a viscosity of 280 cps clearly indicating that only the converting starch of this invention had the ability to undergo a substantial reduction in its viscosity upon being subjected to high tem 120 perature conditions In a repetition of the above procedure, dihydroxymaleic acid in a concentration of 0 4 %, by weight, and araboascorbic acid in a concentration of 0.6 %, by weight, were each, in turn, used to 125 prepare a converting starch product

Upon determining the viscosity of the aqueous dis1,284,668 persions derived from these converting starches by means of the above described procedure, it was found that the dispersion prepared with the

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converting starch product containing the dihydroxymaleic acid had a viscosity of 115 cps while the dispersion prepared with the converting starch product containing the araboascorbic acid had a viscosity of only 74 cps.

Thus, it is seen that each of the converting starch products of this invention yielded dispersions having a significantly lower viscosity as compared with the control which had been prepared using an identical starch which had not, however, been admixed with a modifying agent.

EXAMPLE II

This example illustrates the preparation of additional converting starch products of this invention as well as the preparation of aqueous dispersions derived therefrom.

The procedure used in preparing these converting starch products was identical to that described in

Example I, hereinabove, except that corn starch was used in place of waxy maize starch In this manner, converting starch products were prepared using 0.6 %, by weight of arcorbic acid and dihydroxymaleic acid, respectively An aqueous dispersion of each converting starch product was prepared and these were compared with a control comprising an aqueous dispersion of the untreated corn starch; each of these dispersions having a starch solids concentration of 8 %, by weight The viscositv of each dispersion, after retorting, as determined at about 167 F is given in Table I.

Table I

Contents of Dispersion Viscosity Converting starch product containing ascorbic acid 488 cps

Converting starch product containing dihydroxymaleic acid 308 cps Control containing untreated corn starch 1450 cps The above results again illustrate the ability of the converting starch products of this invention to undergo a substantial viscosity decrease upon being subjected to high temperature conditions.

EXAMPLE III

This example illustrates the preparation of converting starch product based, respectively, on ether and ester derivatives of corn starch.

A total of 994 parts of corn starch which had been etherified by means of the procedure described in

Example I of U S Patent 2,813,093 so as to introduce diethyl aminoethyl substituent groups to the extent that its Kjeldahl nitrogen content was 0 25 %o, by weight, was blended with 6 parts of finely divided ascorbic acid With another identical portion of this starch derivative, there was blended 6 parts of dihydroxymaleic acid.

Aqueous dispersions having a starch solids concentration of 8 % by weight, were prepared from each of these converting starch products A control comprising a comparable aqueous dispersion of the identical starch derivative which had not, however, been treated with the modifying agent was also prepared All of these dispersions were retorted at about 250 F for a period of 40 minutes and then cooled to about 167 F.

Viscosity measurements of each of the thusprepared dispersions are summarized in Table II.

Table II

Contents of the Dispersion Viscosity Converting starch product containing ascorbic acid 122 cps

Converting starch product containing dihydroxymaleic acid 80 cps Control containing etherified starch

219 cps The above results illustrate the substantial decrease in viscosity which the converting starch product of this invention undergo when subjected to high temperature conditions.

In a repetition of the above-described procedure, the etherified corn starch used therein was replaced with corn starch which had been esterified by means of the pro 90 cedure described in Example I of U

S.

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1,284,668 Patent 2,461,139 so as to introduce aceate substituent groups onto the starch molecule.

The degree of substitution of this starch acetate ester was 0 1 The viscosity of each of the thus prepared dispersions are summarized in Table III.

Table III

Contents of the Dispersion Viscosity Converting starch product containing ascorbic acid 127 cps

Converting starch product containing dihydroxymaleic acid 77 cps Control containing esterified starch

2928 cps Thus, the above results again illustrate the substantial decrease in viscosity which the converting starch products of this invention undergo when subjected to high temperature conditions.

EXAMPLE IV

This example illustrates the preparation of another converting starch product which is typical of the products of this invention.

A total of 97 parts of a waxy maize starch was blended with 2 8 parts of ascorbic acid.

An aqueous dispersion comprising 8 parts of the thus prepared converting starch product and 92 parts of water were heated to 1 l 900 F for a period of 5 minutes after which time the dispersion displayed a normal, high viscosity The dispersion was thereupon retorted at 250 'F for a period of 35 minutes After being cooled to a temperature of about 1670 F it was found to display a water-thin viscosity level.

EXAMPLE V

This example illustrates the use of the converting starch product of this invention in preparing a dry, degraded product.

To a slurry comprising 200 pounds of a waxy corn starch and 200 gallons of water was added 2 pounds of dihydroxymaleic acid The resulting slurry was heated at about 190 'F for a period of 20 minutes and then dried by means of a conventional drum drying procedure The resulting dry product was ground to a suitable, conventional particle size A control was run in identical manner omitting the dihydroxymaleic acid.

An aqueous dispersion comprising 8 parts of the thus converted starch product and 92 parts of water was warmed to a temperature of about 1670 F Its viscosity was found to be 575 cps A control, comprising a comparable prepared dispersion using a waxy corn starch which, however, had not been treated with the dihydroxymaleic acid, displayed a viscosity of 2,150 cps when treated in the same manner.

EXAMPLE VI

This example illustrates the preparation of a chicken gravy containing one of the converting starch products of this invention.

A total of 10 parts of uncooked aqueous dispersion containing 6 %, by weight, of a converting starch product based on corn starch which had been admixed with 0 5 %, by weight, based on the corn starch of ascorbic acid was combined with 90 parts of semi-cooked chicken gravy The homogeneous blend was thereupon heated at 'F for a period of 20 minutes and was subsequently cooled to 165 'F When the viscosity of the homogeneous starch-gravy blend was measured at this point by means of a Bostwick

Viscometer, an instrument which measures viscosity in terms of distance flowed within a specified period of time, it was found that it flowed 19 5 centimeters in 1 minute, indicating that it had a rather high viscosity The viscous gravy was poured into conventional h 2 cans which were then sealed in the usual manner The filled cans were then retorted at 250 'F at about 15 psi for a period of 30 minutes so as to thereby effect a substantial reduction in the viscosity of the blend When the viscosity of the retorted product, after being cooled to 1651 F, was measured by means of the Bostwick Viscometer, it was found that the material flowed 24 centimeters in 1.5 seconds, indicating that a substantial decrease

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in the viscosity of the chicken gravy had, in fact, occurred.Data supplied from the esp@cenet database -

Worldwide Claims:


WHAT WE CLAIM IS: -

1 A converting starch product, as hereinbefore defined, comprising a starch base which is intimately admixed with at least 95 one modifying agent selected from ascorbic acid, araboascorbic acid and dihydroxymaleic acid; said modifying agent being present in a concentration of from 0 2 % to 3 0 % by weight, based on the weight of the starch 100 base.

2 A converting starch product according to Claim 1, wherein said modifying agent is present in a concentration of from 0 4 % to 3 0 % by weight, based on the weight of 105 the starch base.

3 A converting starch product according to Claim 1 and substantially as described in any one of the

Examples herein.

1,284,668 4 A method for preparing a converting starch product, as hereinbefore defined, which comprises admixing a starch base with at least one modifying agent selected from ascorbic acid, araboascorbic acid and dihydroxymaleic acid; said modifying agent being present in a concentration of from 0.2 ) to 3 0 by weight, based on the weight of the starch base.

5 A method of preparing a converting starch product, according to Claim 4 and substantially as described in any one of the Examples herein.

6 A converting starch product whenever prepared by a method according to Claim 4 or Claim 5.

7 An aqueous dispersion of a converting starch product according to any one of Claims 1 to 3 or

Claim 6.

8 An aqueous dispersion according to Claim 7, wherein the converting starch product is present in a concentration of from 2 % to 30 % by weight.

9 A starch-containing food product comprising a homogeneous blend of food base ingredients together with a converting starch product according to any one of Claims 1 to 3 or Claim 6.

A process of preparing a starchcontaining food product, which comprises adding to food base ingredients a converting starch product according to any one of Claims 1 to 3 or Claim 6.

11 A process according to Claim 10.

wherein subsequent to the admixture of said converting starch product with said food base ingredients, said starch-containing food product is pressure-cooked to a temperature of from 220 to 350

F for a period of from 1 to 45 minutes.

12 A process according to Claim 10, wherein said modifying agent is dihydroxvmaleic acid, and wherein subsequent to the admixture of said converting starch product with said food base ingredients, said starchcontaining food product is cooked at a temperature of from 185 to 212 ' F for a period of from 20 to 30 minutes.

13 A process of preparing a starchconltaining food product, according to Claim and substantially as described in Example VI herein.

14 A starch-containing food product whenever prepared by a process according to any one of Claims

10 to 13.

A method of converting an aqueous starch dispersion, comprising the steps of ( 1) fornming an aqueous dispersion of the starch base which contains at least one modifying agent selected from ascorbic acid,

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araboascorbic acid and dihydroxymaleic acid, the mnodifyilng agent being present in the aqueous dispersion in a concentration of from 0 2 c' to 3 0 % by weight, based on the weight of the starch base; and ( 2) pressure-cooking the aqueous dispersion formed in step ( 1) to a temperature of from to 350 '

F, for a period of from 1 to 45 minutes.

16 A modification of the method according to Claim 15, wherein said modifying agent is dihydroxymaleic acid and wherein step ( 2) comprises cooking the aqueous dispersion formed in step (

1) at a temperature of 185 to 212 F for a period of from 20 to 30 minutes.

17 A method of converting an aqueous starch dispersion, according to Claim 15 or Claim 16 and substantially as described in any one of the Examples herein.

TREGEAR, THIEMANN & BLEACH, Chartered Patent Agents, Melbourne House, Aldwych,

London, W C 2.

Agents for the Applicants.

Printed for Her Maiesty's Stationery Office by Burgess & Son (Abingdon), Ltd -1972 Published at

The Patent Office, 25 Southampton Buildings, London, WC 2 A l AY from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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79.

GB1286275 - 8/23/1972

AGGLOMERABLE SUGAR COMPOSITION


Applicant(s): CPC INTERNATIONAL INC (US)

IP Class 4 Digits: C13K

IP Class: C13K1/10

E Class: A23L1/00P2; C13F3/00D; C13K1/10



Family: GB1286275

Equivalent: NL6915470; FR2020696; DE1951460; CH544149; BE740236

Abstract:


1286275 Sugar agglomerates CPC INTER- NATIONAL Inc 7 Oct 1969 [14 Oct 1968] 49311/69

Headings A2B and A2E In forming sugar agglomerates a starch hydrolysate having a D.E. of 5-25 and a descriptive ratio of at least 2, is added to crystalline sugar prior to agglomerating. The sugar may be sucrose, dextrose, lactrose or blends thereof. The starch hydrolysate may be prepared by hydrolysing corn, potato, tapioca, grain sorghum, waxy milo, waxy maize or rice starch with enzyme (e.g. bacterial

[alpha]-amylase) and/or acid. The process may comprise mixing dry hydrolysate and wet sugar, dry hydrolysate, dry sugar and water or hydrolysate solution and dry sugar. The agglomerates may be mixed with other substances, e.g. citric acid, magnesium stearate, synthetic orange flavour, chlorophyll, and antibiotics, and formed into tablets, e.g. confectionery or medicinal tablets.Description:


(54) AGGLOMERABLE SUGAR COMPOSITION

(71) We, CPC INTERNATIONAL INC., a

Corporation organized under the laws of the

State of Delaware, United States of America, of International Plaza,Englewood Cliffs, State of New

Jersey, United States of America, do hereby declare the invention, for which we pray that a Patent may be granted to us, and the method by which it is to be performed, to be particularlydescribed in and by the followingstatement:

This invention relates to agglomerable sugar compositions, agglomerated sugars, and methods of making them. More particularly, this invention relates to the use of starch hydrolysates having a D.E.

(dextrose equivalent) of 5 to 25 as agglomerating agents for crystalline sugars.

Crystalline sugars used in the food and pharmaceutical industries are generally of two major types.

The first type is sucrose derived from sugar cane or sugar beets. The second type is dextrose generally produced by the hydrolysisod starch to the monosaccharide.

Since sugar in crystalline form is required by the food and pharmaceutical industries, crystallization of uncrystallized raw sucrose or dextrose is obviously a vital production process. The art has, therefore, developed many methods, now considered conventional, for crystallizing raw sugars. One of the most common of these methods comprises first providing an uncrystallized raw sugar in solution form, next

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concentrating the solution to supersaturation, and then seeding the supersaturated solution with already formed sugar crystals.

By subsequent cooling of the solution, new crystals form and grow. After formation of the crystals, the remaining mother liquor isseparated from the crystals. The crystals are then washed and dried to yield the final crystalline sugar product.

For many purposes, the food and pharmaceutical industries require that crystalline sugars be agglomerated. One of the many areas where agglomerated crystalline sugars are required, is in the production of edible tablets.

The term "edible tablet" is well understood in the art and its conventional meaning is used herein.

Examples of edible tabletsindude candies, breath mints, medicinal pills, placeboes and the like.

Agglomerated crystalline sugars are generally produced by first forming a crystalline sugar according to the above-described method except that priorIto drying, or in the case of dry sugar after moisturizing, an agglomerating agent is added to the sugar. The sugar is then agglomerated by conventional techniques such as at elevated temperatures using a granulator, dried, and sold or used as an agglomerated crystalline sugar product.

Heretofcre, prevailing practice has been to use as the agglomerating agent either a liquid sugar (i.e. solution of a sugar) of the type being agglomerated or a syrup such as corn syrup. For example, in agglomerating crystalline dextrose, a liquid solution of either dextrose or corn syrup was generally employed as the agglomerating agent.

Commercial acceptability of an agglomerated sugar is heavily dependent upon its degree of resistance to caking,fiowability, agglomerate strength and low dusting characteristics, as well as its ability, when used in edible tablet formation, to form a strong, easily compressible, tablet of a desired density.

Generally speaking, it is believed that for any given agglomerated sugar, agglomerate particle size piays an important role in achieving acceptable levels of these desired characteristics. For example, for many agglomerated sugars, as particle (agglomerate) diameter decreases, losses relating to tablet breakage and dusting increase exponentially and production decreases. Further, and for the same and other agglomerated sugars, as the particle(agglo merate) diameter decreases, the weight and volume of a tablet increasesthus resulting in a loss ofcompressibility at constant volume of fill.The problems of dusting, breakage, and compressibility therefore may generally be minimized for any given system using a particular agglomerating agent when forming edible tablets thereof, if the agglomerated particles therein are relatively large, usually above 200 microns and preferably above 400 microns. In practice, if an agglomerated sugar product using any particular agglomerating agent has a conventional screen profile wherein a substantial portion of the agglomerated sugar particles are caught by the screens having a mesh size of about 65 or more (i.e. having mesh numbers lower than 65, Tyler

Standard), the agglomerated sugar exhibits characteristics which are particularly desirable for tablets.

When using heretofore conventional agglomeriting agents, acceptable levels of screen pro files, agglomerate characteristics, and edible tablet characteristics have been achieved only with difficulty and by using large amounts of agglomerating agents and water. In certain instances, such as when sucrose or blends of sucrose and dextrose were sought to be agglomerated, agglomeration has either failed entirely or the agglomerates were only in rare instances of an acceptable quality and were also generally non-reproducible. In many instances where dextrose was agglomerated, the agglomerated product formed was only of low standards. Such results obviously present a very real problem to the industry as a whole.

It is the purpose of this invention to provide the art with agglomerable compositions of dextrose, sucrose, and/or blends of dextrose and sucrose, containing an agglomerating agent, and with agglomerated sugars and edible tablets made therefrom, all of which are of acceptable, and in most instances of improved quality, which compositions eliminate or substantially reduce the above problems in the art.

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A further purpose of the present invention is to provide a crystalline sugar product in agglomerated form which is easily tabletted and the crystals of which are exceptionally strong, as well as a new binder suitable for use in the preparation of agglomerated crvstalline sugars.

These purposes are accomplished in accordance with this invention by replacingCOI1- ventional agglomerating agents, heretofore used, with an agglomerating agent that may be generally characterized as a starch hydrolysate having a D.E. of 5 to 25 and a descriptive ratio of at least as herein defined.

By using this hydrolysate, compositions of agglomerated sugars, and edible tablets may be formed.

According to one aspect of the present inventionthere is provided an agglomerable sugar composition comprising a crystalline sugar and1--10"1 by weight of sugar of an agglomerating agent comprised of a starch hydrolysate having a D.E. of 5 to 25 and a descriptive ratio of at least 2 as herein defined.

The invention also provides agglomerated sugar crystals comprising a major portion of sugar and from1" to 10% by weight of sugar of a starchhvdrolysate having a D.E. from 5 to 25 and a descriptive ratio of at least 2.0.

The invention further provides an edible tablet comprising an agglomerated crystalline sugar and a starch hydrolysate having a D.E. of 5 to 25 and a descriptive ratio of at least2.0.

The invention further provides a method of agglomerating a crystalline sugar, wherein there is added to said sugar prior to agglomeration, a starch hydrolysate having a D.E. of 5 to 25 and a descriptive ratio of at least 2 as herein defined. Due to the presence of the hydrolysate, thecrystalline sugar easily agglomerates when using conventional agglomerating techniques to provide a crystalline sugar agglomerate of strong particles which exhibits excellent screen profiles andílowability and which upon storage and shipping shows less breakage and less dusting than conventional sugar agglomerates.

Crystalline sugars useful in this invention include any type of crystalline sugar product, examples of which include dextrose, sucrose, lactose and blends thereof. Many of these crystalline sugars are well known in the art and are conventional articles of commerce sold under various trade-names. Such sugars are generally produced and crystallized by conventional techniques as hereinbefore described.

The crystalline sugars useful in this invention may be admixed in either dry or wet form with the agglomerating agent. Preferably, the crystalline sugar used is one which is still in its centrifuge cake form following crystallization, which cake has been washed and centrifuged to so that the water content in the cake, (excluding water of hydration which, if present, comprises116% of the cake weight) will be sufficient to provide the necessary amount of water to agglomerate the sugar. In this respect, the amount of water necessary to agglomerate the above-described composition of this invention, excluding waterof hydration, is preferably from lC/o to 8 / 8 by weight of the total composition.

As stated hereinabove, the agglomerating agents used in this invention are starch hydrolysates having a D.E. of 5 to 25. These hydrolysates may be used in an amount of 1% to10% by weight of the sugar solids and preferably from 2% to4% by weight thereof.

The starch hydrolysates having a D.E. of 5 to 25 used in this invention for making crystalline sugar agglomerates are a relatively new class of starch materials. These starchhydrolysates are made by subjecting a source of starch to enzyme or acid treaunent or a combination of both. It is important that the starchhydrolysates have a D.E. (dextrose equivalent) of less than 25 and it is essential that they have a D.E. in the range from 5 to 25.The most preferred materials have a

D.E. within the range of 10 to15. Starch hydrolysates of this type have been found to be excellent agents useful in reducing moisture pick-up of normally hygroscopic edible foods whereas use of other hydrolysates having a

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D.E. substantially outside this range results in inferior products which still show a tendency to entrap moisture, thus tending to cake or become sticky.

The term D.E. is used herein to refer to the reducing sugars content of the dissolved solids in a starch hydrolysate expressed as percent dextrose.

The initial starch which is subjected to hydrolytic treatment may be derived from a wide variety of starchy materialswhich contain cereal starches, waxy starches, and/or root starches. Typical starches are com starch, potato starch, tapioca starch3 grain sorghum starch, waxy milostarch waxy maize starch and rice starch. The term "starch hydrolysate", as used herein encompasses hydrolyzed starch derived from a wide variety of starch sources known in the industry.

Ashereinbefere stated, the starch hydrolysates for use in the present invention are those having a D.E. ranging from 5 to 25 and which are made by any number of specific methods.

In one method referred to in Example 1 as Method A, a starch such as a waxy starch is treated with a single enzyme application of bacterial alpha amylase. More slpecifically, an aqueous slurry of a waxy starch, having a solids content less than505/o by weight, is subjected to thehydrolytic action of bacterial alpha amylase under suitable conditions of fermentation to produce a starch hydrolysate. The hydrolysate is further characterized as having the sum of the percentages (dry basis)ot saccharides therein with a degree of polymerization of 1 to 6 divided by the

D.E. to provide a ratioof at least 2.0. This ratio is referred to as the characteristic or descriptive ratio.Those D.E. products having a descriptive ratio less than 2 are somewhat undesirable in that, for example, they exhibit less water solubility and also tend to form haze in solution as compared to those products with a ratio of at least 2.

The same product as described above, may also be made via a number of other routes.

For example, a mixture of starch and water having a solids content less than 50% by weight may be first subjected to the hydrolytic action of a bacterial alpha amylase followed by a high temperature heating step to solubilize any unsolubilized starch. Since this temperature tends to inactivate the enzyme it is then necessary to cool the solubilized partial hydrolysate and subject it to a second hydrolysis by treatment with additional bacterial alpha amylase to obtain the final starch hydrolysate.

This method is referred to as Method B in Example 1.

A third method of making the D.E. starch hydrolysates referred to asMethod C in Example 1, consists of hydrolyzing a mixture of starch and water by the action of acid to reach a D.E. between 5 and 15.

The partial hydrolysate issubsequently subjected to the action of bacterial alpha amylase to obtain a starch hydrolysate having a D.E. of from 10 to 25.

A particularly preferredstarch hydrolysate useful in the present invention has the following specifications: moisture content less than5% by weight, and D.E.10-13.

As alluded to hereinabove, the agglomerable compositions are preferably formed by adding to wet crystalline sugar, a dry starch hydrolysate agglomerating agent having a D.E. of 5 to 25. Although this procedure is preferred, other methods of formulation may also be used.

For example, the starch hydrolysate agglomerating agent may first be placed in a solution containing up to about60C/ solids with sufficient water to provide from116 /ó by weightwater in the final agglomerable composition. This solution may then be added to dry crystalline sugar by blending or by spraying. As another example, the agglomerablecompositions of this invention may be formed in situ by admixing water, dry crystalline sugar, and dry agglomerating agent with as little moisture as 2%.

The agglomerable compositions of this invention, regardless of the procedure used to formulate them, are easily agglomerated using conventional techniques. The agglomerated products so formed have excellent screen profiles, exhibit good anticaking andflowabilitv characteristics, and contain strong agglomerate particles which resist dusting and breakage.

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The agglomerated products, furthermore, exhibit excellent bulk density and compressibility characteristics and therefore may be readily formed into strong, edible tablets using conventional techniques.

In one typical example of the abovedescribed manner of making and using the invention, an agglomerable composition is formed by thoroughly admixing 97 parts byweight of wet dextrose crystals and 3 parts by weight of 10 D.E. starch hydrolysate, the water content of the mixture being24% by weight excluding water of hydration. The mixture is then put through an agglomerator, such as a

Colton Granulator, and dried. The crystal agglomerates emerge from the dryer at conventional moisture levels. The agglomerates are found to be of a hard crystalline nature.

When subjected to pressure such as in a conventional tabletting machine, the agglomerates require only about one-half the conventional pressure generally necessary to form a strong tablet.

In this respect, manufactured items, as contemplated by this invention, include all forms and shapes of compressed or extruded agglomerated sugars. The basic composition of these items comprises an agglomerated sugar and a starch hydrolysate having a D.E. of 5 to 25. In the case ofplaceboes, no further additives would generally be present in the tablet or pill. In the case of candy mints, breath mints and candy cigarettes, conventional flavorings such as citric acid, "Retsyn" and chlorophyll, artificial flavours, and magnesiumstearate may be added("Retsyn" is a Registered Trade Mark). In the case of medicinal pills, the medicine, vaccine and antibiotic will be added in conventional dosages.

The agglomerable compositions and agglomerates of this invention find many uses in the food and pharmaceutical industries.

Aside from their utility in the edible tablet art, as hereinabove described, they find wide utility in other arts such as in those arts wherein quickdispersibility in water, coarse uniform particle size and freedom from breakage and dusting, are desired.

The following specific examples (from Esample 2 onwards; further illustrate the invention. As such they are not limitations thereon.

All percentages are by weight.

EXAMPLE 1

The following specific procedures illustrate the above-described three basic methods for making the starch hydrolysate agglomeratingagnts used in this invention.

Method A - One StepEnzyme Technique

An aqueous starch slurry was prepared containing 30 ' solids by weight of waxy milo starch. The temperature of the slurry was raised and held between 85 C. and 92 C.

A bacterial alpha amylase preparation was added in an amount just above0.025 / by weight of the starch over a period of slightly more than 30 minutes. The mixture was then held at the same temperature for an additional period of 30 minutes. The temperature was then reduced to below80 C. and the conversion was allowed to continue until the desired D.E. was reached. The temperature of the mixture was then suddenly raised to about1ZOC. in order to inactivate the enzyme and terminate the conversion.

Table 1 below sets forth typical saccharide analyses ofhvdrolysates obtained in accordance with the above procedure. DP designates the degree of polvmerization. DP, represents the total quantity expressed in percent by weight, dry basis, of monosaccharides percent in the hydrolysate. DP3 represents the total quantity of disaccharides percent in the hydrolysate, and so forth.

TABLE 1

Typical Saccaride Analyses

D.E.

5 10 15 20 25

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Hydrolysate

Composition

D P1 0.1 0.3 0.7 0.4 2.4

DP2 1.3 3.4 5.5 7.6 9.7

DP3 1.8 4.3 6.9 9.4 12.0

DP4 1.8 3.5 5.2 6.9 8.6

DP5 1.8 3.6 5.5 7.4 9.3

D P6 3.3 7.0 10.6 14.3 18.0

DP7 and higher 89.9 77.9 65.6 53.0 40.0

TotalDPl-6 10.1 22.1 34.4 47.0 60.0

Descriptive Ratio 2.0 2.2 2.3 2.4 2.4

Method B - Two Step Enzyme-Enzyme

Technique

Unmodified corn starch was slurried in water to provide an aqueous suspension containing 28-32% by weight of the unmodified corn starch. The pH was at 7.5-8.0.To this mixture was added HT-1000 bacterial alpha amylase in an amount of 0.05% by weight based on starch solids.("HT-1000" is a bacterial alpha-amylase, having both liquify ing and saccharifying acturities, whose species is derived from the organism Bacillus subtilis and produced by Miles Chemical Company under the trade markHT-1000. Suitable operating conditions are a pH of 5.5 to 7.5 and a temperature of 200 to75 .)

This starch suspension was added over a 30 minute period to an agitated tank maintained at a temperature of90-920C. After completionuf starchaddiltion, liquefaction was continued for 60 minutes, after which time the hydrolysate was within the D.E. range of 2 to 5.The liquefied starch was then heated to1500C. and held at this temperature for 8 minutes. The heat treatment destroyed residuel enzyme activity and resulted in improved filtration rates and in decreased yield losses upon filtration.

Further saccharification to the final D.E. was accomplished by the addition of moreH.r-1000 bacterial alpha amylase aftercool ing the liquefied starchhydrolysate to a suitable temperature for conversion. The liquefied starch was cooled to 80-85 C. and

HT-1000 added in an amount of 0.02% by weight starch solids. After 14 to 20 hours of conversion the desired terminal D.E. of 20 was obtained.

The final starch hydrolysate product was analyzed and the following analytical values were obtained.

TABLE 2

Descriptive

D.E. DP1 DP2 DP3 DP4 DP5 DP6DP7 Ratio 20.7 2.4 7.5 10.8 8.0 6.8 15.1 49.4 2.4

Method C - Two Step, Acid-Enzyme Technique

Several samples ofcorn starch (A, B & C) were slurried in water providing slurries having Baumes' ranging from 140 to 220. These slurries were partially acidhydrolyzed to a maximum at 15 D.E. The particular D.E. achieved by acid hydrolysis in each of the samples is set forth in Table 3 below. After acid hydrolysis, the slurry was neutralized to a pH between 6 and 7. The neutralized liquor was cooled to between 80 and 850C., and dosed with bacterial alpha-amyise (HT-1000) in the quantity set forth below. A final

D.E. of 19 to 21 was obtained in each of the samples in a period of time between 1 and 3 hours. The final conversion liquors are low in color. These liquors are easily refined and evaporated to about 42 Baume to provide syrups. Dry products may also be obtained,

Tables 3 and 4 below set forth the reaction conditions for conversion and product analyses respectively.

TABLE 3

Enzyme Conversion Conditions

Enzyme

D.H. Dose

of Acid %Dry Temp. (% by weight Time Final

Sample Hydrolysate Substance C. pH starch solids) Hours D.H.

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A 15.2 38 80 6.5 0.01 1 19.7

B 12.9 37.5 85 6.5 0.05 2 20.2

C 10.3 38.1 85 6.5 0.1 2 21.8

TABLE 4

Product Analyses

% Dry Descrip

Final Sub- tive

Sample D.E. stance DP1 DP2DP3 DP4 DP3DP6 DP. Ratio

A 19.7 72 3.9 5.8 8.2 7.2 7.3 10.2 57.4 2.1

B 20.2 72 2.3 5.9 8.5 6.4 6.6 12.6 57.7 2.1

C 21.8 75 2.3 8.3 10.9 8.1 9.2 16.9 44.3 2.5

EXAMPLE 2

Preparation of Crystalline Dextrose

Agglomerates

A starch hydrolysate having a D.E. of approximately 10 wasformed according to the procedure of

EXAMPLE 1,METHOD A.

The analysis of this product was substantially the samcA die analysis of the 10 D.E. product in

TABLE 1. Two of centrifuge cake sugar@ crystalline dextrose, each weighing 22.7Kg@@, were adminred with the hydrolysatc, the hvdrolysate being added in the amount of2 and4 ^ by weight of solids respectively and being either dry or wetted witha smallamount of water as indicated in

Table 5. The originalcentrifuge cakes prior to hydrolysate addition, had approximately 12-15% moisture thereinincluding about 9Y water of hvdraticn.After blending the dextrose with the low

D.E.hydrolysate for about 10 minutes in a DAY brand twin shell "Sigma" (Registered TradeMark) blade mixer, the resulting mixture was then fed into a steam jacketed hot air rotary drier having a temperature of 132 C. After 15 minutes drying time, the dry product was screened with a Tyler No.

10sicve and the amount through was considered the yield (i.e. product).

The agglomerated products exhibited a screen profile as shown in TABLE 5.

For comparative purposes the same basic procedure was followed as just described except that instead of using the hydrolysate of the invention, usual and comparable amounts of the conventional agglomeratingagcnts, i.c. liquid dextrose and corn syrup (60% solids), were used. Three different types of conventional corn syrup were used. In addition, one run was made omitting an agglomerating agent entirely. This run is considered as a control and is listed as batch 1. Another run was made adding only2% H.O to the cake without the addition of any agglomerating agent (batch 16).

TABLE 5, for comparative purposes, includes the screen profiles and other characteristics of these conventional agglomerates. For simplicity, the hydrolysate is referred to in this table asHY, and the liquid dextrose is referred to as LD.

TABLE 5

Moisture %

(% by Over Screen Profile % Through

Batch Additive Amount weight A.I.(a) size 14(b) 20 35 42 60 80 100 1 None - 8.9 82.4 4.0 99.8 98.8

90.4 86.6 73.8 38.4 18.0 2 Corn syrup A 2% 8.1 68.8 5.0 99.6 98.2 86.8 77.4 39.2 16.6 1.2 3 Corn syrup A 4% 7.6 46.8 10.0 97.2 91.4 62.4 47.8 12.6 0.8 0.4 4 Corn Syrup A 6% 9.4 11.4 24.5 71.6 38.2

3.0 1.4 0.4 0.0 0.0 5 Corn Syrup B 2% 8.4 39.4 4.5 99.0 96.8 74.4 62.6 25.8 3.6 0.8 6 Corn Syrup B 4%

8.8 38.0 13.0 96.6 86.4 49.2 33.4 11.4 2.4 1.0 7 Corn Syrup B 6% 8.5 28.0 40.0 91.0 60.0 20.0 11.8 4.0

1.2 0.4 8 Corn Syrup B 8% 5.9 37.2 69.0 82.2 60.4 26.4 18.6 6.4 1.4 0.8 9 HY 2% Dry 8.6 46.2 7.5

98.8 95.6 71.4 60.4 32.8 7.8 2.6 10 HY 4% Dry 7.1 60.8 13.0 97.4 93.6 71.8 59.0 26.0 5.0 2.0 11 HY

2% Wet 8.3 44.0 8.5 99.0 95.2 66.2 57.0 30.6 8.2 3.2 12 HY 4% Wet 7.4 49.4 15.5 96.8 86.6 54.2 42.2

20.2 5.6 2.4 13 Corn syrup C 2% 6.4 68.6 5.0 98.8 95.2 67.4 53.0 20.0 2.4 0.8 14 Corn syrup C 4%

6.7 62.2 9.0 96.4 87.4 56.4 43.8 16.4 0.8 0.0 15 Corn syrup C 6% 6.6 48.8 7.0 95.0 86.0 60.8 43.8 8.8

0.4 0.2 16 H2O 2% 8.6 52.2 52.0 88.4 74.8 53.6 48.4 38.0 26.0 19.8 17 LD 10% 8.4 56.2 56.0 86.6

69.4 41.8 35.4 24.6 15.2 11.2 (a) Attrition index - standard indication and measurement of hardness.

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(b) The numbers 14, 20, 35, 42, 60, 80 and 100 indicate the standard mesh (Tyler screen) size or number of the screens used to obtain a profile.>;/RTI;

Regardless of the typeof agglomerating agent added in thisexaliiple, the resulting product was a coarser sugar than if no agglomerating agent was added or if onlywater was added to thecake prior to agglomeration.

All of the corn syrup products exhibited high tendencies toward caking, while the products of this invention, which use hydrolysate as theagglomerating agent, exhibited acceptable to exccllent anticaking tendencies. In addition, all six andeight percent corn syrup additions resulted in too great a yield loss to be acceptable while two and four percent levels were tolerable. All screen profiles, except for those of the control and water addition runs, were within acceptable limits, the profile of liquid dextrose (batch 17) being least acceptable of all and is almost unacceptable.

Thc above agglomerates of batches1-17 were next pressed into tablets using a conventional tablet machine and pressures as indicated inTABLE 6. The following data resulted.

TABLE 6

Charachteristics of Agglomerates Tablets

Caking Resson for Average Average Kgms/cm/cm

Batch Tendency Unacceptable Unacteptability Thickness (cm) Weight Thickness

1 Normal 0.941 2.0738 0.219

2 High X Caking 0.905 1.8400 0.323

3 High X Caking 0.927 1.9490 0.648

4 High X Yield 0.928 2.1555 0.283

5 High X Caking 0.959 2.1086 0.653

6 High X Caking 0.963 2.1792 0.702

7 High X Yield 0.907 2.1456 1.195

8 High X Yield 0.888 2.0645 0.829

9 (a) Normal 0.007 2.2021 0.322

10 (a) Normal 0.983 2.1261 0.431

11 (a) Slightly Higher 0.988 2.1993 0.556

12 (a) Slightly Higher 0.982 2.1224 0.451

13 High X Caking 0.916 2.0106 0.636

14 High X Caking 0.918 2.0567 0.668

15 High X Caking 0.985 1.9867 1.63

16 Normal X Yield 0.005 2.2842 0.416

17 Normal X Yield 0.1001 2.3184 0.472 (a) Batches 9-12 are the hydrolysate agglomerated tablets, all other are conventional tablets. The batches as numbered in in this table correspond to those of TABLE

5.>;/RTI;

The data in TABLE 6 show that all agglo merates of the corn syrup type and liquid

dextrose type were unacceptable either because

of their hightendency to cake or their low

yield (due to breakage, dusting, etc.). Only those agglomerates which used hydrolysate as an agglomerating agent formed acceptable

tablets from the standpoint of both strength (i.e. high yield) and anticaking characteristics.

Note also that significantly less pressure was used in most instances to form the tablets of this invention.

EXAMPLE 3

For comparative purposes, three test agglomerates and tablets were made from a dextrose filter cake.

The first two tests used the compositions of this invention, the third test used a conventional corn syrup as the agglomerating agent. Agglomeration was conducted in a "Hobart" (Registered Trade

Mark) steam jacketed granulator. The condilations of formulation were as follows:

TABLE 7

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Run Agglom. Temp. of Amount of Agglom. Agent Tendency

No.Agent Agglom.(% by wt. sugar basis) to Cake

1 Hy(a)40tc 3% None

2 HY(a) 40 C.3% None

3 Corn Syrup40 "C. 5% High-plastic

Solids in nature

(a)Hy - hydrolysate formed according to procedure in EXAMPLE 1, METHOD A,

and conforming substantially to the analysis of the 10 DE product in TABLE 1.

The screen profiles of these tests were as follows:

TABLE 8

RUN NO.

Screen (Tyler mesh)

Analysis % through 1 2 3

20 89.8 94.4 98.0

28 77.6 87.0 92.0

35 63.4 75.8 81.8

42 53.4 66.6 73.6

48 43.4 54.8 64.2

60 32.2 40.4 53.4

65 22.4 27.0 41.2

80 14.2 15.6 29.2

100 8.4 7.6 16.4

150 3.2 1.6 3.2

200 1.4 0.6 0.4

The agglomerates formed by the above tests were then formulated into 20 tablets for each agglomerate under similar tabletting conditions. The following characteristics result.

TABLE 9

Average of 20 Tablets

RUNNO. 1 2 3

THICKNESS (cm.) 0.872 0.838 0.938

WEIGHT(gms) 1.9095 1.8804 1.8808

BREAKAGE 1.196 1.688 0.431 (kgms/cm2/cm thickness)

An analysisob the above data clearly illustrates the superiority of the agglomerates and tablets of this invention over conventional agglomerates using corn syrup and tablets made therefrom. For example, when dry hydrolysate is used even in lesser amounts than corn syrup solid, a stronger tablet results as shown by the compared breakage values.

EXAMPLE 4

Following the procedure set forth in Method

B, EXAMPLE 1, a hydrolysate is produced having substantially the same analytical characteristics as set forth in TABLE 2 (e.g.

D.E. = 20.7 etc.). Five percent of this dry agglomerating agent is added to a dextrose filter cake containing about 12% moisture ineluding water of hydration. The mixture is thoroughly blended and added to a "Hobart" mixer fitted with a whisk typestirrer and steam jackets. The mixture is then agglomerated at40oC. The resulting material, having a water content less than 10%, is an acceptable agglomerate exhibiting good anticaking tendencies. When formulated into tablets, acceptable breaking strength results.

EXAMPLE 5

Four hydrolysates are formed, the first three according to Method A, EXAMPLE 1. The analytical characteristics of these first threehydrolysates correspond substantially to those of the 5 D.E., 15 D.E., and 25 D.E. hydrolysates of TABLE 1. The fourth hydrolysate is produced according to Method C,

EXAMPLE 1 and substantially corresponds to SAMPLE C in TABLE 4. Each of these hydrolysates is admixed in dry form in an amount of 2% by weight sugar solids, with a centrifuge cake of crystalline

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dextrose having a moisture content of about 13% including water of hydration. After thorough blending, the crystalline dextrose is agglomerated in a

Hobart mixer at a temperature of 450C. All agglomerates formed exhibit good screen profiles, hardness and anticaking characteristics.

Comparatively, the 15 D.E. hydrolysate agglomerates exhibit the best qualities, while the 5 D.E. and 25

D.E. hydrolysate agglomerates, though acceptable, were the poorest. Tablets formed of these agglomerates exhibit similar characteristics with the 5 D.E. and 25 D.E. hydrolysate tablets being the poorest in comparison with the other two types oftablets, albeit that they are acceptable.

EXAMPLE 6

Formidation of sucroseagglomerates

Two formulations of sucrose agglomerates were made as follows:Form?zlation A

3,175.2 grams oflst strikesubstantially dry centrifugal white sucrose (water content0.36) were dry mixed with 4% hydrolysate (by weight sucrose); i.e., 127g.,d a substantially dry hydrolysate having a

D.E. of about 10. Mixing was conducted for 10 minutes in a Patterson-Kelly twin shell V dry blender whereupon water was added slowly with mixing over a 5 minute period. The amount of water added was 6% by weight total mixture (i.e. approximately 200gms). This mixture was then transferred to trays, agglomerated, and hot air dried at1 100C. for about 3 hours. The agglomerated product formed was screened through a Tyler No. 10 sieve (U.S. No. 12) and theIthrough-product, considered the yield, was found to be 52% (i.e. 1717 gms.).

Formulartios B:

The same procedure was followed here as in FORMULATION A above except that 3% water

(approximately 98ginks.) was used. The yield was found to be about 60% (approximately 2023 gms.).

The characteristics of the two agglomerates formed are set forth in the following table.

TABLE 10

Centrifugal A (6 % water) B (3 % water)

Sugar After Agglomera- After Agglomera

Before tion, Drying tion, Drying

Agglomeration and Screening and Screening % Moisture 0.36 0.25 0.18

Screen Analysis Ó Through 10 100 93.7 100.0

Tyler Sieves

14 99.5 69.6 79.7

20 91.7 39.4 48.8

28 45.8 13.9 24.4

35 11.5 2.0 7.4

42 5.9 0.4 4.3

48 2.9

60 0.7

Bulk Density kgms/m3 791 650 700

On the basis of these data, both batches of agglomerates sucrose exhibited larger particle size than the centrifugal sugar used before agglomeration,FORMULATION A having a larger particle size thanFORMULATION B.

Comparison of the bulk densities verifies this conclusion. The agglomerates produced, in addition to exhibiting good screen profiles (i.e. substantially all of the particles are located between No. 10 and No. 42 screen sizes), were alsovert acceptable agglomerates for the production of tablets, or for sanding confections, such as gum drops.

EXAMPLE 7

125 Grams of sucrose were dry blended with 125 grams of dextrose and S grams of the hydrolysate used in EXAMPLE 6. The mixture was then thoroughly blended at low speed for about 5 minutes, followed by the addition of 10 mis. of water, then further mixed at slighly increased speed for two

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additional minutes. The product was agglomerated and hot air dried for about one hour. The dried product was then screened through a number 10 size Tyler screen and the percent through, considered the product yield, was 81.6 percent.The agglomerated product had the following characteristics:

TABLE 11

50/50 Blend Before 50/50 Blend After

Samples: Agglomeration Agglomeration % Moisture 4.6 2.3

Bulk Density, Average 823 527 kgms/m3

D.E. (dextrose equivalent) 49.3 41.3

Screen Analysis, %

Through Mesh of

Screen (Tyler)

10 100.0 100.0

14 100.0 99.7

20 99.9 91.8

28 99.7 67.5

35 90.9 31.0

42 76.3 18.4

48 62.3 10.5

60 54.2 5.1

65 49.5 2.0

80 45.2 0.6

100 38.9 0.3

150 25.1 0.1

200 15.2 0.0

The agglomerate product exhibited excellent bulk density, screen profile, and flowability and was readily formed into tablets.

The above data illustrate that the hydrolysate acts as a binding agent between the sucrose and dextrose as well as an agglomerating agent for the crystals.

EXAMPLE 8

11.3Kgms. of sucrose were dry blended with 11.3kgms. of dextrose using a "Hobart" blender with a whisk type stirrer. To this blend was then added 0.91 kgms. of the hydrolysate agglomeratingagent of

EXAMPLES 6 and 7 and the mixture was blended for 10 more minutes. There was then added with mixing over a two minute period, one pound of water. This mix was then fed into a steam jacketed, hot-air rotary drier at132to. for approximately 15 minutes. The agglomerated product was then screened with a No. 10 mesh screen (Tyler), and the percent through, considered the product yield, was

75 percent.

The product so formed had the following characteristics:

TABLE 12



Bulk Density, Average 861 652kgms/m3

D.E.

Screen Analysis,(9Ó

Through (mesh size) (Tyler)

10 100.0 100.0

14 99.8 99.6

20 99.2 96.2

28 98.0 89.8

35 89.6 56.6

42 72.2 35.8

48 55.0 20.0

60 44.2 10.8

65 36.4 5.6

80 32.0 2.6

100 28.6 1.2

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150 21.4 0.6

200 18.6 0.4

The product exhibited excellent bull; densits; screen profile, andfiowability as well as being readily formed into tablets. As in the preceding example, the hydrolysate acts as a binding agent as well as a crystal agglomerating agent.

EXAMPLE 9

Typical candy tablets were formulated as follows:

About 97.00% by weight of a dextrose or sucrose product (having a low D.E. starch hydrolysate therein) selected from one of the acceptable preceding EXAMPLES was admixed with 1.88% citric acid,0.12 artifical orange flavoring, and1.00% magnesium stearate. The mixture was then pressed into a candy tablet by aconventienal tablet making machine. The tabletted product exhibited good strength, antibreakage characteristics, and a flavor release characteristic of sugar tablets generally.

EXAMPLE 10

Lactose in the amount of 100 parts is agglomerated by mixing crystalline or powdered lactose with 3 parts of low D.E. starch hydrolysate having a D.E. in the range of10--13 and 3 parts of water. The mixture is passed through a granulator and dried to yield agglomerates of a particle size substantially larger than that of the original lactose.

The agglomerated lactose is particularly useful in food formulations requiring quick dispersibility in liquid or in the formation of tablets.

WHAT WE CLAIMIS:-

1. An agglomerable sugar composition comprising a crystalline sugar and1-10% by weight of sugar of an agglomerating agent




TABLE 12



Bulk Density, Average 861 652kgms/m3

D.E.

Screen Analysis,(9Ó

Through (mesh size) (Tyler)

10 100.0 100.0

14 99.8 99.6

20 99.2 96.2

28 98.0 89.8

35 89.6 56.6

42 72.2 35.8

48 55.0 20.0

60 44.2 10.8

65 36.4 5.6

80 32.0 2.6

100 28.6 1.2

150 21.4 0.6

200 18.6 0.4

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The product exhibited excellent bull; densits; screen profile, andfiowability as well as being readily formed into tablets. As in the preceding example, the hydrolysate acts as a binding agent as well as a crystal agglomerating agent.

EXAMPLE 9

Typical candy tablets were formulated as follows:

About 97.00% by weight of a dextrose or sucrose product (having a low D.E. starch hydrolysate therein) selected from one of the acceptable preceding EXAMPLES was admixed with 1.88% citric acid,0.12 artifical orange flavoring, and1.00% magnesium stearate. The mixture was then pressed into a candy tablet by aconventienal tablet making machine. The tabletted product exhibited good strength, antibreakage characteristics, and a flavor release characteristic of sugar tablets generally.

EXAMPLE 10

Lactose in the amount of 100 parts is agglomerated by mixing crystalline or powdered lactose with 3 parts of low D.E. starch hydrolysate having a D.E. in the range of10--13 and 3 parts of water. The mixture is passed through a granulator and dried to yield agglomerates of a particle size substantially larger than that of the original lactose.

The agglomerated lactose is particularly useful in food formulations requiring quick dispersibility in liquid or in the formation of tablets.

WHAT WE CLAIMIS:-

1. An agglomerable sugar composition comprising a crystalline sugar and1-10% by weight of sugar of an agglomerating agent comprised of a starch hydrolysate having a

D.E. of 5 to 25 and a descriptive ratio of at least 2 as herein defined.

2. An agglomerable sugar composition according to claim 1, wherein the crystalline sugar is one of dextrose, sucrose, lactose, and blends thereof.

3. An agglomerable sugar composition according to claim 1 or 2, wherein said starch hydrolysate has a

D.E. from 10 to 15.

4. An agglomerable sugar composition according to claim 1, 2 or 3, wherein said starch hydrolysate has a moisture content less than 5% by weight and a D.E. from 10 to 13.

5. Anagglomeralule sugar composition according to any of claims 1 to 4, wherein said starch hydrolysate is present in an amount from 2% to4% by weight sugar.

6. Agglomerated sugar crystals comprising a major portion of sugar and from 1% to 10% by weight of sugar of a starch hydrolysare having a D.E. from 5 to 25 and a descriptive ratio of at least 2.0 as herein defined.

7. An agglomerated sugar product as in claim 6, wherein the sugar is one of dextrose, sucrose, lactose, and blends thereof.

8. An agglomerated sugar product as in claim 6 or 7, wherein the starch hydrolysate is present in an amount from 2% to 4% by weight of sugar.

9. An agglomerated sugar product as in claim 6, 7 or 8, wherein the starch hydrolysate has a D.E. from

10 to 15.

10. An edibletablet comprising an agglomerated crystalline sugar and a starchhydto- lysate having a

D.E. of 5 Ito 25 and has a descriptive ratio of at least 2.0 as herein defined.

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11. An edible tablet according to claim 10, which also includes citric acid, magnesium stearate, and an artificial flavoring agent.

12. An edible tablet according to claim 10 or 11, wherein the agglomerated crystalline sugar is one of dextrose, sucrose, lactose, and blends thereof.

13. Anedible tablet according to claim 10, 11 or 12, wherein said starch hydrolysate has a D.E. from

10 to 15.

14. An edible tablet according to any of claims 10 to 13, wherein said starch hydrolysate has a moisture content less than 5% by weight and a D.E. of10-13.

15. An edible tablet according to any of claims 10 to 14, wherein said starch hydrolysate is present in an amount from 2% to43/ by weight sugar.

16. The method of agglomerating a crystalline sugar, wherein there is added to said sugar prior to agglomeration, a starch hydrolysate having a D.E. of 5 to 25 and a descriptive ratio of at least 2 as herein defined.

17. A method according to claim 16, wherein said crystalline sugar is one of dextrose, sucrose,lactose, and blends thereof.

18. A method according to claim 16 or 17, wherein said starch hydrolysate has a D.E. of 10 to 15.

19. A method according to claim 16, 17 or 18, wherein said starch hydrolysate is added in an amount of from 1% to 10% by weight sugar.Data supplied from the esp@cenet database - Worldwide

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80.

GB1301948 - 1/4/1973

GB1301948



IP Class: A23L1/10

E Class: A23L1/182



Family: GB1301948

Abstract:


1301948 Preparing parboiled rough rice T SATAKE 17 Aug 1970 39569/70 Heading A2Q In the preparation of parboiled rough rice. the rice grains are first caused to crack and brown by subjecting them to an air blast at a greatly elevated or lowered temperature, e.g. a heated blast at a temperature of

150 degrees C, in a chamber 3, then moistening the grains in tanks 10 through which water is circulated from a reservoir 13, then steaming the grains in tanks 19 supplied with steam by a steam- producing device 20, and finally drying the grains. The last step is preferably carried out in two stages, viz in a first drier 27 supplied with a blast of air heated to between 100 and 400 degrees C by a heater 30 and, after passing through tempering tanks 34 for adjustment of the water content of the grains, in a second drier 40. The grains are transferred between the various stages by the conveyers and elevators shown.

The chamber 3 may be horizontal (Fig. 2, not shown) instead of vertical.Description:


(54) THE PREPARATION OF PARBOILED ROUGH RICE

(71)1, TOSHIHIKo SATAKE, a Japanese citizen, of2-38, Nishihon-Machi, Saijo

Cho, Kamo-Gun, Hiroshima-Ken, Japan, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement :

This invention relates to the preparation of parboiled rough rice, i.e. brown rice enwrapped in chaffs.

Conventionally, parboiled rice is prepared by subjecting rough rice firstly to a moistening step and secondly a steaming step, followed by a drying step. However, such preparation is accompanied by the serious drawback that it takes more than ten hours to properly moisten the rough rice, unless the moistening step is carried out under pressure.

Hence, it is an object of the present invention to shorten the time necessary for moistening rough rice.

According to this invention I provide an apparatus for preparing parboiled rough rice, which comprises a first device provided with means for subjecting rough rice to a gaseous blast at a temperature sufficiently different from the initial temperature of said rough rice to cause said rough rice to crack to give brown rice with cracks enwrapped in chaffs, a second device operatively connected with the first device for moistening the cracked rice, a steaming device operatively connected with the second device for steaming the moistened rice, and a drying device operatively connected with the steaming device for drying the steamed rice.

403/2197

Furthermore I provide a method of preparing parboiled rough rice comprising subjecting rough rice to a gaseous blast at a temperature sufficiently different from the initial temperature of said rough rice to cause said rough rice to crack to give brown rice with cracks enwrapped in chaffs, moistening the cracked rice, steaming the moistened rice and drving the steamed rice.

The cracked brown rice enwrapped in chaffs may be moistened within a highpressure tank, whereby the time required for the moistening of nice is shortened still further.

Preferably, during the drying step, a blast of gas heated to a temperature between100"C and400"C is applied over the rough rice, which has been just steamed, whereby the time required for the drying step is shortened and it becomes possible to utilize in said step a horizontal agitating type drier which can dry articles without their forming lumps, though the time for which it can hold therein the articles to be dried is short, compared to other driers of other types.

Preferably, the moistening is carried out for a sufficient time so that nutrious substances of the outer coverings of the brown rice penetrate inwardly into the endosperm by means of water absorbed thereinto through the cracks, resulting in an enrichment of the rice, after subsequent polishing.

In order that the invention may be clearly understood and readily carried into effect, two examples of the invention will be more fully described with reference to the accompanying drawings, inwhich:

Fig. 1 is a view schematically showing the apparatus of the present invention, in which cracks are produced in rough rice while it flows vertically; and,

Fig. 2 is a view similar to Fig. 1, in which cracks are produced in the rough rice while it is horizontally agitated.

With reference to Fig. 1, an elevator 1, for loading rough rice, is provided with an outlet opening 2 which is connected to an upper inlet opening of a device 3 for providing rough rice with cracks, in which device 3 the rice flows verticallv. Inside said device 3, there is a blast-supplving outlet of a blower 4 which supplies to the devicethrough said outlet annir blast heated to a high temperature or chilled so as to give a temperature sufficiently different from that of the rice when introduced to device

3 that cracking of the rice occurs. Towards the bottom of the device 3, there is provided an outlet opening 5, from which the rough rice which has been subjected to the blast discharges.When a heated blast is employed, the temperature thereof may preferably be around1500C. By means of the heated or chilled blast applied onto the rough rice while it isdescending through the device 3, the temperature of rice suddenlychallaes and cracked brown rice enwrapped inchaffs results.

The rough rice thus cracked is broughtout froin the device 3 through its outlet opening 5 and isrezeived by a beltconveycr 6 which is provided below the said opening.

The rice carried by theconveyor is releasedtherefrom at one of itshorizontal ends and supplied to an inlet opening 8 of a loading elevator 7, upper outletopening 9 ofwhile onens to the upper inletopenings of a pluramity of tanks 10 in which the rice is moistened. Said tanks may be kept under pressure, if required. Outlet openings of a water supply tube 11 are situated at the upper inlet openings of tanks 10, and an exhaust tube 12 is connected to the bottoms of the tanks and connects with a water supply tank 13. Water circulates by means of a motor through the water supply tube 11, tanks 10, exhaust tube 12 and the water supply tank 13.At the bottom of the tanks 10, there are provided outlet openings 14 which are normally closed and release the moistened rough ricewhen they are opened.

In the above construction, cracked brown rice enwrapped in chaffs is stored in the tanks 10 under water andbecomes properly moistened within about two or three hours.

When the tanks are kept pressurized, the time required for moistening the rice can be shortened to aboutt'venty tothirtv minutes.

A belt conveyor 15 is locatedb-9o-,v the outlet opening 14 of the tanksiO, and operatively connected to a loading opening 17 of another elevator 16 provided with anoutlet opening IS, carries the moistened rough rice to steaming tanks 19. Heated steam is introduced into said steaming tanks 19, by pipes 21 having one end connected to a boiler 20, whereby the moistenedbrosim rice enwrapped inchalets is steamed andbecomes parboiled rice. It should be noted that, duringsteam- ing,

404/2197

theendosperms of the rice grains become melted within the chaffs and the cracks are thereby eliminated.The water contentcf rice at this stage is about 35 to45%.

The rice thus processed is furthertrans- ferred to a drier 27 by means of a conveyor 23 located below exhaust openings 22 of tanks 19 and operatively connected with an elevator 24 having a loading opening 25 and outlet opening 26. Said drier 27 is of a horizontal agitating type which can dry articles without their forming lumps, and hence most suitable fordrying moistened articles such as moistened and steamed rough rice, though the time for which it can hold therein the articles to be dried is comparatively short compared to a drier of other types.In order to shorten the time necessary for drying the moistened and steamed rice and thus make it possible to utiiize adenier of the type stated above, a blast supplying pipe 31 of a device 30 producing a heated air blast is connected to the drier 27, so that blasts heated up tolOO0C to 400 C may be introduced into the drier.The drier27 is providedwith an inletopening 8 which coiinects to the outletopening 26of the e!evator o- 24, and an outlet opening 29

>;RTI frorn which the rice driedin the drier is discharged The rice is further transferred,bv means ofanother elevator32 having a loading opening 33 which is connected to theout- letopening 29 of drier27 and outletcp,.;;l- ings, into tempering tanks 34 in >;RTI VflliCh the rice released from saidoutlet openings into said tanks is stored for apredetermined time so that the water content of rice can properly be adjusted.

Numeral 40 indicates a secondary drier, invAi'ch the rice tempered in the tanks 34 and transferred thereintobv means of an elevator 36 is further dried. Said elevator 36 is provided with a loading opening 37 which iscollected with exhaust openings 35 of tanks 34, and outlet opening 38 which is connectedLO upper inletopening 39 of the secondary drier 40.Numeral 4-1 indicates a belt conveyorwhich is associated wiili the secondary drier for discharging the dried rice therefrom.

The apparatus illustrated in Fig.2 is substantially the same as theone showniii Fig.

1, except that the device indicated by the numeral 3 for providing rough rice with cracks is of a horizontal rotating type inwhich the rice flows horizontally. The parts or devices in Fig.2 which are identical or correspond to those of Fig. 1, are denoted by the same numerals as used in Fig. 1.

WHAT I CLAIMIS: -

1.An apparatus for preparing parboiled rcugh rice, which comprises a first device provided with means for subjecting rough rice to a gaseous blast at a temperaturesufliciently different from the initial temperature of said rough rice to cause saidrough rice to crack to give brown rice with cracks enwrapped in chaffs, a second device operatively connected with the first device for moistening the cracked rice, a steaming device operativelycollected with the second device for steaming the moistened rice and a drying device operativelyconnected with the steaming device for drying the steaming rice.

2. An apparatus as claimed in Claim I, adapted to cause the rough rice to flow vertically within the first device.

3. An apparatus asclaimed in Claim 1, adanted to cause the rough rice to flow horizontally within the first device.




the temperature thereof may preferably be around1500C. By means of the heated or chilled blast applied onto the rough rice while it isdescending through the device 3, the temperature of rice suddenlychallaes and cracked brown rice enwrapped inchaffs results.

The rough rice thus cracked is broughtout froin the device 3 through its outlet opening 5 and isrezeived by a beltconveycr 6 which is provided below the said opening.

405/2197

The rice carried by theconveyor is releasedtherefrom at one of itshorizontal ends and supplied to an inlet opening 8 of a loading elevator 7, upper outletopening 9 ofwhile onens to the upper inletopenings of a pluramity of tanks 10 in which the rice is moistened. Said tanks may be kept under pressure, if required. Outlet openings of a water supply tube 11 are situated at the upper inlet openings of tanks 10, and an exhaust tube 12 is connected to the bottoms of the tanks and connects with a water supply tank 13. Water circulates by means of a motor through the water supply tube 11, tanks 10, exhaust tube 12 and the water supply tank 13.At the bottom of the tanks 10, there are provided outlet openings 14 which are normally closed and release the moistened rough ricewhen they are opened.

In the above construction, cracked brown rice enwrapped in chaffs is stored in the tanks 10 under water andbecomes properly moistened within about two or three hours.

When the tanks are kept pressurized, the time required for moistening the rice can be shortened to aboutt'venty tothirtv minutes.

A belt conveyor 15 is locatedb-9o-,v the outlet opening 14 of the tanksiO, and operatively connected to a loading opening 17 of another elevator 16 provided with anoutlet opening IS, carries the moistened rough rice to steaming tanks 19. Heated steam is introduced into said steaming tanks 19, by pipes 21 having one end connected to a boiler 20, whereby the moistenedbrosim rice enwrapped inchalets is steamed andbecomes parboiled rice. It should be noted that, duringsteam- ing, theendosperms of the rice grains become melted within the chaffs and the cracks are thereby eliminated.The water contentcf rice at this stage is about 35 to45%.

The rice thus processed is furthertrans- ferred to a drier 27 by means of a conveyor 23 located below exhaust openings 22 of tanks 19 and operatively connected with an elevator 24 having a loading opening 25 and outlet opening 26. Said drier 27 is of a horizontal agitating type which can dry articles without their forming lumps, and hence most suitable fordrying moistened articles such as moistened and steamed rough rice, though the time for which it can hold therein the articles to be dried is comparatively short compared to a drier of other types.In order to shorten the time necessary for drying the moistened and steamed rice and thus make it possible to utiiize adenier of the type stated above, a blast supplying pipe 31 of a device 30 producing a heated air blast is connected to the drier 27, so that blasts heated up tolOO0C to 400 C may be introduced into the drier.The drier27 is providedwith an inletopening 8 which coiinects to the outletopening 26of the e!evator o- 24, and an outlet opening 29

>;RTI frorn which the rice driedin the drier is discharged The rice is further transferred,bv means ofanother elevator32 having a loading opening 33 which is connected to theout- letopening 29 of drier27 and outletcp,.;;l- ings, into tempering tanks 34 in >;RTI VflliCh the rice released from saidoutlet openings into said tanks is stored for apredetermined time so that the water content of rice can properly be adjusted.

Numeral 40 indicates a secondary drier, invAi'ch the rice tempered in the tanks 34 and transferred thereintobv means of an elevator 36 is further dried. Said elevator 36 is provided with a loading opening 37 which iscollected with exhaust openings 35 of tanks 34, and outlet opening 38 which is connectedLO upper inletopening 39 of the secondary drier 40.Numeral 4-1 indicates a belt conveyorwhich is associated wiili the secondary drier for discharging the dried rice therefrom.

The apparatus illustrated in Fig.2 is substantially the same as theone showniii Fig.

1, except that the device indicated by the numeral 3 for providing rough rice with cracks is of a horizontal rotating type inwhich the rice flows horizontally. The parts or devices in Fig.2 which are identical or correspond to those of Fig. 1, are denoted by the same numerals as used in Fig. 1.

WHAT I CLAIMIS: -

1.An apparatus for preparing parboiled rcugh rice, which comprises a first device provided with means for subjecting rough rice to a gaseous blast at a temperaturesufliciently different from the initial temperature of said rough rice to cause saidrough rice to crack to give brown rice with cracks enwrapped in chaffs, a second device operatively connected with the first device for moistening the cracked rice, a steaming device operativelycollected with the second device for steaming the

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moistened rice and a drying device operativelyconnected with the steaming device for drying the steaming rice.

2. An apparatus as claimed in Claim I, adapted to cause the rough rice to flow vertically within the first device.

3. An apparatus asclaimed in Claim 1, adanted to cause the rough rice to flow horizontally within the first device.

4. An apparatus as claimed in any one of Claims 1 to 3, in which the first device is provided with means for subjecting the rough rice to a gaseous blast heated to a temperature of about150"C.

5. An apparatus as claimed in any one of

Claims 1 to 3, in which the first device is provided with means for subjecting the rough rice to a chilled gaseous blast

6. An apparatus as claimed in any one of the preceding Claims, in which the second device is provided with means for moistening the rice under pressure.

7. An apparatus as claimed in any one of the preceding Claims, in which the drying device is adapted to transfer the rice horizontally and to receive a gaseous blast heated to a temperature between100"C and400"C.

8. A method of preparing parboiled rough rice, comprising subjecting rough rice to a gaseous blast at a temperature sufficiently different from the initial temperature of said rough rice to cause said rough rice tocrack to give brown rice with cracks enwrapped in chaffs, moistening the cracked rice, steaming the moistened rice, and drying the steamed rice.

9. A method as claimed in Claim 8, wherein the rough rice is caused to flow vertically during its subjection to the gaseous blast

10. A method as claimed in Claim 8, wherein the rough rice is caused to flow horizontaily during its subjection to the gaseous blast.

11. A method according to Claim 8, 9 or 10, wherein the gaseous blast is heated to a temperature of about1500 C.

12. A method according to Claim 8, 9 or 10, wherein the gaseous blast is chilled.

13. A method according to any one of

Claims 8 to 12, wherein the moistening is carried out under pressure.

14. A method according to any one of

Claims 8 to 13, wherein the rice is caused to flow horizontally and be subjected to a gaseous blast heated to a temperature between100"C and400 C during drying.

15. A method as claimed in any one of

Claims 8 to 14, in which the rice is moistened for a length of time sufficient to allow nutrious substances of the outer coverings of the grains of brown rice to penetrate inwardly into the endosperms thereof by means of water absorbed thereinto through the cracks.

16. An apparatus for preparing parboiled rough rice, substantially as hereinbefore described with reference to the accompanying drawings.

17. A method of preparing parboiled rough rice, according to Claim 8, substantially as herein described.

18. Rice whenever prepared using an apparatus according to any one of Claims 1 to 7 or a method according to any one of

407/2197

Claims 8 to 14.Data supplied from the esp@cenet database - Worldwide

408/2197

81.

GB1306384 - 2/7/1973

GB1306384



IP Class: A23L1/10; A23L1/00

E Class: A23L1/164E; A23L1/0522



Family: GB1306384

Abstract:


1306384 Preparing foods NATIONAL STARCH & CHEMICAL CORP 30 April 1970 [5 May 1969]

20798/70 Heading A2B A process for preparing a light textured crispy (e.g. puffed) amylopectin-based food product comprising (I) moistening a composition comprising an amylopectin product and containing less than 5% by wt. of amylose, (2) subjecting the moistened composition to a simultaneous heat, pressure and mixing action to gelatinise and hydrate the amylopectin product, (3) shaping the resultant composition of step (2), and (4) cooking the moistened composition during or subsequent to step (3). The amylopectin product may be amylopectin per se, waxy starch (e.g. waxy maize, waxy sorghum or waxy rice starch) or a derivative thereof (e.g. acetate, propionate and butyrate esters or hydroxyethyl, hydroxypropyl and carboxymethyl esters). The amylopectin product may be mixed with water and other substances and passed into an extruder having a portion where it may be mixed with more water and subjected to step (2) and a die portion having openings (e.g. straight or serrated slits, or round, oval or fluted circular openings). The cooking step (4) may be performed in the die portion so that the food product is puffed as it is extruded into the atmosphere. If not cooked in the die portion the food product is cooked subsequently e.g. in cotton seed, corn, coconut or soy oil. Sub- stances which may be present in the food product include wheat, corn, tapioca starch, amylose, amylose starch, cheese, fruit, nuts, onion, garlic, salt, carotene, methyl cellulose, sodium caseinate, calcium propionate, butter, vegetable- shortening, corn oil, glyceryl monostearate, sweeteners and antioxidants.Description:


(54) IMPROVED PROCESS FOR MANUFACTURE OF

AMYLOPECTIN-BASED FOOD PRODUCTS

(71) We, NATIONAL STARCH AND

CHEMICAL CORPORATION, a corporation organised under the laws of the State of

Delaware, United States of America, having an office at 750 Third Avenue, New York,

New York 10017, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

It is highly desirable that ready-to-eat food products based upon farinaceous materials possess certain properties of texture, taste, and ease of manufacture. Thus, for example, such products should be produced by a process which permits their rapid solidification or setting, thereby enabling them to retain the shape in which they were initially prepared.They should have sufficient strengh and rigidity to permit their being sliced or cut, if such an operation is required. Upon being put into edible form, such products should be crisp and should retain their crispiness over prolonged periods. They should not be unpleasantly tough and, of course, they should have an appealing flavor. Where frying of these

409/2197

food products is required, the absorption of excess quantities of oil during the frying step should be avoided and variations in the amount of oil absorbed should be reduced to a minimum.

Color variations should also be reduced to a minimum, while the shelf life of the products should be the maximum which is attainable.

Present recipes and means of production provide few, if any, special measures which are designed to insure the attainment of the above described properties of appearance, texture and taste. Thus, such prior art products have not set rapidly, have not retained their desired shapes and have proved somewhat difficult to handle and cut. Furthermore, the taste of such prior art products has fluctuated as a result of the inherent variations present in the various natural base ingredients which have been used in their manufacture. The taste of such products has also necessarily reflected the flavor imparted by the cereal flour, notably corn flour, which is ordinarily utilized therein, thereby severely limiting the variability in taste and texturewhich the practitioner desires in making a variety of such ready-to-eat specialty foodi-aduca.

The present invention provides a process for the preparation of a food product which comprises the steps of: (1) moistening a composition comprising an amylopectin product (as hereinafter defined), saidcomposition containing less than 5% by weight of amylose; (2) subjecting themoistened composition to simultaneous heat, pressure and mixing action in order to effect the gelatinization and hydration of saidanzylopectill product; (3) shaping the moistenedcomposition which results from step

2; and (4)cooking the moistened composition and thereby obtaining an edible product characterizedby its light-texture and crispiness; said cooking procedure being conducted at a point in time simultaneous with or subsequent to step 3.

We have found thatwhen amylopectin is used as the base component of the food products of this invention, many advantages are realized. Thus, suchproducts rapidly set immediately upon their emergence from the apparatus utilized in their manufacture. The latter factor increases the shape retention qualities of these products and results in finn products which can better withstand further treatments such as cutting, drying and frying

Furthermore, these products exhibit prolonged storage stability, limited oil absorption upon frying and controlled texture and taste characteristics. Prior to this invention, for example, as set forth in

U.S.Patent 3,407,070, it was thought that it was absolutely essential to utilize high amylose starch or amylose as a significant part of the farinaceous component in the preparation of food products of the type described herein. Thus, the use of amylopectin in significant quantities was thought to result in blendswhich were difficult to extrude and shape because of the gummy texture and poor set of the uncooked mass. Moreover, sub sequent to being cooked, such amylopectincontaining food products were thought to be fragile and to lack crispiness.It is therefore, surprising and unexpected that when amylopection is employed preferably under specified conditions of moisture content, pressure and temperature set forth in this disclosure, that there should, in fact, result easilymore able products possessing superior shaping and extrusion characteristics which yield edible light-textured crisp and tasty food products.

As an example of the wide variety of specialty food products which may thus be prepared by means of the process of this invention, one may list crackers, chips, cereal puffs, and other so-called snack items; the latter products being available in a multiplicity of flavors and shapes.

It is wellknown that starch is ordinarily composed of two fractions, one a branched fraction known as amylopectin, and the other a linear fraction known as amylose. Each starch type contains thesetwo fractions in a specific ratio characteristic of that particular starch. Methods for separating starch into these two components are known. Furthermore, some starches have been genetically developed which are characterized by a large preponderance of the one fraction or the other.

When we use the term "amylopectin product" herein and in the appended claims we refer to (a) amylopectin resulting from the fractionation of whole starch into its respective amylose and amylopectin components, or (b) whole starches, such as waxy maize, waxy sorghum, and waxy rice starches, which are composed substantially entirely of amylopectin, or (c) amylopectin as mentioned under (a) or whole starches as mentioned under (b) but (i) further treated easy with heat and/or acids or with oxidizing agents to form so-called thin boiling products or (ii) chemically cross-linked or inhibited

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or derivatized, as by means of an esterification reaction which would thus yield amylopectin esters such, for example, as the acetate, propionate, and butyrate esters; or, by means of an etherification reaction which would thus yield amylopectin ethers such, for example, as the hydroxyethyl, hydroxypropyl, or carboxymethyl ethers.

According to a preferred embodiment of our process, one or more of the above defined amylopectin products, together with any desired additives, such as shortening, flavors, and colors, in the presence of from 5 to 20% of added moisture, based on the total weight of the moisturized composition, is blended and the resulting mixture is passed through an apparatus, preferably a heated extruder, which is capable of subjecting the mixture to a simultaneous combination of mixing, along with sufficient heat and pressure to gelatinize and hydrate the amylopectin product and to force the resulting mass through the shaping orifice as a solid formed, shape-retaining, food product.

Depending upon the particular process conditions which are utilized, the resulting product, as obtained from the shaping step, may be in its ultimate edible form or it may merely need an additional cooking operation in order to be put into such final form.

Whenever the description of the process of this invention relates to the specific use, therein, of an extruder, it is to be understood that any other type of apparatus capable of functioning in a similar manner is also applicable for use in preparing the products of this invention.

In a variation of the process, the amylopectin product may, if desired, be admixed with one or more fillers, including, for example, flour or meal derived from various cereal grains such as wheat and corn.

Thus, the flour or meal filler can be admixed with the required amylopectin in a concentration up to

50% of the total weight of the solids within the moisturized composition, i.e. the moisturized composition comprising the resulting blend of water, required amylopectin product and filler, which is ultimately passed through the extruder.

The term "filler" is used herein and in the appended claims to mean whole andcom- minuted edible tubers and whole or cracked cereal grains as well as flours and meals derived from the latter. The whole cereal grains may, in turn, be pre-cooked or pretreated in order to obtain fast cooking products.

Typical procedures for achieving such fast cooking products include passing an aqueous slurry of the grain over heated drums at temperatures which simultaneously gelatinize and dry it, or, the use of a chemical treatment.

In addition to the latter fillers or, as the sole additive, we may also introduce an amylose containing material, provided however, that the total amylose content of the composition to be moistened is less than 5% of the total weight of the solids within the final moisturized composition including the amylose containing additive as well as any other fillers which may be present. The term "amylosecontaining material" is used herein and in the appended claims to mean amylose and high amylose starches (i.e. starches which contain at least500% by weight of amylose, as well as starches which contain both amylose and amylopectin in their normal proportions.

The concentration of the amylopectin product in the moistened product should preferably be selected so as to insure a total amylopectin concentration of from 50 to92 of the total weight of the moisturized composition. The total amylopectin concentration refers to the total weight of theamvlopectin content of the amylopectin product along with the weight of the amylopectin which may be present in any high amylose starches or other amylose containing material that may be optionally utilized as part of the final blend.

The moisture levels for our uncooked food products, which may range from 5 to 20% by weight, are particularly suitable in most instances for permitting the immediate cooking or frying of the food product subsequent to its shaping so as to readily produce an edible product. Thus, by reducing the concentration of moisture to a level of about 15% or less it is possible to eliminate the need for an intermediate drying step. However, even where higher concentrations of moisture in the range of about

16% or more are utilized, only a minimal drying period is necessary. In contrast, prior art procedures ordinarily incorporate higher concentrations of moisture in the uncooked farinaceous mass and thereby require a time-consuming, intermediate drying of the shaped mass prior to its being cooked or fried. In this respect see U.S.Patents 3,027,258 and 3,407,070, wherein the use of higher moisture contents are

411/2197

required and, as a result, a rather lengthy intermediate drying step is necessary prior to the final cooking operation. It is, therefore, a distinct advantage of the present process that when low moisture levels are utilized therein, no intermediate drying step is required after the shaping operation and prior to the final cooking or frying of the thus-shaped mass.

The initial dry blend may, if desired, contain a wide variety of additives which serve, forexample, to flavor, color, emulsify and stabilize the resulting amylopectin-based food products. Among such extraneous additives are included: flavoring materials such as dried cheese, dried fruits, nuts, pizza flavor, onion, garlic, sodium chloride, monosodium glutamate, sweeteners, pepper and paprika; coloring agents such as carotene; stabilizers and thickeners such as methyl cellulose and sodium caseinate; preservatives such as calcium propionate; plasticizers; shortening; emulsifiers; and antioxidants. It is to be noted that these additives may be present -in our food products in only minor concentrations which usually do not exceed 10%, based on the total weight of the dry ingredients.Although such additives are generally added to the initial dry blend, some may, if desired, be injected therein as the mass passes through the cooled section of the extruder barrel or die.

The amount of moisture in the extrusion mixture should be sufficient to gelatinize and hydrate the amylopectin under the particular extrusion conditions employed, taking into account the specific amylopectin product being used, the nature and proportions of the other ingredients, the temperature and pressure employed in the extrusion operation and the particular characteristics which are desired in the ultimate food product Thus, concentratins of water ranging from 5 to 20%, and preferably, 10 to

14%, based on the total weight of the composition, are ordinarily used.

It should be noted that the moisture which may be inherently present in the various components of the composition is not included in determining the amount of water which is to be added to the dry blend.

The addition of water is usually accomplished by spraying, i.e. mixing the dry materials while spraying them with water. Where it is not desired to initially add the entire concentration of water to the mixture, the balance may be injected, as steam or as hot water, directly into the extruder.

The resulting mixture, which may be in the form of a dry or damp powder or a viscous suspension, may be slightly preheated, if desired, although such heating is unnecessary in view of the fact that this process is solely dependent upon the exertion of relatively high heat in the extruder barrel in order to hydrate and swell the amylopectin product. The moistened blend is then fed into the extruder by a pump, ram, screw, double motion ribbon blender, or by any other suitable means.

For the extrusion step, one may employ any device capable of subjecting the moisturized blend to a mixing action and to the heat and pressure necessary to gelatinize and hydrate the amylopectin product, while simultaneously applying the pressure necessary to force the mixture through an orifice, or multiplicity of orifices, at the terminal end of the apparatus.

Although we may thus use a batch type pressure cooker or a continuous type pressure conveyor-cooker in conjunction with a roller or similar shaping device, it is preferable to use an extruder which is capable of conducting all of the required operations in a single continuous procedure. The extruder is typically fitted with a cooking section whose temperature is capable of being regulated, a cooling system which is capable of reducing the temperature to below 2120F., and an orifice or die which gives the product its final shape.

A wide variety of orifice shapes may be used including, for example, straight or serrated slits, round or oval openings, fluted circular shapes and annular openings. It is also possible to extrude the product in the form of a ribbon or a thin sheet so that the desired shape of the individual pieces of the ultimate food product may be cut from the resulting ribbons and sheets.

The extruder may also be arranged so that the first section of its barrel contains heating elements which induce hydration and gelatinization of the amylopectin product, whereas the second section of the extruder barrel may be water-cooled so as to be able to remove a considerable amount of heat from the gelatinized mixture Another variation consists in using two or more extruders in tandem, one to heat the other to cool. In either instance, the combined heat, pressure and mixing action serve to

412/2197

effectively homogenize the mixture in spite of the relatively low amounts of moisture which are present

The temperature applied within the extruder barrel will depend upon the amount and type of amylopectin product present in the mixture as well as on the moisture content thereof.In order to realize the most favorable taste and color characteristics in the finished food product the temperature should be as low as possible, consistent with the need to hydrate the amylopectin product. Thus, typical barrel temperatures range from2000F. to 3500F.

The temperature of the extruder die will, in most instances, be kept within the range of from 1000F. to212oF., it being necessary to lower the temperature of the material in the extruder to below2120F. in order to avoid the escape of steam, i.e., to avoid flashing. The precise temperature within the above cited range that may be used is also directly related to the composition of the extruded mixture.

As will be described hereinafter, the reduction in temperatures between the barrel and the die may be omitted where it is desired to utilize the flashing phenomenon in order to put the product into its final expanded form without the need for a subsequent cooking operation.

The pressure utilized within the extrusion mechanism will vary with the type of extruder, the compression ratio and speed of the screw employed, the nature of the material being extruded, the construction of the die, the temperature being used and the amount of water present. Typical pressures thus range from 10 to 5000 psig. (pounds per square inch, gauge) depending on whether the extruder utilizes a transport or a compression auger or combination.

The necessity for allowing the resulting food product to set upon the conclusion of the extrusion operation is primarily dependent upon the concentration of water and the type and concentration of amylopectin product which is present in the food product as well as on the degree of cooling which is applied.

Under optimum conditions, the end product will be extruded as a non-tacky, shape-retaining mass which can be immediately cut at high speeds and which, on further cooling, will increase in rigidity.

The ability to produce products displaying immediate shaperetaining properties may be further enhanced by chilling the shaped product as it leaves the extruder or by moving it through a channel of refrigerated air.

Depending upon the recipe and the extrusion conditions being utilized, the resulting extruded composition may require an additional operation in order to be put into its finale edible form of a fluffy, crisp, lighttextured food product. As previously noted, however, this final cooking operation may be conducted at the extruder die immediately after the exposure of the mixture to the simultaneous action of heat, pressure and mixing.

Thus, if the pressure-cooked product is not cooled upon approaching the extruder die but is, rather, maintained at the high cooking temperature which is encountered in the first section of the extruder, i.e.

2000 to 3500F., there will be a "flashing off", i.e. a release of steam from the product as it emerges from the extruder die and passes into a region of ambient temperatures and pressures. The latter release of steam thus serves to reduce the moisture content of the product as well as to puff, i.e. expand, crisp and color it.

On the other hand, an extruded product which emerges from a cooled extruder die may be put into edible form by being deep-fried.

In this operation the product is immersed in an edible cooking oil such, for example, as cottonseed, corn, coconut, soy or any mixture of the latter oils, and may be cooked for a period of 1/2 to 5 minutes at a temperature in the range of from 3000 to 4000F. The precise combination of time and temperature which are utilized for the deep frying operation will, of course, depend upon the particular product which is being prepared as well as the oil being utilized.

413/2197

In addition, the uncooked products resulting from a typical extrusion procedure, i.e. a procedure where flashing off is not utilized, may be subjected to other cooking techniques, such, for example, as baking, which serve to reduce the moisture content of the products as well as to convert them into fluffy, crisp, light textured, tasty, ready-to-eat food products.

It is to be noted that the food products of this invention can only be adequately described by making reference to the process which has been utilized for their preparation.

The following examples will further illustrate the embodiment of the invention. In these examples, all parts given are by weight unless otherwise noted.

EXAMPLE I

This example illustrates the preparation of a typical ready-to-eat, amylopectin-based food product of this invention by means of an extrusion process.

A dry mix comprising:

(1) 377 parts of waxy maize starch which had been crosslinked with 0.06%, by weight, of epichlorohydrin,

(2) 37.5 parts of a high amylose corn starch which contained 55%, by weight, amylose,

(3) 15.5 parts of vegetable shortening, and

(4) 5 parts of a glycerol monostearate emulsifier were thoroughly blended, in dry form, after which 65 parts of water were added thereto, whereupon the blending operation was continued until a homogeneous mixture was obtained. The resulting homogeneous mixture was then pumped into an extruder having a barrel length of 25 inches and a conveying screw with a diameter of 1 1/4 inch which rotated at a speed of 125 r.p.m. The barrel temperature of the extruder was maintained at 290 to3000F. while it applied a pressure of from about 50 to 300 psig.The cooked material was then passed from the heated barrel into a cooled barrel consisting of a water cooled cylinder in which a 3/4 inch conveying screw moved the material in contact with the cold cylinder walls through a shaping die. The temperature of the material as it passed through the shaping die was about 2000F.

The solid, rope-like food product which emerged from the die exhibited excellent shape retention properties as evidenced by the fact that it could, at this point, be readily cut into thin, shape-retaining slices. Immediately after cutting, and without an interim drying period, the thus cut slices were deep fried in corn oil which was at a temperature of3750F. for a period of 30 seconds. The resulting fried products, which were now ready for human consumption, were found to be exceedingly crisp, lighttextured and tasty.

EXAMPLE II

This example illustrates additional varieties of farinaceous base materials and formulations which can be effectively utilized in preparing food products by means of the process of this invention.

The procedure set forth in Example 1, hereinabove was utilized using the formulations described hereinbelow:

Formulation A parts

Waxy maize starch 710

Corn starch crosslinked with

0.14%, by weight of epi chlorohydrin 124

Butter 31

Onion powder 5

Glyceryl monostearate 5

Water 130

Formulation B parts

Waxy maize starch which had

been inhibited and acetylated

with 4.6%, by weight, of a

1: 50 mixture of adipic acid

and acetic anhydride accord

ing to the process set forth

414/2197

in U.S. Patent 2,935,510 597

Tapioca starch 240

Lard 31

Dried cheese powder 10

Pizza flavor 2

Salt 5


Water 130

In each instance, the products resulting from the extrusion step exhibited excellent shape-retaining characteristics as evidenced by the fact that they could be readily cut into slices immediately upon emerging from the extruder.The resulting slices derived from each formulation were deep fried in corn oil which was at a temperature of3750F. for a period of about 30 seconds. The fried products thus produced were found to be exceedingly crisp and tasty.

EXAMPLE III

This example illustrates the preparation of a typical ready-to-eat, amylopectin-based food product which, in this case, was entirely devoid of any amylose.

The procedure set forth in Example I, hereinabove, was utilized using the following formulation:

parts

Waxy maize starch which had

been inhibited and acylated

with 4.6%, by weight, of a

1: 50 mixture of adipic acid

and acetic anhydride accord

ing to the process set forth in

U.S. Patent 2,935,510 844

Corn oil 41


Water 110

The resulting food product exhibited excellent shape retention characteristics as evidenced by the fact that it could readily be cut immediately after extrusion. The resulting slices were immediately deep fried for a period of about 30 seconds in corn oil which was at a temperature of about3750F. yielding fried products which were crisp, light-textured, and tasty.

EXAMPLE IV

The procedure set forth in Example I, hereinabove, was utilized using the following formulation with the exception that the product resulting from the extrusion step was cut into thin slices and dried so as to have a moisture content of 14% prior to being deep fried in corn oil, which was at a temperature of

3750F., for a period of about 30 seconds.

parts

Waxy maize starch crosslinked

with 0.04%, by weight, of

epichlorohydrin 253

Corn starch crosslinked with

0.14% by weight, of epi

chlorohydrin 54

Lard 12


Water 80

The fried products thus produced were found to be exceedingly crisp, light-textured, and tasty.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIMIS:-

1. A process for the preparation of a food product which comprises the steps of:

415/2197

(1) moistening a composition comprising an amylopectin product (as hereinbefore defined), said composition containing less than 5% by weight of amylose;

(2) subjecting the moistened composition to simultaneous heat, pressure and mixing action in order to effect the gelatinization and hydration of said amylopectin product;

(3) shaping the moistened composition which results from step 2; and

(4) cooking the moistened composition and thereby obtaining an edible product characterized by its light-texture and crispiness; said cooking procedure being conducted at a point in time simultaneous with or subsequent to step 3.

2. The process of claim 1, wherein said composition comprises an amylopectin product which, prior to the application of step 1 or 2, is blended with an additive selected from fillers, amylose containing materials, and mixtures of fillers and amylose containing materials; said fillers, if present, being present in a concentration no higher than 50% of the total weight of the solids of the moistened composition and said amylose containing materials, if present, being present in a concentration such that the amylose content of the composition is less than5% of the total weight of the solids of the moistened composition.

3. The process of claim 1 or 2, wherein said composition is moistened with from 5 to 20% of water based on the total weight of the resulting moistened composition.

4. The process of any of claims 1 to 3, wherein said moistened composition is subjected, in step 2, to a temperature from2000F. to3500fez and thereafter, subjected to a temperature of from10001'. to2120F. while the pressure to which said moistened composition is subjected, in step 2, is in the range of from

10 to 5000 pounds per square inch gauge.

5. The process of any of claims 1 to 4, wherein step 4 occurs subsequent to step 3 and is conducted in a hot edible cooking oil.

6. The process of any of claims 1 to 5, wherein said amylopectin product is a waxy maize starch which has been inhibited with 0.4%, by weight, of epichlorohydrin.

7. The process of any of claims 1 to 3 and 6, wherein the pressure and the temperature to which said moistened composition is subjected in both steps 2 and 3 are maintained in the range of from 10 to

5000 psig and from200 F. to35001'., respectively, the maintenance of said moistened composition at the elevated temperature during step 3 thereby effecting the release of steam from said moistened composition upon the completion of step 3 simultaneous with the passage of the resulting shaped mass into a region of ambient temperature and pressure; the release of steam thus rendering the final product substantially crisp and light-textured.

8. The process of any of claims 1 to 7, wherein steps 2 and 3 are carried out in an extruder and step 4 is conducted at a point in time simultaneous with or subsequent to the expulsion of said edible product from the die of said extruder.

9. The process of claim 8, wherein said moistened composition is subjected, in step 2, to a temperature from200 F. to35001'. and thereafter, subjected in the extruder die, to a temperature from 1000 to2120F. while the pressure to which said moistened composition is subjected, in both the barrel and the die of said extruder, is in the range from 10 to 5000 pounds per square inch gauge.

10. The process of any of claims 1 to 3, 6, 8 and 9 wherein step 4 is carried out directly subsequent to step 3.

11. The process of any of claims 1 to 10 wherein the mentioned composition contains from 50 to 92% by weight of amylopectin based on the total weight of the moistened composition.

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12. A process for the preparation of an amylopectin-based food product substantially as herein described.

13. A process for the preparation of an amylopectin-based food product substantially as described in any of Examples I to IV.

14. The amylopectin-based food product resulting from the process of any of claims 1 to 12.Data supplied from the esp@cenet database - Worldwide

417/2197

82.

GB1310348 - 3/21/1973

EDIBLE PRODUCTS


Applicant(s): UNILEVER LTD (--)


IP Class: A23L1/31; A23L1/325; A23L1/33; A23L1/315

E Class: A23L1/314B4; A23B4/005F4; A23B4/033; A23L1/314B10; A23L1/325E



Family: GB1310348

Equivalent: NL7013800; FR2061471; DE2045988; BE756301; SE370007; NL160479C;

IE34519L; IE34519

Abstract:


1310348 Meat product UNILEVER Ltd 15 Sept 1970 [17 Sept 1969] 45816/69 Heading A2B A coherent shaped dehydrated foodstuff comprises heat-set comminuted meat and a cooked comminuted starchy vegetable material in a form retaining the cellular structure of the vegetable, the vegetable material being bound in a matrix formed by the heat-set meat. The vegetable material is preferably dried potato, but may also be rice grains, barley grains, semolina or apple. The foodstuff may be prepared by (i) forming a mix containing uncooked comminuted meat and a dry precooked comminuted starchy vegetable material in a cellular form, (ii) shaping the mix, (iii) heating the shaped mix so as to set the protein of the meat about the vegetable material to form a matrix binding it, and

(iv) dehydrating the heat-set shaped mix. The mix may also contain comminuted pre-cooked meat.

Exem- plified foodstuffs consist of beef and potato, pork and potato, rice grains, barley, apple or semolina, cod and potato, haddock and potato and chicken and potato. The foodstuff may be shaped into the form of strips, sheets, or balls.Description:


(54) EDIBLE PRODUCTS

(71) We, UNILEVER LIMITED, a company registered under the laws of Great

Britain, of Unilever House,Blackfriars,

London E.C.4, England formerly of Port

Sunlight, Wirral, Cheshire, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the followingstatement:-

This invention relates to dehydrated meat products.

There is a demand for dried meat products which will rehydrate quickly to give a product having a texture simulating that of intact meat. However, such products are difficult to obtain. Intact, that is to say uncomminuted, meat, cannot be dried to yield a product which will rehydrate successfully.

When comminute cooked meat is dried it is capable of rehydration but it will not bind together to form a product which simulates the texture of natural meat. Dehydrated meat products may be prepared from comminuted raw meat by shaping and heat setting the comminuted raw meat and then drying the

418/2197

shaped and set meat. If such a product is dried and rehydrated successfully it may imitate closely the texture of freshly cooked intact meat. However, problems of shrink

age of the product, slowness of rehydration and incomplete rehydration are encountered.

It is an object of the invention to provide

a product which has improved dehydration

and rehydration properties in that it shrinks

less on dehydration and on rehydration takes

up water more easily and quickly to give a

more succulent product and more consis

tently achieves the desired texture simulat

ing freshly cooked intact meat.

The invention provides a coherent shaped

dehydrated foodstuff comprising heat-set

comminuted meat and a cooked comminuted

starchy vegetable material as herein defined in a form retaining the cellular structure of the vegetable, the vegetable material being bound in a matrix formed by the heatset meat.

The invention also provides a method of making a dehydrated meat product comprising (i) forming a mix containing uncooked comminuted meat and a dry precooked comminuted starchy vegetable material as herein defined in a form retaining the cellular structure of the vegetable; (ii) shaping the mix; (iii) heating the shaped mix so as to set the protein of the meat about the vegetable material and form a matrix binding it; and (iv) dehydrating the heat-set shaped mix.

Our most preferred vegetable material is dehydrated potato. The dehydrated potato should be the kind which will rehydrate to form mashed potato, rather than potato flour which does not retain the cellular structure of the potato and which merely forms a paste on addition of water. The dehydrated potato may be in the form of powder, granules or flakes. The term "vegetable material" as used herein includes cereals such as rice grains, barley grains or semolina, and apple, which can be used where its flavour is not objectionable. The vegetable material is preferably coarsely comminuted so that it retains intact endosperm cells.

This cellular structure of the vegetable is retained throughout the shaping, heating and drying steps and creates a porous structure in the dried product, enabling water to be taken up easily on rehydration.

The proportion of the vegetable material added to the meat is preferably between 5 and15two expressed as the dry weight of the vegetable material in the mix. This corresponds to an amount of 10 to35to by weight of the vegetable material in the dried pro

duct. Larger amounts of vegetable material than this while giving a product which will dry and rehydrate successfully are not desired since the resulting products do not have the required meat-like texture. Smaller proportions of the vegetable material, for example 2 to5Qo by weight of the mix may be used if comminuted cooked meat is present in the mix as well as comminuted raw meat and a very short rehydration time is not required.

Any variety of meat can be used, for example beef, pork, lamb, chicken or mixtures of these, fish, such as cod or haddock or shell fish such as prawn. The meat used must be capable of binding with itself to form a coherent mass and therefore at least some of the meat used must be raw meat or meatwhich has been only slightly blan -ched. The meat is preferably comminuted by a colloid mill into a fibrous paste or by a bowl chopper. If a dehydrated meat product having a coarser texture is desired minced meat may be used.

The fat content of the mix formed should preferably be from 4 to20loo by weight, morepreferably 8 to1 3"o when producing dried products having a normal rehydration time of around 10 minutes. If the meat used has a fat content of below4% by weight for example when fish or shell fish is used, it may be advantageous to add a hard fat so that the fat content of the mix is within this preferred range.

Examples of fats which can be added are hardened vegetable oils such as hardened palm oil, hardened groundnut oil, and hardened cottonseed oil, or hard fats derived from animal sources such as refined

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beef tallow, fractionated beef tallow of hardened oleo oil derived from tallow.The fat preferably has amelt- ing point (slip point) of at least35"C.

The use of a cellular vegetable material. according to the invention, is a simple and inexpensive method, needing no extra processing step, of oblaining a meat product which will readily and consistently rehydrate to a firm meat-like texture. Such a meat product, for example in the form of balls of 2 cm diameter will rehydrate fully in about 5 to 10 minutes. If it is desired to product a product which will rehydrate more quickly than this, the formulation of the mix which is heat-set and dehydrated is adapted to give the dried product a more porous texture. The mix may contain cooked comminuted meat, or may have fat or water added to it so that the fat or water content of the mix is greater than that of raw meat.

Cooked comminuted meat has lost its binding powers before it is incorporated into the mix and it appears in the dried product as separate particles bound within the matrix of heat-set meat derived from the raw meat.

The cooked meat is generally more coarsely comminuted than the raw meat which is required to act as a binder. The cooked meat should, preferably however, have a particle size less than 10 mm in any direction since individual particles of cooked meat larger than this will not rehydrate very quickly.

The amount of cooked meat which is incorporated into the mix can be varied within wide limits as the cooked meat hardly detractsfrom the meat-like texture of the rehydrated product and the upper limit to the amount of cooked meat which may be added is determined by the necessity that sufficient comminuted raw meat should be present in the mix to form a firm matrix when heat set for the other ingredients. The amount of cooked meat used is preferably 20 to609b byweight of the total weight of cooked and raw meat.

The fat content of 8 to13to by weight of the mix which is preferred for a dried product having a rehydration time of about ten minute, may be increased to about 20 to3()0,8o when a quickly rehydrating product is desired. This is generally achieved by adding a hard fat to the mix, for example a hardened vegetable oil such as hardened palm oil, hardened groundnut oil or hardened cottonseed oil, or a hard animal fat such as refined or fractionated tongue or oleo oil derived from it. The presence of this large amount of fat results in the loss of a considerable amount of fat in the heat-setting step. When these high amounts of fat are used the mix after cooking of the meat tends to contain 12 to159b by weight of fat.The draining away of this fat leaves pores in the matrix of heat-set meat which remain on dehydration and which enable water to be taken up more quickly on rehydration.

When preparing a dried product having a normal rehydration time, it is preferable not to add water to the mix which is set and dehydrated, since any added water has to be removed again on dehydration and moreover the resulting dried product is mademere fragile. However, the dried product formed from a mix containing added water is also more porous and a more quickly rehydrating dried meat can be prepared if water is added to the mix before heatsetting. If cooked meat is also present in the mix the water used may be the liquor resulting from the cooking process. The amount of water added should generally not exceed15 ,fo by weight of the mix since more water than this results in a tendency to form a sloppy mix which is difficult to shape and set, particularly if extrusion or ball-forming methods are used.

The use of a comminuted cooked meat ingredient, or the addition of extra fat and water can reduce the rehydration time of the dried product to below the normal time for a dried product formed from a mix containing only comminuted raw meat and a cellular vegetable material, which is approximately 10 minutes. Any of these can be used in combination. If a mix is formed which contains 5 to 15% of a cellular vegetable material according to the invention, comminuted cooked meat in an amount approximately 40 to 60% by weight of the total meat content of the mix, from 20 to 30% total fat

(added fat and fat present in the meat) and from 5 to 15% added water, a dried meat product may be obtained which rehydrates in a time as short as 0.5 to 1 minute.Such a rehydration time is considerably shorter than has been achieved with prior artmethods using cooked and raw meat only as ingredients.

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When the mix which is to be dried is being prepared, the meat is preferably at least partly comminuted before being mixed with the vegetable material. The vegetable material can be mixed with any other dry ingredient before it is added to the meat.

One preferred form of mixing the meat with the vegetable material uses a power mixer fitted with a dough hook. The mixture thus formed, which may be a granular product similar tominced meat, or a dough-like paste or of the consistency of sausage meat, may be shaped by any conventional means.

In one form of the invention a paste of milled raw meat and potato powder is formed into a cylinder, for example by means of a sausage stuffer. This cylinder of meat mix is sub-divided into balls, for example by the apparatus described in British

Patent Specification 541,188. This apparatus consists of a pair of rollers which are provided with uninterrupted peripheral grooves registering with each other, the edges of the grooves being substantially in rolling contact with each other so that moulding apertures are formed between the rollers. The rollers preferably rotate at different surface speeds in the same direction, with the roller moving into the nip rotating faster than that moving out of the nip.The apparatus may have a third grooved roller situated below the other two, with the edges of the grooves being substantially in rolling contact with the edges of the grooves on each of the other two rollers, so that the balls formed are subjected to a second moulding process before leaving the apparatus. It may be convenient for the drying procedure to product meat balls having a diameter of about 2 cm by this method and when balls of this size are produced, it is preferred to use 8 to10% by weight of the potato powder or other cellular material. The balls are blanched in steam or in water at 85 to100 C to heatset the meat protein.

The balls may be heated in a water blancher placed beneath the nip of the grooved rollers of the ball forming apparatus so that the meat balls fall into the water.

It will be appreciated that there are many alternative ways of shaping and cooking the meat product.

For example the meat mix may be extruded as a sheet whereby it is at least partly heat-set. The extruded sheet may be treated with steam to cook the meat protein further. The sheet which is extruded is preferably 0.5 to 2.5 cm thick. After it is set the sheet may be cut or broken into pieces, for example pieces having a volume of 1 to 10 cc before drying. Alternatively, the meat mix may be cooked in moulds and then sub-divided. Methods of heat-setting involving "dry blanching" may be used. For example the product may be wrapped in foil and steam heated, or may be heated with air at a high temperature and high humidity.

This method of heat-setting has the advantage that the loss of materials from the meat by leaching is greatly reduced.

Drying of the products preferably takes place using air at a temperature of 50 to 950C, more preferably about90"C. The meat products are dried to a stable moisture content of below10%, preferably about 5 to 6% by weight. The meat products, for example meat balls formed as described above or pieces cut from an extruded sheet, are preferably spread on perforated trays whilst in the dryer. If cooking takes place using air at a high temperature and high humidity, drying may take place using the same apparatus, but reducing the moisture content of the air in contact with the meat product.

The dried meat products of the invention may be used as meat ingredients for dried meals, for example in combination with spaghetti, rice or macaroni and dried vegetables and fiavourings, or for dry soup mixes.

The dried meat products having a low rehydration time may be used as ingredients of quick cooking soups, and those capable of rehydration in 1 minute or less can be used as ingredients of "instant" soup mixes

such as soup mixes used in vending machines.

The invention is illustrated by the following examples in which percentages are by weight.

EXAMPLE 1

This example describes the formation of dried meat balls having the following formulation:

frozen forequarter beef 89.2%

dehydrated potato powder8.0to

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salt 1.1%

flavouring agents 1.7%

The frozen meat was sliced and was then comminuted to a fibrous paste using a colloid mill fitted with a plate having 8 mm holes. The dry ingredients were thoroughly mixed together and were then mixed with the meat in a Hobart (Registered Trade

Mark) mixer fitted with a dough hook.

When the ingredients were thoroughly mixed, the resulting paste was formed into a cylinder using a sausage stuffer. This cylinder of mix was dropped sideways on into the nip formed between two fluted drums. These drums were rotating in the same direction with the drum rotating into the nip moving at about three times the speed of the drum rotating out of the nip. The meat mix was thereby formed into balls which dropped down through the nip onto a conveyor belt which carried them through a water blancher. The meat balls were blanched for about 6 minutes in water at90or. After leaving the blancher the meat balls were allowed to drain whilst being conveyed to a drier. They were then air dried at 900C for 4 hours. The dried meat balls formed had a good shape and had a moisture content of 5 to 6%.

The dried meat balls were rehydrated by simmering in water for 10 minutes and were found to have a very pleasant meat-like texture. Their rehydration ratio (weight of rehydrated product: weight of dried product) varied between 2.4 and 2.6.

EXAMPLE 2

This example illustrates the use of various starch-containing materials in producing dried pork balls.

Samples 1 to 6 included comminuted pre-cooked starchy vegetable materials which retained the cellular structure of a vegetable and are thus examples of the invention. Samples 7 to 15 did not

Sample No. Starch Ingredients

1 Dehydrated potato powder

2 Dehydrated potato flakes

3 Pre-cooked rice grains

(partly ground)

4 Pre-cooked barley

5 Apple nuggets

6 Semolina flour

7 Pre-cooked corn flour include such a material and are included as comparative examples. Samples 7 to 11 included a pre-cooked starchy material which did not have a cellular structure and samples 12 to

15 included raw starch.

The formulation used in preparing the pork balls was:

milled spare rib pork 90%

starchy ingredient 8.5%

salt1.0to

flavoured agents0.5%

The frozen meat was chopped into about 2.5 cm cubes, was minced through a 5 mm plate and was then comminuted by milling in a colloid mill. The milled meat and the additives were mixed in a

Hobart bowl mixer for 4 minutes. The mixer then extruded through a tube with a 2 cm diameter into rods approximately 38 cm long using a piston stuffer. The rods were then dropped into the ball forming machine, described in

Example 1, and the resulting balls were blanched for 8 minutes at90or, were water cooled and were air dried in a bin dryer at55 C for 16 hours, using a small bed depth and air flow of approximately 120 metres per minute.The dried meat balls were subsequently rehydrated by simmering in water for 5 minutes.

The results obtained are tabulated below:

Results of Experiment

The balls dried and rehydrated well, and had a rehydration ratio of 2.6. Both before and after rehydration, the balls were even and smooth surfaced. The rehydrated balls had a good meat-like texture.

As in 1, even smooth surfaced balls were obtained which consistently rehydrated well having a rehydration ratio of 2.6 and a good texture after rehydration.

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The balls both before and after rehydration had a good appearance and rehydrated well with a rehydration ratio of 3.0. The rehydrated balls had a succulent texture.

The balls had a good appearance and rehydrated well. The rehydrated balls had a texture which was succulent but slightly dryer than that obtained in sample 3. The rehydration ratio was 2.7.

The balls rehydrated well and had a good meat-like texture. There was a slight apple flavour present, but this was not considered objectionable by the tasters. The rehydration ratio was 2.1.

Similar results to samples 1 to 5 were obtained with good rehydration and texture.

The rehydration ratio was 2.6.

The samples totally disintegrated during the cooking stage and dried meat balls could therefore not be obtained.

Sample No, Starch Ingredients

(cont.)

8 Pre-cooked farina

9 Pre-cooked chemically

modified waxy maize starch

10 Pre-cooked tapioca

11 Pre-cooked wheat flour

(biscuit type)

12 Raw farina

13 Raw corn flour

14 Raw wheat flour

15 Raw tapioca

It is thus seen that the products of the invention (samples 1 to 6) were capable of

rehydration to give a succulent product having a meat-like texture, whereas when the

cellular materials used in the invention were

replaced by cooked starches without a cellu

lar texture it was not possible to obtain a

coherent dried product and when raw

starches were used the dried product became

tough and case hardened and would not re

hydrate properly.

Storage tests were carried out on the dried

products obtained in sample 1 and sample

12. The dried products were stored separ

ately in screw top glass jars. The products

obtained in sample 1 showed no signs of

spoilage on storing after 10 months, and

when rehydrated were found to have no off

flavour. The products of sample 12, how

ever, became mouldy on storing within 12

Results ofExperiment

(cont.)

Both the dried and the rehydrated balls had an undesirable ragged appearance and there was a tendency to disintegration. The rehydrated samples had a soft pasty texture

The rehydration ratio where this could be measured was 2.3.

The samples disintegrated during the cooking stage as in sample 7.

The samples gradually disintegrated during the cooking and drying procedures.

The samples disintegrated similarly to sample 10.

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The samples became a case hardened on drying and did not dry or rehydrate successfully. The dried balls had a hard outer surface and a centre portion which was sometimes quite wet. The samples had a very tough and unpleasant texture after rehydration. The rehydration ratio was 1.4.

The samples became case hardened on drying and had a similar unpleasant texture to sample 12. The rehydration ratio was 1.8.

Unsuccessful drying and rehydration, together with case hardening similar to samples 12 and 13. The rehydration ratio was 1.7.

Similar results obtained to samples 12 to 14.

The rehydration ratio was 1.6. months since it had not been possible to dry the centre of the balls successfully.

EXAMPLE 3

Dried beef balls were produced using the following formulation:

milled forequarter beef89.5%

dried potato powder8.0go

salt l.lQo

flavourings1.4%

The process used to prepare the dried balls and to rehydrate them was the same as that used in

Example 2. As a comparison dried beef balls were produced by the same process using corn flour in place of the dried potato powder, and also with no additives.

The total solids content of the balls was measured firstly after cooking and before drying, and secondly after drying and rehydration. The following results were obtained:

Starch Ingredient Solids Content of Solids Content of

Used Cooked Balls Rehydrated Balls

Potato powder 31% 33.6%

Corn flour 31% 52.3%

No starch ingredient 34.4% 45.6%

The three samples had very similar solids contents before drying. After drying and rehydration, however, the sample containing potato powder was found to have a much lower solids content and th:s solids content was very similar tothpt of the ballsbefore drying. The other samples had higher solids content after drying and rehydration, and it was thus found that only the balls containing potato powder were fully rehydrated.

The size and density of the dried balls was also measured. The results are as follows:

Starch ingredient Weight of 35bull

in grams

Potato powder 60.8

Corn flour 62.3

No starchy ingredients 41.1

It was thus found that the balls containing potato powder were half as large again after drying as the balls containing no additive, since the latter had shrunk considerably during heat-setting and drying.

There was a loss of material from the mix which was substantially all meat which was prevented by the inclusion of potato powder in the mix. The dried ballscontain:ng corn flour did not show this loss of material but these too had shrunk after heat-setting and drying and had a higher density than the balls containing potato powder which resulted in a much poorer performance on rehydration.

EXAMPLE 4

Dried fish balls were produced from a mix having the following formulation:

milled cod76.5 ,to

dehydrated potato powder8.5%

hardened fat10.5who

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albumen2.0%

salt1.0 ,Jo

sodium alignate 1.0%

monosodium glutamate0.5%

The milled raw cod was mixed with the other ingredients, formed into balls and blanched by the methods described in Example 1. The cooked balls were then transferred to a through draught bin drier with an air flow of 120 metres per minutes and were dried for about 10 hours at 550C.

The cod balls produced retained their shape well on drying and showed good binding and good rehydration. Similar experiments were carried out using haddock and smoked haddock in place of cod.

In these experiments also the fish balls produced dehydrated and rehydrated successfully.

EXAMPLE 5

Dehydration fish pieces were produced using an extrusion method from a mix having the following formulation:

minced raw cod81.54b

dehydrated potato powder 8.0%

hardened fat (hardened palm

mixture) 7.0%

salt 1.0%


Skinned fish fillets were minced through a 5 mm plate. The minced fish was mixed with the other ingredients in a Hobart mixer for about 4 minutes until the mix was homogeneous. The mix was then extruded through a Wetter stuffer fitted with a nozzle 30 cm X 2.5 cm x 0.8 cm. The extruded strip was heat-set in a steam oven at a slightly positive pressure for 8 minutes.

The heat-set strips were broken into pieces

Volume of 35balls Density of

in cc Balls

63.3 0.96

53.5 1.16

41.3 1.00 and were dried in a bin drier at550C for 10 hours, using an air flow of about 120 metres per minute. The dried cod pieces which were produced could be successfully rehydrated by simmering in water for 10 minutes.

EXAMPLE 6

Dried haddock pieces were produced using an extrusion method and a high temperature high humidity apparatus from the following mix:

minced skinned haddock fillets78.5to

dehydrated potato powder9.556

hardened fat (hardened palm

mixture) 9.5%

salt 1.0%


The minced skinned haddock fillets were mixed with the other ingredients and extruded as a strip as described in Example 5. This extruded strip was then heated for 15 minutes in a high temperature high humidity apparatus having a wet bulk temperature of 850C and a dry bulk temperature of1 100C. The heat-set strips produced by this method were dryer than those produced in Example 2.

The heat-set strips were broken into pieces and dried in a bin drier at 550C for 10 hours with an air flow of 120 metres per minutes, and dehydrated haddock pieces which could be successfully rehydrated were obtained.

EXAMPLE 7

Dried beef pieces were prepared from a mix having the following formulation:

cooked minced forequarter beef40 ,ó

raw milled forequarter beef 35%

hard fat (hardened palm mixture) 10 /+o

water 9%

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dried potato powder6%

Frozen forequarter beef was chopped into approximately 2.5 cm cubes and these were separated into two portions. The first portion was cooked by autoclaving for 1 hour at 15 psi and was then minced through a 5 mm Hobart mincer plate. The second portion was first comminuted by mincing through a 5 mm Hobart mincer plate and was then finely milled in a colloid mill. The two meat components were then mixed with the fat, water and potato powder for 4 minutes in a Hobart bowl mixer.

The mix was then extruded through a 5 cmx 1.25 cm cross-section nozzle attached to a piston stuffer.

The extruded strips were steam heated for 8 minutes and were then broken into irregular pieces by hand and were dried for 16 hours at55 C in a bio drier using a small bed depth and an air flow of about 120 metres per minute.

The meat pieces produced were rehydrated by pouring boiling water onto them. After only half a minute the meat pieces had rehydrated well to a pleasant meat-like texture. The rehydration ratio measured after only half a minute was 2.5.

This experiment was repeated except that the beef was replaced with deboned chicken meat containing skin, fat, and meat in their natural ratio. Once again chicken pieces were produced, which rehydrated well in half a minute to a meat-like texture. The chicken pieces had a rehydration ratio of 2.3 after half a minute.

WHAT WE CLAIM IS:

1. A coherent shaped dehydrated foodstuff comprising heat-set comminuted meat and a cooked comminuted starchy vegetable material as herein defined in a form retaining the cellular structure of the vegetable, the vegetable material being bound in a matrix formed by the heat-set meat.

2. A foodstuff according to claim 1, which contains from 10 to 35% by weight of the cellular vegetable material.

3. A foodstuff according to claim 1 or claim 2 wherein the cellular vegetable material is dried potato in the form of powder, granules, or flakes.

4. A foodstuff according to claim 1 or claim 2 wherein the cellular vegetable material is rice grains, barley grains or semolina.

5. A foodstuff according to any one of claims 1 to 4 which also contains particles of dried meat derived from comminuted cooked meat bound in the matrix of heat-set meat.

6. A foodstuff according to claim 5 in which the particles of meat derived from comminuted cooked meat form 20 to6021o by weight of the total meat content of the foodstuff.

7. A process of making a dehydrated meat product comprising (i) forming a mix containing uncooked comminuted meat and a dry precooked comminuted starchyveg- etable material as herein defined in a form retaining the cellular structure of the vegetable; (ii) shaping the mix;(iii) heating the shaped mix so as to set the protein of the meat about the vegetable material and form a matrix bindingit, and (iv) dehydrating the heat-set shaped mix.

8. A process according to claim 7 in which the mix formed contains 5 to15two by weight of any cellular vegetable material.

9. A process according to claim 7 or claim 8 in which a pre-cooked vegetable material is used.

10. A process according to any one of claims 7 to 9 in which the vegetable material is dried potato in the form of powder, granules or flakes.

11. A process according to any one of claims 7 to 9 in which the cellular vegetable material is rice grains, barley grains, or semolina.

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12. A process according to any one of claims 7 to 11, in which the mix formed also contains comminuted pre-cooked meat.

13. A process according to claim 12 in which the comminuted pre-cooked meat is more coarsely comminuted than the uncooked comminuted meat.

14. A process according to claim 12 or claim 13 in which the comminuted cooked meat forms from 20 to 60% by weight of the total meat content of the mix.

15. A process of making a dehydrated meat product according to any one of claims 7 to 14 substantially as described in any one of the examples.

16. A dehydrated meat product made by the process of any one of claims 7 to 15.




drier using a small bed depth and an air flow of about 120 metres per minute.

The meat pieces produced were rehydrated by pouring boiling water onto them. After only half a minute the meat pieces had rehydrated well to a pleasant meat-like texture. The rehydration ratio measured after only half a minute was 2.5.

This experiment was repeated except that the beef was replaced with deboned chicken meat containing skin, fat, and meat in their natural ratio. Once again chicken pieces were produced, which rehydrated well in half a minute to a meat-like texture. The chicken pieces had a rehydration ratio of 2.3 after half a minute.

WHAT WE CLAIM IS:

1. A coherent shaped dehydrated foodstuff comprising heat-set comminuted meat and a cooked comminuted starchy vegetable material as herein defined in a form retaining the cellular structure of the vegetable, the vegetable material being bound in a matrix formed by the heat-set meat.

2. A foodstuff according to claim 1, which contains from 10 to 35% by weight of the cellular vegetable material.

3. A foodstuff according to claim 1 or claim 2 wherein the cellular vegetable material is dried potato in the form of powder, granules, or flakes.

4. A foodstuff according to claim 1 or claim 2 wherein the cellular vegetable material is rice grains, barley grains or semolina.

5. A foodstuff according to any one of claims 1 to 4 which also contains particles of dried meat derived from comminuted cooked meat bound in the matrix of heat-set meat.

6. A foodstuff according to claim 5 in which the particles of meat derived from comminuted cooked meat form 20 to6021o by weight of the total meat content of the foodstuff.

7. A process of making a dehydrated meat product comprising (i) forming a mix containing uncooked comminuted meat and a dry precooked comminuted starchyveg- etable material as herein defined in a form retaining the cellular structure of the vegetable; (ii) shaping the mix;(iii) heating the shaped mix so as to set the protein of the meat about the vegetable material and form a matrix bindingit, and (iv) dehydrating the heat-set shaped mix.

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8. A process according to claim 7 in which the mix formed contains 5 to15two by weight of any cellular vegetable material.

9. A process according to claim 7 or claim 8 in which a pre-cooked vegetable material is used.

10. A process according to any one of claims 7 to 9 in which the vegetable material is dried potato in the form of powder, granules or flakes.

11. A process according to any one of claims 7 to 9 in which the cellular vegetable material is rice grains, barley grains, or semolina.

12. A process according to any one of claims 7 to 11, in which the mix formed also contains comminuted pre-cooked meat.

13. A process according to claim 12 in which the comminuted pre-cooked meat is more coarsely comminuted than the uncooked comminuted meat.

14. A process according to claim 12 or claim 13 in which the comminuted cooked meat forms from 20 to 60% by weight of the total meat content of the mix.

15. A process of making a dehydrated meat product according to any one of claims 7 to 14 substantially as described in any one of the examples.

16. A dehydrated meat product made by the process of any one of claims 7 to 15.Data supplied from the esp@cenet database - Worldwide

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83.

GB1312181 - 4/4/1973

PROCESS FOR PRODUCING A MICROBIAL PROTEINOUS SUBSTANCE


Applicant(s): MORINAGA MILK INDUSTRY CO LTD (--)

IP Class 4 Digits: A23L; A23J; C12K

IP Class: A23L1/28; C12K1/02; A23J1/18

E Class: A23J1/18; A23L1/30P; A61K35/72; A61K39/00B; C12N1/16; C12N1/28; C12N15/01



Family: GB1312181

US3855063; NL7109065; FR2100857; DE2127392; BE767789; SE398513; Equivalent:

FI48752B

Abstract:


1312181 Yeast products MORINAGA MILK INDUSTRY CO Ltd 25 May 1971 [3 July 1970 20 Nov

1970] 16947/71 Heading A2B [Also in Division C6] A process for the production of cellular proteinaceous substance comprises subjecting a hydrocarbon-assimilating yeast of genus Can- dida to mutation by conventional chemical or physical means (specified) inoculating a suspension of the resultant mutants on to a solid culture medium and incubating to form colonies, selecting those strains of mutant with partial or total cell wall deficiencies from the colonies, proliferating these mutants in a culture medium and recovering the resultant cell mass. The intra cellular substance may be extracted from the cell mass. The mutants specifically described and identified are named Candida guilliermoudii, Candida lipolytica and Candida periphelesum. Examples disclose the association of specified dried mutant cells with (1) white fish meal and wheat flour to obtain a feed suitable for fishes

(4) corn grits, rice bran, soy meal, salt and calcium carbonate as a feed for beef cattle (6) wheat flour, salt, honey, gluten, edible oil and flavour to produce on baking a crisp snack food.Claims:


WHAT WE CLAIM IS -

1 A process for the production of easily digestible and extractable proteinous substance, which comprises subjecting a hydrocarbon-assimilating yeast of genus Candida to mutation, inoculating a suspension of the resultant mutants onto a solid culture medium, and incubating to form colonies; selecting those strains of mutant with partial or total cell wall deficiencies from said colonies, and proliferating said mutants with deficient cell walls in a culture medium, and harvesting the resultant cell mass.

2 A process according to Claim 1 wherein the mutants with deficient cell walls are selected from those colonies of which the surface is rough.

3 A process according to Claim 2 wherein the mutants selected are those with cells of a circular form.

4 A process according to Claim 3 wherein the cells of circular form are Gram-stained, and those showing the Gram-negative reaction selected.

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5 A process according to any of the preceding claims wherein an intracellular substance is subsequently extracted from said resultant cell mass.

6 A process according to Claim 1 wherein the mutants with deficient cell walls are selected by isolating those mutants which manifest Gram-positive performance, which have lower electron densities in the outer region of their existing cell walls when observed by electron microscopy, and which have a mannan content which is less than % of that of their parent strains incubated under the same conditions.

7 A process according to Claim 6 wherein the intracellular substance is subsequently extracted from said resultant cell mass.

8 The process as set forth in any of Claims 2 to 5, wherein said mutant is A T C C No.

20,314, Candida periphzelosztm M-7002, which is obtained by mutating cells of Candida species M-7 with N-methyl-N'-nitro-Nnitrosoguanidine as a chemical mutagenic agent.

9 The process as set forth in any of Claims 2 to 5, wherein said mutant is A.T C C No 20,315,

Candida lipolytica M-7005, which is obtained by mutating cells of Candida lipolytica NRRL-Y-6795, by a irradiation of ultra violet light as a physical mutagenic means.

The process as set forth in any of Claims 2 to 5, wherein said mutant is A.T C C No 20,316 Candida guilliermnondii M-7006, which is obtained by mutating cells of Candida guilliertzondii IFO-1062, by using nitrous acid as a chemical mutagenic agent.

11 The process as set forth in either of Claims 6 or 7, wherein said mutant is A.T C C No 20,317,

Candida periphelosunt M-70078, which is obtained by mutating cells of Candida species M-7 by using

N-methylN'-nitro-N-nitrosoguanidine as a chemical mutagenic agent.

12 The process as set forth in either of Claims 6 or 7, wherein said mutant is A.T C C No 20,31,

Candida guillierniondii M-7010, which is obtained by mutating cells of Candida guillierizondii IFO-

1062 by using acriflavin as a chemical mutagenic agent.

13 A feedstuff characterized by comprising the proteinous substance prepared by the processes as set forth in any of the preceding claims.

14 A culture comprising any one of Candida periphelosutm M-7002, Candida lipolytica M-7005,

Candida guilliermonzdii M-7006, Candida periphelosumr M-7007 and Candida guilliermondii M-7010.

A cell mass characterized by high digestibility and easy extractability of intracellular substances, which is prepared by the process as set forth in claims 1 to 12.

16 An intracellular substance of the cell which is obtained by the separation by means of chemical agents or physical means from the cell mass as set forth in claim 15 or the culture as set forth in claim

14.

17 A process for the production of proteinous substance, which comprises subjecting a hydrocarbonassimilating yeast of genus Canrdida to mutation, inoculating a suspension of the resultant mutants onto a solid culture medium and incubating to form colonies, selecting those strains of mutant with partial or total cell wall deficiencies from said colonies, profile-rating said mutants with deficient cell walls in a culture medium, harvesting the resultant cell mass and extracting an intracellular substance from the cell mass.

18 A process for the production of food and feedstuff characterized by incorporating the cell mass obtained by the process as set forth in claim 1 or the intracellular substance obtained by the process as set forth in claim 17, for processing.

430/2197

For the Applicants, F J CLEVELAND & COMPANY, Chartered Patent Agents, Lincoln's Inn

Chambers, 40-43, Chancery Lane, London, WC 2 A 1 JQ.

= o Printed for Her Majesty's Stationery Office, by the Courier Press, Leamingto,n Spa, 197:1.

Published by The Patent Office, 26 Southampton Buildings Londo, WC'2 c A, from', which copies may he obtained.

-Data supplied from the esp@cenet database - Worldwide

431/2197

84.

GB1318614 - 5/31/1973

FRUIT SPREADS




IP Class: A23L1/06

E Class: A23L1/064; A23L1/30C



Family: GB1318614

Equivalent: NL7009236; FR2047076; ES380993; DE2030670; CH544507; BE752412;

IE34317L; IE34317

Abstract:


1318614 Fruit spreads UNILEVER Ltd 22 June 1970 [23 June 1969] 30123/70 Heading A2B A fruit spread of improved keepability is prepared by contacting whole or divided fruit with aqueous sugar syrup without cooking the fruit, to effect a preservative action and emulsifying the mixture of sugar syrup and uncooked fruit with edible oil or fat. By "uncooked fruit" is meant fruit which has not been exposed to heat for a time long enough for the individual shape of the fruit pieces to be lost. The sugar syrup may be heated to pasteurise the fruit. The oil may be aerated (e.g. with N 2 or CO 2 ) the emulsion is preferably a water-in-oil emulsion. The fruit may be used in fresh, dried or frozen form.

The sugar may be sucrose, dextrose, maltose, fructose, lactose, brown sugar, invert sugar or honey. The fruit may be raisins, dates, figs, prunes, apricots, strawberries, blueberries and cherries. The oil or fat may be margarine, butter, coconut, palm kernel, cotton seed, kapok, rape seed, peanut, olive, sunflower seed, sesame, corn, safflower or soybean oil, milk fat, beef tallow or lard. The fat may be hydrogenated. Other materials which may be present in the food include emulsifiers such as mono- and di-glycerides. lecithin and polyoxythylene sorbitan derivatives; thickeners such as corn, tapioca, potato and rice starch, carboxymethylcellulose, methylcellulose, guar gum, xanthan gum, alginates and pectin; stabilisers such as sorbic, malic, phosphoric, tartaric and ethylene diamine tetraacetic acids and alkali metal salts thereof, esters of p-hydroxybenzoic acid, alkali metal propionates, butylated hydroxyanisole. butylated hydroxytoluene, and propyl gallate: flavours such as vanilla, caramel, maple, cinnamon, mint and fruit flavours; and salt, nuts, spices and colours.Description:


(54) FRUIT SPREADS

(71) We, UNILEVER LIMITED, a company organised under the laws of Great

Britain, of Unilever House, Blackfriars,

London, E.C.4, England, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

The present invention relates to fruit spreads and in particular relates to fruit spreads comprising a plastic water and edible oil emulsion food product containing fruit.

432/2197

If fruit is incorporated into food spreads such as for example, peanut butter, margarine and butter, to add taste interest, the fruit tends to become hard after normal storage periods, resulting in a gritty product. Also exudation from the fruit because of syneresis shows up as coloured liquid droplets on the surface of the product, making the product unappetising. The keepability of the product during normal storage time periods is poor and the colour of the product soon darkens and a yeasty smell can be detected. Again, if the fruit is pulverised to form a powder, the identity of the fruit is lost and the appeal of the product is correspondingly diminished, whereas it is a decided advantage for consumer appeal to retain the fruit in a recognisable form.

In accordance with our British patent specificationNo. 1,189,854 a fruit flavoured spread comprises a plastic emulsion of fat and fruit preserve stock, the latter being in the gelled condition. In this product therefore the fruit is preserved by previous cooking with sugar.

The present invention provides a plastic food spread comprising a dispersion made from an edible oil or fat and sugar syrup containing uncooked whole or divided fruit previously preserved by contact with the sugar syrup. A plastic spread can be spread with aknife at 150C but likemagarine normally retains its shape at that temperature.

The invention further provides a process for the preparation of a fruit spread of improved keep ability comprising contacting the fruit in whole or divided form with a sugar syrup without cooking it to effect a preservative action and thereafter emulsifying a mixture of sugar syrup containing the uncooked fruit with an edible oil or fat to form a plastic emulsion.

In another of its aspects the invention provides uncooked fruit preserved in a plastic fat emulsion food product whose aqueous phase comprises sugar syrup. By"uncooked fruit" is meant fruit which has not been exposed to heat treatment for any substantial length of time for the individual shape of separate fruit pieces to be lost; the fruit may however be heated as in pasteurisation, augment the preservative action of the sugar syrup with which it is contacted.

For the purpose of the invention edible oils include those glyceride compositions which being normally at least partly solid at ambient temperatures may therefore customarily be termed fats as well as those which under these conditions are normally liquid.

In accordance with the present invention, the spread may comprise an animal, vegetable or synthetic fat or oil. Sugar syrup as used herein refers to an aqueous solution of sugar which may be made by dissolving sugar in water or purchased as such.

In carrying out the process, it is important that the fruit first be contacted with the sugar syrup before the emulsion is made.

The fruit may be used in fresh, frozen or dried state. It is thoroughly mixed with the sugar syrup for a sufficient time and at a sufficient temperature substantially to improve the keepability of the fruit without cooking it. A period of 20 minutes at ambient temperature is usually adequate to provide a product whichwhen mixed with the oil toform a plastic emulsion shows good keepability, the fruit remaining soft and without extensive exudation by reason of syneresis for a period of several months.Without intending to limit the scope of the invention by the expression of any theory as to its operation, it is believed that this contact ofte sugar in the syrup with the fruit effects substantial equilibrium of the osmotic pressuresbetween the fruit and the sugar syrup, prior to mixing the oil or fat, which is maintained by the syrup in the emulsion, to preserve thefruit in the product.

Suitable edible oils which may be employed in the present invention include thosecom- monks usedn plastic edible oil products, for example margarine and shortening fats or oils, and in general any combination of edible oils,semi-solid or solid fats can be employedgiving a plastic product. They may bepat-tially hydrogenated. Examples of suitable oils include coconut oil, palm kernel oil, cottonseed oil, kapok oil, rapeseed oil, peanut oil, olive oil, sunflower seed oil, sesame oil, corn oil,sallower oil, soybean oil, milk fat, beettallow, mutton tallow, lard, modified lard, and butter fat.

Suitable sugars for use as syrup in the aqueous phase in the invention include forexample common granular or powdered sugars including sucrose, dextrose,maltose, fructose, lactose, and brown and

433/2197

invert sugars as well as mixtures of said sugars. Suitable ready made sugar syrups include socalledliquid sugar, refiners syrup, and honey.

While the particular sugar of combinations of sugars used is not esseiltial to the invention, it is desirable that the productcom- prises from5 /, to 45% and preferably 12% to30 byweight of sugar. It has been found that if less than5% by weight of sugar is present, the product may have a fatty taste.

More than 45% by weight of sugar present will not provide any advantage and may unduly sweeten the product for most consumers.

Suitable fruits for use in the present invention include those that will undergo syneresis.

Theymay be used in the fresh, dried or frozen form.

Examples of fruits which may be used in the invention include Thompson seedless raisins, Zante raisins, golden bleached raisins, dates, figs, prunes, apricots, strawberries, blueberries and cherries as well as combinations thereof. The fruit can be present in the product of the invention in whole, or divided form, and may for example be sliced or chopped. Dried fruits, which may be used, are not completely anhydrous but usually containsome water, the amount removed beingsufficient to prevent decomposition and ensure bacterial stability.

The preparation of dried fruit and its final characteristics is described for example in

Food and Food Products, 2nd Edition,

Volume 3, Chapter 33 by Morris B. Jacobs,published byInterscience.

Before the fruit is mixed with other ingredients, preferably thenormally unusable parts areremoved, e.g., pits, seeds and stems.

When forexonple raisins,blueberries or other small size fruit are used in the product,they can be used whole and stillprovide substantally even distribution throughout the spread. in a preferredfonn oftlie product,however a combination of whole and chopped raisins orbluoborries is used, since such a product while stillsllo-ville clear fruit identification can providemore raisins or blueberries per unit volume of product than can be obtained with only whole raisins or blueberries.

The size ofthe fruitwhen chopped or sliced therein alternatively referred as as"comininuted") can vary over a relativelyvide range.In apreferred ferm ef the invention, apredominant portion of the fruit-par-tide sizes isniore than-l- in length.

when the fruit used inthe process is to be in comminuted form, standardrotary knife cutters such as theAbbe rotary cutter, theBall & jewell rotarycutter, orthe Hobort cutter, can be used toobtain the desired particle size.

Edible emulsifiers may be present in the

product but their addition may not be necessary under certain process conditionswhere the ingredients used tend to form emulsions.

When an emulsifier is used, its concentration in the product issuitably from 0.05% to 1.0% by weight of product. Examples of such emulsifiers are mixtures of mono- anddiglycerides, and acetylated products of such mixtures, lecithin, poiyoxyethylene sorbitan derivatives of fatty acids andpolyoxyethylene sorbitan monoglyceride.Other suitable emulsifiers can be found in Industrial Oil and

Fat Products,2nd Edition by Bailey, publishedbv Interscience. The product is preferably an emulsion of thelvater-in-oil n-pe and any emulsifiers added should therefore promotethe formation of this type of emulsion.

The products of the presentinvention may also contain minor amounts of other edible ingredients includingconventional margarineingredieiits, and the products of the invention include margarine and like plasticfood spreads containing frit dispersed therein on which a preservative action is esercised

434/2197

bythe presence of sugar syrup comprising the aqueous phase of the spread. Suitable additives include for exampleflavouring agents, nuts, spices,dves or colourants, thickeners, forexample gums and starches, stabilisers and mould inhibitors. Also, salt, vitamins and minerals may be added to the product to increase its flavour and/or nutritional value.

Suitableflavouring agents and spices include cinnamon, fruit flavours, mint,maple and vanilla.

Thickeners may be used3 produce a desired viscosity in the aqueous phase so that the fruit can be distributed more evenly. The gums or starches can be any of those commonly used in food products for example carboxymethyl cellulose, guar, methyl cellulose, alginates, xanthan gum, pectin, and corn, tapioca, potato and rice starch.

Suitable mouldinhibitors and stabilisers may also be included in the products of the invention, for example sorbic acid, potassium sorbate, sodium benzoate, esters of parahydroxy benzoic acid, alkali metal salts of propionic acid, butylated hydroxy anisole, butylated hydroxy toluene, propyl gallate, ethylene diamine tetra-acetic acid, malic, citric, phosphoric and tartaric acids and the alkali metal salts thereof.

The amounts of the ingredients present in the products of the present invention are not critical and can vary over relatively wide ranges. Preferably however each of the essential ingredients, water, fruit and sugar is present in a minor proportion of the total composition, whereas the fat is preferably present in the greatest amount as the principal ingredient.More specifically, the concentrations of the ingredients may be as follows:

Product Composition

Percent by Weight

Ingredient of Product

Fat 30--83(40-55)

Sugar5-45 (12-30)

Fruit20 (8-18)

Flavour0--5 (0.02-0.1)

Colouring0-1.0 Thickened (gums and/

orstarchs) o---lo (0.5-4.0)

Mould inhibitors and

Stabilisers0--0.12 (0.05-0.1)

Vitamins and Minerals0-5

Emulsifiers0-1.0(0.15-0.25)

Water (including water

contributed by fruit) 10-40(20-30)

Exceptionally good results are obtained when the ingredients in the product have the concentrations shown in brackets.

Except for any gum or starch, which must be present in the aqueous phase, the optional ingredients may be present in the aqueous or the fat or oil phase prior to mixing the two.

In the first stage of the process for making the product of the invention sugar syrup is mixed with whole or divided fruit and is then preferably treated at an elevated temperature, preferably from174"F. to185 F., in order to pasteurise but not cook the fruit.

This is unncessary if sterile fruit is used. The fruit should preferably be held in the aqueous phase for at least 20 minutes in order to minimise syneresis in the final product.

In a preferred method of preparing the products of the invention, the oil phase is prepared by introducing into a churn the fat or oil ingredient with any other optional ingredient for example colouring agents, flavouring agents, and emulsifiers. The ingredients are then mixed until a homogeneous product is obtained. If a semi-solid or solid fat is used, the churn is heatedlvith heating coils in order to liquefy the mixture, making it easier to pump and blend, the temperature to which the material is heated being dependent on the melting point and the processing characteristics of the fat.After churning the oil phase is then quick chilled before mixing with the aqueous phase, in conventional shortening or margarine equipment, comprising precrystalliser and Votator units in series,

435/2197

if desired after adjusting the density of the fat by incorporating a gas, for example air, nitrogen or carbon dioxide. The amount of gas introduced is preferably from 20% to45 ,. by volume, but more or less may be used according to the density and spreadability required.

The chilled oil phase and aqueous phase are then blended together to form the final product, in a mixer comprising a modified

Votator B unit having fixed and moving interdigitating fingers, supplied through a proportionating pump with the aqueous phase. The product may then be immediately placed in suitable containers for sale.

The oil and wateremulsion comprising the plastic spread is preferably ofwater-in-oil.

The following examples further illustrate the present invention.

EXAMPLE 1

An aqueous phase comprising the following ingredients wasprepared:

Aqueous Phase

Parts By Weight


SucroseSyrup67',ó

sugar solids 26.0

Carboxymethyl cellulose 0.2

Whole Thompson seed

less raisins 3.3Comminuted Thompson

seedless raisins 3.3

Cinnamon 0.32

Whole Zante currant

raisins 6.6

The fruit contained 18 wt. ,' water.

Oil Phase

Hydrogenated cotton seed

oil 48.0

Lecithin 0.11

The balance to 100 parts

by weight of the pro

duct being made up of

colouring (Carotene

3700 units per pound)

and water.

The Thompson seedless raisins were previously chopped in a Hobart cutter to yield an average particle size of about 1/32 inches. The aqueous phase containing the raisins, after standing for 20 minutes, was blended, in accordance with the preferred method disclosed above for preparing the products of the invention, in a modified Votator

B unit with previously chilled oil phase.

The final productwas stable at4SF for a period of 6 months and the fruit retained its initial softness ande;"hibited noextensive syneresis. The productwas also uniform and non-gritty and could easily be spread at ambient temperatures.

In further products chopped dates, figs, prunes, and apricots were substituted for the chopped and whole raisins. All the final products had similar stability and pleasant palatability characteristics.

Example 2

Aqueous and oil phases of the following components were prepared as described in

Example 1, nitrogen in the oil phase giving 0.6 g/c.c. density.

436/2197

Aqueous Phase

Parts By Weight


Lactose 5.0

Dextrose 7.0

Methocel 0.1

Whole blueberries 13.0

Cinnamon 0.02

Fruitflavour 0.08

Sorbic acidO.OS

Citric acid 0.05

Water 13.0Vanilla 0.3

Potassium Sorbate 10.05

The fruit contained85-

90 wt.% water

Oil PhaseHydrogenotod Safflower

Oil 40.0Hydrogenated Papeseed

Oil 25.0

Lecithin 0.10

The aqueous and fat or oil phases were then mixed as in Example 1, to produce a plastic productwhich was appetising and exhibited goodstabilitv under normal storage conditions and inwhich the fruit retained its original softness and showed no extensive syneresis.

Similar products based on milk fat, beef tallow, muttontallow, kapok oil, palm kernel oil, and peanut oil instead of the mixture of safflower and rapeseed oil were prepared andwere similarin stability andpalatability.

Example 3

Parts ByWight


Raisins (Zante, whole) 6.6

Raisins Thompson Seed

less, whole) 3.3

Raisins (Thompson Seed

less, chopped 3.3

Liquid sugar(67 sugar

solids) 13.2

Golden Sucrose(70%

sugar solids) 13.2


Salt 1.0

Butylated hydroxy anisole 0.002

Ethylene diamine tetra

acetic acid 0.005

Caramel (powdered) 0.07

Cinnamon (powdered) 0.26

Carboxymethyl cellulose 0.2

Oleoresin cinnamon 0.02

Water 10.397

The fruit contained1S wt.

% water.

Oil Phase

Parts Byheight


Partiallyhydrogenated cot

tonseed (15%) and soy

437/2197

bean oil(85 , Iodine

Value 95)* 48.00

Monoglyceride 0.22

Lecithin 0.12

Carotene 4.4 ppm 0.06

*Solid Fat Index12 at 21.1 C.,0 at

400C. and not more than 3.5 at33.3.

The aqueous phasewas preparedbv adding the dryingredients to the water in a

Pfaudlermis tank. The sugar syrups and raisins were then added and the entire mixture pasteurisedbv heating for 20 minutes at 1800F. Thepasteurised phase was then cooled to100 F.

A shortening was prepared from the oil phase. The aqueous phase was blended into it in an in-line mixer in the proportion of52/ with48 ,' of the oil phase, the final product being filled into round tubs.

An excellent plastic productwas obtainedwhich was tasty,smooth non-gritty and spreadable.

The product was also stable for greater than 6 months at 450F.

Example 4

Aqueous Phase

Parts ByWeight


Sucrose Syrup(67 - ' sugar

solids) 26.0

Carboxymethyl cellulose

gum 0.2

Whole blueberries 9.9

Example 4 Cont

Aqueous Phase

Parts by Weight


Chopped blueberries 3.3

Cinnamon 0.32

Water 11.95


90wit.% water.

Oil Phase

Parts ByWeight


Hydrogenated cottonseed

oil 48.0

Lecithin 0.11

Partial glyceride emulsi

fiers 0.22

The aqueous and oil phase were prepared and mixed in accordance with the process of Example 1.

The final product was appetising and stable under normal storage conditions and the fruit retained its original softness and showed no extensive syneresis. The product was also tasty, smooth and non-gritty and spread easily at room temperature.

Example 5

A product was prepared as described in

Example 1, using the following ingredients: -

Aqueous Phase

Parts By Weight


Lactose 5.0

Dextrose 7.0

438/2197

Methocel 0.1

Dates(chopped) 13.0

Cinnamon 0.02

Fruit Flavour 0.08

Sorbic Acid 0.05

Citric Acid 0.05

Water 13.0

Vanilla 0.3



25wt. /- water.

Oil PhaseMilk Fat 65.0

Lecithin 0.1

An excellent plastic product was obtained which was tasty, smooth and non-gritty. The product also showed good sta'oility under normal storage conditions.

A similar product was obtained with the inclusion in the oilphase of 0.5 parts by weight of each of

Tween 60 and 80 (polyoxyethylene sorbitan monoglyceride) emulsifiers.

The fruit spreads of the present invention may be spread on bread or used as fillings or toppings for pies, buns and sandwiches.

The words "Methocel", "Hobart", "Votator" and "Tween" used in thisspeeifieation are Registered

Trade Marks. The "Votators" are scraped surface heat exchangers.

We are aware of the Preservatives in Food

Regulations 1962 No. 1532 and the Antiexit'ant in Food Regulations 1966 No. 1500, and in so far as this invention relates to a process for the preparation of food for sale in the United Kingdom and/or sale of food in the UnitedKingdom so prepared, we make no claim to the use of the invention in contravention of the law.

WiIAT WE CLAIMIS:-

1. A plastic food spread comprising a dispersian made from an edible oil or fat and sugar syrup containing uncooked whole or divided fruit previously preserved by contact with the sugar syrup.

2. A fruit spread according to Claim 1 and comprising30-83% fat,5 45% sugar, 240% fruit and10-

40% water by weight of the total composition of the spread.

3. A fruit spread according to Claim 1 or 2 inwhich the fat comprises a margarine or shortening fat.

4. A fruit spread according to Claim 1 or 2 in which the fat comprises butter fat.

5. A fruit spread according to any of the preceding claims which comprises a waterin-oil emulsion.

6. A fruit spread according to any of the preceding claims in which the fruit comprises dried fruit.

7. A fruit spread according to any of the preceding claims which comprises fat as the principal ingredient.

8. A fruit spread according to any of the preceding daims which contains a minor amount of an additional margarine ingredient.

9. A fruit spread according to any of the preceding claims which contains0.05-1.0 wt.

y- of an emulsifier.

10. A fruit spread according to any of the preceding claims which contains a thickening agent.

439/2197

11. A fruit spread according to any of the preceding claims which contains an aerated edible oil or fat.

12. A fruit spread substantially as described with reference to any of the accompanying examples.

13. Process for the preparation of a fruit spread of improved keepability whichcomprises contacting whole or divided fruit with a sugar syrup without cooking the fruit to effect a preservative action and thereafter emulsifying a mixture of sugar syrup containing the uncooked fruit with an edible oil or fat to form a plastic emulsion in which the fruit is dispersed.




Example 4 Cont

Aqueous Phase

Parts by Weight


Chopped blueberries 3.3

Cinnamon 0.32

Water 11.95


90wit.% water.

Oil Phase

Parts ByWeight


Hydrogenated cottonseed

oil 48.0

Lecithin 0.11

Partial glyceride emulsi

fiers 0.22

The aqueous and oil phase were prepared and mixed in accordance with the process of Example 1.

The final product was appetising and stable under normal storage conditions and the fruit retained its original softness and showed no extensive syneresis. The product was also tasty, smooth and non-gritty and spread easily at room temperature.

Example 5

A product was prepared as described in

Example 1, using the following ingredients: -

Aqueous Phase

Parts By Weight


Lactose 5.0

Dextrose 7.0

Methocel 0.1

Dates(chopped) 13.0

Cinnamon 0.02

Fruit Flavour 0.08

Sorbic Acid 0.05

Citric Acid 0.05

Water 13.0

Vanilla 0.3



440/2197

25wt. /- water.

Oil PhaseMilk Fat 65.0

Lecithin 0.1

An excellent plastic product was obtained which was tasty, smooth and non-gritty. The product also showed good sta'oility under normal storage conditions.

A similar product was obtained with the inclusion in the oilphase of 0.5 parts by weight of each of

Tween 60 and 80 (polyoxyethylene sorbitan monoglyceride) emulsifiers.

The fruit spreads of the present invention may be spread on bread or used as fillings or toppings for pies, buns and sandwiches.

The words "Methocel", "Hobart", "Votator" and "Tween" used in thisspeeifieation are Registered

Trade Marks. The "Votators" are scraped surface heat exchangers.

We are aware of the Preservatives in Food

Regulations 1962 No. 1532 and the Antiexit'ant in Food Regulations 1966 No. 1500, and in so far as this invention relates to a process for the preparation of food for sale in the United Kingdom and/or sale of food in the UnitedKingdom so prepared, we make no claim to the use of the invention in contravention of the law.

WiIAT WE CLAIMIS:-

1. A plastic food spread comprising a dispersian made from an edible oil or fat and sugar syrup containing uncooked whole or divided fruit previously preserved by contact with the sugar syrup.

2. A fruit spread according to Claim 1 and comprising30-83% fat,5 45% sugar, 240% fruit and10-

40% water by weight of the total composition of the spread.

3. A fruit spread according to Claim 1 or 2 inwhich the fat comprises a margarine or shortening fat.

4. A fruit spread according to Claim 1 or 2 in which the fat comprises butter fat.

5. A fruit spread according to any of the preceding claims which comprises a waterin-oil emulsion.

6. A fruit spread according to any of the preceding claims in which the fruit comprises dried fruit.

7. A fruit spread according to any of the preceding claims which comprises fat as the principal ingredient.

8. A fruit spread according to any of the preceding daims which contains a minor amount of an additional margarine ingredient.

9. A fruit spread according to any of the preceding claims which contains0.05-1.0 wt. y- of an emulsifier.

10. A fruit spread according to any of the preceding claims which contains a thickening agent.

11. A fruit spread according to any of the preceding claims which contains an aerated edible oil or fat.

12. A fruit spread substantially as described with reference to any of the accompanying examples.

13. Process for the preparation of a fruit spread of improved keepability whichcomprises contacting whole or divided fruit with a sugar syrup without cooking the fruit to effect a preservative action and thereafter emulsifying a mixture of sugar syrup containing the uncooked fruit with an edible oil or fat to form a plastic emulsion in which the fruit is dispersed.

14. Process according to Claim 13 in

441/2197

which sugar syrup is heated to pasteurise the fruit before mixing with the oil or fat.

15. Process according to Claim 13 or 14 in which the fruit is contacted for at least 20 minutes with the sugar syrup before mixing with the oil or fat.

16. Process according to Claim 13, 14 or 15 in which the sugar syrup contains from 5 to 45wit. % of the spscad, of sugar.

17. Process according to any of the preceding claims13-16 in which oil or fat is chilled and worked inscooped surface heatexciiange units before mixing with the sugar syrup containing the fruit.

18. Process according to Claim 17 in which the fat is aerated before mixing with the sugar syrup containing the fruit.

19. Fruit spreads containing preserved fruit whenever prepared by a process as claimed in any of the preceding claim13 to 1S.Data supplied from the esp@cenet database - Worldwide

442/2197

85.

GB1318740 - 5/31/1973

COATED FOOD PRODUCTS


Applicant(s): NAT BISCUIT CO (--)


IP Class: A23L1/10

E Class: A23L1/164B



Family: GB1318740

Abstract:


1318740 Coating cereal products NATION- AL BISCUIT CO 22 Sept 1970 45087/70 Headings A2A and A2B A ready-to-eat cereal, e.g. corn, rice, wheat in puffed, flaked, shredded or extruded form, is coated with an ice cream product in dried or powdered form which is adhered to the cereal by an intermediate coating of an edible binder which may be a sugar syrup, a natural or synthetic gum, a mucilaginous plant extract, starch, dextrin, or an emulsifying agent such as a mono- or di-glyceride c.

Apparatus for performing the coating process comprises a heat exchanger in which a sugar solution is heated rapidly to 240 F. and then cooled rapidly to 170-190 F., and a horizontally mounted rotary drum to one end of which the cooled sugar solution and the cereal are supplied. At about one third of the length of the drum from its discharge end the dried ice cream product, which may be flavoured and may contain an anti-caking agent such as calcium silicate, is introduced by a blower. The coated cereal leaving the drum passes to a dryer maintained at a temperature of 200 F.Description:


(54) COATED FOOD PRODUCTS

(71) We, NATIONAL BISCUIT COMPANY, a corporation of the State of New Jersey,

United States of America, of425 Park

Avenue, New York, New York10022,

United States of America, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularlydescribed in and by the following statement :

The invention relates to the production of coated food products, and, more specifically, to breakfast cereals characterized by a coating of a flavouring composition. The invention also relates to a process for the manufacture of the food articles.

Many cereals are marketed with a coating, for example a transparent or frosted sugar coating, for the purpose of improving their flavour and appearance. Although these products are in general satisfactory, they do not provide sufficient variety of flavours, mouth feel, colour and appearance to meet the everincreasing demands of the consumer.

It is an object of the invention to provide coated cereal products, having a totally new flavour and appearance.

443/2197

It is another object of the invention to provide a process for the manufacture of such coated cereal products. which is economical, suitable for large-scale operation, and which may be conducted continuously.

It is a further object of the invention to provide a process which may be applied to the coating of all ready-to-eat cereals. The term "ready-to-eat" cereals includes cereals which are puffed or partially puffed, such as corn, rice and wheat, whether explosively by the gun method or popped in an ordinary poppingmachine. It also includes cereals which are flaked, shredded, or extruded before reaching the consumer.

According to the invention, there is provided a ready-to-eat cereal having a coating of an ice cream productwhich is a member selected from the group consisting of freezedried ice cream, spray-dried ice cream, powdered ice cream mixes, dehydrated ice cream mixes and mixtures thereof, and an intermediate coating of an edible binder which holds the ice cream product adherent to the surface of the cereal, the ice cream product forming from5% to 35% by weight of the coated cereal.

The coating of the ice cream product gives the consumer the characteristic attractive flavour of ice cream. As is implicit in the preceding paragraph, the term "ice cream product" as used herein refers to freezedried ice cream or spray-dried ice cream or any of the conventional ice cream mixes which generally comprisesmilk solids, cream, sugar, salt, together with a stabiliser, for example algin, and which usually contain flavouring and colouring agents. Other products obtained by the dehydration of ice cream mixes, for example, by foam-mat drying, are also included in the term "ice cream product".The term also includes a mixture of two or more of these products, for example a mixture of freeze-dried ice cream and/or spray-dried ice cream with one of the commercially-available powdered ice cream mixes, which are used to make icecream.

Freeze-dried ice cream is a commercially available product, obtained by drying ice cream under vacuo in a frozen state, at a temperature of00F or lower. It is available as a powder of about 2% moisture content the powder having a particle size passing through a 16-mesh sieve. Freeze-dried ice cream is available in many flavours, such as vanilla, chocolate, coffee, maple and fruit flavours.

"Spray-dried" ice cream as used herein means the powder obtained by melting conventional ice cream and heating the melt in an atomizer whereby the material quickly loses water and is deposited as apowder.

Both the freeze-dried ice cream and spraydried ice cream arehygroscopic materials which have a tendency to become tacky.

Although several investigators have attempted to impart a coating of freeze-dried or spray-dried ice cream to various edible products, these efforts, to our knowledge, have been unsuccessful, for several reasons.

If the application of the flavouring composition the ice cream product, is made quickly, a substantial amount of the dry composition does not adhere to the article and is wasted.

If, however, the application is conducted over a more extended period of time, the composition becomes tacky and neither the flavour nor the appearance of the coated articles are satisfactory.

It has now been found, surprisingly, that a food product of excellent appearance, highpalatability and with an ice cream flavour is obtained by coating the cereal products with a binder, followed by the application, substantially immediately thereafter, of the flavouring composition consisting essentially of the ice cream product.

Thus the invention also provides a process for the production of a coated ready-to-eat cereal, which comprises the steps of (a) precoating the cerealwith an edible binder by which the surface of the cereal becomes tacky; (b) immediately coating the pre-coated cereal with a dried flavouring composition consisting essentially of an ice cream product which is a member of the group consisting of freezedried ice cream, spray-dried ice cream, powdered ice cream mixes, dehydrated ice cream, mixes and

444/2197

mixtures thereof whereby the flavouring composition adheres to the surface of the pre-coated cereal; and (c) drying until the moisture content of the coated cereal is from2 jó to3% by weight.

In the practice of the invention, a readyto-eat cereal article, prepared by any of theknown processes such as extrusion, puffing or flaking, has a binder applied to it, for example by spraying or tumbling in a suitable mixing vessel. The application of the coating of the flavouring composition may be achieved by different methods, such as dusting or spraying or tumbling in a revolving apparatus with the flavouring composition.

A variety of substances may be used as the binder, provided that viscosity is sufficiently low, in the range of 100 to200,000 centipoises at room temperature, so that a solution of the substance may be conveniently applied onto the cereal articles. More specifically any of the known natural orsynthetic gums, such as gum karaya, gum arabic,tragacanth, carrageenan, carboxymethylcellulose and methyl cellulose may be used.Aqueous solutions ofcarboxvmethy!- cellulose of moecular weight200,000 havingconcentrations of 0.5 ,Ó, 1% and 9 Olo and viscosities at room temperature of 200 centipoises,

1050 centipoises and 200,000cenh- poises respectively, are suitably used as the binder.Muciliaginous plant extracts such as psyllium seeds, quince seeds, locust bean, are also suitable. It is also possible to use a solution or suspension of starch or dextrins, in the concentration of 1 to 50% of the finished coated cereal.

Also suitable as a binder are the polyhydroxy esters of fatty acids, known in the cereal industry as emulsifying agents, including mono- and di-glycerides, polysorbitan monostearate, polyoxyethylenestearale, sorbitan monoleate and polyglyceral oleate.

According to one embodiment to the invention, a sugar syrup which improves the flavour of the finished products, is used as the binder. In such case, the cereal articles, prior to the application of the ice cream product, are coated with a sugar syrup. In this manner, the moisture content of the sugarcoated cereal generally increases to6-7% and the surfaces of the articles become tacky, so that the flavouring composition readily adheres thereto. One preferred binder is applied as a syrup containing

7580 ó by weight of sucrose and25-20% by weight of water.

The sugar may be sucrose or mixtures of sucrose with other sugars, for example glucose or lactose or maltose, provided that the sugar crystallizes out readily upon cooling.

A sugar syrup prepared from 80 parts by weight of solid sucrose and 20 parts by weight of water, having a viscosity of 850 centipoises at1'0 F, is advantageously used.

Swectening, low-calone ingredients may also be used, if desired, provided that they do not interfere with the crystallization of the coating in the finished product. Invert sugar, if present in substantial amounts, may retard or prevent the sugar from crystallizing out.

Th proportion of sugar in the finished goods may be varied over a wide range, and even a small amount, as low as1?' by weight of the finished gods, is sufficient to hold the flavouring composition adherent to the cereal particles. If a sweeter product is desired, the proportion of sugar may be increased up to50 Ó by weight of the finished goods.

In one method of carrying out the process of the invention, a solution is prepared fromS0 parts by weight of sucrose and 20 parts by weight of water. The material is heated to2300F to bring about complete dissolution and then cooled to1500-1900F. A number of factors are important in carrying out the process.Although heating and cooling may be conducted in an open kettle, it is preferred, in order to obtain complete dissolution of the sucrose in a short period of time without causing undue formation of invert syrup, to heat the material rapidly to240"F and cool rapidly to1700--1900F. It has been found that a very satisfactory product is obtained if the heating and cooling step are carried out rapidly, in a period of between 1 and 2 minutes, and if the sugar syrup is applied immediately onto the cereal articles, followed by application of the ice cream composition.

it is essential that the flavouringcoin- position be applied quickly, before the binder loses its tackiness.

For this purpose, it is advantageous to apply the flavouring composition in the same operating unit as that in which the sugar coating is carried out and to carry out the two operations in a continuous

445/2197

manner. The time required to carry out the coating of the binder and the application of the ice cream composition may vary, but it is preferable to conduct the two operations in a periodof 2-3 minutes.

One method of carrying out the process will now be described more in detail with reference to the accompanying drawing which shows one form of apparatus for effecting the process. A sugar solution consisting of 80 parts by weight of sugar to 20 parts by weight of water, is heated to 1700F in a vessel

1. The syrup is then delivered by means of a pump P or other suitable means to a heat exchanger section 2 comprising heat exchangers 2a and 2b in which heating and cooling of the syrup is con ducted. The operating conditions are so adjusted that the temperature of the syrup is raised rapidly to240"F in unit2 and is then rapidly lowered tol700-1900F in unit 2b.The process is truly continuous,with efficient mixing being maintained throughout both the heating and cooling stages in the heat exchange section, the total residence time of the syrup is section 2 being between 1 and 2 minutes.

The sugar syrup is immediately and continuously delivered from section 2 into a supply tank 3, from which it is introduced at a controlled rate into a coating unit 4. At this stage the sugar syrup is at a temperature of1700-1900F.

One hundred pounds of a cereal product is introduced into the coating unit 4 through line 5. Although a mixing vessel, provided with inner rotating means may be used as the coating unit, it is preferred to use a rotating barrel having suitable means for the introduction of the flavouring composition, so that the latter comes into contact with the cereal particles after they have been precoated with the sugar syrup and while the coating is still tacky. More specifically, the flavouring composition comes into contactwith the precoated cereal particles in the last third portion of the coating unit, after the sugar syrup and the cereal articles have travelledbwo-third of the coater, and have become thoroughly mixed.The flavouring composition is preferably introduced by means of a blower 6 located outside the coating unit, in theprox'imity of the outlet 7, so that the flavouring composition is brought into contact with the sugar-coated cereal particles in the last third portion of the coating unit. The moisture content of the cereal articles, after coating With the sugar syrup and application of the flavouringcomposition, is67%.

The flavouring composition consists of 10 parts by weight offreeze-dried ice cream and 10 partsroy weight of a commercially available powdered ice cream mix per 100 parts by weight of cereal articles.

It is advantageous, particularly where substantial moisture is present in the atmosphere, to add to the flavouring composition an anti-caking agent, for instance calcium silicate. A small amount ofthe anticaking agent, between 0.05 and0.1 ó of the finished food products, that is about0.5% of the flavouring composition, is sufficient for this purpose.

The entire operation of coating with the sugar syrup and application of the flavouring composition, is conducted continuously preferably in a period of2-3 minutes. After drying for20 minutes at2000F in the drier 8, the moisture content is2-3 % preferably between 2 and 2.5%.

The finished cereal articles are of excellent taste, attractive colour and not tacky. When milk is added to the finished cereal particles, their flavour is characteristic of conventional ice cream. The finished read-to-eat cereals suitably comprise, by weight 66% of cereal product, 20% sugar and 13% of ice cream product, but the proportions may be varied between 15% andi66% of cereal particles, between1% and 50% of sugar and between5% and35% of the flavouring composition.

On cooling, the sucrose crystallizes in the form of microcrystalswhich uniformly cover the entire surface of the cereal articles.

The invention is illustrated further in the following examples.

EXAMPLE 1

To 80 pounds of finegranulated sugar were added 20 pounds of water and the mixture was heated up to171)"F. The syrup formed was fed, at a rate of1500 ounces per hour, into a heat exchange section in which it was heated to240"F and then cooled to170"F in the course of one minute.

446/2197

The syrup so obtained was immediately introduced into one end of a rotating drum coater of 6 feet length and 18 inch diameter.

A toasted and flaked rice cereal of20,10 moisture content was also introduced into the same end of drum coater at a rate of 300 pounds per hour and the cereal was coated with the syrup.

The flavouring composition was separately prepared from equal parts by weight of a freeze-dried vanilla ice cream and a commercial powdered vanilla ice cream mix, with0.5% calcium silicate. The flavouring composition was introduced in the dry form into the drumcoater by means of a current of air at a rate of 960 ounces per hour in a manner such that it came into contact with the syrup-coated cereal at a position about two-thirds along the length of the coater. When the cereal articles reached the end of the coater, coating with the dry flavouring composition was complete and essentially the entire portion of the dry flavouring composition which has been introduced, was used up.

The entire operation of coating with the sugar syrup and application of the flavouring composition, was conducted continuously in a period of 2minutes. The productemerg- ing from the drum coater had a moisture content of67%. After drying for 20 minutes at20f)0F, the moisture contentwas reduced to2.5if,.

The finished product was of an attractive white colour and not tacky, and on the adition of milk, it had a flavour characteristic of vanilla ice cream.

Substitution of flaked cereals which had not been previously toasted, for the toasted and flaked cereals used above, gave equally satisfactory results.

EXANIPLE 2

The procedure of Example 1 was repeated but with a flavouring composition prepared from equal parts by weight of a commercial powdered vanilla ice cream mix and spraydried ice cream. For this purpose, commercial vanilla ice cream wasalloyed to thaw and introducedthrough a nozzle of the centrifugal atomizer kind, into a conventional experimental spray drier, 6 feet high, and about 5 feet diameter, at a temperature of64068 0F. Hot air at a temperature of4020F was introduced into the drier at a rate of 60 cubic fet per minute. The air temperature at the outlet was1680-2040F.

The density of the spray-dried ice cream was22 pounds per cubic foot.

The finished goods, on the addition of milk, developed the characteristic flavour of vanilla ice cream and are indistinguishable from the product of Example 1.

WHAT WE CLAIMIS:-

1. A ready-to-eat cereal having a coating of an ice cream product which is a member selected from the group consisting of freezedried ice cream, spray-dried ice cream, powdered ice cream mixes, dehydrated ice cream mixes and mixtures thereof, and an intermediate coating of an edible binder which holds the ice cream product adherent to the surface of the cereal, the ice creamproduct forming from 5% ,{, to 35 Ó by weight of the coated cereal.

2. A ready-to-eat cereal according to claim 1, in which the binder is a member selected from the group consisting of natural and synthetic gums, starch, dextrins, monoanddi-glyzerides of fatty acids, and sugars.

3. A ready-to-eat cereal according to claim 1 or claim 2, in which the binder issucrose, the binder forming from 1 ó to 50 Ó by weight of the coated cereal.

4. A ready-to-eat cereal according to any one of the preceding claims, in which the ice cream product is a mixture of equal parts by weight of freeze-dried ice cream and a powdered ice cream mix.

5. A process for the production of a coated ready-to-eat cereal, which comprises the steps of

(a) pre-coating the cereal with an edible

binder by which the surface of the

cereal becomes tacky;

447/2197

(b) immediately coating the pre-coated

cereal with a dried flavouring com

position consisting essentially of an

ice cream product which is a mem

ber of the group consisting of freeze

dried ice cream, spray-dried ice

cream, powdered ice cream mixes, de

hydrated ice cream mixes andmix-

tures thereof whereby the flavouring

composition adheres to the surface

of the pre-coated cereal, and

(c) drying until the moisture content of

the coated cereal is from2% to3

by weight.

6. A process according to claim 5, in which the edible binder is a member selected frown the group consisting of natural and synthetic gums, starch, dextrins, mono- and di-glycerides of fatty acids and sugars.

7. A process according to claim 5 or claim 6, which is conducted continuously.

8. A process according to any one ofclaims 5 to 7, in which the binder is a syrup containing between

75 and80 C, by weight sucrose and25-20% by weight water, and the moisture content of the precoated cereal after said precoating step is67 ,,.

9. A process according to claim 8, in which the binder is a syrup containing substantially80% by weight sucrose and20% by weight water.

10. A process according to any one of claims 5 to 9, in which the binder is a sugar applied in the form of a syrup and the syrup, prior to said precoating step, is heated to240 F and then cooled to170'--190"F within a period of from 1 to 2 minutes.

11. A process according to any one of claims 7 to 10, in which the precoating and coating steps are continuously conducted in the same coating zone, with a total residence time of from 2 to 3 minutes, and the flavouring composition is introduced into the coating zone after the sugar syrup hascom- pleted coated said cereal.

12. A process according to any one of


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86.

GB1327473 - 8/22/1973

FOOD COMPOSITIONS COMPRISING AMINO ACID DERIVATIVES


Applicant(s): KYOWA HAKKO KOGYO KK (--)

IP Class 4 Digits: A23L; C07D; C07C

IP Class: A23L1/30; C07C101/24; C07C127/14; C07C129/12; C07D49/36

E Class: A23L1/305A; C07D233/54C2D5



Family: GB1327473

Equivalent: FR2056652; DE2038163

Abstract:


1327473 Insolubilising amino acids in foods KYOWA HAKKO KOGYO KK 6 Aug 1970 [7 Aug

1969 16 March 1970] 38023/70 Head- ings A2E and A2Q [Also in Division C2] A food composition comprises a foodstuff component e.g. rice and at least one water insoluble salt of a basic aminoacid said salt being derived from a C 12-18 alkyl ester of sulphuric acid, a C 12-18 fatty acid or a naphthal- enesulphonic acid. The composition may be prepared by direct incorporation of the salt in the foodstuff or by contacting a foodstuff containing the basic aminoacid or a water soluble salt thereof with the desired acid or with a sodium or potassium salt thereof. Basic aminoacids mentioned are lysine, arginine, ornithine, citrulline and hystidine and acids mentioned are lauryl-, stearyl- and palmitylsul- phuric acids and lauric, palmitic, stearic, 2, 6- and 1, 5-naphthalene-disulphonic and

[alpha]-naphthalene sulphonic acids.Description:


(54) FOOD COMPOSITIONSCOMPRISING AMINO

ACID DERIVATIVES

(71) We, KYOWA HAKKO KOGYO

KABUSHIKI KAISHA, a Japanese Body

Corporate of No. 6-1,1-Chome, Ohte-machi,

Chiyoda-ku, Tokyo-to, Japan, do hereby

declare the invention for which we pray that apatent may be- granted to us and the method

by which it is to be performed to be particu

larly described in and by the following statement:

The present invention relates to compositions

of water-insoluble basic amino acid derivatives

suitable for edible and pharmaceutical pur

poses.

Heretofore, basic amino acids, such as for

example lysine and arginine, have been widely

used in the form of their hydrochloric acid

salts for edible and pharmaceutical purposes.

449/2197

However, because of the fact that these hydro

chloride salts are highly water soluble, it is

difficult to incorporate them effectively into

foodstuffs since they tend to be extracted from

the foodstuffs during processing and cooking.

It has now been found that basic amino

acids such as lysine and arginine and their salts

can be rendered water-insoluble by contacting

them with various alkyl sulfuric acids, fatty

acids, naphthalenesulfonic acids or their cor

responding sodium and potassium salts to pro

vide water-insoluble addition salts. The salts

of the present invention retain the chemical and

physiological properties of the basic amino

acids from which they are derived.

According to one feature of the present in

vention there is provided a food composition

comprising a foodstuff component and at least

one salt of a basic alpha amino acid with a

C12-C18 alkyl ester of sulphuric acid, a

C12-C18 fatty acid or a naphthalenesulfonic

acid.

According to a further feature of the pre

sent invention there is provided a process for

the preparation of a food composition comprising a foodstuff component and at least one waterinsolubilised basic alpha amino acid which process comprises contacting a basic alpha amino acid or a water-soluble salt thereof with aC12-C1s alkyl ester of sulfuric acid, aC12--C,, fatty acid or a naphthalenesulfonic acid, or with a sodium or potassium salt of such an acid, and subsequently incorporating thewaterzinsolubilised basic alpha amino acid thus obtained into the said foodstuff component. Preferably at least an equivalent amount of the alkyl ester of sulfuric acid, fatty acid, naphthalenesulfonic acid or salt thereof is used.

According to a still further feature of the present invention there is provided a process for waterinsolubilizing the basic alpha amino acid content of a foodstuff containing a basic alpha amino acid which comprises contacting the foodstuff with an effective amount of aC12-C18 alkyl ester of sulfuric acid, aCl2C,8 fatty acid or a naphthalene-sulphonic acid or with a sodium or potassium salt of such an acid. The foodstuff may, for example, be rice.

It has been found that basic amino acids can be water insolubilized by contacting them, or an appropriate salt thereof, with an alkyl ester of sulfuric acid containing from 12 to

18 carbon atoms, a fatty acid containing from

12 to 18 carbon atoms, a naphthalenesulfonic acid or their corresponding potassium or sodium salts to provide an addition salt of the amino acid which is only very slightly water-soluble. Basic amino acids which may be used in the present invention are exemplified by such 'acids as lysine, arginine,ornithine, citrulline and histidine, which may, be either in the free form or in the form of salts such as hydrochlorides, acid phosphates, sulfates, nitrates, formates, acetates, propionates or butyrates.

The alkyl esters of sulfuric acid and the sodium and potassium salts thereof which can be used in the process of thepreset invention are those wherein the alkyl group contains from 12 to 18 carbon atoms.

The alkyl group can be either straight-chained or branched.

Particularly preferred compounds are lauryl sulfuric acid, stearyl sulfuric acid, palmityl sulfuric acid and their sodium and potassium salts. The fatty acids and sodium and potassium salts thereof which can be used in the present invention include those wherein the fatty acid or fatty acid ion contains from 12 to 18 carbon atoms. For example, lauric acid, palmitic acid, stearic acid and their sodium and potassium salts may be used. 2,6-Naphthalenedisulfonic acid, 1,5-naphthalenedisulfonic acid,a-

450/2197

naphthalenesulfonic acid and their sodium and potassium salts may be used as the naphthalenesulfonic acid or salt thereof.

The amount of the alkyl sulfuric acid, fatty acid naphthalenesulfonic acid or salt thereof which is added to the basic amino acid will vary, depending upon the type of foodstuff in which the addition salt is to be incorporated, but it is advantageously at least equivalent to the amount of the basic amino acid present

The higher alkyl esters of sulphuric acid, higher fatty acids, naphthalenesulfonic acids or their corresponding aforementioned salts are preferably dissolved in a suitable solvent such as water before being contacted with the basic amino acid.However, they may also be suspended in a water-containing organic solvent

It is also possible to add a basic amino acid to a foodstuff to which may then beadded the higher alkyl ester of sulfuric acid, higher fatty acid, naphthalenesulfonicwsid or a sodium or potassium salt thereof.

It has been shown that in this manner extraction or leaching of the amino acid from the foodstuff by water can be essentially eliminated.

It appears that a water-insoluble addition salt forms when the basic amino acid, or salt thereof, is contacted with the alkyl ester sulfuric acid, fatty acid,naphthalenesulfomc acid or sodium or potassium salt thereof.

These addition salts are relatively stable so that it is difficult to solubilize the amino acid by the double-decomposition which may occur in the presence of an inorganic salt. The physiological activity of the basic amino acid is still retained in the salt. This is evidenced by the fact that water-insoluble lysine salts prepared according to the process of the present invention react quantitatively with L-lysine decarboxylase.

The following Table, Table 1, shows the chemical and physical properties of the prow ducts obtained in the Examples which follow, and analogous methods to those described in the Examples.

TABLE 1

Elemental Analysis

Molecular

Compound Weight Calculated Found

Lysine lauryl sulfate 412.24 C 52.44% 51.89% (C18H4 0O6N2S1)

H 9.709.81

N 6.79 6.44

Lysine stearyl sulfate 496.30 C 58.07 58.00 (C24H52N206S3

H 10.47 10.36

N 5.64 5.58

Lysine palmityl sulfate 468.28 C 56.42 56.66 (C22H48N2O6S1)

H 10.25 10.30

N 5.97 5.33

Arginine lauryl sulfate 440.24 C 49.10 49.02 (C18H4 0N4O GS)

H 9.08 9.04

N 12.72 12.78

TABLE1 (Continued)

Elemental Analysis

Molecular


Arginine stearyl sulfate 524.30 C 54.97% 54.85%

(C24H52N4O6S)

H 9.91 9.95

N 10.68 10.70

Arginine palmityl sulfate 496.28 C 53.24 53.19

(C22H48N408S)

H 9.67 9.60

N 11.28 11.10

Citrulline lauryl sulfate 441.24 C 48.99 48.85

(C18H39N3O7s)

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H 8.83 8.92

N 9.51 9.62

Citrulline stearyl sulfate 525.30 C 54.87 54.90

(C24H51N307S)

H 9.70 9.65

N 7.99 8.10

Citrulline palmityl sulfate 497.28 C 53.17 53.31 (C22H47N3O7S)

H 9.45 9.33

N 8.44 8.64 Ornithine lauryl sulfate 398.23 C 51.26 51.18 (Cl,H38N206S)

H 9.54 9.61

N 7.03 7.15

Ornithine stearyl sulfate 482.29 C 57.27 57.15 (C23H5 0N2O6S)

H 10.36 10.40

N 5.80 5.91

Ornithine palmityl sulfate 454.27 C 55.51 55 41

(C2lH46N206S)

H 10.12 10.21

N 6.16 6.25

Histidine lauryl sulfate 421.24 C 51.31 51.25 (Cl8H3sN3o6S)

H 8.30 8.41

N 9.97 9.87

TABLE 1 (continued)

Elemental Analysis

Molecular


Histidine stearyl sulfate 505.30 C 57.04% 57.12% H 9.30 9.25

N 8.31 8.42

Histidine palmityl sulfate 477.28 C 55.35 55.40 >;RTI (C22H43N3O6S)

H 9.01 9.00

N 8.79 8.85Lysinelaurate 346.18 C 62.44 62.40

(C18H38N204)

H 10.97 10.89

N 8.08 8.00

Lysine stearate 430.53 C 66.95 66.90

(C24H50N2O4)

H 11.61 11.65

N 6.50 6.52

Lysine palmitate 402.22 C 65.69 65.59 (C22H46N2O4)

H 11.43 11.33

N 6.96 6.90Argininelaurate 374.18 C 57.77 57.67

(C18H38N4O4)

H 10.15 10.10

N 14.96 14.89

Arginine stearate 458.53 C 62.86 62.84 (C24H5 0N4O4)

H 10.90 10.95

N 12.21 12.26Argininepalmitate 430.22 C 61.41 61.39

(C22H46N404) H 10.69 10.56

N 13.01 13.00

Citrulline laurate 375.18 C 57.62 57.56

(C18H37N3O5)

H 9.86 9.89

N 11.19 11.25

TABLE 1 (continued)

Elemental Analysis

Molecular


Citrulline stearate 459.53 C 62.72% 62.80% (C24H40N3O5)

H 10.66 10.59

N 9.13 9.25

452/2197

Citrulline palmitate 431.22 C 61.27 61.20 (C22H45N3O5)

H 10.43 10.36

N 9.73 9.78 Ornithinelaurate 332.17 C 61.46 61.40

(C17H36N204)

H 10.83 10.75

N 8.42 8.55

Ornithine stearate 416.52 C 66.31 66.11 (C23H48N2O4)

H 11.52 11.61

N 6.72 6.90 Ornithinepalmitate 388.21 C 64.96 64.92 (C21H44N2O4)

H 11.33 11.42

N 7.21 7.31 Histidinelaurate 355.18 C 60.86 60.75

(C18H33N3O4)

H 9.29 9.31

N 11.82 11.89 Histidinestearate 439.53 C 65.57 65.49 (C24H45N3o4)

H 10.23 10.25

N 9.55 9.65 H 9.97 9.87

N 10.21 10.30

Dilysine-2,6- 580.34 C 45.52 45.50

naphthalenedisulfonate

(C22H36N4O10S2) H 6.20 6.15

N 9.64 9.62

TABLE 1 (continued)

Elemental Analysis

Molecular


Dilysine-1,5- 580.34 C 45.52% 45.52%


(C22H36N4OloS2) H 6.20 6.12

N 9.64 9.60Lysine- - 354.22 C 54.24 54.20

naphthalenesulfonate

(Cl6H22N205S) H 6.21 6.19

N 7.90 7.90

Diarginine-2,6- 636.34 C 41.52 41.46


(C22H36N8O10S2) H 5.65 5.45

N 17.65 17.68

Diarginine-1,5- 636.34 C 41.52 41.31


(C22H36N8OloS2) H 5.65 5.74

N 17.65 17.81Arginine-x- 382.22 C 50.27 50.25 naphthalenesulfonate

(C16H22N4O5S1) H 5.75 5.65

N 14.65 14.74

Dicitrulline-2,6- 638.34 C 41.39 41.25


(C22H34N6Ol2S2) H 5.32 5.45

N 13.15 13.21

Dicitrulline-1,5- 638.34 C 41.39 41.19

naphthalenedisulfonate (C22H34N6Ol2S2) H 5.32 5.45

N 13.15 13.29 Citrulline-a- 558.28 C 47.32 47.21 naphthalenesuffonate

(C22H34N6O9S1) H 6.09 6.20

N 15.04 15.04

Diornithine-2,6- 552.32 C 43.48 43.45


(C20H32N4O10S2) H 5.79 5.85

N 10.13 10.05

Diornithine-1,5- 552.32 C 43.48 43.25


(C20H32N4O1082) H 5.79 5.81

N 10.13 10.30

453/2197

TABLE 1 (continued)

Elemental Analysis

Molecular

Compound Weight Calculated Found naphthalenesulfonate

>;RTI (C15H20N2O5S1) H 5.87 5.92

N 8.23 8.40Dihistidine-2,6- 598.34 C 44.15 44.10


(C22H26N6O10S2) H 4.34 4.23

N 14.03 14.21

Dihistidine-1,5- 598.34 C 44.15 44.22


(C22H26N6OloS2) H 4.34 4.25

N 14.03 14.15-Histidine-x- 363.22 C 52.90 52.85 naphthalenesulfonate

(Cl6Hl,N305Sl) H 4.68 4.71

N 11.56 11.61

The following non-limiting examples further illustrate the preparation of water-insolubilised basic alpha amino acids:

Example 1.

55 g. (0.3 mol.) of L-lysine hydrochloride was dissolved in water (150 ml.). Separately, 103 g. (0.3 mol.) of sodium palmityl sulfate was dissolved in water (500 ml.). Both solutions were gradually combined with each other and stirred. After 2-3 hoursa white precipitate began to appear and the precipitation was completed after keeping the mixture in a cold roomovernight. The precipitates were separated by filtration and were dried to give the waterinsoluble product (Product I). Its characteristics were compared with those of lysine hydro chloride. The data is given in Table 2.

As can be seen, although the solubility of

Product I is only about 1/200 of that of Llysine hydrochloride, its reactivity is the same towards Llysine-decarboxylase.

TABLE 2

Solubility Reactivity with

Sample in waterL-lysine-decarbo:cylase

L-lysine hydrochloride 40.0 (w/w%) 98%

Product I 0.2(w/w%) 98%

Example 2.

63 g.(0.3 mol.) of arginine hydrochloride was dissolved in water (100 ml.), to which a solution

(150ml.) containing 89 g. (0.3 mol.) of sodium lauryl sulfate was gradually added with stirring. The precipitate which formed was separated by filtration and dried to give a product designated as Product

II. Its solubility characteristics are compared with L-arginine hydrochloride in Table 3.

Table 3.

Sample Solubility in Water

L-arginine hydrochloride 52(W/W%)

Product II 1.0(W/W%)

Example 3.

Unpolished rice grain or unhulled rice grain was soaked in water, steamed for 20 min., cooled, dried and polished. The treated rice grain (1 Kg.) was soaked in30% lysine hydrochloride aqueous solution

(1 liter). After about 10 hours, the solution was completely absorbed into the treated ricegrailL The treated rice grain was dried and subjected to a gradual adsorbing of 30% sodium laurylsulfate (300 ml.), and then dried to give a pro duct which contained2Y% lysine as thehydro chloride. After soaking this rice product in water for 1 hour less than5% of the lysine had been extracted from the product

Example 4.

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73 g. of free lysine was dissolved in water (100 ml.). Separately, 125 g. of palmitic acid was dissolved in ethanol (250 ml.). A white precipitate began to appear immediately after the solutions were combined with each other.

The precipitate was separated by filtration to give Product III. The solubility of Product III in water

(250C) was found to be about 1/1800 of that of lysine hydrochloride, as shown in Table 4.

Table 4.


Lysine hydrochloride 45.92(W/W!%)

Product III 0.06(W/W%)

Example 5.

87 g. of free arginine was dissolved in water (20 ml.) and 10 g. of lauric acid was dissolved separately in ethanol (20 ml.). The two solutions were combined to give aprecipitate. The precipitate was separated by filtration to give the Product IV. Its solubility characteristics in water (250 C) are compared with free arginine in Table 5.

Table 5.


Free arginine 17.05(W/W%)

Product IV 0.35(W/W%)

Example 6.

25 g. ofsodium 2,6-naphthalenedisulfonate was dissolved in hot water (300 ml.) and was treated with a strong acidic cation exchange resin to give the free form. The solution was neutralized in free lysine and was then concentrated to give the Product V. The amount of the Product V obtained was 20 g. and its solubility in water (250 C.) is shown in Table 6.

Table 6.


Lysine hydrochloride 45.92kW/W%)

Product V 25.7(W/v%)

Example 7.

22 g. of free lysine was dissolved in water (50 ml.), to which an ethanolic solution (50 ml.) containing palmitic acid (13 g.) was added with shaking. The solution was then neutralized in 2,6naphthalenedisulfonic acid solution which was prepared in such a way that 20 g. of 2,6naphthalenedisulfonic acid disodium salt was pre-treated by strong acidic cation exchange resin to give the free form and was concentrated at a concentration of about2050!%. After several hours, filtration and washing were carried out to give the Product

VI. Its solubility is shown in Table 7.

Table 7.


Lysine hydrochloride 45.92(W/v%) Product VI 0.3 (W/W%)

Example 8.

63 g. (0.3 mol.) of L-lysine nitrate was dissolved in water (200 ml.). Separately, 103 g.

(0.3 mol) of sodium palmityl sulfate was dissolved in water (500ml.) by heating. Thesolo. tions were combined with each other and stirred. The combined solution was kept at room temperature overnight to give a precipitate.

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The precipitate was separated by filtration and dried to give a product designated as Product

VII (111 g.). Its solubility is shown in Table 8.

Table 8.


L-lysine nitrate44.50(W/W0/0)

Product VII 0.3(W/W%)

Example 9.

47 g. (0.2 mol.) of L- arginine acetate was dissolved in water (150 ml.), to which solution (100 ml.) containing 58 g. (0.2 mol.) of sodium lauryl sulfate was gradually added with stirring to give the

Product VIII (70 g.). Its solubility is shown in Table9.

Table 9.


L-arginine acetate50.94 (W/WI%)

Product VIII 1.0(W/W,%)

WHAT WE CLAIM IS:

1. A food composition comprising a foodstuff component and at least one salt of a basic alpha amino add with aC12-C1a alkyl ester of sulphuric acid, aC12-C18 fatty acid or a naphthalenesulfonic acid.

2. A food composition comprising a foodstuff component and at least one salt of a basic alpha amino acid with aC,2-C18 alkyl ester of sulphuric acid.

3. A food composition comprising a foodstuff component and at least one salt of a basic alpha- amino acid with aC12-C,8 fatty acid or a naphthalenesulfonic acid.

4. A food composition as claimed in claim 2 wherein theC12-C18 alkyl ester of sulphuric acid comprises lauryl sulfate, stearyl sulfate or palmityl sulfate.

5. A food composition as claimed in claim 3 wherein theC,2C1g fatty acid comprises lauric, stearic or palmitic acid.

6. A food composition as claimed in claim 3 wherein the naphthalenesulfonicacid comprises 2,6 - naphthalenedisulfonic acid, 1,5naphthalenedisulfonic acid or,-naphthalene- sulfuric acid.

7. A food composition as claimed in claim 1 wherein the basic alpha amino acid comprises lysine, arginine, citrulline, ornithine or histidine.

8. A food composition as claimed in claim 2 wherein the basic alpha amino acid comprises lysine, arginine, citrulline,ornithine or histidine.

9. A food composition as claimed in claim 3 wherein the basic alpha amino acid comprises lysine, arginine, citrulline,omithine or histidine.

10. A process for the preparation of a food composition comprising a foodstuff component and at least one water-insolubilised basic alpha amino acid which process comprises contacting a basic alpha amino acid or a water-soluble salt thereof with aC12-C13 alkyl ester of sulphuric add, aC12-C18 fatty acid or a naphthalenesulfonic acid or with a sodium or potassium salt of such an acid, and subsequently incorporating the water-insolubilised basic alpha amino acid thus obtained into the said foodstuff component.

11. A process for the preparation of a food composition comprising a foodstuff component and at least one water-insolubilised basic alpha amino acid which process comprises contacting a basic alpha amino acid or a water-soluble salt thereof with aC12C18 alkyl ester of sulphuric acid or with a sodium or potassium salt of such an acid, and subsequently incorporating the water-insolubilised basic alpha amino acid thus obtained into the said foodstuff component.

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12. A process for the preparation of a food composition comprising a foodstuff component and at least onewatervinsolubilised basic alpha amino acid which process comprises contacting a basic alpha amino acid or a water-soluble salt thereof with ac12-C18 fatty acid ora naphthalenesulfonic acid or with a sodium or potassium salt of such an acid, and subsequently incorporating the water-insolubilised basic alpha amino acid thus obtained into the said foodstuff component.

13. A process as claimed in claim 10 wherein the basic alpha amino acid is contacted with at least an equivalent amount of aC12Cls alkyl ester of sulphuric acid, aC12-C18 fatty acid or a naphthalenesulfonic acid, or of a sodium or potassium salt of such an acid.

14. A process as claimed in claim 11 wherein the basic alpha amino acid is contacted with at least an equivalent amount of aC12-C18 alkyl ester of sulphuric acid, or of a sodium or potassium salt of such an acid.

15. A process as claimed in claim 12 wherein the basic alpha amino acid is contacted with atleast an equivalent amount of aC12-C,8 fatty acid or a naphthalenesulfonic acid, or of a sodium or potassium salt of such an acid.

16. A process as claimed in claim 10 or 13 wherein the basic alpha amino add is in the form of its hydrochloride, acid phosphate, sulphate, nitrate, formate, acetate, propionate or butyrate salt

17. A process as claimed in claim 11 or 14 wherein the basic alpha amino acid is in the form of its hydrochloride or acid phosphate.

18. A process as claimed in claim 12 or 15 wherein the basic alpha amino acid is in the form of its hydrochloride or acid phosphate.

19. A process as claimed in any of claims 10, 13 or 16 wherein the basic alpha amino acid is lysine, arginine, citrulline, ornithine or histidine.

20. A process as claimed in any of claims 11, 14 or 17 wherein the basic alpha amino acid is lysine, arginine, citrulline,,omithine or histidine.

21. A process as claimed in any of claims 12, 15 or 24 wherein the basic alpha amino acid is lysine, arginine,citrolline, ornithine or histidine.

22. A process for water-insolubilizing the basic alpha amino acid content of a foodstuff containing a basic alpha amino acid which comprises contacting the said foodstuff with an effective amount of aC12-C18 alkyl ester of sulphuric acid, aC,2-C13 fatty acid or a naphthalenesulfonic acid, or with a sodium or potassium salt of such an acid.

23. A process for water-insolubilizing the basic alpha amino add content of a foodstuff


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87.

GB1327528 - 8/22/1973

FLAVOURED FOODSTUFFS AND THEIR PRODUCTION


Applicant(s): INT FLABORS FRAGRANCES INC (--)


IP Class: A23L1/10; A23L1/16; A23L1/26

E Class: A23L1/182B; A23L1/22B2



Family: GB1327528


Abstract:


1327528 Flavoured grain product INTER- NATIONAL FLAVORS & FRAGRANCES INC 27 Sept

1971 [16 Oct 1970] 44934/71 Heading A2B In a particulate grain product, in particular rice, at least some of the particles are coated with a mixture of a flavouring agent and an edible, cold-waterinsoluble film-forming resin. Grain products include rice, corn, buckwheat, and barley, homing grits, farina, broken or fragmented grains, or grain based discrete particulate products such as noodles.

Suitable resins include shellac, prolamines, and ethyl cellulose. The coating may be applied as a composition comprising the resin and flavouring in a solvent or dispersant such as ethanol or propylene glycol, and may additionally include other ingredients such as stabilisers, thickeners, surface active agents, conditioners, and flavour intensifiers.Description:



NO DRAWINGS ( 21) Application No, 44934/71 ( 22) Filed 27 Sept 1971 ( 31) Convention

Application No 81623 ( 32) Filed 16 Oct 1970 in ( 33) United States of America (US) ( 44) Complete

Specification published 22 Aug 1973 ( 51) International Classification A 23 L 1/101/26 1/16 ( 52)

Index at acceptance A 2 B 1 B 6 A 6 G ( 72) Inventors CARMINE DONNARUMMA, HARVEY

FARBER CHARLES H GRIMM, SIMPEY KURAMOTO DON MARMO and HERBERT S STEIN (

11) 1327528 ( 19) ( 54) FLAVOURED FOODSTUFFS AND THEIR PRODUCTION ( 71) We,

INTERNATIONAL FLAVORS & FRAGRANCES INC, a corporation organised and existing under the laws of the State of New York, United States of America, having an office at 521 West 57th Street,

New York, New York, United States of America, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement:-

The present invention relates to processes for altering the flavors of particulate edible materials and to the products obtained according to such processes.

Many grain products have a bland or unwanted flavor due to prior processing, the particular strain of grain used, or for other reasons Moreover, there are also local preference factors involved, and these

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can limit the market for a foodstuff, even though the foodstuff is equally, or even more, nutritious or is superior in other ways.

An instance of this has occurred in connection with the recently developed "miracle rice" These new rice strains are superior in yield and speed of growth, but to some people the flavor is not as acceptable as the flavor of older, traditional forms of rice.

Moreover, in countries such as Indonesia a more highly flavored rice, variously known as "radjalele",

"tjiandjur", "festive rice" or simply "number one rice", is prized Its relatively high cost limits its use to ceremonial or gala occasions, and "miracle rice" is considered to be far inferior to radjalele.

Attempts have been made to add flavoring materials to rice These attempts have involved adding flavor directly to the rice by a number of methods, but a successful product has not been obtained

Many peoples wash the rice prior to cooking, and the washing is continued until the wash water runs clear so that all starch and surface materials are removed T is thereafter steamed and/or cooked It has been found in the past that such washing and cooking remove any flavoring agents which have been added to the rice.

Rice has been enriched by entrapping vitamins and minerals in a coating and then whitening the resulting off-colored product, as shown for example in U S Patent 2,712,499, but no satisfactory method of flavoring rice or kindred products has been known in which flavoring is adhered or otherwise adsorbed on or bonded to the grain so that flavor release will occur during steaming, boiling, or otherwise cooking the grain so that the aroma is sensed during cooking and so that the flavor is sensed during ingestion of the grain.

This invention now provides a particulate grain product especially rice, at least some of the discrete particles of which are coated with a mixture of a flavoring composition and an edible, cold-waterinsoluble, film-forming resin.

The particulate grain product of the invention can be produced by applying a coating composition containing the flavoring composition, the resin and a solvent or dispersing agent for the resin to the particles of the grain product, and drying the coating composition on the surface of the particles The coated grain product thus produced can either be regarded as a finished product and cooked and consumed as such, or be mixed in a minor proportion with a major proportion of uncoated particles of the grain product to produce the finished product; in the latter instance, the coated grain product first produced is referred to herein as a pre-mix.

As used herein, "particulate grain products" is taken to include the grain particles themselves such as rice, corn, buckwheat and barley, as well as particulate products obtained from grains, such as hominy grits and farina It will be understood that the grain products can also include broken or 1,327,5283 fragmented grains or grain-based discrete particulate products such as noodles like "Ramon" noodles

Certain preferred aspects of the invention are particularly concerned with rice The rice treated according to the processes disclosed herein includes conventional long and short-grain rices, as well as the new "miracle rice" It will be understood by those skilled in the art that a number of different miracle rices, such as IR-5, IR-20 and so on are available, and all can be treated according to the present invention.

The film-formers utilized in the, described processes are edible and cold water-insoluble.

It is also desirable that they be tasteless As used herein, insolubility in cold (less than I 00 F) water means that the film-former can withstand substantial periods of immersion and abrasion during washing Moreover, the film-former should permit hot water or steam penetration and the gelatinization of starch during cooking.

As noted, the film-former should also be edible, that is, capable of being ingested in ordinary amounts without causing gastrointestinal or other disturbances in the metabolism Desirably, the film-forming materials used are those formally approved by governmental or other public health officials, and it is preferred that they be generally recognized as safe.

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A film-former is a material capable of forming an adherent film on the particulate material The film so formed is preferably relatively thin, and while the film should cover a substantial portion of the surface of the particle, it need not be a completely continuous integument, nor need it be free from minor imperfections such as pinholes.

The film-former should also be capable of being dissolved or at least highly dispersed in a vehicle, preferably one which is a solvent.

The vehicle or solvent is desirably non-toxic and approved for food use, and the filmformer must accordingly be soluble or highly dispersible in the liquid, such liquids being referred to hereinafter simply as solvents.

Examples of solvents are ethanol and propylene glycol, and ethanol is especially preferred since it appears to have a protective effect on the flavoring composition in many embodiments of the invention.

The coating of film-former and flavoring composition formed on or around the particulate grain product should be capable of liberating the flavor so that it can be sensed when the grain product is ingested The liberation of the flavor can be achieved by controlling the solubility or the frangibility of the filmformer to permit disintegration or rupture of at least part of the coating upon cooking and/ or eating Thus, for example a resin which is cold water insoluble but hot-water soluble would permit the flavor to be retained on the rice during repeated washings; however, it would liberate the aroma and/or flavor on cooking A frangible film-former is one which would be ruptured or broken to release the flavor, for example, upon swelling of the grain product during cooking Thus, the film-former should be

"flavor-liberable" as by being disintegratable, frangible, or hot water-soluble.

Accordingly, preferred film-formers include pharmaceutical glaze (shellac), prolamines, and ethyl cellulose The prolamines are fractions of certain naturally-occurring proteins.

Thus, zein from corn, gliadin from wheat, and similar prolamines can be used When shellac is used it should be of pharmaceutical or food grade quality.

Flavoring composition as used herein means one which alters the flavor of the foodstuff by supplementing or fortifying a natural or artificial flavor in the foodstuff or one which supplies substantially all the flavor and/or aroma character to the foodstuff The term "alter" in its various forms will accordingly be understood to mean the supplying or imnarting of a flavor character or note to an otherwvise bland or tasteless grain product, or augmenting an existing flavor characteristic where the natural flavor is deficient in some regard, or supplementing the existing flavor impression to modify the organoleptic character of the grain product.

Flavoring compositions for use herein can include flavor materials, vehicles, stabilizers, thickeners, surface active agents, conditioners, and flavor intensifiers.

Flavoring materials include saturated and unsaturated alcohols, including primary and secondary alcohols; esters; carbonyl compounds including ketones and aldehydes; lactones; other cyclic organic materials includ 105 ing benzene derivatives, alicyclics, heterocvclics such as furans, pyridines and pyrazines; sulfur-containing materials including thiols, sulfides and disulfides; proteins, amin, acids; lipids; carbohydrates; so-called flavor 110 potentiators such as monosodium glutamate) guanylates, and inosinates; natural flavoring materials such as cocoa, vanilla, and caramel, essential oils and extracts such as anise oil and clove oil, and artificial flavoring materials 115 such as vanillin Stabilizers include preservatives such as sodium chloride, antioxidants such as calcium and sodium ascorbate, ascorbic acid, butylated hydroxyanisole, butylated hydroxytolu 120 ene and propyl gallate, sequestrants such as citric acid, EDTA and phosphates.

Thickeners include carriers, binders, protective colloids, suspending agents and emulsifiers, such as agar-agar, carrageenan, cellu 125 lose and cellulose derivatives such as carboxymethyl cellulose and methyl cellulose, natural and synthetic gum such as gum arabic and gum tragacanth, and other pro1,327,528 teinaceous materials, lipids, carbohydrates, starches, and pectins.

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Surface active agents include materials such as mono and/or diglycerides of fatty acids such as capric acid, caprylic acid, palmitic acid, myristic acid, stearic acid, and oleic acid, lecithin, defoaming and flavor-dispersing agents such as sorbitan monostearate, potassium stearate, hydrogenated tallow alcohol.

Conditioners include compounds such as buffers and neutralizing agents such as sodium acetate, ammonium bicarbonate, ammonium phosphate, citric acid, lactic acid, and vinegar; colorants such as carminic acid, cochineal, tumeric and curcumin; and enzymes Vehicles, in the flavor composition, can be edible or otherwise suitable materials such as ethyl alcohol, propylene glycol and water.

It has been found that many grain products are particularly amenable to the addition of carbonyl flavoring materials such as diacetyl, acetylpropionyl and dipropionyl.

Accordingly, in certain preferred embodiments such carbonyl compounds are present in the flavor composition or in the solution with the film-former and solvent, desirably in amounts of 0 01 to 1 5 percent of the solution (Throughout this Specification, parts, percentages, proportions and ratios are by weight unless otherwise stated).

The flavoring compositions used in connexion with the present invention generally contain from about 80 to 95 percent vehicle.

The amount of flavoring agent added to the grain product can vary over a wide range, and the amount used depends upon a number of factors including the flavoring level or intensity desired, the particular flavoring materials and adjuvants used, the grain product employed, local preference factors, whether or not the flavor is to be added as a pre-mix or to all of the particulate grain product.

In flavoring rice for use as a pre-mix, it has been found that at least about two ounces of flavoring composition (based upon a flavoring composition containing from 85-95 percent of a vehicle or carrier) for each ton of particulate grain product is preferably used to obtain suitable flavoring, and amounts on the order of four ounces of such flavoring per ton are most preferred Generally amounts in excess of ten ounces per ton of such composition are not recommended.

When a pre-mix is not used and the entire quantity of particulate grain product is coated, larger volumes of flavoring composition are utilized Thus, in one aspect of the present invention, from one to two thousand ounces of a flavoring composition containing from 99 to 99 75 percent vehicle or carrier would be used for each ton of rice.

Generally the coating composition will contain 70-99 % of solvent or dispersing vehicle, and from 1 to 30 % of film-forming resin The coating composition for spraying onto the entire mass of particulate grain product desirably contains from 0 2 to 1 0 % of the flavoring composition Coating composition for application to particulate grain product when the product is used as a pre-mix desirably contains from five to twenty percent of the flavoring composition and from about one to about thirty percent of film-former.

The coating composition can be applied to the particulate grain product by a variety of conventional techniques The composition can be sprayed onto the particles by air, hydraulic, or electrostatic gun methods, in a tower or by means of fluidized bed techniques.

One of the easier methods for smaller scale production is to tumble the particles in a rotating cylinder or drum such as a coating pan or coating machine and to spray the required quantity of the composition on to granules as they are kept in motion to expose the surfaces of all the particles.

Anti-agglomeration appliances are desirably utilized if the tumbled particulate solids tend to adhere to one another through the action of the resin in the coating composition Thus, when the particles are coated while they are tumbled in a coating pan, a counter-rotating bar and/or inert spheres such as porcelain balls can be used When spheres are used in a coating pan to prevent agglomeration and sticking, the thickness of the coat can readily be judged by reference to the coating obtained on the spheres.

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After the coating-composition has been applied to the surfaces of the particles, the coating is then dried Pre-mix is used herein to mean coated particles which can, in turn, be admixed with and thoroughly interspersed through a larger mass of particulate grain product The pre-mix can comprise a single grain product or a plurality of grain products, and the pre-mix can be interspersed through grain products which are the same or different It is preferred in certain embodiments that the pre-mix and the final product comprise the same grain products Thus, a rice pre-mix would be used for flavoring a rice product.

The pre-mix is interspersed in minor quantity through a major quantity of unflavored grain products

In certain embodiments, it has been found that the pre-mix should comprise from about one to about ten percent of the total finished product, and preferably the pre-mix comprises from two to four percent of the total product.

It is important that the pre-mix be substantially uniformly interspersed throughout the final product

Conventional equipment can be used to carry out this process step.

The method used should not injure the coating on the grain, and any tendency greatly to increase the fines is usuallv suppressed.

Thus, baffled and unbaffled drum mixers, 1,327,528 baffled and unbaffled double-cone mixers and twin-shell mixers can be used, as can continuous flow systems which meter appropriate quantities of the pre-mix into the larger mass.

The pre-mix product so produced comprises discrete particulate grain products having a coating or film of the flavored final product in a mass of discrete grain product particles having dispersed therethrough a quantity of the pre-mix as set forth herein.

While it will be appreciated by those skilled in the art that the entire mass can be treated with coating composition as herein described, in certain preferred aspects of the present invention the use of a premix simplifies the application of coating to the particulate grain product by reducing the quantity of solvent required, reducing the amount of particulate grain product which must be dried, and so on.

The following examples are given to illustrate embodiments of the invention as it is presently preferred to practice it It will be understood that these examples are illustrative, and the invention is not to be considered as restricted thereto except as indicated in the appended claims.

EXAMPLE I

An Indonesian rice flavor is prepared by admixing the following ingredients:

Ingredient Vanillin Valeric acid gamma-Undecalactone Acetylpropionyl Oil celery seed

Benzodihydropyrone Maltol Butyric acid Diacetyl Alcohol 95 %O Amount (parts) 0.5 0.5 0.5 1.0 1.0

1.5 1.5 2.5 4.0 87.0 0 The flavoring composition so prepared is then admixed with a 28 % solids pharmaceutical glaze in the ratio of 15 parts of the composition to 85 parts of glaze.

Two hundred grams of IR-20 rice is introduced into a coating pan, and four one-inch diameter porcelain spheres are added to obviate sticking and agglomeration of the rice.

The rice is then tumbled in the pan and 20 g of the flavoring composition-glaze mixture so prepared is sprayed in the form of a fine mist onto the rice A stream of hot air is directed onto the rice in the coating pan to facilitate drying.

This coated rice is then utilized as a premix for blending with a much larger quantity of rice to be flavored In this instance, 2 kg.

of IR-20 rice is admixed with 60 g of the pre-mix in a solids blender The finished rice product is then ready for cooking and consumption.

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One-half a kilogram of the finished rice 65 product so prepared is washed with cold water and flushed until the water runs clear.

After the rice is washed, it is placed into a rice cooker comprising an inner imperforate bowl and a slightly larger outer bowl fitted 70 with a cover The rice is placed into the inner bowl, and at this time it is noted that the rice has an odor like that of radialele A small quantity of water is placed in the outer bowl, the inner bowl is put into it, and 75 the cover is placed on the outer bowl The cooker is heated for fifteen minutes to steam the rice, and the steamed rice is then held in the cooker for an additional fifteen minutes.

After the cooking, the rice is eaten and is 80 found to have an excellent flavor and aroma.

The panelists all state that the rice is comparable to "number one", "festive", or radjalele rice, and some feel it is actually a superior product The rice texture and con 85 sistency are in no way impaired by the process set forth in this Example Similarly prepared IR-20 rice without the pre-mix of the foregoing Example is judged to be bland and relatively tasteless 90 EXAMPLE II

A solution is prepared by admixing 2 5 g of Hercules Type N-22 ethyl cellulose with 97.5 g of 95 % ethanol, and 15 g of the rice flavor of Example I is added to 85 g of 95 the solution.

Twenty grams of the flavored solution is then sprayed onto 200 g of IR-5 rice while the rice is tumbled in a coating pan containing four porcelain spheres to prevent 100 agglomeration and sticking of the rice grains.

After the solution has been sprayed on the rice, drying is accelerated by passing a stream of heated air over the sprayed rice.

The drying time required for the rice 105 coated with ethyl cellulose-containing mixture is much shorter than for the pharmaceutical glaze of Example I, and there is less of a tendency for the rice granules to stick or agglomerate 110 The dried rice ( 20 g) is then thoroughly mixed with 2 kg of IR-5 rice in a dry blender When the rice is cooked, according to the procedure of Example I it is found to have an excellent flavor which is compar 115 able to radjalele.

EXAMPLE III

The procedure of Example II is repeated, and the resulting pre-mix in the amount of g is added to 2 kg of IR-5 rice When 120 the rice is washed and cooked as set forth in Example I, it is found to have an excellent very intense flavor comparable to radjalele.

-A 1,327,528 EXAMPLE IV

An imitation sweet corn flavor is prepared by admixing the following ingredients:

Ingredient cis-3-Hexenol Heliotropine gamma-Nonalactone gamma-Octalactone Vanillin Butyl butyryl lactate Diacetyl Alcohol 95 % Amount (parts) 0.1 0.5 0.5 1.5 1.9 2.0 3.0 90.5 0 Twelve grams of the foregoing mixture is admixed with 88 g of a solution of 2 5 g of ethyl cellulose in 97 5 g of ethanol.

Hominy grits in the amount of 200 g are placed into the coating pan as in Example II 20 g of the flavoring composition-ethyl cellulose is sprayed on, and the sprayed grits are dried as in Example II to provide a premix.

The pre-mix prepared above is added to kg of grits and thoroughly blended in a Patterson-Kelley dry mixer A 250 g portion of the grits is then prepared and cooked conventionally The cooked grits are judged to have an excellent corn flavor.

EXAMPLE V

A barbecue spice flavor is prepared by admixing the following ingredients:

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Ingredient Oil garlic Oil coriander Oil mustard seed Oil carrot seed Oil sage Dalmation Oil parsley seed Oil black pepper Oleoresin capsicum Oil celery seed Alcohol, 95 % Amount (parts) 0.1 0.2 0.2

0.3 0.3 0.5 0.5 1.5 2.5 93.9 0 The foregoing flavor composition is mixed with an ethanolic solution of pharmaceutical glaze, sprayed onto rice, and dried to form a pre-mix as in Example I.

The pre-mix is then thoroughly blended with untreated rice as in Example I When the rice is washed and cooked as in Example I, the rice has a pleasant barbecue taste A meat flavor can also be added further to vary the flavor and to provide a very satisfying product.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS:-

1 A particulate grain product, at least some of the discrete particles of which are coated with a mixture of a flavouring composition and an edible, cold-water-insoluble, film-forming resin.

2 The product of claim 1 in which the particles are rice.

3 The product of claim 2 in which the rice is miracle rice.

4 The product of claim 1, 2 or 3 in which the resin is shellac, a prolamine, or ethyl cellulose.

The product of any preceding claim in which the flavouring composition comprises a carbonyl compound.

6 The product of claim 5 in which the carbonyl compound is diacetyl or acetylpropiony I.

7 The product of any preceding claim comprising, as well as a minor proportion of the said coated particles, a major proportion of discrete particles which are not coated with the said mixture.

8 The product of claim 1 substantially as hereinbefore described, or as illustrated in any of the

Examples.

9 A process for the production of a particulate grain product of any of claims 1 to 6 and 8, comprising applying a coating composition comprising the flavouring composition, the resin, and a solvent or dispersing vehicle for the resin, to the particles of the grain product, and drying the coating composition on the surface of the particles.

The process of claim 9 in which the coating composition contains 0 2 to 1 % of a flavouring composition containing 99 to 99.75 % of a vehicle or carrier.

11 A process for the production of a particulate grain product of claim 7, comprising applying a coating composition comprising the flavouring composition, the resin, and a solvent or vehicle for the resin to the particles of the grain product, drying the coating composition on the surface of the particles, and mixing a minor proportion of the said particles with a major proportion of particles not coated with the said cornposition.

12 The process of claim 11 in which the coating composition contains 5-20 % of the flavouring composition containing from 85% of a vehicle or carrier.

13 The process of any of claims 9 to 14 in which the solvent or vehicle is ethanol.

14 The process of any of claims 9 to 13 in which the coating composition contains 70-99 % of solvent or dispersing vehicle.

The process of any of claims 9 to 14 for producing a product of claim 5, in which the coating composition contains 0 01 to 1.5 % of the carbonyl compound.

464/2197

16 The process of any of claims 9 to 15 in which the coating composition contains 1-30 % resin.

17 A process for the production of the i 6 1,327-528 X particulate grain product of claim I substantially as hereinbefore described in any of For the Applicants, the Examples CARPMAELS &

RANSFORD, 18 The particulate grain product of claim Chartered Patent Agents, 1 whenever produced by a process of any of 24, Southampton Buildings, Chancery Lane, claims 9-17 London, WC 2 A 1

AZ.

Printed for Her Majesty's Stationery Office, by the Courier Press, Leamington Spa, 19 ' 3 Published by The Patent Office, 25 Southampton Buildings, London, WC 2 A 1 AY, fromn which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

465/2197

88.

GB1339087 - 11/28/1973

RICE SNACK PRODUCT


Applicant(s): NESTLE SA (--)


IP Class: A23L1/10

E Class: A23L1/164E


Priority Number: CH19710005639 (19710419)

Family: GB1339087

NL7205259; FR2133675; ES401859; DE2216881; CH530172; BE781576; Equivalent:

SE386574

Abstract:


1339087 Snack products NESTLE SA 4 April 1972 [19 April 1971] 15300/72 Heading A2B An intermediate which may be deep fried to give a crisp snack is in the form of shaped pieces comprising at least 70wt% gelatinised rice, 0-10wt% cold swelling starch, 7-15wt% colour and flavour, and 0-

15wt% water, the rice having been gelatinised after shaping. The snack derived therefrom may comprise 25- 40wt% fat, 50-75wt% gelatinised rice flour, 0-10% flavour and colour, and have a density of 50-90 gm/l. The intermediate may be prepared by forming a dry mix into a dough, shaping into pieces, heating to gelatinise the starch whilst maintaining the water content at above 27wt%, and drying to below 15wt% water.Description:


(54) RICE SNACK PRODUCT

(71) We, NESTLE S.A., of La Tourde-Peilz, Switzerland, a Swiss company, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention is concerned with the production of a crisp snack product from rice.

The product may be in the form of pieces having various shapes such as tubes, shells, gnocchis and twists and such pieces are generally flavoured by addition of spices or flavouring compositions and may also be coloured.

Moreover, the product is puffed by deep-frying and thus has a very light crisp texture.

Such snack items are normally prepared from starchy materials such as potato, but it has been found that rice flour provides an excellent base for the preparation of snack products having a desirable light, crisp texture.

According to the invention, a process for preparing a snack product or an intermediate therefor comprises forming a dough from a dry mix comprising at least 70% by weight of rice flour, and water, shaping the dough into separate pieces, subjecting the shaped dough pieces to a heat treatment to gelatinise the starch present, the water content of the dough pieces during the gelatinisation treatment

466/2197

being maintained above 27% by weight, drying the gelatinised pieces to a water content below15% by weight to form an intermediate for preparing a snack product and optionally deep-frying the dried pieces to form the snack product.

It should be noted that the deep-frying need not be carried out immediately after drying, as the dried pieces are per se a stable intermediate product that may be stored, although, of course, the product is fried prior to consumption. The intermediate product according to the invention is in the form of shaped pieces comprising at least 70% by weight gelatinised rice, 0 to 10% by weight cold swelling starch, 7 to 15% by weight of flavourings and/or colourings and 0 to15% by weight of water, the rice having been gelatinised after shaping.

The invention also provides a crisp snack product, in the form of pieces puffed by deep frying, containing 25 to40 ,b by weight of fat, 50 to75In, by weight of gelatinised rice and 0 to 10% by weight of flavourings and/or colouring and having a density between 50 and 90 g/litre, the product having been formed by deep-frying an intermediate product as described above.

The starting material for the process of the invention is a rice flour, preferably having an average particle size of about 300 microns.

Particularly preferred is a rice flour of which75/ó by weight passes through a screen with 439 micron apertures and all remains on a screen with 180 micron apertures. In general, the starch of the rise flour is not gelatinised but, in a variant of the process, a mixture comprising ungelatinised flour and pregelatinised rice flour may be used, with the major proportion of the total rice flour being ungelatinised.

Before forming the dough the rice flour may be dry blended with different flavourings and/ or colourings, such as spices and salt, these constituents normally representing 7 to15 só by weight of the blend. In particular, any of the following may be added: spices or mix tures of spices including paprika, curry, caraway, pepper; natural or synthetic flavours such as onion, tomato, cheese, meat or smoked ham; and protein hydrolysates. The flavourings and colouring may alternatively be added to the deepfried product. The mixture may also comprise small amounts, preferably 1 to10% by weight, for example5 % by weight, of modified cold swelling starch.

The rice flour, to which have optionally been added flavourings, spices and modified starch, is mixed with water in sufficient quantity to obtain an extrudable dough. The water content of the dough prior to the gelatinisation treatment is generally between 25 and 45% by weight, preferably 30 to38%.

The resulting dough is then shaped, for example, by extrusion, to provide pieces hav ing any desired shape, andprefembly athidt- ness of 0.5 to 1.5 mm. If extrusion is used, the pressure may be between

20 and 80kg/cm2 and the temperature of the extruded product is generally not above40 C. Extrusion produces a continuous ribbon or tube which is cut into pieces, and, according to the die used, the pieces may have the shape of, for example, shells, twists, gnocchis or tubes.

After shaping, the pieces are subjected to the gelatinisation treatment. In a preferred embodiment of the process, the product is placed on perforated trays and the treatment is carried out in a chamber or tunnel supplied with saturated or superheated steam. The operation may be performed at a pressure close to atmospheric and generally takesbetween 2 and 15 minutes, preferably 8 to12 minutes at around100 C. During the gelatinisation treatment the water content of the product should be at least 27 bv weight and the temperature is desirably maintained above97"C. The minimum duration of the treatment depends on these two factors but may be prolonged beyond the maximum times indicated above without affecting the quality of the final product.

As the gelatinised pieces are soft and tend to stick together, their separation without damage is facilitated by predrying, preferably at temperatures between 20 andSONG, for example between about

40 and50so. The predrying may advantageously be performed in a recirculating air drier, the product remaining on the trays used for gelatinisation, and the duration of the operation is selected having regard to the air temperature. It is generally between 5 and 30 minutes, whereby the water content of the pieces should desirably be reduced to below 320; byweight

The predried product is then subjected to a final drying step. This operation may be carried out in a continuous drier comprising a conveyor band on which the predried gelatinised pieces are

467/2197

placed.During the final dryingstcp, the water content of the product is lowered to below13; by weight.

In particular, the water content may be between 5 and14 ;. by weight, and is preferably 7 to9%. The drying may normally beperformed at any temperaturebetween 20 and90"C but, preferably, the temperature is maintained relatively low,between 40 and30 C. The duration of the operation is related to the temperature; for the values indicated above, it is between about 3 and 4 hours. The dried pieces are a useful intermediate product, and they may be stored in appropriate air-tight containers.

The final snack product is obtainedbv deepdrying the dried pieces. The frying is preferablv carried out by immersing the pieces in a bath of oil or fatwhich is held at between 180 and230 C, for 4 to 14 seconds. Good results are obtained by deep-frying in fat heated to 200 to210 C, the contact time of the shapes with the fat being limited to 5 to 7 seconds.

The fried product is in the form of attractive puffed pieces having a volume which is 4 to 7 times that of the unfried product. The pieces have a crisp texture and a very pleasant flavour. They are very light, their density lying between 50 and 90 g/litre, as compared with 250 to 300 g/litre for the dried intermediate product. The low density is anained despite adsorption of fat during frying, which may represent 25 to40 /) by weight of the flnished product, and is directly attributable to the excellent puffing properties of rice flour. One particular feature of the product is its stability, in that if packed in appropriate containers, it retains its properties after prolonged storage at ambient temperature.

The invention is illustrated by the following example, in which the percentages are by weight.

Example

The starting material is a rice flour the particle size distribution of which is as follows:

Screen

(size of apertures in

microns) Product retained

560 0.5

535 1.0

439 5.0

320 31.5

225 24.0

180 18.0

125 4.5

105 7.5

fines 8.0

The following ingredients are dry blended in amixer:

8.5 kg of rice flour

0.5 kg of modified cold swelling starch

1.0 kg of an onion flavour composition, then 3.6 litres of water at20"C are added to the dry blend

(moisture content10',,). The mix is stirred for about 1 minute to form a coarse dough containing about34 Ó of water.

The dough is fed into a screw extruder for pasta products which has a head provided with 10 annular dies 0.7 mm in thickness. The extrusion pressure is55 kg/cn and the dies shape the product into gnocchis, which are joined end to end and severed at the exit of the head with a rotating knife.

The dough shapes are placed on perforated trays which are fed into a tunnel supplied with saturated steam. The product is treated at atmospheric pressure for 12 minutes, at about100"C, to obtain gelatinisation of the starch.

Tb steam passes from below and because of the large number of openings in the trays, the gnocchis are in contact with steam over most of their surface. During the whole length of the treatment, the water content of the product is around32%.

The rays of gelatinised product are loaded into a recirculating air drier where the moisture content of the shapes is lowered to about 23 to25c,'. The predrying is carried out at a temperature of45"C for about 20 minutes.

468/2197

The predried product may then be removed from the trays without damage and Bed directly to a continuous drier. The final drying is carried out at45"C for 3 hours and 50 minutes.

At the end of this operation, the moisture content of the product3 reduced to 7 to 8%.

The pieces of gelatinised and dried dough are then deep-fried by immersion for about 4 seconds in fat heated to207"C. The fried pieces have a fat content of 29%.

The product has a very attractive appearance (shape, colour) and the gnocchi-shaped pieces have a smooth uniform surface. The density of the product is65 g/litre, the texture is firm and crisp and the flavour very pleasant.

Suitably packed, the product retains its properties after a storage period of more than three months at ambient temperature.

WHAT WE CLAIMIS:-

1. A process for preparing a snack product or an intermediate therefor which comprises forming a dough from a dry mix comprising at least70r,Ó by weight of rice flour, and water, shaping the dough into separate pieces, subjecting the shaped dough pieces to a heat treatment to gelatinise the starch present, the water content of the dough pieces during the gelatinisation treatment being maintained above27'g', by weight, drying the gelatinised pieces to a water content below15% by weight to form an intermediate for preparing a snack product and optionally deep-frying the dried pieces tofonn the snack product.

2. A process according to claim 1 in which the dough has a water content of 25 to43 : by weight prior to the gelatinisation treatment.

3. A process according to claim 2 in which the dough has a water content of 30 to 38% by weight.

4. A process according to any one of the preceding claims in which the dough is shaped by extrusion at a pressure of 20 to 80kg/em2.

5. A process according to any one of the preceding claims in which the gelatinisation treatment is effected at a temperature of at least97"C.

6. A process according to any one of the preceding claims in which the gelatinised pieces are dried in two stages.

7. A process according to claim 6 in which the water content of the pieces is reduced to below 32% by weight in the first drying stage and to 5 to14% by weight in the second stage.

8. A process according to claim 6 or claim 7 in which the first drying stage is effected at a temperature of 20 to80"C and the second at a temperature of 20 togOOC.

9. A process according to any one of the preceding claims in which the drying is effected at a temperature of 40 to50"C.

10. A process according to any one of the preceding claims in which the major proportion of the rice flour is ungelatinised.

11. A process according to any one of the preceding claims in which the dry mix comprises 1 to 10% by weight of modified cold swelling starch.

12. A process according to any one of the preceding claims in which the dry mi. comprises flavourings and/or colourings.

13. A process according to any one of the preceding claims in which the dough is shaped into pieces having a thickness of 0.5 to 1.5 mm.

469/2197

14. A process according to any one of the preceding claims in which the dried pieces are deep-fried for

4 to 14 seconds in fat at a temperature of 180 to230"C.

15. A process for preparing a snack product or an intermediate therefor substantially as herein described with reference to the

Example.

16. A snack product or an intermediate therefor prepared by a process according to any one of the preceding claims.

17. An intermediate product adapted to provide crisp snack products on deep-frying, in the form of shaped pieces comprising at least 70% by weight gelatinised rice, 0 to10% by weight cold swelling starch, 7 to15% by weight of flavourings and/or colourings and 0 to 15% by weight of water, the rice having been gelatinised after shaping.

18. A crisp snack product, in the form of pieces puffed by deep-frying, comprising 25 to40 9' by weight of fat, 50 to 75,Ó by weight of gelatinised rice flour and 0 to 10% of flavourings and/or colouring and having a density between 50 and 90 g/litre, the product having been formed by deepfrying an intermediate product as claimed in claim 17.

19. A crisp snack product substantially as herein described with reference to the

Example.


470/2197

89.

GB1339241 - 11/28/1973

METHODS OF PEPARING FISH-BASED FOODSTUFFS


Applicant(s): RICHARDSEN H (--)

IP Class 4 Digits: A23B

IP Class: A23B3/06

E Class: A23L1/325H; A23B4/06F2


Priority Number: NO19710000998 (19710316)

Family: GB1339241

Equivalent: NO128390B

Abstract:


1339241 Frozen foodstuffs H RICHARD- SEN 3 Jan 1972 [16 March 1971] 145/72 Heading A2D A method of preparing a foodstuff comprises placing portions of a first foodstuff which is fish fillet layers having at least one intermediate layer of a second foodstuff, and deep freezing the whole. The foodstuff may then be cut into suitable portions prior to cooking. The first foodstuff may be deep frozen and the second foodstuff which may be rice, may be partly cooked.Claims:



(54) METHODS OF PREPARING FISH-BASED FOODSTUFFS

(71) I, HELGE RICHARDSEN, a Norwegian Subject of Henrik Wergelands veg 5, 9000Tromsf,

Norway, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention relates to methods of preparing fish-based foodstuffs and particularly to a product based on fish and another noncohesive foodstuff in which the method resides in cooking the other foodstuff such as rice or vegetables, together with the fish.

A problem arising in cooking of, for example, rice, or vegetables with fish, is that the rice and vegetables do not bind the fish in such a manner that the finished product can be readily deep-fried.

According to the invention there is provided a method of preparing a fish-based foodstuff, wherein portions of a first foodstuff which is fish-fillet are placed in layers having at least one intermediate layer of a second non-cohesive foodstuff, whereafter the fish and the second foodstuff are deep frozen into a cohesive body which can be cut into portions prior to being cooked.

In the context of this invention the expression "non-cohesive" refers to the nature of the other foodstuff which when prepared has no tendency to form a uniform mass and is difficult to adhere to the relatively uniform and cohesive fish and the method of the present invention seeks to overcome this problem and

471/2197

to produce a unitary product having a sandwich-like structure capable of division without separation of the two foodstuffs from each other even during cooking.

By means of thedeep-freezing process, the complete sandwich-like element will be cohesive so that it can be sliced into suitable pieces or shaped on conventional slicing-machines, it being thereafter grilled or deep-fried. By adjustment of the slicing-machine uniform pieces of the same weight are obtained. In one embodiment according to the invention, the raw material in the intermediate layer is previously cooked and the fish fillet may be previously deep-frozen in order to facilitate cutting into thin slices.

By the method according to the invention, a nourishing, savoury product that will keep, is produced.

An embodiment of the invention will now be explained with reference to the following example.

In the bottom of a mould or form the width of which corresponds to the length of the finished product, slices of cleaned, preferably frozen fish fillet are placed. Upon this, a layer of the second foodstuff to be included is disposed, in other words the intermediate layer, which can consist for example of a noncohesive quantity of flavoured or spiced rice, possibly with a certain percentage of shell fish such as peeled or shelled shrimps, the rice being preferably precooked, or possibly precooked vegetables; slices of the optionally frozen fish fillet being then placed on top of this intermediate layer.

Depending on the depth of the mould or form, a sheet of thick polyethylene is then placed on top and the process repeated for the next layer in the same way.

After filling and packing in the form as described hereinabove, the food is deep-frozen whereby a frozen cohesive unit is obtained which can be subsequently cut into suitable slices and desired shape, whereafter the food is treated in the conventional manner as for so called 'fish sticks', it being for example grilled or deep-fried.

After grilling or frying, the product remains a cohesive unit, the sandwich-form of the food being apparent when the cooked portions are sliced, a layer of fish fillet being located on either side of an intermediate layer.

WHAT WE CLAIMIS:-

1. A method of preparing a fish-based foodstuff, wherein portions of a first foodstuff which is fish fillet are placed in layers having at least one intermediate layer of a second non-cohesive foodstuff, whereafter the fish and the second foodstuff are deep frozen into a cohesive body which can be cut into portions prior to being cooked.

2. A method according to claim 1, wherein raw materials in the intermediate layer are at least partly precooked.

3. A method according to claim I or claim 2, wherein the fish fillet is previously deep frozen.

4. A method according to any one of claims 1 to 3, wherein the cutting of the fishbased foodstuff is by slicing and the adjustment of the slicing apparatus is such that pieces of uniform composition and equal weight are produced.

5. A fish-based foodstuff when produced in accordance with the method of any one of the preceding claims.

6. A method of preparing a fish-based foodstuff substantially as hereinbefore described.Data supplied from the esp@cenet database - Worldwide

472/2197

90.

GB1349254 - 4/3/1974

STARCH BASED FOODS


Applicant(s): SICALLY (--)


IP Class: A23L1/10; A23L1/16; A23L1/14

E Class: A23L1/182; A23L3/44; A23L1/16; A23L1/30C



Family: GB1349254

Equivalent: LU63029; FR2088695; DE2119767; BE766126

Abstract:


1349254 Starch based foods SICALY 22 April 1971 [22 April 1970] 10864/71 Heading A2B Freezedried readily reconstitutable starch based foods, for example pasta, rice, and flour based sauces, which have absorbed a fatty substance before freeze drying are prepared by cooking a starchy substance in or in the presence of water, then mixed with a fatty substance and the mixture is kept hot at a temperature not above the boiling point of water or above 160 C, and which is within 70 C of said boiling point at the pressure of operation for a period long enough for the starchy substance to absorb the fatty substance, the resulting product being thereafter freeze- dried, any required adjuvants being added prior to freeze drying.Claims:


**WARNING** start of CLMS field may overlap end of DESC **. retains all its organoleptic qualities inde finigtely. Inother experiments this product

is added to other freeze-driedfoods includ

ingvegetables, meats, sauces and fish, and

these mixtures keep just as well as the pro

duct on its own. To reconstitute the rice dish

alone or mixed with other freeze-dried products, add water to the product and heat

gently for 3 or 4 minutes.

EXAMPLE 3Preparatioiz of a sauce base

175 g of wheat flour and 150 g of fatty

substance are added to 1.5 litres of cold

water. The whole is heated to75"C

i.e., to a temperature high enough to gel the starchpresent - for 5 minutes. Theresult ing mixture is freeze-dried conventionally.

The resulting freeze-dried product is reducedto powder form. If kept away from damp, the freeze-dried powder keeps indefinitely with noimpairment of its organoleptic qualities. Similar considerations

473/2197

apply when the powder is mixed with other freezedried food products. To prepare a sauce ready for immediate use, add sufficient hot water to thepowder to achieve the required consistency.

Of course, thetemlperatures hereinbefore

specified refer to a working pressure of

760mm Hg and may therefore be modified

in known manner when the pressure ins below or above 1 atmosphere.

WHAT WE CLAIMIS:-

1. A process for theproduction d a

freeze-dried,starch-based food, in which a

starchy substance is cooked in water or in

the presence of water and is then mixed with

a fatty substance and the mixture is kept

3t a temperature which is not above the

boiling point of water orabove 1600C, and

which is within70"C of said boiling point,

at the pressure at which this is being done for a time long enough for the starchy substance to absorb the fatty substance, and the resulting mixture is then freeze-dried, any requiredadjutants being added to the mixture before the freeze drying.

2. A process according to claim 1, in which the mixture is kept at atmospheric pressure at a temperature in the range30 to80do, for from 2 to 120 minutes.

3. A process as claimed in claim 2, in which the mixture is kept atatmospheric pressure at a temperature in the range40 to75"C for from 5 to 60 minutes.

4. A process according to any preceding claim in which the proportion of fatty substance is more than5% by weight of the starchysubstance.

5. A process according to claim 4 in which the proportion of fatty substance is from 15 to 100% by weight of the starchy substance.

6. A process according to any of claims 1 to 5, in which the starchy substance is in the form of a paste, rice or a cereal flour.

7. A process according to any of claims 1 to 4, in which the fatty substance is a hydrogenated fattysubstance having a melting point ofapproxilmately 34-36"C at atmospheric pressure.

8. A process as claimed in claim 1 for the preparation of food substantially as herein described.

9. A food obtained by the process of any of the preceding claims.Data supplied from the esp@cenet database - Worldwide

474/2197

91.

GB1351974 - 5/15/1974

PROCESSING FOODSTUFFS


Applicant(s): KYOWA HAKKO KOGYO KK (--)

IP Class 4 Digits: A23B; A23L; A23J; A21D

IP Class: A23J3/00; A23L3/00; A21D15/00; A23B3/14

E Class: A23L1/00P4; A23L1/305A; A21D2/24B; A23J3/22C; A23L1/00P8B



Family: GB1351974

Equivalent: US3840676; FR2117506; DE2160716

Abstract:


1351974 Processing foodstuffs KYOWA HAKKO KOGYO CO Ltd 22 Nov 1971 [11 Dec 1970]

54158/71 Heading A2D A processed foodstuff comprises a mixture of a foodstuff, a prolamin and an amino acid or salt thereof. The prolamin may be gliadin, zein, rice-gliadin or kafirin, and may be applied to the foodstuff in solution or suspension in for example water, aqueous alcohol or an organic acid. The foodstuff may be dipped into or sprayed or brushed with the prolamin solution or suspension.

The amino acid or salt thereof may be applied to the foodstuff before, simultaneously with or after the prolamin treatment. The amino acid may be neutral, acidic or basic; numerous such acids are exemplified in the specification. In the examples there is described the processing with prolamin and an amino acid or salt thereof of fish-paste, dough and extruded soy bean protein. The processed foodstuffs have enhanced storage properties.Claims:


WHAT WE CLAIM IS:-

1 A composition for treating foodstuffs which comprises a prolamin and an amino acid or a salt thereof in a non-toxic liquid solvent.

2 A composition according to claim 1, wherein the non-toxic liquid solvent is water, aqueous alcohol or an organic acid.

3 A composition according to claim 1 or Tensile strength (g/cm 2) 3.66 X 103 3.5 X 103 3.26 X 103

3.5 X 103 3.2 X 103 2.16 x 103 2 X 103 2.32 x 103 2.12 X 103 2.4 x 103 2 X 103 2.34 X 103 2 X 103

2.26 X 103 2.4 X 103 2.2 X 103 2.0 X 103 2.1 X 103 2.1 X 103 2.82 X 103 2.94 X 103 0.17 X 103

0.27 X 103 0.94 X 103 2, wherein the prolamin is gliadin, zein, ricegliadin or kafirin.

4 A composition according to any preceding claim, wherein the amino acid is Llysine, L arginine, L histidine, glycine, L alanine, L valine, L leucine, L isoleucine, L serine, L threonine, L cysteine, L methionine, L phenylalanine, L tyroProlamin Rice-gliadin Kafirin Gliadin -33 Control I Control II

Control III , , , , , , J., ,3 , ,1 Control II Control III 1,351,974 sine, L tryptophan, L praline, L hydroxypraline, L aspartic acid or L glutamic acid.

475/2197

A composition according to any preceding claim, substantially as hereinbefore described with reference to either one of foregoing Examples 5 and 7.

6 A method of processing foodstuffs which comprises intimately contacting a foodstuff with a composition according to any preceding claim, and drying the resultant mixture.

7 A method of processing foodstuffs which comprises intimately contacting a foodstuff with an amino acid or a salt thereof in a nontoxic liquid solvent and a prolamin in such a solvent, and drying the resultant mixture.

8 A method according to claim 7, wherein the non-toxic liquid solvent is water, aqueous alcohol or an organic acid.

9 A method according to claim 7 or 8, wherein the prolamin is gliadin, zein, ricegliadin or kafirin.

A method according to any one of claims 7 to 9, wherein the amino caid is Llysine, L-arginine, L histidine, glycine, Lalanine, L valine, L leucine, L isoleucine, L serine, L threonine, L cysteine,

Lmethionine, L phenylalanine, L tyrosine, L tryptophan, L proline, L hydroxyproline, L aspartic acid or L glutamic acid.

11 A method according to any one of claims 7 to 10, wherein the foodstuff is coated with the prolamin and the amino acid by dipping, spraying or brushing.

12 A method according to any one of claims 7 to 11, wherein the p H of the foodstuff is between 6 and

9.

13 A method according to any one of claims 7 to 12, wherein the drying step is carried out at a temperature of from 70 to C.

14 A method according to claim 7, substantially as hereinbefore described with reference to any one of the foregoing Examples.

A processed foodstuff comprising a mixture of a foodstuff, a prolamin and an amino acid or a salt thereof.

16 A processed foodstuff according to claim 15, wherein the foodstuff is bound together by a mixture of a prolamin and an amino acid or salt thereof.

17 A processed foodstuff according to claim 15 or 16, wherein the prolamin is gliadin, zein, ricegliadin or kafirin.

18 A processed foodstuff according to any one of claims 15 to 17, wherein the amino acid is L lysine,

L arginine, L histidine, glycine, L alanine, L valine, L leucine, L isoleucine, L serine, L threonine,

Lcysteine, L methionine, L phenylalanine, L tyrosine, L tryptophan, L proline, Lhydroxyproline, L aspartic acid or L glutamic acid.

19 A processed foodstuff according to claim 15, when prepared by a method according to any one of claims 6 to 14.

For the Applicants, D YOUNG & CO, Chartered Patent Agents, 9 and 10 Staple Inn, London W C 1.


Published by the Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

476/2197

92.

GB1352938 - 5/15/1974

THERMO-GELABLE POLYSACCHARIDE


Applicant(s): TAKEDA CHEMICAL INDUSTRIES LTD (--)

IP Class 4 Digits: A23L; C08B; C12D

IP Class: C08B25/00; A23L1/04; C12D13/04

E Class: A23L1/054C; C12P19/04



(19700407)

Family: GB1352938

Equivalent: US3822250; US3754925; NL7103987; FR2085025; ES389475; DE2114066;

CH557424; BE764772; NL174846C; IT1046089

Abstract:


1352938 Food preparations from polysaccharides TAKEDA YAKUHIN KOGYO KK 19 April 1971

[24 March 1970 7 April 1970 (2)] 25858/71 Heading A2B [Also in Division C3] The Specification is directed to a novel polysaccharide, designated PS which is a microbial metabolite composed of glucose units connected to each other via mainly #-1, 3-glucosidic linkages. Among its many characteristics, it has a M.W. of from 44000 to 77000, contains no nitrogen, is soluble in aqueous

0.5N NaOH solution, formic acid and dimethyl sul- phoxide, silghtly soluble in aqueous ammonia but sparingly soluble or insoluble in plain water, ethanol or acetone, and is gellable by heating in the presence of water forming a gel irreversibly. The polysaccharide PS may be incorporated into food material in amount ranging from 0.05 to 13% by weight- relative to the finished food as served and in the case of starch-containing food, in amounts ranging from 0.0015 to 1 part PS per part of the starch.

The finished foods may contain water in an amount of 7-200 times the weight of PS. The agar-like gel obtained by gelling PS is stable even under strongly acidic conditions. A very large number of food (or feed) constituents and food products that may be enhanced with the aid of the polysaccharide PS are specifically mentioned. The preparation of an edible jelly from PS, cane sugar, citric acid, sodium tri- polyphosphate, guar gum and water is disclosed. Examples are directed to the incorporation of PS in

Japanese kamaboko based on salted fish, potato starch, sweet cake and monosodium glutamate

(optionally containing preservative such as sorbic acid or 2 - (2' - furyl - 3 - (5' - nitro - 2' - furyl) - acrylamide)); a simulated jelly-fish delicacy made by steaming a paste of PS in water; a substitute for

Japanese konnyaku powder prepared by extending konnyaku powder with the polysaccharide PS; a konnyaku-like gel based on sodium tripoly- phosphate, stearyl monoglyceride and sodium glutamate; salad dressing based on corn oil and vinegar; Berliner ham; corned beef; sausage meat; Hamburg steak based on ground beef, butter-roasted hashed onion, egg, rusk and spices; noodles; cookies based on butter, granular sugar, egg yolks and wheat flour; rice; bean jam jelly based on starch, cane sugar and bean jam; cream jelly based on milk, whole eggs and cane sugar; a jelly premix based on cane sugar, citric acid, sodium tripolyphos- phate and guar gum; ice-cream based on fresh cream, unpasteurised milk, defatted condensed milk, cane sugar, sucrose palmitate and stabiliser; and a confection based on egg white and cane sugar. The polysaccharide PS may be used as a coating for breading pork chops, in the preparation of imitation fruits for cakes, also in sesame curd and margarine.Claims:


477/2197

WHAT WE CLAIM IS:-

1 A process for producing a thermogelable /J 1,3 glucan type polysaccharide PS, which comprises cultivating aerobically a PSproducing microorganism in an aqueous culture medium containing assimilable carbon and nitrogen sources with other nutrients required by the microrganism, until the PS is substantially accumulated in the culture broth; and recovering the accumulated PS therefrom.

2 A process according to claim 1, wherein the microorganism is Agrobacterium radiobacter.

3 A process according to claim 2, wherein the microorganism is Agrobacterium radiobacter ATCC-

6466.

4 A process according to claim 2, wherein the microrganism is Agrabacterium radiobacter Strain U-

19.

A process according to claim 1, wherein the microorganism is Alcaligenes faecadis var. myxogenes Strain NTK-u.

6 A proces according to claim 5, wherein the culture medium for the microorganism contains 50 to

1000 milligrams per litre of uracil.

7 A process according to any of claims 1 to 6 wherein the PS produced in the culture medium is dissolved once in a 0 1 to 1 5 normal concentration of aqueous alkali hydroxide solution, and the solid matter in the solution is then removed.

8 A process according to any of claims 1 to 7 wherein the culture medium comprises O 1 to 0 5/% by weight per volume of calcium carbonate.

9 A process according to claim 1 substantially as herein described with reference to any of the specific examples.

The thermo-gelable /8 1,3 glucan type polysaccharide PS when made by a process according to any of claims 1 to 9.

11 A polysaccharide which is a microbial metabolite composed of glucose units connected to each other via mainly P 1,3 glucosidic linkages and which has the following characteristics: 1) specific rotation lalJ,:

-16 + 3 (c= 0 5, dimethylsulphoxide) + 31 + 6 (c= 1 0, O 1 N Na OH); 2) average molecular weight, measured by light-scattering spectrometry, of from 44,000 to 77,000; 3) elementary analysis:

C 43 58 % + 1 %, H 6 46 % 0 5 %, N 0 00 %; 4) positive colour reactions in the Molisch test, phenolsulphuric acid test and anthrone test; 5) exhibiting no significant absorption band in its ultraviolet absorption spectrum; 6) infrared absorption spectrum exhibiting significant absorption bands at the wave numbers (cm-1):

3600-3200, 2950-2900, 1640, 1420, 1365, 1310, 1260, 1200, 1160, 1120, 1100, 1080, 1070, 1040,

1020, 980 and 890; 7) soluble at 25 C in an aqueous 0 5 N Na OH solution, dimethylsulphoxide or formic acid; slightly soluble in aqueous ammonia; sparingly soluble or insoluble in plain water, acetone or ethanol; 8) gelable by heating in the presence of water, forming a gel; and 9) the gel formed by heating its 2 % aqueous suspension is stable in the p H range from 2 to 9 5 and exhibits a gel strength of from 650 x 103 to 1300 x 103 dynes/cm 2, measured by the method hereinbefore specified.

12 A method of producing an improved foodstuff, which comprises incorporating a 95 gelable 6 1,3 glucan type polysaccharide PS into a food material, the amount of PS relative to the finished food as served being 0.05 to 13 % by weight; and thereafter subecting the mixture to heating 100 13 A method

478/2197

according to claim 12, wherein the finished food contains water in an amount of 7 to 200 times as much as the weight of PS contained therein.

14 A method according to claim 12 or 105 13, wherein the feed material contains starch, and the amount of the PS incorporated therein is 0 0015 to 1 part per part of the starch contained in the food material.

A method according to claim 12 sub 110 stantially as herein described with reference to any of the specific examples.

16 Foodstuffs made by a method according to any of claims 12 to 15.

17 A foodstuff composition, which com 115 prises 0 05 to 13 % by weight of PS, relative to the total amount of the finished foodstuff as served.

18 A composition according to claim 17, containing water in an amount of from 7 to 120 times as much as the weight of PS contained in the finished foodstuff as served.

19 A composition according to claim 17 or 18, wherein the composition is a thermo16 1,352,938 16 irreversible gel comprising to 113 % by weight substantially as herein described with refer 10 of the PS relative to the finished fodstuff as ence to any of the specific examples. served.

A composition according to any of ELKINGTON & FIFE, claims 17 to 19, wherein the food material

Chartered Patent Agents, contains starch and the amount of the PS High Holborn House, incorporated therein is 0 0015 to 1 part per 52/54 High Holborn, part of the starch contained London, W C 1.

21 A composition according to claim 17 Agents for the Applicants.

Printed for Her Majesty's Stationery Office, by the Courier Press Leamington Spa, 1974.

Published by The Patent Oflice, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

479/2197

93.

GB1358097 - 6/26/1974

SNACK FOOD PRODUCT


Applicant(s): RALSTON PURINA CO (--)


IP Class: A23L1/10; A23J3/00; A23L1/12

E Class: A23L1/164E; A23L1/217B



Family: GB1358097

Equivalent: NL7110950; LU63713; FR2104030; DE2140859; BE771104; SE382906

Abstract:


1358097 Snack product RALSTON PUR- INA CO 17 Aug 1971 [17 Aug 1970] 38588/71 Heading

A2B A snack food intermediate is prepared by making a dough from a pre-gelatinised starch material, a starch-modifying agent, from 14 to 25% by weight of a heat-settable oil seed protein and water, and forming the dough into the intermediate without heat-gelling the protein material. The starch material may be wheat, rice, corn, poato or tapioca starch or flour, and the starch-modifying agent is preferably a mono- or di-glyceride of a fatty acid having at least 14 carbon atoms, e.g. glyceryl monostearate. The intermediate may be shaped by extrusion into a sheet or ribbon. The intermediate may then be fried to form a crisp food product. A preferred fried food product comprises 47-56% starch, 2-6% moisture, 16-

25%. oil seed protein and 12-35% fat, all percentages being by weight.

480/2197

94.

GB1361510 - 7/24/1974

PROCESSING COMMON SALT


Applicant(s): SATO SHOKUHIN KOGYO KK (--)

IP Class 4 Digits: C01D

IP Class: C01D3/06

E Class: A23L1/237



Family: GB1361510

Equivalent: FR2141967; DE2228946; IT1048972

Abstract:


1361510 Modified common salt SATO SHO- KUHIN KOGYO KK 6 June 1972 [15 June 1971]

26414/72 Heading A2B [Also in Division Cl] Modified common salt particles a major part of which are substantially spherical, porous, of diameter from 50 to 200 microns, of bulk density from 0.4 to 0.7 g/cm>;SP;3>;/SP; and are comprised of a plurality of microcrystals of common salt bonded together by a dry water soluble substance which has a viscosity of at least 500 cps measured as a 2% aqueous solution thereof at 25 C are prepared by dissolving said substance in brine and spray drying the resulting solution. The salt content of the brine may be at least 15% by weight and the water soluble substance may be guar gum, propylene glycol alginate, tamarind seed polysaccharide, locust beangum tragacanth gum, carrageein gum or carboxymethylcellulose and may be present in an amount of from

0.1% to 10% by weight of the common salt in the brine. Seasoning substances, e.g. spices and herbs, colouring matter, anti-oxidants, perfumes and food mixture modifying agents may be added to the brine in an amount up to 5% by weight of the common salt. The resulting modified salt particles may be mixed with edible organic solvents, e.g. soyabean oil, ethyl alcohol or propylene alcohol and added to foodstufls, e.g. butter, cheese, baking dough, rice crackers, potato chips and cornflakes or mixed with particulate seasoning material, e.g. sesame or monosodium glutamate.Description:


(54) IMPROVEMENTS IN OR RELATING TO THE

PROCESSING OF COMMON SALT

(71) We, SATO SHOKUHIN KOGYO

KABUSHIKI KAISHI, a corporation organised under the laws of Japan, of 1268, Aza

Shinmachi, Oaza Komaki, Komaki-shi, Aichiken, Japan, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention relates to a modified form of common salt and to a process for the production thereof.

Conventional common salt is usually strongly hygroscopic and generally deliquesces by absorbing moisture from the air and solidifies into an agglomerate form. This phenomenon is particularly liable to take place with common salt of fine particle size. A further problem which is frequently encountered with common salt is that because of the high density of crystalsthereof-bulk densities as high as 1.15 g/cm3 being frequentlyencountered- and the large size thereof, usually from 150 to 500 microns, the

481/2197

solid salt enters into solution slowly and possesses, intera'ia, poor mixing properties and adhering properties. To prevent the solidification of common salt, it is common practice to add thereto such compounds as calcium carbonate and magnesium carbonate in an amount of from 0.1 to 1% by weight.It has also been proposed to coat salt particles with such compounds as calcium phosphate and calcium stearate or with such materials as oils, fats and surface active agents. However successful in preventing common salt from deliquescing that these materials may be, the other problems characteristic of common salt generally remain unsettled.

When comon salt is used in the manufacture of processed foodstuffs such as rice crackers, sprinkling seasoning, powdered soup, snack foods, butter and cheese, it is generally desired that the salt should possess the minimum possible bulk density, good solubility in the medium being processed and excellent fluidity, mixing properties and adhering properties. In order to meet these requirements, there has been produced very fine particle salt by crushing baked salt or flake salt of small bulk density obtained by crystallising common salt in flake form. However, the aforesaid problems have remained with these materials. Recently, processes for modifying common salt using such water soluble compounds as potassium ferrocyanide and ferric ammonium citrate have been described.However, the use of potassium ferrocyanide in the production of a food additive is not always desirable and ferric ammonium citrate is not suitable because it discolours common salt and foodstuffs containing common salt

According to one aspect of the present invention, there is provided a modified form of common salt a major part of the particles of which are substantially spherical, are porous, have a sphere diameter of from 50 to 200 microns and a bulk density of from 0.4 to 0.7g/cm', which particles are comprised of a plurality of microcrystals of common salt which are bonded together by means of a dry water soluble substance which has a viscosity of at least 500 cps measured in a 2% aqueous solution thereof at 250C.

According to a second aspect of the invention, there is provided a process for the production of modified common salt particles which comprises dissolving in brine a water soluble substance which has a viscosity of at least 500 cps. measured as a 2% aqueous solution thereof at250C. and spraydrying the resulting solution.

Examples of said water soluble substances which can be used in the production of the modified common salt are guar gum, propylene glycol alginate, tamarind seed polysaccharide, locust beangum, tragacanth gum, carrogeenin gum and carboxymethylcellulose.

This substance, which is hereinafter termed "the high viscosity substance" is added to the brine which generally has a common salt content of at least15% by weight, in an amount

which is preferably within the range of from

0.1 to 10% by weight of the common salt

content of the brine. The high viscosity sub

stance is thoroughly dissolved in the brine to

form an aqueous solution which is instanta

neously dried by being sprayed into a dry

atmosphere. The common salt is obtained in

the form of very fine crystals of the order of

1 micron or less, the very fine crystals of

the common salt being bonded together by

means of the high viscosity substance to form

enlarged particles in which the salt micro

crystals are largely coated with the water

soluble high viscosity substance.The particles

obtained are porous and are substantially

spherical in shape having a finely pitted sur

face.

Reference is now made to Figure 1 of the

accompanying drawing which is a micro

photograph of a number of modified common

salt particles obtained by the process of the

invention magnifiedx125. Figure 2 shows

482/2197

a microphotograph (magnificationX 500) of a

single porous spherical common salt particle

obtained by the process of the invention.

These particles generally possess a sphere diameter of from 50 to 200 microns and a bulk density of from 0.4 to 0.7g/cmg. It is assumed that the viscosity of the high viscosity substance is responsible for the

crystal size of the common salt crystals obtained being constrained to lie within the

aforesaid range.

Although the high viscosity substance will preferably have a viscosity of at least 2000

cps (measured with a 2% aqueous solution thereof at250C.), it is possible to employ high viscosity water soluble substances which have a viscosity in the range of from 500 to 2000 cps measured under the aforesaid conditions, if a suitable amount of the sub

stance is employed so that precipitation of the salt does not occur. A general indication of the suitability of a high viscosity substance for use in the present invention is that it

should not cause precipitation of the salt even in an aqueous solution of common salt of above 20% by weight.The viscosities measured under the aforesaid conditions of the water soluble high viscosity substances mentioned above are asfollows:

guar gum 20,000 cps

locustbeangum 11,000 cps tragacanth gum 1,500 cps

carrogeenin gum 2,000 cps

tamarind seed

polysaccharide 4,200 cps

propylene glycol

alignate 4,500 cps

carboxymethylcellulose 500 cps

When the high viscosity substance has a viscosity of at least 2000 cps, this substance is preferably used in an amount of from 1

to 2.5% by weight of the common salt. In

general, the amount of high viscosity sub

stance used will depend upon the viscosity

thereof.However even if a particularly high

viscosity substance is used, if the amount

thereof employed is below 0.1%, the process

may not work satisfactorily and if the amount

is above 10%, the purity of the common salt

is reduced and the taste thereof deteriorates.

It has been found that guar gum is particularly suitable and can be used economic

ally, amounts of less than 5% by weight of the common salt employed generally being

satisfactory for producing excellent modified

common salt

Although the concentration of common salt in the brine can be less than 50% by weight,

the cost of removal of water and the production efficiency in such cases become increasingly critical in commercial operation and a practical lower limit for the common salt concentration is15 % . However, it is not impossible to use lower common salt concentrations. Other water soluble food additives can be included in the brine to modify the common salt particles obtained.For example, other seasoning matter including spices and herbs, perfume, colouring matter or anti-oxidant substances can be added thereto, generally in an amount of not more than 5% by weight of the common salt. The particular additives employed will depend upon the intended use of the processed common salt

The modified common salt particles obtained by the process of the invention have the following characteristic features all of which have not been found hitherto together in a single form of common salt:

A) The aggregation of common salt crystals is prevented. This occurs, for example if the relative humidity rises above 75%, when atmospheric moisture causes the crystal surface to deliquesce so that a saturated solution of common salt is produced thereon. The solution is then concentrated, dried and the salt is recrystallised so as to form a bridge between adjacent crystal particles which are thus adhered

483/2197

together. In contrast, very fine common salt particles obtained by the process of this invention are coated with the highly viscous substance so that the deliquescencebridge formation phenomenon mentioned above is not likely to occur even during high humidity conditions.

B) The common salt particles obtained by the process of this invention are porous and nearly spherical in form (they may be partly in broken spherical form) and possess a bulk density of 0.4 to 0.7 g/cm3 and a diameter of from 50 to 200 microns. The round surface of the particles is finely pitted and the fluidity, the mixing properties and the adhering properties of the common salt particles are excellent

Thus, when addition of salt is effected when manufacturing such processed foods as rice crackers, potato chips and cornflakes, or when the salt particles are uniformly mixed with such particulate seasoning materials as sesame and monosodium glutamate, it is now possible to produce an intimate mixture of the salt with such other seasoning materials.In addition, the salt taste is not so strong as in conventional common salt so that a greater amount thereof can be used than hitherto to achieve even greater enhancement of the flavour of food.

C) The common salt produced according to the process of this invention is highly porous and yet is present in the form of small particles comprising very fine crystals. It thus possesses improved solubility and absorptive properties so that when, for example, it is used in salting on butter, cheese, dough for baking or other foodstuffs, it can be mixed therewith uniformly and can be dissolved therein rapidly so that working efficiency is improved. When 30 parts of an organic solvent, more particularly a solvent which can be consumed by humans, for example soyabean oil, ethyl alcohol or propylene glycol, are mixed with 100 parts of the common salt produced according to the invention, all the solvent is adsorbed therein and dry particles are obtained.This property effectively broadens the range of uses of the salt since many desired flavouring, colouring or texture modifying additives can be dissolved in a suitable solvent and adsorbed in the common salt and thus incorporated therewith in a foodstuff.

D) Common salt generally induces oxidation of materials with which it is in contact.

For example, if common salt is sprinkled on fried potato chips, oxidation of the oil in which the chips have been fried is accelerated by the common salt adhered thereto. However, common salt produced by the process of this invention is coated with a water soluble high viscosity substance which isolates oil from the salt and considerably delays the onset of oxidation so that the taste of fried foodstuffs does not deteriorate for a long time.

The anti-oxidation effect can be enhanced by incorporation in the salt particles of an anti-oxidant substance as mentioned above.

The following Examples illustrate the invention:

Example 1

A salt water solution was prepared by dissolving 990 grams of ordinary grade common salt in 2,800 ml. of water. 15 gram of guar gum was added to the salt water and was completely dissolved therein by stirring. The mixed solution obtained was heated to700 C. and instantaneously dried by being sprayed into a dry air flow having a temperature of1000 C. 990 gram of processed salt particles having a bulk density of 0.7g/cm3 were obtained.

Example 2

A salt water solution was prepared by dissolving 946 gram of ordinary grade common salt in 3000 ml. of water. 20 gram of tamarind seed polysaccharide, 0.4 gram of butyl hydroxyanisole, 30 gram of monosodium glutamate and 2 gram of citric acid were added to the salt water and dissolved therein with stirring. The resulting mixed solution was then instantaneously dried by being sprayed into a dry air flow having a temperature of1100C. 990 gram of processed salt particles having the foregoing characteristic features, being flavoured and containing an anti-oxidantwere obtained. The salt has a bulk density of 0.63g/rm3 and was particularly suitable for sprinkling on snack foods.

Example 3

Brine was prepared by dissolving 970 gram of ordinary grade common salt in 4000 ml.

484/2197

of water. 30 gram of propylene glycol alginate were added to the brine which was thoroughly stirred to ensure complete solution of the additive. The mixed solution was then dried in the same manner as in

Example 1 and 990 gram of modified salt particles were obtained.

Example 4

45 gram of carboxymethylcellulose were dissolved in 4,800 ml. of water. 955 gram of ordinary grade common salt were added to the solution which was thoroughly stirred to achieve complete solution of the salt therein.

The mixed solution was then dried in the same manner as set out in Example 1 and 990 gram of modified salt particles were obtained. The salt particles had a bulk density of 0.6 g/cm3.

In summary, the present invention allows the attainment of modified salt particles by spray drying an aqueous solution of common salt containing a small amount of a water soluble highly viscous substance. The modified salt is obtained in the form of spherical particles consisting of an aggregation of a large number of very fine salt crystals. The modified salt particles have excellent mixing properties, absorptive properties and adhering properties, do not deliquesce and can therefore be preserved for a long time.

WHAT WE CLAIMIS:

1. A modified form of common salt, a major part of the particles of which are substantially spherical, are porous, have a sphere diameter of from 50 to 200 microns and a bulk density of from 0.4 to 0.7 g/cm3, which particles are comprised of a plurality of microcrystals of common salt which are bonded together by means of a dry water soluble substance which has a viscosity of at least 500




are excellent Thus, when addition of salt is effected when manufacturing such processed foods as rice crackers, potato chips and cornflakes, or when the salt particles are uniformly mixed with such particulate seasoning materials as sesame and monosodium glutamate, it is now possible to produce an intimate mixture of the salt with such other seasoning materials. In addition, the salt taste is not so strong as in conventional common salt so that a greater amount thereof can be used than hitherto to achieve even greater enhancement of the flavour of food.

C) The common salt produced according to the process of this invention is highly porous and yet is present in the form of small particles comprising very fine crystals. It thus possesses improved solubility and absorptive properties so that when, for example, it is used in salting on butter, cheese, dough for baking or other foodstuffs, it can be mixed therewith uniformly and can be dissolved therein rapidly so that working efficiency is improved. When 30 parts of an organic solvent, more particularly a solvent which can be consumed by humans, for example soyabean oil, ethyl alcohol or propylene glycol, are mixed with 100 parts of the common salt produced according to the invention, all the solvent is adsorbed therein and dry particles are obtained.This property effectively broadens the range of uses of the salt since many desired flavouring, colouring or texture modifying additives can be dissolved in a suitable solvent and adsorbed in the common salt and thus incorporated therewith in a foodstuff.

D) Common salt generally induces oxidation of materials with which it is in contact.

For example, if common salt is sprinkled on fried potato chips, oxidation of the oil in which the chips have been fried is accelerated by the common salt adhered thereto. However, common salt produced by the process of this invention is coated with a water soluble high viscosity substance which isolates oil from the salt and considerably delays the onset of oxidation so that the taste of fried foodstuffs does not deteriorate for a long time.

485/2197

The anti-oxidation effect can be enhanced by incorporation in the salt particles of an anti-oxidant substance as mentioned above.

The following Examples illustrate the invention:

Example 1

A salt water solution was prepared by dissolving 990 grams of ordinary grade common salt in 2,800 ml. of water. 15 gram of guar gum was added to the salt water and was completely dissolved therein by stirring. The mixed solution obtained was heated to700 C. and instantaneously dried by being sprayed into a dry air flow having a temperature of1000 C. 990 gram of processed salt particles having a bulk density of 0.7g/cm3 were obtained.

Example 2

A salt water solution was prepared by dissolving 946 gram of ordinary grade common salt in 3000 ml. of water. 20 gram of tamarind seed polysaccharide, 0.4 gram of butyl hydroxyanisole, 30 gram of monosodium glutamate and 2 gram of citric acid were added to the salt water and dissolved therein with stirring. The resulting mixed solution was then instantaneously dried by being sprayed into a dry air flow having a temperature of1100C. 990 gram of processed salt particles having the foregoing characteristic features, being flavoured and containing an anti-oxidantwere obtained. The salt has a bulk density of 0.63g/rm3 and was particularly suitable for sprinkling on snack foods.

Example 3

Brine was prepared by dissolving 970 gram of ordinary grade common salt in 4000 ml. of water. 30 gram of propylene glycol alginate were added to the brine which was thoroughly stirred to ensure complete solution of the additive. The mixed solution was then dried in the same manner as in

Example 1 and 990 gram of modified salt particles were obtained.

Example 4

45 gram of carboxymethylcellulose were dissolved in 4,800 ml. of water. 955 gram of ordinary grade common salt were added to the solution which was thoroughly stirred to achieve complete solution of the salt therein.

The mixed solution was then dried in the same manner as set out in Example 1 and 990 gram of modified salt particles were obtained. The salt particles had a bulk density of 0.6 g/cm3.

In summary, the present invention allows the attainment of modified salt particles by spray drying an aqueous solution of common salt containing a small amount of a water soluble highly viscous substance. The modified salt is obtained in the form of spherical particles consisting of an aggregation of a large number of very fine salt crystals. The modified salt particles have excellent mixing properties, absorptive properties and adhering properties, do not deliquesce and can therefore be preserved for a long time.

WHAT WE CLAIMIS:

1. A modified form of common salt, a major part of the particles of which are substantially spherical, are porous, have a sphere diameter of from 50 to 200 microns and a bulk density of from 0.4 to 0.7 g/cm3, which particles are comprised of a plurality of microcrystals of common salt which are bonded together by means of a dry water soluble substance which has a viscosity of at least 500 cps. measured as a 2% aqueous solution thereof at250C.

2. Common salt as claimed in claim 1, in which all of the individual common salt crystals have a particle size less than 1 micron.

3. Modified common salt as claimed in claim 1 or 2, in which the surface of the spherical particles is finelypitted

4. Modified common salt as claimed in any one of the preceding claims, in which said substance has a viscosity of at least 2000 cps.

486/2197

measured as a 2% aqueous solution thereof at250C.

5. Modified common salt as claimed in any one of the preceding claims, wherein said substance is selected from guar gum, propylene glycol alginate, tamarind seed polysaccharide, locust beangum, tragacanth gum,carrogeenin gum and carboxymethylcellulose.

6. Modified common salt as claimed in any one of the preceding claims, which contains homogeneously dispersed in said particles at least one water soluble food additive selected from seasoning substances, colouring matter, anti-oxidants, perfumes and food texture modifying agents.

7. Modified common salt as claimed in claim 1, substantially as hereinbefore described.

8. A process for the production of modified common salt particles which comprises dissolving in brine a water soluble substance which has a viscosity of at least 500 cps. measured as a 2% aqueous solution thereof at250C. and spray-drying the resulting solution.

9. A process as claimed in claim 8, in which the concentration of common salt in the brine is at least

15% by weight.

10. A process as claimed in claim 8 or 9, in which said substance is present in solution in the brine in an amount of from 0.1 to 10% by weight of the common salt.

11. A process as claimed in claim 10, in which said substance is present in the brine in an amount of from 1 to2.5 % by weight of the common salt.

12. A process as claimed in any one of

Claims 8 to 11, in which said substance has a viscosity of at least 2000 cps measured as a 2% aqueous solution thereof at 250C.

13. A process as claimed in any one of claims 8 to10, wherein said substance is selected from guar gum, propylene glycol alginate, tamarind seed polysaccharide, locust beangum, tragacanth gum, carrogeenin gum andcarboxymethylcellulose.

14. A process as claimed in claim 8 or 9, wherein said substance is guar gum which is dissolved in the brine in an amount of not more than 5% by weight of the common salt dissolved therein.

15. A process as claimed in any of claims 8 to 14, wherein the solution which is spray dried additionally contains dissolved therein at least one water soluble food additive selected from seasoning substances, colouring matter, anti-oxidants, perfumes and food textare modifying agents.

16. A process for the production of modified common salt, substantially as described in any one of the foregoing Examples.

17. Modified common salt whenever produced by the process claimed in any one of claims 8 to

16.Data supplied from the esp@cenet database - Worldwide

487/2197

95.

GB1367190 - 9/18/1974

PROCESS FOR PREPARING PROTEINACEOUS MATERIALS


Applicant(s): HOFFMAN H A (--)


IP Class: A23J3/00; A23L1/36

E Class: A23L1/20D4; A23J3/22C2



Family: GB1367190

Equivalent: SU482933; OA4171; NL7212644; JP48080758; FR2168281; ES406783;

DE2244692; CH560012; BE788541; NO135559B; IE36920; FI53533C; FI53533B

Abstract:


1367190 Proteinaceous foods H A HOFF- MAN 4 Sept 1972 [17 Jan 1972] 40990/72 Heading A2B

Artificial meat is made by leaching chunks of compacted fused vegetable material in water to dissolve soluble constituents and hydrate the chunks, and the chunks are dried prior to rehydration. Compaction is carried out for 1 to 5 minutes at at least 1800 p.s.i., preferably 2000 to 5000 p.s.i., at water boiling temperature. The initial shunks contain 7 to 9% of water, and the final dried chunks 6 to 8%. The vegetable protein material has a nitrogen solubility index of 30 to 70, and is obtained from soya bean, peanuts, lentils, mung bean, rape, cotton or sesame seed, alfalfa, or millet. The leaching is carried out for 1 to 1 hours with water at at least 150 F, preferably 190 to 212 F, at atmospheric pressure and with a pH of 5 to 10. The chunks may be washed in water at 130 to 212 F and the drying carried out with hot air. The chunks may be coated or impregnated with oleaginous material after drying. The size of the chunks may be 1/4 to 1 inch. The dried chunks can before or after rehydration be mixed with ground meat, rice, corn meal, other proteins, flavour enhancers, and other ingredients. The dried product may be packaged in multiwall bags or fibre drums, and the rehydrated product may be canned or frozen.Claims:



Feed Chunks Final Chunks

Protein (N x 6.25) 52.5 61.5

Fat 1.0 3.3

Fiber 3.0 3.0

Ash 6.5 5.2

Carbohydrate (Difference) 37.0 27.0

The comparison shows that the chunks as prepared by this invention possess a protein content which is higher than the feed chunks.

The final chunks were rehydrated as in Example 1. The resultant rehydrated chunks are bland, lightcolored,meat-like in texture andpalatable. They do not contain any noticeable bitterbeany >; flavor

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and taste. Further, there is no objectionable odor when any storage package is opened, during the rehydration or at any time thereafter. The rehydrated chunks are very high in protein content The rehydrated chunks haveimproved

Texturometer cohesiveness over the" starting" chunks when hydrated and can be rehydrated much more rapidly.

WHAT I CLAIMIS:-

1. A method of preparing a proteinaceous product in which chunks of hard, compacted, substantially fused vegetable proteinaceous material are leached with water for a time in accordance with the mean size of the chunks to hydrate the chunks to at least a substantial extent and dissolve at least some of the soluble constituents and thereafter the chunks are dried.

2. A method according to claim 1, in which the chunks of proteinaceous material have been prepared from an initial vegetable material containing some moisture byheatirrg under a pressure of atleast

1,800 Ibs. per sq. inch to convert said moisture into steam and compact the vegetable material.

3. A method according to claim 2, in which the initial vegetable material contains from 5 to 10% by weightmoisture.

4. A method according to claim 3, in which the moisture is reduced by the heating under pressure to from 6 to 8% by weight.

5. A method according to any one of claims 2 to 4, in which the initial proteinaceous vegetable material has an NSI of 30 to 70.

6. A method according to any one of claims 2 to 5, in which the pressure is from 2000 to 5000 lbs. per sq. inch at from 150 to 2000C.

7. A method according to any one of claims 2 to 6, in which the heating and pressure is applied for from 1.5 to 5 minutes.

8. A method according to any one of the preceding claims, in which the water is at a temperature of at least1500F. (660 C.).

9. A method according to claim 8, in which the water has a temperature of from 190 to2120F. (880--

1000C.).

10. A method according to any one of claims 1 to 9, in which the leaching is for from14 to1 hours.

11. A method according to any one of claims 1 to 10, in which the leaching is carried out at atmospheric pressure.

12. A method according to any one of claims 8 to 11, in which the water has a pH of from5--10.

13. A method according to any one of claims 1 to 12, in which the chunks are washed before drying.

14. A method according to claim 13, in which the wash is with water of from 130 to2120F. (74--

1000C.).

15. A method according to any one of the preceding claims, in which the drying is effected with hot air.

16. A method according to any one of claims 1 to 15, in which the final moisture content of the dried chunks is from 4 to 8% byweight

17. A method according to any one of claims 1 to 16, in which the compacted chunks pass through a 1 inch opening screen and are retained on a9 inch screen.

18. A method of preparing a proteinaceous material according to claim 1, substantially as hereinbefore described.

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19. Chunks of proteinaceous material when produced by a process according to any one of the preceding claims.

20. Chunks according to claim 19, which have been hydrated in hot or boiling water.

21. A food formulation containing chunks according to either of claims 19 and 20.Data supplied from the esp@cenet database - Worldwide

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96.

GB1372979 - 11/6/1974

PARBOILING AND DRYING OF PADDY


Applicant(s): FERNANDO M M H I (--)


IP Class: A23L1/10

E Class: A23L1/10H2; F26B11/02D; F26B11/04E


Priority Number: LK19720006899 (19720603)

Family: GB1372979

Equivalent: JP49048859; FR2187237; DE2327966; AU5639873

Abstract:


1372979 Parboiled rice M M H I FERN- ANDO 1 June 1973 [3 June 1972] 26352/73 Heading A2Q

Moist rice paddy is parboiled and dried by passing it along a conduit externally heated by burning paddy husks. In a particular apparatus, the conduit is a tapering drum 7-Fig. 2-fitted with longitudinal fins 8 and rotating about a horizontal axis in the upper part of furnace 11. Moist paddy in hopper 1-Fig.

3- is supplied to one end of the drum via conveyor 3, funnel 5 and conduit 6. Paddy husks are fed

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from hopper (13)-Fig. 4, not shown- into the air supply of blower 14 from which a blast of airborne husks are supplied via conduit 19 to the lower part of furnace 11. The rate of supply of air and husks is thermostatically controlled to ensure a constant temperature in drum 7. The treated paddy is discharged via chute (21)-Fig. 4, not shown-at the opposite end of the furnace.Description:


(54) PARBOILING AND DRYING OF PADDY

(71) I, MAHASOORIYA MAHAMALIMAGE

HUBERT IGNATIUS FERNANDO, a citizen of Sri

Lanka, of 22/4 Santamore, Puranappu Rajamawatha, Moratuwa, Republic of Sri Lanka, do hereby declare the invention, for which

I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention relates to the treatment of paddy in order to gelatinize or parboil the starch content of the paddy and in order to dry the paddy.

Known processes for parboiling and drying paddy require a number of separate operations using large amounts of water and energy in complex equipment. Usually the paddy is steamed and then dried by hot air.

The aim of the present invention is to simplify the process so that it requires minimal expenditure of resources and can be practised using equipment which is not complex.

The invention provides a process for the treatment of paddy to gelatinize or parboil the starch content of the paddy and to dry the paddy, in which moist paddy is passed through a conduit which is heated externally by heat generated by the combustion of paddy husks, the heat transmitted to the paddy being sufficient to gelatinize or parboil the starch and subsequently dry the paddy.

Thus the steam required for gelatinization or parboiling is contained in the paddy itself.

It is preferable for all the heat supplied to the exterior of the conduit to begener- ated by the combustion of paddy husks.

The invention also provides apparatus for practising this process, the apparatus comprising a conveyor running from a supply of moist paddy to a hopper which discharges into an elongate drum, means for rotating the drum, the paddy travelling along the drum under the action of gravity, and a furnace through which the drum extends.

The invention will be described further, by way of example only, with reference to the accompanying diagrammatic drawings, in which:

Figure 1 is a plan view of one embodiment of apparatus according to the invention;

Figure 2 is a fragmentary section on line11-11 of Figure 1;

Figure 3 is an end elevation in the direction of arrow III in Figure 1; and

Figure 4 is an end elevation in the direction of arrow IV in Figure 1.

Moist paddy to be treated by the illustrated apparatus is loaded into a supply trough 1 from where the paddy falls into a reservoir box 2. The paddy is raised by a bucket conveyor 3 which feeds a receptacle or hopper 5. The cylindrical stem 6 (Figure 3) of the hopper 5 has a viewing window (not shown) and contains an inlet regulator door (not visible) which regulates the rate of discharge of the hopper.

The hopper 5 discharges into one end of a paddy-treating channel in the form of an elongate tapering drum 7 (Figure 2). The drum is rotated continuously and has longitudinal fins 8 which agitate the paddy by raising it and allowing it to fall freely. The drum 7 passes through the upper space 9 of a furnace chamber 11 which is lined with firebricks 12.

The furnace is fired with paddy husks in the following way. Paddy husks are loaded into a hopper 13

(Figure 4) which discharges into the air intake of a blower 14 through a regulating gate 17 (Figure 1) which thus controls the rate at which air and husks are supplied by the blower. The regulating gate 17

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is connected by a linkage 18 to a thermostatic control device (not shown) responsive to the temperature within the furnace. The husks are driven by the blower 14 through a blast pipe 19 into the furnace grate beneath the drum 7. Here the husks come into contact with husks which are already burning. The air blast maintains the embers in a glowing condition so that they burn efficiently. Hot gases from the furnace leave through a flue 20.

The heat produced by the combustion of the paddy husks is transmitted (by radiation and convection) to the drum 7 which is thus heated externally and conducts this heat to the moist paddy in the drum).

This causes gelatinization or parboiling of the starch content of the paddy and subsequently causes drying of the paddy. The rotation of the drum 7 and the fins 8 ensure that the paddy is heated uniformly. The paddy travels along the drum 7 under the action of gravity and discharges from the end of the drum to a chute 21.

The moving parts of the apparatus are driven from a single motor 22, which is arranged to drive an endless belt 23. To communicate motion to the moving parts of the apparatus, the belt 23 is tightened by a simple clutch comprising a pivotable handle 24 carrying an idle roller 26 over which the belt passes. The belt drives a pulley 27 connected to the impeller of the blower 14.

The belt also drives a pulley 28 whose shaft 29 (Figure 1) carries a pinion (not shown) which meshes with a ring gear 31 (Figure 3) mounted on one end of the drum 7, in order to rotate the drum.

The end of the drum 7 remote from the ring gear 31 is connected to a coaxial shaft 32 carrying a pulley

33 which drives an endless belt 34 passing round a driven pulley 36 whose rotation is transmitted by a shaft 37 to the upper wheel 4 of the bucket conveyor 3.

The motor 22 comprises an internal combustion engine or an electric motor. It could be replaced by a steam engine in which the steam is generated by heat supplied by the combustion of paddy husks.

WHAT I CLAIMIS:-

1. A process for the treatment of paddy to gelatinize or parboil the starch content of the paddy and to dry the paddy, in which moist paddy is passed through a conduit which is heated externally by heat generated by the combustion of paddy husks, the heat transmitted to the paddy being sufficient to gelatinize or parboil the starch and subsequently dry the paddy.

2. A process as claimed in claim 1, in which all the heat supplied to the exterior of the conduit is generated by the combustion of paddy husks.

3. A process as claimed in claim 1 or 2, in which the paddyhusks are burnt in a furnace chamber through which the conduit passes.

4. A process as claimed in claim 3, in which paddy husks are supplied to the furnace chamber by an air blast.

5. A process as claimed in claim 3 or 4, in which the rate at which paddy husks and air are supplied to the furnace chamber is controlled by a thermostatic control device responsive to the temperature within the furnace.

6. A process as claimed in any of claims 1 to 5, in which the conduit is a drum which is rotated as the paddy passes through it.

7. Apparatus for the treatment of paddy by a method according to claim 1, theap- paratus comprising a conveyor running from a supply of moist paddy to a hopper which discharges into an elongate drum, means for rotating the drum, the paddy travelling along the drum under the action of gravity, and a furnace through which the drum extends.

8. Apparatus as claimed in claim 7, in which the drum tapers.

9. Apparatus as claimed in claim 7 or 8; in which the drum has longitudinal internal fins.

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10. Apparatus as claimed in any of claims 7 to 9, including a hopper for paddy husks discharging into an inlet of an air blower which, in turn, discharge into the furnace.

11. Apparatus as claimed in claim 10, in which the outlet from the air blower to the furnace includes a regulating gate for controlling the rate at which husks and air are supplied to the furnace, the gate being linked to a thermostatic control device responsive to the temperature within the furnace.

12. Apparatus for the treatment of paddy, substantially as described herein with reference to and as shown in the accompanying drawings.

13. A process for treating paddy, substantially as described herein with reference to the accompanying drawings.

14. Paddy treated by a process or apparatus as claimed in any of the precedingData supplied from the esp@cenet database - Worldwide Claims:

Claims of GB1372979 claims.Data supplied from the esp@cenet database - Worldwide

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97.

GB1375515 - 11/27/1974

CHEMICAL MODIFICATION OF RICE



IP Class: A23L1/10

E Class: A23L1/182; A23B9/26



Family: GB1375515

Equivalent:

IT1048123

US3835225; NL7307926; JP49042843; FR2196758; ES416149; DE2334944;

Abstract:


1375515 Cross-linking rice grains RE- SEARCH CORP 19 July 1973 [20 July 1972] 34373/73

Heading A2Q The heat-stability of rice grains is improved by treating them with a starch cross-linking agent. The treatment is also applicable to parboiled rice grains. Before cross-linking, the grains may be treated with an aqueous sodium chloride/sodium hydroxide solution. Cross- linking agents specified include epichlorohydrin, cyanuric chloride, phosphorus oxychloride, sodium metaphosphate, sodium trimetaphosphate, formaldehyde, acrolein, 1- octenyl succinic anhydride, adipic anhydride, citric acid and acetic anhydride in combination, 1, 2, 3, 4-diepoxybutane, bis-epoxy propyl ether, ethylene glycol bis-epoxy propyl ether and 1,4-butane diol bis-epoxy propyl ether. The treated rice may be washed with water and its pH adjusted to above 4 with hydrochloric acid.

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98.

GB1384149 - 2/19/1975

PROTEIN FREE ALIMENTARY PASTES AND A PROCESS FOR THEIR

PRODUCTION


Applicant(s): SALZA S (--)


IP Class: A23L1/16

E Class: A23L1/16; A23L1/0522; A23L1/0522B


Priority Number: IT19710069449 (19710721); IT19710070938 (19711130)

Family: GB1384149

Equivalent: US3836680; NL7209813; FR2146872; ES405061; DE2235030; CH573222;

BE786423; SE386815; NO136329B

Abstract:


1384149 Pasta S SALZA 18 July 1972 [21 July 1971 30 Nov 1971] 33475/72 Heading A2B A proteinfree pasta comprises a mixture of ungelatinised starch and gelatinised starch, the latter acting as a binder for the former. It may be prepared (a) by kneading all the starch, in the presence of water and an emulsifier such as a monoglyceride of a C 14 to C 18 fatty acid at a temperature below 60 C, heating to 60-75 C, and then cooking and extruding, or (b) kneading only part of the starch with the water and emulsifier, the remainder being added when the homogeneous mass is heated to 60 to 75 C. The cooking step may be carried out at atmospheric pressure, heating to 80-95 C within 10 - 12 minutes, or by heating to 110-120 C within 6-10 minutes at superatmospheric pressure. The starch may be obtained, for example, from corn, rice, wheat or potato. The preferred composition is 52-64 parts water and 0.8-1.2 parts emulsifier per 100 parts starch.Description:



( 11) 1 384 149 ( 21) Application No 33475/72 ( 22) Filed 18 July 1972 ( 19) ( 31) Convention

Application Nos 69449 ( 32) Filed 21 July 1971 70938 30 Nov 1971 in ( 33) Italy (IT) ( 44) Complete

Specification published 19 Feb 1975 ( 51) INT CL 2 A 23 L 1/16 ( 52) Index at acceptance A 2 B 1 B 1

JY 1 Z ( 54) PROTEIN FREE ALIMENTARY PASTES AND A PROCESS FOR THEIR

PRODUCTION ( 71) I, SILVO SALZA, an Italian citizen of 46 Via Sottoborgo, 56100 Pisa, Italy, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:-

The invention is concerned with the production of alimentary pastes which are substantially free of glutens and therefore of proteins, and which are accordingly suitable for the nourishment of persons suffering from chronic uraemia and other dysfunctions.

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The basic ingredient of such aproteinic pastes is starch The origin of the starch, for example, whether from cereals, roots or potatoes, is of no importance.

In the manufacture of the commonly used alimentary pastes, gluten acts as a binder.

However, this substance is proteinic As a binder in protein free pastes, in lieu of gluten it has been suggested to use cellulose derivatives, such as carboxymethylcellulose or natural polysaccharide gums, such as guar gum or alginic acid.

The fundamental problem connected with the manufacture of alimentary pastes in general, and of protein free pastes in particular, is that of their stablity in cooking When cooked, the paste should not turn sticky and agglomerate into a gluey mass From this viewpoint, a substituition of gluten by cellulose derivatives and/or natural polysaccharide gums has not been successful.

Also the presence of these rather costly substances in the food may in some cases be unadvisable, owing to their effects upon some physilogical functions.

According to the present invention there is provided a process for the production of a protein-free, starch-based alimentary paste, comprising forming a protein-free mixture of ungelatinized starch and gelatinized starch, the latter acting as a binder for the former, and working the mixture into the desired shape of alimentary paste, for example spaghetti, maccaroni or rigatoni.

The present invention further provides an elinmentary paste comprising a protein 50 free mixture of ungelatinized starch and gelatinized starch, the latter acting as a binder for the former.

To promote the mutual dispersion of these two constituents in the mixture, it is pre 55 ferred to add small amounts of an emulsifier, such as monoglycerides of the alimentary C 14 C 18 fatty acids, together with suitable dyes to confer a desired colour to the resulting alimentary paste 60 The process of the invention can be carried out either in two stages or in a single stage, the resulting products being identical in their properties.

In the two-stage process, one part of the 65 starch is mixed to a homogenous mass with the necessary amount of water and optionally emulsifiers, and then heated, under continuous mixing, to the temperature at which its gelatinzation starts, which, accord 70 ing to the type of starch used, is in the range of 60-750 C Subsequently, the remaining starch is added and the resulting mass is cooked till the required mixture is obtained.

This is then immediately extruded to the de 75 sired shapes, said extrusion causing the quick cooling of the mass and consequently the rapid interruption of the cooking process.

In the single stage process, the whole amount of the starch is kneaded with the 80 necessary amount of water, and optionally said mono-gylcerides as emulsifiers This first portion of the stage is performed at a temperature which does not reach the temperature ( 60-75 C) at which the gelatiniza 85 tion of the starch begins until the mixture has been kneaded to a completely homoEgenous mass From this point on the mass is:

cooked at a high temperature, up to a point where only part of the starch is converted 90 1 384 149 to gelatinised starch and thereafter it is ii passed through the extruder and cooled a The proportion of said monoglycerides h ranges from 0 8 to 1 2 (preferably 1 0) parts in weight for 100 parts in weight of the total starch used The proportion of water c depends on the consistency which is to be c conferred to the mass during its extrusion, t in view of the type of alimentary paste which has to be produced Also the eva poraton of the water during the process must t be taken into account, unless the whole t procedure is carried out in a closed appa 1 ratus, such as a closed combination mixer extruder unit For conventional pastes, 52 to 64, preferably 57 to 59 parts in weight of water are used for 100 parts in weight of the total amount of starch Any type of starch may be used for this process, such as starch produced from wheat, potatoes, rice and corn However, as mentioned in the examples, a mixture of various starches is preferred for best results.

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Independently of whether the process is performed in a single or in two stages, the cooking proper is preferably regulated so that the mixture reaches a temperature of 80-95 C within 10 12 minutes when using an open apparatus, that is when cooking under atmospheric pressure, and a temperature 110-120

C, preferably between 110 and C within 6 10 minutes, preferably within 8 minutes, when using a closed apparatus, that is when cooking under a higher pressure This cooking stage is of great importance for the process, because tests have shown that the chemical and physical interactions which confer to the final product its stability to cooking develop during this stage If the mass is not cooked or it is not cooked at the temperature and for the times indicated above, the resulting product falls far below the desirable requirements.

The following Examples illustrate the process of the present invention.

EXAMPLE I

12 kg of potato starch, 30 kg of corn starch and 18 kg or rice starch were kneaded in a closed mixer with 35 litres water in the presence of 0 600 kg of monoglycerides of Cll C,6 fatty acids as emulsifiers and a suitable, officially permitted dye The mixture was heated so that its temperature reached 65 C after it had been kneaded into a homogeneous mass Thereafter the cooking proper was begun during which the temperature of the mass was raised linearly, under continuous mixing, within 8 minutes to

C, at the end of which period the heat supply was interrupted The mass was then passed through an extruder to form spaghetti and conveyed into a drying chamber Within approximately 15 seconds from its issue from the extruder, the temperature of the spaghetti had dropped below 65 C and when t was removed from the conveyor, it was already almost dry and its temperature lad sunk to 35-40 C.

EXAMPLE II

The process of Example I may be carried 70 out in two stages In the first stage, part of the 60 kg of the already mentioned mixure of starches was kneaded, together with litres of water and 0 600 kg of said monoglycerides in a closed mixer-extruder, while 75 he temperature of the mixer was raised so that 65 C was reached after the mixture had become completely homogenous Subsequently, the remaining starch was added and the temperature of the mixture raised, 80 uinder continuous kneading, to reach 110 C at the end of 8 minutes The remaining operations as well as the results were identical in both Examples.

g batches of the spaghetti obtained 85 with each of the methods used in the Examples were cooked for

8 minutes in 1 litre water, strained and poured into soup plates They could be stirred and lifted with a fork without difficulty, since they neither 90 become entangled or pasted together, nor broke.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT I CLAIM IS:-

1 A process for the production of a protein-free, starch-based alimentary paste, 95 comprising forming a protein-free mixture of ungelatinized starch and gelatinized starch, the latter acting as a binder for the former and working the mixture into the desired shape of alimentary paste 100 2 A process according to claim 1, comprising the steps of kneading the starch, in the presence of an emulsifier, in water at a temperature reaching 60-75 C only after the mixture has been kneaded to a homogeneous 105 mass, cooking said homogeneous mass to a point where part of the starch is still ungelatinized, and subsequently extruding it to the desired shapes.

3 A process according to claim 2, where 110 in the cooking of the starch is performed at atmospheric pressure and the homogeneous mass of starch is heated within 10-12 minutes to a temperature of 80-95

C, and subsequently extruded 115 4 A process according to claim 2, wherein the cooking of the starch is performed at a pressure above atmospheric pressure and the mass of starch is heated, within 6-10 minutes to 110-120 C and sub 120 sequently extruded.

A process according to claim 1, wherein part of the total amount of starch is mixed with water and an emulsifier at a temperature reaching 60-75 C only after the 125 mixture has been worked to a

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homogeneous mass, the remaining starch is kneaded into said mass, and the whole is cooked for a period of 10-12 minutes at a temperature reaching 80-95 C at the end of said period, 130 1 384 149 and subsequently extruded.

6 A process according to claim 1, wherein part of the total amount of starch is mixed with water and an emulsifier at a temperature reaching 60-75 C only after the mixture has been worked to a homogeneous mass, the remaining starch is kneaded into said mass, and the whole is cooked at a pressure above atmospheric pressure for a period of 6 to 10 minutes at a temperature reaching 110-120

C at the end of said period, and subsequently extruded.

7 A process according to any one of claims 2 to 6, wherein the emulsifier is a monoglyceride of a C,, to

C,8 fatty acid.

8 A process according to any one of claims 2 to 7, wherein the emulsifier is present in the proportion of

0 8 to 1 2 weight percent of the total starch in said mixture.

9 A process according to claim 2, where 20 in the proportion between starch, water and emulsifier is

60:35:0 6, A process according to claim 1 substantially as described in either of the Examples 25 11 An alimentary paste whenever obtained by a process according to any one of claims 1 to 10.

12 An alimentary paste comprising a protein-free mixture of ungelatinized starch 30 and gelatinized starch, the latter acting as a binder for the former.

BROOKES & MARTIN Chartered Patent Agents.

High Holborn House, 52/54 High Holborn, LONDON WC 1 V 65 E.

(Agents for the Applicants).

Printed for Her Majesty's Stationery Office by The Tweeddale Press Ltd, Berwick-upon-Tweed, 1975.

Published at the Patent Office, 25 Southampton Buildings, London, WC 2 A IAY, from which cooiea may be obtained.Data supplied from the esp@cenet database - Worldwide

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99.

GB1392151 - 4/30/1975

FORTIFICATION OF FOODSTUFFS WITH N-ACETYL-L-METHIONINE


Applicant(s): PROCTER and GAMBLE (--)

IP Class 4 Digits: A23J; A23K

IP Class: A23K1/00; A23J1/00

E Class: A23L1/305A; A23L1/10B; A23J3/22C; A23J3/00; A23J3/26; A23K1/16G1; A23L1/38



Family: GB1392151

Equivalent: US3878305; NL7307293; JP49124244; FR2185360; ES415159; DE2326444;

CH583003; BE800030; SE388113; NL177564C

Abstract:


1392151 N-acetyl-L-methionine fortified foodstuff PROCTER & GAMBLE CO 24 May 1973 [25

May 1972] 24852/73 Heading A2B A proteinaceous foodstuff, deficient in S- containing amino acids, is fortified with N- acetyl-L-methionine free of the corresponding D-isomer. The foodstuff may be collagen, alfalfa, soy bean, cotton seed, peanut, sun flower, flax meal, wheat, corn, barley, oats, rice, casein, non-fat milk solids, whey, lactalbumin and fish concentrate.

500/2197

100.

GB1401572 - 7/16/1975

MEAT PRODUCT


Applicant(s): FOOD TECHNOLOGY (--)


IP Class: A23L1/31; A23L1/325; A23L1/315

E Class: A23L1/00P8B4; A23L1/325H; A23L1/31H; A23L1/325E; A23B4/10; A23L1/314B8



Family: GB1401572

Abstract:


1401572 Meat and fish preparations FOOD TECHNOLOGY INC 8 Aug 1973 37523/73 Heading A2B

Meat or fish preparations include a powder made by dehydrating a mixture of a sugary syrup in which the solids consist mainly of monosaccharides or both mono- and disac- aharides, not more than 40% of the sugar solids being higher saccharides, and a partially gelatinised starch having a gelatinisation temperature of at least 150 F. The powder may either be coated on the meat of the meat product or mixed homogeneously with it, and it reduces loss in weight and volume when the meat product is cooked. The preferred amount of powder is 1 to 10% by weight of meat. The syrup may be honey or molasses, or high fructose corn syrup and the starch may be wheat rice or corn starch. An emulsifying agent, e.g. hydroxylated lecithin or glycerol mono- or di-stearate and an antihumectant, e.g. calcium stearate, micron- ised silica, tricalcium phosphate or magnesium carbonate, both in amounts up to 1%, may be included in the powder. Preferred composition of the powder is 40 to 80 parts syrup solids to

60 to 20 parts starch. The meat may be beef, pork, mutton, chicken, fish or others, and the meat product coated with or containing the powder may be sausage, hamburger, patty, or fish fingers.

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101.

GB1407442 - 9/24/1975

COOKING APPARATUS


Inventor(s): PRATOLONGO M (--)

Applicant(s): SANTA MARTHA BAY SHIPPING (--)

IP Class 4 Digits: B01J

IP Class: B01J3/00

E Class: A23L1/01D; A47J27/18; G01F11/28; G01F11/30; G07F9/10B


Priority Number: IT19710029724 (19711009); IT19710029725 (19711009); IT19710029726

(19711009)

Family: GB1407442

Equivalent: US3827344; NL7703280; NL7213634; JP48048656; GB1407443; FR2156181;

ES412826; ES407402; DE2247071; DD99921; CH546058; BE789745; SE7506673; SE383092;

NO137177B

Abstract:


502/2197

1407442 Pressure cooker SANTA MARTHA BAY SHIPPING & TRADING CO Ltd 29 Sept 1972 [9

Oct 1971 (3)] 45162/72 Heading B1X Apparatus for cooking, in hot water, metered quantities of foodstuffs such as rice, noodles and the like, comprises a pressurized cooking chamber provided with means to maintain, in said chamber, pre-selected water pressures and temperatures, said chamber having openings for the introduction of raw foodstuff and for the extraction of cooked food respectively, the apparatus further comprising metering means for introducing raw foodstuff to the cooking chamber, a hot water generator for heating water to temperatures over 100 C the generator being connected to said cooking chamber, to maintain food in the chamber submerged in hot water during a cooking operation, and a separator connected to an extraction opening of the cooking chamber by duct means with an obturating member being disposed between the cooking chamber and the separator to enable the separator to receive cooked food from the chamber when said member is opened due to a pressure differential between the chamber and the separator and to separate the cooking water from the cooked food. As shown, foodstuff is supplied from a hopper 38 (see Specification 1407443) to a pre-cooking chamber 28 and thence to cooking chamber 26 which is supplied with hot water from boiler A.

Chamber 26 has an outlet 45 for cooked food leading via obturating member 48 to a centrifugal separator C. Valve 36 is operated as necessary to release vapour from chamber 26 during cooking.

When the food is cooked, obturating member 48 is opened and the pressure in chamber 26 conveys the food to the separator.Description:



( 11) 1 407 442 ( 21) Application No 45162/72 ( 22) Filed 29 Sept 1972 ( 19) ( 31) Convention

Application Nos 29724 ( 32) Filed 9 Oct 1971 29725 9 Oct 1971 29726 9 Oct 1971 in ( 33) Italy (MI) (

44) Complete Specification published 24 Sept 1975 ( 51) INT CL 2 BO 1 J 3/00 ( 52) Index at acceptance Bl X 31 34 ( 54) COOKING APPARATUS ( 71) We, SANTA MARTHA BAY SHIPPING

AND TRADING Co, LTD, of I Handelskade 8, Curacao, Netherlands Antilles, a company constituted under the laws of the Netherlands, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly des-

cribed in and by the following statement:-

This invention relates to apparatus for the quick and controlled cooking in hot water of metered quantities of foodstuffs, such as rice, noodles, spaghetti and the like.

An object of the invention is to achieve metering and quick cooking of foodstuffs, as well as distribution of the cooked food to consumers, for example in vending machines.

It is particularly important to cook foods for self-distribution within a very short period Therefore it is necessary to reduce the so called "technical times", such as required to introduce the raw product into a cooking vessel and to unload the cooked product from said vessel, to close and to open said vessel, to allow water to drain off the cooked food and to separate it from the cooking liquid, as opposed to the real cooking time of the foodstuff.

Another object of the invention is to provide for dressing of the cooked food immediately following the cooking operation, to maintain a quantity of water in the food.

Still another object of the invention is to provide additives or dressings to the cooked food, in such a way as to admix said dressings thoroughly and evenly with the food.

The invention provides apparatus for cooking, in hot water, metered quantities of foodstuffs such as rice, noodles and the like, comprising a pressurized cooking chamber provided with means to maintain, in said chamber, pre-selected water pressures and temperatures, said chamber having openings for the introduction of raw foodstuff and for the extraction of cooked food respectively, the apparatus further comprising metering means for introducing raw foodlPrice 33 pl stuff to the cooking chamber, a hot water generator for heating water to temperatures over 100 C the generator being connected to said cooking chamber, to maintain food in the chamber submerged in hot water during a cooking operation, and a separator connected to an extraction opening of the cooking chamber by duct means with an

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obturating member being disposed between the cooking chamber and the separator to enable the separator to receive cooked food from the chamber when said member is opened due to a pressure differential between the chamber and the separator and to separate the cooking water from the cooked food.

In particular, to cook filamentary material such as spaghetti and the like, the cooking chamber comprises a main chamber and an elongate pre-cooking chamber having a cross-section smaller than that of the main chamber.

The invention will now be described by way of an example with reference to the accompanying drawings in which:

Figure 1 is an isometric projection, with sectioned parts, of a cooking vessel and separating unit;

Figure 2 is a vertical part-section of the cooking vessel; Figure 3 is a cross-section through another form of cooking vessel; Figures 4 and 5 are sections, along lines IV-IV of Figure 3 and the lines V-V of

Figure 4 respectively; Figure 6 is a vertical cross-section of a metering device for long noodles or spaghetti; Figures 7 and 8 are cross-sections alone lines VII-VII and VIII-VIII of Figure 6 respectively.

Considering now Figures 1 and 2 of the drawings, the units shown comprise:

A heat generator to feed a cooking chamber B with pressurized hot water, the outlet of the container leading to a centrifugal separator C.

A heating element 10 of heat generator cl for a shaft 54, the axis of said shaft being displaced downwardly with respect to the axis of said chamber, said shaft firmly retaining a fork 56 with a roller

58 forming a mixer Fork 56 is advantageously rotated 70 in the direction of arrow X of Figure 2 and the fork is so dimensioned that the cylindrical roller thereof 58 co-operates with the lower part of chamber 26.

The outlet tube 46 of cooking chamber 75 B enters the upper part of the centrifugal separator C, the bottom of which is provided with a mouthpiece 75 equipped with a closing disc 68 and one or more drainage openings 74 which may be equipped with 80 filtering and retaining members for the food are provided above said closing disc, said opening or openings each having an outlet tube 76.

Considering now the alternate embodi 85 ment of the apparatus shown in Figures 3, 4 and 5, the parts which are the same as or equivalent to those hereinbefore described are marked with the same reference numerals with subscripts "a" and said em 90 bodiment is provided with a fluid pressurized control or driving member to automate the above described apparatus.

In said alternate embodiment, the boiling or cooking vessel B has a pre-cooking cham 95 her 28 a the lower part of which connects to cooking chamber 26 a having the shape of a truncated cone The larger base of said cooking chamber 26 ' faces downwardly and said chamber is closed by a cover 50, 100 which supports a shaft 54 a of a motor F, to drive a blade 56 a As shown in Figure 5, blade 56 a is combined with a shifting cone 80, the walls of which are substantially parallel with the inner walls of chamber 26, 105 An obturating member 24 a is actuated by a cam 82, said cam being driven by a corresponding motor, for the gradual introduction of hot water into the pressurized vessel or chamber B

110 Chambers 26 a and 28 a, are provided with heating means for the controlled heating thereof, such means consisting, in the illustrated case, of spaces 84 and 86 surrounding the walls of said chamber 115

During the cooking or boiling operation, the pressure in container B is controlled by a pin valve (not shown) associated with an outlet 34 a the pre-cooking chamber 28, being connected to the outlet 34 a, through 120 curved slits 88 provided in the upper wall of pre-cooking chamber 28 a, immediately below an obturating member 30 a,, in such a way that, due to the relatively wide passage provided by slits 88 and to the limited height 125 of said slits, it is possible to release the excess of pressure of container B with limited speed, to prevent the cooked food from being entrained by the vapour.

The movable parts of obturating mem 130 A, which element is preferably of the elec t tric type has at an upper part thereof, a c plurality of probes, 12, 14, 16, and 18, the first and last of said probes providing for t the control of the minimum and maximum water levels in the boiler The intermediate i probes 14 and 16 are designed to control the operation of a feed pump (not shown) attached to

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connection 20 The probes are connected to appropriate control apparatus to adjust the performance of the boiler, in such a way that the water supply to the boiler is independent from the extraction of hot water from the boiler.

Heat generator A connects to chamber B by means of a tube 22 provided with controlled obturating member 24, to perform a food cooking operation as will be described.

The cooking chamber or vessel B as shown in Figures 1 and 2 serves to cook or boil noodles and the like, such as, for instance, "spaghetti" said noodles being introduced into the vessel in the form of a metered bundle D.

The vessel B comprises a cylindrical chamber 26 having the desired capacity, connected, at the upper end thereof, to a cylindrically shaped pre-cooking chamber 28, having a smaller diameter than that of chamber 26, the axis of said pre-cooking chamber being perpendicular to the axis of chamber 26 The diameter, and length of pre-cooking chamber 28 are substantially the same as those of the food bundle

D The top of pre-cooking chamber 28 is closed by means of an obturating member 30 provided with feed hopper or feed box 32 for the raw material D Further, pre-cooking chamber 28 has towards its upper end and next to obturating member 30, a duct 34 provided with a pin valve 36 to control communication between pre-cooking chamber and the atmosphere The loading hopper or feed box 32 is situated below and in alignment with a container 38, the bottom of which has a swinging plate 40 integral with a shaft 42 of a motor 44 and the upper part of said container is connected to the outlet of a volumetric metering device E, (not shown in Fig 1) and which for example of the type as shown in

Figures 6-8.

Cooking or boiling chamber 26 has, at the centre thereof, a connection 45 for a duct 46 with an obturating member 48 to connect said chamber to a centrifugal separator C Duct 46 can extend in any desired direction, for example tangentially to the chamber 26 or radially to the chamber as shown and it can have a length of up to 2 to 3 metres or more The duct 46 can also be provided with means for delivering material quantities of dressings or the like to the cooked food Chamber 26 is closed by means of a cover 50 with a support 52 1,407,442 1,407,442 bers 30, and 483 advantageously consist of pierced balls, to allow for the free passage of the cooked food, it being possible to actuate such balls by means of alternate motors F and G (Fig 3) through controlled electric valves, automatically to actuate the operating cycle of the apparatus by means of a programmer.

Metering device E, shown in Figures 6,Data supplied from the esp@cenet database - Worldwide

Claims:


7, 8, and which is claimed per se in our

Application No 54985/74 (Serial No.

1,407,443) divided from the present application is particularly suitable for metering spaghetti or like filamentary foodstuffs and comprises a container 100 for the filamentary material D, which is initially deposited into said container in a vertical direction with the axes thereof inclined by an angle X (for example of 300) with respect to axis VIIVII of the container, in such a way that the filamentary elements D then come to rest with their ends against front wall 102 of said container, the elements being influenced by gravity to move towards an outlet 103 of the container The opening is provided at the bottom of container 100, the section of which is rectangular and the container connects, by means of said section, with two inclined downwardly converging outlet walls.

A stop 105 is provided in outlet 103, said stop being attached, through a pivot 109, to an arm 106, pivotally connected at 107, to the body of the container 100.

By means of a driving member 101, arm 106 is moved in the direction of arrow Y.

in opposition to a return spring 108 in such a way that stop 105 moves down until reaching position

1051, to allow the discharge of a bundle of the filamentary material D held between the stop and a

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metering blade 110 into a collecting container 38 so that the individual elements of the filamentary material are disposed with their axes in a substantially vertical direction.

The transverse cross-section of the collecting container 38 is selected in accordance with the requirement to displace or to pack the cooked material.

As already mentioned with reference to the embodiment shown in Figures 1 and 2, plate 40 is inserted between the outlet opening of collecting container 38 and the feed hopper 32 and said plate is moved in the direction of arrow Z, in order to discharge the metered material D into the cooking chamber situated below the container The metered quantity of spaghetti D' which is delivered at each of the operations performed by the plate, is determined by the position of blade 110 which is integral with a swinging arm 112 fulcrumed, at 113 to the body of the device Blade 110 is constrained to slide in a slit

114 in the container 100 which is provided at a height L, from stop 105.

If blade 110 is rotated in the direction of arrow K (toward position 1101 shown in Figure 8), said blade penetrates into material D, to meter a constant portion established by width L 2 of mouth-piece

103, as well as 70 by distance L, between stop 105 and blade The blade is designed to retain material D which is situated above it, during the opening of stop 105, i e during the discharge operation of the metered quantity 75 D, which is then conveyed to collector 38.

The width of slit 114 and of blade 110 should be less than one/half of the outer diameter of the individual spaghetti filaments, to prevent said filaments from wedging with each 80 other.

The front edge 115 of blade 110 is preferably inclined with respect to the radial direction in such a way as to provide a permanent fit of the outermost part of the 85 blade into slit 114 and the progressive outspreading of the spaghetti which is performed by said blade, in an inclined direction with respect to the axis of the spaghetti.

The metering operation is thus performed 90 by alternate movements of the blade 110 and the stop

105.

The quantity of material which is extracted with each metering operation can be varied by changing the height L, by means 95 of set screw 116 which moves the end-stroke position of stop 105.

Stop 105 is orientated through pivot 109, so as to be at an angle to the axis of material D when it drops into the outlet 103 Re 100 turn-spring 108 can also operate as a damping means for the dropping material and/or to compensate possible irregularities during the performance of blade 110.

A stiff diaphragm 118 in the form of a 105 wedge integral with container 100, co-operates in maintaining the spaghetti parallel to each other and parallel with the side-walls.

In the operation of the apparatus, initially, the obturating members of the apparatus are 110 in the following positions: obturating member 30 is open; pin-valve 36 is closed; obturating members 24 and

48 are closed: locking-disc 68 for the centrifugal separator C is closed; swinging blade 40 of container

38 115 is closed.

When spaghetti is to be cooked, it is metered and delivered by the metering device E, into container

38, where the spaghetti is retained by means of plate 40 120 Thereafter, the plate 40 is caused to move away from container 38, to allow the spaghetti-bundle drop into the cooking vessel B situated below the container The drop of the raw material is damped by a water 125 cushion, previously introduced; or by the amount of water which is left in chamber 26 after the performance of the preceding unloading operation Then obturating member 30 closes and cock 24 opens, to intro 130 1,407,442 duce a quantity of boiling water from boiler A, into chamber 26 To facilitate collection of the material in chamber 26 during the cooking step, a fork 56 is operated and then rotated during the entire cooking or boiling time

The stirring operation of the material which is performed during the cooking or boiling step also provides for expansion of the external layer and a quick soaking of said material, thus ensuring quick and uniform cooking thereof Furthermore, the stirring operation of the material during the cooking stage is performed in countercurrent with respect to the direction along which the material is loaded into and unloaded from container B, to ensure uniform cooking During the softening and cooking stage

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of the food, valve 36 is actuated at intervals to release, from the pressurized vessel B, the excess of vapour, for the purpose of ensuring good cooking conditions in accordance with the quality of material to be cooked The material is cooked in hot water, without coming into contact with the vapour, by maintaining, in vessel or container B, the necessary liquid level and by releasing, at regular intervals.

the vapour which forms in said chamber, due to the stirring operation When the spaghetti reaches the desired cooking degree, obturating member 48 is quickly actuated to connect the boiling or cooking vessel B with the centrifugal separator C.

As said separator is charged by atmospheric pressure, whereas cooking or boiling vessel B is charged by a higher pressure (for instance of over 2 atm), the cooked spaghetti and the cooling liquid are conveyed substantially instantaneously into duct 46 and then unloaded into the centrifugal separator C

To convey the cooked food from the pressurized vessel B into the centrifugal separator C, it is possible to use conveying ducts 46 of any practical length; or crosssection, as the conveyance of said cooked material is, at any time, ensured by the pressure difference existing between the cooking chamber B and the centrifugal separator C.

The material delivered by duct 46 and which is unloaded in a tangential direction into the centrifugal separator, is centrifuged and, as it looses kinetic energy, it collects at the bottom of the centrifugal separator, whilst the vapour is released to the atmosphere through duct 64.

Since the pressure which prevails in the centrifugal separator C is reduced part ol the hot water content of the cooked material is released, in such a way that the watei content of the ready cooked material is low Chamber 60 of the centrifugal separator C allows the collection not only of the centrifuged and cooked material, but also certain amount of the cooking liquid whicl is carried by the cooked food If the cooke>; food is served immediately to the consumer, part of said liquid is preserved in the cooked food and the quantity of said liquid varies centrifugal separator, whereas the remaining according to the position of drainage opening 74 in the wall of chamber 60 of the liquid is drained off through duct 76 Finally, the cooked food is unloaded through discharge opening 68.

It is possible to modify the above described cooking vessel, as well as the apparatus which incorporates said vessel according to the quality of food to be cooked The cooking vessel can be maintained at required temperatures by circulating an appropriately heated fluid through the free spaces

84 and 86.

WHAT WE CLAIM IS:1 Apparatus for cooking, in hot water, 85 metered quantities of foodstuffs such as rice, noodles and the like, comprising a pressurized cooking chamber provided with means to maintain, in said chamber, preselected water pressures and temperatures, 90 said chamber having openings for the introduction of rawv foodstuff and for the extraction of cooked food respectively, the apparatus further comprising metering means for introducing raw foodstuff to the cooking 95 chamber, a hot water generator for heating water to temperatures over 100 C the generator being connected to said cooking chamber, to maintain food in the chamber submerged in hot water during a cooking 100 operation, and a separator connected to an extraction opening of the cooking chamber by duct means with an obturating member being disposed between the cooking chamber and the separator to enable the separa 105 tor to receive cooked food from the chamber when said member is opened due to a pressure differential between the chamber and the separator and to separate the cooking water from the cooked food 110 2 Apparatus as claimed in claim 1, particularly for cooking foods comprising elongate filaments such as "spaghetti" wherein the coolking chamber comprises a main chamber and an elongate pre-cooking cham 115 ber having a cross-section which is smaller than that of the main chamber.

3 Apparatus as claimed in claim 1 or 2, wherein the cooking chamber has a vapour escape outlet controlled by obturat 120 ing means, and passage means providing communication between the cooking chamber and the outlet and dimensioned and configured to prevent the escape of foodstuff from the chamber when vapour is re 125 leased.

4 Apparatus as claimed in any preceding claim, wherein the cooking chamber is provided with mixing means to mix the foodstuff during the cooking operation 130 1,407,442 Apparatus as claimed in claim

4, wherein the mixing means is carried by a cover of the chamber and is arranged to co-operate with at least part of the peripheral wall of said chamber.

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6 Apparatus as claimed in claim 2, wherein the two chambers have substantially orthogonal axes.

7 Apparatus as claimed in claims 2 and 5, wherein the two chambers have coincident and aligned axes, and the mixing means is carried by a bottom wall of the main chamber and has a rotational axis in a substantially vertical plane.

8 Apparatus as claimed in claim 7, wherein the bottom wall of the main chamber carries a shifting member to move material delivered from the pre-cooking chamber in a radial direction.

9 Apparatus as claimed in claim 8, wherein the main chamber has the shape of a truncated cone, with its base forming the bottom wall which carries the mixing means as well as the shifting member which is in the shape of a cone.

Apparatus as claimed in any preceding claim wherein the extraction opening through which the cooked food is discharged from the cooking chamber is disposed either radially or tangentially to said chamber.

11 Apparatus as claimed in any preceding claim wherein the separator is a centrifugal separator.

12 Apparatus as claimed in claim 11, wherein the centrifugal separator is provided with a drainage opening to drain excess water therefrom at the bottom of the separator, with a discharge assembly for removing cooked food by gravity from the separator.

13 Apparatus as claimed in claim 12, wherein the drainage opening is formed by adjustable members to vary the position of said opening with respect to the separator in order to vary the quantity of liquid maintained in the cooked food.

14 Apparatus according to claim 13, wherein the drainage opening is formed in a peripheral wall of the centrifugal separator and said opening is provided with a filtering and retaining member for the food.

Apparatus as claimed in any preceding claim wherein the duct means connecting the cooking chamber to the separator comprises members for delivering metered quantities of dressings or the like into the cooked food.

16 Apparatus according to any preceding claim wherein the metering means comprises a container provided with members 60 for directing filamentary foodstuffs towards an outlet duct at the bottom to said container, said container being provided with a blade movable across the container.

17 Apparatus as claimed in claim 16, 65 wherein the blade is in the shape of a sector to facilitate penetration into a pile of filamentary foodstuff material present in the container, along an inclined path with respect to the material 70 18 Apparatus as claimed in claims 16 or 17 including a movable stop in the delivery duct below the blade and control means for the blade and stop to operate same to meter predetermined quantities of 75 filamentary material by alternate operations of the blade and stop.

19 Apparatus as claimed in claim 18, wherein the stop is carried by a swinging arm influenced by spring means adapted to 80 maintain the stop in a raised position in engagement with the filamentary material.

Apparatus as claimed in any of claims 16 to 19, wherein the container includes a wedge-shaped block for controlling 85 the supply of filamentary material to the discharge duct said container being inclined to the vertical in such a way that one end of a pile of filamentary material contained therein will rest against a wall of said con 90 tainer.

21 A process for cooking foodstuffs such as rice, noodles, spaghetti and the like, comprising introducing a metered quantity of the raw foodstuff into the cooking cham 95 ber hermetically sealing an inlet opening and an outlet opening of said cooking chamber; introducing pressurized water having a temperature of over 100 C into the cooking chamber, stirring the foodstuff in the 100 water during the cooking thereof, extracting vapour from the cooked food, by unloading at least part of the cooking or

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boiling liquid through the outlet opening to obtain a rapid drop in pressure; removing excess cooking

105 liquid from the cooked food: removing vapour developed during rapid drop in pressure from the cooked food and absorbing the kinetic energy of the cooked food unloaded from the cooking chamber

110 22 Cooking apparatus substantially as herein described with reference to the accompanying drawings.

MARKS & CLERK.

Printed for Her Majesty's Stationery Office by Burgess & Son (Abingdon), Ltd -1975 Published at

The Patent Office, 25 Southampton Buildings, London, WC 2 A IAY from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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102.

GB1412905 - 11/5/1975

PROCESS FOR DEHYDRATING HIGH FRUCTOSE CORN SYRUP OR

MIXTURES THEREOF WITH HONEY


Applicant(s): FOOD TECHNOLOGY (--)


IP Class: A23L1/10

E Class: A23L1/09; A23L1/236D4; C13K11/00



Family: GB1412905

Equivalent: US3833413; FR2197534; DE2344281

Abstract:


1412905 Dehydrating corn syrup compositions FOOD TECHNOLOGY Inc 8 Aug 1973 [5 Sept

1972] 37526/73 Heading A2B A slurry comprising high fructose corn syrup (i.e. at least 40% by wt. of the solids are fructose) and soy protein material e.g. soy flour, which contains at least 45% protein of which 20% is water soluble and in which the wt. ratio of water soluble protein to fat is at least 1.5:1 is dehydrated by heating a thin film thereof e.g. on the surfaces of heated drums. A typical slurry composition contains 70 parts corn syrup to 30 parts soy protein material, of which 15 to 85% of the corn syrup may be replaced by honey and 0.25 to 29.75 parts of the soy protein material may be replaced by ungelatinised starch having a gelatinisation temperature above 150 F. The starch may be preheated to 15 to 30 below gelatinisation temperature so that on dehydration it is only partly gelatinised. An emulsifier e.g. glycerol mono- or di-stearate or hydroxylated lecithin may be included.

The starch may be wheat, corn or rice flour. Up to 90% of the protein may be water soluble and the ratio of water soluble protein to fat may be up to 90:1. The product is milled after dehydration.Claims:


WHAT WE CLAIM IS: -

1 A process for dehydrating high fructose corn syrup as hereinbefore defined, or a mixture thereof with honey, which comprises intimately mixing said syrup with an at least 80 partially defatted soy protein containing material to form a slurry, and subsequently subjecting said slurry in a thin film to a heated surface for a period of time sufficient to dehydrate said slurry, the quantity of said soy 85 protein containing material being sufficient to enhance the crispness of said film when dehydrated the protein content of said soy protein containing material being at least 45 % by weight, the water soluble protein content be 90 ing at least 20/' by weight of the total protein content, and the weight ratio of water soluble protein to fat content being at least 1.5:1.

2 A process as claimed in claim 1 in which 95 honey is mixed with said high fructose corn syrup so that the weight ratio of honey solids to high fructose corn syrup solids is within the range of 15: 85 to

85: 15.

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3 A process as claimed in claim 1 or 2 100 in which said soy protein containing material is a soy flour having a water soluble protein weight of the total protein content.

4 A process as claimed in claim 3 in which the weight ratio of water soluble protein to 105 fat content of said soy flour is within the range of 1 5:1 to 90: 1.

A process as claimed in any one of claims 1 to 4 in which said soy protein containing material comprises approximately 30 110 parts by weight of the slurry and said high fructose corn syrup approximately 70 parts by weight.

6 A process as claimed in claim 1 in which an ungelatinized starch having a gelatiniza 115 tion temperature of at least 150 F is added to said slurry containing said hgh fructose corn syrup and said soy protein containing material, the slurry is heated to a temperature to 30 degrees below the gelatinization tem 120 perature of said starch and held at said temperature until said starch is conditoned to the extent that it will only partially gelatinize when subsequently heated above the gelatinization temperature, and subsequently sub 125 jecting said slurry in a thin film to a heated surface above said gelatinization temperature for a period of time sufficient to dehydrate said slurry and simultaneously to partially 1,412,90,5 gelatinize said starch to obtain a thin crisp de in an amount sufficient to give a weight ratio hydrated film of crystalline character which is of high fructose corn syrup solids to honey essentially non-adhesive and readily ground to solids within the range of 15: 85 to 85:15.

a dry appearing flowable powder, the quantity 9 A process as claimed in claim 1 substanof said soy protein containing material, said tially as hereinbefore described in the starch and said high fructose corn syrup being Example.

within the range of 0 25 part to 29 75 parts 10 A dehydrated high fructose corn syrup by weight of soy protein containing material product that has been prepared by a process and 29 75 parts to 0 25 part by weight of as claimed in any one of the preceding claims.

said starch per 70 parts by weight of said high fructose corn syrup or mixture thereof with FOOD

TECHNOLOGY INC. honey Per: Boult, Wade and Tennant, 7 A process as claimed in claim 6 in 34 Cursitor Street, which said starch is wheat starch London EC 4 A 1 PQ.

8 A process as claimed in claim 6 or 7 Chartered Patent Agents.

in which liquid honey is added to said slurry Printed for Her Majesty's Stationery Office, by the

Courier Press, Leamington Spa, 1975.


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103.

GB1464158 - 2/9/1977

METHOD AND APPARATUS FOR PREPARING CHIPTYKE SNACK FOOD

PRODUCTS


Applicant(s): GEN MILLS INC (--)


IP Class: A23L1/164

E Class: A23L1/164E; A23L1/217B; A21B5/08; A47J37/12B



Family: GB1464158

Equivalent: US4096791; US3935322; NL7405640; LU69943; JP50029764; FR2226936;

DE2420534; CH594358; IE39379L; IE39379

Abstract:


1464158 Snack products GENERAL MILLS INC 29 April 1974 [27 April 1973] 18694/74 Heading

A2B Snack products are made by forming a dough from a starch containing material and water, sheeting the dough and forming it into a ribbon of interconnected dough pieces, frying the ribbon in an oil bath, removing from the oil bath and separating the fried ribbon into individual pieces. The starch containing material may be potato flakes or granules, wheat or rice flour, or ground corn, corn germ or corn grits. The thickness of the dough sheets may be 0.015 to 0.06 inches. The dough pieces may have a diameter of 1 to 2 inches, interconnected by portions of width # to # inches. The ribbon may be formed from the sheet by a cutting roller. The moisture content of the dough may be 25 to 45%.

The ribbon is separated 5 to 10 seconds after frying by bending or cutting. The dough may also contain vegetable oil, salt, colouring and flavouring. The snack may be salted after frying.Claims:


WHAT WE CLAIM IS:-

1 A method of preparing chip-type snack food products comprising mixing a starch containing material and water to form a dough, sheeting and forming the dough into S 1,6,5 S a ribbon of interconnected dough pieces, conveying the ribbon of dough pieces through a heated oil bath to produce a ribbon of onterconnected deep fat fried chips, removing the ribbon of fried chips from said oil bath and then separating the ribbon of fried chips into individual chips.

2 A method as claimed in claim 1 wherein said dough sheet has a thickness of O 015 to 0 06 inches.

3 A method as claimed in claim 2 wherein said chip-type products are potato chips and wherein said dough sheet thickness is 0 02 to 0 03 inches.

4 A method as claimed in any preceding claim wherein said dough pieces are generally circular, having a diameter of between 1 and 2 inches and are connected by a portion having a width of 1/8 to

3/8 inches.

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A method as claimed in any preceding claim wherein the ribbon of interconnected dough pieces is formed by cutting said ribbon from said sheet.

6 A method as claimed in any preceding claim wherein said dough has a moisture content of from 25 to 45 percent by weight.

7 A method as claimed in any preceding claim wherein said starch containing material is dehydrated potato material.

8 A method as claimed in any preceding claim wherein each dough piece is shaped during frying.

9 A method as claimed in any preceding claim wherein the oil bath is of such volume that the rate of oil consumption is about the same as or greater than the rate of oil degradation in the tank.

A method as claimed in any preceding claim wherein the ribbon of chips is separated by allowing the ribbon to become friable and then applying a bending force to the ribbon at connection regions between dough pieces.

11 A method of preparing chip-type snack food products substantially as described with reference to the accompanying drawings.

12 Chip-type snack food products when produced by the method of any preceding claim.

13 Apparatus for use in preparing chiptype snack food products comprising means for mixing a starch containing material and water to form a dough, means for forming a dough sheet from said dough, cutting means for continuously cutting a ribbon of interconnected dough pieces from the sheet, an oil bath for deep fat frying said ribbon of dough pieces, means for conveying said ribbon through said oil bath and severing means for severing the fried ribbon at predetermined locations to provide a plurality of individual fried chips.

14 Apparatus as claimed in claim 13 wherein said severing means comprises means for applying a bending force to the ribbon.

Apparatus as claimed in claim 13 or 14 wherein said conveying means is arranged to shape the dough pieces during frying.

16 Apparatus for use in the preparation of chip-type snack food products substantially as described with reference to the accompanying drawings.

For the Applicant, FRANK B DEHN & CO, Chartered Patent Agents, Imperial House, 15-19

Kingsway, London, WC 2 B 6 UZ.

Printed for Her Majesty's Stationery Office, by the Courier Press, Leamington Spa, 1977 Published by

The Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.

1,464, 158 ISData supplied from the esp@cenet database - Worldwide

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104.

GB1465843 - 3/2/1977

PROCESSES FOR PREPARING SNACK-FOODS FROM STARCH


Applicant(s): ABE S (--)


IP Class: A23L1/164

E Class: A23L1/164



Family: GB1465843

Abstract:


1465843 Snack foods S ABE 28 March 1974 13888/74 Heading A2B A snack food is made by forming a dough comprising a gelatinous starch i.e. containing at least 88% amylopectin and at least 20% by wt. of rice flour and/or other cereal materials based in the wt. of starch, kneading the dough using a steam kneader, forming into sheets or rods, cooling, forming into the final desired shape, drying and baking.

The starch may be derived from rice, corn, millet or Koaliang. The other cereal material may be corn flour, rice bran, corn grits or corn meal. The kneading may be carried out for 8-10 minutes using steam pressure of e.g. 0.5 kg/ cm>;SP;2>;/SP;. Cooling may be carried out by refrigerating at 1-5 C for 6-18 hours. The cooled material may be aged at 5-35 C for 8-24 hrs., and then cut to the desired shape before baking. Drying may be at 25-80 C.Description:


(54) IMPROVEMENTS IN ORRELATING TOPROCESSES:

FOR PREPARING SNACK-FOODS FROM STARCH

(71) I, SHUNJI ABE of l-banchi Oaza

Tsuchikawa, Ojiya-shi, Niigata-ken, Japan, of Japanese Nationality do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

The present invention relates to a process for preparing snack-foods from glutinous type starch containing 20% or more of rice flour and/or other cereal material.

The term "glutinous type starch" as used herein means a starch which has no or a very low content of

Amylose and substantially comprises Amylopectin for example at least88% Amylopectin.

Previously, many attempts have been made to prepare snack-foods from glutinous type starch such as waxy corn starch, glutinous millet starch and glutinous kaoliang starch. However, in spite of improvements to the steps and operations of the prior art snack-foods having the same soft texture as those obtained from glutinous rice were not obtained; the snack food products obtained in the prior art were found to have a rough texture due to hardness and insolubility of the snack food in the mouth.

In a conventional method of preparing snack-foods, a raw material is kneaded with steam, thereby producing a cake material, that is a dough cake. It is inevitable that the water content of the cake material rises due to the introduction of steam intosteam kneader and that the physical properties of the cake material deteriorate with the progress ofstarch formation. Particularly when using starch as the

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raw material, the starch absorbs water boundlessly in proportion to the time for kneading with steam because it has no cell membranes to inhibit it from swelling. Therefore, when

starch is kneaded with steam, a-starch formation proceeds to too great a level, thereby lowering the viscosity of the cake material produced.Further, the cake material produced is too soft to be cut into a desired shape and is difficult to solidify by cooling. Furthermore, as the cake material is easy to break during the drying step, it has been difficult to obtain commercially available snack-foods therefrom.

According to one aspect of the present invention there is provided in a process of preparing a snackfood, the steps of kneading with steam a mixture of one or more glutinous type starches (as hereinbefore defined) and 20% or more, based on the weight of the mixture, of rice flour and/or other cereal material to produce a cake material and thereafter immediately cooling the mixture to a temperature sufficient to form a solidified material.

According to a second aspect of the present invention there is provided a process of preparing a snack food, which comprises mixing by kneading with steam for a period of time sufficient to produce a homogenous cake material a glutinous type starch (as hereinbefore defined) selected from the group consisting of glutinous rice starch, waxy corn starch, glutinous millet starch and glutinous kaoliang starch with at least20% based on the weight of the mixture of a flour selected from the group consisting of rice flour and other cereal flour, immediately thereafter rapidly cooling the mixture to a temperature sufficient to form a solidified material, shaping and forming the solidified material into the desired shape, drying the shaped and formed material and baking the dried material under conditions sufficient to form a puffed snack food product.

The present invention further relates to a snack food whenever prepared by the process of one of the two preceding paragraphs.

The inventor of the present invention has tried to prepare snack-foods of improved quality from glutinous type starch and has found that if glutinous type starch is mixed with 20% or more of rice flour and/or other cereal material such as cereal flour, the water content of the mixture does not change so much during steam kneading thereby enabling the production of a fine and homogeneous cake material or dough cake. That is, rice or other cereal material which is difficult to swell on account of the cell membranes thereof enters into starch particles, that is, it is mixed therewith and when the resulting mixture is disturbed or agitated to cause swelling by steam kneading a physically stable cake material or dough cake can be obtained.

The present invention enables the provision of a process for preparing snackfoods having a good taste and soft texture which could not be produced from glutinous type starch by prior art methods, wherein glutinous type starch containing 20% or more of rice flour and/or other cereal material is used as the raw material.

Glutinous type starch mixed with 20% or more of rice flour and/or other cereal material is used as the raw starch material. Examples of glutinous type starch include glutinous rice starch, waxy corn starch, glutinous millet starch and glutinous kaoliang starch. The glutinous type starch mentioned above or a mixture thereof may be mixed with rice flour such as glutinous rice flour or non-glutinous rice flour, and/or other cereal material such as corn flour, rice bran, corn grits, corn meal.

The mixing ratios of rice flour and/or other cereal material to the raw starch materialib 20% or more in accordance with desired products.

The above glutinous type starch material containing 20% or more of rice flour and/ or other cereal material is kneaded with steam, preferably with the addition of water and for about 8 to 10 minutes to give a homogeneous dough cake. After kneading,il! necessary, steam may be discharged from a steam kneader so as to remove a bad smell or the odour of the starch material and obtain snack-foods of good taste. As in the conventional preparation of snack

foods such as crackers, pellets and Kakino

tane (a product shaped like persimmon seed) from rice, it is preferred to prepare a fine and homogeneous cake material by satisfactorily kneading with steam.Since an unhomogeneous cake material is easy to break in a drying step and leads to un

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satisfactory swelling in the baking step, sufficiently swelled products can not be obtained from an unhomogeneous cake material. Therefore, the step of kneading with steam is preferably carried out carefully in order to produce a fine and homogeneous cake material.

In the next stage, the homogeneous cake material prepared above is immediately transferred to a cooling step. In the cooling step, it is essential to cool the cake material itself to a lower temperature as quickly as possible after preparation thereof. That is, the cake material is preferably cooled to about5 C. within at least 6 hours after preparation thereof. The cooling is then further continued to give a solidified material having a hardness sufficient for the next cutting step. The more quickly the cake material is cooled, the more favourable the taste and texture of the snack-foods become. However, freezing of the cake material should be avoided because this deteriorates the quality of the product. A satisfactorily swelled product with soft texture is normally only obtained when the cooling is carried out as explained. above.

The rapid cooling and solidifying of the cake material is effectively carried out in such a way that the cake material is extruded into a sheet of from 1.0 to 1.5 cm in thickness by a kneading and extruding machine and the sheet material is taken out, that is placed, on a plate spread with a flour, then immediately put into a cooling apparatus, for example, a refrigerator at a temperature of from 1 to50C. and allowed to stand for from 12 to 18 hours therein. When the thickness of the material is more than

1.5 cm, a special high power refrigerator should be used. In this way, by means of the rapid cooling and solidifying of the cake material prepared from the raw starch material containing 20% or more of rice flour and/or other cereal material, a satisfactorily swelled snack-food of good taste and soft texture can be obtained.

Moreover, if the temperature of the cake material itself falls to less than5"C. by the rapid cooling, the cake material becomes easier to cut. Therefore, the cake material is, preferably, further cooled and solidified by allowing it to stand in a refrigerator for a certain time as described above.

Then, the cooled and solidified material is cut to a desired shape of from 1.0 to 2.5 mm in thickness and then dried. When the thickness is more than 2.5 mm, it is difficult to dry the shaped material effiiciently which effects the swelling of the material in the baking step. The temperature of the solidified material is preferably low for cutting thereof. The cutting is preferably carried out at a room temperature of from 2 to150C. within 2 hours.

Subsequently, the cut and shaped material is effectively dried with ventilation at a low temperature, for example, by a ventil ating drier at from 25 to80 C., preferably from 25 to50 C., within 6 hours. The drying of the shaped material should be performed as rapidly as possible to prevent retrogradation of the material. A conventional drier for non-glutinous rice crackers at from 60 to80"C. may be also used in the drying step, thereby giving a product of satisfactory quality. However, compared with the drying by a ventilating drier at a lower temperature, the shaped material is unhomogeneously dried and the quality of the product is apt to deteriorate.

After drying, the dried material is normally allowed to stand for from 8 to 24 hours (aging) for the purpose of adjusting the water content thereof to a definite or desired level and obtaining homogeneously baked products. The aging is carried out at a temperature of from 5 to35 C., preferably at from 5 to15 C., because a higher temperature accelerates the retrogradation of the material. In the next, that is the baking, step, the material is preferably baked a little at a time so as to produce a favourably swelled product of improved quality.Further, in the seasoning step after baking the baked material is spread with a desired liquid relish when the temperature of the material is about from 30 to50 C, since the seasoning at a lower or higher temperature, except the specified range and in particular the range of from 35 to50"C., can not give the satisfactorily glazed product.

As described above, snack-foods of improved quality having soft texture and good taste such as crackers, pellets, and

Kakinotane can be obtained from the raw starch material containing 20% or more of rice flour and/or other cereal material according to the process of the present invention.

As machines available for the process of the present invention, there may be exemplified as follows; rice pearling equipment, a continuous automatic rice washer, an automatic cake making machine, a

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steam kneader, a kneading machine for a strip cake material, a kneading and extruding machine, a grain-type automatic cake making machine, a prefabricated refrigerator, a cutting machine for pellet material, a turning-type cutting machine for a pellet material, a one-stage ventilating drier, a three-stage ventilating drier, a jumbosize automatic reciprocating moving oven, a moving gas oven, a water jackettype shaking machine, a rotating drum-type glazing machine, a seasoning machine such as an automatic seasoning machine and a moving drier for finishing.

The present invention provides a process for preparing snack-foods of improved quality such as crackers, pellets, and Kakinotane, by using glutinous type starch containing 20% or more of riceflour and/ or other cereal material as the raw material. That is, the snack-foods obtained by the process of the present invention can be efficiently puffed and spongy, and also have a good texture similar to those obtained from glutinous rice. They can have, further, the favourable taste of the starch used as the raw material. When the process of the present invention is carried out, the conventional equipment for preparing snack-foods from glutinous rice can be used for all steps thereof. Accordingly, the desired snack-foods of the present invention can be easily prepared in any factory designed for producing snack-foods from glutinous rice.Although new steps for cooling and shaping can be added in the process of the present invention, the overall time required for all steps can be drastically reduced because as compared with the prior processes of the time for drying is shorter and the operation is simpler. It follows that the yield of the products can be increased.

It can not be clearly understood why the snack-foods of the present invention, such as rice crackers, pellets and Kakinotane have qualities similar to those of the snack-foods derived from glutinous rice.

However, it is presumed that the following are the main reasons: 1) The raw materials respectively comprise about 100% of amylopectin which has similar properties to those of glutinous rice starch.

2) Starch swelling is prevented by mixing 20% or more of rice flour and/or other cereal material having cell membranes therein with the above starch having no cell membranes, thus obtaining a homogeneous cake material by disturbing the swelling property.

3) According to the prior processes, prepared cake material is immediately dried at a comparatively higher temperature to prevent the material from retrogradation, thereby obtaining snack-foods. In contrast, the present invention intends to obtain snack-foods from a less retrograded cake material by quickly cooling. Such a rapid cooling effect on the cake material is also considered to be one of the reasons why the snack-food produced according to the present invention canlie efficiently puffed and have soft texture similar to those made of glutinous rice.

The following Examples further illustrate the present invention.

Example I

A mixture of 40 kg of commercially available waxy corn starch and 40 kg of glutinous rice flour of 80 to 100 mesh in average particle size prepared by milling scraps of glutinous rice after polishing, washing with water and draining, was put into a steam kneader. (The standard of mesh is inch; for example 80 mesh means 1/80 inch). After adding 40 kg of water thereto, the mixture was kneaded with steam under the initial pressure of 2.0kg/cm- and a steam pressure of 0.5kg/cm for 8 minutes to prepare a cake material. At the end of kneading the cover of the steam kneader was taken off and steam was discharged so as to remove a bad smell or odour. The cake material was supplied to a Kakinotane making machine and extruded into a stick whose section was shaped like persimmon seed.The stick material was placed on a plate spread with a flour, then immediately put into a refrigerator at a temperature of from 2 to5 C and left for 18 hours therein to be cooled and solidified. The solidified material was cut into pieces shaped like persimmon seeds of 1.3 mm in thickness, then dried in a ventilating drier according to the conventional method until the water content was reduced to from 22 to23 %. Subsequently, the dried material was allowed to stand for 1 day at a room temperature in an air-tight container(aging). After aging the material was baked at280 C in 5 kg portions at a time in a baking oven.Soy glazing liquid was applied to the baked material by a rotating drumtype glazing machine and the baked material was dried to obtain a snack-food like

Kakinotane of improved quality. The product had a soft texture similar to those made from glutinous rice.

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Example 2

80 kilograms of a mixture of commercially available waxy corn starch and nonglutinous rice flour

(mixing ratio 7 : 3) was put into a steam kneader. After adding 50 kg of water thereto, the mixture was kneaded with steam under a steam pressure of 0.5 kg/cm2 for 9 minutes to prepare a cake material. At the end of kneading the cover of the steam kneader was taken off and the steam was discharged so as to remove a bad smell. The thus prepared cake material was further passed though a kneader in order to make a homogeneous cake material. The homogeneous cake material was extruded into a sheet of 1.0 cm in thickness by a kneading and extruding machine and taken out on a plate spread with flour. The sheet material was at once put into a refrigerator at from 2 to5"C and left for 14 hours so as to be cooled and solidified.The solidified material was cut into pieces (lOmm X 45mm

X 1.2mm) and dried in a ventilating drier at a temperature of from 30 to35"C until the water content was reduced to about 20%. The dried material was allowed to stand overnight at room temperature in an air-tight container, then baked at280 C in 1.0 kg portions at a time in a baking oven. The thus baked material was spread with salad oil in the amount of 10% based on the material by a rotating drum-type glazing machine and seasoned with salt, thereby obtaining a fried snack-food of improved quality.

Example 3

A mixture of 50 kg of glutinous millet starch prepared from commercially available glutinous millet by alkaline process, 25 kg of commercially avaliable rice bran and 5 kg of corn flour was put into a stem kneader. After addition of 50 kg of water, the mixture was kneaded with steam under a steam pressure of 0.5 kg/cm2 for 7.5 minutes. Thereafter, the cover of the steam kneader was immediately taken off and steam was discharged so as to remove a bad smell. In this way, the produced cake

material was further passed through a kneader, thereby making a homogeneous cake material. The homogeneous cake material was extruded into a stick of diameter of 2.5 cm by a Kakinotane making machine.The stick of material was taken out on a plate spread with a flour, then at once put into a refrigerator

at5 C and left for 18 hours therein so as to be cooled and solidified.

The solidified material was cut into pieces shaped like persimmon seeds of 1.7 mm in thickness and dried in a ventillating drier at a temperature of from 30 to35"C for 3.5 hours until the water content was reduced to about 30%. Subsequently, the dried material was allowed to stand for 20 hours at room temperature in an airtight container, then baked in 8 kg portions at a time in an automatic baking oven.

The baked material was glazed and seasoned to obtain a snack-food like Kakinotane of improved quality.

Example 4

A mixture of 50 kg of commercially available waxy corn starch, 25 kg of rice bran and 5 kg of corn flour was put into a steam kneader. After adding 45 kg of water, the mixture was kneaded with steam under a steam pressure of 0.5 kg/cm2 for 8.5 minutes, thereby producing a homogeneous cake material.

The cake material was treated in the same manner as described in Example 3 to obtain a snackfood like

Kakinotane of improved quality.

As mentioned above, there can be obtained snack-foods with good taste and soft texture similar to those made of glutinous rice, from glutinous type starch containing 20% or more of rice flour and/ or other cereal flour according to the process of the present invention.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT I CLAIM IS:

1. In a process of preparing a snackfood, the steps of kneading with steam a mixture of one or more glutinous type starches (as hereinbefore defined) and 20% or more, based on the weight of the mixture, of rice flour and/or other cereal material to produce a cake material and thereafter immediately cooling the mixture to a temperature sufficient to form a solidified material.

2. A process according to Claim 1, which process further comprises shaping, drying and baking the solidified material to obtain the desired product.

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3. A process according to Claim 1 or 2, which comprises kneading with steam for a period of time sufficient to produce a homogeneous cake material.

4. A process according to Claim 2 or 3, wherein the shaping is carried out by cutting to a desired shape.

5. A process according to any one of the preceding claims, wherein the glutinous type starch is one or more of glutinous rice starch, waxy corn starch, glutinous millet starch or glutinous kaoliang starch.

6. A process according to any one of the preceding claims, wherein the other cereal material iscornfiour, rice bran, corn grits or corn meal.

7. A process of preparing a snack food, which comprises mixing by kneading with steam for a period of time sufficient to produce a homogeneous cake material a glutinous type starch (as hereinbefore defined) selected from the group consisting of glutinous rice starch, waxy corn starch, glutinous millet starch and glutinous kaoliang starch with at least 20% based on the weight of the mixture of a flour selected from the group consisting of rice flour and other cereal flour, immediately thereafter rapidly cooling the mixture to a temperature sufficient to form a solidified material, shaping and forming the solidified material into the desired shape, drying the shaped and formed material and baking the dried material under conditions sufficient to form a puffed snack food product.

8. A process according to any one of the preceding claims, wherein the steam kneading is carried out for from 8 to 10 minutes.

9. A process according to any one of the preceding claims, wherein the cake material is cooled after kneading to about5 C. within at least 6 hours of the preparation thereof.

10. A process according to any one of the preceding claims, wherein the cooled cake material is aged for 8 to 24 hours at a temperature in the range of from 5 to35"C.

11. A process according to Claim 10, wherein the cooled cake material is aged for from 8 to 24 hours at a temperature in the range of from 5 to15 C.

12. A process for preparing a snackfood, substantially as described in foregoing Example 1.




16. A snack-food whenever prepared by the process of any one of the preceding claims.Data supplied from the esp@cenet database - Worldwide

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105.

GB1467873 - 3/23/1977

MANUFACTURE OF READY-COOKED RICE


Applicant(s): ANDO M (--)


IP Class: A23L1/182

E Class: A23L1/182C



Family: GB1467873

Abstract:


1467873 Pre-cooked rice M ANDO 11 June 1974 25945/74 Headings A2B and A2E Pre-cooked rice is prepared by soaking rice grains in water, gelatinising by boiling or steaming, adjusting the moisture content to 18-70%, pressing e.g. between rollers having a nip of 0.1-10 mm or between metal plates, adjusting the moisture content of the pressed rice to 8-25%, and puffing by frying in oil at a temperature of 130-200 C. The rice can be made ready-to-eat by treatment with boiling water, and may be mixed with powdered soup, mushrooms, shrimps, eggs, parsley or peas. The rice may be de-oiled e.g. by centrifuging, after puffing. The soaked rice may be mixed with a surfactant e.g. glycerine or sugar esters, edible oil or talc before gelatinisation, and the gelatinised rice may be dried by mixing with e.g. wheat or rice flour, starch, cellulose powder or talc.Description:


(54) MANUFACTURE OFREADY-COOKED RICE

(71) I, MOMOFUKU ANDO, a

Japanese Citizen of7-34, Masumicho, Ikeda,

Osaka, Japan, do hereby declare the invention for which I pray that a Patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the followingstatement:-

The present invention relates to a process for manufacturing ready-cooked rice which can be reconstituted into a form ready to eat, having a good flavor and pleasant sensation to the tongue, in a very short time only by pouring on boiling water.

The study and development of so-called ready-cooked rice, such as pre-cooked boiled rise, rice gruel, porridge of rice and vegetables and so on, have been carried on, and these foodstuffs have been on the market. However, they have many defects in the pre-cooking and quality5 and no satisfactory product has so far been developed. The conventional manufacturing processes for ready-cooked rice may be divided broadly into three categories as follows:

(1) Rice is boiled and then dried.

(2) Rice is boiled, dried and then fried in

oil.

(3) Rice is boiled, flattened and then dried.

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However, the pre-cooked rice made by the first process as mentioned above in (1) needs a longer time for reconstitution and lacks the stickiness peculiar to boiled rice and a pleasant texture to the tongue.

The second process as mentioned above in

(2) requires a high oil temperature for frying the rice after boiling. Therefore, it is rather difficult to maintain good quality of the boiled rice. Furthermore, the rice made by this procress has the defect of not being easily reconstituted by merely pouring boiling water on it.

The rice made by the third process as mentioned above in (3) cannot be reconstituted fully but rather remains in a flattened state, and is far removed from boiled rice in flavour and feel of eating.

After consideration of these defects in the conventional products, the invention has as an object the manufacturing of improved precooked or processed rice foodstuffs which can be reconstituted to a form having as good flavor and pleasant feeling of eating as boiled rice in a very short time, e.g. a few minutes only after pouring of boiling water on them.

According to the present invention, there is provided a process for preparing ready cooked rice which comprises (1) soaking rice in water5 (2) gelatinizing the soaked rice, (3) adjusting the moisture content of the gelatinized rice to1870% by weight, (4) pressing the resultant rice, (5) adjusting the moisture content of the thus pressed rice to825% by weight, and (6) frying the thus obtained rice at a temperature of 130--2000C.

Preferably, the pressing step is performed by passing the gelatinized rice between rolls

having a nip between the rolls of0.1-1.0 mm.

A manufacturing process according to the invention is described in detail below by way of example.

Any edible rice, irrespective of kind and quality, can be used for the starting material.

The grains of rice are first washed with water and soaked in water or liquid seasoning.

Then, surfactants such as glycerine fatty acid esters, or sugar esters, or edible oil or talc, are mixed with them. After that, they aregelatinized by boiling or steaming.

Since the surfactant or edible oil or talc is is added in order to prevent the gelatinized rice grains from joining with one another and

sticking to the surfaces of the rolls used in the subsequent pressing, a small quantity of such additive will suffice.

The rice should be gelatinized to the heart by proper means, such as the usual steam cooking or pressure steam cooking.

Next, the gelatinized rice is exposed to the air at a temperature of2Q-100"C, for instance. After adjusting the water content to1870% by weight, pressing is performed.

Excess water may be absorbed by means of cereal flour, such as dry wheat flour, rice flour, or starch, or celullose powder or talc.

In the pressing step, the gelatinized rice may be forcibly passed through the nip between rolls, or pressed by metal plates. However, from a productivity and economic viewpoint, pressing by rolls is preferable.

In the case of pressing by rolls, if the gelatinized rice is forcibly passed through between metal rolls as it is, the grains joint with one another and stick to the rolls. Therefore, it is desirable to dry the gelatinized rice beforehand so that the moisture content is reduced to less than 35%. If it is over 35%, it is necessary to lower the temperature of the grain surface to some extent. If it is dried to less than 18%, it becomes stiff and is broken when pressed.

Therefore, in general the moisture range of1835% is the most suitable.

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The pressing degree may be adjusted by changing the gap between the rolls through which the gelatinized rice is forcibly passed.

If too strong a pressure is exerted on the gelatinized rice, cracks are caused in the rice which loses its ability to be reconstituted. However, if the pressing is too weak it has no effect. In such cases, it is necesary to adjust the nip between the rolls.

Generally speaking, when the moisture is high, it is necessary to make the nip between the rolls wider, and vice verso

As a result of experiment, it was found desirable that the nip between the rolls should be adjusted to be0.1-1.0 mm as shown in Table 1 under the conditions therein.

Japanese Patent Publication No.4921770 describes a process of flattening boiled rice to a width of15-

2.0 mm and says that flattening to less than 1.5 mm results in flaking of the rice.

This is because in that case free water in the rice is evaporated, and the rice loses its elasticity as it is flattened by heated rolls whereby the free water is evaporated.

In the present process however it is desirable that the nip between the rolls should be considerably narrower compared with that in the prior process just mentioned, since puffing of the rice by a frying process will take place later.

Besides, the present process differs in the pressing method from the previous process.

Pressing in the present process does not cause evaporation of free water. It aims at partial destruction or slipping of the internal construction of the gelatinized rice so that subsequent puffing by frying is easily accomplished.

The pressed rice is dried so that the moisture content becomes825% by weight in order to make puffing of the pressed rice easier, and then the frying process takes place in previously heated edible oil. As shown in Table 2, gelatinized rice which has been pressed can be processed at a lower temperature within a shorter time as compared with non-pressed gelatinized rice.

The effective oil temperature used in the present process ranges from1300C to200"C, while nonpressed gelatinized rice requires17O-2200C. Thus, flattened gelatinized rice can be processed at a comparatively lower temperature and this avoids oil rancidification and the quality of the products being lowered by scorch or other causes.

It is remarkable that a product having an excellent capability of reconstitution is obtained by this process even when processing at temperatures as low as130-1700C.

The function of adequate pressing can be considered as follows:

The gelatinized rice with its adjusted moisture content, adequate plasticity and elasticity, is forcibly passed through between the rolls so that the grains are pressed and flattened. However, when it is pressed through the proper size of nip between the rolls, it is restorable to almost the same shape as originally.

When the gelatinized rice is pressed, the internal construction is partly broken or slipped to make a number of particles inside the rice grain. In other words, each grain of rice is converted into a greater number of particles and can more easily be puffed by frying.

As a result, the entire structure of the rice can be heated uniformly and simultaneously, as well as quickly, in the frying process.

Therefore, the rice can be fried in oil at a lower temperature in a shorter time compared with nonpressed gelatinized rice, and the whole grain is also easily puffed.

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Boiling water soaks into the interior of this puffed gelatinized rice completely as soon as it is poured on, and the rice reconstitutes uniformly without any hard core.

Since the structure is not completely destroyed, but only compressed and slipped, boiling water will permeate the fried rice sufficiently and quickly enough to restore it to a complete granular shape.

Puffed gelatinized rice produced by this process is far superior to conventional non-pressed gelatinized rice in terms of the time required for restoration, and in flavor and feeling of eating after restoration, as shown in Table 1.

Pre-cooked rice foodstuffs having as pleasant a feeling of eating as boiled rice may be obtained merely by pouring boiling water in the bowl containing this puffed rice mixed with powdered soup and a mixture of desiccated vegetables, eggs, meat and the like as desired, for instance, pilaf, chicken and rice, rice cooked together with various vegetables, meat, shrimps, and stew.

As shown in Table 3, the rice fried in oil after being pressed has better effect on removing oil therefrom and also more uses than nonpressed fried rice.

Rice gruel, baby food, relishes, rice cakes, can also be made by adjusting the pressing degree and the temperature of the frying oil.

TABLE 1

Pressing degree for boiled rice and quality after restoration

EMI3.1

>;tb; >;SEP; Time >;SEP; required

>;tb; >;SEP; for >;SEP; restoration

>;tb; >;SEP; Pressing >;SEP; degree >;SEP; Apparent >;SEP; after >;SEP; pouring

>;tb; (Distance >;SEP; between >;SEP; rolls) >;SEP; specific >;SEP; boiling >;SEP; water >;SEP;

Quality >;SEP; after

>;tb; >;SEP; (mm) >;SEP; gravity >;SEP; (min) >;SEP; restoration

>;tb; >;SEP; No >;SEP; pressing >;SEP; 0.34 >;SEP; 7 >;SEP; Undercooked,

>;tb; >;SEP; Unpleasant >;SEP; feeling

>;tb; >;SEP; of >;SEP; eating.

>;tb;

>;SEP; (*) >;SEP; 0.20 >;SEP; 5 >;SEP; No >;SEP; elasticity.

>;tb;

>;SEP; Unpleasant >;SEP; feeling


>;tb;

>;SEP; 1.8 >;SEP; 0.34 >;SEP; 7 >;SEP; Undercooked.

>;tb;


>;tb; >;SEP; of >;SEP; eating. >;SEP;

>;tb;

>;SEP; 1.6 >;SEP; 0.33 >;SEP; 6 >;SEP; Undercooked.

>;tb;



>;tb;

>;SEP; 1.4 >;SEP; 0.32 >;SEP; 5 >;SEP; Partly >;SEP; undercooked.

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>;tb;

>;SEP; Inferior >;SEP; feeling


>;tb;

>;SEP; 1.2 >;SEP; 0.28 >;SEP; 4 >;SEP; Partly >;SEP; undercooked.

>;tb;

>;SEP; Inferior >;SEP; feeling


>;tb;

>;SEP; 0.8 >;SEP; 0.26 >;SEP; 3 >;SEP; As >;SEP; pleasant >;SEP; feeling

>;tb; >;SEP; of >;SEP; eating >;SEP; as >;SEP; boiled

>;tb; >;SEP; rice.

>;tb;

>;SEP; 0.4 >;SEP; 0.28 >;SEP; 3 >;SEP; As >;SEP; pleasant >;SEP; feeling


>;tb; >;SEP; rice.

>;tb;

>;SEP; 0.2 >;SEP; 0.24 >;SEP; 1.5 >;SEP; As >;SEP; pleasant >;SEP; feeling


>;tb; >;SEP; rice.

>;tb;

>;SEP; 0.05 >;SEP; 0.22 >;SEP; 1.0 >;SEP; Not >;SEP; restored >;SEP; to

>;tb; >;SEP; the >;SEP; original >;SEP; granular

>;tb; >;SEP; shape. >;SEP; No >;SEP; elasticity.

>;tb;

Remarks appertaining to Table 1.

1) Japan-grown rice gelatinized and dried to a moisture content of 26% by weight

was passed through the fixed nip between the rolls.

2) Apparent specific gravity was for puffed rice fried in palm oil at a temperature

of 1600C after adjusting the moisture content of the pressed gelatinized rice to

13% by weight.

3) Diameter of the rolls was approx. 200mm and the revolving speed of the rolls

was 10 r.p.m.

(*) Conventional non-flattened puffed boiled rice fried in oil at a temperature of

2000C for 15 seconds was used.

TABLE 2

EMI4.1

>;tb; >;SEP; The >;SEP; oil >;SEP; content

>;tb; >;SEP; Frying >;SEP; oil >;SEP; after >;SEP; deoiling >;SEP; Time >;SEP; required

>;tb; temperature >;SEP; process >;SEP; for >;SEP; restoration >;SEP; Quality >;SEP; after

>;tb; >;SEP; ( C) >;SEP; (%) >;SEP; (sec) >;SEP; restoration

>;tb; >;SEP; a. >;SEP; 19 >;SEP; 100 >;SEP; Some >;SEP; scorched

>;tb; >;SEP; 220

>;tb; >;SEP; b. >;SEP; 17 >;SEP; 5 >;SEP; Scorched

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>;tb; >;SEP; a. >;SEP; 16 >;SEP; 180 >;SEP; No >;SEP; elasticity

>;tb; >;SEP; 200

>;tb; >;SEP; b. >;SEP; 15 >;SEP; 15 >;SEP; Good, >;SEP; but

>;tb; >;SEP; insufficient >;SEP; elasticity

>;tb; >;SEP; a. >;SEP; 14 >;SEP; 240 >;SEP; Insufficient >;SEP; elasticity

>;tb; >;SEP; 190

>;tb; >;SEP; b. >;SEP; 13 >;SEP; 25 >;SEP; Good

>;tb; >;SEP; a. >;SEP; 12 >;SEP; 360 >;SEP; Undercooked

>;tb; >;SEP; 170


>;tb; >;SEP; a.>;SEP; 10 >;SEP; - >;SEP; >;SEP; Undercooked, >;SEP; No >;SEP; good

>;tb; >;SEP; 150


>;tb; >;SEP; a. >;SEP; - >;SEP; >;SEP; Impossible >;SEP; to >;SEP; fry >;SEP; in >;SEP; oil

>;tb; >;SEP; 130

>;tb; >;SEP; b. >;SEP; 3 >;SEP; 180 >;SEP; Good, >;SEP; but >;SEP; slightly

>;tb; >;SEP; undercooked

>;tb; >;SEP; 120 >;SEP; Impossible >;SEP; to >;SEP; fry >;SEP; in >;SEP; oil

>;tb;

Remarks appertaining to Table 2.

a. = Non-pressed gelatinized rice.

b. = Pressed gelatinized rice

Moisture content of rice = 13.5% by weight

Distance between the rolls ...... O.1mm

TABLE 3

Pressing degree, amount of oil removed and quality after restoration

(Fried at a temperature of 1650C)

EMI5.1

>;tb; Distance >;SEP; between >;SEP; The >;SEP; oil >;SEP; content >;SEP; before >;SEP; The

>;SEP; oil >;SEP; content >;SEP; after

>;tb; >;SEP; the >;SEP; rolls >;SEP; deoiling >;SEP; process >;SEP; the >;SEP; deoiling >;SEP; process

>;tb; >;SEP; (mm) >;SEP; (%) >;SEP; (%) >;SEP;

>;tb; >;SEP; No >;SEP; pressing >;SEP; 25 >;SEP; 0 >;SEP; ) >;SEP; >;SEP; 12.1

>;tb; >;SEP; (*) >;SEP; ' >;SEP; 21.3 >;SEP; >;SEP; 14.3

>;tb; >;SEP; 0.8 >;SEP; 23.0 >;SEP; 7.3

>;tb; >;SEP; 0.4 >;SEP; 21.2 >;SEP; 5.1

>;tb; >;SEP; 0.1 >;SEP; 23.1 >;SEP; 7.1

>;tb; (*) In this case deep frying at a temperature of 2000C for 15 seconds.

As the rice processed by frying usually contains2030% by weight of oil, as shown above, it is suitable for certain foodstuffs such as pilaf.

However, by removing oil from this puffed gelatinized rice, for example by physical means such as applying centrifugal force or blasting with hot air, or by chemical means such as applying a solvent like ethyl alcohol asmen- tioned in Japanese Laid-open Patent Publications Nos.48-68410, 48-68411 and48-68412, pre-cooked rice foodstuffs suitable for sushi (vinegared fish and rice), rice with soup, white-polished rice, can be obtaned.

Example 1.

2.0 Kg of rice grains were washed with water and soaked in water for 15 hours.

After draining off the water, 20 grams of monoglyceride was uniformly mixed with the watersoaked grains of rice. Then they were put in a pot and stirred for 25 minutes at a steam pressure of 1 Kg/cm2.

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The thus gelatinized rice was exposed to a hot air blast of60-800C so that the moisture content of the rice became 26% by weight, and such partially dried gelatinized rice was forcibly passed through a nip of 1.0 mm between two rolls to obtain pressed rice.

This pressed rice was exposed to hot air at60-800C to reduce the moisture content to 13% by weight.

After that, it was processed in palm oil heated to a temperature of 1900C for 10 seconds to obtain the product.

Furthermore, the following ingredients were put in a polystyrene bowl;

Powdered soup 6.0 g

Freeze-dried mushroom 0.5 g shrimp 1.0 g

egg 1.0 g parsley 0.3 g green peas 1.0 g

Then 100 grams of the rice product was added and mixed with these ingredients. 150 cc. of boiling water was poured into the bowl, which was then covered and left standing for three minutes. Thus, pilaf having good flavor and pleasant feeling of eating was made.

Example 2.

2.0 Kg of rice grains were washed with water and soaked in water for 15 hours.

After draining off the water, 20 grams of monoglyceride was uniformly mixed with the water-soaked grains of rice. Then they were put in a pot and steamed for 25 minutes at a steam pressure of 1 Kg/cm2.

The gelatinized rice was exposed to a hot air blast of6O-800C so that the moisture content of the rice became 30% by weight, and such partially dried gelatinized rice was forcibly passed through a nip of

1.0 mm between two rolls to obtain pressed rice.

This pressed rice was exposed to hot air of60-800C to reduce the moisture content to 24% by weight.

After that, it was processed in palm oil previously heated to a temperature of140"C for 10 seconds to obtain the product.

This puffed rice was placed in a baskettype centrifuge having a diameter of 230 mm and processed for

30 seconds at 1,200 r.p.m., maintaining a temperature of60"C. Thus puffed rice having an oil content of5% by weight was obtained.

80 grams of the resultant puffed and deoiled rice was put in a polystyrene bowl.

Then, the following ingredients were mixed therewith.

Powdered soup 5.0 g

Laver 0.5 g

Rice-cake cubes 2.0 g

300 cc of boiling water was poured into the bowl, which was then covered and left standing for three minutes. Thus, a product of rice with soup having as pleasant feeling of eating as boiled rice was obtained.

Example 3.

Fried rice obtained by the process applied in

Example 1 was processed to remove oil in such a way as mentioned in Example 2, and readycooked rice suitable for sushi (vinegared fish and rice) and which is reconstituted by boiling water in three minutes was obtained.

Example 4.

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By changing the temperature of the palm oil to1800C instead of140"C in the same process as mentioned in Example 2, rice gruel which can be reconstituted in 30 seconds with boiling water was obtained.

WHAT I CLAIM IS:

1. A process for preparing ready-cooked rice which comprises (1) soaking rice in water, (2) gelatinizing the soaked rice, (3) adjusting the moisture content of the gelatinized rice to1870% by weight, (4) pressing the resultant rice, (5) adjusting the moisture content of the thus pressed rice to825% by weight, and (6) frying the thus obtained rice at a temperature of130-2000 C.

2. A process according to claim 1, wherein the pressing nip is performed by passing the gelatinized rice between rolls having a nip between the rolls of0.1-1.0 mm.

3. A process according to claim 1 or claim 2, wherein the gelatinization is carried out by boiling.

4. A process according to claim 1 or claim 2, wherein the gelatinization is carried out by steaming the soaked rice.

5. A process according to any one of the preceding claims, wherein the moisture content of the gelatinized rice is adjusted to1835% by weight.

6. A process according to any one of the preceding claims, wherein the gelatinized rice is dried with cereal flour, cellulose powder or talc.

7. A process according to any one of the preceding claims,wherein surfactant, edible oil or talc is mixed with the soaked rice prior to gelatinizing.

8. A process according to any one of the preceding claims, wherein after frying the rice is subjected to a process for reducing its oilcontent.

9. A process for preparing ready-cooked rice, substantially in accordance with any of the Examples herein.


527/2197

106.

GB1474394 - 5/25/1977

PROCESSES FOR COOKING EXTRUDING AND EXPANDING FOOD

MIXTURES


Applicant(s): ISOCHEM SA (--)


IP Class: A23L1/00; A23P1/00; A23L1/195

E Class: A23L1/308; A23L1/18B2; A23L1/00P14B2



Family: GB1474394

Equivalent: NL7408428; FR2233946; DE2429312; CH585029

Abstract:


1474394 Cooking and extruding starch- based foodstuffs ISOCHEM SA 21 June 1974 [21 June 1973]

27539/74 Heading A2B A food mixture containing raw starch, possibly associated with vitamins and proteins, and 0-2 wt.% fat and 14-16 wt. % water is cooked, extruded and expanded by means of an extrusion press having (a) two co-penetrating worms and a draw plate avoiding the stagnation of material and (b) at least one heating device. The heat treatment may be carried out at a pressure of 200 kg/cm>;SP;2>;/SP; or higher for 20-150 seconds in two or more stages at 40-180 C. The starch may be derived from various cereal, vegetable and fruit sources, particularly degermed maize, semolina, raw rice and wheat. The initial mixture may contain up to 30 wt. % protein, particularly soya, meat, fish and milk proteins. Various other ingredients are mentioned. Examples describe the preparation of hyposoda protein foods and anti-diarrhoea foods comprising (1) decorticated raw rice or degermed maize semolina and milk powder protein, (2) dehydrated carrot, deoiled raw soya flour, tannin, powdered seeded carob pulp and raw rice semolina, and (3) powdered seeded carob pulp, deoiled sunflower aleurone and crude rice semolina.Claims:



tion adopted, it is possible to prepare food compositions coloured carrot red orcMoro- phyll green. As regards the sweet dishes, the association of a rice starch treated according to the invention, with a pectin, ensures instant thickening, especially for milk sweets and puddings.

3. In general, the thickening mentioned above is durable for more than 10 hours from the minute following dilution.

WHAT WE CLAIMIS:-

1. A process for cooking, extruding and expanding a food mixture containing starch, possibly associated with vitamins and protein materials by means of an extrusion press, wherein the food mixture which contains raw starch, a quantity of fats from0 to 2% by weight in relation to the weight of the said food mixture and a totalamount of water of 14 to 16% by weight in relation to the weight of

528/2197

the said food mixture, is cooked, extruded and expanded by means of an extrusion press having (a) two co-penetrating worms and a draw plate avoiding the stagnadon of material and (b) at least one heating device.

2. A process according to Claim 1, characterised in that the food mixture is subjected to heat treatment at a pressure greater than or equal to 200 kg/cm2 for 20 to 150 seconds.

3. A process according to Claim 2, whereinthe heat treatment comprises at least two stages, one consisting of preheating to40"C and the other of heating to a temperature between 1200 and1800C.

4. A process according to Claim 3, wherein the heat treatment comprises preheating at40"C for 40 seconds, heating at1200C for 40 seconds and then heating at1600C for40 seconds.

5. A process according to Claim 3, wherein the heat treatment comprises preheating to40 C for 50 seconds, heating to70"C for 40 seconds and then heating at1700C to1800C for 30 seconds.

6. A process according to Claim 3, wherein th heat treatment comprises preheating at40"C for 10 seconds, heating to1200C for 10 seconds, heating to160"C for 7 seconds then heating to1800C for 3 seconds.

7. A process according to any of Claims 1 to 6, wherein the starch is selected from maize, rice and wheat starch, and in that the protein substances are selected from soya,mill:, deoiled sunflower aleurone, meat and fish proteins.

8. A process according to any ofClaims 1 to 7, wherein the food mixture comprises13 parts by weight of a dry extract of lactoserum containing75 % by weight lactoproteins and85 parts by weight of semolina from cereals selected from raw rice or degermed raw maize.

9. A process according to any of Claims 1 to7 wherein the food mixture contains 50 parts by weight of seeded and dried carob pulp, 15 parts by weight of deoiled sunflower aleurone and containing50% by weight of protein in relation to the weight of sunflower aleurone, 33.2 parts by weight of rice semolina, 1 part by weight of NaCI, 0.80 part ofCaCO, and 0.02 part by weight vanillin.

10. A process according to any of Claims 1 to 7, wherein the food mixture contains 6 parts by weight of dehydrated carrots containing 6% by weight residual humidity, 2.40 parts by weight of deoiled raw soya and having a protein content of50% by weight, 0.6 parts by weight of oak bark tannin, 1 part by weight NaCl, 0.80 part by weightCaCO3, 10 parts by weight dehydrated seeded carob pulp containing6% by weight residual humidity, 79.20 parts by weight raw rice containing12% by weight residual humidity and 0.02 part by weight vanillin.

11. A process according to any of Claims 1 to 10 wherein the initial extruded portion of mixture has water addedthereto to aid in moistening the extrusion press.

12. A process as claimed in Claim 1 and substantially as herein described.

13. A process substantially as herein described in any one of the accompanying examples.

14. Dietetic anddietetico-therapeutic products obtainedaccording to the process of any of the Claims

1 to 13.Data supplied from the esp@cenet database - Worldwide

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107.

GB1477753 - 6/29/1977

PROTEINACEOUS SNACK FOODS


Applicant(s): CANADIAN PATENTS DEV (--)


IP Class: A23L1/20; A23L1/164

E Class: A23L1/20D



Family: GB1477753

Abstract:


1477753 Proteinaceous snack food CANA- DIANS PATENTS & DEVELOPMENT Ltd 29 April 1975

[16 May 1974] 17791/75 Head- ing A2B A puffed fried snack food contains protein and gelled starch derived from non-oilseed legumes e.g. peas, faka beans (horse beans), white pea beans and kidney beans. It may be made by grinding the legume material to form a flour, slurrying with aqueous liquid to give a solids content of 15 to 40%, drying on a heated surface to form sheets and gel the starch, reducing the sheets to flakes or strips, and frying. Cereal flour e.g. wheat, corn or rice, and vegetable protein concentrate may also be included. Preferred drying temperature is 110 to 140 C using a drum dryer, and frying temperature 170 to 210 C for 8 to 16 seconds. The final protein content is normally 12 to 30% and the starch content 40 to 70%.

530/2197

108.

GB1484518 - 9/1/1977

SNACK PRODUCTS


Applicant(s): TOMS FOODS LTD (--)


IP Class: A23L1/34

E Class: A23L1/36B2; A23L1/00P8B4



Family: GB1484518

Abstract:


1484518 Snack food TOMS FOOD Ltd 14 July 1976 [15 July 1975] 29695/75 Head- ing A2B A snack food is made by subjecting a particulate food product, particularly peanuts, to at least two coating cycles, each cycle comprising contacting the product with an edible binding agent followed by coating with an edible coating composition containing a modified pregelatinised starch and cooking the resultant food product. The particulate food product may be other nuts or an extruded starch product.

The binding agent is suitably water soluble and may be dextrin and the pregelatinised starch may be acid modified. The coating composition may contain other starch products e.g. derived from corn, maize, rice or potatoes particularly potato granules.

531/2197

109.

GB1508940 - 4/26/1978

POLYDEXTROSE-BASED FARINACEOUS COMPOSITIONS


Applicant(s): PFIZER (--)

IP Class 4 Digits: A21D

IP Class: A21D2/00

E Class: A23L1/16; A21D2/18; A23L1/308P; C08L5/00



Family: GB1508940

Equivalent: US4042714; NL7611015; LU76015; JP52051043; FR2328405; DE2644621;

CH616319; NL160152C; IT1069966; FI60489C; FI60489B

Abstract:


1508940 Low-calorie farinaceous compositions PFIZER INC 14 Oct 1976 [20 Oct 1975 23 July

1976] 42792/76 Heading A2B A low-calorie farinaceous composition comprises 20-75% by weight modified polydextrose, 2-20% proteinaceous material, 10-40% [alpha]-cellulose or microcrystalline cellulose, and 5-20% flour. The polydextrose is a highly branched polydextrose wherein the linkage of

1-;6 predominates and has an average molecular weight of 1500-1800 and contains (a) 0.5-5 mole % of polycarboxylic acid groups selected from citric, fumaric, tartaric, succinic, adipic, itaconic and malic acids and (b) 5-20% by weight of a polyol selected from sorbitol, glycerol, erythritol, xylitol, mannitol and galactitol chemically bonded thereto. The proteinaceous material may be egg white, milk solids,

Na or Ca caseinate, soybean isolate, gluten or yeast. The flour may be wheat, corn, rice, rye or soya flour. 8-30% of corn, wheat, potato, rice, tapioca yam or cassava, starch may also be present. The compositions may replace 50-100% of wheat flour used in conventional foods. Examples relate to onion flavoured rings, noodles, pancakes and bread.Description:



Application No 42792/76 ( 22) Filed 14 Oct 1976 Convention Application No 624 026 ( 32) Filed 20

Oct 1975 Convention Application No 707 983 Filed 23 July 1976 in United States of America (US)

Complete Specification published 26 April 1978

INT CL 2 A 21 D 2/00 Index at acceptance A 2 B 1 A l B 1 C 1 H 1 JY 1 K 1 L 1 X ( 11) 1508940 (

19) ( 54) POLYDEXTROSE-BASED FARINACEOUS COMPOSITIONS ( 71) We, PFIZER, INC, a corporation organized under the laws of the State of Delaware, United States of America, of 235 East

42nd Street, New York, State of New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following state' menrit:This invention relates to modified polydextrose-based farinaceous food compositions.

Modified polydextrose (polyglucose) is disclosed in U S Patent No 3,766,165 Its use in various dietetic foods is also disclosed in U S.

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Patent No 3,876,794.

U.S Patent No 3,766,165 discloses that glucose polymers which can be used as dietetic food ingredients can be produced directly from glucose by a process of anhydrous melt polymerization using edible acids as catalysts and as cross-linking agents Using this process two types of polydextrose

(polyglucose), watersoluble and water-insoluble, can be simultaneously produced by anhydrous melt polymerization; and either type can be produced separately by appropriate adjustment of the initial acid concentration, the reaction duration and the reaction temperature This invention is only concerned with the watersoluble polydextrose.

The use of the insoluble forms as a nonnutritive substitute for flour is also disclosed in U S Patent No

3,766,165 The watersoluble forms function as a replacement for sucrose in many foods but because of solubility they cannot function as flour replacements.

It has now been discovered that a lowcalorie farinaceous composition can be prepared comprising a low-calorie farinaceous composition comprising from 20 to 75 % by weight of modified polydextrose as hereinafter defined, from 2 to 20 % by weight of proteinaceous material selected from egg white, milk solids, sodium caseinate, calcium caseinate, soybean isolate, gluten and yeast, from 10 to 40 % by weight of cellulose derivative selected from alpha cellulose or microcrystalline cellulose and from 5 to

20 % by weight of flour This composition can be used as a replacement for some or all of the flour ordinarily used in food compositions, such as pastas, pancakes and leavened baked foods.

Detailed Description of the Invention.

The term modified polydextrose (MPD) as used in this specification refers to a watersoluble highlybranched polydextrose wherein the linkage of 1 6 predominates, having a number average molecular weight between 1,500 and 18,000 and containing (a) from 0.5 to 5 mole percent of polycarboxylic acid ester group wherein the acid is selected from the group consisting of citric, fumaric, tartaric, succinic, adipic, itaconic and malic acids and (b) from 5 to 20 % by weight of a foodacceptable polyol selected from the group consisting of sorbitol, glycerol, erythritol, xylitol, mannitol, and galactitol which is chemically bonded thereto Citrated and tartrated polydextrose may be used in either the neutralized or acid forms, and the preferred forms are citrated polydextrose with sorbitol, neutralized (Type N) or acid

(Type A) form Thus the term modified polydextrose includes citrated polydextrose modified with sorbitol.

These water-soluble modified polydextroses can be combined with protein, cellulose and small amounts of flour to produce low calorie farinaceous compositions with all of the necessary physical characteristics of flour These new compositions are highly palatable and especially useful in the preparation of low calorie pastas, pancakes and leavened baked goods The term "pasta" is meant to include formed and shaped products such as macaroni, lasagna, spaghetti and noodles.

Modified polydextrose-based farinaceous compositions perform similarly to wheat flour at different replacement levels, 50-100 %, depending on the food system In addition, compared to natural flours they are low-calorie compositions These compositions allow direct o v-1 ( 21) ( 31) ( 31) ( 32) ( 33) (

44) ( 51) ( 52) 1,508,940 replacement of at least 50 % of the wheat flour in all recipes without otherwise altering either the other ingredients used or the method of preparation The products obtained are -comparable in flavor, texture and color to products containing ordinary use levels of flour.

The farinaceous compositions of the invention contain from 20 to 75 % by weight of modified polydextrose The proteinaceous material is present in a concentration of from 2 to 20 % by weight and may for example be supplied in the form of egg white, milk solids, sodium caseinate, calcium caseinate, soybean isolates, gluten or yeast The preferred source, however, is egg white The cellulose derivative is present in a concentration of from 10 to 40 % by weight and may be alpha cellulose or microcrystalline cellulose Flour is also present in a concentration of from 5 to 20 % and may for example be wheat, corn, rice, rye or soya bean flour The preferred flours are wheat and rye Starch may also be present as an optional ingredient in a concentration of from 8 to 30 % and may for example be a modified or unmodified corn, wheat, potato, rice or tapioca starch However, the preferred starch is wheat starch.

533/2197

The farinaceous compositions of the invention are readily prepared by intimately mixing the modified polydextrose with the proteinaceous material in aqueous dispersion, adding and mixing the cellulose derivative and the flour and drying the resulting mixture using conventional methods The starch if present may be added before the drying step.

The invention will be more fully understood in the light of the following specific examples.

Example I.

A modified polydextrose-based farinaceous composition was prepared according to the following formula:

Ingredients Egg white solids (egg albumen) Water Modified polydextrose, type N powder (MPD)

Microcrystalline cellulose, food grade (Avicel p H-101, FMC Corporation; Avicel is a registered trade mark) All-purpose wheat flour Grams 75.00 00 500 00 250 00 00 Total 1,125 00 The egg white solids was dissolved in water by mixing for 10-15 minutes A fluffy white consistency was developed The modified polydextrose was added to this and mixed for 45 minutes A creamy smooth mixture of glossy appearance and free of lumps was obtained.

The microcrystalline cellulose was then added and mixed for 20 minutes The flour was then added and mixed in the homogeneous mixture obtained, which had a pasty consistency It was then spread on trays and placed in a preheated oven ( 800 C) After drying for 72 hours the material was milled to a fine powder.

The light tan powder was found to have a cereal-like odor and taste and was insoluble in water

However, it absorbed water and behaved in a manner similar to wheat flour.

The following data for the milled modified polydextrose-based farinaceous composition were determined and compared to a commercially available wheat flour:

MPD-Based Farinaceous Composition Percent moisture p H of 25 % slurry Water absorption (%)'

Color 6.80 5.65 40.00 light tan Wheat Flour 12.00 5.70 58.70 off-white Flavor(odor and taste) Fat content (%) Protein content (%) Digestable carbohydrates (%) Calories/100 grams toasted cereal 0.14

7.60 12.82 127 00 Water absorption is the amount of water hydrated in the insoluble portion of the materials in excess of water exposed at 701 C for 3 hours. cereal 1.00 10.50 76.10 364 00 3 1,508,940 3 Example II.

A modified polydextrose-based farinaceous composition containing fond grade alpha celluIngredients

Modified polydextrose, powder Egg white solids Water Alpha cellulose (Solka (registered trade mar grade, Brown Compa All-purpose wheat flour lose in place of microcrystalline cellulose, was prepared in a manner similar to Example I 5 Grams 500 0 75.0 0 250 0 0 Total 1,125 0 The following is a comparison of the above composition with a commercially available wheat flour:

MPD-Based Farinaceous Composition Results:

Wheat Flour Percent moisture in dry milled materials 6 8 12 0 Calories/100 grams 127 0 364 0 Protein content (%) 7 6 10 5 Fat content (%o) O 14 ' 1 0 Digestible carbohydrate composition 12 8 76 1

Example III.

Modified polydextrose-based farinaceous compositions utilizing sodium caseinate, calcium caseinate, combinations of sodium and calcium caseinate, various soya bean isolates, gluten, and baker's yeast as the proteinaceous binding agent for modified polydextrose in the 25 fabrication of a farinaceous composition were prepared according to the general method outlined in Example I The resultant products were also found to be similar to wheat flour.

1,508,940 Formula Ingredients (In Grams) A B C D E F G H I J K Gluten Sodium caseinate 7 5 15 22

5 Calcium caseinate 22 5 15 7 5 30 Soybean isolate (Profan 90, Grain Processing Corp) Soybean

534/2197

isolate (Supro 900 (registered trade mark), Ralston Purina Co) Soybean isolate (Promide D, Central

Soya Co, Inc) Soybean isolate (Promide F, Central Soya Co, Inc) Bakers yeast Water 140 140 140 140

140 270 270 140 140 70 Modified polydextrose, type N powder Microcrystalline cellulose All-purpose flour 200 200 0 900 0 oo x 200 200 200 200 200 200 200 100 100 100 100 100 100 100 100 100 100

50 50 50 50 50 50 50 50 50 50 520 520 520 520 520 520 650 650 520 520 450 Example IV.

Modified polydextrose-based farinaceous compositions were prepared utilizing a combination proteinaceous material such as egg white solids, and modified and unmodified starches derived form either wheat, corn, tapioca, or other natural sources such as rice, potatoes, yams and cassava.

The following formulas are given to show usage levels of materials, including starch, in the fabrication of modified polydextrose-based farinaceous compositions The same general method of preparation given in Example I was used with the exception that the starches were added after the modified polydextrose and the protein material were mixed Physical data on the resultant milled products are also given below to show the similarity of these products relative to flour.

Totals:

-A Formula Ingredients (In Grams) A B C D E F G H I J Egg white solids Water Modified

Polydextrose, type NP (NP means Neutralised Powder) Microcrystalline cellulose (Avicel, p H 101,

FMC Corp) All-purpose flour Unmodified wheat starch Modified corn starch (Resista -Trade Mark

Staley Mfg Co)Modified corn starch (Consista, Staley Mfg Co) Modified corn starch (Thin & Thick,

Staley Mfg Co) Modified corn starch (Dura Gel, Staley Mfg Co) Modified corn starch (Frya Snack,

Corn Products Company) Modified corn starch (Dry Short, Corn Products Company) Modified corn starch (Amaizo Trade Mark Quick Set, Corn Products Cempany) Modified tapioca starch

Pregelatinized wheat starch 124 8 355 1 136 4 44.6 1248 355 1 136 4 44.6 124 8 355 1 136 4 44.6 1248

355 1 136 4 44.6 124 8 355 1 136 4 44.6 124 8 355 1 136 4 44.6 124 8 355 1 136 4 44.6 124 8 355 1

136 4 44.6 124 8 355 1 136 4 ' 44.6 124 8 355 1 136 4 44.6 112 1 L 2.1 11 '9 1 1JL 1 l L 112 1 112 1

1121 112 1 112 1 112 1 ' 112 1 800 800 800 800 800 800 800 800 800 800 1 Jt 0 0 o Total: oh Results A B C D E F G H I J Dried 72 hrs at 70 C (Yield in Grams) 698 686 680 698 699 695 699

698 705 692 Percent moisture(Dry milled) 6 0 4 2 3 3 4 8 5 7 5 3 6 0 5 6 7 0 5 2 p H ( 25 % slurry) 6 1

6 0 6 1 6 0 6 1 6 0 6 1 6 0 6 0 6 0 Color light tan ; off-white Example V.

Modified polydextrose-based farinaceous compositions with color, organoleptic and physical properties and behaviour similar to that of Examples I, II, and III were obtained utilizing modified polydextrose Type A (acid form) in place of the bleached and neutralized form.

Example VI.

Onion-flavored rings were formulated with the eleven modified polydextrose-based farinaceous compositions described in Example III (i e, containing respectively gluten, sodium caseinate, calcium caseinate, soybean isolates, baker's yeast, and various combinations of sodium and calcium caseinate)

Standard control onion-flavored rings were used to establish the functionality of these modified polydextrose compositions The compositions for standard and experimental onion-flavoured rings are given below In these applications all modified polydextrose-based farinaceous substitutes were used at

75 % wheat flour replacement levels with satisfactory results from the standpoint of flavor, texture, and color These observations were made when the finished products were compared to the standard control.

The all-purpose flour, wheat gluten, black pepper, salt, onion powder, and modified polydextrosebased farinaceous composition were preblended in a mixer Each composition was blended and then mixed until a homogeneous mixture was obtained (approximately 5 minutes) The bottom and sides of the bowl and paddle was scraped, water added, and mixing continued for an additional 5 to 10 minutes

A thick moist dough developed The blended mass was extruded through a die orifice 1/16-inch in diameter The ribbon of the extruded dough was then cut to 6-inch lengths and formed into rings Each of the rings was dusted with the 200 Mesh lU S.

Sieve Series (ASTM E-11-61)l modified polydextrose-based farinaceous composition specified in each of the formulated products of Recipe II or with flour in the case of the composition in Recipe I

535/2197

The rings were then deep-fried in an oil bath at 180 C for about 3 minutes until a golden yellow color with desirable texture and appearance was obtained The resulting products had a moisture content of approximately 5 %. to 0 x C \g 1,508,940 Ingredients Dry milk solids All-purpose flour Wheat gluten Black pepper powder

Salt Onion powder Butter Water MPD-based farinaceous compositions Totals:

Recipe I Standard (control) 21.0 124 7 4.2 5.6 11.4 9.7 71.3 248 2 Grams Recipe II MPD Compo si tion Described in Example III

21.0 31.2 4.2 5.6 11.4 9.7 71.3 93.5 248 2 Grams Example VII.

Noodles were prepared utilizing each of the modified polydextrose-based farinaceous compositions described in Example IV For each of the modified polydextrose-based compositions a noodle formulation (Recipe II) was prepared in which the modified polydextrosebased farinaceous compositions were used as a total replacement ( 100 %) for the semolina and wheat flour normally used in noodles and pasta formulations (Recipe I) The noodles produced were compared to the standard after drying to 10 % moisture content In addition, they were boiled in a 2 % solution of sodium chloride for

20 minutes Again the noodles were compared to the standard for color, texture, and flavor similarity In addition the Ingredients Semolina (Farina) flour Wheat flour MPD composition (from Example IV)

Whole eggs (fresh) Salt Corn oil Water water absorption rate of the noodles was established after boiling for 20 minutes at 1000 C.

The results indicated that these flour compositions at 100 % replacement levels were quite acceptable from the standpoint of texture and flavor, and comparable to the standard containing practical levels of semolina and wheat flour Such observations were recorded after the noodles were fabricated and dried to a moisture content of 10 %, as well as after being cooked for 20 minutes The color of the standard noodles was slightly lighter than the noodles containing the various modified polydextrose-based farinaceous compositions The latter were found to absorb an average of 5 % more moisture than the standard.

Recipe I Standard Recipe II Containing one of the experimental farinaceous compositions described in

Example IV

00 51.5 46.0 1.0 3.0 9.5 Totals: 211 0 Grams 151 5 46.0 1.0 3.0 9.5 211 0 Grams 1,508,940 Basically the preparation of the above noodles consisted of first preblending the dry ingredients (semolina, wheat flour, and salt in Recipe I, or salt and modified polydextrosebased farinaceous composition in Recipe

II), adding the whole eggs, oil and water, and mixing these ingredients together for 5 to 10 minutes The resultant dough was kneaded to obtain a plastic homogeneous mass and then extruded through dies under pressure in such a way that the product emerges in long ribbons After extrusion, the noodles were dried to approximately a 10 % moisture content and sealed in Cellophane (Trade Mark) bags.

Example VIII.

Pancakes were made by incorporating each of the modified polydextrose-based farinaceous compositions described in Example I using the following proportions of ingredients and according to the directions given below.

Ingredients MPD-based composition (described in Example I)

Modified polydextrose type N Sodium bicarbonate Glucono-delta-lactone Non-fat milk solids Fresh whole eggs Sodium saccharin Salt Water Tol Grams 109 0 45.0 1.0 2.0 10.0 50.0 0.1 2.5 69.0 tal 288 6

The modified polydextrose-based farinaceous composition, modified polydextrose, sodium bicarbonate, glucono-delta-lactone, sodium saccharin, and non-fat milk solids were mixed until a homogeneous mixture was obtained, about 5 minutes The water was added and mixed for an additional

2-3 minutes Whole eggs were added and mixing continued for an additional 2-3 minutes Two full tablespoons were poured on a pre-greased, preheated ( 350 F) pancake griddle and allowed to cook until bubbles appeared on surface of pancakes ( 2-3 minutes) They were then turned ond browned on the opposite side for approximately the same amount of time.

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The resultant products were found to have an acceptable color, flavor, and texture and was rated very similar in all respects to a standard pancake made with wheat flour, sugar, baking powder, whole milk, whole eggs, and butter.

Example IX.

Breads using each of the MPD-based farinaceous compositions described in Example V were prepared according to the following formula.

Ingredients Enriched all-purpose flour MPD-based composition, Example V Instant dry yeast

Granulated sugar Non-fat milk solids Salt Calcium phosphate, monobasic Emulsified shortening

Azodicarbamide, 0 1 % solution Potassium Bromate, 0 45 % solution Sodium stearoyl-2-lactylate

Water, 60 C Grams 00 00 6.25 20.00 5.00 4.50 0.50 8.20 2.83 2.50 0.50 113 72 Total 414 00 All the ingredients were thoroughly mixed.

Subsequently the dough produced was transferred to pre-greased bread pans, covered and placed in a warm (approximately 60 C) moist area and allowed to ferment for 21 hours.

The risen dough was removed from the pans and placed on a working surface The dough was punched and molded into the desired shape and replaced in the pre-greased pan.

The bread dough was allowed to attain full proof by permitting it to ferment at 60 C for an additional

2-1 hours It was then baked at 430 C for 18 minutes.

The resultant breads had the appearance, texture, and flavor of home-made bread.Data supplied from the esp@cenet database - Worldwide

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110.

GB1513507 - 6/7/1978

AUTOMATIC GRAIN COOKING APPARATUS


Applicant(s): CH UN HSIUNG CHIANG (--)


IP Class: A47J27/18

E Class: A23L1/10H2; A47J27/18; G07F9/10B; G07F11/70



Family: GB1513507

Abstract:


1513507 Grain cooking apparatus CH'UN HSIUNG CHIANG 29 July 1976 31684/76 Addition to

1447069 Heading A4D [Also in Divisions A2 and B8] The grain cooking apparatus shown comprises a rice feed gate 22, Fig. 3, actuated by a solenoid 20 and an auxiliary gate 25 connected to the solenoid core 21 by a rod 23 pivoted at its centre whereby opening of the gate 22 closes the auxiliary gate 25, discharging a predetermined quantity of rice. A knob 154 is used to pre-set the quantity of rice desired, this causing pinion 15 to lower rack 14 a predetermined amount. During subsequent operation, rotation of a worm driven wheel 17 engages a broken flange 18 on wheel 17 with an L-shaped member 13 on the upper end of rack 14 thereby depressing rack 14 and turning pinion 15, each tooth of pinion 15 actuating a micro-switch 16 to operate solenoid 20, releasing a portion of rice. A suction pipe 50, Fig.

1, connected by pipe 540 to a pump operated by motor 10, extends into the inner kettle and may be raised or lowered by a knob 54 to determine the liquid level in the inner kettle. After the rice and water have entered the inner kettle and the liquid level reduced to that desired, a post 172 on wheel 17 lifts post 50a and suction pipe 50. An indentation 501 on post 50a then engages switch MS 21 MS 22 to turn off the motor 10 and pump while the rice is being cooked.Description:


(54) AN AUTOMATIC GRAIN COOKING APPARATUS

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(71)I, CIMUN HSIUNG CHIANG,Cllinese citizen, formerly of No. 5Tien-Hein Hsiang,Kuang-Fu

Li. Pan Chiao, Taipei, Taiwan, and now of 7, Lane 185, Ho Ping Road,

PanCiao, Taipei Hsien, Taiwan, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the followingstatement:

This invention relates to grain cooking apparatus and is an improvement in or modification of the invention which is the subject of Patent No. 1,447,069.

In the apparatus described in the Complete Specification of Patent No. 1,447,069 there is a device for measuring and supplying grain to a washing basin. The device includes a triangular plate secured to a wormwheel and a solenoid operable to open a gate at the mouth of a hopper for a specified period of time, allowing grain to be discharged therefrom, when the triangular plate is moved by the wormwheel into contact with a microswitch included in a circuit for controlling operation of the solenoid. The position of the microswitch relative to the triangular plate may be adjusted so that the interval during which the plate is in contact with the microswitch as the wormwheel rotates can be adjusted, thereby determining the amount of grain to be discharged.In actual production it has proven to be a difficult task to ascertain the most suitable position of the triangular plate on the wormwheel and the degree of adjustment required to insure consistency in the measuring of the grain to be discharged. Furthermore, use of a single solenoid gate did not eliminate or substantially reduce clogging of grain in the hopper and, in consequence, inconsistent amounts of grain were discharged from the hopper. In addition, the device as disclosed on the Complete Specification of Patent No.

1,447,069 does not embody means whereby the amount of water in the cooking kettle can be easily regulated or whereby excess water therein can be automatically drained therefrom so as to insure proper consistency of the cooked grain.

According to the present invention, there is provided a grain cooking apparatus as claimed in claim 1 of Patent No.1,447,069 wherein there is provided means for feeding the grain from the hopper to the basin, said means including a plurality of spaced gates movable into the path of the grain from the hopper to block the passage of grain therefrom and movable away from saidpath, the said gates being operable sequentially so that a predetermined quantity of grain may be initially retained therebetween and subsequently released for feeding to the basin.

Following is a description by way of example only and with reference to the accompanying drawings of one method of carrying the invention intoeffect -

Figure 1 is a front perspective view of cooking apparatus in accordance with the present invention,

Figure 2 is a rear perspective view of the apparatus shown partly in cross-section,

Figure 3 is a detailed view of a grain discharging mechanism of the apparatus,

Figure 4 is a view in partial cross-section of a device for regulating an amount of water in a cooking kettle of the apparatus,

Figure 5 is a circuit diagram of an electrical circuit of the apparatus,

Figures 6A and 6B are diagrammatic representations of a transmission for operating a plunger of the apparatus,

Figure 7 is an exploded perspective view of a cooker of the apparatus.

As shown in Figs. 1 and 2, the present invention consists of a grain hopper 90 and control means which are disposed over a grain washing basin 40, the basin being provided over and communicative with a conventional electric grain cooker 80. It will be understood that the hopper 90, control means, grain washing basin 40 and the electric cooker 80 are provided in a cabinet with the electric cooker 80 being provided with a sliding block 80a so that it may slide in and out of the cabinet along suitable rails.

For the sake of clarity, the cabinet and the rails thereof have been removed.

Both the grain and water control means are driven by a single motor 10 which is provided with a gear box 11. From one side of the gear box 11 is extended a main driving rod 101 which is provided at the opposite end with a bevel gear 102 which meshes with a second bevel gear 103 provided on the upper end of a vertical shaft 104 which extends down into the grain washing basin 40.

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At the lower end of the vertical shaft 104 is provided an agitating paddle 105. A plunger rod 42 is disposed through the vertical shaft 104 extending beyond both ends of the shaft.

The lower end of the plunger rod 42 is provided with a plunger 45 which acts as a seal between the washing basin 40 and the interior of the electric cooker 80. The upper end of the plunger rod 42 extends upwardly beyond the bevel gear 103 and is provided with a roller 43 which abuts a cam 70. A coil spring 44 is provided to insure that the roller 43 follows the cam accurately and to provide for freedom of movement of the plunger shaft 42, (see Figs. 6A, 6B). This constitutes the grain washing mechanism.

The grain supply mechanism consists of a gear 111 provided on the main rod 101 drivingly connected to a second gear 112 by a sprocket chain 106. The second gear 112 is provided on a worm 107 to drive a worm wheel 17. The worm wheel 17 is provided with a circular broken flange 18. The amount of grain to be discharged is determined by setting a selector dial 154 for the number of servings desired. A rod 153 is connected to a gear 15 which engages with teeth 141 of a square rack 14. Secured to the rack14 at a suitable position thereon is a generally L shaped wing member 13 which extends beyond the circular flange 18. At the other side of gear 15 is provided a microswitch 16 to activate a solenoid

20 to open a grain discharge gate 22 disposed at the base of the hopper 90 (see Fig. 3).An auxiliary gate

25 is provided a suitable distance above the discharge gate 22 and is connected to the core 21 of the solenoid 20 by a connecting rod 23. The connecting rod is pivoted at its centre point 24.

The water supply system consists of a main reservoir 39 provided with a microswitch 391, a hose portion 37a, a valve 38, a hose portion 37b, a lead in hose 31a provided with a magnetic valve 31, a supply chamber 30, a valve 33, and various hoses 35, 36, 331 and 402.

The valve 38 is operated by a cam 71 ex

erting pressure against a lever 382 mounted

on a spring 381. The magnetic valve 31 is

operated by the microswitch 391 and valve 33 is operated by a spring mounted lever 332 and a post

703 provided on the cam 70, (see

Fig. 2). The supply chamber 30 has disposed therein a supply pipe 32 having its upper end extending beyond the chamber 30 and having teeth meshed with a pinion 34 and having an inlet hole 321 provided on its lower half.

The pinion 34 is disposed at one end of a rod 341, at the other end of whichis - provided a knob 342 for adjusting the height of the inlet hole of the pipe.

A suction pipe 50 is provided through the top of the cooker 80 and is connected by a hose 540 to a pump 554 driven by the motor 10. The height of the suction pipe in the cooker is adjustable by a slide knob 54 which is attached to the tip of the suction pipe 50 by means of a bar 53, (see Fig. 1).

The mode of operation will now be explained with reference to the electrical circuit diagram shown in

Fig. 5.

The cooker 80 is initially removed from the cabinet. This is a conventional grain cooker and it should suffice to explain that in this conventional cooking method raw grain, preferably rice, is put in a removable inner kettle 84 with a proper amount of water after washing. The amount of water put in the inner kettle 84 is determined by the desired consistency of the cooked grain, i.e. the more water placed inthinner kettle with the grain, the softer the grain will become. After placing the inner kettle in the cooker, a specified amount of water is placed in the outer kettle 89. The outer kettle is heated electrically, causing steam to form so that the grain is gently steamed. The water in the inner kettle is heated gently and that which does not evaporate is absorbed by the gram.

After the inner kettle 84 has been placed in the outer kettle 89 and the cooker 80 has been connected to an electrical source by means of placing a suitable plug (not shown) into the socket 81 and the on-off switch 82 has been switched to"on", the cooker is slid into the cabinet until the lid flange 85 abuts the flange 85a of the lid 83 which is suitably secured to the bottom of the washing basin, so that holes 41 and 86 which are of the same size are concentric with each other. The selector knob 154 is set to indicate the number of servings desired. when knob

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154 is turned in the direction shown by the arrow a (see Fig. 3) the rack 14 will likewise be driven in the direction shown by arrow al by virtue of its meshed relationship with the gear 15. The knob 342 is then set to regulate the amount of water to be supplied to the outer kettle 89. The higher the hole 321 of the pipe 32 is raised, the more water will be supplied to the outer kettle 89.

Situated in a suitable position next to the bare 50a are ganged microswitches MS2, and

MS22. In its normal position the bar 50a is provided with an indentation 501 opposite

the microswitches MS21 andMS22 so that

the microswitches will remain open. When the correct amounts of grain and the water

of the inner kettle have been selected, the knob 54 is depressed causing the indentation

501 to move away from the microswitch

MS21 and MS22 and causing the microswitch to be closed, (see Fig. 5).

Provided that a switch902 (to be described later) is closed and the reservoir 39 is full of water so that the float type microswitch 391

closes the b terminal, when switchesMS and MS22 are closed, the motor 10 (M) will be activated and indicator lamp L1 will illuminate indicating that the knob 54 has been depressed. When the water in the reservoir falls below a specified level, the microswitch 301 will open and contact terminal a, closing the water feed circuit consisting of an indicator lampL2 and a magnetic valve31 .(M.V.).

The magnetic valve 31 will be opened to allow a water supply to flow into the reservoir. When a sufficient amount of water has entered the reservoir, the switch 391 will return to terminal b, the magnetic valve will close, the indicator lamp L2 will be extinguished and the motor 10(M) will operate.

The motor 10 drives both the vertical shaft 104 and the worm 107, the worm in turn driving the worm wheel 17 to rotate.

As the worm rotates two cams 70 and 71 are rotated by virtue of the fact that they are provided on a common shaftwhich turns in response to rotation of the wormwheel 17.

The cam 71 serves to open the valve 38 when the smaller diameter 711 is in contact with the spring biased lever 382, and allow water to flow from the reservoir 39 to the water receiving chamber 30. Due to the fact that the valve 33 is closed, no water will be able to flow through hose 331 but instead will flow through the hole 321 and the hose 35 into the grain washing basin 40 where the paddles 105 are already rotating as the shaft

104 is rotated. It is important that water be

supplied to the washing basin 40 before the grain so as to prevent damage to either the grain or the paddles 105.

As water begins to flow into the basin 40, the circular flange 18 of worm wheel 17 catches the wing member 13 and drives the rack 14 upward in the direction of the arrow

b causing the gear 15 to turn the direction of the arrow b, (see Fig. 3). With every pitch of the gear 15 a tooth of the gear will cause a lever 161 to close or open a microswitch 16 momentarily. When microswitch 16 is closed it will activate a solenoid 20 whichwifl open the gate 22 at the base of the hopper 90.

As the gate 22 slides out along a guide way

121 allowing grain in the chamber 12 to be discharged into the grain washing basin 40 below, the upper gate 25 slides into the hopper 90 along guideways 322 by virtue of its pivotal connection to slide gate 22, preventing grain from dropping into the chamber 12. The chamber 12 is designed to hold a specified amount of grain, i.e., one serving, so that the exact amount of grain discharged into the washing basin 40 can be strictly controlled. As the tooth of the gear 15 passes and releases the lever

161 the microswitch will be opened, deenergizing the solenoid 20.

As the solenoid releases the core 21, a spring 26 will quickly pull the gate 22 back into place along guideway 121 and the upper gate 25 will be opened allowing the chamber 12 to be filled in preparation for discharging another serving of grain into the washing basin 40. This operation will be repeated once for every time a tooth of the gear 15 passes the microswitch 16.

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As the grain is being washed in the washing basin 40 a continuous supply of clean water flows in through the flexible hose 35.

Due to the agitation of the water by the paddles, the dirty wash water will rise to the top as the clean water is supplied from the base of the basin. Dirty water is drained by means of an outlet 401 whereby waste water flows into a hose 402 and out of the basin 40.

As the grain is being washed, the cam 70 continues to turn, exerting downward force against the spring mounted roller 43 so as to keep the plunge 45 in a sealing relationship between the washing basin 40 and the cooking apparatus 80. When the grain has been thoroughly washed the cam 70 will have rotated so that a point 701a on its diameter is in contact with the roller 43, (see Figs.6A, 6B). Upon further rotation of the cam the deep valley 701 will allow the plunger shaft 42 to rise, pulling the plunger 45 out of engagement over the holes 41, 86 so that the grain and water in the washing basin may be discharged into the inner kettle 84, (see

Figs. 6A, 6B and Fig. 7).

At this time the diameter 712 of the cam 71 will have forced the valve 38 to close by exerting downward force on the lever 382, cutting off the water supply to the waterreceiving chamber 30.

The cam 70 is also provided with a small post 703 at a suitable position thereon to operate a lever arm

332. Just as the cam is ahout to release theplunk shaft 42 the post 703 will exert downward pressure on the lever 332 which is pivoted over the valve 33.

As the end of the lever situated near the cam and in contact with the post is moved downward, the end thereof positioned over the valve 33 will rise, opening the valve and allow the water in the chamber 30 below the level of the hole 321 to flow through the pipe 331 and through a hose 36 extending into the outer kettle 89 by means of a hole 87.

As shown in Fig. 4, the water level regulating device for regulating the amount of water in the inner kettle 84 is comprised of a suc tion pipe 50 extending through a hole 88 in the lid 83 and into the inner kettle 84 and a drain pipe 553 including a plurality of check valves 556, 555, a filter 557, a collection trough 558, and drainage pump. The drainage pump is comprised of a crank shaft 551 driven by the motor 10 through the gear box 11, a flexible diaphragm 552 attached thereto and a diaphragm housing

554. As the motor 10 runs it drives the crank shaft 551 which extends into the diaphragm housing 554 provided on the drain pipe 553. The edges of the diaphragm 552 are securely sealed to the bottom walls of the housing 554 at the point where they meet the opening in the drain pipe 553. All edges of the diaphragm 552 are sealed so as to provide for good suction.When the crank shaft 551 drives the diaphragm 552 to contort and enter the flow path of the drain pipe 553 it will create high pressure therein causing any liquid or air to be displaced. As the valve 556 is a unidirectional check valve, the liquid or air can escape only in the direction of the arrows, through the check valve 555. Likewise, as the diaphragm 552 is pulled up and into the housing 554, a suction will be produced, and as no liquid may return after passing the check valve 555 liquid will flow from the check valve 556. In this way, excess water may be pumped from the inner kettle.

A fine wire mesh screen 51 is provided at the mouth of the suction pipe 50 to prevent grain from being drawn out of the kettle 84.

If any small kernels of grain get past the screen 51, they will be trapped by a second screen 557 provided in the pipe 553. A trap 558 is also provided to collect any such grain.

To control the amount of water to be pumped, the knob 54 may be moved up or down in a slot 63 provided in the wall of the cabinet 60. The rod 50a is held in place by means of spring 621 provided in the frame 62. In any event, the suction pipe50-will be removed from the inner kettle 84 automatically by means of a post 172 attached to the worm wheel 17 and a post 52 attached to the square rod 50a which is secured to the top of the pipe 50. As the rod 50a is raised the indentation 501 thereon will come into contact with the microswitches MS21 and

MS22, opening the sameso that hoth switches

MS21 and MS22 are opened, turning off both the indicator lamp L1 and the motor 10.

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Just before the motor 10 is turned off, another post 171 (see Fig. 3) on the side of the worm wheel 17 opposite the last post 172 will come into contact with and close a microswitchMSt causing a switch to go from terminal b to terminal a (see Fig. 5), thus activating the circuit to start the cooking apparatus 80 to cook the grain now located therein.

It should be noted that the microswitch

MS1 is normally closed (terminal a). This is to insure that if there is no water in the reservoir 39 at the commencement of an operating cycle the motor will not operate until the water supply circuit comprised of switch 391, lamp L2 and the magnetic valve 31 has been activated to replenish the reservvoir 39 with water. As soon as the motor begins to operate the post 171 will disengage with the microswitch MS1 and the switch will change to terminal b.

The switch 901 shown in Fig. 5 is a timer.

The grain cooking apparatus can be set to begin operation at any time by means of the timer.

In this way it is possible to provide for a safe, dependable automatic grain cooking apparatus which is capable of accurately discharging precise predetermined amounts of grain from a hopper to a washing basin and further to a cooking kettle, and the amount of water desired for cooking the grain may be accurately regulated.

WHAT ICLAIM IS:

1. Grain cooking apparatus as claimed in claim 1 of Patent No. 1,447,069 wherein there is provided means for feeding grain from the hopper to the basin, said means including a plurality of spaced gates movable into the path of the grain from the hopper to block the passage of grain therefrom and movable away from said path, the said gates being operable sequentially so that a predetermined quantity of grain may be initially retained therebetween and subsequently released for feeding to the basin.

2. Grain cooking apparatus according to

Claim 1 wherein said gates are operable by drive means adapted so that the interval between sequential movement of said gates into said path may be controlled.


Claim 2 wherein said gates comprise a pair of parallel plates pivotally connected to opposite ends of a lever, the lever being pivotally mounted intermediate its ends, and one of the plates being movable by a solenoid.


Claim 3 wherein the drive means includes a pair of toothed gears inengagemeni with one another, one of the gears being a driving gear and the other of the gears being a driven gear, an electric switch adapted to be sequentially engaged by teeth of the driven gear when the driven gear is driven and an auxiliary electric circuit including the electric switch and the solenoid.


Claim 4 wherein the drive gear is engaged for a period by a constant drive source and control means is provided for adjusting the interval of the period.



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111.

GB1522284 - 8/23/1978

NON-FRIED DRY INSTANT COOKING NOODLES AND A METHOD FOR

PRODUCING SAID NOODLES


Applicant(s): KANEBO LTD (--)


IP Class: A23L1/10

E Class: A23L1/16



Family: GB1522284

Equivalent: US4098906; NL7700363; FR2348657; ES454806; DE2659027; NL162826C;

IT1067698

Abstract:


1522284 Non-fried instant noodles KANE- BO KK 31 Jan 1977 [19 April 1976 5 Aug 1976] 03823/77

Heading A2B Non-fried instant cooking noodles, reconstitutable in water at 85 C within 3 minutes, comprise a starch material, constituted mainly by wheat flour and having an alpha conversion degree

(by a defined enzyme test) of at least 93%, and 1-6wt.% NaCl; are coated with 0.2-5wt.% oil and 0.01-

5wt.% emulsifier for said oil; and have a structure of irregularly-shaped cells. (All percentages are with respect to the dry weight of the noodles). The noodles are made by (i) forming a mixture of starch component, NaCI, water and, optionally, additives such as binding gums, Na polyphosphate and Na/ K carbonates and phosphates, into noodles, preferably of thickness not more than 1.3mm, (ii) coating with an aqueous emulsion containing the oil and emulsifier, (iii) heating with steam of pressure 0.5-

1.5kg/cm>;SP;2>;/SP;, preferably for 2-5 minutes, to convert the starch, and (iv) drying at 60 C or above, e.g. with hot air at up to 130 C for 5-80 minutes, to form the porous structure. The noodles from

(i) may contain 25-40wt.% water and the cooling step (ii) may apply 2.7-18% water based on the dry weight of the raw noodles. The dried noodles should not contain more than 15wt.% water. The starch component preferably contains at least 70wt.% wheat flour and may also include cornflour, buckwheat flour, rice flour and starch. The oil may be rice bran oil, corn oil, rape oil, sesame oil, soybean oil or salad oil, and the emulsifier may be a sucrose, sorbitan, propylene glycol or glycerin fatty acid ester or lecithin.Description:



( 21) Application No 3823/77 ( 22) Filed 31 Jan 1977 ( 31) Convention Application No 51/044 778 (

32) Filed 19 April 1976 ( 31) Convention Application No 51/093 318 ( 32) Filed 5 Aug 1976 in 33)

Japan (JP) ( 44) Complete Specification published 23 Aug 1978 ( 51) INT CL 2 A 23 L 1/10 ( 52)

Index at acceptance A 2 B 1 B 1 C 1 JY i S IT 1 X 1 Z ( 11) 1522284 ( 54) NON-FRIED DRY

INSTANT COOKING NOODLES AND A METHOD FOR PRODUCING SAID NOODLES ( 71)

We, KANEBO KABUSHIKI KAISHA of 3-26, Tsutsumi-Dori, 3-Chome, Sumida-Ku, Tokyo, Japan, a company organized according to the laws of Japan, do hereby declare the invention, for which we

544/2197

pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:The present invention relates to non-fried dry instant cooking noodles which have no oily odor and an excellent storage stability, can easily recover the state of regularly cooked noodles in a very short time with hot water and show slippery feeling, good eat feeling and taste upon eating, and to a method for producing said noodles.

As instant cooking noodles, fried instant cooking noodles obtained by boiling raw noodles and then dehydrating tthe boiled raw noodles with hot oil and non-fried dry instant cooking noodles obtained by boiling raw noodles and then drying by heating have been heretofore known.

However, in the above described fried noodles, the oil deteriorates when such noodles are stored for more than 6 months after the production, whereby the eat feeling and taste are readily degraded, oily odor is generated and the flavor of a seasoning agent, such as soup and the like cannot be fully developed.

Furthermore, a large amount of oil is contained, so that said noodles are not suitable for cooking and eating of vermicelli and buckwheat vermicelli which need a relatively light taste.

For obviating these defects, the production of the above described non-fried noodles has been proposed but it has been difficult to eliminate defects of mutual stickiness between noodles due to excessive swelling of some of the raw noodles and unevenness of the a conversion degree, which are liable to be caused upon boiling, lowering of the recovering ability with hot water and deterioration of eat feeling and taste, and such noodles have not yet been commercially produced.

A process for producing non-fried instant cooking noodles wherein an emulsion of an edible oil of the oil in water type is mixed 50 with wheat flour to form raw noodles and the formed raw noodles are boiled and then the boiled noodles are dried by heating, has been known but the stickiness between noodles resulting from excessive swelling upon boiling 55 and unevenness of a conversion degree deteriorate the recovering ability with hot water, eat feeling and taste and lower the value of the product and this process has.

therefore not been commercially carried out A 60 desirable requirement to be provided in the instant cooking noodles is that the noodles uniformly recover the state of regularly cooked noodles within a temperature range suitable for eating and as low as possible in 65 a short time, but the commercially available non-fried dry noodles need heating in boiling water for about 5 minutes and the fried noodles must be left standing for more than 3 minutes in hot water at higher than 900 C 70 If instant cooking noodles capable of recovering the state of regularly cooked noodles with hot water at a temperature of lower than 850 C in a short time can be produced, hot water at a temperature which has been 75 lowered by storage for a long time, for example, in a vacuum flask, can be used and water which has been boiled on a high mountain under a low atmospheric pressure and thus is of lower boiling temperature than nor 80 mal can be satisfactorily used and the production of such noodles has been widely demanded.

The inventors have diligently studied in order to obviate the above described defects of the prior art and found that in non-fried dry 85 instant cooking noodles obtained by coating the surface of raw noodles containing sodium chloride with an aqueous emulsion of an edible oil and then subjecting the thus treated noodles to a heat treatment (a conversion 90 treatment) with steam and the like, a conversion is uniformly high, a specific cellular, porous structure having irregularly shaped cells connecting the interior with the outer surface 1,522,284 is formed, so that hot water added upon cooking is smoothly and easily absorbed in the noodles and said noodles recover uniformly the state of regularly cooked noodles, a good eat feeling is obtained upon eating and further in this case an emulsifier present on the outer surface is dissolved to reduce the surface tension of the hot water and contributes to the rapid penetration, uniform absorption and recovery, and the sodium chloride present in the inner layer and the edible oil on the surface of noodles give a slippery feeling and a moderate elasticity (resiliency) upon eating and good eat feeling and taste are obtained, and further the sodium chloride coexisting with a-starch restrains and prevents 1 S conversion of starch and the storage stability for a long period of time can be attained Thus, the present invention has been accomplished.

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An object of the present invention is accordingly to provide non-fried dry instant cooking noodles which have no oily odor, can be stably stored for a long period of time without deteriorating the eat feeling and the taste and recover uniformly and easily the state of regularly cooked noodles within a very short time (within 3 minutes) by addition of hot water at 850 C and show moderate slippery and elastic feeling and good eat feeling and taste upon eating.

A further object of the present invention is to provide a method for producing commercially easily and cheaply the non-fried dry instant cooking noodles.

The present invention consists in non-fried dry instant cooking noodles capable of recovering to the regularly cooked state within 3 minutes of contact with hot water at 850 C and comprising a starch component which is mainly wheat, flour having an alpha conversion degree as measured by the enzyme process of at least 93 % and from 1 to 6 % by weight, based on the absolute dry weight of noodles, of sodium chloride; the noodles being provided with a cellular structure of irregularly shaped cells connecting the interior with the outer surface and being coated with from 0 2 to 5 % by weight, based on the absolute dry weight of the noodles, of ani edible oil and from 0 01 to 5 % by weight, based on the absolute dry weight of the noodles, of an edible emulsifier for said oil.

Furthermore, the present invention consists in a method for producing non-fried instant cooking noodles which comprises coating the surfaces of raw noodles comprising a starch component consisting mainly of wheat flour and containing from 1 to 6 % by weight, based on the absolute dry weight of the noodles, of sodium chloride with an aqueous emulsion of an edible oil so that the noodles are coated with from 0 2 to 5 % by weight, based on the absolute dry weight of the noodles, of the edible oil and from 0 01 to 5 % by weight, based on the absolutedry weight of the noodles, of an emulsifier for said oil; heating the coated raw noodles with steam having a pressure of from 0 5 to 1 5 kg/cm until the alpha conversion degree of the starch component, as measured by the enzyme process, becomes at 70 least 93 %; and drying the thus treated noodles at a temperature of not less than 600 C to expand the noodles surfaces to form a cellular structure of irregularly shaped cells connecting the interior of the noodles with the outer 75 surface.

The term "a conversion degree of the starch component measured by the enzyme process" used herein means the a conversion degree of the dry instant cooking noodles determined 80 by the enzyme

(diastase) process explained hereinafter.

The dry instant cooking noodles according to the present invention are mainly constituted of a starch component having an a conver 85 sion degree of at least 93 % and the starch component consists mainly of wheat flour.

The raw noodles to be used in the present invention are constituted of wheat flour or a mixture consisting mainly of wheat flour and 90 containing cereal flour or starch; 25-40 % by weight of water; if necessary a well known improving agent for noodles, such as sodium polyphosphate or " Kansui (an aqueous solution containing potassium carbonate, sodium 95 carbonate, potassium phosphate and sodium phosphate); an edible additive and a seasoning agent "Kansui" is an agent for increasingthe viscosity of noodles and is an extract of banana and Taiwan plantain 100 The content of wheat flour in the starch component is preferred to be 70-100 % by weight based on the absolute dry weight of the starch component.

The cereal flour includes, for example, buck 105 wheat flour and rice flour and the starch includes, for example, corn starch, potato starch, waxy corn starch and wheat flour starch.

The water content in the raw noodles is preferably 25-40 % by weight, since when the 110 water content is less than 25 % by weight, the starting mixture maintains a powdery state and it is difficult to form noodles, while when the water content is more than 40 % by weight, after the steaming treatment for con 115 verting the starch into a-form, the noodles stick with one another.

The raw noodles usually used in the present invention are formed by the following processes, wheat flour, cereal flour, starch, an im 120 proving agent for noodles, a seasoning agent and water are mixed and kneaded and the formed blend is rolled and molded by means of a cutter or the above described blend is molded by means of an extruder, but the form 125 ing process is not limited to these processes.

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The fineness of the noodles is not limited and any of thick form and thin form may be used.

Sodium chloride is uniformly dispersed and contained in the raw noodles to be used in the 130

1,522,284 present invention and the amount is 1-6 % by weight, preferably 2-4 % by weight based on the absolute dry weight of the noodles When the content of sodium chloride is less than 1 % by weight, the recovering speed is slow and if a large amount of water has been contained in storage for a long period of time, the a converted starch component returns to f 3-form (lowering of a conversion degree), while when said content is more than 6 % by weight, the recovered noodles are insufficient in elasticity and resiliency and become brittle and the eat feeling is liable to be deteriorated Thus, such contents should be avoided.

As mentioned above, when 1-6 % by weight of sodium chloride is contained in the noodles, even if a relatively large amount of water is absorbed during the storage for a long period of time, fl conversion of the a converted starch is prevented and such a content contributes to the stability and improves the recovering ability and the eat feeling upon addition of hot water, so that the addition of sodium chioride is remarkable in the functional effect and is one characteristic of the present invention.

Furthermore, the noodles containing an improving agent for noodles, such as sodium polyphosphate, an aqueous solution of a mixture potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate; and a viscous binder, such as gum, carboxymethylcellulose and the like improve the eat feeling and the taste.

The raw noodles are coated with an aqueous emulsion of an edible oil and then heated with steam As the aqueous emulsion, use is made of an emulsion composed of an edible oil, water and an edible emulsifier.

As the edible oils to be used in the present invention, mention may be made of rice bran oil, corn oil, rape oil, sesame oil, soybean oil and salad oil.

As the emulsifiers, mention may be made of non-ionic emulsifiers, such as sucrose fatty acid esters

(for example monostearate, monopalmitate, dipalmitate, monooleate, disterate, sorbitan fatty acid esters

(for example, tristearate), propylene glycol fatty acid esters (for example monostearate, tristearate); glycerin fatty acid esters (for example, glycerin capric acid ester, ester of glycerin and a mixed acid of capric acid and caprilic acid) and anionic emulsifier, such as lecithin.

For coating the surface of noodles with the aqueous emulsion, it is preferable to spray or sprinkle the aqueous emulsion of an edible oil so that the noodles are coated with 2 7-18 % by weight, preferably 5

4-10 8 % by weight, of water, 0 2-5 % by weight, preferably 0.3-4 % by weight, of the edible oil and

0.01-5 % by weight, preferably 0 02-3 %, by weight of the emulsifier, such percentages being based on the absolute dry weight of the noodles (It will be understood that commercially available instant cooking noodles have a water content of about 7 to 8 % by weight; the expression " absolute dry weight " refers to the weight of the solids content of the noodles, i.e after the usual 7 to 8 % water has been 70 removed) In this case, when the amount of water coated is less than 2 7 % by weight, it is difficult to promote the a conversion and the recovering speed is slow and the eat feeling is deteriorated, while when said amount is more 75 than 18 % by weight, the noodles excessively swell upon the steaming and therefore the noodles readily stick with one another and the eat feeling is deteriorated Accordingly, these amounts are not preferable 80 When the amount of the edible oil coated is less than 0 2 % by weight, it is difficult to restrain an excessive swelling of the noodles and the mutual stickiness between the noodles is liable to be caused and the eat feeling tends 85 t G be deteriorated, while when said amount is more than 5 % by weight, the eat feeling and the storage stability for a long period of time tend to be deteriorated.

Although the composition of the edible oil 90 in the emulsion is not limited, a preferred emulsion of the oil in water type obtained by emulsifying a mixture of 1-65 % by weight of the edible oil and 35-99

% by weight of water with the edible emulsifier, the emulsifier 95 being present in such an amount that after coating on of the emulsion the amount of edible emulsifier on the noodles is 0 01-5 % by weight based on the absolute dry weight of the noodles 100 As a means for coating the surface of noodles with

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the aqueous emulsion of the edible oil, it is preferable to spray the emulsion from a spray gun or sprinkle the emulsion from a shower system But said means is not limited 105 to these processes.

After the raw noodles are coated on the surface with the aqueous emulsion of the edible oil, the noodles are heated with steam (steaming) For the steaming, the usual well known 110 conditions when the raw noodles are heated with steam, can be applied but it is preferable to contact the raw noodles with steam having a pressure of 0 5-1 5 kg/cm 2 for about 2-5 minutes The steamed noodles are generally 115 subjected to a drying step to dry the noodles to a water content of less than about 15 % by weight As the drying process, usual hot air heating, infrared heating, microwave heating and the like may be applied The drying 120 temperature is preferred to be 60-1300 C, more preferably 90-1100 C.

The drying time is 5-80 minutes, preferably 10-30 minutes, more particularly 12-20 minutes 125

During such a drying step, the water in the a-starch matrix moderately swelled in the above described steaming step evaporates rapidly and in this stage, the whole matrix expands and the irregular very fine network 130 -T continuous cells are formed and a specific cellular structure is obtained.

The a conversion degree of the starch component constituting the non-fried dry instant cooking noodles according to the present invention is at least 93 %, preferably at least 94 %, more particularly at least 96 % If the a conversion degree is less than 93 %, when the hot water is added, the recovery is difficult and such noodles give the wheat flour-like raw feeling and the eat feeling is not good.

Furthermore, the non-fried dry instant cooking noodles according to the present invention comprises only a very small amount of edible oil, while the amount of the edible oil in the general fried instant cooking noodles is about 15-20 % by weight and is very large Moreover, the edible oil in the non-fried noodles of the present invention is a fresh edible oil and is not heated at a high temperature ( 1500 C) as in the fried instant cooking noodles, so that even if the noodles are stored for about one year, the deterioration and change of quality of the oil do not occur, said oil does not deteriorate the eat feeling and taste of the instant cooking noodles and further the noodles show moderate slippery feeling and taste.

Since the edible oil substantially coats only the surface of the noodles, said oil does not prevent the penetration of hot water as seen in the fried noodles wherein the surface and the inner texture are covered with an oil film.

Furthermore, the coexisting fine particles of the emulsifier are immediately dissolved by contacting with hot water to reduce the surface tension of hot water and increase the penetration of hot water and the hot water rapidly penetrates into spaces between the edible oil particles and into the inner portion of the noodles from the continuous very fine cells on the surface of the noodes coated with the emulsifier particles and the noodles can recover the state of regularly cooked noodles in a short time This is one characteristic of the present invention.

The amount of the edible emulsifier is 0.01-5 % by weight, preferably 0 02-3 % by weight, based on the absolute dry weight of the noodles The dry instant cooking noodles are shaped into a fine linear form, the cross-section of which is rectangular and the length of the shorter side, that is the thickness is preferably 1 3 mm at the largest, more preferably 0 7-0 9 mm When the thickness is larger than 1 3 mm, the recovery speed becomes slow, so that such a thickness is not preferable.

The width, that is the length of the longer side of the cross-section of the noodle is generally 1-2 2 mm

The cross-sectional form is not limited to rectangular and may be cir-cular, oval, hollow and can be optionally selected but it is not preferable for the same reason as described above to become excessively large.

The dry instant cooking noodle has a porous structure wherein the interior of each noodle is connected to the outer surface by irregular cells, so that upon cooking, the hot water rapidly penetrates and is absorbed and the 70 noodles recover the state of regularly cooked noodles in a short time In this case, the irregular very fine network cells extending to the interior from the outer surface of the noodles serve a capillary function owing to the very 75 fine spaces in the cross-section of the noodle and this capillary function, the osmotic pressure due to dissolution of sodium chloride present in the inner portion of the noodle and the reduction of the surface tension of the added 80 hot water due to the

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above described emulsifier coated on the surface of the noodles act synergistically and the penetration of the hot water and the recovery of the noodles are considerably promoted and further a moderate 85 elasticity (resiliency) is given to the recovered noodles upon eating and the good eat feeling is obtained.

The dry instant cooking noodles according to the present invention are substantially dried 90 but the water content is generally not more than 15 % by weight, preferably not more than 10 % by weight, more particularly 6-8 % by weight When the water content exceeds 15 % by weight, mold grows in storage 95 for a long period of time and the protein in wheat flour may be readily decomposed, so that such an amount is not preferable.

The dry instant cooking noodles according to the present invention have no oily odor and 100 are stable without deteriorating the eat feeling and the taste even after storage for a long period of time and the recovery is attained uniformly and completely in a short time, so that the noodles can be easily cooked and 105 further the slippery feeling, the good eat feeling and taste can be obtained upon eating and consequently the noodles are very high in commercial value as a form of instant cooking wheat vermicelli, instant cooking vermicelli, 110 instant cooking buckwheat vermicelli and so on.

As mentioned above, the non-fried instant cooking noodles according to the present invention have a variety of characteristics and 115 merits but a particularly noticeable characteristic as compared with the conventional instant cooking noodles is that the noodles can be completely reformed into the boiled noodle form within 3 minutes by means of hot water at 120 850 C.

Hitherto, the fried noodles capable of recovering the state of regularly cooked noodles within 3 minutes by means of hot water at a temperature of higher than 90 C have 125 been well known but in this technical field, the temperature of 856 C is considered to be a fairly low temperature and any instant cooking noodles which can completely recover the state of regularly cooked noodles within a

130 1,522,284 A 1.522,284 time as short as 3 minutes at such a low temperature have never been developed.

The non-fried dry instant cooking noodles according to the present invention can recover the state of regularly cooked noodles within 3 minutes at 85 C and in a preferred embodiment, can recover fully said state within 3 minutes at 83 C and is some case, may completely recover said state within 3 minutes at 80 C and the noodles have a very excellent recovering ability Accordingly, hot water which has been stored in a vacuum flask for a long time, so that the temperature has fallen, can be applied or hot water which has been boiled on a high mountain where the atmospheric pressure is low, can be satisfactorily used and further the fear that mouth is burnt upon eating is avoided and the convenience upon eating is immeasurable.

The following examples are given for the purpose of illustration of this invention and are not intended as limitations thereof.

In the following examples, "part " and %" mean by weight, "a conversion degree" means the a conversion degree of the above described starch component measured by the enzym (diastase) process and is determined as follows.

( 1) Process for measuring a conversion degree by the enzym (diastase) process.

The sample is adjusted as follows.

The fried instant cooking noodles are degreased with ethyl ether at 50 C and then more than 20 g of noodles is pulverized In the non-fried noodles, more than 20 g of noodles is directly pulverized The powders having a fine grain size of less than 100 meshes are used.

In the measurement, 5 conical flasks of 100 ml are used with respect to one sample and these flasks are referred to as A, A 4 and B 1 00 g of the above described adjusted sample is respectively weighed and taken in the A,-A 4 flasks The unevenness of the weighed amounts a conversion degree= ( 2)

Functional estimation upon eating.

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Estimated points of taste and recovery are used to show the functional estimation upon test eating;

400 cc of hot water at 85 C is poured on to 70 g of instant cooking noodle samples and after they are left to stand for 3 minutes, a 13 person panel judges the samples.

10: Very good, 8: Good, 6: Normal, 4: Bad, 2: Very bad.

in the four flasks is made to be within -+ 5 %.

ml of water is added to each of the five 45 flasks and among them, A 2 and A 4 are heated and boiled for 15 minutes and then quenched to room temperature in ice water.

On the other hand, to A,, A, and B is added ml of 5 % aqueous diastase solution respec 50 tively and all the 5 flasks are kept at 37 Cl C for 90 minutes while shaking in a thermostat containing water, after which 2 ml of 1 NHICI is added to the flasks A,, A 3 and B to stop the diastase reaction and the content 55 in each flask is transferred into a 100 ml mess flask and water is added thereto to 100 ml.

Each solution is filtered by means of a dry filter paper and from the filtrates obtained from the flasks

A 1-A 4 and B, 10 ml of filtrate 60 is fed in a conical flask with ground stopper by a pipette and said filtrates are referred to as a,-a 4 and b.

In this stage, a conical flask with ground stopper containing 10 ml of water taken up by 65 a pipette is prepared for a blank test 10 niml of N/10 aqueous solution of iodine is added to each of the 6 flasks.

Then 18 ml of N/10 aqueous solution of sodium hydroxide is added to each of the 6 70 flasks in turn over the same interval, timed by means of a stop watch, and the flask is corked and shaken and then left to stand for 15 minutes When the first flask has stood for 15 minutes, 2 ml of 10 % sulfuric acid is added 75 to each flask in the same order and over the same interval as when N/10 aqueous solution of sodium hydroxide was first added, rapidly as soon as the stopper is opened and the resulting solutions are titrated with N/10 aqueous solu 80 tion of sodium thiosulfate and the titrated values of a a 4 and b are referred to as P,-P, and Q and the titrated value of the blank test is referred to as r e conversion degree (%) is determined by the following 85 formula.

(r-P,)-(r-P 4)-(r-Q) (r'-P,)-(r-P-)-(r-Q) x 100 These points are shown by the average value.

The eat feeling test results (stick to teeth wheat flour-like raw feeling) show the number of persons among a 13 person panel 105 who indicate these feelings upon eating the samples which have been immersed in 400 cc of hot water at 85 C for 3 minutes.

Points 8-10 for estimating the recovering ability correspond to the estimation of the 110 recovery when the commercially available noodles, which are eaten after boiling, are boiled.

1 1 C 6 U 228 ( 3) Porous structure.

The outer surface and the cross-section of the test noodles are observed by an electron microscope and it is determined whether or not a cellular structure connecting the interior with the outer surface is provided, the cells of the cellular structure having irregular shapes and sizes.

Example 1.

To 500 parts of wheat flour was added a mixed solution of 170 parts of water, 10 parts of sodium chloride and I part of a solution of a mixture of potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate and the resulting mixture was rolled to a thickness of 0 85 mm by rollers and shaped into raw noodles by means of No 20 cutter The raw noodles ( 681 parts) were uniformly sprayed with an emulsion consisting of 940 parts of water, 60 parts of salad oil and 2 parts of sucrose oleic acid ester by means of a spray gun and 12 % of the emulsion was coated on the surface of the raw noodles ( 0.72 %, based on the absolute dry weight of the raw noodles, of salad oil, 0 02 % of the emulsifier and 11 26 % of water were coated).

550/2197

Thereafter, the thus treated raw noodles were heated with steam of 1 0 kg/cm 2 for 3 minutes (the water content after steaming: 38 %) and then dried by hot air at a temperature of 1000 C in an air speed of 15 m/sec until the water content of the noodles become 8 % to obtain the instant cooking noodles of the present invention sample 1 having the irregular very fine network porous structure connecting the inner layer to the outer surface.

As a comparative sample 1, the emulsion was sprayed and then the noodles were treated in the same manner as described above except that only the steaming was not carried out.

As a comparative sample 2, the emulsion was sprayed in the same manner as described above and then dried by hot air at 100 C for 2 minutes at en air speed of 3 m/sec, after which the same steaming as in the present invention was carried out to dry the noodles to a water content of 38 % and then the same drying as in the present invention was carried out.

As a comparative sample 3, the raw noodles were treated in the same manner as in the present invention except that the noodles werecoated with 11 28 % of water instead of the emulsion.

As a comparative sample 4, the raw noodles were treated in the same manner as in the present invention except that the emulsion was not applied.

As a comparative sample 5, the raw noodles were treated in the same manner as in the present invention except that 0 72 % of salad oii alone was coated.

The instant cooking noodles of the above described present invention sample 1 and the comparative samples 1-5 were immersed in hot water at 850 C for 3 minutes and the taste estimation of these samples were determined and the recovering ability of these samples after immersed in hot water at

830 C, 850 C and 900 C for 3 minutes respectively was determined and the obtained results are shown in the following Table 1.

13522 S 284 c 1,522,284 TABLE 1

Comparative Sample Present invention 1 2 3 4 5 Sample 1 Functional estimation upon eating Stick on teeth (persons) Slippery feeling is insufficient (persons) Slippery feeling is excessive (persons)

Elasticity is insufficient (persons) Elasticity is excessive (persons) Too hard (persons) Wheat flour-like raw feeling (persons) Taste estimation (points) Recovering ability at C for 3 minutes (points)

Recovering ability at 83 C for 3 minutes (points) Recovering ability at C for 3 minutes (points)

Properties of products Content of Na Ci (%) a conversion degree (%) Amount of edible oil coated (%)

Amount of emulsifier coated (%) Very fine network cells having irregular shapes ?L 91.

30.4 0.72 0.02 None 2.24 33.6 0.72 0.02 None 2.24 92.3 None As seen from the above results, the instant cooking noodles having a slippery feeling (good feeling estimation) and a good recovering ability can be obtained by satisfying the requirements constituting the present invention.

As a comparative sample 6, a mixture of 500 parts of wheat flour, 1 part of a mixture of potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate, 10 parts of sodium chloride and 83 parts of 2.24 90.7 None 2.24 89.8 0.72 None 2.24 0.72 0.02 Present the emulsion in Example 1 was kneaded and the raw noodles were shaped in the same manner as in the present invention sample 1 in Example 1 and then heated by steam and dried without being coated with the emulsion to obtain instant cooking noodles.

The qualities of the thus fanormed instant cooking noodles, commercially available fried instant cooking noodles, commercially available non-fried dry noodles and the non-fried noodles of the present invention sample 1 in Exam'ple 1 are shown in the following Table 2.

TABLE 2

Commercially available fried Commercially instant cocking available Present invention Comparative

Sample 6 noodles dry noodles Sample 1 Immediately Immediately after After Ahter After after After

Test Item production 6 months 3 months 3 months production 6 months Functional estimation upon

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eating Stick on teeth (persons) 5 8 0 3 0 0 Slippery feeling is insufficient (persons) 10 2 6 7 0 0

Slippery feeling is excessive (persons) 0 0 0 0 0 0 Elasticity is excessive (persons) 0 0 8 6 0 O Too hard

(persons) 12 13 12 13 0 0 Wheat flour-like raw feeling (persons) 13 12 12 13 0 0 Oily odor (persons) O

1 13 0 0 O Taste estirmation (points) 4 4 4 4 10 8 Recovering ability at 85 C for 3 minutes (points) 4 4

4 4 10 10 Recovering ability at 83 C for 3 minutes (points) 4 4 4 4 10 10 Recovering ability at 900 C for 3 minutes (points) 4 4 4 4 10 10 1-. cc 4 o pc TABLE 2 (Continued) Commercially available fried Commercially instant cooking available

Present invention Comparative Sample 6 noodles dry noodles Sample 1 Immediately Immediately after

After After After after After Test Item production 6 months 3 months 3 months production 6 months

Properties of products Content of Na CI (%) 2 24 2 24 0 86 0 67 2 24 2 24 a conversion degree (%) 91

0 90 1 95 0 90 5 96 2 95 0 Amount of edible oil coated (%) 0 72 0 72 165 0 0 72 0 72 (containing)

(containing) (coating) (coating) Amount of emulsifier coated (%) 0 02 0 02 O O 0 02 O 02 (containing)

(containing) (coating) (coating) Very fine network cells having irregular shapes None None None None

Present Present Note: ( 1) In the amounts of the edible oil and the emulsion in the above Table 2, the term "containing" attached under the numeral value means the content in the noodles and the term

"coating" means the amount coated on the surface of the noodles.

( 2) Even the commercially available non-fried dry noodles were immersed in hot water at 950 C for

10 minutes, the recovering ability was 6 points and these noodles were not satisfactorily recovered and when the dry noodles were immersed in boiling water for minutes, the noodles was able to be satisfactorily recovered.

( 3) In the test after 3 months and 6 months, the samples storage in a chamber at 250 C and 70 % RH were used. o O 1,2,8 10 Note:

( 1) In the amounts of the edible oil and the emulsion in the above Table 2, the term "containing" attached under the numeral value means the content in the noodles and the term " coating " means the amount coated on the surface of the noodles.

( 2) Even the commercially available nonfried dry noodles were immersed in hot water at 950 C for

10 minutes, the recovering ability was 6 points and these noodles were not satisfactory recovered and when the dry noodles were immersed in boiling water for 10 minutes, the noodles was able to be satisfactorily recovered.

( 3) In the test after 3 months and 6 months, the samples storage in a chamber at 250 C and 70 % RH were used.

As seen from the above results, the instant cooking noodles according to the present invention wherein the emulsion is coated on the surface of the noodles, can provide more excellent slippery feeling, taste and recovery estimation than the noodles wherein the emulsion is contained in the noodles.

Furthermore, the commercially available non-fried dry noodles cannot be recovered even with hot water at 950 C and when the commercially available fried instant cooking noodles are immersed in hot water at 830 C for 3 minutes, these noodles are not recovered and further even if such fried noodles are immersed in hot water at 850 C for 3 minutes, these noodles are not satisfactorily recovered.

Furthermore, it has been found that 3 months after production, the fried noodles have oily odor and do not show excellent taste and flavor The pores in the dry noodles of the present invention are noticeably different from those of the fried noodles in the size and form.

Fig 1 is an electron microscopic photograph (magnification: 50 times) showing the surface and the cross-section of the non-fried dry instant cooking noodles of the present invention obtained in Example

1.

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Fig 2 is an electron microscopic photograph (magnification: 50 times) showing the surface and the cross-section of the commercially available fried instant cooking noodles.

Example 2.

To wheat flour alone, a mixture of wheat flour with buckwheat flour or a mixture of wheat flour with a starch and a gum was added a solution of 170 parts of water, and sodium chloride and/or a mixture of potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate and the mixture was thoroughly stirred and mixed in a mixer and the resulting blend was treated in the same manner as in the present invention sample 1 in Example 1.

The weight percentage of the components in each sample is shown in the following Table 3 as the absolute dry weight.

TABLE 3

Present invention sample 1 2 3 4 Wheat flour (%) 96 41 66 14 70 75 86 39 Buckwheat flour (to) 28 35

Starch (NO) 21 56 9 26 K 2 CO,, Na 2 CO,, KP 04 and Na PO 4 (kansui) (%) 0 22 0 32 Gum (SO) 1 95

1 00 Amount of Na CI contained (%o) 2 24 4 40 4 33 2 23 Amount of salad oil coated (%) 1 10 1 08 1

06 1 09.

Amount of sucrose ester coated (N) 0 03 0 03 0 03 0 03 The results of the functional estimation immersed in hot water at 850 C for 4 upon eating after the samples 1-4 of the minutes are shown in the following Table 4.

present invention in the above Table 3 were 1,522,284 TABLE 4

Present invention sample Test Item 1 2 3 4 Functional estimation upon eating Stick on teeth (persons)

O O O O Slippery feeling is insufficient (persons) O O O O Slippery feeling is excessive (persons) O O

O Of Elasticity is insufficient (persons) O O O O Elasticity is excessive (persons) O 0 O O Too hard

(persons) O O O O Wheat flour-like raw feeling (persons) O O O O Taste estimation (points) 10 10 10

10 Recovering ability at 850 C for 3 minutes (points) 10 10 10 10 Recovering ability at 830 C for 3 minutes (points) 10 10 10 10 Recovering ability at 900 C for 3 minutes (points) 10 10 10 10 Properties of products a conversion degree (%) 96 2 94 3 97 6 96 4 Very fine network cells having irregular shapes Present Present Present Present As seen from the results in the above table, the instant cooking noodle samples 2-4 consisting mainly of wheat flour and containing corn flour, starch, gum, sodium chloride and the like can provide excellent instant cooking noodles having the same qualities as in the present invention sample 1 in Example 1.

Example 3.

In this example, the instant cooking noodles having various thicknesses were produced in the same manner as in the present invention sample 1 in Example 1 except 'that the thickness of the noodles was varied The obtained results are shown in the following Table 5 1,522,284 1,522,284 TABLE 5

Thickness of noodle Test Item 0 5 mm 0 8 mm 1 3 mm 2 0 mm Functional estimation upon eating

Stick on teeth (persons) 0 O O O Slippery feeling is insufficient (persons) 0 0 0 0 Slippery feeling is excessive (persons) 0 0 0 0 Elasticity is insufficient (persons) 5 0 0 0 Elasticity is excessive (persons) 0

0 1 3 Too hard (persons) 0 0 3 7 Too soft (persons) 6 0 0 0 Wheat flour-like raw feeling (persons) 0 0 3

9 Taste estimation (points) 7 10 7 4 Recovering ability at 85-OC for 3 minutes (points) 10 10 8 5

Recovering ability at 830 C for 3 minutes (points) 10 10 8 4 Recovering ability at 900 C for 3 minutes

(points) 10 10 9 6 Properties of products a conversion degree (%o) 97 1 96 3 93 1 88 6 Very fine network pores having irregular shapes Present Present Present Present As seen from the results in the above table, the noodles having the thickness of 1 3 mm at the largest show excellent qualities.

Example 4.

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The instant cooking noodles containing various amounts of sodium chloride in the noodles were produced in the same manner as in the present invention sample 1 in Example 1 except that said amount was 0, 1, 3, 6, 10 % 10 (based on the absolute dry weight of the noodle).

The obtained results are shown in the following Table 6.

1,522,284 TABLE 6

Content of sodium chloride in noodles Test Item 0 % 1 % 3 % 6 % 10 % Functional estimation upon eating Stick on teeth (persons) 0 0 0 0 0 Slippery feeling is insufficient (persons) 0 0 0 0 0 Slippery feeling is excessive (persons) 0 0 0 0 0 Elasticity is insufficient (persons) 0 0 O 3 9 Elasticity is excessive (persons) 2 0 0 O O Too hard (persons) 4 1 0 0 0 Wheat flour-like raw feeling (persons) 0 0 0

0 0 Taste estimation (points) 6 9 10 8 6 Recovering ability at 85 C for 3 minutes (points) 6 9 10 10 10

Recovering ability at 83 C for 3 minutes (points) 6 6 10 10 10 Recovering ability at 90 C for 3 minutes (points) 8 10 10 10 10 Properties of products a conversion degree (%) 96 1 96 2 96 5 96 7 97 0

Very fine network pores having irregular shapes Present Present Present Present Present As seen from the results of the above table, the amount of sodium chloride contained in the noodles must be 1-6 %.

Example 5.

The instant cooking noodles having various amounts of salad oil coated on the surface of the noodles ivere produced in the same manner as in the present invention sample 1 in Example 1 except that said amount of salad oil 10 was varied to 0 %, 0 2 %, 1 1 %, 3 %, 5 % and % by weight (based on the absolute dry weight of the noodle) by adjusting the composition and the sprayed amount of the aqueous emulsion of said oil The obtained results 15 are shown in the following Table 7.

TABLE 7

Amount of edible oil coated Test Item 0 % 0 2 % 1 1 % 3 % 5 % 10 % Functional estimation upon eating Stick on teeth (persons) 7 3 0 0 0 0 Slippery feeling is insufficient (persons) 10 2 0 0 0 0

Slippery feeling is excessive (persons) 0 0 0 0 3 9 Elasticity is insufficient (persons) 6 1 0 0 0 0

Elasticity is excessive (persons) 0 0 0 0 3 10 Too hard (persons) 0 O O O 4 7 Wheat flour-like raw feeling (persons) 4 0 0 O 0 1 Taste estimation (points) 5 7 10 10 7 5 Recovering ability at 85 C for 3 minutes (points) 6 8 10 10 ? 6 Recovering ability at 83 C for 3 minutes (points) 6 7 10 10 7 6

Recovering ability at 90 C for 3 minutes (points) 6 9 10 10 7 6 Properties of products Content of Na CI

(%) 2 25 2 25 2 24 2 23 2 22 2 02 a conversion degree (%) 96 8 96 7 96 2 96 0 95 4 93 8 Amount of emulsifier coated (%) 0 03 0 03 0 03 0 03 0 03 0 03 Very fine network pores having irregular shapes

None Present Present Present Present None As seen from the results of the above table, the amount of the edible oil coated on the surface of the noodles must be O 2-5 %.

Example 6.

The instant cooking noodles having various amounts of an emulsifier (sucrose higher fatty acid ester) coated on the surface of the noodles were produced in the same manner as in the present invention sample 1 in Example 1 except that said amount of emulsifier was varied to 0 %, 0 01 %, 0 023, 1 %, 3

%, 5 , and 7 % by weight (based on the absolute dry weight of the noodle) by adjusting the composition and the sprayed amount of the aqueous emulsion The obtained results are shown in the following Table 8.

1,52,2,284 1,522,284 TABLE 8

Amount of emulsifier coated Test Item 0 % 0 01 % 0 02 % 1 % 3 % 5 % 8 % Functional estimation upon eating Stick on teeth (persons) 4 2 0 0 0 0 0 Slippery feeling is insufficient (persons) 3 0 0 0 0 0 0

Slippery feeling is excessive (persons) 0 0 0 0 1 3 9 Elasticity is insufficient (persons) 0 0 0 0 1 2 8

Elasticity is excessive (persons) 0 0 0 0 0 0 0 Too hard (persons) 2 0 0 0 0 0 0 Wheat flour-like raw feeling (persons) 0 O 0 O O O O Taste estimation (points) 6 8 10 10 8 7 5 Recovering ability at 85 C for 3 minutes (points) 9 9 10 10 10 10 10 Recovering ability at 83 C for 3 minutes (points) 9 9 10 10

10 10 10 Recovering ability at 90 C for 3 minutes (points) 10 10 10 10 10 10 10 Properties of products

Content of Na CI (%) 2 25 2 25 2 24 2 23 2 22 2 20 2 18 a conversion degree (%c) 92 8 95 7 96 2 96 4

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96 5 96 8 97 2 Amount of salad oil coated 1 11 1 11 1 10 1 08 1 07 1 05 1 01 (%) As seen from the results of the above table, the amount of the emulsifier coated on the surface of the noodles must be 0

01-5 % by weight, preferably 0 02-3 % by weight.

Example 7.

To 500 parts of wheat flour was added a mixed solution of 170 parts of water, 10 parts of sodium chloride and 1 part of a mixture of potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate and the resulting mixture was rolled to a thickness of 0 8 mm by rollers and shaped into raw noodles by means of No 24 cutter The raw noodles ( 681 parts) were uniformly sprayed with an emulsion consisting of 900 parts of water, 100 parts of salad oil and 2 parts of sucrose palmitic acid ester by means of a spray gun and 12 % of the emulsion was coated on the surface of the raw noodles (

1 2 % based on the absolute dry weight of the raw noodles of salad oil, 0 02 % of sucrose palmitic acid ester of the emulsifier and 10 8 % of water were coated) Thereafter, the thus treated raw noodles were heated with steam of 1 0 kg/cm 2 for 2 minutes (water content after steaming:

38 %) and then dried by hot air at a tempera1,522,284 ture of 1000 C in an air speed of 20 m/sec until the water content of the noodles became 7 % to obtain the porous instant cooking noodles of the present invention sample having the very fine pores.

As a comparative sample 7, the emulsion was sprayed and then the noodles were dried in the same manner as described above without effecting the steaming.

As a comparative sample 8, the emulsion was sprayed in the same manner as described above and then dried by hot air at 1000 C for 2 minutes at an air speed of 3 m/sec, the same steaming as in the present invention was carried out to dry the noodles to a water content of 38 % and the same drying as in the present invention was carried out.

As a comparative sample 9, the raw noodles were treated in the same manner as in the present invention except that the noodles were 20 coated with 10 8 % of water instead of the emulsion.

As a comparative sample 10, the raw noodles were treated in the same manner as in the present invention except that the emulsion 25 was not applied.

As a comparative sample 11, the raw noodles were treated in the same manner as in the pre sent invention except that 1 2 % of salad oil alone was coated 30 The instant cooking noodles of the above described present invention sample and the comparative samples 7-11 were determined with respect to the degree of stickiness between the noodles and the eat feeling and taste 35 estimation The obtained results are shown in the following Table 9.

TABLE 9

Comparative Sample Present Test Item 7 8 9 10 11 invention Functional estimation upon eating

Stickiness between noodles Very Very Very Much None None much much much Stick on teeth

(persons) 0 0 6 7 0 0 Slippery feeling is insufficient (persons) 12 12 5 5 0 0 Slippery feeling is excessive O O O 0 10 0 (persons) Elasticity is insufficient (persons) 0 0 11 10 0 0 Elasticity is excessive (persons) 0 0 0 0 O O Too hard (persons) 13 13 0 13 13 0 Wheat flour-like raw feeling

(persons) 13 13 3 12 13 0 Taste estimation (points) 2 2 6 4 2 10 As seen from the results of the above table, the process wherein the raw noodles are applied with the emulsion consisting of an edible oil, water and an emulsifier, heated with steam and then dried, which satisfies the requirements constituting the present invention, can provide the instant cooking noodles which do not cause stickiness between the noodles (separating step can be omitted) and give the slippery estimation. feeling and the good taste Example 8.

The instant cooking noodles were produced in the same manner as in the present invention sample in

Example 7 except that the pressure of steam and the steaming time were varied as shown in the following Table 10 The obtained results are shown in Table 10.

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1,6 TABLE 10

Pressure of steam (kg/cm 2) 0 2 0 5 0 5 1 0 1 0 1 5 1 5 2 0 2 0 Steaming time (min) 2 2 5 2 5 2 5 2 5

Functional estimation upon eating Stickiness between noodles 0 0 0 0 0 0 0 0 0 Stick on teeth (persons)

5 0 0 0 0 0 0 0 0 Slippery feeling is insufficient (persons) 0 0 O O O O O O O Slippery feeling is excessive (persons) 0 0 O O O O O O O Elasticity is insufficient (persons) 5 0 0 0 0 0 0 0 0 Elasticity is excessive (persons) 0 0 1 0 3 1 3 5 6 Too hard (persons) 0 0 0 0 0 0 0 0 O Wheat flour-like raw feeling

(persons) 4 0 0 0 0 0 0 0 0 Taste estimation (points) 6 10 8 10 7 9 7 6 5 As seen from the results of the above table, in the same manner as in the present sample the pressure of steam and the steaming time in

Example 7 except that the drying temperamust be 0 5-1 5 kg/cm 2 and 2-5 minutes ture and the drying time were varied as'10 5respectively shown in the following Table 11The obtained Example 9 results are shown in Table 11.

The instant cooking noodles were produced 1,522,284 TABLE 11

Drying temperature ( C) 20 60 70 80 90 100 110 120 130 150 Drying time (min) 80 60 45 30 23 15 12

10 8 4 Functional estimation upon eating Stickness between noodles none none none none none none none none none slight Stick on teeth (persons) 2 0 0 0 0 0 0 0 0 0 Slippery feeling is insufficient

(persons) O 1 1 0 1 0 0 0 1 5 Slippery feeling is excessive (persons) 2 0 0 0 0 0 0 0 0 0 Elasticity is insufficient (persons) 4 2 0 1 0 0 0 0 3 7 Elasticity is excessive (persons) 0 0 1 0 0 0 0 2 0 0 Too hard

(persons) 0 0 0 0 0 0 0 O 1 10 Wheat flour-like raw feeling (persons) 0 0 0 0 0 0 0 0 0 0 Taste estimation (points) 6 7 7 8 9 10 10 8 7 4 As seen from the results in the above table, the drying temperature is preferred to be 60-130 C, more particularly 90-1410 C.

Example 10.

The instant cooking noodles were produced in the same manner as in the present sample in Example 7 except that the raw noodles having the water content as shown in the following Table 12 were used and the qualities of the obtained noodles were determined The obtained results are shown in the following

Table 12.

I-4 Irl t^ N j ti 1 r.

TABLE 12

Water content of raw noodles (%) 20 25 30 35 40 45 Functional estimation upon eating Stickiness between noodles none none none none none slight Stick on teeth (persons) 0 0 0 0 0 1 Slippery feeling is insufficient (persons) 4 0 0 0 0 0 Slippery feeling is excessive (persons) 0 0 0 0 0 0 Elasticity is insufficient (persons) O O O 0 2 5 Elasticity is excessive (persons) 1 0 0 0 0 0 Too hard (persons) 5 1 0

O 0 4 Wheat flour-like raw feeling (persons) 6 2 1 0 0 0 Taste estimation (points) 4 7 8 10 8 5 As seen from the results in the above table, the water content of the faw noodles is preferred to be 25-40 %.

Example 11.

The instant cooking noodles were produced in the same manner as in the present invention sample in

Example 7 except that sucrose stearic acid ester or sorbitan stearic acid ester was used instead of sucrose palmitic acid ester 10 and the qualities of the obtained noodles were determined The obtained results are shown in the following Table 13.

TABLE 13

Sucrose Sorbi tan stearic stearic Emulsifier acid ester acid ester Functional estimation upon eating

Stickiness between noodles none none Stick on teeth (persons) 0 0 Slippery feeling is insufficient

(persons) 0 1 Slippery feeling is excessive (persons) 0 0 Elasti'city is insufficient (person) 0 0 Elasticity is excessive (persons) 0 0 Too hard (persons) 0 0 Wheat flour-like raw feeling (persons) 0 0 Taste estimation (point) 10 10 As seen from the results in the above table, these can be effectively used as emulsifiers.Data supplied from the esp@cenet database - Worldwide

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112.

GB1572413 - 7/30/1980

METHODS OF PREPARING SHAPED RICE FOOD


Applicant(s): NAGATANIEN HONPO CO LTD (--)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/182C; A23L1/18C



Family: GB1572413

Equivalent: US4276321; JP53124638; FR2386270; DE2737569; IT1091309

Abstract:

Abstract not available for GB1572413


A method of preparing a shaped rice food comprising the steps of wrapping a boiled rice pretreated to be substantially non-viscous in a heat-shrinkable film in a predetermined shape, and heating the wrapped rice, thereby softening and swelling the rice and shrinking the film so as to compress the swollen rice utilizing the shrinking force of the film. The boiled rice may be frozen before wrapped in the heat-shrinkable film. Shaped rice food of various tastes can be provided by this method.Description:



( 11) 1 572 413 ( 21) Application No 34303/77 ( 22) Filed 16 Aug 1977 ( 31) Convention Application

No 52/040056 ( 32) Filed 8 Apr 1977 in ( 33) Japan (JP) ( 44) Complete Specification Published 30 Jul

1980 ( 51) INT CL 3 A 23 L 1/182 Index at Acceptance A 2 Q 3 B 13 14 A A 2 B 318 411 412 620

622 660 14 D 506 603 604 611 614 616 BD CB ( 72) Inventor: YOSHIO NAGATANI ( 54)

IMPROVEMENTS IN OR RELATING TO METHODS OF PREPARING SHAPED RICE FOOD (

71) We, NAGATANIEN HONPO COMPANY LIMITED, a Japanese corporation of 36-1, 2-chome,

Nishishinbashi, Minato-ku, Tokyo, Japan, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly

described in and by the following statement:-

This invention relates to a method of preparing a shaped rice food including so-called onigiri', and more particularly to a method of preparing a shaped rice food presenting various tastes and flavours which the conventional shaped rice food is unable to present.

In general, 'onigiri' (Japanese rice ball food), or a shaped rice food, is prepared by manually compressing a boiled rice into a desired shape, with suitable ingredients such as a pickled plum, a piece of salmon and a cod roe contained therein, and with appropriate surface coatings, as desired In some cases, a boiled rice is housed in a mold of a desired shape and compressed for preparing onigiri' of a desired shape The resultant 'onigiri' is not deformed if held in a hand in the eating step It should be

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noted that the bonding strength among the rice grains serves to retain the shape of 'onigiri' of the general type.

The taste and flavour of 'onigiro' may be enhanced by adding suitable ingredients and soups to the boiled rice But, the addition of an excessive amount of ingredients and soups weakens the bonding strength among the rice grains, failing to retain the shape of 'onigiri' and resulting in restriction of the taste and flavour presented by 'onigiri' of the general type.

There are various kinds of rice-based food including, for example, 'tendon', or a bowl of rice topped with a fried prawn and the like, unadon', or a bowl of rice topped with roasted eel, a chinese dish of fried rice, and curried rice Either of these kinds of food presents its peculiar taste and flavour produced by the ingredients and soups disposed on the surface of the boiled rice It would be advantageous to prepare a shaped rice food, or 'onigiri' which presents the taste and flavour of the rice-based food mentioned above However, it is impossible to prepare onigiri' with a sufficient amount of, for example, soup added to the boiled rice.

Naturally, the surfaces of the rice grains are covered with the soup if the soup is added in a sufficient amount resulting in so much reduction in the bonding strength among the rice grains that it is impossible to prepare 'onigiri' of a desired shape It is possible to retain the required bonding strength among the rice grains if the amount of soup is suitably restricted But, in this case, the resultant 'onigiri' is incapable of presenting a desired taste and flavour.

An object of this invention is to provide a method of preparing a shaped rice food which can present various tastes and flavours and retain its original shape when held in the hand.

Another object is to provide a method of preparing a shaped rice food without directly utilizing the bonding strength among the grains of boiled rice.

According to the present invention, a method of preparing a shaped rice food, comprises treating boiled rice to such an extent that the grains of the boiled rice change from their normal state where they are capable of mutual bonding to a second state where they, are incapable of mutual bonding, wrapping said treated boiled rice in a heatshrinkable film in a predetermined shape, and heating said wrapped treated boiled rice to soften and swell the grains of said rice and shrink said heat-shrinkable film to compress said treated rice by the shrinking force of said film, thereby producing a shaped rice food.

It is preferred to freeze the boiled rice in a desired shape before wrapping in the heatshrinkable film, as later described. e) ( 52) ( 19) 1,572,413 The starting material of rice used in this invention is prepared by boiling a polished rice with water in an ordinary manner, followed by treating the boiled rice such that the rice grains will not bond together when compressed In other words, it is impossible to prepare a shaped rice, which retains its shape when held in a hand in the eating step, from the boiled rice It is acceptable that some of the rice grains are bonded together when compressed manually or within a mold.

In general, a polished rice boiled with water contains about 60 to 65 % by weight of water and can be bonded together When various ingredients, soup and one or more kinds of liquid or fluid flavourings are added in a sufficient amount, the boiled rice is rendered substantially non-bonding Typical examples of the ingredients, flavourings and soups used in this invention include various kinds of fish and shellfish, eggs, meat, vegetables, refined sake, soy, sesame seeds, table salt, and soups of sukiyaki,

'gyunabe', or beef cooked in Japanese style, 'tendon', or a bowl of rice topped with fried prawn and the like, 'gyudon', or a bowl of rice topped with cooked beef, 'katsudon', or a bowl of rice topped with fried pork, 'oyakodon', or a bowl of rice topped with cooked chicken and eggs, 'unadon', or a bowl of rice topped with roasted eel, 'chukadon' or a bowl of rice topped with a special chinese food, and curried rice Many other additives known to the art may be used in this invention As stated above, these ingredients or flavourings are added in an amount sufficient for rendering the boiled rice to be substantially non-bonding It is of no difficulty to determine the actually added amount in view of the object of this invention, though the amount required for simply rendering the boiled rice substantially non-bonding differs depending on the kinds of ingredients or flavourings used Ii is also possible to fry

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the boiled rice using an edible oil such as salad oil or sesame oil with or without suitable ingredients added to the boiled rice so as to render the boiled rice substantially nonbonding.

The substantially non-viscous rice thus obtained is wrapped in a heat-shrinkable film in a desired shape The wrapping may be effected manually or mechanically In the manual wrapping, a suitable amount of the treated rice is wrapped manually in a heatshrinkable film of a suitable size and formed into a desired shape On the other hand, the mechanical wrapping utilizes a mold having a plurality of concaves of a desired shape The treated rice is housed in each of the concaves and, then, the mold is inverted so as to allow the treated rice housed therein to be disPosed on a sheet of heat-shrinkable film.

Finally, the sheet of heat-shrinkable film is cut off and each mass of treated rice is wrapped in the film thus cut off The treated rice can be wrapped in this fashion in a desired shape such as triangular, square or circular in cross section.

It is convenient to utilize freezing in the 70 wrapping step In this case, the treated rice housed in the concave of a mold is allowed to stand under temperatures of, for example, -20 C to -SC or lower The rice thus frozen retains its shape when taken out of the 75 concave and, consequently, facilitates wrapping in the heat-shrinkable film The wrapping can be effected mechanically in an ordinary fashion

It should be noted that the heat-shrinkable film should preferably be 80 brought into tight contact with the rice and the edge portions of the film should preferably be overlapped so as to fully utilize the shrinking force of the film in the subsequent step of heating the wrapped rice 85 The heat-shrinkable film used in this invention should be shrinkable in the subsequent heating step and should be capable of exerting a sufficient shrinking force on the rice wrapped therein It is of no difficulty for those 9 C skilled in the art to select a suitable heatshrinkable film meeting the above-noted requirements In general, the film starts shrinking at 500 C and finishes shrinking at 900 C, with about 15 % to about 30

% of area 9 f shrinkage Polyvinylidene chloride provides a typical example of a heat-shrinkable film used in this invention and is available on the market under the trade names of 'Kurewrap', produced by

Kureha Kagaku Kogyo 1 ( K.K, Japan, and 'Saran-wrap' ('Saran' is a Registered Trade Mark) produced by AsahiDow Chemical Co Ltd, Japan.

The rice wrapped in a heat-shrinkable film can be stored in a frozen state under temper 1 atures of -20

C or lower and subjected to the subsequent heating step when desired.

When heated, the rice wrapped in a heatshrinkable film is softened and swollen The rice under this condition is imparted with an 1 increased ability to bond At the same time, the film is caused to shrink

It follows that the shrinking force of the film is exerted on the swollen rice, resulting in mutual bonding of the rice grains so as to provide a shaped rice 1 food, or 'onigiri' The heating may be carried out by an ordinary steaming means or by using an electric heater such as an electronic oven It suffices to heat the wrapped rice at between 50 C and 900 C, but no inconvenience I is presented if the heating is carried out at higher temperatures, for example, at 100 to 1200 C The resultant 'onigiri' is not deformed when held in a hand in the eating step.

As described in detail, the method of this invention permits preparing 'onigiri' without directly utilizing or depending on the bonding strength among the grains of boiled rice This makes it possible to add various ingredients, soups and flavourings to the boiled rice in 3 1,572,413 such a large amount as to render the rice substantially non-viscous It follows that this invention preparing a shaped rice food, or onigiri', of desired taste and flavour.

Example I

Suitable amounts of scrambled eggs, sliced ham and leek cut into tiny pieces were fried with salad oil so as to prepare ingredients and mixed with a fried rice in an amount of 1 5 times as much by weight as the ingredients.

Then, the mixture was frizzled with suitable amounts of soy, table salt and pepper added thereto so as to obtain a non-viscous frizzled rice.

The frizzled rice in an amount of 50 g was wrapped in a polyvinylidene chloride film mm square and

12 p thick such that the edge portions of the film were overlapped.

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The wrapped rice was formed into a triangular shape in cross section and stored 24 hours in a refrigerator maintained at -5 C, followed by taking out the frozen rice from the refrigerator and heating it in an electronic oven for about 50 seconds After the heating, the film was removed, obtaining onigin' which was not deformed when picked by fingers.

Example 2

A soup presenting a flavour of beef was prepared first from a mixture of suitable amounts of mince beef, soy, refined sake, sugar and chemical seasonings 8 g of soup thus prepared was added to 50 g of boiled rice disposed on a polyvinylidene chloride film 150 mm square and 12,u thick, immediately followed by wrapping in a manner to overlap the edge portions of the film and to form the wrapped rice into a triangular shape in cross section The rice wrapped in this fashion was subjected to freezing and, then, to heating as in Example 1, obtaining a satisfactory 'onigiri'.

8 g of soup prepared above was added to g of boiled rice disposed lightly, i e.

without compressing, in an 'onigiri'-shaped container The container was then stored for 24 hours in a refrigerator maintained at -50 C, followed by taking out the frozen rice from the container and wrapping it in a film equivalent to the polyvinylidene chloride film mentioned above, in a manner to overlap the edge portions of the film The rice wrapped in this fashion was stored in a refrigerator and then heated in an electronic oven After the heating, the film was removed, obtaining 'onigiri' which was not deformed when picked by fingers.

Example 3 g of properly seasoned raw egg was fully stirred and uniformly poured over 50 g of boiled rice disposed on a polyvinylidene chloride film 150 mm square and 12,a thick.

Then, the rice was wrapped in the film in a manner to overlap the edge portions of the film and formed into a circular shape in cross section The rice wrapped in this fashion was frozen for 6 hours in a refrigerator maintained at 18 "C and then heated for 80 seconds in an electronic oven The resultant hot 'onigiri' was not deformed when picked by fingers 70Data supplied from the esp@cenet database -

Worldwide Claims:


WHAT WE CLAIM IS:

1 A method of preparing a shaped rice food comprising treating boiled rice to such an extent that the grains of the boiled rice change from their normal state where they are 75 capable of mutual bonding to a second state where they are incapable of mutual bonding, wrapping said treated boiled rice in a heatshrinkable film in a predetermined shape and heating said wrapped treated boiled rice to 80 soften and swell the grains of said rice and shrink said heat-shrinkable film to compress said treated rice by the shrinking force of said film, thereby producing a shaped rice food.

2 The method according to claim 1, 85 which further comprises the steps of disposing the treated rice in a container of a predetermined shape and freezing the boiled rice disposed in the container, prior to the wrapping of the rice in a heat-shrinkable film 90 3 The method according to claim 1, which further comprises freezing the wrapped rice prior to the heating step.

4 The method according to claim 1, wherein the heat-shrinkable film is formed of 95 polyvinylidene chloride.

The method according to claim 1, wherein at least one other ingredient and/or flavour is added to the boiled rice.

6 The method according to claim 1, 100 wherein the boiled rice is fried with an edible oil to obtain the treated rice.

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7 The method according to claim 4, wherein the heating is carried out at a temperature within the range of from 50 C to 105 900 C.

8 A method of preparing shaped rice food, substantially as hereinbefore described with reference to the

Examples.

9 A method of preparing shaped rice 110 food as in claim 1 and substantially as hereinbefore described.

HULSE & CO, Chartered Patent Agents, Cavendish Buildings, 115 West Street, Sheffield 51 1 ZZ

Printed for Her Majesty's Stationery Office, by Croydon Printing Company Limited, Croydon, Surrey,

1980.

Published by The Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained.


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113.

GB186634 - 3/3/1924

IMPROVEMENTS IN AND RELATING TO THE PRODUCTION OF FOOD

PRODUCTS


Applicant(s): WARD BAKING COMPANY (--)

E Class: A23L1/10E


Priority Number: USX186634 (19211001)

Family: GB186634

Abstract:


A product that may be eaten by itself or used as an ingredient in bread or cereal foods, infants' foods, c., confectionery, or ice-creams is made from products such as "rice polishings" or other milling refuse containing cereal germs, such as wheat or maize germs. The germs, with which ground roasted peanuts may be mixed, are free from oil by a solvent, such as benzol or carbon tetrachloride, the oil being used for making soap or otherwise. The germs are then cooked to gelatinize the starch, which is saccharified by means of an infusion of malt. They are then treated with digestive ferments, such as papain, trypsin, pancreatin and pepsin, acid being added if necessary. The action is stopped by boiling and the resulting liquid filtered and concentrated or evaporated to dryness. Alfalfa may be added to the germs. Either the treatment with malt or that with digestive ferments may be omitted, the latter being sometimes preferable when the product is to be used for bread. The starch may be hydrolyzed by acids instead of malt, when the treatment with digestive ferments precedes the hydrolysis. The germs may be extracted with water or alcohol without preliminary treatment, or after extraction of oil only, and the extract concentrated.

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114.

GB190922787 - 10/6/1910

AN IMPROVED PROCESS FOR THE PRODUCTION OF A SUBSTITUTE FOR

EGGS IN THE PREPARATION OF FOOD-STUFFS


Inventor(s): BRUUN CHRISTIAN (DE)

Applicant(s): BRUUN CHRISTIAN (DE)

E Class: A23L1/32H


Priority Number: GBT190922787 (19091006)

Family: GB190922787

Abstract:


22,787. Bruun, C. Oct. 6. Food preparations serving as substitutes for egg albumen are prepared by mixing separated milk, concentrated in vacuo, with.a solution of agar and rice-starch, and adding soda, salt, and potato-meal. Egg-yolk is added to the product.Claims:


Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that what I claim is ;

The process for the production of a substitute for eggs for use in preparing foodstuffs, cakes or the like, which is characterised by introducing into boiling water agar and rice-starch and then stirring the mixture until it becomes clear and sticky, after which milk, condensed at low temperature under vacuum, is mixed with the former together with an addition of soda, salt and potato meal, the whole being stirred and boiled, then allowed to cool and mixed with eggyolk, substantially as hereinbefore described.Data supplied from the esp@cenet database - Worldwide

563/2197

115.

GB191030350 - 1/1/1912

SOJA FLOUR AND ITS DERIVATIVES


Inventor(s): LI YU YING (FR)

Applicant(s): LI YU YING (FR)

E Class: A23L1/20D4



Family: GB191030350

Abstract:


30,350. Li, Y. Y. Dec. 31. Preparing flour from special materials.-Flour is prepared from soya beans containing little fat, or from which most of the oil has been removed, by pressing the whole beans, the cakes produced being ground. The flour is employed (1) with ordinary flour, green-pea or rice flour, and an extract of soya to form an alimentary paste, the starch being extracted and the flour gelatified with hot water; (2) with cabbage, turnips, carrots, sorrel, potatoes, green peas, broad or kidney beans, tomatoes, c., or jelly or gravy of crayfish, for preparing soups; (3) with or without flour of wheat, oats, barley, rice, maize, c. and material containing hydrocarbons and mineral matter, to make bread, for which a culture of yeast germs in a soya base, which flavours the production of special ferments such as sojaobacilli, may be used; (4) with eggs, butter, c. for making cakes or rusks.Description:


>;Desc/Clms Page number 1;

COMPLETESPECIFICATION.

Soja Flour and its Derivatives.

EMI1.1

I, Yu Y1NG Li, of 4(i, rue veltis Papin, aux Vallees (Seine), France, Engineer, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-7'his invention has for its objectthe manufacture of soja (Chinese pea) flour for use in the preparation of a special kind of bread, alimentary pastes, rusks, cakes, soups, etc.

Soja grains contain a considerable proportion of fatty matter which con-siderably impedes the operation of grinding. In order to obviate thesedisad- vantages, operations may be carried on in twoways.,' (J) In the first place grains are selected which are relativelypoor in fatty matters, so that the grinding is greatly facilitated.(2) The oil may be first extracted from the grains by pressure, and the cakesemployed for making the flour, which forms theprincipal ingredient in a large number of alimentary products.

EMI1.2

564/2197

For example, the soja fioui- may be mixed in any proportions whatever with ordinary kinds of flour, and 1111 extract of soja. ma,y- be added as desired, wherebyvery good alimentary pastes can be obtained.

In connection with these latter, the starch is first extracted, andgelatlfica-

EMI1.3

tion clfected in hot water for -preparing the pastes.

To these pastes, which may be used with advantage in place of macaroni, vernticaili, 9ell:1()Illo,. and all the Italian pastes, an addition of green-pen flour,. rice-flour, etc., may .be made.

An excellent soup may also be made by uteai-ts of soja. grains reduced to powder or to senioline.

Inorder to vary it,cabbage, turnips, carrots, sorrel, potatoes, green peas, broad beans, kidney beans,tomatoes,etc., may be added.

By adding- jelly or gravy made of crayfish,bisk soups can be made, which are flavouredin the ordinary manner.

EMI1.4

With soja flour,a. highly palatable kind of. bread can Ite made which may berecommended to persons suffering from diabetes.

In order to make this bread a yeast is prepared front a culture of ordinary

EMI1.5

yeast germs in a soja base, the presence of soja being favourable to the gerntina- tion of special kinds of ferment and particularly ofsojaobaccilli, although any other kind of ferment, barm, etc., may be used.

It may also be made by mixing soja. flour with other kinds of flour, made

EMI1.6

from wheat, oa.ts, barley, rice, maize, etc.,"thus ensuring the production of bread containing a. large quantity of nitrogen, and substances containing hydrocarbons and mineral matters.

Inorder to obtain a. perfect bread all that is necessary is to mix the soja flour with all one of the comestible kinds of flour.

EMI1.7

The suja. rusks and ca.kes are made with soja. flour mixed with eggs, butter, etc.

It has hitherto been proposed to make bread, cake, biscuits, and the like from wheat flour. and soja. meal mixed together in a" raw or uncooked state, then made into a dough and baked, and for this purpose the bulk of the oil has

EMI1.8

been extracted from the soja. meal, by first crusl1Ïlig or grinding the seed of the plant, then expressing the oil by pressure and subsequently grinding the compressedcake so formed.


It will be observed that by the present invention the oil is extracted from the soja grains by direct pressure and without subjecting them to a preliminary crushing or grinding treatment.

Having now particularly described and ascertained the nature of my said invention, and in what manner the same is to beperformed,I declare that what I claim is:-.

1. The herein described process for themanufacture of flour from soja.

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(Chinese pen) grains, consisting in extracting the , oil from the grains by pressure, and subsequently grinding the cakes.Data supplied from the esp@cenet database - Worldwide Claims:


2.The manufacture, by means of the soja flour obtained in the manner described in the preceding claim, and mixed with other products, of alimentary pastes, soups, bread, rusks,4:11CPS, G' G.Data supplied from the esp@cenet database - Worldwide

566/2197

116.

GB191218947 - 8/19/1913

IMPROVEMENTS IN OR RELATING TO THE TREATMENT OF CEREAL

GRAINS


Inventor(s): ANDERSON ALEXANDER PIERCE (US)

Applicant(s): ANDERSON ALEXANDER PIERCE (US)

E Class: A23L1/182



Family: GB191218947

Abstract:


18,947. Anderson, A. P. Aug. 19. Steaming grain; gelatinizing grain; processes of treating grain; roasting granular substances. -Cereal grains such as rice, hulled or unhulled, in an air-dry condition

(containing from 10 to 20 per cent of water) are subjected to a rolling or tumbling motion under the action of heat in an air-tight container until gelatinization of the starch at the surface takes place, producing an impervious shell. The material is placed in a suitable receiver such as that described in

Speci- fication 18,950/12, or that shown in Fig. 1, consisting of a drum 2 pivoted on a spindle 4 between the side members 3 of a carrier, having wheels which run between guide-rails mounted on gearrings 8 in an oven heated by gas c. The gear-rings and drum are rotated by means of a shaft 10>;a;. The lid 18 of the drum presses against a roller 19 and has soft-metal packing to form a tight joint, the drum being preferably made of bronze having a higher coefficient of expansion than the side members 3.

When the desired pressure is attained in the drum, the formation and thickening of the shell may be assisted by the injection of dry or superheated steam from a pipe 16>;a; leading through a stuff- ingbox 12>;a; and a pipe 12>;b; to a flat perforated pipe 14, Fig. 4, within the drum. A pressure gauge 16

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and a by-pass are provided. The product may be " puffed " by immersing in oil at from 200-260 C., or by introducing it into an oven in a perforated receptacle such as an ordinary corn-popper, or by the process described in Specification 18,949/12. Specification 13,353/02, [Class 49, Food c.], also is referred to.Description:




Improvements in or relating to the Treatment of Cereal Grains.

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I, ALEXANDER PIERC ; ; Awl,nsov, of 5552, Everest Avenue, Chicago, Illinois, UnitedStates ofAmerica, Chemist, do hereby declare thenature of thisiuven= tion and its what manner the same is to be performed, to be particularly described and ascertained in and by the following statement

This invention relates to an improvement in the art of treating cereal grains and to a new product thereby obtained. The invention is. highlyadvantageous to the treatment of any and all ofthe cereal grains, but is especially applicable to the treatment of rice, whether, hulled orunhulled rice, which latter is usually known as " paddy rice ".

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. In the Si ; eciJi >; :ati >; ; n of Patent No. 1i},35;J of 1902, there is set forth a profess of swelling starch materials, including the cereal grains. During the practice of tlle said process, I havejt1discoverod that by a modification of the same I alrlenabled to provide the grains with a coating at an intermediate stageof the process; namely, prior to the final step of swelling the grains. By this means 1 obtained a novel product, as will be more fully explained hereinafter.

Broadly considered, the inventionconsists increating upon the individual kernels or grains an artificial coating which is resistant tothe escape of steam or water vapour from the interior of the kernel. The most perfect method of producing such a coating on the grain is obtained when the kernels are subjected to a treatment whereby there takes place within the graina drying out or desiccation process and at the same time acondensation of moisture onthesurface

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of the grain, this moisture basing hot enough to cause gelatillisation of the surface 6tar >; '!, -layers.

Such processis to be clearlydistinguishedfrontcooking the grain by the action of the heat and moisture of steam supplied to the mass from an external source in order to develop the soluble starch,dextriuc andsugar, andCOnW!I't the cooked product into soft and plastic grains, as according to my process the steam employed is generated out of the moisture of the grain itself, such grain when subjected to treatment having a moisture content of grain in asubstan- tially air-drycondition, and this self-generated steamit:! caused to

Fig. 1 ..is a side view of the piping together with a longitudinal sectional elevation of the drum-support in the oven, the latter being indicated in dotted lines;

Fig. 2 is a rear end view of the arrangement shown in Fig. 1;I'ig, 0 shows the drum in charging and discharging positions, the latter being indicated in dotted lines;

Fig. 4 is a sectional view of the rear end ofthe drum or cylinder; and

Fig. 5 is a section of. the drum in the line 5-5 of Fig. 4.

The material to be treated is put into a drum 2, mounted upon a suitable car, capable of being rolled about and brought to the various parts of the apparatus -for handling. The car consists of two side members .3, 3 having a trunnion 4 extending therebetween at the rear end; a shaft or axle 'connects the

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forward ends of said members. Small wheels or rollers 6 are mounted outside of the members 3, upon the projecting ends of trunnion 4 and shaft 5.

As indicated in Fig.the drum is pivoted at its rear end between the side members 3. The cars run on a track 7 within the oven consisting of four rails fastened to the inside of the cage 8. 'At each end of the cage isa- ring 9 having teeth outside forming a gear, which meshes with another gear 10, adapted to rotate the cage. The gears 10 and rollers 11 support the cage and enclosed drum, in addition' to causing rotation thereof by any'suitable power applied to one of their supporting shafts outside the oven,

After the drum has been. run into the oven, a connection is made at 12, this connection communicating through a pipe 12b through an end passage or con-neection in the drum with a flattened pipe 13 inside of the drum, through which steam may be admitted to the drum, or throughwhtch the internal pressurein the drum may be reduced or exhausted.When steam is admitted it escapes into the drum through numerousholes .14 in the pipe, said holesbecoming more frequent in proportion to the drop in pressure as the steam advances.

By means of gears 9 and 10 the cage containing the drum is rotated slowly during'the heating.Rotation is permitted by the stuffing box 12a which at the same time maintains the steam-supply or exhaustconnection. The arrange-

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ment of the piping shown is as follows: 15", 15", 1J , 15^z, and. 15" are valves and 16 is a pressure gauge. 16a is a steam supply-pipe connected to any suitable source of steam-supply. By opening valves

15b and15", and closing valves 15d, and 15", the steani is by-passed around the drum. By closing

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valves 15u ,end 15,1 and opening 15 , the pressure in the drum may. be brought to any desired point, as shown by gauge 16.. To reduce the pressure in the

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drum, valve 15 may be closed and valves 1511 and 105" opened, whereby the. pressure escapes into the atmosphere through the pipe 151. Thus, by proper valve-manipulation the conditions of pressure and temperature in the drum may be regulated and controlled absolutely within the desired limits. It will be understood that the oven is heated by any suitable or desiredmeans,;as, for example, by gas.

The lid 18 of the drum is clamped tightly closed, a suitable soft-metal gasket being provided to cause an air-tight connection, when the drum is in the horizontal position in the .frame. This sealing of the lid is accomplished by'reason. of the fact that the outer face of the lid is curved so that when it is in engagement with the roller 19 on thenxle 5, it is firmly pressed against the mouthof the drum so as to render the same airtight. In order that the heating may not unseal the lid, prefer to make the drum of bronze, or some material,

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having a higher C:oeftiClCl1t of expansion than the side members a of the frame.

To remove the drum from the oven after the heating, valve 151! isclosed,the drum is disconnected at

12, and is run out of the oven to a raising and loweringmechanism suitably connected with the drum through the arm 17,By means of this mechanism thedrum is lowered ahont theshaft 4 as a pivot, as indicated in dotted lines in Fig. 3. The lid 18, previouslyheld shut by theroller 19, is opened and the contents are discharged. In charging,, the drum is raised by.

>;Desc/Clms Page number 3; the oame arm or screw 17 until it tilts-upwardly, when the material to be treated may be fed into the drum.,

For the purpose of making a full and complete description of my invention I shall describe in detail the preferred manner of carrying out the process, at the same time realizing that variations may be made therein without departinghorn the principle of the invention.

A sufficient quantity of the material to be treated as, for instance, rice in a substantially air-dry condition, is poured into the drum or cylinder to fill the latter from about one-third to two-thirds. The cylinder is now sealed air-tight, and is heated, while being rotated,to-:1 temperature of about 150 to

300 degrees C. , for a period of twenty minutes to two hours or more, the valve 15c being closed so that no steam enters the drum from anexternal source. The time of treatment, of course, depends upon the

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size of the cylinder, the temperature of the oven, and the kind of heat applied, it being evident that the higher the temperature, the shorter the time, or'Vice VC1'Slt.

Owing to the fact that rice grains when in a. substantially air-dry condition contain a certain amount of moisture (say from ten to twenty per cent.) the first effect of the heating is to evaporate or drive off aportion of this moisture.

The result is that the confined space in the cylinder soon becomes saturated with moisture in the form of steam or water vapour, and with increase of temperature a corresponding increase of pressure takes place within the cylinder. During tins treatment the wall of the cylinder is ata, higher temperature than that 'of the rice. By the rotation of the cylinder the rice is tumbled or agitated in such a way as to expose all portions of the surface of the grains to' the action of the moist air and the heat. As the rice grains are cooler than the surrounding steam atmosphere, the moisture of the latter continually condenses on the rice grains, giving them a surface layer of free water in the form of " sweat". It is evident from the conditions of the treatment that the free water on the surface of the rice gramshas been drawn from the interior of the grams, and that therefore the interior of the grain is dryer than the peripheral portion, con-tainingin, fact a. less percentage of moisture than the rice contained at the beginning of the treatment when in its air-dry condition. As soon as the temperature of the rice reaches

70 degrees C., this surface moisture or "sweat" begins to act. on the exposed and peripheral starch layers, hydrating orgelittinising them. With the increasing temperature and pressure' of the con- .fined rice and surrounding steam, this hydratingetfect becomes more marked; so that when a pressure of from 10 to 100 pounds has developed, 'the free water or " sweat " has been taken up by the peripheral portions of the rice grains and formed there a continuous sealed, glassy and horn-like layer or coating com-pletely surrounding the interior of the kernel. This interior, on account of its having been practically free from the action of the film of surface water, is retained essentially in its normal condition.

As soon as the desired pressure has developed within the cylinder, say from 10 to 100 pounds,

(depending upon the temperature to which it is desired to heat the grain, 'said temperature varyingfrom.

11,0 to170 degrees C.,) all the pressure is reduced slowly, as by blowing off through valves 15 , 15d and 15a, the cylinder is then opened and the rice taken out.

It is well known that the starch granules of rice develop during the growth of the grain in a limited or cramped space,causingin the ripened or matured grain a very solid and compact structure wherein. the starch granules arc so closely packed that they resemble the bricks in' a brick wall, excepting that in the raw grain they are not cemented together like the' bricks in a brick wall.

When, however, the rice grains are treated as above described, so as to draw the moisture of the grain from its interior and condense it on the surface, the starch granules of the periphery become more or less hydrated; at the same time, swelling slightly, they press upon each other to such an extent that, there -


results a coalescence of their contact planes. Thus, a continuous horny,glassy, and impervious surfacecoating is formed, covering the interior of the grain.

The above steps in the carrying-cut of the process may be slightly varied ; for instance, when. the desired pressure has been reached, it may be increased suddenly by injecting a small quantity of dry steam at a higher pressure than that of the cylinder. Steam preferably slightly,,superheated is used for this purpose. Now, after allowing the steam to condense on the surface of thegrains for a short time, the whole pressure is slowly reduced as by being, blown out, as above explained, and the cylinder is opened and emptied of its rice. The steam thus injected thickens the coating already present on the grain, and .hasbeen found to aid in its formation, especially when the rice under treatment contains a low percentage of moisture, or when some. of the moistureof. tho grain has leaked out of the cylinder during the treatment on account of imperfect sealing. The quantity of steam so admitted should be only sufficient -to have the moisture equal to about what would be present with the grain in substantially airdry conditions.

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Unhulled rice, known as paddy-rice, may be treated in the same manner as hulled rice. During the treatment there will take place a desiccation. of the interior of the grain with a peripheral condensation of the moisture from thehotter surrounding steam-atmosphere, such condensation making the rice grain of the paddy'resistant in the manner similar to that of hulled rice above .explained. The surface condensation takes place also on the hull of the paddy which tends to soften and loosen the hull from the grain, making it come off more. easily in the final swelling or puffing by methods given below.

Also, when hulled by the usual methods of hulling rice by machinery, paddy rice, treated by my method hulls much more easily and with less breaking up of the grain than when hulled in its raw, untreated condition.

'1'he new product which forms a part of the subject matter of thisapplication. comprises, broadly considered, a substantially unexpanded cereal grain having .in artificial outer layer resistant to the escape of moisture from the interior of the grain., since now the moisture cannot escape by passing between the granules of starch but must pass or diffuse through them, which process requires more time. The interior of the grain is retained in its normal condition,-that is to say, it is not essentially resistant to the passage of steam or water vapor.

When the resistant grains of rice are cut in halves and. the cut surfaces examined with a lens,. theyshow a coating clearly in the form of a glassy, horny peripheral ring. The thickness of this ring varies with the extent of the treatment and with the amount of moisture the grains contained during the treat-ntent. The horny periphery rarely extends to the center of the grain; although if it is desired, to change the entire grain to this horny condition, this can be done by continuing the treatment in the steam-atmosphere, as aboveexplained.

Another characteristic of my new rice product is that i.t can be puffed imme-diately after the above treatment or at any desired time thereafter. To do this the resistant rice grains are subjected to a treatment whereby aninternal pressure is produced in the grains. This treatment consists broadly in heating the grain'ata temperature varying from about 175 to 400 degrees C. , for a period of about five seconds to one hour or more,according to the method of applying the heat. In this way the moisture contained in the kernels is rapidly converted -into steam. As the latter cannot escape with sufficient rapidity through the resistant .periphery of the grain, a pressure is generated in the interior of the kernel.whereby the latter is swelled or expanded, furthermore, as the periphery of the kernel is of such a nature as to be plastic in its heated condition, the peripheral coating or ring stretches under the influence@ he internal pressure, 'becoming inflated and cellular with the steam. Tinsena. the grain, although swelling, to retain its originalshape,-that is to say, the shape of the swelled grain is substantially homologous to that of the natural grain.

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Such pufling as here expiated can be Offictv4 in various ways ; tlius thiij


grains may be puffed .by creating a pressure inside of the kernels by immersing them in fat or oil kept at a temperature of from 200 to 260 degrees C. If the kernels have been made sufficiently resistant and are in the right hygroscopic condition, (that is, substantially air-dry), they swell evenly, enlarging several times in volume in five to ten seconds. Another simple method of puffing the new rice product is to place it in a suitable receptacle, preferably perforated or reticulated, as, for example, an ordinary corn-popper. This is then intro-duced into any suitably heated chamber, (as the oven of a cookingstove) said chamber being at a temperature of about 225 to 400 degrees C. The material is .agitated during the heating, as by shaking the popper, so thatthe* grain receives its heat substantiallyuniformly, whereby it will puff up and enlarge several times in volume by becoming cellular and inflated with steam. , On cooling, the grain remains in this enla.rged or puffed condition. It is now ready as a food without any further treatment. The puffing of the grain may likewise be accomplished by injecting steam-preferably super-heated steam-into the drum, toIncrease the pressure in the grains as well as in the surrounding medium, and then suddenly reducing the pressure in the drum, as by opening the lid, whereby the Internal pressure of the grains causes the grains to puff up and greatly increase in size, as described in my Application for PatentNo..18,949 of 1912 filed contemporaneously herewith.

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While it is preferable to effect the tumbling action in a rotatory apparatus, it may in some cases be desirable or sufficient to produce the tumbling action in an apparatus which does not rotate but produces snch a motion of the particles or grains as will be substantially equivalent in effect to the tumbling action obtained by a rotatory vessel.Data supplied from the esp@cenet database - Worldwide

Claims:


Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that what

I claim is ; -

1. The process described which consists in confining cereal grain such as for instance rice in an airtight receptacle and heating the interior of the receptacle toa sufficient degree to drive out the moisture in the grain and convert the same into steam, meanwhile agitating the grain, and owing to the temperature within the receptacle being higher than that of the grain, allowing the steam generated from the moisture of the grain to condense on the surface thereof, the heating being continued to allow the moisture on the grain in the presence of the heat to gelatinize the peripheral starch layers of the individual grains so as to form thereon a horny gelatinized outer layer.

2. A modification of the process described in Claiming Clause 1, consisting in injecting steam which may be superheated, into the receptacle whereby the outer layer of the grain is thickened and then reducing the steam pressure within the receptacle.

3. A new article of manufacture consisting of rice or other cereal grains of substantially natural size, having an artificial hard gelatinized outer layer resistant to the escape of fluid under pressure from the interior of the grain, produced substantially as described.Data supplied from the esp@cenet database -

Worldwide

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117.

GB191502607 - 1/27/1916

PROCESS FOR THE MANUFACTURE OF FOOD PRODUCTS FROM

AMYLACEOUS MATERIALS


Inventor(s): FRANZIE MOZES (NL)

Applicant(s): FRANZIE MOZES (NL)

E Class: A23L1/30; A23L1/30C


Priority Number: NLX191502607 (19140219)

Family: GB191502607

Abstract:


2607. Franzie, M. Feb. 19, 1914, [Conven- tion date]. Cereal preparations; fruit preparations.- Cereals, such as peeled rice, are boiled or steamed, cooled to about 65 C., mixed with fruit, such as bananas, mangoes or tamarinds or fruit extract containing starch-decomposing ferments, and left for some hours above 50 C. to produce fermentation. The prdduct is dried in vacuo at a temperature below 40 C., formed into sheets, further dried, and ground. The rice may be steamed, dried, and powdered before treatment. Banana extract is prepared by digesting bananas with water at about 50 C. and passing the digestod mixture through a sieve. Specification 7043/92 is referred to.Description:




Process for the Manufacture of Food Products from Amylaceous

Materials..

I,M07,ESFRANZIE, Doctor, of 5, Louise deColignystraat, The Hague, Holland, do hereby declare the nature of my said invention, and in what manner the same is to be-performed, to be particularly described and ascertained in and by the following statement:

The object of this invention is the manufacture of a nutriment for children in a conservable and dry form and to put the same on the market in a suitable state for preservation.

It is well known in what successful manner the Javanese mothers use a food, consisting of rice to which bananas areadded.

After having chewed the rice together with the banana the children are nourished with themixture which nourishing takes place directly from the mother's mouth.

If such a mixture is prepared and left for a fairly long period it will soon become. tainted and this cannot be prevented merely by drying the pap.

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The mixing of rice, meal and the like, with banana-sauce is not novel and is already described in the

British Specification No. 7043 A.D. 1892, and the fermentation of cereals with malt or diastase is also known.

With the process according to this new invention not only is acouservable product obtained in a dry condition but also a fermentation takes place by the starch-decomposing action of the ferments in the fruits or fruit extracts utilised, so as to form sugar and a food product is obtained that is dry and conservable, and besides possesses dietetical properties.

This process may be applied to all kinds of cereals, which contain much albumin or fat, as well as to those, which contain only a little of the latter substances and with different sorts of bananas and other fruits,. which contain starch-decomposing ferments, such as mango and tamarind.

According to this invention peeled rice may be boiled with 3 times its volume of water and when it is done it is cooled to about 65 C. and mixed afterwards with banana (plantain)sauce, prepared by first divesting the bananas of their


peel, and then reducing them for instance by passing through a sieve or ,by any other suitable manipulation.

The mixture preferably consists of about two parts of dry rice to one part of banana sauce. The mixture is left at rest during about 12 hours, care being taken that the temperature does not fall below 50 C.

Then a fermentation takes place; the starch-molecule is decomposed and a product is formed which is rich insugar.

From the fermented product 75 per cent. of water is extracted in vacuum at a temperature not above 40

C. asa slow drying process would corrupt the pap and by drying quickly a sticky and tough substance would be formed which cannot be brought into atconservahle state,

The product is subsequently formed into tliin sheets and is quickly heated for some hours untilT5-50

C. and then further dried slowly at a lower temperature, when a hard brittle substance is obtained. The thin sheets may be formedby rolling out the mass between rollers to obtain a large surface for easy drying, which is (for instance) performed by heating in a drying room wherein the sheets are placed onsuitable plates or the like. Grinding may be done in a mill, then

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the mass may pass tlij 'O'Igb hi,,,,,iovo and be ground still finer until an equally fine powder isobtained resembling yellowish flour.

The ricepap may also be mixed with an aqueous extract of the bananas (prepared by digestingbannnasauce during about two hours with water at about 50 C. and thereupon passing the mass through a sieve) in proportionscorresponding to those given above and a useful product is also obtained.

Moreover the rice may first be teamed dried and powdered and the powdered rice may be submitted to the influence of banana-sauce or the banana-extract and afterwards treated as mentioned a.bove.Data supplied from the esp@cenet database - Worldwide Claims:


Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that whatI claim is:-

A process for the manufacture of dietetical food products in aconservable state characterised by the feature that cereals, after having been boiled or steamed, arc submitted to the influence of fruits or fruit extracts containing starch decomposing ferments, fermentation taking place so as to form sugar, after which the whole is dried and eventually ground and powdered.Data supplied from the esp@cenet database - Worldwide

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118.

GB191513094 - 7/13/1916

IMPROVEMENTS IN PUFFED CEREAL FLAKES AND METHOD OF

PREPARING SAME


Applicant(s): POSTUM CEREAL COMPANY LTD (US)

E Class: A23L1/18C6



Family: GB191513094

Abstract:


13,094. Postum Cereal Co., [Assignees of Martin, F. B.]. April 29, [Convention date]. Roasting granular substances; flake products, obtaining.-Consists in converting maize, rice, or other cereal grain, either whole or cracked, into flakes, which are then heated to form an external film and afterwards subjected to a higher temperature to vaporize the contained moisture by which the flakes are puffed. The cereal grits c. are cooked in water under steam-pressure, with salt and sugar or the like if desired. They are then partly dried on the surface by passing through the meshes of a revolving reel, which separates the individual granules, to a drying-apparatus. After resting in a curing-bin until the internal moisture is evenly distributed and the granules become tough, they are flaked between water cooled smooth rolls, set to form flakes of considerable thickness. The flakes are heated in a roaster to form a tough film on the surface, and the temperature is then raised to vaporize the moisture and puff the flakes, and the roasting is completed at a somewhat lower temperature. The roasting-apparatus may be a perforated rotary drum having internal agitating-vanes and heated by- open flame so arranged as to produce three successive zones of the requisite temperatures.

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119.

GB198594 - 6/7/1923

PROCESS OF MANUFACTURING SEASONINGS OR LIKE FOOD STUFFS

FROM FISH OR SHELLFISH


Applicant(s): TOSHIICHIRO ENDO (--)

E Class: A23L1/23



Family: GB198594

Abstract:


198,594. Endo, T. Aug. 1, 1922. Food preparations; condiments.-Fish or shell fish are improved in flavour and rendered suitable for the preparation of condiments by cultivating Aspergillus oryzac on them. Parched rice bran, bean refuse c. may be mixed with the fish c. The fish is boiled or steamed and water and oil expressed. When rice c. are not employed the fish is treated with sulphuric acid before adding the spores of Aspergillus. When the treatment is complete the material may be boiled in water and the extract concentrated or dried to produce a seasoning, or it may be made into sauce with salt water, or added to boiled and mashed soya beans for food.

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120.

GB2043101 - 10/1/1980

FOODSTUFFS FROM RICE BY THE ACTION OF BIFIDOBACTERIA


Applicant(s): YAKULT HONSHA KK (--)

IP Class 4 Digits: A23L; C12N; C12R

IP Class: A23L1/28; C12N1/20; C12R1/01

E Class: A23C9/123D; A23L1/03M; C12N1/20



Family: GB2043101

Equivalent: US4298619; NL8001106; JP55131370; FR2449411; DE3005060; CH642517

Abstract:



Foods and drinks containing bifidobacteria are produced by inoculating and cultivating bifidobacteria or a mixture of bifidobacteria and lactic acid bacteria in a medium containing alpha -starch-transformed rice and bifidobacteria-fermentable sugars, and processing the resultant cultivated medium to produce foods and drinks containing bifidobacteria. The alpha -starch-transformed rice is produced by cooking rice. The medium for cultivating bifidobacteria may contain milk, and cultivating may be carried out under aerobic conditions.Description:


1 GB 2043 101 A 1

SPECIFICATION

Method for producing foods and drinks containing bifidobacteria BACKGROUND OF THE

INVENTION

This invention relates to a method for producing foods and drinks containing bifidobacteria.

Bifidobacterium predominates in intestinal bacterial flora of suckling infants, and is being watched with keen interest since it has an influence on the health of breast-fed infants.

There are many reports on the study of the physiological significance of this bacterium, clarifying (1) the inhibitory effect on putrefaction by putrefactive bacteria, (2) the inhibitory effect on production of toxic amines, (3) the digestive effect on human milk casein by the action of phosphoprotein phosphatase, and (4) the effect of suppressing the growth of pathogenic bacteria by lowering intestinal pH following production of organic acids such as lactic acid, acetic acid, and formic acid.

However, this Bifidobacterium favourable to infants is present in a very small amount in the 15 intestines of bottle-fed infants, which is considered to be one of the causes for their susceptibility to intestinal diseases, greater than that of breast-fed infants.

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Aimed at approximating the intestinal flora of bottle-fed infants to that of breast-fed infants, an attempt has been made to produce Bifidobacteriurn-containing powdered milk for infants and to modify powdered milk for infants in such a manner as to be similar to a mother's milk.

However, due to the problems as mentioned below, it has been difficult to practice an industrial cultivation of Bifidobacterium in a medium consisting of milk only.

That is, as compared with dairy lactic acid bacteria which are widely used in processing milk,

Bifidobacterium has the following problems:

(1) An industrial mass cultivation is difficult since Bifidobacterium requires strict anaerobic 25 conditions for growth, and accordingly entails a large equipment cost and requires high level cultivation techniques; (2) The nutritional requirement for the cultivation is complicated and fastidious and therefore the bacteria do not substantially propagate on a pure cow's milk medium containing no growth promoting substance such as yeast extract, peptone and the like; and (3) Acetic acid, the main metabolic product of Bifidobacterium, is highly stimulative, and therefore generally impairs the taste and flavour of foods and drinks containing the same.

We have found that bifidobacteria having the above mentioned properties can be prosperously propagated under the same aerobic culture conditions as in the cultivation of dairy lactic acid bacteria in a medium containing as the main component a pasty or milky product of a-starch- 35 transformed non-glutinous or glutinous rices, polished, whole, non- polished or powdered, and further containing sugars fermentable by Bifidobacterium, such as glucose, lactose, fractose, galactose and the like (the sugar may vary depending on the species of Bifidobacterium used), and that the cultivated product has a good flavour since the fermentation product, acetic acid, well matches with the flavour of cooked rice.


An object of this invention is to provide a method for producing foods and drinks containing bifidobacteria, characterized by inoculating and cultivating bifidobacteria or bifidobacteria and lactic acid bacteria in a medium comprising a milky mixture containing rice treated for a-starch transformation and sugars fermentable by bifidobacteria or further containing milk components in addition to the above ingredients, and optionally processing the cultivated product into a form suitable for foods and drinks.


Figures 1 and 2 show graphs illustrating the state of cultivation with the passage of the cultivation time.

Figure 3 shows the results of the organoleptic evaluation of a product cultivated with bifidobacteria.

DETAILED EXAPLANATION OF THE INVENTION The above mentioned properties of bifidobacteria are illustrated by the following experiments.

Viable cell count expressed by count per mi was measured in accordance with the method described

"J. Food Hyg. Soc. Japan- (Vol. 18, pp. 537-546, 1977). Titratable acidity was expressed by amount in mi of 0. 1 N NaQI-1 solution required to neutralize 10 mi of sample. 60 Experiment 1 A culture medium for this Experiment was prepared by adding about 750 ml of water to 150 g each of washed unpolished-, whole-, and polished- non-glutinous rices, heating each mixture at 1 20'C for 15 minutes, emulsifying it by a mixer, adding 30 g of lactose to it and finally 65 GB 2 043 101 A 2 topping up to

1000 mi by the addition of water. A reconstituted skim milk having a non-fat milk solid concentration of 15 % was used as a reference culture medium.

Each culture medium thus prepared was placed in a 2000 mi-conical flask having a cotton plug, and was then sterilized at 1 2WC for 20 minutes. After cooling, 3.0 % of each starter of bifidobacteria previously prepared was inoculated in the respective medium, and was subjected to a static culture at

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37'C for 24 hours. Acidity and viable cell count were then measured, and the results are shown in Table

1.

Table 1

B. bifidum Y1T4005 B.bifidum E B.breve Y B.breve S 25 13.1ongum ATCC15707 B.adolescentis

B.infantis 30- I Media Bifidobacteria lactose unpolished rice whole rice polished rice lactose + milk lactose acidity viable count acidity viable count acidity viable count acidity viable count 8.3 6.8 x 1011

- 7.2 5.0 X 1011 9.6 7.9 X 108 9.0 6.6 X 1011 5.8 4.1 X 1011 5.5 4.8 8.1 6.6 x 1011 7.0 5.5 X 10' 9.4

7.1 X 10' 9.1 6.3 x 1011 5.6 4.3 X 10' 3.9 x 1011 1.4 x 1011 7.2 5.6 X 1011 6.3 6.8 4.2 X 1011 8.3 6.9

X 1011 8.5 5.6 X 1011 5.0 4.0 X 101 5.0 3.6 X 1011 4.4 4.6 1.5 X 108 3.8 2.5 x 108 8.9 X 107 4.2 x

108 20 2.3 5.8 X 105 3.3 3.1 X 10' 2.5 4.2 X 104 2.8 2.0 X 104 25 3.8 X 104 5.9 X 104 Note: Starting

Viable Cell Count: 8.5 X 105 1.3 X 107, Acidity 1.31.5 In the reference milk medium, strains other than B. bifidum YIT 4005 (a mutant of bifidobacteria having properties of propagating under aerobic conditions in a milk medium Deposit No. FERM-3372 at Fermentation Research Institute, Government

Industrial Research, Ministry of International Trade and Industry Japan) were not totally propagated.

On the other hand, in the respective milky culture medium containing rice as the starting material, all the bifidobacteria were vigorously propagated.

According to other experiments wherein the concentration of culture medium was varied, it was proved that propagation was accelerated in proportion to the increase in the concentration 40 of rice until the concentration of rice reached 20 %. If the concentration exceeds the above value, starching occurs and accordingly amylase treatment is required. However, this treatment did not have a substantial influence on the propagation.

With regard to unpolished-, whole-, and polished-glutinous rices, substantially the same results as in the above were obtained.

Experiment 2 The same procedures as in Experiment 1 were repeated, except that a medium used for this experiment was prepared by cooking unpolished-, whole-, and polished-non- glutinous rices, emulsifying it at a concentration of 15 %, and adding to the emulsion 2.0 % of lactose and 50 1.0- 15 % of skim milk powder.

Table 2 shows the results obtained with media containing skim milk powder at a concentra tion of 5

%. In the media containing milk components in addition to rice and sugar, the propagation of bifidobacteria was accelerated as compared with Experiment 1 wherein milk component was not used.

The effect of the milk components on accelerating propagation was enhanced in proportion to the increase in the concentration of skim milk powder until the concentration reached 10 %. If the concentration exceeded the above value, no further enhancement of the effect on accelerating propagation was achieved.

Substantially the same results are to be obtained by the use of whey powder.

3 GB 2043 101 A 3 Table 2 rice unpolished rice whole rice polished rice i( Bifido bacteria acidity viable count acidity viable count acidity viable count B.bifidum 13.5 6.2 X 101 13.3 6.0 X 109 12.6 5.8

X 109 Y1T 4005 B.bifidurn E 9.5 7.6 X 108 9.6 7.0 X 10' 9.4 6.8 X 1011 10 B.breve Y 11.8 5.0 x 109

10.7 3.3 X 109 10.1 3.4 X 109 B.breve S 10.0 9.0 X 1011 9.0 8.2 X 1011 9.1 7.8 X 1011 B.1ongurn

7.9 6.7 X 1011 7.6 5.8 X 1 U1 7.2 5.3 X 108 ATCC-15707 B.adolescentis 6.5 5.1 X 1011 6.3 5.0 X

1011 6.0 4.1 X 1013 15 B.infantis 6.6 4.9 X 108 6.0 4.1 X 101 5.6 3. 9 X 1011 Note: Starting Viable

Cell Count: 1.0 3.4 X 107, Acidity: 1.7 2.0 Experiment 3 Two species of bifidobacteria or a mixture of bifidobacteria and lactic acid bacteria were inoculated in a milky medium prepared in such a manner as to contain 15 % of unpolished non glutinous rice, 5 % of skim milk powder and 2 % of lactose, and was subjected to a static culture at 37'C. The inoculurn of the starter of each strain was respectively 2

%. Figs. 1 and 2 25 show the results of the acidity and viable cell counts measured with the passage of time during cultivation in comparison with the results obtained by single cultivation of each strain. The strains used in this Experiment.are as follows:

579/2197

B,: B. bifidum Y1T 4005 B2: 8. breve Y LA: Lactobacillus acidophilus As can be seen from the two

Figures, a certain species of strain was vigorously propagated in a rice-containing medium when subjected to a mixed cultivation.

Experiment 4 B. bifidum YIT 4005 was inoculated in a medium containing 15 % of whole rice, 5 % of skim milk powder and 2.0 % of lactose and in a skim milk medium having a non-fat milk solid concentration of 15 %, and was cultivated at 37 C for 24 hours. With regard to the -culture thus obtained, organoleptic evaluation was made by a panel consisting of 10 trained panelists. The 40 results are shown in Fig. 3.

Both cultures had almost equal values each other with regard to acidity and ratio of acetic acid/lactic acid (see Table 3). However, culture of the rice-containing medium was evaluated to have a better flavour since the flavour of cooked rice well matches with acetic acid and the stimulative smell of acetic acid is weaker as compared with the product cultivated in the milk- 45 containing medium.

Table 3

Medium Culture Acidity Acetic Acid/ Lactic Acid medium consisting 6.8 1.75 of milk only medium containing 7.5 1.80 rice The present invention was accomplished in view of the above knowledge.

Thus, the present invention resides in a method for producing foods and drinks containing bifidobacteria, characterized by inoculating and cultivating bifidobacteria or bifidobacteria and lactic acid bacteria in a medium comprising a mixture containing rice treated for a- starch transformation 4

GB 2043 101 A 4 and sugars fermentable by bifidobacteria or further containing milk components in addition to the above ingredients, and optionally processing the cultivated product into a form suitable for foods and drinks.

As clearly described above, any glutinous or non-glutinous rice can be used in the method of 5 this invention, and the rice may or may not, be polished or milled, to any degree. When these rices are used in a medium for cultivating bifidobacteria, they are preferably made into a homogenous milky state by the method used in Experiment 1 or a method of grinding and heating in water. An appropriate concentration of rice in a medium is 10-20 %, preferably 15 Sugars such as lactose, fructose and glucose are the most preferable bifidobacteria-fermenta- 10 ble sugars since they are easily available and fermentable by all of the bifidobacteria. It is not necessary to use pure sugars, but any edible material containing these fermentable sugars, for example, lactose-containing milk, skim milk, whey and the like can be used as a medium component. Milk components are particularly preferable since they accelerate the propagation of bifidobacteria and provide a product having a good nutrition balance.

A part or the whole part of 15 the rice may be previously treated with amylase or with amylaseproducing Aspergillus oryzae, Aspergillus niger, Bacillus subtilis and the like to groduce glucose in an amount sufficient for the propagation of bifidobacteria, and the glucose thus produced may be used as a fermentable sugar for bifidobacteria. This method has advantages in that the emulsification of rice proceeds along with saccharification, and that a unique flavour can be obtained.

The concentration of bifidobacteria-fermentable sugars in a medium should preferably be 1 -5 %, more preferably about 3 %.

Any cultivation supplements or seasonings, spices, nutritions and the like may be added to a medium in addition to the above components.

Bifidobacteria to be inoculated in the above mentioned homogenous milky medium are not specially limited, and 2 species or more of bifidobacteria may be used. In combination with bifidobacteria,

Lactic acid bacteria may be inoculated, preferable examples of which include Lactobacillus acidophilus, L. casei, L. bulgaricus, Streptococcus thermophilus and the like.

The cultivation of bifidobacteria can be carried out under aerobic conditions in the same manner as in the cultivation of ordinary lactic acid bacteria, and strictly anaerobic conditions are 30 not required.

This is a great advantage of this invention, and the conventional apparatus and techniques used in the cultivation of lactic acid bacteria can be used as they are.

580/2197

Under normal cultivation conditions, viable cell count reaches maximum after 18-24 hour cultivation, and pH is gradually decreased because acid is formed along with the passage of the cultivation time.

The production of acetic acid by bifidobacteria starts at the initiation of 35 cultivation. If the cultivation is further continued, viable cell count starts to be decreased after 24 hours and the production of acid is continued for some time but the production of acid stops to some extent. Thus, taking the use of the cultivated product into consideration, cultivation is stopped when the pH of the medium reaches 4.2 to

5.6. In most cases using bifidobacteria per se, the viable cell count of bifidobacteria should preferably be more than 107 per ml. According 40 to the culture method of this invention, it is quite easy to obtain a viable cell count of 1 911-9/ml.

The product of this invention contains acetic acid 80-120 mM/I and lactic acid 50-70 mM/I as the main metabolites in addition to the viable bifidobacteria. The contents of these acids are not specially different from those in conventional bifidobacteria culture, but the acetic acid well matches with emulsified rice and therefore the cultivated product of this invention deserves much higher organoleptic evaluation than the conventional cultivated products. Thus, the cultivated product of this invention can be served, as it is, or as a food containing viable bifidobacteria without flavouring. The product of this invention may be served as a drink by optionally adding sweetening materials, fruit juice, water, spices or the like to modulate the concentration and flavour. The product can also be served as powdery or tablet-like foods or 50 medicinal preparations containing viable bifidobacteria by drying. As long as the bifidobacteria do not perish, any conventional processing techniques and any processed forms can be used.

The present invention is further illustrated by the following Examples.

Example 1

To 15 Kg of fully washed polished non-glutinous rice, was added 70 liters of water, and the resultant mixture was heated at 121 C for 15 minutes. The mixture was then emulsified in a mixer, and the mixture was topped up to 100 liters by the addition of water. To this mixture, was added 2 Kg of skim milk powder, and the mixture was sterilized at 121 C for 40 minutes. 60 The mixture was then cooled to 37'C while stirring.

Into the milky rice medium thus prepared, 3 % by volume of the starter of B. bitidum YIT-4005 was inoculated, and was cultivated at 37'C for 24 hours.

After cultivation, the culture was homogenized in a homogenizer (150 Kg /CM2), and 40 liters of syrup containing 4.8 Kg of sucrose was mixed therewith, thus producing a drink having an acidity of

5.4 and containing bifidobacteria in a count of 4.3 X 108/mi. The product thus 65 #M r Y GB 2 043

101 A 5 obtained had a less stimulative smell and provided a satisfactory taste and flavour.

Example 2

To 15 Kg of thoroughly washed whole glutinous rice, was added 70 liters of water, and the mixture was heated at 121 C for 15 minutes. In order to facilitate emulsification, 50 g of liquifying amylase

(70,000 units/g) was added to the mixture, and the mixture was erriulsified in a mixer. To this mixture,

1 Kg of lactose and 10 liters of cow's milk were added, and the mixture was topped up to 100 liters by the addition of water. The mixture was then sterilized at 121 C for 40 minutes, and was cooled to 37C while stirring. Into the medium thus prepared, 5 % of the starter of B. adolescentis was inoculated, and was cultivated at 37 C for 40 hours. 10 After cultivation, the culture was treated in the same manner as in Example 1 to obtain a drink having an acidity of 6.1 and containing viable bifidobacteria in an amount of 8.0 X 1 07/Ml.

Example 3

To 2 Kg of thoroughly washed polished non-glutinous rice, was added 7 liters of water, and the mixture was heated at 121 'C for 20 minutes. After cooling, 200 g of seed starter of Aspergillus oryzae was added to the mixture, and the mixture was shaken at 37,C for 40 hours to saccharify a part of the rice, thus forming glucose. Thereafter, the mixture was emulsified in a mixer, and was topped up to 10

581/2197

liters. To the emulsion thus prepared, was added 5 liters of 20 syrup containing 600 g of sucrose and 30 g of gelatin, and the resultant mixture was sterilized.

Into the medium thus prepared, 2 % each of the starter of B. breve Y and B. longum (ATCC-1 5707) was inoculated for culture at 37'C for 12 hours to obtain a sweetwine flavoured yoghurt-like food. The product thus obtained had an acidity of 5.2, and the viable cell count was 2.2 X 108/mf for B. breve Y and 7.8 X 107/MI for 8. longum.

Example 4

One Kg of polished nonglutinous rice was thoroughly washed and dried. The rice was then powdered by a grinder, and 5 liters of water was added to the powdered rice. The mixture was then heated at 121

C for 15 minutes. After cooling the mixture to 55C, 2 g of saccharifying 30 amylase (50,000 units/g) was added to the mixture while stirring thoroughly, and the resultant mixture was treated at 55'C for 1 hour. After the amylase-treatment, the mixture was topped up to 10 liters by the addition of water, and was sterilized. After cooling to 37C, the mixture was inoculated with the starter of Saccharomyces sake, and was cultivated at 30'C for 20 hours.

Thereafter, the culture medium thus prepared was sterilized again, and 2 % each of the starter 35 of B. bifidum E and Lactobacillus acidophilus was inoculated into the medium. The cultivation was carried out at 37'C for 30 hours.

After cultivation, the culture was homogenized in a homogenizer, and 2 liters of syrup containing 300 g of sucrose was added to the culture. The product thus obtained contained a small amount of alcohol, and had a titratable acidity of 9.6 and the viable cell count of 1.5 X 40 108/Ml for bifidobacteria and

6.6 X 107/Ml for lactobacilli.

Example 5

To the culture prepared using the same materials in the same manner as in Example 1, were added 5

Kg of skim milk powder, 5 Kg of sugar and 1 Kg of Vitamin C, and the mixture was 45 dried by a spray drier, thus producing 26.5 Kg of powdery food containing 7.1 X 1 011/g of bifidobacteria.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1. A method for producing foods and drinks containing bifidobacteria, characterized by 50 inoculating and cultivating bifidobacteria or bifidobacteria and lactic acid bacteria in a medium comprising a mixture containing rice treated for a-starch transformation and sugars fermentable by bifidobacteria or further containing milk components in addition to the above ingredients and optionally further processing the cultivated product.

2. A method according to Claim 1, wherein said sugars fermentable by bifidobacteria are 55 obtained by saccharifying a part of said rice treated for a-starch transformation.

3. A method according to Claim 1, wherein said cultivation is carried out by inoculating two species or more of bifidobacterial strains.

4. A method according to claim 1, wherein said cultivation is carried out substantially as herein described in any one of the Examples.

5. A food or drink when prepared by the method of any one of claims 1 to 4.

Printed for Her Majesty's Stationery Office by Burgess Ft Son (Abingdon) Ltd.-1 980. Published at

The Patent Office, 25 Southampton Buildings, London, WC2A 1 AY, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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121.

GB2116414 - 9/28/1983

INSTANT RICE PUDDING MIX


Inventor(s): DAVIES DAVID LAWRENCE (--)

Applicant(s): GEN FOODS LTD (--)


IP Class: A23L1/187

E Class: A23L1/187


Priority Number: GB19830006636 (19830310); GB19820007231 (19820312)

Family: GB2116414

Abstract:


An instant rice pudding mix comprises a mixture of a powder comprising 15 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat; 5 to

25% by weight of a dried skim-milk powder; up to 3% by weight of an emulsifier and 0 to 4% by weight of an edible gum; and granules formed by the extrusion of a dough formed from 87 to 100% by weight of rice flour, up to 4.0% by weight of a starch- complexing agent, up to 5% by weight of an aerating agent and up to 4.0% of dried skim milk powder and/or dried whey powder mixed with a proportion of water sufficient to produce an extrudable dough. The pudding mix of the invention may conveniently be made up by the addition of hot or boiling water to produce a product having the texture of a traditional rice pudding. The pudding mix of the invention may be packed in pouches, envelopes or other protective cartons which afford moisture-barrier features.Description:


SPECIFICATION

Instant rice pudding mix

The present invention relates to an instant rice pudding mix and, in particular, to a rice pudding mix which, when mixed with hot or boiling water rehydrates rapidly to provide a dessert pudding with the texture and appearance of a traditional rice pudding.

European Patent SpecificationNo. 0016649 (ApplicationNo. 80300890.3) describes a process for producing a reformed rice product by the cold extrusion of a dough formed from a composition comprising a mixture of pregelatinised and ungelatinised flour, sodium chloride and fat in powder form, to obtain simulated rice grains and then drying the simulated rice grains at an elevated temperature.

The reformed rice product produced in this manner rehydrates in water in about three minutes and the time required for the preparation of a simulated rice from such a product is thus significantly reduced.

We have now developed an instant rice pudding mix which is a mixture of granules preformed from rice flour by extrusion and a powder containing a starch which provides the overall body of the pudding on rehydration of the pudding mix with hot or boiling water. An instant rice pudding mix of

583/2197

this type would not, however, be formed from the reformed rice product disclosed in European Patent

Specification No.

0016649.

Accordingly, the present invention provides an instant rice pudding mix which comprises a mixture of a powder comprising 15 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat: 5 to 25% by weight of a dried skimmilk powder; up to 3% by weight of an emulsifier and 0 to 4% by weight of an edible gum and granules formed by the extrusion of a dough formed from 87 to 100% by weight of rice flour, up to 4.0% by weight of a starchcomplexing agent, up to 5% by weight of an aerating agent and up to 4.0% by weight of dried skimmilk powder and/or dried whey powder mixed with a proportion of water sufficient to produce an extrudable dough.

The rice pudding mix of the present invention preferably comprises from 55 to 80% by weight of the powder and from 20 to 45% by weight of the granules.

The finely divided sugar which is used in the pudding mix of the invention may be glucose, corn syrup solids, fructrose or most preferably, sucrose.

Artificial sweetening aids may be included in the composition, if desired.

The starch which is used in the pudding mix of the invention is preferably waxy rice starch. The starch is apowder, 99% by weight of which passes through a 105 micron sieve.

The finely divided fat used in the pudding mix of the invention can preferably be provided by the use of a spray-dried fat emulsion which includes the emulsifier component therein.

The edible gum used in the pudding mix of the invention is preferably guar gum of xanthan gum.

The granules may be formed by the extrusion of the dough at an elevated temperature preferably in the range of from 700 to1 400C. The granules are dried in a manner known per se, for example by air drying or microwave heating at an elevated temperature. Alternatively and preferably, a thick rope may be extruded which is then dried as described above and subsequently reduced in size to granules. The granules preferably have the size and appearance of rice grains (i.e. about2mm - 4mm).

The rice flour used in the formation of the granules is preferably formed by the grinding of

long grain rice, although rices with other grain

lengths may be used.

The dough may contain up to 5% by weight of an aerating agent which will release a gas during extrusion to develop an aerated structure. Suitable gas forming agents include sodium bicarbonate,

ammonium carbonate, solid carbon dioxide and baking powder, which is the preferred aerating agent.

In an alternative embodiment of the invention the aerating agent may be omitted from the composition or the amount thereof

significantly reduced if a gas such as carbon

dioxide or nitrogen is injected into the dough

during the extrusion process to provide the dough

with an aerated structure.

Flavouring and colouring materials may be

included in the rice pudding mix, as desired, as an

ingredient of either or both components.

The present invention is further illustrated by the following Example.

Example

A dough was formed by the addition of 28% by weight of water to the following dry mixture of

ingredients.

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Medium grain rice flour97.1 5%

Baking Powder 2.00%

Glyceryl monostearate 0.75%Xanthangum 0.10%

This dough was extruded at a temperature of 660C through a single screw extruder to form a rope which was dried at1 21 0C in an air-flow oven for 20 minutes. The dried extrudate was then comminuted to form granules of the size and appearance of rice grains.

A powder was formed by blending the following dry ingredients.

Pulverised sucrose 25.00%

Waxy rice starch 33.00%

Dried fat emulsion 32.00%

Dried skim-milk powder 8.50%

Colour and Flavouring 1.50%

A pudding mix was prepared by compounding 20% by weight of the granules with 80% by weight of the powder.

The rice pudding mix of the invention is typically made-up by the addition of 430 ml of hot (minimum temperature 800C) or boiling water to 100 grams of the mix. The texture of the product is typical of that of a traditional rice pudding. This would not be achieved by the separate addition of hot or boiling water to each of the granules and powder components and subsequently combining them, since the grains would then lose their discrete nature.

The rice pudding mix of the present invention may be packed in pouches, envelopes and other protective cartons which afford moisture-barrier features.Data supplied from the esp@cenet database -

Worldwide Claims:


CLAIMS

1. An instant rice pudding mix which comprises a mixture of a powder comprising1 5 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat; 5 to 25% by weight of dried skim-milk powder; up to 3% by weight of an emulsifier and0 to 4% by weight of an edible gum; and granules formed by the extrusion of a dough formed from 87 to

100% by weight of rice flour, up to 4.0% by weight of a starch-complexing agent, up to 5% by weight of an aerating agent and up to 4.0% by weight of dried skim-milk powder and/or dried whey powder mixed with a proportion of water

sufficient to produce an extrudable dough.

2. An instant rice pudding mix as claimed in claim 1 which comprises from 55 to 80% by weight of the powder and from 20 to 45% by weight of the granules.

3. An instant rice pudding mix as claimed in claim 1 or claim 2 wherein the finely divided sugar is glucose, corn syrup solids, fructose or sucrose.

4. An instant rice pudding mix as claimed in any one of the preceding claims wherein the starch is waxy rice starch.

5. An instant rice pudding mix as claimed in any one of the preceding claims wherein the finely divided fat is a spray-dried fat emulsion which includes the emulsifier therein.

6. An instant rice pudding mix as claimed in any one of the preceding claims wherein the edible gum is guar gum or xanthan gum.

7. An instant rice pudding mix as claimed in any one of the preceding claims wherein the rice flour used in the formation of the granules is formed by the grinding of the long grain rice.

585/2197

8. An instant rice pudding mix as claimed in any one of the preceding claims wherein the starchcomplexing agent is glyceryl monostearate.

9. An instant rice pudding mix as claimed in any one of the preceding claims wherein the aerating agent is sodium bicarbonate, ammonium carbonate, solid carbon dioxide or baking powder

10. An instant rice pudding mix substantially as hereinbefore described with reference to the

Example.

11. An instant rice pudding mix as claimed in any one of the preceding claims which is packed in a pouch or an envelope or another protective carton which affords moisture-barrier features.Data supplied from the esp@cenet database - Worldwide

586/2197

122.

GB2116415 - 9/28/1983

IMPROVED RAPID COOKING FOODSTUFFS


Inventor(s): BLACKWOOD GRAEME CHARLES (--)

Applicant(s): MARS INC (--)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/16; A23L1/105B


Priority Number: GB19830007320 (19830316); GB19820007694 (19820316); GB19820025883

(19820910)

Family: GB2116415

Abstract:


A rapid cooking food product, especially a rice or a pasta is produced by treating the food product with a starch degrading enzyme under starch degrading conditions. The enzyme is an enzyme which attacks either the 1,4-glucoside links or the 1,6- glucoside links in the starch molecules and is preferably ???amylase or pullulanase or a mixture thereof. Rice that can be cooked merely by pouring on boiling water and leaving it to stand can be produced by the process.Claims:


Claims

1. A process for producing a rapid cooking

starchy foodstuff which comprises subjecting the foodstuff to the action of one or more starch

degrading enzymes under starch degrading

conditions.

2. A process according to claim 1, wherein the

starch degrading enzyme is an enzyme which

attacks the 1,4-glucoside links.

3. A process according to claim 2, wherein the

enzyme is -amylase, -amylase or amylomaltase.


starch degrading enzyme is an enzyme that

attacks the 1,6-glucoside links.


enzyme is pullulanase, isomylase or dextrine-1,6

glucosidase.


587/2197

enzyme is -amylase or pullulanase, or a mixture

therof.

7. A process according to any one of claims 1

to 6 wherein the concentration of enzyme used is

such that the desired degree of enzymatic

degradation is achieved in a period within the

range of 5 minutes to 24 hours.


concentration of enzyme is such that the desired

degree of enzymatic degradation is achieved in a

period within the range of 30 minutes to 4 hours.


to 8 wherein after the enzyme treatment enzyme

activity is removed.


to 9 wherein after the enzyme treatment the

product is dried to a moisture content at which the product has adequate stability against

spoilage to enable packaging, storage and

distribution.


to 10 wherein the foodstuff is cereal grains.

1 2. A process according to claim 11 wherein

the cereal grain is rice.


the rice is in the form of paddy, cargo, brown,

white or parboiled rice.

14. A process according to claim 12 or 13

wherein the enzyme treatment is combined with a

parboiling treatment of paddy or cargo rice, the

enzyme being added to any of the steeping steps

of the parboiling process.


the cereal grains are wheat or oats.

1 6. A process according to any one of claims 1

to 10 wherein the foodstuff is a pasta.

17. A process according to claim1 6 wherein

the pasta is macaroni or spaghetti.

18. A process according to claim 1, conducted

substantially as described in any one of the

Examples herein.

19. Rapid cooking rice whenever produced by a process according to any one of claims 1 to 14 or 18.

20. Rapid cooking pasta whenever produced by a process according to any one of claims 1 to 10 or 16 to 18.Data supplied from the esp@cenet database - Worldwide

588/2197

123.

GB2146224 - 4/17/1985

INSTANT RICE GRUEL


Inventor(s): KOYAMA SADAO (--)

Applicant(s): TOKIWADO KAMINARI OKOSHI CO LI (--)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/18C6



Family: GB2146224


Abstract:



Novel instant rice gruel is provided which consists of swelled up and alpha converted rice produced such that raw rice is steamed or boiled to contain 12-13% water, and is then swelled up to 5 to 7 times as its original volume, and of suitable amount of alpha converted, glutinous rice granules. Its process also is provided. The rice gruel can be quickly and conveniently cooked. Further, the instant rice gruel can be used as emergency food.Description:


1 GB 2 146 224A 1

SPECIFICATION

Instant rice gruel and method for producing same This invention relates to instant or quickly prepared rice gruel which has never been imagined, 5 and a process for producing the same.

Rice gruel is normally prepared in the manner that raw rice is boiled for many minutes or even an hour. Under this fixed idea, there has never been occurred to provide quickly cooked rice gruel.

One of the objects of the present invention is to provide quickly prepared rice gruel.

Another object of the invention is to provide rice gruel which can be conveniently cooked.

Still another object of the invention is to provide a new type of emergency food.

Other objects and advantages of the invention will be apparent to those skilled in the art.

The production process of the instant gruel is explained by way of example in the order of respective stages of the process.

589/2197

Selection of raw rice to be used:

All suitable rice cropped everywhere in the world, can be used including polished (polished, cleaned or milled rate: 20-80%) or unpolished or unmilled rice. The water content in the rice is preferred to be

13-15%.

Washing of rice:

The rice is washed with water so as to wash out sugar content adhered to the rice. One reason therefor is to remove oily substance contained in the sugar and so prevents its being acidified which would result in degradation of the rice and issuance of odour.

The water should be used at a temperature from 1 5C to 35C, and of the amount of over 200% by weight of the rice to be washed.

First impregnation: 30 This step comprises impregnating the rice in warm saline solution containing 1

- 1. 5% salt. 30 The purpose of the impregnation in water is to make the rice absorb sufficient water so that its starch content may be collapsed when heated for conversion into alpha molecule. The reason for impregnating rice in saline solution is to keep the water content in the water-swelled rice at appropriate level. The impregnation is effected under the following conditions:

Temperature: Warm solution of 40-60'C Water used: 170-200% on the basis of rice to be impregnated.

Duration: 5-10 hours for 1 5-35C solution 40 4-8 hours for 40-50C solution (shortening of time can be realised) Absorbed water: (5-10 hours): 130-150% of rice Water removal: wire cloth of 20-12 mesh for

1 /2-1 45 hour, automatic centrifuge for 15 seconds, Water content after removal of unabsorbed water:

130-150% on the basis of rice.

50 First alpha conversion:

The first conversion process is effected by steaming the rice under pressure of 0.5 kg /CM2-1 kg

/CM2 for 20-30 minutes, or by boiling rice.

Second impregnation:

2 GB 2 146 224A 2 Water: warm water of 40-60C Duration: 0.5-1 minute Purpose: To further absorb water so that conversion due to water contained 5 and heat applied thereto, may be increased.

Water absorbed: 190-200% on the basis of material rice Water removal: same as first impregnation 10

Second alpha conversion:

This step is effected at steam pressure of 0.5 kg /CM2_ 1 kg /CM2 for 1015 minutes. Excessively long steaming of rice causes melting of rice. The reason for steaming rice twice under pressure is to make rice to absorb as much water as possible for realising total alpha 15 conversion and to obtain uniform rice property.

Third impregnation:

The third impregnating step is effected in a manner similar to the procedure of the second impregnation step. if necessary, the rice may be seasoned with aqueous solution of 0.5 each of 20 salt, sugar and seasoning material, for 3-5 minutes at this third step. The impregnation is effected under the following conditions:

Water used: 200-300% on the basis of material rice 25 Water absorbed: 200-230% Purpose of impregnation:

Uniform water absorption so that rice granules may be uniformly unfastened and uniformly dried.

590/2197

Salt and sugar: used for preventing rice from being cracked and for stabilising swelling Seasoning material: used for seasoning and 35 nourishment Water temperature: 25-60C Attention should be given so that rice granules are not broken off, not being dried irregularly and not requiring additional work and time. After the rice is impregnated, excess water is 40 removed.

Drying with hot air:

Air temperature: 80-11 OT Duration: 1-3 hours Water content after dried:

12-14% of material rice (Water content at this stage is not uniform between surface part and core part).

Ageing:

Ageing is effected for about 4-5 days by keeping rice in paper bags so that water content at every portion or rice granules may become uniform. Most preferable content at immediately prior to the next, swelling, step is 12-13%.

Swelling:

Rice volume is swelled to 5 to 7 times of orginal volume, by applying heated solid medium to the aged rice. For example, solid granules of salt or calcium carbonate (durable at 250 C) are used which have been heated to 120 C or over (preferably 150-170 C) in a rotary drum. The 60 rice is swelled up with the heat conveyed from the heated solids, within about 20-30 seconds.

Alternatively, the aged rice may be swelled up by direct heat through metal cloth, roasting, frying with oil, or by applying high-frequencey waves (by means of a microwave oven).

Addition of assistant material:

GB 2 146 224A 3 If necessary, sticky material such as alpha converted glutinous rice may be added so that rice gruel may have viscous property. In the event that no sticky property is necessary for the final instant gruel product, addition is not necessary.

Amount used: 30-50% of swelled up rice 5 Material: alpha converted glutinous rice powder, waxyalpha powder (glutinous corn) or like material as can be used for preparing alpha converted rice cake food. 10 Other material such as seasoning material and dried vegetables may be added to the swelled up rice granules. The seasonings are used for giving good taste and for nourishment in the amount of 5-

7% of the swelled rice. The seasonings, including oils and fats if preferred, may be added in a form of powder, granules etc., containing less than 8% water.

Dried vegetable may be added for giving good taste, for nourishment and for giving good appearance, in an amount of 2-4% based on the swelled up rice. The vegetable, having less than 5% water, may be freeze dried or hot air dried product.

The swelled up rice for instant gruel may have a form of:

A. rice granule (original rice granule); B. broken rice granule (half of original rice granule size to powder size); C. rice powder; or D. mixture of A, B and/or Hot water is added to thus produced instant rice gruel product to prepare eatable state gruel as follows:

full size rice granule: 400-650% water on the basis of swelled up rice broken rice: 400-650% rice powder: 500-700% As explained, the instant rice gruel according to the embodiment of the invention is obtained from boiled rice by steps of repeated impregnation process, repeated alpha conversion process, hot air drying, ageing and adding thereto seasonings if necessary.

591/2197

The table below shows relationship between swelled up rate and the recovery condition at the 35 ready for eat state of the product. As will be seen from the table, the best result is obtained if swelled up rate is 5 to 7 times that of original rice volume. (See next page) -P.

TABLE

Swelled up Poured wat.

(Times) Temp. (C) 4.

Poured wat. Recovery Impreg.,time state (min.) Practical State time required (min.) :it 9 2.5 100 3

SImrtage in water 5 Flexible recovery 3 absorption, no 6 le recovery 1 3 11 5 11 9 3.5 3 91 6 cl 1- 100

3 A bit recovery 4 A bit flevAble recovery like 4.0 tine shortage gruel 3 No recovery 5 11 3 Camplete recovery, 2 Recovered like boiled rice 5.0 3 recovery 3 P 3 CaTlete recovery 2 Recovered like boiled rice 6.0 3 recovery 3 11 3 Camplete recovery 2 Recovered like boiled rice, 7.0 RetCOVere d as melting touch boiled rice 3 1% 3 it 3 91 2 11 8.0 (a bit burnt 80 3 U 3 19 - colour) 0 CO j 0) N) NJ -0.

GB 2 146 224A 5 The physical characteristic of the instant gruel according to thw present invention can be summarised as follows:

1. As the result of repeating impregnation and steaming steps, starch content is fully converted to alpha state. The alpha converted gruel is tasteful and digestive.

2. Since salt and subar are disolved in water during impregnation, obtained product is glossy, 5 and water permeates uniformly through rice granule, resulting in prevention of cracking and in uniform swelling. Dried granules can be smoothly separated.

3. Due to the swelling up, the rice can recover its original boiled state swiftly. Further, soup seasoning can be swiftly absorbed which results in complete permeation of tasteful seasoning.

4. Since alpha converted glutinous rice is mixed in the swelled up rice granule, suitable sticky 10 property is provided. Accordingly, the instant gruel tastes good and sticky when cooked, just as the normal gruel.

5. Since water content in the swelled up rice is less than 5%, the instant gruel can be preserved for long periods. If good care is taken for not absorbing water, the product is excellent as a preserve or storage food. Seasoning of the gruel can be effected easily.

Example constituent example No.

1 2 3 20 swelled rice alpha converted glutinous rice granule seasoning (powder, granule or liquid prepared in sheet form) dried vegetable g 65 g 659 32 27 22 5 5 3 3 3 hot water 280-350 cc The instant gruel of the invention can be prepared ready for eat state if hot water is poured over it and it is mixed with a spoon for about 2-3 minutes. Any one of the type 1, 2 or 3 shown above as well as the amount of hot water can be optionally selected depending on user's 35 liking.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1. Instant rice gruel consisting of swelled up and a converted rice produced such that raw rice is steamed or boiled to contain 12-13% water, and is then swelled up to 5 to 7 times as 40 its original volume, and optionally contains suitable amount of a converted, glutinous rice granules.

2. A method for producing instant rice gruel comprising steps of providing plural water processing plus plural alpha conversion steaming, drying the water- processed rice by hot air, ageing dried rice in bags or the like, heating the aged rice to swell up, and mixing therewith 45 assistant material such as sticky material if necessary.

592/2197

3. Instant rice gruel substantially as hereinbefore described with reference to any of the examples set forth herein.

4. A method of producing instant rice gruel according to any of the examples set forth herein.

Printed in the United Kingdom for Her Majesty's Stationery Office. Dd 8818935. 1985, 4235

Published at The Patent Office, 25 Southampton Buildings. London, WC2A l AY, from which copies may be obtainedData supplied from the esp@cenet database - Worldwide

593/2197

124.

GB2204570 - 11/16/1988

IMPROVEMENTS IN OR RELATING TO APPARATUS FOR FEEDING

GRANULAR MATERIAL TO PROCESSING MACHINES


Inventor(s): HILL DEREK ALBERT (--)

Applicant(s): BAKER PERKINS PLC (--)

IP Class 4 Digits: A23L; B65G

IP Class: A23L1/164; B65G11/00

E Class: A21C9/04; A23L1/164F2



Family: GB2204570

Abstract:


Apparatus 1 for feeding granular material e.g. grits or pellets formed from corn, wheat or rice to the nip of a pair of flaking rolls comprises a feed hopper 4, disposed above the rolls 3, a magazine 5 disposed between the hopper 4 and the nip 2, the magazine 5 defining a plurality of internal passageways 6a, 6b for conveying granular material from the hopper 4 to the nip 2, and reciprocatory means 7 for controlling the flow of granular material through the passageways 6a, 6b. The passageways 6a, 6b are disposed in two substantially parallel rows, and are formed by grooves in opposite side surfaces of a plate 10, the grooves being covered by side plates 11, 12 secured to the plate 10. At approximately one third depth of the magazine 5, slot-like apertures 21 are formed, in order to provide access to the otherwise closed passageways 6a, 6b. The apertures in the plate 11 locate resilient fingers 13 and those in the plate 12 resilient fingers 14. The fingers 13, 14 are mounted on laterally-spaced bars 15 and 16 respectively, and reciprocatory movement of the fingers 13, 14 and bars 15, 16, causes the fingers 13,

14 in turn to arrest the falling columns of material moving down the passageways 6a, 6b. The apparatus may be used in the production of flaked breakfast cereals.Description:


"Improvements in or relating toApparatus for Feeding GranularMaterial to Processing

Machines"BACICGROUMD TO THEI0,rVEEION

594/2197

This invention relates to apparatus for feeding granular material to processing machines and has particular application to the production of breakfast cereals from corn, wheat and rice bases, and especially cereals in flake form. The basic materials are first cooked, generally under pressure, then fed in granular form as grits (single grains), or pellets (balls of a number of grains), to the nip of a pair of closely spaced flaking rolls which, by a spreading action, form them into the individual flakes.

As used herein, the collective term "granular material" is intended to embrace grits, pellets, and like forms of granular material.

Similarly, the collective term "grain" is intended to embrace a pellet, i.e. a ball of a number of grains, as well as a single grain.

In the production of breakfast cereals, it is essential that the grains of the granular material are kept separate from one another asthe pass through the flaking rolls. Otherwise, malformed flakes known as doubles, or strips thereof, result, which malformation is undesirable. In the case of known apparatus for the production of breakfast cereals, the granular material passes to the flaking rolls by way of a feed roll, the cylindrical surface of which may have flutes or pockets formed therein, the flutes being either straight or spiral and the pockets staggered.

Although the flutes and pockets assist to feed granular material to the nip of the flaking rolls, the formation of doubles and other undesired shapes still occurs.

SWS92.Y OF THEINVEfPTION

According to the present invention, apparatus for feeding granular material to the nip of a pair of flaking rolls, comprises a hopper, disposed above the rolls, a magazine disposed between the hopper and the nip of the rolls, the magazine defining a plurality of passageways for conveyinggranular material from the hopper to said nip, and means for controlling the flow of granular material through the passageways.

The passageways are preferably divided into groups, and the means for controlling the flow of granular material through the passageways may be operable to interrupt flow through the passageways of one group while permitting free flow through the passageways of another group, and vice versa.

Such control means may comprise providing the magazine with two rows of passageways, and with two rows of apertures, one each side of the magazine, which apertures provide access to the passageways0

Each aperture locates a movable finger; the fingers being operable in such a way that the fingers on one side of the magazine are moved into their associated passageways in order to interrupt the flow of granular material therethrough, while the fingers on the opposite side of the magazine arewithdraqn from their associated passageways, in order to permit free flow of granular material along the latter.

Alternatively, the magazine may be provided with a row of passageways for conveying granular material from the hopper to the nip, and a distribution control member perforated by a row of passageways operable to reciprocate along a path between the hopper and the magazine.

BRIEF DESCRIPTION OFTTIE DRATIN^GS

An embodiment of the invention will now be described by way of example only, with reference to the accompanying drawings, wherein:

Figure 1 is a fragmentary end view of apparatus for feeding granular material to a processing machine,

Figure 2 is a fragmentary plan view of the apparatus,

Figure 3 is a fragmentary front view of the apparatus,

Figures 4 and 5 are side views of parts of the flow control fingers assembly,

Figure 6 is a plan view of the flow control fingers assembly,

Figure 7 is a sectional view, taken on the lines VII - VII of Figure 6, and

Figure 8 is a view in perspective which illustrates a modification.

In the drawings, like reference numerals refer to like components.


595/2197

With reference first to Figures 1, 2 and5, apparatus l,for feeding granular material to a processing machine (not shown) is illustrated. The apparatus 1 is for feeding granular material to the nip 2 of a pair of flaking rolls 3 and comprises a feed hopper 4, disposed above the rolls 3, a magazine 5 disposed between the hopper 4 and the nip 2, the magazine 5 defining a plurality of internal passageways 6a, 6b for conveying granular material from the hopper 4 to the nip 2, and means 7 for controlling the flow of granular material through the passageways 6a, 6b.

The passageways 6a, 6b are disposed in two substantially parallelrolls, (Figure 2). The passageways

6a, 6b are juxtaposed, a passageway 6a being disposed between a pair of adjacent passageways 6b. The passageways 6a form one group of passageways. The passageways 6b form another group.

The passageways 6a, 6b extend from top to bottom through the magazine 5, in a divergent manner.

(See Figure 3). This arrangement ensures that granular material discharged from the magazine 5 is distributed over the full extent of the roll nip 2.

The passageways 6a, 6b are formed by grooves formed in opposite side surfaces of a plate 10, the grooves being covered by side plates 11, 12 secured to the side surfaces of the plate 10. At approximately one third depth of the magazine 5, (see Figure 3), oppositely-disposed slot-like apertures

21 are formed, to provide access to the otherwise closed passageways 6a, 6b. Only one set of apertures

21 is shown as Figure 3 is a view from one side only.

The apertures in the plate 11 locate resilient'fingers 13. The apertures in the plate 12 locate resilient fingers14.

Figure 2 shows the grooves defining the passageways 6a, 6b from above, as well as the fingers 13, 14 which are spaced to cooperate with the passageways. The passageways 6a, 6b diverge (Figure 3). In

Figure 2 the fingers 13, 14 are shown in dotted lines.

The fingers 13, 14 are mounted on laterally-spaced bars 15 and 16 respectively. (See Figure 2). As shown in Figures 4 to 6, the fingers 13, 14 curvedown towards each other. The ends of the bars 15 and

16 are interconnected by plates 17 which have grooved rollers 25 mounted on their outer sides. The grooved rollers 25 are supported for reciprocatory movement on linear bearings 26, which in turn are mounted by brackets 27 to the side frame of the apparatus 1.

As best shown in Figure 2, reciprocatory movement of the means 7, i.e. the assembly comprising fingers 13, 14, bars 15, 16 and plates 17 and rollers 25, is brought about by an actuating linkage 30 comprising rods 31 carrying bearings 32 which are located by journals 37 carried by the end plates 17.

The rods 31 also carry bearings 33 which are eccentrically mounted on a rotatable shaft 34 journalled in bearing blocks 35, 36.

The shaft 34 is driven by an electrically powered motor. (Not shown).

Operation of the feeding apparatus 1 takes place as follows :

The hopper 4 is filled with a supply of granular material in pellet form. The pellets enter the magazine

5 to pass, under the influence of gravity, down through the passageways 6a, 6b of the magazine to the nip 2 of the flaking rolls 3.Thie to the divergence of the passageways 6a, 6b towards the nip 2, the pellets leaving the passageways are distributed along the full length of the nip, thereby fully utilizing the output capacity of the rolls 3.

In order to control the rate at which the pellets reach the nip 2, with a view ro ensuring that no doubles occur, the control means 7 assembly is reciprocated whereby the fingers 13, 14 operate in turn to arrest the falling columns of pellets moving downwardly along the passageways 6a, 6b, and release pellets in passageways 6a so as to permit free flow therein as the reciprocatory assembly is moved in one direction, and then to release pellets in passageways 6b when the assembly is moved in the opposite direction.

The fingers 13, 14, being resilient, do not damage the pellets as they move in the slot-like apertures formed in the plates 11, 12, towards and away from thepassageways 6a, 6b.

596/2197

Figure 8 is an "exploded" view in perspective illustrating a modification, wherein apparatus la makes use of a magazine 5a, the upper end of which is closed by a plate 40 fixed to the upper end, the plate being perforated by a row of equi-spaced inlet apertures 41.

The apertures 41 comprise passageways for conveying granular material from the hopper 4 to the nip of the flaking rolls (not shown) disposed below the magazine 5a.

The apparatus la is provided with means 7a for controlling the flow of granular material through the apertures 41. The means 7a comprise a distribution control plate 42 perforated by a row of equi-spaced apertures 43 and actuator means 44 for causing the plate 42 to reciprocate along a substantially horizontal path, between the hopper 4 and magazineSa.

The top plate 40 fixed to the magazine 5 5 is perforated by ten apertures 41 and the movable distribution control plate 42 by five apertures 43. Apertures 41 and 43 are of substantially the same size. The pitch of apertures 43 differs from those of the apertures 41. In this example, the pitch of the apertures 43 is spaced at twice the pitch of the apertures 41. The arrangement is such that as the distribution control plate 42 is reciprocated, the granular material falling from the hopper 4 passes through all the apertures in the distribution control plate, but then only through alternate apertures 41 of the magazine 5a, in a shuttlelikemanner.Data supplied from the esp@cenet database - Worldwide

597/2197

125.

GB2216766 - 10/18/1989

METHOD AND MEANS FOR COOKING GRAIN


Inventor(s): WONG MAN-CXUEN (--)

Applicant(s): WONG MAN CXUEN (--)


IP Class: A23L1/182; A47J36/20

E Class: A23L1/10H2; A47J27/00; A47J36/20



Family: GB2216766

Abstract:


A cooking apparatus suitable for use in cooking grain 3 (e.g. rice) having a predetermined size in water, comprises a vessel 1 having a base 5 through which heat 2 is supplied to the interior of the vessel 1 and above which is supported in closely spaced apart proximity thereto on plate 4 supporting the grain 3 in use of the apparatus. The plate 4 has a large plurality of small perforations 8 extending substantially across it, the perforations 8 having a smaller diameter than the predetermined grain size.

A cloth 6 of food grade fibrous material is placed on top of the body of rice 3 in the saucepan. The rice is heated to a high temperature below boiling, then boiled for a few minutes, the heating discontinued, and the rice left to stand until water absorption is complete.Description:


METHOD ANDWEANS FOR COOKINGGRAIN

The present invention relates to the cooking of grain, in particular by cooking thereof in water so that a significant amount thereof is absorbed by the grain.

598/2197

With conventional methods of cooking grain in this way the amount of water that can be absorbed is more or less firmly limited with attempts to increase the bulk of the grain e.g. by extending the cooking time simply resulting in dissolution and/or general loss of texture in the grain.

It is an object of the present invention to avoid or minimise one or more of the above disadvantages.

The present invention provides acooking apparatus suitable in cooking grain having a predetermined size in water which apparatus comprises a vessel having a base through which heat is supplied to the interior of the vessel in use of the apparatus, above which base is supported in closely spaced apart proximity thereto a plate means extending across said base for supporting the grain in use of the apparatus, said plate means having a large plurality of small perforations extending substantially thereacross, said perforations having a smaller diameter than said predetermined grain size.

The present invention also provides a method of cooking grain comprising the steps of placing the grain in a body of water sufficient to completely immerse the grain and in excess of that which can be absorbed by said grain in the course of cooking thereof for an extended period of time, placing a sheet of food grade fibrous maternaln said body of water on top of said grain, heating said water for several minutes to a high temperature below boiling, then boiling for a few minutes, discontinuing heating, and then standing until water absorption by said grain is substantially complete.

With the method and apparatus of the present invention it has been found that the amount of water which is absorbed by the grain during cooking thereof by substantially conventional procedures is significantly increased thereby producing an increased bulk for a given weight of grain whilst at the same time preserving the integrity of the individual grains and maintaining an acceptable grain texture.

In general the grain should be cookedfor at least 10 minutes and preferably for from 10 to 12 minutes.

The amount of water to be used will depend on whetherany pre-treatment of the grain has been effected and the particular form of cooking process used e.g. whether it is one in which all the water is absorbed during cooking or one where a surplus is drained off at the end of the cooking time. In general though the amount of water used will be from 150 to 250% w/w of the amount of grain to be cooked, preferably about 200% w/w with all the water being absorbed during the cooking process.

Advantageously the grain is allowed to stand in the pot for at least 15 minutes, preferably from 20 to 25 minutes after removal from the heat and prior to serving.

Various types of grain may be cooked by means of the present invention including all those which are normally cooked in water and including for example rice, buckwheat and oats.

The present invention also provides a cooking aid for cooking grain in a saucepan or cooking pot of a predetermined diameter and comprising a disc of a food grade fibrous material having a diameter substantially equal to or slightly less than the internal diameter of said saucepan.

Various forms of fibrous material may be used including paper towelling material which may be of the relatively soft multi-ply absorbent type or the stronger perforated type, as well as fabric material especially open-weave type material such as is used in dish cloths.

Further preferred features of the invention will appear from the following example given by way of illustration only.

EZ SLE - COOKING OF RICE

A quantity of rice (450g.) is placed in a saucepan (ca. 20cm. diameter) with water (9OOmls) and some cooking oil (15mls). A disc of clean open-weave type fabric material such as may be used in a dish cloth and having a diameter equal to or slightly less than that of the saucepan is placed in the water on top of the rice. The water is placed initially on a moderately high heat,about 2/3 of maximum

Mark 4 on a conventional 1 to 6 scale for about 10 minutes and then brought to the boil on a high heat

(Mark 6) for about 2 minutes. The saucepan was then removed from the heat, and allowed to stand for some 20 to 25 minutes. The fabric disc is then removed, and the rice decanted into a dish and stirred with a fork.The grains werefound to be easily separate.

599/2197

An equivalent quantity of rice was also cooked using the same procedure but without the fabric disc.

The cooked rice obtained by each method was then weighed to show the amount of water absorbed in each case (obtained by deducting the original dry weight from the cooked weight).

Results

Cooking Method With Fabric Without Fabric

Final Cooked Weight: 1350glOlOg.

Initial Uncooked Weight 450g. 450g.

Amount of water absorbed 900g. 560g.

The above results show that a significantly greater amount of water absorbed using the method of the invention as compared with the known method thereby producing an increased bulk whilst maintaining a relatively firm grain texture and good grain integrity and allowing easy separation.

Various modifications may be made to the above-described process without departing from the scope of the present invention. Thus, for example, the cooking oil may be omitted and/or a small quantity of salt added, though the procedure described above is preferred as it tends to minimize protein loss from the grain and also helps to provide a sweeter taste in the cooked grain.

Further preferred features and advantages of the apparatus of the invention will appear from the following detailed description given by way of example of a preferred embodiment of an apparatus of the invention, illustrated with reference to the accompanying drawing in which:

Fig 1 is a vertical cross section through an embodiment of an apparatus of the invention.

Fig 1 shows a vessel in the form of a saucepan 1 disposed on a hot plate 2 for cooking of some rice grain 3 disposed in the saucepan 1. The apparatus comprises the saucepan 1,circular plate 4 on the base 5 of the saucepan 1 and a cloth of food grade fibrous material 6 placed on top of a body of the rice grain 3 in the saucepan. The saucepan 1 is also partly filled with an appropriate volume of water required for the amount of grain 3 being cooked in the pan 1.

In more detail the plate means 4 has a plurality of short legs 6 consisting downwards projections having a horizontal extent and disposition such as to support the plate above the pan base 5 in closely spaced proximity thereto. A large plurality of small bore diameter perforations 8 extend through the thickness of the plate 4 to allow circulation of hot water from the heated power base 5 upwardly through the grain 3 whilst supporting the grain 3 and preventing it from coming into direct contact with the base 5.

The size of the perforations number 8 may be varied depending on various factors such as the diameter of the grain but conveniently is from 0.1 to1.5mm preferably from o.2 to1.02mum.

It will be appreciated that various modifications may be made to the above from all constructions without departing from the scope of the present invention. Thus, for example, instead of having downward projections 6 there could be provided upwardly extending projections on the base of the pan on which the plate 4 could be rested.

The plate could be permanently secured to the pan base but is desirably removably disposed in the pan in order to facilitate cleaning. In this connection, a suitable handle means such as a knob 9 may be provided on the upper face 10 of the plate 4.Data supplied from the esp@cenet database - Worldwide

Claims:


CLAIMS

9. A method of cooking grain comprising the steps of placing the grain in a body of water sufficient to completely immerse the grain and in excess of that which can be absorbed by said grain in the course of cooking thereof for an extended periodtime, placing a sheetcf food grade fibrous material in said

600/2197

body of water on top of said grain, heating said water for several minutes to a high temperature below boiling, then boiling for a few minutes, discontinuing heating, and then standing until water absorption by said grain is substantially complete.

10. A method as claimed in claim 9 for cooking rice wherein the water is heated to a high temperature below boiling for from 8 to 12 minutes, boiled for from 1 to 3 minutes and stood for at least 15 minutes.

11. A method as claimed in claim 10 wherein the water is heated for 10 minutes, boiled for 2 minutes, and stood forfrom 20 to 25 minutes.

12. A method of cooking grain as claimed in any one of claims 9 to 11 wherein said grain is cooked on an apparatus according to claim 1.

13. A method of cooking grain substantially as described hereinbefore with particular reference to the accompanying drawings.

1. A cooking apparatus suitable for use in cooking grain having a predetermined size in water, which apparatus comprises a vessel having a base through which heat is supplied to the interior of the vessel in usecf the apparatus, above which base is supported in closely spaced apart proximity thereto a plate means extending across said base for supporting the grain in use of the apparatus, said plate means having a large plurality of small perforations extending substantially thereacross, said perforations having a smaller diameter than said predetermined grain size.

2. A cooking apparatus as claimed in claim 1 wherein said plate means is provided with downwardly projecting horizontally extending projection means constituting spacer means formed and arranged for supporting the plate above said base in closely spaced relation thereto.

3. A cooking apparatus as claimed in claim 2 wherein said plate means is provided with a plurality of horizontally spaced apart downwardly extending projections.

4. A cooking apparatus as claimed in any one of claims 1 to 3 wherein said perforations have a diameter of from 0.1 to 1.5mm.

5. A cooking apparatus as claimed in claim 4 wherein said perforations have a diameter of from 0.2 to l.Omm.

6. A cooking apparatus as claimed in any one of claims 1 to 5 wherein said plate means is detachably disposed in said vessel and has an- upwardly extending handle means for use in lifting said plate means out of the vessel.

7. A cooking apparatus as claimed in any one of claims 1 to 6 wherein is provided a sheet of food grade fibrous material having an extent sufficient to extend across the vessel substantially to cover a body of grain disposed in said vessel in use of the apparatus.

8. A cooking apparatus substantially as described hereinbefore with particular reference to the accompanying drawings.

Amendments to the claims have been filed as follows 1. A method of cooking grain comprising the steps of placing the grain in a body of water sufficient to completely immerse the grain and in excess of that which can be absorbed by said grain in the course of cooking thereof for an extended period of time, placing a sheet of food grade fibrous material in said body of water on top of said grain, heating said water for several minutes to a high temperature below boiling, then boiling for a few minutes, discontinuing heating, and then standing until water absorption by said grain is substantially complete.

2. A method as claimed in claim 1 for cooking rice wherein the water is heated to a high temperature below boiling for from 8 to 12 minutes, boiled for from 1 to 3 minutes and stood for at least 15 minutes.

601/2197

3. A method as claimed in claim 2 wherein the water is heated for 10 minutes, boiled for 2 minutes, and allowed to stand from 20 to 25 minutes.

4. A method of cooking grain as claimed in any one of claims 1 to 3 wherein said grain is cooked on an apparatus comprising a vessel having a base through which heat is supplied to the interior of the vessel in use of the apparatus, above which base is supported in closely spaced apart proximity thereto a plate means extending across said base for supporting the grain in use of the apparatus, said plate means having a large plurality of small perforations extending substantially thereacross.

5. A method of cooking grain substantially as described hereinbefore with particular reference to the accompanying drawings.Data supplied from the esp@cenet database - Worldwide

602/2197

126.

GB2228173 - 8/22/1990

METHOD FOR THE MANUFACTURE OF SNACK FOODSTUFFS


Inventor(s): ITO HIDEAKI (--); ITO HARUO (--)

Applicant(s): YUGEN KAISHA ITO SEISEN KOJO (JP); ITO SEISENBU HONTEN KK (JP)


IP Class: A23L1/10; A23L1/217

E Class: A23L1/164E; A23L1/217B; A23L1/164



Family: GB2228173

Abstract:


A method for the manufacture of snack foodstuffs containing rice, barley, wheat, millet or potato as the main ingredient, together with other auxiliary ingredients and additives comprises adding water to the main ingredients, auxiliary ingredients and additives, and agitating the mixture while injecting high pressure steam. The material is then passed through rollers so as to form a sheet, dried and cut or punched into the desired shape. If necessary, the resultant material can then be subjected to further processing to form the final product.Description:


Method for the Manufacture of Snack Foodstuffs

This invention is related to the automatic mass production method of snack foodstuffs which are rather light and nice smelling, eaten betweenmeals -or like relish for liquors, and helps promote appetite. It can produce snacks in a short period of time without wasting time, and the product can be preserved for a long period of time without softening or causing decay easily.

In other words, in this invention, the starch of rice, barley, wheat, millet, potato, etc. is used as the main ingredient~, and to the auxiliary ingredients such as pulverized foodstuff containing protein or its powder, starch, beans, sesame, and fishery products, additives such as colorant, blowing agent, spices, flavoring are added, and to this semi-processed material, water or hot water is added, then while ejecting high pressure steam. agitation is done by changing the number of revolution (rpm) in accordance with the formation degree of gluten in the main ingredient, and cooking, kneading, and conversion into alpha starch is advanced to obtain a rice cake like pasty substance.

This is then put through the rolls and pressed into sheets and pre-drying is done. Subsequently, the sheets are cut or punched out to form adequate shapes for respective applications, and transferred to the main dryer, or the thin rice cake like substance pressed by the rolls are dried, then crushed to make granular forms. In this way, the invention consists of the process to make the semi-processed material, and the process to manufacture the snack by roasting, steaming, frying, etc.

(Brief Description of Drawings)

In explaining the details of this invention, first of all, if a brief explanation of the attached drawings is made, it will be as follows:

603/2197

Fig. 1 is a partial cross section front view which shows the first half of the No. 1 process for manufacturing the kneaded stock for rice cake cubes and millet-and-rice cake from the raw materials.

The main ingredients, auxiliary ingredients, additives, hot water, etc. are mixed, and steam-kneaded in the steam kneader. Subsequently, the kneaded stock is passed through the compression rolls and made into sheets, then placed on the conveyor, and while it is undergoing pre-drying it is rolled up.

Fig. 2 shows a partial cross section front view of the latter part of No. 1 process where subsequent to the process shown in Fig. 1, the semi-processed material for the diced rice cake that underwent predrying is cut, punched out, and sent to the dryer where they are dried by hot air, then packed into bags.

Fig. 3 is a partial cross section front view showing the latter half of the No. 1 process as a separate process in which the materials dried by hot air in Fig. 2 are crushed and carefully sorted out to make raw semi-processed material for snack foodstuff and packing them into bags as raw materials for snack food-stuff.

Fig. 4 is a partial cross section front view showing as secondary process in which the foodstuff stock manufactured by the primary process is fried in oil, and packed in bags as diced rice cake.

Fig. 5 is a partial cross section front view of the process showing a separate No. 2 process from that shown in

Fig. 4, and after secondary drying, flavor is added by the flavor adding machine, then after it is dried by the finishing dryer, it is packed in bags.

Fig. 6 is a process in which glutinous rice is put into rice cleaning machine, and after immersing the rice in water washing immersion tank, it is put into a pulverizer, then steam kneaded in a steam kneader, and after placing it in a solidifying vessel, it is put into a refrigerator.

Subsequently, it is shaved by shaving machine and cut by a cutter.

Fig. 7 shows a process subsequent toFia. 6 where the cut materials are dried in a heat dryer, fried in an automatic frying machine, put into the centrifuge to remove excess oil, then put into a cooling unit to remove heat and make fried diced rice cakes.

Fig. 8 shows a process in which unpolished unglutinous rice is put into a rice polishing machine, then after immersion in the water washing immersion tank, it is made into flour by the flour grinder.

Subsequently, the flour is put into a steam kneader, then after passing through the cooling vessel, it is kneaded by the kneader and made into strips by the compression rolls.

Next, this is cut, shaped, and dried in the No. 1 dryer.

Subsequently, the semi-processed material is put into a maturing box and made into a matured semiprocessed material by letting it sit. In this way,-it shows the process in which the semi-processed material.

In Fig. 9, the manufacturing method in which the semiprocessed material in the process shown in Fig.

8 is dried again in the dryer, fried in oil by the automatic drying machine, then removed of excess oil by centrifuge, flavored in the flavoring machine, and sold, are shown.

(Detailed Description of the Invention)

An actual-execution example of this invention will be explained by diagram.

As shown in Fig. 1, charge25 Kg of Wheat (.1), 2X 5 Kg of Starch Powder (2), 200 g of Salt (3), 250 g of Blowing

Agent (4), 100 g of Flavoring (5), and 15Z of Hot Water into the Steam Kneader (6).

Inject high pressure steam (7) of 3.5X 4 Kg/cm2 into the Steam Kneader (6) for 3.5X 4 minutes, and conduct agitation by turning the agitator blade at 180X 300 rpm.

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In this way, aim at making alpha starch.

Subsequently, pass through rolls (8), and roll to the specified thickness and width.

Put the immature semi-processed material that has been rolled up by winder 10 via the chain conveyor

(9) on the pre-drying shelf (11) for 10 to 12 hours, and make the semi-processed material mature by letting it sit.

Next, as shown in Fig. 2, cut the semi-processed material lengthwise and width-wise with a cutter

C12) or punch out with press type punching machine(.13), then place it on the belt (15) at the side of the hot air dryer (14) which is heated by heavy oil heat source or steam heat source, and conduct primary drying at a temperature of 60X 800C for 4X 6 hours.

Subsequently, the hardened semi-processedmaterial is put into an assorting machine (17) and assorted, and packed in bags (18) as semi-processed material.

In addition, as shown in Fig. 3, there are cases in which the semi-processed material dried by primary drying is put into a pulverizer (19) and crushed, then assorted by the assorting machine (20), and made into raw materials (21) for snack foodstuffs.

Furthermore, in case colored semi-processed material, sesame, laver, kelp, shrimp, small fishes, animal proteins, etc. are mixed into the aforementioned diced cake semiprocessed material, these substances are incorporated by stopping the steam kneading in the previous process where wheat (1), starch (2), salt (3), blowing agent (4), flavorings (5), and warm water are charged to the steam kneader

(6), then after charging the aforementioned colored semi-processed material, sesame, laver, etc., the steam kneading is resumed again. Next, in the secondary process, as shown in Fig. 4, the snack foodstuff semi-processed material is made in the secondary dryer (22) at a temperature of 60X 800C for 8X 12 hours, then fried in oil by the automatic frying machine (23) at a temperature of 180X

2500C.

Subsequently, the excess oil is removed by the centrifuge (24) and- the diced rice cake is packed in bags (18) while weighing with an automatic scale (25), or as shown in Fig. 5, after drying in a secondary dryer (22) and roasting in a roaster (26), it is made to pass through flavoring machine (27), and after passing it through the finishing dryer (28), it is weighed by the weighing scale (25) and packed in bags (18).

As for Execution Example No. 2, as shown in Fig. 6, the glutinous rice (29) is put into a rice cleaning machine (30) and the seed skin is removed. Next, it is immersed in water cleaning immersion tank (31), and cleaned as well as having water soak into it. After drainage, put the rice into the pulverizer (19) and pulverize it.

To 110 Kg of this pulverized rice, add 900 g of salt (3), some flavoring (5), and 40% of warm water, then charge them to the steam kneader (6).

Inject high pressure steam (7) of 0.5 Kg/cm2 to the steam kneader (6) for 12X 13 minutes, then agitate them by revolving the steam kneader blades at about 50X 75 rpm, and change the starch into alpha starch.

After kneading, extrude the semi-processed material in a rod shape, and put it into a doughnut shaped solidifying vessel (32) and store it in the refrigerator (33) at a temperature of 2X 5OC for 2X 3 days, and harden the semi-processed material.

Subsequently, remove the hardened semi-processed material from the refrigerator (33) and shave the surface with a rice cake shaver (34), then further shave the surface or cut the semi-processed material into the desired shapes with a cutter (12). Dry the semi-processed material that has been cut and made into desired shapes in a dryer (14) until the moisture content becomes 18X 25% (Fig. 7).

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Fry this semi-processed material in a frying machine (23) at2000C, remove the excess oil with a centrifuge (24), lower the temperature with a cooling unit (35), then after drying, pack them into bags.

As shown in Fig. 8, in case of Execution Example

No. 3, put unpolished non-glutinous rice (36) into the rice polishing machine (30), and remove the seed skin.

Put the rice into water washing immersion tank (31), and after draining it, put it into a flour mill (37), then make it into a powdered form.

Next, put 120 Kg of rice powder, 900 g of salt (3), some flavoring (5), and 40% of warm water into a pressurized steam kneader (6) for 3.5X 4 minutes and simultaneously agitate it for 12X 13 minutes by revolving the steamed kneader blades at about 50X 75 rpm, and change the starch into alpha starch, then later pass it through a cooling tank (39). After lowering the temperature to 60X 65 C, extrude it with an extruder (38), and make it into strips by using rolis(40)and make it into the desired shape and size with punchers.

The semi-processed material which has been made into the desired shapes shall be passed through the

No. 1 Dryer (14), and dried until the moisture becomes 18X 25%.

The dried semi-processed material shall sit for 15~ 24 hours at room temperature in a maturing box

(41).

As shown in Fig. 9, dry in No. 2Dryer (22) until the moisture content becomes 15%.

Next fry this semi-processed material in the frying machine (23), and remove the excess oil in a centrifuge (24), add flavor in a flavor adding machine (27), and pack them after cooling.

Although no drawings are attached, as Execution

Example No. 4, in place of wheat, powder of corn, and add powder of other grains, vegetable powder, add powder of seeds, either all or partial, at the ratio of 5X 20%, then mix with water and baking powder, and after making a rice cake like viscous substance by steam heating and kneading in the steam kneader, pass through rolls and make thin sheets, and after drying, crush into pieces about0.5cm2, and make this the semi-processed material. After drying and roasting this make into flakes.

As regards to Execution Example No. 5, to 100 parts of wheat flour add 50X 150 parts of potato starch, some baking powder, flavoring, water or warm water, conduct cooking (digestion) in steam kneader, then after kneading, make it into a pasty rice cake like substance. After maturation, cut into adequate size pieces, then dry them, and make into semi-processed material.

Later by roasting this in roasting machine, frying it in oil, or after baking it, add flavor by the flavoring machine. In this way, diced rice cakes and Japanese crackers having flavor and smell like potato chips can be produced.

In Execution Example No. 6, to 25 Kgs of wheat flour, add about 50% of steamed potatoes with the skin on, then add some flavorings and blowing agents and 700 cc of hot water having a temperature of

800C. Agitate this mixture inside of the steam kneader while injecting steam at about 0.5 atm. pressure, and cook for 5 minutes.

Roll to a thickness of 3X 4 mm with rolls, and after cooling by blowing air, roll onto a pipe, and let is sit for about one day and one night. Subsequently, cut it into thin pieces, dry further until the moisture content is 15X 17%, and use this as a semi-processed material.

Next, dry this semi-processed material at a temperature of about 600C for 4X 6 hours, and fry it in oil at about200 C. This will result in diced potato crackers which have smell and taste like a potato.

As Execution Example No. 7, to 120X 180 parts of wheat flour, add 100 parts of"okara" (bean curd refuse) immersed in weak alkaline solution adjusted to about pH 7.5X 8.5, 30X 70 parts of starch,

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12N 28 parts of water, and some flavoring and blowing agents, then put them into steam kneader and digest (cook) by kneading and make a pastry rice cake like substance.

Subsequently make thin 1X 3 mm/mm sheets out of them by passing them through rolls.

After cooling and letting it mature, cut to the specified size and shape and make semi-processed material for diced rice cakes by drying until the moisture is 13X 20%.

Pre-heat this semi-processed material, and either fry them in oil or roast them. Subsequently, add flavor, and the diced rice cake is completed.

(Effect of the Invention)

Since this invention follows the above processes, the main ingredients, auxiliary ingredients and the additives are dispersed uniformly. In addition, since the starch is converted into alpha starch, and the drying is sufficient, it can be preserved for a long period of time as foodstuffs without becoming soft or decaying.

Furthermore, they can be mass produced with comparatively small labor. and light, delicious, crispy snack foodstuffs can be supplied.Data supplied from the esp@cenet database - Worldwide

Claims:


CLAIMS

1. Manufacturing method of snack foodstuff semiprocessed material for granular foodstuffs containing the starch of rice, barley, wheat, millet, potato, etc. as the main ingredient, and granular or powdered foods containing proteins, starches, beans, sesame, small fishes and shellfishes as the auxiliary ingredients, in addition to such additives as food colorings, blowing agents, spices, flavorings, etc., said foodstuffs being made by adding water or hot water thereto, steaming and kneading them by injecting high-pressure steam while changing the revolutional frequency (rpm) in accordance with the formulation degree of gluten in the main ingredient, converting the starch into alpha starch and changing the material into a rice cake, then passing it through rolls to make it into sheets, performing their pre-drying, then cutting them or punching them into size and shapes that match the application purpose, and assorting them after main drying.

2. The manufacturing method of snack foodstuffs in which

after the main drying in Claim 1, the semi-processed

material is further crushed and assorted.

3. Method of manufacturing fried foodstuffs, cracker

like foodstuffs by frying in oil, roasting, toasting,

coloring, etc. the foodstuff semi-processed material manufactured in accordance with Claim 1.

4. Manufacturing method of semi-processed material of diced rice cake by adding water or hot water to the main

ingredients, auxiliary ingredients, and additives shown in

Claim 1, and agitating them while injecting high pressure

steam, then charging colored granular rice and millet cake

stock manufactured by the method described in Claim 2

then continuing steam kneading again, in continuation of method described in Claim 1.

5. Manufacturing method of snack foodstuff semi-processed material for diced rice cake like snacks by using wheat

flour as the main ingredient, and adding starch within20t,

and some salt, blowing agent, flavoring, and warm water,

then charging them to the steam kneader, and while injecting high pressure steam, conduct agitation by revolving the blades of the kneader at 180X 300 rpm, subsequently, pass through rolls so that the specified thickness and width can be obtained, then roll up by winding equipment via the chain

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conveyor, next, dry and let it mature, subsequently, cut or punch out to suitable size and shape, and dry by hot air dryer.

6. Manufacturing method of snack foodstuff semi-processed material in which glutinous rice which has been polished and crushed is put into the steam kneader together with some salt, flavoring and warm water, and while injecting high pressure steam, is agitated by revolving the blades at 50X 75 rpm, and extruded from an extruder which converts the starch into alpha starch which resembles a pasty rice cake, which is put into a solidifying vessel, and left sitting in the refrigerator for a few days, after cooling and solidifying the semi-processed material in the refrigerator for a few days, take it out, arrange the shape, perform cutting, then let it dry so that it will become a semiprocessed material with a moisture content of about 20%.

7. Manufacturing method of snack foodstuff semiprocessed material in which non-glutinous rice is made into a powder and used as the main ingredient, and put into the steam kneader together with some salt, flavoring, and warm water, and while injecting high pressure steam, the agitation is done by revolving the blades at 50X 75 rpm, after passing it through the cooling vessel, extrude it out and adjust the shape and size by punching out the pieces, then dry them in a dryer, and let it mature in a maturing box, and make the moisture content about 15%.

8. Snack foodstuff manufacturing method in which the powder of other grains, vegetable powder, and powder of seeds either all or partial, are added to corn powder at a ratio of 5X 20%, and mixed together with some baking powder and water, then made into a pasty rice cake like substance by steam heating and kneading in the steam kneader subsequently it is made into thin sheets by the rolls, and after drying, crushed and made into semi-processed material, after the semi-processed material is dried, it is roasted and made into flakes.

9. Manufacturing method of snack foodstuff in which steamed potatoes with skin is added to wheat flour at a ratio of about 50% together with some flavoring, blowing agent, and hot water, then steam heated and kneaded in the steam kneader1 subsequently, the semi-processed material is made into sheets by the rolls, then dried by hot air and left to mature, after it is dried even more, and made into semi-processed material, it is fried in oil at high temperature.

10. Manufacturing method of snack foodstuff in which dried potato powder is mixed with wheat flour at the ratio of 50X 150% together with some baking powder, flavoring, water or hot water, then put into a steam kneader where cooking and kneading are done to make a pasty rice cake like material, subsequently, it is made into sheets and left to mature, after cutting it into suitable sizes and shapes, it is dried to form semi-processed material.

11. Manufacturing method of snack foodstuff in which wheat flour 120X 180%, starch 30~ 70%, water 12~ 28% and some flavoring, and blowing agent are added to"Okara", Bean curd refuse, which has been immersed in alkaline solution for several hours, and then put into the steam kneader where they are mixed and cooked, and made into a pasty rice cake like material, subsequently, this is made into sheets, and after cooling and letting it mature, it is cut into specified shapes and sizes, then dried to a moisture content of 12X 13%, and made into semi-processed material.Data supplied from the esp@cenet database - Worldwide

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127.

GB2239778 - 7/17/1991

PROCESS FOR PREPARATION OF FROZEN BAKED RICE


Inventor(s): CASTELLAR MANUEL VELARTE (--)

Applicant(s): CASTELLAR MANUEL VELARTE (--)


IP Class: A23L1/182; A23L1/48

E Class: A23L1/182; A23B9/10; A23B9/12


Priority Number: ES19900000023 (19900104)

Family: GB2239778

Equivalent: SU1837797; JP4152852; FR2656503; ES2019521; DE4100149; IT1244358

Abstract:


A composition consisting of enough rice and water, spiced with sautéed oil, tomato, pork, bacon, lunch meats, garlic, saffron, salt, sliced potatoes, cut-up tomatoes and other optional ingredients is seasoned in a flat bottom low crockery or aluminium pan. It is baked in an industrial wood oven for approximately 90 minutes at a temperature between 200 DEG and 300 DEG C then immediately after baking it is subjected to cooling at room temperature for 20 minutes, followed by packaging for example in retractile plastic material and freezing. The process is useful because it offers the consumer a finished baked dish ready for consumption in a moment without the need to cook it.Description:


2 -7 -7 E3 1 Z r 19 I- Process for the preparation of frozen baked rice

The present invention refers to a process for preparation of a frozen baked dish, consisting of rice, with the classic or typical components of so-called baked rice, with the variations to the taste of each geographic area, which is offered to the public in optimal conditions for consumption. It only needs to be heated before consumption.

The baked dish that is presented is known as "baked rice" which is seasoned in a circular, flat bottom. low crockery pan.

Its composition consists of enough rice and water, flavoured with saut?ed oil, tomato, pork, bacon, lunch meats cut in portions, garlic, saffron, sliced potatoes, cut up tomatoes and other verv varied inaredients. on occasions the water-is replaced b\? broth from stew and a certaln amount of chick peas form part- of the ingredients o the baked rice.

Thi,s type of rice is widely consumed especially on the - and its composition is very rich and

Mediterranean coast varied.

It is typical that this rice is baked in an industrial wood oven so that the taste is most suitable.

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It is also presently baked in home gas or electric ovens.

The invention proposes a process for offering the public the baked dish so-called "baked rice" seasoned in a circular, flat bottom, low crockery pan, with the classic composition, according to the geographic areas, baked in a wood oven. The diameter of these pans varies depending on the capacity or portions of rice.

The baking usually lasts around an hour and a half at a temperature between 200 and 300'Cdepending on the 2 i 5 2 C. dimensions of the crockery pan.

Immediately after baking it is subjected to cooling at room temperature for about twenty minutes so that the rice settles and immediately it is packaged in retractile plastic material and ultrafrozen. It is kept at a temperature between -10c and -20 a C.until it is to be consumed, for a period of time less than

12-15 days.

For consumption the retractile plastic package is removed and the top part is covered with aluminum foil.

1 C, The pan is put in a microwave oven or gas or electric oven in order to defrost it for approximately 10-15 minutes depending on the oven used.

Once it has defrosted, the aluminum foil is removed and the pan is put in a gas or electric oven for approximately 5 minutes, after which it is ready to be served.

The final result, according to the tests carried out is a baked dish with all the properties of a recently cooked one, qiven, that no preservatives nor additives have been added to its comiDosition.

A possible alternative to the use of a crockery pan is a more or 'Less thin aluminum tray with enough resistance for transport which would reduce the weight when the product is to be transported a long distance.

0 i 1Data supplied from the esp@cenet database - Worldwide

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128.

GB2280348 - 2/1/1995

PROCESSING LOW VALUE ANIMAL PRODUCTS


Inventor(s): NOBLE PETER (--)

Applicant(s): HILBOROUGH MILL FOODS LTD (GB); PPL MARKETING LTD (GB)


IP Class: A23K1/10; A23L1/312

E Class: A23K1/00B2; A23L1/00P14B2; A23K1/10C; A23N17/00B; A23P1/14B2



Family: GB2280348

Abstract:


A process for converting fresh, low value animal materials into feed products comprises mixing predetermined proportions of fresh, low value animal materials and pumping them through a size reducing means and mixing them in a screw type extruder with starch and protein bearing ingredients such as cereals, cereal substitutes, rice, gluten and root crops to produce a cooked extrudate and then drying the extruded material.Description:



The present invention relates to a process for converting into a feed product, low value materials remaining in an animal processing plant after most of the flesh has been removed from the animal carcasses. Such materials typically include bones with meat attached and other low value products such as offal.

Traditionally this material is sold to renderers who produce from such material meat and bone meal and tallow for use in the animal feeds and cosmetic industries. Due to a restricted demand for such products, however, it is becoming increasingly difficult for meat processing plants to sell their low value material and indeed, in many cases, it is necessary for the processing plant to pay in order to dispose of it.

Off-site processing of this material is also becoming less attractive as the transport of such material is controlled in the UK under the Animal By-Products Order 1992 and equivalent legislation in other EC countries to implement Council Directive 90/667/EEC. The cost of such transport is high since60-80t of the material is water which must be driven off during the rendering process.

In practice this cost is borne by the meat processing plant.

There exists a substantial and growing technical problem for the meat industry to sell this material at a reasonable price or without incurring a loss.

Accordingly, in the present invention a process is provided which enables the low value material to be processed at the meat processing plant thus eliminating the need for transportation and its associated

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cost. The process is capable of using a wet feedstock of the low value material and added ingredients and utilises all of the low value material produced, thereby eliminating storage problems prior to collection. The only unusable effluent from the process is water in the form of steam which can be readily recondensed and treated.

Depending on the added ingredients, the product can be adapted to numerous purposes, for example, sale as feed for all livestock, including pets, cattle, pigs, poultry or fish. If the processing plant is handling a single species of animal, there is the added advantage of being able to channel the resultant feedstuff exclusively into feeding different species. This is not the case for rendered meat and bone meal which contains waste material from many species. This process can also be used for production of snacks containing meat and cereals for human consumption, although it should be appreciated that a higher value meat component would be used for this application.

There are in existence various processes for producing extruded and expanded food items from various ingredients. As described in more detail herein it has been found advantageous to use a twin screw extruder.

Such extruders are normally employed with a"dry" feedstock but an example of a prior art process for fish and vegetable waste using such a twin screw extruder is described in EP-A-0 169 106 (Clextral).

The Clextral process teaches that moisture may be vented off half way along the extruder barrel (degassing) in order to reduce the water content of this product. Nevertheless the resulting product has a water content between15-30t at which the product would suffer from the technical problem of not being shelf-stable. The use of the extruder to dry the product as suggested in Clextral is difficult to control in terms of product expansion and uniformity.

Clextral also suggests the use of relatively "soft" waste materials and does not therefore teach any essential preparation.

The present inventors have, however, appreciated that the use of an extruder as a means to significantly reduce water content as taught by Clextral is unsuitable for fresh wet animal by-products and the invention is therefore characterised in that the water content of the feedstock is controlled and the resulting expanded product is subsequently dried as a separate step in the process.

The present process therefore has the significant technical advantage that the moisture content of the material passing through the extruder is accurately controlled by further addition of water to the extruder barrel thus producing a consistent, well formed product.

Although some moisture is removed as steam as the product expands, further drying must be employed to reduce the water content to levels which ensure relatively long term shelf stability.

One of the most attractive end products is pet food.

Therefore the remainder of this description will be directed at a process for the manufacture of pet food, although it should be appreciated that the end product may be suitable for alternative applications. Where the process is carried out alongside a processing plant producing meat for human consumption, there is an added advantage that the potential exists to run recipe combinations which ensure that all of the ingredients will have been passed fit for human consumption. This, together with traceability of the meat back to the origin of the animals, provides a complete account of production methods employed and an appealing quality guarantee to consumers.

An embodiment of the process will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which:

Figure 1 is a flowchart of the material preparation

stages of the process; and

Figure 2 is a flowchart of the extrusion and packing

stages of the process.

One of the advantages of the process to be described is that it is intended to be operated in or alongside a meatjfish/poultry processing plant taking its input directly from the low value material generated

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when animals are processed. Preferably these materials should not be stored prior to use, as immediate processing ensures freshness and avoids refrigeration costs. However the process can, if necessary, be used on "imported" materials. The remainder of the description assumes that the process is being carried out in or alongside a meat processing plant.

The ingredients for the process fall into two categories, those which are low value materials from meat production carried out in the meat processing plant, and the added ingredients which include a starch and protein providing component, such as cereals, cereal substitutes, rice, gluten and oil seeds, as well as other optional ingredients added to provide flavour, texture, consistency, colour and nutritional properties.

The process consists of pre-treatment stages illustrated in Figure 1 followed by the cooking and extrusion stage illustrated in Figure 2. In the pre-treatment stages transport of the ingredients and mixtures between the various stages of the process is enclosed and may be carried out using pumps such as those manufactured by

SIMO Industries A/S of Denmark (SIMO), but it will appreciated that alternative means may be used as appropriate. The SIMO pump is essentially a double chambered positive pump which also reduces the size of the material being pumped. This acts as the first stage of a size reduction process essential to the operation.

The low value material ingredients are fed to the process from the meat processing plant. Certain parts of the process are more appropriately carried out in the meat processing plant and others in a separate plant. The division between equipment located in the meat plant and the equipment which should be located in a separate plant is illustrated in Figure 1 by the line 2.

The low value animal material ingredients of the process are various offals and bone with meat attached. These two types of low value material are prepared separately and then combined into a meat paste which is mixed with added dry ingredients and liquid in an extruder. Other special ingredients may be added at other stages during the process.

The offal is cut using a cutter 4 which takes its input directly from the meat plant. This machine will

"slash" the material and facilitate cleaning in a subsequent stage. A suitable cutter is model TV90 manufactured by

Loma Engineering Limited, although any machine capable of cutting the offal into thin strips would be suitable. The temperature of the offal is in excess of 300C which makes it susceptible to rapid deterioration. The process allows prompt treatment of the offal before decay can begin and unpleasant smells develop. This gives an obvious environmental advantage over traditional methods of storing low value material until there is sufficient to be sent to a rendering plant.

The output of offal cutter 4 is delivered to an offal cleaning machine 6. A suitable machine is model

570P manufactured by La Parmentiere of France, although any machine capable of passing a flow of water over the offal and tumbling it in order to clean it would be suitable.

The material entrained in the waste water is discharged into a separate output 7 where it is collected.

The cleaned offal is then fed directly to a drainer 8 to remove excess water which is directed to a separate output 9 and collected. A rotating drainer manufactured by La Parmentiere of France is suitable, although any machine capable of centrifugally (or otherwise) separating water from the offal would also be suitable.

It would also be possible to wash the offal by hand before processing. Ideally the water content of the washed offal will be in the range70-90k which includes both the intrinsic water content of the offal and the residual water remaining after the washing process. A press (not shown) may be used to reduce the water content if desired.

The output of the rotating drainer 8 discharges to a weighing system 10a. The weighing system can be a simple"eurobinn which is filled, weighed and tipped into the next stage of the process, or a more complex system employing weighing silos which can automatically discharge predetermined amounts of the ingredients into the process.

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The other main low value material used is bone with meat attached which can be derived either or both from the output of a cutting/boning facility at the meat processing plant or as the residue from a mechanically recovered meat process (MRM) used to recover meat adhering to the bones. Where joints have been boned in a boning room they will typically have been chilled and therefore from this source will be cold, typically at 4100C. Bone from MRM will be at a higher temperature in the range1500 to

250C and, as in the case of the offal, can be processed promptly avoiding the need to store and refrigerate. Where boning or MRM operations are not continuous, it is possible to store the bone in a silo 16 to be used in the process during periods where no waste bone is being generated.The bone from all sources is fed via a SIMO pump 14 to a holding silo 16 and from silo 16 is discharged under gravity to the weighing system 10b.

Where alternative sources of bone are used it will be appreciated that several pumps may be needed to supply system 10b. The proportion of the bone, meat, offal and other ingredients in the output mix from the weighing system 10 is determined by the nutritional requirements of the resulting product.

Where, as will normally be the case, the plant is designed to work in conjunction with a particular meat processing plant, the recipe may be tailored to take into account the proportion of bone, meat and offal that is available from processing in that plant. It is also possible to provide a control means for the operator to select one of several different preset proportions. Each preset value being for use with a specific workload of the meat processing plant.Such control means would also control a downstream metering pump 20 and feeder 22 (to be described in greater detail later) which control the relative amounts of the animal derived ingredients and the starch and protein ingredient for extrusion. A suitable control means could include a microprocessor connected to a key pad for operator input and provided with a display to confirm the input and provide operator instructions. The control means would then generate the necessary electrical signals to operate the metering devices by means of a wiring loom connected to suitable transducers.

Where the recipe of the product to be produced requires the addition of wet ingredients such as egg, tripe, vegetables or other types of low value material from the meat processing plant or elsewhere, a further silo 18 is provided. Addition of these extra ingredients at this point of the process allows them to be minced and blended accurately. For other types of ingredients addition direct to the extruder or, for dry ingredients, from a separate silo 25 coupled to the feeder 22, is preferred (to be described in greater detail later).

The next stages of the process reduce the low value ingredients to a finely minced mixture in which the particles of meat and bone are less than a predetermined maximum size. The particle size is important regarding both extrusion efficiency and appearance of the finished product. The maximum size may be in the range 0.3mm to 3mm and preferably the particles have a size range of 0.3mm to 0.5mm.

The size reduction is achieved in three stages in the process being described, although the reader will appreciate that depending on the maximum particle size to be achieved, more or less stages may be necessary or desirable.

The material from weighing system 10a is discharged into a mincer 26 which converts the offal into a free flowing slurry. A suitable mincer is Mincemaster 30 manufactured by K.S., although any machine capable of mincing offal to 6mm pieces would be suitable. The output of mincer 26 is discharged into a mixer/blender 28 which acts to completely homogenise the ingredients prior to pumping to the final size reduction stage. The output from weighing system 10b is discharged into a grinder 24 which reduces the particle size to roughly 6mm. A suitable grinder is model Weiler 1109B manufactured by

Weiler, although any machine capable of grinding bone to 6mm would be suitable. The output of grinder 24 also discharges to the mixer/blender 28. A suitable mixer is model RS1300 manufactured by

Risco Brevetti, although any mixer/blender capable of providing a homogeneous mixture of ground bone and offal would be suitable. The output of the mixer/blender 28 is discharged into a pump 30 which transfers the blended material for further size reduction. A suitable pump is model 5070VI manufactured by Altec Waukesha, although any pump capable of pumping a meat and bone mixture to the next stage of the process would be suitable.

If for any reason the plant is to be closed down, provision is made to connect an alternative pipe 32 to the output of pump 30 to enable the ingredients to be temporarily stored or disposed of if necessary.

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The output of pump 30 discharges into a micro-cutter 34.

A suitable micro-cutter is modelMCH10 100A manufactured by Stephan. The micro-cutter 34 is set to cut the input mixture down to the required maximum particle size. That material whichpasses from the micro-cutter 34 is the output A of the mincing means and is fed into a live silo 36 for further processing. The live silo provides a buffer in the system to facilitate continuous production despite variations in the input supply. However it is not intended that the live silo 36 should be used to store material for any prolonged period and typically the time from entering to leaving the live silo will be maintained at a maximum of 60 minutes. It should be appreciated that an alternative system capable of mincing or size reduction and blending into an homogeneous "meat paste" would be suitable.

A metering pump 20 is used to draw the mix from the silo 36 at a predetermined rate. A suitable pump is model V134 manufactured by Altec Waukesha, althougn any positive pump capable of accurately pumping the meat paste would be suitable. The output of the metering pump 20 is fed to an input of an extruder 38. An alternative waste pipe 39 may be connected to pump 20 in order to divert the mix to disposal means in order to empty the plant or if the extruder cannot accept input.

The input of the extruder 38 is also fed with the input B of feed means for supplying the added ingredients, typically a blend of starch containing cereal, protein containing oil seeds or gluten and other special or minor ingredients such as vitamins, trace elements and salt.

The extrusion process needs a certain amount of water in a barrel of the extruder for cooking to proceed in a controlled fashion and for the final product to be well formed after expansion at the extruder head. The present process therefore provides for control of input moisture content such as to achieve a moisture content of up to 40% coming from the extruder. This figure represents the moisture content before additional moisture (typically 35W) is lost in the form of steam. The moisture content may be controlled in various ways including monitoring moisture content of the meat paste and making adjustments by addition of further liquid in the form of water, steam or blood.Oil can also be added at the extruder although oil in the extruder barrel may interfere with expansion and is therefore better added later as a coating if required by the nutritional needs of the recipe.

Bulk silo(s) 40 are used to store the major dry ingredients and the minor dry ingredients are added to a hopper 44.

A predetermined quantity of cereals, gluten, oil seeds and minor ingredients, with a particle size in the range of0 to 3mm, are fed to a blender 42 where they are mixed together as a batch. After blending, the contents of blender 42 are transferred to hopper 44 which acts as a buffer in the system to facilitate continuous production.

A suitable blender is a ribbon blade mixer manufactured by APV Baker Ltd. The output from the hopper 44 is fed by a feeder 22 to the extruder 38. A preconditioner (not shown) can be used to treat starch based cereals to increase the extruder capacity, although this is not desirable with gluten based mixtures. The feeder 22 feeds the blended added ingredients via a conditioner or directly to output B at the required rate. A suitable feeder is commercially manufactured by APV Baker Ltd. The metering pump 20 and the feeder 22 are set such that the proportion of blended meat paste to blended dry ingredients is in the range 2:1 to 1:10.

Additional liquid ingredients are supplied via metering pumps 48. Water is added in the range 2% to

14%. Steam is added in the range 1% to 5%. Blood can be added in the range 2% to 10%. Oil can be added in the range 1% to 4%.

These proportions are by volume of the total feedstock post extruder. It is necessary to have at least

25% starch in the extruder barrel in order to provide satisfactory extrusion of this blend of material, however should products of different bulk density be required, the starch content will be varied accordingly.

At the extruder 38, the dry ingredients and the meat paste mixture are combined together. The extruder

38 is a twin screw type. It should also be appreciated that any alternative system capable of mixing and metering dry and wet ingredients and feeding to the extruder would be suitable.

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Twin screw extruders are well known in food and pet food processing but they normally operate on a relatively "dry" feedstock with water added to the barrel to control the cooking process. In this process the feedstock has a high water content because of the presence of the meat paste mixture, typically up to 40%, and this is regulated as previously described so that the resulting product has an output moisture content which may be in the range 3540%. For use in this process, however, the extruder is modified. The design of the twin screw extruder allows the feedstock to be intimately mixed and cooked thoroughly. The configuration of the screws is such that clearances are smaller than normally used and consequently the amount of heat produced from friction is sufficient to produce the temperature necessary for adequate cooking and sterilisation.The combination of heat produced from friction and barrel heating allows the cooking temperature in the product to reach 1100C-1400C which also provides sterilisation of the product. The barrel temperature is maintained in the range 150-2500C.

Higher temperatures may cause product burning.

Control of product quality in terms of degree of expansion and texture is achieved by the addition of varying amounts of water direct into the extruder barrel.

It has been found possible to modify for use in this process a Model MPF125 twin screw extruder manufactured by APV Baker Ltd. It will be appreciated that other designs of extruder may, by appropriate adjustment, also be suitable.

The screw configuration, found to give acceptable results, was as follows: 4.5D Feedscrew, 4 x 600

Forward Paddles, 2D Feedscrew, 4 x 600 Forward Paddles, 3 x 600 Reverse Paddles, 1D

Feedscrew, 3 x 600 Forward Paddles, 2 x 600 Reverse

Paddles, 0.5D Single Leadscrew, 3 x 600 Forward paddles, 4 x 300 Reverse Paddles, 1D Single

Leadscrew.

In this configuration D represents the barrel diameter and the figures given show the length of the particular sections of the screw in terms of barrel diameter. The second screw is identical to the configuration of the first so that the two screws mesh in a standard manner.

The output from the extruder is normally in the range 2 tonnes per hour to 4 tonnes per hour dependent on operating parameters and recipes, although it must be appreciated that different extruder models will give higher or lower outputs. The product discharged from the extruder 38 passes through a die-plate and cutter 50 where the product is shaped and sized. The extruded and shaped product is conveyed to a drier 52 and then through a coating system 54 to a cooler 56. The drier reduces moisture content to10-

12k at which the product is shelf stable. In the coating system 54, the hot, dried extrudate may be coated with ingredients such as oil, colour, flavour or vitamins.

The cooled product may then be stored in bulk containers 58 prior to being fed to a packaging line 60.

These steps are typical of the processing of extruded products.

It will be appreciated that a substantial amount of water will be evaporated during the cooking process in the extruder and subsequently in the drier. This steam and the washing water used in the offal cleaning machines 6 and 8 is the only effluent from the process.

The process may be automated and requires minimum operator input.

It will be appreciated that the plant described is capable of producing a complete balanced food for livestock, including pets, poultry and fish, in one continuous process from the meat, poultry or fish processing plant to finished product and providing complete traceability throughout.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1. A process for converting fresh low value animal

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material into a feed product comprising the step of

extruding it in a twin screw extruder (38) with a

starch providing ingredient in order to produce an

expanded cooked product, characterised in that the

process further comprises a size reduction step such

that the maximum particle size of the material at

the input of the extruder is in the range of 0.3 to

3mm; in that the water content of the input material

is controlled; and in that the resulting extruded

product is dried as a separate step in the process.

2. A process as claimed in claim 1, wherein the

particle size of the input animal material is in the

range 0.3 to 0.5mm.

3. A process as claimed in claim 1 or 2, wherein the

water content controlling step is regulated to

ensure the water content at the extruder output is

up to 40%.

4. A process as claimed in any one of the preceding

claims, wherein the low value material is

transferred from an adjacent meat, poultry or fish

processing plant.


claims, wherein the starch providing ingredient is

selected from cereals, cereal substitutes, oil

seeds, rice or root crops.


claims, wherein the proportions of offal and bone

with meat in the low value animal material is

controllable.


claims, wherein the proportions of low value animal

material and starch-providing ingredient is in the

range 2:1 to 1:10.


claims, wherein liquid in the form of one or more of

water, steam, oil or blood is added at the extruder.

9. A process substantially as herein described with

reference to the accompanying drawings.

10. A plant adapted for carrying out the process as

claimed in any one of the preceding claims.

11. A plant adapted for carrying out processing of fresh

low value animal material into an expanded food

product comprising: mincing means (4, 14, 24, 26,

28, 30, 34) for reducing the maximum particle size

of said animal material to within the range 0.3 to

3mm at an output (A); feed means (24, 40, 42, 44,

22) for supplying at an output (B) at least one

additional ingredient providing starch; a twin screw

extruder (38) having an input connected to the

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outputs (A, B) of the said mincing means and feed

means and an output; liquid supply means (40) for

controlling water content of the input of the

extruder (38); and drying means (52) connected to

the extruder output for drying theextruded expanded

product.Data supplied from the esp@cenet database - Worldwide

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129.

GB2289205 - 11/15/1995



Inventor(s): HIRATA YOSHIHIRO (--)

Applicant(s): PHILD CO LTD (JP)


IP Class: A23L1/0532

E Class: A23L1/182; A23L1/0532; A23L1/168B


Priority Number: GB19940009028 (19940506); AU19940061845 (19940503); JP19920361663

(19921214)

Family: GB2289205


Abstract:


A rice porridge comprising rice, water and a gelatin agent is sealed in a container. The gelatin agent may for example be agar-agar. Due to the stickiness imparted by the gelatin agent, the taste and consistency of the rice porridge may be enjoyed even when the porridge is cold. This rice porridge product may be manufactured by heating the mixture of rice, water and gelatin agent either after or before sealing it in the container.Description:




This invention relates to a rice porridge prepared by adding a gelatin agent and heating, and to a method of manufacturing such a rice porridge.


Rice porridge is generally prepared by heating a mixture of rice and water. In some cases, nutrients and flavouring ingredients are also added to the mixture.

Rice porridge prepared in this way has an agreeable taste and consistency because the starch in the rice, which is the principal constituent of the porridge, is sticky at the high temperature of preparation.

At lower temperatures, however, the rice starch easily ages and breaks up so that when the porridge is cold, it no longer has the agreeable consistency and taste which it had at high temperature.


It is therefore an object of this invention to provide a rice porridge product which maintains an agreeable taste and consistency even at lower temperatures.

It is another object of this invention to provide a rice porridge product in a form which is convenient to carry and which is suitable for long-term storage.

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It is yet another object of this invention to manufacture such a rice porridge product easily and efficiently.

In order to achieve the above objects, this invention provides a rice porridge product that comprises rice porridge prepared from rice, water and a gelatin agent and sealed in a container.

The gelatin agent is preferably comprises agaragar.

Also preferably, the rice and agar-agar are sealed the container in a proportion of 3:2.

This invention also provides a method of manufacturing rice porridge. The method comprises a step of sealing rice, a gelatin agent and water in a container, and a step of heating the container.

Alternatively, the method comprises a step of heating a mixture of rice, a gelatin agent and water, and a step of sealing the mixture in a container.

In either case, the gelatin agent is preferably agar-agar.

Also preferably, the rice and agar-agar are sealed in the container in a proportion of 3:2.

The details as well as other features and advantages of this invention are set forth in the remainder of the specification.


The rice porridge product and its method of manufacture according to this invention will now be described with reference to specific examples.

The starting ingredients for manufacturing the product are rice, water and agar-agar. The blending proportion of these ingredients is rice:agar-agar = 3:2, and 100 g water/30 g rice. The blending proportions of rice, agar-agar and water may be varied as desired.

Flavouring ingredients such as Japanese "miso" paste and salt may also be added to the above ingredients. The blended ingredients may be heated by, for example, boiling.

Agar-agar is used as a gelatin agent so that the rice porridge has the same consistency at low temperature as at high temperature after manufacture.

Instead of agar-agar, other gelatin-like agents (for example, which form a gel at room temperature) may be used such as oligosaccharides obtained from grains or tubers, for example starch, devil's tongue or mannan; oligosaccharides obtained from seaweed; and gelatin.

The method of manufacturing this rice porridge will now be described. The rice, agar-agar and water are sealed in a reheatable package, and the package is heated until the ingredients are sticky. As a result of this process, the ingredients are heated and rice porridge is produced.

Alternatively, the above ingredients may be heated in a cooking vessel such as a pot to produce rice porridge, whereof suitable quantities are then sealed in reheatable packages. In this case, cans may be used instead of reheatable packages as sealing containers.

When it is desired to consume the rice porridge in the package or can, the container is opened, and the contents may then be consumed immediately. The rice porridge may be heated in a microwave oven or eaten cold.

When the porridge is eaten hot, the starch in the rice is sticky (gel-like), and this gives the rice porridge its glutinous consistency. At high temperatures the agar-agar is dissolved, and it does not contribute any stickiness. In other words, the stickiness of the porridge at high temperature is due to the starch in the rice.

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At lower temperatures, however, much of the sticky rice starch breaks up due to aging. The agar-agar, on the other hand, is a gel at lower temperatures, and it holds the water released by the broken rice starch. The stickiness of the porridge is therefore not lost even at lower temperatures, and a sticky porridge may be enjoyed over the whole temperature range from hot to cold. As the stickiness of the porridge is maintained over a wide temperature range, a sticky porridge may be eaten immediately after the container is opened without heating, and as the porridge is sealed in the container, it is convenient to carry and may be stored over long periods of time.

The rice porridge provides a means of consuming a large amount of vegetable fiber which is present in gelatin agents such as agar-agar, and as the main ingredient of the porridge is carbohydrate, it provides a source of quick energy. The consumer feels satisfied with a low amount of calories, and as the product is sticky, the consumer also obtains a feeling of volume.

In addition, rice porridge is easily digested and absorbed.

In one preparation, 100 g water was added to 30 g rice, 20 g of agar-agar was added, and the mixture sealed in a reheatable package. The package was boiled for approx. 60 min until rice porridge was produced, and after first cooling the porridge to room temperature, it was boiled for approx. 5 min and the package opened.

When the porridge was consumed, the taste and consistency were no different to the taste and consistency of freshly-prepared porridge. The same result was obtained when the contents of the reheatable package were transferred to a dish, and heated in a microwave oven instead of boiling.

Moreover, the taste and consistency were the same when the package was opened and the contents consumed without heating after the product was cooled to room temperature.

In another preparation 100 g water was added to 30 g rice, 20 g of agar-agar was added, the mixture transferred to a pot, stirred, and heated for approx. 60 min until rice porridge was obtained. This rice porridge was sealed in a can. When the can was opened and the contents consumed at room temperature, they had a good consistency due to the agar-agar. The rice was not excessively sticky, and the porridge was still delicious.

Rice porridge manufactured in this way can be consumed within a certain time period as in the case of any other canned products and it may therefore be stored for the duration of that period.Data supplied from the esp@cenet database - Worldwide

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130.

GB232543 - 1/21/1926

IMPROVEMENTS IN METHODS AND APPARATUS FOR MAKING PUFFED

PRODUCTS, AND THE PRODUCT OBTAINED THEREFROM


Applicant(s): ANDERSON PUFFED RICE COMPANY (--)

E Class: A23L1/00P14B; A23P1/14B



Family: GB232543

Abstract:


232,543. Anderson Puffed Rice Co., (Assignees of Anderson, A. P.). April 21, 1924, [Convention date]. Extrusion machines.-Plastic substances, such as starchy food products, are puffed or rendered porous by subjecting them to pressure and heat in admixture with an expansible material, such as gas or moisture, and passing the material through an orifice so that the pressure is suddenly reduced. In treating flour or milling-stock of any grade, the material is mixed with water up to 25-35 per cent and placed in a chamber 10 to which a pressure of 500 to 5000 1b, per sq. in. can be applied, as by an hydraulic or screw plunger 14. The material is forced through pipes 16 in a steam cooker 11 at a temperature of 225-400 F., at which temperature the starch becomes plastic. The material then emerges from the header 17 through apertures having a total cross-section substantially less than that of the pipes 16 and of any desired form to produce filaments, ribbons, or sheets 19 resembling macaroni c.

The chamber 12 surrounding the header 17 is heated to about 600 F. by air supplied from a pipe 22 and escaping at 23, the temperature being less at the outlet end. The filament c. that expand and form a porous mass on leaving the header 17 are rapidly dried and set, being guided by a roller 25 on to an endless conveyer 24. The product may be cut into suitable lengths during or after drying.

622/2197

131.

GB2363073 - 12/12/2001

ORAL REHYDRATION FORMULATION COMPRISING HYDROLYSED

CEREALS AND/OR LEGUMES AND A ZINC SALT


Inventor(s): KHAN JAWAID TARIQ (PK); AKHTAR SALEEM (PK)

Applicant(s): HIGHNOON LAB LTD (PK)

IP Class 4 Digits: A61K; A61P

IP Class: A61K31/70; A61K35/78; A61K33/30; A61P1/12

E Class: A23L1/105B; A61K35/78; A23L1/20D; A23L1/304; A23L1/308A; A61K31/70; A61K33/30



Family: GB2363073

Abstract:


Oral rehydration formulations are prepared by grinding cereals and/or legumes to a powder which is then cooked with water until gelatinised, acidified to pH 5.5 to 6.0, hydrolysed and filtered, zinc salt is added and the mixture is neutralised and dried. The hydrolysation step may be carried out with a amylase or with acid alone, the acidification may be carried out with hydrochloric acid and the neutralisation may be carried out with sodium bicarbonate. The cereal may be rice and the legume may be lentils. A suitable zinc salt is zinc citrate. The formulations are suitable for treating diarrhoea and dehydration.Description:


2363073 ORAL REHYDRATION FORMULATION

FIELD OF THE INVENTION:

The present invention relates to an improved cereal based antidiarrheal rehydrating pow'der product fortified with Zinc; a process for its preparation and compositions comprising thereof.

BACKGROUND AN]:) PRIOR ART:

Diarrheal disease- i-s. a maj.o-r ca-u-se of morbidity and mortality in the world. According to W.H.O. estimates, about 5 million infants and children die every year due to diarrhea; 70% in underdeveloped, countries, about 25% in developing countries and about 5% in developed countries.

-The Glucose-ORS solution although efficiently replaces faecal losses of water and salts, but it has one major shortcoming in that it does not reduce stool volume during diarrhea or shorten the duration of illness, which are the results that mothers and many health workers seek. The underdeveloped world, where 70% of the 5 million children are reported to die of diarrhea, unfortunately have no other sources of nutrition because the mothers of such children are poverty stricken and are not gifted with the breast milk. The miseries are further compounded when the poverty also makes it impossible for the rnothers to buy the powder milk.

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Cereal based ORS though superior to conventional Glucose based ORS w,s not available in ready to use form. It has to be cooked at the moment of feeding and has no stability or shelf-life. Moreover, it could not be administered to the newborn/infants (4-6 months).

The results of the studies carried out in Bangladesh and India showed the supereMacy of ORS solution containing rice powder over the Glucose-ORS solutions. The promising results of these studies make the cereal based oral rehydrating therapy a new hope.to combat child killer diarrheal problems.

Acco, rding to some leading medical authorities, "Such a product, if it could be produced inexpensively and proved sufficiently stable for prolonged storage, would have the important advantage of actually reducing the s-everity and duration of diarrhea and thus acting as -an antidiarrheal drug"[New Eng. J. Med. 319 (20):1364(1998)]. Such a product can also get a real- acceptance and use by both health workers and mothers, especially if its benefits are evident to them. It might also results in less use of ineffective drugs and antibiotics.

The efforts made in this respect were first covered 'bythe applicant in their previously granted

Pakistan Patents, No.

131654 which discloses an anti-diarrheal rehydrating powder product in which the glucose based on

WHO rqcommended formula is replaced with a precooked cereal or cereal-legume powder; and No.

131738 which discloses an anti-diarrheal drug in which glucose. polymers coupled w, ith proteins or polypeptides, derived from Rice and Moong pulse as a result of enzymatic or acid hydrolysis, and glucose polymers, derived from the cereal Rice alone, are use(.

The present invention is an improvement of the applicant's previous granted Patent Nos. 131654 and

131738 in which the process for the preparation of a cereal-based anti-diarrheal rehydrating powder product is modified such that the result is a product, fortified with essential micronutrient Zinc.

The development and production of such a product is taken up as a compelling demand, if not exactly as a challenge, by the inventor. Th6 inventor through its strenuous efforts, is able to isolate useful ingredients having binding and nutritional properties of Rice (Oryza sativa) and Lentil (Phaseolus mungo) having 100% solubility and increased shelf-life. The product is further fortified with Zinc. The product is named as PEPTILOSE. The tradition of using Rice and Lentil as a weaning food (Khitcheri) in the sub-continent has been found to decrease the stool output in human beings suffering from diarrhea.

It has been found that Zinc deficient children share two characteristics:

1. A low intake of meat or, dairy products, which contains Zinc.

2. A h i gh intake 0 f phytates which interferewith the bioavailability of Zinc.

The effect of zinc supplementation on diarrhea include improved absorption of water and electrolytes by the intestines, regeneration of gut epithelium or the restoration of its function, increased levels of enterocyte brush-border enzymes and enhanced immunologic mechanisms for the clearance of infection, including cellular immunity and higher levels of secreting antibodies.

(References from 43-68 The New England Journal of Medicine. Volume 333 September 28, 1995

Volume 131 SUMMARY OF THE INVENTION:

The present invention relates to an. Oral Rehydration Therapy (ORT) product wherein the glucose component of a standard WHOORS is'replaced, partially or completely, by Rice (Oryza sativa) 2 a nd

Dal moong (Phaseolus mungo) Powder, supplemented with polyp. eptides.

The invention particular relates to ar, ORT product which is z further -fortified with Zinc.

The invention also. relates to a process for preparing this.product According to a- preferred embodiment -of the present i i nvention, the product. is formulated. in pharmaceutically acceptable -

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forms such as tablets,, effervescent tablets, powders, granules, solutions and the like.' According to another embodiment of the present invention, the pro duct is used in combination 'with WHO recommended ORS.

According to yet another preferred embodiment of the present invention, the product can be used as a food product, ready to mix. cereal form, as child nutrition.

In an embodiment of the invention, onl, cereal (e.q Rice or an other cereal) is used.

Irb another embodiment of the invent-ion the ORT dzug.is made frorr any edible cereal and source of starch andlor any edible legume and source of protein, used singly or in combination In an proportion.

Still in another embodiment. of the invention the preoelatinize-:1 cereal and 1equmes are soaked in water and hydrolyzed with acid, enzvme or both at low tem-perature.

DETAILED DESCRIPTION OF THE INVENTION:

The present invention describes a product for the treatment of diiarrehea having nutritional properties of Rice (Oryza sativa) and Lentil (Phaseolus mungo) with 100% solubility and increased shelf-life. The product comprising o f oligosaccharides and polypeptides which are derived from cereals like Rice and

'Legumes through acid hydrolysis and/or with enzymati'c hydrolysis. The product is further fortified with Zinc and is named as PEPTILOSE.

PrPTILOSE is a pale yellow powder very soluble in water and practically insoluble in ethanol, methanol and.ether.

Chemically, Peptilose' is Glucose polymers and peptides derived A. Ri ((Oryza sativa), from controlled hydrolvsis o4' a mixture of ce I and Lentil (Phaseolus mungo). The manufacturing process involveo gelatinizar-ion, partial hydrolyzation of the cereal powder, 3 fortification with Zinc (19-20 mg

Zinc / 100 gim) and finally spray drying 0 fL the hydrolyzate. Ma i or components 0 f this mixture is carbohydrate material which constitutes about 88. 95% f 0.80% to _of the mixture. Proteins are present in the range oL 1.30%. Peptilose has DE (Dextrose Equivalent) Value 17-22 and it contains carbohydrates as Oligosacchar ides with an empirical Zormula:

H.(C6H1oO5),-0H, Where n =2-10 Compounding Peptilose with the WHO recommended electrolytes, a novel preparation of ORS has been developed which is named as OPJI=. Oralnu successfully replaces the dificit of salts and water in diarrhea and reduces the volume and duration of illness by acting as absorption promoting anti-diarrheal drug. Another potential benefit o, f this improved ORS is that the reduced severity and duration of diarrhea will make 'it possible to introduce an early effective feeding regime.

Oralnu contains 34 g of oral. powder to be Each sachet oJ dissolved in clean water to make 1000 ml before administration. The composition of 34 g Oralnu is as follows:

Peptilose 26.1 g Sodium Chloride 3.5 g Potassium Chloride 1. 5 g Trisodium Citrate 2.9 g The ORT product of present invention can form ORT tablets, when mixed with Sodium Chloride, Potassium'

Chloride, Citric acid and Sodium bicarbonate, PROCESS FOR THE PREPARATION:

The process for the preparation of Peptilose,. according to the present invention, comprises the following steps:

a) Cereals (for example Rice (Oryza sativa) and Lentil (for example. Dal moong,.(Phaseolus mungo,) are thoroughly cleaned and grounded into flour. The powder is mixed with 5, weights of water and then set aside until it is soake d and swelled.

b) The mixture is then heated and gelatinized. The pH is adjusted from 5. 5-6-O'by-the addition of acid (for example Hydrochloric acid).

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c) Mixture is then hydrolyzed by heating with an enzyme (for example aamy-lase) on the basis of the weight of Rice and Dal moong and is stirred. The mixture is heated with constant agitation until it stops giving characteristic 4 blue colour when tested with iodine solution (0. 2 N Iodine solution).

7 n, Alternatively, the pregelatinized cerl and legunes are soaked in water and hydrolyzed with acid, enzyme or'both at low temperature.

d) The hydrolyzed solution is cooled and filtered through 80100 mesh screen.

e) Brix of the filtrate is measured and Zinc salt (e.g. Zinc citrate) is dissolved in the filtrate. The pH is again ad justed by the addition of alkali, (for example sodium bicarbonate powder).

f) The resultant liquid (filtrate) is - spray dried and thus obtained the product PEPTILOSE. This drying step may also be carried out through drum drying, open tray drying, tunnel drying e-!-:-e.

g) The Peptilose when mixed with electrolytes and flavouring agents yields the effective Oral

Rehydration Salt (ORS) nameLORALNU.

The ORT (Oral Rehydration Therapy) product of the present invention can be used in the manufacture of medicaments for the therapeutic treatment of diarrhea in humans especially in children, which is capable of improving the diarrhea by the following mechanisms.

MECHANISM OF ACTION OF PEPTILOSE / ORALNU:

Oligosaccharides by their nature adhere to receptors in the small intestine. Like breast milk, the dominant component of Peptilose is also oligosaccharides, which is split by maltase into glucose at the intestinal brush-border. This digestive process supplies a large number of glucose molecules to transport sodium ions from the lumen into the blood. This process generates -less luminal osmotic

"back drag" than the direct ingestion of an equivalent amount of glucos e (as in case of glucose based

ORS). The cereal proteins also provide small peptides and amino acids, which facilitate the absorption of additional sodium 'ions by independent co-transport pathways.

The osmotic activity of -Peptilose base ORS (ORALNU) solution (about 240 mOsm/L) is lower than that of blood or other tissues (about 290 mOsm/L). This causes water to be rapidly absorbed from the

Peptilose-ORS solution., The osmolality of the Glucose ORS solution (about 320 mOsm/L) exceeds that of blood, hence absorption is less. If the amount of the glucose in the ORS solutio n was increased to support the absorption of more salt, the solution would become markedly hyperosmotic and instead of I improving diarrhea, water would be drawn -from blood into the intest.inal. lumen and make.the diarrhea worse.

T . is also hypothesized that Peptilose competitvely binds to the receptors for enteropathogenic E.coli on the brush-border membrane of the enterocytes. Enteropathogenic E.coli produce "attaching and effacing" lesions characterized by localized destruction of brush-border microvilli in infected enterocytes. Escherichia coli don't produce recognized enterotoxins or show Shigella like invasiveness.

The diarrhea -results from interaction of enteropathogenic E.coli with surface receptors in the brushborder membrane.

Peptilose inhibits seceretory re'llux in a bacteria! adherent enteropathy. Peptilose functioning as ligand blOcker can preve'nt the colonization of the upper intestinal tract.

The CRT product of the present invention can be used as a. food supplement in variety of flavours. It can be packed in sachet, carton or any other suitable packaging for use purposes.

The CRT product of the present invention and pharmaceutical compositions incorporating such pro, duct can be administered in conventional dosage forms, prepared by comb.ining the CRT product with standared pharmaceutical carriers according to conventional procedure. These procedures may involve

- mixing, I granulating, compressing or dissolving of the ingredients as. appropriate, to the desired preparation.

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A wide variety of pharmaceutical forms can be employed. The compositions may be in the form dry powders, of table.ts, effervescen-t tablets powders, granules or li4uids preparations.

EXAMPLE

The present invention can be illustrated with the following example Cereal (for example Rice, Oryz, a sativa, 45 g) and Lentil (for example Dal moong, phaseolus mungo, 5 g) were thoroughly cleaned, grounded into 'lour and mixed with water in. 1:5 ratio.

The mass is then heated and gelatinized which is marked by the disapearance of graininess-. The pH of the gelatinized mass adjusted between 5.5 and 6".0 by the addition of 5% acid (for example H ydrochloric Acid), After thorough m1xing and pH adjustment, 0.1% (on the basis of the weight of Rice and Dal moong) of the enzyme (for example c4-amylase) was.added and the mixture was stirred at 800

C for 20 min. utes. After 20 minutes, the mixture was heated with constant agitation until it stopped giving the characteristic blue colour w,,-,.en a small portion. or, t'he mixture was tested with 0.02N

Iodine solution. Stainless steel vessels were used in all steps of the cooking.

6 The hydrolyzed solution was cooled and filtered through 80-100 mesh screen. The Brix of the filtrate was measured. The Q grams (whereas, Q= 0A0561 x Brix x volume of filt ' rate in litres) of

Zinc Citrate wa ' s dissolved in the filtrate and pH of the solution was adjusted to 7.0 by the addition of alkali (for example sodiumt, powder). This, obtained product was named as PEPTILOSE.

PEPTILOSE when mixed with electolytes and some flavour yielded an effective Qral Rehydrtion Salt

' (ORS) which was named as ORALNU. Thus for an example, 26.1 g peptilose was mixed with 3.5 g

Sodium Chloride, i. 5 9 Patassium Chloride, 2.9 g Tri-Sodium Citrate dehydrate and 0.1 g dry flavour

(e.g. Lemon Powder Flavour). Thirty four grams (34 g) of this material was packed in airtight sachets and used as ORT for diarrhea when dissolved in one litre of water.

7Data supplied from the esp@cenet database - Worldwide Claims:


CLAIM:

GIA14 1. A process for the production of an oral Rehydration Therepy product fortified with essential mineral, Zinc, comprising the steps of a. grinding of cereals/legumes to a powder and cooking with 5 weights of water until free from graininess and completely gelatinized; b. acidifying the mass with HCl to a pH from 5.5 to 6.0; C. hydrolyzing the mass by heating with 0.1% c4-amylase until it stops giving blue colour with 0.2N Iodine,solution; d. filtrating the obtained liquid through 80-100 mesh screen; e. adding Zinc salt; f. neutralizing with Sodium bicarbonate; g. spray drying the resultant liquid; and h mixing the solution as an antidiarrheal drug 2. A process as claimed in claim 1, wherein the hydrolysis was carried out with an acid alone (Hydrochloric acid as an example) instead of using an enzyme.

3. The process as claimed in claim 1 wherein only cereal (e.g. Rice or any other cereal) is used.

4. The process as claimed in claim 1 wherein combination of cereal and legume is.used.

5. A process as claimed in claim 1, wherein the ORT drug is made from any edible cereal and source of starch and/or any edible legume and source of protein, used singly or in combination in any proportion.

6. A process as claimed in claim 1, wherein the pregelatinized cereal and legumes are soaked in water and hydrolyzed with acid, enzyme or both at low temperature.

7. A process as claimed in claim 1, wherein the hydrolyzate is dried by means of drum drying, open tray drying, tunnel drying, spray drying e-t-e.

8 8. A process as claimed in claim 1, wherein the (x-amYlase is used alone or in combination with some other debranching enzyme.

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9. A process as claimed in claim 1, wherein the product is fortified with Zn-citrate and/or with any other salt of Zinc which favourably affects the anthropometric and immunologic parameters of a diarrheal child.

10. A process as claimed in claim 1,.wherein the pH is adjusted with any acid or alkaline reagent other than Hydrochloric acid or Sodium bicarbonate.

11. A process as claimed in claim 1, wherein the hydrolyzate powder has partially substituted glucose in the WHO recommended ORS.

12. An ORT (oral reh_ydration therapy) product, prepared by the process as claimed in claims 1 to 11, comprising Peptilose comppsed of glucose polymers and peptides.

13. An ORT produc as claimed in claim 12 which is fortified with Zinc salt.

14. An ORT product as claimed in claim 12, wherein said peptilose comprising dried and powdered hydrolyzate components,. when mixed with ORS salts i.e., Sodium Chloride, Potassium Chloride and

Tri-sodium Citrate forms ORT Powder.

15. An ORT product, as claimed in claim 14, when mixed with Sodium Chloride, Potassium Chloride,

Citric acid and Sodium bicarbonate, it forms ORT tablets.

16. An ORT product as claimed in claim 12 which provides as Oral Rehydration Therapy for dehydration.

17. An ORT product as claimed in claim 12 wherein the essential micronutrient helps to stop diarrhea.

18. An ORT product, as claimed in claim 12, wherein the product is used as a drug or food or food supplement.

19. An ORT product as claimed in claim 12 wherein the Peptilase contains oligosaccharides of the empirical formula:

H (C6H1005) n-OH where n=2-10 20. An ORT product, as claimed in claim 18, wherein the food is made with the addition of permissible flavours, colours and preservatives.

9 21. A pharmaceutical composition comprising ORT product", prepared by the process as claimed in claims 1 to 11, and a pharmaceutically acceptable carrier or diluent.

22. The pharmaceutical composition of claim 20, which is packed and presented in the forms of dry powder, granules or aqueous solutions.Data supplied from the esp@cenet database - Worldwide

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132.

GB245474 - 11/11/1926

IMPROVEMENTS IN METHODS OF PREPARING FLAKED CEREAL FOOD

PRODUCTS


Applicant(s): HEINZ CO H J (--)

E Class: A23L1/168B



Family: GB245474

Abstract:


245,474. Heinz Co., H. J., (Assignees of Harding, E. R.). Jan. 3, 1925, [Convention date]. Cereal preparations in flaked form are prepared by cooking with the grain substantially pure cellulose, the mass being dried incompletely and then separated mechanically into the original kernels which are dried and flaked. The cellulose employed is preferably derived in finely divided condition by chemical treatment of vegetable substances such as corn cobs; cotton, or wood pulp. Cellulose obtained in other ways may, however, be used, provided it is substantially pure and free from starch or other substances which become gelatinous on cooking. In the application of the invention to the preparation of flaked rice, for example, cellulose to about 10 per cent by weight of the rice to be prepared is brought into suspension in water, the rice is added and the whole mixed and cooked. The cooked cereal is then prepared by flaking by incomplete drying followed by mechanical separation into fragments as in an horizontal rotating cylindrical container fitted with internal longitudinal ribs or ledges. The

Specification as open to inspection under Sect. 91 (3) (a) refers to United States of America

Specification 1,495,789 and also to the mere cooking of cereals wherein, in order to ensure the preservation of the identity of the individual kernels, cellulose in finely divided condition is added.

This subject-matter does not appear in the Specification as accepted.Description:



Convention Date (United States): Jan. 3, 1925.

2459474 Application Date (in United Kingdom): Jan. 4, 1926. No. 237/26.

Complete Accepted: Nov. 11, 1926.


Improvements in Methods of Preparing Flaked Cereal Food Products.

We, H. J. HEINZ COMPANY, a company organized according to the laws of the State of

Pennsylvania, United States of America, of 1062, Progress Street, Pittsburgh, Allegheny County,

Pennsylvania, United States of America, Assignees of EDWIN REGINALD HARDING, a citizen of the United States of America, of 6363, Alderson Street, Pittsburgh, County of Allegheny, State of

Pennsylvania, United States of America, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the

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following statement:This invention relates to improvements in the preparation of food products and specifically of cereal food products.

In the cooking of cereals, and this is notably true of barley, rice and oats, a gummy mass is produced, which is objectionable on several accounts; such a gummy mass, served at table, is 26 unpleasant in the mouth. If the mass be dried or baked, a hard product results, which, taken into the mouth becomes superficially slimy and unpleasant.

Again, in the production of flaked cereals, the gumming together alluded to occurs in the initial cooking and results in the loss of identity of the individual kernels of grain; the mass when dried has to be broken into fragments, preparatory to flaking, and these fragments approximating to the original' grains in size, are not (as are the original kernels) uniform in size. Furthermore, drying and fragmenting are slow and difficult operations.

According to the invention, in order to avoid these drawbacks, a flaked cereal is prepared by cooking with the grain finely divided pure cellulose and 46 then mechanically separating the mass [Price 11-] into the original kernels, drying and flaking the kernels.

The cellulose is substantially pure, preferably derived in finely divided condition by chemical treatment of such 50 vegetable sources as corn-cobs, cotton, cotton linters (short, hair-like fibres remaining on the seeds after the removal of the cotton), and wood pulp. Cellulose so prepared is insoluble and tasteless, 65 bland and soft. Its effect on boiled cereal, eaten hot,, as well as on other preparations of cooked cereal, is primarily mechanical, preventing the formation of gummy masses or hard C0 masses. It has no appreciable effect to change the flavour of cooked cereals, and when used in the course of manufacture of prepared breakfast foods, it accomplishes the ends indicated, without (5 appreciable modification in taste.

We are, however, not limited in the practice of this invention to cellulose so derived and may employ substantially pure cellulose derived from any source. 0 It must more particularly be free from starch or other substances which become gluey or gelatinous on cooking. Bran, therefore, as hitherto used in diluting cereal foods (in that it contains, besides 7,5 cellulose, considerable starch) will not do; if bran is to be used in the practice of the invention, as a material rich in cellulose, it must be prepared for such use by the removal of its starch content. 80 This may, of course, be done by processes known to the art.

The invention is particularly described in its application to the preparation of flaked rice. 85 The rice employed may be of such quality as is desired, brown or polished.

We measure cellulose in quantity amounting to about 10 per cent. by weight of the quantity of rice to be prew i7A - d 245,474 pared. We bring the cellulose into suspension in water, add the rice to this suspension, mix thoroughly and cook.

The usual practice of preparing the cooked cereal for flaking is now followed, that is to say it is dried incompletely and then separated into fragments. Separation occurs before and during drying.

This separation into fragments may conveniently be accomplished within a cylindrical container rotating on a horizontal axis, and provided interiorly with longitudinal ribs or ledges. Within this cylinder the mass of cooked and 16 incompletely dried rice is tumbled and broken up. Flaking and toasting operations follow, differing in no respect from those operations as they are now performed upon other grains.

The presence of cellulose is of great value in the preparation of the product.

Without cellulose the kernels become pasty on the surface and adhere together in large lumps. In the form of these aggregates the material dries slowly, and when dry has to be broken apart by crushing.

During tempering the kernels or granules again stick together and have to be worked apart before feeding to the rolls for flaking. A great deal of hand manipulation or special machinery is required to get the batches in shape for flaking, and it would be expensive and practically impossible to dry and temper the material in large batches on a commercial scale. With cellulose present, the cooked material, if it has the right moisture content, can be broken up easily and the individual jiernels stay

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separated during drying and tempering. 40 Without cellulose, rice flakes, after becoming thoroughly moistened in the mouth, become gummy, and have a slightly slimy taste which is not noticeable when the product contains cellulose. 45 The invention is described in its application to the production of flaked rice; similarly it may be applied, and with like effect, in the preparation of other grain in flaked form. 60 Having now particularly described and ascertained the nature of our said invention and in what manner the same is to be performed, we declare that what weData supplied from the esp@cenet database - Worldwide Claims:

Claims of GB245474 claim is:-

Ub The method of preparing a flaked cereal which consists in cooking for the purpose described with the grain finely divided substantially pure cellulose, drying incompletely and then mechanically 60 separating the mass into the original kernels and drying and flaking the kernels.

Dated this 4th day of January, 1926.

ABEL & IMPRAY, 30, Southampton Buildings, London, W.C. 2, Agents for the Applicants.

Redhill: Printed for His Majesty's Stationery Office, by Love &; Malcomson, Ltd.-1926.Data supplied from the esp@cenet database - Worldwide

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133.

GB299803 - 3/17/1930

IMPROVEMENTS IN OR RELATING TO CEREAL FOODS


Applicant(s): JERSEY CEREAL COMPANY (--)

E Class: A23L1/18C6



Family: GB299803

Abstract:


299,803. Jersey Cereal Co., (Assignees of Luke, C. E.). Nov. 1, 1927, [Convention date]. Drawings to

Specification. Products obtained in special forms; treatment by flattening and heating.-Grain kernels, such as those of rice, are prepared by cooking with seasoning and colouring-material such as salt, syrup and the like. The cooked grains are then passed through rolls that flatten them relatively slightly. The flattened grains are placed in an oven at 400 -450 F. and at atmospheric pressure and toasted. The toasted kernels become greatly puffed and bodily expanded throughout whilst possessing roughly their original proportions. Wheat, corn, and barley may be treated similarly to rice.Description:

Description of GB299803 i. 'L) 1 --

PA TEN! SPEIF1 CAIO PATENT SPECIXFI1AN'FIN-Convention Date(United 8tates): Nov. 1,7927.

299,803 Application Date (in United Kingdom): Oct. 17, 1928. No. 30,0,q5/28.

Complete A ccepted: March 17, 1930.

COMPLETE SPECIFICATION-.

I Improvements in or relating to Cereal Foods.

We, JERSEY CEREAL COMPANY, a corporation of the State of Pennsylvania, having a place of business at Cereal, Westmoreland County, Pennsylvania, UIiited States of America, assignees of

CI1411LES EDGAR LunF, Citizen of the Umited States of America, residing at Irvin, Westmoreland

Couity, Pennsylvania, United States of America, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:- This. invention relates to cereal foods alid particularly to an -expanded and toasted rice kernel and the process of making the same.

In manufacturing puffed grain cereals, one method heretofore extensively used is that. of cooking the grain kernel under steam at high pressure and suddenly liberating the grain kernels. When the kernels are liberated the steam entrapped in the cells expands, thereby bursting or disrupting the cell walls. A kernel so treated wvill expand as much as eight times its original volume. The expanded kernel is comiipressible and has an outer 3O siurace that is substantially sinooth-to the naked. eye.;A sectioxi through the expanded kernel presents a pithy appearanee in which small spaces are defined by irregular fibrous walls which are deform3 able. When deformed, as by compressing, the kernel does not return to its original. ihape. Such puffed grains are not toasted during the puffing operation.

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It has also heretofore been proposed to prepare ready-to-eat flaked cereals by a process inclnldiiig the steps of eooking cereal grits, thereafter drying or curing the grits to form a filmn on the exterior thereof, thereafter passing' said grits between rolls for ieduciig them to flakes and lien toasting said flakes, When, in accordance with a prior practice of such a process, the rolls were set to formn what arkhwn in the art as " thick flakes 60r in contrast to shaving-like thin flakes, these " thick flakes " in the toasting step have formed on their opposite surfaces numbers of small bubbles or blisters as a [P/rice

1/1-1 result of steam formed from moisture in the interior.of the flakes forcing its way 55 outwardly through the exterior film.

This formation of bubbles, on the surfaces of the flakes has been termed a puffing.

In contradistinction to the above, the method of the present invention, which 60 includes in a general way the, steps of cocking cereal grains or kernels or parts thereof, then subjecting the same to pressure, and, thereafter, to toasting heat, is characterized by the feature that the pressure to which the cooked kernels or parts thereof are subjected is only sufficient to flatten them relatively slightly, and such that the kernels when toasted become greatly puffed and bodily expanded 70 throughout and in all directions whilst possessing roughly their original proportions. The pressure by which the cooked kernels are rendered. capable of puffing and, expanding throughout as distinguished from merely having small bubbles formed on their surfaces, is such that the kernels are only slightly flattened and do not lose their identity as kernels, in distinction to pressure sullch as would tgs reduce the kernels to flakes, including what has been known tc, the art as " thick flakes ".

The product produced by the method of the present invention. may have on its 85 surface, irregularly spaced blisters, but in addition to this. the kernels are bodily puffed and expanded throughout and in all directions, the expanded, toasted grain-as a whole is non-compressible and go withstands a considerable pressure before crushing, and when crushed, it breaks up into a large number of small particles.

The accompanying drawings, illustrate the present preferred embodiment of the 95 invention, in which-, Figure L is an, enlarged perspective view of a cooked graini kernel.

Figure 2 is. an enlarged perspective view of the grain kernel after the toasting 1on and puffing operationFigum-e 3 is a cross-sectional view' thereof taken- along the section linesIII-111 of Figure 2, and Figure 4 is a cross-sectional view 105 of a puffed grain formed by suddenly J releasing the grain kernel from under without affecting the characteristics of high pressure. the finished cereal.

Referring to Figure 1, a grain element Referring to Figures 2 and 3, after or part thereof, illustrated as a grain of being pressed the kernel 1 is placed in a rice 1 is prepared by cooking it with toasting oven at

400 or 4500 F. and at 70 seasoning and coloring material such as atmospheric pressure. The kernel expands salt, syrup and the like. The bran on the throughout to from three to four times grain may be removed before the grain is the size of the original rice grain and is cooked. The cooking operation is that roughly of the proportions of the original customarily employed in cooking grain in kernel, taking on a toasted colour. The the manufacture of the well-known flaked outer surfaces 4 of the puffed kernel show 75 cereal foods; that is to say, the grain is small irriegularly placed blisters 5 and cooked with water and flavouring material consist of a shell of brittle, non-deformin a steam cooker usually at a pressure of able fibrous material tapering towards a from 15 to 25 pounds per square inch. ridge 6. The interior of the puffed cereal At the end of this -cooking operation the is defined by a series of intersecting ribs so grain elements are uniformly cooked and or webs 7 of the same material as the surare soft and pliable. The kernel, after faces 4. The webs 7 define substantially cooking, is substantially-of its original hollow spaces 8 of considerable extent.

size and exhibits a slightly irregular sur- The webs 7 are also non-compressible face 2 and the seam 3 of the natural and, accordingly, the puffed cereal is 85 grain. capable of withstanding considerable presThe cooked grain which, dueNtia the sure before it collapses. When collapsing cooking operation, as in the case of grains the surfaces 4 and the webs 7 break up used to make flaked cereal foods, is in a. into a large number of fragments such as uniformly cooked, softened and pliable 'are characteristic of the crushing of a 90 condition is then passed through rolls brittle material.

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that flatten it slightly without, however, While there is a doubt as to the exact reducing it to a flake. nature of the reaction within the grain While it is not certain what exact kernels during the toasting and puffing reaction takes place within the rice ker- operations, it is thought that the moisture, 95 nels during the pressing operation, it is whether confined in crevices, in the indi- ^ possible that one or two actions, or a vidual cells, or by the surface of the I combination of them takes place. One kernel, as previously explained, expands '.

explanation is that the pressing operation under the toasting heat against atmodisrupts the intercellular structure of the spheric pressure, thereby forming the 100 kernel sufficiently to form small crevices spaces 8.

or pockets, thereby weakening the kernel. Referring to Figure 4, there is shown When the kernel is toasted, steam accu- a cross-sectional view of a grain of rice mulates in the crevices and pockets and expanded by suddenly releasing it from expands it. This toasting operation is under high pressure, as is done in a wellthe same as that employed heretofore in known prior process. The cross-section of making rice flakes and corn flakes, except this grain shows a pithy or spongy surthat, due to the slight flattening of the face as compared with the well-defined , kernels, the latter became puffed and webs 7 and openings 8 of a kernel exexpanded throughout and in all direc- panded according to the present process. 110 tions, in addition to being toasted. The grain kernel shown in Figure 4 is Another explanation of the behaviour compressible as compared with the nonof the rice is that the compressing opera- deformable characteristics of the kernel tion renders the surfaces of the kernel, produced by the present invention. The and possibly those of the individual cells, outer surface of the kernel shown in

115 more impervious to the escape of moisture Figure 4 is free from bubbles such as the than in uncompressed kernels. The blisters 5 appearing on the outer surface moisture thus confined expands during of the cereal as shown in Figures 2 and 3.

the toasting operation to puff the kernel. While the method is described in con- 2 The individual cells, however, are not nection with a rice kernel, it is to be ruptured as has been found to be the case understood that other food cereals such as where the kernel is " flaked ', as the wheat, corn, barley and the like may be term has heretofore been used in the art. used in the same process, and that the use

With the present process it is not neces- of such grains is contemplated within the 1nS sary to permit the rice to temper or cure scope of the appended claims.

between the cooking operation, the roll- Having now particularly described and ing operation and the toasting operation ascertained the nature of our said invenhereinafter described. The several steps tion and in what manner the same is to may be taken substantially simultaneously be performed, we declare that what we 1.1o 299,803 299,803Data supplied from the esp@cenet database - Worldwide

Claims:

Claims of GB299803 claim is:

1. A method of preparing a cereal food product which consists in cooking cereal grains kernels or parts thereof, subjecting t the cooked kernels or parts to pressure from opposite sides and then applying toasting heat, characterized by the feature that the pressure to which the cooked kernels or parts are subjected is only sufficient to flatten them relatively slightly and such that the kernels when toasted become bodily puffed and expanded throughout and in all directions whilst possessing roughly their original proportions.

2. A method of making an expanded or puffed cereal product according to claim 1, wherein the cereal grains are whole rice kernels.

3. A method according to claims 1 and 2, wherein the said puffing or expanding is effected by applying the heat at atmospheric pressure.

4. A cereal food product when prepared by the method claimed in claim 1, 2 or 3, and consisting of cooked cereal grain kernels or parts thereof puffed or expanded in all directions so as to be cellular

634/2197

throughout and rendered crisp and non-compressible so that, when crushed, they break into small particles.

5. A rice food product when made by the method claimed in claim 1, 2 or 3, and consisting of cooked whole rice kernels which are expanded in all directions to at least twice the size of the original kernels and of cellular sti:ructure throughout, substantially as described.

6. The method of preparing a rice food product, substantially as described.

7. The cereal food product substantially as described, when prepared by the method hereinbefore described and claimed.

Dated this 16th day of October, 1928.

JERSEY CEREAL COMPANY, Per Boult, Wade & Tennant, 111/112, llatton Garden, London, E.C.

1, Chartered Patent Agents.

Redhill: Printed for His Majesty's Stationery Office, by Love & Malcornson, Ltd.-1930 j 1 i i i 1 i i i 1 i i i i J 1 i i i - ---.iData supplied from the esp@cenet database - Worldwide

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134.

GB350684 - 6/18/1931

VITAMINIZED FOOD SEASONINGS


Applicant(s): EDWIN MAYBURY (--)

E Class: A23L1/302; A23L1/221



Family: GB350684

Abstract:


Food seasonings and sauces containing vitamins are obtained by subdividing moist vitamin-containing vegetable extracts and coating the particles thereof with rice, yeast, or egg ground to a flour to produce a free running powder which is mixed with the seasoning ingredients which include spices, onion, lemon, breadcrumbs, herbs, salt, pepper, horseradish, and milk, all in dried form. The powdered extracts may be prepared by mixing the vegetable extracts with powdered rice, yeast, or egg to give a paste which is passed through a mincer and a perforated plate in front of which is a revolving knife which cuts the paste into small particles. The material is subjected again to this treatment using a plate with smaller perforations, and is next placed in a mixer having horizontal sieves, of varying mesh, to which a horizontal vibrating motion is imparted. Powdered rice, yeast, or egg is added in the mixer, and the particles become coated therewith. Four parts by weight of the product may be mixed with 40 parts of seasoning and the mixture may be used for sausages, meat, or other foods. Horseradish or onion sauce may be obtained by drying the horseradishes or onions and grinding to a fine powder which is mixed with an equal amount of flour or dried milk and flavoured with pepper or salt. The powdered vegetable extract is blended with the mixture in a mixer having sieves or gratings to which a horizontal vibrating motion is imparted, and by addition of water to the product the sauce is obtained.Description:

Description of GB350684 f

1 1, --- 1 j ' L -- (-- r 1 a ''' j f,'- 1 1 PATENT SP F CAfl6N Application Date: May 14, 1930. No,

14,857/30.

Complete Left:, Feb. 9, 1931, Complete Acocepted:. June 18, 193 1.

PROVISIONAL SPECIFICATION.

Vitaminized Food Seasonings.

I, EDWIN MAYBTJTRY, 1, Thornsett Road, Anerley, S.E. 20, British Suabject, do hereby declare the nature of this invention to be as follows:

5This invention relates to seasonings and particularly seasonings used in the manufacture of food sausages. meat and fish pastes or the like. Such seasonings have uisuailly 'been made by mixing, the various ingredients together and-when added to or blended with the food sausages pork veal fowl stuaffing or the like a distinct and palatable favour is imparted to them.

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i5 The object of the present invention is to provide seasonings, which are made with the -usual flavouring spices onion lemon dried breaderumbs herbs. salt or the like with vitamin activity by blenaing with them or adding to them other ing0redients containing active vitamins.

namely dried vegetable extractives or the like in fine powder and egg also in dried powder.

According to the present invention the seasonings impart an improved and richer flavour to the food sausages or the like and in addition owing, to the blended oar added vitamins they are endowed with health properties which are imparted to the food sausages or the like.

According to the present invention seasonings are made from ingredients such as spices onion lemon dried Ibreadcrumbs, 35herbs salt and the like in proportions varying with the food or the like to be flavoured which have been subjected to adrying process at a low temperature by passing dry warm air over them and then reducing the ingredients to a powder by grin ding or pulverizing.

According to the present invention vegetable extractives or the like are prepared at a low temperature under vaciuum 4r5 possessing great vitamin activity and egg are blended with or added to. the seasonings. all in the form of dry free running powder by falling through a series of horizontal o-ratings or sieves of varying mesh having a vibratory motion and thus, is attained a perfect analytical 'blend.

The prepared seasonings are packed in tins to ensure dryness and free running.

[Thrice 11-] To utilise the seasonings they are added -or blended in varying quantities to the S5 food sausages or the like according to taste and to the particular food requiring seasonings during the manufacture preparation or cooking of the food sausages or the like. 60 As an example the proportion of ingredients are 40 parts of ordinary seasonings being a blend or mixture of spices lemon onions herbs. dried breadcrumbs salt and the like in varying proportions dried pow- 605 dered and free, running, 4 parts of dried and powdered vegetable extractives or the like and 1 part dried and powdered egg the whole 'being, allowed to fall thro-ngh gratings or sieves to effect a perfect 70 analy-t'ical blend.

Vegetable extractives. containing vitamins are obtained by subjecting vegetables to pressure in a suitable press the liquid resulting is without loss of time '1 treated with neutral metal salts or reagents which are removed later [by means of sulphuretted hydrogen. The mixture is filtered solvents. such as alcohol glycerine acetone or the like are added & 80 placed in a Soxhlet apparatus & heated in vacuo at a low temperature.

Hitherto vegetable extractives have been unsuitable owing to their moist condition for use in blending with peppers 85 and the like.

According to the present invention to overcome the moistness of vegetable extractives, which contain vitamin activity so that they will blend with peppers spices 90 bread crumbs dried onion herbs. or the like vegetable extractives, a-re treated so that they will liave each particle coated with dried powdered rice yeast egg or the like thus eaclh particle is. kept separate. 95 The 'Powdered rice yeast egg or the like absorbs the moisture. Thus the veketable extractives become dry and free ruinninge and in a suitable condition to blend freely with peppers. spices bread crumbs 100 or the like necessary for the manufacture of seasonings, used in making sausages & the flavouring, of all kinds of food.

According to the present invention vegetable extractives are divided into10 fine particles by any suitable means such 3509684 as passing them together with powdered rice yeast egg or the like through a mincer similar to an ordinary meat mincer provided with a plate having 'holes, in it of suitable diameter & a revolving cutter.

The vegetable extractives pass through the holes in the plate without sticking & the revolving knife cnts the material into sinall pieces which are again reduced in to M,,ze by repeating the process a plate with smaller holes being substituted -until the required fineness is obtained. The ex-tractives, are next placed in a mixer which consists 'of horizontal sieves of varying mesh and having a vibrating horizontal motion. Powdered rice yeast egg or the like is added and each particle 'of vegetable extractive passing through the sieves & meeting with the powdered egg yeast rice or the like becomes

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completely coated with the powder & is now in a free runilingy condition for forming a complete blend with peppers spices. breadcrumbs or the like.

Dated this 14th day of May, 1930.

EDWIN MAYB1URtY.


Vitaminized Food Seasonings.

I, EDwiN M'AYBuRy, 1, Thiornsett IRoad, Anerley, London, S.E. 20, British -Sub ject, do hereby declare the nature of this, invention and in what manner the same is to be performed, to bhe particularly described 30and ascertained in and by the following statement:

This invention relates to seasonings or sauces and particularly those used in the flavoutring or manufacture of food, sausages, meat or the like, and provides aeas'onings which are made with the usual flavouaring spices, onion, dried breadcrumbs, herbs, salt, pepper or the like, withi vitamin activity by blending with them or adding to, them other ingredients containing active vitamins such as, vegetable -extractives. Vitamin-containing vegetable extractives contain moisture and this invention provides for mixing the vitamnin-containing vegetable extractives with- powdered rice, egg, yeast or the like into a paste and passing through a mincer and a 'plate with holes, in it.

There is. a revolving knife in front of the plate which cuts the paste into small particles. The process

(with a plate containing smaller holes) is repeated until the required degree of fineness. is obtained.

Thle small particles are next placed in 55a mixer which consists of horizontal sieves Of varying rnesh having a vibratory horizontal motion. Powdered rice, egg or yeast ground to the fineness of flour is added freely wiete mixing is proed ing, and thus each particle of vitamnincontaining vegetable extractive is completely coated with the powdered rice, egg or yeast and is now in a condition for

65blending with the -usual flavouring spices., onion, dried br-eadcrumbs, herbs, salt, pepper, dried mnilk Or the like.

According to the 'present invention seasonings are made from ingredients such as, spices, onion, lemon, drie breadcrumbs, herbs, salt, pepper, horseradish.70 or the like, in proportions, varying with the food to beflavoured which have all been subjected to a drying process by passing dry warm air over them and then reducing the ingredients to a powder by grind-.7 ing or pulverizing.

According to the present invention vegetable extracts containing vitamins are obtained by subjecting vegetables to pressure and the resulting liquid is, treated Q with various salts, and reagents, such as neutral head acetate, which are removed by means of sulphuretted hydrogen. The mixture after filtration is treated with solvents. such as alcohol, acetone or the gr like and placed in a Soxhlet apparatus. and heated in an atmosphere below the atmospheric pressure at a -low temperature.

As an example of the preparation of sauces, such as horseradish or onion sauce, 9 Horseradish or onion or similar roots are dried & ground to a fine powder, and mixed with flour or dried milk in equal proportions by weight and SO parts, by weight of this mixture are then flavoured 95 wit pepper or salt and then two parts by weight of vitamin containing vegetable extractives, each particle being coated with powdered egg, ric oyests & being consequently in a free running condition 100 are added. The mixture is allowed to fall throug-h gratings or sieves having a vibratory horizontal motion thus effecting a perfect blend. Sauces, thus prepared are made ready for use by the addition 'of 1os water.

As a further etample, the proportions of ingredients are 40 parts 'by weight of ordinary seasonings, being a blend or mixture of spices, lemon, onion, herbs, breadcrumbs, salt, pepper and the like, all dried and free runniing, in varying proportions., and 4 piarts of dried and powdered vitamin vegyetable extractives each 350,684 350,684 0 particle being coated or dusted with powdered rice, egg, or yeast and being consequently in a free running condition, the whole being, allowed to fall through-i gratings or sieves, thus effecting a perfect blend.

638/2197

The prepared vitamin-containing food seasonings are made -up in suitable packets, tins or glass bottles to ensure them being always in a dry state.

The vitamin-containing food seasonings made according to the present method do not require any preservative and will keep indefinitely, and as they are prepared for j5 use simply by the addition of water a oreat saving of time in the preparation of food is. effected.

Having now particularly described and ascertained the nature of my said invention and in what manner the same is toData supplied from the esp@cenet database - Worldwide

Claims:

Claims of GB350684 be performed, I declare that what I claim

Is:

1. A method of preparing food seasoning(,s whereby they will acquire vitamin activity, which consists in treating each 25 particle of a vitamin-containing vegeta'ble extract with powdered rice, egg, or yeast ground to a fineness of flour so as to coat each particle with the flour, thus, producing a free running powder which is mixed 3 with the seasoning-, which is obtained by mixing ingredients such as dried powdered spices., onion, breadcrumb, herlbs, salt, pepper, horseradish, milk or the like, in the required proportions for the partic-ular food requiring flavouring or for preparing sauces.

2. Vitaminized food seasonings or sautces. when prepared according to the method claimed in Claim 1.

4 Dated this 9th day of February, 1931.

EDWIN MAYB-URY.

Redhill: Printed for His Majesty's Stationery Office, by Lore & Malcomson, Ltd---1931Data supplied from the esp@cenet database - Worldwide

639/2197

135.

GB367340 - 2/12/1932

A PROCESS OF MANUFACTURING NUTRITIOUS POWDERS


Applicant(s): RIKIZO NOMURA (--)

E Class: A23L1/48; A23B9/06; A23C9/154; A23C9/156B; A23L3/28



Family: GB367340

Abstract:


Food preparations readily soluble in cold or warm water are obtained by mixing two or more cereal or like flours, such as rice, soya bean or wheaten flour with a fruit juice such as plum juice or apple or cucumber juice alone or mixed with other fruit juices, and preparing a mixture of Japanese yam powder with meat juice or chicken soup, or fish, allowing the mixtures to ferment separately after which they are treated with ultra-violet rays to arrest fermentation and sterilize them, mixed together and added to fresh milk. The mixture is allowed to ferment, then treated with ultraviolet rays to arrest fermentation and sterilize it, and finally reduced to a powder and packed in containers, which are hermetically sealed. The meat juice may be prepared by compressing pork or beef to which a small quantity of common salt is added.Description:


-It Z A-i F ? i;, V 7


Application Date: Sept 12, 1930 No 27,261/30.

Complete Accepted: Feb 12, 1932.

-i COMPLETE SPECIFICATION.

A Process of MLanufacturing Nutritious Powders.

I, R Ih Izo Nov Iu RA, a subject of the Emperor of Japan, whose postal address is No 16 f-4, Juso

Nishinocho, Higashiyodog'awaku, Osaka, Japan, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statei O lhis invention relates to the manufachtre of food powders.

The object of the invention is to provide a process of manufacturing nutritious powders containing full nutriment and t 5 heating value notwithstandinlg their small volume The products have also the advantage that they are easily digested and are capable of being preserved for a very long time as compared with the other like foods.

The process for the manufacture of food powders according to the invention consists in ( 1) preparing a mixture of two or more cereal or like flours such as rice, soya bean or wheat together with fruit juices, (

2) preparing a mixture of Japanese yam powder together with meat juicee or fish, allowing each of the ingredients 1 and 2 respectively to ferment.

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followed by a treatment with ultra violet ravs in order to arrest fermentation and sterilize the products mixin the powdered products ( 1) and ( 2) thus treated with fresh milk, allowing the mixture to ferment and sulbmitting the fermeinted product to treatment with ultra violet rays in order to arrest fermentation and sterilize the product which is then reduced to a powder and packed into hermetically sealed containers.

In carrying the invention into effect the powders comprising the mixtures of two er, more flonus and fruit juice are prepared and allowed to ferment and then 4 À 5 subjected to the ultra violet lay treatment and dried In the second step of the process another mixture of powdered Japanese yam and meat juice, chicken soup, or fish are prepared, and the mixj jlure allowed to ferment and then treated with the ultra violet rays and dried In file thirdc step of the process the two kinds lf nnwder thus prepared are added to 367,340 fresh milk and allowed to ferment The product is then subjected to treatment 55 under the ultra violet rays and powdered after which it is packed into hermetically sealed containers.

If the materials obtained in the first and second steps of the process, before 60 they are sufficiently dried that is while still in a condition of a thick mass, and at a relatively low temperature, are put into the fresh milk, it takes a comparatively long time to complete the drying in 65 consequence of which the fresh milk may be putrefied by the invasion of bacteria in the course of fermentation in the third step of the process In order to avoid this putrefaction of the fresh milk, these 70 materials are treated under the ultraviolet rays and dried after which they are then pat into the freslh milk Moreover the fresh milk mixed with the previously described materials can be easily dried by 75 heating at the low temperature for a short time The nutritious powders obtained by means of the process according to this invention are easily dissolvable in cold or warmn water 80 The powders obtained' by the process contain the essentials for nutrition, for instance, fat, nitrogen, sugar, sfarch, sodiumi clloi'ide and so on in the coniiition in which they are easily dissolved in 85 cold or warm water, and are more valluable as foods than the usual powdered or condensed milk food They are also easilv prepared for use and 'when these products are used, there is no need to talke 90 other supplementary food, for instance, firuitq, juice or vegetable soup as with the usual milk foods made from natural milk or artificial milk The products made nccording to the invention are the most 95 ideal for babies' health because they are fully cterilized by means of treatment under the ultraviolet rays.

An example of the process according to the invention is as follows: 00 A mixture of 8 276 lbs of glutinous rice flour and 16 534 lbs of uncleaned rice flour are mixed with 0 911 litres of fruit juice obtained by compressing 9 92 lbs.

of green plums to which is added about io 05 0.09 litres of a concentrated solution of 367,340 common salt This mixture is allowed to ferment and is then subjected to the action of ultra violet rays and evaporated to dryness, the product constituting the first mixture Another example of the first mixture may be prepared by taking 8 267 lbs of soya bean flour admixed with 8 267 lbs of wheat flour and mixing therewith 0.15466 litres of fruit juice obtained by o compressing five to ten apples or cucumbers mixed with O 546 (i litres of any other fruit juice This is then,allowed to ferment being afterwards subjected to the action of ultra violet rays and then evar porated as in the previous example

A second mixture is prepared by taking 12.:3 lbs of Japanese yam powder to which has been added O

3644 litres of meat juice ebtained by compressing pork or beef to wlhich is added a small quantity of salt.

If desired instead of the meat juice a smiall quantity of fish may be employed and in either case the mixture is allowed to ferment and is then subjected to the ultra violet ray treatment and reduced to a powder.

Either of the first mentioned mixtures are then mixed with the second mixture and the whole is allowed to ferment in 1 822 litres of fresh milk.

The fermented product is then subjected to ultra violet ray treatment and reduced to a powder after which it is packed into hermetically sealed containers.

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Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that what IData supplied from the esp@cenet database -

Worldwide Claims:


1 Process for the manufacture of food products consisting in ( 1) preparing a mixture of two or more cereal or like flours such as rice, soya bean or wheat together with fruit juices, ( 2) preparing 45 a mixture of Japanese yam powder together with meat juice or fish, allowing each of the ingrellienlts 1 lud 2 iespectively to ferment followed by a treatuent with ultra violet rays in order to 50 arrest fermentation and sterilize the products, mnixing the powdered products ( 1) and ( 2) thus treated with fresh milk, allowing the mixture lo ferment and suibmitting the fermented product to treat 55 ment with ultra violet lays in order to arre t fermentation and sterilize the prodluct which is thein reduced to a powder and paceked into hermetically sealed containers.

2 The imnproved food product when prepared by the process hereinbefore described and claimed.

Dated this 12th dlay of September, 19:30.

MIARIKS & CLERK.

Redhill: Printed for His Majesty's Stationery Office by Love & Malcomson, Ltd -1932.Data supplied from the esp@cenet database - Worldwide

642/2197

136.

GB386167 - 1/12/1933

IMPROVED MANUFACTURE OF FOODSTUFFS RICH IN PROTEINS


Applicant(s): TRES CHEMISCH PHARMAZEUTISCHE (--)

E Class: A23L1/202; A23L1/212B


Priority Number: ATX386167 (19311228)

Family: GB386167

Abstract:


Foodstuffs rich in gluten proteins are prepared by separating the germinal substance of seed kernels of the carob tree or related plants of the mimosaceae or caesalpiniaeae families, e.g. cercis siliquastrum, cercis canadensis and cercis chinensis, and, after drying if desired, converting into mill products, e.g. by coarsely comminuting, rough grinding, grinding to flour, or converting into flakes by steaming and rolling, the operations being conducted so as to avoid substantial denaturing of the gluten-forming proteins. In separating the germ substance by the wet method and drying before comminuting, the drying is effected at a temperature sufficiently low to avoid injury, e.g. not above 40-50 DEG C., and may be assisted by using a vacuum or a heated current of air. The milled products are bleached by adding small amounts of solid acids such as citric acid or other acid-reacting solids, or by adding dilute acid solutions as mists, or by means of oxidizing or other bleaching agents such as hypochlorites, sodium para-toluene sulphochloramide, peroxides, persalts, c. To prepare a dough from the germ flour obtained its excessive water-absorbing power is first reduced by thinning it with food flours preferably flours poor in or free from gluten, such as rice, potato or legume flour, or with slightly swelling materials such as cellulose, e.g. in the form of bran, starch, casein, c., or by adding salts such as potassium bitartrate or other tartrates, borates, citrates, or phosphates which will modify the waterbinding properties of the gluten. The thinning substance added may consist of the germ products the water-absorbing power of which has been diminished or destroyed, e.g. by heating to 150-260 DEG C. until slight roasting occurs. Baking powders if used should contain an excess of acid. The baked products may be ground to grits or flour for such uses as in soups or sauces or for sprinkling baked meats. In making macaroni and like paste goods, to prevent a spongy mass forming on cooking the dough hemicellulose is added, e.g. by adding the milled products of whole plant seeds in the endosperms of which hemicellulose is stored up, or the endosperms only of such seeds, e.g. carob seed endosperms. The paste goods are dried in the usual manner to preserve them.ALSO:Foodstuffs rich in gluten proteins are prepared by separating the germinal substance of seed kernels of the carob tree or related plants of the mimosaceae or caesalpiniaceae families, e.g. cersis siliquastrum, cercis canadensis, and cercis chinensis, and, after drying if desired, converting into mill products, e.g. by coarsely comminuting, rough grinding, grinding to flour, or converting into flakes by steaming and rolling, the operations being conducted so as to avoid substantial dematuring of the gluten forming proteins. In separating the germ substance by the wet method and drying before comminuting, the drying is effected at a temperature sufficiently low to avoid injury, e.g. not above 40-50 DEG C., and may be assisted by using a vacuum or a heated current of air. The milled products are bleached by adding small amounts of solid acids such as citric acid or other acid-reacting solids, or by adding dilute acid solutions as mists, or by means of oxidizing or other bleaching agents such as hypochlorites, sodium para-toluene sulphochloramide, peroxides, persalts, c. To prepare a dough from the germ flour obtained its excessive water absorbing power is first reduced by thinning it with food flours preferably, flours poor in or free from gluten, such as rice, potato or legume flour, or with slightly swelling materials such as cellulose, e.g. in the form of bran, starch, casein, c., or by adding salts such as potassium bitartrate or other tartrates, borates, citrates, or phosphates which will modify the water-binding

643/2197

properties of the gluten. The thinning substance added may consist of the germ products the waterabsorbing power of which has been diminished or destroyed e.g. by heating to 150-260 DEG C. until slight roasting occurs. Baking powders if used should contain an excess of acid. The baked products may be ground to grits or flour for such uses as in soups or sauces or for sprinkling baked meats.Description:



Convention Date (Austria): Dec. 28, 1931.

- 3 Ii9 --386,167 Application Date (in United Kingdom): March 21, 1932. No. 8378/32.

Complete Accepted: Jan. 12, 1933.


Improved Manufacture of Foodstuids Riclh in Proteins.

We, TILES CIIxMISC_-PHARMAZEUTISCIuE i INDUSTRIE UND HANDELS A.G., of tllbi-ut a

42, Budapest VIII, Hungary, a Company organised under the laws of the Kingdom i of ilungary, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly i described and ascertained in and by the following statement- n

The invention enables foodstuffs which i are rich in gluten proteins to be manufactured independently of wheat. The essential feature of the invention consists in that the germinal substance of seed j5 kernels of the carob tree (ceratonia siliqua) or of related plant genera of the families of the MinosaceaB or Coesalpiniaceme, for example the Cercis species (Cercis siliquastrum, Cercis canadensis, Cercis chinensis) is separated from the seeds, and, if required, dried, under such conditions as to avoid substantially denaturing the gluten-forming proteins, and thereafter converted into mill products

(coarsely comminuted, rough-ground, ground to meal or converted into flakes by steaming the grits and rolling) while likewise taking precautions for the purpose of avoiding substantially denaturing.

A} The term " denaturing " is used to include any change in the nature of the glutenforming proteins which would suibstantially alter the gluten-developing character of the said proteins. 'Such alteration is not perceptible externally and does not necessarily lead to any detectable change in the chemical composition, but can be readily ascertained by a practical test. It is an essential feature of the -40 present invention that during separating, drying and milling of the germinal matter, denaturing of the proteins, either through mechanical or thermal influences, must be substantially avoided.

The seed kernels of the plant genera specified contain lhemicelluloses (also called gum substances or reserve celluloses) as a compact store in the form of the endosperm consisting of two lamellae.

These lamelle enclose the embryo with its organs, the germinal substance -rich in proteins. The gum substances of such seed lr-r71nels have already been utilised echnlically. Thus, for example, husked

Lnd de-germinated carob bean kernels are 55 on the market in the form of flour, which is used for the manufacture of adhesives, sizes and dressings and binding agents.

The invention is based on the surprising discovery that the germinal substance 60 of such seed kernels contains proteins which, in their physical behaviour and 2hemical composition, resemble the gluten proteins of the wheat grain (which do not occur in wheat, however, as the constituents of the germinal substance) to such an extent that it is possible to speak of a perfect agreement. More particularly, the germinal substance of the seed kernels of the fruit of the carob tree is 70 rich in such proteins which, in regard to salts, acids and alkalies and also various anions and cations, behave physicochemically absolutely like wheat gluten proteins. In addition, the germinal substance contains various amounts of polysaccharides and cellulosic substances but no starch.

644/2197

Wheat flour differs from the flour of all other cereals in the property of leaving behind in an almost pure state the bulk of its protein compounds on continued kneading of the dough under water or under a jet of water, in the form of a coherent resilient mass, the so-called 85 gluten. The wheat grain however contains the gluten proteins dispersed in the flour cells constituting the endosperm.

In contradistinction thereto the organs which, in the seed kernels of the plant 90 families specified, are the carriers of the gluten proteins, can be separated mechanically as a whole from the other organs.

It is therefore possible to obtain products rich in proteins simply by converting the 95, separated germinal substance as a whole into grits, groats, flour or flakes by the methods usually employed in treating cereals. Apart from this however, this process means a valuable contribution to Soyj the technical production of foods, because among the bread cereals, only the gluten proteins of rye share with the similar glutens of wheat the high swelling power to which are due the peculiar dough- i05 forming properties and baking capacity WM of the: e two bread cereals, and because gluten-developing seeds other than wheat have heretofore not been known at all.

Inl order to separate the germinal subE stance, the latter, after the seed kernels have been husked, is detached from the enid spjelm5s oy iknownimechanical miethods, in doing which care should be taken that during huskig, and degermination of the seed kernel, there does not occur, either through mechanical or thermal influences, a substantial denaturation of the glutenforming proteins. In carrying out the separation by the wet method and drying 15w the germinal substance before conimiiuting the same, this drying operation has to le effected at so low a temperature (preferably not above 40-50o C.) that such inijury is likewise avoided. It is advisable to promote drying by means of a vacuumll or a heated current of air.

In their original character, the milled products have an egg-vellow colour. Onl suspDending them in water, however, the 2 5 colour changes to green, the water also assuming this colour. This undesired colouration, which is evidently due to the chlorophyll or its derivatives contained in the milled products, many be eliminated by o the action of dilute acids. For this purpose the milled products may be intiinatelv mixed for example with small quantities of solid acids (such as citric acid) or with other solid agents having an >;a acid reaction. Acids may also be incorporated with the milled products as very dilute solutions in the formt of mists. In this way it is also possible to prevent the dough assuming a greenish colour when -} worlked up with weakly alkaline baking powders. Exaetly {he same results are obtained when the acid or acid-acting substances are only added to the water used for preparino- tihe dorfrh.

-45 The milled products mlay also be decolorised byt a bleach of the usual type, more particularly with oxidising bleacehing agents (for example hypochlorites, sodium paratoluene-sulpho-clhloramide, peroxides, persalts or the like), instead or by the action of acids.

A palatable baked product cannot be made from wheat gluten alone. In wheat flour, the gluten proteins are diluted by a very considerable excess of starch. In the germinal substance flour of the plant seeds specified. for example carob bean kernels, the gluten proteins are only diluted with comparatively small quanftities of other substances. Therefore for this reason alone this flour provides a douwh which, although it is compact and resilient, cannot be baked successfully.

In addition, the germinal substance flour, due to its higher gluten conteni, possesses a much greater capacity for absorbing water tlhan -wheat flour. Whereas the quantity of water for preparing a normal bread dough from wheat flour amounts to 50-70 per cent. of the weight of the 7n flour, the germinal substance flour for example of the carol) bean kernel absorbs M10-200 per cent. of its own weight of water in forming a doutglh of similar consistency. Bv thinning the germinal sub-.

stance flour w-itlh food flours tflonis which are low in gluten or free from gluten being preferably seleeted), or wIth other slightly swelling additions, such as cellulose (for example in the form of bran) or starch, 80 casein or the like, the baking capacity may be enhanced to the required extent.

Su.1 additions have previously been made to wheat flour for the same purpose. Thus, it is known to work up milled lwheat 85 _-l11ten or purpe wbleit c'litc albimen with bran, which has been freed from carbohydrates in anAv manner, into baked products for diabetics. It has further been pr opo)sed to bake

645/2197

wheat gluten albumen 90 in adlmixture with the flour or germs of the cereals. Likewise, it has also been proposed to render pure wheat gluten capable of being baked by admixture W cth casein. 95

A1nother method is the addition of suitable salts. It is already known that the water-binding property of wheat gluten mav be modified by the action of acids, bases and salts. D'ifferent additions have 100 been investigated for the effect with the sam1e molecular concentration and were arranged in a series, it being found that the influence of' anions preponderates ill res'r'tinng the absorption of water. This

105 also applies for the near Terminal subs' ance.1oSlom. Amiong the different additmonlS cr:.ino rinto considei atioon in practice. -'artiate, hare a prroouneed effeet.

It il th1ere'fore xi-a1le to add tartrates, 11G for examl'e potle s n 1ita' irate, to the milled Drod'cts ulnde' consideraliion i order to redvree the pn-tew blldUn ' Jiewer.

For the sanme mrllp3oSe, hlowever, borates, pbsplat-es and 1citiates or the li!e coi.11 115 be used for example.

The sanme ol)ject mav finally be ot ined by impairing tbe swelling power of the Milled products themselves, or by deprivingl them entirely of swelling power, for 120 example by heating, and using them for thinning unaltered mill products. If for this purpose the mill products are heated at temperatures between 1500 and 2600 C.

ilii slight roasting occurs, a very perreptible improvement in the taste occurs at the same time.

All this applies cliiefly for baked products and only applies in the second place for paste goods

(macaroni and the like). 130 3863,iG7 3SQ),]6i On the contrary, in the case of paste goods prouticeed from germinal substance fiour according to the invention, the disadvantage is tound that a spongy mass is A formed on cooking the dough. This may be counteracted by an addition of hemicelluloses, of any origin to the flour or paste. Preferably, milled products of whole plant seeds, in the endosperms of which hemicelluloses are stored up, or the endosperms of such seed grains, will be used either alone or in combination.

The mill products may be worked up in the usual manner into dough and baked.

The paste goods may be dried in the usual manner for the purpose of preserving them. Further, the finished baked products may be ground to grits or flour with the object of making flours for special purposes, such as for soups or sauces made of roasted flour or for baked meats sprinkled with flour.

EXAMPLES.

1. The seed kernels of Ceratonia siliqua are husked either in the dried or soaked condition. The separation of the germinal substance is most simply effected by splitting the husked seeds and sieving out the crumbly embryo parts. To 100 - 3 kilograms of a flour obtained by milling this germinal substance is added 0.2 to 0.5 kilograms of solid citric acid in the form of powder, and the whole is thoroughly mixed. As much water is now added to the flour as will form a compact and plastic dough, which may be baked in thin layers in the way of making unleavened bread. The effect of the addition of citric acid is that the dough 0retains its yellowish colour, and the change to a green colour occurring on contact with water without the addition of acid does not take place.

2. Seventy kilograms of a gluten-free flour, for example rice flour, potato flour or lenume flour is mixed with 30 kilograms of the milled germinal substance of Ceratonia siliqua. The mixed flour, due to its content of gluten proteins introduced with the germinal substance flour, may be made into a dough in the usual-manner and baked with yeast.

Baked products can also be prepared from the same flour by means of baking powder without the addition of leaven or yeast. As compared with the usual method of making baked products by means of baking powders, the only difference is that the acid should be in excess 6Q in the baking powder. For example, for every kilogram of germinal substance flour, 90 kilograms of a baking powder are used consisting of 30 grams of sodium bicarbonate and 60 grams of tartaric acid.

646/2197

The flour mixed with the baking powder ba is made into a dough with 0.8 litre of water per kilogram of flour and is baked.

3. For making a pastry, 80 kilograms of g(erminal substance flour from Ceratonia siliqua are mixed with 20 kilograms of 7Qf starch-free bran, mixed with water and the usual ingredients, kneaded to a dough and baked.

4. 100 kilograms of a flour of the germinal substance from Ceratonia siliqua is 7S thoroughly mixed with 0.3 to 0.8 kilograms of potassium bitartrate. Due to the reduction in swelling power, the flour absorbs considerably less water during the formation of dough than without this 80O addition. The dough may be used for making paste goods (macaroni and the like) or baked products, and more particularly bread. For the latter purpose, kilograms of this flour, for example, 85 is worked up in the usual manner with litres of water, with the addition of 2 kilograms of salt, 3 kilograms of yeast and 5 kilograms of dextrose, into a homogeneous dough, is left to ferment and 9a baked in the oven. The bread obtained in this way possesses a crust of normal quality. The crumb is yellowish, if the flour has not been previously bleached, and has the porosity of rye bread as well 95; as a pleasant bread-like odour and taste.

5. Seventy kilograms of flour of the germinal substance of Ceratonia siliqua is mixed with 30 kilograms of a portion of the same flour which has previously been 100 converted by heating

(scorching) into a form which is capable of swelling only slightly or not at all. The mixed meal with addition of the necessary ingredients is made into a dough which is baked in 105 the usual manner.

6. Seventy kilograms of flour of the germinal sihbstance of Ceratonia siliqua is mixed with 5 kilograms of a flour obtained by milling the endosperms of Ceratonia 110 siliqua and with the addition of suitable quantities of salts, egg yolk (if desired also 10 kilograms of the scorched flour of the general substance) are worked up with water to a hard dough which is cut, 115 stamped or pressed into suitable shapes, and is then subjected to a drying process such as is generally employed for the preparation of paste goods.

Having now particularly described and 120 ascertained the nature of our said invention and in what manner the same is to be performed, we declare that what weData supplied from the esp@cenet database - Worldwide Claims:


1. A process for manufacturing foodstuffs which are rich in gluten proteins of the kind of wheat gluten proteins, characterised in that the germinal substance of seed kernels of the carob tree (Ceratonia siliqua) or of related plant genera i30 43 86,167 of the families of the Miimosacee or CsesalpiniaceuT, for example the Cercis species (Cercis siliquastrum, Cercis canadensis, Ceicis chinensis) is separated from m the seeds, and, if required, dried, under ouch conditions as to avoid substantially denaturing the gluten forming proteins, and thereafter converted into mill produrts (coarsely comminuted, roughioriid7 gid iound to meal or converted into flake3 bv steamin- the grits and rolling) while lilceuise taking precautions for the purpose of a.-oidinog substantially denaturlo 2 A process as claimed in claim

1, eharacterised in that the milled products of thie neirminal substance are treated with dilute acids.

3. A form of carry-in out the process as claimed in claim 2, characterised in that small quantities of solid acids (for example citric acid) or of other solid agents having an acid reaction or solutions of such additional substances for 2; example in the form of mist are incorporated with the milled products.

4. A process as claimed in clainm 2, characterised in that the milled products are decolourised by a bleaching process of the usual tvpe, more particularly by means of oxidising bleaching agents.

5. A process for manufacturing foodstuffs, characterised in that the waterbinding power of the mill products made by the process according to claims 1 to 4, is reduced by thinning with food flours

(preferably low in gluten or gluten-free) -or with other slightly swelling additions, such as cellulose

647/2197

(for example in the form of bran), starch, casein or the like, or by addition of salts, such as for example potassium bitartrate, which reduce the swelling power of wheat gluten proteins.

6. A process as claimed in claims 1 to 5, characterised in that the milled products are brought, for example, by heatma', into a slightly or non-swelling condition and are employed for thinning unaltered milled products.

r0 7. A form of carrying out the process as claimed in claim 6, characterised in that, for the purpose of converting theim into a form incapable of swelling, the milled products are heated at temperatures bekwcen 130i and 26O0 C. until 55 slightly roasted.

A. A process for manufacturing foodstuifs, characterised in that hemicellulose of any oiain, for example mill products o0 xWhole plant seeds in the endosperms of 6 hi Ii hemicellluloses are stored or the endospe.rm of such seed grains, are added to the -erminal substance flour made by the pro es acorsing to claims 1 to 4, or to the dough prepared therefrom. 65 9. A process for manufacturing paste goods or baked products., characterised in that a dough rich in proteins is made in the usual manner fromn mill products produced according to any of the preceding 70 claimns, whereuapon this dough may be baked in the usual manner.

10. A form of carrying out thle process as claimed in claim 9, characterised in that acids or substances with an acid 7s action are adtled to the water for making the dough.

11. A pro ess as claimed in (lainms 9 and 10, characterised in that the paste goods are dried in the usual manner for 80 the purpose of preserving same.

12. A process for the manufacture of flour for special purposes as claimed in claimis 1 to 11, characterised in that the finished bakled products are ground to SS writs or sour.

13. TI'he process for the manufacture of foodstuHff rich in proteins substantially as described.

14. Foodstuffs when manufactured by 9o the process claimed in any of the preceding claims.

Dated this 21st day of March. 1932.

TPRES ClT EMISCII-PIIARMAZEITTSCITE INDI7STRIE VND HAN'DELS A.-G., Per: Boult,

Wade & Tennant, 111/112, Hatton Garden, London.

E.C. 1, Chartered Patent Agent,;.

Redlill Printed for His 3Maiesty's Stationery Office, by Love & Malcomson, Ltd.-1933.

-4Data supplied from the esp@cenet database - Worldwide

648/2197

137.

GB402188 - 11/30/1933

PROCESS OF TREATING CEREAL FOODS


Applicant(s): JOHN LEONARD KELLOGG (--)

E Class: A23L1/18C6



Family: GB402188

Abstract:


Cereal grains are cooked in the presence of moisture, rolled while still moist and hot, partially dried and then sprayed or otherwise treated with some substance that after drying leaves a coating of such a character that the escape of steam from within the grain is prevented during a subsequent heating to a high temperature until the grains are browned and puffed by the steam pressure therein. In a specific example the grains, such as those of wheat, rice, oats, corn c., are cooked in a steam cooker at fifteen pounds pressure and passed directly to hot flattening or shredding rolls: grains of wheat are given a cup-shaped form in passing through such rolls. The grains are then dried until the moisture content is from ten to fifteen per cent, preferably tempered and then provided with a moisture occluding coating for example by spraying with a solution containing a small amount of egg albumen or with a solution of salt and sugar in the proportion of twenty parts of water to two and one half parts of salt and from three to five parts of sugar: the grains are then again partially dried and tempered finally being subjected in an oven to a temperature of 325 DEG to 600 DEG F. Rice may be prepared with the step of rolling or shredding omitted.

649/2197

138.

GB422491 - 1/14/1935

IMPROVEMENTS IN OR RELATING TO THE TREATMENT OF RICE, RICE

OFFALS, PADDY AND THE LIKE


Applicant(s): SAM HARRISON GIBBON (--)

E Class: A23L1/182



Family: GB422491

Abstract:


422,491. Treating rice. GIBBON, S. H., 242, Lauderdale Mansions, Lauderdale Road, Maida Vale,

London. July 14, 1933, Nos. 20024, 20991, and 34225. [Class 58] Rice is soaked in warm water at 70

C. for about five hours in tanks 1, its water content being thus raised to 25 per cent to 30 per cent ; the soaked rice then travels on an endless band conveyer 4 through a refrigerating chamber 3 in which its temperature is maintained at -40 C., the passage through the chamber taking seven minutes. The rice falls from the conveyer 4 on to a conveyer 5 by which it is carried through a hot water tank 6, the water in which is kept at boiling point, thence passing info a rotary drier 8. The rice may be unhusked, husked, milled, or in the form of rice offals.Claims:

Claims of GB422491 be performed, I declare that what I claim 7. Rice which has been subjected to

is:- the process according to any one of the 1. The step in the processing of rice, foregoing claims.

which consists in bringing the rice to a 8. Plant for the processing of rice temperature below the freezing point of arranged and operating substantially as 90 water, for example about -40 C. for the herein described with reference to the purpose specified. accompanying drawing.

2. A step in the processing of rice for improving its food value, which consists Dated this 10th day of

July, 1934.

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in subjecting it, while in a condition in BO1ULT, WADE & TENNANT, which its water content is upwards of 111 & 112, ilatton Garden, 20%, to the action of a refrigerating London, E.C.1, medium whereby the temperature of the Chartered Patent Agents.

Leamington Spa: Printed for His Majesty's Stationery Office, by the Courier Press.-1935.Data supplied from the esp@cenet database - Worldwide

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139.

GB432694 - 7/31/1935

IMPROVEMENTS IN AND RELATING TO PROCESSES FOR THE

TREATMENT OF SOYA BEANS AND THE PRODUCTS OBTAINED THEREBY


Applicant(s): ALFRID BORKOWSKY (--)

E Class: A23L1/20B4



Family: GB432694

Abstract:


Shelled soya beans are steeped from 30 to 60 minutes in warm water until they swell slightly and their moisture content amounts to about 20 per cent. They are then dried on or between heated rollers after preferably having been squeezed to a thickness of one millimetre by passage between rollers. The rate at which the beans are passed through the heated rollers is such that the bean flakes when cool have a moisture content of not more than 6 per cent. The flakes are subjected to the action of a strong current of air and may be worked up into meal or flour. The process may be carried out under reduced pressure. The beans may be pressed cool to express approximately half their content of fats. Materials such as rice, potatoes, cereals, e.g. wheat, rye, barley, oats, c. may be steeped with the beans and passed through the rollers to form a mixed food.ALSO:Shelled soya beans are steeped for from thirty to sixty minutes in warm water until they swell slightly and their moisture content amounts to about 20 per cent. They are then dried on or between heated rollers after preferably having been squeezed to a thickness of one millimetre by passage between rollers. The rate at which the beans are passed through the heated rollers is such that the bean flakes when cool have a moisture content of not more than 6 per cent. The flakes are subjected to the action of a strong current of air and may be worked up into meal or flour. The process may be carried out under reduced pressure. The beans may be pressed cool to express approximately half their content of fats. Materials such as rice, potatoes, cereals, e.g. wheat, rye, barley, oats, c. may be steeped with the beans and passed through the rollers to form a mixed food.Description:


[Second Edition.]


Application Date: Feb. 7, 1935. No. 4021/35. 4325694 Complete Specification Accepted: July 31,

1935.


Improvements in and relating to Processes for the Treatment of Soya Beans and the Products obtained thereby.

(Communication from abroad from of moisture at a temperature of 1000C, ALFRID BonRowsKY, a

German citizen, while if the moisture content is low a 55.

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of 57, Morewoodstrasse, Wandsbek- sufficient improvement in flavour is not Hamburg, Germany.) obtained.

I, HENRY WITHERS KICKWEED It has also been proposed to heat the JENNINGS, a British subject, of 51/52, beans, in some cases after being moistChancery Lane, London, W.C.2, do ened, in a apparatus resembling a coffee 60 hereby declare the nature of this inven- roaster. This process is not satisfactory tion and in what manner the same is to because the parts of the beans in contact be performed, to be particularly described with the hot metal surface are overand ascertained in and by the following heated, whereas the interior of the beans, statement:- owing to their poor conductivity, re-

As is well known, Soya beans have a mains relatively cool for some time. The disagreeable taste so that it is not pos- lecithin is, therefore, decomposed owing sible to make them palatable by cook- to the local overheating and the product ing them in the ordinary manner like has a disagreeable taste.

other leguminous vegetables. Many pro- Again it has been proposed, primarily 70 cesses, some of which have been patented, for the purpose of improving the keepare, therefore, known by means of which ing power of Soya bean meal, to steep Soya beans were made palatable or were the beans, in a disintegrated condition, attempted to be made so. in water acidified with acetic acid for In general, only the high content of about 6 hours, during which time the 75 albumen in this vegetable was taken into disintegrated beans absorb about three account in these prior processes, which times their weight of water. The paste can be easily understood because the obtained was then dried, for example, albumen in the Soya bean, like animal on heated rollers. This process is again albumen is very easily assimilated by the unsatisfactory because, apart from the 80 human organism, while it is not accom- undesirable addition of acetic acid, the panied by the undesirable substances large amount of water which is added which accompany animal albumen, must be removed and necessitates either namely uric acid in the case of meat and a high temperature or prolonged heating sulphur compounds in the case of eggs. or both, so that the lecithin must in any 85 Unfortunately, however, too little atten- case be decomposed; owing to the large tion has previously been paid to the amount of added water which has to be nutrient material as a whole which is removed the process also is uneconomical.

naturally present in Soya beans. This Now the object of the present invenmaterial consists, in addition to albumen, tion is to provide a process by which 90 mainly of fat, lecithin and carbo- the flavour of

Soya beans is improved hydrates. The albumen in all natural without altering the lecithin. This is substances in which it is found is always possible with the process of the invenassociated with 'lecithin and fat and, tion because the duration of the heating therefore, this complex must not be in the presence of moisture is kept so 95 broken down if a nutrient material of short that there is not sufficient time for high value is to be produced. the lecithin to alter.

In the attempt to give Soya beans an According to the invention, the shelled unobjectionable taste, many different Soya beans are steeped in water until processes have been suggested. Thus, it they swell up slightly, and are then 100 has been proposed to subject the beans, rapidly dried by passing them between without being disintegrated, to treatment heated rollers or by passing them after with steam for a period of from 5 to 20 having been previously flattened over minutes. This treatment has the dis- heated rollers or both. Preferably, the advantage that an undesirable alteration beans are steeped in warm water until 10.5 takes place in the lecithin in the presence their moisture content amounts to about [Price Is.] ,, . LJ s L 2V 2 432,694 20% and the steeped beans are For some purposes it is desirable to squeezed flat and passed in flat condi- reduce the content of fat in the beans, tion between or over heated rollers. In for example to about one-half. For this order to ensure thorough drying the purpose the beans, after being shelled, material may be allowed to remain in may be pressed, for example in an 7,0 contact with the surface of one of the Anderson press, after which they are rollers as long as possible, or it may be steeped in warm water and treated as dried on or between more 'than one pair previously described. The finished proof rollers. duct then has a, fat coiltent of about 10% The process may be carried out as as compared with a content of about 75 follows: 18% in a product from which no fat has The shelled Soya beans are allowed to been expressed.

swell slightly fin warm water, after which The keeping power of a fatty meal of they are squeezed and rolled to the thin- this nature is very important. Provided ness of paper between heated rollers. the moisture content of the finished pro- so The swelling is carried out until the duct is not higher than 6%, thle product beans have a mnoisture content of about will keep for a long time.

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20%. Whlen -the ben-.s have this con- In order to produce a co-mple'.e rlixed tent of moisture they can be pressed flat food the process can lie modified by with a relatively low pressure. The pre- steeping starchy products such as rice, 8.i pared Soya beans are then. passed in a potatoes, cereals, for exawipLe wheat, rye, layer of paper thiniess bsetwveen the barle-y, oats, etc., tcg- lethei vwith the

Soya, heated rollers, so that a spointanecus beans and then prssug thein in eoinm7on evaporation of the water which has been thr orgh the b1et d r C c1 s.

t^heln up when ithe beans swell o eurs. Ha i n n p c der:21 e rd 910 T 'e evzinor Lt-io can be consideray inl- ascertained 'Le ;t,-re 2 ai wer erea'e -\iwitll the as istane Gf a rapid tion andl in tiat 3' rer 2 sane is to 1-.e urt -eilt of air. 0-rwin, to the thinnr.ess of perfo-ried, I chlare ti't n3at T h a Jthe iever in.v-fhjch.he beans are passed is betw.; the rollers the necessary transfer 1. A process f'r rh e of ar

9.3 of ne..u is efected in a fraetisn of a edible product fron1i Sc y -eordseegud, in which time the evaporation ing to which the sthcll -. are steeped of the water is also completed and the in water until thev y ip 'ngrp - an desired effect in the imAProvement of the are then rapidly cdried bv passing them flavour also takes place without the between- heated rollers or kv ting tl.ei 100 sensitive constituents of the beans, after having been p wu31y flattened namely the lecithin and the albumen, over heated rollers, or Loth.

being changed. 2. A process for the productioln f an EXA3IPLE.. edible product from Sova beans accord1OO Kg. of shelled Soya beans are ing to which the slhelledc beans are steeped 105 softe-ned for about 30 rminutes in a water in warm water until their inisture conbath at a temperature of 50aC. If the tent amounts to about 20%, and the beans are very dry, the duration of the steeped beans are squeezed flat nlid passed treatment must be extended to 60 in flat condition between or over heated minutes. The Soya beans are removed rollers. 110 from the water and then squeezed be- 3. A process in acordanlce wvith claim tween rollers to a thickness of about 1 or 2, wherein the drying is carried out 1 m-nm. After this, the prepared beans under a reclaieed pressure.

are- passed between rollers. which are 4. A process in akccrdance Vith claimn heated by steam or hot water. The 1, 2 or 3, in wiiv- h abouit hclf the oil 113 clouds of stcami produced are driven away content is expressel from the cold beans by a strong current of air. The rate at after dryiing,.

which the beans are passed through the a. A process in aceordc1tnee with anv of rollers is such that tlle beai firkes, when the claims 1 to J-, 1Clheleijl the drying is cool, ha,-ve a moisture co-n-teint of not more carried on ntil the lmoisture content. of 120 than 6B%. The Soya fialaes which leave the filnished p oC1-l is a7out 6%.

the rollers are subjected to the action of 6. A process in accordance with any a strong current of air for the puirpose of the claims i to 3, in which the treatof efiectin- farther drvi-nig and for cool- ment is carri'ed out on.. the Soya beans ing them. The flakes produced caii then in comminon with a starchyeli preduct such 125 be used for immediate consumption or as potatoes, rice, maize or other cereal.

can be o worked up into the form of meal 7. A process for the production of an or flour. The process can also be carried edible product from Soya beans substanout under reduced pressure in order that tially as describzd or in accordance with a low temperature may be maintained. the preceding example.

130 432,694 3 8. An edible Soya beans product when For the Applicant produced by a process claimed in any of GILL, JENNINGS & the preceding claims. EVERY-CLAYTON, Dated the 7th day of

February, 1935. Chartered Patent Agents, 51/52, Chancery Lane, London, W.C.2.

Abingdon: Printed for His Majesty's Stationery Office, by Burgess & Son.

[Wt. 8021B.-501411936.1Data supplied from the esp@cenet database - Worldwide

Claims:

GB432694 : No claims available


654/2197

140.

GB436765 - 10/17/1935

PROCESSES FOR TREATING AND STABILIZING WHEAT GERM


Applicant(s): CEROBREX LTD (--)

E Class: A23L1/172; A21D2/36D


Priority Number: CAX436765 (19331113)

Family: GB436765

Abstract:


Wheat germ is treated to stabilize it against rancidity and to improve its keeping qualities by grinding it to about the fineness of flour, mixing with it prior or subsequent to or during the grinding common salt to absorb moisture and inhibit too rapid a diastatic action of yeast in baking, and then adding an inert non-fatty filler such as potato flour, rice flour, rice polishings or corn flour. The salt added may be 5-8 per cent by weight of the wheat germ and the potato flour 15-20 per cent. The product is dried before or after addition of the filler by heating without free access of air or in a current of carbon dioxide, nitrogen or other inert gas, e.g. by heating to 200-225 DEG F., preferably 212 DEG F., for 20 minutes in a closed oven. The product may finally, preferably while still warm, be enclosed in containers which are airtight or proof against free air circulation and which may be filled with carbon dioxide, nitrogen or other inert gas. The Specification as open to inspection under Sect. 91 comprises also the use in place of common salt of other substances having the required characteristics. This subject-matter does not appear in the Specification as accepted.Description:

Description of GB436765 k,- (. '


Convention Date (Dominion of Canada): Nov. 13, 1933. 436,765 Application Date (in United

Kingdom): Nov. 6, 1934.

Complete Specification Accepted: Oct. 17, 1935.

COMPLETE SPECIFICATION

No. 31845/34.

Processes for Treating and Stabilizing Wheat Germ We, CmROBnEX LIMITED, incorporated under the Dominion of Canada Companies Act, Manufacturers, of Lumsden Building, Toronto, 2, Canada

(Assignees of S PETER. JOHN DONK, of 24 Scarth Road, Toronto, County of York, Province of

Ontario, Canada, a citizen of the United States of America, and ALExANER Ross MACDONALD, of

300 Avenue Road, Toronto, County of York, Province of Ontario, Canada, a subject of the King of

Great Britain and Northern Ireland) do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-

655/2197

This invention relates to new and useful improvements in processes of treating wheat germ so as to make it useful in the manufacture of bakery and other food products.

In the process of the manufacture of flour from the wheat grain or berry it has been found that unless the wheat germ is wholly or to a large extent removed in the process of grinding, the resultant flour is not satisfactory for production of bread and other products because(a) the keeping quality of the flour is impaired due to the fatty constituents of the germ (amounting to approximately 12% of its weight) becoming rancid due to or as result of oxidation; (b) the presence of the wheat germ is favourable to the growth of grain parasites such as weevils and molds; (c) of a streaky discoloration due to localization of the fatty constituents of the germ.

The wheat germ being relatively high in protein, and in mineral salts (primarily organic phosphates), and in valuable vitamins, all of which are important and desirable elements in a properly balanced diet and refined white flour as ordinarily used for bread being largely deficient in these elements, one of the principal objects of this invention is to make available for introduction into the ordinary bakers' mixture for bread, an even larger proportion of wheat germ than is ordinarily present in the wheat grain or berry.

The mode we have followed in practicing our invention isFirst, by grinding the fresh wheat germ as released in the flour mill in the process of milling the wheat berry to a fineness as closely approximating that of flour as the nature of the material permits 60 with the primary object of disseminating to the greatest degree the moisture and the fatty constituents contained in the germ and with the secondary object of permitting the easy blending of the ground 65 product with flour in subsequent baking operations. In practicing the invention we have found that this grinding operation should be carried on in a hammer or nutmeg grinder, i.e., a grinder in which 70 the article is pulverized by impact. We have also found that good results are obtained by grinding the wheat berry so fine that it will pass a 120 mesh screen.

Second, the admixture with the wheat 75 germ either prior to, during the process of grinding of sodium chloride or dry commercial baker's or dairy salt in suitable proportions, 5 to 8% by weight, of salt having been found effective. The purposes of such admixture are:(a) to provide a ready absorbent for moisture which might otherwise be attracted by the ground germ and tend to promote rancidity; 85

(b) to inhibit a too rapid diastatie action of the yeast used in baking due to the presence of the known enzymes in the wheat germs and to compensate for the action of the enzymes of the germs. 90 Third, by thereafter adding to the mixture of the finely ground wheat germ and sodium chloride or salt, an inert non-fatty filler, similarly finely ground, such as potato flour. The proportion of the filler 95 to the germ is 15--20% by weight and its purpose is:

(a) to absorb the fatty constituents of the wheat germ released by the grinding; (b) thereby to disseminate to a greater 100 extent the said fatty constituents; (c) so to occlude the said fatty constituents as to minimize exposure to oxidizing agents causing rancidity. Rice flour, rice polishings or corn flour may also 105 be used as a filler though we have found potato flour best.

Fourth, by heating the resultant mixture without free access of air or in a current of inert gas such as carbon dioxide 110 aB ;.'= '-: i;". s', u- a S f 436,765 or nitrogen, at a temperature and for a time sufficient thoroughly to dry it, the object being to remove such percentage of moisture as would promote rancidity. In practice, heating to a temperature of 200--225 F. and preferably of 212 F.

for twenty minutes in a closed oven has proved effective. The dehydration may also be performed prior to the adding of filler.

Fi/th, by packaging the said mixture as promptly as practicable, preferably while still warm, in containers being either (a) airtight; or (b) proof against free air circulation; or (e airtight or proof against free air circulation but with the interstices filled with an inert gas such as carbon dioxide or nitrogen.

WVhile the mode of practicing the invention has been described in certain specific forms or manners, it will be obvious that the general principles here disclosed may be varied, or embodied in different

656/2197

modes or processes from those described without departing from the spirit of the invention as defined in following claims.

Having now particularly described and ascertained the nature of our said invention and in what manner the same is to be performed, we declare that what weData supplied from the esp@cenet database - Worldwide Claims:


1. The process of treating wheat germ to produce a stabilised product free from rancidity and of good keeping quality, characterised in that the wheat germ ground to about the fineness of flour is mixed prior to, during or subsequent tai the grinding operation with sodium chloride or salt to absorb moisture and inhibit too rapid diastatic action of yeast, and is then thoroughly mixed with an inert non-fatty filler, such as potato flour.

2. The process as claimed in claim l, characterised in that the sodium chloride is preferably from five to eight per centum by weight of the wheat germ, and the potato flour is preferably from fifteen to twenty per centum by weight of the germ.

3. The process as claimed in claim 1 or 2, characterised in that the resultant product containing the wheat germ is dried preferably without free access of air or in an inert atmosphere and preferably by heating it to a temperature of from 2/0-225o F.

4. The process as claimed in claim 1, 2 or 3, characterised in that the product while dry is packed in containers which are airtight or proof against air circulation and filled with an inert atmosphere such as carbon dioxide or nitrogen.

5. The process of treating and stabilising wheat germ, substantially as described.

6. Wheat germ whenever stabilised by the process claimed in the preceding claims.

Dated this 6th day of November, 1934.

ALBERT L. MOND, 19, Southampton Buildings, Chancery Lane, Lindon, W.C.2,.

Agent for the Applicants.

Iteamington Spa: Printed for His Majesty's Stationery Office, by the Courier Press.-195.Data supplied from the esp@cenet database - Worldwide

657/2197

141.

GB438509 - 11/13/1935

PROCESS FOR THE PRODUCTION OF A FOOD


Applicant(s): CREDITS INTERNATIONAUX S A SOC (--)

E Class: A23L1/168B



Family: GB438509

Abstract:


A food preparation which can be kept for long periods without disintegration is obtained by mixing milk powder made from whole or skimmed milk with oats, wheat, maize, rice or other cereal kernels or vegetables which are wholly or mainly in the form of flakes and pressing into blocks. The moulds used may be heated to impart greater strength to the outer layer of the blocks. The flakes may be coated by spraying in a rotating drum with fat or oil, preferably in the form of an aqueous emulsion, and are preferably first dried to a moisture content of about 2-5 per cent. Pulse, vegetable ingredients and similar dried substances in flake or other disintegrated form may also be included in the blocks.

Lecithin, vitamin concentrates and other nourishing substances, and medicaments may also be added and may be mixed with 40-60 per cent of oil and 50 per cent of water to improve distribution.

Flavouring substances such as salt, sugar and fruit essences may also be included. The proportion of flakes may be greater than that of milk powder, e.g. 60 per cent of oat or other flakes, 24 per cent of dried milk, 5 per cent of fat and the remainder other substances such as sugar and salt. The blocks may be dried. They may be wrapped in moistened parchment, artificial parchment c., and then dried, the wrapping shrinking onto the blocks, and may then be coated with paraffin c. Specification 5373/94,

[Class 49], is referred to. The Provisional Specification describes the addition of the cereal food flakes to milk concentrate, e.g. during the last stage of the drying process in making milk powder, and where milk powder is used the addition of water to the mixture, or to the milk powder to form a paste or solution to which the flakes are added, and then compacting the mass into tablets c. A tastless medium such as agar agar which promotes disintegration in a liquid, may also be added.Description:


Communication from:-SOCIETE DE

CREDITS INTER2NATIONAbx S.A., a company organized under the laws of the Confederation of

Switzerland, of 1, Rue De La Tour De L'ile, Geneva, Switzerland.

I, LEONARD MELLERSHI-JACKSON, of the firm of Easeltine, Lake & Co., Chartered Patent

Agents, of 28, Southampton Buildings, Chancery Lane, London, W.C.2., in the County of Middlesex, a subject of the King of Great Britain, do hereby declare the nature of this invention to be as follows:The invention relates to a food in pressed or compact form prepared from cereal food flakes, such for example as oat, wheat, rice, maize and other flakes.

According to the invention, oat or other cereal food flakes are mixed with viscous lecithin and an edible oil. As a typical example, the mixture may be in the proportion of 50 grammes of oatflakes to 2 to 3.5 grammes of lecithin to per cent. oil.

658/2197

Preferably the oil is added to the lecithin and the flakes are added thereafter, but the process is not limited to the actual sequence in which the three constituents named are mixed together.

The flakes in the presence of the lecithin and oil become adhesive and held together and in this form readily combine with a milk powder or concentrate and with such sweetening or flavouring agents as may be desired, such as sugar, salt and lemon juice or essence.

The mixture of flakes, lecithin, oil and milk powder or concentrate and of the sweetening or flavouring agents, if present, is compressed or compacted, if necessary after removal of excess moisture, to form a substantially solid mass.

In making the mixture, particularly that part of it consisting of the flakes, lecithin and oil, care should be taken to preserve the form of the flakes, so as not to unduly hinder the subsequent swelling of the mass in making it ready for consumption and also not to detract from its appearance when so made.

In order to increase the durability of the compressed mass, use is preferably made of skimmed milk powder, the in[Price 11-3 hice 4s M P L38,5 09 ferior nutritive value of which is increased by the presence of the lecithin. 55 Preferably the mixture of flakes, lecithin and oil is added during the last stage of the drying process of the milk powder. In this case, as a typical example, a mixture of oatflakes, lecithin and oil is added to 60 the milk powder in the proportion of 50 grammes oat-flakes to 14 grammes dry milk powder. The flake mixture, however, may be added to already dried milk powder, but in this case it will usually be 65 found necessary to add water to assist the combination and even distribution of the various ingredients. Here, with a proportion of 50 grammes flake mixture to 14 grammes dry milk powder there may be 70 added, for example, 5 grammes water.

The water may be added at any stage of the mixing, but preferably it is added t.o the milk powder to form a paste or solution, in the presence of heat, and the 75 flake mixture is thereupon or subsequently added to the paste or solution.

The mass produced is pressed or compacted in the cold, but preferably in the warm state, into suitably shaped objects, 80 such as tablets, cakes and the like of any desired form and size. The tablets or the like are durable as regards both storage and retention of shape without necessitating the presence of an artificial preserving and binding medium. Thus, most, if not all, the constituents of the product are of distinct nutritive value.

With such a compressed product it is possible, by the simple process of boiling 90 for 2 or 3 minutes, to make a tasty porridge or like dish in which.iilk is already present and which has a higher nutritive value than ordinary porridge owing to the addition of lecithin. In order tn facilitate dissolving of the tablet or the like on boiling, a tasteless medium that promotes disintegration in the presence of a liquid, such as agar-agar, may be incorporated therein. 100 The preparation produced in accordance with the invention enables porridge or the like to be made from a compact and substantially dry mass in cases where, for example, owing to lack of space or for 105 other reasons, it is difficult to carry cereal I

AMENDMENT - SEE LAST PAGEI ufSERV COPY PATENT SPECIFICATION

Application Date: March 13, 1934. No. 7986/34. 4 Complete Specification Left: April 3, 1935.

Complete Specification Accepted: Nov. 13, 1935.

PROVISIONAL SPECIFICATION

Process for the production of a Food 438,509 food flakes, milk, sugar, salt and other constituents individually. While being very durable, occupying little space and having high nutritive value, the cornpressed tablets or the like according to the invention, are particularly suitable as food for travellers, tourists, seafaring people and explorers under all climatic conditions, and for mass feeding. They are also suitable for infant feeding owing 10 to their high nutritive value (a tablet weighing approximiately

67 grammes may contain approximately 271 calories).

Dated this 13th day of March, 1934.

659/2197

HASELTINE LAKE & CO.

28, Southampton Buildings, London, England.



Process for the production of a Food I, LEONARD MELLERSH-JACISON, of the firm of Hlaseltine

Lake & Co., Chartered Patent Agents, 28, Southampton Buildings, Chancery Lane, London, W.C.2, in the County of Middlesex, a subject of the King of Great Britain, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-

This invention relates to the production of a food and its main object is to enable a food containing milk to be made in a form in which it can be kept for long periods without deterioration and in a form suitable for easy handling and transport and ready for cooking to produce a platable and nourishing milk dish. It has hitherto been difficult if not impossible to produce foods incorporating milk and suitable for a long period of preservation without expensive tin packing, as the milk in the form of milk powder is submitted to destructive influences, which make the product unsuitable for food.

By the present invention an alteration happens as to the destructive chemical influences in the milk powder, i.e. the natural chemical process of the destruction as to the milk powder is prevented by the present invention.

It is very desirable that the food containing milk shall be capable of being readily cooked without making lumps and this also is attained by the present invention.

According to the invention the milk in the form of milk powder is intimately mixed with the kernels of cereals or with vegetables which are wholly or mainly in the form of flakes and the mixture is then pressed into blocks under pressure to form durable blocks, whereby through the utilisation of flakes and the formation of durable blocks the material is maintained in an intimately mixed condition and the rancification of the milk powder is hindered. Flakes which are well dried before mixing (such as flakes of the kernels of oat, wheat, rice, maize or flakes of vegetables) are especially suitable. Substances necessary on account of 65 taste, such as salt, sugar, fruit essences, etc., may be introduced into the mixture before the pressing.

Tfhe food flakes may be sprayed in a rotating drum with fat or oil substances, 70 preferably in the form of an aqueous emulsion, whereby a uniform covering of the food particles is effected. The food flakes thus treated readily combine with the additional substances assisted by the 75 adherent nature of their fatty or oily coating, and at the same time prevent the formation of lumps during the cooking and render possible a uniform distriblution of the individual ingredients to each 80 compressed block.

In order to obtain great durability. it is preferable to withdraw all but about 2 to 5% of the water content from the flakes by drying them before they are 85 coated with the fat or oil.

The flakes thus prepared are then mixed with the milk-in the form of milk powder-and the other additional substances, such as salt, sugar or fruit 90 essences, in order to produce the desired flavour.

The mixture is then compressed into suitable forms, for example cubes, blocks, tablets, etc., and the blocks may be again dried in a drying chamber, 95 whereby the water added to them during the spraying with the aqueous emulsion of fat or oil is withdrawn.

In order to increase the durability of the edges, which readily crumble away, 100 the dies and mnatrices used for the compression of the blocks are preferably heated, whereby greater strength is imparted- to the outer layer of the cornmpressed blocks. 105 For the food produced by the process according to the invention the ingredients may be in the proportion of about 60% flakes by weight,

24%o milk powder, and the remainder other substances preferably including about 5% fat or oil. A composition of approximately 30 2'rammies oat flakes. 12 grammes dried milk, 2.5 g.rammes fat, 5 grammes sugar and 1 gramme salt, has 11.5 438,509 been fouwd suitable. The proportion of fLakes is

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much greater than that of the milk powder and the proportion of fat or oil is. preferably much less than the proportion of milk powder.

In order to preserve the natural strong taste of the flakes, and to increase the durability of the food, it is preferable to use skim milk powder instead of whole milk powder. The mucous and too fatty taste which is unpleasant to many palates and which arises when oat flakes for example are cooked with milk, is hereby also obviated.

In order to increase the nutritive value of the food and to produce additional nutritive values or medical values, it is possible to add, in addition to the layer of fat, lecithin or vitamins or other highgrade nourishing substances or medicaments, or in order to achieve a uniform distribution these substances may be added in the layer of fat or oil. The lecithin or the vitamins or other high - grade nourishing substances or medicaments may be mixed with about 40-60% oil and 50% water with slight heating before the addition. For example, in order that the thick flowing lecithin may be better distributed, it is preferable to mix it with about 40-60% cocoanut oil and 50% water, with slight heating. By the distribution of lecithin and vitamin concentrates or other medicaments in this form, the inherent bad taste of these substances is masked, and they may be more easily taken by children or other persons - for whom such pharmaceutical products are prescribed.

The compressed blocks prepared in accordance with the invention proauce, when placed in cold water and boiled for 4-l1 minute, a prepared and flavoured flake milk dish, for example an oat flake milk dish.

In order to be able to achieve, without unhygienic contact of the blocks with the hand, the breaking up of them, it is preferable to pack the block in parchment, artificial parchment, cellophane (Registered

Trade Mark), or like paper for purposes of preservation, the said paper being placed about the block in the moist state and sealed. The block thus packed is then again dried, whereby the packing paper shrinks and closes tightly about the block. By the tight enclosing of the contents thereby realised, the block is protected from disadvantageous deformation by undesired pressure or impact. When it is to be used, the block may be crushed with the hand in the packing without contact with the substance.

In order that the food may be made very durable and be protected against weather influences and in order that greater durability of the packing itself may be obtained, the packed block may be covered with paraffin or like impervious substance. 70 By reason of their great durability, the small amount of space which they occupy and the short time required for their preparation, as well as the high nutritive value which is produced, for example, 75 upon the addition of lecithin and vitamins, the blocks prepared and packed by the process according to this invention are particularly suitable for use on expeditions, excursions, and in all cases 80 where fresh food, in particular milk, can only be carried and prepared with difficulty.

In addition to the flakes, use may be made in the food produced according to 85 the above process of pulse, dried vegetable ingredients, or similar dried substances in flake or other disintegrated form.

These ingredients are then dried and broken up in the manner hitherto 90 known, and if need be covered with the fat substance in accordance with this process. Milk powder and the flakes and any desired flavouring or other substances are then added according to the abovedescribed process. The mass thus produced may then be compressed and packed in the hereinbefore described manner.

Also it has been proposed in Patent 100 Specification No. 5373 of 1894 to mix milk powder with meal or bran of cereals, or so-called round grain such as peas, or the pulp of white beat, and to press this mixture into cakes. 'The flakes of the 105 present invention do not consist of meal or bran or husks but consist of substances which are mainly or wholly vegetables or the kernels of cereals, and the present invention also differs from the previous 110 proposals by the selection of the kernels of cereals or the vegetables in the form of flakes whereby in conjunction with the formation of a durable block or cake the rancification of the milk powder is hindered and the formation of lumps during cooking is avoided. The term " flakes " herein employed is intended to refer only to particles in the shape of small films or layers like scales such as the 120 scales of a fish, e.g., the well known " rolled oats." For the purpose of the present invention the cereals or vegetables are mainly or wholly in the form of flakescertainly much more than half of 125 the cereals or vegetables are in the form of flakes.

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Having now particularly described and ascertained the nature of the said invention and in what manner the same is to 130 te 438,509 be performed, as communicated to me by my foreign correspondents, I declare thatData supplied from the esp@cenet database - Worldwide

Claims:

Claims of GB438509 what I claim is: -

1. A process for producing a durable milk dish ready for cooking wherein the milk in the form of milk powder is intimately mixed with the kernels of cereals or with vegetables which are wholly or mainly in the form of flakes and the mixture is then pressed into blocks under pressure to form durable blocks, whereby through the utilisation of flakes and the formation of durable blocks the material is maintained in an intimately mixed 1.5 condition and rancification of the milk powder is hindered.

2. A process for producing a durable milk dish ready for cooking as claimed in claim 1, wherein the food flakes are coated with oil or fat, and subsequently the coated flakes are intimately and homogeneally mixed with milk in the form of milk powder, and the resultant material is formed into blocks under pressure whereby a durable block is formed which is ready for cooking and when cooking will not form into objectionable lumps.

3. A process as claimed in claim 2, wherein the oil or fat is applied to the food in the form of an aqueous emulsion.

4. A process as claimed in claim 2 or 3, wherein the proportion of flakes is much greater than that of the milk powder and the proportion of fat or oil is preferably much less than the proportion of millk powder.

5. A process as claimed in claim 4, wherein the ingredients are in the proportions of about 60% flakes by weight 24% milk powder, and the remainder other substances preferably including about 5% fat or oil.

6. A process as claimed in claim 1 or 2, characterised by the fact that the water content with the exception of 2-5% is withdrawn from the flakes by drying before the mixing.

7. A process as claimed in claim 2, 3, 4, 5 or 6, wherein the food is dried after being compressed into blocks. 50 8. A process as claimed in any of the precedfinig claims, wherein the dies and matrices used for the compression into ckis are heated.

9. A process as claimed in any of the 55 preceding claims, wherein the milk is il the form of skim milk powder.

10. A process as claimed in any of the preceding claims 2 to 9, wherein lecithin or vitamins or other high-grade nourishing substances or medicaments are added to the flakes either as well as or in the layer of oil or fat.

1H. A process as claimed in claim 10, wherein the lecithin or the vitamins or 65 other high-grade nourishing substances or medicaments are mixed with about 40-60% oil and 50% water with slight heating before the addition.

12. A process as claimed in any of the 70 preceding claims, wherein the block produced is, for the purposes of preservation, packed in parchment, artificial parchment, cellophane, or similar wrapping, which is placed about the said block in 75 the moistened state, sealed, and then dried with the block, so as to shrink it thereonto.

13. A process as claimed in claim 12, in which the wrapped block is subsequently coated with paraffin or the like impervious substance.

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14. A process for the production of a food substantially as hereinbefore described. 85 15. A food block when produced by the process claimed in any of the preceding claims.

Dated this 3rd day of April, 1935.

HASELTINE LAKE & CO.

28, Southampton Buildings, London, England, and 19-2.5 West 44th Street, New York, U.S.A.

Agents for the Applicant.

111111K ERRATUM SPECIFICATION No. 438 Page 3, line 104, for " " beet " beat " read THE

PATENT OFFICE, October 12th, 1936.

50--99 mP -1935.

;,-09. lmwData supplied from the esp@cenet database - Worldwide

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142.

GB446762 - 5/6/1936

IMPROVEMENTS IN OR RELATING TO THE TREATMENT OF RICE


Applicant(s): SAM HARRISON GIBBON (--); STEEL BROTHERS and COMPANY LTD (--)

E Class: A23L1/182



Family: GB446762

Abstract:


446,762. Treating rice. STEEL BROS. & CO.,Ltd., 6, Fenchurch Avenue, and GIBBON, S. H., 242,

Lauderdale Mansions, Lauderdale Road. Maida Vale, both in London. Nov. 9, 1934, No. 32367. [Class

58] Rice, husked or unhusked, is soaked in water until it has a water content of upwards of 15 per cent and is then subjected to dry heat in a chamber within which a temperature between 200 and 475 C. is maintained until the rice attains a temperature between 90 and 98 C., the rice being then discharged.

The heating drum consists of a rotatable cylinder 1 provided with fixed end plates 2, 3, carrying a feed shoot 4 and a discharge shoot 5 respectively ; a worm 6 on the interior of the drum feeds the material to the outlet. The drum is heated by devices 7, 8 and 9 arranged below, at each side, and inside the drum respectively. Specification 179,206, [Class 58], is referred to.Description:


- -- -

.' 1 ' i-,1- -, --- - -1-. L---


Application Date: Nov. 9, 1934. No. 32367/34 44 Complete Specification Left: May 24, 1935.

Complete Specification Accepted: May 6, 1936.


Improvements in or relating to the Treatment of Rice We, STEEL BROTHERS & COMPANY

LIMITED, a British Company, of 6, Fenchurch Avenue, London, E.C.3, and SAM HARRISON

GIBBON, a British Subject, of 242, Lauderdale Mansions, Lauderdale Road, Maida Vale, London,

W.9, do hereby declare the nature of this invention to be as follows:This invention comprises

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improvements in or relating to the treatment of rice for the purpose of improving its value as a foodstuff.

The present invention is concerned with a process for the treatment of rice (either husked or unbusked) which consists in first soaking it in water under conditions so selected as to augment the water content of the rice to the region of 21 to 23 %, and thereafter treating the rice in a dry atmosphere at an elevated temperature.

It has now been found that improved results are obtained when the final heating is effected at a substantially higher temperature than that (e.g. 150 to 190 C.) which was originally contemplated in connection with the above process.

In one example embodying this invention the starting material was unhusked rice having a natural water content of about 11%. This was soaked for 2 hours in water at 90 C., and at the end of this operation the water content was 18 to 16,762 20%. The soaked rice was passed from the soaking tank into a centrifugal drier and treated therein for about a minute in 35 order to remove surface moisture.

From the drier the rice was passed into a revolving drum0 within which the temperature of the air was maintained at about 400 C. The duration of this final heating 40 varies according to the nature of the original material and other factors but satisfactory results have been obtained with treatments lasting from 15 seconds to 2 minutes with the temperature 45 already indicated, i.e. about 400 C. The object of the process is to produce a final product having a light gelatinous appearance, and the temperature and duration of the final heating step must be carefully controlled in order to obtain the desired result, and in this connection care must be taken to see that the final processing is not carried too far.

It is to be noted that the present invention is applicable to the treatment of rice whether in the husked or unhusked condition.

Dated this 9th day of November, 1934.

BOULT, WADE & TENNANT, 111 & 112, Hatton Garden, London, E.C.1, Chartered Patent Agents.


Improvements in or relating to the Treatment of Rice We, STEEL BROTHERS & COMPANY

LIMITED, a British Company, of 6, Fenchurch Avenue, London, E.C.3, and SAM HARRISON

GIBBON, a British Subject, of 242, Lauderdale Mansions, Lauderdale Road, Maida Vale, London,

W.9, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-

This invention comprises improvements in or relating to the treatment of rice for the purpose of improving its food value.

The invention provides a step in the processing of rice which consists in subjecting it, while in a condition in which 75 its water content is upwards of 15%, to dry heat in a chamber within which a temperature between 200 and 475 C.

(preferably between 350 and 450 C.) is maintained, and keeping the rice under 80 these conditions until its temperature is in the region of 90 to 98 C., the rice being discharged on the attainment of that temperature. It is found that by the employment of high temperatures in 85 a heating chamber that a hard grain is ¦ AMENDMENT - SEE LAPGE] 1 cy 1 - ,, ' 446,762 obtained-which is very suitable formilling. The time of heat treatment, if a temperature between 350' C. and 450' C.

is employed, is normally less than two minutes. The heat treatment is carried out with the use of direct live heat (i.e.

radiant heat) without the addition of steam or moisture other than that contained in the rice with the advantageous result that the rice leaves the heating zone partially dried, thus reducing the time occupied in the subsequent drying step. which is normally employed.

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It is important in carrying the invention into effect that the water content of the rice during the heating treatment should be upwards of 15% (Preferably between 18 and 28%) and in order to obtain this water content it is usually necessary first to soak the rice. The invention includes apparatus when used for carrying out the treatment of rice as described above and comprising in combination a soaking tank (or tanks). a rotary heating drum arranged for the reception of the soaked rice from the soaking tank and a drier arranged for the reception of rice from the heating drum.

In the ordinary process for the preparation of parboiled rice, the paddy is first soaked in water, steamed by saturated steam, and then dried, the complete proeess occupying a considerable length of time. It is contemplated that the process according to this invention, which is of much shorter duration, may be used in place of the normal parboiling operation to confer somewhat similar or other beneficial effects on the rice grain, and in particular an improvement in quality.

It has already been proposed (see Patent Specification No. 17.9,206) to process previously soaked rice by subjecting it to heat under atmospheric pressure in an internally heated chamber, the heat being transferred to the rice by contact with the walls of the chamber and by radiation from the walls. This earlier proposal however did not disclose the use of temperatures between 200 C. and 475 C.

within the heating chamber which forms an essential feature of the present invention.

One effect of treating rice by the process according to this invention is to improve the appearance of the product.

Most rice in its initial form is quite brittle and of somewhat chalky appearance, while the normal parboiling treatment gives a yellow appearance to the rice. The treatment according to the present invention on the other hand gives the rice a light gelatinous appearance.

Some specific examples of carrying the invention into effect will now be described with reference to the accompanying diagrammatic drawings in which:Figure 1 is a longitudinal section of the heating drum employed, and 70 Figure 2 is a cross-section of the heating drum.

In one example, unhusked long grain rice having an original water content of about 11.2% was soaked in water in tanks 75 until the rice had a total water content of about 28% (i.e. including surface moisture). The surface moisture was larely removed and the rice was then passed into a heating drum rotating at a speed of 5 80 revolutions per minute and having an internal temperature of about 440 C.

In_ this example 50 pounds of soaked rice at a temperature of about 65' C.. were passed into the drum in 25 seconds and were discharged, at a temperature of 96 C., from the drum in 35 seconds after the full 50 pounds had been inserted. The rice was then carried to a rotary drier and dried to a water content of about 12% after 90; which it was passed to storage, the final product having a good gelatinous appearance.

The heating drum consisted of a rotatable cylinder 1 provided with fixed end 95; plates 2, 8 one of which carried a feed shoot 4 and the other a discharge shoot 5.

The rice was fed along the length of the drum during its rotation by means of a worm 6 on the interior surface of the 100 cylinder. The drum was heated by means of combustors of the surface combustion type-two combustors 7 being arranged below the cylinder, three combustors 8 being arranged at each side of the 105, cylinder and two combustors 9 being arranged inside the cylinder and facing downwards towards the rice 10 lying on the bottom of the cylinder.

In another example which gave a satisfactory final product 50 pounds of soaked round grain paddy were fed into the heating drum in 30 seconds and were discharged at a temperature of 97 C., the drum rotating at four revolutions perminute.

It is to be understood that in both of the above examples the heating temperature given is that of the inside of the heating drum and that the temperature out- 120:

side the drum may be considerably higher for example, up to 475' C. It is further to be understood that the best internal temperature depends upon the nature of the grain, upon the rate of feed, upon 125 the

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initial temperature of the grain and upon several other factors and that for any particular set of conditions the best temperature must be found by experiment. 130 446,762 The invent Lion is applicable to rice in either the husked or the unhusked condition Having now particularly described and ascertained the nature of our said invention and in what manner the same is to be performed, we declare that what weData supplied from the esp@cenet database - Worldwide

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143.

GB455261 - 10/16/1936

A PROCESS FOR THE PRODUCTION OF EASILY SOLUBLE PUDDING

PREPARATIONS


Applicant(s): ABRAHAM VAN DANTZIG (--)

E Class: A23L1/0522; A23L1/187



Family: GB455261

Abstract:


Easily soluble pudding preparations are obtained by mixing a solution of fondant sugar with a melt of drop sugar and adding to the mixture the usual starch flour, e.g. rice, maize or potato starch flour, and flavouring substances such as caramelized sugar, almonds, jams, fresh fruits, yolks or whites of eggs, c., or mixtures thereof, a viscous paste being obtained after cooling. To obtain a hard mass the fondant sugar is added directly to the drop sugar melt without dissolving in water, and the mass obtained may be cut into pieces and packed. The starch flour may be mixed with the sugars before these are mixed together. The sugars may be partly replaced by starch glucose. The drop sugar may be prepared by melting sugar at 122 DEG C., or by adding a small quantity of water and boiling down at 125 DEG C.

Examples are given.Description:



Application Date; March 10, 1936 No 7257/36.

455,261 ,'" Complete Specification Accepted: Oct 16, 1936.


A Process for the Production of Easily Soluble Pudding Preparations I, ABRAHAM V Ai DANTZIG, of Stettenstrasse 11, Frankfurt a M, Germany, a Dutch Subject; do hereby declare the nature of this invention and in what S manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-

Pudding powders consisting of mixtures of rice, potato or maize starch or the like and flavouring and colouring substances and possibly some sugar are known These pudding powders are known as " custard powder " or " blanc-manges " or " pudding powder," and these pudding powders are used by the cook as follows:

The powder is first stirred with cold water or cold milk, so as to avoid the presence of small lumps, the resulting suspension is then stirred and mixed, adding sugar, with hot milk and is thereafter boiled up for a short time.

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In contradistinction to the aforementioned well known dry pudding powders, this invention concerns a process for the production of either soft or hard pudding preparations, which require no further stirring in the cold but can be dissolved at once in hot milk or the like.

It is well known that according to the degree of heating, different kinds of sweetmeats may be produced from the same quality of sugar Thus on heating the sugar previously dissolved in a small quantity of water, to a relatively low temperature, but in such a way that the water evaporates, a floury mass (fondant) is obtained By stronger heating a mass which becomes glassy on cooling (drop sugar) is obtained and, on still stronger heating, a crisp mass (caramel) In the process for the production of easily soluble pudding preparations according to this invention, fondant sugar in solid form or in aqueous solution is mixed with a melt of drop sugar and the required quantity of starch flour and flavouring substances is added to the mixture.

In order to produce soft pudding preparations fondant sugar is prepared in a manner known per se from a pre-determined quantity of sugar and this sugar is then dissolved in a quantity of hot water n a kettle sufficient to produce a sugar lPrice 1/-l paste In order to impart a honey-like consistency to this sugar paste, a further 55 quantity of sugar is heated in a second kettle to the consistency of drop sugar.

The necessary quantity of pudding powder, as hereinbefore referred to, is thereafter divided between the sugar paste ob 60 tained from the fondant sugar and the melted drop sugar, and both mixtures are mixed together with stirring The desired flavouring substances, such as caramelised sugar, almonds, jams, fresh 65 fruits, yoke or white of eggs etc or mixtures thereof are then added to the resulting mixture After cooling down a viscous pudding paste is obtained, which has the property that it does not ferment 70 and the sugar does not crystallise out from the mixture, notwithstanding the high proportion contained therein The viscous pudding pastes may then be packed in tins, prepared paper, glass, the material 75 known under the Registered Trade Mark Cellophane, or in collapsible tubes or the like.

The following examples serve to illustrate how soft pudding preparations 80 according to this invention may be produced:

1 300 kgmns of fondant sugar are dissolved in 75 litres of water, whereby a fondant paste is produced

100 kgms of 85 sugar are converted by heating in a second kettle to 122 C into drop sugar.

270 kgms of pudding powder are then mixed with the fondant paste and the drop sugar respectively in the ratio of 90 3 1 These two mixtures are then stirred together and 100 kgms of orange paste (prepared from fresh fruit) are added.

After partial cooling, the resulting preparation is put up in small packets 95 2 250 kgms of fondant sugar and 50 kgms of starch glucose are dissolved in litres of water, whereby a sugar paste is produced

100 kgms of sugar are converted by heating in a second kettle to 100 1220 C into drop sugar These two sugars are then mixed together and 270 kgms.

of pudding powder and 50 kgms of cocoa or chocolate powder are admixed therewith After partial cooling, the result 105 ing mixture is put up in small packets.

__ 455,261 3 200 kgms of fondant sugar are dissolved in 50 litres of water 200 kgmns.

of sugar are heated in a small quantity of water to 125 C and boiled down to drop sugar These two sugar solutions are then mixed together and 270 kgms.

of pudding powder and 150 kgms of raspberry pulp (prepared from fresh fruit) are added to the resulting mixture In this way a raspberry pudding derived from natural fruit is obtained.

When making hard pudding preparations, the fondant sugar produced by heating is not dissolved in water, but is added directly to the sugar which has been previously heated in a kettle to the consistency of drop sugar To the resulting sugar mixture there is added with stirring the necessary quantity of pudding powder and the desired flavouring substances.

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Fbr example, if it is desired to produce caramel pudding, the necessary quantity of sugar is melted to form caramel in a further kettle, and this caramel sugar is then added to the aforesaid mixture of fondant sugar and drop sugar The required pudding powder may also be added to the three aforesaid kinds of sugar before mixing the same.

Whether the caramel sugar is mixed with the fondant sugar and the drop sugar or only with one of them depends upon the degree of humidity of the outer air during the process of production However, it is advisable to mix the caramel sugar both with the fondant sugar and the drop sugar In this way, caramel l,udding preparations are obtained, which differ advantageously from the powders or pastes hitherto known in that they are not hygroscopic and consequently of almost unlimited durability, since the caramel sugar which is known to be very hygroscopic is deprived of this property by the addition of the other kinds of sugar.

After having produced the mixture in the aforesaid manner, it is poured on to a cooling table or placed in a refrigerator and, after refrigeration, is cut by hand or machine into pieces of the required size which may then be packed and are ready for sale.

The following example serves to illustrate how hard pudding preparations according to this invention may be produced.

A small quantity of water is added to kgms of sugar and the latter is boiled down by heating to 120 C to drop sugar. kgms of fondant sugar are then melted in the resulting drop sugar melt, whereby a mixture of drop sugar and fondant sugar is obtained 270 kgms of pudding powder and 100 kgms of orange 65 paste

(prepared from fresh fruit) are then added to this sugar mixture The resulting mass is then placed on cooling tables or introduced into cooling chambers, whereby a hard pudding mass is obtained, 70 which is then cut into pieces of the required size, which are packed ready for sate.

In the aforementioned sugar mixtures the sugar may be partly replaced by 75 starch glucose.

Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that what I 80Data supplied from the esp@cenet database - Worldwide

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144.

GB456944 - 11/18/1936

A PROCESS FOR PRODUCING A FLAVOURING AND SEASONING

PREPARATION


Applicant(s): ALFRED STAEGER (--)

E Class: A23L1/39



Family: GB456944

Abstract:


A flavouring and seasoning preparation more particularly for use in making savoury rice dishes is obtained by heating a mixture of meat extract, extract from kitchen vegetables, purified animal fat and common salt, mixing with spices then boiling the mixture to sterilize it and packing in sterile condition.

The spices used include paprika, saffron, curry, nutmeg, pepper or tomatopur>;\;aee, separately or in admixture. To impart flavour further additions preferably precooked may be made before the boiling step, e.g. dried mushrooms, chopped meat, and chopped vegetables, or onions roasted in fat. In an example, 1,2 kilos of meat extract, 0,7 kilos of extract prepared by pressing the juices from vegetables, boiling the juices, removing scum and concentrating in a vacuum pan, 1,3 kilos. of calf fat, 2 kilos. of beef fat, these fats having been boiled or roasted to free from water or other impurities, and 4 kilos. of cooking salt, are heated and mixed and 0,7 kilos. of roasted finely chopped onions, 0,05 kilos. of ground nutmeg and 0,05 kilos. of ground pepper are added under constant stirring. After boiling to sterilize and mixing in a mechanical stirrer, the mixture while still hot is placed in a machine which squirts it through nozzles into seamless cellulose skins. The ends of the sausages so prepared are tied and dipped in paraffin wax to seal them and the sausages then packed.Description:


-ui-Af$EFP V E CI"PY


Application Date: Dec 6, 1935 No 33814/35.

456,944 Complete Specification Accepted: Nov 18, 1936.

(Under this application, which was originally made under Section 91 of the Patents and Designs Acts;

1907 to 1932, a Specification was laid open to public inspection on June 8, 1936).


A Process for Producing a Flavouring and Seasoning Preparation I, Arrn 1 D STGGER, o f 577,

Badenerstiasse, Zurich, Switzerland, a Swiss Citize 4, do hereby declare the nature of this invention and in what manner the same is to be performed to be partioularly described and ascertained in and by the following statement:-

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This invention consists in a process for producing a flavouring and seasoning preparation which is intended in particular for use in the preparation of savoury rice dishes.

Previous to my invention it has been proposed to produce a thick gravy by boiling together water, flour and a colloidal substance to produce a mixture, then emulsifying partially oxidised meat fat, or fat treated with ultra-violet rays, or the volatile flavouring products contained in the said fat, with the said mixture and adding thereto relishing products such as salt, pepper, curry, mustard, cream, meat or yeast extract, Japan soya, sugar, lecithine, aromatic essences, cheese, or the like, and finally boiling the mixture to evaporate part of the water contents and filling the same into tins and sterilizing it.

According to the process in accordance with the invention, meat extract edible, kitchen vegetable extract and purified animal fat with the addition of common salt are heated together and mixed with spices, whereupon the mixture is boiled for the purpose of sterilization and is then packed in a sterile condition All 'those spices are suitable which are adapted for the preparation of rice dishes, such as tomato pur 6 e, curry, paprika, saffron, nutmeg and pepper, which if desired may be combined with one another To refine the flavour of the thus obtained mixture, further additions may be made before the boiling if desired, for example dried mushrooms, chopped meat and chopped vegetables or onions roasted in fat Preferably all these additions are precooked.

The sterile packing of the completely boiled up product preferably takes place S by filling the same into a cellulose skin which is thereupon sealed in an air tight Eprice e X manner and may be enclosed in further packing materials, or by filling the same into boxes and tubes.

The product so produced has the ad 55 vantage that for the preparation of rice dishes no other ingredients are necesasry apart from the rice and this product, whereby -the housewife is relieved of the whole work of preparing the savoury 60 EXAMPLE.

In a large, heatable vessel, there are heated and mixed together 1 2 kilogrammes of meat extract (as found in commerce, for example the meat extract 65 sold under the trade name " Liebig's Meat Extract

") 7 kilogrammes of edible, kitchen vegetable extract, produced in the hereinafter described manner, 1

3 kilogrammes of calf fat which has been 70 freed of water or other impurities by boiling or roasting, 2 kilogrammes of beef fat which has been freed of water or other impurities by boiling or roasting, and 4 kilogrammes of cooking salt, and 7 kilo 75 grammes of roasted finely chopped onions 05 kilogrammes of ground nutmeg nut, and 05 kilogrammes of ground pepper are added under constant stirring.

This mixture is boiled for the purpose 80 of sterilization Thereupon the mixture is treated in a mechanical stirrer until it is in the condition of a thick mush Whilst still in a hot state the mixture is placed in a machine which squirts it through 85 nozzles into seamless cellulose skins.

The thus obtained small sausages are then tied and have their ends dipped in hot paraffin to prevent the intrusion or penetration of germs These small 90 sausages are then wrapped up by means of an aluminium foil and packed in a small carton and finally the carton has a covering of sheet cellulose stuck round it.

The mixture is then so durable that it 95 remains fresh and always ready for use for months, and under suitable storage for years According to the kind and aroma of the mixture another spice can be added before it is boiled up For the herein 100 before described quantity of mixture, for example the following are necessary:VV"' 456,944 2:0 t grammes of curry powder, or 6 Q tion and in what manner the: same is toData supplied from the esp@cenet database - Worldwide Claims:

Claims of GB456944 grammes of saffron, or in addition to the be performed, I declare that what I claim

thickened vegetable extracts which must is:then only be employed in small quanti A process for obtaining a flavouring 1 ties, trebly concentrated tomato essence and seasoning preparation, which in par 2, Qr cooked and salted vegetables of every ticular is intended for the preparation kind may be added Many variations are of sav Quxry rice dishes, characterized in possible in the last detail that meat extract, edible, kitchen vegetThe edible, kitchen vegetable extract is able extract, and purified

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animal fat with produced by pressing the juices from kit the addition of common salt are heated 3 C chen vegetables, boiling the said juices, together and mixed with spices, and the removing therefrom thescumwhichispro mixture is then boiled for the purpose of duced by -the said boiling, and then thick sterilization and thereupon packed in e'ing the juices by evaporation of the sterile condition 1 E water therefrom by heating them in a Dated this 5th day of Deceinber, 1935.

vacuum pan until they are converted into For the Applicant, a thick brew which constitutes the said F

BOSSHARDT, vegetable extract Chartered Patent Agent, -Javing now particularly described and 3,

Regent Rouse, Cannon Street, eascertained the nature of my said inven Manchester, 4 Ileanington Spa:

Printed for His Majesty's Stationery Office, by the Courier Press -1936 - _ ó _: -:z IData supplied from the esp@cenet database - Worldwide

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145.

GB472465 - 9/17/1937

IMPROVEMENTS IN AND RELATING TO THE PUFFING OF CEREALS


Applicant(s): WILLIAM JOHN PLEWS (--)

E Class: A23L1/18C2


Priority Number: DEX472465 (19341217)

Family: GB472465

Abstract:


Cereals, having a fat content of 4,5 per cent or more such as oats, are heated directly by means of steam under pressure and of such degree of superheat that the sudden reduction of pressure required to effect puffing can be and is effected after a period insufficient to permit of appreciable modification of the fat content of the grain: this period is never more than five minutes and is generally between one and a half and two minutes. In a specific example, oats having a moisture content of between 6 and 8 per cent are placed in a container and steam at a pressure of about 220 lb. per square inch and carrying about 150

DEG F. of p superheat is fed in. In about half a minute the pressure in the container rises to line pressure, and this pressure is maintained for a period of about one minute, the steam supply then being shut off and the closure of the container opened, thus releasing the pressure and causing the oats to puff. A suitable form of apparatus for carrying out the treatment is described in Specification 472,466.

The Specification as open to inspection under Sect. 91 comprises also the application of the process specifically to wheat, maize, rye, barley and rice. This subject-matter does not appear in the

Specification as accepted.Claims:

Claims of GB472465 be performed, I declare that what I claim is:1 A process for the production of 105 Muffed products from raw cereal grains having a fat content of

4 5 % or above, by the method of heating said grains under pressure in the presence of steam and sud(dlenly greatly reducin g the said 110 pressure, wherein, in order to pproduce a product having a commercial shelf life, the heatin of the raw cereal grains is effected directly by means of steam under pressure and of such degree of superheat 115 that the sudden reduction of pressure can be and is effected after a period insufficient to permit of appreciable modification of the fat content of the cereal grains 120 2 A process a-ccording to claim l in which the steam carries at least 500 F. superheat.

3 A process according to claim 2 in which the, steam is a-t a pressure of about 125 lbs per square in-eli.

4 The process as claimed in any of the preceding claims in which the period of exposure of the grains to the action of the steam is between 11 and 2 minutes 130 472,465 The process of producing puffed products from cereal grains with a fat content of 4 5 % or above substantially as described.

6 Puffed products when prepared by the process claimed in any preceding claim.

Dated this 17th day of December, 1935.

674/2197

DICKER, POLLAK, MERCER, TENOJ & MEYER.

Chartered Patent Agents, 20-23, Holborn, London, E C l, Agents for the Applicants.

T Leamington Spa: Printed for His Majesty's Stationery Office, by the Courier Prma,-1937,Data supplied from the esp@cenet database - Worldwide

675/2197

146.

GB507384 - 6/14/1939

IMPROVED CEREAL PRODUCTS AND A PROCESS FOR THEIR

MANUFACTURE


Applicant(s): ALBERT EUSTACE BERRY (--)

E Class: A23L1/164F2



Family: GB507384

Abstract:


507,384. Conditioning grain ; reducing grain. BERRY, A. E. June 24, 1938, No. 18786. [Class 58]

[Also in Group VI] In making flaked cereal products from cereal grains, for example maize, oats or rice, by conditioning and softening by addition of water, cracking by passage through rollers to release the germ and form grits, separating the grits from the meal and germs and cooking them, for example with steam, and flaking by passage between rollers which may be heated,' steep water rich in organic phosphates and protein produced in the manufacture of starch from maize by steeping the maize in water containing a small percentage of sulphur dioxide is added at a stage in the process before the finished cereal product is obtained. The flakes as they leave the flaking rollers may be treated with the steep water, for example by spraying on 15-25 per cent by weight of the steep water, and arc then passed to a drier to remove excess water and may then be cooked to impart the desired crispness. In a modification, the steep water is alternatively or additionally added by using it for the preliminary conditioning and softening of the grain. The steep water may be filtered and concentrated to 15-18

BeaumÚ before use. The cooking prior to flaking partially disrupts the starch cells and solubilizes the starch. The product may be used for direct consumption, or in the fermentation industry.Description:


PAESEIVF COPN


Application Date: June 24, 1938. No. 18786/38. 507,5 Complete Specification Left: Jan. 9, 1939.

Complete Specification Accepted: June 14, 1939.

PIROVISIONAL SPECIFICATION

Improved Cereal Products and a Process for their Manufacture I, ALBERT EUSTACE BERRY, a

British subject, of Winslow load, Hammnersmith, London, W.6, do hereby declare the nature of this invention to be as follows:The present invention relates to improved cereal products and a process for their manufacture. Such cereals may for example comprise maize, corn, oats, rice and the like.

It is known to prepare flaked corn or maize by a process involving the steps of conditioning and softening by the addition of water, then cracking by passing between rollers to release the germ and form " grits," separating the meal and germ from the grits and thereafter cooking the grits with steam so

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that they readily flake when passed subsequently between rollers. The flaked corn or maize so produced is crisp in character and has a pleasing appearance and taste.

The present invention concerns improvements in this product and process whereby not only are the flakes given an attractive flavour but they are made richer in protein and organic phosphates, so that the general character and food value of the product is enhanced.

According to the present invention the process for the manufacture of flaked maize or corn for example comprises the step of enriching the maize or corn with the organic phosphates and protein present in concentrated ' steep water," which is a solution obtained by steeping maize in water containing a small amount of sulphur dioxide (about 0.3%) and concentrating the solution of the " solubles" so obtained to a convenient specific gravity. Preferably, this concentrated steep water is of about 15 to 18 Beaume, and is sprayed on to the flaked maize as it normally leaves the flaking rollers.

The flakes so treated are then passed on to a dryer to remove the excess water and produce the requisite crispness, and by using a cooking temperature the product has an additional attractive cooked flavour due to the " steep water" additions made to the maize.

To describe in detail one way for making my improved flaked product I proceed as follows:Raw maize is cleaned to remove dust 55 and foreign matter and passed over all electric magnet to remove pieces of iron.

The cleaned maize is then passed to a conditioning bin and has added to it, by a mechanical device a predetermined quantity of water and the addition is regulated so that at the end of the conditioning period the maize has absorbed a definite quantity of water, of the order of 20%, more or less. The conditioning period is 65 generally about 24 hours.

The next stage is breaking the maize through rolls to release the germ and break each cob of maize into small pieces which are known as grits. 70 The maize grit, after separation from the germ, is next passed through a vessel called a cooker, into which steam is injected. The function of cooking with steam is to soften the grit so that it may be 75 easily rolled into a flake at the next stage, and at the same time the starch cells are partially disrupted and the starch. gelftinised and made soluble. If the grits are undercooked they are hard and difficult to 80 roll into flakes; if too soft they stick to the flaking rolls and cause what is called pasting." The process of cooking the grits also gives rise to the formation of a certain amount of maltose and dextrin. 85 Flaking consists in passing the cooked grits over smooth rolls that may be heated or otherwise.

After the maize has passed the flaking rolls I impinge by means of a fine spray 90 or atomiser on to the flakes from 15%1, to 20% of concentrated " steep water," which, as is known, is obtained in the manufacture of starch from maize corn, by steeping the corn in water containing 95 a small percentage of sulphurous acid to prevent fermentation. After the corn has been softened this steep water is separated, filtered and concentrated to 15 to 1S Beaume. After this it is allowed to settle 10( and the clean liquor used to spray or inipinge on the flaked maize leaving the flaking rolls.

Steep water that is used at this stage is rich in phosphates and protein, and is 1.5 sprayed to the extent of 15 % to 25 % upon 384 507,384 the maize flakes. The flakes afterwards pass on to a dryer to remove extra moisture, and by raising the temperature an attractive cooked flavour is imparted.

" Steep water," as is well known in the art, is obtained by the wet-milling process for the separation of starch from maize, and its particular manufacture need not be described in further detail, except that it should be free from objectionable suspended matter and of good colour by appropriate separation. On a dry basis the solids contained therein may comprise approximately 8% of organic phosphorus as P20s,

6% of organic potash as KO0, a smaller proportion of organic calcium as CaO, some organic acids, as lactic, and it is also very rich in nitrogeneous substances. By this addition, in the form of " steep water" to the flaked maize, the food value of the product is considerably increased.

It will be appreciated that the process may be modified without departing from the purpose of my invention. Thus, steep water may be used as a medium for steeping the corn or maize in prior to the cracking into grits, in which case " light steep water" may be used, that is, of a much lower gravity than

15 to 18 Beaume, 80 and that this procedure may be an alternative to or additional to spraying the

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flakes with " heavy " or " light steep water," provided the flaked maize finally produced has been enriched with a coatin.g 35 or impregnation, or both, of the organic phosphates and protein of " steep water" solubles, of the kind hereinbefore described.

The flaked product so produced by my 40 improved process is of value as a more complete food than ordinary flaked maize, as will be appreciated from the character and composition of the improved product.

Dated the 24th day of June, 1938.

J. E. EVANS-JACKSON & CO., Bath House, 57-60, Holborn Viaduct, London, E.C.1, and at 34,

Dame Street, Dublin, Ireland.

Agents for the Applicant.


Improved Cereal Products and a Process for their Manufacture I, ALBERT EUSTACE BERitRY, a

British subject, of Winslow Road, Hammersmith, London, W.6, do hereby declare the nature of this invention and in what manner the same is to be performed to be particularly described and ascertained in and by the following statement: -

The present invention relates to improved cereal products and a process for their manufacture. Such cereals may for example comprise maize, oats, rice and the like.

It is known to prepare flaked maize by a process involving the steps of conditioning and softening by the addition of water, then cracking by passing between rollers to release the germ and form " grits," separating the meal and germ from the grits and thereafter cooking the grits with steam so that they readily flake when passed:subseqently between rollers.

The flaked maize so produced is crisp in character and has a pleasing appearance and taste.

The present invention concerns improvements in this product and process whereby not only are the flakes given an attractive flavour but they are made richer in protein and organic phosphates so that the general character and food value of the product is enhanced.

According to the present invention the process for the manufacture of flaked cereal products, for example maize comprises the step of enriching the maize with the organic phosphates and protein present in concentrated " steep water," which is a solution obtained by steeping maize in water containing a small amount of sulphur dioxide (about 0.3%) and concentrating the solution of the " solubles " 85 so obtained to a convenient specific gravity. Preferably, this concentrated steep water is of about 15 to 18 Beaume, and is sprayed on to the flaked maize or other cereal grain as it normally leaves 90 the flaking rollers. The flakes so treated are then passed on to a drier to remove the excess water and produce the requisite crispness, and by using a cooking temperature the product has an additional 95 attractive cooked flavour due to the" steep water " additions make to the maize.

To describe in detail one way for making my improved flaked product I proceed as follows:- 100 Raw maize is cleaned to remove dust and foreign matter and passed over an electric magnet to remove pieces of iron.

The cleaned maize is then passed to a conditioning bin and has added to it, by a 105 mechanical device, a predetermined quantity of water and the addition is regulated so that at the end of the conditioning period the maize has absorbed a definite quantity of water, of the order of 20% 110 by weight, more or less. The condition.

ing period is generally about 24 hours.

507,384 The next stage is breaking the maize through rolls to release the germ and break each grain of maize into small pieces which are known as grits.

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The maize grit, after separation from the germ, is next passed through a vessel called a cooker, into which steam is. injected. The function of cooking with steam is to soften the grit so that it may be easily rolled into a flake at the next stage, and at the same time the starch cells are partially disrupted and the starch gelatinised and made soluble. If the grits are undercooked they are hard and difficult to roll into flakes, if too soft they stick to the flaking rolls and cause what is called " pasting." The process of cooking the grits also gives rise to the formation of a certain amount of maltose and dextrin.

Flaking consists in passing the cooked grits over smooth rolls that may be heated or otherwise.

After the maize has passed the flaking rolls I impinge by means of a fine spray or atomiser on to the flakes from 15% to 25% by weight of concentrated " steep water," which, as is known, is obtained in the manufacture of starch from maize corn, by steeping in water containing a small percentage of sulphurous acd to prevent fermnentation. After the corn has been softened this steep water is separated, filtered and concentrated to 15 to 18 Beaume. After this it is allowed to settle or filtered and the clean liquor used to spray or impinge on the flaked ma.ize leaving the flaking rolls.

Steep water that is used at this, stage is rich in phosphates and protein. and is sprayed to the extent of

15%/ to 25% by weight upon the maize flakes. The flakes afterwards pass on to a drier to remove extra moisture, and by raising the temperature an attractive cooked flavour is imparted.

"Steep water," as is well known in the art, is obtained by the wet-milling process for the separation of starch from maize, and its particular manufacture need not be described in further detail, except that it should be free from objectionable suspended matter and of good colour by appropriate separation. On a dry basis the solids contained therein may comp)rise approximately 8%, of organic phosphorus as PO,

6% of organic potash as K.O, a smaller proportion of organic calcium as CaO, some organic acids, as lactic, and it is also very rich in nitrogeneous substances. By this addition in the form of " steep water " to the flaked maize, the food value of the produet is considerably increased.

It will be appreciated that the process may be modified without departing from the purpose of my invention. Thus, steepl) water may be used as a medium for steeping the maize in prior to the cracking into grits, in which case, " light steep water ' 70 may be used, that is, of a much lower gravity than 150 to 18 Beaume, and that this procedure may be an alternative to or additional to spraying with " heavy" or " light " steep water, provided the 75 flaked maize finally produced has been en.

riched with a coating or impregnation, or both, of the organic phosphates and protein of " steep water

'" solubles of the kind hereinbefore described. SO Where it is sufficient to apply the "corn solubles " steep water as the medium for steeping the maize in prior to the cracking into grits, it is possible to shorten the process of manufacture by dispensing with the drying and additional cooking operation after the flakes have left the flaking rollers, unless this further operative step is desirable for enhancing crispness and flavour. 90 The flaked product so produced by my improved process is of value as a more complete food than ordinary flaked maize, as will be appreciated fromi the character and composition of the improved product. 95 It will also be appreciated that the improved flaked cereal product may have other uses than for direct consumption, e.g., it may be used in the fermentation industry. 100 Having now particularly described and ascertained the nature of my said invention, and in what manner the same is to beData supplied from the esp@cenet database - Worldwide

679/2197

147.

GB511722 - 8/23/1939

IMPROVEMENTS IN OR RELATING TO CITRUS-CEREAL BREAKFAST

FOOD AND METHODS FOR THE MANUFACTURE THEREOF


Applicant(s): RAMON BUSTAMANTE (--)

E Class: A23L1/212B



Family: GB511722

Abstract:


511,722. Food preparations. BUSTA- MANTE, R. Sept. 1, 1938, No. 25556. [Class 49] A breakfast food is prepared by removing the juice from citrus fruit and freeing the solids from pectin and oil, drying, and comminuting to a flour, concentrating the juice and adding sugar in quantity sufficient in view of the degree of concentration to prevent fermentation, making a dough of the citrus flour, juice and cereal flour, baking and comminuting. As described, oranges are washed and ground to comminute the seeds, rind and pulp and strain the juice therefrom. Cane sugar or honey is added to the juice in amount depending on the quantity of natural sugar present therein and the degree of sweetness desired and the juice is concentrated in a vacuum pan to a specific gravity of about 1.2 at a temperature sufficiently low to conserve the Vitamin C content. The rind oil which evaporates may be condensed as a by-product. The concentrated juice may be kept in drums at about 50-60 F. until required for use. The solid residue is freed from pectin, oil and naringin by adding water in amount sufficient to allow of easy stirring and then sufficient sodium bicarbonate to neutralize the product. The rind oil which rises to the surface is skimmed off and the solids are separated in a filter press from the liquid which contains the pectin which has been converted into soluble sodium pectate and the naringin. The solids are subjected to hydraulic pressure to bring the moisture content down to about 30 per cent. and dried in a few minutes to a moisture content of about 10 per cent. in a drum c. drier at about 100-110 F. In modifications, calcium hydroxide replaces the sodium bicarbonate, or the pulp is subjected without these additions to antolysis, after dilution with water, at a pH of 4.5 in a vat kept by a water- jacket at about 130 F., the pectin being converted into a soluble salt and removed with the naringin as before, the oil being skimmed off. A plastic dough mass containing the orange solids, flour, concentrated juice, whole wheat, rye,. corn or rice flour, powdered sugar, bran flour, shortening, salt and cod liver oil is baked at not over 130 F. to prevent carmelization of the sugar and to bring the dough to a consistency at which it can be formed by extrusion into shreds, flakes c. which are toasted at 300 F. and sprayed during agitation with orange extract or strained juice from which the oil has not been eliminated. The product is dried and packaged.Description:


RESERVE COPY


Application Date: Sept. I, 1938. No. 25556/38.

511,722 Complete Specification Accepted: Aug. 23, 1939.

680/2197


Improvements in or relating to Citrus-cereal Breakfast Food and Methods for the Manufacture thereof

I, RAmoN BUSTAMANTE, a, Citizen of Cuba, of Corner of Oak and Florida Avenues, Tampa,

Florida, United States of America, do hereby declare the nature of this invention, and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:-

This invention relates to a citrus-cereal breakfast food and methods for the manufacture thereof.

One of the objects of the invention is the utilization of substantially the entire citrus fruit, both its solid and liquid content, in conjunction with cereal and other Iutritive ingredients, in the manufacture of a granular breakfast food, characterized by crunchiness, crispness, low hygroscopicity with the palatable flavour of the fresh citrus fruit, devoid of bitterness or other objectionable taste characteristics.

Another object of the invention is the provision of a process for the manufacture of a. citrus cereal breakfast food of the type described, which makes it possible to produce a product which is standardized as regard's those factors such as flavour, hygroscopicity, etc., which ordinarily would be variably affected by seasonal and other variations in the chemical or physical qualities of the citrus fruit.

Still another object of the invention is the provision of a process for making a citrus fruit flour substantially free from pectose, pectin, pectic acid, fruit oil, and the bitter fruit flavour principles, and therefore standardized as regards flavour and minimum hygroscopicityv.

A further object of the invention is the production of a citrus fruit flour made from the entire solid constituents of lthe fruit, substantially free from pectin or pectous compounds, fruit oils, naringin, resperidin, or other bitter flavouring and therefore of standard composition regardless of seasonal variations in the chemical or physical constituency of the fruit from which it is made.

A (cccdingl y tl('w preseInt iIven'ioln l)isists in a process for preparing a compos'te citrus-cereal breakfast food in which substantially the entire citrus fruit is incor[Price 11-] porated, comprising dejuicing the fruit and separately treating the juice and the solid part of the fruit remaining after dejuicing, by freeing the said solid part of pectin and oil, drying it, and comminuting it into flour, concentrating the juice and supplementing the natural sugar in the juice with added sugar, making the

60 juice proof against fermentative deterioration by virtue of the conjunctive relationship between the degree of concentration and the amount of added sugar, making a dough incorporating the thus treated

65 citrus flour, the thus treated juice, and cereal flour, baking the dough and commiinuting it.

The invention also provides a cereal breakfast food when prepared or produced 70 by the method above set forth.

Other features and objects of the invention will appear from the following description thereof -

While the invention contemplates the 75 employment of any species of variety of citrus fruits, a breakfast food embodying oranges as its foundation, and the process of manufacturing this orange breakfast food will be particularly described 80 herein for the purpose of illustrating the invention.

Oranges have a maturing season extending over a period of several months and the chemical and physical constituency of 85 the orange varies greatly during that period, not only due to the stage of maturity of the orange, but to other factors such as the amount of rainfall, sunshine, periods of abnormal heat or 90 cold, etc., and if breakfast food were made employing oranges just as they are gathered from time to time during the maturing season, the prod-uct would be unstandardized both as to flavour, crispness, its affinity for moisture, etc.

In its commercial phases therefore the process involves the breaking, down of the orange into two fractions which can be separately treated so as to, secure substantiatly unilforim iailndardizotioi of te(

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product. These two fractions are the juice and the solid residue of the orange remaining after the extraction of tbe juice.

511,722 - In carrying out the process, the oranges 7are washed and put whole into a grinder or mill so designed as to press and strain the juice from the oranges and to crush, grind or otherwise comminute the seeds, rind and pulp.

The juice strapined of seeds is collected in suitable containers and cane sugar or honey added thereto, in sufficient quantity to bring the solution up to the required Brix test. The amount of sugar or honey to be added is determined in accordance with the amount of natural sugar present in the juice and the degree of sweetness desired. The juice is then concentrated to a specific grTavity of substantially 1.2 by boiling in a vacuum pan at a temperature sufficiently low to preserve the Vitamin C content of the juice. In this boiling, the oil of the rind is evaporated off almost entirely from the juice and may, if desired, be separately condensed and disposed of as a by-product. The resulting product because of its concentration and sugar content can be preserved indefinitely in drums or other suitable containers at storage temperatures of from about 50 F. to 60 F. In the manufacture of the breakfast food, this supply of juice, which can always be prepared to a ulmiform standard, can be drawn upon as required.

The solid residue consisting of the rind, pulp-rag,and seeds, all in finely comminuted form, is treated for the removal of the pectin, the orange oil and the naringin. With this end in view, it is run into suitable vats, water being added in an amount sufficient to permit the mass to be stirred easily.

Depending upon the maturity of the fruit, pectin is present largely in the rind in variable degrees of solubility.

Immature fruit contains water-insoluble peetose which after the fruit matures is converted into pectin and in over-maturity to, pectic. acid. Of the pectin compounds present in the mature fruit used in the breakfast food of the present invention, it is safe to say that from 10 to 15 per cent.

are pectose and pectin, which are,insoluble in water. If this material is allowed to remain in its natural state in the processing citrus flour, it multiplies the drying time and cost. Even if this factor be disregarded, and the material were to be dried in spite of the presence of waterinsoluble pectose or pectin, the breakfast food would not only be a little tough but also extraordinarily hygrosc.opic. These water absorbent features present costly and - unnecessalry. packaging problems which are avoided by the removal of the pectin.

The naringin is a bitter glucoside which if present in the breakfast food causes a bitter and commercially -objectionable taste.

The oil of the rind is also an objectionable feature if allowed to remain in the 70 breakfast food in the quantities natural to the volume of food used in percentage by weight of the final product Grinding the whole orange finely releases the oil, some of which is expressed into the juice 75 and evaporated off as has been described while the rest of it remains in the pulp.

Alternative methods may be employed in the treatment of the pulp. In one of these methods sodium bicarbonate is added 80 to the pulp-water mixture in sufficient amounts to neutralise the mixture. After a short time, depending upon the extent of agitation and the temperature of the mixture, the following reactions have taken 85 place. The oil of the rind has risen to the top of the vat and may be skimmed off.

Free pectin has been converted into sodium pectate which is water-soluble and is in solution. The naringin is naturally 90 soluble and has leached into the solution.

When these reactions have taken place, the oil is skimmed off and the mixture run through a filter press. The liquid drawn off from this operation contains 95 sodium pectate in liberal quantities which may be recovered as a by-product. The liquor also contains the naringin. The pressed cake of pulp, seeds and rind is then subjected to hydraulic pressure to; bring 100 it down to about 30 per cent. moisture content by weight. It is then run into a drier which may be of the drum or iany other heated type and dried at a temperature of about 100 to 110 F. which will 105 bring the moisture content

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dowvn to about per cent. in a few minutes. The rough ground product at this point is to all intents and plu)oses, bone (i r. It is then run through a pulverizing apparatus of 110 mesh fineness so that the resulting flour is uniform, irrespective of whether the particle is from the hull,,albedo, outer skin, inner rind or what not of the orange.

The flour can then be sacked or put in 115 other suitable containers and stored just as is done in any other flour for indefinite periods until required for the manufacture of the breakfast food.

It is to be understood that this method 120 of processing the pulp, etc., into flour retains some traces of sodium pectate which are not sufficient to affect the minimum hygroscopicity of the product and which may have some health value 125 because of the p)resence of the sodium.

One variant of the above method of tlie converting of the solid portions of the orange into flour is to substitute calcium hydroxide for the sodium bicarbonate. 130 511,722 The resulting pectin salt is calciumi pectate. This method may be preferable in that the trace of calcium, in the flour is a desirable mineral in the building of hones in the human body.

The third method of preparing a standard orange flour makes use of no chemicals. The pulp rind and seed mnixture in the vat is subjected to autolysis.

In this case the vat is water jacketed so that a temperature of substantially 130 F. may he maintained.

The amount of water added to the pulp is only sufficient to dilute it to a ph of 4..5. Pnder these conditions, the enzymes natural to the fruit cause per-digestion of the pectin and the conversion of it into a soluble salt which is drawn off in the liquid. Concurrently, the naringin is leached out and the oil rises to the top by gravity just as inl the other alternative methods of treatment.

Given these citrus ingredienits. namely.

thile standardized dry orange flour on the one hand and the standarized concentrated juice on the other, together w'th other essentials, the manufacture of the breakfast food proceeds,as follows: A mixture is made of the following ingredients in the welgiht proportions as given Orange flour - -

Concentrated juice Cereal flour (whole wheat, rye, oat, corn or rice) - - - Sugar in powder form Bran flour - - - Shortening - - Salt to taste Cod liver oil gorams 856, . 300..

350, 2.50 This mixture is a plastic doulgh mass which is baked at a suitable temperature until the consistency of the mass:s brougoht to a point whlere it may lbe formed by extrusion or by anly other suitable means, into crumbles, shreds, flakes or other forms customary in brealkfast foods.

The temperature at which the mass is baked is held below any temperature which would caramelize the hloney or the sugar or whch would (lestroy the vitamin content of the product being, processed.

Where oranges are used as the lbae of the product, the temperature of the baking oven should not exceecld 1.30 F.

It is significant that the concentrated juice is the only liqauid iincorpoirated into the mixture and that lli contains just enouph moisture to)be evaporatedl at about the timne the flour has been bakled, leaving the product of the proper consistency for final granulating.

After havillng been formed into the crumbles, flakes, etc., as described, the 65 product is toasted for a few minutes at 300 F. to eliminate its final moisture content and give it the necessary p]easing crispness or crunchiness desired inll the commercial product. 70 It will be understood that in the production of a standardized product, substant'ally all of the oil has been eliminated, a certain percentage of which, although less thian the percentage found 75 in the natural fruit, is essential to, the proper flavour. Consequently, after toasting, thle product is then sprayed with orange extract. or strained orange juice from which the oil has not been el'iinated. If the extract alone is used albout one ounce to one ki]ooram of the product is applied. The product is agitated of course during the application,f the spray so that each particle may be as fully 85 coated as possible. The p;roduct 's then dried so that the alcohol of the extract or the wxater of the sprayed juice may be eliminated. It is thlen ready for packagingll. and shipment. 90 The process of the present invention effects: (1) the

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preservation for indefinite per:ods of the two fra tionis of the orange which togethler constitute substantially the entire fruit, namely, the concenlltrated 95 juice and the pectin-free citrus flour: (2) the emnplovyment of these fractions in the manufacture of breakfast food as a year round industry altogethler independent of the frutiting seasian; (3) the preservation 100 of the vitamin content of the oranloe: (4) the l)roduction of a product which is nourishing, palatable, possessingg the crisp quality characteristic of breakfast foodsand 'i which hygroseol)iritv is minimized throuoh the substantial absence of pectin.

In carrying out the process above described, no chemical or artificial preservative, or colouring matter, or harmful 110 foreign suhstances are used. Throughout ithe entire operation of produc.ng tlhe product, the temperatures employed are controlled so as to preserve the original filavour, vitamin content and natural salts 115 of the freshl fruit beilngl procesqed. A most imlportant feature of the invention is inherent hn the fact that the juice of the fresh fruit forms a binding agent for the other ingredients of the finished product. 120 This binding effect is made possible by the evaporation of water from the juice during the baking and filnal drying operat ion While I have inl the above decripltioni 125 disclosed what I believe to be a preferred and practical embodiment of my invention, it will be understood that mlodificaa 511,722tions may be made in the said embodiment without departing from the nature of the invention.

Having now particularly described and ascertained the nature of my said invention, and in what manner the same is toData supplied from the esp@cenet database - Worldwide

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148.

GB515351 - 12/4/1939

IMPROVEMENTS IN OR RELATING TO THE PRODUCTION OF DRY

STARCH PRODUCTS SUITABLE FOR THE PREPARATION OF

BLANCMANGES, PUDDINGS AND THE LIKE BY SWELLING IN COLD

WATER


Applicant(s): AUGUST ADOLPH SALZBURG (--)

E Class: A23L1/0522; C08B30/14



Family: GB515351

Abstract:


515,351. Starch. SALZBURG, A. A. May 25, 1938, Nos. 15604, and 30820. [Class 121] [Also in

Group VI] A starch product from which blanc-niange pudding, creams, custards or sauces can be made by stirring with cold water is obtained by drying in finely-divided condition, as by spraying in hot air, a paste made by treating starch with hot water and/or milk at a temperature below 100 C. The starch used may be that obtained from cereals, e.g. maize, wheat, rye or rice starch. The paste may be made at temperatures ranging from 73 to 88 C.Description:


RESERVE COPY


Application Date: May 25, 1938.

.,, Oct. 25, 1938.

No. 15604/38.

No. 30320/38.

515,351 One Complete Specification Left: Feb. 22, 1939.

(Under Section 16 of the Patents and Designs Acts, 1907 to 1938.) Specification Accepted: Dec. 4,

1939.


No. 15604 A.D. 1938.

Improvements in or relating to the Production of Dry Starch Products suitable for the Preparation of

Blancmanges, Puddings and the like by Swelling in Cold Water I, AUGUST ADOLPH SALZBURG, of 51, Linden Lea, East Finchley, London, N.2, a German Citizen, do hereby declare the nature of this invention to ibe as follows: This invention relates to a method of producing from maize starch a dry

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preparation which, when made into a paste with cold water, gives a suspension capable of quickly gelling to a swelled form which is- firm to cutting and is of advantageous application in the making of puddings.

It is known that maize starch, upon boiling with water, manifests itself directly as a pudding starch, that is to say, it passes at once into the form of a swollen product which is able to set after the fashion of a pudding or blancmange upon cooling.

It has now been found that it is possible to produce from maize starch a dry preparation which is capable of solidifying to a pudding-like and firm gel even when made up with cold water.

According to this invention, maize meal or maize starch in appropriate concentrations is converted into a paste by warming with water or aqueous liquids and this paste is then subjected to a rapid drying performed at moderate temperatures.

The product thus obtained is a dry preparation having advantageous cold-swelling properties and is suitable for making puddings and for serving as a base for various kinds of food products. When desired, the maize starch may have other constituents added to it such for example as sugar, cocoa, milk, albumen, fruitjuices and the like.

The proportion of maize starch employed in,making the the dry preparation will vary according to the nature of the food product which is to be made from t5 the dry preparation. For instance, it is known that every kind of starch requires a certain minimum quantity of water or aqueous liquids for production of a paste or swelling formation. In the case of maize starch, when used alone, the 50 quantity of liquid required for complete swelling is about 400% relatively to the quantity of the starch.

Theoretically, therefore, completely formed starch swellings or pastes can be produced containing 55

25% of maize starch expressed in terms of the quantity of liquid. In practice, however, preparations of this nature cannot be used for the present purpose, as they are of a stringy consistency and are so highly

60 viscous that they have no fluidity and cannot be conveyed in the apparatus used in the manufacture even with the aid of pumps. It is possible, however, to obtain sufficiently fluid preparations from maize

65 starch in ranges of concentration containing about 6% to 15% of starch (expressed always in terms of the quantity of liquid).

It is essential, therefore, when using the maize starch alone, to produce a suspension containing about

6% to 15% of the starch in water or an aqueous liquid in the production of the dry preparation.

For the production of the dry preparation in commercial form, it is generally 75 desirable to introduce other constituents such for example as sugar, cocoa, milk, albumen, fruit-juices and the like as aforesaid. However, for these additions, which are desirably introduced during the 80 manufacture of the preparation previously to making the starch into a paste, some modification of the procedure is adopted. For example, the addition of milk in place of water increases the 85 viscosity of the paste, whereas on the other hand the addition of sugar reduces the viscosity, while the addition of unpasted meals or powders such as cocoapowder renders the paste-mixture smooth, 90 that is it acts similarly to the addition of sugar. With such additions as reduce the viscosity, the starch concentration in the paste can in some circumstances be correspondingly increased while, conversely, in the case of the addition of viscosityincreasing agents, the starch concentration in the paste must in some circulmstances be reduced. In appropriate cases, addition of sugar or unpasted powder-substances such as cocoa-powder, can be employed to reduce the viscosity of the paste-mixture or to render the paste o10 smooth. Such an addition may be made before or after the preparation, and before drying, of the paste. In all cases, it is important that the paste should remain fluid in itself or, at least, fluid under pump pressure so that it ecan conveniently be supplied to a drying apparatus and dried therein.

In cases of additions of fruit-juices, the starch concentration may have to be made higher, because it decreases during the manufacture owing to decomposition- of the starch by the fruit acids. As this decomrposition effect does not remain completely arrested even at the end of the manufacture, a dry preparation with a fruit-juice content does not possess the fame keeping qualities as - preparations having additions of milk, cocoa, albumen and the like which will keep practically indefinitely.

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In carrying out the-invention, the paste is produced from the maize starch at temperatures below 100

C. A suitable temperature is from 73 to 88 C. and advantageously about 78 C. After formation, the paste is suitably supplied or pumped to a comminuting device which converts it into a fine dust-like or atomised condition in which it may at once be dried in known manner by a current of hot air.

On -such an apparatus drying may be effected at such moderate temperatures as are desirable to produce the desired dry perparation and by way of example tihe temperature may be from about 500 . to 45 70t C.

In practice it has been found that preparations made from the maize-starch alone, without any additions, owing to:

their capacity for swelling in cold water, 50 have a tendency, precisely owing to this property, to form lumps upon being made up into a paste with water. This drawback, however, can be very easily obviated during manufacture by adding sugar to 55 the starch, or to the paste of starch and water or aqueous liquid before drying, or to the preparation after drying but beforeuse. This sugar acts after the manner of a wetting agent to produce or enhance 60 wetting by the water or aqueous liquid when the powder is made into a paste to produce a pulding or other food product.

In general, the dry preparation can also be improved by homogenising in known 65 manner-the pastemixture from which it is prepared. Where additions of other substances than the starch are made, the homogenising may permissibly be effected after the addition of all the substances 70 to be introduced into the final product.

In this case care must be taken that the paste-mixture is not substantially cooled upon supply to the homogenising apparatus, otherwise difficulties may arise in 75 the atomisation. It is also advantageous to avoid such cooling in other cases.

Dated this 25th day of May, 1938.

JENSEN & SON, 77, Chancery Lane, London W.C.2, Chartered Patent Agents.


No. 30820 A.D. 1938.


Blancmanges, Puddings and the like by Swelling in Cold Water I, AUGUST ADOLPH SALZBURG, of 51, Linden Lea, East Finchley, London, N.2, a German Citizen, do, hereby declare the nature of this invention to be as follows: In my pending application for patent No. 15604 filed on the 25th May,

1938, I have described a method for the production of a dry preparation from maize meal or maize starch capable, when stirred with cold water, of solidifying to form a firm blancmange-like substance.

The method consisted mainly in converting maize meal or maize starch into a paste by warming it at a temperature below 100' C. with water or some other aqueous liquid, for example with milk or fruitjuice, and spray-drying this paste by atomization in 95 a current of warm air. The range of temperatures to be used in the conversion of the maize meal or starch into a paste was stated to be 73 to 88 C. and the optimum about 78 C. 100 In the further-development of this' invention and in my efforts to apply it to other cereal products, I found each particular starch to have its own specific and optimal temperature for conversion into a 105 515,351 515,351 paste, which, when dried and stirred with cold water, would form a jelly of a solidity and stability such as required in a blancmange. I found that if the conversion of the starch into a paste occurs at a higher or lower temperature, the solidity and stability of the jelly, prepared from the spray-driel paste, by stirring with cold water remains below the optimum.

- While maize starch is best reduced to a paste by heating it in the presence of water up to about 78

C., which is somewhat below the temperature at which this, starch is altogether pastified, wheat starch has been found to require the, temperature of 88 0., which is the temperature at which complete pastification is obtained. It may be noted that the danger of overswelling and loss of solidilfication which occurs with over-heating of the other varieties of starch, e.g. maize starch, does not exist with wheat starch.

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The temperature best suited for the formation of a satisfactory paste from rice starch is 78 C., as in maize starch.

Rye starch can also be used in the production of a dry preparation according to this invention, but in some cases such a preparation possessed a less desirable taste or smell.

In all cases the conversion into a paste must be effected withI relatively large quantities of water in order to obtain a sumelemndy easily flowing paste adapted to be fed to the atomizer by means -of a pump.

1 have found that atomization of the paste in a current of warm or hot air of about 50 to 1500 C. is the best, if not the only means for commminutming and drying the paste, and for obtaining a dry preparation able to swell in cola water and abie to form a jelly of the solidity and stability best suited for a blancmange or pudding. The properties of this jelly and of the blancmange formed from it depend upon the drying of the paste in the finest possible comminution. This is probably due to the extremely large suro50 face of the starch particles which enable them to swell in cold water. On principle, any drying method is suitable which leads to the formation of a large surface powder. A powder, obtained by grinding lumps or flakes, or a film of dried starch paste is not able to form a firm and solid jelly when swelling in cold water.

The drying temperature should. not exceel the point beyond which charring of the particles occurs nor the point at which caramnelization of sugar sets in.

While about 100 parts of cold water will transform about 15 parts of a dry preparation made from maize.starch into a blancmange-forming jelly, larger quantities of water will reduce such a preparation to a cream, still more water to custard and finaily to a sauce.

The consistency, moulding and wetting capacity and taste of blanemanges prepared from the dry products according to this invention can be -considerably improved by the introduction of an inert gas or a compound developing such gas, as for instance bicarbonate of soda and tartaric acid, into the dry preparation. The constituents of a. gas-developing mixture may also be admixed separately to different portions of the paste about to be dried. For instance from 2 to 8% of 80 such compounds, relative to the weight of starch, may be added.

The dry preparations made from wheat starch have been found to be at least equal and in higher concentrations even 85 superior to preparations made from maize starch as far as the solidity of the jelly is concerned. This is rather surprising in view of the fact that wheat starch jellies prepared with boiling water are 90 greatly inferior in quality to maize starch jellies.

Other materials, for instance, cut, dried and ground fruit, preferably in the fornm of flakes formed from fruit pulp or powder 95 from fruit juices or fruit pulp may be admixed to the dry preparation.

In practising my invention, I may for instance proceed as follows:

EXAMPLE 1. 100 0.275 kgs. cocoa are boiled in water and cooled by adding 10 litres whole milk.

1.35 kgs. maize starch are stirred with 15 litres milk. The suspensions of cocoa and starch a-re mixed with 10 litres water, and 105 the mixture is heated to 760 C., whereby a paste is formed, which is then spraydried with air of 94 C. The dry powder obhtaine/ in this operation is mixed with 1.9 kgs. powdered sugar. 110 EXAMPLE 2.

0.49 kgs. cocoa and 0.81 kgs. sugar are boiled in 10 litres water and the suspension cooled by adding

20 litres, water.

4.08 kgs. maize starch are stirred with 27 115 litres water, the two suspensions are mixed and the mixture heated to 78 C.

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The paste thereby obtained is spray-dried with air heated to 150'0 C. The dry powder obtained in this operation is intimately 120 mixed with 3.74 kgs. powdered sugar.

The mixture is divided in two halves.

One half is intimately mixed with 86.71 grammes tartaric acid, the other half with 97.29 grammes bicarbonate of soda. The 125 two mixtures are then intimately mixed with each other.

EXAMPLE 3.

0.324 kgs. cocoa and 0.405 kgs. sugar are boiled in 10 litres water and cooled 180 515,351 by adding another 10 litres water. 1.814 kgs. maize starch are stirred in 7.5 litres water and mixed with the cocoa suspension, the mixture then being heated to 80 C. whilst stirring, to form a paste which is then spraydried with air heated to 150 C. To the powder thus obtained are admixed 1.67 kgs. powdered sugar. To one half of this mixture are added 39.59 grammes tartaric acid, to the other half 44.41 grammes bicarbonate of soda and the two halves are then mixed again.

EXAMPLE 4.

To 1.36 kgs. rice starch are added 0.6 kgs. sugar and the mixture is stirred with 27.25 litres of water.

The mixture is heated to 78 C. and stirred to obtain a paste, which is then spray-dried with air heated to

130 C. To the powder resulting in this operation 700 granimes powdered sugar are admixed.

EXAMPLE 5.

5.445 kgs. wheat starch and 1.134 kgs.

sugar are stirred into 54.5 litres water.

The suspension thus obtained is heated to 88 C. in order to form a paste, which is then spray-dried with air heated to 140 C. The fine powder resulting in this operation is mixed with 4.3 figs. finely powdered sugar.

The preparations made from wheat starch have been found to be at least equal and in higher concentrations even superior, to preparations made from maize starch as far as the solidity of the jelly is concerned. This is rather surprising in view of the fact that wheat starch jellies prepared with boiling water are greatly inferior in quality to maize starch jellies.

Other materials, for instance cut, dried and ground fruit, preferably in the form of flakes formed from fruit pulp, or powder obtained by drying fruit-juices or fruit pulp may be admixed to the dry preparation.

The consistency, moulding and wetting capacity and taste of blancmanges prepared from the dry products according to 50 this invention can be considerably improved by the introduction of an inert gas or a compound developing such gas, as for instance bicarbonate of soda and tartaric acid, into the dry preparation. 55 The constituents of a gas-developing mixture may also be admixed separately to different portions of the paste about to be dried. For instance from 2 to 8 per cent.

of such compounds, calculated on the 60 starch, may be added.

It may be useful to emphasize the fact that in contrast with other processes of preparing cold-waterswelling-starch, in which starch is mixed with cold water in 65 about equal proportions and dried-by spraying at a high temperature, the present process does not include the step of drying starch suspended in cold water.

In the present process the starch is heated 70 in water to swell at the temperature optimum specific for this particular starch, which ranges between 73-88 C.

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This imparts to the paste the particular property of forming, after drying with 75 cold water a jelly of a solidity and stability such as required in a blanc, mange or a pudding. In this process no decomposition of the starch takes place.

The process is a two-stage process in that 80 the starch is first reduced to a paste by heating it with water to a predetermined temperature between 73 and 880 0. and then drying this paste, preferably by spraying or atomizing with warm air, in 85 such manner as to, produce a finely subdivided powder having the large surface area which enables this powder to swell with cold water and to yield a jelly of the consistency, solidity and stability required go90 of a pudding or blancmange which can be cut with a knife and can easily be detached therefrom.

Dated the 25th day of October, 1938.

JENSEN & SON, 77, Chancery Lane, London. W.C.2, Chartered Patent Agents.



Blancmanges, Puddings and the like by Swelling in Cold Water I. AUGUST ADOLPH SALZBURG, of 51, Linden Lea, East Finchley, London, N.2, a German Citizen, do, hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement -

The present invention relates to starch products suitable for the preparation, with cold water and without heating, of blanemanges, puddings, creams, custards and sauces. It is particularly concerned

105 515,351 with dry preparations which may contain, besides starch, certain additions and which, when stirred with cold water, will form suspensions which within a few minutes form jellies which can be cut with a knife and have the consistency, solidity and stability required of a blancmange.

It is well known that green (natural) starch swells in hot water. Potato starch, when treated (boiled) with hot water, forms after cooling a tough stringy sticky paste, which is not brittle. The same applies to starch from other tubers, such as arrowroot starch. In contradistinction thereto the starches of cereals, for instance maize starch, wheat starch, rye starch and rice starch, when boiled with water and cooled, are converted into jellies possessing all those properties which are characteristic of blancmange, in that they are stable and elastic and can be cut with a knife, from which they can readily be detached.

Apparently a starch jelly possesses the solidity, stability and elasticity required in a blancmange only if during solidification a kind of skeleton is formed within the gel substance by the non-hydrolysed parts of the starch-granules, e.g. the envelopes of the granules, and supports the hydrolysed part of the gel. While potato starch and other staicles of simixar constitution show a tendency to swell too far and to be reduced to a shapeless mass, maize starch swells much more sLowly and only at higher temperature, and after the sweling process some of the original granular matter, probably the envelopes ot the starch granules, forms the elements from which the gel skeleton is being built up. Other cereal starches such as wheat starch and rice starch undergo a similar conversion; they sweil readily, but not too tar, and starches of this nature, therefore, deserve the name of natural Iblancmangeforming starches. Rye starch behaves similarly, but it may in some cases impart to the dry preparation an undesirable taste or flavour.

I have now found that it is possible to produce from natural blancmange-forming starches dry preparations which, when mixed with cold water, solidify to form a blanmange-like jelly. It is surprising that these starches, when converted into such dry preparations, retain their favourable limited swelling capacity which enables the skeleton mentioned above to be built up.

I have found that such dry preparations can be prepared by first reducing the starch to a paste by gelatinising it in the presence of hot water at a temperature 6.5 below 100 C., and thereafter drying the paste by a process which leaves its physica, structu.e uncianged, so that the dried product, on taking up water again, will swell and in swoien condition will.e identical with the swolien starch (paste), 7(0 whien was subjected to the drying process. lhe paste, which besides the starch an.1 water may contain

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additional matter, is finely subdivided and dried min this state of fine subdivision. Preferably, the paste

75 is atomized and rapidly dried at a moderately raised temperature.

The reduction of the starch to a paste (pastification) is preferabky carried out at a temperature within the range of 73-88 80 C. Within this range of temperatures there exists for each kind of starch an optimum temperature for pastification, at which a paste is obtained resulting in a dry prepaeaton which, when mixed with 85 cold water, forms a blancmange-jelly possessing the optimum solidity and stability. If reduction of a starch is effected at a higher or lower temperature than this optimum temperature, the 90 solidity and stability of the jelly forming the blancmange will as a rule be inferior.

With maize starch the optimum temperature is at or near 78 C., i.e. somewhat below the temperature at which this starch is completely pastified. With wheat starch the optimum temperature of 880 C.

is also the temperature at which complete pastiheaton takes place. The difference 100 between the two cases is due to the fact tuat wheat starch,.being less readily pastifief, can only be reduced to a paste by heating it up to the temperature at which complete pastification takes place and 105 that the danger of too far-reaching swell ing and of the loss of the property of forming on solidification a stable jelly does not exist. The temperature best suited ior the formation of a satisfactory 110 paste from rice starch is 78

C., similar to maize starch. In all eases. the conversion of the starch into a paste must be effected with relatively large quantities of water in order to obtain a sufficiently 115S easily flowing paste or a paste which can at least be fed to an atomizer or spray, ing device by means of a pump. In the case of maize starch, which requires about the four-fold quantity of water, 120 relative to the weight of the starch, in order to swell completely, a proportion of 6-15 parts by weight of the starch per parts by weight of water has been found to be suitable. Higher concentrations of starch may be useful if the paste is fed to the spraying device under increased pressure. For instance at a concentration of 10 parts starch- and

100 parts water a paste is formed, which can 130 a 515,351easily be fed to a spray-drying device by pumping.

--- Since it is frequently desirable to add to the dry preparation during manufacture additional substances, for instance sugar, eocoa, milk, fruit-juices and the like, it will in certain cases be recommendable to add these substances to the paste before it is dried. In that, case the physical properties of the paste may be changed to- such an extent that it may becomne advisable to operate with a different concentration. Thus for instance an addition of milk instead of water will increase. while the addition of cane sugar will reduce, the viscosity of the paste.

Other kinds of sugar, for instance 'glucose. fructose and arabinose, act similarly to cane sugar. An addition of nonpastifiable meals. for instance cocoa meal, renders the paste mixture more supple, thus bringing forth a similar change to a reduction of the viscosity. If -additions are made which reduce viscosity, the percentage of starch in the mixture may 'be increased. On the other hand, if viscosity raising materials are added, a lower concentration of the starch may be chosen in order that the paste can easily be fed to the dryer and atomized therein.

- For instance in order to keep up the easy flow of a paste obtained from about 7 kilogrammes maize starch and 100 litres water, if whole milk is added, the percentage of starch- should be reduced to, about 5.4 kgs. per 100 litres of liquid. In order to obtain a desirable proportion of starch to milk albumen, such a paste may for instance be prepared from 1.35 kgs.

starch, 15 litres whole milk and 10 litres water, the maize starch being stirred with -the water to form a suspension and the whole milk being added thereafter. A paste prepared from 1.35 kgs. starch, 1.50 kgs. sugar, 0.275 kgs. cocoa, 10 litres water andd 15 litres whole milk by first -boiling the cocoa in water, then adding the sugar, and then the whole milk and the maize starch showed the, same degree of easy flow. When the paste is, fed to the dryer by pumping, it may be formed from 1.35 kgs. starch, 2.15 kgs. sugar, 0.32 kgs. cocoa and 10 litres water, in which case it contains more than 28 per cent. by volume of starch and other constituents. In certain cases the content of dry substances may be raised to

40-50 per cent. by volume.

A relatively higber starch concentration must be chosen if fruit-juices are mixed with the paste, since this causes a decomposition of the starch during the production of the preparation and- this decomposition will probably continue in the finished dry preparation. Such preparations therefore do

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not possess the practically unlimited stability of those which besides starch contain milky substances, cocoa or albumen.

Before the paste is fed to the drying 70 apparatus, it may first be homogenized in a homogenizing apparatus in order to reduce its degree of viscosity. Homogenization may at the same time increase the suppleness of the paste, but in order to 75 attain this the paste must be prevented from cooling. As a rule it will suffice if the paste is not allowed to cool below about 40-50 C. If it has been homogenized, it is recommended to maintain 80 the temperature, at which pastification has taken place, until drying commences.

I have found that the desired fine subdivision of the paste about to be dried is preferably effected by spraying or atomization into air heated to. from 50 to 150 C. I may for instance spray the flowing mass by means of a rapidly rotating disc into a current of hot air and cause the dried particles to be removed from the 90 drying zone at a controllable speed. The most favourable properties of the jelly which forms the pudding, depend on the fact that the paste is dried in its finest subdivision, giving an optimum surface 95 area to the powder thus obtained, which enables it the better to swell in cold water and to form a blancmange-jexiy.

On principle, the drying method used should be such as. to evaporate the water l0 in fractions of a second and result in the formation of a powder, the particles of which possess a sufficient surface area, thus enabiing the powder mixed with cold water to form a blancmange-jelly. This 105o property of swelling -is not attained if starch paste is dried in scales or lumps, which dry comparatively slowly, and ground after drying. My investigations have shown, however, that if a starch 110 paste, obtained by treating a jelly-forming starch with a quantity of hot water at a temperature below 100 C. such that the resulting paste is easy flowing-or can be conveyed by pumping, is dried in astate of fine subdivision, the drying takes place rapidly and the resulting dry preparation is a powdered product having the desired properties. This product when brought in contact with and after having 120 adsorbed, water, will practically be the same product as before the drying- Thus the dehydration process, carried through when drying such a paste under conditions of fine subdivision, is reversible in 125 that it.does not change the constitution of the material except. by expulsion of water, so that the dry preparation can be recon-verted into the starting product by taking up water, i.e. by simple hydration. This 180 515,351 fact is characteristic of the new process as distinguished from the drying of the paste under mechanical action, for instance by compressing the product be.

tween heated metal surfaces or by spreading it on heated cylinders. Such drying methods have been used for instance in the production of potato flakes, but, if applied to starch pastes, would not lead to l0 the formation of preparations fit for conversion with cold water into blancmangejellies.

Care should be taken during the drying that the temperature is not such that the paste particles might be injured and par.

ticular care should be taken to avoid contact of the finely subdivided or atomized paste droplets with an air current at a temperature such that charring of the paste might arise or the sugar present iB the starch might undergo caranelization.

In certain cases a drying temperature as low as 0-70 C. will be suitable.

When mixing about 11.3 to 15 parts of the dry preparation thus produced from maize starch with 100 parts cold water, a blanchange is obtained, in which the solidify and stability of the jelly is about equal to that of a blancmange produced by mixing 9 parts of the ordinary kind of blancmange starch with 100 parts of Loiling water. If a higher percentage of water is mixed with the dry preparation creams, custards or sauces are formed instead of blancmange.

In the preparation of blanemanges from the cold-swelling dry preparations, especially if they are produced froim maize or rice starch, lumps may form on the addition of water. This drawback can easily be avoided by mixing the dry preparation with a finely subdivided soluble solid carbohydrate, for instance with finely powdered sugar which acts. as a wetting agent for the cold water or milk. A mixture of 100 kjigs. of a maize starch dry preparation with 40 kgs. powdered sugar has 'been found to be suitable. Similar additions, also act favourably in dry preparations which contain, besides starch,

692/2197

milk, cocoa and other suitable ingredients. Wheat starch preparations as a rule do not require the addition of a solid carbohydrate since they do not tend to form lumps. Sugar added to the paste before drying also acts as a wetting agent.

The consistency, moulding and wetting capacity and taste of,blanemanges prepared from the dry products according to this invention can be considerably improved by the introduction of a compound developing an inert gas. as for instance bicarbonate of soda- and tartaric acid, added to the dry preparation. The constituents of a gas-developing mixture may also be admixed separately with different portions of the paste abhout to be driedl. For instance from 2 to 8 per cent.

of such compounds, calculated on the starch, may be added. 70 In practising my invention, I may for instance proceed as follows: EXAMPLE 1.

0.275 kgs. cocoa are boiled in water and cooled by adding 10 litres whole milk. 75 1.35 kgs. maize starch are stirred with 15 litres milk. The suspensions of cocoa and starch are mixed with 10 litres water, and the mixture is heated to 76 C., whereby a paste is formed. which is then spraydried with air of 94 C. The dry powder obtained in this operation is mixed with 1.9 kgs. powdered sugar.

EXAMPLE 2.

0.49 kgs. cocoa and 0.81 kgs. sugar are 85 bo.'led in 10 litres water and the suspension cooled by adding 20 litres water.

4.08 kgs. maize starch are stirred with 27 litres water, the two suspensions are mixed and the mixture heated to 78 C. 90 The paste thereby obtainel is spray-dried with air heated to 150 C. The dry Dowder obtained in this operation is intimately mixed with 3.74 kgs. powdered sugar.

The mixture is divided in two halves. 95 One half is intimately mixed with 86.71 grammes tartaric acid, the other half with 97.29 grammes bicarbonate of soda. The two,mixtures are then intimately mixed with each other. 100 EXAMPLE 3.

0.324 kgs. cocoa and 0.405 kgs. sugar are boiled in 10 litres water and cooied by adding another 10 litres water. 1.814 kgs. maize starch are stirred in 7.5 litres 105 water and mixed with the cocoa suspension, the mixture then being heated to 80 C. whilst stirring, to form a paste which is then spraydried with air heated to 150 C. With the powder thus 110 obtained are admixed 1.67 kgs. powdered sugar. To one half of this mixture are added 39.59 grammes tartaric acid, to the other half 44.41 grammes bicarbonate of soda and the two halves are then mixed 115 again.

EXAMPLE 4.

To 1.36 kgs. rice starch are added 0.6 kgs. sugar and the mixture, is stirred with 27.25 litres water.

The mixture is 120 heated to 78 C. and stirred to obtain a paste, which is then spray-dried with air heated to 130 C. With the powder resulting in this,operation 700 gramnmes powdered sugar are admixed. 125 EXAMPLE 5.

5.445 kgs. wheat starch and 1.134 kgs.

sugar are stirred into 54.5 litres water.

The suspension thus obtained is heated to 88 C. in order to form a paste, which 130 515,351 is then spray-dried with air heated to 140 C. The fine powder resulting in this operation is mixed with 4.3.gs. finely powdered sugar.

The preparations made from wheat starch have been found to be at least equal and in higher concentrations even superior, to preparations, made from maize starch as far as the solidity of the jelly is concerned. This is rather surprising in view of the fact that wheat starch jellies prepared with boiling water are greatly inferior in quality to maize starch jellies.

693/2197

Other materials, for instance cut, dried and ground fruit, preferably in the form of flakes formed from fruit pulp, or powder obtained by drying fruit-juices or fruit pulp may be admixed with the dry preparation.

It may be useful to, emphasize the fact that in contrast with other - processes of preparing cold-water swelling starch, in which starch is mixed with cold water in about equal proportions and dried by spraying at a high temperature, the present process does not include the step of drying-starch suspended in cold water. In the present process the starch is heated in water to swell at the temperature specific for the starch in use. This imparts to the paste the particular property ot forming, aiter diymng, wiltn coid water a jeliy of a solidity and stability such as requlred in a olanemange or a padding. In tins process no decomposition of the starch takles place. The process is a two-stage process mn that the starch is first reduced to a paste by heating it with water to a predetermined temperature and then drying this paste, preierably by spraying or atomizing with warm air, in such manner as to produce a finely subdivided powder havinrg the large surface area which enables this powder to swell with cold water and to yield a jelly of the consistency, solidity and stability required of a pudding or blancmange which can be cut with a knife and can easily be detached therefrom.Various changes may be made in the details disclosed in the foregoing description without departing from the scope of the appended claims or sacrificing the advantages of the invention.

Having now particularly described and ascertained the nature of,my said invention and in what manner the same is toData supplied from the esp@cenet database - Worldwide

Claims:

Claims of GB515351 be performed, I declare that what I claim is: 1. The method of producing cold-swelling preparations from blancmange- or pudding-forming starch products, characterized thereby, that such a starch product is converted into a paste with a quantity of hot water at a temperature below 100 C. such that the resulting paste is easy flowing or can be conveyed by pumping, and that this paste is then dried in a state of fine subdivision, whereby the physical structure of the starch is left unchanged, so that the dried product, if contacted with water, will swell and in swollen condition will be identical with the swollen starch (the paste) before the 75 same was dried.

2. The method of Claim 1, further characterized thereby that a natural blancmange- or pudding-forming starch such as a cereal starch is used. 3. The method of Claim 1 or Claim 2, further characterized thereby that pastification is effected at a temperature ranging between about 73 and 88 C.

4. The method of Claim 3, further 85 characterized thereby that pastification of maize starch or rice starch is effected at about 789 C., or that of wheat starch at about 88 C.

5. The method of Claim 1, further 90 characterized thereby that there is added to the paste, before it is dried, a substance adapted to reduce its degree of viscosity.

6. The method of Claim 1, further characterized thereby that to the paste, 95 betore it is dried, a sugar is added.

7. The method of Uiaim 1, further characterized thereby that to. the paste, beiore it is dried, a pulverulent substance, for instance cocoa meal, is added, which 100 does not form a paste, but increases the suppleness ol the starch paste.

8. The method of Claim 1 or Claim 2, further characterized thereby that in the pastification of the starch the water is replaced partly or altogether by an aqueous liquid nutrient. for instance milk.

9. The method of Claim 1, further characterized thereby that the paste, before being dried, is first homogenized, the 110 temperature at which the starch is reduced to a paste, being preferably maintained until the drying process starts.

694/2197

10. The method of Claim 1 or Claim 2, further characterized thereby that the 115 dry preparation is mixed with a solid pulverulent soluble carbohydrate, for instance with sugar.

11. The method of Claim 1 or Claim 2, further characterized thereby that a small 120 quantity of a compound developing an inert gas is added to the paste to be dried or to the dry preparation.

12. The method of producing a cold swelling dry preparation suitable for the 125 production of blancmanges, puddings, creams, custards and sauces, substantially as described.

13. A dry preparation suitable- for the preparation of blanomanges, puddings 130 515,351 and the like when prepared according to reference to the examples.

any of the methods defined in Claims 1 to Dated the 25th day of October, 1938.

12. JENSEN & SON, 14. A dry starch preparation when 77, Chancery Lane, London, W.C.2, prepared substantially as described with Chartered Patent Agents.

Leamington Spa: Printed for lHis Majesty's Stationery Office, by the Courier Press.-1939.Data supplied from the esp@cenet database - Worldwide

695/2197

149.

GB544360 - 4/9/1942

IMPROVEMENTS IN OR RELATING TO THE TREATMENT OF CEREALS

PRIOR TO FLOUR MILLING


Applicant(s): JOHN HERON ROGERS (--); FRANCIS HERON ROGERS (--); ERICH GUSTAV

HUZENLAUB (--)

E Class: A21D2/36; A23L1/10B; A21D6/00; B02B1/00



Family: GB544360

Abstract:


544,360. Treating grain. ROGERS, J. H., ROGERS, F. H., and HUZENLAUB, E. G. Oct. 8, 1940, No.

15014. [Class 58] A process for enriching grain consists in (a) steeping the grain with or without pressure in warm water or in warm solution obtained by a previous steeping of grain or grain offals, whereby is obtained a solution rich in vitamin and salts extracted from the grain, the steeping being carried to such. an extent that the grain absorbs at least sufficient water to bring the grain to the condition in which its rate of absorbency is at its maximum, (b) withdrawing the residual enriched solution, (c) drying the grain, (d) during the process of drying and when the content of water in the grain is such that the rate of absorbency is at its maximum, redamping the grain with the solution for a short period as by spraying, and (e) completing the drying operation. Before steeping, the grain may be de-aerated. The grain may first be partly milled, a solution of vitamin and salts prepared from the offals thereof being used for steeping and redamping the partly milled grain. It is stated that the maximum rate of absorption of water appears in most cereals to exist when the grain contains between 18 and 38 per cent. of water. The drying may be effected in a steam-heated vacuum dryer. The pH value of the steeping solution may be maintained on the acid side-say, pH5. After withdrawal of the solution from the grain the solution may be filtered and treated with deodourizing and bactericidal agents-e.g. activated charcoal, may be supplemented by water, additional extract, Vitamin B, extract or soluble mineral matter, and may be used for treating further batches of grain. After steeping, the cereal-e.g. rice-may be damped by low pressure steam and parboiled.

696/2197

150.

GB563792 - 8/30/1944

A PROCESS AND APPARATUS FOR THE TREATMENT OF RICE AND OTHER

CEREALS


Applicant(s): STEEI BROTHERS and COMPANY LTD (--); FRANK MYRIE HOLL (--)

E Class: A23L1/182



Family: GB563792

Abstract:


563,792. Treating rice c. STEEL BROS. & CO., Ltd., and HOLL, F. M. March 29, 1943, No. 5033.

[Class 58] A process for treating rice and other cereals consists in cleaning the grain and transferring it to a vessel in which it is first steeped in water which is kept in a state of circulation and then steamed at atmospheric pressure, the treated grain then being transferred to a drying machine. The circulation of the water may be effected by steam jet pumps which also serve to maintain the steeping water at a constant temperature. Cowls may be arranged above the vessel to collect steam and vapour during the steeping process and such steam may be used to maintain the temperature of the grain during its transfer to the drying machine. In the construction shown, the grain from the washers 2 is transferred to the steeping and steaming vessels 8, and is subsequently fed by a jacketed conveyer 9 and elevator

9a to a drying device 11. Waste circulating water from the vessels passes to a heating tank 3 whence it is fed by a pump 6 to a hot well 4. A further pump 6a delivers the heated water back to the vessels,

697/2197

151.

GB566856 - 1/17/1945

MANUFACTURE OF POTATO FLOUR PRODUCTS


Applicant(s): SUZANNE MABEL LAVINIA TRITTON (--)

E Class: A23L1/2165



Family: GB566856

Abstract:


Cooked potato mash is mixed before drying with a starch or a cereal flour to avoid, or reduce, the tendency of the mash to assume a horny character. The starch or cerial flour is preferably dried before use. In the case of a cereal flour having a gluten or similar protein content not sufficiently high to undergo undesirable swelling and toughening in the presence of water, e.g. rice flour, up to about 10 per cent of the weight of the mash may be added. With cereal flour having a high content of gluten or like protein, e.g. wheat or rye flour, the amount added is increased to about 200 per cent or the potato mash is first mixed with a small proportion of a starch or flour, e.g. potato flour, having a low gluten content and then with less than 200 per cent of a cereal flour having a high gluten content. A mixture having a loose granular form suitable for drying, is obtained by extruding the mash through a sieve directly into the starch c. in a rotary ribbon type mixer of the Gardner type. Alternatively, a preliminary mixing may be effected in a tumbler mixer and the final mixing in a disc mill of the Bentall type.

Mixing may also be effected on a vibratory screen or sieve. Drying may be effected on trays or a travelling band dryer, in a rotary dryer, such as a Simon or Mitchell dryer, or a travelling column dryer, such as a Kestner T.V. or Rema dryer, or in a ribbon-type mixer provided with a steam jacket. The dried material is cooled, ground and sieved.Description:


I, SUZANNE M[ABL LAVINIA TRITTON,

a British Subject, of 27, Exeter Gardens, Ilford, Essex, do hereby declare the nature of this invention to be as follows:In the manufacture of cooked potato flour the potatoes are first cooked, for example by steaming or boiling with water, the cooked potatoes are then mashed, and the mashed potato substance is dried to eliminate substantially the whole of its content of moisture. The drying may be conducted by spreading tile mashed potato substance ill the form of a thin film on a heated rotating cylinder, and scraping the dried potato substance from thile cylinder in the form of flakes, which are ground to produce the potato flour.

The above method, however, suffers from the disadvantage that during the drying operation the mashed notato sub-.

stance tends to assume a horny character.

According to the present invention, the 26 tendency of the mashed potato substance to assume a horny character during the drying operation is avoided or eonsiderably reduced by drying it in admixture with a suitable proportion of a starch or flour which is capable of absorbing moisture.

698/2197

The starch or flour is preferably dried before use so as to increase its capacity for absorbing moisture.

The proportion 8,5 of starch or flour admixed with the mashed potato substance need only be relatively small, for example, about 10 per cent. of the weight of the mashed potato substance, provided. in the case of a flour, that it has a low content of gluten or similar protein. Such a flour is, for example, rice flour. The quantity may be less than 10 per cent., although such a small proportion may necessitate mild drying conditions, so that a higher proportion which permits of more rapid drying may be preferred.

Flours containing relatively large amounts of gluten or similar protein, such as wheat flour or rye flour, cannot be used in such small proportions because the swelling and toughening of the protein constituent which occurs in presence 566.856 of the large amount of moisture in the potato substance would give the dried 55 product an undesirably horny character.

When such flours are used the proportion added should be considerably increased so as to reduce the ratio of moisture to flour in the mixture sufficiently to avoid (14) any undesirable swelling and toughening of the protein constituent. A suitable proportion of flour for this purpose is about 200 per cent. of the weight of the mashed potato substance. Although it 65 is unsuitable to use such flours when a product consisting mainly of potato flour is desired, their use affords a convenient method of preparing, mixtures of such flours with small quantities of potato 70 flour. In order to increase the quantity of potato flour in such mixtures, the mashed potato substance may first be mixed with a, small proportion of a starch or a flour having a low content of gluten 76 or the like, for example potato flour, and then mixed with a, smaller proportion of a flour having a high content of gluten or the like than if the latter were used alone. 80 Thus, for example, there may be incorporated with 50 parts b'v weight of mashed potato substance. 10 parts by weight of starch or potato flour and 50 parts by weight of wheat flour. 85 An example of the method of preparing a mixture of potato flour and wheat flour in accordance with the invention is as follows: The potatoes are washed, peeled, if desired. and cut into fine slices. 90 The cut slices are immersed in an aqueous solution of sulphur dioxide in knovn manner for the purpose of preventing subsequent discoloration of the potato substance, and are again washed.

The 95 potato slices are then cooked by steaming or by boiling in water, the adherent water is allowed to drain thoroughly from the cooked slices and the latter are then mashed. 1 part by weight of the mashed 100 potato is extruded throungh a sieve into 2 parts by weight of dried wheat flour, and the whole is mixed by gentle agitation in a rotary mixer, for example, of the Gardner type. The mixture is then 105 heated at a temperature of about 50" C.


Application Date: Feb. 24, 1943. No. 3033/43.

Complete Specification Left: Feb. 24, 1944.

Complete Specification Accepted: Jan. 17, 1945.

PROVISIONAL SPECIIF'ICATION Manufacture of Potato Flour Products , ------ --- L,,. 'L,-:I --- - j -1 i ' 1 ' '; 1 ' '1 '; on shallow trays in a drying chamber or tunnel, preferably in a dlraughlt of air.

The dried mnaterial is then cooled, gound and sieved.

6 When a mixture containing a higher proportion of potato flour is desired(, 50 parts by weight of the mashed potato may be extruded through a sieve into 10 parts by weight of starch or dried potato flour, and, after these ingredients have been mixed, 50 parts by weight of wheat flour may be added. After gentle mixing, the mnaterial may be dried on ti:L;, cooled, ground and sieved as described in the preceding paragraph.

Dlated this 24th day of February., 1!94:.

ABEL & IMRAY, Agents for the Applicant, Quality House, Quality Court, Chancery Lane, Lonldon,

W.C.2.


699/2197

Manufacture of Potato Flour Products I, SUZAN.rE MABEL LAVINIA T lTITTOY, a. British

Subject, of 27, Exeter Gardens, Ilford, Essex, do hereby declare the nature of this invention and in what manner the same is to be performed, to be particularly described and ascertained in and by the following statement:--

This invention relates to the manufacture of potato flour products which COlnprise mixtures of potato flour and starch or a cereal flour. The tern potato flour " is used herein to denote a dry powder obtained by drying cooked potato mash.

According to the present invention, potato flour products comprising a mixture of potato flour and a starch or a cereal flour are made by dryving cooked potato mash in admixture with such a proportion of a starch or cereal flour in pulverulent form that the tendency of the potato mash to assume a horny character during the drying' operation is avoided or considerably reduced.

The added starch or cereal flour is 1)'preferably dried before use so as to increase its capacity for absorbing mnoisture. The proportion of starch or flour admixed with the potato mash need only he relatively small, for example, about 10 per cent. of the weight of the 1)otato mash, provided, in the case of a flour, that its content of gluten or similar protein is not sufficiently high to undergo undesirable swelling and toughening in the presence of water. Such a flour is, for example, rice flour. The quantity may be less than 10 per cent., although such a small proportion may necessitate mild drying' conditions, so that a higher proportion which permits of more rapid drying may be preferred.

Cereal flours containing relatively large amounts of,gluten or simrilar protein, such as wheat flour or rye flour, cannot be used in such small proportions because the swelling and toughening of the protein constituent which occurs in presence of the large 'amount of moisturo in the potato mash would give the dricrd ploduct an undesirably horny character.

Whlen such flours are used the proportion added should be considerably increased so as to reduce the ratio of moisture to flour in the mixture suflieiently to avoid any 70 undesirable swelling, and toughening of the protein constituent A suitable proportion of flour for this purpose is about peri cent of the weight of the potato mash. Although it is unsuitable to use 75 such flours alone slwhen a product consisting inainly of potato flour is desired, their use alfords a convenient mnethod of preparilng mixtures of such flours with small quantities of potato flour. In 80} order to increase the quantity of potato flour in such mixtures, the potato mash mav first be mixed with a small propportion of a starch or a flour hatviong a low content of gluten or the like, for 85 example potato flour, and then mixed wvith a smaller proportion, that is to say less than about 200 per cent., of a cereal flour having a high content of gluten or the like than if the latter were used 90 alone. Thus, for example. there may be incorporated with 50 parts by weight of potato mash, 10 parts by weight of starch or potato flour and 0) poarts by weight of wheat flour. 95 I'hlle potato mash is Dreferal)lv mixed with the pulverulent material in such manner as to produce a mixture having' a loose oranulal form. which is especially suitable for the drying operation. For 100 this purpose the 1)potato mash may be formed into threads. for example by extrusion through a sieve, and gently mixed in this form with the pulverulent material.

The mixing is advantaneously 105 performed in a rotary ribbon type mixer.

for example of the Gardner type, the potato mash being extruded directly into the pulverulent material previously placed in the mixer, and the mixture 110 being worked up into granular form in the mixer.

Alternatively. a preliminary mixture may be made by mixing the potato mash with the pulverulent mnaterial in a tumbler n-ixer. From the 115 566,856 preliminary mixture thus obtained a more intimate mixture is produced in a mnixing apparatus in which the material is brought by agitation and disintegration into a loose granular form, care being taken that the material is not subjected to a kneading action during the treatment. A suitable mixing apparatus is a mixer of the kind in which the material is agitated and disintegrated by friction in the space between opposed rotating and stationary discs, and discharged from the mixer by centrifugal action, the space between the discs being sufficiently wide to prevent any kneading action which would cause the material to become pasty A suitable mixer of this kind is a high speed disc mill of the Bentall type. Another suitable mixing apparatus is a vibratory screen or sieve, on which the material is agitated by the reciproeatory movement of the screen or sieve, and through which it passes in loose granular form. A suitable screen

2,5 or sieve is one having 6 meshes to the inch.

700/2197

The loose granular material is then dried in any suitable drying apparatus.

For this purpose there may be used a rotary dryer of the kind comprising a rotating cylinder having on its inner surface lifting baffles to cause the material to fall through a current of air heated by steam pipes within the cylin36 der, for example, a Simon or Mitc.hell dryer. There may also be used a iravellinug column dryer in which the material is caused by a current of hot air to ascend in a vertical shaft, and the dried material is drawn off at the upper end of the shaft.

Examples of such dryers are the Kestner T.V. dryer and the Rema dryer. Alternatively, the granular material may be dried onl trays or a travelling band dryer may be used.

Instead of drying the loose granular material in a separate drying apparatus, the mixing may be performed in a ribbon type mixer of the kind described above and provided with a steam jacket, whereby, when the mixture has been brought into granular form, it can be heated in the mixer to effect the necessary drying.

The following Examples illustrate the invention, the parts being by weight:

ExxkMPLE 1.

A product consisting of a mixture of potato flour and wheat flour is made as follows: The potatoes are washed, peeled, if desired, and out into thin pieces, for example, chips or narrow strips, of substantially uniform thickness. If desired, the cut pieces may be immersed in an aqueous solution of i65 sulphur dioxide or of a sulphite in known manner for the purpose of preventing subsequent discoloration of the potato substance, and again washed. The potato pieces are then cooked by steaming or by boiling in water. The product will have 70 become mashed during the cooking, but.

if desired, it may subsequently be further mashed. Adherent water is removed from the potato mash by draining or by treatment in a hydroextractor. 75 1 part of the potato mash is extruded through a sieve into 2 parts of dried wheat flour placed in a mixer of the Gardner type. The whole is then mixed by gentle agitation to produce a loose 80 granular mixture, which is then dried in a rotary dryer or a

Kestner T.V. dryer.

The dried material, which powders easily, is cooled, ground and sieved.

EXAMPLE 2. 85

A product consisting of a mixture of potato flour and wheat flour is made as follows: 1i part of potato mash obtained as described in the first paragraph of Example 1 is mixed in a tumbler mixer 90 with 2 parts of dried wheat flour. The resulting preliminary mixture is then fed into a high speed disc mill of the Bentall type from which the treated mixture is continuously discharged in a loose 95 granular form.

The granular mixture is then dried, cooled, ground and sieved as described in Example 1.

Instead of treating the preliminary mixture in a Bentall type mill, it may be 100 formed into a similar loose granular product on a vibratory screen or sieve.

When a product containing a higher proportion of potato flour is desired, the above procedure may be modified by first 105 mixing 50 parts of the potato mash, which has been extruded through a sieve, with 10 parts of starch or dried potato flour, and then incorporating 50 narts of wheat flour in a tumbler mixer. The 110 resulting preliminary mixture is then further treated as described in this Example.

Having now particularly described and ascertained the nature of my said invention and in what manner the same is to be performed, I declare that what IData supplied from the esp@cenet database -

Worldwide

701/2197

152.

GB578614 - 7/4/1946

IMPROVEMENTS IN THE TREATMENT OF CEREALS FOR HUMAN

CONSUMPTION


Applicant(s): ERICH GUSTAV HUZENLAUB (--)

E Class: A23L1/182



Family: GB578614

Abstract:


578,614. Treating grain. ROGERS, F. H. (Huzenlaub, E. G.). Dec. 22, 1943, No. 21472. [Class 58] In order to reduce the time necessary for cooking cereal grain, it is subjected to a pretreating process which produces cracks or crazing therein, such process comprising the step of heating the grain to a temperature level at which its latent or imparted moisture content tends to be expelled and then immediately and suddenly cooling the grain. The process, which may be applied to grain such as rice or barley in a milled or partly milled condition, may be carried out under normal atmospheric pressure or under vacuum or pressure. As an example the grain'may be spread over a heated surface or over a heated transport band and raised from 10 C. to 100 C., or even more, above atmospheric temperature.

A draught of cold air is then caused immediately and suddenly to pass over the grain to produce the cracking or crazing. Alternatively the grain may be heated in a vessel under vacuum and a large valve then opened to admit cool air at a high velocity. The grain may, in another modification, be heated under pressure in a vessel, the pressure being produced by latent or applied moisture in the grain, or the grain may be damped and placed under pressure by admitting steam. Immediately prior to the cooling the pressure is released and relatively cold air admitted. In a further modification the grain from the heated conveyer band or heated vessel is discharged into bins which are naturally or artificially refrigerated.

702/2197

153.

GB579981 - 8/22/1946

IMPROVEMENTS IN OR RELATING TO QUICK COOKING RICE PRODUCTS

AND PROCESS OF PREPARING SAME



E Class: A23L1/182



Family: GB579981

Abstract:


579,981. Rice. STEVENS, A. H. (General Foods Corporation). May 10, 1943, No. 7374. [Class 58] A quick-cooking rice product is prepared by cooking rice for a period sufficient to gelatinize the starch and increase the moisture content to about 65-70 per cent. without causing substantial damage thereto and then drying the swollen grains by removing moisture from their surfaces at a rate sufficiently faster than it can diffuse thereto from their interiors so as to set them in their enlarged condition and produce a porous structure therein. The rice may be soaked initially for 30-60 mins. in cold or warm water below the gelatinization point, i.e., 65-70 C., and may be cooled before drying by means of cold air or water. Soaked rice is cooked in boiling water for about 8-10 mins. and unsoaked rice for about 21-23 mins. After cooking and draining, the rice may be spread in a layer not more than about 1 in. in depth and dried by forced air circulation. With an inlet temperature of 140 C. and an air velocity through the grains of 200 ft. per min., the grains are dried to 8-14 per cent. moisture content in 10-15 mins.

Vitamins and other nutrition principles may be added as by immersing the grains in, or spraying them with, a solution thereof before or after drying. The product may be prepared for use by cooking in 1-1 times the volume of boiling water for about 2-3 mins. or by soaking in warm or cold water or milk.

703/2197

154.

GB582904 - 12/2/1946

IMPROVEMENTS IN THE PROCESS OF ENRICHING CEREAL GRAINS WITH

NATURAL VITAMINS


Applicant(s): ERICH GUSTAV HUZENLAUB (--)

E Class: A23L1/10B



Family: GB582904

Abstract:


A process of enriching cereal grain with natural vitamins consists in grinding the scutellum of wheat grains to a powder to reduce the vitamin-retaining properties of the scutellum, and using the ground scutellum to increase the vitamin content of a liquid in which the grain is steeped, thereby enriching the natural vitamin content of the endosperm of the steeped grain. Thus the first batch of a series of batches of wheat grain may be steeped in hot water in the manner described in Specification 519,926, such steeping causing most of the vitamins in the husk and germ to be transferred to the scutellum. The grain may then be gelatinized, and is then dried and milled, the scutellum being separated from the germ and bran and then ground into a powder. This powder is then added to the steeping liquid drained from the first batch before the second batch is immersed therein or simultaneously with the second batch. This process is repeated for the subsequent batches, the steeping liquid being filtered after each batch is treated, until the scutellum removed contains the maximum quantity of natural vitamins of the B complex that it is capable of absorbing. Thereafter, all or only a part of the powdered scutellum from a batch is returned to the steeping water. In a modification powdered scutellum or other vitamin B carrier may be introduced into the steeping water of the first batch. The powdered scutellum may also be employed to enrich the steeping water for rice or other cereal grain. In another modification, the powdered scutellum is obtained from wheat grains in the natural unprocessed state.Claims:

Claims of GB582904 be performed, I declare that what I claim is:1 A process of enriching cereal grain with natural vitamins which consists in grinding the scutellum of wheat grains to 125 powder so as to reduce the vitamin retain3 ing properties of the scutellum, and using Lthe ground scutellum to increase the vitamin content of liquid employed in steeping cereal grain for the purpose of 130 i 1 i i t i i 482,904 enriching the natural vitamin content in the endosperm of the steeped grain.

2 A process according to Claim 1 wherein the powdered scutellum is introduced into the liquid in which said grain is stee Red.

3 A process according to Claim 1 wherein the powdered scutellum is introduced into the v essel containing the said liquid in which said cereal grain is steeped.

4 A process according to Claims 1, 2 or 3 wherein the scutellum is obtained from grain which has been previously steeped to enrich the natural vitamin content therein.

704/2197

A process according to Claims 1, 2 or 3 wherein the scutellum is obtained from wheat grain not enriched with vitamins.

6 A process according to Claims 1, 2 or 3 wherein the liquid in which a batch of whole cereal grain is steeped is separated from said batch and employed for steeping successive further batches of cereal grain, said liquid being separated from each said further batch of grain and enriched with scutellum derived from a previous batch of cereal grain enriched by steeping, prior to being employed for treating a further batch of cereal grain for enrichment of the endosperm thereof with natural vitamins.

7 A process according to Claim 6 wherein the liquid in which a batch of cereal grain is steeped is filtered to remove the powdered scutelium thedefrom before being mixed with further powdered scutellum and added to a further batch of grain 40 8 A process according to Claim 6 wherein the liquid in which batches of whole cereal grain are steeped is enriched -with successive additions of scutellum until the vitamin content of said liquid 45 is sufficient to ensure the saturation with vitamins of the scutellum of said batches of grain the endosperm adsorption of vitamins by said batches of grain being thereafter ensured by the addition to said 50 liquid of the whole or part of the scutellum obtained from a previous batch of enriched grain.

9 A process according to any of Claims 1 to 8 wherein the scutellum is 55 ground to a fineness approximating to that of the starch granules of the cereal grain to be treated.

A process according to any of Claims 1 to 9 -wherein the operation of 60 steeping the cereal grains is carried out by the process described in British Patent Specification No 519,926.

11 A process of enriching cereal grains with natural vitamins as described 65 herein.

Dated this 6th day of July, 1944.

HERON ROGERS & CO, Agents for Applicant, Bridge House, 181, Queen Victoria Street, London, E

C 4.

Leam ington Spa: Printed for His Majesty's Stationery Office, by the Courier Press -1946 Published at

The Patent Office, 25, Southampton Buildings, London, W C 2, from which copies, price is Od each

(inland) Is Id (abroad) may be obtained.Data supplied from the esp@cenet database - Worldwide

705/2197

155.

GB668288 - 3/12/1952

IMPROVEMENTS IN OR RELATING TO PROCESSES AND APPARATUS FOR

THE PREPARATION OF PARBOILED RICE


Applicant(s): DANIEL SALOMON FERNANDES (--)

E Class: A23L1/182



Family: GB668288

Abstract:


668,288. Treating grain. FERNANDES, March 13, 1950, No. 6278/50. Class 6(iii) 30531/48. Class 58.

In a process for converting crude rice into parboiled rice, while conserving in the kernels the full vitamin contents originally present, the crude rice is first soaked by imparting thereto, while in a thinlyspread condition, a slowly progressing and rolling motion and supplying water to said kernels, at a temperature preferably between 75 and 95 C so that it permeates the kernels gradually, whilst the quantity of water supplied is at most only in slight excess of the amount taken up by the kernels, whereby the minimum of vitamins are washed out of the kernels; whereafter the soaked rice is slowly conveyed in a thinly-spread condition and with a rolling motion through an open vessel supplied with steam at a uniform temperature not exceeding 100 C, whereby the vitamins diffused in the kernels are fixed; and finally drying the parboiled rice at substantially atmospheric pressure and moderate constant temperature. As shown, the soaking, steaming and drying are carried out in three separate apparatus, each similar and comprising a horizontal rotatable drum 1 (perforated only for the drying process), having a helical conveying member 2 fixed to the wall and provided with conical nozzles 5, 6 at the ends, the former being rotatably supported by a hollow sheet metal cone 7 carrying a hopper 9.

Through a perforated tube 11 extending axially through the drum water and steam may be passed for the steeping and steaming processes and hot air blown through by a fan for the drying process. In a modification (Fig. 4, not shown) of the apparatus for the soaking step, the discharge end of the drum is provided with an extension having a perforated wall and a conical nozzle end into which the conical nozzle 6 of the drum extends and is provided with a helical conveying member. A receptacle under the extension catches the draining from the soaked crude rice. In another modification, Fig. 5 (not shown), the hot steeping water from the receptacle which is provided with a steam inlet to maintain temperature is pumped back through the perforated tube 11.

706/2197

156.

GB675292 - 7/9/1952

IMPROVEMENTS IN OR RELATING TO PUFFING OF CELLULAR PRODUCTS


Applicant(s): GUARDITE CORP (--)

E Class: A23L1/00P14B; A24B3/18B



Family: GB675292

Abstract:


A method of puffing or expanding cereals comprises removing air from the cereals by placing it under vacuum in an atmosphere of steam, increasing the steam pressure, and then suddenly reducing the pressure below atmospheric, the pressure drop being sufficiently great to expand the cell walls beyond their elastic limit. Rice, or other cereals, are first freed of air and, whilst under the vacuum, flavouring, sugar, salt, vitamins, or nutritious salts may be added by atomising water containing the desired ingredients in the vacuum. The cereal is then cooked for 5-6 minutes at 20 lb. per square inch steam pressure, after which the steam pressure is raised to 90-100 lb. per square inch and suddenly reduced to below 8 in. mercury, and preferably to 0.1 in. mercury, to expand the cereal particles. Specifications

488,638, 508,264, and 631,840, [both in Group VI], are referred to.

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157.

GB683183 - 11/26/1952

IMPROVEMENTS IN OR RELATING TO RICE PRODUCTS



E Class: A23L1/18C6



Family: GB683183

Abstract:


A process of treating rice comprises cooking the same in the presence of moisture, drying the cooked rice to a moisture content within the range of about 10-14 per cent, compressing the individual rice kernels and pieces thereof while the temperature of said kernels and pieces is within the range of about

140 DEG -210 DEG F and thereafter subjecting the same to a high temperature whereby they are puffed. In an Example 100 lbs. of rice are mixed with a flavouring syrup made from 2.75 lbs. salt, 13 lbs. sugar and 18 lbs. water and cooked under 15 lbs. steam pressure for 1-2 hours, cooled and dried to about 12-13 per cent moisture in a conventional drum dryer and then tempered for 6-10 hours. The mixture is then deposited in a thin bed on a vibrating conveyer and heated to a temperature of 160-190

DEG F by means of a series of about 6 infra red radiant heaters above the vibrator and p electrical strip heaters attached to the bottom of the conveyer. The hot rice falls uniformly from the edge of the pan between flaking rolls set at a pressure to reduce the rice kernels to 0.035 in. thickness. The compressed grains or pieces are then conveyed to a rotary toasting oven where they are simultaneously toasted and puffed to give a crisp friable toasted and puffed rice product several times the size of the original kernel. U.S.A. Specifications 1,832,813 and 1,925,267 are referred to.Description:



683 Date of Application and filing Complete Speclfication: Dec. 12, 1950.

No. 30326/50.

Application made In United States of America on April 26, 1950.


Index at acceptance:-Class 58, A4, C2, H(3: 4c).


Improvements in or relating to Rice Products We, GENERAL FOODS CORPORATION, a corporation organised under the laws of the State of Delaware, UJnited States of America, of 250, Park

Avenue, New York, State of New York, United States of America, (Assignees of MATTISON WELLS

ALDERMAN, WILLIAM FREDERICK MASSMANN, Jr. and ELMER WILLIAM MICHAEL), do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

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The present invention relates to the production of expanded or puffed readyto-eat rice products, more particularly to an improved process therefor.

It has long been known that cereal products could be puffed by treating the kernels under steam at high pressure and suddenly liberating the pressure with the result that as the steam expands the cell walls of the kernel are thereby disrupted and burst. However, the resulting product is compressible and does not have the frangibility or crispness which is deemed desirable in a breakfast cereal product.

Also, it is lacking the goldenbrown colour of the usual toasted product.

To this extent, therefore, it is somewhat less than a completely satisfactory product. It was not until the introduction of the process of Luke, as disclosed in 36 U.S. Patent No. 1,832,813, that a crisp, toasted, puffed breakfast cereal product could be provided. The Luke proposal involves essentially the slight compression of the cooked and partially dried cereal grains or grain elements. Such slight compression renders the grains or elements thereof capable of being puffed when they are subsequently toasted.

In carrying out the Luke process, however, certain difficulties are experienced.

In the usual case, the cereal grains, such as rice, are cooked and thereafter dried to [ PriN.

about 18% and tempered or stored in bins or silos for the purpose of effecting the even distribution of their moisture content. The grains are then compressed by passage between revolving rolls. Next they are introduced into a gas-fired toasting oven maintained at 300 -600 F. to simultaneously toast and puff them. This 55 type of puffing is called oven-puffing as opposed to the aforementioned pressure or

"gun" type of puffing. The oven which is used to toast and puff the grains is essentially an enclosed, horizontally revolving, cylindrical screen which is tilted to provide for the progress of the grains therethrough as the cylinder revolves. It has been found that the moisture content of the rise grains cannot be 65 reduced appreciably below 18% without the same fracturing when they are compressed by passage between the rolls. On the other hand, a moisture content as high as 18%, makes the rice grains somewhat 70 sticky so that many' of them stick to the sides of the revolving screen of the oven with the result that they burn. Of cours:.

the grains which are burned must be removed from the product in order to provide one which is marketable. The manual labour that is involved in picking over the puffed product in order to remove the burned grains or pieces materially adds to the cost of the processing. 80 It was with the purpose of eliminating this problem that the proposal was made in U.S. Patent No. 1,925,267 to McKay, to dry the cooked cereal grains or pieces to 15-30% moisture, temper the grains, 85 flatten them by passage between rolls, dry the flattened grains to 5-14% and then over-puff the same. In order to carry this process out properly, it is necessary not only to have two drying 90 steps but also to have two tempering operations. Adequate tempering requires between 6 and 10 hours of storage in tempering bins or silos. It is readily seen ri 1,183 683,188 that the drying and tempering storage capacity would have to be doubled in order to properly carry out the McKay proposal. Such would amount to an item of considerable expense so that the advantages of this proposal in eliminating the need of picking over the product to remove- burned rice grains is off-set by a disadvantage of similar magnitude.

It has now been found that rice grains and elements thereof containing between 10-14% moisture may be compressed by passage between revolving steel rolls without being fractured provided the kernels or grain elements are at a temperature within the range of about 140' -210 F. at the time of such compression. Without in any way limiting the present invention by the advancement of theoretical explanation, it is believed that the kernels or grain elements must be sufficiently plastic to avoid their being fractured during the compressing operation and that this plasticity is dependent not only upon the moisture content but also upon the temperature of the rice grains and grain elements. In other words, for the rice to be suitably plastic for compression or flattening purposes, the grains or pieces at 18% moisture need only to be at a temperature of about room temperature or somewhat above, whereas grains of lower moisture content being insufficiently -plastic at -room temperature or slightly above require heating to the aforementioned temperature range to become suitably plastic for successful compression or flattening by rolling, Of course, there is a limit to the extent to which heating the grains can be relied upon to compensate-for the lower moisture content thereof in order to provide the necessary plasticity. The minimum moisture content is about 10% and rice grains or pieces of less than

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this moisture content require heating to temperatures which approach those relied upon for the puffing operation and are therefore excessive. Premature puffing is tobe avoided since the resultant product is not puffed to the same desirable degree as is provided by puffing the. flattened grain. The upper moisture content of about 14%5 is determined by the increasing tendency of the grains to stick to the sides of the rotary toasting oven at moisture contents appreciably above 14%. - There is no such tendency in -grains that have been dried to 14% moisture. The same considerationis as those set forth'above also determine the aforementioned temperature range of about- 140' -210 F. to which the rice grains or elements thereof are heated for compression purposes in accordance with the process of the present invention.

The temperature of the rice grains or elements thereof may be raised to the aforementioned temperature range by any 70 conventional means for the purposes of being flattened by passage between the rolls. The heating may be effected, for example, by passing the grains through a horizontally revolving drum which is 7.5 heated by the counter current passage of hot gases or live steam therethrough or the application of a gas flame or steam to the outside of the drum. Precaution should be taken, however, to avoid appreciably altering the moisture content of the grain when it is heated by the direct application of hot gases or stem. Such can be avoided, on the one hand, by the humidification of the hot gases to the 85 proper degree and, on the other hand, by the use of properly controlled superheated steam to minimize condensation on the grains. As an adjunct to the use of superheated steam it is, of course, possible to dry the rice grains or elements thereof to a somewhat lower moisture content, say, 9.5%, in order to compensate for the small moisture pickup, say, 0.5-

1.0%, that might result from heating the rice in this manner. The aeating can also be effected by the use of electrical or dielectric heating. The latter involves passing the grains between a pair or series of pairs of opposed plates carry-100 ing exceedingly high and opposed electrical charges. It is preferable, however, from the standpoint of practical operating considerations to employ infra-red heating to a temperature range of about 140 105 -210 F. substantially immediately before compression. A combination of infrared heating with elctrical heating can also be used. The use of such permits the practical economic rapid heating of 110 the rice grains immediately prior to their passage between the rolls. It also permits the grains or pieces to be heated in a relatively thin layer. The importance of this last resides in the fact that the 115 increased plasticity which results - from heating the grains to the aforementioned temperature range results in the grains being somewhat sticky. For this reason there is a tendency for them to lump together and it is, therefore, highly preferable that it be possible to heat the grains in the aforementioned thin layer and also immediately prior to their passage between, the rolls. -

125 The following examples sets -forth in detail one manner in which the process of the piresent invention may be employed.

It will be understood, however, that the invention is not to be limited by such de683,183 3 tails but is to be regarded in its broader aspects and construed by reference to the appended claims. pounds of rice are mixed with a flavouring syrup made from 2.75 pounds of salt, 13 pounds of sugar and 18 pounds of water. The mixture is placed in a rotary cooker and cooked under 15 pounds steam pressure for one or two hours, or until all of the rice is thoroughly cooked.

The cooked rice is cooled and dried to a moisture content of about 12-13% in a conventional drum drier and then transferred to a tempering bin where it is allowed to remain for between 6 and 10 hours, preferably 8 hours, for the purpose of tempering, i.e., to permit the moisture contained in the interior of the partially dried grains to become evenly distributed throughout the same. The mixture is then deposited in a thin bed on a vibrating conveyor and heated thereon to a temperature of 160-190 F. by means of a series of about 6 infra-red radiant heaters which are located above the vibrator and also by means of electrical strip heaters attached to the bottom of the conveyor. The hot rice falls uniformly from the edge of the pan between standard, conventional flaking rolls which are set at such a pressure that the rice kernels are reduced to about 0.035 of an inch in thickness. In any event, the rice kernels are

36 compressed to such a degree that the ovenpuffed product is of such a bulk density that 1000 c.c. thereof weigh 140 g. +10%. From the rolls the compressed grains or pieces are then conveyed to a rotary toasting oven of the type described above wherein the compressed grain and pieces are simultaneously toasted and puffed to provide a crisp, friable, toasted and puffed rice product several times the size of the original kernel.

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As indicated above in connection with the specific example, it is preferred that for compression purposes the moisture content of the rice grains be between 1213% and be heated to a temperature within the range of about 160-190' '.

Such provides for best results from the standpoint of avoiding the fracturing of the grain upon compression and prevent66 ing the compressed kernels from sticking to the side walls of the oven during subsequent toasting and puffing.

As is well known to those skilled in the art, the degrees of compression to which the grains or pieces thereof are subjected controls in large measure the degree of puffing that is obtained when the compressed grains are subsequently toasted.

The compression or flatttening must occur to a sufficient extent to insure disrupting the internal cell walls of the grain and thereby alter its structure. Otherwise no substantial amount of puffing will occur.

On the other hand, if the grains are compressed to such an extent that the degree 70 of compression begins to approach that of a flaking operation the degree of puffing that is obtained during subsequent toasting is also considerably less than satisfactory. Such considerations, however, are 75 well known to those skilled in the art and it is to be understood that the scope of the appended claims is intended to cover any and all degrees of compression capable of providing a product of any substantially satisfactory degree of puffing.Data supplied from the esp@cenet database - Worldwide

Claims:


What we claim is:-

1. A process of treating rice which comprises cooking the same mn the presence of moisture, drying the cooked rice to a 85 moisture content within the range of about 10-14%, compressing the individual rice kernels and pieces thereof while the temperature of said kernels and pieces is within the range of about 140 90 -210 F'., and thereafter subjecting the same to a high temperature whereby they are puffed.

2. A, process according to claim 1, in which the rice is tempered after being 95 dried and before being heated for the purposes of compression.

3. A process according to claim 1 or 2, in which the rice is dried to a moisture content within the range of about 1213% and heated to a temperature within the range of about 160 -190 F. for the purposes of compression.

4. A process according to any one of the preceding claims, in which the rice is 105 heated to a temperature range of about 140 -210 F'. by the application of infrared heat substantially immediately beTfore compression.

5. A process according to any one of the 110 preceding claims, in which the compressed rice kernels and pieces thereof are subjected to a toasting and puffing temperature within the range of about 300'

600 F. 1115 G. A process of treating rice which comprises cooking the same in the presence of moisture, drying the cooked rice to a moisture content within the range of about 12-13%, tempering said dried rice 120 for a period of about 6--10' hours, compressing the individual rice kernels and pieces thereof while the temperature of said kernels and pieces is within the range of about 160 -1r90'

1P., and there-125 after subjecting the same to a high temperature whereby they are toasted and puffed.

7. The process of treating rice substantially as hereinbefore described with 130 683,183 683,183 reference to and- as illustrated in the Exanmple.

- 8. Rice whenever treated by the method according to any one of the preceding 5-6 claims.

For; GENERAL FOODS CORPORATION Stevens, Langner, Parry & Rollinson, Chartered Patent

Agents, 5/9, Quality Court, Chancery Lane, Lonaon, W.C.2, and at 120, East 41st Street, New York 17,

711/2197

New York, U.S.A. leamington Spa: Printed for Her Majesty's Stationery Office, by the-Courier Press.-

1952.

Published at The -Patent Office, 25, Southampton Buildings, London. W.C.2, from which copies may be obtained. -Data supplied from the esp@cenet database - Worldwide

712/2197

158.

GB713803 - 8/18/1954

DIETARY SALT SUBSTITUTE


Applicant(s): FOUGERA and CO INC E (--)

E Class: A23L1/237B



Family: GB713803

Abstract:


A dietary salt substitute for sodium chloride comprises particles which consist wholly or largely of potassium chloride and which have a coating comprising glutamic acid, potassium glutamate or calcium glutamate and a binder which does not react with the ingredients of the salt substitute and has no particular taste. The preferred substitute contains 70-85 per cent of potassium chloride and 0.05-2 per cent of glutamic acid. Examples are concerned with heating potassium chloride, stirring a heated aqueous solution of glutamic acid and karaya gum, soluble starch, or soluble starch with gum arabic into the salt, continuing the stirring until the particles are dry, and sieving the dry product. A further example describes mixing potassium chloride with a minor amount of maize starch, incorporating into this mixture an aqueous solution of glutamic acid and gum arabic, agitating the mixture so formed, drying by hot air, and sieving the dry product. Other binders referred to are: low-viscosity carboxymethyl cellulose, potato starch, rice starch, and glycogen.Description:



71 E Date of Application and filing Complete Specification: Feb 20, 1952.

No 4536/52.

Application made in United States of America on April 3, 1951.

Complete Specification Published: Aug 18, 1954.

-Class 49, A 7.


Dietary Salt Substitute We, E FOUGERA & CO (INC), a corporation organised and existing under the laws of the State of New York, United States of America, of 75, Varick Street, New York, State of

New York, United States of America, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is performed, to be particularly described in and by the following statement:-

This invention relates to a new product adapted to be used as a dietary substitute for sodium chloride and it has particular relation to a product of this type which contains as main ingredients potassium chloride and glutamic acid The invention also relates to a method of preparing said new product.

713/2197

The main object of this invention is to provide a dietary substitute for sodium chloride which consists of individual particles having the taste, appearance and stability of table salt.

Another object of the invention is to provide a sodium chloride substitute of the before mentioned type which is capable of withstanding, without decomposition temperatures encountered in the preparation, cooking and baking of food products.

A further object of this invention consists in providing a sodium chloride substitute of the before mentioned type which has no irritating or other undesirable effect on the human organism.

It is also an object of the present invention to provide a simple and efficient process for combining the individual ingredients to the desired stable particles.

It has been known that patients resorting to sodium restricted diet, suffer from a lack of palatability of these diets In order to counteract this effect, it has been suggested to use, as a substitute for table salt, various mixtures, with the object of imparting the flavour of table salt to the food As examples of such substitutes, mixtures consisting of potassium chloride and ammonium chloride, or mixtures containing the ammonium salt of lPi-ie 218 l glutamic acid and/or other amino acids, may be mentioned.

A satisfactory dietary substitute for table salt must have the appearance, stability and lack of toxicity of sodium chloride Furthermore, the substitute must duplicate the taste of sodium chloride and withstand temperatures used in the preparation of food, such as baking or cooking temperatures It has been reported that potassium chloride and ammonium chloride have a disagreeable taste Also it has been shown that the ammonium ion is an agent capable of stimulating the bronchial mucosa, causing a secretion of mucus and promoting coughing.

Another fact to be considered consists in that the ammonium ion is capable of disturbing the acidbase-balance of the blood and, therefore, is not a desirable agent to be taken over prolonged periods of time as a salt substitute.

Finally, it has been established that products containing the ammonium ion may release ammonia under the conditions encountered in the cooking of foods and are, therefore, not suitable for use under such conditions.

It has been found that a product which meets the above mentioned requirements and is adapted to be used as a dietary substitute for table salt can be obtained by coating particles of potassium chloride

(KCI) with glutamic acid (HOOC CH(N Ho) CHI CHO.

COOH), and employing an inert binder in order firmly to attach the coating to the particles of potassium chloride The coated particles thus formed do not shown the taste of potassium chloride and they are stable in that they can be stored for a period of time without substantial change, and are of crystalline, granular appearance, duplicating that of sodium chloride As a result of the process according to the invention, the taste of the product obtained substantially duplicates that of sodium chloride, as demonstrated by the taste threshold test Thus, the properties of the product of the invention render it suitable for use in flavouring food 1.803 Index at acceptance:products Furthermore, because of its lack of ammonium ion, this product can be used for cooking purposes and imparts a desirable salinity to the foods.

As an inert binder a starch, or a gum, or a mixture of a starch and a gum, can be used.

These binders are inert because they do not react chemically with an ingredient of the salt substitute, and because they do not have a particular or specific taste.

In accordance with one aspect of the invention a process for preparing a dietary salt substitute for sodium chloride comprises mixing solid particles of potassium chloride with an aqueous solution containing an inert binder and dissolved glutamic acid or potassium glutamate or calcium glutamate and evaporating water from the mixture to form a coating on the potassium chloride particles.

714/2197

By proceeding in this manner, solid particles are formed, each of which has a core consisting substantially of potassium chloride and a minor amount of an inert binder and has a coating consisting substantially of an inert binder and glutamic acid, or potassium glutamate, or calcium glutamate.

According to another aspect of the invention a dietary salt substitute for sodium chloride comprises individual solid partices the -30 bulk of which consists of potassium chloride, said particles having a coating comprising an inert binder and glutamic acid or potassium glutamate or calcium glutamate.

In the following examples, the parts refer to parts by weight unless otherwise stated.

EXAMPLE 1.

83.3 parts of potassium chloride are heated to 1000 C and placed in a suitable mixing vessel fitted with a rotary stirring device An aqueous liquid containing in solution, 2 parts of gum arabic, 14 parts of soluble starch and 0.08 parts of glutamic acid, is heated to -80 and sprayed on to the potassium chloride while the latter is being stirred.

Stirring is continued until the potassium chloride particles are substantially completely dry The product is forced through a 30 sieve and packaged.

EXAMPLE 2.

A mixture of 83 3 parts of potassium chloride with 14 8 parts of maize starch which together form a core is mixed with an aqueous solution containing 0 08 parts of glutamic acid and 2 parts of gum arabic

The mixture is agitated until it is damp dry Hot air, of for example, a temperature of 700 C, can be blown over the particles of the mixture in order to complete drying After the granules are dry, they are sieved and packaged.

EXAMPLE 3.

83 parts of potassium chloride are placed in a mixing vessel provided with a stirrer, and are heated to

80 -90 C, and a hot ( 800 C) aqueous solution containing 1 0 part of Karaya gum and 0 08 parts of glutamic acid is uniformly applied by spraying to the potassium chloride particles under stirring.

Further treatment is the same as in Example 1.

EXAMPLE 4 7 C

83 parts of potassium chloride are treated with an aqueous solution of about 70 C, which contains 0

085 parts of glutamic acid in solution and 16 5 parts of soluble starch.

The potassium chloride is heated to about 71 1000 C and placed in a suitable mixing vessel fitted wih a rotary stirring device The aqueous solution is sprayed on to the potassium chloride while the latter is being stirred Stirring is continued until the potassium chloride 8 ( particles are substantially completely dry and the product is then forced through a # 30 sieve and packaged.

EXAMPLE 5.

83 parts of potassium chloride are treated 8, with an aqueous solution, of a temperature of about 800

C, containing in solution 0 05 parts of glutamic acid, 14 parts of soluble starch, and 2 parts of gum arabic, in the manner described in Example 1 9 ( In the above examples carboxy-methyl cellulose (low viscosity) can be partly or entirely substituted for the gums, and potato starch, rice starch or glycogen or a mixture of these starches can be partly or entirely sub 9 ' stituted for the starches acting as inert binders mentioned in the above examples Furthermore, an equivalent amount of potassium or calcium glutamate can be partly or entirely substituted for the glutamic acid, in preparing 10 the products of our invention In carrying out our invention, the water is used in an amount sufficient for dissolving or dispersing the glutamic acid and the binder, and for obtaining a uniform coating on the potassium 10 particles.

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The products obtained according to the above examples are homogeneous and show the following characteristics:

1 The products are crystalline colorless 11 cubes, soluble in water, insoluble in alcohol, petroleum ether, acetone and chloroform; 2 The refractive index of the crystals is 1.4655; 3 The specific gravity of the crystals is 11 1.644 at 25 ' C.

4 The crystals contain in the average:

Potassium Chlorine Nitrogen 43.50 % 39.48 % 0.00731 % The taste threshold as determined by standard methods is 1 x 10-5.

In carrying out our invention it is indispensable to form a uniform product consisting of individual particles which have sub 12 stantially the same structure and composition having an adhering surface coating comprising the glutamic acid and binder The preferred 713,803 713,803 range of the amount of glutamic acid is 0 05 to 2 0 %, based on the weight of the substantially dry end product of the invention.

The amount of potassium chloride in the end product amounts preferably to 70 to 851 %.

Although the bulk of the product according to our invention always consists of potassium chloride, the latter can be used in combination with suitable admixtures, such as potassium formate, calcium formate, calcium citrate, and magnesium citrate.

The term " particles " is used in the present specification and claim to denote particles corresponding in size to that of particles of standard table salt and passing for example through a sieve 30, namely a sieve the openings of which are 0 0232 " and the wires of which have a diameter of 0 0132 ".

The words " stable " and " stability " mean that the salt substitute of the invention is stable on storage i e is not unduly affected by the humidity of the atmosphere, and is not decomposed e g when a food product containing it, is subjected to boiling temperatures.Data supplied from the esp@cenet database -

Worldwide Claims:


What we claim is: -

1 A process for preparing a dietary salt substitute for sodium chloride, comprising mixing solid particles of potassium chloride with an aqueous solution containing an inert binder and dissolved glutamic acid or potassium glutamate or calcium glutamate and evaporating water from the mixture to form a coating on the potassium chloride particles.

2 A dietary salt substitute for sodium chloride comprising individual solid particles the bulk of which consists of potassium chloride, said particles having a coating comprising an inert binder and glutamic acid or potassium glutamate or calcium glutamate.

3 A dietary salt substitute as claimed in claim 2 containing 70 to 85 % by weight of potassium chloride and 0 05 to 2 0 % by weight of glutamic acid.

4 A dietary salt substitute as claimed in claim 2 or 3, wherein the inert binder is a gum.

A dietary salt substitute as claimed in claim 2 or 3 wherein the inert binder is a starch.

6 A dietary salt substitute as claimed in claim 2 or 3 wherein the inert binder is a mixture of a gum and a starch.

7 A dietary salt substitute according to claim 2 wherein individual solid particles have a core consisting of a mixture of potassium chloride and a minor amount of an inert binder.

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8 The process for preparing a dietary salt substitute for sodium chloride substantially as hereinbefore described.

9 The dietary salt substitute for sodium chloride as hereinbefore described with reference to Examples

1-5.

For the Applicants, RAWORTH, MOSS & COOK, Chartered Patent Agents, 75, Victoria Street,

London, S W 1.

Leamington Spa: Printed for Her Majesty's Stationery Office, by the Courier Press -1954.

Published at The Patent Office, 25 Southampton Buildings London W C 2 from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

717/2197

159.

GB716685 - 10/13/1954

IMPROVEMENTS IN OR RELATING TO EGG SUBSTITUTES


Applicant(s): MONTIE MAEHEALY (--)

E Class: A23L1/32H



Family: GB716685

Abstract:


An egg substitute comprises tapioca flour mixed with powdered skim milk and egg white, and a gasforming agent, e.g. a mixture of cream of tartar and sodium bicarbonate. An example is: 100 lb. of rice flour, 25 lb. of tapioca flour, 25 lb. of powdered skim milk, 10 lb. of powdered egg white, 3 lb. of cream of tartar, 1 lb. of sodium bicarbonate, and 8 oz. of yellow colouring. In preparing a ready-made cake flour, 4 to 8 g. of this egg substitute is mixed with each pound of cake flour.Description:



7169685 - I Date of Application and filing Complete Specification: Aug. 7, 1952.

Application made in United States of America on Aug. 10, 1951.

Complete Specification Published: Oct. 13, 1954.

Index at acceptance,:-Class 49, B1(B:H:L), B4.


Improvements in or relating to Egg Substitutes I, MONTIE MAEHEALY, a Citizen of the United

States of America, residing at 1611 Crescent Drive, Flint, Michigan, United States of America, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:-

The present invention relates to nutritive 1O food compounds and more particularly to an egg substitute admixture for use in improving domestic and commercial confectionery products such as cakes, baked products and other edible foods in which eggs are commonly used.

One object is to provide an egg substitute composition in dry powdered form which can be conveniently mixed with various prepared flours in lieu of the eggs required which will materially improve the texture of the cake or other confectionery product, and will otherwise improve products produced from domestic and commercial ready-mixed cake flours when a small quantity of the composition is admixed with such cake flours.

It has been found that an egg substitute composition employing tapioca flour, when hydrated has a propensity to form a colloidal jel portion and another portion which absorbs water forming semi-solid

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masses, and that such hydrated tapioca flour entrains gases to an unexpectedly high degree which insures maintenance of cake volume and controlled fineness of texture.

In preparing my composition, I use the following ingredients, the parts being by weight:Rice flour...

...... 100 lbs.

Tapioca flour (best grade)... 25 lbs.

Powdered skim milk...... 25 lbs.

Powdered hen egg white... 10 lbs.

Cream of tartar...... 3 lbs.

Bicarbonate of soda...... 1 lb.

Colouring (Primole yellow egg shade)... ... 8oz.

The above-named ingredients are com[Price 2 / 81 pounded as follows: I first take a miter bowl and pestle; add a small amount at a time of the cream of tartar and colouring and mill out thoroughly, 50 using 1 lb. of cream of tartar to the 8 oz. of colouring. When the colouring is thoroughly milled out with cream of tartar, mix it thoroughly with the 10 lbs. egg white and then sift over the other ingredients. Next, 55 mix the remaining two lbs. of cream of tartar into the lot of ingredients, and then add and mix the 1 lb. of sodium bicarbonate, sifting the mixed ingredients five or six times.

The rice flour and tapioca flour together 60 with the powdered skim milk are intimately mixed by agitation, and then the egg white, cream of tartar and colouring mixed as above are sifted into the rice flour, tapioca flour and skim milk. After the ingredients have been 65 mixed as above, the remaining 2 lbs. of cream of tartar are added and the 1 lb. of sodium bicarbonate is introduced. The entire composition is then repeatedly sifted five or six times to thoroughly intermix the 70 various particles.

Thus, a dry-type powdered egg substitute is formed which can be packaged and sold successfully on the market because of its effectiveness and low cost and good keeping qualities when compared with

75 real eggs.

An essential ingredient of the preparation is the use or introduction of tapioca flour in a dry-type egg substitute. Tapioca flour is formed by milling tapioca pellets or granules, 80 and possesses the unusual characteristic property when heated in bulk with water, milk or other liquid to form a colloidal jel, while another portion at the same time absorbs liquid so forming semi-solid masses. 85 In the baking of cakes good results have been obtained by adding 4 g. of the above composition to a 1 lb. package of prepared cake mixture which is sold on the market under a variety of different trade names. 90

However, most prepared cake mixes include sugar, cake flour, vegetable shortening, bakNo. 19899/52.

7 16,685 ing powder. egg white. salt and artificial flavoring to form a batter composition. which when mixed with milk or water. provides an adequate cake batter for a white cake. The makers of various cake mixes require in addition to milk or water, one or two eg,, volks in the production of yellow cake.

In tests.

it has been found that by substituting from 4 to 8 g. of the present composition for the two egg yolks required in the making of yellow cakes from prepared cake mixtures, extremely good results were obtained, and in certain of the tests with varving amounts of the present admixture between the limits cf 4 to 8. the grain texture of the cake was improved without materially decreasing the cake volume. As an example. cakes were baked with a prepared cake mixture which includes sugar. cake flour, vegetable shortening. baking powder. egg white, salt and artificial flavoring with varying amounts ranging from 4 to 8 g. of the egg substitute added in lieu of the required two egg yolks for yellow type cakes.

EXAMPLE A

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A cake was baked using a I lb. package of any "Instant cake mix'" at present on the market. including the above ingredients of conventional proportions to which was added 4 g. of the egg substitute and the cakes being prepared and baked in accordance with wellknown practice, as well as the directions on the cake mix package which specify the addition of one half cup of milk to the cake mix and beating the mixture two minutes with an electric mixer. and then adding two thirds of a cup of milk and beating for one minute. likewise with an electric mixer. In lieu of the two egg yolks required, 4 g. of the egg substitute composition was mixed there.

with with the first one half cup of milk. The batter was then baked in a pre-heated oven at a temperature of 375: F. for a period of between 20 to 25 minutes. It was found that the volume decrease was very slight. but the grain texture was very good and was free of large voids and tunnels.

EXAMPLE B

A cake was baked in accordance with the procedure set down in Example A. and using the same cake mix, but substituting 8. of the egg substitute composition instead of the 4 g set down in Example A.

The cake showed a good volume as before, and the grain texture likewise was good and free from voids and tunnels.

There are numerous prepared cake mixes which are sold both for commercial and domestic purposes.

Such prepared cake mixes generally include dehydrated flour by weight 10 parts. powdered skim milk by weight 2 parts. powdered egg white 2 parts.

leavening agent by weight 1} parts. salt by weight 0.70 parts. and flavoring such as vanillin 0.20 parts.

Slight deviations from the above amounts of ingredients provide cake mixes of different types, and the ingredients are mixed generally in the order indicated.

When mixing the egg substitute composition with a prepared mix, including some or all of the ingredients above mentioned which are common to cake mixes of the prepared type. 1 teaspoonful of egg substitute composition is dissolved in one third cup of water 75 or milk and added to the cake mix preparation for each egg required.

While the invention has been described primarily for se in connection with prepared cake mixes, it is obvious that it can be 80 used with equal facility as an egg substitute for various types of batters prepared in accordance with conventional techniques domestically as well as commercially. For instance, the egg substitute composition can 85 be used to replace the egg ingredients in batters for pancakes, griddle cakes, biscuits, corn bread and johnny cake by simply substituting 1 teaspoonful or 4 g. of the egg substitute composition for each egg called 90 for in the batter recipe.

The use of tapioca flour in the present egg substitute produces the moisture content of the prepared cake mix by the absorption of moisture, and in addition entrains gases during mixing in such a manner as to cause even and fine cake texture uniformly throughout the entire cake when the cake mixture is baked to form cakes or other products. It is believed that the absorption of moisture from 100 the prepared cake mixture retained by the flour. which in some cases is as high as 13 per cent. and holding these particles of moisture during mixing of the egg substitute composition and cake flour are the reasons 105 the finished baked product possesses such even and uniform texture. It is believed that the reason such good results are obtained is due to the absorption of moisture from the prepared cake flour.

The colloidal 110 jel portion of the tapioca flour is believed to entrap gases formed by the acids such that uniform distribution of the tapioca flour throughout the batter will form evenly distributed voids when the cake is subjected 115 to heat treatment as by baking. It is known that the tapioca flour particles divide into colloidal jel portions and moisture absorbing portions when subjected to moisture and heat. 120 Applicant's egg substitute in analysis includes the following:

Moisture... 9.0 , Protein... ...... 13.6 %, Fat...... 1.2,, 125 Ash 0.6 , Crude Fiber (derived from husk in rice flour)...Trace only Carbohydrates (by difference).. 75.6% Dye... ......... Trace 130 716,685 The unusual properties of tapioca flour which includes the ability to react with moisture and heat to form colloidal jet and moisture absorbing portions in a manner different than other flours results in a finished bakery product of smoother, more uniform and better texture, and enhances the tasting qualities when the egg substitute composition is used to replace eggs in various cooking and baking processes. During

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baking, the egg substitute and batter mix are heated to a temperature in the neighborhood of 375 F., which causes the entrained moisture in the tapioca flour to be liberated in the form of steam. Carbon dioxide gas is formed in the baking process by the bicarbonate of soda and the cream of tartar.

While in the foregoing description I have described the egg substitute as used in cakes and other baked products, I wish it clearly understood that this is for explanatory purposes only, and that the product is for use in all edible food products in which real eggs are presently used.Data supplied from the esp@cenet database - Worldwide Claims:


What I claim is:-

1. An egg substitute in dry powder form comprising tapioca flour mixed with powdered skim milk and egg white, and a gasforming agent.

2. An egg substitute according to Claim 1 wherein the gas-forming agent is a mixture of cream of tartar and sodium bicarbonate.

3. An egg substitute as claimed in Claim 1 or 2 for use in baking products which also contains rice flour. 35 4. An egg substitute as claimed in any of the preceding claims consisting of 100 lbs. of rice flour, 25 lbs. of tapioca flour, 25 lbs.

powdered skim milk, 10 lbs. powdered egg white, 3 lbs. cream of tartar, 1 lb. sodium 40 bicarbonate, and 8 oz. of primole yellow egg shade colouring.

5. A ready made cake flour which contains an egg substitute comprising rice flour, tapioca flour, powdered skim milk, powdered egg white, cream of tartar, sodium bicarbonate, and primole yellow egg shade colouring, said egg substitute being admixed with the cake flour in the proportions of 4 to 8 g. to each pound of cake flour. 50 6. The method of producing a ready made cake flour as claimed in

Claim 5, which comprises first mixing cream of tartar with the colouring by milling; adding the egg white to the cream of tartar and colouring mixture; 55 mixing rice and tapioca flour and powdered skim milk with the cream of tartar, colouring and egg white mix, and finally mixing sodium bicarbonate therewith, the resulting egg substitute being mixed with the cake flour. 60 MARKS & CLERK.

Printed for Her Majesty's Stationery Office by Wickes & Andrews, Ltd., E.C.4. 39/244.-1954.

Published at The Patent Office, 25, Southampton Buildings, London, W.C.2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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160.

GB719870 - 12/8/1954

IMPROVEMENTS RELATING TO CEREAL PRODUCTS


Applicant(s): WHITWORTHS HOLDINGS LTD (--); ERNEST RUDOLF STEINER (--)

E Class: A23L1/182



Family: GB719870

Abstract:


Cereal grains, e.g. grains of wheat, rice or maize, which have been freed from the outer husks, partly or wholly freed from bran, and coarsely ground if desired, and have been treated to possess a uniform moisture content of 22-28 per cent, are cooked at 212 DEG F., e.g. by the injection of live steam, until the starch is gelatinized and the protein denatured, and are then, after rolling into flakes if desired, dried rapidly to a moisture content of not more than 3 per cent by being spread upon a band which travels in an inert atmosphere, e.g. waste gas from gas burners, through an oven maintained at 210-260 DEG F. for atmospheric pressure or at lower temperature for reduced pressure.Claims:


T- What- we claim is:-

1. A process for preparing a fully cooked cereal product, in whihcerea'l grains which have been threshed and cleaned, freed from their outer husks or hulls and partly or wholly freed from bran, and treated to have a uniform moisture content of 22 to 28%, are cooked at a temperature of about 212 F. until he starch granules are gelatinized and i!the proteilidenatured, and dried rapidly to-a: moisture content of not more than 3%:-byr spreading a thin layer on a band travelling through an oven at 210-

260 F., in an inert atmosphere at normal pressure, or under reduced atmospheric pressure at a correspondingly lower tempera-ture. 2. A process as claimed in claim 1, in which the -rains are coarsely ground 50 before cooking to produce products such as wheat semolina, ground rice or ground maize.

3. A process as claimed in claim 1 or 2, in which the grains are rolled into 55 flakes, after moistening and either before or after cooking.

4.'A process as claimed in any of claims 1-3, in which de-hulled oats or groats are freedffrom-pericarj by vet brushing, con-ditioned to a moisture content of 25%, steamed to gelatinize the starch, rolled into flakes, and passed through a heating tunnel in a layer about one flake thick on a travelling band so as to be further 65 cooked and then dried.

5. k process as claimed in claim 4, in which at the entrance to the heating tunnel the flakes meet a a steamy atmosphere so that the average moisture content is 70 further increased to about 3.5%, then in the first part of the tunnel live steam is injected and the temperature is maintained at 210- 12 F., and the flakes are cooked for about 5 minutes, and in the 75 second part of the tunnel a temperature of 250-

260 -F. is maintained and the flakes are-dried in an inert atmosphere to a moisture content of under

3%. 6. The process for preparing a fully 80 cooked cereal product, substantially as described. 7. The fully cooked cereal prodfct, when produced by the-process according to any of the preceding claims.

M.-ARKS & OLEIRK.

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.-'- -- - ' PROVISIONAL SPECIFIOATION _ ------ 2 Improvements- relating to Cereal Produ-cts:

: W=e,0]E1W D1xTwOnTnSf _OLDINGS=L1-kIMIrI,-!moisture contentof about 25%, are cooked a:British Company, of -Victoria Mills, at a temperature of about 212 F. until 105 WVellingborough,

Northamptonshire, and the starch granules are gelatinized and ERNEST RuDOL_ STmDINE, a British

Sub-- the protein denatured, and dried rapidly 90- jet, of the Company's address, do hereby to a moisture content of not more than declare this 'nvention to be described in 3%.

: the following statement:-:- The grains may be coarsely ground 110 : -This invention relates to a process for before cooking to produce products such preparing a. fully cooked. cereal product, as semolina, ground rice or ground maize.

retaining a maxinmm amount of the In. some cases the moistened grains are natural:vitamins, and capable of retain- rolled into flakes, or the grains may be - ing its freshness over long periods -of rolled after cooking. 115 storage. '- Theldrying is effected by any rapid Acc.fording to the invention, suitable method, preferably by spreading a layer cereal grains which have' been threshed tone grain thick on a band travelling and c!leaned, freed from their outer husks through an oven at 210-260 F., in an orhulls and partly or wholly freed from inert atmosphere or under reduced atmo- bran, and treated to have a uniform spheric pressure at a lower temperature, I -_ 19,870 The dried product may be in the form of whole grains, fragments of grains, or flakes.

The varieties of cereals used areselected, and the treatments are carried out rapidly, and at as low temperatures as possible, so as to avoid undue destruction -of vitamins, and lipolytic and oxidative actions on natural oils and fats.

A particular application of this invention for the production of a cooked, readyto-eat, cereal product from -oats is as follows:De-hulled oats or groats are treated for 1-6 removal of the pericarp by a wet brushing process and conditioned to a moisture content of approximately 25%. The conditioned groats are subjected to a short steaming process in a steaming tunnel in order to gelatinize the starch and are then -of a suitable consistency for rolling into flakes about '/74 to 1/,2 inch in thickness. The flakes are further cooked and then dried by spreading evenly in 26 a layer about one flake thick on a travelling band passing continuously through a heating tunnel.

The arrangement of the heating tunnel is as follows: At the entrance the flakes meet a steamy atmosphere such that they become coated with an extra quantity of condensed water to bring the average moisture content up to about 85%.

The wetted flakes then pass into the first part of the heating tunnel where the temperature is maintained at 210-212 F. with the additional injection of live steam for 5 minutes in order to complete the cooking process. The flakes then pass into the second part of the tunnel which 40 is maintained at a temperature of 250'260 F. where they are rapidly and thoroughly dried in an inert atmosphere to a moisture content of under 3%.

The inert atmosphere is obtained by 45 filtering the waste gas from gas burners, carefully controlled to burn with a minimum of excess air. It is convenient to arrange for this inert gas to enter the tunnel and flow through it in the reverse 60 direction to the travelling band. Alternately, the inert atmosphere may be provided by superheated steam, introduced in the second part of the tunnel and drawn back into the first part where it will con- 56 dense and maintain cooking conditions with advantage, provided the amount of steam and of condensation is not excessive. Such steam automatically plays the part of the live steam which must in any 60 case be injected into the first part of the tunnel and also maintains the steamy atmosphere at the entrance.

By cooking at a minimum moisture content and drying rapidly to a low moisture 65 content under inert conditions, at the same time avoiding high temperatures in the drying process, and, provided also, that the product is stored in air-tight and moisture-proof containers, it is possible 70 to avoid deterioration of the final product -due to lipolytic or oxidative action to which most cereals, and oats in particular, are susceptible.

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The product is suitable for eating 75 directly with hot or cold milk and without further cooking.

MARKS & CLERK.

Leamington Spa: Printed for Her Majesty's Stationery Office, by the Courier Press.-1954.

- Published at The Patent Office, 25, Southampton Buildings, London, W.C.2, from which .. '- -X - copies may be obtained.Data supplied from the esp@cenet database - Worldwide

724/2197

161.

GB737372 - 9/28/1955

IMPROVEMENTS IN OR RELATING TO QUICK COOKING RICE AND

PROCESS OF PREPARATION THEREOF


Applicant(s): ATAULLAH KAHN OZAI DURRANI (--)

E Class: A23L1/182



Family: GB737372

Abstract:


A process for preparing quick-cooking rice comprises subjecting rice grains of 17-34 per cent moisture to heat to gelatinize substantially completely the exterior portions of the grains without effecting more than partial gelatinization of the interior portions of the grain to provide whole rice grains having 21.1-

34 per cent moisture and having exterior sheaths of moist gelatinized starch in a pliable rubbery condition and internal cores of relatively brittle, at least partially gelatinized, starch and then subjecting the treated grains to mechanical compression which modifies the internal structure of the grains without reducing them to a flaked condition. The grains may first be soaked at a temperature below the gelatinization temperature to raise their moisture content to 17-34 per cent and may then be cooked under conditions equivalent to 235 DEG F. for 100-10 minutes respectively. In an example 100 pounds of white rice with a moisture content of about 8 per cent is placed in a 100-gallon vessel with 60 gallons of water and allowed to soak for 30 minutes at 75 DEG F. and thereafter drained for 15 minutes after which the rice having a moisture content of about 25 per cent is transferred to a 80-gallon autoclave and treated with dry steam at 8 pounds pressure for 60 minutes after which time the outer portions of the grain are substantially completely gelatinized and the inner portions are partially gelatinized but still contain a small amount of gelatinized starch granules, the moisture content being about 28 to 30 per cent, the rice grains are removed from the cooker, transferred to a conveyer belt in a layer about one grain thick and passed between smooth rolls set to reduce the thickness of the grain to about 50 per cent of their precompression thickness, the grains thereafter being dried, e.g. by using a forced draught hot-air drier using air at 180 DEG F., to a moisture content of 10 to 14 per cent and the product being then packaged. Specification 737,450 is referred to.Description:



y. ^ Date of Application and filing Complete Specification

No. 3104/51.

____ y 1 (Patent of Addition to No. 657,691 dated April 22, Complete Specification Published Sept.

28, 1955.

Index at acc.pt, e:-Class 58, A(i: 4f, H3. HI4(A: C), H6D.

$2-oPv 737,372 Feb. 8, 1951.

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1948).

COAIPLETE SPECIFICATION

Improvements in or relating to Quick Cooking Rice and process of preparation thereor EPPATUM

SPECIFICATION 1i'0. 7a7,372

Page 1, line 1, for "Kakin" read "Kharn".

THE PATENT OFFICE, 4th April, 1956 DE 33445/2(6) /3519 150 3/56 R proteins and minerals, and a silicious outer.

husk or hull. In this condition, the rice is iknown as paddy or rough rice. In order to make it suitable for human consumption, at least the husk must be removed from the grain.

Rice kernels from which only the hull has been removed are known as brown or husked rice.

If rough or brown rice is milled to remove some or all of the pericarp or bran, the rice product known as white rice is obtained. In order to mill the rice conveniently, its originally higher moisture content is reduced by drying to about 10 to 14%. By removing the bran, the valuable nutritional elements contained therein are lost.

For the preservation of the nutritional elements contained in the bran, the rice is usually parboiled before milling to remove the bran.

The parboiling process may vary somewhat but in general consists in soaking the paddy in cool or warm water below the gelatinization temperature of the kernel which is at about 150 to 1600 F. The water penetrates through the pores of the hull and bran, dissolves to large extent the soluble nutritional elements contained in the bran and carries them into the kernel. The starchy constituents of the kernel absorb the water and retain and preserve the nutritional elements dissolved therein from the bran. The kernel also swells by the absorption of water but, because the temperature is held below the gelatinization tempera[Price 3s. Od.3 secure the latter, steam under superpressure 6D is sometimes released upon the rice grains.

Gelatinization is accompanied by further swelling of the kernals which therefore burst the hulls. The parboiled rice kernai is soft, pliable and rubbery and will bend without breaking. 70 It is the general practice to dry the parboiled rice to a moisture content of about 10 to 14% and to mill the rice to remove the hull and most or all of the bran. Freshly havested rice sometimes has a moisture content as high as 75 about 26% and the initial soaking of the rice may therefore be omitted or shortened if freshly havested rice is used with a moisture content of 26% or more. Thereby the procedure of parboiling the rice as described 80 above can be simplified.

When parboiled rough rice is dried to a stabilized moisture content of about 10 to 14% for subsequent milling, the milled rice product forms a hard and stiff mass which is 85 translucent and of a color from dark to light brown and somtimes almost white. Examined under a magnifier or held up to the light, the interior of the kernal appears uniformly translucent and its exterior smooth. It does not 90 absorb water readily, and it therefore takes from 25 to 45 minutes to cook it before it is ready for consumption. The cooked rice is rubbery and chewy, and contains up to abour to 70% moisture. 95 The parboiled rice product prepared in any Prce 25p -,g.s' an X A.0 7 jeer C M. iz$t.

R i C 4. e ' RL.' 0 1S,.1 PATENT SPECIFICATION

737,372 Date of Application and filing Complete Specification Feb& 8, 1951.

(Patent of Addition to No. 657,691 dated April 22, 1948).

Complete Specification Published Sept. 28, 1955.

Index at acceptgnce:-Class 5$, A(1: 4), H3, H4(A: C), H6D.

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Improvements in or relating to Quick Cooking Rice and process of preparation thereof I,

ATAULLAH KAHN OZAI-DURRANI, a citizen of the United States of America, of P.O. Box 526,

Stuttgart, Arkansas, United States of America, do hereby declare the invention, for i which I pray that a patent may be granted to me and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a method of preIt) paring a quick cooking rice product and to the rice product itself.

A grain of rice when harvested, includes an inner endosperm and germ which consists mainly of starch or gluten, depending on the type of the rice, covered by a pericarp or bran layer which contains all the oil, fats, vitamins, roteins and minerals, and a silicious outer husk or hull. In this condition, the rice is known as paddy or rough rice. In order to make it suitable for human consumption, at least the husk must be removed from the grain.

Rice kernels from which only the hull has been removed are known as brown or husked rice.

If rough or brown rice is milled to remove 2f5 some or all of the pericarp or bran, the rice product known as white rice is obtained. In order to mill the rice conveniently, its originally higher moisture content is reduced by drying to about 10 to 14%. By removing the bran, the valuable nutritional elements contained therein are lost.

For the preservation of the nutritional elements contained in the bran, the rice is usually parboiled before milling to remove the bran.

3f5 The parboiling process may vary somewhat but in general consists in soaking the paddy in cool or warm water below the gelatinization temperature of the kernel which is at about 150 to 160 F. The water penetrates through the pores of the hull and bran, dissolves to large extent the soluble nutritional elements contained in the bran and carries them into the kernel. The starchy constituents of the kernel absorb the water and retain and preserve the nutritional elements dissolved therein frpm the bran. The kernel also swells by the absorption of water but, because the temperature is held below the gelatinization tempera[Pce 3s. Od.3 ture ot the starch, does not gelatinize. Thus the initial moisture content of the kernel can 50 be raised to higher moisture content at temperatures above room temperature; after saturation is reached, the soaking of the rice is stopped and any excess of the water in which the rice has been soaked, is drained off. The 55 soaked rice is then heated above its gelatinization temperature so that the kernel gelatinizes; during gelatinization, the kernel takes up additional moisture so that the completely gelatinized rice contains between about 33% and 60 42% moisture, depending on the conditions under which it has been parboiled. The rice is parboiled preferably by treating it with steam of desired temperature; in order to secure the latter, steam under superpressure 65 is sometimes released upon the rice grains.

Gelatinization is accompanied by further swelling of the kernals which therefore burst the hulls. The parboiled rice kernal is soft, pliable and rubbery and will bend without breaking. 70 It is the general practice to dry the parboiled rice to a moisture content of about 10 to 14% and to mill the rice to remove the hull and most or all of the bran. Freshly havested rice sometimes has a moisture content as high as 75 about 26% and the initial soaking of the rice may therefore be omitted or shortened if freshly havested rice is used with a moisture content of 26% or more. Thereby the procedure of parboiling the rice as described 80 above can be simplified.

When parboiled rough rice is dried to a stabilized moisture content of about 10 to 14% for subsequent milling, the milled rice product forms a hard and stiff mass which is 85 translucent and of a color from dark to light brown and somtimes almost white. Examined under a magnifier or held up to the light, the interior of the kernal appears uniformly translucent and its exterior smooth. It does not 90 absorb water readily, and it therefore takes from 25 to 45 minutes to cook it before it is ready for consumption. The cooked rice is rubbery and chewy, and contains up to about to 70% moisture. 95 The parboiled rice product prepared in any Prize 25p 'a - i; &,_ L ---W ---- 41, Z 1 i ' -- t 7_; bb rn" & at 737,372 of the

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manners described hereinbefore, contains a large percentage of the nutritional elements which were in the bran. The consumers, nevertheless, prefer ordinarily milled rice A which has not been parboiled, because it is, upon cooking, white in colour, soft in texture and not rubbery.

It is an object of the invention to provide a quick cooking rice and a process for obtaining the same.

It is another object of the invention to treat rice so as to promote its penetration by boiling water and thereby reduce the time required for cooking the rice.

1 It has now been found that rice can be rendered quick cooking bysubjectingwholerice grains having an exterior sheath of moist gelatinized starch in a pliable rubbery condition and an internal core of brittle, at least partially gelatinized starch, to mechanical compression so that the internal structure of the grains is modified without reducing the grains to a flaked condition, the rubbery sheath maintaining the grain integral while permitting the formation of cracks and fissures which facilitate penetration of water into the grains on subsequent cooking thereof. A rice grain having the aforementioned relatively brittle core surrounded by a pliable, rubbery sheath of moist gelatinized starch may be provided by treating the grain so that the core is gelatinized to a lesser degree than the outside portion and is consequently brittle. The mechanical compression which is relied upon 36 to modify the internal structure of the individual grains is usually provided by passing the grains between rolls although other ways may be used. Such compression distorts the rubbery sheath without substantially disrupting the same and modifies the internal structure of the grain by fracturing the brittle core, producing a number of more or less minute cracks or fissures which extend from the surface of the grain into its interior and through 46 which water can penetrate rapidly in the subsequent cooking. The grain is retained integral by the external sheath which nevertheless, is deformed and also ruptured at points.

In carrying out the practice of the invention rough rice, brown rice, or white rice may be employed.

Ordinarily, however, it is preferred to use milled or white rice. When the invention is carried out in accordance with the preferred embodiment thereof, the rice is soaked 56 at a temperature below that at which starch becomes gelatinized (1500 F.) for a period of time sufficient to raise the overall moisture content of the grain to within the range of about 17 to 34%. In order to do this at room temperature a period of 10 to 60 minutes is required, the lower moisture content being imparted by the shorter soaking time and vice versa. It is preferred to soak the grain to about 25%, the period of time required in this case being about 30 minutes.

After such brief soaking periods the moisture distribution within the grain is by no means uniform and, in fact, the moisture content of the outer or exterior portion of the grain is substantially higher than that of the 70 interior portion. Whether the lack of uniformity is due to variations in the structure or composition of the inner and outer portions of the grain or is simply due to the fact that equilibrium is not obtained within the brief 7J soaking period, it is nevertheless important that there be a relatively greater amount of moisture contained in the exterior or surface portion than in the central portion or core.

Thereafter, when the soaked grain is heated 80 to effect gelatinization, as hereinafter described, the starch granules contained in the outer portion of the grain are substantially completely gelatinized to a rubbery condition while the interior portion or core of the grain 85 is only partially gelatinized and relatively brittle, containing an appreciable amount of birefringent material, i.e., starch granules which exhibit a maltese cross when viewed with microscope using polarized light. When 90 the rice grain is soaked to a moisture content of less than about 17%, the- degree of gelatinization accomplished by the subsequent cooking is insufficient so that when the grain is subjected to mechanical compression the 91 core is too brittle and the grain disintegrates.

On the other hand, when the grain is soaked to a moisture content of 35% or more, cooking results in overgelatinization of the core so that it is not brittle and cracks and fissures are not 100 formed upon mechanical compression.

After the grains have been soaked as indicated above, they are heated to effect gelatinization, the period of heating required varying inversely with the temperature 106 employed and with the percentage of moisture contained in the grain as a result of such soaking. The temperature for gelatinization is not critical and may range from somewhat about 1500 F. to temperatures at which

728/2197

scorching 110 occurs. Using a temperature such as 235 F., for example, rice which contains only 17% moisture must be heated for about 100 minutes while rice which contains as much as 34% moisture need only be heated for 10 115 minutes in order to substantially completely gelatinize the starch of the outer portion of the grain and gelatinize that contained in the inner portion or core to a lesser extent, leaving a sufficient amount of ungelatinized starch 120 granules in the core so that it is brittle in contrast to the rubbery pliable outer portion.

In case the soaked grains are heated or cooked by means of steam, it may be necessary to make allowance for condensation of moisture 125 on the grains in order to avoid increasing their moisture content above 34%. For example, steaming for periods in the neighbourhood of minutes may increase the moisture content of the grains by 3 to 5%, and in such case 130 737,372 3 the moisture content of the grains at the end of soaking should not exceed about 30%. In any event the partially gelatinized rice grains at this point in the process contain 21.1 to 34% moisture. In the case where the rice has been soaked to from 17 to 21 % moisture, gelatinization by means of steam or water immersion is preferred so that the moisture range of 21.1 to 34% may be attained prior to the compression step.

The rice is then ready for subjection to mechanical compression for modification of its internal structure as mentioned above. Preferably, this compression is effected by passing the rice grains through compression rolls set at such a distance apart as to provide a reduction of thickness of the grains without compressing them into flakes. In order to facilitate the handling of the grains in passing them to and through the compression rolls they may, if desired, be dried somewhat in any suitable manner but this is not required. Preferably, however, the surfaces of the grains are cooled before passing them to the rolls so as to set and toughen the exterior layers of starch, for example, by subjecting the grains to a blast of cold air or to the action of cold water.

The degree of compression to which the grains should be subjected depends in part on the extent of gelatinization of the grains during the preceding cooking operation and in part on the desired softness or texture of the rice when subsequently cooked for consumption. In general, it will be found that the greater the degree of compression, the greater the production of cracks and fissures and the softer the texture of the rehydrated product for given conditions of pre-cooking and final cooking or rehydration.

Also, grains which have been gelatinized to a lesser degree by precooking require a heavier compression in order to obtain the same degree of softness in the rehydrated product. For rice soaked and precooked according to the conditions described above, it has been found that the thickness of the grains should be reduced to from about 30% to about 80% of their thickness before compression in order to provide a rehydrated product having a texture and other characteristics of regularly cooked rice.

After compression the rice grains are dried to a stable moisture content for packaging, storage and/or commercial distribution, usually in the range of 10 to 14%.

In applying the process described above to rough rice, it is necessary to remove the hulls from the rice grains. The hulls are preferably removed while the grains are in a moist pliable condition by passing them between rolls which are set at a distance such that the hulls are loosened and cracked, broken or rubbed off.

This hulling operation can be conveniently performed immediately following the cooking step with the rice at an overall moisture con%5 tent in the range mentioned above, namely, 17 to 34%. The loose hulls are suitably separated from the grains as by placing them on a conveyor and passing them under aspirators.

Since the operation of loosening the hulls thus involves the use of relatively light compression between rolls, it may, if desired, be performed simultaneously with the compression of the grain as described above, in which case the grains leaving the rolls are aspirated before being dried. 75 A detailed example of the manner 'm which the process of the present invention may be employed to provide the quick cooling rice product follows: 100 pounds of white rice with a moisture content of about 8% is placed 80 in a 100 gallon vessel or tank together with about 60 gallons of water and allowed to soak for 30 minutes at room temperature 75' F.).

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Thereafter it is transferred from the tank to a screen and allowed to drain for 15 minutes. 85 At this point the rice contains about 25% of moisture. Then the rice is transferred to an gallon autoclave and treated with dry steam at 8 pounds gauge pressure for 60 minutes at the end of which time the outer portions of 90 the rice grains are substantially completely gelatinized and the inner portions or cores are partially gelatinized but still contain a small amount of ungelatinized starch granules or birefringent material. The overall moisture 95 content of the grains is about 28 to 30%.

The rice grains are then removed from the cooker and transferred to a conveyor belt, being spread out thereon in a layer about one grain thick which is conveyed to and passed 1(k) between smooth rolls set to reduce the thickness of the grain to about 50% of their thickness before compression. After passing through the rolls the rice is dried in any conventional manner to a stable moisture content of 10 to 105

14%. A convenient and rapid way of effecting drying is to employ a forced draft hot air drier using air at 1800 F., the drying being effected in about 15 minutes. The product is packaged and distributed in the usual commercial 110 manner. It may be rehydrated to the texture and character of ordinarily cooked rice by the housewife by simply placing the same in water heating the water to a boil and allowing the rice to stand in the hot water in a covered 115 vessel or pan for 10 minutes.

In the Specification of my-copending

Application No. 12572 of 1954 (Serial No.

737,450) of even date herewith, I have described and claimed a process for preparing 120 quick cooking rice which comprises subjecting brittle completely gelatinised rice grains having a moisture content of above 15 % and up to and including 20% to heat and moisture to increase the total moisture

125 content by 1-2% with the added moisture substantially confined to the surface layers of the grains to produce pliable rubbery sheaths surrounding relatively brittle cores and then subjecting said treated grains to mech737,372 737,377 anical compression so that the internal structure of the grains is modified without reducing the grains to a flaked condition.Data supplied from the esp@cenet database

- Worldwide

730/2197

162.

GB737446 - 9/28/1955

IMPROVEMENTS IN OR RELATING TO QUICK COOKING RICE AND

METHOD OF PREPARATION THEREOF


Applicant(s): ATAULLAH KHAN OZAI DURRANI (--)

E Class: A23L1/182



Family: GB737446

Abstract:


In a process of preparing quick-cooking rice, hulled rice grains are steamed for a period of 30 seconds to 15 minutes and thereafter dried to a stable moisture content to alter the structure of the grains so that upon subsequent cooking the rice will absorb water rapidly so that the cooking time is reduced. The hulled grains may be soaked to increase the moisture content to 25-30 per cent and then steamed for a period of 30 seconds to 5 minutes. Steaming may be carried out in a conventional manner, e.g. by an autoclave, a rotary cooker, preferably in an apparatus providing for the rapid passage of steam through the grain, e.g. by passing the rice through a cylindrical cooker in the centre of which is a perforated steam line through which steam under e.g. 50-100 pounds pressure is ejected at such a rate that even though it is vented from the column a pressure of about 5-10 pounds is maintained within the column.

Drying may be effected by spreading the rice in thin layers for a period of about two days or by blowing air across or through the layers for 12 to 24 hours or in a forced draught drier for about 30 minutes the optimum drying temperature being about 140 DEG F. and the grain being reduced to a moisture content of 10-14 per cent. In an example 100 pounds of white rice with a moisture content of about 14 per cent is placed in a 100-gallon vessel together with about 60 gallons of water and allowed to soak for 30 minutes when it is removed and drained and transferred to an 80-gallon autoclave and treated with steam at 8 pounds pressure for 5 minutes after which the grains are removed and dried in any conventional manner to a moisture content of 10 to 14 per cent, e.g. in a forced draught hot-air drier using air at 140 DEG F., the drying being effected in about 30 minutes after which the product is packaged.Description:


PATENT I i IC ACCATITION

737,446

Date of Application and filing Complete Specification Feb. 8, 1951.

No. 35727/53.

(Divided out of No. 737,372).


ERRATA SPECIFICATION No. 737.446

731/2197

Page 3, line 13, for "with " read "within Page 3, line 97, after "draining" delete "the" Page 3, line 121, for " table" read " stable" Page 4, line 23, for "porcess" read "process" TIE PATENT OFFICE, 6th

April, 1956. ana tO Tne rice pruuuut, itit:.

A grain of rice when harvested, includes an inner endosperm and germ 16 which consists mainly of starch or gluten, depending on the type of the rice, covered hy a pericarp or bran layer which contains al the oil, fats, vitamins, proteins and minerals and a silicious outer husk or hull. In order to make it suitable for human consumption, at least the husk must be removed from the grain. Rice kernels from which only the hull has been removed are known as brown or husked rice. If rough or brown rice is milled to remove some or all of the pericarp or bran, the rice product known as white rice is obtained.

In order to mill the rice conveniently, its originally higher moisture content is reduced by drying to about 10 to 14%. By removing the bran, the valuable nutritional elements contained therein are lost.

For the preservation of the nutritional 36 elements contained in the bran, the rice is usually parboiled before milling to remove the bran. The parboiling process may vary somewhat but in general consists in soaking the paddy in cool or wrarm water below the gelatinization temperature of the kernel which is at about 150 to 160 F. The water penetrates through the pores of the hull and bran, dissolves to large extent the soluble nutritional elements contained in the bran- and carries them into the kernel.

The starchy constituenlts of the kernel absorb the water and retain and preserve [Price 3s. Od.] off.

The soaked rice is then heated above its gelatinization temperature so that the kernel gelatinizes.

During gelatiniza. tion the kernel takes up additional moisture so that the completely gelati- 5 nized rice contains between about 33.% and 42% moisture, depending on the conditions under which it has been parboiled. The rice is parboiled preferably by treating it with steam of proper temperature. In order to secure the latter, steam under superpressure is sometimes released upon the rice grains. Gelatinization is accompanied by further swelling of the kernels which therefore burst 75 the hulls. The parboiled rice kernel is soft, pliable and rubbery and will bend without breaking. It is the general practice to dry the parboiled rice to a moisture content of about 10 to 14% and to mill 80 the rice to remove the hull and most or all of the bran. Freshly harvested rice sometimes has a moisture content as high as al)out 26% and the initial soaking of the rice may therefore be omitted or 85 shortened if freshly harvested rice is used with a moisture content of 26% or more. Thereby the procedure of parboiling the rice as described above can be simplified. 90 When parboiled rough rice is dried to a stabilized moisture content of about 10 to

14% for subsequent milling, the milled rice 1'roduct forms a hard and stiff mass which is translucent and of a color from 95 dark to light brown and sometimes almost ,. _j.$; 4 + Inde PATEN IFICATION

737446 Date of Application and filing Complete Specification Feb. 8, 1951.

No. 35727/53.



Index at acceptance: --Class 58, A(1: 4), H6D.


Improvements in or relating to Quick Cooking Rice and method of Preparation thereof I,

ATAULLAR ICHAN OZAI-IDURRANI, a citizen of the United States of America, of P.O. Box No.

526, Stuttgart, Arkansas, United States of America, do hereby A declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described min and by the following statement:-

This invention relates to a method of preparing a quick cooking rice product and to the rice product itself.

732/2197

A grain of rice when harvested, includes an inner endosperm and germ Li which consists mainly of starch or gluten, depending on the type of the rice, covered by a pericarp or bran layer which contains all the oil, fats, vitamins, proteins and minerals, and a silicious outer husk or hull. In order to make it suitable for human consumption, at least the husk must be removed from the grain. Rice kernels from which only the hull has been removed are known as brown or husked 26 rice. If rough or brown rice is milled to remove some or all of the pericarp or bran, the rice product known as white rice is obtained.

In order to mill the rice conveniently, its originally higher moisture content is reduced by drying to about 10 to 14%. By removing the bran, the valuable nutritional elements contained therein are lost.

For the preservation of the nutritional 36 elements contained in the bran, the rice i. usually parboiled before milling to remove the bran. The parboiling process may vary somewhat but in general consists in soaking the paddy in cool or warm water below the gelatinization temperature of the kernel which is at about 150 to 160 ' F. The water penetrates through the pores of the hull and bran, dissolves to large extent the soluble nutritional elements contained in the bran and carries them into the kernel.

The starchy constituents of the kernel absorb the water and retain and preserve [Price 3s. Od.] the nutritional elements dissolved therein from the bran. The kernel also swells by 50 the absorption of water but, because the temperature is held below the gelatinization temperature of the starch, does not gelatinize. Thus the initial moisture content of the kernel can be raised to 56 higher moisture content at temperatures above room temperature. After saturation is reached, the soaking of the rice is stopped and any excess of the water in which the rice has been soaked, is drained 60 off. The soaked rice is then heated above its gelatinization temperature so that the kernel gelatinizes. During gelatinization the kernel takes up additional moisture so that the completely gelat]inized rice contains between about

33,% and 42% moisture, depending on the conditions under which it has been parboiled. The rice is parboiled preferably by treating it with steam of proper temperature. In order to secure the latter, steam under superpressure is sometimes released upon the rice grains. Gelatinization is accompanied by further swelling of the kernels which therefore burst 75 the hulls. The parboiled rice kernel is soft, pliable and rubbery and will bend without breaking. It is the general practice to dry the parboiled rice to a moisture content of about 10 to 14% and to. mill 80 the rice to remove the hull and most or all of the bran. Freshly harvested rice sometimes has a moisture content as high as about 26% and the initial soaking of the rice may therefore be omitted or 85 shortened if freshly harvested rice is used with a moisture content of 26% or more. Thereby the procedure of parboiling the rice as described above can be simplified. 90 When parboiled rough rice is dried to a stabilized moisture content of about 10 to

14% for subsequent milling, the milled rice product forms a hard and stiff mass which is translucent and of a color from 95 dark to light brown and sometimes almost L4 737,446 white. Examined under the magnifier or held up to the light, the interior of the kernel appears uniformly translucent and its exterior smooth. It does not absorb 6 water readily, and it therefore takes from to 45 minutes to cook it before it is ready for consumption. The cooked rice is rubbery and chewy, and contains up to about 65 to 70% moisture.

The parboiled rice product prepared in any of the manners described hereinbefore, contains a large percentage of the nutritional elements which were in the bran. The consumers, nevertheless, prefer ordinarily milled rice which has not been parboiled, because it is, upon cooking, white in color, soft in texture and not rubbery.

It is an object of the invention to provide a quick cooking rice and a process for obtaining the same.

It is another object of the invention to treat rice so as to promote its penetration by boiling water and thereby reduce the time required for cooking the rice.

It has now been found that rice can be rendered quick cooking by steaming the same for a period of

30 seconds to 15 mi'nutes and thereafter drying. Such steaming renders the rice porous and thereby facilitates the entry of water which is required to properly cook thle rice and, accordingly, the cooking time is considerably shortened. The steaming can be of a very short duration and the exact time required is, for the most part, determined by apparatus limitations. However, it can be said that in the usual case a 30 second steaming period will suffice although to steam for longer periods, say, 5-15 minutes, is beneficial. The optimum period of steaming is determined not only by apparatus dimensions, design, etc., but also by the variety of the rice which is processed and by whether brown, white or parboiled rice of commerce is used. The steaming period is also determined, of course, by the

733/2197

temperature or pressure of the steam that is employed. Steam of any reasonable degree of pressure and steam which has been slightly superheated may be used as well as the moist steam which is ordinarily used in commercial practice.

While a quick cooking rice is provided by steaming the rice. as indicated above, it is preferred to soak the rice prior to the steaming step. - The soaking may serve to increase the moisture content to any extent desired but it has been found that the greater the degree of soaking the better the results with respect to texture, appearance and the like of the final cooked rice. It is preferred, therefore, to raise the moisture content to at least about 25% and it is still more preferred to soak the rice grains until they are substantially saturated and contain about 30% moisture.

Soaking the rice before steaming the 7 same provides an improvement not only with respect to the final product but also in that which is sold to the consumer..

The product which is steamed and dried is opaque while the product which is soaked 7J before steaming is, after drying, translucent, longer grained and a generally better appearing product. As aforementioned, similar improvements are apparent with regard to the final cooked 8 product as served at the table. That which has been prepared by soaking, steaming and drying is longer grained, of generally better appearance, and of softer texture after being reconstituted- 8 by the housewife.

The conditions of steaming are to no particular extent altered by any previous soaking to which the rice grains may have been subjected. Although increas- 91 ing the moisture content of the grains serves to decrease to a slight extent the tendency of the grains to absorb moisture during steaming, it is generally preferred that the steaming treatment be 9' sufficient to increase the moisture content thereof by about 4-6%. In the case of soaking the rice grains to 25-30% moisture segmentation of the grains is caused thereby. Such segmentation increases 1( the tendency of the grains to break up but this tendency can be overcome to a large extent by increasing the steaming period to increase the extent of gelatin-.

zation which apparently serves to cement 1( the segments together. A steaming period of about 5 minutes is usually found to be sufficient to achieve this end.

It is intended that the periods of steaming recited herein are to be interpreted 1] to mean that the rice reaches the temperature of about 212 F. and is maintained thereat for the recited periods, for example, the period of 30 seconds mentioned herein. 1] In carrying out the practice of the present invention any hulled rice, e.g., brown, white or the parboiled rice of commerce may be employed. While the preferred processing conditions for white 1l and brown rice call for soaking to saturation (30%), and steaming for about minutes and drying, the parboiled rice is best treated by soaking only to about 20% which requires only about 5 12 minutes, steaming for about 30 seconds and drying.

While steaming may be carried out in any conventional manner using an autoclave, a rotary cooker and various other 1' N and low in the exterior portion. After cooling and storing for about 4-8 hours, however, the distribution becomes essentially even.

It is sometimes found desirable in connection with handling the rice, and especially if the same has been soaked to a relatively high moisture content such as 30%, to allow the same to drain, say, for 10 to

20 minutes. It is also desirable 75 in connection with handling the rice after steaming to blast it with cold air, the same not only serving to remove surface moisture and prevent lumping, but also to set the grain and to some extent 80 toughen it so that it may be subsequently handled with a minimum amount of breakage.

Soaking to achieve the objectives set forth above may be carried out by soak- 86 ing the rice for about

30 minutes with the calculated amount of water required to increase the moisture content of the rice to the desired degree, or it may be effected by soaking the rice for a lesser 90 period, sa'y, 5 minutes, with excess water, the rice being drained thereafter, On the other hand, it is also possible to combine the rice with a calculated amount of water, tumbling the same in a rotary 95 cooker for about 5 minutes and thereafter without draining the start the introduction of the steam which may be continued for, say, 5 minutes after which the rice may be drained if necessary and then 100 dried.

734/2197

A specific example of the manner in which the process of the present invention may be carried out follows hereinbelow: 100 pounds of white rice with a 106 moisture content of about 14% is placed in a

100 gallon vessel or tank together with about 60 gallons of water and allowed to soak for 30 minutes at room temperature (75 F.). Thereafter it is 110 transferred from the tank to a screen and allowed to drain for 15 minutes. At this point the rice contains about 30% of moisture. Then the rice is transferred to a 80 gallon autoclave and treated with 115 steam at 8 pounds gauge pressure for 5 minutes. The overall moisture content of the grains is about 34 or 35%. The rice grains are then removed from the cooker and dried in any conventional 120 manner to a table moisture content of 10' to 14%. A convenient and rapid way of effecting drying is to employ a forced draft, hot air drier using air at 140'

F., the drying being effected in about 30 125 minutes. The product is packaged and distributed in the usual commercial manner. It may be rehydrated to the texture and character of ordinarily cooked rice by the housewife by simply 130 conventional apparatus, it is preferred to use such apparatus as will provide for the rapid passage of the steam through the rice grains so that in effect the grains are " blasted " with high pressure steam.

This may for example, be carried out by passing the rice through a cylindrical cooker in the center of which is a perforated steam line through which steam under, say, 50-100 pounds is ejected at such a rate that even though it is vented from the cooker a pressure of about 5-10 pounds is maintained with the cooker. In such a case the hold-up period for the rice may be the previously mentioned 30 seconds or it may be as high as 5-15 minutes. The same steaming technique is also conveniently carried out in using a rotary cooker provided with a suitable 0 vent so that the steam is permitted to rapidly pass through the cooker, provision being made for the best possible contact with the grains. The latter is usually effected by tumbling the grains in the path of the steam. Using such apparatus, however, usually requires that the operation be carried out in a batchwise fashion and for this reason the aforementioned column which can be rendered continuous is preferred.

The soaked and steamed grains may be dried in any conventional manner using slow drying as well as rapid drying techniques. It is believed that a somewhat better color is obtained in the final product if relatively slow drying is employed although from the standpoint of efficiency this is not ordinarily desirable and the improvement in color does not warrant it. Drying may be effected by simply spreading the rice out in thin layers, in which case it requires a period of about two days or this period may be reduced by blowing air across or through the layer of rice, in which case the rice will be dried to a suitable moisture content in 12 to 24 hours. By employing a forced draft drier through which the layers of rice are conveyed and if at various stages the drying air is directed upwardly and downwardly through the rice as well as transversely across the top of the layer, it is possible to dry the rice in about

30 minutes. In i5 this connection, it has been found that the optimum drying temperature is about 140

F. As indicated above, the drying should continue until the rice grains have been reduced to a suitable moisture content which is generally regarded as being within the range of 10-14%. After relatively rapid drying, of course, the moisture within the rice grains is not evenly distributed, being 66 relatively high in the interior portion 737,446 4 737,446 placing the same in water, heating the water to a boil, continuing boiling for 3 minutes and allowing the rice to stand in the hot water in a covered vessel or pan for 10 minutes.Data supplied from the esp@cenet database - Worldwide Claims:


What I claim is:-

1. A process for preparing quick cooking rice which comprises steaming hulled rice grains for a period of 30 seconds to 15 minutes and thereafter drying the rice to a stable moisture content, said process serving to alter the structure of the grains in order that upon subsequent cooking the rice will absorb water very rapidly so that the time required for cooking is reduced.

- 9. A process according to Claim 1, which comprises soaking the hulled Leamington Spa:

Published at the grains to increase the moisture content thereof to 25-30%, and then steaming 20 the soaked grains for a period of 30 seconds to 5 minutes.

3. A-porcess according to Claim 2, in which ungelafinized hulled grains are soaked to a moisture content of about 25 30% and steamed for about 5 minutes.

735/2197

4. A process according to Claim 2, in which parboiled hulled rice grains are soaked to a moisture content of about 20% and steamed for about 30 seconds. 30 5. Quick cooking rice whenever prepared by a process according to any one of the preceding claims.

STEVENS, LANGNER, PARRY & ROLLINSON', Agents for the Applicants.

Printed for IHer Majesty's Stationery Office, by the Courier Press.-1955.

Patent Office, 25, Southampton Buildings, London, W.C.2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

736/2197

163.

GB737450 - 9/28/1955

IMPROVEMENTS IN OR RELATING TO QUICK-COOKING RICE



E Class: A23L1/182



Family: GB737450

Abstract:


A process for preparing quick cooking rice comprises subjecting brittle gelatinized rice grains having a moisture content of above 15 per cent and up to and including 20 per cent, which may be obtained by gelatinizing soaked grain having a moisture content from 25-30 per cent, to heat and moisture to increase the total moisture content by 1-2 per cent with the added moisture substantially confined to the surface layers of the grains to produce pliable rubbery sheaths surrounding relatively brittle cores and then subjecting the treated grains to mechanical compression, e.g. by passing through rollers and preferably compressing their thickness from 30-80 per cent of their pre-compression thickness so that the internal structure of the grains is modified without reducing the grains to a flaked condition. The rice may be gelatinized by soaking to raise the moisture content to about 35 per cent or above followed by treatment with substantially dry steam, soaked to a lower moisture content and treated with moist steam or it may be simply cooked in substantially the same manner as employed in the kitchen after which it is then dried to a moisture content of 10-20 per cent, preferably 10-14 per cent, and thereafter remoistened, e.g. with wet steam to an extent sufficient to raise the overall moisture content of the grains by 1-2 per cent and the bulk of the moisture thus added being concentrated in the outer portion of the grain. After compression the rice grains are dried to a stable moisture content, e.g. 10-14 per cent, for packaging, storage and distribution.Description:


PAT!I&0 CI tC k4b N

7379450

Date of Application and filing Complete Specification Feb. 8, 1951.

No. 12572/54.


(Patent of Addition to No. 657,691 dated April 22, 1948) Complete Specification Published Sept. 28,

1955.

Index at acceptance:CIass 58, A(1:4), H4(A: C).


Improvements in or relating to Quick-Cooking Rice I, ATAULLAH KHAN OzAi-DuRRANI, a citizen of the United States of America, of P.O. Box 526, Stuttgart, Arkansas, United States of

737/2197

America, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a method of preparing a quick cooking rice product and to the rice product itself, and is a divisional of my copending Application No. 3104 of 1951 (Serial No. 737,372).

A grain of rice when harvested, includes an 16 inner endosperm and germ which consists mainly of starch or gluten, depending on the type of the rice, covered by a pericarp or bran layer which contains all the oil, fats, vitamins, proteins and minerals, and a silicious outer husk or hull. In this condition, the rice is known as paddy or rough rice. In order to make it suitable for human consumption, at least the husk must be removed from the grain. Rice kernels from which only the hull has been removed are known as brown or husked rice. If rough or brown rice is milled to remove some or all of the pericarp or bran, the rice product known as white rice is obtained. In order to mill the rice conveniently, its originally higher moisture content is reduced by drying to about 10 to 14%.

By removing the bran, the valuable nutritional elements contained therein are lost.

For the preservation of the nutritional ele3S ments contained in the bran, the rice is usually parboiled before milling to remove the bran.

The parboiling process may vary somewhat but in general consists in soaking the paddy in cool or warm water below the gelatinization temperature of the kernel which is at about 150 to 1600 F. The water penetrates through the pores of the hull and bran, dissolves to large extent the soluble nutritional elements contained in the bran and carries them into the kernel. The starchy constituents of the kernel absorb the water and retain and preserve the nutritional elements dissolved therein from the bran. The kernel also swells by the absorption of water but, because the [Ptice 3s. Od.] 4S M temperature is held below the gelatinization 50 temperature of the starch, does not gelatinize.

Thus the initial moisture content of the kernel can be raised to higher moisture content at temperatures above room temperature, after saturation is reached, the soaking of the rice is 55 stopped and any excess of the water in which the rice has been soaked, is drained off. The soaked rice is then heated above its gelatinization temperature so that the kernel gelatinizes; during gelatinization, the kernel takes up additional moisture so that the completely gelatinized rice contains between about 33% and

42% moisture, depending on the conditions under which it has been parboiled. The rice is parboiled preferably by treating it with 65 steam of desired temperature; in order to secure the latter, steam under superpressure is sometimes released upon the rice grains.

Gelatinization is accompanied by further swelling of the kernels which therefore burst the 70 hulls.

The parboiled rice kernel is soft, pliable and rubbery and will bend without breaking. It is the general practice to dry the parboiled rice to a moisture content of about 10 to 14% and to mill the rice to remove the hull 75 and most of all the bran. Freshly harvested rice sometimes has a moisture content as high as about 26% and the initial soaking -of the rice may therefore be omitted or shortened if freshly harvested rice is used with a moisture 8() content of 26% or more. Thereby the procedure of parboiling the rice as described above can be simplified.

When parboiling rough rice is dried to a stabilized moisture content of about 10 to 14% 85 for subsequent milling, the milled rice product forms a hard and stiff mass which is translucent and of a color from dark to light brown and sometimes almost white. Examined under a magnifier or held up to the light, the interior 90 of the kernel appears uniformly translucent and its exterior smooth. It does not absorb water readily, and it therefore takes from 25 to minutes to cook it before it is ready for consumption. The cooked rice is rubbery and 95 chewy, and contains up to about 65 to 70% moisture.

The parboiled rice product prepared in any - ú. ft 737,450 of the manners described hereinbefore, contains a large percentage of the nutritional elements which were in the bran. The consumers, nevertheless prefer ordinarily milled rice which has not been parboiled, because it is, upon cooking, white in color, soft in texture and not rubbery.

738/2197

It is an object of the invention to provide a quick cooking rice and a process for obtaining the same. It is another object of the invention to treat rice so as to promote its penetration by boiling water and thereby reduce the time required for cooking the rice.

la -It -has now been found that rice can be rendered quick cooking -by subjecting whole rice grains having- an -exterior sheath-of moist gelatinized starch in a pliable rubbery condition and an internal core of brittle. at-least partially gelatinized starch, to mechanical compression so -that the internal structure of the grains is modified without -reducing the grains to a flaked condition,:the rubbery sheath maintaining -the grain integral while permitting the -formation of -cracks and fissures which facilitate penetration of water into the-grains on subsequent cooking thereof. A rice gramin having the aforementioned relatively brittle core-surrounded by a-pliable, rubbery-sheath -30 of moist gelatinized starch is provided by substantially completely gelatinizing the grain, drying the same to a -relatively low moisture content at which it is brittle and thereafter remoistening the outer portion of the grain to -

;l provide a-pliable, rubbery-sheath and leave the internal portion.or core brittle. The mechanical compression which is relied upon to modify the internal:structure of the individual grains -is usually provided by passing -the 4,; grains between-rolls although other ways may be used. Such compression distorts the rubbery sheath without substantially disrupting the same and modifies the internal structure tof the grain -by fracturing the -brittle core, producing a number of more or less minute -cracks,or fissures which extend from -the surface -of the grain into its interior and through which water can penetrate -rapidly in the subsequent cooking.

The grain -is retained integral by the external sheath which -nevertheless, is deformed and also ruptured at-points.

In carrying out the practice of the inven-tion rough rice, -brown -rice, or white rice may 655 be.employed. Ordinafily, however, it is preferred-to use milled or white rice.

When the invention is carried out in -accordance with the preferred embodiment -thereof, substantially completely gelatinized rice of above 15% and up to and including 20% moisture is subjected to treatment with moisture and heat so as to bring about an -increase in the overall moisture content if 1-2%, the bulk of the moisture being con66 centrated in the exterior portion of the grain.

The rice is then ready for subjection to mechanical compression for modification of its internal structure as mentioned above. Preferably, this compression is effected by passing fhe rice grains through compression rolls set 70 at such a distance apart as to provide a reduction of thickness of the grains without compressing them into flakes. In order to facilitate the handling of the grains in passing

-them to: -and through -the compression rols m:

they may, if desired be dried somewhat in any suitable manner but this is not essential. Preúerably, however, the surfaces of the grains are cooled before passing them to the rolls so as to set and toughen the exterior layers ot 80 starch, for example, by subjecting the grains -to -a -blast of cold air or to the action of cold -water. - - The degree of compression to which the grains should be subjected-depends in part on 85 the desired softness or texture of the rice when subsequently -cooked for consumption. In general, it -will be found that the greater the - degree of compression, the greater the production of cracks and fissures and the -softer -the 90 texture of -the rehydrated product for given conditions of pre-cooking and final cooking or rehydration. For rice soaked and precooked --according to theconditions -described above it has been found thatthe thickness of the grains 9S -should 'be reduced to from about 30% to about 80-%- of their thickness before compression in order to provide a rehydrated product having the -texture and other characteristics of regularly cooked rice. 1u After compression the rice grains are dried to a -stable- moisture content for packaging, storage and/or commercial distribution, -usually-in-the range of 10 to 14%.

- In applying the process described above to 10 rough rice, it is necessary to remove the hulls from the rice grains. The hulls are preferably -removed while the grains are in a moist pliable condition by passing them between rollswhich are set at a distance such that the hulls I1 are loosened and cracked, broken or rubbed off.

The loose hulls-are suitably separated from the grains as by placing them on a conveyor and passing them under aspirators. Since the operation of loosening the hulls thus involves 11 the use of relatively

739/2197

light compression between rolls, it may, if-desired, be performed simultaneously with the compression of the grain as described above, in which case the grains leav--ing-the rolls are aspirated before being dried. 12 In this manner there is provided the pliable rubbery sheath -whichis essential for maintaining the grain integral while the brittle core is cracked or fissured as a result of the mech--anical compression. The brittleness of the core 12 in this case-primatily results from its relatively low moisture cointent. If the core is Completely --gelatinized -its moisture content must be about 10% or slightly above in order for it to be sufficiently brittle for fissures and 18 ture content of about 15% and up to and 50 including 20% to heat and moisture to increase the total moisture content by 1-2% with the added moisture substantially confined to the surface layers of the grains to produce pliable rubbery sheaths surrounding relatively 55 brittle cores and then subjecting said treated grains to mechanical compression so that the internal structure of the grains is modified without reducing the grains to a flaked condition. 60 2. A process for preparing quick cooking rice according to claim 1 wherein soaked rice grains having a moisture content of from 2530% are gelatinized and then the grains are dried to provide the brittle completely gelatin- 66 ized rice grains.

3. A process according to claim 1, in which the grains are compressed to from 30% to 80% of their thickness before compression.

4. A process according to any of the precedO 70 ing claims, in which paddy or rough rice is employed and the hulls are loosened from the grains during the mechanical compression, and are thereafter separated from the grains.

5. The process of preparing quick cooking 75 rice, substantially as hereinbefore described.

6. Quick cooking rice whenever prepared by a process according to any one of the preceding claims.

7. Quick cooking rice according to claim 6 840 in the form of the whole at least partially gelatinized grains whereof the structure has been altered by the formation of cracks and fissures so that the grains are capable of rapid rehydration in water and can be quickly 85 cooked to the condition of soft textured whole grain cooked rice.

8. Quick cooking rice according to claim 7, in which the grains are porous e.g., as a result of cracks and fissures extending from the surface into the exterior of the grain whereby water can penetrate to the central part of the grain.

STEVENS, LANGNER, PARRY & ROLLINSON, Chartered Patent Agents, Agents for the Applicant.

cracks to be formed upon subsequent mechanical compression. On the other hand, if the core contains about 20% of moisture then an adequate amount of ungelatinized starch must be contained therein for the desired brittleness to be secured. It must be remembered that immediately after drying the rice grains the bulk of the moisture content thereof will be concentrated in the interior portion of the grain with the exterior portion being relatively dry. In such cases " tempering " as by allowing the same to stand for a suitable period, will provide for the more or less even distribution of the moisture content of the grains between the interior and exterior portions thereof.

The rice may be gelatinized in any conventional manner. For example, it may be subjected to soaking to raise the moisture content to from 25-30% followed by treatment with substanutially dry steam, soaked to a lower moisture content and treated with moist steam or it may be simply cooked in substantially the same manner as is employed by the housewife in the kitchen. Such methods provide rice in which the starch is substantially completely gelatinized and the moisture content of the grains is about 35% or above and may be as high as 65 to 70%. The cooked grains are then dried to a moisture content of 10 to 20%, preferably a stable moisture content of 10 to 14%, and thereafter remoistened as by blasting with wet steam to an extent sufficient to raise the overall moisture content of the grains 86 by 1 to 2% and the bulk of the moisture thus added being concentrated in the outer portion of the grain.

Rice prepared in accordance with the present invention is, as aforementioned, a quick cooking product, capable of being cooked to soft textured, fluffy whole grains by simply placing the dry grains in water, bringing the water to a boil, discontinuing heating and allowing the water and rice to stand in

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a 46 covered vessel or pan for about 10 minutes.Data supplied from the esp@cenet database -

Worldwide Claims:


What I claim is -

1. A process for preparing quick cooking rice which comprises subjecting brittle completely gelatinized rice grains having a moisLeamington Spa: Printed for Her Majesty's Stationery Office. by the Courier Press.-1955.

Published at the Patent Office, 25, Southampton Buildings, London, W.C.2, from which eopies may be obtained.

737,450Data supplied from the esp@cenet database - Worldwide

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164.

GB755750 - 8/29/1956

IMPROVEMENTS IN OR RELATING TO A METHOD FOR PREPARING

QUICK-COOKING RICE



E Class: A23L1/182; A23L1/18C2



Family: GB755750

Abstract:


755,750. Quick-cooking rice. GENERAL FOODS CORPORATION. Feb. 25, 1954 [July 29, 1953],

No. 5571/54. Class 58. Rice is gun-puffed to yield quick-cooking rice having a volume 2 to 3 times its original volume. The puffing gun may have a cylindrical barrel closed at one end and fitted at the other end with a hinged door releasably locked by trigger mechanism. The rice may be soaked in water and heated in the gun barrel, by a gas flame and/or live saturated steam under pressure, until it attains a terminal temperature between 325 and 370 F. and a terminal moisture content ranging from a value between 18 to 38 per cent at 325 F. to 28 per cent at 370 F., as defined by areas C 1 and C 2 on the graph, and thus subjected to a water vapour pressure corresponding to that of saturated steam at the particular rice temperature concerned, this pressure being suddenly released to the atmosphere by triggering-off the gun. The rice may be subjected to the terminal conditions prevailing in area D of the graph and after puffing, any puffed rice produced with a volume greater than that of the quick- cooking rice of the invention, may be removed. The rice may be puffed by using apparatus described in

Specification 700,140. The pressure in the gun may be boosted by the introduction of air or carbon dioxide or an inert gas such as nitrogen.Description:


ENS I C

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X Pv NT -SPECIFICATION

7559750 Date of Application and filing Complete Specification: Feb 25, 1954.

No 5571/54 Application made in United States of America on July 29, 1953.


Index at acceptance:-Class 58, C( 1: 2).

COMPLETE SPECIFICA Ti ON "Improvements in or relating to a Method for Preparing Quickcooking Rice".

We, GENERAL FOODS CORPORATION, a Corporation organised under the laws of the State of

Delaware, United States of America, of 250, Park Avenue, New York, State of New York, United

States of America, do hereby deqlare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

The present invention relates to a method of preparing quick-cooking rice products.

Objects of the invention include the provision of a process for preparing quick-cooking rice products capable of extremely high yields, requiring only a limited number of simple manipulations, a small capital investment and simple, readily available equipment and not requiring a separate drying step.

Generally, in the cooking of rice as it is carried out in the home, the rice is immersed in boiling water and after a suitable period is fully gelatinized and hydrated with the result that its volume has been increased 2-3 times as compared with the volume of the original raw rice It would appear that the amount of enlargement so provided is such that the elastic limit of the rice is not exceeded because upon slowly drying the cooked rice it shrinks to about its original volume On the other hand, rice which is gun-puffed in order to provide the well-known ready-to-eat breakfast cereal is enlarged 8-10 times the volume of the raw rice Upon drying no shrinkage occurs and it is impossible to reconstitute this product to provide anything even closely approximating the regularly cooked rice discussed above, thus indicating that the gunpuffing procedure enlarges the rice to such a degree that the elastic limit of the rice is exceeded.

It has now been found that quick-cooking rice products may be provided by means of gun-puffing so long as the degree of enlargement is no more than that effected by the normal cooking procedure as discussed above, namely, of the order of 2-3 times its original size The conditions required for such gunpuffing, although similar to those employed with the gun-puffing of the prior art by which 50 a ready-to-eat breakfast cereal is provided, are distinguished by the fact that the temperatures employed are distinctly lower and the moisture contents of the rice are considerably higher than are employed for the production 55 of the ready-to-eat breakfast cereal The conditions of temperature and moisture, as discussed above and hereinafter, relate to those which obtain just prior to the release of pressure or the actual step of gun-puffing and, 60 therefore, are generally referred to as "terminal" temperature and moisture conditions.

The terminal temperature is the temperature of the rice itself and terminal moisture is the moisture content of the rice While any 65 feasible amount of pressure may be employed in the gun-puffing to which the present invention relates, the water vapor pressure to which the rice is subjected, whether it represents a partial pressure of the system or the total 70 pressure thereof, is substantially that corresponding to the pressure of aturated steam, i.e, the water vapour pressure, at the terminal temperature selected.

The rice which may be employed in accord 75 ance with the process of the present invention may be any of the different varieties and types of rice available, including such varieties as Rexoro, Blue

Bonnet, Zenith (Blue Bonnet and Zenith are registered Trade 80 Marks) While brown rice may be employed it is generally preferred to use white or completely milled rice since it is this product for

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which the American consumer has a distinct preference 85 As indicated above, the degree of enlargement effected by the gun-puffing should not exceed to a very appreciable degree that normally effected in the course of cooking by immersion in water To illustrate, 142 g of 90 (Prl r.

WM 755,750 raw rice generally has a volume of about 170.

c c, whereas after cooking by immersion it has a volume of the order of 500-600 c,c, the weight having been increased, of course, by virtue of the absorption of water On the other hand, 142 g of rice after being gunpuffed to rice of the ready-to-eat breakfast cereal type has a volume of about 1500-1800 c.c Suitable degrees of puffing effected in io O accordance with the present invention will provide a product in which 142 g has a volume of 300-600 c c, although somewhat lower and somewhat higher degrees of puffing are sometimes operative to provide a quickcooking rice product Upon rehydration

142 g of rice which has been gun-puffed to such -a degree will generally have a volume equal to that of regularly cooked rice, i e, of the order of 500-600 c,c.

The terminal conditions of rice temperature and moisture which should be employed in carrying out the process of the present inm vention have been found to be inter-related and capable of reasonably exact definition.

This is shown by the graph contained in the accompanying drawing, in which the terminal moisture content of the rice is plotted against the I terminal temperature of the rice Regardless of the moisture content of the rice fio puffing of any appreciable or useful degree is obtained at terminal rice temperatures below about 325 F Thus, conditions in the area designated by A are not within the purview of the present invention Similarly, the areas B and E define conditions not suitable for the practice of the invention Use of conditions defined by the area designated by B provides a product which is excessively sticky so that clumps are obtained and a suitable product is not provided This is, in all likelihood, due to arn excessive moisture content which causes surface stickiness and prevents the provision of discrete, individual rice grains required for a satisfactory product On the other hand, conditions in the area designated by E and characterized by relatively lower terminal rice moisture contents and relatively higher terminal rice temperatures provide the greatly enlarged or puffed product generally employed as a ready-to-eat breakfast careal.

The conditions to which the present invention is particularly directed are found in areas C, Ci and D

In the latter area the product obtained is a mixture of the quick-cooking rice to which the present invention is directed and the aforementioned more highly puffed ready-to-eat breakfast cereal having a volume greater than 2-3 times the volume of the raw iice In such a case the process would necessarily incorporate a: step whereby the two types of products are separated This would entail a certain amount of additional expense, but might not be considered objectionable, especially in the case of a manufacturer engaged in the-production of both types of products It is preferred, however, to use the conditions designated by areas CQ and C 2 and still further preferred to operate with the conditions of area C 1 The product provided by the conditions of C is generally of a softer 70 texture and is an entirely satisfactory product except that it is believed that the general public prefers the somewhat firmer product provided by the use of the conditions of area C 1 75 When operating in accordance with the present invention, the rise is also subjected to awater vapor pressure equal to the pressure of saturated steam at the particular terminal temperature selected For example, at 325 F 80 a preasure of

80 lbs /sq in (gauge) and at 370 F a pressure of 150 lbs /sq in (gauge) must be employed Additional pressure may be used by introduction of air, carbon dioxide, nitrogen or some other inert gas, but serves 85 no known useful purpose.

Upon obtaining the terminal conditions as discussed above, it is then only necessary to release the pressure to a lower pressure.

Generally, from the standpoint of ease of 90 operation, releasing the pressure of the puffing apparatus to the atmosphere is preferred and no known advantage is gained by releasing to other than atmospheric pressure.

The manner of achieving the necessary ter 95 minal conditions is not critical Generally, the desired moisture content of the rice may be provided by soaking the ordinary milled rice of commerce having a moisture content of about 10-14 % in an excess of water or 100 spraying or tumbling the same with

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water prior to any other treatment A 30 minufte soak at room temperature increases the moisture content to about 30-35 % and it is only necessary to slightly increase the soaking tem 105 perature to reach 38 % which is about the maximum that should be employed as shown by the graph If a lesser terminal moisture content is desired the rice may be soaked for a shorter period of time In some cases it

110 may be desired to dry the rice, especially where it is desired to obtain both the quickcooking and the ready-to-eat breakfast cereal rice products.

Fdllowing soaking or drying, the rice may 115 be stored or "tempered" in order to insure even distribution of moisture throughout the individual rice grains The length of the tempering period can be varied according to the temperature of storage and the amount of 120 water added to or removed from the rice, but usually only about 30-60 minutes at room temperature is necessary for the purposes of the present invention.

The moisture content of tlihe rice may also 125 be increased by condensation thereon of the steam which is generally used in the process to heat the rice and provide the necessary pressure For example, if a moisture content of 38 % is desired, rice may be soaked at room 130 755,750 temperature to about

30-35 % and an additional 8 3 % of moisture may be provided by condensation of the steam used to provide the temperature and pressure necessary for gun-puffing Also, it is satisfactory to use this method to raise the moisture content of rice which is introduced into the puffing gun at lower moisture corntents, say, about 12 % moisture to a value as high as, say, 24 % and in this manner a separate soaking step is avoided It is generally undesirable, however, to rely on thi manner of proceeding to add very large amounts of moisture to the rice because the moisture which has condensed on the surface of the rice does not become as thoroughly distributed throughout the rice grain as when soaking is used and tends to increase the amount of gelatinization which occurs on the surface of the rice particles during heating resulting in a somewhat sticky product.

The desired terminal rice temperature may be obtained by any method of heating, including conduction, radiant, dielectric or convection heating, or a combination of the same.

It is preferred that the terminal temperature be achieved by the use of steam The heat conductivity of rice is such that the required terminal temperature is easily and quickly reached in this manner In so doing the required water vapor pressure within each grain is automatically obtained Prior to steaming, however, it is preferred to raise the temperature of the rice by dry heat This prevents excessive condensation of steam on the rice and permits better control of terminal rice moisture This can be done simply by applying a gas flame to the gun-puffing chamber containing the rice prior to the introduction of steam, the chamber which is usually a horizontal cylinder being rotated about its horizontal axis to tumble the rice and prevent scorching.

It is possible to carry out the process without the use of steam from an external source.

The moist rice in the enclosed space may be heated, as, for example, by applying a gas flame to the gun-puffing chamber, which is rotated to prevent scorching as aforementioned, with the result that some of the moisture is removed from the rice to provide the necessary water vapor pressure and at the same time leave in the rice enough moisture for a suitable terminal moisture content As soon as a suitable terminal rice temperature is obtained the pressure is released to effect gun-puffing This is not a preferred method of operation, however, because removal of the moisture from the rice as a result of the heating largely occurs at the surface of the grains and causes difficulty with regard to controlling the process, When the above-discussed terminal conditions of rice moisture and temperature have been achieved the water vapor pressure in the gun-puffing apparatus is equivalent to about Liae pressure or saturated steam at the terminal temperature of the rice Ihe only thing remammg is to release the pressure of the system to tne atmosphere in a manner as instan 70 taneous as possiole This can be accomplisned in any device capable of quick-opening as, For example, a Retitle with a quickly releasable closure The well-known gunpurling apparatus from the cereal industry is 75 particularly well adapted for the required quick opening This gun comprises a cylinaer capable of withstanding the pressure empioyed and containing a movable closure at one end The closure is locked while the 80 terminal conditions of rice temperature and moisture content and water vapor pressure are being ettected The lock is releasable by a trigger mechanism and is released either manually or automatically when the desired 85 conditions have been obtained Puffing guns are of various kinds and any of them may be used, for example, puffing guns which operate in a continuous manner of the type described in

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British Patent No, 700,140 are satisfactory go The time required to achieve the necessary terminal conditions and the necessary water vapor pressure is not important The process should be carried out as rapidly as conveniently possible to prevent excessive gelatini 95 zation from occurring and, of course, it is obvious that if the rice is held for excessive periods of time at high temperatures and moistures gelatinization will occur to such an extent that a badly clumped product will re 100 suit The time ordinarily required to achieve the necessary conditions causes no undesirable gelatinization, but on the contrary the amount of gelatinization which occurs in this period is desirable Time, therefore, is a factor only 105 to the extent that excessive time or delay be avoided.

In order to illustrate the preferred embodiments of the invention the following detailed examples are set forth: 110 EXAMPLE 1.

Approximately 8 pounds of ordinary commercially milled rice of the Blue Bonnet variety at 14 % moisture was soaked in an excess of water at room temperature for 115 approximately 15 seconds The rice was then drained thoroughly and allowed to temper at room temperature for 45 minutes At this point the rice contained approximately 20 % moisture by weight and the moisture was 120 uniformly distributed throughout each grain of rice The soaked rice was then placed in the chamber of a gunpuffing device This apparatus consisted of a cast iron cylinder 6 inches in diameter and 22 inches in length, 125 closed at one end and the other end was fitted with a hinged door with an air-tight seal secured by a trigger release mechanism.

The rice was sealed within the cylinder and a gas flame was applied to the cylinder well 130 I 3

755,750 until the rice reached a temperature of about 2750 F At this point saturated steam at a pressure of 90 lbs sq in (gauge) was introduced into the cylinder to raise the temperature of the rice to 330 'F At this point the rice had a moisture content of 29 % The pressure was then instantaneously released to the

-atmosphere by manually releasing the trigger mechanism The resulting rice product was essentially completely gelatinized, had a dry volume of 350 cc per 142 g, and a moisture content of 8-9 %.

142 g of the quick-cooking rice prepared according to the example was placed -in 340 c c of boiling water and allowed to stand in the water for 5 minutes A product resulted which had a volume of 550 c c, was uniformly cooked, soft textured, and similar in all respects to rice prepared according to conventional means The volume of 142 g of the raw rice of the Blue Bonnet variety when cooked in an excess of boiling water for 30 minutes is about 550 c c.

EXAMPLE-2.

Approximately 8 pounds of ordinary commercial rice of the Rexoro variety at 14 % moisture-was soaked in an excess of water at room temperature for approximately 30 minutes The-rice was then drained thoroughly and allowed to temper at room temperature -for 60 minutes At this point the rice contained approximately 35 % moisture by weight and the -moisture was uniformly distributed throughout the rice The soaked rice was thenplaced in the chamber of the gun-puffing device described herein above in Example 1, sealed, and a gas flame was applied to the cylinder wa Al of said device until the rice had reached the temperature of about 325 F, requiring 8-10 minutes At this point the water vapor pressure within the gun-puffing chamber was about 80 Ibs sq in (gauge) and the moisture content of the rice had been decreased to a slight degree The pressure was then instantaneously released to the atmosphere as described above, the resulting puffed rice being completely gelatinized and having a volume of about 370 c c per 142 g.

and a moisture content of about 10-12 %.

O Upon reconstitution with water as described in Example 1 the volume was increased to 560 c c, was thoroughly cooked and otherwise similar in all respects to regularly prepared rice The volume of 142 g of -raw rice of the Rexoro variety when cooked in an excess of boiling water for 30 minutes is about

550 c c.

EXAMPLE 3.

Approximately 8 pounds of ordinary milled rice of Zenith variety at about 12 % moisture was placed in the chamber of the gun-puffing device described herein above in Example 1, sealed, and steam at

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100 lbs sq in (gauge) was admitted to the chamber to raise the temperature of the rice to about 338 "F

This 65 required about 3 minutes and at the end of this time the moisture content of the rice had been raised to about 24 % The pressure was then instantaneously released to the atmosphere as described in

Example 1 and the re 70 sulting puffed rice was completely gelatinized, had a volume of 310 c c per

142 g and a moisture content of 10-11 % When reconstituted as described in Example 1 the cooked rice had a volume of 500 c c, was completely 75 cooked and otherwise similar in all respects to regularly prepared rice The volume of 142 g of raw rice of the Zenith variety when cooked in an excess of boiling water for 30 minutes is about 500 c c 80 What we Qlaim is:

1 A process of preparing quick-cooking rice which comprises gun-puffing the rice to a volume of the order of 2-3 times the volume of the raw rice 85Data supplied from the esp@cenet database -

Worldwide

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165.

GB766822 - 1/23/1957

IMPROVEMENTS IN OR RELATING TO QUICK-COOKING RICE



E Class: A23L1/182



Family: GB766822

Abstract:


In preparing quick-cooking rice, dehulled rice is treated with water and heated to bring its moisture content progressively to between 60 and 75 per cent by weight, the amount of water being limited to that which the rice can absorb at the temperature of treatment. The treatment may comprise passing the rice through a series of water sprays of progressively increasing temperature until it attains a temperature of about 100 DEG C. The rice should, preferably, acquire a moisture content of about 30 per cent before gelatinization temperature (about 65 DEG C.) is passed. The rice may be sprayed with water at room temperature, then with hot water and/or steam to bring its temperature to about 100 DEG

C. and then with hot or cold water to bring its moisture content to between 60 and 75 per cent. Before being sprayed with hot water and/or steam, the rice may be steeped in or sprayed with hot water at a temperature between 60 and 100 DEG C. to remove fatty material. Initially, the rice may be flashsteamed and then subjected to flash treatment with a fat-dissolving solvent, e.g. hexane or pentane. The moistened and gelatinized rice may be compressed mechanically, e.g. between rollers or rigid surfaces.

It may be frozen and/or dried to a moisture content between 10 and 14 per cent. Quick-cooking rice having a specific gravity of 0,48 may be produced from rice having a specific gravity of

0,85.Description:



Date of Application and filing Complete Specification: April 27, 1954.

766,822 No 12128/54 ax;% 2 ; 1 Application made in United States of America on April 30, 1953

Application made in United States of America on Aug 18, 1953 Complete Specification Published: Jan

23, 1957.

Index at acceptance:-Class 58, A 4, AH( 3: 4 A: 4 C: 4 D: 6 D), C 2.

International Classification:-B 02 b F 26 c.


Improvements in or relating to Quick-cooking Rice I, ATAULLAH KHAN OZAI-DURRANI, a citizen of the United States of America, of P O.

Box No 526, Stuttgart, State of Arkansas, United States of America, do hereby declare the invention, for which I pray that a patent may be granted to me and the method by which it is to be performed, to be particularly described in and by the following statement:-

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The present invention relates to a novel process for preparing a quick cooling rice product which may contain substantially all of the nutritional and flavor components originally present in the rice grain and to the rice product obtained.

It is an object of the present invention to provide a quick cooking rice product of large grain size and which contains the desirable nutritional and flavor components of the rice in substantially the same quantities present in the original rice grains.

It is another object of the present invention to provide a quick cooking rice product of high nutritional quality and which possesses excellent physical and aesthetic characteristics and which is not likely to become rancid during storage.

It is a further object of the present invention to provide a process for producing a quick cooking rice product which process is saving in time and materials and which may be conveniently conducted in a continuous fashion.

Other objects will be apparent to those skilled in the art from reading the following matter:

The invention will be described in part by reference to the appended drawing which comprises an enlarged photolithograph of grains of three rice products obtained by the present invention showing the excellent large grain size obtained and the attractive appearance of the grains as compared with the grains of three prior art rice products Figures 1, 2 and 3 show enlarged grains of three products of the present invention Figure 4 shows the product obtained according to U S patent No.

2,438,939 Figures 5 and 6 are of milled and parboiled rice, respectively.

The prior art is familiar with processes for preparing quick cooking rice products Most of these processes either suffer from the defect of being somewhat time-consuming or relatively costly or more often the product produced has 50 lost significant amounts of starch and other important nutritional and flavor components originally present in the rice grain These losses result primarily from the soaking and cooking processes used to convert the slower 55 cooking raw rice grains into a product which may be rapidly and easily prepared for the table by the consumer.

The prior art processes of preparing quick cooking rice usually involve a cooking step to 60 soften the grains This cooking step, as well as other steps, in the preparation of these products, such as a water soaking step, require the use of excess amounts of water Such treatment serves to solubilize and extract a goodly portion of the 65 rice starch and valuable flavor, vitamin and mineral components from the rice grain Treatment such as this may result in a loss of as much as 25 % of the original weight of rice employed in the process Obviously, such losses 70 have serious economic disadvantages for upon removal of the soaking and cooking water, the soluble solids extracted from the rice grains are lost to the final product as they cannot be conveniently replaced 75 One such prior art process for preparing a quick cooking rice is that disclosed in prior U.S Patent No 2,438,939 While the process of this prior patent provides a quick cooking rice product which marked a significant step 80 forward in the cereal art, and while we believe thatthe product obtained was the first succ ssful commercial quick cooking rice product and is even today the foremost commercial quick cooking rice product, it does not overcome the 85 disadvantage described above The process of the patent comprises essentially soaking rice grains in excess water until they are substantially saturated with moisture, and then cooking them in excess boiling water to gelatinize the 90 starch and increase the moisture content even further After a washing with cold water, the gelatinized and moisturized rice is then dried in accordance with the method described in the patent These soaking, cooking and wvashing steps all contribute to the removal of and loss of valuable starch, vitamins, mineral and flavor components from the grain Thus in spite of the need for improvement, the problem until now has gone unsolved.

In addition to the economic disadvantages inherent to the loss of the components in the rice grains, the losses in nutritional and aesthetic values are also very important In many parts of the world rice plays an important if not staple role in the human diet In such cases it is critical that the nutritional, flavor and aesthetic values remain substantially intact for if they are not available in the rice, the remainder of the diet may not compensate for their absence.

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Even where rice plays only a minor role in the diet, the flavor, odor, texture and appearance of the rice are important considerations in addition to the aesthetic pleasures derived from eating cooked foods which excel in these properties The pleasure of eating attractive food whets the appetite and thereby provides the necessary stimulation to ingest a proper diet One of the important features of the present invention is to provide a rice product which still possesses to an optimum degree the naturallyoccurring aesthetic values originally present in the rice in spite of the fact that the product also provides the convenience of quick cooking This is a goal which the food producing industry has been striving to attain for many years Additionally, this invention provides a product of large grain size which adds to the attractiveness of the product.

Shortcomings in the nutritional and aesthetic properties are not limited to the quick cooking rice products of the prior art Rice which has been cooked by the conventional cooking of milled or brown rice is equally deficient in these values Most consumers desire a wellcooked rice product for the table, i e, one in which the grains are soft and tender and not gritty or only partially cooked The methods used in cooking white and brown rice require washing and rinsing prior to boiling for substantially long periods of time in large excesses of water Consequently, washing and rinsing and most of all the cooking removes about 250 o of the original weight of the rice and eliminates substantially all of the vitamins and minerals and most of the taste and flavor normally inherent to rice.

A method less frequently used in preparing rice for sale to the consumer is parboiling.

Parboiling procedures may vary somewhat but in general they consist of soaking rice paddy (rice as harvested) in cool or warm water below the gelatinizing temperature (which is about 65 C) of the rice grain The water soaks into the rice grain and in doing so carries part of the soluble nutritional components contained in the rice bran into the kernel The resulting soaked paddy is then parboiled by heating, usually by steam, above the gelatinizing tem 70 perature of the rice grain to produce gelatinization of the starch The parboiled rice is then dried to a stable moisture content of about 100 % to 14 O by weight to facilitate removal of the siliceous hull of the rice paddy and of the rice 75 bran

The dried grain obtained after milling is hard and stiff and translucent Such product must be cooked and because of its hard, stiff grain, it requires substantially more cooking time than ordinary dehulled rice, and even then 80 the rice grains are never as soft as cooked ordinary rice or cooked quick cooking rice.

Also, in spite of the fact that the parboiled rice contains about half of the natural vitamins found in harvested rice, it is not well accepted 85 by consumers because its color, flavor, taste and texture are unusual to most rice-consuming people Additionally this product is more costly than ordinary rice and is more difficult to mill after the parboiling treatment Thus 90 this product also does not meet the requirements of a satisfactory rice product.

As a means of compensating for the deficiences of the prior art products discussed above, enrichment with one or more of the 95 components which have been romoved, or partially removed, has been considered This, however, is by no means the answer to the problem, for enrichment entails added costs both in the materials to be used and in the labor 100 and time required to incorporate these materials into the grains Also, difficulties inherent to the enrichment with some of these lost components make it impractical to provide a product which is equivalent in nutritional and 105 aesthetic values to the original rice grains At best, enrichment cannot attempt to reproduce the flavor, taste and texture deficiencies of the rice products of the prior art.

As a result of an intensive research inves 110 tigation I have discovered that I can produce, in accordance with the process of this invention, a rice product which is quick cooking, which possesses a large grain size and an attractive appearance and texture, which retains the 115 nutritional and flavor components originally present in the rice grain to an extent heretofore believed impossible, and which is relatively free from rancidity even after period of shelf storage 120 The process of the present invention is applicable to rice which has been dehulled and which is in any of the various stages of milling, i.e, brown rice which still has the outer bran layer containing all the oil, fats, vitamins and 125 proteins, or the completely milled rice sold commercially as white rice and which comprises substantially only the endosperm which is primarily starch Parboiled rice may also be treated in accordance with the process of the 130 _____JMMMMNMMMM 766,822 This coefficient varies

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somewhat with different types of rice and with the temperature of the rice and of the water It also varies with the extent of milling of the rice and other conditions, such as parboiling The amount of water may, 70 if desired, be progressively increased in the successive sprays; but no more water is to be used than the rice grains can absorb Also, in addition, the temperatures of the water in the sprays may be varied, as, for example, by 75 supplying water of progressively increasing temperatures to the successive sprays.

As pointed out above, the quantity of water sprayed on to the rice is to be limited so as not to substantially exceed the amount which the 80 rice grains can absorb It is an important advantage of the process that it may be operated continuously as well as batch-wise Also, it is not necessary to cook, soak or re-soak the rice in baths of water during the process such as is 85 done in other processes for preparing quick cooking rice products Suchi cooking or soaking in baths of water usually results in a loss of some of the nutritive values and components, including starch, vitamins and minerals, due to go extraction The present process minimizes such losses.

Spraying, I have found, permits the rice pores to absorb water quicker and transmit it more rapidly to the inner segments and interior 95 of the grain than does submerging in a volume of water Rice is hygroscopic in its physical behavior When the humidity of the atmosphere is subjected to substantial changes the rice will gain or lose moisture accordingly and 100 humidified air may be used to increase the moisture content.

In a preferred embodiment of the invention, dehulled or milled rice is contacted initially with a spray of water maintained at room 105 temperature or at the temperature of the available water supply The rice, contained, for example, in movable wire-screen baskets or passing along a suitable wire-screen movable conveyor, is passed under successive sprays, 110 which may be of progressively rising temperatures until the temperature of the sprayed rice has been increased to a desired value.

During the passage of the rice through the sprays the quantity of water emerging from the 115 sprays may be adjusted so that the moisture content of the rice increases as the temperature of the sprays increases Preferably the temperature of the rice is not permitted to exceed the gelatinization temperature (about 650 C) 120 until the rice grains are completely saturated with water, i e, until the rice contains approximately 30 % total moisture and has increased about 10 % in volume From the standpoint of economy it is preferable to use water of the 125 temperature of the normal water supply

The use of water of a temperature of between 20 and 600 C prior to reaching a moisture content in the rice of about 30 % is usually satisfactory.

The use of water of gradually increasing tem 130 invention.

The process of the present invention comprises treating dehulled rice grains with heat and water to progressively increase their temperature and their moisture content to a total of 60 to 75 %' while limiting the amount of water utilized to substantially that which the rice will absorb at the temperature of treatment, and, if desired, thereafter drying the moisl O turized rice grains to a stable moisture content of 10 to 14 %.

This treatment preferably coincides with a correlated increase in the temperature of the moisture and of the rice until the rice contains a maximum moisture content without producing an undue amount of rupturing of the walls of the starch cells contained within the rice grain The point at which rupturing of the starch cells begins is somewhat dependent upon the variety of rice used Some rice varieties will incur rupturing or disintegration of the starch cell walls when the moisture content reaches about 75 %, while other rice will not up to a moisture content of about 82 %.

As stated above, this wvill vary somewhat upon the type of rice, but the percentage of moisture which will produce rupturing may easily be determined beforehand and precautions taken not to substantially exceed this concentration of moisture The net result is that the starch cells of the rice grain are gradually softened by the combined increase in moisture content and in the temperature of -the starch cells and moisture in the rice grains The starch cells contained in the resulting rice grains will become greatly expanded in volume and will have softened with a substantial swelling and dispersal of the starch in the cells The starch will be in a gelatinized, but uncooked, state.

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The gelatinized product may then be cooled and dried by suitable means, which will be hereinafter described, so as to reduce the moisture content to a percentage at which the rice may be stored with stability until used.

A suitable stable-moisture content is between % and 14 % I find that if these conditions are observed an excellent product is obtained with grains of large dimensions, which are relatively free from "splitends" All percentages are by weight.

In treating the dehulled rice to progressively increase the water content I prefer to use only so much water as the rice will absorb at the particular temperature to which it is being subjected It is convenient to increase the moisture content of the rice by passing the rice along screens and subjecting the moving rice to successive sprays of water If desirable, the amount of water passing from the successive sprays may be varied, so that upon emergence of the rice from the sprays the moisture content of the rice grains has been raised to the desired percentage The amount of water emerging from the sprays may be varied in accordance with the coefficient of absorption of the rice.

766,822 perature or of constant temperature in excess of that of the available water supply is not necessary during this initial soaking or saturation stage of the process.

It is advisable that the rice does not absorb excess moisture during this initial saturation stage of the process This is prevented by first determining the moisture content of the untreated rice and spraying only enough water over the rice to increase the total moisture content to about 300 The time necessary for the rice to reach the saturation point will depend upon the degree to which the grains have been milled and the temperature of the hydrating water sprays.

For thoroughly mailed rice, this usually requires about 30 minutes and somewhat longer for rice grains w;-hich have been previously parboiled or which have been subjected to a lesser degree of milling and which still have some of the bran coating surrounding the endosperm Generally speaking, it may be said that from 15 to 120 minutes will suffice depending upon the factors mentioned above In most cases where the process is conducted on a continuous basis using milled rice the entire process may be completed within one hour.

At this stage of the process, the rice, with a total moisture content of about 30 '0, feels dry to the touch and is free-flowing However, w Nhen this grain is viewed under magnification, it will be seen to have small water droplets encircling the entire surface of the grain with slight undulations of the outer surface of the grain A longitudinal or lateral cross-section of the grain when viewed under high magnification, Nill be found to comprise enlarged starch granules suspended in water The grain is almost impervious to the transmission of light and appears to be a compressed, snow-like, white mass

Thus the translucency, which is accompanied by some white speckles, usually found in some dehydrated, completely milled, white grains, is transformed into a white opacity During this initial hydration step or saturation stage, it is observed that the rice grain does not absorb moisture uniformly, but rather through five to eight or more distinct channels or segments running crosswise of the grain which distribute the moisture to other parts of the grain Also, that end of the rice grain from which the embryo has been removed provides for rapid water penetration It is probably for this reason that in the early stages of the hydration, the grains take on a checkered appearance As the moisture content increases the rice grains become a solid opaque white mass which upon close examination will show the division of the grains into segments The moisture seems to become equally distributed throughout the grain, particularly after onehalf hour of spray treatment The rice is easily friable to a granular, moist flour-like state Brown rice, which still contains the bran coating, generally does not assume the same outward appearances and will not absorb water as rapidly as the completely milled white rice, but if the bran coating is removed from the grain, the starchy endosperm will be observed to have undergone the same transformations as 70 the completely milled white rice.

It is not essential that the rice grains be completely saturated with moisture during this initial saturation treatment In fact, as a practical matter, it is difficult to attain complete 75 saturation without keeping the rice in contact with moisture over a rather substantial period of time The moisture content at saturation will vary depending upon the temperature of the rice and water as well as the nature of the

80 rice used The saturation concentration at normal room temperatures is about 30 %O as stated hereinabove Because of practical considerations this amount of moisture is rarely achieved without the

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application of heat for the 85 reasons stated above Concentrations of 27 % to 2900 total moisture may be considered the equivalent of complete saturation with moisture at this stage of the process for the purposes of the present invention The moisture content 90 of the rice grains after this so-called "initial saturation step" need not necessarily approach even this concentration, although a higher moisture content attained prior to gelatinization improves the quality of the final product 95 The above described

"initial saturation step" may also be completely or partially eliminated if the dehulled rice used as starting material has a substantial moisture content For example, parboiled rice may be milled at a moisture 100 content of about 170 % to 30 % In such a case it will not be necessary to subject the rice to the "initial saturation step" However, rice is usually reduced in moisture to a content of 10 % to 14

% to facilitate milling and to permit stable 105 storage over long periods of time Since the rice used usually contains only this amount of moisture, the "initial saturation step" is recommended in order to increase the moisture nearer to the saturation point 110 I next prefer to take the dehulled rice, which may or may not have been subjected to previous moisture saturation treatment, and which thus may contain from between 10 %, and 30 % moisture, and subject it to a treatment with hot 115 water at a temperature of 600 to 1000 C, and preferably between 80 ' and 900 C, for a period of about 30 seconds to 10 minutes This hot water treatment may be conducted in a number of ways Among other purposes served, this 120 hot water treatment accomplishes a removal of the fatty material found on the surface or within the grain of the milled grains of rice The removal of this fatty material is effected by a quick spraying of hot water over the surfaces of 125 the grain more rapidly than the rice will absorb or by submerging the rice in hot water for a short period and then removing the water.

The removal of the fatty material from the rice grains is important Rice, even though 130

______JMMMMMMMMW 766,822 766,822 5 very vigorously milled, contains about O 3 % of its weight of fatty material, most of which is in the form of a film over the surface of the grain.

The fatty material consists of high and low molecular weight fractions Some of these fractions are volatile, others are liquid at room temperature, while others are solids The specific gravity of all fractions is less than that of water and thus all fractions will float on water If this fatty material is permitted to remain on or in the rice grains, it tends to oxidize or decompose and causes rancidity of the rice when stored in an unventilated container, which is usually the case, or in a humid environment

This rancidification has a detrimental effect upon the nutritional components and imparts to the rice a disagreeable flavor and taste and a shaggy appearance to the grain.

This rancidity persists in the rice during storage and even upon certain methods of cooking and other subsequent treatments with water Steaming of the rice does not necessarily prevent rancidification

While escaping steam may remove some of the more volatile components of the fatty material, it appears to decompose or hydrolyze the higher molecular fractions to form higher fatty acids which may cause rancidity This is shown by the fact that rice which has been steamed becomes rancid as does rice which has not been steamed Thus the removal of the fatty material is a desirable step in the preparation of an aesthetically satisfactory product.

The hot water treatment step described hereinabove produces other distinct advantages.

Treatment at the temperatures recommended produces an almost spontaneous surface gelatinization of the rice grain which tends to seal off the surface of the grain by making the surface less permeable and thus tends to capture the internal water-soluble nutritional and flavor materials which might otherwise tend to escape from the rice grain during washing or further contact with water This treatment also makes the rice grains less fragile and more able to withstand further treatment without breaking or cracking This contributes to another important advantage of the product of the invention which is relative freedom from mis-shapen, broken and split grains During the course of the treatment the moisture content of the rice will increase to about between % and 60 % total moisture Thus this step produces an enhancement of the moisture content and some gelatinization of the starch due to the preheating of the rice Both of these are important objectives of the process.

It is desirable to use no more water in removing the fatty material than is necessary, since all excesses of water have a tendency to extract and remove from the rice grains some of the valuable nutritional and flavor components However, by using no more water than necessary these losses may be reduced to a negligible amount.

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The hot water treatment also performs an additional function in that it tends to provide a more uniform, and therefore more attractive, rice product Rice, when harvested, is not a uniform product

Even when rice grains are 70 taken from the same stem or sheaf they differ in appearance from each other For example, milled rice is not uniform in color The generally translucent grains are interspersed with white opaque spots This lack of unifor 75 mity between grains makes the rice product less appealing to the consumer The hot water step just described aids in making all the grains pleasantly and uniformly opaque The resulting rice grains are slightly slippery to the touch and 80 the surface has a sheen or glassy appearance rather than a dead white opaqueness as observed in the "initial saturation step" When chewed the product is gritty because most of its starch cells have not been softened by sufficient 85 exposure to hot water and all of the cells have not been gelatinized to make the product edible in accordance with the eating standards of most people.

If desired, rice grains which have been 90 subjected to the above hot water treatment in accordance with the present invention may be dried to a stable moisture content of from 10 % to 14 %, and in this form the rice will resist insect infestation and will be less subject to 95 becoming rancid upon storage

Such dried rice is not readily subject to atmospheric changes.

The product may be cooked in accordance with standard household cooking practices to provide a cooked rice having better taste, physical and 100 nutritional values than milled rice which has been cooked.

As an alternative to the above hot water step, raw rice or dehulled rice may be first subjected to a flash steaming for a matter of a fraction of 105 a minute with wet steam to agglomerate sugars and other materials which are normally found about the coating of the rice This may be done without adding more than about 1 % total moisture to the dehulled rice and only slightly 110 raising its temperature

This treatment is of such short duration that substantially no gelatinization is permitted to occur and by agglomerating or stabilizing the sugars and other watersoluble materials found on the surface of the

115 rice grain, the solvent treatment which follows is accelerated and the prevention of formation of undesirable emulsions during the solvent extraction which we will now describe is made possible The rice which has been flash 120 steamed is then subjected to a flash treatment with a fat-dissolving solvent, such as a low boiling petroleum fraction and preferably hexane or pentane, in liquid or vapor form for a period of a few seconds up to a few minutes 125 When the solvent is washed over the grains it carries with it practically all of the fatty material normally found on or in the grain leaving intact most of the nutritive and flavor components.

Subsequent to the hot water washing treat 130 766,822 ment described above the grains may be optionally cooled by subjecting them to a cold water spray or a cold air blast This treatment is strictly optional and is not necessary to obtain a satisfactory product.

The next phase of my preferred process may be said to comprise in general the subjecting of the rice to further spraying with moisture,desirably starting at the temperature of the last treatment of the rice and progressively increasing the temperatures until the temperature of the spraying water and the rice attain a temperature of approximately 100 'C During the course of this treatment the total moisture content will increase to between preferably about 60 % and about 75 % The quantity of water sprayed over the rice should be limited so as not to substantially exceed the amount which the rice can absorb

The rice is white and somewhat stickier than the rice which contains about 30 %/ moisture The entire grain is tender throughout and easily crushed It appears like and tastes like cooked rice The volume of the rice grains becomes approximately two or three times that of the original non-hydrated rice.

It is desirable to accomplish the further heating and hydration of the rice described generally in the paragraph above in two steps, the first of which is to subject it to a series of wet steam or hot water sprays which quickly increases the temperature of the rice grains to about 95 or 1003 C and provides a completely gelatinized, but not necessarily cooked, rice having about 5 % more total moisture content than the hot water washed rice Ordinarily the rice will contain about 40 %" to 67 % total moisture after this gelatinization step and is flexible enough to withstand further mechanical manipulation As described in connection with the "initial saturation step" described hereinabove this steaming step, which is accomplished by the use of wet steam or steaming boiling water sprays, should be practised by using no more moisture than the rice will absorb, although rice which is gelatinized does not lose starch as rapidly as ungelatinized rice when treated with excess water The rice grains are now

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translucent and are no longer segmented or slippery or friable There is no grittiness upon chewing the grains The starch in the cells of the grains is now of a homogeneous nature and in the form of a semisolution or colloidal dispersion in water.

As a result of the above steaming treatment, the rice grains may adhere to each other and form aggregates To break these up, it is advisable to subject these aggregates to a combined spray of hot air and hot water or alternately spraying the aggregates with hot air and then hot water One should bear in mind that the water used in the sprays will be absorbed by the rice and contributes to the overall moisture content of the grains Care should be taken to avoid any excessive agitation of the rice which may cause mechanical injury to the grains.

After the above-described steaming or gelatinization step, the hot rice may, as the second step, be further exposed to a spray of 70 either hot or cold water to increase the moisture content to a convenient maximum, which is usually about 700 % total moisture or generally about 60 % to 75 %, total moisture It is preferable to use a hot water spray for a period 75 of time of about 2 minutes to 30 minutes depending upon the temperature of the spraying water and the moisture content of the the rice at the beginning of the spraying treatment The rice, upon reaching a maximum 80 moisture content which will not materially rupture the starch cells, is now soft and tender.

The product has been enlarged to about two or three times the orginal dimensions of the dehulled rice and has a distinctive taste and 85 flavor found only in rice having a maximum concentration of its flavor components present.

If desired the moisturized and thoroughly gelatinized rice may also be optionally subjected to a jet of compressed air or other mechanical 90 means for breaking up clumps of rice grains which may exist.

In a modification of the process described above, the rice grains may be passed through a continuous series of water sprays of progres 95 sively increasing temperatures until the grains attain a temperature of about 100 C and a moisture content preferably between about % and 75 %, without limiting the moisture content to about 30 %' before attainment of the lo C gelatinization temperature.

In another modification, the rice may first be.subjected to a flash steaming, i e, steaming for a brief period such as a few seconds, and then passed through the sprays in accordance 105 with the preferred embodiment of the invention By such pre-steaming treatment any tendency of the rice grains to stick together is minimized.

The water sprayed on to the rice grains may, 110 if desired, contain coloring or flavoring materials to enhance the taste and aesthetic qualities of the rice.

The rice, after having been gelatinized and moisturized to an extent compatible with 115 retaining the starch cell walls and identity of the grain intact, may then be treated in any suitable manner to reduce the moisture content of the rice grain so long as there is no substantial reduction of the increased size of the grain 120 above referred to This reduction of moisture content, or drying, may be accomplished by subjecting the grains to air drying until a stable moisture content of about between 10 % and %', or about 13 %, total moisture is reached 125 The drying temperature is not critical A blast of hot or cold air, or any combination of these, may be suitably used Alternatively, the rice grains may be chilled substantially below room temperature, either by cold water or cold air, 130 766,822 some voids within the grain are produced.

These voids serve as a channel for water absorption.

The excellent appearance of the novel products of the present invention is shown in 70 the appended drawing The first three rice grains at the top of the vertical column (Figs.

1, 2 and 3) are of three quick cooking products obtained in accordance with the present invention The grains show their relatively 75 larger size as compared with rice of the prior art The segments running across the width of the grains are visible All six figures were photographed at the same time so that all grains are enlarged to the same degree Figure 1 80 shows a grain of the Niro variety of rice which has been dried by a hot air blast at 79 C.

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Figure 2 is a grain of Blue Bonnet rice dried under the same conditions The term "Blue Bonnet" is a registered Trade Mark The 85 grain of Figure 3 differs from that of Figure 2 in that the product has been dried at about room temperature, or 270 C The somewhat opaque product of Figure 4 is the quick cooking product obtained in accordance with Patent No 90 2,438,939 The product of Figure 5 is raw or milled rice of the Blue Bonnet variety, sold under the trade name Carolina rice The product of Figure 6 is parboiled converted rice, sold under the registered Trade Mark "Uncle 95 Ben's" rice.

An important modification of the present invention comprises subjecting the grains of rice, after having been treated by any one or more of the moisture-increasing stages of the 100 process recited above, to mechanical compression After mechanical compression, the grains may, if desired, be returned to the process for further treatment This compression serves to modify the structure of the grains 105 even further and to aid in enhancing the absorption of moisture in any subsequent steps of the process and to enhance the quick cooking properties of the final product.

The mechanical compression referred to 110 hereinabove may be accomplished by any of a number of means, such as by passing the grains through rolls or cylinders or by merely pressing the grains between two rigid surfaces Various degrees of compression may be used, although 115 excellent results may be obtained by compressing the width of the grains by about onethird of the width before compression.

I find, for example, that we may conveniently compress the rice after the hot water treatment 120 described above, with or without drying or cooling the surface of the rice grains As a result of the compression there takes place within the body of the grains a fracturing of the ungelatinized parts of the grains or any 125 gelatinized part which has been chilled, or dried, or stiffened by brief contact with hot or cold water The gelatinous casing in the present instance will serve as a container for the fracturedinternal structure I find that, inpartic 130 and then subjected to a hot air blast It is preferred that the air blast is forced through the spaces between the grains of the rice so that the moisture of each grain is reduced substantially simultaneously There is thus obtained uniform dehydration throughout the grains of the rice without collapsing the cell walls.

A hot air blast of about 1250 C is preferred because it will remove moisture more rapidly than cold air and will prevent collapsing of the rice grains during the initial stages of the drying.

Because of its more rapid drying, a hot air blast is more economical A hot air blast will set the rice in an enlarged condition, and contributes to the further gelatinization and accomplishes to some extent initial cooking of the rice, and will produce voids in the rice grain due to the rather rapid escape of moisture from the interior of the grain The production of internal voids or fissures in the rice grains is preferred since it will aid in accelerating cooking of the rice when prepared for eating Since hot air will provide more rapid drying, the dried rice grains tend to be in a slightly more enlarged condition than grains dried by cold air.

When the moisture content is reduced to about 10 % to 14 %,O) the specific gravity is reduced to approximately between I and l of the original dehulled rice The dried rice becomes segmented (about 6 to 8 segments) again when the moisture content reaches about % and these segments are retained in the product having a reduced moisture content of about 10 % to 14 % The rice has a specific gravity of about 0 4 and 0 6 depending upon the total amount of moisture incorporated into the product prior to drying and the conditions of drying When viewed under magnification the grain is found to have a slightly rough surface with a number of very small protuberances.

The grains have a white translucency and are of large size which imparts an attractive appearance to them The grains are usually free from "split-ends" or cracks at the terminal end of the grain The product retains a maximum of the vitamin, mineral and other nutritional components present in the rice used as the starting material as well as excellent flavor characteristics.

The quick cooking properties of the product of the invention are believed due in part to the fact that the dried product with a total moisture content of 10 % to 14 % is segmented roughly across the width of the grain into from 6 to 8 segments These segments provide channels for the moisture to pass through The rice starch has been gelatinized which also makes it more amenable to moisture absorption

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Another very important factor is the fact that the starch cells have been dried in a swollen extended state thus providing greater surface area to absorb water Anotherfeaturewhich contributes to rapid water absorption during cooking is the fact that when the rice is dried to a stable moisture content by rapid means, such as a hot air blast, 766,822 ular steaming or completely gelatinizing the rice grains that the compression step is desirable in obtaining an excellent quick cooking rice product.

Another desirable embodiment of the compression modification of the invention comprises subjecting the grains to compression after they have been treated by a spray of steaming water or steam to substantially completely gelatinize the entire grain and surface dried to a slight extent This treatment imparts minute fractures to the grain coating so that after the grain has been dried to a stable moisture content it will absorb water very rapidly through the grain coating when cooked for table use Such a product will cook in a comparatively short time This dried product will have in addition to the fissures running across the width of the grain, a thin fissure transversing the center of the length of the grain.

Another important specific embodiment of the compression modification of the invention comprises mechanically compressing rice grains which have been treated with hot water, but during which water treatment no more than the external parts of the grains have been gelatinized, and then subsequent to compression treating the grains with steam or hot water to thoroughly gelatinize the grain The moisture content may then be increased with hot or cold water until a total moisture content of about 600 % to

75 %' is obtained The grains may then be dried to a stable moisture content.

The product of the invention may be quickly and easily cooked without further loss of nutritional or flavor components A convenient and recommended cooking technique comprises adding a cup and a quarter of water to a cup of the dried rice product of the invention The mixture is brought to the boiling point, the source of heat is removed and the mixture is permitted to stand for about 10 minutes in a closed container The rice absorbs all of the water and is ready to be served The cooked rice product is of tender texture and excellent in flavor characteristics and appearance Of course, the cooking procedure used may vary widely in accordance with the personal preferences of the consumer For example, boiling water may be added to cover the rice product and after a few minutes time will be absorbed by and Will cook the rice Other procedures may also be used.

In order more clearly to disclose the nature of the present invention, specific examples illustrating the preparation of a typical product will hereinafter be described.

EXAMPLE I.

About 6,000 grams of Rexoro milled rice was subjected to sprays of water at room temperature (about

26 C) using 1,365 grams of spraywater The rice became substantially saturated with water The total weight of 7,365 grams indicated an increase of the total moisture content from 13 38 %o to 28 63 O,

The moisture-saturated rice was then immersed in a bath of hot water which initially had a temperature of 97 C and after five minutes bad a final temperature of 80 ' C due to heat loss 70 The water was then removed from the rice and the rice was weighed The weight of the rice which was now substantially free from fatty materials had increased to 7,500 grams indicating a total moisture content of about 390

'$ 75 This rice was then placed in a perforated cylinder and exposed to a spray of steaming water for about five minutes to increase its weight to 7,900 grams indicating a total moisture content of about 41

During this 80 treatment practically all of the starch cells in the rice grains became gelatinized The grain was rubbery to the touch The flavor of the product was excellent This product, while still hot from the water-steam spraying treat 85 ment, was then further subjected to spraying with hot water, also in an amount less than the amount that the rice would absorb By this step the weight of the rice was increased to 13,495 grams of gelatinized and hydrated rice 9 o product indicating a moisture content of about 700 The product then was about twice the size of the original rice grains and had a distinctive taste and flavor which was very appetizing and pleasing This rice was then 95 subjected to a hot air blast of about 80 ' C until the moisture content of the rice was reduced to 1390 total moisture

The resulting product had a specific gravity of 0 475 as compared to the 0 85 of the milled rice used as starting 100 material.

The dried quick cooking rice produced in accordance with this example may be rapidly cooked by adding to one cup of the dried rice, one cup and a quarter of water and bringing 105 the mixture to a boil The source of heat is removed and the mixture left for 10 minutes with the pan covered The rice

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absorbs all of the water When eaten the rice has a tender texture and is of excellent flavor and contains a 110 practical maximum of all the nutritional components originally present in the rice.

EXAMPLE 2.

About 15,000 grams of Blue Bonnet rice having a total moisture content of 11 60 , was 115 sprayed with 3,555 grams of water at 270 C.

The water was absorbed by the rice thus increasing the moisture content to 28 500 This substantially water saturated rice was then submerged in hot water of a temperature of 120 970 C for 5 minutes during which the temperature of the water dropped to 790 C This raised the weight of the rice by 5,155 grams and the moisture content to 440 ' The rice was removed from the water bath and subjected 125 to a steam-water spray for 150 seconds to increase the weight of the rice by 670 grams for a moisture content of 450 and the temperature to 990 C The rice was then sprayed with cold tap water at 260 C for

10 minutes 130 766,822 moisturized rice grains to a stable moisture 55 content of 10 to 14 %.

2 A method according to claim 1, in which said rice grains are passed through a series of water sprays of progressively increasing temperatures until said grains attain a temperature 60 of about 1000 C, without limiting their moisture content or while limiting their moisture content to about 30 % prior to attainment of the gelatinization temperature.

3 A method according to claim 1, in which 65 said rice grains are passed through a series of water sprays while not permitting the temperature of said grains to exceed the gelatinization temperature, and said rice grains are thereafter passed through a further series of water 70 sprays until said grains attain a temperature of about 100 C.

4 A method according to claim 3, in which said further treatment of the rice grains is effected by first passing said grains under a 75 series of hot water or steam sprays until said grains attain a temperature of about 1000 C.

and then spraying said heated grains with water to increase their moisture content to a total of to 75 %

80 A method according to claim 3 or 4, in which, before said rice grains are passed through said further series of water sprays, they are treated with hot water at a temperature of 60 to 1000 C to effect removal of any fatty material 85 thereon.

6 A method according to any of claims 1 to 4, in which said rice grains are initially subjected to a flash-steaming treatment.

7 A method according to claim 6, in which 90 said flash-steamed rice grains are then subjected to a flash treatment with a fat-dissolving solvent.

8 A method according to any of claims 1 to 7, in which said rice grains, after any one or 95 more of said moisture-increasing stages, are subjected to mechanical compression.

9 A method according to any of claims 1 to 8, in which said moisturized rice grains are frozen 100 A method of preparing quick-cooking rice substantially as hereinbefore described.

11 Quick-cooking rice when prepared by the method according to any of claims 1 to 10.

STEVENS, LANGNER, PARRY & ROLLINSON, Chartered Patent Agents, Agents for the

Applicants.

during which the weight of the rice was increased by 13,155 grams to produce a moisture content of

64 75 % The product was dried with a hot air blast at 800 C to a stable moisture content of 11 34 %

The resulting dried quick cooking rice, a grain of which is shown in Fig 2 had a specific gravity of 0 48 as compared to 0.85 for the original rice The appearance, color, flavor and texture of the product was excellent.

758/2197

When the rice of this example was cooked with one and a half times its volume of cold water, by bringing the mixture to a boil in 4 minutes, the heat removed, the container covered and permitted to stand for 11 minutes, the rice was found to be thoroughly cooked and excellent in every respect The total moisture content of the cooked rice was found to be 75 % and after draining the excess moisture and removing any excess moisture adhering to the grains, the internal moisture content was 69.46 % of the weight of the grains.

As a further alternative the moisturized and gelatinized rice grains produced in accordance with the present invention may be quickly frozen, thereby providing a desirable product which need not be subjected to drying and which may be sold in frozen form It may be quickly and readily cooked by the consumer by merely pouring hot water upon it or by thawing and warming the frozen material Also, if desired, the frozen grains may be dried after freezing by subjecting the product to a hot air blast; such dried product having marked advantages.

Where hot air blast is used in drying the rice, the temperature of the rice should not be raised above the caramelization temperature of the starch Hot air temperatures in the order of 125 C are below the caramelization temperature of starch and may be suitably employed The temperatures of the hot air blast may be varied according to the results desired, however, so long as the rice is not heated above its caramelization temperature.Data supplied from the esp@cenet database - Worldwide

Claims:


What I claim is:-

1 A method of preparing quick-cooking rice, which comprises treating dehulled rice grains with heat and water to progressively increase their temperature and their moisture content to a total of 60 to 75 % while limiting the amount of water utilized to substantially that which the rice will absorb at the temperature of treatment, and, if desired, thereafter drying the Printed for Her Majesty's Stationery

Office by J Looker Ltd, Poole, Dorset 1957.

Published at The Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.


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166.

GB766889 - 1/30/1957

PROCESS FOR THE TREATMENT OF EDIBLE OR INGESTIBLE

SUBSTANCES AND THE PRODUCTS THEREOF


Applicant(s): WILLY RAU (--)

E Class: A23L1/00P4; A23L1/0522; A23L1/00P2; A23C9/16; A23P1/04



Family: GB766889

Abstract:


A granular or powdered ingestible substance, exemplified by dried milk, sugar, cocoa, or a granular or powdered pharmaceutical preparation, drug, analgesic, vitamin or hormone, and another ingestible substance which is compatible with the first, is soluble or swellable in aqueous liquids and is coating or binding agent are compounded without undue rise in temperature, to form grains in which cores of the first substance are embedded in the second substance. The coating substance, exemplified by sugar, a mixture of sugars, or starch, an edible vegetable gel, pectin, or gelatine with sufficient sugar to render it non-hygroscopic, may be added as a highly concentrated liquid, and may penetrate the cores as well as coating them. The core substance may be a mixture. Treatment of swellable or soluble core substances may comprise spraying of the core substance with the coating substance in liquid form, granulating and drying the sprayed product, spraying the dried granules with the coating substance in more concentrated liquid form, and again granulating and drying. Examples are concerned with (i) making a cocoa preparation which is readily dispersible in hot milk by spraying cocoa powder in a rotating drum with a hot, supersaturated solution of sugar while maintaining the cocoa at 33 DEG C., granulating the mixture, and drying the granules at not above 33 DEG C., (ii) making a milk preparation which may be stirred into warm or hot water to form a stable dispersion by spraying dried milk powder in a rotating drum with hot 75 per cent sugar solution while maintaining the powder at not above 50 DEG C., partially drying the product at 30-45 DEG C., pressing it through a sieve to produce 1 mm. granules, completing the drying, spraying these grains with 75 per cent sugar solution, drying, and sieving to separate dust from the coated grains, and (iii) making a blancmange preparation for stirring into hot milk or water by moistening a mixture of maize starch, swollen rice starch, sugar, and vanilla or fruit flavouring, and, if desired, dried whole or skimmed milk, in a rotating drum with a hot 80 per cent sugar solution, pressing the mass through a sieve to produce 1 mm. grains and drying completely at 30-

40 DEG C.Description:



Date of Application and filing Complete Specification: March 10, 1954.

766,889 No 6992154.

I l '( 7 1 t Application made in Netherlands on April 16, 1953.

Complete Specification Published: Jan 30, 1957.

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Index at acceptance:-Classes 49, B 1 (B:H:S); 81 ( 1), B( 3:4:6); -and 129, A 4.

International Classification:-A 23 g i,,A 61 k.


Process for the Treatment of Edible or ingestible Substances and the Products Thereof I, WILLY

RAU a German citizen, of Eulenstrasse 55, Hamburg-Altona, Germany, do hereby declare the invention for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the follow ing statement:-

Many edible substances such as dried milk, sugar, cocoa, starch and so forth.

which are commercially supplied ready mixed in powdered or granular form, and are used in the preparation of food and beverages, only keep for a short time, are sensitive to heat and acids, do not easily dissolve, and may also undesirably affect one another After dissolving or dispersing in liquids they often lead to coagulation or the formation of lumps.

Hitherto it has been sought to prolong the keeping time of these edible substances by various chemical additions and impregnations, or by physical action such as sterilisation or pasteurisation, or by the choice of packing or wrapping materials, and by the evacuation of air from the package.

Again, improved solubility or dispersion has been sought by finer grinding and by mechanical effects produced by the conditions under which the substances are mixed.

Orally taken pharmaceutical preparations such as medicinal substances, drugs, analgesics, vitamins and hormones are also often supplied in powdered or granular form and suffer from the same sort of disadvantages as edible substances such as short storage life, sensitivity to heat and moisture, and in the case of mixtures undesirable reactions with one another They may also have further disadvantages such as unpleasant or harmful effects on those parts of the digestive tract with which they come into contact before reaching the proper point for absorption into the system: as an instance some analgesics have an irritating effect on the lining of the stomach It is, of course, common to press such preparations into tablets and further to provide such tablets, in themselves complete, with a coating of sugar which helps to preserve the preparation itself and avoids the preparation being tasted when 50 it is taken But such coatings are quickly dissolved in the digestive tract, the possible size of the tablets is small, and the dose can only be in steps of a tablet.

The purpose of the present invention is 55 on one hand to minimise the above mentioned disadvantages of edible substances of powder or granular form and of pharmaceutical and the like preparations and, on the other hand, to achieve simplified preparation 60 of the substances for consumption as food or beverages or ingredients therein or as curative, remedial or the like agents A further purpose is to provide new substances by treatment of the raw materials For con 65 venience the substances with which the invention deals will hereinafter be referred to as ingestible substances.

According to the present invention, preparations having valuable properties are 70 obtained from an ingestible substance or substances of powder or granular form by combining therewith another ingestible substance which is compatible with the aforesaid ingestible substance, and which is soluble or 75 swellable in aqueous liquids and can serve as a coating or binding agent, by a treatment which combines the substances in such a way that small cores of the former substance or substances are embedded in the soluble 80 or swellable substance, or in other words the former substance or substances are coated with a substance which could or would be present in the food, beverage or pharmaceutical preparation when it is consumed or 85 which could or would be added thereto at the time, care being taken that the temperature of the cores is not unduly raised during the treatment and that the product is given or retains a granular structure 90 766,889 If the coating substance is suitably chosen the granular product has improved keeping qualities compared with the core substance or substances and the latter are rendered much less sensitive to warm air whether dried or moist while when the product is added to liquids, it dissolves or disperses in a fewx seconds without forming luimps By the invention each small aggregate or particle of 10the core substance or substances has an insulating, protecting and enclosing substance all round it which serves to maintain tilhe granularity of

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the product during storage without special precautions Thuls it becomes possible to mix several such products together without difficulty after prolonged storage In the case of pharmaceutical preparations, the enclosing substance ma) serve to delay the liberation of the core sub20stance or substances, until a desired part of the digestive tract is reached.

The soluble or swellable substance can according to the invention be added in concentrated liquid form to the substance to be treated for example sprayed on with constant stirring of the mass until it is moist when the grains of the substance to be treated will be coated with the liquid substance The moist mass is then formed into a granulate in such a way that each grain of the treated substance remains completely coated.

It is inmortant that the granulation should take place before the material has dried and n hardened In some cases the granulating operation may expose the core substance here and there In such cases it is desirable to treat the dried grains with steam just sufficient to moisten the surface as this causes the coating to spread over the exposed core substance and to leave the grains with a smooth unbroken coating.

According to a particular form of the invention a water soluble substance is caused to penetrate a swellable substance, and the two together serve as a coating material for an insoluble substance.

The core substance may itself be a mixture of substances, or a number of different o 50 substances may be separately treated and the resulting grains mixed and then treated afresh in a similar manner to produce larger coated multiple grains within which the several core substances are separated by the coating substance.

Various sugars of greater or smaller sweetness and mixtures thereof can be used as the soluble substance Gelatine edible vegetable gels, pectin, and starch can be used as swellable substances, but in view of their hygroscopic nature it is desirable that when they are used as coatings, sufficient sugar should be incorporated to render them substantially non-hygroscopic.

Cocoa is an example of an insoluble core substance to which the invention can be applied Sugar generally needs to be applied in the high concentration represented by a supersaturated hot solution e g a 70 to per cent solution at a temperature of 70 50: C to 00 C The core substance should be cool and should remain cool and the sugar solution must therefore be added sufficiently slowly to ensure that the temperature of the core substance does not rise too high The 75 permissible value depends on the substance.

and is for example up to about 33 ' C for cocoa, but may be up to about 50 in the case of dried milk or starch It will be understood that starch can serve in some 80 cases as a core material and in others as the coating material.

In practising the invention, the core substance will usually be insoluble or difficultly soluble, but the invention is not so limited 85 If the core substance is soluble or swellable care must be taken to carry out the operation of applying the coating material in highly concentrated liquid form, in such a way that the core material does not dissolve 90 to an extent which would bring it to the surface of the granules of the final product.

For example the process may be carried out in two stages in the first of which a small quantity

(calculated according to the nature 95 of the core substance) of the coating substance in somewhat less concentrated liquid form is spraaed on when it is absorbed by the core substance which in some cases will thus be caused to swell The water is 100 pairtially removed bv drying and the subs Kance is then granulated as described below.

In the second stage the grains are sprayed afresh with coati Lng substance in highly concentrated liquid form and again granulated 105 and dried in a similar manner to that employed with an insoluble substance.

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According to a further embodimnent of the invention, natural or synthetic flavouring substances can be added in liquid or powder 110 form to the substance to be coated so that they also become coated with the swellable or soluble substance and the flavouring is thus fully protected.

In one mode of granulating the moistened 115 mass, the mass is pressed through a sieve, the mesh of which determines the size of the grains The condition of the mass must be such that the grains remain separate i e, it must not be too wet, but in a condition 120 between tenacious-plastic and dry to the touch for example 2 per cent moisture content, and it must be made and maintained at not too high a temperature If the grains are then fully dried without heating they 125 become hard and can be stored without special precautions.

Another mode of procedure depends on the discovery that if the mass is of the above specified consistency, i e, between tenacious 130 766,889 plastic and dry to the touch, and if the temnperature is also as specified, it can be granulated without actually pressing it through a sieve, by a mechanical tearing and pressing action, when the mass itself breaks up into grains These can be sorted by sifting to separate those of the desired size, say i minm diameter, which are then dried without heating The larger and smaller grains can be returned to the apparatus in which the mechanical treatment is going on, after remoistening to the extent necessary to restore the consistency, i e, to replace moisture which has been lost.

The mechanical treatment can be carried out by the use of a device comprising a trough with which co-acts a rotary shaft carrying more or less sector shaped blades set inclined and spaced in interrupted helical formation, the blades also being perforated or apertured so that as the blades rotate some of the mass constantly falls back through the apertures or perforations oppositely to the axial movement occasioned by the helical arrangement of the blades, into the gaps between the blades resulting in a tearing or rubbing apart of tilhe plastic mass This action takes place continuously notwithstanding the gaps between the blades, so that the whole of the mass put into the trough is worked The mass is also moved axially by the action of the peripheral parts of the blades to which the anertures or perforations do not extend An outlet is provided in the bottom of the trough opposite that end of the blade system, so that when sufficient Granulation has taken place by rotating the shaft in the appropriate direction the grains can be displaced towards the outlet through which they are discharged Elsewhere the mass will be subject to the tearing and rubbing action, whichever the direction of the rotation of the shaft When under or oversize grains are returned to the trough the shaft should be rotated to carry them away from the outlet, and they are then spread between the blades and the wall of the trough into a thin homogeneous layer which builds up away from the outlet To enable this action to be controlled the spacing between the trough and the edges of the blades is made adjustable through a few millimetres, particularly at a position remote from the outlet The appropriate spacing depends on the tenacity of the mass and if too small, a pressing action occurs which heats the mass excessively and hinders the desired granulation It is also desirable that a grid should be arranged at the outlet to prevent large pieces of the mass which have escaped granulation from passing out The spacing between the edges of the blades and the grid may be adjustable separately from the spacing remote from the outlet; the closer the grid bars are together the greater can be the spacing between the blades of the grid, and vice versa

The above described spreading action takes place away from the outlet, hence separate adjustment of the spacing between the blades and trough is desirable 70 here.

It is also desirable that the end blades remote from the outlet should have only small apertures or none at all as this prevents the mass fromn getting through at this region 75 and improves the tearing and rubbing apart of the mass.

The shaft is preferably double ended, i e, the outlet is provided in the middle of the trough, and there are two blade systems of 80 opposite hand extending from the middle of the shaft towards its opposite ends The length of each blade system should be such that adequate reduction is obtained by the time the worked mass reaches the outlet The 85 precise proportions will depend on the tenacity and composition of the mass the speed and pitch of the blades and similar factors.

For the production of a dried milk product 90 with high keeping qualities, to dried milk powder is added e g is sprayed on a 70 to per cent sugar solution at a temperature of 70 to 90: C sufficiently slowly to avoid raising the temperature of the milk powder 95 above 50: C The mass while moist is pressed through a sieve and dried at a tenmperature of 30-50 C The milk particles are impregnated with

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sugar by this treatment and become hare grains By repeating the opera 100 tion with a further quantity of sugar solution the grains become completely coated with sugar in a hard, glazed form thus protecting the milk particles from access of atmospheric oxygen and moisture, while the coating itself 105 is substantially non-hygroscopic and not liable to bacterial attack.

A cocoa product which very rapidly dissolves or disperses can be prepared by spraying cocoa powder with a hot supersaturated 110 solution of sugar ( 70 to 80 per cent sugar at a temperature of 70 to 90 C according to the quiality of the cocoa) care being taken that the temperature of the cocoa itself does not become too high Preferably, this 115 temperature both during spraying and drying is held below 33 C: the whole then remains finely dispersible As the temperature of the cocoa during the treatment rises above 33 ' C, so the dispersibility of the cocoa 120 sugar granulate falls off.

It is desirable when aromatic substances are present, to work at as low a temperature as possible of the solid substances If, fo:example, a coffee ingredient is present, the 125 temperature should not rise above 28 = C In a further embodiment of the invention a dried milk product made on the above des cribed lines, after the first step of impregnation with sugar and formation of hard grains 130 766,8 9 can have cocoa powder mixed with it before the second operation the sugar solution added in the second operation then coating particles of the mixture so that each final grain consists of milk cocoa and sugar As well as cocoa powder edible starch can alsc be added to the first stage milk product Here again, it is desirable to work at a temperature not above 33: C.

By means of the invention ingestible sub.

stances can be preserved and preparations combining a number of substances can be produced thus a number of substances separately coated can be separately stored and mixed when they are to be used in any desired proportion and quantity: or the separately coated substances can be stored ready mixed without mutual reaction and the required quantity measured out for use.

In the case of pharmaceutical preparations this makes possible thile dispensing of doses of any desired size and in the case of separateiv stored substances the production of various mixtures at the time of use By suitable choice of the nature and proportion of the coating substance the rate at whichl the coating is dissolved in the digestive tract may be adapted to the title andi place at which absorption into thie systerm of the cone substances is to ta e place, and in the case o' mixtures different times and npla es for the several igr'dtents can be achieved In this way both losses and undesirable effects can be avoided It is also possible where the nature of the substances allows to produce combined preserved preparations in which several different substances are combined by the coating substance into multiple grains.

Thus the substances may be mixed before coating or the coating substance as well as coating the exterior of the grains may also separate the several core substances within the grains and such comkined preparations may be pharmaceutical preparations or they may be used for the preparation of foodstuffs or beverages.

The granular or powder form materials so prepared according to the invention can be subjected for example to pressure in a press whereby a product in the form of blocks or tablets is obtained, which can be of a size sav for a single portion of foodstuff or beverage or for a dose of any desired size of a pharmaceutical preparation Such pressing into blocks or tablets can be effected at any convenient time for example at the time of dispensing in the case of pharmaceutical preparations stored in the granulated form prepared according to the invention Such tablets can be given coatings of other substances including insoluble so-called pharmaceutical lacquers in the case o' pharmaceutical preparations or substances which delay absorption into the system.

Tile physical structure of some embodiments of the invention are diagrammatically illustrated by wax of example in the accompanying drawings.

Fig 1 shows a grain consisting of particles 1 of cocoa or other foodstuff embedded in or 70 coated with sugar 2.

Fig 2 shows a grain 3 of milk powder treated with sugar solution in the first step.

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the sugar solution having mainly penetrated into the interior of the grain as indicated 75 at 4.

Fig 3 shows the grain of Fig 2 in the finished form with a glazing or coating 3 of hard sugar.

Fig 4 shows a grain according to Fig 2 80 with which cocoa powder 6 has been admixed and the whole then given an outer coating 7 of sugar by a further treatment step.

Fig 5 shows a mixture of ingestible substances united by a soluble material into a 85 grain.

Fi- 6 shows an agglomeration of:

plurality of grains according to Figs 1 3 4 and 5.

For the treatment according to the inven 90 tion any substance can be used as the embedding or coating substance which has the necessary characteristics is acceptable in flavour and which is to or can be used to supplement the treated ingestible substance 95 as for example sugar or a mixture of various sugars or gelatine starch or the like with an admixture of sutfficient sugar to make it substantially non-hvygroscopic Gelatine.

starch or the like may on the other hand be 100 the treated substance or an ingredient of a treated mixture of substances, as will be exemplified hereinafter.

A main field of use for the new process is the treatment of raw edible substances which 105 easily go bad as for instance dried milk.

particularly dried whole milk which on account of the sensitivity of the easily attacked fat components can only be stored for a short time and substances of strongly 110 hygroscopic character such as gelatine and edible starch It has been found with materials such ns dried whole milk treated according to the invention in which a sugar solution has first mainly penetrated the in 115 terior of the particles the particles then being completely coated with sugar that the sugar within and around the grains forms a protective layer which keeps out atmospheric oxygen and bacteria and also prevents the 120 grothl of germs It has further been found that in contradistinction to untreated dried whole milk dried whole milk powder treated in the new way is practically non-hygroscopic even after long storage in the tropics that is 125 in moist warm air, it is not damaged and does not,o bad.

Apart from the conserving action described the firm embedding or coating of the substance achieves a further effect namely, that 130 766,889 in the case of such substances as dried milk or cocoa, owing to the separation of the individual particles of the coated substance by the coating substance the coated substance is dissolved or finely dispersed on stirring the granulate into a boiling liquid such as water, without agglomerating or forming lumps, because during the course of the gradual dissolution of the coating substance a uniform distribution of the embedded material or mixture takes place Formerly this was only possible if the substance was first very carefully and thoroughly stirred in cold water.

It should further be mentioned that by isolating different substances, which can be effected by coating the individual particles of each, undesirable action on one another of the substances can be avoided

This is 20the case, for instance, if acid and alkaline substances are to be stored together before they are dissolved An example is baking powder in which case the particles of the alkaline ingredient may be coated with sugar in accordance with the invention Many pharmaceutical preparations can be dealt with similarly.

The following examples will further elucidate the invention.

Example 1.

This example will illustrate the preparation according to the invention of a rapidly soluble cocoa granulate.

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16 kg of cocoa powder are shaken through a sieve having 525 meshes per square cm to remove any lumps The cocoa powder is then put into a rotating drum Separately 24 kg of sugar is dissolved in a boiler in 6 or 7 litres of water at a temperature of 80 ' to go 9 C, and the hot supersaturated sugar solution is broken up under pressure of three atmospheres into a fine mist within the rotating drum on to the cocoa powder so that the latter is uniformly moistened by the solution The sugar solution is added sufficiently slowly to ensure that the temperature of the cocoa powder is maintained in the neighbourhood of 33 C Desirably, the drum is provided with a stirrer in order to obtain uniform distribution and moistening of the cocoa powder Although the moisture introduced by the sugar solution amounts to only about 17 per cent or the like, the moist mass forms lumps of the size of a potato The lumps are then carefully pressed through a sieve to produce grains of about 1 mm diameter which are then dried at a temperature of about 33 C down to a moisture content of 2 per cent or less

Alternatively to granulating through a sieve, the above described mechanical tearing and pressure of the lumps can be employed In either case the dried granulate is sieved to separate the grains from particles of smaller (or larger) sizes which can be used again for preparing fresh granulate in a rotating drum to which in this case only water at 70 to 900 C is sprayed as the granulate already contains the necessary sugar The grains of desired size produced retained in the final sieving con 70 sist of particles of cocoa completely embedded in hard sugar as in Fig 1 If desired the grains may be slightly steamed to improve the hard sugar coating In consequence of the production of the mass and the careful 75 drying, both at low temperature, the granulate has the property of dissolving or dispersing in a few seconds; if stirred into hot milk little or no skin is formed If the mass is made or the granulate dried at a higher 80 temperature ability to dissolve quickly is lost and a product difficult to dissolve is obtained.

Example 2.

16 kg of milk powder are shaken through a sieve having 525 meshes per square cm to 85 remove any lumps The milk powder is then charged into a rotating drum Separately 12 kg of sugar is dissolved in 3 litres of water at a temperature of 800 to 90 ' C in a pressure vessel, and the hot supersaturated 90 sugar solution under a pressure of about 3 atmospheres is sprayed as a fine mist over the milk powder within the rotating drum so that the powder is uniformly penetrated, the speed of addition of the solution being such 95 that the temperature of the powder does not exceed 50 C Advantageously, the drum is provided with a stirrer to ensure uniform distribution and penetration of the sugar solution in the milk powder The material is 100 now uniformly partially dried at a temperature of 30 to 45 C and reduced by pressing it through a sieve so that a granulate with a grain size of about 1 mm diameter is obtained which is then hardened by 105 completion of the drying.

By this treatment as Fig 2 shows, the sugar solution has substantially wholly penetrated into the grains of milk powder The above procedure is now repeated with a 110 further hot supersaturated sugar solution again consisting of 12 kg of sugar dissolved in 3 litres of water, and after sieving and drying the material is then sieved with a fine mesh sieve to free it from milk-sugar dust 115 which can be used in a further operation.

By this second stage grains in accordance with Fig 3 have been produced in which the grains of milk powder have in the first stage been penetrated by sugar and in the second 120 stage completely coated with a glazing of sugar The granulate so obtained is easily dissolved or dispersed in warm water at a temperature of 30 to 100 C so that a sterile milk emulsion can be prepared without 125 coagulation or destruction of the emulsion taking place The emulsion is very finely dispersed and even on long standing practically no separation occurs The granular milk product according to the present 130

766,889 invention is practically not hygroscopic and does not becomne rancid on lona storage, so that its keeping qualities are very high because the fatty acids cannot oxidise This preparation is useful, for example for the same purposes for which sweetened condensed milk in tins has hitherto been used.

Example 3.

For the production of a blancmange or similar powder 20 kg of maize starch, 10 kg.

of swollen rice starch, and 20 kg of sugar are taken, together with such flavouring substances as may be desired The maize and rice starches, to which colouring and fiavourings such as vanilla, vanilla flavoured sugar and fruit flavourings can be added, are sieved and charged into a rot atino drum, mixed thierein and sprayed with a solution of ka sugar in 4 to 5 litres of water at 80to 90: C in such a way that

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the material is uniformly mnoistened The mass is then uniformlv reduced ly pressing it through a sieve to produce grains of about I min.

diameter hich are hardened by fully drying.

he dry ing is elffected at a temperature of 30 to 40 C, the granulate so obtained is agair.

sieved with a fine meshed sieve to remove the dust w-hichl can, for example, be used in a furtlher process for mnaking the same product By this treatment as shown in Fig 3 grains are produced each Iof which consists of a mixture of the original grains embedded ant coated with hard sugar A simiiar

_ranulat% can be prepared also incorporating dried whole milk or skimmed milk The flavourine materials added are so sealed by this treatment that they remain fully effective.

The new powder can be shaken without any particular precautions into boiling hot milk or if the

Granulate incorporates dried milk powder into hot water, and, after stirring, a short cooking and cooling yields a homogeneous lump-free blancmange because the individual grains of starch treated by the process have been completely separated from one another by the sugar coating and can no longer stick together when the granulate is put into water or milk The essential thing is that when the granulate is put into the liquid the sugar coating maintains the separation of the starch particles until the distribution in the liquid is complete.Data supplied from the esp@cenet database - Worldwide

Claims:


What I claim is:-

1 A process for treating an ingestible sub stance of powder or granular form which consists in combining therewith another ingestible substance which is compatible with the aforesaid ingestible substance and is soluble or swellable in aqueous liquids and can serve as a coating or binding agent in such a way, that small cores of the former substance are embedded in the soluble or swellable substance without their temperature being unduly raised the product consisting of grains of the former substance coated with the latter substance.

2 A process according to Claim I in which the coating substance is added as a highly concentrated liquid.

3 A process according to Claim I or 2 in 70 which a water soluble substance is caused to penetrate a swellable substance, and the two together serve as a coating material for ai insoluble substance.

4 A process according to Claim I or 2 in 75 which the soluble or swellable substance penetrates the core substance as well as coating it.

A process according to Claim I or 2 as applied to swellable or soluble core substance 80 in which the process is effected in two steps in the first of which a small quantity of the coating substance in a somewhat less concentrated liquid form is sprayed on and the mass is granulated and dried while in the

85 second stage grains produced in the first stage are sprayed afresh with coating substance in highly concentrated liquid form and again Granulated and dried.

6 A process according to Claim 1 or 2 in 90 which the first mentioned substance is a mixture.

7 A process according to Claim 6 in which the mixture is a mixture of soluble and insoluble substances 95 S A process according to any preceding Claim in which a number of substances are separately treated the grains are mixed, and the mixed grains are treated in a similar manner to produce larger coated multiple 100 grains within which the several substances are separated from one another by the coating substance.

o A process according to any preceding Claim in which flavouring substances in the 105 form of powder or liquid are added to the first mentioned substance so as to be coated therewith by the soluble or swellable substances.

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A process according to any preceding 110 Claim in which the coating substance consists of sugar or a mixture of sugars, or of starch, edible vegetable gel pectin, or gelatine with a sufficient proportion of sugar incorporated to render it substantially non-hygroscopic 115 I 1 A process according to any preceding Claim in which the coating substance is added to the first mentioned substance in the form of a solution, preferably hot and supersaturated, being sprayed on, and th granular 120 form being maintained or subsequently re-constituted.

12 A process according to Claim 11 in which the solution is added to produce a mass at a relatively low temperature having a 125 character between tenacious-plastic and dry to the touch the mass is then pressed through a sieve to granulate it and the granules are dried without heating.

13 A process according to Claim 11 in 130 766,889 which the solution is added to produce a mass at a relatively low temperature having a character between tenacious-plastic and dry to the touch, the mass is then subjected to a mechanical tearing and pressing action whereby it breaks up into grains, and the grains of desired size are sorted out by sifting and then dried without heating.

14 A process according to Claim 13 in which the mechanical treatment is effected by a device comprising a trough, with which co-acts a rotary shaft carrying more or less sector shaped blades set inclined and spaced in interrupted helical formation, the trough having an outlet at one end of the helical formation.

A process according to Claim 17 in which the blade remote from the outlet is unperforated or has only small perforations.

16 A process according to Claim 14 or 15 in which the spacing between the periphery of the blades and the trough is adjustable in the region of the outlet.

17 A process according to Claim 14, 15 or 16 in which the spacing between the periphery of the blades remote from the outlet and the trough is adjustable.

18 A process according to any of Claims 14 to 17 in which a grid is provided in the outlet to prevent the passage of large pieces of the mass.

19 A process according to any of Claims 14 to 18 in which the shaft is double ended there being an outlet in the middle of the trough and two blade systems of opposite hand extending from the middle of the shaft towards its opposite ends.

A process according to any preceding Claim in which the first mentioned substance is dried milk powder and the coating sub 40 stance is sugar sprayed on as a 70 to 80 per cent solution at a temperature of 70 to 900 C the process being carried out in two stages, in the first of which grains penetrated by sugar are obtained, and in the second 45 of which these grains are coated with sugar in a hard glazed form, the spraying being carried out in both stages at such a speed that the temperature of the powder or grains does not exceed 500 C, and the drying 50 in both stages being carried out at 300 to ' C.

21 A process according to any of Claims 1 to 19 in which the first-mentioned substance is cocoa powder which is held at a tempera 55 ture of about 33 C, while the coating substance is applied by spraying a hot supersaturated solution of sugar, the mass then being granulated and dried at a temperature not above about 330 C 60 22 The process substantially as set forth in any of the specific examples given herein.

23 A process according to any of Claims 1 to 19 in which the first-mentioned substance is a pharmaceutical preparation 65 24 A process according to any preceding Claim in which the grains are afterxvards pressed into tablets or blocks.

A granular preparation of ingestible substances when made by the process 70 claimed in any preceding claim.

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Agents for the Applicants, SEFTON-JONES, O'DELL & STEPHENS, Chartered Patent Agents, 15,

Great James Street, London, W C I.

Printed for Her Majesty's Stationery Office by Wickes & Andrews, Ltd E C 4 684 t 2 -1957.

Published at The Patent Office, 25, Southampton Buildings London W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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167.

GB771378 - 4/3/1957

IMPROVEMENTS IN THE PREPARATION OF QUICK-COOKING CEREAL

PRODUCTS



E Class: A23L1/182



Family: GB771378

Abstract:


In preparing a quick-cooking cereal, e.g. rice or barley, the cereal is substantially gelatinized and rinsed with water. The resulting substantially discrete grains are compressed, e.g. between rolls, and dried, e.g. in a current of air at 79 DEG C. until they have a moisture content between 3 and 14 per cent. The cereal, preferably washed, may be soaked in water at a temperature below the gelatinization point, e.g. room temperature, until it has absorbed all or nearly all the water required for uniform gelatinization, which may then be brought about by heating the soaked cereal, e.g. in steam at super-atmospheric pressure. The gelatinized grains may be allowed to take up more water during rinsing or they may be soaked in water between rinsing and compressing. The grains may be compressed within 90 minutes of rinsing and may be washed between compressing and drying. The cereal may be treated with an antioxidant, preferably citric acid, which may be added to the soaking or wash water.ALSO:Quickcooking rice or barley, e.g. treated with citric acid (see Group I) is used in dry soup mixtures and puddings.Description:



77 19378 ax Date of Application and filing Complete Specification Sept 22, 1954.

No 27428/54.

iii B y{ 1 Application made in United States of America on Sept 30, 1953.

____ X S Complete Specification Published April 3, 1957.

Index at acceptance -Classes 49, Bl B; and 58, A 3 B, AH( 3: 4 C: 6 B 2: 6 D).

International Classification -A 231 B 02 b.


Improvements in the preparation of Quick-Cooking Cereal Products We, UNILEVER LIMITED, a company registered under the laws of Great Britain, of Port Sunlight, in the County of Chester,

England, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

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This invention relates to the preparation of edible quick-cooking cereal products such as rice or barley.

Raw polished grains of rice usually require at least twenty minutes' boiling in water or soup to be rendered tender and palatable The cooking time for barley, such as raw pearl barley, is generally considerably longer.

It is an object of the present invention to provide a process of preparing a quick-cooking edible cereal product such as rice or barley whose preparation for consumption in a form similar to that resulting from cooking the raw grains takes considerably less time than said cooking.

It is a further object of the invention to provide such quick-cooking cereal products which may be dried to a sufficiently low moisture content to be suitable for inclusion in dry packaged mixes such as soup mixes without affecting the storage properties of the mix and which dried products are capable of being cooked to palatibility without undue disintegration by the methods and in the time normally recommended for the preparation of soups from dry soup mixes.

The present invention provides a process of preparing a quick-cooking cereal product, such as rice or barley, which process comprises the steps of converting the cereal into a substantially gelatinized form, rinsing the gelatinized cereal with water, subjecting the substantially discrete grains so obtained to compression and then drying the grains to a desired moisture content.

For the sake of simplicity, the following description of the invention is given with reference to one particular cereal product, namely rice.

It is important that the substantially discrete grains to be compressed are sufficiently resilient to allow the grains to spring back 50 towards their pre-compression shape when the application ox a suitable compressive force ceases Generally the grains do not return entirely to their pre-compression shape

They spring back to a thickness which is greater, 55 usually several times greater, than that to which they are reduced at the height of compression, to give somewhat wider, thinner and longer grains than the pre-compression grains.

With the object of obtaining sufficiently 60 resilient grains, the gelatinization step may conveniently be effected by first soaking the preferably previously washed grains in water below the gelatinization temperature so as to allow them to imbibe all or nearly all the 65 moisture required for uniform gelatinzation and then completing the conversion to the gelatinized form by the application of heat.

A soaking time of 30-60 minutes in water at room temperature is usually adequate 70 although longer times, even soaking overnight, are not generally deleterious This is because the amount of moisture imbibed by the grains during soaking does not increase greatly with time after an initial period, usually between 75 and 30 minutes, of fairly rapid moisture uptake For instance, a long grain rice known as "

Patna " has been found to have a moisture content of about 28 % after an initial wash, followed by 15 minutes' soaking With con 80 tinued soaking the moisture content rises only slowly and tends to level off at 31-32 % after the first hour's soaking Somewhat higher figures may be obtained with other varieties of rice Thus with rice known as " Zenith " (the 85 word " Zenith" being a Registered Trade

Mark) the levelling off occurs at about 35 %.

It is preferable to rinse the soaked rice to wash away any loose surface starch which may tend to cause undue caking during the subse 90 quent heating step.

The heating may be carried out conveniently in an autoclave by steam at super-atmospheric pressure, which steam should be relatively dry 771,378 to guard against obtaining a rice which lacks sufficient elasticity to spring back after the compressive treatment which is to follow Care should be taken, however, not to allow steam condensate to cause the formation of local areas of over-soaked mushy rice grains unsuitable for the subsequent compressive treatment The time of heating depends on the load in the autoclave and on the thickness of the rice layers An increase in the steam pressure may reduce the time required for substantially complete gelatinization but the use of high pressure may tend to cause a darkening of the grains.

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Substantial completeness of gelatinization has been obtained when the grains acquire a rubbery character throughout and the white centres within the grains disappear Using steam at 1100 gramsjcm pressure for 30 minutes on layers of 4 5 cms depth has given satisfactory results but as little as 15 minutes' heating has been successfully used in conjunction with thinner layers.

The cake of gelatinized grains so obtained is discharged into the rinse water, preferably running water

Agitation during rinsing is very advisable to assist in breaking up the cake into substantially discrete grains Rinsing also has the important and desirable effect ot raising the moisture content of the grains It has been found that the grains to be compressed should preferably have a moisture content of at least

40 % although rice containing no more than 35 % moisture has been successfully processed under certain conditions Usually the moisture content of the rice can be raised to at least 40 % by one or two minutes' rinsing.

Rice so treated and then compressed and dried is very suitable for incorporation in packaged dry mixes, for instance soup mixes For other table uses a fluffier, less firm rice, when prepared for consumption, is often preferred.

This may be achieved by raising the moisture content of the rice grains still further before compression by allowing them to soak in water at ordinary or elevated temperatures, if desired for a considerable time For instance, the moisture content of Patna rice was raised to about 43 % after 1-2 minutes' rinsing whilst a moisture content of about 55-60 % was obtained by allowing the same rice to soak for 30-60 minutes With another variety of rice, "Zenith", the same soaking period resulted in an even higher moisture content of 60-65 % The moisture content of rice is not usually raised beyond 65

% before compression.

The compressive treatment to which the rinsed or rinsed and soaked grains are subjected is preferably such as to flatten the grains only momentarily The applied pressure should be sufficient to compact the grains but should not be so great as to produce flake formation The elasticity and resilience of the grains should not be destroyed so that the grains will spring back towards their pre-compression shape when the pressure is released.

Passing the grains between a pair of opposed spaced rolls with smooth surfaces and rotating at the same speed to prevent flaking action is a suitable method of carrying out the com 70 pressive treatment

The spacing between the rolls is usually of the order of one-quarter to one-third of the thickness of tfie grain to be compressed Gradual application of pressure permits greater compression without undesir 75 able effects and the use of large diameter rolls is preferred because the nipping of the grains becomes more gradual as the diameter of the rolls increases The spacing of the rolls is usually in the range from

0 25 to 0 75 mm, 80 depending on the kind of rice being processed.

It should be noted that the spacing of the rolls for barley is usually of the order of oneeighth of the thickness of the grain to be compressed 85 There need be no interval between the rinsing or rinsing and soaking treatment and the compression step The very desirable lubricating action of the surface moisture acquired during the rinsing or rinsing and 90 soaking treatment may be lost by evaporation or absorption if the time interval between removing the grains from the water and compressing them is too long The lubricating action is valuable in promoting a free flow of 95 discrete grains from a hopper to the rolls without undue clumping or bridging Lack of lubricity may also tend to cause a slight abrasion of the grains as they pass between the rolls As a rule it is, therefore, not advisable 100 to let more than 90 minutes elapse between removing the grains from the water and compressing them and it is preferred to compress within 30 minutes, in the case of high-moisture rice 15 minutes 105 The amount of compression, usually the roller spacing in relation to the type of grain being processed, may be used to control the reconstitution properties of the dry product and the tenderness of the rice when prepared 110 for consumption The greater the compression within the limit of allowing subsequent spring back, the quicker the rice may be prepared for consumption and the more tender the rice so prepared 115 It has been found very advisable to wash the grains after the compression step to promote easy separation of the grains after subsequent drying Presumably, the juices pressed to the surface of the grains tend to 120 cause the grains to agglomerate during drying unless the precaution of washing the grains prior to drying is taken.

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The grains may be dried in any convenient manner, although it has been found that the 125 use of high temperatures for prolonged periods may lead to a darkening of the product The moisture content of the rice is usually reduced to no more than 14 w Rice intended for dry soup mixes is preferably dried to between 3 130 771,378 and 5 % moisture whilst rice destined for other table uses is generally dried to a moisture content of 5-14 %.

The grains of dried rice so obtained are S somewhat longer and thinner than the grains of the original raw rice but do not approach a flaked condition The grains exhibit thin, parallel white lines transverse to their major axis Most of these lines may be seen under the microscope to present small " bubble-like

" voids The grains are less friable than other commercially available quick-cooking rice grains Upon preparation for consumption, such as by adding them to water, bringing the mixture to the boil quickly, removing the vessel from the flame and allowing the contents to stand in the covered vessel for 10 minutes, the product swells to substantially separate and' whole grains similar to, though somewhat longer and thinner than, those obtained by preparing the corresponding raw rice for consumption The grains do not disintegrate to any great extent on prolonged cooking or even reboiling.

The process is flexible in that the properties of the rice prepared for consumption can be controlled simply by adjusting the amount of rinsing and, if desired, soaking between gelatinization and compression This rinsing or rinsing and soaking also makes it possible to obtain high yields of a substantially uniform product.

To inhibit fermentive spoilage of the dry product and development of rancidity on storage, it has been found advisable to treat the rice with an anti-oxidant during the process of the invention Citric acid is the preferred anti-oxidant The anti-oxidant may, for instance, be added to the water in which the rice is soaked in preparation for gelatinization or to the wash water with which the grains, having undergone compression, are washed prior to drying Concentrations as low as 0 02 % of citric acid in the soaking or washing liquid have been found effective.

Any particular cereal product may require variations in the conditions of the various process steps For instance, barley requires longer soaking and heating treatment in the gelaSO tinization step than rice and, as mentioned previously, requires a relatively smaller aperture between the compression rolls

Usually barley is soaked for at least 12-3 hours, depending on the particular barley used.

The invention will now be illustrated by means of the following examples.

EXAMPLE 1

Milled polished long grain rice of the variety known as " Patna " was first washed and then soaked for an hour in water at room temperature The rice was then rinsed in fresh water.

The rinsed rice was then heated for 30 minutes in an autoclave with dry steam at about 1100 grams/cm 2 pressure The depth of the rice layer in the autoclave was about 4 5 cm After 65 this pressure cooking, the rice was substantially completely gelatinized The cake obtained was discharged into water at room temperature in which it was rinsed with agitation for 2 minutes The substantially discrete grains so 70 obtained were transported without delay to a hopper above a pair of opposed spaced rolls rotating so as to draw the grains between the rolls Both rolls were smooth, had a diameter of 29 cm, a length of about 30 cm and rotated 75 at 40 revolutions/minute The aperture between the rolls was about 0 45 mm The rice was passed through the rolls at the rate of about 240 kg /hour The compressed rice was then dried in a cabinet drier, the rice being 80 dispersed in trays at a density of 0

40-0 54 grams of rice solids per cm 2, with air at a temperature of 790 C flowing horizontally over the trays at 153 metres/minute A drying time of between 3 and 3 hours was 85 satisfactory.

EXAMPLE 2

Raw pearled barley of the variety known commercially as Acme 110 and containing 9.2 % moisture was soaked overnight in a 90 % by weight solution of citric acid in water The soaked barley having a moisture content of 42 5 % was rinsed in fresh water to remove surface material and loosened bran particles It was then heated for 45 minutes 95 in the manner described in Example 1 The barley so obtained had a moisture content of 44.5 %, was rubbery and had a uniformly translucent character This

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barley was discharged into water and agitated slightly so as lo 1 to separate into individual grains The grains obtained had a moisture content of about 53 %.

These were then subjected to mechanical compression as described for rice in Example 1, except that the spacing between the rolls was 105 0.35 mm if the barley was intended for puddings or 0 38 mm if required for dry soup mixes The grains entering the rolls set 0.35 mm apart had a thickness of 2 9 mm and after compression sprang back to a thickness of 110 2.5 mm The barley was then rinsed, during which step its moisture content rose to about -55 % and was then dried to a moisture content of 10 % by the procedure of Example 1 The dried barley grains had large central voids 115 mostly open through at least one thin wall.

Most of the grains had crevices extending into and through the thicker walls.Data supplied from the esp@cenet database - Worldwide Claims:


What we claim is: -

I A process of preparing a quick-cooking 120 cereal product, such as rice or barley, which process comprises the steps of converting the cereal into a substantially gelatinized form, rinsing the gelatinized cereal with water, subjecting the substantially discrete grains so 125 obtained to compression and then drying the grains to a desired moisture content.

2 A process according to Claim 1 in which the conversion of the cereal to a substantially 771,378 gelatinized form is effected by soaking the cereal in water below gelatinization temperature until it has imbibed all or nearly all the moisture required for uniform gelatinization and then heating the cereal with steam at super-atmospheric pressure.

3 A process according to Claims 1 or 2 in which the rinsing of the gelatinized cereal is followed by or extended to soaking before the substantially discrete grains are compressed.

4 A process according to any one of the preceding claims in which the grains are compressed within

90 minutes of being removed from the rinse or soak water.

5 A process according to any one of the preceding claims in which the grains are compressed by being passed between a pair of rolls.

6 A process according to any one of the preceding claims in which the grains are 20 washed between compression and drying.

7 A process according to any one of the preceding claims in which the grains are dried to a moisture content between 3 and 14 %.

8 A process according to any one of the 25 preceding claims in which the cereal is treated with an anti-oxidant.

9 A process of preparing a quick-cooking cereal product such as rice or barley substantially as hereinbefore described 30 A quick-cooking cereal product when prepared by any of the processes claimed in Claims I to 9.

For and on behalf of:UNILEVER LIMITED, R Jonas, Agent for the Applicants.

Published at the Patent Office, 25, Southam Stationery Office, by the Courier Press -1957.

Leamington Spa: Printed for Her Majesty's pton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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168.

GB774549 - 5/8/1957

IMPROVEMENTS IN OR RELATING TO THE PRODUCTION OF

DISPERSIONS IN STARCH


Applicant(s): CORN PROD REFINING CO (--)

E Class: A23L1/302; C08B30/20



Family: GB774549

Abstract:


In making a cold water paint which will reconstitute with water, an aqueous slurry of a starchy substance capable of forming a solution of mono-dispersed molecules is cooked at above the normal gelatinization temperature with mechanical agitation to produce a clear solution of monodispersed molecules, the pigment is dispersed in this solution, and the dispersion is dried to particles, flakes or films in which the starchy substance constitutes a protective colloid for the pigment particles, and is clear, coherent and non-gummy. The starchy substances exemplified by roasted dextrins of 80 per cent or more solubility in water, thin-boiling hypochlorite- or peroxide-oxidized starches, hydroxyethyl, hydroxypropyl, methyl and ethyl derivatives of starch of a low degree of esterification and rendered thin-boiling by acid modification or oxidation, mixed carboxylic and sulphonic esters of starch and slightly acetylated starches of thin-boiling nature, waxy maize and waxy sorghum starches rendered thin-boiling by hydrolysis or oxidation, and acid or enzyme hydrolysed starches of dextrose equivalent

4-20, of high solubility in cold water, and giving only red to plum colouration with iodine. A substance which renders the dried starchy substances less friable and enhances its protective character, e.g. calcium chloride, glycerol, glycol, urea, dicyandiamide, ammonium thiocyanate, formamide, a glucose or maltose syrup, may be added, preferably to the cooked solution. A substance which assists dispersion of the pigment in the solution may be incorporated. U.S.A. Specifications 2,170,954 and

2,641,547 are referred to.ALSO:In imbedding a feed supplementary material, e.g. a vitamin A or b carotene preparation, in a dry starchy matrix for protection against evaporation, bleaching, oxidation or rancidification, an aqueous slurry of a starchy substance capable of forming a solution of monodispersed molecules is cooked above the normal gelatinization temperature with mechanical agitation to produce a clear solution of mono-dispersed molecules, the material to be protected is dispersed in this solution, and the dispersion is dried to particles, flakes or films in which the starchy substance constitutes a protective colloid for the dispersed material, and is clear, coherent and non-gummy. The starchy substances may be derived from maize, tapioca, wheat, rice, sorghum, sago, potato and arrowroot, and are exemplified by roasted dextrins of 80 per cent or more water solubility, thin-boiling hypochlorite- or peroxide-oxidized starches, hydroxyethyl, hydroxypropyl, methyl and ethyl starches of a low degree of esterification rendered thin-boiling by acid modification or oxidation, slightly acetylated starches and mixed carboxylic and sulphonic starch esters of thin-boiling nature, waxy maize and waxy sorghum starches, rendered thin-boiling by hydrolysis or oxidation, and enzyme or acid hydrolyzed starches of dextrose equivalent of 4-20, of high solubility in water and giving only red to plum colouration with iodine. A substance which renders the dried starchy substance less friable and enhances its protective character, e.g. calcium chloride, a glucose syrup such as corn syrup, a maltose syrup, glycerol, glycol, urea, dicyandiamide, ammonium thiocyanate or formamide, may be added, preferably to the cooked solution. A substance which assists dispersion of the feed material may be added. Examples are concerned with making poultry feed supplements by plate drying and spray drying dispersions of xanthophyll oil from maize in prepared solutions of the starchy substances and

775/2197

corn syrup. U.S.A. Specifications 2,170,954 and 2,641,547 are referred to.ALSO:In preparing particles, flakes and films of materials imbedded in a dry starch matrix, there is employed an aqueous slurry of a starchy substance capable of forming a solution of mono-dispersed molecules, the slurry being cooked above the normal gelatinization temperature with mechanical agitation to produce a clear solution of mono-dispersed molecules, the material to be imbedded being dispersed in this solution, and the dispersion being dried to a product in which the starchy substance constitutes a protective colloid for the dispersed material and is clear, coherent and non-gummy. The starchy substances may be derived from maize, tapioca, wheat, rice, sorghum, sago and arrowroot, and are exemplified by roasted dextrins of 80 per cent or more water solubility, thin-boiling hypochlorite- or peroxide-oxidized starches, hydroxyethyl, hydroxypropyl, methyl and ethyl starches of a low degree of esterification rendered thinboiling by acid modification or oxidation, slightly acetylated starches and mixed carboxylic and sulphonic starch esters of thin-boiling nature, waxy maize and waxy sorghum starches rendered thinboiling by hydrolysis or oxidation, and acid or enzyme hydrolyzed starches of dextrose equivalent 4-

20, of high solubility in water and giving only red to plum colouration with iodine. A substance which renders the dried starchy substance less friable and enhances its protective character, e.g. a glucose syrup such as corn syrup, a maltose syrup, glycerol, glycol, calcium chloride, urea, dicyandiamide, ammonium thiocyanate or formamide, may be added, preferably to the cooked solution. A substance which assists dispersion of the material may be incorporated. U.S.A. Specifications 2,170,954 and

2,641,547 are referred to.ALSO:In embedding materials in a dry starchy matrix, e.g., in diluting medicines, preparing plant-coating insecticides and in protecting dry spices, spice oils, diet supplements, vitamin preparations and fatty substances against deterioration by evaporation, bleaching, oxidation and rancidification, an aqueous slurry of a starchy substance capable of forming a solution of mono-dispersed molecules is cooked above the normal gelatinization temperature with mechanical agitation to produce a clear solution of mono-dispersed molecules, the material to be imbedded is dispersed in this solution, and the dispersion is dried to particles, flakes or films in which the starchy substance constitutes a protective colloid for the dispersed material, and is clear, coherent and nongummy. The starchy substances may be derived from maize, tapioca, wheat rice, sorghum, sago, potato and arrowroot, and are exemplified by roasted dextrins of 80 per cent or more water solubility, thinboiling hypochlorite-or peroxide-oxidized starches, hydroxyethyl, hydroxypropyl, methyl and ethyl starches of a low degree of esterification rendered thin-boiling by acid modification or oxidation, slightly acetylated starches and mixed carboxylic and sulphonic starch esters of thin-boiling nature, waxy maize and waxy sorghum starches rendered thin-boiling by hydrolysis or oxidation, and acid or enzyme hydrolysed starches of dextrose equivalent 4-20, of high solubility in water and giving only red to plum colouration with iodine. A substance which renders the dried starchy substance less friable and enhances its protective character, e.g. a glucose syrup such as corn syrup, a maltose syrup, glycerol, glycol, calcium chloride, urea, dicyandiamide, ammonium thiocyanate or formamide, may be added, preferably to the cooked solution. A substance which assists dispersion of the material may be added.

Examples are concerned with (i) making vitamin A-containing flakes by plate drying a dispersion of an oil solution of vitamin A palmitate in a prepared solution of the starchy substance and corn syrup, (ii) making odourless flakes of rodent repellant by plate drying a dispersion of powdered crystals of aniline-trinitrobenzene in a prepared solution of the starchy substance and corn syrup, and (iii) making a free-flowing, non-greasy shortening preparation by plate drying an emulsion of melted vegetable shortening in a prepared solution of the starchy substance and corn syrup. U.S.A. Specifications

2,170,954 and 2,641,547 are referred to.Description:



Improvementsin orrelating to the Production of Dispersions in

Starch

We, CORN PRODUCTS REFINING COMPANY, acorporation organized underthe laws of the

State of New Jersey,United States of America, of 201 North Wells Street, Chicago 6, Illinois,

United States of America, do hereby declare theinvention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:

This inventionrelates to a method of dispersing various materials, and morepaacu- larlywaterinsoluble materials, in solutions of specific starches or derivatives thereof, and then drying theresaltant dispersions in order to produce dry products in wiiich the dispersed phase is imbedded in a starchy matrix and is protected from air oxidaton, chemical changes and evaporation.

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There is frequent need to protect liquid and solid substances, for example, to avoid toxic contact with the skin, or to prevent deterioration such as may be caused byair oxidation orevaporaticn. As one instance of such changes, it is not generally practicable to supplement poultry feeds by spraying the latter withbeta-car@tene concentrates, since the useful carotene pigment is rapidlybleached cut bysubs quest exposure to air and to light.Simi- larly, themanufacturers of packaged desserts have found it necessary toenrjcse flavoring oils in a gelatine capsule to prevent less of flavor or development of off-flavors.Another

instance is the protection of vitamin A by elaborate processes of coating the vitamin with

anaii-imermeable film. One of the mlore common methods now in use emulsifies the vitamin A

(either as an oil concentrate or as the melted acetate) in a warm solution ofgala tine. This emulsion is in turn emulsified in a vegetable oil to give a polyphase dispersion, which is then allowed to cool below the gelling point of the gelatine. The spherical globules of the latter are then separatedfawn the oil phase and dehydrated with alcohol, to give dry particles of gelatine containingembedded spherules of thevitamin.

A multitude of other instances may be cited, and for many of these, it is not economically feasible to resort to such complex processing, as described above for vitamin A. There is need for a simple and inexpensive means of protecting such materials as insecticides, dry spices ard spice oils,medicinals and diet supplements, fatty substances subject to rancidity changes, and the like.

It is an object of the present invention to provide a method whereby various materials may be protected against physical and chemical deterioration. It is a further object to provide amethod forimbedding water-insoluble liquids or solids in a continuous starchy matrix, such that the liquid or solid is finely dispersed through and surrounded by the starchy matrix.

Yetanother object is to provide a method for dispersing a liquid in a dry matrix such that the final product will be in a powdered freeflowing form.

According to the invention there is provided a process of imbeddinga material in a starchy matrix in dry form, characterized by the steps of cooking an aqueous slurry of starchy substance capable of forming a solution of monodispersed molecules with mechanical agitation at a temperature above the normal gelatinization temperature of said substance so as to obtain a clear solution in which themolecules of said substance are mono-dispersed, dispersing in said solution the material to beimbedded in a form compatible with andnct adversely affected by the aqueous starch system, and drying the resultant dispersion, whereby said starchy substance constitutes ai protective colloid for the dispersed material havinglow retrogradation tendencies and being capable of forming coherent, stable, non-gummy film or flake.

Thus the method of the invention provides the necessary protection for liquids and solids against physical and chemical deterioration.

For example, by the process of this invention, a barrier can, be provided against deterioration by atmospheric oxygen in the case of vitamin

A or its derivatives. The precursor of vitamin

A in xanthophyll cil, for example, can be protected so it may be added to poultry feed without losscf the vitamin values.

Again by meanscf this invention, it is possible to dilute highly activemedicinals, or mixtures ofmedicinals, te a safe and uniform diluticn. Ourmethod of dilution is advatageous over more dryblending with a diluent

since each particle in our finished product represents a uniform dispersion of then;=di- cinal in the starch used.

This invention permits the packaging of liquid substances in dry form, such that the liquid isimur.vbilized behind a barrier of starch substance to prevent bleeding or staining, or to hinder evaporation of volatile substances, or toprcvide a product which may be handled more conveniently than prior products. For example, cur invention may be used to produce free-flowing shortenings for bakery goods by enclosing the emulsified liquid oil or melted fat in a starchy matrix.

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Another example of an application to thisinvention is in theins-cticide field. A solid or liquid insecticide may be surrounded by a starchy matrix and reduced to powdered form.

Such powder can be dusted on fields. Subsequent contact of the individual particle with rain or dew would partially dissolve or swell the starchy matrix, causing it to adhere to the plant.

Yet another application of the invention is for those useswhere it is necessary to reconstitute a stable colloid by dissolution inwater.

For example, a cold-water paint can be made by uniformly dispersing an insoluble pigmentin a suitable starch matrix. This material will reconstitute with water to give a paint of a uniform shade.

Liquids and solids which are toxic to the skin may beembedded in a starch matrix in accordance with the invention and thus be more readily handled. Also mutually reactive agents may be imbedded in separate starch matrices, the dried materials mixed and stored, chemical reaction taking place when the dry mixture is wetted with water. In fact, this invention is useful in protecting any material which is compatible with, i.e., is not adversely affected by, aqueous starch referred to hereinafter.

In the practice of the invention a plasticizer may be optionally used to produce a less friable dry product, and a surface-active agent may be used to assist dispersionwhen a liquid is being treated. In general, as contemplated in this invention, themechanism of encasing a dispersed phase of a finely divided liquid or solid with an impervious film! requires that the starchy material be of relatively high molecularweight, be molecularly dispersible in water, and have theability tomaintaln dispersed material is stable suspension. Such a starchy material should likewise exhibit low retro gradaticn tendencies in solution, and the dried films therefrom should exhibit a certain mechanical strength and coherence. A starchysub stance which separates as an insoluble phase from solution before cr during drying of the film is not satisfactory, as will be apparent from the text which follows hereinafter.

Finally, for practical reasons, the starchy substance should be capable of dissolving in water to give solutions of relatively high concentration. sNlore specifically, the starchy materials (including starch derivatives) satisfactory for purposes of the present invention are those which possess the following five properties:

1. The starchy material should be capable of being dissolved by cooking to give a solution ordispersion in which the individual starchymclecules are substantiallyrrJono-dispersed.

Optimum benefitscf this invention will not be realized if any substantial portion of the starchy material persists as swollen but undissolved granules or as fragments of such swollen granules. Those versed in the art will be able to judge whether this specification has been met by such means as inspecting the hot cooked starch paste under the phase micro scope (whenno significant portion of swollen granules or fragments should be visible), orcy centrifuging the hot cooked paste (when there should be no substantial precipitate of insoluble material). Under ordinary conditions of cooking,urirrodified corn and potato starches do not permit realization of the benefits of this invention, since too much of the total starch substance persists as swollen granules or fragments thereof. Obviously, if any substantial amount of swollen granules or fragments persists, these will be detrimental to the final starchy matrix in two respects: (a) this material will represent material which is not functioning to enclose a dispersed phase in the matrix; and (b) the presence of such discontinuities will weaken the final dried film or matrix, creating fissures which are detrimental to the effectiveness of its protection.

2. The aqueous starch system must also act as a good suspending agent or protective colloid for the dispersed phase of liquid droplets or of solid particles. Those skilled in the starch art with the aid of simple preliminary tests will readily differentiate between those starch systems which are good protective agents and those which are not. However, in elucidation of this concept of protective colloid action, it is not contemplated, for example, that the dispersed phase shall merely be dispersed through a

5 to 7 per cent paste of swollen corn starch granules, i.e., a cooked paste of raw corn starch, since such a dispersion would bemaintained primarily by the presence of swollen granules, in contravention of qualification 1 above. Such a system would not produce a film which would enclose and bind the individual particles of the dispersed phase. Theineffectiveness of such a system is illustrated in

Example 1, described hereinafter.

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3. The starchy substance should give a stable non-retrograding solution, i.e., it should show little or no tendency to precipitatefrom solution as insolublemicro particles. Such retrograded starchy material doesnct contribute to the starchy matrix and in addition weakens the continuity of this matrix, thusdiminishing its protective action. As a criterion of absence ofretrogradation, the starchy substance should give a substantially clear solution and should drydown to a flake orfilmi which likewise possesses good clarity. Such a starch will function effectively in this invention, assuming other stipulations are likewise met, as specified herein.

4. The starchy substance by itself must be one which can be dried downfium solution to give a coherent film or flake which is stableand free-flowing, with no tendency either to powder or toform a stickyguml. This quality may be readily established by thesimple test of platingout a solution of the starch substance on glass and allowing this film to dry spontaneously at room temperature. It is believed that this property requires that the starchy substance must possesshigh-polymeric molecular size in order to impart the requisite structural strength andnon-hygroscopicity to the film or flake. Thus in Example 1, a partially hydrolyzed corn starch of16-18 dextrose equivalent gives excellent protection to xanthophyll oil. This samematerial has an intrinsic viscosity of 0.04 innormal potassium hydroxide solution, and yields a strong red orplum coloration withiodine, whichproperties may be indicativecf a molecular weight of20-30 glucose units. A reference to the

term "intrinsic viscosity" may be found in "Chemistry and Industry of Starch," by Kerr, 2nd editions pages 226 and 675, Academic

Press, New York, 1950. Moreimportant for purposes of defining the starches which are effective in the present invention, this16-18

D.E. product dries down from solutionto. give a strong coherent film which is neither powdery nor gummy. In contrast, ordinary 42 D.E. corn syrup dries down to a softgummy hygroscopic film andhence does not fulfill the stipulated requirement. In addition, cornsyrup does not provide adequate protective colloid action as specified above'. However, as will subsequently be shown, corn syrup does have usefulness in the present invention as a plasticizer for the primary high-polymeric starchy material.

5. The starchy substance should be soluble in hot water to give solutions of high solids content. The concentrations which have been; employed in the practice of this invention have ranged from0.5v.0 parts of water per part of starch,depending on the viscosity of the particular starch substance used.

While not definitive nor restrictive, the viscosities of the hot cooked. starch solutions herein employed have usually been in the regioncf 15-50 centipoises determined on the hot cooked solution, i.e. at85-95

C. More dilute systems can be employed, but some of the useful advantages of this invention will thereby be deprcited. Diluted starch solutions (even where the starchy substance is of a preferred type do not maintain the dispersed liquid or solid material in stable suspension. Also, there is the added cost of evaporating large quantities of water.

Among the starchy substances which are satisfactory for purposes of this invention are the following general types:

A. The torrefaction or roasted dextrins (variously designated as canary dextrins, yellow dextrines and

British gums), which show high solubility in cold water (i.e., usually 80 percent or above), high solution stability(i.e., minimum retrogradation, precipitation and "set-back"), and a very lowcontent of linear starch substance (i.e., as qualitatively indicated by the absence of blue color with iodine; these products usually give red or plum colorations).

B. Thin-boiling oxidized starches, commercially produced by oxidation withhypochiorite or peroxide, especiallythose having a Scott hot paste viscosity of about 90 to about 45 (on the basis of 100 grams of starch in 280 ml. of water) These starches yield clear stable solutions, with minimalprecipitation or

"set back."

The Scott hot paste viscosity is widely used in characterizing industrial starch products.

The method is described in the following references:

J. A. Radley "Starch and its Derivatives" 3rd edition, Vclume 2, pages 406-407, Chapmand and Hall,

London, 1953.

R. W. Kerr "Chemistry and Industry of

779/2197

Starch" 2nd edition, pages 119-121,

Academic Press, New York, 1950.

C. Theeherified starches, including the hydroxyethyl, hydroxypropyl, methyl and ethyl derivatives oflow or moderate degree of substitution (0.04 to 0.25 ether groups per glucose unit). Inadditional, these products should be rendered thin-boiling by acid-modification oroxidation prior to or after derivatization, in order to assist dissolution of granule structure and to permit use of higher starch concentrations. A suirable degree of thinning would correspond to a5-gram alkali fluidity of about 60 to 90, as measured by the well-known method of Buel (8th Int. Congr. Pure Applied

Chem., Orig. Com., 13, 63 (1912), J. A.

Radley, loc. cit. pages 421-422; R. W. Kerr, loc. cit. pages.133134).

D. Starch esters, for example, thesightly acetylated starches described by Cross,Bevan and

Traquair(Chemt.-Zeit, 29,527-528 (1905)), orcommercially available products described as mixed carboxylic and sulfonic esters of cornstarch. To assist dissolution of the granule, the starch esters should be at leastmoderately thin-boiling, for example, an acetylated starch having a 5-gram alkali fluidity of 56, or asulfocarboxylic ester having a5-gra.n alkalifluidity of 26.

E.Starchs which are naturally devoid of a linear fracticn, such as waxy maize orwaxy sorghum starches. To assist dissolution of the granule and to permit use of higher starch concentrations, these starches should be rendered thin-boiling by appropriate means, e.g., by acid or enzyme hydrolysis, or by oxidation or dextrinization. A minimum degree of such thin-boiling conversion would correspond to a 5-gram alkali fluidity of about 50.

F. Converted starch products within the range of from approximately 4 D.E. to approximately 20 D.E., produced by acidic or enzymic hydrolysis, having high solubility in cold water, the solutions showing good stability againstretrogradation, and giving no blue coloration with iodine (suitableproducts give reel to plum colors).

Also, combinations of the above types may be employed, for example, a hydroxyethyl torrefaction dextrin, or ap@oduct prepared by dextrinizing an 18 D.E. hydrolyzed starch.

Also, the parent starch may be derived from corn (maize), tapioca, wheat, rice, sorghum, sage, potato, arrowrcot, waxy maize, waxy sorghum, or mixturesthereof. The above list ismerely illustrative of the various types of starchy substances which may be used for purposes of the present invention and is by no meansexclusive, the intent being to include all starchy substances which meet the five requirements previously cited. The term "starchy substance" as used herein and in claims is intended to include those varieties, modifications and derivatives of starch which meet the aforementioned requirements.

In further elucidation and characterization of the requisite starchy substances, the follow

ing groups of modified starches have been found to be relatively ineffectual and these products are therefore considered outside the purview of this invention.

G.Unmodified starches. Evencn prolonged cocking, the swollen granules do not break down to give a molecularly dispersed solution.

If a vitamin oil is dispersed in such a cooked starch paste and examined under the microscope, the oily droplets will be found to bemerely interspersed between theswollen granules and not surrounded by a solution of the starchy substance. Hence such systems provide little or no protection to the disporsed phase. Also, it is not possible to cook these starches atrhe high solidsconcentrations necessary for realization of thebenefits of this invention.

H. Chemically cross-bonded or "inhibited" starches, for example, derivatized with phoFhorus oxychlorideto, give ester bridges, or with epichlorohydrin to give ether crosslinkages. Such starches

(even when of waxy origin) retain their swollen granule structure on prolonged cooking and hence do not give a molecularluy dispersed solution suitable for use in this invention.

I. Thin-boiling acid-modifiedstatches.

780/2197

Exaniination of pastes of these starches with the phasemicroscope shows that the greatly swollen granules tend to persist even afterprolonged cooking and do not disintegrate to give a molecularly dispersed solution. In addition, these starches show pronounced retrogradation tendencies, giving insoluble precipitates which defeat the purpose of this invention. However, as noted in Type E above, the thin-boiling waxy starches do function effetimely in this invention by virtue of the ready dissolution of granule structure and theirfreedom from retrogradation.

J. White dextrins. This group of common commercial products can be cooked up to give molecularly dispersed solutions of high solids content. However, such solutions show oxaggerated retrogradation tendencies, tending to precipltate out of solution or to give "mushy" pastes or hard gels. These characteristics are not in accord with the purposes andrequire- ments of this invention. Howevcr, it should be noted that whitedextrins produced from the waxy starches would not exhibit these undesirable characteristics and hence would be within the scope ofType E above. Similarly, the productcorrespcndmg to a whitedextrin cf a hydroxyethyl corn starch would possess the requisite five qualifications above cited and hence would be within the scope of Type C.

K. So-called corn syrups, with a D.E. range from about 30 to about 60 (on dry substance basis). These products areconverted beyond the point where they provide adequate prot ietive colloid action to the dispersed phase.

For example, low concentrations of vitamin oil can be temporarilyemulsified in 42 D.E. corn syrup by vigorous agitation, but the microscope shows a continual and progressive coalescence of oil droplets.

Moreover, such systems are extremely difficult to dry, and the products ate highly hygroscopic. Evon when dried under special laboratory conditions, the dispersed oil tends tobl@ed out of the product.

However, it should be noted that corn syrups in this D.E. range may be useful adjuncts in conjunction with starch products of Type A to Type F, inclusive. In these instances, thecern syrup merely functions in as@condary role as a plasticizer for the starchy substance, and it is the starch which provides the five requirements previously defined. Even when corn syrup is so used as a plasticizer, its proportion should not be excessively high, or the undesirable qualities of the corn syrup may over-balance the useful properties imparted by the starch.

Although the incorporation of a starch plasticizer is not absolutely essential to the success of this invention) its judicious use may give a dried: product of somewhat less friable character and enhance the protective character of the matrix. Suitable plasticizers include calcium chloride, glycerol, glycol, urea, dicyandiamide, ammonium thiocyanate, formamide, maltose syrups and corn syrup (glucose syrup). Choice of a specific plasticizer will depend on such factors as the following: (1) the plasticizer must be compatible with the dispersed phase, for example, it should not react detrimentally with the dispersed substance; (2) it should not interferewith the contemplated end-use, for example, an acceptable plasticizer should be employed where the final product is to be used in foods; (3) it should be chosen in accordance with the type of protection desired, for example, use of a plasticizer is particularlydesrrable whereprotection againstoxidative deterioration is involved.

Dueto, the large variety of contemplated products and end uses and the large variety of plasticizers available, it is not possible to set forth specific details concerningth type and amount of plasticizer to be used. Thosetilled in, the art will be able, with the aid of the information disclosed herein and preliminary tests, to determine the necessity, type, and amount of plasticizer.

As oneinstance, several plasticizers were tested for the protection of xanthophyll oil in a matrix ofhypcchlorite-oxidized starch prepared according to Example 1; protection was judged by determining the proportion of neutral carotinoid surviving after heating at 75 C. for one week and for four weeks:

% Carotinoid after Heating at 75 C.

For 1 week For 4 weeks

No plasticizer 46 28 20% Glycerol 34 15 20% Urea 62 4120% Corn syrup(cn dry basis) 62 44

(Note: Percentage plasticizer calculated on starch basis).

781/2197

Hence, in this particular instance, itappears that glycerol is actually detrimental to the survival ofoxygen-sensitive carotinoids, while urea and corn syrup are of very substantial benefit. Since there is some development of undesirable brownish color with urea, corn syrup has been employed in most xanthophyll oil formulations. Theamount of plasticizer must likewise be, suited to the particular use.

In the same fashion, thepercentage protection afforded; to xanthophyll oil byall oxidizedstanch matrixwith various amounts of corn syrup is as follows:

% Carotinoid after Heating at 75 C.

% Corn Syrup* For 1 week Far 4 weeks

None 46 28

20 62 44

40 70 54

60 81 70

80 76 62 *As percentage corn syrup (dry basis) calculated on dry starch

basis. Whileprotecticnl is; improved with higher proportions

of corn syrup, excessiveamounts will yield sticky products

which are not free-flowing at high humidities. In general, it

is preferable to add the plasticizer to the cooked starch solu

tion, since certain of these materials (e.g. glycerol and corn

syrup) may impededissolution of the swollen granules.

A special group of substances is excluded from, this invention, though theyare; some

times incorrectly referred to as"plasticizers" for starch. These comprise the softening andantigelling agentswhich act either by oily

lubrication or bytiering upl the linear starch

fraction asan, insoluble complex; these include

such materials as mineral oil and paraffin

waxes, soaps, tallows and sulfonated oils. Such alaterials would represent a discontinuous phase in the starch coating, thereby impairing its impermeability and film structure.

emulsifier will depend on thespecific product and intended use. Forexample, it must be

compatible with both starch and dispersed

phase. Or for use in a food product, the emulsifier must necessarily be acceptable from

a food standpoint.

Here again, in view of the large variety of ccntempiared products and end uses and the large varietyet surface-active agents available, it is not possible to set forth specific details concerning the type and amount of surfaceactive agent to be used.

Thoseskiiled in the art will be able, with the aid of the information disclosed herein and preliminary tests, tode@ermine the necessity,type, and amount of surface-active agent.

As a general procedure in carrying cut the invention, an appropriate starch is suspended in water, and the mixture is thoroughly cooked to gelatinize and dissolve the starch granules. A plasticizer for the starch substance, of the type previously described may be advantageously added and preferably after cooking the paste. The liquid or powdered solid material to be protected is then mixed into the starchy solution by suitable means to give a finely-divided emulsion or dispersion, which is subsequently dried in appropriate fashion. The recommended methods and possible variations of each step in this process will become apparent from the following discussion and from the cited oxamples.

The amount of water must be regulated to accommodate the particular starch, with the purpose of producing a final cooked solution of syrupy consistency. It is advantageous to have the viscosity as high as possible. Viscous concentrated starch solutions have a greater protective colloid action than diluted systems, preventing coalescence of liquid micro-droplets01. sedimentation ofdispersed solid particles

In part, thismay he attributed to the effect of viscosity on rate of sedimentation, as expressed by

Stoke's Law. In preterred laboratory preparations hereinabove described, whichwere dried by

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spreadingan giass plates,tijC ratio of water to starch has been from 0.5:1to, 4:1. Thetame range is satisfactory for most industrial belt or dium dryers. A somwilat higherproportion of water must necessarily be used if the paste is to be spray-dried (as in Example 2 below). Hence, the proportion of water will be governed by the particular type of starch and the process of drying, as well as the requirement that sufficient water be used to effect substantiallycomplc@e solution of the starch substance, as defined in the fist qualification above.

The starchy substrateshould The cooked until substantially all granule structure is

brokendown and dissolved.Usually the paste will go through a thick stage asthe granules swell, followed by a markedThinning as the swollen granules are dissclved. For

practical purposes, it is sufficient to cook at 95 to100 C. untilthe viscosity is reduced to a minimum, a cooking time usually of 15 to 30 minutes with small batches. Themix- ture should be stirred throughout the gelatinization and cooking stages, to prevent the formation of lumps and to assist in the breakdown anddissolution of granule structure. The intention is to reduce the starchy substrate as far as possible to amono-dispersed solution before addition of the solid or liquid suspended phase.

Additional heating or even pressure-cooking may assist toward this end.

Heat exchangers may be used advantageously in the preparation of the starch solution.

When a satisfactory starchy substrate has been achieved, thc desired liquid orfinely- powdered solid material is gradually added with vigorous agitation to effect a uniform dispersion. In most instances, this additionmay be made directly to the hot solution.

However, certain vitamins are destroyed by heat, and the starch substrate must first be cooled to a safe tomperature. Certain other materials solidify within the range of temperatures here employed; in such cases, it is advantageous to add the material at a temperature above its melting point, homogenize the mixture to produce a finely divided emulsion of the melted dispersed phase, then coolbelow the crystallizing temperature with continuous stirring. An instance is the dispersion of vitamin A acetate, which melts at about 56 C. In this case, the starch substrate is held at a temperature sufficiently high to melt theVitamin A acetate (e.g.,60 C.), the latter is added and emulsified, and the system then cooled to crystallize thevitamin.

Onsmall laboratory batches,emulsification of liquids or melted solids can beeffected with an ordinary high-speedpropeller-type stirrer.

With larger batches, some type of mechanical emulsifier or homogenizer is requifed to break down liquid globulet to small dimensions.

The state of dispersion can be readily determined by examining under the microscope. In general, it is preferred to effect a fairly uniform globulesiz@ in the range of 5 to 20 microns diameter. Solids, of course, must be powdered to thedcsired dimensions before addition to the starchy substrate. In the course of emulsifying, considerable airmay be whipped into the mixture. Since this may cause some deterioration of oxygen-sensitive materials during processing, the entire system may beenclcsed andflooded with carbon dioxide or otherinert gas during the operations of cooking the starchsubstrate and effecting the emulsification of the sensitive material.

For example, this technique has been emploved in processing vitamin A preparations, with substantial benefit in minimizing inactivation of the vitamin (see Example 3).

The system generally thickens up somewhat on addition and dispersion of the solid or liquid phase, assuming a consistency simi lar to that of a salad dressing. Thiscreamy dispersion maythen be dried in a variety of ways. As practiced on a laboratory scale, the cream! maybe spread in a thin layer(û.25 to 0.5 mm. thick) on glass plates, and allowed to dry spontaneously. This may have the disadvantageof permuting a slight deterioration of highly oxyen-sensitive materials, probably by absorption of atmospheric oxygen into the wet starch substrate during the slow drying.

However,cnce the starch film is dried down, further deterioration is usually negligible.

783/2197

Optimum drying conditions can be achieved by applying the creamy emulsiont-o the surface of a stainlesssteel beltdrier' bymeans of a doctor blade or roll, said belt then passing through a drying tunnel against a countercurrent of warm dry air or inert gas. Under these conditions, drying is effected within a few minutes, thus minimizing the deterioration which may occur during slowspontane ous drying. Anothermethod isspray-drying, which issomewhat lessdesirable when the dispersed liquid globules are sensitive to oxygen.

As obtained by drying on glass oroil astainless steel belt, the product is in the form of scales or flakes or as a continuous film. If these flakes are examined under the microscope, the imbedded liquid globules will be found to have the same dimensions as in the parent emulsion. If desired, the flakes or film may be readily crushed to required dimensions. Under optimum conditions, such a material shows no evidence of oiliness or wetness, even when it contains 25 to 30 per cent of imbeddedliquid. After crushing to pass a30-mesh U.S. Standard screen, as little as 1 to 3 per cent of the total liquidcompo- nent is exposedcn the surface. With certain costly vitamin preparations, it may be econmically advantageous to recover this small amount of exposed material before it is oxidized by washing with naphtha orsimilar hydrocarbon solvent. The products obtained by spray drying are impalpable powders.

When the final product is to be blended into a large bulk of other mateial, the creamy emulsion may be suitably admixed with this main bulk of material,followed by adrying operationon the composite material. An instance is the addition of corn xanthophyll oil to poultry feed, whereby thexanthophyll cil is first emulsified in a suitable starchy base, and the resulting cream, sprayed cn the dried or partially dried feed, to give a final blend containing 0.5 to 2.0 per cent xanthophyll oil.

If necessary, the composite feed may then be subjected to a further drying operation. The only requirement here is that contact with the feed shall not cause breakdown of the xanthophyll oil emulsion; stability of the latter may be assisted by increasing the viscosity of the starchy substrate.

The following examples, which are intended as typical andinformative only and not in a limiting sense, will illustrate the process and products of this invention:

EXAMPLE I

This example shows a typical method forprotecting xanthophyll oil in various starchmatrices wherein drying is effected by flake drying.

One hundred parts of the indicated starch (containing 8 to 10 per cent moisture) was slurried in the amount of wate specified below 25 parts of commercial corn syrup (glucose syrup of 43 Baume and 42 per cent dextrose equivalent) added, and the mixture cooked for 30 minutes at 95 to100 C. with continuous agitation. Themixture was then cooled to 50

C. with stirring, and 40 parts of corn (maize) xanthophyll oil added, emulsification being effected by high-speed agitation with a propeller-type stirrer. After 10 minutes agitation, microscopic examination showed the oil to be dispersed in uniform.; droplets about 10 microns in diameter. Thecreamy paste was then spread out in a thin layer on glass plates and allowed to dry overnight at roomtemperature.

Two tests were employed. to measure the efficiency of the starch matrix in immobilizing the xanthophyll cil. As an indication of the amount of unprotected xanthophyll, the dryflaked product wasextracted by agitating with cold petroleum naphtha, and the cartinoidpigments in the naphta estimated spectrophotometrically at 450 millimicrons wave-length. In the following tabulation, this extractable pigment is expressed as percentage of the total carotene preseent, representing that portion; ofthe xanthophyll oil not protected within the starchy matrix. As a more conclusive test indicating survival against oxidation, the dry flaked product was heated in an air oven at 75 C. for periods of one and four weeks (conditions known to be highly adverse to survival of oxygensensitive materials), and the residual carotinoid then determined, expressed as percentage of original content. Assay was by conventionalmeans, i.e., digesting the sample in alcoholicFctassium hydroxide, extracting with naphtha followed by spectrophotometric measurement at 450 millimicrons, with calibration against pure recrystallized betacarotene.

Survival at75" C.

Parts Solvent

Starch Type Water Extract 1 Week 4 Weeks Remarks

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Light canary corn A 60 7 88- Very tight dextrin, by roasting film. Microwith acid catalyst. dispersed

Solubles = 97% oil droplets18 D.E. Corn starch F 70 22 79 79 Hard tighthydrolysis product. film

Solubles = 100%

In what follows, the thin boiling starches are defined in terms of their alkali fluidity numbers and the oxidised starches are defined in terms of their Scott hot paste viscosities.

Concentration of the hot paste corresponds to 100 grams in 280 ml of water.

0/

gO Survival at75" C.

Parts Solvent

Starch Type Water Extract 1 Week 4 Weeks Remarks

Light yellow corn A 80 4 87 76 Dried on dextrin, by roasting heated metal with acid catalyst. plate

Solubles = 98%

Same A 80 3 84 74 Same paste,

but dried at

room temper

ature

British gum, tan A 140 2 79 74 in color, by roasting with acid catalyst.

Solubles = 80%

Dark yellow corn A 50 9 82 73 Micro disdextrin, by roasting persed oil with acid catalyst. droplets

Solubles = 97% 85-Fluidity waxy E 220 4 78 69 maize starch

Light canary corn A 70 5 76 68 dextrin, by roasting with acid catalyst.

Solubles =99 Ó 18 D.E. corn starchF-A 50 6 79 66 hydrolysis product, subsequently dextrinized.

Solubles = 100%

British gum, by A 120 6 71 60 roasting corn starch with acid catalyst.

Solubles = 90% 50-Fluidity thin- E 320 11 65 51 Hard, very boiling waxy maize brittle starch flake

Survival at75" C.

Parts Solvent

Starch Type Water Extract 1 Week 4 Weeks Remarks 5 D.E. corn statch F 90 15 62 51 Tight film hydrolysis product.

Solubles = 95% 80-Fluidity hydro- C 300 6 68 46 xyethyl corn starch 0.05 D.S.

55-Scott hypochlor- B 260 10 62 44 ite-oxidized corn starch 26 Fluidity sulfonic- D 420 9 75 40 carboxylic starch ester

Corn gum, light tan A 200 9 58 42 Paste thickens color, by roasting on cooling, neutral starch. due to retro

Solubles = 10% gradation 4 D. E. corn starch F 120 15 46 43 Hard tight hydrolysis product. film.

Slightly

Solubles = 95% oily surface 90 Scott hypochlorite C 260 12 56 39 oxidized corn starch 45-Fluidity acetylated D 400 11 52 38 Hard tight corn starch, 1.8% film esterified acetic acid

Corn gum, light tan A 300 25 43 36 "Short" color, by roasting paste, gels alkaline starch. on cooling,

Solubles = 4% due to retro

gradation

Corn gum, light tan A 720 9 41 35 Retrograded color, by roasting paste alkaline starch.

Solubles = 2%

Hydroxyethyl potato C 500 34 41 31 Very tight starch. 0.25 D.S. film

Low-converted oxidized B 360 20 38 22 "Short" corn starch paste, non

uniform dis

persion

White dextrin, by J 100 37 22 17 heating acidified corn starch at2I0 F.

785/2197

Solubles = 23%

Corn gum. G-A 360 31 25 15 "Short"

Solubles = 4% paste 44-Fluidity acid I 320 16 42 12 modified potato starch

%

%Survival at 75 C.

Parts Solvent

Starch Type Water Extract 1 Week 4 Weeks Remarks 75-Fluidity acid I 260 35 25 13 modified corn starch

White dextrin from J 110 34 25 12 Very tight corn starch. opaque film

Solubles = 65%

White dextrin from J 120 37 15 8 Tight film corn starch.

Solubles = 25%

Corn gum, by roastingG-A 260 47 18 0 Paste thickens alkaline starch. on cooling

Solubles = 5%

White dextrin from J 120 41 15 0 corn starch.

Solubles = 45%

White dextrin from J 170 25 10 0 corn starch.

Solubles = 4%

White dextrin from J 140 74 0 corn starch.

Solubles = 15%

Unmodified corn G 1000 89 13- Oily film starch (2 days)

White dextrin from J 180 100 1- Oily film corn starch. (1 day)

Solubles = 4% 90-Fluidity corn I 240 100 2- Oily film starch (2 days)

Dry roll-gelatinized- - 82 0 corn starch flakes (1 day) sprayed with 20% xanthophyll oil

Bakery color (wheat- - 100 2 flour with approximately 10% xantho- (1 day) phyll oil)

(Note: Dextrin solubles determined by extracting with water at 25 C.)

Th. each instance, the general type of starch is identified with a letter (A to J) corresponding to the various classifications previously described. It will be noted that the 18 D.E. corn starch hydrolysis product and the various torrefaction dextrins provide optimum prsection. Slightly less effective are the thinboiling waxy starches, the thin-boilinghypo- chlorite-oxidized starches, and the thin-boiling esters and ethers. Inferior or negligible prtecttcn isafforded by the thin-boiling acidmodified potato and corn starches, the corn white dextrins, and the unmodified starches.

The last two examples in the foregoing listing show the complete absence of protection when the xanthophyll oil is merely applied to the surface of the starch, indicating a difference between the present invention and the processes described in U.S. Patent Specification

No. 2,641,547 and U.S. Patent Specification

No. 2,170,954. According to the disclosures of the abovementioned U.S. patent specifica tions, such materials as chicken fat or spice oils are merely coated on the surface of dry pregelatinized starch flakes. The last mentioned example is; acommercial productmarketed toi bakersto; impart colorto certain bakery goods. Thus the above mentioned prior specifications disclose a material which is not embedded in starch but is coated on the surface of the dry pregelatinized starch flakes.

The various modified starches show a wide range of protective ability,depending on the extent tot which each; individual starchmeets the fiverequirementsl herein stipulated. In several instances, the effectiveness; of a particular product mayseem out of line with its type of modification. For example, two torrefaction dextrins, indicated asG-A, show extremely poor protection (15 per cent and 0 per cent survival of pigment after four weeks at 75 C.). However, these so-called torrefaction dextrins are lowconverted products, with only 5 per cent cold-water solubles.

Consequently, they retain much of the character of unmodified starch, including difficult solubility of the granules andpronounced retrogradation tendencies.

786/2197

EXAMPLE II

This example shows a typical method of protecting xanthophyll oil in a starch matrix wherein drying is effected by spray-drying.

A mixture of 50lb. of 55-Scott hypochloriteoxidized corn (maize) starch, 12.5lb. of corn syrup; and

375 lb. of water was brought to a boil in a jacketed kettle equipped with propeller agitator, cooked for

15ririnutes, and allowed to cool for 10 minutes. The larger proportion of water was necessary tot reduce theviscosity of the system to a practicable level for spray-drying. A supplementary turbine-type homogenizer was; then placed in the paste, and 12.5 lb. of xanthophyll oil was added. After mixing for

30 minutes, the globule size was not uniform, ranging from 5 to 50míicrons. The emulsion was therefore passed through a pressure homogenizer (inlet pressure = 5000 psi, outlet = 4000 psi) en route torhe nozzle of a countercurrent spray drier. Temperature of the inlet air to the drier was300 F., and feedrate was 0.72 gals. per minute. This gave a fine intensely-yellow powder, with a moisture content of 3 per cent and a bulk density of 26Th per cubic foot.

The oily phase was apparently, microdispersed in process, and no oily globules could be distinguished under the microscope at 500 dimeters magnification. Extraction of this material with cold petroleumnaphta removed 5 per cent of the totalcarotintoid.

After ageing at 75 C. for one and four weeks, the amounts of survivingcarotinoid were 69 per cent and

21 per cent,respectively. In this instance, spray-drying did not give quite as much protection against oxygen asflaky drying, probably due to extremely fine dispersion of the oil.

EXAMPLE III

This example shows protection of vitamin

A.

A mixture of 50 grams of 55-Scott hypochlorite-oxidized corn(maize) starch, 12.5 grams of commercial corn syrup and 120 ml. of water was cooked at 95 to 100 C. for 15 minutes, then cooled tot40 C., continuous agitation being maintained throughout. During the cooling period, the paste was flooded with carbon dioxide to displace air. When thetem.perature reached40 C.,10 grams of acommercial concentrate of vitamin A palmitate in oil (containing1,000,000 U.S.P. units per. gram) was added in rapid dropwisefashion to the paste,with vigorous agitation tot effect emulsification.

Flooding with carbon dioxide was continued during this stage. After uniform emulsification had been achieved, the sample was coated on a glass plate and allowed tot dry overnight at room temperature, tot give lustrouslemon-yellow flakes. A similar preparation was also made using 50 grams of85-fluidity waxy maize starch. Microscopic examination of the dried flakesshoved that considerable crystallization of the vitamin A palmitate had occurred within the individual oil globules. Vitamin assays were run on the initial dried products, and likewise after ageing at room temperature for 3 weeks and for 3 months. Vitamin content was determined by the 1945 A.O.A.C. method, expressed in

U.S.P. units pergram;.

WithWith

Hypo chlorite- 85-Fluidity

Time of Oxidized Waxy

Ageing Starch Maize

Initial 116,000 109,000

3 Weeks 101,000 105,000

3Months 106,000 118,000Approximately 25 per centloss of potency was apparently incurred during flake-drying, probably due to absorption of atmospheric oxygen by the wet paste during the slow drying period. However, the dried. product was completely stable at room temperature, within the accuracy of the assay method.

EXAMPLE IV

This example illustrates dilution of anilinetrinitrobenzene complexin- a starch matrix.

Theaniline-trinitrobenzene complex is a crystalline solid claimed to have merit as a rodent repellent. It is a co-ordination complex of aniline and trinitrobenzene, probably combining by hydrogen bonding rather than by primary valence; the complex is dark red in colour and has a strong aromatic odour.

787/2197

When diluted down in various media, it tendsto; bleach out on exposure. The following procedure was employed to give stable dilations of 1 per cent, 15 per cent and 25 per cent of this material. A mixture of 50grams of 55-Scotthypachlorite-oxidized corn (maize) starch, 12.5 gramscf corn syrup and 130 ml. of water was cocked until aboma- geneous solution was attained. The anilinetrinitrobenzene complex wasfinely pa wdered, and 0.6 gramscf this material was stirred into the starch substrate to give a smooth anduniform dispersion, whch was then dried out on a glass plate. Similar preparationswere made withlSgram and 20-gram additions of the complex. Allthree preparations were stablecn storage over aperiod of several months as shown by no loss in color. An interesting feature is thatthese preparations (unlike the parent complex) had little or no odor, indicating immobilization of the complex.

EXAMPLE V

This example illustrates the incorporation of shortening in a dry, free-flowing starch matrix. Fifty grams of 55-Scott hypchlorite-o.sidizçd corn! (maize) starch wassuspended in 120 ml. of water, cooked at95;

C. for 15 minutes with agitation, and 37.5 grams of regular corn syrup added.Twenty ml. of melted vegetable shortening was then emulsified into the paste which was subsequenily coated and dried on glass plates.

Similar preparations were made, but with the addition of 40 ml. and 60 ml. of the melted shortening.

The dried products containing 20 and 40 ml. of fat werefree-flolsing and lacking in superficial

"greasiness" while the product containing 60ml. showed evidence ofextraneous fat. Benzene extraction of the three samples removed 12 per cent, 33 per cent and 64 per cent of the total fat, respecrively. By means of this particular formulation as much as 32 per cent of shortening (on the basis of the total composition) may beincorparaLd in a starch matrix to give a freflcwing andnon-greasy dry shortening.

What we claimis: -

1. Aprocess of imbedding a material in a starchy matrix in dryform characterized by the steps of cooking an aqueous slurry of starchy substance capable of forming a solution ofmont-dispersed molecules with mechanical agitation at a temperature above the normal gelatinization temperature of said substance so as to obtain a clear solution in which the moleculescf said substance are mono dispersed, dispersing in said solution the material to be imbedded in a form copatib.e with and not adversely affected by the aqueous starch system, and drying the resultant dispersion, whereby said starchy substance constitutes a protective colloid for the dispersed material having low retrogradation tendencies and being capable of forming coherent, stable, non-gummy film or flake.Data supplied from the esp@cenet database - Worldwide Claims:


2. A process in accordance with claim 1, wherein said dry starchy matrix is in freeflcwable form and wherein a plasticizer is added to the solution prior to the drying step.

3. A process in accordance with claim 1, wherein said dry starchy matrix is in free flowable form and wherein an emulsifier is added to the solution to assist dispersion of said material.

4. A process in accordance with claim 1, wherein said dry starchy substance, constituting said matrix, is atorrefacticn dextrin in free flowable form.

5. A process in accordance with claim 1, wherein said dry starchy matrix is in free flowable form and said starchy substance is a starch hydrolyzate having a Dextrose Equivalent value of between 4 and 20 per cent.

6. A process in accordance with claim 1, 2 or 3, wherein the material imbedded in the resultant final product is a water-insoluble material dispersed in said solution.

7. A process in accordance with claim 6, wherein the drying of the resultant dispersion is effected by spray drying.

788/2197

8. A process in accordance with claim 6, wherein the drying of the resultant dispersion is effected upon said dispersion being formed into a thin layer.

9. A process in accordance with claim 6, wherein said dispersion is mixed with a dry material prior to the drying step.

10. A process in accordance with claim 1 or 6, characterized by said starch being oxidized starch having a Scott hot paste viscosity of about 90 to about 45 on the basis of 100 g of starch in280 ml of water.

11. A process in accordance with claim 10, wherein said starch is etherified starch having a 5 gram alkali fluidity of about 60 to about 90.

12. A process in accordance with claim 10, wherein said starch is a starch ester from the group consisting of acetylated starches and mixed carboxylic-sulfonic esters of starch.

13. A process in accordance with claim 10, wherein said starch is a waxy maize or sorghum starch.

14. A process in accordance with claim 13, wherein said starch is a thin boiling waxy starch.

15. Process of imbedding a material in a starchy matrix in dry form substantially as herein described.

16. The composition of matter produced by the process asclaimed in any of the preceding claims.Data supplied from the esp@cenet database - Worldwide

789/2197

169.

GB777525 - 6/26/1957

IMPROVED GRAIN PRODUCTS AND THE MANUFACTURE THEREOF


Applicant(s): HOFFMANN LA ROCHE (--)

E Class: A23L1/10B



Family: GB777525

Abstract:


A vitamin-enriched foodstuff comprises milled cereal grain, e.g. rice or maize grits, impregnated with riboflavin or a riboflavin-active substance and coated with an edible water-repellant protective coating containing titanium dioxide in suspension. The grain may be steeped in a solution of riboflavin or riboflavin-active substance in dilute sulphuric acid, dried and coated with a solution of zein dissolved in ethanol or isopentanol, each 100 ml. of which contains 15 to 60 g. of titanium dioxide. The coating mixture may also contain abeitic stearic, palmitic and oleic acids. The steeping solution may contain water-soluble vitamins such as thiamin, niacin, pantothenic acid, pyridoxin, vitamin B12, ascorbic acid, biotin and folic acid. The coated grain may be dusted with talc, e.g. containing a compound of phosphorus, sodium, potassium, calcium, magnesium, copper, manganese, chromium or iron, preferably iron pyrophosphate, and dried. Specification 646,747 [Group I] is referred to.Description:



Date of Application and filing Complete Specification: June 10, 1955.

777,525 No 16689/55.

Application made in United States of America on June 22, 1954.

,, t " Complete Specification Published: June 26, 1957.

Index at acoeptance:-Class 49, B 1 (B:C:C:L)Q D 1 G 1.

International Classification:-A 23 d, 1.


Improved Grain Products and the Manufacture Thereof We, F HOF Fu AXNN-LA ROCHE & CO,

AKTIENGESELLSCHAFT, a Swiss Company, of 124-184 Grenzacherstrasse, Basle, Switzerland, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement:The present invention is concerned with improvements in or relating to enriched grain products: more particularly, the invention is concerned with improved fortified foodstuffs comprising cereal grain products enriched with Vitamin B 2 (otherwise known as riboflavin) and with a process for the manufacture thereof.

790/2197

It is well known that the commercial milling of cereal grains destroys much or all of the vitamins and minerals naturally occurring therein After the milling process, the cereal grains (e g, dehulled rice or maize grits) are therefore often enriched with vitamins and minerals to restore the lost nutrients The white rice and maize grits of commerce are generally enriched with Vitamin 13 (otherwise known as thiamine), niacin and iron Riboflavin is also substantially destroyed in the milling process and it is desirable to restore this essential vitamin also One process for enriching cereal grains with vitamins

(including riboflavin) and minerals is already known (See British Patent Specification No 646,747)

This process consists in impregnating the cereal grains with a solution containing vitamins and mineral substances and coating the impregnated grains with an edible coating which comprises a film-forming agent, an adhesive agent and a plasticizer and which is insoluble in cold water but removable in hot water.

However, when cereal grains are enriebed with a vitamin material containing lPrice 3,f Jtc 45 6 d riboflavin there is imparted to the grain particles a yellow-orange colour which distinguishes the riboflavin enriched material from the conventional product of commerce and makes it less acceptable to,50 consumers In a grain product in which the enriched material is incorporated in the form of a premix, the coloured grains may be individually removed from the mixture (especially during culinary opera 55 tions) and thus the benefits of the vitamin and mineral enrichment are lost to the consumer

Coatings which have hitherto been applied to enriched rice and corn grits have failed to mask the colour 60 It has now been found, according to the present invention, that a coating material will effectively mask the colouration imparted to cereal grain by enrichment with riboflavin and render the enriched 65 grain indistinguishable from the unenriched material.

Accordingly, the present invention provides as a novel fortified foodstuff a riboflavin-enriehed cereal grain coated 70 with an edible water-repellant coating material containing sufficient titanium dioxide in suspension to mask the colour of the riboflavin.

Aceording to the process provided by 75 the invention, the novel fortified foodstuff aforesaid is manufactured by impregnating a milled cereal grain with riboflavin or with a riboflavin-active material in aqueous acid solution and then coating the 80 resulting enriched grain with an edible water-repellant protective coating material containing titanium dioxide in suspension.

Solutions of riboflavin or of a riboflavinactive material in an aqueous mineral 85 acid (e g, sulphuric acid) are suitable for the impregnation Any riboflavin-active material which is soluble in acidic media may be used Water-soluble vitamins, for example thiamine, niacin pantothenic 90 777,525 acid, pyridoxine, vitamin B 12, ascorbie acid, biotin and folic acid may also be incorporated in the acid solution After drying, the ribofiavin-impregnated grain is then coated with the protective coating material containing titanium dioxide in suspension The latter material comprises basically corn protein or prolamine, such as zein, or other edible water-repellant film The titanium-dioxide is suspended in the coating material in a proportion of about 15 % to 60 % on a weight by volume basis; e g, 15 to 60 grams of titanium dioxide to 100 ml of coating material (in the form of a solution) A lower aliphatie alcohol such as ethanol or isopropanol is used as the solvent in the solution of the coating material In addition, an adhesive agent, such as abietie acid, a plasticizer such as a higher fatty aeid (e g, stearie acid, palmitice acid or oleic aeid L may be included in the coating material It is preferred to dust talc on to the enriched and coated cereal grain while the coating material is still tacky Minerals normally found in cereal grain such as iron, calcium, magnesium, potassium, sodium, phosphorus, manganese and copper (in the form of compounds thereof, e g, iron phosphate), may also be added to the cereal grain

The latter may be done, for example, by including the iron in the dusting powder.

The vitamins and minerals may be added to the grain or a highly fortified premix may be prepared

Preferably a premix is formed by enriching a portion of the cereal grain with a highly concentrated amount of vitamins and minerals in the manner aforesaid The premix is then mixed with unenriched milled cereal grain in a proportion of about 1 part of enriched grain to about 199 parts of unenriehed grain to prod Luce a mixture containing the desired proportion of vitamins and minerals Cereal grain such as rice and maize grits which have been enriched and coated in accordance with the invention closely resemble eommercially available forms of cereal grains acceptable to the consumer and are not readily distinguishable therefrom.

791/2197

We are aware of the Public Health (Preservatives etc, in Food) Regulations 1925-27, and insofar as the present invention relates to the manufacture for sale in the United Kingdom of foodstuffs preserved by the process herein described, we make no claim to use the invention in contravention of the law.

In order that the process of this invention may be more clearly understood and readily put into effect, the following examples are now given by way of illustration:

EXAIPL Er 1 A solution eontainhium 10 - of conentrated sulphuric aeid '22 g of water, 1 4 g of riboflavin 1 S _ O 1 niacin and 3 06 g.

of thiamine uwas pom'ed over 1,952 g of 70 medium grain rice in an open vessel with rapid mixing

Tihe mixing was eontimnued for 10 minutes Thie vitaimin-imprex'nated rice was then dried in a curerent of warm air for 2 hours at 4:3: 75 A coating solution ontaining:30 1 of zein, 19 6 g of ablietic acid 24:3 g of a fatty acid mixture comprising 90 % stearic acid, 6 %c pahmitic acid and 4 % oleic acid,

206 25 ml of isopropanol and 80 7.5 ml of water was prepared 25 g of titanium dioxide were slurried in

135 ml. of this eoating solution.

The titanium dioxide-containing coating solution was then applied to the vitamin-85 impregnated rice by stirring the enrie hed rice into the solui-in While the rice was still wet, a mixture of 62 g of iron pyrophosphate andl 90 g of tale was dusted onl to the rie I The coated rice was o 90 mixed for a feiw miuttes and then dried in a current of warm air for one hour at 430 C The balance of the coating solution was then applied to the dry enriched rice kernels and an additional 67 5 g of talc 95 were dusted on to the wet mixture The rice was mixed for 15 minutes and then dried at 43 c C, for 2 hours.

EXAMNIPLE 2 A vitamin solution containing 98 g of 100 water, 32 g of sulphurice acid, 5 84 g of riboflavin, 64 g of niacin and 9 1 g of thiamine was poured while warm over 1,580 g of maize grits in an open vessel with rapid mixing Mixing was continued 105 for 10 minutes and then the vitaminimpregnated grits were dried in a current of warm air for 2 hours at 430 C.

A coating solution containing 71 5 g of zein, 78 3 g abletie acid, 28 93 g of the l 10 fatty acid mixture employed according to Example 1, 639 ml of isopropanol and 17 ml of water was prepared 100 g of titanium dioxide were slurried in 400 ml. of this coating solution 115 The slurry was then applied to the vitamin-impregnated maize grits by stirring the maize grits into the slurry While still wet, a mixture of 247 g of iron pyrophosphate and 146 g of tale was 120 applied to the maize grits as a dusting powder The impregnated and coated maize grits were mixed for a few minutes and then dried for one hourn at 43 C The balance of the coating_ solution was then 125 applied to the dry maize grits An additional 80 g of tale were dusted on to the grain The enriched and coated maize grits were mixed for 5 minutes and then dried in a current of warm air at 43 C 130 777,525Data supplied from the esp@cenet database - Worldwide

Claims:


What we claim is:-

1 A fortified foodstuff comprising a riboflavin-enriched milled cereal grain coated with an edible water-repellant coating material containing titanium dioxide in suspension.

2 A fortified foodstuff in accordance with Claim 1, wherein the enrichment contains water soluble vitamins in addition to the riboflavin.

3 A fortified foodstuff as claimed in Claim 1 or Claim 2, wherein the cereal grain comprises rice or maize grits.

4 Fortified foodstuffs as claimed in any one of the preceding claims, wherein the coating material comprises a maize protein such as zein.

792/2197

Fortified foodstuffs as claimed in any one of the preceding claims, wherein the said coating material comprises zein, abietic acid and an edible higher fatty acid.

6 A process for the manufacture of fortified foodstuffs as claimed in any one of the preceding claims, which process comprises impregnating a milled cereal grain with riboflavin or a riboflavinactive substance in aqueous acid solution and coating the resulting enriched grain with an edible, waterrepellant coating 30 containing titanium dioxide in suspension.

7 A process as claimed in Clairn 6, wherein the impregnation is brought about by treating the grain with an aqueous acid solution containing riboflavin or a 35 ribofiavin-active substance.

8 A process as claimed in Claim 6 or Claim 7, wherein the said coating comprises zein and, in suspension, 15 % to % titanium dioxide on a weight by 40 volume basis.

9 A process in accordance with any one of the preceding process claims, wherein the cereal grain is rice or maize grits.

A process for the manufacture of 45 fortified foodstlluffs, substantially as described with reference to the examples given.

W D WHITAKER, Patent Agent for F H Orim ANN-LA Roo CE & Co, Aktiengesellschaft.

Printed for Her Majesty's Stationery Office by Wickes & Andrews, Ltd, E C 4 684/2 -1957.

Published at the Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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170.

GB779576 - 7/24/1957

A METHOD AND DEVICE FOR COOKING AND DRYING RICE


Applicant(s): ROGER PAUL CHARLES CARCASSONNE (--)

E Class: A23L1/182


Priority Number: FRX779576 (19550817)

Family: GB779576

Abstract:


779,576. Cooking rice. LEDUC, R. P. C. CARCASSONNE-. Dec. 9, 1955 [Aug. 17, 1955], No.

35378/55. Class 58. In a continuous process for cooking rice, raw rice is fed from a hopper 6 to form a layer, e.g. about 10 cm. thick, on a travelling endless belt 1 partly submerged in water 3. The rice is carried on the submerged part AB of the belt, e.g. for 10 to 15 minutes, and on the unsubmerged part

BC, e.g. for 20 to 30 minutes, to allow the rice to absorb some water and excess water to drain away.

The layer of soaked rice, e.g. containing 20 to 25 per cent by weight of water, is carried on the belt through a chamber 11, wherein it is cooked, e.g. for 10 to 15 minutes in live steam at atmospheric pressure, and then through a chamber 15, wherein the undisturbed layer of cooked rice is partially dried in hot air, e.g. at 90 C. for 15 to 20 minutes. The partially dried rice, e.g. containing 18 to 20 per cent of water, passes from the belt 1 into apparatus 24, wherein the mass of rice is reduced to individual grains between teeth 27 on a rotating cylinder 26 and a flexible strap 25. The rice grains are conducted onto an endless travelling belt 29, e.g. to form a layer about 5 cm. thick, and are carried through a chamber

30, wherein they are dried in a current of hot air, e.g. at 80 C., until they contain between 10 and 12 per cent of water. The chambers 11 and 15 may be duplicated and the steam and/or hot air may be passed upwardly or downwardly, or successively upwardly and downwardly through them. The belt 1 may be replaced by two belts, one carrying the rice through the soaking and draining stages, the other carrying the rice through the cooking and partial-drying chambers.

794/2197

171.

GB781062 - 8/14/1957

IMPROVEMENTS IN OR RELATING TO QUICK-COOKING CEREAL AND

METHOD OF MAKING SAME


Inventor(s): ALLISON JIM E (--); CARMAN CHARLES R (--)


E Class: A23L1/18C2



Family: GB781062

Abstract:


In making a quick-cooking puffed cereal, e.g. rice, oats, wheat, farina (centres of hard wheat) and hominy, having for about 20 minutes after immersion in water at 200 DEG F. a rate of hydration at least one third higher than the original cereal, air is removed from the cereal, e.g. by moistening it and reducing the pressure, and replaced by steam under pressure, the cereal is cooked in steam at increased temperature and pressure, e.g. to effect substantially complete gelatinization of the starch content, the pressure is reduced explosively to puff the cereal and kept reduced until the cereal is set, i.e. does not collapse when it comes under atmospheric pressure. The puffed cereal may be dried in air or in steam under reduced pressure. Preferably, the moisture content of puffed wheat, farina and hominy is brought to a value between 10 and 15 per cent before reimposition of atmospheric pressure. The cereal may be cooked at a pressure between 25 and 75 lb. per sq. inch which may be reduced to 2 inches of mercury absolute or less, e.g. to a value between 0,1 and 0,2 inch. During the puffing and setting of rice, its temperature may be brought below 101 DEG F., preferably, below 40 DEG F. The puffed rice may contain small uniformly distributed cavities and after being immersed for 4 minutes in water at temperatures between 190 and 210 DEG F. it may absorb 20 to 28 per cent of its dry p weight of water per minute for a period of 10 minutes. The ratio of the puffed volume to the original volume may be between 1,66 and 3,50 for rice, oats and wheat, between 1,50 and 2,50 for farina and between 2,50 and

5,50 for hominy. The ratio of the specific gravity of the puffed cereal to that of the original cereal may be between 0,285 and 0,600 for rice, oats and wheat, between 0,400 and 0,666 for farina and between

0,182 and 0,400 for hominy. Specification 675,292 is referred to. Reference has been directed by the

Comptroller to Specification 759,478.

795/2197

172.

GB782832 - 9/11/1957

IMPROVEMENTS IN AND RELATING TO CEREAL PRODUCTS AND THEIR

MANUFACTURE


Inventor(s): DAVIES WILLIAM HALLIDAY (--)

Applicant(s): QUAKER OATS LTD (--)

E Class: A23L1/18F; A23G3/00; A23G3/20



Family: GB782832

Abstract:


782,832. Coated cereals. QUAKER OATS, Ltd. July 15, 1955 [July 19, 1954], No. 21010/54. Classes

49 and 127. A coated cereal product is produced by heating or toasting pieces of cereal product, agitating the pieces with a heated sugar syrup in a heated container, discharging the product from the container, cooling, and separating the individual coated pieces. The coating preparation may be a

796/2197

mixture of white granulated sugar, light amber Australian honey and water heated to 300 F. The heated container may be provided with paddles which displace the cereal product to the discharge port; the sugar syrup is preferably introduced at a point intermediate the cereal product feed inlet and the discharge port. Puffed wheat or puffed rice is passed from an oven 1 into a heated mixing trough 9 for coating with sugar syrup delivered to the trough from a steam-heated pan 17, and the product is discharged on to an air-cooled, wire mesh conveyer 26, passed between crushing rollers 32 and then graded at a sieve 33.Description:



Inventor:-WILLIAM HALLIDAY DAVIES.

Date of Filing Complete Specification: July IS, 1955.

Application Date: July 19, 1954.

782,832 No 21010/54.

j Complete Specification Published: Sept I, 1957.

Index at Acceptance:-Classes 49, BIB; and 127, F.

International Classification:-A 23 g, l.


Improvements in and relating to Cereal Products and their manufacture.

We, QUAKER OATS LIMITED, of Southall, in the County of Middlesex, a Company registered in

Great Britain, do hereby declare the invention, for which we pray that a patent may be granted to us, and themethod by which it is to be performed, to be particularly described in and by the following statement: -

The object of this invention is to provide a coated cereal product of an attractive and palatable character and a method and means for manufacturing the same.

The invention comprises the steps of heating or toasting small articles or pieces of cereal product, preparing a sugar solution, cooking the sugar solution to provide a cooked syrup suitable for coating, mixing and agitating the heated cereal product and the previously cooked syrup in a heated container in required proportions for coating the articles, discharging the coated articles, cooling said articles and effecting separation of the cooled articles.

The invention also consists in an installation for carrying out the method according to the preceding paragraph, comprising a heating or toasting oven to which the cereal product can be fed, means for feeding the heated product from the oven at a controlled rate to a heated mixing trough, means for preparing a sugar solution and delivering such solution to a sugar cooker in which a cooked syrup suitable for coating is produced, means for feeding said coating syrup at a controlled rate to the mixing trough, mechanical agitating means in the trough arranged and driven to displace the cereal and coating syrup along the trough to a discharge and to coat the articles with the syrup, means for cooling the coated articles received from said discharge, and means for effecting separation of the cooled articles.

According to a further feature of the invention the sugar solution or mixture is fed to the trough at a point intermediate to the (Prier cereal product feed and the discharge to ensure that the cereal and coating components are mixed at approximately the same temperature.

According to a further feature of the in 50 vention the coated cereal products are discharged upon a moving band of wire mesh or similar material and cooled thereon, preferably by subjecting the band to

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a cooling air current 55 The invention also comprises an improved sugar coated cereal product made in accordance with the method or in the installation as previously defined The figure of the accompanying drawing illustrates in diagram 60 form an installation or plant for preparing sugar coated cereal products in accordance with the invention.

In carrying the invention into effect according to one convenient mode, described 65 by way of example with reference to the drawing as applied to the manufacture of sugar coated puffed or swelled cereal products, having the character of the products known as puffed wheat or puffed rice for 7 C example, there is provided a toasting oven 1 of the Johnson type to which the cereal product is fed at 2

This known oven may for example be about twenty feet in length and contains a perforated cylinder

(not 75 shown), heated by gas jets supplied at 3, through which, the product is passed, as a result of which its moisture content is reduced and its temperature is raised to the neighbourhood of 300 'F Air is exhausted 80 from the oven by a pipe 4 and a fan 5, and dust is removed by a conduit 6 to a container 7

The heated product passes from the further end of the oven through a conduit 8 to the inlet end of a heated mixing 85 trough 9 which may, for example, have a length of up to twelve feet Heating is provided by a jacket supplied with steam at The trough 9 is preferably of U-section and mounted therein is a combined conveyor 90 782,832 and agitator (not shown) comprising an interrupted worm or spiral The spiral, the central shaft carrying the spiral, and the agitator or paddle devices are steam heated Sand when rotated the product is progressively displaced along the trough and at the same time is subjected to a mixing and agitating action by the spiral and agitator devices.

A mixing pan 11 is provided having a heating jacket supplied by steam at 12.

Sugar, water and honey are fed to the mixing pan by conduits or pipes 13, 14 and 15 respectively and thence the mixture passes by way of a pipe 16 to a dissolving pan 17 which is heated by steam supplied at 18.

Vapours from the dissolving pan are removed by a hood 19 connected to an exhaust fan 20 The sugar mixture is led to a sugar cooker indicated generally at 21.

21 a, which is of the known microfilm type and is supplied with heating steam at 22.

Vapours from the cooker are withdrawn by a pipe 23 by means of the fan 20 It will be understood that the proportions of ingredients may be widely varied to produce a coating mixture, but it is found that

70 to 90 % of white granulated sugar and 10 to 30 O of light amber Australian Honey mixed with 10 to 30 ' of water in relation to the total sugars as specified above is satisfactory The syrup is cooked to a temperature of about 300 F and is fed at a controlled rate through a pine or conduit 3524 to an intermediate point in the length of the mixing trough 9 This arrangement of the feed ensures that any loss of temperature in the cereal product after leaving the toasting oven is made un by heat imnarted to the product from the heated mixiung trough during the first part of its travel therein before it is mixed with the sugar colution or svriu, the trouci beine maintained at a temnnerature in flthe neiqbbourhood of 300 F Tt followq that mi-ing of the cereal nroduct and simar solution will fake tnlace vwith these products at annnroxim Tately the srne temnnerature it heine mnderstood tint ihe th-nnerfqtrl:r a;m-n nlove is by way of example only and may be varied The mixing of the cereal and sugar components by the rotating blades results in the individual articles being coated with the solution The sides of the trough are dimensioned so that the tops of said sides are substantially above the tops of the rotating parts and the feed rate is arranged so that the parts are always submerged in the mixture of cereal and sugar to prevent coating of the parts The coated articles are discharged by the spiral and agitator devices through an outlet 25 and nass to a travelline band 26, preferably of wire mesh, by which they are conveyed to a cooling zone.

Cool air is directed upon the conveying band 26 by fan 27 and a distributor 28 and vapours are removed by a hood 29 connected to the exhaust fan 5 From the band 26 the products pass to a cooling band 30 also provided with an exhaust hood 31 con 70 nected to the fan 5 It will be understood that the bands 26 and 30 or either of them may be contained in chambers which are maintained at a pressure slightly below atmospheric by the action of the exhaust fan 75 From the outer end of the band 30 the products pass through crushing rolls 32 and thence to a sieve 33 which is of the known reciprocating type for grading the product.

798/2197

Lumps are discharged at 34 and fines are 80 discharged at 35 The graded product is discharged at 36 and passes into a container 37 The sieve is provided with an exhaust hood 38 connected to the fan 5 An arrangement of magnets indicated at 39 is provided 85 for removing any iron or steel particles which may have gained access to the product during manufacture.

It will be understood that the means whereby the coated products are distributed 93 on the cooling band and the mode of cooling may be varied Also other means may be employed to effect separation and loosening of the coated products Thus for example this may be effected while the products are 95 on the band by means of a revolving shaft provided with projecting arms or spikes, and a pressure roller, preferably having a iesilient covering such as sponge rubber, acting on the band 100 This invention can be supplied to the manufacture of a variety of sugar coated cereal products having the character of small articles or pieces which may be in the forms of flakes or the like including wheat, rice 105 and corn or maize The invention can be applied with particular advantage, however, to puffed cereal products, of the character of puffed wheat or puffed rice for example.Data supplied from the esp@cenet database - Worldwide Claims:


What we claim is:

1 In the production of a coated cereal product, the method comprising the steps of heating or toasting small articles or pieces of cereal product, preparing a sugar solu 115 tion, cooking the sugar solution to provide a cooked syrup suitable for coating, mixing and agitating the heated cereal product and the previously cooked syrup in a heated container in required proportions for coating 120 the articles, discharging the coated articles, cooling said articles and effecting separation of the cooled articles.

2 The method as claimed in Claim 1 in which the cereal Product comprises puffed 125 or swelled cereal Products as for example puffed wheat or puffed rice.

3 The method as claimed in Claim 1 or 2, comprising mixing and agitating the cereal and coating syrup in a heated con 130 I 782,832 tainer or trough provided with moving or rotating paddles or the like.

4 The method as claimed in Claim 3, comprising mixing and agitating the cereal and coating syrup by paddle devices arranged so that they act to displace the cereal products along the trough or container to a discharge.

The method as claimed in any of the preceding claims comprising feeding sugar solution or mixture to a heated container or trough at a point intermediate the cereal product feed and the discharge.

6 The method as claimed in any of the preceding claims comprising discharging the coated products upon a moving band for cooling purposes.

7 An installation for carrying out the method as claimed in Claim 1, comprising 220 a heating or toasting oven to which the cereal product can be fed, means for feeding the heated product from the oven at a controlled rate to a heated mixing trough.

means for preparing a sugar solution and delivering such solution to a sugar cooker in which a cooked sugar syrup suitable for coating is produced, means for feeding said coating syrup at a controlled rate to the mixing troueh, mechanical agitating means in the trough arranged and driven to displace the cereal and coating syrup along the trough to a discharge and to coat the articles with the syrup, means for cooling the coated articles received from said discharge, and means for effecting separation of the cooled 35 articles.

8 An installation as claimed in Claimrn 7, in which the coating syrup feed to the trough is arranged intermediate the cereal product feed and the discharge to ensure 40 that the cereal and coating components are mixed at approximately the same temperature.

9 An installation as claimed in Claim 7 or 8, comprising a moving band upon 45 which the coated articles are discharged, and means for cooling the articles on the band.

799/2197

An installation as claimed in Claim 9, in which the band is formed from wire mesh and cooling is effected by air current 50 11 A sugar coated cereal product made in accordance with the method as claimed in any of the Claims I to 6 or in the installation as claimed in any of the Claims 7 to 10 55 12

The method and means for nroducing a coated cereal product substantially as hereinbefore described with reference to the accompanying drawing.

MARKS & CLERK.

PROVISIONAL SPECIFICATION Improvements in and relating to Cereal Products and their manufacture.

6 o O We, QUAKER OATS LIMITED, of Southall, in the County of Middlesex, a Company registered in Great Britain, do hereby dedclare this invention to be described in the following statement:The object of this invention is to provide a coated cereal product of an attractive and palatable character and a method and means for manufacturing the same.

The invention comprises the steps of heating small articles or pieces of cereal product, preparing a heated sugar solution or mixture suitable for coating, mixing and agitating the heated cereal product and the solution or mixture in a heated container in required proportions for coating the articles, and discharging the coated articles or pieces to cooling means.

The invention also comprises a method as defined in the preceding paragraph ap:80 plied to puffed cereal products, as for example the known nuffed wheat or puffed rice, or products having similar physical characteristics.

The mixing and agitating of the cereal :85 and coating components is preferably earried out in a heated trough provided with moving or rotating paddles which are preferably arranged so that they also act to displace the cereal and coating components along the trough to a discharge 90 The invention further comprises an installation for carrying out the method as defined in either of the two preceding paragraphs, including a heating or toasting oven to which the cereal product can be fed, means for 95 feeding the heated'product from the oven at a controlled rate to a heated mixing trough, means for heating a sugar solution or mixture and feeding it at a controlled rate to the mixing trough, and mechanical 100 agitating means in the trough arranged and driven for displacing the cereal and coating components along the trough to a discharge.

According to a further feature of the invention the sugar solution or mixture is fed 105 to the trough at a point intermediate to the cereal product feed and the discharge to ensure that the cereal and coating components are mixed at approximately the same temperature 110 According to a further feature of the invention the coated cereal products are discharged upon a moving band of wire mesh 782,832 or similar material and cooled thereon, preferably by subjecting the band to a cooling air current.

The invention also comprises an improved sugar coated cereal product made in accordance with the method or in the installation as previously defined.

Other features of the invention will be described in the following example of a mode of carrying the invention into effect.

In carrying the invention into effect according to one convenient mode, described by way of example as applied to the manufacture of sugar coated puffed cereal products, having the character of the products known as puffed wheat or puffed rice for example, there is provided a toasting oven of the

Johnson type to which the cereal product is fed This known oven may for example be about twenty feet in length and contains a perforated cylinder heated by gas jets through which the product is passed.

as a result of which its moisture content is reduced and its temperature is raised to the neighbourhood of 300 'F and is fed from thence to the inlet end of a heated mixing trough which may have a length of ur to twelve feet for example Heating may be provided by a steam jacket The trough is of U-section and mounted therein is a combined conveyer and agitator comprising an interrupted worm or spiral having blades of crescent or similar shape mounted on a rotatable shaft and arranged so that when

800/2197

rotated the product is progressively displaced along the trough and at the same time is subjected to a mixing and agitating action by the blades These blades may be replaced by a tubular steam heated spiral connected to a steam heated central shaft.

Sugar and honey or other suitable sugar mixture is dissolved in water in a pan and led to a tank from which the solution is fed to a sugar cooker of the known microfilm type It will be understood that the proportions of ingredients may be widely varied to produce a coating mixture, but it is found that 70 to

90 ' of white granulated sugar and 10 to 30 % O of light amber Australian honey mixed with 10 to 30 .

of water in relation to the total sugars is satisfactory The syrup is cooked to a temperature of about

300 F and is fed at a controlled rate to an intermediate point in 55the length of the mixing trough This arrangement of the feed ensures that any loss of temperature in the cereal product after leaving the toasting oven is made up by heat imparted to the product from the heated mixing trough during the first part of its travel therein before it is mixed with the sugar solution, the trough being maintained at a temperature in the neighbourhood of 300 F It follows that mixing of ithe cereal product and sugar solution will take place with these products at approximately the same temperature, it being understood that the temperature given above is by way of example only and may be varied.

The mixing of the cereal and sugar compo 70 nents by the rotating blades results in the individual products being coated with the solution The sides of the trough are such that they are substantially above the tops of the rotating blades and the feed is ar-75 ranged so that the blades are always submerged in the mixture of cereal and sugar to prevent choking of the blades The coated products are discharged by the blades through an outlet at the end of the 80.

trough and pass to a travelling coolino band, preferably of wire mesh by which theare conveyed to a cooling zone To ensure an even layer of coated products on the band it is preferred to provide a rotating distri 85 butor beneath the outlet from the mixine trough Such distributor may have paddl_ blades which are set both ways across the band from the centre thereof and are arranged to effect a distribution of the coated 90 products across the width of the band Th' distributor may be gas or steam heated tc

Crngl ofctril t prevent clogging of material to paddle blades.

The cooling band is arranged to pass 95 through a cooling section or chamber which is provided with air ducts by which cooling air is directed upon the coated product.

Preferably the cooling chamber is maintained at a pressure slightly below atmo 100 o spheric by means of an exhaust fan having a slightly greater capacity than the input fan To effect separation and loosening of the cooled coated products, they may be subjected, while upon the band, to the I,5 action of a pre-breaking agitator of the revolving type and a pressure roller having a resilient covering such as sponge rubber.

The roller is suitably located or weighted and is arranged above a suitable supporting 110 surface beneath the band near the discharge end thereof The separated products are discharged over the end of the band to a sieve, preferably of the reciprocating type.

The sieve is preferably arranged so that 115 both fine material and over-size lumps can be separated

Aspiration may also be employed for the purpose of separating material of a greater density than the coated puffs Magnetic means may also be nro 120 vided to remove any iron or steel particles which may have gained access to the product during manufacture.

This invention can be anplied to the manufacture of a variety of sugar coated 125 cereal products having the character of small articles or pieces which may be in the form of flakes or the like including wheat, rice and corn or maize The invention can be applied with narticular advan 130 782,832 6 tage, however, to puffed cereal products of the character of puffed wheat or puffed rice for example.

MARKS & CLERK.

Printed for Her Majesty's Stationery Office by Kingston Printers Ltd, Portsmouth 335/3 -1956.

801/2197

Published at The Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

802/2197

173.

GB783632 - 9/25/1957

IMPROVEMENTS IN OR RELATING TO THE TREATMENT OF CEREAL

GRAINS


Applicant(s): TAKEDA PHARMACEUTICAL (--)

E Class: A23L1/10B


Priority Number: JPX783632 (19540215)

Family: GB783632

Abstract:


In preparing vitamin-enriched cereal foods, grain, e.g. rice, is treated with a solution, in a non-toxic, volatilizable solvent, of a 2-methyl - 4 - amino - 5 - [N - (31 - acylthio - 51-acyloxy - D 21 - pentenyl -

21)] foraminomethyl-pyrimidine or a salt thereof in which each acyl group may be open-chain, e.g. acetyl, propionyl or butyryl, or may be aryl-acyl, e.g. benzoyl or methylbenzoyl. Preferred enriching substances are 2 - methyl - 4 - amino - 5 - [N - (31 - acetylthio - 51 - acetoxy - D 21 - pentenyl - 21)]foraminomethyl pyrimidine and 2-methyl-4-amino - 5 - [N - (31 - benzoylthio - 51 - benzoxy-D 21 - pentenyl - 21)] - foraminomethyl - pyrimidine and their hydrochlorides. The solvent may be ethanol, acetone, water or dilute acetic or hydrochloric acid. The grain may be immersed in or sprayed with the solution at temperatures between 10 DEG and 50 DEG C. and then dried. After having been treated with an acidic solution, the grain may be neutralized with sodium bicarbonate solution and/or steamed for 30 to 200 seconds, before being dried.Description:



783,632 Date of Application and filing Complete Specification: Feb 15, 1955.

No 4529/55.

Application made in Japan on Feb 15, 1954.

Complete Specification Published: Sept 25, 1957.

Index at acceptance:-Class 49, Bl B. International Classification:-A 231.


Improvements' in or relating to the Treatment of Cereal Grains We, TAKEDA PHARMACEUTICAL

INDUSTRIES, LTD, a Japanese Corporate Body of 27, 2chome, Doshomachi, Higashi-ku, Osaka,

Japan, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to improvements in the treatment of cereal grains.

803/2197

The object of the invention is to provide improved vitamin-B,-enriched cereal grains and processes of manufacturing them.

More particularly, the invention deals with rice enriched in activity of vitamin B, by pyrimidine compounds as hereinafter described and also with its manufacturing processes.

Enrichment of food with thiamine has been well known, and generally thiamine has been employed in the form of its hydrochloride, nitrate and other salts.

However, these salts, being liable to be decomposed by the moisture in the air during storage, are not very suitable for enrichment of food such as cereal grains, which need to be stored for a considerable time.

We have now discovered a method for enriching cereal grains by using pyrimidine compounds as hereinafter described or their salts.

Cereal grains are generally washed with water before use, and, in the ease of rice, it is subjected to cleaning or polishing to be sold as cleaned rice As a result of these processes of washing and polishing, most of the natural vitamins in the rice will be lost Therefore, various methods have been suggested to reinforce it For instance, cleaned rice is coated with a water-soluble thin membrane in which the necessary vitamins are compounded; or an edible film, containing a film-forming agent, an adhesive agent and a plasticizer, besides vitamins, is formed over the grains Such methods aim at making up for the loss of vitamins with a membrane containing these vitamins, and only the hydrochloride, nitrate and other salts of thiamine have been applied for the purpose. l Price 3 s 6 d l In accordance with the present invention there is provided a method for enriching cereal grains which comprises treating cereal grains with a solution in a non-toxic volatile solvent of a 2methyl-4-amino-5-lN-( 31-acylthio-511 acyloxy A 2-pentenyl-21)l formaminomethylpyrimidine or a salt thereof, in which each of the acyl groups is an open-chain acyl group or an aryl acyl group.

The acyl group may be that of a saturated aliphatic monocarboxylic acid having up to 6 carbon atoms in the molecule such as acetic, propionic or butyric acid, or a monocyclic aromatic carboxylic acid such as benzoic or a toluic acid.

These compounds, without toxicity, have good properties for enrichment Especially, 2-methyl 4 amino-5-lN-( 31-benzoylthio-511 benzoxy-A 2-pentenyl-21)l formaminomethylpyrimidine (referred to as D B T for short) and 2 methyl 4-amino-5-lN-( 3 '-acetylthio-511 acetoxy-2-pentenyl-2 ')l formaminomethylpyrimidine (referred to as D A T for short) and their hydrochlorides, being free from any objectionable odour, are most suitable for such a purpose.

Moreover, these derivatives are efficiently utilised, since they are not invalidated by aneurinase and can be reserved for a long time in the body (" Vitamins," Japan Vitamin Society, Volume 6, 684-5 (

1953), Volume 7, ( 1954); J Pharm Soc Japan 73, 705 ( 1953)) On account of these characters, it appears that they are far more effective than thiamine hydrochloride when used as an enriching agent.

For the preparation of enriched cereal grains with these derivatives, the following steps are employed.

The cereal grains are immersed in a solution of one of the above pyrimidine compounds in a non-toxic volatile solvent and the grains are subsequently taken out and dried Ethanol, acetone, water and dilute acids may be used I as the solvent Strong heating or cooling is not necessary during the immersion The immersion can be successfully performed at a temperature range from 100 C to 500 C or generally at room temperature Several hours are generally enough for the immersion, although it depends upon the temperature and the quantity of cereal grains used.

The invention can also be carried out by spraying the above-mentioned solution pyrimidine compounds onto the surface of cereal grains and subsequently drying them.

804/2197

For the purpose of minimizing the waste of the pyrimidine compounds and to simplify the process of drying, it is desirable to use as small a quantity of the solvent as possible, within the limit of being able to dissolve the fortifying substance completely, and to soak the grains uniformly.

The amount of the pyrimidine compound to be absorbed by cereal grains depends upon the absorptive power of the grains and depends upon the ratio of the enriched grains to ordinary grains in the case of cooking the enriched grains together with the ordinary grains This is from 0 01 g to 0 2 g per 100 g of cereal grains, and 0 1 g to 0 2 g is generally advisable A larger amount than this is unnecessary and makes it difficult to uniformly mix the enriched grains with ordinary grains On the other hand, a smaller amount is less preferable since it requires a too great ratio of enriched grains to ordinary grains to secure an adequate overall enrichment of the grains Further, this range is suitable from the standpoint of storage of the enriched material without any appreciable decrease in its vitamin-B 1 potency.

When grains are enriched with thiamine the enriched grains must be steamed to starch their surface in order to keep them from losing their potency by washing However, the grains enriched with D B T do not lose their potency by washing with water even if the steaming process is omitted 100 g of ordinary unenriched cereal grains mixed with 10 g to 1 g of enriched grains provides a sufficient amount of vitamin-B 1 for an adult in a day.

Instead of enriching 100 g of cereal grains with 0 01 g to 0 2 g of these pyrimidine compounds, 100 g of the grains can be enriched with but 0 5 to 2 mg of the compounds In that case the enriched grains may be used for food as such.

Salts of the pyrimidine compounds, such as the hydrochloride, are soluble in water and easily soluble in dilute acid.

In order to enrich grains with the hydrochloride, the method stated above may be employed, but another process is also available.

For example, after the grains are allowed to absorb a solution of this compound or the free base of it in acidic water which contains a nontoxic volatile acid such as acetic acid or hydrochloric acid through the same steps described above, they are treated with steam so as to form a thin layer of paste over the surface of the grains and at the same time to evaporate the volatile acid The time of steaming must be short 30 seconds to 200 seconds is suitable Too long steaming does harm, for paste formation will go too far In place of steaming, a neutralizing agent, e g sodium bicarbonate, may be used, if desired, to neutralize the excess acid before drying.

The enriched grains, prepared as above, retain their potency even though they may be stored for a relatively long period before use The quantitative analysis of the pyrimidine compounds after standing for six months revealed only a slight decrease in their potency and showed that the aim of enrichment can be attained effectively by the method of the present invention.

In the following data, D B T and thiamine hydrochloride are compared with each other.

1 The solubility of the compounds in water, alcohol and acetone. per 1 g.

D.B T H Cl salt 500 c c. insoluble c c. per 1 g. thiamine HCI-salt 1 c c. c c.

805/2197

insoluble 2 The results of the elution test of the rices enriched with the two vitamines.

Five times by weight of water was added to 1 g of the enriched rice (which contains 1 2 mg of D B T or thiamine hydrochloride), and after standing with occasional stirring the quantity of the compound, eluted by water, was measured.

Period of thiamine Elution D B T HCI-salt After 5 min.

After 10 mmn.

After 20 min.

4.4-4 8 % 5.6-5 8 % 5.9-6 5 % 12-14 %o 17-20 % 25-26 % 3 The comparison of the stability of the two vitamins during boiling of the enriched rice One gram of the enriched rice was added to 99 g of ordinary rice and the mixture was boiled and the amount of the vitamin remaining was measured.

Amount remaining D.B T 95 6 % Thiamine H Cl-salt 85 2 % The following examples illustrate the nature of the invention and the manner in which it may be performed:per 1 g.

D.B T.

Water 951 % alcohol Acetone 9000 c c.

870 c c. c c.

783,632 and the pyrimidine compound free As this is less soluble in water, the loss of the pyrinmidine compound during boiling can be diminished Finally, after steaming for 30 to 200 seconds, the rice is dried.Data supplied from the esp@cenet database - Worldwide Claims:


What we claim is:-

1 A method for enriching cereal grains which comprises treating cereal grains with a solution in a non-toxic volatile solvent of a 2-methyl 4 amino-5 lN-( 31-acylthio-51-acylI oxy A 2 _ pentenyl 21)l formaminomethylpyrimidine, or a salt thereof, in which each of the acyl groups is an open chain acyl group or an aryl acyl group.

2 A method according to claim 1 in which the 2-methyl 4-amino-5 lN-31-acylthio 5 '1 acyloxy-Alpentenyl-21)l formaminomethylpyrimidine is 2-methyl 4-amino 5 lN-( 31EXAMPLE 1.

kg of cleaned rice are washed with water and placed in a cylindrical vessel To this is added a solution of 5 g of 2-methyl-4-amino1 5 lN ( 31 benzoylthio 51 benzoxy 2pentenyl 21)l formaminomethylpyrimidine hydrochloride in 2 litres of water and 0 4 kg.

of acetic acid The vessel is revolved so as to secure good contact between the rice and the solution

After four hours, the absorption is substantially complete The rice is then taken out of the vessel and exposed to steam for from one to three minutes A paste is formed upon the surface of the rice grains which serves to protect the vitamin and retain it within the grains The rice is then allowed to dry.

This enriched rice may be mixed with one hundred times its weight of ordinary rice and used for food.

EXAMPLE 2.

A solution of 7 2 g of 2-methyl-4-amino1 lN ( 31 benzoylthio 51 benzoxy-A 2pentenyl-2 ')lformaminomethyl-pyrimidine in 1 litre of 801 % alcohol is added to 5 kg of cleaned rice in a vessel and

806/2197

the vessel is revolved carefully so as to facilitate absorption The rice is separated from the solution after three hours Any remaining alcohol is removed and the rice is dried.

The enriched rice thus obtained may be used after mixing with ordinary rice.

When tested after six months storage it was found that only 3 6 % of the pyrimidine compound had been lost.

EXAMPLE 3.

kg of cleaned rice are spread in a thin layer upon a board and onto this a solution of 0 5 g 2-methyl-4amino-5-lN-( 31-benzoyl1 thio-51-benzoxy-A 2-pentenyl-21) l formaminomethyl-pyrimidine in 200 c c of 80 % alcohol is sprayed The rice, dried without any other treatment, can be used for food. g of the rice contained 0 987 mg of the compound.

EXAMPLE 4.

kg of cleaned rice, after washing with water, are placed in a cylinder and 10 g of 2-methyl 4 amino-5lN-( 31-benzoylthio-5 'benzoxy-A 2 pentenyl-21)l-formaminomethylpyrimidine dissolved in a mixture of 0 8 kg.

of acetic acid and 1 litre of water is added.

The vessel is revolved as described in Example 1 After completion of the absorption, a solution of 5 5 g of sodium bicarbonate in small quantity of water is added and the revolution repeated In this way, the acid is neutralized 1 benzoylthio 51-benzoxy A 2 _ pentenyl-2)lformaminomethyl-pyrimidine or 2methyl-41 amino 5 lN ( 31-acetylthio 51-acetoxy-A'pentenyl-2 ')l-formaminomethyl-primidine.

3 A method according to either of claims 80 1 or 2 which comprises immersing the cereal grains in an ethanol solution of the said pyrimidine and subsequently drying the treated grains.

4 A method according to claim 3, in which 85 the immersion treatment is carried out at a temperature of 10 -50 C.

A method according to either of claims 1 or 2 which comprises spraying the cereal grains with an ethanol solution of the said 90 pyrimidine and subsequently drying the treated grains.

6 A method according to either of claims 1 or 2 which comprises immersing the cereal grains in an aqueous solution of the said pyri 95 midine or a salt thereof containing a non-toxic volatile acid, subsequently neutralising the treated grains with an aqueous solution of an alkali metal bicarbonate and drying the thus treated grains 100 7 A method according to claim 6, in which the said pyrimidine salt is the hydrochloride.

8 A method according to either of claims 6 or 7, in which the volatile acid is acetic or hydrochloric acid 105 9 A method according to any of claims 6-8, in which the treated grains are steamed fore from

30 to 200 seconds before drying.

A method according to any of the preceding claims, in which the cereal grains are 110 rice grains.

11 A method of enriching cereal grains according to claim 1 and substantially as hereinbefore described with reference to any one of Examples 1-4 115 12 Enriched cereal grains whenever pro783,632 783,632 duced by the method according to any of the preceding claims.


Applicants.

Leamington Spa: Printed for Her Majesty's Stationery Office, by the Courier Presr -1957.

807/2197

P Nblished at The Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

808/2197

174.

GB784865 - 10/16/1957

IMPROVEMENTS IN OR RELATING TO QUICK COOKING RICE



E Class: A23L1/182



Family: GB784865

Abstract:


The process for preparing quick-cooking rice disclosed in the parent Specification is modified in that the rice grains, subjected to mechanical compression, have exterior portions of moist, substantially completely gelatinized starch in a completely pliable condition, and interior portions ranging from relatively brittle, at least partially gelatized starch to substantially completely gelatinized starch in a completely pliable condition. Rice may be soaked in water until it attains a moisture content between

17 and 36 per cent then steamed, e.g. in an autoclave, or boiled in water to effect gelatinization and increase its moisture content to a value preferably not exceeding 40 per cent. The resulting rice may be soaked in water to bring its moisture content between 60 and 70 per cent before or after being mechanically compressed. The rice may be compressed between rolls or in a press. The compressed rice may be dried in a swift current of hot air until it contains between 10 and 14 per cent moisture.Description:

Description of GB784865 c; -% I N -, ' q 41 '

-7 4 4 PATENT SPE Ci FICATION 7894,g 5 Date of,, i tion and Filing Ccmplet 6

Specification: Aug31, 1954 1 N'o2522/54.

Application made in United States of America on Sept IQ,; 953.

f Patent of Addition to No 657,691 dated April 22, 19 X 8 as imprc'er use or modified by No 737,372 dated Feb 8, 195 'L Complete Specification Published: Oct 16, 1957.

Index at Acceptance:-Class 58, A 3 B, AH( 3: 4 A: 4 C: 6 D).

International Classification:-B 02 b.


Improvements in or relating to Quick Cooking Rice.

E Ri ATA SPECIFICATION NO 784, 865

Page 3, line 42, for irt read air,.

809/2197

Page 4, line 68, for,isomewhate read "scaeiat THE PAT Ei NT OFFICE, 25th A Tovember, 1957 in the external portions or sheath of the rice grain should comprise moist, substantially completely gelatinized starch in a completely pliable condition, as set forth in the above-mentioned specification, the internal portions or core of the grain need not be relatively brittle but may range from this condition

(i e, partially gelatinized and relatively brittle) to a condition of substantially complete gelatinization and pliability.

If the internal portions have not been gelatinized at all, the degree of brittleness is too high for the purpose of the present invention But rice which has been soaked to 'n about 30 % moisture and then steamed to fully gelatinize the exterior portions while the interior portions are only slightly gelatinized, and also rice which has been fully gelatinized, dried and then steamed briefly to moisten only the exterior portions of the grain, are both suitable for application of the step of mechanical compression

So also is a rice grain having fully pliable exterior portions along with interior portions of substantially equal pliability Thus it will be seen further that the moisture content of 34 ,% mentioned in the above specification is not a limiting value.

According to the present invention there DB 00840/1 ( 22)/3606 150 111/57 R increase its moisture cunot Lrut LU a uuataial degree, say, 17-36 %, preferably 25 %, and steamed to partially or completely gelatinize the rice and further increase its 65 moisture content, say, by 1-8 %, but as a rule not to exceed 40,/o The rice is coimpressed and then dried in any suitable manner.

2 Ungelatinized, milled rice is soaked to 70 increase its moisture content to a substantial degree, say,

17-36 %, preferably 25 35 %, and steamed to completely gelatinize the rice and further increase its moisture content, say, by 1-8 %, but as a rule not to ex 75 ceed 40 % The rice is mechanically compressed and placed in water to increase its moisture content to 60-70 % On the other hand, after steaming as above described, the rice may be soaked in water to raise its 80 moisture content to 60-70

% as above and thereafter compressed Preferably, the rice is contacted with the soaking water while still hot from the steaming since this provides the rice in an enlarged condition which 85 greatly facilitates soaking At a moisture content appreciably above 70 % the advantages of compression are not as great as when the rice contains less moisture The rice is then dried in any suitable manner, 90


Dcte of Appiication and Filing Complete Specification: Aug31, 1954 No 25239/54.

Application made in United States of America on Sept 10, 1953.

(Patent of Addition to No 657,691 dated April 22, 1948 as improved upon or modified by No 737,372 dated Feb 8, 1951).

Complete Specification Published: Oct 16, 1957.

Index at Acceptance:-Class 58, A 3 B, AH( 3: 4 A: 4 C: 6 D).

International Classification:-BO 2 b.


Improvements in or relating to Quick Cooking Rice.

1, A 1 AULLAH KHAN OZAI-DURRANI, a citizen of the United States of America, of 7th Street, and Grand Avenue, Stuttgart, Arkansas, United States of America, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a method of preparing a quick cooking rice product and to the rice product itself.

The present invention is an improvement in or modification of earlier Specification

810/2197

Serial No 737,372.

It has been found that while the starch in the external portions or sheath of the rice grain should comprise moist, substantially completely gelatinized starch in a completely pliable condition, as set forth in the above-mentioned specification, the internal portions or core of the grain need not be relatively brittle but may range from this condition (i e, partially gelatinized and relatively brittle) to a condition of substantially complete gelatinization and pliability.

If the internal portions have not been gelatinized at all, the degree of brittleness is too high for the purpose of the present invention But rice which has been soaked to about 30 ,,, moisture and then steamed to fully gelatinize the exterior portions while the interior portions are only slightly gelatinized, and also rice which has been fully gelatinized, dried and then steamed briefly to moisten only the exterior portions of the grain, are both suitable for application of the step of mechanical compression

So also is a rice grain having fully pliable exterior portions along with interior portions of substantially equal pliability Thus it will be seen further that the moisture content of 34 %,h mentioned in the above specification is not a limiting value.

According to the present invention there is provided a process for preparing qui 2 cooking rice which comprises suijectini rice grains, having exterior portions of moist, substantially completely gelantinized starch in a completely pliable condition and 50 interior portions ranging from relatively brittle, at least partially gelatinized starch to substantially completely gelatinized starch in a completely pliable condition, to mechanical compression to distort and modify 55 the structure of the rice grains without ducing them to a flaked condition.

The following procedures illustrate by way of example various ways in which the invention can be carried out: 60 1 Ungelatinized, milled rice is soaked ti increase its moisture content to a substantial degree, say, 17-36 %, preferably 25%, and steamed to partially or completely gelatinize the rice and further increase its 65 moisture content, say, by 1-8 %, but as a rule not to exceed 40 % The rice is compressed and then dried in any suitable manner.

2 Ungelatinized, milled rice is soaked to 70 increase its moisture content to a substantial degree, say,

17-36 %, preferably 25 35 %, and steamed to completely gelatinize th 3 rice and further increase its moisture content, say, by 1-8 %, but as a rule not to ex 75 ceed 40 % The rice is mechanically compressed and placed in water to increase its moisture content to 60-70 % On the other hand, after steaming as above described, the rice may be soaked in water to raise its 80 moisture content to 60-70

% as above and thereafter compressed Preferably, the rice is contacted with the soaking water while still hot from the steaming since this provides the rice in an enlarged condition which 85 greatly facilitates soaking At a moisture content appreciably above 70 % the advantages of compression are not as great as when the rice contains less moisture The rice is then dried in any suitable manner,90 preferably at relatively high temperature cient to raise the moisture content to about and air velocities

30 % Such soaked grains have the non3 Ungelatinized, milled rice is soaked to uniform moisture distribution described in increase its moisture content to a substant our above specification, and when they are ial degree, say, 17-36 %o, preferably 25-35 %, heated for brief periods, the pliable sheath 70 and steamed briefly to render only the sur and brittle core described in our above face portion of the grains pliable and gelat specification are produced, as well as the inized The rice is compressed, steamed for results of compression and drying therein an additional period to complete gelatini described The same results are obtained zation throughout the rice grains and then when parboiled or otherwise pregelatinized 75 dried in any suitable manner Before dry dry rice grains are moistened, compressed ing the rice may be soaked in hot or cold and dried as in procedures 5 and 7 outwater as desired to increase its moisture lined above.

content to 60-70 %O in which case it is pre But relatively long periods of heating the ferably dried using relatively high tempera soaked grains will produce grains that ares O tures and air velocities substantially completely pliable throughout.

4 Dried, milled rice, either ungelatinized A similar condition is produced when the or parboiled or otherwise gelatinized, is grains, either ungelatinized or parboiled, placed in hot or boiling water to raise the are placed in hot or boiling water to inmoisture content to 60-70 %, and in the crease their moisture content to about 60-85 case of the former, effect gelatinization The 700, as in the fourth procedure, and

811/2197

when rice is compressed and thereafter dried, pre previously gelatinized rice is steamed long ferably at relatively high temperatures and enough to increase its moisture content to air velocities 17-25 /as in the sixth procedure in the 5 Dried, milled, parboiled or otherwise eighth procedure on the other hand the 90 gelatinized rice is contacted briefly with external portions after drying may be somewater to moisten the surface of the grains what less moist and hence less pliable than and then steamed for a short period, the the internal portions but are still sufficiently moistening and steaming serving to increase pliable to prevent disintegration of the the overall moisture content of the rice by grains during compression 95 1-5 %, the bulk of the moisture being con In the preferred e-ibodilment of the incentrated at the surface of the grains The vention, ungelatinized milled white rice (the rice is then mechanically compressed and ordinary rice of commerce) is treawed subdried in any suitable manner stantially as set foth in our above specifica6 Dried, parboiled or otherwise gelatin tion except that the moisture content after 100 ized rice is steamed for a sufficient time to soaking ma sometimes be hioher than increase the overall moisture content of the specified therein say 36 and mray somerice to 17-25

%' and render the entire grain times be inceased during steaming by as fully pliable The rice is then mechanically much as 8-,; at such higher moisture concompressed and dried in any suitable man tents the steaming period may be as little 105 ner In the case of rough rice, the com as 3 minutes

Compression of the grains pression step serves to crack and loosen the then takes place between rolls as set forth hulls which may be separated from the in our above specification.

grains in any conventional manner in the case of grains having relatively 7 Dried, milled, parboiled or otherwise high moisture contents, e g, in the neigh 10 gelatinized rice is placed in cold water for a bourhood of 65 %, a press may be preperiod of time sufficient fo raise its moisture ferred to rolls in order to avoid undue disto 30-70 %, say, 30-60 minutes The rice is integration of the grains.

then compressed and dried While any suitable drying method can be 8 Ungelatinized, milled rice is soaked to employed, circulation of heated air through 115 increase its moisture content to a substanial a bed of rice is highly efficient and usually degree, say 30 %,0, steamed to substantially to be preferred

Any temperature may be fully gelatinize the grains throughout and used below that at which scorching or disincrease its moisture content to about 350,', coloration occurs say 375 4 f J O F ShrinkThe rice is then dried in any conventional age may occur at temperatures of the order 120 manner to 17-25 %, compressed and dried of 150 '-200 F, however and when the It is preferred that a tempering step be em moisture content of the rice is high, say ployed after the first drying step so that the 55-70 %, temperatures and air velocities of moisture distribution within the grains may the order of 280 F and

200 ft /mill are be uniform and the moisture of the exterior preferred In the case of relatively low 125 portions be thereby increased so that said moisture content, say 17-40 K, still higher portions will have greater pliability temperatures of the order of 325 '-350 'F.

When it is desired to soak the rice prior have the advantage of producing a slight ento steaming or cooking, 30 minutes soak largement of the grains.

ing at room temperature is generally suffi EXAMPLE I 130 784,865 784,865 pounds of ungelatinized white rice ith a moisture content of about 12 are placed in a 100 gallon vessel or tank together with about 60 gallons of water and allowed to soak for 30 minutes at room Temperature ( 75 F) Thereafter the rice is transferred from the tank to a screen and allowed to drain for 15 minutes At this point the rice contains about 30 %,' of moisl: ture Satisfactory results are obtained in accordance with this embodiment of the invention if the conditions of soaking are varied so that the moisture content may range from about 17 %, to about 36 %, preferable results are obtained at 25-35 %.

Then the rice is transferred to an 80 gallon autoclave and treated with dry steam at 8 pounds gauge pressure for 5 minutes at the end of which time the outer portions of the rice grains are substantially completely gelatinized containing no birefringent material and the inner portions while somewhat gelatinized still contain an appreciable amount of ungelatinized starch granules or birefringent material

The overall moisture content of the grains after steaming is about 34 %- 7 Generally, rice prepared in this manner may have a moisture content of about 17-40 %, and be suitable for compression The rice grains are then removed from the cooker and transferred to a conveyor belt, being spread out thereon in a layer about one grain thick The grains are thus conveyed to and passed between smooth rolls set to reduce the thickness of the grain to about % of their thickness before compression.

812/2197

After passing through the rolls the rice is dried in any conventional manner to a stable moisture content of 10 to 14 % A convenient and rapid way of effecting drying is to employ a forced draft, hot air drier using ir at 325 -350 F, the drying being effected in 5-10 minutes The product has a density of

0 70 g /cc It is then packaged and distributed in the usual commercial manner.

EXAMPLE II pounds of ungelatinized white rice with a moisture content of about 12 % is placed in a

100 gallon vessel or tank together with about 60 gallons of water and allowed to soak for 30 minutes at room temperature ( 75 F) Thereafter, it is transferred from the tank to another tank containing boiling water and boiled for about 10 minutes to fully gelatinize an hydrate the grains raising their moisture content to 65 % The rice is then cooled and transferred to a horizontally moving screen o 60 from the end of which it falls onto one of a pair of smooth compression rolls spaced apart sufficiently to compress the grains to about 70 %, of their thickness before compression In order to facilitate handling at to this point a stream of cold water is played onto the same roll onto which the rice grains are deposited so that at the time of compression the grains are in effect slurriel in water this prevents the grains from sticking to the rolls so that disintegration is 70 prevented oi at least minimized From the rolls the compressed rice grains and the water fall onto a horizontally moving screen The rice grains are drained in the first tfew feet of their travel on the con-75 veyor Thereafter, hot air at a temperature of about 285 F is blown upwardly through the bed of rice grains at an air velocity of about 200 feet per minute If desired, at a subsequent point in the screen's travels the 80 hot air may be passed downwardly through the bed of rice grains In this manner, the relatively enlarged size of the grains resulting from the complete gelatinization and hydration of the rice is preserved to a great 85 degree and the rice is reduced to a stable moisture content of 10,14 %, the final product having a density of 0 25-0 45 g /cc.

EXAMPLE III 90 pounds of milled, parboiled or otherwise gelatinized, dried rice with a moisture content of about 12,', are placed in an 80 gallon autoclave and steamed at 8 lbs,'sq.

in (gauge) for 8-10 mrinutes to raise the 95 moisture content thereof to 22 % and render said grains completely pliable throughout Thereafter, said grains are compressed by passing the same through rolls, spaced so as to reduce the grains to about 60 %, of 100 their thickness before compression, and the rice is dried to a stable moisture content of 10-14 %, in the manner described in detail in Example I above, the final product having a density of 0 70-0 75 g /cc 105 EXAMPLE IV pounds of milled, parboiled or otherwise gelatinized, dried rice with a moisture content of about 12 % are placed in about gallons of water contained in a 100 gal-110 lon tank at room temperature ( 75 F) and allowed to soak in the water for two minutes The soaked rice is then removed from the water, drained for a half minute and placed in an 80 gallon autoclave and 15 steamed at 8 Ibs /sq in (gauge) for 1-2 minutes to render the surface portion of the grains pliable and increase the overall moisture content of the grains by about

%, the interior portions of the grains re-120 maining substantially unchanged Therearter, said grains are compressed by passing the same through rolls, spaced so as to reduce the grains to about 80 % of their thickness before compression, and dried to 125 a stable moisture content of 10-14 % in the manner described in detail in Example I above.

EXAMPLE V pounds of milled, parboiled or other 130 wise gelatinized, dried rice With a moisture content of about 12 'o are placed in about gallons of water in a 100 gallon tank and allowed to remain therein for about one hour at room temperature ( 75 F) and raise the moisture content of the rice to 50,

The rice is then drained for 15 minutes Thereafter said grains are compressed by passing the same through rolls, spaced so as to reduce the grains to about 80 ' of their thickness before compression, and dried to a stable moisture content of 10-14 ', in the manner described in detail in Example I above The density of this product is O 65-0 75 g /cc.

EXAMPLE V 1 pounds of ungelatinized rice with a moisture content of 12 %, is placed in a 100 gallon tank together with 60 gallons of water and soaked for 30 minutes at room temperature ( 75 F)

Thereafter it is transferred from the tank to a screen and allowed to drain for 15 minutes At this point the rice contains 30 %, moisture The rice is transferred to an 80 gallon autoclave and treated w.ith steam at 8 lbs /sq in for 10 minutes and completely gelatinized Thereafter the rice is returned to the soaking tank and allowed to soak in the water for an additional period of 20 minutes which serves to increase the moisture content of the rice to about 65 ',, The rice is then removed from the soaking water, drained for 15 minutes.

813/2197

blasted with cold air to toughen the surfaces of the grains and then subjected to mechanical compression by passing the same through rolls spaced so as to reduce the grains to about 70, of their thickness before compression and dried to a stable moisture content of 10-14-, as described in detail in

Example 11 above The density of this product is 0 4 g /cc.

If desired, the rice may be soaked and 45steamed to fully gelatinize the same, compressed and then soaked in water to fully hydrate the same to 60-70, moisture and then dried.

Also, the rice may simply be soaked, steamed to fully gelatinize the same, and then compressed and dried.

EXAMPLE Vli pounds of ungelatinized white rice with a moisture content of about 12 %, is placed in a 100 gallon vessel or tank together with about 60 gallons of water and allowed to soak for 30 minutes at room temperature ( 75 F) Thereafter the rice is transferred from the tank to a screen and allowed to drain for 15 minutes At this point the rice contains about 30 % of moisture The rice is then transferred to an 80 gallon autoclave and steamed at 8 Ibs /sq.

in (gauge) for 5 minutes at the end of which time the outer portions oi ile rice grains a,:

completely gelatinized ailnd the inner p):tions:h:ile some;haic gelatinzedl still contain an appreciable amount of ungelatinizec starch granules The rice grains are then 70 compressed by passing the same through rolls spaced so as to reduce the grains tc about 70 ',, of their thickneses before compression as described in detail in Examples I and 11 above The rice is then returned 75 to the 80 gallon autoclave and steamed for an additional 5-10 minutes to render the same completely gelatinized throughout.

after which it is removed from the autoclave and dried to a stable moisture content of 80 about 10-14

', using the drying condition described in Example 1 The density of this product is 0 50-0 70 g /cc.

I will be evident that at any appropriate stage in the process the rice grains can be 85 washed with water or solvent extracted te decrease their fat content and thereby decrease any problemn of rancidificazion thamight exist Also any suitable antioxidant catn be added if desired One very eff-90 ective method of eliminating any possibility of a rancidity problem is to soak the rice il.

hot water, say, at 175 '-30 n F for 5-10 minutes This may be employed at any stage of the process, but it is preferred that 95 it should follow the preliminary soaking step which is employed in many of the embodiments of the invention described above.Data supplied from the esp@cenet database -

Worldwide Claims:


What we claim is: 100

1 A process for preparing quick cooking rice which comprises subjecting rice grains.

having exterior portions of moist, substantially completely gelatinized starch in a completely pliable condition and interior por-105 s tions ranging from relatively brittle at least partially gelatinized starch to substantially completely gelatinized starch in a completely pliable condition, mechanicai compression to distort and modify the 110 structure of the rice grains without reducing them to a flaked condition.

2 A process according to Claim 1, in which the rice grains are hydrated before said mechanical compression 1155 3 A process according to Claim 2, in which said rice grains contain from 60-70 ' moisture before said mechanical compression.

4 A process according to Claim 1, in 120 which ungelatinized rice grains are soaked in water below their gelatinization temperature to increase their moisture content to 17-36 %,, and the soaked rice grains are steamed to substantially completely gelatin-125 ize the same and to further increase their moisture content, preferably not in excess of 40 %, before said mechanical compression.

814/2197

A modification of the process according to Claim 4, in which the steamed rice 130 784,865 grains are further soaked in water to increase their moisture content to 60-70 % prior to said mechanical compression.

6 A process according to Claim 1, in which dried ungelatinized rice grains are soaked in hot or boiling water to increase their moisture content to 60-70 % and to substantially completely gelatinize the same prior to said mechanical compression.

7 A process according to Claim 1, in which previously gelatinized and dried rice grains are steamed for a sufficient period of time to render the rice grains substantially completely pliable throughout prior to said mechanical compression.

8 A process according to any of Claims 1 to 7, in which said rice grains are compressed to reduce their thickness to from % to 80 % of their thickness before said mechanical compression.

9 A process according to any of Claims 1 to 8, in which the compressed rice grains are finally dried to a moisture content of 10 to 14 %.

A process according to any of Claims 25 1 to 9, in which rough rice grains are soaked and steamed and the hulls are loosened from the rice grains during said mechanical compression and thereafter separated from said grains 30 11 A process for preparing quick cooking rice substantially as hereinbefore described with reference to the examples.

12 Quick cooking rice whenever prepared by the process according to any of 35 Claims 1 to 11.

STEVENS, LANGNER, PARRY & ROLLINSON.

Chartered Patent Agents.


Printed for Her Majesty's Stationery Office by Kingston Printers Ltd, Portsmouth 335/3 -1955.

Published at The Patent Office, 25 Southampton Buildings, London, W C 2, finn bhich copies way be obtained.

SData supplied from the esp@cenet database - Worldwide

815/2197

175.

GB804923 - 11/26/1958

IMPROVEMENTS IN OR RELATING TO READY-TO-EAT FOOD PRODUCTS


Applicant(s): KELLOG CO (--)

E Class: A23L1/164F2



Family: GB804923

Abstract:


In making ready-to-eat cereal flakes, cooked and dried pliable particles of rice or maize moving in a continuous stream are spray-coated with warm water, then promptly mixed and uniformly coated with uncooked high-protein-content flour containing more than 50 per cent. by weight of wheat gluten and rolled into flakes, which are baked, e.g. for 15 to 30 seconds in an oven at 390 to 450 DEG F. to puff the flakes slightly and give them a light-golden colour, and are then finally cooled, e.g., after having been sprayed with a vitamin solution. The flour may comprise form 15 to 30 and the rice or maize from

85 to 70 per cent. by weight, of the flakes. The cooked and dried rice or maize particles may contain 20 per cent. by weight of water and may be flavoured with salt, malt extract, syrup or sugar. The amount of water added to them during spray-coating may be between 8 and 14 per cent. of the total weight of solid matter in them. Before the flakes are baked, they may be dried until they contain between 10 and

15 per cent. of water. The particles of rice are, preferably, whole grains: the particles of maize may be relatively large grits. The total protein-content of the flour may be between 60 and 80 per cent. A suitable flour contains the following substances in parts by weight: wheat gluten 1000, wheat-germ meal 180, dried skim milk 125, dried, debittered brewer's yeast 31.ALSO:In making ready-to-eat cereal flakes, cooked and dried pliable particles of rice or maize moving in a continuous stream are spraycoated with warm water, then promptly mixed and uniformly coated with uncooked high-proteincontent flour containing more than 50 per cent by weight of wheat gluten and rolled into flakes which are baked, e.g. for 15 to 30 seconds, in an oven at 390 DEG to 450 DEG F. to puff the flakes slightly and give them a light-golden colour, and are then finally cooled, e.g., after having been sprayed with a vitamin solution. The flour may comprise from 15 to 30 and the rice or maize from 85 to 70 per cent, by weight, of the flakes. The cooked and dried rice or maize particles may contain 20 per cent of water and may be flavoured with salt, malt extract, syrup or sugar. The amount of water added to them during spray-coating may be between 8 and 14 per cent of the total weight of solid matter in them. Before the flakes are baked, they may be dried until they contain between 10 and 15 per cent of water. The particles of rice are, preferably, whole grains; the particles of maize may be relatively large grits. The total protein-content of the flour may be between 60 and 80 per cent. A suitable flour contains the following substances in parts by weight: wheat gluten 1000, wheat-germ meal 180, dried skim milk

125, dried, debittered brewers' yeast 31.Description:



804,923 Date of Application and filing Complete Specification Feb 24, 1956.

No 5804/56.

816/2197

Application mode in United States of America on April 18, 1955, Complete Specification Published

Nov 26, 1958.

Index at acceptance: -Classes 49, B 1 (B: H: K: L: W); and 58, C 2.

International Classification: -A 231 F 26 c.


Improvements in or relating to Ready-to-Eat Food Products We, KELLOGG COMPANY, a corporation organized and existing under the laws of the State of Delaware, United States of America, having a place of business in the City of Battle Creek, State of Michigan, United States of America, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to the production of ready-to-eat food products of the breakfast cereal type.

More specifically, the present invention relates to the production of flaked products of composite character and enhanced nutritional properties, and to the novel composition thereof and the manner of making same.

It is a particular object of the present invention to enhance the protein content of such high-starch lowprotein content materials as rice and maize and accordingly the invention provides a ready-to-eat composite palatable flaked food product of the breakfast cereal type comprising baked flakes of cooked particles of rice or maize, having a coherent coating of relatively high-protein-content flour containing more than 50 % by weight of wheat gluten, said flour being uncooked prior to the baking step.

The invention further provides a method of forming a composite palatable flaked food product of the breakfast cereal type which comprises continuously moving forwardly a stream of cooked and dried pliable particles of rice or maize, spraying and mixing said particles with warm water to coat their surfaces therewith, promptly admixing with said moistened particles, and before absorption thereby of said moisture, a quantity of uncooked relatively high-protein-content flour containing more than 50 % by weight of wheat gluten, to adherently and substantially uniformly coat said particles with said flour, promptty rolling the resulting coated particles lo form flakes, and baking the flakes to a slightly puffed condition.

It is known to form cereal products of enhanced protein content of other types and compositions, such as shreds, by jointly oook' ing rice, corn or the like particles with soya bean particles, subsequently masticating the composite under pressure, as by shredding to form a substantially uniform divided homogeneous composite, followed by toasting the resulting shreds On the other hand, an attempt to form a flaked composite by cooking maize particles, and intermediate the cooking adding defatted soya bean particles, of a size capable of passing through a sieve having 10 openings per linear inch, in the proportion of one-third by weight of the corn, followed by drying, rolling into flakes and toasting, resulted in a non-uniform product containing a considerable proportion of separated soya fines which became much darker than the remaining comp 6 sited material, and further the product had a distinctly noticeable beany and bitter taste characteristic of the original soya bean material, all of which rendered the product unsatisfactory as a ready-to-eat composite food product of the breakfast cereal type.

As distinguished from the foregoing, the product formed of the components and by the process of the present invention is of a uniform character wherein the added highprotein-content material remains firmly associated with the surfaces of the flakes, and is highly palatable and easily assimilated and digestible.

In carrying out the process of the present invention, we employ particles of rice, preferably in the form of whole kernels, or maize particles of relatively large size, such as No 4 grits, i e of a size capable of passing through a screen having 4 linear openings per inch, these materials having a relatively low protein content in the order of 7-8 % These particles are first washed and steamed and then subjected to cooking in water, together with seasoning and colouring material, such as salt, malt extract, syrup, sugar, in a conventional manner such as, for example, in a rotary cooker under 15 to 25

817/2197

pounds per square inch steam pressure for a period of between one to two hours, or until the particles are uniformly cooked throughout, with no free white centres, and until they are soft and pliable but still individual particles The cooked particles are then discharged at a moisture content of about 40 %, dried in a suitable manner, as with air at a temperature of 1401150 F.

for about ten minutes to a moisture content of about 25 % and tempered for five to six hours at 100-

115 ' F Any adhering particles are separated and the resulting particles are further dried at a temperature of 245-255 F to a 21-22 % moisture content and then permitted to cool at normal room temperature for about 60 minutes to a moisture content of approximately -20 %.

These pre-cooked and dried particles after having been sprayed with warm water are then coated with a flour of from about 60 % to about 80 %' protein content and containing more than 50 %' by weight of commercial wheat gluten The cooked and dried rice or maize particles may comprise 70 % to 85 % and the protein flour 30 % to 15 % by weight of the composite food product, and the composite food product may thus be enriched to a total flour content as high as approximately % to 30 %, and preferably to approximately 20 % to 25 % by weight.

In forming the composite food product, the thus precooked particles are fed forwardly in a conveyor equipped with mixing and propelling paddles and, just prior to addition of protein flour, warm water is sprayed on to particles in the amount of from about 8 to about 14 % of water by total weight of the solids That is to say, the particles should not have an opportunity to absorb the added moisture before the protein flour is added, and the amount of added water is limited to permit the gluten content to become just sufficiently adhesive so that, by slow mixing for several minutes the particles can be uniformly coated and remain separated in individual particles with maximum retention of the proportionally added amount of protein flour The coated particles are then moved forwardly and permitted to temper for a few minutes and are then promptly fed between rolls and bumped to medium thin flakes.

These flakes are then dried to a moisture content of 10-15 %, tempered, and then baked for a short period so as to minimize destruction or modification of the proteins and also to convert the flakes to a slightly puffed, light golden condition After leaving the baking oven and before cooling, the flakes may be sprayed with vitamins.

The following is a specific example of a suitable protein flour composition having an average protein content of about 70 % and a moisture content of about 7 % by weight: Parts by weight Protein content

% Wheat gluten 1000 81-82 Wheat germ meal 180 33-35 Dried skim milk 125 34-35 70 Dried debittered brewers yeast 31 46-52 As previously indicated, the wheat gluten content should comprise a major amount by weight of the protein flour by reason of its 75 relatively high protein content, specific glutenous character and desirable amino acid content making possible introduction and secure association of a maximum amount of proteins with a minimum amount of material 80 The additional total minor amount of other, high protein content materials may be employed in various proportions and comhbinations, not necessarily restricted to the materials and amounts described, when 85 desired as a palatable supplement to the wheat gluten.

The following is a specific example of our process: Whole rice kernels cooked and flavoured 90 as previously described, and at a moisture content of 20 %, were passed through a feeder into a conveyor trough equipped with mixing and propelling paddles, moving at the rate of 26-30 revolutions per minute As the rice 95 kernels moved forwardly in a uniform stream, protein flour of the aforementioned composition was added thereto to provide 81 % of rice to 19 % of protein flour Just prior to the point of protein flour addition, water at a 100 temperature of 110-180 ' F was sprayed on to the rice at the rate of 10 % of the total weight of the two solids, the point of water introduction being about thirty seconds in advance of the point of protein flour introduc 105 tion, so that the rice was uniformly coated with water without being given an opportunity to absorb it before the flour was added.

Mixing while moving forwardly was then continued for approximately three minutes, 110 during which time the rice became evenly coated and separated into individual kernels, each carrying an adherent layer of protein flour If the speed of mixing is too great or if the rice has, an opportunity to absorb the 115 moisture before the flour is added, proper end results are not obtainable.

818/2197

The coated rice was then transferred to a slow moving belt to allow approximately four minutes for tempering and then conveyed 120 directly to bumping anolls and bumped tot form medium thin flakes

If too much time is allowed to elapse before bumping, the coating may fall off before it becomes firmly imbedded and adhered through the bumping 125 step The composite flakes were then dried to approximately 12 % moisture at about 165 F., tempered 25 minutes at approximately 1000 F and then passed through an oven and baked for 15 to 30 seconds at an oven 13 Q W 4.92 804,923 temperature of

390 0450 ' F, to a slightly puffed, light golden condition After discharge from the oven the flakes were subjected to a vitamin solution spray The flakes had a S protein content of approximately 20 % by weight.

WHAT WE CLAJM IS: 1 A ready-to-eat composite palatable flaked food product of the breakfast cereal type comprising baked flakes of cooked particles of rice or maize, having a coherent coating of relatively high-protein-content flour containing more than 50 % by weight of wheat gluten said flour being uncooked prior to the baking step.Data supplied from the esp@cenet database - Worldwide

Claims:


2 A food product as claimed in Claim 1 hav-

ing a flour content of from 15 % to 30 % by weight, wherein the cooked particles contitute 70 % to 85

% by weight of the product.

3 A method of forming a composite palatable flaked food product of the breakfast cereal type which comprises continuously moving forwardly a stream of cooked and dried pliable particles of rice or maize, spraying and mixing said particles with warm water to coat their surfaces therewith, promptly admixing with said moistened particles, and before absorption thereby of said moisture, a quantity of uncooked relatively high-protein-content flour containing more than 50 % by weight of wheat gluten, to adherently and substantially uniformly coat said particles with said flour, promptly rolling the resulting coated particles to form flakes, and baking the flakes to a slightly puffed condition.

4 A method according to Claim 3, wherein the flour comprises from 15 % to 30 % and the cooked and dried rice or maize particles comprise 85 % to 70 % by weight of the composite food product.

A method as claimed in either of Claims 3 or 4, wherein the pliable particles of rice or maize are dried to a moisture content of approximately 20 % by weight, and wherein the warm water added to said rice or maize particles forms some 8 % to 14 % of the total weight of the solids in the food, the mixing being continued after addition of said flour to form individual particles with an adherent substantially uniform coating of said flour, and the coated particles, after having been rolled into flakes, being passed through a heated oven for baking.

6 A method according to Claim 5, wherein the oven is heated to a temperature of 3900 F to 450 F, and the flakes remain in the oven for a period in the region of 15 to 30 seconds.

7 A method according to any one of the preceding Claims 3 to 6 which comprises drying the flakes to a moisture content of approximately 12 %, prior to baking.

8 A ready-to-eat composite palatable, flaked, baked food product of the breakfast cereal type substantially as hereinabove described.

9 A method of forming a ready-to-eat composite palatable, flaked, baked food product of the breakfast cereal type substantially as hereinbefore described.

HASELTINE, LAKE & CO, 28, Southampton Buildings, London, England, Agents for the Applicants.

Leamington Spa: Printed for Her Majesty's Stationery Office, by the Courier Press,-1958.

819/2197

Published at the Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

820/2197

176.

GB807084 - 1/7/1959

A METHOD OF PREPARING QUICK-COOKING AND NON-GLUTINOUS

CEREALS


Inventor(s): RUTGERS REIJER (--); SCHUT JOHANNES (--)

Applicant(s): KONINK PELLERIJ MERCURIUS V H (--)

E Class: A23L1/182; B02B1/00



Family: GB807084

Abstract:


In a method of preparing quick-cooking cereals, e.g. from rice or groats, the grains, unhusked if necessary, are cooked with a moderate amount of water at a temperature up to 130 DEG C. preferably under a superatmospheric pressure up to 2 atmospheres, until they have a final moisture content of at most 60 per cent., and are dried in two stages, viz., a rapid drying above 130 DEG C. to form porous grains, and an after-drying below 130 DEG C. The cooking, which substantially gelatinizes the grains, is such that a loose granular mass is obtained, e.g. by keeping the mass in movement and by supplying steam directly only in the later cooking stage. Drying is by means of a hot gas, such as air, in a drum drier, or the grains may be dried in vacuo. A thin coating of starch or talc applied to the grains on drying separates them from each other and from the wall of the drying vessel. The grains may be weakly crushed, preferably after the cooking, without causing the formation of flakes; if crushed prior to cooking the grains are soaked in water below 50 DEG C. until 30-50 per cent. of water is absorbed, they are then slightly crushed, cooked with a small amount of added water and with steam and dried in two stages as described above. Tempering treatments may be applied to the grains at any stage of the process to prevent the grains from caking together. The colour of the final product may be improved by cooking in the presence of a little acid, e.g. hydrochloric, sulphuric, tartaric or citric acid, or vitamin C.

Flavourings such as sugar solution and/or malt extract may be added. Salt, minerals and vitamins as nutritives can also be added.Description:



Inientors: RETJER RUTGERS and JOHANNES SCHUT 8079 084 Date of Application and filing

Complete Specification Aug 9, 1955.

No 22884/55.

Complete Specification Published Jan 7, 1959.

Index at'acceptance: -Class 58, A 3 B, AI( 3: 4 C: 6 A: 6 82: 6 C: 6 D: 6 X: 7).

International Classification: -BO 2 b.


821/2197

A method of preparing Quick-Cooking and Non-Glutinous Cereals We, N V KONINKLIJKE

PELLERIJ " MERCURIUS " V/H GEBROEDERS LAAN, a company organised under the laws of the

Netherlands, of Veerdijk, Wormerveer, Netherlands, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a method of preparing quick-cooking and non-glutinous cereals.

Cereal products, especially rice and groats, are mostly consumed in the form of grains.

However, the cooking of cereals takes rather a long time Husk bearing cereals, such as barley, oats or rice, are previously unhusked. the grains need not be polished.

The object of the invention is the preparation of rapidly cooking cereals, the grains of which after the cooking largely retain their normal shape and outward appearance, so do not cook down to a porridge, but remain separated and are non-glutinous.

The method according to the invention is characterised in that grains are cooked for a considerable time with a moderate amount of water, preferably under pressure at a temperature up to 1300 C until a final moisture content of at most 60 % is reached, whereupon drying is effected in two steps, a rapid drying above 1300 C in order to form porous grains and an after-drying at a temperature lower than C.

The grains may be weakly crushed, preferably after the cooking.

By effecting the drying in the manner stated above the grains will expand slightly and pores are formed The grains, however, substantially retain their original shape If the finished grains are cooked for a short time with water, the grains will substantially assume the shape.

which untreated grains would assume, the difference being that the former will not cook to pieces and will become done and soft much more rapidly.

The method according to the invention essentially differs from the so-called parboiltreatment, in which treatment the grains are moderately steamed with the use of a small amount of water and are dried at a rather low temperature until solid grains are formed, the cooking time of which does not differ much from that of untreated cereals.

The moisture content of the grains prior to their being weakly crushed according to the invention generally amounts to at least 30 %.

The present method differs from the known methods not only in the manner of drying, but also by the manner of cooking and by the moisture content of the grains after the cooking In addition it is more economical.

The cooking under pressure and/or with the me of a limited amount of water is known per se and is very usual in the preparation of so-called breakfast-cereals Insofar as in the method of preparing breakfast-cereals, semolina or flour are started from, the raw material is already different In some methods whole grains or large grain parts are treated In breakfast cereal production methods, however, flakes and puffed products e g the so-called crispies, are prepared, which are very strongly swollen and porous Said known products are also prepared in various other manners e g.

without pre-cooking, from flour When mixed or cooked with liquid the grains do not obtain their original shape again Furthermore these known products are of a brown colour The difference between the present method and the known methods consists inter alia in that in the latter methods the heating treatment is applied to a relatively dry (moisture content 5-15 %), hard product, so that a final structure is obtained that is entirely different from the final structure of the products obtained by the method according to the invention.

822/2197

The method according to the invention mav be carried out as follows:The cereals are cooked with a moderate amount of water, which is entirely or largely absorbed by the grains, so that there is no An_; s

S r a-I large amount of cooking water left, in which much material, e g salts, lower carbohydrates, amino acids and starch, could dissolve or disperse, and thereby be lost The cooking may be effected at atmospheric pressure, but preferably a superatmospheric pressure up to 2 ats and a temperature up to

1300 C are used; very suitable is a superatmospheric pressure of from O 7-1 O ats and a temperature ranging between 115-1200 C The cooking is so effected that a loose granular mass is obtained This may be achieved, e g, by keeping the mass in movement and by supplving steam directly only in the later cooking stage The cooking is continued until the grains have substantially gelatinized Should the cooked product form a rather loose mass instead of solid cakes, said loose mass may be further loosened into separate grains, if desired after tempering.

The above temperatures relate to the cereals.

The steam used may also be slightly superheated.

The cooked grains may be weakly crushed, both in hot condition immediately after the cooking and after the cooling, preferably at a temperature of from 30-40 C It is also possible to appjy a tempering time between cooking and crushing The crushing of the grains should not cause large deformations, which might result in the formation of flakes.

The crushing can be effected by means of a light pressure, e g by passing the grains between crushing rollers that are spaced rather far apart After the crushing and prior to the drying process a tempering treatment may be applied which consists essentially of allowing the grains to stand for a period of time such that the moisture and temperature distribution throughout the grains become more uniform and thus counteracts a caking together, if any, of the grains.

The grains may also be crushed prior to the cooking In this case they should first be soaked at a temperature of 50 C or lower until 30-50 % of water has been absorbed.

After the crushing operation the grains are then, if desired after a tempering, cooked with water and steam at temperatures up to 1300 C, preferably 1150 C to 1200 C The cooking must be carried out carefully then in order to retain a loose mass of grains; the temperature should be gradually increased.

It will be appreciated that the tempering treatment may be applied one or more times between the steps of the method i e between crushing and cooking and/or between cooking and crushing and/or between cooking and drying and/or between crushing and drying.

The crushed or uncrushed cooked product has a moisture content ranging between 30 and 60 % The moisture content amounts to e.g 30-35 %O in the case of rice and in the case of groats to 43-50 % O

The drive is effected so rapidly that the grains will swell and become slightly porous, the temperatures applied ranging between 130 and 300 C In case hot drying air is used the temperature to be applied also depends on the speed of the air An embodiment of the drying is e g the 70 drying in a drum-dryer, in which the drying may be carried out in two stages, first at a high temperature of e g 200-260 C, until the grains have somewhat swollen and have obtained a fixed hard wall Thereupon the 75 drying is continued at a temperature below 1300 C until a dried entirely fixed spherical final product has formed, which preferably has a moisture content of from 4-14 % The shape and the colour of the finished product 80 strongly resembled that of the starting material; however, the grains have a lower density.

After the cooking the grains sometimes are still slightly wet The working up of the 85 grains may then be facilitated by the provision thereon of a thin coating of starch, cold swelling starch, or powdered talc, whereby the grains are kept separate from each other and from the wall of the drying vessel 90 For carrying out the drying process any suitable drying apparatus may be used.

A drying of the grains while they are in movement is preferred, more particularly the drying by means of a rotating drum-drying 95 apparatus The grains may also be dried in vacuao Furthermore it is possible to pass a hot gas over the grains; it is also possible to heat the dryer externally.

823/2197

The cooking time of the product slightly 100 varies in dependence on the operating conditions and also in dependence on the type and the variety of cereal In the case of rice it usually amounts to 2-7 minutes, in the case of groats this time is slightly longer 105 In order to improve the colour of the final product a little acid, e g hydrochloric, sulphuric, tartaric or citric, may be added to the water during the cooking.

The colour of the product may be improved 110 by the addition, prior to the cooking, of a small amount of vitamin C to the cereals This amount may be added to the cooking water.

It is also possible previously to soak the cereals in a solution of vitamin C until the desired 115 amount has been absorbed The remainder of the amount of water to be used is then added prior to the cooking The improvement of the colour relates both to the pre-cooked intermediate product, the dried product and to 120 the food prepared by cooking the product.

The method according to the invention is not only suited for the preparation of products from whole grains, but it may also be applied to coarsely broken grains 125 If desired, the taste and smell of the product may be modified The natural smell of the grain may be weakened by blowing off steam during the cooking and also additional smells, if any, may be removed in this manner Fur 130 807,084

807,084 thermore it is possible prior or after the cooking to add a flavouring substance, e g a sugar solution and/or malt-extract It is also possible to add salt, minerals and vitamins as nutritives.

The invention will be described with some examples.

EXAMPLE I.

2000 grams of groats are introduced into a pressure cooker together with 1200 mls of water and with the application of jacket heating, are cooked for 75 minutes at a superatmnospheric pressure of 0 7-0 8 kg /cm ' and a temperature of 115-118 C The groats are subsequently discharged and cooled to 30 C; subsequently the product is weakly crushed During the crushing the moisture content amounts to 50 %.

The groats are subsequently dried at about 250 C When after a short time e g 2-3 minutes, the grains have obtained their correct shape and a fixed wall the temperature is lowered to 130 C and the groats are further dried at this temperature until they have a moisture content of 11 %.

EXAMPLE II.

2000 grams of groats are soaked in 1200 mls of water in which 1 gram of ascorbic acid has been dissolved, until 350 mls of the solution have been absorbed The greats are introduced into the pressure cooker with 850 mls.

of water and further treated as indicated in Example I.

The product has a lighter colour than the product according to Example I.

EXAMPLE III.

2000 grams of groats are introduced into a rotating pressure cooker with 1000-1200 mls.

of water and cooked with the application of jacket heating for 30 45 minutes at a superatmospheric pressure of from 0 7-0 8 kg / cm.' and a temperature of 115-118 C Subsequentiy a little excess water is removed, if necessary, and the cooking is continued by supplying superheated steam at 130-140 C.

to the cooker until the cooking time totals 75 minutes During this cooking a superatmospheric pressure of 0 7-0 8 kg /cm 2 and a temperature of 115-120 C is maintained.

The moisture content of the cooked product amounts to 60 %.

The groats are subsequently cooled and dried according to Example 5 to form a somewhat porous product.

824/2197

EXAMPLE IV.

2000 grams of well washed rice are cooked with 700-800 mls of water in a pressure cooker with the application of jacket heating for 30 minutes at a temperature of 110-116 C and a superatmospheric pressure of 0 50.6 kg /cm 2 Subsequently the excess water is removed and the cooking is continued with moderately superheated steam at about 130 C During the steaming the temperature in the cooker is maintained at 116 C, the associated superatmospheric pressure being 0 6 kg./cm ' The duration of the cooking totals minutes.

The rice, after being discharged and cooled, is allowed to stand for 20-24 hours in a closed vessel

(tempering) in order to enable the moisture to distribute itself uniformly over the grains The moisture content amounts to about %.

The rice is weakly crushed and subsequently dried according to Example I to a somewhat porous product having the desired moisture content.

EXAMPLE V.

2000 grams of groats are soaked in 800 mls.

of water at 50 C The water is absorbed in about 3 hours, whereupon the groats are tempered for 16 hours Subsequently the groats are slightly crushed 800 mls of water containing 20 mls of 1 N HC 1 are added and the batch is heated to a temperature just above the gelatinization temperature ( 65-70 C).

When after 2 5-3 hours the dilute acid has entirely been absorbed, the temperature is slowly raised (in

30 minutes to 100 C) The last-named temperature is maintained for 40 minutes, whereupon the groats are discharged.

The moisture content then amounts to 50 %.

Finally the groats are dried in the manner as described in the preceding examples.

EXAMPLE VI.

2000 grams of coarsely broken groats are cooked with 1000 mls of water in a pressure cooker with the application of jacket heating for 60 minutes at a temperature of about 110 C and a superatmospheric pressure of 0 5 kg / cm.2 After discharging the groats their moisture content amounts to about 40 %

Subsequently the cooked broken groats are tempered for 8-10 hours and subsequently dried in the manner as described in the preceding examples.

EXAMPLE VII.

2000 grams of wheat grains are cooked with 1100 mls of water in a rotating pressure cooker with the application of jacket heating for 45 minutes with steam at 0 6-0 7 kg / cm.2 (temperature 115 C)

Subsequently excess water, if any, is removed and the cooking is continued directly with superheated steam ( 125-130 C) in the cooker until the cooking time totals about 90 minutes A superatmospheric pressure of 0 4-0 5 kg /cm ' and a temperature of 110-113 C aremaintained.

The moisture content of the cooked product amounts to 55-60 % The cooked product may subsequently be dried immediately or only after the crushing treatment, as desired The drying is in either case further carried out as in the preceding examples.Data supplied from the esp@cenet database

- Worldwide

825/2197

177.

GB822614 - 10/28/1959

FAT COMPOSITIONS AND PREPARATION THEREOF



E Class: A23L1/187; A23L1/30C; A21D2/16; A21D2/32; A23D9/013



Family: GB822614

Abstract:


A free-flowing fatty powder comprises a dried emulsion of a fat and a partial ester of a glycol with a saturated higher fatty acid encapsulated in a hydrophilic solid or in a mixture of such a solid and a sugar or other carbohydrate. The fat is exemplified by hydrogenated cottonseed, coconut, peanut and maize germ oil, lard, modified lard, butter, oleomargarine; the partial ester by a mono- or distearate, palmitate, laurate, myristate, ricinoleate or behenate of propylene glycol, and a monoester-containing preparation of such a fatty acid and a polyoxyethylene, butylene or dipropylene glycol; the hydrophilic solid by dried fat-free milk, whey and butter milk, sodium caseinate, soy protein derivative, gelatine, hydrolysed fish protein, egg albumen, dried whole egg or egg yolk, cellulose ethers, pectin, algins, gum arabic, gum tragacanth; the sugar by sucrose, dextrose, corn syrup solids, lactose, and the other carbohydrate by flour, a raw or gelatinized starch of wheat, maize, waxy maize, tapioca, sago, potato, sorghum or rice. The fat and partial ester, and lecithin, if used, are melted together, the melt is emulsified in a solution of the encapsulating solid, preferably with the aid of an homogenizer, and the emulsion is spray-dried. A stable topping may be made by whipping the powder with milk and vanilla flavouring, and a frozen dessert resembling ice-cream may be made by freezing such a whipped product. Cake mixes, for making up to batters with water and eggs, contain the powder mixed with flour, sucrose, sodium chloride, sodium bicarbonate, sodium acid pyrophosphate, and, if desired, dextrose or cocoa. Mayonaisse and hollandaise sauces may be made by mixing vinegar, salt, mustard, egg yolk and water with the powders. Spreads for sandwiches, canap>;\;es and hors d'oeuvres may be made by incorporating water and spices or onion juice with the powders. The powders may be incorporated in pudding powders and in milk shakes.Description:



NO DRAWINGS 822,614 Date of Application and filing Complete Specification May 25, 1956.

No 16223/56.

Application made in United States of America on June 23, 1955.

Complete Specification Published Oct 28, 1959.

Index at acceptance: -Classes 28 ( 1), B, L; and 49, Bl (A: B: C: H: J; L: T), B 6 (C: F).

International Classification: -A 23 d, g, b.


826/2197

Fat Compositions and preparation thereof We, GENERAL FOODS CORPORATION, a corporation organised under the laws of the State of Delaware, United States of America, of 250 North Street,

White Plains, New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to powdered freeflowing fat composition and to a process for preparing the same.

Powdered fat compositions consisting generally of small particles of fat encased in a coating of edible, water-soluble solids, and their use in various food products such as cakes, pastries, bread and toppings are well known.

It has been proposed, for example, to dry emulsions of shortening fat and non-fat milk solids either by spray drying or drum drying to provide a powdered free-flowing shortening composition The use of protein materials such as buttermilk solids, whey solids, whole eggs, egg yolks, gelatine, or hydrolysed soy protein gums such as cellulose ethers, gum tragacanth, gum acacia; and carbohydrates such as starches and sugars; either individually or in combination, as substitutes for the encapsulating nonfat milk solids has also been proposed Furthermore, improved powdered fat products have been prepared employing " emulsifiers " such as lecithin, partial esters of glycerol and the higher fatty acids, and partial esters of sorbitol and the higher fatty acids These powdered fat compositions offer the advantages of ease of handling and of incorporation with other dry free-flowing ingredients during the preparation of various food products They have enjoyed a fair amount of commercial success Their use has largely been limited, however, to products wherein the rate and amount of fat released on addition of an aqueous liquid is of relatively little importance For example, a large potential use of powdered fat compositions is in prepared cake mixes The present mode of incorporating shortenings into these mixes roughly parallels that of the housewife which involves the step of creaming the shortening with one or more of the dry ingredients such as sugar or flour This creaming step is necessary to ensure an adequate distribution of the shortening throughout a cake batter prepared from such a mix.

It is obvious that the use of powdered shortenings would provide a great advantage to a cake mix manufacturer, by eliminating the costly and time-consuming creaming operation and at the same time provide for an improved distribution of shortening throughout the resulting cake batter However, when the hitherto available powdered shortenings are employed in a cake mix, the quality of a cake prepared from such a mix is extremely poor and the reason generally attributed for this poor quality cake is the difficulty with which the fat portion of the powdered fat composition is released to be effective in cake baking For this reason, attempts have been made to improve the rate at which the shortening is released on contact with aqueous liquids However, for various reasons, none of these attempts has been completely successful and the use of powdered shortenings remains restricted to those areas where the rate of fat release is relatively unimportant.

Powdered fat compositions for use in preparing whipped topping are also well known.

These materials offer the advantage of ease of handling and of freedom from spoilage on storage for long periods of time However, because these products generally do not have the texture and appearance of natural whipped cream, they have not enjoyed a large degree of commercial success More important, however, these materials usually perform in an inconsistent manner, providing in many cases little or no overrun on whipping.

It is therefore an object of the present invention to provide a powdered, free-flowing fat composition which will effectively release its fat content upon contact with aqueous liquids.

Still another object of this invention is to provide a powdered, free-flowing fat composition which on reconstitution with milk or water and whipping will provide a whipped topping similar to whipped cream in texture and appearance and superior thereto in respect to stability.

In accordance with the present invention, there is provided a powdered, free-flowing fat composition comprising a dried emulsion of a fat and the partial ester of an edible glycol and a higher saturated,

827/2197

fatty acid in a matrix of hydrophilic encapsulating solids or a mixture of these solids -and carbohydrates or sugars.

The present invention also provides a method of making powdered, free-flowing fat composition which comprises melting the fat together with said partial ester, -and with lecithin if used, emulsifying the same-in a solution of the encapsulating solids, or a mixture of these solids and carbohydrates or sugars and then effecting spray drying.

The present invention yet further provides a powdered, free-flowing fat composition comprising 30 to

80 parts by weight of fat, 0 5 to parts by weight of hydroxylated lecithin, 5 to 30 parts by weight of non-fat milk solids, 2 to 35 parts by weight of sucrose and 3 to 20 parts by weight of propylene glycol monostearate Preferably, the encapsulating solids are proteinaceous in nature.

In this manner a powdered free-flowing fat composition is provided which is suitable for a wide range of uses including cakes, pastries, breads, toppings and spreads On incorporation of these compositions in the dry mixes, a mix which may be reconstituted in a very short time and with a minimum of effect is obtained and which, at the same time, provides a final food product of exceptionally high quality.

It has further been found that the addition of various lecithins, and their hydroxylated or phosphorylated derivatives, to the above fat composition provides for greater improvement in the rate of fat release on reconstitution, and improved quality in the final food product The term lecithin, as used herein is intended to mean phosphatide compositions derived from materials such as soybeans, maize, cottonseed, peanuts, egg yolks or liver, containing lecithin in varying degrees of purity Also, phosphatides modified by hydroxylation or phosphorylation may be employed Hydroxylated soy lecithin is preferred.

The benefits of this invention are particularly apparent in powdered fat compositions containing a shortening fat, non-fat milk solids and sugar In the preparation of these materials, the process which is generally employed requires that an emulsion be made of the fat in an aqueous solution of the milk solids and sugar This emulsion is then dried by any suitable means such as spray drying or drum drying

Where the material is drum dried, the final flaked product is comminuted to provide a powdered, freeflowing shortening In the case of spray drying, however, the final product is in a form which is particulate and free-flowing The particles in this latter case are generally considered to be hollow 70 spheres consisting of a matrix of the non-fat milk solids and sugar in which a fine distribution of fat globules is embedded.

The esters of a glycol and a higher fatty acid which may be employed according to this 75 invention include propylene glycol mono and distearate, mono and dipalmitate, mono and dilaurate, mono and dimyristate, mono and diricinoleate and mono and dibehenate Other glycols may be employed as the glycol portion 80 of the ester, but the presence of a monoester is essential These included the polyoxethylene glycols, the butylene glycols and di-propylene glycol, and include the polymers of the various simple glycols While all the glycols mentioned 85 here will function according to the invention in bringing about a rapid release of fat from the shortening composition on contact with aqueous liquid, propylene glycol is preferred as being the most effective Considering now 90 the preferred esters of propylene glycol and a higher fatty acid, mixtures of fatty acids may be employed For example, an ester prepared by reacting propylene glycol with commercial " triple pressed " stearic acid which contains 95 approximately 45 %,, stearic acid and 55 %,, palmitic acid has been found to function in an acceptable manner Also, esters prepared by reacting the propylene glycol with fatty acids from natural animal and vegetable fats such 100 as lard or hydrogenated cotton seed oil, have been found to be suitable but less preferred.

Best results have -been obtained according to this invention through the use of substantially pure propylene glycol mono-stearate and this 105 material is preferred The level of the glycol fatty acid ester employed in the composition of this invention will, of course, vary with the nature and type of ester employed and the intended end use of the compositions 110 Although relatively low levels of glycol fatty acid esters in the dry fat composition of the present invention provide improved -results when such compositions are employed in a cake mix or a powdered topping composi 115 tion, it is preferred -that the levels of such glycol esters contained in the fat composition be of the order of 10 % to 16 %' of such composition Also, the glycol esters may be employed in the fat composition with other

828/2197

emulsifiers 120 such as the mono and diglycerides higher fatty acid esters to provide the desired improvement in cake mixes or toppings.

The encapsulating solids which may be employed according to this invention include 125 all of those materials well known in the art.

The various hydrophilic colloids, such as nonfat milk solids, whey solids, sodium caseinate, soy protein derivatives, egg albumen, gelatine, hydrolyzed fish protein, buttermilk solids, 130 822,614

822,614 whole eggs and egg yolks may be employed.

Similarly, various gums such as the cellulose ethers, pectin, algins, gum arabic and gum tragacanth may be employed In conjunction with the above-mentioned materials, either alone or mixtures thereof, carbohydrates, such as flour, raw or gelatinized starches from various sources such as maize, tapioca, potato, sago, sorghum, rice, waxy maize, wheat and sugars, such as sucrose, dextrose, corn syrup solids and lactose may be employed These materials may be employed in any suitable combination.

It is preferred to employ, according to this invention, a mixture of non-fat milk solids from fresh skim milk and sucrose as the encapsulating solids.

Shortening fat constituents of these compositions may be any of those normally employed in the preparation of the particular food product to which the final composition will be directed For example, in preparing these shortening compositions for use in cakes or other baked goods, the usual shortenings such as lard, modified lard, hydrogenated cotton seed, coconut, peanut and corn oil, butter, oleomargarine, or any combination of food oils, semi-solid or solid fats, may be employed.

These materials may have the melting point range, saponification value, iodine number, and other characteristics found to be desirable in the preparation of the particular baked goods desired On the other hand, the characteristics or nature of the fat to be employed in a whippable topping composition may vary from that desired in a baked product.

In the preparation of the powdered fat compositions of this invention, the fatty constituents are melted together with the selected glycol fatty acid ester and emulsified in a warm solution of the encapsulating solids The mixture is then further emulsified by a suitable homogenizer and the emulsion is dried, as by roller drying or spray drying, preferably by spray drying.

It has been found desirable where milk solids are employed to limit the amount of heat which is applied to the composition after the milk solids have been added The preferred procedure, therefore, requires that the fatty materials be heated to a temperature of approximately 1600 F and that the milk solids and sugar solution be heated to from F to 1400 F The fatty materials and milk solids are then immediately mixed and emulsified, the resulting temperature of the emulsion being roughly 1500 F

This emulsion is then immediately cooled to approximately 100 ' F prior to drying The skim milk solids which are employed are preferably those from fresh skim milk, and drying temperatures during drying are preferably held to a minimum Spray drying, of course, permits the use of minimum temperatures during drying.

The compositions of this invention have been found to be useful in a variety of food products As aforementioned, the ability of these compositions to release the fat component quickly and effectively has a particular advantage in the case of prepared culinary mixes, and more particularly, those directed to the preparation of a shortening cake Not only do the powdered shortenings of this invention provide the expected benefit of ease of incorporation with the other dry ingredients during manufacturing of the mix but also the quality of the final cake is greatly improved This improved quality apparently is brought about by the improved manner in which the shortening fat is released during batter preparation and also because of a more favourable fat distribution throughout the prepared batter.

Furthermore, a batter can be prepared from these improved cake mixes with much less difficulty and in a shorter time than with conventional mixes For example, conventional mixes require the addition of liquid ingredients in at least two separate portions during batter preparation Also, from 3 to 5 minutes of mixing by machine or from 5 to 8 minutes of strenuous beating by hand is required to fully develop the cake batter On the other hand, the improved mixes of this invention are prepared by initially adding

829/2197

the total amount of liquid ingredients to the dry mix, followed by from 1 to 12 minutes of simple stirring by hand to provide a completely developed batter This reduction in time and effort required to fully develop a cake batter provides a significant improvement over conventional mixes.

The improved results attributed to the powdered fat composition of this invention are not restricted to baked goods For example, an excellent whipped cream substitute may be prepared by the simple addition of milk or water to the dry fat composition followed by vigorous beating in a household mixer for from 2 to 5 minutes In this manner, a whipped topping similar in many respects to whipped cream is provided This topping has improved stability and texture characteristics over those of the prior art including whipped cream The degree of overrun is increased and the work required to provide a whip is decreased In addition, where the usual prior products require-water for reconstitution, the present compositions can be successfully reconstituted and whipped with fresh whole milk This is a decided improvement, because the fat of the whole milk formerly interfered with the whipping of toppings of this type, resulting in decreased overrun and difficulty in whipping.

Following are specific examples of powdered fat compositions of this invention, and compositions in which they can be employed in concert with other materials.

-3 EXAMPLE 1.

Ingredients Parts by Weight Hydrogenated cotton seed oil 300 C congeal point 36 Propylene glycol monostearate 13 Hydroxylated soy lecithin 1 Sucrose 25 Non-fat milk solids 25 In preparing a powdered fat from these ingredients, the hydrogenated cotton seed oil, propylene glycol mono-stearate and lecithin are melted together and mixed at a temperature of 1600 F At the same time, the sucrose and non-fat milk solids are dissolved in 100 parts by weight of water and heated to 1400 F The two mixtures are combined with simple mixing and homogenized in a Manton-Gaulin homogenizer at 500 lbs per sq in (gauge).

The Manton-Gaulin homogenizer is a twostage positive pressure homogenizer with provision for varying the pressure on homogenizing valves in each stage The original valve type homogenizer was invented by Gaulin and consists of a valve and a high-pressure pump The Manton-Gaulin homogenizer is a modification of this consisting of a second stage in a second valve The emulsion after homogenization is cooled to below 1000 F and then fed directly to a spray drier operating at an inlet temperature of 3800 F to 390 F.

and an outlet temperature of about 220 F.

The spray dried is of a conventional design and comprises a cylindrical tower 10 feet in diameter and

30 feet in height The drier is of the cocurrent type wherein warmed drying air is introduced at the top of the drier and removed at the bottom The drier has a spray drying nozzle, ST-48-27 described fully in

" Industrial Spray Nozzles," published by Spraying Systems, Incorporated, 1953, Catalogue No 24, pages 25-27 The nozzle is located in the center of the drier, approximately 2 5 feet from its top and adapted to direct the atomized solution downwardly in a conical spray pattern An air sweeping device within the drier is preferably employed to Ingredients Sucrose Cake flour Sodium chloride Sodium bicarbonate Sodium acid pyrophosphate Powdered fat composition of Example 1 Cocoa Dextrose In preparing the above mixes, the ingredicnts are thoroughly mixed together by any of the usual means employed in intimately mixing dry powders In preparing a cake batter from these mixes, 20 ozs of the mix is added to one cup of water and eggs In the case of maintain the drier walls free from the dried material.

The emulsion is fed to the nozzle at a pressure of approximately 500 lbs per sq in 50 (gauge) The resulting particulate free-flowing powder is preferably cooled immediately to 350 F and thereafter stored at room temperature.

EXAMPLE 2.

In preparing a whipped topping from the material in Example 1, 4 ozs of the powdered fat composition is combined with one cup of milk at refrigerator temperature and whipped in a household mixer at high speed for 2 to 3 minutes The resulting product has an overrun of over 200,' and upon

830/2197

flavoring with a small quantity, for example one teaspoonful, of vanilla extract, has the texture, taste, and appearance of natural whipped cream In addition, the whipped product is extremely stable and remains substantially unchanged for a period of 24 to 48 hours in a refrigerator.

Furthermore, if the whip has collapsed slightly on storage, it may be rewhipped with no adverse effects.

EXAMPLE 3.

A highly acceptable frozen dessert very similar to ice cream is provided by placing the whipped product of Example 2 together with a teaspoonful of a suitable flavoring material into a tray and placing the same in a freezing compartment of a household refrigerator for several hours Thus, any flavoring material may be used to provide whatever flavor may be desired Therefore, flavors such as vanilla extract, chocolate, strawberry, apple or any other desired fruit extract may be used Unlike the usual frozen desserts, this material does not require mixing during frezing and the final frozen dessert is free from undesirable ice crystallization and has a fine, smooth texture.

EXAMPLE 4.

The powdered fat of Example 1 is employed very successfully as a shortening ingredient in prepared cake mixes Typical formulas of such mixes are as follows % by Wt % by=_Wt % by Wt.

White = Yellow Devil's Food 33.4 36 0 35 0 36.5 35 0 31 0 0.7 0 7 0 7 0.6 0 6 1 1 1.0 1 0 0 6 26.0 26 0

26 0 4 2.0 _ the Yellow and Devil's Food mixes, two whole eggs are employed for each 20 oz of mix,

110 while in the White cakes only two egg whites are employed.

The development of batter here is extremely simple After the mixed ingredients have 822,614

822,614 been thoroughly wetted with ingredients, which usually takes onds, an additional one minute ring by hand with a spoon is fully develop a cake batter TI also, of course, be carried out v household mixer, batter devel requiring only approximately 1 The batter is then divided be layer cake tins and baked at 20-30 minutes Where the batt, by hand, the resulting layers ha' ely good volume ranging on the 1200 cc in a White cake to 13 Yellow cake and 1350 cc in the cake The batters prepared by m: result in cakes having a voluk cc greater In general, this a increase of from 50 to 100 cc it cakes made from conventional mn more, these cakes are of an exce grade based on their shape, co grain and eating quality.

An additional important advar mixes is found after storage of several months Where convex lump badly, with consequent it culty in batter preparation, the mi cribed retain their free-flowing over long periods of storage and to prepare as they were original EXAMPLE 5.

Following are formulas of compositions found particular shortenings in cake mixes.

Hydrogenated cotton seed oil C congeal point Propylene glycol monostearate Hydroxylated soy lecithin Sucrose Non-fat milk solids Sodium caseinate In these two examples, the mi been replaced either partially o with sodium caseinate The emul pared and dried as in Example 1 dered fat product is employed as EXAMPLE 6.

A mayonnaise is prepared by gmns of the powdered fat produc 1 with 25 ml of vinegar, 0 5 mls of water, 1 g of mustard, egg yolk, and mixing these for o this manner, a mayonnaise of sui appearance and eating qualities is an alternative procedure, the eg and salt together with an algin are incorporated into the emulsic 1 prior to drying In this case, having the following composition the aqueous about 30 secIngredients of simple stir Hydrogenated cotton seed oil sufficient to ( 26 Fcongeal point) 52 he mixing can Propylene glycol monostearate 12 with the usual Egg yolk 12 opment again Propylene glycol alginate 1 minute Sugar 5 tween two 8 " Salt 4 375 F for Non-fatmilk solids 10 er is prepared

Lecithin, hydroxylated soy 2 ve an extrem Sodium caseinate 2 average from An emulsion of these materials is prepared 00 cc in the and dried according to the procedure outlined Devil's Food in

Example 1 In this manner, a dry, fat conachine mixing taining, mayonnaise mix is provided which on

831/2197

me averaging addition of vinegar and water and a small mounts to an amount of stirring provides a mayonnaise pron volume over duct of superior quality. ixes Further EXAMPLE 7.

ptionally high A highly acceptable Hollandaise sauce may lour, texture, be prepared from the mayonnaise composition of Example 6 by the addition of a butter ntage of these flavour, colour, and appropriate spices either the mixes for to the emulsion prior to drying or to, the mixntional mixes ture during reconstitution with either milk or ncreased diffi water as described hereinbefore, in an amount dixes here des of one cup for 4 oz of the powdered fat corncharacteristics position In use, the mixture is heated slightly remain as easy and applied to the desired food product, such ly as asparagus The sauce thus prepared has the flavor and appearance of conventional Hollandaise sauces and is very simply prepared.

powdered fat Further, this sauce may be cooled, stored and ly useful as reheated with little danger of separation of ingredients such as occurs with conventional A B Hollandaise sauces.

EXAMPLE 8.

A spread for sandwiches, canapes, hors 43.0 43 0 d'oeuvres, and the like is prepared from the 16.0 16

0 powdered fat product of Example 1 by the 1.0 1 0 addition of water and suitable spices or other 30.0

34 0 flavouring materials, among others, vinegar, 8.0 salt, mustard, dried egg yolk, or any butter 2.0 6 0 flavour such as butyrates or caproates A margarine type spread results from mixing 125 ilk solids have g of the product of Example 1 with 35 ml of or completely water A simple flavoured spread is prepared lsions are pre by thoroughly mixing 180 g of a product of and the pow Example 1 with 150 mls of water and 50 ml.

in Example 4 of expressed onion juice.

EXAMPLE 9.

A pudding of superior texture somewhat combining 80 resembling a custard type pudding is prect of

Example pared by adding the powdered fat product of g of salt, 35 Example 1 to a conventional cooked starch g of dried pudding mix in a ratio of 1 part by weight of ne minute In powdered fat to 7 5 parts by weight of the perior texture, pudding mix The pudding is then prepared in s obtained As the ordinary manner by adding water, cooking gg yolk solids and chilling. late stabilizer EXAMPLE 10.

mn of Example A dry mix for use in preparing flavoured an emulsion milk shakes is prepared according to the fols is employed lowing formula; J Ingredient Gms.

Powdered fat composition of Example 1 25

Sucrose 75 Cocoa 20 Powdered barley malt flavouring 1 5 Dextrose 35 gins of this composition is added to 1 cup of milk and blended in a mixer for a short time to provide a full bodied milk shake, similar to those prepared with ice >; all.Data supplied from the esp@cenet database - Worldwide

Claims:


WHAT WE CLAIM IS:

1 A powdered, free-flowing fat composition comprising a dried emulsion of a fat and the partial ester of an edible glycol and a higher saturated fatty acid in a matrix of hydrophilic encapsulating solids of a mixture of these solids and carbohydrates or sugars.

2 A composition according to Claim 1, wherein the encapsulating solids are proteinaceous in nature.

832/2197

3 A composition as claimed in Claim 1 or 2 in which said partial ester-is an ester of propylene glycol and a higher fatty acid, such as propylene glycol monostearate.

4 A composition as claimed in any of Claims 1 to 3 in which said encapsulating solids comprise hydrophilic colloids, if desired together with carbohydrates.

A composition as claimed in Claim 4, in which encapsulating solids comprise non-fat milk solids and a sugar.

6 A composition as claimed in Claims 1 to 5, in which the encapsulating solids also have lecithin or hydroxylated or phosphorylated derivatives thereof enclosed therein.

7 A composition as claimed in Claim 6, comprising 30 to 80 parts by weight of fat, 0 5 to 5 parts by weight of hydroxylated lecithin, to 30 parts by weight of non-fat milk solids, 2 to 35 parts by weight of sucrose and 3 to 20 parts by weight of propylene glycol monostearate.

8 A method of making the powdered, freeflowing fat composition according to Claims 1 to 7, which comprises melting the fat together with said partial ester, and with lecithin if used, emulsifying the same in a solution of the encapsulating solids, or a mixture of these solids and carbohydrates or sugars and then effecting spray drying.

STEVENS, LANGNER, PARRY & ROLLINSON, Chartered Patent Agents.





833/2197

178.

GB859810 - 1/25/1961

IMPROVEMENTS IN OR RELATING TO PUDDING AND CUSTARD

COMPOSITIONS


Inventor(s): WOOD FRANK (--); KNOX ROBERT (--)

Applicant(s): BROWN and POLSON LTD (--)

E Class: A23L1/0522; A23L1/187



Family: GB859810

Abstract:


A composition which dissolves in cold milk to form a pudding or custard comprises a mixture of pregelatinized root starch and pregelatized cereal-type starch, the starches being of particle size to pass a B.S.I. 100 mesh, but not a B.S.I. 250 mesh, screen and the proportion of cereal-type starch being 20-

75% and sufficient to ensure full dispersion without the presence of sugar. A root-type starch, exemplified by potato, sago, tapioca, waxy maize and waxy sorghum starches, yields a clear aqueous solution of stringy consistency; a cereal-type starch, exemplified by maize, rice, sorghum and wheat starches, yields a pasty, opaque solution, shorter in character. The composition may contain up to 10% of tetra-alkali metal pyrophosphate as a milk protein coagulant. If dried milk is included in the composition, the pudding or custard is prepared with water instead of milk. Examples are of formulations, containing no sugar, of pregelatinized potato starch, pregelatinized sorghum starch, tetrasodium pyrophosphate, flavouring, and colouring.Description:



NO DRAWINGS hwventors: FRANK WOOD and ROBERT KNOX 859,810 Date of filing Complete

Specification: Feb 5, 1957.

Application Date: Feb 14, 1956.

Complete Specification Published: Jan 25, 1961.

No 4629/56.

Index at acceptance:-Class 49, B 1 (B: H: J).

International Classificasion:-A 23 b,1.


Im'provemieitsl isn Or relathng to lluoding andc Custard l Compositions We, BROWN & POLSON

LIMITED, a British Company, of Wellington House, 125/130 Strand, London, W C 2, do hereby

834/2197

declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to starch dispersions and applications thereof and is concerned more particularly with so-called "Instant Pudding" and "Instant Custard " compositions which, when mixed with cold milk, set er thicken within a relatively short period of time, that is, within about 15 minutes, to form a dessert having the consistency and appearance of a coolred starch pudding or of a thick pourable custard.

Known "Instant Pudding" compositions comprise pre-gelatinised starch, sugar a coagulant for the protein in the milk, for example, tetrasodium, pyrophosphate, and an accelerating agent such as calcium acetate or sodium ortho-phosphate The starch content has usually been of the root type such as farina, tapioca or sago, and although such a composition will, when added to cold milk, produce a fine textured edible dessert, the pudding is not satisfactory in all respects.

Thus, for example, the sugar, which acts as a dispersing agent to prevent "ballingup" of the starch, has to be used in substant;al proportions and to be intimately premixed with the starch to be effective, and the sweetness of the pudding may not suit the taste or dietetic requirements of all consumers Again, the consistency of the pudding and the setting time are dependent to a considerable extent unon the proportions of coagulant and accelerator used in the mixture, but the concentration of these chemicals must be kent relatively low, otherwise they impart an obiectionable taste to the pudding.

In the production of these instant pudding ccmpositions, the main aim is to obtain a composition which will disperse rapidly and lPrice 3 s 6 d l without lumpiness in milk or water and will produce a pudding of fine texture and smooth taste, and these factors are dependent upon the type and particle size of the starch used.

Pregelatinised cereal type starches, although 50 dispersing uniformly in water, have a relatively low solubility and have also a tendency to impart to the pudding a flavour which is not acceptable to all consumers Thus, as previously mentioned, the use of a root type 55 starch has been preferred, but the finer the particle size of this type of starch, the greater is the "balling up" effect in the presence of water or milk, hence the use of sugar as a dispersing agent 60 The present invention provides pudding and custard compositions which have all the desirable qualities of good dispersion, fine texture and smooth taste and are improvements on known instant compositions of 65 this character in that the use of sugar as a dispersing agent is dispensed with, the inclusion of a coagulant for the milk protein is rendered optional and, even where a coagulant is used, rapid setting or thickening 70 is obtained without the assistance of an accelerator.

According to the invention the improved composition for the purpose mentioned comprises a mixture of a pre-gelatinised root-tvype 75 starch and a pre-gelatinised cereal-tvye starch, both as hereafter defined, which starchesl have a particle size such that they will pass a B S I 100 mesh screen but net a

B S I.

250 mesh screen, the proportion of cereal 80 type starch in the mixture being from 20 % such that in use full dispersion is obtai-ed without the presence of sugar.

The term "root-type starch" is used herein to define starches which yield a relatively 85 clear aqueous solution with a stringy consistency, such starches being mainlv the root starches such as potato, saao and tapioca although waxy maize and waxy sorghum are included Similarly, the term "cereal-type 90 rc bay starch " is used to define starches which yield a pasty opaque aqueous solution and are shorter in character, the main starches in this group being maize, rice, sorghum and wheat.

It has been found that by using a blend of the two types of starch, advantage is taken of the favourable properties of both types in that the lower soluble cereal starch delays the absorption of water by the highly soluble root starch, whereby an excellent dispersion of the starch mixture is achieved without the use of a dispersing agent Moreover, the dispersing action of the cereal starch permits the use of a root starch of finer particle size than would normally be possible, so resulting in a pudding of finer texture.

835/2197

The root and cereal type starches may each be pre-gelatinised separately, preferably in the presence of a little super glycerinated fat if roll dried, or the two raw starches may be blended in the desired proportions and pregelatinised together, also, if desired, with a little super glycerinated fat, either method resulting in a starch mixture having excellent dispersion properties in cold milk without the use of sugar.

Generally, it is preferred to include in the composition up to 10 % of a milk protein coagulant, e g a tetra-alkali-metal-pyrophosphate, use of a coagulant in this proportion imparting no unpleasant taste to the pudding, and the following is a specific example of such a composition for the production of a strawberry flavoured "Instant Pudding":

EXAMPLE 1

Pregelatinised potato starch sorghum starch Tetrasodium pyrophosphate Strawberry flavcuring Edible colouring Total 61.00 % 31.62 %I 6.79 % 0.39 % 0.2 % % 32.4 grams of the above mixture are dry blended with sugar to taste 1 pint of cold milk (preferably not sterilised) is rapidly poured onto the dry powder with vigorous agitation by hand whisk, which agitation is continued for one minute On standing undisturbed the pudding sets in 15 minutes and is ready to serve.

Whilst the inclusion of a coagulant permits a quick setting pudding to be obtained with a relatively small quantity of starch mixture per unit quantity of milk, the use of a coagulant is not essential, as it has been found that, without a coagulant, a pudding which sets within a reasonable period, say 10 to 15 minutes, can still be obtained by increasing the amount of starch mixture One example of such a composition is as follows:

EXAMPLE 2

Pregelatinised potato starch sorghum starch Flavouring Edible colouring Total % 49.3 % 0.6 % 0.1 %

% To 60 grams of the mixture, after dry blending with sugar to taste, is added 1 pint of cold milk, the procedure and the resultant pudding being similar to that of Example 1 above.

The present invention makes possible for the first time the production of a completely sugar-less

Instant Pudding to meet the needs, for example, of diabetics and others confined to a non-sugared diet

One method of preparing such a pudding is to crush four to six 0 2 grain saccharin tablets, or the equivalent of other non-sugar sweetening agent, in a bowl and add 1 pint of cold milk, stirring until the saccharin is completely dissolved.

32.4 grams of the mixture specified in Example 1 or 60 grams as specified in Example 2 are then sprinkled on the milk and with a whisk rotary beater or the like agitation is maintained for one minute

Setting takes place within 15 minutes as with the sugar sweetened puddings.

Whilst the above described examples refer specifically to " solid " puddings, the same basic starch composition may also be used to produce an Instant Custard, and one detailed example of such a custard is given below:

EXAMPLE 3

Pregelatinised potato starch sorghum starch Tetrasodium pyrophosphate Vanilla flavouring Cream flavouring Edible colouring Total 61.27 %.

30.64 % 6.74 % 0.77 % 0.38 % 0.20 % % 24 grams of the above mixture are dry blended with sugar to taste and 1 pint of cold milk is then rapidly poured on, the procedure following that set out in Example

1 After standing for 15 minutes the mixture thickens to the consistency of a thick but pourable custard, but it will be understood that the actual consistency of the final custard may be varied according to requirements by adjusting the amount of starch mixture used per pint of milk.

In all the examples given above, the particle size of the starches is within the range specified.

836/2197

It is to be understood that the highliy soluble starch content may itself consist of a mixture of two or more root type starches and, similarly, the less soluble starch content may consist of a mixture of two or more 859,810 about 31 % pregelatinised cereal type starch, the balance being constituted by the coagulant, flavouring and colouring.Data supplied from the esp@cenet database - Worldwide

Claims:


4 A composition as claimed in Claim 1,

wherein the starch mixture consists of about % pregelatinised root type starch and about 491 % pregelatinised cereal type starch, the balance being constituted by flavouring and colouring.

The method of preparing an instant pudding or custard which comprises dry blending the starch composition as claimed in any of Claims 1-4, with isugar to taste, pouring cold milk onto the mixture, agitating vigorously and then allowing the product to set or thicken.

6 The method of preparing an instant pudding or custard which comprises sprinkling on to cold milk in which has been dissolved saccharin or other non-sugar sweetening agent a starch composition as claimed in any of Claims 1-4, agitating the mixture vigorously and then allowing the product to set or thicken.

7 The composition for use in preparing an Instant pudding or custard substantially as set forth in any of Examples 1-3 herein.

8 The method of preparing an instant pudding or custard substantially as set forth in any of Examples

1-3 herein.

HERON ROGERS & CO, Agents for Applicants, Bridge House, 181, Queen Victoria Street, London,

E C 4.

cereal type starches If desired, dried milk may be included in the composition, in which case the pudding or custard is prepared simply by the addition of water with the requisite agitation.

Thus it will be seen that the invention provides anr improved pudding or custard composition which embodies the minimum of chemical additives and which can be used to prepare a non-sugared dessert where so desired, for example, for dietary purposes, or can be sweetened by consumers according to their own taste, as adequate dispersion of the starches is not dependent upon any added sugar.

WHAT WE CLAIM IS: 1 A composition for use in preparing an instant pudding or custard in the manner herein defined, comprising a mixture of a pre-gelatinised root-type starch and a pregelatinised cereal-type starch, both as herein defined, which starches have a particle size such that they will pass a

B S I 100 mesh screen but not a B S I 250 mesh screen, the proportion of cereal-type starch in the mixture being from 20-751 % such that in use full dispersion is obtained without the presence of sugar.

2 A composition as claimed in Claim 1, which also includes up to 10 % of a tetra alkali-metal pyrophosphate as a milk protein coagulant.

3 A composition as claimed in Claim 2, wherein the starch mixture consists of about 61 % of pregelatinised root type starch and PROVISIONAL SPECIFICATION Improvementsl in or relating to

Pudding 'and Cusitard, Compositions We, BROWN & POLSON LIMITED, a British Company, of

Wellington House, 125/130 Strand, London, W C 2, do hereby declare this invention to be described in the following statement: This invention relates to pudding coma positions and more particularly to socalled " Instant Pudding " compositions which when mixed with cold milk set within 15 minutes to form a dessert or pudding having the consistency and appearance of a cooked starch pudding.

Known " Instant Pudding" compositions comprise pregelatinised starch, sugar, a coagulant for the protein in the milk, for example, Sodium Tetrapyrophosphate, and an accelerating agent such as

837/2197

Calcum Acetate or Sodium Orthophosphate Although such a composition will, when added to milk, produce a fine textured edible dessert, the pudding is not satisfactory in all respects.

Thus, for example, the sugar, which acts as a dispersing agent to prevent "ballingup " of the starch, has to be used in substantial proportions to be effective and the sweetness of the pudding may not suit the taste of all consumers Again, the consistency of the pudding and the setting time are dependent to a considerable extent upon the relative proportions of coagulant and accelerator 95 used in the mixture, but the concentration of these chemicals must be kept relatively low otherwise they impart an objectionable taste to the pudding.

The present invention provides an " Instant 100 Pudding " composition which is an improvement on known compositions of this character in that it dispenses with the use of sugar as a dispersing agent and will set without the assistance of an accelerator 105 According to the invention the improved pudding composition for use as above mentioned comprises in admixture a pregelatinised root type starch, such as farina, tapioca, waxy maize or waxy sorghum in this proportion of 110 approximately 60-80 o/% of the mixture, a pregelatinised cereal starch, such as maize, slightly chlorinated maize or sorghum, in the proportion of approximately 20-400 % of the mixture, and up to 10 % milk protein 115 coagulant, the particle size of the starches being of the order hereafter defined.

859,810 In carrying out the invention, the root and cereal type starches may each be pregelatinised separately, preferably in the presence of a little water-soluble glyceryl monosterate, for example, O 5

%, the two raw starches may be blended in the desired proportions and pregelatinised together, and with either method it is found that upon mixing with milk an excellent dispersion is achieved without the use of sugar In explanation of this unexpected property of the starch mixture, it may be noted that root type starches when pregelatinised by known methods are very soluble and by reason of this property absorb water rapidly and do not disperse uniformly.

On the other hand, cereal type starches when pregelatinised are much less soluble in water and have improved dispersion, and it has been found that by blending the two types of starch within the proportions specified the lower soluble starch delays the absorption of water by the highly soluble starch Thus adequate dispersion within the milk is obtained without the use of a separate dispersing agent.

It has also been found that a pudding made from the improved composition will set satisfactorily within 15 minutes without the use of an accelerator and still using a coagulant in such proportion that there is no risk of imparting an unpleasant taste to the pudding.

The particle size of the starches is also controlled or chosen to assist dispersion The finer the root type starch, the greater is the " balling-up " effect in the presence of water or milk whereas the larger the particle size, the rougher is the texture of the finished pudding The addition of the cereal type starch permits a finer root type starch to be used than would otherwise be possible but in practice a compromise has to be reached between rapid dispersion and fine texture.

However, very good results are obtained with a blend of pregelatinised root type starch of a particle size to pass a 100 mesh screen but not a 200 mesh screen and a finer cereal type starch which will pass a 150 mesh screen but not a 250 mesh screen In the case of the starches pregelatinised together the resulting product should be ground to pass a 100 mesh screen but have a maximum of % through a 200 mesh screen.

The following is a specific example of the improved composition, said example being for the production of a strawberry flavoured "Instant Pudding " Pregelatinised farina -sorghum Sodium tetrapyrophosphate Strawberry flavour Edible colour Total 61 00 % 36 62 % 6 79 % 0 39 % 02 % %

32.4 grams of the above mixture are dry blended with sugar to taste 1 pint of milk (preferably not sterilised) is rapidly poured onto the dry powder with vigorous agitation by hand whisk, which agitation is continued for one minute On standing undisturbed the pudding sets in 15 minutes and is ready to serve.

It is to be understood that the highly soluble starch content may itself consist of a mixture of two or more root type starches and, similarly, the lesser soluble starch content may consist of a mixture of two

838/2197

or more cereal type starches If desired, dried milk may be included in the composition in which case the pudding is prepared simply by the additicn of water with the requisite agitation.

Thus it will be seen that the invention provides an improved pudding composition which embodies the minimum of chemical additives and which can be used to prepare a non-sugared dessert where so desired, for example, for dietary purposes, or can be sweetened by consumers according to their own taste as adequate dispersion of the starches is not dependent upon any added sugar.

HERON ROGERS & CO, Agents for Applicants, Bridge House, 181, Queen Victoria Street, London,

E C 4.


Published by The Patent Office, 25, Southampton Buildings, London, W C 2, from which copies may be obtained.

-_ 4 859,810Data supplied from the esp@cenet database - Worldwide

839/2197

179.

GB882238 - 11/15/1961

IMPROVEMENTS IN OR RELATING TO CULINARY PREPARATIONS


Inventor(s): KELLER HAROLD MATTHEW (--)


E Class: A23L1/0522; A21D2/02; A21D2/26B4



Family: GB882238

Abstract:


A dry mix for gravies and sauces comprises, by weight, 65 to 85% of finely divided starchy material, e.g. wheat, tapioca, corn, potato, rice and waxy maize starches and/or flours, 10 to 20% of a leavening material and 5 to 15% of a material for separation of the individual starch particles e.g. shortening, non-fat milk solids, whey solids. Preferred shortening materials are edible oils, hydrogenated vegetable fats and animal fats; alternatively a dry shortening, e.g. shortening plus non-fat milk solids, may be used. The leavening material is suitably an admixture of an edible carbonate or bicarbonate e.g. sodium bicarbonate, and an edible acidic substance e.g. one or more edible alkali metal or alkaline earth metal acid phosphates such as sodium pyrophosphate, mono- or di-calcium phosphate. The mix may contain added flavouring and colouring and to make gravy it is added, with stirring, to a boiling mixture of fat and water.Description:



8829238 Inventor: HAROLD MATTHEW KELLER Date of Application and filing Complete

Specification:

September 16, 1959.

No 31628/59 Complete Specification Published: November 15, 1961

Index at Acceptance:-Class 49, B 1 (B:C:H).

International Classification:-A 23 b, c, d.


NO DRAWINGS Improvements in or relating to Culinary Preparations We, GENERAL MILLS INC of 9200 Wayzata Boulevard, Minneapolis 26, Minnesota, United States of America, a corporation of the State of Delaware, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:This invention relates to culinary preparations, and more particularly to dry mixes for the preparation of gravies and sauces.

840/2197

Gravies and sauces are frequently made by gelatinizing starch or flour in the presence of water and in the presence of flavouring materials, such as the fat left after the cooking of meat In the preparation of gravies and sauces considerable skill is required to prevent lumping When starch or a cereal flour is added to hot water there is the immediate tendency for some of the particles at the outside of a mass of starch or cereal flour to become gelatinized and thus prevent the penetration of the water into the interior of the mass of starch or cereal The result is a number of lumps of substantial size composed of dry flour or cereal on the inside surrounded by a gelled coating It is, therefore, generally required to separate these gelled masses by straining.

In order to overcome this lumping, the starch or cereal is commonly dispersed in cold water and this dispersion is then gradually heated to the boiling point with constant agitation to prevent any lumping during the gelatinization process Even this procedure is quite tedious and not always successful in preventing lumping.

It is an object of the present invention to provide an improved dry mix for the preparation of gravies and sauces which is lPrice 3 s 6 d 1 readily dispersible in water with substantially less risk of lumpformation occurring 45 According to the invention, therefore, there is provided an improved dry mix preparation for the production of gravies and sauces comprising 65-85 % by weight of a finely divided starchy material, 10-20 % 50 by weight of a leavening material and 5% by weight of a separating material, said separating material being one or more of shortening, non-fat milk solids and whey solids

55 The finely divided starchy material used may comprise a wide variety of materials including in particular those starchy materials hitherto used for the production of sauces and gravies Suitable starchy 60 materials include a wide variety of starches such as corn, potato, rice, wheat, tapioca, and the waxy maize starches In place of these isolated starches (or in addition thereto) flours derived from these sources, includ 65 ing wheat flour, rice flour, potato flour, and the like may also be used.

The separating material, which is generally shortening, assists in keeping the individual starch or flour particles separated 70 and thus reduces the opportunity for the formation of gel masses The shortening may be used in the form of an edible oil or hydrogenated vegetable shortening or animal fat or a mixture thereof The 75 separating material, e g shortening is preferably distributed thoroughly on the starch material e g the flour, so as to coat the individual flour particles and to produce a generally freeflowing mixture In place of 80 an ordinary plastic fat it is possible to use so-called dry shortenings which are combinations of shortening with non-fat milk solids Generally these dry shortenings are in the free-flowing form and require mere 85 admixture with the remaining ingredients 4 v -,t,7 O

882,238 of the mix In place of shortening materials it is possible to use other materials, such as non-fat milk solids or whey solids, to effect a separation of the individual starch or flour particles.

The leavening material may, if desired, be used in the form of a pre-mixed leavening These leavenings are generally composed of an alkaline component, such as an edible carbonate or bicarbonate particularly sodium bicarbonate in combination with an acid component, such as an edible alkali-metal or alkaline earth metal acid phosphate particularly sodium acid pyrophosphate, or monocalcium phosphate, or dicalcium phosphate It is usually preferred to employ either monocalcium phosphate or sodium acid pyrophosphate in combination with dicalcium phosphate The monocalcium phosphate and the sodium pyrophosphate are relatively reactive at low temperatures and, accordingly, some disperson is effected even before the water temperature becomes very high Sodium pyrophosphate is slightly preferred because of its better storage stability, especially when the starchy material is not dried below its normal equilibrium moisture content The dicalcium phosphate is a desirable component in that it is slower acting and will tend to disperse any small lumps which are not broken up initially by the fastacting leavening components.

A preferred dry mix according to the invention is one containing approximately % by weight of finely divided starch material, 20 %' by weight leavening material, and 10 % by weight of separating material.

The dry mixes according to the invention can contain materials in addition to the three materials mentioned namely, the finely divided starch material, the leavening material and the separating material, such as gravy and sauce mix adjuvants e g, flavours, colouring matter and the like As an alternative such further materials may be added at the time the finished gravy or sauce is prepared.

841/2197

In order that the invention may be well understood the following examples are given, by way of illustration only.

(In these examples, the mix products were converted into gravies by a standard procedure which consisted of bringing one cup of water and 1 tablespoon of fat to the boiling after which 2 tablespoon of the mix was added and stirred slightly to prevent burning The stirring was not vigorous enough to break up any lumps if formed.

The leavening was relied on as the sole means of dispersing the mix and to break up any lumps that tended to form initially)Example 1

A series of mixes was prepared containing 70 % 1 cereal, 20 %,o leavening and 10 % of a dry, powdered shortening The leavening was 6 6 % sodium bicarbonate, 75 %/.

dicalcium phosphate and 5 9 %-5 sodium acid pyrophosphate, the percentages being cal 7 U culated on the total weight of the mix The shortening was a mixture of 70-75 ,' animal fat and 25-30 % non-fat milk solids One contained wheat starch as the cereal material, another contained potato flour, 75 and a third contained rice flour All dispersed without the formation of lumps The wheat starch product dispersed somewhat more slowly and had a pudding-like consistency when cooled The potato flour 80 product dispersed readily and had a delightful potato odour and a tan colour The rice flour product dispersed the best The rice flour employed was a fairly coarse granulation, which aided dispersion 85

Example 2

A series of dry mixes were prepared, all containing 20 % leavening; one with 5 %.

shortening and 75 % flour, another with %o shortening and 70 %,' flour, and third 90 with 15 % shortening and 75 % flour The leavening and shortening were those used in Example 1 The one with the 5 % shortening had a slight tendency to form lumps initially, but these lumps disappeared 95 upon continued cooking and without vigorous agitation The product with the %so shortening effected a very desirable dispersion rapidly, and no lumps were formed The product with the 15 % shorten 100 ing dispersed very nicely without lump formation, but the product was somewhat greasy initially in the dry form, and would be somewhat less desirable than the product containing the 10 % shortening, since

105 it would not readily lend itself to use in a shaker of the salt-cellar type.

Example 3

A series of mixes were prepared, all of which contained 10 % of the powdered 110 shortening described in Example 1 The quantity of leavening was varied, as indicated in the following table, and the balance of the product was made up of wheat flour as the cereal fraction All of these pro 115 ducts were dispersed in water and cooked in the manner described and all dispersed ultimately without lumping, although there may have been some slight lumping initially during the cooking operation The descrip 120 tion of the leavening components in each of these tests is indicated in the following table.

Mix No Leavening Component 12 r 1 2 95 % Sodium Acid Pyrophosphate 3.75 % 3.30 % 2 4 43 %

3.75 % Dicalcium Phosphate Sodium bicarbonate Sodium Acid Pyrophosphate Dicalcium Phosphate

13 ( 882,238 Mix No Leaveninug Component 4.30 % Sodium bicarbonate 3 4 43 % Sodium Acid

Pyrophosphate 5 63 % Dicalcium Phosphate 4.94 % Sodium bicarbonate 4 5 90 % Sodium Acid

Pyrophosphate.

5.63 % Dicalcium Phosphate 5.97 % Sodium bicarbonate 5 4 43 % Sodium Acid Pyrophosphate 7.50

% Dicalcium Phosphate 5.57 % Sodium bicarbonate 6 2 95 % Sodium Acid Pyrophosphate 7.50 %

Dicalcium Phosphate 4 55 % Sodium bicarbonate 7 5 90 % Sodium Acid Pyrophosphate 4.10 %

Sodium bicarbonate 8 8 85 % Sodium Acid Pyrophosphate 6.15 % Sodium bicarbonate 9 5 90 %

Sodium Acid Pyrophosphate 7.50 % Dicalcium Phosphate 6.60 % Sodium bicarbonate Based on total weight of the mix.

Example 4

842/2197

A series of dry mixes were prepared containing the leavening described in Example 1 at a level of 20

% Whey solids were used as the separating material, at levels of 5 %, % and 15 %, with the cereal ingredient wheat flour employed to make up the balance These products dispersed readily and were as effective as the examples embodying shortening All of these products were very free flowing in the dry form, even at the high levels of whey solids.

In fact it is possible to exceed the 15 % limit of this compound when either whey solids or non-fat milk solids are employed.

At these higher levels, however, the amount of flour is decreased to the extent that more product is needed in order to obtain the correct consistency for the gravy or sauce.

Example 5

Example 4 was duplicated substituting non-fat milk solids for the whey solids The products were almost as effective as those employing the whey solids.

In the above examples the mixes were tested by addition to boiling water and fat -50 as this is a very severe test of the tendency to lumping In actual use it may be preferable to add the mixes to hot water somewhat below the boiling point for improved results.Data supplied from the esp@cenet database -

Worldwide

843/2197

180.

GB884315 - 12/13/1961

METHOD OF PREPARING A QUICK-COOKING RICE PRODUCT


Inventor(s): ROSSEAU FRANCIS VINCENT (--); ROSSEN JORGEN (--)


E Class: A23L1/182



Family: GB884315

Abstract:


In preparing quick-cooking rice, fissured rice grains are cooked in a moisture-permeable, e.g. foraminous or porous, container by submerging it in hot, e.g. boiling, water or a hot aqueous cooking liquid, contained in a vessel, for a period of time, e.g. 10 minutes, and at a temperature sufficient to hydrate and gelatinize the starch. The container is then removed from the vessel and water or aqueous cooking liquid is allowed to drain away. The container is, preferably, provided with a handle and may be made of high wet-strength paper, perforated metal foil or flexible plastic material and may be a bag.

Readily reconstitutable dehydrated vegetables and meats and seasoning such as salt may be incorporated with the rice in the container. The fissured rice grains may be produced by heating raw rice at a temperature between 110 DEG and 225 DEG F for 20 to 30 minutes, before or after it is placed in the container, in steam or a dry hot gas such as air or by means of dielectric or radiant heating.ALSO:A food preparation comprises readily reconstitutable dehydrated vegetables, meats and, if desired, seasoning such as salt incorporated with a quick-cooking rice product made by cooking fissured rice in a moisture-permeable container submerged in hot water for a period of time and at a temperature sufficient to gelatinize the starch (see Group I).Description:


PATENT SPE Ci FICATION

8 NO DRAWING 58 4,315 Inventors: FRANCIS VINCENT ROSSEAU and JORGEN ROSSEN.


October 30, 1959.

No 36992/59.

' Complete Specification Published December 13, 1961.

Index at Acceptance: Classes 58, A 3 (A: B), AH( 3: 6 D: 6 X), C( 1: 2), and 49, B 1 (B:F:J).

International Classification: A 23 m A 23 b.

Method of preparing a quick-cooking rice product.

844/2197

COMPLETE SPECIFICATION -We, GENERAL FOODS CORPORATION, a corporation organized under the laws-of the State of Delaware, United States of America, of 250 North Street, White Plains,

State of New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a method of preparing a quick-cooking rice by cooking in a moisture permeable container.

The object of the present invention is to provide a method by means of which the rice may be cooked rapidly and undergo a minimal loss of desired nutrition while at the same time having good texture.

In accordance with the present invention, there is provided a method of preparing a quick-cooking rice product which comprises cooking fissured raw rice in a moisturepermeable container by submerging said container in hot water or a hot aqueous cooking liquid for a period of time and at a temperature sufficient to hydrate and gelatinize the starch of the rice.

In carrying out the present invention raw rice grains are heated to provide said rice grains with fissures and thereafter the fissured grains are packaged in a container permeable to an aqueous cooking liquid such as boiling water.

It has been found that a container of the arorestated type with the fissured rice contained therein can be cooked in about ten minutes and will have an eating quality quite reminiscent of home cooked rice.

The heat treatment step required to produce the fissured rice may preferably involve subjecting the raw rice grains to a dry, hot gaseous atmosphere or to other heating means such as dielectric heating or radiant heating sufficient to produce numerous small cracks or fissures extending inwardly from the surface of the grain In treating the raw rice in accordance with the preferred procedure the grain may simply be any suitable convection oven, or a hot dry atmosphere of air, steam or other gas may 50 be passed through or over the grains by forced circulation Insufficient heating, as manifested by too low a final temperature, will not produce sufficient cracking or fissuring to effect the desired improvements in the 55 cooking properties of the rice Excessive heating, as manifested by too high temperature, results in undue breakage of the grains.

In lieu of heating the grains to induce the fissures therein prior to packaging the grains 60 may also be heated in a container altbough for-obvious reasons this latter procedure will be less preferred.

The period of heating should be correlated with the heating conditions to produce the 65 proper final surface temperature of the rice, which temperature will be dependent to some extent upon the moisture content of the raw rice At a normal moisture content of around 11 % by weight the final temperature the 70 rice should be between 140 -225 F at a moisture level of 18 %, which is about the maximum, the final rice temperature should be between 110 -200 F; drier rice, however, can also be treated In general periods of 75 20-30 minutes are desirable to insure uniform and thorough heating and fissuring of the grains.

Preferably after fissuring the raw grains are then introduced into a foraminous or 80 porous container, typically a container made of high wet-strength paper through which moisture will readily migrate and from which moisture will readily drain The container may be made of a suitable flexible plastic 85 or metal foil material punctured with holes to permit the ingress and egress of the aqueous cooking liquid

However, it is not intended in the present invention to forecloise the use of a foraminous container of

90 any type, provided that the container is capable of effectively permitting entry of moisture to the raw rice when the rice is immersed for a suitable cooking period in hat or boiling water.

The size of the container, which may be a bag, should be sufficient to accommodate the rice in its hydrated swollen condition.

Otherwise the rice will tend to be compacted and will not become fully hydrated and cooked in a short period of time The container preferably has provided thereon a handle whereby the container may be first immersed in a pot or other container of cooking water and whereby the container of rice may be

845/2197

thereafter suspended to permit drainage of cooking water therefrom after it is removed from the cooking vessel.

Advantageously by clooking the rice within the contents of the liquidpearmeable container the slime stemming from liberated starch will not tend to accumulate on the side of the cooking vessel but will be absorbed by the container Advantageously seasoning such as salt may be incorporated in the contents of the container by the manufacturer prior to packaging In addition readily reconstitutble dehydrated vegetables and meats may be incorporated as part of the contents of the container.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS:

1 A method of preparing a quick-cooking rice product which comprises cooking fissured rice grains in a moisture-permeable container by submerging said container in 35 hot water or in a hot aqueous cooking liquid for a period of time and at a temperature sufficient to hydrate and gelatinize the starch of the rice.

2 A method according to claim 1, com 40 prising heating raw rice grains to induce fissures therein and packaging the fissured rice grains in said container.

3 A method according to claim 2 wherein the rice is fissured by means of a 45 dry heated gas.

4 A moisture-pennrmeable container with fissured raw rice grains therein and adapted for use in the method according to claim 1.


Applicants.

Sheerness: Printed for Her Majesty's Stationery Office, by Smiths Printers and Duplicators 1961.

Published at the Patent Office, 25 Southampton Buildings, London, W C 2 from which copies may be obtained.


846/2197

181.

GB888649 - 1/31/1962

PROCESS FOR TREATING FOOD AND PRODUCT RESULTING THEREFROM


Inventor(s): SORGENTI HAROLD ANDREW (--); NACK HERMAN (--); SACHSEL

GEORGE FELIX (--)

Applicant(s): BATTELLE DEVELOPMENT CORP (--)

E Class: A23F5/04B; A23L1/01K



Family: GB888649

Abstract:


In roasting coffee, the beans are immersed in a suitable particulate material, e.g. sodium chloride, sand, and the bed fluidized by an air stream directed through it at an appropriate velocity and temperature.

The roasted beans may then be separated by passing the finer particles through a sieve that retains the coffee beans.ALSO:Food, e.g. potatoes, nuts, meat, fish, poultry, onions, shrimps, vegetables, is cooked or frozen by immersing it in a fluidized bed of heated or cooled solid discrete particles of a non-toxic nature, e.g. comprising one or more of sodium chloride, tricalcium phosphate, limestone, mono-sodium glutamate, sugar, rice, beans, lentils. Flavouring, seasoning, and preserving materials may be added to the fluidized bed, which is heated or cooled by passing a current of hot or cold gas through it, e.g. air or pure oxygen, which may include smoke and entrained flavouring agents. To prevent the fluidized particles from adhering to it the food may be coated with a non-toxic, finelydivided substance, e.g. potato flour, which may p incorporate a flavouring substance. In an example, potato chips, coated with potato flour and placed in a wire basket, are immersed in a fluidized bed of sodium chloride particles maintained at a temperature between 250 DEG and 550 DEG F., preferably between 300 DEG and 400 DEG F., until cooked; alternatively, the potato chips may be only partly cooked and then frozen in a fluidized bed maintained at 0 DEG F. whereafter they may be kept for a period, before thawing and completely cooking in an oven.Description:



NO DRAWINGS Inventors: HAROLD ANDREW SORGENTI, HERMAN NACK and GEORGE

FELIX SACHSEL Date of Application and filing Complete Specification June 7, 1960.

No. 19971j60.

Complete Specificction PublishedJan. 31, 1962.

Index at acceptance: -Classes 49, Dl(A:D3), E2; and 58, C2.

International Classification -A231. A23f.


847/2197

Process for treating Food and Product resulting therefrom ERRATUM SPECIFICATION NO.

888,649

Page 2, line 34, for "overall' read "over-all" Page 2, line 106, for "or" read "are" Page 2, line 112 and

Page 3, line 4, for "caloric" read "calorie" Page 3, line 31, for "detail," read "detail."

Page 3, line 33, for "in" read "is" Page 3, line 58, for "pick-up" read "pickup" Page 3, line 75, for

'effective" read "effectively" Page 3, line 79, for "potatao" read "potato" Page 3, line 84, for

"resonable"l read "reasonable" Page 4, line 28, for "temperatnure"l read "temperature" TEE PATENT

OFFICE, 12th iMarch. 1962 DS 61434/1(18)/R.153 200 2/62 PL tat to become rancid.

Many foods are prepared by cooking in a heated gas. The gas most commonly used is air plus any combustion gases that may be present. Unfortunately, air has a low coefficient of convection, necessitating relatively long cooking times.

It is an object of this invention to provide a food-treating process wherein the above dis,1 woen a gas alone is usea. Inis is due to tne lower coefficient of convection for a gas, the coefficient being a measure of the ihermal resistance of the gas. Because of the greater efficiency, much greater rates of heat transfer 80 are achievable and good uniformity of heating is obtainable.

The treatment of foods in a fluidized bed presents a unique situation. For example, in = PATENT

SPECIFICATION

NO DRAWINGS Inventors: HAROLD ANDREW SORGENTI, HERMAN NACK and GEORGE

FELIX SACHSEL 888.649 Date of Application and filing Complete Specification June 7, 1960.

No. 19971/60.

Complete Specification PublishedJan. 31, 1962.

Index at acceptance:-Classes 49, DI(A:D3), E2; and 58, C2.

International Classification: -A231. A23f.


Process for treating Food and Product resulting therefrom We, THE BATTELLE DEVELOPMENT

CORPORATION, of 505, King Avenue, Columbus, Ohio, United States of America, a corporation of the State of Delaware, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to an improved process for treating food.

Many processes presently exist for cooking food products. These processes are based on cooking in a liquid, or cooking in a gas. The two liquids most commonly used for cooking foods are water and oil or molten fat. Cooking in water has the disadvantage that the item being cooked picks up water, and consequently dehydration is not possible. In addition, the maximum cooking temperature that can be achieved is relatively low. Cooking in oil or molten fat permits higher cooking temperatures than water, but has the disadvantage that the food being cooked picks up and retains large quantities of the oil or fat. This retained fat or oil affects and masks the flavour of the food. The caloric value of the food is also altered. Foods containing substantial amounts of retained cooking fat or oil cause digestive disorders in many people. The shelf and storage life of foods cooked in fat or oil is limited and determined by the time it takes for the retained oil or fat to become rancid.

Many foods are prepared by cooking in a heated gas. The gas most commonly used is air plus any combustion gases that may be present. Unfortunately, air has a low coefficient of convection, necessitating relatively long cooking times.

848/2197

It is an object of this invention to provide a food-treating process wherein the above disadvantages are wholly or substantially eliminated.

It is a foremost object of this invention to provide a fast, greaseless cooking method.

The above objects are achieved by the present invention by immersing food in a fluidized bed of solid, discrete particles and treating the food in the fluidized bed. If the bed particles are cold, then cooling of the food occurs; if the bed particles are hot, then heating of the food takes place. The bed particles may be used for flavoring, seasoning, and as a coating material. Because of this radically different method of treating food, new food products result.

In this process a bed of solid, discrete particles is subjected to an upward gaseous current, the size and weight of the particles and the velocity and nature of the current being so chosen that the force exerted by the current is sufficient to counterbalance the gravitational force on free particles and to expand the bed, thus allowing movement of the particles, but is insufficient to convert the bed into stream of particles. A bed of solid, discrete particles subjected to and expanded by such an upward gaseous current in the manner described is hereinafter referred to as a fluidized bed.

A fluidized bed is a very effective heat-transfer system to a foreign material. Much greater rates of heat transfer are achievable by combining a solid and a gas to transfer heat than when a gas alone is used. This is due to the lower coefficient of convection for a gas, the coefficient being a measure of the thermal resistance of the gas. Because of the greater efficiency, much greater rates of heat transfer are achievable and good uniformity of heating is obtainable.

The treatment of foods in a fluidized bed presents a unique situation. For example, in the disclosure of the use of a fluidized bed for the drying of fabrics, it is reported that the bed material seems to adhere to the fabric and must be removed by vibrating the fabric after it leaves the bed. It can be seen that this would be a very undesirable result in the case of food treatment. The adherence of the bed material to the food must either be eliminated or controlled, if a tasty product is to be obtained. In addition, a process for the drying of fabrics is merely concerned with the removal of water from the mate:ial.

Cooking frequently brings about a chemical change in the food and thus cooking is as sensitive as a chemical reaction.

A physical characteristic of a fluidized bed is that it resembles a liquid. An object may be immersed in a fluidized bed of solid, discrete particles in the same manner that it may.be immersed in a liquid. In addition, an object may be passed through a-fluidized bed, just PS it may be passed through a liquid.

Thus, the food to be treated is immersed in the fluidized bed at the appropriate temperature. It is allowed to remain there until the treatment is finished. The food is then removed from the bed.

The process of this invention may be readily used to either add to. or remove heat from the food depending merely upon whether the fluidized bed is hot or cold. However, to simplify the discussion, adding of heat to the food will be discussed in sufficient detail to convey the overall concept of the invention.

Since a food product is involved, that portion of the fluidized bed wherein the food is immersed must be constructed of a material suitable for food preparation, such as aluminum or stainless steel. The bed material is selected because of its ability to be fluidized, its stability at the temperature at which -the bed is to be operated, and its safeness.from a health standpoint. There are several materials that meet these requirements. Among those that have been tried and found successful are sodium chloride, tricalcium phosphate, limestone, limestone-salt mixtures, and monosodium glutamate. Where the bed is to be cperated at a relatively low temperature, certain foodstuffs such as sugar, rice, beans, and lentils may make suitable bed materials.

It is preferable that the bed material not adhere to the food. Of course, - adherence of the bed material to the food may be a desirable circumstance where the bed material is to provide seasoning or flavoring to the foods or is to provide a coating. If a bed material is a particularly desirable one to use, but it adheres to the food, and this is undesirable, this aspect can be overcome by coating the food with a material that the bed material will not adhere to before immersing the food in the bed. A specific example of this procedure wvill be described in detail when the cooking of potatoes is discussed.

849/2197

The temperature of the bed is dictated by the food to be cooked and the cooking time desired. There are many methods for raising or lowering the bed temperature. One method by which the bed temperature may be 70 regulated is by heating the gaseous current passed through the bed. The bed particles are raised to the temperature of the gas stream. Cooling of the bed may also be accomplished in many ways. Refrigerating 75 the gaseous current before passing it through the bed is one method.

Food taste and flavor could probably be varied by fluidizing the bed with gases other than air. Pure oxygen is one possibility. Flavor 80 could also be varied by entraining or mixing flavoring agents in the gaseous current used to fluidize the bed. For example, smoke could be readily mixed with the fluidizing gaseous current. Smoked foods and foods with a smoky 85 flavour are very much in demand.

In a production-type setup, the food to be treated in -the fluidized bed could be suspended in the bed by means of wire baskets.

This could be done on a continuous basis. 90 Still another possibility would be the use of a moving screen-type conveyor through -the bed. The speed of the baskets or the conveyor could be regulated to provide the properexposure time in the bed. 95 The process of this invention is especially useful and valuable as a substitute for the preparation of food by the method of deepfat -frying. Foods prepared by the deep-fat frying process pick up large quantities of the 100 fat during the preparation. -Because of the large amounts of fat retained-bby foods prepared in this. manner they have unique characteristics as food products. For example,-such properties as taste, digestability, and caloric 105 value or affected. -

By the process of this invention, no oil or fat is present in the cooking step and any -fat given off by the food during cooking reduces the caloric value of the cooked article. Thus, by this process 110 new food -products with unique tastes and flavors and with a lower caloric content can be prepared. Specific examples of new products resulting from this process are nuts and sliced potatoes cooked in a fluidized bed. 115 No cooking fat is picked up by the nuts or potatoes because none is present.

Foods prepared by this process include meats, poultry, fish, nuts, vegetables, and coffee. Epecially suited for cooking by this 120 process are potatoes, nuts, parched sweet corn, shrimp, onion rings, and coffee.

The cooking of potatoes by the process of this invention yields a unique and especially tasty product.

A fat- and oil-free potato chip 125 and "French fried" potato have been prepared. The potato chip product resulting from the process of this invention contains considerably fewer calories than presently available potato chips prepared by deep-fat frying. 130 888,649 888,649 Fat comprises one-third to one-half parts by weight of a potato chip prepared-by deep-fat cooking. This retained fat -increases the caloric content of the potato chip and also controls and masks the taste and flavor.

If it is desirable or necessary to coat the food to be treated in the fluidized bed to prevent or reduce adherence of a particular bed material to the food, the food may be coated with an inert nontoxic material to which the bed particle -will not -adhere be fore immersing the food in the- cooking bed.

The coating material can be applied to the food by tumbling or by means of -a fluidized bed separatefrom the cooking bed. 'The coating material can be -fluidized -in a -bed and the food immersed in the bed.

The food to be - treated can be flavored either by adding flavoring material- to the coating agent, the gaseous fluidizing- current, the cooking bed, or by adding the flavoring materials to the- food after it is removed. from the cooking bed. For special effects two or more bed materials may be mixed together.

Thus, the same fluidized bed could simultaneously be used for cooking, flavoring, and adding of a preservative, to- the food.

Since the cooking of potato - slices, commonly called potato chips, exemplifies the process of this invention,-the preparation of this food product will-be discussed in detail, The first step in the. preparation of the potato chip product in the. slicing of the raw- potato.

850/2197

Insofar as possible, uniformity of thickness of the slices of each batch -is' maintained. In cooking potato chips, there is frequently a formation of bubbles on- the chip. This bubble formation can be eliminated -or minimized by making a plurality of punctures in the raw potato slices. When the -potato

-slices are cooked, the exterior surface becomes moist.

Most fluidized bed materials wil adhere to this moist surface. When the potato slices were cooked in a fluidized bed of sodium chloride, adherence and retention of sodium chloride occurred -in various degrees. Thus, it was possible to salt the potato chips in the cooking step. Pickup of the bed material by the potato product can be controlled by 1) selection of the' bed material and 2)- by coating the potato slices before-cooking. Tricalcium phosphate is the.only fluidized-bed-material that was tried that did not adhere in-some degree to the potato slice during cooking.

Cooking in a combined -bed-of tricalcium phosphate and sodium chloride would also result in a salted, cooked product, -with, a smaller-salt pick-up' by the product.-To coolc potato chips in a fluidized -bed of sodium chloride.particles -without pickup and retention- of sodium chloride by the potato -slices, it-is necessary to-coat the potato slices with an inert, nontoxic material -to -whih the -salt does not- adhere.,Prdferably, the coating- should not adversely affect the taste, color, or cooking characteristics of the -potato -.slices.

Coating -materials used for.preparing potato chips included potato -flour, flour, baking powder, monosodium,glutamate, potato flour -suspensions, and monosodium -.glutamate solution. Dry potato flour -was. extremely -satibfactory -for:reducing the salt pickup during cooking without leaving - a taste, t-film, for color change. 'The potato slices may -be -'effective coated --with potato flour by - immersing.the Slices -in a fluidized bed.of -the - flour. Of course, other methods of - coating the potato slices - with! potatao flour may also "be used. 'For-example, the slices may be tumbled-in potato flour.

When the potato-slices have been coated, they -are -next immersed in:a fluidized bed' of sodium- chloride 'particles. A satisfactory product -results.in -a -resonable -time -when the bed 'is maintained at a -temperature of -not lessthan 2500 F. and not more than -550 -F.

The most tasty -product- is- obtained when the bed'temperatucedis- not-less than 3000 F. -and not more than 4000 F. -A stream ef heated air is used to fluidize the bed and to maintain it at the proper temperature. Good tem-perature -control -and uniform-heating of the - food -product Jis attainable in the fluidized --bed- method of cooking. When the potato chlp has cooked to-the desired degree, it is removed from the fluidized bed. An attractive potato chip, with a brown color, and with a unique pleasing- taste results from this process. Since no fat or oil is picked up by the potato in the cooking process, and, in fact, starch is given off and lost by the potato during its preparation, a new fat-free potato chip product results that has a substantially lower calorie content-than presently available products.

The principles applicable to the preparation of a potato chip product by this process are also applicable to the preparation of a "French fried "-type potato product. A "-French- fried '-type.potato product as -the term is used -herein-results when -a potato is cut into the- shape of a-French fried potato, but is- cooked in -a: fluidized -bed -so that. the cddked potato is free from cooking fat and grease. 'In -general, these -principles are -also applicable to the - preparation -of -other food products.

-If it:is--desired to prepare a frozen food product,-it merely would be necessary- to cool the fluidized - bed ianstead-of: heating it.

The following examples are intended to more clearly define;and'illustrate the process and products of

-this -invention.

EXAMPLE -1.

-Raw potatoes w=ere scrubbed-anwd -washed to 125 remove dirt, and a portion of -the -peel. The potatoes--were slicedi-into three different- thiknesses, using --a conventional potato -slicer. In one batch the slicer was set to obtain 34 slices 480 per inch, in another 25 slices per inch, and in a third 17 slices per inch. No noticeable change in the finished product in texture, color, or bubble formation occurs because of variation in the thickness of the slice cooked.

851/2197

Cooking time is, of course, dependent on the thickness of the slice, the thicker slice requiring a longer time.

Potato slices of approximately uniform thickness were tumbled with potato flour so as to obtain a coating of the flour on the slice. The coated slices were then transferred to a wire basket. This basket was immersed in a fluidized bed of sodium chloride particles. The temperature of the fluidizod bed was regulated at 3300 F. Temperature control was achieved by heating the air circulated through the bed.

The potatoes were removed from the fluidized bed when cooked.

When potatoes sliced to a thickness of 25 slices per inch were used, cooking time at a temperature of

330 F. was less than 3 minutes. A taste panel gave this product a very favourable rating.

EXAMPLE 2.

The procedure of Example 1 was repeated with the exception that the bed was maintained at a temperatnure of 4750 F. Cooking time at this temperature was about 45 seconds, for potatoes sliced to a thickness of slices per inch.

EXAMPLE 3.

Potatoes were sliced to a thickness of 25 slices per inch. The potato slices were then coated with potato flour and immersed in a fluidized bed of sodium chloride. The temperature of the cooking bed was 330 F. A crisp, evenly browned product was obtained after a cooking time of 165 seconds.

EXAMPLE 4.

Potatoes were sliced to a thickness of 25 slices per inch and coated with potato flour.

The effect of temperature on the quality of the potato chip product and cooking time was investigated.

The following table summarizes the results of these tests:TABLE 1.

EFFECT OF TEMPERATURE ON PRODUCT QUALITY AND COOKING TIME.

Temperature Cooking t F. second 550 35 475 45 400 85 330 165 275 240 EXAMPLE 5.

Raw potatoes were sliced to a thickness of slices per inch. The potato slices were placed in a wire basket and immersed in a fluidized bed of tricalcium phosphate. The potato slices were not coated before cooking.

The temperature of the fluidized bed was regulated at about 3500 F. A potato chip with good appearance and taste was obtained after a cooking time of about 4 minutes. The fluidized bed material, tricalcium phosphate, did not adhere to the potato slices.

EXAMPLE 6.

Raw potatoes were cut into the shape of French fried potatoes (3X3/8X3/8 inches).

They were then immersed in a fluidized bed of sodium chloride. The bed was maintained at a temperature of 330 F. The potatoes were completely cooked in 8 minutes and were evenly browned, crisp, and tasty. ime, S Quality Dark brown in spotslight elsewhere; saltiness low; crisp Dark brown in spotslight elsewhere; saltiness low; crisp Dark brown in spotslight elsewhere; saltiness low; crisp Evenly browned; saltiness low; crisp Very lightly browned; crisp; saltiness low EXAMPLE 7.

Potatoes cut into the shape of French fried potatoes (3 X 3/8 X 3/8 inches) were coated with potato flour and immersed in a fluidized bed of sodium chloride. The temperature of the fluidized bed was

852/2197

3300 F. Sodium chloride pickup and retention by the potato strips during the cooking step was negligible. The potato strips were completely cooked in about 8 minutes.

EXAMPLE 8.

Potatoes cut into the shape of French fried potatoes (3 X 3/8 X 3/8 inches) were coated with potato flour and immersed in a fluidized bed of sodium chloride. The temperature of the fluidized bed was

3300 F. The potatoes were removed from the fluidized bed after a cooking time of 4 minutes. At this time, the potato was in a partially cooked state. The partially cooked potatoes were then immersed in a fluidized bed of sodium chloride main888,649 Dark brown in snots888,649 tained at a temperature of

00 F. or lower.

When frozen, the potatoes were removed and stored for a one-week period. The potatoes were then removed from frozen storage, thawed, and the balance of the cooking was performed in an oven for a period of about minutes.

EXAMPLE 9.

Green cashew nuts were cooked in a fluidized bed of sodium chloride. The temperature of the bed was 3300 F. The nuts were completely cooked in about three minutes, were evenly browned, and had excellent taste and flavor, with little or no salt pickup.

Presently, cashew nuts are cooked commercially by deep-fat frying at 4500 F. The storage period of cashew nuts that have been deep-fat fried is limited since the fat picked up in the cooking process becomes rancid.

Nuts cooked in a fluidized bed give off fat contained in the nut during the cooking process. Thus, the result is a cooked nut product that has a lower caloric value than the raw nut.

EXAMPLE 10.

Onion rings were cooked in a fluidized bed of sodium chloride. The bed temperature was approximately 3500 F. The onion rings were removed from the fluidized bed when cooked.

EXAMPLE 11.

Onion rings were cooked in a fluidized bed of tricalciumr phosphate. The fluidized bed was maintained at a temperature of approximately 3500 F. The onion rings were removed from the bed when cooked.

EXAMPLE 12.

Breaded shrimps were cooked in a fluidized bed of sodium chloride at a temperature of 3500 F. The shrimps were completely cooked in two to three minutes. The shrimps prepared in this manner were tasty and the breading had a definite salt taste.

EXAMPLE 13.

Shelled, raw, unbraided, green shrimps were cooked in a fluidized bed of sodium chloride at a temperature of about 3500 F.

After cooking, the shrimps were eaten.

EXAMPLE 14.

Frankfurters were cooked in a fluidized bed of sodium chloride. The temperature of the bed was approximately 180' F.

EXAMPLE 15.

853/2197

Frankfurter emulsion (i.e. the loose mixture of ground meat and other ingredients) in a casing was cooked in a fluidized bed of sodium chloride. The cooking temperature was approximately 1800 F. At this temperature the frankfurters were cooked throughout in 6 minutes.

EXAMPLE 16.

Coffee can be roasted by the fluidized bed process of this invention by immersing the coffee to be roasted in a suitable particulate material. For example, sodium chloride, sand, or any other particulate material can be fluidized by an air stream of appropriate velocity. Coffee beans are then added to the fluidized particles and intimately mixed therewith, said particles being at an appropriate temperature to roast the coffee. When the coffee beans are roasted, they may be separated from the particles of the fluidized bed by any appropriate means. Separation may be accomplished by passing the finer particles through a sieve that retains the coffee beans.Data supplied from the esp@cenet database - Worldwide

Claims:


WHAT WE CLAIM IS:-

1. A process for treating food wherein the food is immersed in a fluidized bed of solid discrete particles.

2. The process as claimed in Claim 1, wherein the treatment is one of cooking and which comprises the steps of immersing the food to be cooked in a fluidized bed of hot, solid, discrete particles and removing the cooked food from the fluidized bed.

3. The process as claimed in Claim 1 wherein the treatment is one of cooling and freezing and which comprises the steps of:

immersing the food in a fluidized bed of cold, solid, discrete particles and removing the food from the fluidized bed.

4. The process as claimed in Claim 2, wherein the fluidized bed comprises nontoxic, inorganic, hot, solid, discrete particles.

5. The process as claimed in Claim 4, wherein the cooked food is then immersed in a fluidized bed of nontoxic, cold, solid, discrete particles; in order to prepare frozen food which is then removed from the fluidized bed.

6. The process of Claim 4 when used to prepare a cooked nut product.

7. The process of Claim 4, when used to prepare a potato product.

8. The process as claimed in Claim 7, wherein, the potato is cut into pieces having appropriate shapes before immersion in the fluidized bed.

9. The process as claimed in Claim 7 or 8, wherein the potato pieces are coated with in inert, nontoxic material before immersion in the fluidized bed.

10. The process as claimed in any of Claims 7 to 9, wherein said bed is maintained at a temperature of

2500 to 5500 F.

11. The process as claimed in any of Claims 7 to 9, wherein the fluidized bed is maintained at a temperature of 300 to 4000 F.

12. The process as claimed in any of Claims 9 to 11, wherein the inert material is potato flour.

854/2197

13. The process as claimed in any of the 888,649 preceding claims, wherein the fluidized bed material is comprised of solid discrete particles of tricalcium phosphate, sodium chloride or a mixture thereof.

14. A process for treating food substantially as herein described and illustrated by the examples herein.

15. The products made by the process of any of the preceding claims.

For the Applicants, F. J. CLEVELAND & COMPANY, Chartered Patent Agents, 29, Southampton

Buildings, Chancery Lane, London, W.C.2.

Leamington Spa: Printed for Her Majesty's Stationery Office, by the Courier Press.-1962.

Published at The Patent Office, 25, Southampton Buildings, London, W.C.2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

855/2197

182.

GB900855 - 7/11/1962

IMPROVEMENTS IN OR RELATING TO JELLY FOOD PREPARATIONS


Applicant(s): AUGUST OETKER NAHRMITTELFABRIK (--)

E Class: A23L1/0522; A23L1/187; A23L1/0562B; A23L1/052


Priority Number: DE1957O005830 (19571101)

Family: GB900855

Equivalent: DE1151168

Abstract:


A gellable product for the easy preparation of foods such as puddings, cakes and tarts, mayonnaise, and sauces is made by drying on hot rollers a mixture of starch with an aqueous solution of a gelling agent such as gelatine, pectin, agar, an alginate, or a gum. An example is concerned with spraying, by steam at 3-4 atmos. pressure, a mixture of a suspension of 1 kg. of untreated maize, wheat, rice, potato, or tapioca starch in 5 litres of cold water and 0.25-0.5 kg. of gelatine dissolved dissolved in 5 litres of hot water on to the rollers.

856/2197

183.

GB903837 - 8/22/1962

A PROCESS FOR THE TREATMENT OF RICE


Inventor(s): DANIEL REIJER RUTGERS GIJSBERT (--)

Applicant(s): KONINK PELLERIJ MERCURIUS V H (--)

E Class: A23L1/182



Family: GB903837

Abstract:


In producing dry-cooking, fluffy rice, polished rice, brown rice, wet-cooking rice or broken rice, preferably containing under 16%, by weight, of moisture, is steamed for 2 to 15 minutes at a rice temperature between 75 DEG and 130 DEG C. and its moisture content is then raised to between 16% and 24% by adding water, dilute hydrochloric, phosphoric, nitric, sulphuric, citric, tartartic, or lactic acid, aqueous hydrogen peroxide, or a buffer solution having a pH between 3,5 and 5,5, e.g. containing citric acid and disodium phosphate. The moistened rice is tempered, to distribute the moisture more uniformly and allow any caked rice to disintegrate, then heated, e.g. for 2 to 20 minutes, in live steam at a gauge pressure between 0,3 and 1,0 atmospheres and finally dried, e.g. until it has a moisture content of 16% or below. Small amounts of oxidants, such as hydrogen peroxide, chlorine dioxide and nitric acid, may be added at any stage of the process. Specifications 493,528, 579,981 and 737,446 are referred to.Description:




903,837 Imentors: R El JER RUTGERS GIJSBERT BERNARD DANIEL V'AN SCHAIK Date of pplication and filing Com;piete August 6, 1960.

Specification:

No.

27348 6 C O C;,mpiete Specification Published: 4 u,,zust 22 1962

Index at Accetpance:-Class 58, A( 3 B:4 ') AH( 3:6 B 2:6 D) C 2.

International Classification:-Bo 2 b, c.


NO DRAWINGS A Process for the Treatment of Rice ERRATUM SPECIFICATION NO 903,837

857/2197

Page 1, in the heading Inventors, for Reier Rutgers Gi Jsbert Bernard Daniel Van Schalkl " read,Reijer Rutgers and Gi Jsbert Bernard Daniel Van Schaik " THE PATENT OFFICE, 6th June 1963 separate dry grams which remain so to the palate and which should preferably have a fluffy outward appearance The preparation of dry-cooked rice offers many difficulties in that freshly harvested rice will cook wetter than stored rice and that many kinds or varieties of rice especially round and medium types cook appreciably wetter than do other types In cooking so-called dry-cooking rice, also the consumer will encounter difficulties, although quite a numbzr of rice cooking recipes have been proposed The rice water ratio is a matter of some judgment and in the preparation of large amounts of dry-cooking rice it is difficult to achieve a uniform distribution of the water and a caked nonhomogeneous mass which has burnt to the pan may result.

The invention relates to a precess for prrocessing rice in order to obtain a rice of better dry-cooking quality, since the invention seeks to provide a rice which is capable of being cooked always to a dry product whatever the variation in cooking methods and even when very much water is DS 73415/1 (

7)/R 109 200 5/63 PL and after being dried it is milled The arnount of breakage during the milling will be small and the milled rice obtained is rich in vitamins The milled parboiled rice.

however is transparent and yellowish and 65 the cooking time thereof is usually longer than the cooking time of ordinary rice.

When parboiled rice is cooked, whilst separate grains are obtained they are not particularly dry or fluffy and furthermore 70 they tend to be toughly elastic.

The invention relates to a process for the preparation of dry-cooking rice grains.

which process is characterised by the steps of presteaming rice for 15-2 minutes at a 75 rice temperature of from 75-130 C increasing its moisture content to 16-24 %, by weight by means of water or an aqueous solution tempering the rice heating it in live steam under a gauge pressure of from

0 3-1 80 atmospheres for 20 to 2 minutes and finally drying the rice.

The process according to the invention is distinguished from the well known processes for preparing so-called parboiled rice 85 and quick-cooking or minute rice, which 1 PATENT SPECIFICATION

9035837 Inventors: REIJER RUTGERS GIJSBERT BERNARD DANIEL VAN SCHAIK Date of

Application and filing Complete Specification:

August 6, 1960 No 27348/60 Complete Specification Published: August 22, 1962

Index at Accetpance:-Class 58, A( 3 B:4), AH( 3:6 82:6 D), C 2.

International Classification:-B 02 b, c.


NO DRAWINGS A Process for the Treatment of Rice We, N V KONINKLIJKE PELLERIJ

"MERCURIUS" v h GEBROEDERS LAAN, a Company organised under the laws of the Netherlands, of 32, Zaanweg, Wormerveer, the Netherlands, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a process for the treatment of rice, in particular, for the preparation of drycooking fluffy rice grains.

It is known that consumers of rice may prefer a wet-cooking rice or a dry-cooking rice, the former type forming a sticky glutinous mass and the latter type forming separate dry grains, which remain so to the palate and which should preferably have a fluffy outward appearance The preparation of drycooked rice offers many difficulties in that freshly harvested rice will cook wetter than stored rice, and that many kinds or varieties of rice, especially round and medium types cook appreciably wetter than do other types In cooking so-called dry-cooking rice, also the consumer will encounter difficulties,

858/2197

although quite a number of rice cooking recipes have been proposed The rice: water ratio is a matter of some judgment and in the preparation of large amounts of dry-cooking rice it is difficult to achieve a uniform distribution of the water and a caked, non-homogeneous mass which has burnt to the pan may result.

The invention relates to a process for processing rice in order to obtain a rice of better dry-cooking quality, since the invention seeks to provide a rice which is capable of being cooked always to a dry product whatever the variation in cooking methods and even when very much water is used By applying the process of the invention it is possible to convert rice that is 45 wet-cooking by nature into a dry-cooking rice and to make it suitable for consumers who prefer a dry-cooking rice.

The processed rice may be cooked to form a mass of grains that remain separate, 50 and, in addition, have the desired fluff y outward appearance, instead of being slimy.

Furthermore the colour of the rice and of the cooked rice prepared therefrom is white, as was the initial rice and the cooked 55 grains are dry but not hard or tough These properties distinguish the product of the invention from the so-called parboiled rice.

In preparing parboiled rice, paddy is heated in moist condition rather intensively 60 and after being dried it is milled The amount of breakage during the milling will be small and the milled rice obtained is rich in vitamins The milled parboiled rice.

however, is transparent and yellowish and 65 the cooking time thereof is usually longer than the cooking time of ordinary rice.

When parboiled rice is cooked, whilst separate grains are obtained they are not particularly dry or fluffy and furthermore 70 they tend to be toughly elastic.

The invention relates to a process for the preparation of dry-cooking rice grains, which process is characterised by the steps of presteaming rice for 15-2 minutes at a 75 rice temperature of from 75-130

'C, increasing its moisture content to 16-24 % by weight by means of water or an aqueous solution, tempering the rice, heating it in live steam under a gauge pressure of from 0 3-1 80 atmospheres for 20 to 2 minutes and finally drying the rice.

The process according to the invention is distinguished from the well known processes for preparing so-called parboiled rice 85 and quick-cooking or minute rice, which I 903,837 last-named rice cooks in a few minutes or after standing for some time in hot condition.

in parboiling rice more water is added viz until the moisture content of the rice amounts to 25-40 % the heating time is ionger, e g 30-35 minutes or the temperatures applied are higher The rice is mainly entirely gelatinised in the parboiling treatI O ment (cf e g British patent 493,528).

For the preparation of quick-cooking rice even more severe conditions are necessary than for parboiling rice, and in consequence a higher moisture content and longer steamin periods are employed

Thus, for example U K patent 579,981 mentions a pre-cooking treatment in which a moisture content of from 65-70 % is imparted to the rice Another method is described in U K patent 737,446, according to which rice is soaked until it has a moisture content of about 25-30 % and is steamed preferably at atmospheric pressure, i e a rice temperature of about 100 'C.

It has now been found that, in the process according to the invention in which the rice is steamed under a superatmospheric pressure, the breakage in the rice obtained, both in dry and in cooked condition, greatly increases if a moisture content of 24 % or upwards is applied and that the product is not properly dry-cooking By applying open steaming, i e without superatmospheric pressure which method is preferred according to U K patent 737,446, the breakage in the dry product increases with increase of the moisture content at steaming, while the breakage is always higher than if the heating is effected under pressure In the cooking of rice thus treated the breakage especially increases at a moisture content at steaming of about 24 % If the moisture content is higher and if this rises to 25-30

%, a rice product is obtained which is fairly quick-cooking, but only moderately dry-cooking.

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The process according to the invention is not only distinct from the method according to U K patent

737,446 as regards the choice of the moisture content of the rice and the conditions under which the steaming takes place, but an essential difference lies in the pre-steaming treatment of the process of the invention which clearly improves the dry-cooking properties and which appreciably reduces the breakage By applying the process according to the invention it is even possible to convert wetcooking rice into dry-cooking rice.

According to the invention the moisture content of the rice is raised to 16-24 %, pree.g 10-16 % (air dry) This pre-steaming and the rice is briefly heated under pressure This will result in a reduced breakage and in a better dry-cooking quality than if higher moisture contents and longer heating times are applied The drycooking properties of rice become considerably poorer if breakage of the rice grains occurs either in the dry product or 70 during the cooking and the preparation of the food However, the avoidance of breakage alone is not sufficient to achieve better dry-cooking properties By heating rice having a moisture content lower than 75 16 ',, under pressure a product is obtained, which indeed has little breakage, but there is little or no improvement in the drycooking properties By steaming at a moisture content of 16-24 % 0, without apply 80 ing a superatmospheric pressure no improvement of the dry-cooking properties is obtained while there is an increase risk of breakage.

The dry-cooking properties are im 85 proved and the occurrence of breakage is practically prevented by pre-steaming rice having a conventional moisture content of e.g 10-16 % (dry air) This pre-steaming is effected at temperatures of from 75 90 'C, i e both under atmospheric and under superatmospheric steam pressure, preferably at a temperature in the neighbourhood of 1000 C ( 85-105 'C) This presteaming under atmospheric or under 95 superatmospheric pressure in itself does not result in a sufficient improvement in the dry-cooking properties Pre-steaming under atmospheric pressure even results in a decrease in said properties and a pre-steaming 100 upwards of 100 CC under a superatmospheric pressure will result in too slight an improvement The great improvement in the cooking behaviour of the rice is achieved according to the invention by hav 105 ing the pre-steaming treatment followed by a new steaming treatment but now at a somewhat higher moisture content and under pressure Breakage is substantially entirely prevented thereby 110 The pre-steaming is preferably effected for a rather short period of e g from 5-2 minutes at 95-130 'C or for 15-10 minutes.

at 75-90 'C Preferably dry steam is used and the pre-steaming is carried out in an 115 insulated vessel, the rice grains absorbing from 4-6 % of moisture during the presteaming treatment.

After the pre-steaming treatment the rice is moistened until it has a moisture con 120 tent of from 16-

24 % and the rice is tempered prior to being steamed under pressure These moisture contents hold good for rice having a temperature of from 20-40 'C A properly dry-cooking product 125 is also obtained if the rice temperature prior to the steaming under pressure is higher, for example 40-80 'C The moistening may be effected with a hot or a cold liquid.

After the addition of moisture the rice 130 903,837 3 is tempered in order to allow any rice which has caked together to disintegrate into loose grains again and at the same time to prevent the tendency of the rice to cake during the pressure steaming treatment, while furthermore the result is achieved that the moisture added will be better and more uniformly distributed throughout the grains and each grain.

The steaming under pressure is effected for a rathier short time The gauge pressure preferably ranges from 0 5-0 75 atmosphere at a rice temperature of from 110-120 'C.

A lower pressure will result in a smaller improvement in the dry-cooking properties, at higher pressures and temperatures the colour of the rice deteriorates The time may vary from 2-20 minutes dependent on the pressure The steam may be saturated or superheated.

Preferably a slight amount of acid is added together with the moistening water, whereby the drycooking properties are further improved and the colour remains lighter Keeping the colour of cereals lighter by the addition of acid is already known per se Suitable acids are the mineral acids permissable in nutritive substances (e g hydrochloric acid, phosphoric acid, nitric acid, sulphuric acid) or organic acids (e g citric acid, tartaric acid, lactic acid) It is preferable to add a buffer solution, e g a citric acid disodium phosphate buffer having a p H of 3 5-5 5.

860/2197

After the heating under pressure the rice is dried at temperatures that are not critical, but in such a manner that breakage, discolouration or caking is avoided Before and/or after the drying, lumps may be removed by screening and may be disintegrated; the material that is too fine may also be removed by screening The product is dried until it has a moisture content at which it has good keeping properties, generally to a moisture content of at most 16 %.

In order to apply the process according to the invention it may be necessary carefully to pre-dry the initial rice if the moisture content thereof is higher than 1601.

The dry product obtained has not gelatinised entirely and is not very translucent The rice grains have some cracks in them but they are sufficiently firm to enable them to be handled Said cracks are not so serious that upon cooking the rice grains will break and affect the dry-cooking properties The cracks as present in the rice treated according to the invention promote the dry-cooking and -the fluffy outward appearance of the rice.

The times mentioned are dependent on the rate of heating of the rice It has been assumed that both during the pre-steaming and during the pressure steaming the rice will reach a temperature practically matching the superatmospheric pressure within one minute If the rice is slower in reaching said temperatures the times will become longer The apparatus used will naturally 70 affect the times required.

As has been stated hereinbefore it is the intention to prevent breakage of the rice grains However, it is also possible according to the invention to process so 75 called broken rice, to obtain a considerable improvement in the dry-cooking properties thereof In this case the starting material consists of an amount (up to 100 %) of broken rice grains of varying sizes 80 Suitable starting materials for the process of the invention are long, medium and round rice, preferably polished rice but it is also possible to use brown rice The long Siam-rice which is a fairly dry-cooking 85 type of rice, will obtain improved drycooking properties if subjected to the process according to the invention while allowing a much larger variation in the amount of water added for cooking than in the case 90 of untreated Siamrice A round glutinous rice which normally cannot be cooked dry and fluffy at all, is converted into a reasonably dry-cooking product by the process according to the invention, which product, 95 even with e g 5 times the amount of water, still admits of being cooked into a mass of separate grains.

Ordinary rice is often cooked with slightly more than two parts by volume of 100 water for 15-20 minutes, whereupon the lid is taken off the pan ahd cooking is continued for 5-10 minutes for drying the rice.

If the processed rice is cooked in this manner a beautifully dry and fluffy rice is 105 obtained It is also possible to cook the rice a somewhat shorter time e g from 12-14 minutes The processed rice, however also admits of being cooked dry much more easily and with much more water 110 than rice not processed according to the invention.

It is possible, for example, to cook the processed rice in 5 times the amount of water for 7-15 minutes, pour off the excess 115 of water (which in the case of ordinary rice is often not possible at all) and to leave the rice standing in hot condition for about 10-15 minutes In that case a beautifully granular dry, fluffy rice is obtained This 120 mode of cooking is simple and requires little care and attention and cannot miscarry.

It is also possible to leave the rice standing in the excess of cooking water and to 125.

pour this off only just prior to serving the rice It is also possible to leave the rice standing for one night, to heat it in the excess of water and to pour off the water or to heat the rice in fresh water In all

130 r 903,837 903,837 cases a reasonably dry rice is obtained, the degree of dryness on the raw material, the possible variations in the treatment and the mode of cooking The cooked rice is just as white and soft as the rice obtained by cooking non-processed rice.

The processed rice is particularly suited for the preparation of cooked, sterilised, canned rice, in which preparation difficulties are experienced in keeping the grains in dry and separate condition and in achieving grains which will cook homogeneously.

861/2197

Prior to or ofter the pre-steaming, the moistening and the heating under pressure it is possible to add oxidants, such as a small amount of hydrogen peroxide, chlorine dioxide or nitric acid Such an oxidation treatment is already known in itself in its application to cereals In the present case a certain improvement in the dry-cooking properties is possible, by such an oxidation treatment but this treatment may have undesirable side-effects, such as a deterioration of the colour, of the keeping properties and the development of an offflavour.

In the following examples the invention is further elucidated In all cases a product was obtained, which as compared with 3) the initial material showed a distinct improvement in dry-cooking properties and fluffiness.

Example 1.

Siam-rice was pre-steamed for 4 minutes at 90 'C, whereupon water was added until the moisture content of the rice was 19 %.

After tempering the rice was steamed for 3 minutes at a rice temperature of 116 C, and under a gauge pressure of 0 75 atmospheres The rice which had a moisture content of 24 % after said treatment was subsequently dried to a moisture content of 12 %.

Example 11.

Siam-rice having a moisture content of 12 % was steamed for 2 minutes at 100 C.

and thereafter mixed with a cold buffer solution having a p H of 4 2 prepared from 0.1 molar citric acid solution and 0 2 molar disodium phosphate solution, so that the moisture content was raised to 21

% After tempering the rice was steamed for 4 minutes under a gauge pressure of 0 75 atmospheres with superheated steam, the rice reaching a temperature of 118 C.

After this treatment the rice was dried.

Example III.

Siam-rice after being pre-steamed for 10 minutes at 85 C was given a moisture ( 60 ( content of 21 % by means of a buffer solution having a p H of 4 7 and after tempering it was steamed for 7 minutes under a gauge pressure of 0 5 atmospheres and then dried.

Example IV.

Egyptian round rice was pre-steamed at C for 4 minutes and its moisture content was raised to 20 % by means of a citric acid disodium phosphate solution having a p H of 4 4 After tempering the rice was

70 steamed for 3 minutes under a gauge pressure of O 75 atmospheres (rice temperature 113 C) and afterwards dried.

Example V.

Egyptian rice having a moisture content 75 of 11 %/ was pre-steamed for 4 minutes at C and its moisture content was raised to 17 % by means of a cold buffer solution having a p H of 4 4 and consisting of 0 2 molar citric acid and 0 4 molar disodium O 80 phosphate After tempering the rice which had a temperature of 33 a C was placed in an autoclave and heated for 9 minutes under a gauge pressure of 0 5 atmospheres whereupon the rice was afterwards dried 85 Example VI.

Siam-rice was pre-steamed at 105 C for 3 minutes, its moisture content was raised to 21;, by means of water, whereupon the rice was tempered and then steamed for 3 90 minutes under a gauge pressure of O 75 atmospheres and the rice was then dried.

Example VII.

862/2197

Siam-rice after being pre-steamed for 10 minutes at 90 'C had its moisture content 95 raised to 22,%, by means of water and 10 milligrams of citric acid per kilogram of rice was tempered and steamed for

18 minutes under a gauge pressure of 0 3 atmospheres (rice temeprature 107 C) and 100 was finally dried.

Example VIII.

Italian rice having a moisture content of 13 %,, was ore-steamed for 3 minutes at C whereupon its moisture content was 105 raised to 19 % by means of cold water and 0.7 milligrams of hydrochloric acid per kilogram of rice After tempering the rice was heated for 6 minutes with steam under a gauge pressure of 0 6 atmospheres and was 110 afterwards dried.

Example IX.

Burma rice after being pre-steamed for 7 minutes at 95 C, had its moisture content raised to 21 e by means of a citric 115 acid disodium phosphate buffer having a p H of 4 5 and after tempering it was steamed for 3 minutes under a gauge pressure of 0 75 atmospheres and was afterwards dried 120

Example X.

Australian broken rice was pre-steamed for 3 minutes at 105 C with superheated steam, was brought to a moisture content of 24 % by means of a hot citric acid solu 125 tion, was tempered in hot condition, and was steamed for 3 minutes under a gauge pressure of 0 75 atmospheres the rice reaching a temperature of 115 C and was then dried 130 903,837 Example XI.

Brown rice after being pre-steamed for minutes at 90 'C, had its moisture content raised to 22 %; by means of a citric acid disodium phosphate buffer having a p H of 4.4, was tempered and steamed for 7 minutes under a gauge pressure of 0 6 atmospheres and was afterwards dried.

Exaniple XII.

:0 Siam rice having a moisture content of 13 %O was pre-steamed for 3 minutes at 93 C, brought to a moisture content of % by means of cold water and 0 5 grams of hydrogen peroxide per kilogram of rice, was tempered, was steamed for two minutes under a gauge pressure of 0 75 atmospheres and was afterwards dried.Data supplied from the esp@cenet database - Worldwide

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184.

GB957839 - 5/13/1964

PROCESS AND APPARATUS FOR THE PREPARATION OF IMPROVED

CEREAL FLOURS


Applicant(s): JEAN PHILIPPE LEPETRE (--)

E Class: A23L1/105B; A21D2/02; A21D6/00; B02B1/00; B02B1/04; B02C9/00; C08B30/04B



Family: GB957839

Equivalent: LU39811; FR1262595; CH406815

Abstract:


957,839. Treating cereal grains. J-P. LEPETRE. Feb. 27, 1961 [March 1, 1960], No. 7114/61. Heading

A2Q. A flour of 40% greater digestive quality than that of conventional flour and in which the starch has a substantially unbranched structure, is prepared by subjecting cereal grains to enzymatic autolysis in an aqueous acidic solution at a temperature of 15 to 65 C., a pH of 4.2 to 6.8, an oxidation-reduction potential of 250 to 450, a resistivity of 115 to 180 ohms per centimetre, and an oxygen content of 2 to 6 cc. per litre of solution, and then high pressure milling the autolysed grains at an elevated temperature whereby they are substantially dried and ground to flour. Under preferred operating conditions the grains are washed in a solution acidified to pH 6.2-6.5 and given a preliminary digestion under specified conditions for up to five hours, the solution in which the enzymatic autolysis of the grains takes place is acidified initially to a pH of 4.6 with orthophosphoric acid and the grains are stirred in the solution for from 1 to 10 hours until the pH of the solution reaches the iso-electric point of the proteins of the grains, thereafter the solution is restored to a pH of about 5.6 by addition of a specified phosphoric acid, permitting the appearance in the solution of appreciable quantities of

[alpha] and # amylases, and the mixture is allowed to stand for from 1 to 4 hours prior to being milled between cylinders to about 150 C. Cereals mentioned are wheat, barley, maize, rice and rye. The grain, after washing and preliminary digestion in a column 1 during which light and heavy impurities are removed by manipulation of screens 7 and 8, respectively, passes to the autolysis column 2 provided with a thermostatically-controlled jacket 12 and probes 18, 19, for the control of the oxygen content of the liquor and of its pH, oxidation-reduction potential and resistivity, and is subsequently drained on a plate 22, dried to flour on heated rollers 30 and further dried during its passage down the conduit 33 by warm air fed through a duct 34; the dried grain may finally be treated by blade or hammer pul- verisers

(not shown). The autolysis liquor used in the column 2 is prepared in the auxiliary column 2a from the waste bran and middlings obtained from flour milling and drainage liquor from the column 2 collected into the three tanks 25, 26 and 27 according to its pH; the same reactions take place in the auxiliary column as in column 2, but they are allowed to go to completion until the enzymes have no further action. Parts of the apparatus in direct contact with the grains are covered with a ceramic or plastics material.

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185.

GB963739 - 7/15/1964

PROCESS AND APPARATUS FOR THE PRODUCTION OF FLAVOURED

CEREALS


Applicant(s): MINNIE RUTH LARRALDE (--)

E Class: A23L1/18F; A23L1/182B; A23L1/22B



Family: GB963739

Abstract:


A flavoured grain cereal for example rice, wheat or barley, is produced by providing the outer surface of the grains with a coating of a desired flavouring, covering the coated grains with an envelope of flour obtained or formed from the cereal grain breakage, whereby the grains remain separated from one another, and finally surrounding the envelope with a thin film of hydrogenated fat to delay moisture absorption by the flavoured cereals thus produced. Crude cereal grains may be covered with a mix consisting of an edible saturated fat and a flavouring extract, and then coated with the envelope of flour and the thin film of hydrogenated fat. A savoury flavouring may be applied in a finely ground or flaked condition to puffed grains coated with a glucose syrup, and the flavouring is then covered with glucose syrup before enveloping the grains in the breakage flour and coating with the hydrogenated fat; the flavoured cereal grains produced are then rapidly cooled to a temperature between 0 DEG and 5 DEG

C. A colouring agent may be added to the flour forming the flour envelope. Flavourings mentioned: apple syrup, lemon, orange, apricot, raspberry, strawberry, tomato powder, chicken paste, cheese, salted fish, curry, dehydrated onion or garlic, herbs such as mint, thyme, laurel and oregans, and sodium glutamate. Examples are disclosed.Description:



DRAWINGS ATTACHED.

963,739 Date of filing Complete Specification (under Section 3 ( 3) of the

Patents Act, 1949): Nov 3, 1960.

Application Date: Nov 9, 1959.

Application Date: Aug 17, 1960.

No 37966/59.

No 28570/60.

Complete Specification Published: July 15, 1964.


865/2197

Index at Acceptance:-A 2 B( 1 B, 1 C, IE, IF, IJ, IL).

International Classification:-A 23 b, d, 1.


Process and Apparatus for the Production of Flavoured Cereals.

I, MIN Ni E Ru TH LARRALDE, a British Subject, of 133 Rue Saint-Dominique, Paris 7 eme,

France, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to the production of flavoured cereals, whether such cereals be in the crude form or have previously been puffed by any well known process, such cereals generally being rice, wheat or barley.

It is amongst the objects of this invention to provide a puffed cereal with a flavour other than the natural flavour, for example a fruit, sweet or savoury flavour, and which will have the added advantage of a relatively low hygroscopic character.

A further object is to provide a flavoured crude cereal and having attained this to ensure that it will remain moisture-proof for a reasonable length of time.

It is well known, of course, that puffed cereals, such as puffed rice, have for some time been a popular form of breakfast food and that such cereals have been made by various processes and generally by a simple gun-puffing operation.

Such known cereals, however, have certain disadvantages in that it has not been possible to provide such cereals with a flavour other than the natural form, whilst the cereals are highly hygroscopic and thus tend rapidly to lose the desirable quality of crispness.

According to the present invention a process for producing a flavoured grain cereal (e g rice, wheat or barley) consists in providing the outer surfaces of the grains with a coating of a desired flavouring, covering the coated grains with an envelope of flour obtained or formed from the cereal lPrice 4 s 6 d l grain breakage, whereby the grains are separated from one another, and finally surrounding the said envelope with a thin film of hydrogenated fat to delay moisture absorption by the flavoured cereals thus produced.

If the cereal to be treated is puffed, e g in any known manner, the grains, after puffing, are then treated as set out above.

If the flavouring to be imparted to the puffed cereal is of a sweet character, the said flavoured coating is encased as stated above by a grain breakage flour envelope; if, however, the flavouring selected is of a savoury character, it is preferred to provide the puffed grains with a glucose syrup coating, before applying the savoury flavoured coating, which latter coating is then again covered with glucose syrup before enveloping the grains in the cereal flour.

If the flavouring is of a sweet character, it is applied to the puffed grains in the form of a syrup but if the flavouring is of a savoury nature, e g, cheese, salted fish, spices and.

the like, the flavouring is applied in a, finely ground or flaked condition.

As stated above, when it is desired to delay moisture absorption, the flour envelope has applied thereto a film of hydrogenated fat, which may be vegetable or animal fat, said fat thus forming an outer container for the flavoured puffed cereal, which container provides an efficient protection against atmospheric moisture which is the main cause of cereals losing their degree of crispness.

866/2197

When it is desired to produce a flavoured crude cereal the process preferably consists in providing a mix consisting of an edible saturated fat and a flavouring extract, which mix is introduced into a quantity of crude cereal, whereafter the mixture of crude cereal CIA tM Iz (ZIN grains and mix is agitated to ensure that such grain is provided with a coating of the mix, applying to the said coated grains an enclosing envelope of a flour obtained or formed from the cereal being treated and rapidly cooling the thus treated cereal to solidify the edible fat and flavour mix.

The fat used must have a melting point above room temperature and preferably an hydrogenated fat having a melting point above 400 C is used.

It will thus be appreciated that the cereal grains are each provided with a covering including an edible hydrogenated fat, a flavouring and a flour obtained from the cereal.

The hydrogenated fat in the mix must be in the liquid state, so that during the process of producing the flavoured cereal the fat can cool slowly, its viscosity therefore increasing during the process.

Preferably, when the mix is introduced into the crude cereal, the mixture is agitated to separate the grains, so that each grain may receive its coating of the mix, and thus enable the coated grains subsequently to be covered with an envelope of the flour When the flour envelope is provided the treated cereal undergoes a very rapid cooling at a temperature below the temperature at which the hydrogenated fat wholly solidifies; it is preferred to utilise for this rapid cooling part of the process cold air at a temperature between O to 50 C During this rapid cooling the hydrogenated fat solidifies almost instantaneously and the flavouring extract which is included inside the fat in the form of microscopic drops or disposed as very fine grains if a powdered extract be used, becomes perfectly protected by the solidified fat, whilst the flour adheres to the fat layer.

Whether producing a flavoured crude or puffed cereal a colouring agent may be added to the flour forming the flour envelope.

An one example of producing an apple flavoured puffed cereal according to this invention, the puffed grains are prepared according to any well known method, e g.

by using a puffing-gun; such grains have a moisture content of about 5-6 %.

EXAM 1 PLE 1.

The breakage, that is to say the grains which are broken when the pressure of the puffing-gun is suddenly released, is obtained from the puffed grains for utilisation as will be described below An apple syrup is then prepared from two parts by weight of sugar and one part by weight of water, so that the syrup has a specific gravity of 36-38 Baum 6 at 150 C To this syrup the apple extract or juice, and colouring, if desired, is added Alternatively, a natural syrup consisting of concentrated apple juice is used.

pounds of puffed grains are placed in a mixing device, e g a rotatable drum; into 65 the mixture 20 pounds of apple syrup S.G 380 B at 15 C is introduced, the syrup being heated to a temperature of between 350 C and 710 C.

This syrup is too heavy to penetrate the 70 grains and, therefore, forms a coating on the outside of each grain when the mixture is rotated Thereafter a flour produced from the cereal breakage is prepared by grinding the breakage into very fine flour 15 pounds 75 of such flour is then introduced into the mixer so as to form an outer envelope covering the syrup coating.

The provision of this dry flour envelope renders it possible for the grains to be 80 separated one from another and so renders it possible to obtain a simple and efficient drying of the product.

An illustration of one grain of flavoured puffed cereal thus produced is shown in 85 enlarged section in the drawing accompanying the Provisional Specification No.

867/2197

37966/59, in which A is the puffed cereal, B is the apple syrup coating and C is the flour envelope It will thus be seen that the 90 flavoured coating B is enclosed in a container formed by the puffed grain

A and the flour envelope C so that the flavouring is protected against deterioration.

It will, of course, be appreciated that 95 although reference has been made to apple flavouring, the puffed cereal can be given different fruit flavourings such as orange, lemon, raspberry or any other desired sweet flavouring 100 It will be clear that due to the Specific Gravity of the syrup, it cannot penetrate the puffed grain and, therefore, forms only a coating whose thickness can be regulated as desired, whilst the provision of the flour 105 envelope causes instant separation of the syrup-coated puffed grains which, prior to the introduction of the flour, generally adhere to one another As stated above the flour envelope enables drying to be done effectively 110 and simply and this can be performed in any known type of dryer, preferably a rotatable dryer at a maximum temperature of 36

C, the temperature being reduced so that final drying air is cool 115 As has been stated above, the moisture content of puffed grain is between 5-6 % and utilising the syrup at 380 B With a water content for the apple syrup of 30 % the following table is obtained: 120 963,739 963,739 Weight Moisture % lbs. lbs. lbs.

6 Water content.

3 lbs.

6 lbs.

1 lb. lbs 10 lbs.

With a weight of puffed cereal, syrup and flour of 100 pounds, the water content is 12 pounds, that is to say 12 %; it is preferred that the drying operation should be performed to reduce the water content to no more than 6 % and in such a case it will be necessary to evaporate by drying at a low temperature only 6 pounds water for every.

pounds of materials put in the dryer; thus drying can easily and readily be performed Furthermore, drying at low temperatures allows inclusion in the syrup of vitamins which are affected by high temperature, e g, if the drying temperature had to be in the neighbourhood of 70 C, the vitamins would be destroyed.

EXAMPLE 2.

For producing a savory flavoured puffed cereal, e g, cheese.

50 pounds of puffed cereal are placed in the mixer, a glucose syrup 36 Baum 6 is prepared and 6-8 pounds thereof added to the puffed cereal to form an adhesive layer on the grains 20 pounds of a mixture made with finely ground dried cheese, salt and spices, is then added which savoury mixture adheres to the adhesive glucose layer; thereafter another 6 pounds glucose syrup is added to provide a further layer on top of the savoury flavouring and finally 12-15 pounds of grain breakage flour is added; thereafter the flavoured puffed cereal is dried in the same manner as described above.

In order to render a flavoured puffed cereal less hygroscopic, the said cereal, produced in accordance with either of the examples given above, is placed into liquid hydrogenated fat at a temperature between C and 80 C The grains are dipped in the fat for a few seconds, extracted, and the excess fat allowed to drain off The grains are then subjected to a strong current of very cold air, e g, at a temperature of 0 o-80 C.

868/2197

If a fruit syrup with a lower concentration than 36 Baum 6 is used, to avoid the syrup penetrating into the grain, thus deflating the grain, it is preferred to provide a layer of hydrogenated fat on the grain before the syrup is applied.

Examples will now be given of fruit flavoured crude cereals according to this invention, although it is obvious that many variations are possible, for example in addition to the flavourings referred to in the examples set out below other flavourings such as lemon, mint, apricot, strawberry or the like as well as curry and cheese may be employed.

EXAMPLE 3.

APPLE RICE.

(a) Quantity of rice treated (b) Hydrogenated fat (melting point 50/55 C) (c) Apple extract (d) Rice flour + colouring EXAMPLE 4.

RASPBERRY RICE.

(a) Crude rice treated (b) Hydrogenated fat (c) Raspberry extract (powder) (d) Rice flour + colouring

EXAMPLE 5.

ORANGE RICE.

(a) Crude rice treated (b) Hydrogenated fat (c) Orange extract (paste) (d) Rice flour + colouring

EXAMPLE 6.

CHICKEN RICE.

Crude rice treated Hydrogenated fat Chicken paste Dehydrated onion Herbs, thyme, laurel, or the like

Flour + colouring + sodium glutamate E XAMPLE 7.

TOMATO FLAVOURED RICE. grs. grs.

17 ccs.

3 grs. grs. grs. grs. grs. cos.

1 gr.

Crude rice treated Hydrogenated fat Tomato extract in powder form Dehydrated onion , garlic Herbs: laurel, oregano, or the like Flour + colouring + sodium glutamate grs. ccs.

1 cc.

869/2197

grs.

17 grs.

1 gr.

0.02 gr. grs. grs 95 grs. grs.

2 grs.

0.5 grs.

0.1 gr. grs.

In all these Examples 3 to 7 inclusive, the thin film of hydrogenated fat is the outermost 105 layer of the flavoured grain cereal.

One form of apparatus which can be utilised to carry out the above process Puffed Rice Apple Syrup

Rice Flour Total whether it be the intention to produce a flavoured crude or a flavoured puffed cereal is diagrammatically illustrated in the Figure of the accompanying drawing The apparatus will first of all be described for producing a flavoured crude cereal and comprises a tank 1 into which hydrogenated fat is led through a pipeline 2, the tank including means for melting the said fat An outlet 3 from said tank leads to a container 4 into which flavouring extract either in the form of a liquid or a powder is fed through a pipeline 5 The container 4 thus provides for the mix consisting of the fat and the flavouring extract This mix is led from the container 4 through a pipeline 6, tank 7 and pipeline 8 to a first conveyer 9, into which crude cereal from a hopper 10 is introduced The conveyer which can be of any desired known type is arranged in a plane inclined to the horizontal and above a similar second conveyer 91 which is inclined in the opposite direction The mix and crude cereal from the conveyer 9 fall through a pipeline 11 to the second conveyer 91 into which the flour envelope material with a colouring if desired is fed from a mixing tank 12, pipeline 13, hopper 14 and pipeline 15 It will thus be seen that the second conveyer is arranged to feed through a pipeline 16 the crude cereal with the coating of mix from conveyer 9 and with a flour envelope introduced in the conveyer 91 t Wa third conveyer 17, where the thin film of hydrogenated fat is provided through a further tank 20 In this conveyer 17 the treated crude cereal is subjected to rapid cooling, the conveyer finally discharging its contents through a pipeline 18 to any desired delivery position for example to a hopper 19 The rapid cooling is effected preferably by a blast or cold air forced through the conveyer 17, in a direction contrary to the feed of treated cereal If desired, further cold air may be introduced into the pipeline 18 as the finished product is delivered to the hopper 19.

It has been stated above that the conveyers can be of any known type but it is preferred to use a conveyer in which a plurality of stirring or agitating blades are provided.

When it is desired to utilise the apparatus shown in the Figure for producing a flavoured puffed cereal, the syrup is prepared in tank 1 and the flavouring introduced into the syrup in container 4 The puffed cereal is fed through the hopper 10 to the conveyer 9 where it mixes with the flavoured syrup, whilst the flour breakage and colouring is again introduced into the conveyer 91 through the hopper 14 and pipeline 15 A further tank, however, shown at 20 is then provided for introducing into the third conveyer 17, which receives the puffed cereal with the syrup flavouring and flour envelope, liquid hydrogenated fat.Data supplied from the esp@cenet database - Worldwide Claims:


870/2197

WHAT I CLAIM IS:-

1 A process for producing a flavoured grain cereal, for example rice, wheat, or barley, which consists in providing the outer 70 surfaces of the grains with a coating of a desired flavouring, covering the coated grains with an envelope of flour obtained or formed from the cereal grain breakage, whereby the grains remain separated from one another, 75 and finally surrounding the said envelope with a thin film of hydrogenated fat to delay moisture absorption by the flavoured cereals thus produced.

2 A process as claimed in Claim 1 in 80 which the grains of the cereal are puffed in any known manner prior to coating with flavouring and enveloping in flour, whereby flavoured puffed cereals are provided.

3 A process as claimed in Claim 1 in 85 which the grains consist of crude cereal grains, which grains are covered with a mix consisting of an edible saturated fat and a flavouring extract, the mixture of crude cereal grains and mix being agitated to ensure 90 that each grain is provided with a coating of the mix, to which coating is applied the flour envelope and the thin film of hydrogenated fat the mass then being rapidly cooled to solidify the edible fat and flavour 95 mix.

4 A process as claimed in Claim 1 or 2 in which the flavouring is of a sweet character and is applied to the grains in the form of a syrup 100 A process as claimed in Claim 2 in which the flavouring is of a savoury nature and is applied to the grains in a finely ground or flaked condition after said puffed grains have been coated with a glucose syrup, the 105 flavouring then being covered with glucose syrup before enveloping the grains in the breakage flour.

6 A process as claimed in any of the preceding claims in which the hydrogenated 110 fat is either a vegetable or animal fat.

7 A process as claimed in any of the preceding claims in which the hydrogenated fat has a melting point above room temperature and preferably above 40 C 115 8 A process as claimed in Claim 6 or 7 when dependent on Claim 3 in which the rapid cooling is effected at a temperature between 0-5 C.

9 A process as claimed in any of the 120 preceding claims in which a colouring agent is added to the flour forming the flour envelope.

A process for producing flavoured cereals substantially as hereinbefore des 125 cribed.

11 A flavoured puffed cereal substan963,739 963,739 tially as hereinbefore described with reference to Example 1 and 2.

12 A flavoured crude cereal whenever produced in accordance with Examples 3-7 herein.

13 Apparatus for producing flavoured, puffed or crude cereals substantially as hereinbefore described with reference to the accompanying drawing.

For the Applicant, CARPMAELS & Rl ANSFORD, Chartered Patent Agents, 24 Southampton

Buildings, Chancery Lane, London, W C 2.

Abingdon: Printed for Her Majesty's Stationery Office, by Burgess & Son (Abingdon), Ltd -1964.

Published at The Patent Office, 25 Southampton Buildings, London, W C 2, from which copies may be obtained.Data supplied from the esp@cenet database - Worldwide

871/2197

186.

GB964213 - 7/22/1964

METHOD AND APPARATUS FOR THE HEAT TREATMENT OF ORGANIC

GRANULAR MATERIAL


Applicant(s): NAT BISCUIT CO (--)

E Class: A23L1/18C2; A23L1/18C



Family: GB964213


Abstract:


964,213. Gelatinizing and puffing cereal grains. NATIONAL BISCUIT CO. Jan. 17, 1962 [Feb. 15,

1961], No. 1669/62. Heading A2Q. To effect gelatinization of rice, maize, wheat or oat grains before they are puffed, a hot compressed gas, such as air, is passed through a bed of the grains, at a velocity sufficient to maintain the bed in a fluidized condition, so that individual grains are freely suspended in the gas and subjected, continuously, to heating by the gas and to a pressure sufficient to prevent premature puffing. In treating rice according to the invention, rice from a hopper 15, Fig. 1, is fed through a valve 14 into a vessel 12, which is in communication with the atmosphere through a pipe 18 and a valve 25; a valve 17 in the outlet pipe 16 being closed. The valves 25 and 14 are then closed and compressed air is fed, from a compressor 23 through pipes 22, 20 a valve 24 and the pipe 18, into the vessel 12. The valve 17 is then opened and the rice passes into a chamber 27, which is surrounded by a heatinsulating jacket 30, to form a bed of rice on the perforated plate 42 of a closed butterfly valve 33 near the base of the chamber, which is connected, by a pipe 36 and a valve 56, with the pressure chamber 53, Fig. 2, of a puffing gun 52. The valve 56 is closed and compressed air is fed, through a circulating pump 46 a heater 47, a pipe 40 and a valve 41, into the pipe 36 and through the plate 42 to

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fluidize the bed of rice in the chamber 27. The compressed air leaves the chamber through a screen 48 and a pipe 32 leading into the pipe 20. The valve 41 is closed and valves 33 and 56 are opened to allow the gelatinized rice to pass through the pipe 36 into the puffing gun chamber 53, which has a flared outlet 59 closed by a conical valve 63. The pressure and temperature in the chambers 27 and 53 may range, respectively, between 175 and 250 p.s.i. and 450 and 650 F. Valve 56 is then closed and valve

63 is opened to discharge the rice from the chamber 53, through the outlet 59, into a bin 55 in which the pressure is at, or slightly below, atmospheric pressure.Description:


PATENT 'SPECIFICATION

Date of Application and filing Complete Specification: January 17, 1962.

9649213 A No 1669/62 Application iade in United States of Ainerica (No 89508) on t \ u l February

15, 1961.


( Crown Copyright 1964.

Index at Acceptance:-A 2 Q ( 3 A, 3 B, 13, 15, 16 A, 17, 21, 22).

International Classification:-B 02 c.


DRAWINGS ATTACHED Method and Apparatus for the Heat Treatment of Organic Granular

Material We, NATIONAL Bl SCUIT COMPANY, a corporation organised under the laws of the State of New Jersey, United States of America, of 425 Park Avenue, New York, 22, State of New York,

United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to a process and apparatus for the heat-treatment of granular organic material to effect gelatinization of the organic material and more particularly relates to a novel method and apparatus for gelatinizing cereal grains in the production of puffed cereal products such as puffed rice, puffed wheat and other similar grains.

In the prior art it has been common practice to puff cereal grains such as rice, wheat and corn by means of an explosion process in which the grains are cooked by steam in a chamber of a puffing gun for a predetermined length of time After a quantity of grain has been sufficiently heated to produce gelatinization, and the pressure and temperaturo within the gun chamber have reached a suitable level, the chamber is suddenly opened to atmospheric pressure, thus effecting a sudden expansion or

"puffing" of the grain.

Various disadvantages arise with the use of this method, however, and apparatus and processes heretofore employed have been unsatisfactory for a number of reasons Because of the time involved in bringing the cereal grains to the gelatinization point, this operation is costly and time-consuming The length of time required to gelatinize each batch of starting material is also not conducive to a continous method of production.

Furthermore, a steam-heating process tends to make the cereal grains stick together or lPri adhere to the wall of the gun chamber Consequently, it is difficult to obtain a product 45 of uniform appearance and consistency.

These and other disadvantages make it necessary to provide other methods of production which are more reliable and better suited to high production needs 50 It is, therefore an important object of this invention to provide an improved process and apparatus for gelatinizing and puffing cereal grains

873/2197

which can operate at a reduced time cycle of production over that of the 55 prior art and which will produce a more uniform appearing puffed cereal product.

It is also another object of this invention to provide a process and apparatus for gelatinizing cereal grains which does not 60 necessarily depend upon the introduction of steam to effect gelatinization of the cereal grain, thus avoiding the problems attendant on the use of steam.

It is also an important object to provide 65 a process and apparatus in which the problems encountered when the cooking chamber is an integral part of the puffing gun are avoided.

According to the invention, there is 70 provided a process for effecting gelatinization in granular organic material such as cereal grains, by subjecting the granular material to a hot gaseous medium under a pressure sufficient to 75 prevent puffing of the grains, in which the hot compressed gaseous medium is passed into a bed of the granular material at a velocity sufficient to maintain the bed in a fluidized condition with the individual 80 grains freely suspended in the gaseous medium and continuously subjected on all sides to the heat of the gaseous medium.

According to a further feature of the invention there is provided apparatus for 85 carrying out the process of the invention, the ef C 1 -.4 I 964,213 apparatus including a heating chamber containing the granular material, the chamber having an inlet and an outlet for hot gaseous medium under pressure and being sealed to prevent the escape of said gaseous medium other than through the inlet or outlet, the:nlet being positioned for the granular materrial to be subjected to a flow of gaseous medium in a direction to fluidize a bed of the granular material when the gaseous medium is circulated through the chamber at a sufficient velocity, a heater, a compressor, and a circulating pump for heating and compressing the gaseous medium and for circuating the hot compressed gaseous medium at high velocity between the inlet and the outlet.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings, in which:

Fig 1 is a schematic flow diagram illustrating the process and apparatus embodying the principles of this invention; and Fig 2 is an enlarged sectional view of the puffing gun apparatus employed in the flow diagram of Fig 1.

The invention will be described in connection with the puffing of cereal grains, such as wheat, rice, or corn i e maize, but it is to be understood that it is not intended to restrict the invention thereto, since the invention is susceptible of application in the heat-treatment of other food products.

The process of the present invention differs in a major respect from that of the prior art in that, instead of gelatinizing a batch of cereal grains in a relatively static, high-temperature, high-pressure, steam atmosphere such as is employed in the prior art, the cereal grains are gelatinized in a highvelocity, high-temperature, high-pressure atmrosphere utilizing either exclusively or predominantly the moisture that is normally present in the cereal grains.

In a preferred form of the process of the present invention, a fluidized bed of the pressurized cereal grain is heated in a relatively dry, high-velocity flow of heated gas for a period sufficient for the moisture contained in the cereal grains to effect gelatinization thereof, the velocity of the flow being sufficient to maintain the bed of cereal in a fluidized condition Thereafter, the product of gelatinization may be abruptly depressurized so as to effect a corresponding expansion of the cereal grain to produce the final food product in puffed form By heating the cereal grains in a fluidized bed state in a relatively dry atmosphere until gelatinization occurs, it has been found that the total time required to produce gelatinization of the cereal grains is substantially shortened cornpared with that required in the conventional gelatinization process.

The steps involved in the present method of gelatinization may be carried out in two or more vessels so that when the cereal 70 grain in one vessel reaches the pressure and temperature condition necessary for initiating gelati nization, it may be passed to another vessel for the completion of the gelatinization process While the gelatinization 75 of the cereal grain is being completed in tihe second vessel, a

874/2197

succeeding change of cereal grain can be prepared for gelatinization in the first vessel Thus, the steps in the present process of gelatinization may be sub 80 stantially continuously performed, although each individual vessel operates intermittently on a batch basis in the gelatinization process In the present process the moisture required for the gelatinization of the cereal 85 grain is derived from the moisture that is normally present in the whole cereal grain.

Referring now to Fig 1, there is shown a pressure chamber or vessel 12 for the reception of grain kernels from a grain source 90 or hopper 15 The vessel 12 has a grain feed inlet line 13 having a charging valve 14, and has a grain outlet conduit 16 having a discharge valve 17 for the discharge of pressurized grain The pressure vessel 12 may 95 be of chemically inert metal which does not react with or affect the food product being processed therein, such as stainless steel.

The movement of the grain during the course of treatment in the process of the present 100 invention is shown in Fig 1 by a heavy solid arrow to indicate the direction of flow.

To achieve the gelatinization of the grain kernels, for example rice, in accordance with the invention, rice is preliminarily pressur 105 ized prior to being heated to the desired gelatinization temperature

This is accomplished by closing the charging and discharge valves 14, 17, and introducing gas under pressure into the vessel 12 through a gas 110 pipe 18, extending through a gastight opening in the pressure vessel 12 High pressure gas, usually compressed air, is supplied to the gas pipe 18 from a manifold line 20 v means of a supply line 22 which operates to 115 transfer compressed air from a compressor 23 to said manifold line 20 A closure valve 24 is provided in the manifold line 20 to control the flow of compressed air into the vessel 12, and a valve 25 in the manifold line, is pro 120 vided for exhausting compressed air from the vessel 12, during which time the valve 24 is closed.

The valves 17 and 24 are closed and the valve 25 is opened prior to the opening of 125 the valve 14 for the purpose of relieving the gas pressure in vessel 12 prior to and during the charging thereof, allowing such pressure to exhaust through lines 18 and 20 to atmosphere Atmospheric conditions having 130 964,213 been thus restored to pressurizing vessel 12, valve 14 is opened in order to proceed with rice grain charging The vessel 12 is pressurized after charging by closing the valves 14 and 25 and by subsequently opening the valve 24.

The rice grains in the pressure vessel 12 are then passed to an adjoining heating chamber 26, by opening the discharge valve 17 in line 16 which connects the pressure vessel 12 with the heating chamber 26 This heating chamber preferably comprises a double-walled container having an elongated inner pressure vessel 27 of chemically inert metal, such as stainless steel, for receiving the pressurized rice grain from the pressure vessel 12, and a surrounding shell or jacket 28 of suitable metal material, for example, carbon steel, completely encompassing the inner vessel, and providing an intervening insulation space 30 filled with a suitable heat-insulation material, such as asbestos or "Marinite"

(registered Trade Mark) However, the vessel 27 may be wrapped with a suitable thickness of insulation and the other jacket 28-dispensed with, if so desired.

The heating chamber 26 is formed as illustrated -to provide a pair of outlets, one through the upper portion of the inner vessel 27 by way of the outlet line 32 and the other through the lower portion of the vessel 27 through a valve 33, such as a movable perforated plate valve of the butterfly type, which fits the contour of the vessel wall As illustrated the valve 33 has a stem part 34 extending through a bearing support 35 disposed transversely in the insulation space Rotation of this valve 33 about the axis of the stem 34 into open position discharges the contents of the inner vessel 27 into a puffing gun inlet line 36

Secured to one end of -the stem 34 is a projecting arm 37 which may be pivotally secured to a link 38 that in turn may be actuated, either manually or automatically, as by a solenoid switch, to rotate the valve 33 into the desired open or closed position.

For the purpose of gelatinizing the rice grains in the inner vessel 27, hot air or other suitable heating gas is passed through a hot air inlet line 40 having a control valve 41 and into the interior of the inner vessel through a plurality of apertures 42 in the butterfly valve 33 The heating air leaves the vessel 27 via the outlet line 32.

In order to achieve an effective system for uniformly heating the rice grains, the inner vessel 27 should be of such size as to, provide a fluid bed of grains when the heating gas is drawn therethrough

875/2197

In carrying out the invention, there is provided a convergent section 44, at the entrance to the inner vessel to increase the velocity of the heating gas -65 in its upward travel through the heating column

Conversely, a divergent section 43 is provided at the opposite end of the inner vessel to reduce the velocity of the heating gas Thus, a loose mass or fluidized bed of rice grains to be gelatinized is continuously 70 shaken and uniformly exposed to rising air currents.

The flow of compressed air that is to ore used in the heating vessel 27 is through the conduit 22 into the manifold 20 where it is 75 drawn into a circulating pump 46 and is forced through a heater 47 into the inlet line 40 The exhaust pipe 32 recycles the hot air into the manifold 20 Since the pressure of the heating gas in the exhaust pipe 32 is 80 slightly higher than the pressure in the manifold 20, the exhaust heating air will flow into the manifold and toward the low pressure side of the -pump 46 A perforated screen 48 disposed at the entrance to the ex 85 haust pipe 32 prevents the egress of any light, smallersized rice grains-from the heating vessel 27.

A by-pass line 50 having a suitable bypass valve 51 is provided between the inlet go line 40 and the manifold 20-to allow continuous operation of the pump 46 when the heating control valve 41 is closed.

The heating-gas flow cycle is shown in Fig 1 by a dotted arrow to show direction 95 of flow.

Upon completion of the heating operation, the rice grains are admitted in thechamber of a puffing gun

52 under approximately the same pressure as in the pressure 100 chamber 12 and the heating chamber

26.

There, the pressure is suddenly reduced, causing an explosion or puffing of the rice grains to the desired degree.

A preferred construction of the puffing 105 gun 52 is shown in Fig 2 This construction comprises a tubular barrel-like casing or puffing gun chamber 53, of steel or other:

high-strength material, which may be fitted or bolted to the wall 54 of a bin or hopper 110 The rice is supplied to the gun chamber 53 of the puffing gun 52 through a valve 56 in the inlet line 36 and through a' receiving opening 57 into the gun chamber 53, and 115 the products of expansion are, discharged from the gun chamber through a-discharging opening 58 and thence through a divergent nozzle 59 into an opening 60 'in the wall of -the receiving bin 55 which is main 120 tained at atmospheric pressure or under a slight vacuum The operating mechanism of the -puffing gun comprises a shaft 61 which extends the length of the puffing gun through an airtight 125 -end seal or gasket 62 into the interior of the' gun chamber 53 where it passes through the discharge -opening 58 When the interior of the chamber 53 is under operating pressure the discharge opening 58 is closed by a suit 130

964,213 able valve at the end of the shaft 61, preferably a conically shaped valve 63 which seats in the nozzle 59 This valve also abuts the edge of the bin opening 60 Opening of -the valve, 63, which is effected by a longi-^ tudinal movement of th shaft 61, causes a sudden imbalance or reduction in pressure and is accompanied by an outrush of -the -high pressure air into the clearance space -around the conical valve 63 Simultaneously, the rice grains are hurled vigorously through the discharge opening into the receiving hopper while undergoing the puffing transformination:occasioned by the abrupt change in pressure All will be appreciated, when the valve 56 is open and the valve 63 is closed the static ipressure within the chamber of the puffing gun will be identical to the static pressure within the heating chamber.

The means for reciprocably moving the shaft 61 to open and close the valve 63 may be performed by suitable electrical, pneumatic or hydraulic apparatus (not shown) or by hand if so desired.

In operation, the following sequence of steps is performed, either manually or automatically in the following timed sequence.

Starting with each of the valves 14, 17, 24 and 25 in the closed position, 25 is opened, and valve 14 is subsequently opened for a sufficient period of time to admit a predetermined, metered quantity of cereal grains.

876/2197

for example, rice, from the supply hopper 15 into the pressure chamber 12 Valves 14 and 25 are then closed, and valve 24 is opened to bring the pressure in the chamber 12 to the proper level During this entire operation valve 17 remains closed.

While the pressure conditions in the yessel 27 can vary between approximately 175 and 250 p s i in the case of most cereal grains, a desirable pressure range is approximately 200 to 225 p si and a preferred pressure is approximately 200 to 210 p s i.

It will be realized, however, that the pressure range will vary depending upon the particular food material that is being processed For example, rice or oats may be heat-treated at pressures slightly above atmospheric pressure.

Once the desired pressure in the pressurizing vessel 12 has been obtained, valve -I 7-is oplned-4 toadmit-the-pressurized rice grains into the pressure vessel 27 During the admission of the rice into said vessel 27, the valve 24 remains open to equalize the pressure in said pressure vessel 12 via the pipe 18 The rice falls by gravity into the vessel 27 and-is deposited upon the apertured butterfly plate valve 33 which is in the close Ud position Thereupon, the valve 17 is closed and valves 24 and 25 are subsequently closed aid open ed,_respectively This de-.

piessurizes the vessel 12 so that valve 14 can be opened-to admit te succeeding batch of rice during the period that the previous batch is being heated in the heating vessel 27.

To circulate heating air in the chamber 27, the valve 41 in-line 40 is opened, there 70 by effecting a closed high-velocity circuitry of heating air consisting of lines 40, 32, and the portion of the manifold

20 having the pump 46 This circulation of heating air is shown by the dotted arrows in Fig 1, and is 75 lof a velocity such as to maintain the bed (f rice in a fluidized, floating condition.

It will be realized that the heating period will vary with the temperature and pressure, but generally this step is carried out at 8 G a temperature between about 450 to 650 F, for about 1 to 5 minutes, desirably at a temperature between about 475 to 550 F for about 1 I t 6 3 minutes, and preferably about

480 to 525 F for about 2 to 2 minutes 85 Upon the completion of the heating step, three valves are operated approximately simultaneously The flow of air through vessel 27 is terminated by shutting valve 41 and opening by-pass valve 51 At the same time 90 the butterfly valve 33 is briefly opened to permit the gelatinized rice to fall under gravity through valve 56 and into the gun chamber 53 As the rice grains are relatively dry, there is little tendency for them to adhere to 95 each other or to the surrounding walls of the apparatus Following the closure of the butterfly valve 33, the valve 56 is closed, and the puffing gun is discharged.

During the heating cycle period, the suc 10ceeding batch of rice grains is pressurized by shutting the valve 25, and opening valve 24 in the same manner as previously described.

Similarly, the heating cycle for the succeeding batch is accomplished by opening the 105 valve 17 leading into the heating chamber, and then closing the valve 17 During admission of the pressurized rice into the heating vessel 27, the by-pass valve 51 is in operation and valve 41 is closed 110 The above-described operating procedure may be performed by a conventional timing mechanism (not shown) or by hand, if so desired.

EXAMPLE 1 115

Forty-eight ( 48) ounces of rice grains are admitted into a pressure chamber and subjected to a pressure of 200 p s i g The pressurized rice is then transferred to a heating vessel and heated to a temperature of about 120 500 F in a flow of air of sufficient velocity (e.g 1800-2000 ft per minute) to maintain -tihe bed of rice grains in a fluidized condition for approximately 3 minutes to gelatinize the starch granules therein Upon comple 125 tion of the gelatinization, the rice is fed into a pre-heated puffing gun chamber and dis charged into a bin at atmospheric pressure, causing the rice to assume the puffed form, The entire operation takes approximately 3-130 964,213 minutes or less In contrast, the conventional method of heating, pressurizing and sudden decompression of a similar amount of rice in a single chamber takes approximately 8 jto 11 minutes.

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EXAMPLE 2

Example 1 is repeated substituting for the rice grains, wheat grains According to the conventional method of puffing wheat, the process takes at least 81 to 11 minutes, whereas the present method takes approximately 3 minutes or less.

EXAMPLE 3

Example 1 is repeated substituting for the rice there-used, corn i e maize The entire operation takes 3 minutes in contrast with the conventional operating time of 8-; to I 1 minutes.

From the above description it will be seen that the present method and apparatus for heating a fluidized bed of cereal with a gaseous heating medium is admirably suited for a large-scale continuous method of producing puffed cereal products, and provides improved means for achieving a superior and more uniformly treated product.Data supplied from the esp@cenet database - Worldwide

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187.

GB966891 - 8/19/1964

COSMESTIBLE COATING COMPOSITION AND METHOD OF PRODUCING

SAME


Applicant(s): DCA FOOD IND (--)

E Class: A23L1/176



Family: GB966891

Abstract:


Compositions for breading foods, including frozen foods, to be fried are in the form of 3-0.8 mm. size agglomerations of particles having 20-90% of a farinaceous material in non-gelatinized state and 1-

12% of water. Dried milk, salt, sugar, spices such as pepper and clove, emulsifiers such as lecithin, flavouring, leavening and colouring agents, oils and fats such as hydrogenated vegetable oil shortenings and lard, and gluten, preferably undenatured may be incorporated. The farinaceous materials are wheat, maize, soya, oat, rice, rye and potato flours. According to Example I, 320g. of water at 40 DEG F. are sprayed with mixing on to 1000g. of wheat flour, 20g. of glucose, 1.5g. of sodium acid pyrophosphate, 1.5g. of sodium bicarbonate and 0.5g. of spice while stirring in a paddle mixer, the damp mass is forced through a stainless steel wire cloth with 8 openings per inch, and the particles are dried on an oscillating table under infra-red lamps, the dried particles being finally sieved; according to Example III 250g. of water are sprayed on to 1000g. of wheat flour, 50g. of skim milk powder and 20g. of spice cascading in a revolving, tilted pelletizing pan to form spheroids, the spheroids are passed through a hammer mill fitted with a wire cloth of 1/4 -\ba1/2 inch apertures, and the fragments are sieved and dried similarly.Description:


L S E I F C ATI


NO DRAWINGS 966,891 4, s Date of Application and filing Complete Specification: Aug 9, 1961.

No 28822/61.

Application made in United States of America (No 102,644) on April 13, 1961.



Index at acceptance:-AZ B (i B, 1 H, 1 J, 1 T, 1 W) International Classification:-A 23 b, I


Cosmestible Coating Composition and method of producing same CORRECTION OF CLERICAL

ERROR SPECIFICATION NO 966869 i

879/2197

The following correction is in accordance with the Decisicn of the Assistant Comptroller acting for the Comptroller-C General, dated the 15th day of February 1965.

Page 1, line 4, for ';gth Street, i read; 36th Street, THE PATENT OFFICE, burt ilarch, 2965 D

35449/5 stuffs with a baked farinaceous particulate coating material such as cracker meal or bread crumbs Heretofore, cracker meal has generally been commercially produced by combining flour of many types and origin with such additional materials as sugar, spices, non-fat dry milk, leavening such as sodium bicarbonate, salt and other ingredients, together with water, to form an extrudable mass The mass is then extruded under heavy pressure in a cohesive state and baked The baked product is thereafter broken into small pieces and finally is ground to a fine state to form the cracker meal The conventional cracker meal includes a starch component which is in a gelatinised state and a protein component which is in a de-natured state and is characterised by the lack of residual moisture absorption vwhen applied to a food substrate, inferior adhesion properties and inability to prevent distortion attending the cooking of the food The conventionally produced cracker meal, particularly when applied to frozen foods, possesses many other drawbacks and disadvantages.

In the preparation of cracker meal-coated frozen foods, as for example, frozen fish sticks, the raw fish is initially in a frozen state and lPro ing equipment, thereby appreciably increasing the cost of the end product Moreover, the resulting foodstuff is of an inferior nature, since in its final form, ready for consumption portions thereof have been cooked more than once The frozen food product, as received by the consumer, is normally reheated in the oven for 10 to 15 minutes at 400 F to 450 F.

The food substrate at this point has lost some of its freshness and eating qualitv and the breading coating is no longer crisp and dry.

It is thus obvious that the conventional frozen breaded food product leaves much to be desired.

It is, therefore, an object of the present invention to provide an improved comestible coating composition in a particulate agglomerates form that is, particulate material in which the individual particles are, in turn, each formed of an agglomeration of the constituent materials which are in a more finely divided state than the resultant particles.

According to the present invention, a comestible coating composition comprises in a particulate agglomerated form between 20 / and 90 /% of a farinaceous material in a nongelatinised state and between 1 '/ and 12/.

of water The particles may advantageously PATENT SPECIFICATION

NO DRAWINGS 966,891 4 W b N Date of Application and filing Complete Specification: Aug 9,

1961.

CS -o %,^ No 28822/61.

Application made in United States of America (No 102,644) on April 13, 1961.

C Complete Specification Published: Aug 19, 1964.


Index at acceptance:-AZ B( 1 B, 11, IJ, IT, 1 W) International Classification:-A 23 b, I COMPLETE

SPECIFICATION

Cosmestible Coating Composition and method of producing same We, DCA FOOD INDUSTRIES

INC, a corporation, of the State of New York, United States of America, having an office and place of business at 45 West 46th Street, New York 18, New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

880/2197

The present invention relates to a comestible particulate coating composition and to a method of producing the same.

In the preparation of fried foods, such as fish, shrimp, poultry, meat and vegetables, it is conventional to coat the substrate foodstuffs with a baked farinaceous particulate coating material such as cracker meal or bread crumbs Heretofore, cracker meal has generally been commercially produced by combining flour of many types and origin with such additional materials as sugar, spices, non-fat dry milk, leavening such as sodium bicarbonate, salt and other ingredients, together with water, to form an extrudable mass The mass is then extruded under heavy pressure in a cohesive state and baked The baked product is thereafter broken into small pieces and finally is ground to a fine state to form the cracker meal The conventional cracker meal includes a starch component which is in a gelatinised state and a protein component which is in a de-natured state and is characterised by the lack of residual moisture absorption when applied to a food substrate, inferior adhesion properties and inability to prevent distortion attending the cooking of the food The conventionally produced cracker meal, particularly when applied to frozen foods, possesses many other drawbacks and disadvantages.

In the preparation of cracker meal-coated frozen foods, as for example, frozen fish sticks, the raw fish is initially in a frozen state and lPacut to the desired size and shape of the product The frozen fish sticks are coated with a suitable batter of an adhesive nature and the cracker meal then applied thereto, to cover completely the fish stick with the cracker meal, which adheres thereto by reason of the batter, and forms what is known in the art as a breading The breaded product is then fried to cook and brown the breading and fix it to the fish or other food substrate As a result of this frying step, the food substrate is heated considerably and, in many cases, partially cooked, a consequence which is highly undesirable The above procedure necessitates the rapid refreezing of the food product, generally with blast or plate freezing equipment, thereby appreciably increasing the cost of the end product Moreover, the resulting foodstuff is of an inferior nature, since in its final form, ready for consumption portions thereof have been cooked more than once The frozen food product, as received by the consumer, is normally reheated in the oven for 10 to 15 minutes at 4000 F to 4500 F.

The food substrate at this point has lost some of its freshness and eating quality and the breading coating is no longer crisp and dry.

It is thus obvious that the conventional frozen breaded food product leaves much to be desired.

It is, therefore, an object of the present invention to provide an improved comestible coating composition in a particulate agglomerates form that is, particulate material in which the individual particles are, in turn, each formed of an agglomeration of the constituent materials which are in a more finely divided state than the resultant particles.

According to the present invention, a comestible coating composition comprises in a particulate agglomerated form between 20 % and 90 % of a farinaceous material in a nongelatinised state and between 1 % and 12 % of water The particles may advantageously 7,1 _ _ __ _ include a fatty material which is absorbed into the surface of the particles.

The coating composition particles range from 3 m m to 0 08 m m in size The farinaceous material may advantageously comprise wheat, maize, soya, oat, rice, rye, potato flour, or other farinaceous materials, or mixtures thereof In addition, there may be admixed with the farinaceous materials suitable additives such as dry milk, salt, sugar, spices such as pepper, cloves, emulsifiers such as lecithin, flavouring, leavening, or colouring agents, which may constitute up to 79 % of the coating composition

Fatty material, when employed, may be in the form of a solid fat or an oil, for example lard, vegetable shortenings, in normally solid or liquid states, hydrogenated oils or emulsifiers Where a protein material, for example gluten, is included in the composition, it is advantageously in its undenatured state.

In the preparation of the coating composition in accordance with the present improved process, the farinaceous material in flour form is admixed with the desired additives such as those mentioned above and between 7 % and % by weight of water is admixed therewith The resulting mixture is then formed into agglomerated particles substantially of the range conventionally employed in cracker meal, for example between 6 mesh and 200 mesh The agglomeration of the mixture is advantageously effected

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by the use of the conventional pelletising equipment The pellets may then be ground in the well known fashion to the desired particle size as aforesaid where the originally formed pellets exceed this size.

The resulting particles are thereafter heated, advantageously to 1500 F to 2200 F, for a period of 3 to

30 minutes, reducing the water content to 1 % to 12 % It should be noted that other drying processes may be employed, for example vacuum drying, whereby to obtain the aforesaid moisture content in the absence of substantial gelatisation or denaturing of protein.

The above heating step is advantageously effected by exposing the particles to infrared radiation After the particles have been dried as aforesaid, they may then be coated with a fatty material, advantageously between 2 % and 15 % by weight of the particles The fatty material may be applied by spraying and is readily absorbed so that there is no surface grease present The resulting material unexpectedly possesses the appearance of a breading material, and when browned during drying or otherwise coloured, the appearance is that of a fried breading material A further unexpected property of

60 the composition produced above, in addition to its resemblance to cracker meal, bread crumbs, and other material of a similar nature is that-unlike the latter-the present composition is non-gelatinised and non 65 denatured in protein structure As a consequence, the coating material of the present invention has superior taste and eating qualities and possesses adhesive properties to the food substrate which have been heretofore 70 unattainable.

The improved coating composition may be applied to a food substrate whether in the frozen, unfrozen or raw state, by employing any well known adhesive batter in the usual 75 manner The resulting product has the appearance of a fried breaded foodstuff and possesses the advantages of this type of food and relatively few of the disadvantages thereof particularly when the product is a 80 frozen food.

In preparing the frozen food product, the food processor merely coates the frozen food in its final frozen state and shape, with the subject coating composition as aforesaid, and 85 then packages the product without the necessity of further flash freezing This is in sharp contrast to conventional procedures, wherein the processor coats the frozen foodstuff with a batter and meal, bread crumbs 90 or other breading compounds, fries the product and then rapidly re-freezes it, a practice which is expensive and requires a considerable additional power consumption and equipment The consumer, in preparing the 95 conventional breaded frozen product for consumption, re-heats the same by baking or the -like, which results in a re-cooking of part of the foodstuff resulting in an appreciable depreciation in the eating qualities of the 100 food substrate as well as the crumb coating.

On the other hand, when the consumer prepares the presently coated foodstuff by heating it, the food substrate is cooked for the first time and is at its optimum condition and 105 the crumb coating is at its peak eating condition.

EXAMPLE I

A substantially uniform damp mass of the following ingredients was produced by spraying the water at 400 F into the dry ingredients while effecting the thorough mixing thereof in a hooded Hobart

(Registered Trade Mark) mixer fitted with a paddle:

966,891 966,891 Grams Wheat flour 1000 00 Glucose 20 00 Sodium acid pyrophosphate 1 50

Bicarbonate of Soda 1 25 Spice 0 50 Water 320 00 The resultant mass was then forced through a stainless steel wire cloth having 8 openings to the inch and the resulting particles dried by placing them on an oscillating table and exposing them for 18 to 20 minutes to three 250 watt infra-red heating lamps suspended five inches above the centre of the bed of materials The dried particles were then sieved to the desired particle size range.

EXAMPLE II

The procedure of Example I is followed, the ingredients employed being 1,000 grams of flour and 375 grams of water.

EXAMPLE III

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A mixture of 1,000 grams of wheat flour and 50 grams of non-fat dry milk solids and grams of spices were placed in a revolving tilted pelletising pan and 250 grams of water were sprayed upon the cascading material to form damp spheroids No particular order need be followed in placing the materials in the pan The spheroids were then passed through a hammer mill fitted with a wire cloth of between 1/4 " and 1/2 " aperture and the output sieved, the desired size particles being dried in the manner set forth in Example I, the undersized particles being returned to the pelletiser and the oversized particles being recycled through the hammer Mill.

EXAMPLE IV

The procedure of Example III is followed except that the ingredients employed are 1,000 grams of wheat flour and 700 grams of water.

EXAMPLE V

A damp mass of 2,000 grams of wheat flour and 280 grams of water was forced under a pressure of

10,000 pounds per square inch through a die having 3/16 inch by 1/4 inch holes and the resulting pellets were dried on an oscillating table by exposure for 4 minutes to infra-red lamps The dried product was then passed through a hammer mill and sized as earlier described If desired, the sized dried particles may be advantageously further treated by spraying 160 grams of a vegetable oil thereon.

The procedures described above and the composition of the end products may be modified in the manner earlier set forth For example, a fatty material may be applied to the sized dried particles within the ranges previously indicated The coating materials described above are applied to a food substrate in the usual manner Where the food substrate is frozen, it is not heated and requires no freezing following the application of the coating but is merely packaged and cold storaged in the conventional fashion.Data supplied from the esp@cenet database - Worldwide

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188.

GB974883 - 11/11/1964

IMPROVEMENTS IN OR RELATING TO THE PRODUCTION OF SHAPED,

STORABLE FOOD PRODUCTS


Applicant(s): THERESE PEZZEI (--)

E Class: A23L1/40; A23L3/42


Priority Number: AT19590008736 (19591202); AT19590008913 (19591209)

Family: GB974883

Equivalent: CH443869

Abstract:


A storable food is made by forming a pulp by adding an edible liquid to an edible substance which acquires bonding properties on being mixed with liquids, then adding to the pulp a comminuted, edible, absorbent substance in such a quantity that the liquid of the pulp is absorbed by the absorbent substance, the particles of which remain bound together by the residue of the pulp to form a mass of mouldable consistency, whereupon the mass is formed into shapes and the shapes are dried. The pulp may contain proteins such as gluten, casein and gelatine, potato, flour, fruit, vegetables, ground cereal products, carbohydrates; the absorbent and flavouring substances may be cheese, mushrooms, spices, sweetening agents, honey, cocoa, dried mean, dried, e.g. spray dried, foods, ground dried fruit, candied peel, "seed grains", skinned milk powder, dried yeast, marzipan, nougat. Examples are concerned with the preparation of pasta-type products, for adding to soup, from strained, cooked vegetable such as asparagus, cooked wheat flour paste, spray-dried mushroom flovouring or powdered dried mushrooms, flour and yeast, the preparation of dry "bread dumplings", for reconstitution in a hot liquid, from a paste of cooked wheat flour, with, if desired, gelatine or gluten and lactic acid solution, bread crumbs or cubes, dried vegetable, dried whole egg and cream of tartar, and the preparation of pasta-like products for sweet dishes, of ingredients for cake or fruit bread, and of cake decorations from casein, boiled comminuted cereal grains, e.g. rice flour, chopped dried fruit, e.g. grapes, dates, almonds, a vitamin preparation, sugar or sugar syrup, crumbed ginger-bread, poppyseed, ground, dried pears.Description:


Cf

C


NO DRAWINGS.

o Date of Application and filing Complete Specification.

Nov 30, 1960 No 41203/60.

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Application made in Austria (No 8736) on Dec 2, 11 Application made in Austria (No 8913) on Dec

9, 11 Complete Specification Published: Nov 11, 1964.

) Crown Copyright 1964.

Index at Acceptance:-A 2 B( 1 B, IE, IF, 11 I, IJ, 1 K, IL, IS, IV); A 2 D( 2 B 2, 3 B).

International Classification:-A 23 b, 1.


Improvements in or relating to the Production of Shaped, Storable Food Products.

I, THERESE P Ezz EI, an Austrian Citizen, of Eugenstrasse 4, Solbad Hall, Tirol, Austria, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a method of preparing storable food, and concerns the preparation not only of foodstuffs to be added to soups, and foods to be eaten with meat or other savoury dishes, but also of various sweet dishes of fruit bread, decoration for cakes or like confectionery, and diet foods of any taste.

The method according to the invention comprises producing a storable food in which a pulp is prepared by the addition of an edible liquid to an edible substance which acquires bonding properties on being mixed with liquid, and thereafter a comminuted, edible, absorbent substance is added to the pulp in such a quantity that the liquid of the pulp is absorbed by the absorbent substance, the particles of which remain bound together by the residue of the pulp to form a mass of a mouldable consistency, whereafter the mass is formed into shapes and the shaped material is dried.

The substance of pulpy consistency may include, for example, gluten, casein, potatoes, fruit or vegetables, proteins such as albumen, cearial products, carbohydrates, and mixtures thereof Flavoutring materials such as cheese, mushrooms, spices, sweetening substances, honey or cocoa can be added.

The absorbent substance, which forms the major part of the finished food, may include, for example, cereal flakes or germ, cooked, dried, and comminuted foods, spray-dried foods, comminuted or ground dried fruit, skimmed milk powder, yeast, as well as l 1 l 974,883 ? 59.

159.

flavours such as dried meat, cheese, spices, comminuted sweets, candied peel, "seed grains", for example poppy-seed nougat and mixtures thereof.

Depending on whether savoury foods such as cheese, meat, mushrooms and vegetables or sweet materials such as honey, cocoa, marzipan and dried fruits are used as foodstuffs or flavours, the method is suitable for the preparation either of food to be added to a soup and foods to be eaten with meat and other savoury dishes, or of preserved sweet dishes, fruit bread, and decorations for cakes, pastries and like confectionery The food can be rendered eatable by being brought quickly to the boil with water, or by being scalded by having hot soup or other edible liquid poured over it Diet foods may be prepared by the addition of medicinally and dietetically active substances such as vitamins.

The following are examples relating to the preparation of materials to be added to soups, preserved foods and sweet dishes.

(a) Mushroom-flavoured soup additive:

7-15 parts by weight of chopped vegetable, such as asparagus, are boiled together with the necessary amount of liquid, and are then strained.

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After an optional addition of 3-10 parts by weight of wheat flour, the boiling may be briefly continued, whereafter flavouring materials such as mushroom extract may be admixed In this manner a pulp is prepared.

10-20 parts by weight of a sufficiently cooked mushrooms, dried and powdered, or mushroom substance prepared by a spraydrying process, and 5-15 parts by weight of edible wheat flour or yeast are worked into the pulp until the liquid has been completely absorbed.

The resulting product is shaped in a conventional machine for shaping pasta foods to form material to be added to soup The shaped elements are dried.

(b) Preparation of storable bread dumplings:

2-6 parts by weight of wheat flour are cooked with adequate liquid to form a pulp.

If desired, 1-5 parts by weight of edible gelatine or gluten, dissolved in liquid (lactic acid) may be incorporated in the pulp.

10-20 parts by weight of coarse crumbs or small cubes of dried white bread together with flavouring such as dried soup vegetables, dried whole egg powder, and a small amount of powdered cream of tartar, are worked into the pulp until the liquid is absorbed and the residue of the pulp serves as a binder for the admixed bread crumbs.

Then dumplings or small loaves are formed and dried.

Hitherto, there have been available no products for use as a main food or as accessories or additions to a main food which merely require scalding or pouring over of a hot liquid or cooking for a very short time.

Containing as it does only ready-to-eat substances, the storable food prepared according to the method of the invention requires no actual cooking, but is eatable when it has been scalded with hot liquid or has been boiled for a very short time The housewife or the commercial kitchen may serve this preserved food not only as a material added to a soup or as a food to be eaten with meat but also as a main dish.

Preparation of sweet dishes:

(c) 3-8 parts by weight of casein (with the addition of liquid) or 5-10 parts by weight of comminuted cereal grains boiled with liquid, with admixed flavouring materials, if desired, constitute the pulp.

20-40 parts by weight of chopped dried fruit, such as grapes, dates or almonds, and flavouring materials, are mixed with the pulp.

To absorb the remaining moisture, 15-30 parts by weight of cereal flakes, with or without the addition of 2-6 parts by weight of a vitamin preparation, are worked into the mass which is thereafter shaped by machine and dried.

This sweet dish consisting of dried fruit and cereal flakes provides an excellent uncooked energy food because it can be prepared without baking and can be enriched with substances having medicinal and dietetic activity.

(d) 6-10 parts by weight of fruit pulp are cooked together with sweetening agents such as sugar or syrup, and 3-6 parts by weight of rice flour are added, whereafter the cooking is continued for a short time to obtain a pulp.

20-40 parts by weight of ground pastry (gingerbread crumbs), with an optional admixture of poppyseed and ground dried pears, are worked into the pulp The mixture is suitably brought to a mouldable consistency in which it is suitable for being shaped, for example in a conventional machine for making pasta.Data supplied from the esp@cenet database - Worldwide

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189.

GB980390 - 1/13/1965

STARCH ACYLATES AND PROCESS FOR THEIR PREPARATION


Applicant(s): STALEY MFG CO A E (--)

E Class: A23L1/0522B; C08B31/04; A21D2/18E; A21D13/00B; C08B31/00B2; C08B31/16



Family: GB980390

Equivalent: US3238193; DE1296382

Abstract:


In a process for making cross-linked starch acylates a cereal or a "root-type" starch is treated, in any order, with a cross-linking agent comprising at least one polyfunctional etherifying or esterifying agent in an amount from 0.01-10% by weight of dry starch and an acylating agent (1.0-40% by weight of starch) while maintaining the starch in granular form. If the starch is cereal starch, it is reacted with the cross-linking agent until the alkaline fluidity (as defined) is 50 c.c.-90 c.c., and it is acylated with a vinyl ester, or an anhydride of an aliphatic monocarboxylic acid having 1-18 carbon atoms. If the starch is "root-type," the cross-linking reaction is continued until the alkaline fluidity is 30 c.c.-90 c.c., and it is acylated with a vinyl ester of the above monocarboxylic acid. The granular form of the starch is maintained throughout the process. The product has a CIV viscosity at pH 3.5 of at least 700 g.-cm. after 15 minutes, and at least 496 g.-cm. after 40 minutes. Cereal starches are e.g. corn, rice and wheat; root-type starches are e.g. potato, waxy maize, waxy sorghum, cassava. The polyfunctional crosslinking agent may be unsaturated aldehydes e.g. acrolein, crotonaldehyde; dihaloalkanes e.g. ethylene dichloride, 1,2-propylene dibromide, 2,6-hexylene dichloride; dialdehydes e.g. glyoxal, adipaldehyde; methylol compounds e.g. dimethylol urea; epihaloalkanes e.g. epichlorohydrin, 1,2-epoxy-4chlorobutane, 1,2-epoxy-5-bromopropane, and polybasic acid halides e.g. phosphorus oxychloride and adipyl chloride. Specified acylating agents include vinyl acetate, vinyl hexoate, vinyl stearate, acetic anhydride and propionic anydride. When vinyl esters are used, acetaldehyde formed in situ during the alkaline acylation may be utilized as an additional cross-linking agent during cross-linking with the poly-functional agent. The process may be carried out by suspending granular starch in a polar solvent, e.g. water, alcohols or dioxan, adding an alkaline catalyst and cross-linking agent, and heating at e.g.

100 DEG F. at pH 9-13, until the required alkaline fluidity is attained. After termination of the crosslinking reaction by e.g. adjustment of pH or by addition of sodium bisulphite, the acylating agent is added and acylation carried out at e.g. pH 7.0-12.5 and 65-115 DEG F. Reaction is terminated by adjusting the pH to 6.0, and the cross-linked acylate is isolated by filtration or centrifugation. If acetaldehyde is utilized as an auxiliary cross-linking agent, the acylation is carried out first and the pH adjusted to below 4.0 before the addition of the polyfunctional cross-linking agent.Claims:



TABLE V

Number of cc. that Separated in Each Cycle

Starch 1st Cycle 2nd Cycle 3rd Cycle

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Unmodified Corn Starch 16 20 24

Cleargel* Starch 6 S 7

Acrolein Cross-Linked Starch

Acetate of Example II 0.5 0.5 1

Acrolein-Acetaldehyde

Cross-Linked Starch

Acetate of Example VII0 0 0.5

Phosphorus Oxychloride

Cross-Linked Starch

Acetate of Example IX0 0 0 * Cleargel starch is a commercial cross-linked waxy corn piestarch.

The above shows the improved freeze-thaw properties of the cross-linked starch acylates of this invention.

While the preceding examples show that the cross-linked cereal starch acylates of this invention have improved paste characteristics when the cross-linked starch has a two gram alkaline fluidity in the range of 50 cc. to 90 cc., we have found that each of the preferred cross-linking agents has its own most advantageous alkaline fluidity range and per cent acyl by dry weight of the starch range.

Normally we prefer to cross-link cereal starches having from2-3.5% acyl by weight to an alkaline fluidity of from about 55 cc. to 75 cc. with acrolein, from about 55 cc. to 75 cc.wfth epichlorohydrin and from about 68 cc. to 85 cc. with phosphorous oxychloride in order to get products having the most advantageous paste properties. When acetaldehyde is used as an auxiliary cross-linker, it is usually preferable to have an alkaline fluidity of from about 75 cc. to 85 cc.

WHAT WE CLAIM IS:

1. A granular cross-linked cereal starch acylate of an aliphatic monocarboxylicv acid having from 1 to

18 carbon atoms having an alkaline fluidity as hereinbefore defined of from 50 cc. to 90 cc., a CIV viscosity as hereinbefore defined at pH 3.5 of at least 700gm.-cm. after 15 minutes andCW viscosity at pH 3.5 of at least 496 gm.-cm. after 40 minutes, said starch acylate being cross-linked through the hydroxyl groups of the starch with a cross-linking agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterifying agent.

2. A granularcross-linked cereal starch acylate of an aliphatic monocarboxylic acid having from 1 to18 carbon atoms having an alkaline fluidity as hereinbefore defined of from 50 cc. to 90cc. a CIV viscosity as hereinbefore defined at pH 3.5 of at least 700 gm.-cm. after 15 minutes and a CIV viscosity at pH 3.5 of at least 600 gm.-cm. after 40 minutes, said cereal starch acylate being cross-linked throught1-'e hydroxyl groups of the starch with across-lin6ing agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterifying agent

3. The starch acylate according to claim 1 or 2, wherein a cereal starch acylate is crosslinked through the hydroxyl groups of the starch with acetaldehyde and a polyfunctional etherifying agent or apolvfunctional esterifying agent.

4. The starch acylate according to anycf claims 1 to 3, which is a cereal starch acetate.

5. The starch acylate of any of claims 1 to 4, wherein the polyfunctional cross-linking agent is acrolein.

6. The starch acylate of any of claims 1 to 4, wherein the polyfunctionalcross-linkin agent is phosphorous oxychloride.

888/2197

7. The starchacvlate of any Of claims 1 to 4, wherein the polyfunctional cross-linking agent is epichlorohydrin.

8. The starch acylate of any of the claims 1 to 7, wherein said starch acylate is a starch acetate having from 1.5 to3.5 / by weight acetyl groups.

9. A process of forming a starch acylate which comprises subjecting cereal starch in suspension to process steps, in any sequence, which comprise treating the cereal starch with a cross-linking agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterification agent in an amount from0.01'% to101% by weight of dry starch to react with the hydroxyl groups of the said starch until the crosslinked starch has an alkaline fluidity as hereinbefore defined of from 50 cc. to 90 cc., and acylating cereal starch with a vinyl ester or an anhydride of an aliphatic monocarboxylic acid having from 1 to

18 carbon atoms, the acylating agent being present in an amount of from1.0% to40% by weight of the starch and maintaining the starch in granular form.

10. The process ofdaim 9 wherein the starch is acylated with a vinyl ester of an alipahtic monocarboxylic acid having from 1 to 18 carbon atoms at an alkaline pH, whereby acetaldehyde is generated in!lieu, and the pH of the reaction mixture containing free acetaldehyde is adjusted below 4 and maintained below 4 to cause the acetaldehyde to react with the starch.

11. A process of forming a cereal starch thickening agent, which comprises treating cereal starch in suspension with a crosslinking agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterifying agent in an amount from0.01% to10% by weight of dry starch to react with the hydroxyl groups of the cereal starch until the cross-linked starch has an alkaline fluidity as hereinbefore defined of from 50 cc. to 90 cc., acylating said quantity of cereal starch with a vinyl ester or ananhvdride of an aliphatic monocarboxylic acid having from 1 to 18 carbon atoms, the acylating agent being present in an amount of from 1.0% to40 /O by weight of the starch, and maintaining said cereal starch in granular form.

12. The process according to any of claims 9 to 11, which includes the step of separating a granular cross-linked starch acylate from the reaction mixture.

13. A process of forming a cereal starch thickening agent which comprises treating cereal starch in suspension with a cross-linking agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterifying agent in an amount of from 0.01% to10% by weight of dry starch to react with the hydroxy groups of the cereal starch until the cross-linked starch has an alkaline fluidity as hereinbefore defined of from 40 cc. to 60 cc., acylating said crosslinked starch with a vinyl ester of an aliphatic monocarboxylic acid having from 1 to 18 carbon atoms in an amount of from 1.0% to 40% by weight of the starch, whereby acetaldehyde is generated in situ, adjusting the pH of the reaction mixture to below 4, whereby the acylating reaction is terminated maintaining the pH below 4 to cause said acetaldehyde to react with the starch until the cross-linked starch acylate has an alkaline fluidity of from 60 cc. to 90 cc. and then separating the granular cross-linked cereal starch acylate from the reaction mixture.

14. A process of forming a cereal starch thickening agent which comprises acylating cereal starch in suspension with an amount of from1.{Y% to401% by weight of dry starch of a vinyl ester of an aliphatic monocarboxylic acid having from 1 to 18 carbon atoms or an anhydride of an aliphatic monocarboxylic acid having from 1 to 18 carbon atoms, treating said cereal starch acylate with a crosslinking agent which comprises at least one of a polyfunctional etherifying agent or a polyfunctional esterifying agent in an amount of from0.01'% to1U% by weight of dry starch to react with the hydroxyl groups of the cereal starch and separating a granular cereal starch acylate having an alkaline fluidity as hereinbefore defined of from 50 cc. to 90oc. from the reaction mixture.

15. The process according to any of claims 9 to 14, wherein the polyfunctional crosslinking agent is acrolein.

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16. The process according to any of claims 9 to14 whereinlinking ' ein the polyfunctional crosslinking agent is phosphorous oxychloride.

17. The process of any of claims 9 to 14, wherein the polyfunctional cross-linking agent is epichlorohydrin.

18. The process of any of claims 9 to 17, wherein the vinyl ester is vinyl propionate.

19. The process according to any of claims 9 to 17, wherein the vinyl ester is vinyl acetate.

20. The process of any of claims 9, 11, 12 and 14, wherein the anhydride is acetic anhydride.

21. A granular cross-linked starch acylate substantially as herein described with particular reference to the Examples.

22. A process of forming a starch thickening agent substantially as herein described with particular reference to Examples I to XIII.Data supplied from the esp@cenet database - Worldwide

890/2197

190.

GB981054 - 1/20/1965

A METHOD OF SEASONING FOODSTUFFS


Applicant(s): YOSHITOMI PHARMACEUTICAL (--)

E Class: A23L3/3463; A23L1/227; A23L1/229B



Family: GB981054

Equivalent: US3214276; DE1492729; CH447792

Abstract:


Foods are seasoned by sodium cysteine-S-sulponate, NaSO3.S.CH2.CH(NH2)COOH, produced by the action of sodium bicarbonate, sodium sulphite and ferrous sulphate on an aqueous solution of l-cystine or produced microbiologically. The sodium cysteine-S-sulphonate synergizes the seasonings monosodium glutamate and 51-nucleotides such as disodium 51-inosinate and guanylate. Foods seasoned include beef, poultry meat, whale meat, fish pastes, ham sausage, rice and wheat products, vegetables and dried vegetables, fruits, jams, sweets, food oils and fats, milk, sauces, coffee powder, ice-creams.

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191.

GB985613 - 3/10/1965

ENRICHMENT OF FOODS AND FEEDS



E Class: A23L1/302; A23K1/16B; A23L1/303; A61K31/59



Family: GB985613

Equivalent: DE1517044

Abstract:


To a food or feed is applied an aqueous emulsion or dispersion of fat-soluble vitamin or carotenoid mixed with a predominant amount of dextrin, sugar or cellulose derivative in aqueous solution, which emulsion or dispersion contains emulsifier, e.g. gum acacia, hydrolysed collagen, antioxidant, e.g. butylated hydrozyanisole, butylated hydroxy-toluene, 6-ethoxy-2,2,4-trimethyl-1,2-dihydro-quinoline, and preservative, e.g. sodium benzoate, sorbic acid. Examples of enriching wheat flakes, breakfast cereal, corn flakes, exploded rice and exploded oat cereals, baked dog biscuits, broiler mash pellets and hen mash pellets with vitamin A palmitate, vitamin D2 (calciferol), vitamin D3 resin, a -tocopherol, dla -tocopherol acetate, b -carotene, b -apo-81-carotenal and canthaxanthene.Claims:


WHAT WE CLAIMIS -

1) A process for the enrichment of food or feeds which comprises applying to the basic food or feed a composition which consists of an aqueous emulsion or dispersion of fatsoluble vitamins or ofcaroteneoids or mixtures thereof in admixture with a predominant amonut of dextrins, sugars or cellulose derivatives or mixtures thereof in the form of an aqueous solution, said emulsion consisting of said vitamins and/or carotenoids, an edible emulsifier, an edible antioxidant, an edible preservative and water.

2) A process in accordance with claim 1, wherein said composition is formed prior to application by making a solution of the edible antioxidant in the fat-soluble vitamin and/or the carotenoid (with the addition of an edible glyceride oil if necessary), emulsifying the solution thus obtained in an aqueous solution containing an edible matrix emulsifier and mixing the so-formed emulsion with the dextrins, sugars or cellulose derivatives or mixtures thereof contained in aqueous solution.

3) A process as claimed in claim 1 or claim 2, wherein the composition is applied to said food or feed by spraying.

4) A process as claimed in any one of the preceding claims, wherein the emulsifier is gum acacia, hydrolysed collagen or dextrin.

5) A composition for the enrichment of foods or feeds, which composition comprises an aqueous emulsion containing a fat-soluble vitamin or carotenoid or a mixture thereof, an edible emulsifier, an edible antioxidant and an edible preservative and, in admixture therewith, a predominant amount of dextrins, sugars or cellulose derivatives or mixtures thereof in the form of an aqueous solution.Data supplied from the esp@cenet database - Worldwide

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192.

GB985809 - 3/10/1965

IMPROVEMENTS RELATING TO FOOD PRODUCTS


Applicant(s): ROGERS BROTHERS COMPANY (--)

E Class: A23L1/216B; A23L1/0534; A23L1/216B2



Family: GB985809

Equivalent: LU39954; CH460510; SE308440; SE308439; ES266285

Abstract:


In a process for preparing a French fried food product, a food is cooked and comminuted, a thermal gelling binder is admixed with the food, the binder is wetted with water, the total moisture content of the mixture, however, being not substantially above the moisture content of the food in its natural state, the binder is solvated within the mixture by maintaining the temperature of the binder and the mixture at a temperature not exceeding 90 DEG F., preferably between 41 DEG F. and 50 DEG F., in order to assure substantial intermixing between the binder and the food, and the resulting product, before or after a partial or a complete French frying, is packaged. Suitable binders have the following general formula: >;FORM:0985809/A1-A3/1; wherein the radicals R, R1 and R2 may be hydrogen, alkyl such as methyl, ethyl, propyl, and isopropyl, or hyroxyalkyl such as hydroxymethyl, hydroxyethyl, hydroxypropyl and hydroxy-isopropyl, and at least one is methyl and/or ethyl. Preferred binders are dimethyl cellulose ether (solvating being performed by cooling to below 55 DEG F.), hydroxyethyl methylcellulose, ethyl hydroxy-ethylcellulose, and hyroxypropyl methyl-cellulose. The binder may be gelled by any heat processing such as French frying (preferred), pan frying, baking, retorting and broiling. Foods include many specified fruits and vegetables, and meat, to which there may be added specified seasonings and flavourings, monoglycerides, non-fat dry milk solids and high protein materials such as soy bean products. The term "vegetable" covers such foods as chard, spinach, water cress, cabbage, parsley, broccoli, cauliflower, artichoke, asparagus, kohlrabi, potatoes, beets, turnips, carrots, rutabaga, legumes, maize, rice, tomatoes, peppers, squash, pumpkins, eggplant and okra.

Absorbents such as potato, wheat or maize starch, processed flours of potato, wheat, maize, barley or rice, dehydrated particles of the food, or inorganic compounds such as calcium chloride or silica gel, may be added to the mixture after wetting the binder and while the mixture is still hot, or immediately before extruding or otherwise shaping the mixture. The food products produced may, for example, be crisp snack items such as chips or puffs, or food spreads. According to one of many examples, to 1160 grams of potato mash prepared by ricing steam-cooked potatoes through a 1/8 -inch sieve, there was added 8 grams of dimethylcellulose ether having an average viscosity of 8000 centpoises. After intensive mixing for 10 minutes, the mixture was cooled to a temperature of 50 DEG F., extruded through a plate having holes 3/8 -inch square and then dropped into stabilized cottonseed oil heated to about 380 DEG F. to be French fried for about 1 1/2 minutes. In further examples 26 grams of potato starch were included in the mixture. In another example 80 grams of potato flakes, 20 grams of dehydrated diced potatoes and 6 grams of dimethylcellulose ether were mixed together. This mixture was rehydrated with 200 c.c. of water at a temperature of about 140 DEG C. under intensive agitation.

The procedure of the previously mentioned examples was then followed. In certain examples mixtures of binding agents were employed. Specification 985,808 is referred to.Description:


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0 M


DRAWINGS ATTACHED 9858 09 Date of Application and filing Complete Specification: March 24,

1961.

No 10796/61.

Application made in United States of America (No 19800) on April 4, 1960.

Application made in United States of America (No 81119) on Jan 6, 1961.

Complete Specification Publ Ished: March 10, 1965. i Crown Copyright 1965.

Index at acceptance:-AM B (IB, i C, IE, IF, IH, IJ, i L, IS) Int CI:-A 23 b, I COMPLETE

SPECIFICATION

Improvements relating to Food Products ERRATA SPECIFICATION No 985,809

Page 2, line 35, for "obviates" read "obvivates" Page 9, line 33, for "wa sthen" read "was then" THE

PATENT OFFICE 4th May 1965 thermal gelmng cuxuw methods whereby such products are formed.

Another aspect of the invention is the preparation of a dry mix which can be stored indefinitely until it is to be shaped and fried.

At the present time the known processes for producing fried potato products from fresh potatoes involve peeling and trimming raw potatoes, washing and then slicing or cutting to obtain desired shapes The potato pieces are blanched and immediately deep fried or kept in cold storage, i e under refrigeration at a temperature of about 350 to 450 F, until used When immediately fried, the resulting product is then usually frozen and distributed as a household food which can be prepared by oven heating In addition, the fresh cut pieces may be partially fried, frozen and subsequently re-fried at the time they are prepared for consumption If the product is to be used by hotels, restaurants or cafeterias, it is often packaged and stored.

The processes available in the art at the present time for producing French fried products or fried snack items, suffer one important disadvantage in that they require more or less uniform raw vegetable material This undesirable requirement would also be present if vegetables of any kind other than the common potato were to be used As can be readily understood, departures from unilPrice deviations from a norm in producing irench fried potatoes and similar products is the loss due to the variation in size of potatoes Only the pieces of potato which are large enough for the finished product can be usefully employed Slivers and odd-shaped pieces must be discarded or converted into less desirable food products.

Another of the principal difficulties in processing potatoes other than fresh potatoes into the form of the "French" fried product has been to obtain a firm, fresh potato-like texture in mixtures reconstituted from prepared potato solids such as mashed, dehydrated, flaked, powdered and otherwise processed potatoes.

In the prior art as known, there have been attempts to use methyl cellulose ethers as a binder with food products Such disclosures are embodied in, for example, the Rivoche U.S patents 2,791,508;

2,798,814 and 2,887,382 In each of these prior art teachings, a solution of the binder is used to permit steaming or freezing of the otherwise substantially raw food Thus substantially high water content necessary according to the patents presents a problem if the limited patented procedure is varied For instance, if the food product is uniformly cooked, for example, by deep fat frying or baking, the I, -J


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DRAWINGS ATTACHED 985,809 Date of Application and filing Complete Specification: March 24,

1961. adin Uie Sttso Amr No 10796161.

Application made in United States of America (No 19800) on April 4, 1960.

GO Application made in United States of America (No81119) on Jan6, 1961.

Complete Specification Published: March 10, 1965.


Index at acceptance:-A 2 B ( 1 B, IC, 1 E, IF, III, 1 J, IL, i S) Int Cl:-A 23 b, I COMPLETE

SPECIFICATION

Improvements relating to Food Products We, ROGERS BROTHERS COMPANY, of Idaho Falls,

Idaho, United States of America, a Company organized and existing under the laws of the State of

Delaware, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates broadly to a process for preparing preformed food products More particularly it relates to a process for producing heat processed food products formed from a mixture of comminuted foods and thermal gelling edible binder and to the methods whereby such products are formed.

Another aspect of the invention is the preparation of a dry mix which can be stored indefinitely until it is to be shaped and fried.

At the present time the known processes for producing fried potato products from fresh potatoes involve peeling and trimming raw potatoes, washing and then slicing or cutting to obtain desired shapes The potato pieces are blanched and immediately deep fried or kept in cold storage, i e under refrigeration at a temperature of about 350 to 450 F, until used When immediately fried, the resulting product is then usually frozen and distributed as a household food which can be prepared by oven heating In addition, the fresh cut pieces may be partially fried, frozen and subsequently re-fried at the time they are prepared for consumption If the product is to be used by hotels, restaurants or cafeterias, it is often packaged and stored.

The processes available in the art at the present time for producing French fried products or fried snack items, suffer one important disadvantage in that they require more or less uniform raw vegetable material This undesirable requirement would also be present if vegetables of any kind other than the common potato were to be used As can be readily understood, departures from unilPrice formity in raw vegetable material lead to waste and losses in the product yield They also produce operating difficulties or require process changes to operate the process.

Some of the properties of the vegetables which may vary are: size and shape, sugar content, solid content, and specific gravity.

The problems caused by variations of such properties in potatoes are discussed in detail in "Potato

Processing", published in 1959 by the A V I Publishing Company, Inc, West Port, Connecticut, and edited by two members of the United States Department of Agriculture, W F Talbert and O Smith.

One example of the waste attributable to deviations from a norm in producing French fried potatoes and similar products is the loss due to the variation in size of potatoes Only the pieces of potato which are large enough for the finished product can be usefully employed Slivers and odd-shaped pieces must be discarded or converted into less desirable food products.

Another of the principal difficulties in processing potatoes other than fresh potatoes into the form of the "French" fried product has been to obtain a firm, fresh potato-like texture in mixtures reconstituted

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from prepared potato solids such as mashed, dehydrated, flaked, powdered and otherwise processed potatoes.

In the prior art as known, there have been attempts to use methyl cellulose ethers as a binder with food products Such disclosures are embodied in, for example, the Rivoche U.S patents 2,791,508;

2,798,814 and 2,887,382 In each of these prior art teachings, a solution of the binder is used to permit steaming or freezing of the otherwise substantially raw food Thus substantially high water content necessary according to the patents presents a problem if the limited patented procedure is varied For instance, if the food product is uniformly cooked, for example, by deep fat frying or baking, the exterior of the patty product of the patented process will gel quickly to form a relatively firm, impervious barrier to the steam developing within the product When the steam is finally sufficiently pressurized, it will explode the product To avoid this occurrence, the patented process must be limited to nonuniform heating, such as pan frying, in order that the developed steam may pass through the side of the patty not in contact with the heated surface and therefore, not fully gelled In addition to this drawback, it has been found that a product having an amount of water substantially in excess of the amount in the natural food, seriously hinders extrudability, and results in an undesirably soggy and poorly formed product.

Applicants co-pending British application No 10795/61 lSerial No 985,808 l discloses a process for preparing a fried potato product from raw white potatoes comprising preparing an extrudable, moist mixture consisting essentially of potato cells which are intact, potato cells which have been ruptured and the starch contained therein, and a thermal gelling binder, effecting solvation between the binder and the mixture by maintaining the binder and the mixture at a temperature not exceeding 900 F, shaping the resultant product and deep fat or French frying the shaped product This process calls for the presence of potato starch to facilitate binding and a special cooling step The binder is a methylcellulose ether.

The present invention obviates the difficulties attributable to non-uniformity heretofore experienced in producing fried and other heat processed vegetable products from fresh vegetables Although various cellulose ethers cited in the above noted prior art are the preferred binders in the present process, the present process is, nevertheless, entirely different from prior processes, in that a great variety of final heat processing procedures may be used, in addition to which the product will have a uniform texture and composition and retain its proper preformed shape during the heat processing step In particular, one embodiment of this invention provides a product which retains its shape during and after extrusion or shaping, and during deep fat frying.

In addition, the shaped vegetable product has a taste and texture substantially equal to the taste and texture of heat processed vegetable products prepared directly from raw vegetables.

One object of this invention is to provide a method of -producing novel food products from any food source.

Another object of this invention is to provide a mixing and preforming method of French frying food products never before capable of being french fried because of size or textural limitations.

Another object of this invention is to utilize substantially all of the raw food, with the exception of only the skin and defective portions of the food without regard to the size, shape, sugar content, solids content, or specific gravity 70 Another object of the invention is to provide a means of manufacturing preformed heat processed food products from a dry mix which may be stored indefinitely after it has been formulated, and which at a later time is 75 simple to prepare for consumption.

Another object of the invention is to provide a dry mix which can be readily prepared into products having a flavour and texture which equals that of a food produced directly 80 from cut raw foods immediately after slicing or otherwise shaping, regardless of the heat processing means used.

Another object of the invention is to produce heat processed products, including crisp 85 snack items such as chips and puffs, from either cooked fresh foods or from a mixture of dry food ingredients which may be high in protein and low in fat content.

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The present invention is a process for pre 90 paring a French fried food product comprising: cooking and comminuting a food, admixing a thermal gelling binder, wetting the binder with water, the mixture having a total moisture content not substantially above 95 the moisture content of the food in its natural state, solvating the binder within the mixture by maintaining the temperature of the binder and the mixture at a temperature not exceeding 900 F in order to assure substantial 100 intermixing between the binder and the food, and subsequently packaging.

The invention also in a preferred process includes the step of shaping the mixture conveniently by extrusion to a pre-determined 105 form and treating, it to a form retaining firmness.

Ordinarily solvation is caused to take place chronologically between the wetting of the binder and the treating of the shaped object 110 It can therefore be said, in general, that the process of the present invention comprises formulating a mixture of a thermal gelling edible binder and food mash, wetting the binder, then solvating and gelling the mixture 115 It is also contemplated that the thermal gelling edible binder can be mixed with dehydrated food products, subsequently rehydrating the food product, wetting the binder, solvating, and then gelling 120 The term "gelling" includes any heat processing such as frying, French frying, baking, retorting, broiling.

It is intended that this invention include meats, fruits and vegetable products within 125 the term

"food" products as used herein.

The preferred edible binders are polymeric ethers of cellulose that are thermally gellable, and have the basic formula:985,809 further experiments that the use of an absorbent is not always necessary to obtain a satisfactory product This is particularly true when: ( 1) a food has a high solid con 60 tent such as approximately 50 % and ( 2) when the thermal gelling binder, (such as Methocel MC), releases a relatively small amount of water Because of the fact that a relatively low amount of water is released during the 65 gelation of the MC binder, dimethylcellulose ether, namely Methocel MC, and for the further reason that the dimethylcellulose ether binder forms a harder gel than the hydroxypropyl methylcellulose, namely Methocel HG, 70 no absorbent is generally necessary with the dimethylcellulose ether binder, and yet the product substantially retains its shape during the gelation, as well as during any subsequent heat processing This shape retention ob 75 tains even if a small amount of water is vaporized, which was released by the binder, or which was in the food product.

Optionally, according to the present invention, a water absorbent may be admixed in 80 any of the food binder compositions, to help prevent the free water from interfering with proper extrusion of the product, which would result in a soggy, poor textured product and to desirably distribute any water within the 85 product after gelation In this connection, it has been found desirable though not absolutely necessary, to use an absorbent with certain gels, such as Methocel 60 HG, which releases a relatively large amount of water 90 These absorbents may be selected from the starches, such as potato, maize, wheat; inorganic compounds, such as calcium chloride or silica gel; processed flours, such as wheat, potato, maize, barley, rice; or dehydrated 95 particles of the same foodstuff.

Important features of the present invention are the wetting step and the solvating step after the binder is mixed with the food The wetting step incorporates into the binder 100 material, water, to thereby condition the binder for the subsequent step of solvating the binder The wetting is generally accomplished by heating the binder in the presence of water, which may be the water in the natural 105 food product, or the water added to rehydrate a previously dehydrated food To properly wet the binder, the heat, no matter how applied, must be sufficient to raise the temperature of the water in contact with the 110 binder to at least 60-100 C, and preferably 80-900 C.

The solvating of the binder hydrates the binder to a fluid state, permitting a thorough intermixing of the binder into the food 115 To accomplish the solvating to the extent necessary, the wetted binder in the food mixture must be cooled below a temperature dependent upon the particular type of binder used

The temperature varies with the par 120 wherein R, R 1 and R, are selected from the group consisting of hydrogen, alkyl (such as ethyl, methyl, propyl isopropyl and the like), and hydroxy alkyl (such as hydroxyethyl, hydroxymethyl, hydroxypropyl and hydroxyisopropyl); and wherein at least one R, R 1 and R 2 is selected from the group consisting of ethyl and methyl.

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Within the group of compounds represented by the above formula are those having the unique property of gelling with the application of heat, and thus may be termed thermal gelling cellulose ethers

These compounds all absorb water upon cooling to solvate, and form a gel upon heating, accompanied by a loss of water Only the cellulose ethers that are thermally gellable form a part of this invention

However, it is to be noted that any edible thermal gelling compound, even if not within the above formula may be used in the practice of this invention An important feature of these thermal gelling compounds is that the gelation property is reversible from either the solvated or gel state by controlling the temperature of the gel.

Included within this term "thermal gelling cellulose ethers" are:

(a) Alkylcellulose ethers such as, methyl and ethyl cellulose ethers (produced respectively by Kalle &

Co and Hinkel in Germany and Mo Och Domajo in Sweden), and the methyl-cellulose ethers

(produced as Methocel MC type by Dow Chemical Co in the United States).

(b) Alkyl hydroxyalkylcellulose ethers such as hydroxyethyl methylcellulose produced as Tylose

TWA/MK-3000 by Kalle & Co, in Germany, ethyl hydroxyethylcellulose (produced as Modocoll-600 by Mo Och Domajo in Sweden), and the hydroxypropyl methylcellulose such as "Methocel 60 H C ",

"Methocel 65 H C " and "Methocel 90 H G " produced by Dow Chemical in the United States

TYLOSE, MODOCOLL and METHOCEL are Registered Trade Marks.

It is set forth in Applicants co-pending application No 10795/61 lSerial No.

985,808 l that the water which is released during gelation should be absorbed by a suitable absorbent such as potato starch; otherwise, the heating will cause the liberated water to vaporize and produce a soggy product.

However, it has been determined through 985,809 ticular binder, but is readily determinable as the range of maximum clarity of a solution of the binder, and is between the point at which there is a tendency to gel due to high temperature and a thickening due to cold In general, to accomplish the solvating for the Methocel HG types, the cooling must be below about 900 F and does not have a lower limit However, the optimum cooling temperature from a practical standpoint is approximately within the range 72-82 F.

For the Methocel MC binder, the cooling must be below about 550 F; and also has no lower limit The practical range is 41-500 F.

Broadly speaking, the proper solvating is achieved by cooling the wetted binder to a point below its degelling temperature, which varies with the particular thermal gelling binder.

The gelation point of these binders varies, depending upon various factors such as structure and viscosity The Methocel 65 HG type gels at 65 C when undiluted with water and at a viscosity of 400 cps, while the Methocel 90 HG gels at 900 C All these compounds are available in different viscosities ranging from 10 to 15,000 cps, and can be used However, the most usually used viscosity is within the range of 4,000 to 8,000 cps It has also been found that the MC (dimethylcellulose ether) type forms a harder gel than the HG (hydroxypropyl methylcellulose ether) type which may be more useful for certain products.

These binders can be used in amounts preferably from about one part per hundred parts of food solids, to about thirty parts per hundred parts by weight of food solids.

When the thermal gelling binder is omitted, the product tends to fall apart when fried or otherwise heat processed, due to the failure of the inherently weak structure of the comminuted food to hold a predetermined shape.

As the amount of binder used increases, the product becomes increasingly compact and firm, and maintains this firmness during the heat processing The amount of the absorbents that may optionally be added is dependent upon the type of absorbent, the binder, the available water and the type of product desired The proper amount is readily ascertainable by one familiar with such products.

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An important feature of the present invention is that the binder-food mix contains moisture not substantially greater than that in the natural food, and in no case should the moisture in the mixture of binder and food exceed 2 % to 3 %, and preferably less than 2 %, of the moisture in the natural product.

If the moisture were higher, extrudability is effected, and there is danger of the product exploding in an atmosphere of uniform heating, such as baking or deep fat frying To avoid any moisture content above 3 % of the moisture in the natural product, all raw foods are generally, although not necessarily so, cooked in a steam atmosphere which maintains the water content at the most desirable level, viz, the amount of water in the original food.

A vegetable mash may form one constituent of the present invention and can be derived from a variety of vegetable sources, for example, leafy vegetables, such as chard, spinach, water cress, cabbage and parsley; flower vegetables, such as broccoli, cauliflower, artichoke, asparagus and kohlrabi; tubers, such as potatoes, beets, turnips, carrots and rutabaga; seed vegetables, such as legumes, maize and rice; and the vegetable fruits, such as peppers, squash, pumpkins, eggplant and okra.

Descriptions of the features of these various families can be found in "Food Chemistry" by Lillian

Hoagland Meyer, published by Reinhold Publishing Corporation of New York, 1960, p 219 Similarly, fruits and meats of any kind may be comminuted to serve the purposes of the present invention.

The vegetable mash can be produced from raw vegetables by a variety of methods Some of these methods in the case of potatoes are illustrated in the accompanying drawing, such as using raw potatoes, potato flakes, granules and dice.

Procedure 1, shown in the drawing, shows the preparation of the potato mash from fresh, raw materials and the subsequent introduction of the thermal gelling edible binder.

Procedure 2, shown in the drawing, shows the preparation of the potato mash from dehydrated mashed potatoes derived from granules The binder can be added in the dry state, and the mixture subsequently rehydrated to form the moist mash-edible binder mixture.

Procedure 3, shown in the drawing, shows the combination of crushed dehydrated potato flakes and the crushed potato dice, with an edible binder in the dry state The mixture can be subsequently rehydrated to form a moist mash-edible binder-mixture.

Procedure 4, A, B, and C shown in the drawing, shows the incorporation of the various types of dehydrated mashed potato products with the mash derived from fresh potatoes to adjust different variables, as desired.

Equivalent techniques can be used to produce the moist mixture from other vegetables.

In addition, dried vegetables can be used, such as field dried peas and beans.

Optional ingredients which can be added include seasonings and flavour imparting additives, such as cheese or dried onion, added dry starch containing materials, such as potato flour, wheat flour and maize meal, monoglycerides, non-fat dry milk solids, high protein materials, such as soy bean products, and the like.

985,809 snack item, the frying can be continued until the product is dry enough to be packed and stored in a standard manner at room temperature Alternatively, the frying period can be reduced to one ( 1) or two ( 2) minutes, if it is desirable to store or package the product in a semi-finished state, so that it can be subsequently fried or similarly heated at the time it is to be used In this semifinished state, the exterior of the product has gelled to a firm retaining shape.

It is to be understood that regardless of the form or type of product to be made according to this invention, it is necessary, if a particular shaped product is desirable, to at least condition the product to

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a form retaining firmness, which may be accomplished by heating at least the exterior of the product before packaging, and/or freezing or cold storage; otherwise, there will be no shape retention If so partially firmed, subsequent heat processing, baking or deep fat frying will produce a high quality product.

Although it might be expected that cooling the food product to the binder solvating temperature subsequent to the frying, the partial frying, or any heat processing or conditioning would solvate the binder and cause the product to lose its shape, it has been found that while the binder does solvate, the heat processing (such as deep fat frying) when continued until the food, as distinguished from the binder, in the food product, is conditioned to a form retaining firmness, the food itself forms a tough shape retaining film on the exterior of the food product.

The amount of the heat processing necessary to form this film, of course, varies with the particular food and the amount of heat applied, but can be readily determined by a skilled processor.

DRY MIX PROCEDURE A second method of preparing the moist vegetable mixture uses a dehydrated or dry mashed vegetable as the vegetable constituent.

For example, dehydrated mashed potatoes can be derived from flakes, granules, crushed dice, or similar products Other dehydrated vegetables can be used as well As another example, a dried mash can be derived from crushed field dried legumes.

The binder can be mixed dry with the dehydrated or dried mashed vegetable in the dry state The dry mixture which can contain some or all of the required amount of edible binder, can be stored indefinitely at room temperature until it is desired to prepare a fried or otherwise heat processed product, or it can be used as soon as it is formed, if cooled to proper temperature The mixture can be added to water, thereby rehydrating the dry ingredients to a moisture content not substantially greater than that equal to the natural product In the instance The binder and the food constituent are mixed preferably while warm, and sufficiently to distribute the binder uniformly through the mixture By this procedure, the binder is wetted to condition it for the solvation step The binder in moist mixture is then solvated by cooling to a temperature equal to or below the degelling point of the particular binder used

Thereupon, the mixture can be readily extruded or shaped, and will retain its shape and texture during the gelling of the binder, by any heat processing, such as a frying step that follows.

Set out below in more detail are procedures for producing an edible binder-food mixture from fresh cooked vegetables, and from dehydrated vegetable products, and heat treating to gel the resultant mash

Also set out below in more detail are procedures for formulating the mixture in a dry mix form, rehydrating the mix, and heat treating.

FRESH COOKED VEGETABLE PROCEDURE In preparing preformed heat processed products from fresh mashed vegetables, the process broadly comprises cooking the raw vegetables to obtain a typical cooked vegetable, mashing the vegetable, and mixing into the hot mash a suitable thermal gelling edible binder to wet the binder; solvating by cooling the mixture, and subsequently extruding, forming or cutting the mash into desired shapes, heat processing to gel the binder, and packaging.

In the instance of vegetables, such as those in the flower, tuber and seed families, the binder is added in concentrations preferably from about one ( 1) part per hundred parts by weight of solids, to about ten

( 10) parts per hundred parts by weight of solids In the instance of vegetable fruits and leafy vegetables, the binder is preferably added in concentrations of from about five ( 5) parts per hundred parts by weight of solids to about thirty ( 30) parts per hundred parts by weight of solids.

The product can be gelled by heat processing in any conventional manner, such as by deep fat frying

The frying can be either complete or partial, according to the ultimate use anticipated.

For example, in the instance of French fried potatoes, the extruded pieces can befried in an edible oil at a temperature of about 350 F for a period of approximately two ( 2) to four ( 4) minutes, to yield a

French fried product which can be immediately consumed, or can be packaged or stored in an appropriate manner In the instance of extruding in a French fry shape, the product can be quick frozen after the heat processing, and subsequently prepared for consumption by heating in a hot sack, or by

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baking in an oven In the instance of forming a crisp 985,809 of dehydrated mashed potatoes, it has been found that for each hundred ( 100) parts of dry potato solids, about two hundred ( 200) parts of water produced an acceptable dough consistency for extrusion.

Alternatively, the dehydrated mashed vegetables can be rehydrated, the binder added and wetted, and the resulting hot mixture cooled, extruded or shaped and fried.

The preparation of the dehydrated products themselves form no part of the present invention They can be prepared by techniques presently known in the art Potato granules can be prepared by any of the methods described in the United States Department of Agriculture's Circular AIC-297, entitled

"Dehydrated Mashed Potatoes-A Review".

Potato flakes can be produced by one of the processes described in U S patents 2,759,832; 2,780,522; or 2,787,553; or by any other comparable process Methods for dehydrating other vegetables are described in "Dehydration Manual" published by the United States Department of Agriculture.

One formulation of a potato dry mash comprises from about 5 percent to about percent by weight of crushed dehydrated potatoes, and from about 65 percent to about percent by weight of ground potato flakes.

This formulation can be reconstituted with cool water to produce a mash having the consistency and texture substantially equal to that of mash derived from raw potatoes However, the mixture must be heated before or after the binder is added, to properly wet the binder.

In order to enhance uniform blending with other ingredients when using potato flakes, it is preferable to use flakes which pass through a 20-mesh screen, United States Standard.

Commercially available flakes, however, which have been screened through a 1 inch opening sieve, have been used without complicating the process Reducing the size of the potato flake by crushing, sometimes produces an excessive amount of free starch, which tends to make the product more pasty, and consequently, reduces the firmness of the gel or structure during the heat processing step.

This weakness of structure can be overcome by incorporating potato solids of the crushed dehydrated dice type (having inherently less free potato starch) into the crushed potato flakes.

Another form of dehydrated potato useful for this purpose is a crushed dehydrated product manufactured from dehydrated diced potatoes For example, a suitable mash can be obtained from a conventionally prepared diced, blanched, dehydrated potato which has been passed through a hammermill fitted with about a 1/16 inch diameter screen opening.

The crushed dehydrated potato provides a firm, non-mushy but not crunchy or granular consistency to the French fried product.

When using dried legumes, Zea maize or Daucus carota, it has been fouv 4 that a mash suitable for extrusion can be obtained from ground vegetables which pass through a United States Standard 30mesh screen 70 Regardless of their specific form, flakes, granules or crushed dice, or naturally dried, etc, and regardless of the manner in which they are prepared, finely divided dehydrated vegetable products have been found to lend 75 themselves readily to the preparation of the moist mixture of vegetable mash in accordance with this invention.

Dehydrated or dried vegetables or batches of fresh vegetables having different proper 80 ties, can be blended together to obtain uniformity Furthermore, unique and novel combinations of different vegetables can be used.

In addition, starchy materials, such as potato, maize, rice and wheat starch and flour, and 85 high protein materials, such as soy bean flour, can be added to increase solid content and nutritive value As shown in the Examples below, the point in the process at which starchy materials are added to the mixture 90 will influence the form and texture of the final product.

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As indicated in the drawing, potato granules can be added, if desired, directly to cooked potatoes, prepared as described below, to 95 increase the potato solid content.

Two modes of utilizing potato flakes are shown in the drawing In one, the flakes are crushed as described above and then mixed with the edible binder and the cooked 100 potato.

The crushed dehydrated blanched dice can be added to increase the solids content of the potato mixture prepared from fresh cooked potatoes, or as indicated in the drawing, the 105 crushed dehydrated dice may be blended with crushed flaked dehydrated potatoes, and handled as described above.

Also, fresh raw potatoes having different sugar and solids content can be blended to 110 gether to produce a uniform mash In addition to the use of potatoes, other vegetables are blended according to the present invention in a similar manner.

An important feature of the present in 115 vention is that the moisture content of the food-binder mixture be not substantially greater than the moisture present in the natural food If the moisture content is above this limit, the food product will not extrude 120 in a smooth uniform texture, and the steam formed in the product during gelling will often explode the product during a uniform continuous heating, such as baking and frying 125 The following Examples will serve to illustrate these and other aspects of the invention, and are to be considered as illustrative, rather than as limiting.

985,809 The final product had a golden brown colour, a smoothly extruded exterior surface and a well cooked, mealy centre The taste was the same as a product prepared directly from a raw potato.

It has also been determined that the type of product obtained will vary according to the time of the addition of an absorbent in relation to the cooling or solvating step For example, if the absorbent is added to a hot mash-binder mixture, and the product is cooled, subsequent heat processing, such as deep fat frying, causes puffing, in which the outer layer of the product pulls away from the inside Such a product has advantages as a snack item If on the other hand the absorbent is added after solvating, subsequent frying produces a mealy inside that is not separated, and also permits before the frying, a relatively smooth and attractive surface.

The following two examples illustrate this.

EXAMPLE 5.

Following the procedure of Example 1, 26 grams of potato starch was added to the cooled binderpotato mash mixture and the mixture was then extruded and fried.

The final product had a golden brown colour and had a well cooked centre The outer surface showed a more smooth, firm extrusion then when the starch was omitted.

The taste was the same as a product prepared directly from a raw potato.

EXAMPLE 6.

Following the procedure of Example 1, 26 grams of potato starch was added to the warm binderpotato mash mixture and the mixture was then cooled and fried.

The final product had a golden brown colour, had a well cooked centre, and was puffed The outer surface showed a smooth extrusion The taste was the same as a product prepared directly from a raw potato.

EXAMPLE 7.

Following the procedure of Example 1, the dimethylcellulose ether-potato mash mixture was cooled, rolled into small balls, and shaped and pressed to form round, thin pieces about the size of the

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conventional potato chip The pieces were then fried in saturated cottonseed oil at a temperature of about 3800 F. for a period of four minutes.

The product retained its shape during frying, and became crisp It had the appearance and taste of a potato chip prepared directly from a raw potato.

EXAMPLE 8.

Eighty grams of potato flakes, crushed through a U S Standard 20-mesh sieve, 20 grams of dehydrated diced potatoes, crushed through a U S Standard 20-mesh sieve, and six grams of dimethylcellulose ether having EXAMPLE 1.

Idaho Russet potatoes having a solid content of about 20 % were selected at random, peeled, trimmed, sliced to -g" thick pieces, and cooked in steam at atmospheric pressure for 30 minutes The cooked potatoes were riced through t 1 diameter openings to remove traces of peel fragments To a 1160 gram sample of the potato mash was added eight grams of dimethylcellulose ether having an average viscosity of 8000 centipoise The ingredients were mixed in a "Hobart" (Registered Trade Mark) mixer at a speed setting No 2, 196 r p m for a period of 10 minutes.

The mixture was then cooled to a temperature of 500 F in a refrigerator It was then extruded through a plate having -" square holes and dropped into stabilized cottonseed oil heated to a temperature of about

3800 F.

The preformed pieces were fried for a period of about a minute and a half The extruded pieces retained their shape while emerging from the extruder and also while frying, to produce a product having a well cooked, natural appearing centre, a self-containing exterior surface and a pleasing uniform golden brown colour The taste was the same as French fried products produced directly from raw potatoes.

EXAMPLE 2.

Following the procedure of Example 1, a sample containing one gram of the dimethylcellulose ether mixed into 1160 grams of potato mash was formulated, cooled, extruded and fried The final product had a golden brown colour, a somewhat rough extruded exterior surface, and was somewhat puffed, although it retained its original preformed shape The centre of the piece was mealy, well cooked, but slightly pulled away from the exterior The taste was the same as a product prepared directly from a raw potato.

EXAMPLE 3.

Following the procedure of Example 1, a sample of two grams of the dimethylcellulose ether integrated into 1160 grams of potato mash was formulated, cooled, extruded and fried.

The final product had a golden brown colour, a rough extruded exterior surface, was a little puffy, although it retained its original preformed shape The centre was mealy and slightly pulled away from the exterior.

The taste was the same as a product prepared directly from a raw potato.

EXAMPLE 4.

Following the procedure of Example 1, a sample of eight grams of dimethylcellulose ether, having an average viscosity of 15 centipoise, integrated in 1160 grams of potato mash was formulated, cooled, extruded and fried.

985,809 an average viscosity of 8000 centipoise were mixed together.

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To this mixture 200 cc of water at a temperature of about 140 F was added and the mixture was mixed for a period of one minute with a Hobart mixer operating at low speed, 60 r p m The mixture was then allowed to stand for several minutes to insure complete rehydration of the crushed dehydrated particles After rehydration, it was cooled to a temperature of about 500 F in a refrigerator Following the procedure set out in Example 1, the mixture was extruded and fried.

The product has a pleasing uniform golden brown appearance, a soft but not mushy interior, and possesses a typical and pleasing potato flavour.

EXAMPLE 9.

Following the procedure of Example 1, a sample of eight grams dimethylcellulose ether was mixed with 580 grams of potato mash, 330 cc of hot water 1500 F, and 80 grams of maize meal, the mixture was cooled to 50 F and five grams of potato starch was added The mixture was then extruded and fried.

The final product had an excellent shape and texture The maize flavour did not mask the potato flavour The colour was golden brown, and the centre had a well cooked mealy appearance.

EXAMPLE 10.

Following the procedure of Example 1, a sample of eight grams dimethylcellulose ether was mixed with 580 grams of potato mash, 330 cc of hot waater 1500 F and grams of soy bean flour The mixture was cooled to 410 F and five grams of potato starch was added The mixture was then extruded and fried.

The final product had an excellent shape and texture The soy flavour did not mask the potato flavour

The colour was golden brown and the centres had a well cooked mealy appearance.

EXAMPLE 11.

Following the procedure of Example 1, a sample containing one gram of the dimethylcellulose ether mixed into 1160 grams of hot potato mash was formulated, cooled to 450 F, shaped into a ball about the size of a baking potato, and fried The product retained its shape during frying The final product had a golden brown colour The outside surface was self-containing Cutting the mass, it was-found that the centre of the piece had the taste and texture of a baked potato prepared directly from a raw potato The appearance of the product as a whole was very similar to a baked potato.

EXAMPLE 12.

One hundred six-five grams of maize meal was cooked in 660 cc of boiling water for a period of 30 minutes Eight grams of dimethylcellulose ether having an average viscosity of 8000 centipoise was then added and the ingredients admixed in a Hobart mixer for a period of 10 minutes at speed No 2, r p m 196 The mixture was cooled to a temperature of about 500 F It was then extruded through an extrusion plate having " openings and dropped into saturated cottonseed oil heated to a temperature of about 3800 F The product was fried for about four minutes The product retained its shape during frying.

The final product had a pleasing maize meal flavour, a firm exterior surface which was somewhat rough with rounded corners.

EXAMPLE 13.

Following the procedure of Example 12, grams of maize meal was cooked in 550 cc of boiling water for a period of 30 minutes.

Eight grams of dimethylcellulose ether was added and the ingredients were admixed and cooled to

500 F Then five grams of potato starch was admixed into the mixture in a Hobart mixer at speed No 2,

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196 r p m for a period of about one minute The mixture was extruded and fried The product retained its shape during frying.

Tue final product had a golden brown colour and a pleasing maize flavour The exterior surface showued a firm smooth extrusion The shape was that a very regular French fry.

EXAMPLE 14.

A sample of 1160 grams of fresh carrots was cooked in steam at atmospheric pressure for a period of about 45 minutes, and then riced Eight grams of dimethylcellulose ether was added and the hot ingredients admixed in a Hobart mixer at low speed, 60 r p m.

for a period of two minutes The mixture was then cooled to a temperature of about 500 F, extruded through a plate having s" openings, and dropped into saturated cottonseed oil heated to a temperature of about 3800 F Frying was continued for four minutes Product retained its shape during frying The final product was a bright orange colour The exterior surface was soft but self-containing The centre was soft and had a moist cooked appearance.

EXAMPLE 15.

Following the procedures set out in Example 14, a mixture of 1160 grams of riced 985,809 had a light brown colour and was dry and 60 crisp.

To 65 grams of the sample was added four grams of dry maize meal and the mixture pressed into the shape of a chip and deep fat fried The product retained its shape 65 during frying The final product had a light brown colour, and was crisp and crunchy.

EXAMPLE 19.

A 165 gram sample of dried Great 70 Northern beans was ground and put through a 30-mesh screen

The finely divided vegetable was then added to 550 cc of boiling water Eight grams of dimethylcellulose ether was added and the ingredients admixed in 75 a Hobart mixer operated at speed

No 2, 196 r p m for a period of two minutes.

The mixture was then cooled to a temperature of about 500 F One-half of the sample was extruded through a plate having a I" 80 opening and dropped into saturated cottonseed oil heated to a temperature of about 3800 F.

The pieces held their shape during frying.

The final product had a yellow colour The outside shape was firm, and showed a smooth 85 extrusion, although somewhat rounded and tough The inside was soft and chewy, and had a pleasing flavour.

The other half was pressed into the form of a chip and deep fat fried The final go product had a yellow colour and a pronounced pleasing bean flavour, and was dry and crisp.

EXAMPLE 20.

Following the procedures of Example 19, 95 dried Perfection No 112 peas were finely divided, mixed with boiling water and dimethylcellulose ether added The mixture was then cooled to 500 F One-half was extruded and fried The other half was 100 shaped into chips and fried The product retained its shape during frying The portion which was extruded produced a dry, smooth, square product having a green colour.

The half shaped into chips produced a very 105 mealy textured product which had a particularly crunchy quality.

EXAMPLE 21.

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A 500 gram sample of green bell peppers were sliced and steamed for a period of 30 110 minutes

They were then chopped into a rough mash, with the skins included After re-warming to 1600 F eight grams of dimethylcellulose ether having a viscosity of 8000 centipoise was added The mixture 115 was admixed for one minute in a Hobart mixer, operated at speed No 2, 196 r p m.

The mixture was then cooled to 500 F, extruded through a plate having s" openings, carrots and, eight grams of dimethylcellulose ether was prepared and cooled Twenty grams of potato starch was integrated into the mixture It was then extruded and fried.

The product retained its shape during frying.

The final product had a bright orange colour The exterior surface was self-containing and showed generally a smooth extrusion The centre of the pieces had a moist, soft, cooked appearance.

EXAMPLE 16.

Following the procedures of Example 14, a mixture of 580 grams of riced carrot and 57 grams of dried maize meal and four grams of dimethylcellulose ether was formulated and heated to a temperature of 1800 F and then cooled to 500 F The product was then extruded and fried The product retained its shape during frying.

The final product had a bright orange colour The exterior surface was self-containing and showed a smooth extrusion The centre was moist and soft, and had a well cooked appearance.

EXAMPLE 17.

Following the procedures of Example 16, a mixture of 580 grams of riced carrots, 57 grams of dried maize meal and four grams of dimethylcellulose ether was formulated and heated to a temperature of

1800 F The mixture was cooled to 500 F and then ten grams of potato starch was mixed into it.

The final mixture wa sthen extruded and fried The product retained it shape during frying.

The final product had an orange colour.

The exterior surface was firm and smooth, and the product had a very regular shape.

The centre was soft, moist, and had a well cooked appearance.

EXAMPLE 18.

After preparing a moist mixture by adding 82.5 grams of maize meal with 275 cc of boiling water, removing the mixture from the heat and adding four grams of dimethylcellulose ether, the mixture was cooled to 500 F and ten grams of potato starch was added The sample was then divided To one hundred grams of this sample, ten additional grams of potato starch was added, and the mixture pressed into the shape of a chip and fried The product retained its shape during frying The final product had a light brown colour and was dry and crisp.

To another one hundred grams of this sample, five grams of wheat flour was added, and the mixture pressed into the shape of a chip and then fried The product retained its shape during frying The final product 985,809 985,809 and dropped into saturated cottonseed oil heated to a temperature of about

375 F and fried for 45 seconds The product retained its shape during frying.

The final product had a dark brown colour.

Thle exterior surface was self-containing, although rough due to skin particles The centres were soft

The taste was that a fried pepper prepared directly from the raw product.

EXAMPLE 22.

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A 250 gram sample of shredded white cabbage was steamed for 45 minutes at atmospheric pressure It was then mashed and riced to form a finely divided mass After re-warming to 160 F, six grams of dimethylcellulose ether having a viscosity of 8000 centipoise was added The mixture was admixed for one minute in a Hobart mixer operated at speed No 2, 196 r p m The mixture was then cooled to 50 F, extruded through a plate having openings and dropped into saturated cottonseed oil heated at a temperature of about 375 F and fried for 45 seconds The product retained its shape during frying.


The exterior surface was self-containing and the centre was soft The taste was that of fried cabbage prepared directly from the raw product.

EXAMPLE 23.

Following the procedure of Example 22, one gram of potato starch was added to the cooled mash The mixture was then admixed, cooled to 45 F, and fried The product retained its shape during frying The final product had a dark brown colour.

The exterior surface was self-containing, smooth and firm The centre was soft The taste was that of fried cabbage prepared directly from the raw product.

EXAMPLE 24.

Following the procedure set out in Example 22, a 250 gram sample of cauliflower was steamed for 30 minutes at atmospheric pressure It was then riced After rewarming to 160 F, four grams of dimethylcellulose ether was added The mixture was then cooled to 50 F, extruded and fried The product retained its shape during frying.


The exterior surface was self-containing, and the centre was soft The taste was that of fried cauliflower prepared directly from the raw product.

EXAMPLE 25.

Following the procedure set out in Example 24, one grant of potato starch was added to the cooled mixture The mixture was then admixed, cooled and fried The product retained its shape during frying, and yielded a very smooth exterior surface.


The exterior surface was self-containing and firm The centre was soft The taste was that of fried cauliflower prepared directly from the raw product.

EXAMPLE 26.

An eight gram sample of dimethylcellulose ether having a viscosity of 8000 centipoise was added to one hundred grams of commercially canned apple sauce The mixture was warmed to a temperature of about 180 F, and then cooled to a temperature of about F The mass was pressed into the shape of a chip and baked until dry The chip was dry and crisp It had a brown colour and a characteristic apple flavour.

EXAMPLE 27.

A 165 gram of dried Great Northern beans was ground to pass through a U S Standard 30-mesh screen The finely divided vegetable was then added to 500 cc of hot water ( 150 F.) Eight grams of hydroxypropyl methylcellulose (Methocel 90 HG) having a viscosity of 8000 centipoise was added and the ingredient admixed in a Hobart mixer operated at Speed No 2, 196 r p m for a period of two minutes The mixture was then cooled to a temperature of about 50 F.

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One-half of the sample was extruded through a plate having openings and dropped into a saturated cottonseed oil heated to a temperature of about 380 F.

The pieces held their shape while frying.

The final product was brown The exterior surface was self-containing, and the centre soft The flavour was that of a bean.

The other half of the sample was pressed into the form of a chip, and fried The final product was dry and crispy, and had a bean flavour.

EXAMPLE 28 105 Idaho Russet potatoes having a solid content of 20 0 % were selected at random, peeled, trimmed, sliced to -I-" thick slabs and cooked in steam at atmospheric pressure for 30 minutes

The cooked potatoes were 110 riced through " diameter openings to remove traces of peel fragments, and 500 grams were placed in a iobart-planetary type mixer.

To this was added 4 grams of hydroxypropyl methylcellulose (Methocel 65 HG) having a 115 viscosity of 4000 centipoise and mixing at Speed No 2, 196 r p m was performed for minutes.

During this time, the potatoes cooled by natural evaporation to 95 F The mash 120 was allowed to cool further to 82 F and was then extruded using a household type lo 985,809 minutes 500 grams of the hot cooked tomatoes were placed in a Hobart Planetary Type Mixer To this was added 100 grams of dimethylcellulose and two edible moisture 65 absorbents, potato starch 100 grams, and calcium chloride 50 grams, to form a doughlike mass The procedure as set out in Example 1 was then followed.

Resulting product was a puffed type pro 70 duct with a self-containing outer layer, chewy inside, and having a good tomato flavour.

Shown above are Examples illustrating the preforming of products from a variety of vegetables, such as potatoes, cabbage, cauli 75 flower, carrots, peas, corn, beans, tomatoes and peppers Also illustrated are Examples of using a variety of dry flavouring additives, such as maize meal, starch, wheat flour and soy flour, which also act as absorbents 80 The products of the Examples were subsequently packaged.

Preforming of the foods, using mixtures of the thermal gelling binders, is also possible and often desirable 85 The purpose of using more than one particular binder is to have available in the mixture, materials that undergo solvation or maintain gelation at different steps in the process or treatment of the product before 90 it is eaten.

Compounds such as Methocel 90 HG (hydroxypropyl methylcellulose) solvate at temperatures below about 900 F and then will form a gel upon subsequent heating 95 and will again degel when the temperature of the mixture drops below about 900 F.

Compounds such as Methocel MC (dimethylcellulose) solvates at temperatures below about 550 F then form and maintain a gel when 100 the temperature subsequently rises.

By using a Methocel HG type binder in combination with a Methocel MC type binder in the vegetable mash, a mixture is obtained which has two gelatinizing and solvating sys 105 tems When the mixture is cooled to a temperature somewhat below 900 F, and preferably to about 720 F, the HG type binder undergoes salvation to produce a lubricant for shaping and upon subsequent heat pro 110 cessing forms a gel to hold the product together When the temperature of the mixture again falls below about 900 F, solvation reoccurs Hence, the HG binder does not hold the product firm at room temperatures 115 The

MC type binder does not enter into the process at the above temperature levels unless it has first undergone salvation Once the product has been shaped and heat treated, however, it is usually frozen

Upon freezing, 120 the MC binder is solvated, and upon subsequent warming sets up a gel which holds the product firm at temperatures above about 550 F Therefore, incidental cooling of the product, as sometimes occurs between warm 125 ing the product and eating by the consumer, cookie press fitted with a 3 square opening directly into an oil bath containing stabilized cottonseed oil held at 3500 F

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After 4 minutes, the French fries were a pleasing uniform golden brown colour, and possessed a firm, well cooked natural appearing interior.

Part of the product was frozen and stored at 0 F When prepared by heating in an oven at 4000 F for about 15 minutes, it was judged superior in quality to typical commercial products obtained from raw potatoes and heated in the same manner.

EXAMPLE 29.

A quantity of small slivers and pieces of raw Idaho Russet potatoes, such as those removed from a typical commercial French fry production were steamed at atmospheric pressure for 15 minutes, at which point they were soft and well cooked 500 grams of these pieces were added to 4 grams of hydroxypropyl methylcellulose (Methocel 65 HG.) having a viscosity of 4000 cps, and mixed in the

Hobart Planetary Mixer atspeed 2, 198 r p m for two minutes By evaporative cooling, the temperature was reduced to 1200 F, and the mixture was allowed to stand in a cool location until the temperature fell to below about 850 F The resulting mass was then extruded and fried in a manner similar to that described in Examples 1 and 28, with equivalent results.

EXAMPLE 30.

Following the procedure of Example 1, a sample of 8 grams of hydroxyethyl methylcellulose (Tylose

TWA/MK-3000) mixed into 1160 grams of potato mash was formulated, cooled to 680 F, extruded and fried.

The final product retained its French fried shape, was greasy, puffed, and had a rough extruded surface Another sample prepared exactly as above was cooled to 500 F before extrusion The final product retained its French fried shape, had a smooth extruded surface, and a very good flavour, but was slightly tough.

EXAMPLE 31.

Following the procedure of Example 1, a sample of eight grams of ethyl hydroxyethylcellulose

(Modocoll-600) mixed into 1160 grams of potato mash was formulated, cooled to 68 F, extruded and fried The final product retained its French fried shape, but was puffed, greasy and had a rough extruded surface Another sample prepared in the same way was cooled to 500 F before extrusion The final product retained its French fried shape, was slightly puffed It had, however, developed a slight off flavour.

EXAMPLE 32.

Fresh tomatoes were selected at random, cooked in steam at atmospheric pressure for 985,809 12

985,809 will not result in undesirable softening of the binder mixtures, a tabulation of the operating product steps and the state of the binders is set 5 In order to illustrate the interaction of out in Table I.

TABLE I

Sequence of Solvation and Gelation of Mixed Binders When Vegetable Mash Shaped at 72 F.

Steps in the Formation of the Product 90 HG MC 4000 Mixing binder into hot potato mash wetting wetting Cooling to 72 F solvation only slight solvation Extrusion at 72 F lubricating mash inactive

Frying gelation inactive Freezing solvation solvation Finish heat processing gelation gelation Cooling to room temperature during serving solvation retains gelation Methocel HG type binders also exhibit prior to shaping and the MC type is the some lubricating and extrusion improving binder depended upon to hold the product 15 properties, and it may therefore be desirable firm during subsequent heat processing The to incorporate this binder into the mixture, sequence of solvation and gelation in this even though the vegetable mash is to be instance is shown in Table II.

cooled to a temperature below about 55 F.

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TABLE II

Sequence of Solvation and Gelation of Mixed Binders When Vegetable Mash Shaped at 50 F.

Steps in the Formation of the Product 90 HG MC 4000 Mixing binder into hot potato mash wetting wetting Cooling to 50 F Solvation Solvation Extrusion at 50 F lubrication -some lubrication Frying gelation gelation Freezing solvation solvation Finish heat processing gelation gelation Cooling to room temperature during serving solvation retains gelation Set out below is an Example of the use of the mixtures of Methocel gels in preforming French fried potatoes.

to a temperature of 3750 F for a period of seconds The pieces were in the shape of the traditional

French fry, and held their shape during frying The samples were frozen and again fried in saturated cottonseed oil, heated to a temperature of about 3750 F for a period of 45 seconds The appearance of the extruded surface and the centre of the final product are recorded on Table II Also shown in Table

III are tenderness measurements observed after the potato pieces had stood at room temperature for 10 minutes after the final frying These measurements were made by cutting the end of the French fry piece, contacting a probe of a penetromometer to the centre of the cut end and measuring the force necessary to move the probe into the potato piece a given distance.

EXAMPLE 33.

Use of Mixtures of Metiocel Binders.

Idaho Russet potatoes were selected at random, peeled, cooked in steam at atmospheric pressure for a period of 30 minutes.

The potatoes were then mashed To 1,160 gram samples of the hot mashed potatoes were added 5 grams of salt for flavouring, and 4 grams of glucose marketed under the Regis1 O tered Trade Mark

"Cerelose", to increase the degree of browning.

Mixtures of dimethylcellulose ethers and propylene glycose hydroxymethyl cellulose ethers, shown in

Table III below, were then added to the samples, and the samples were cooled to a temperature of about 750 F and extruded through a plate having 3 inch square openings The extruded potatoes were dropped into saturated cottonseed oil heated TABLE III

Gel Mixtures Extrusion Penatromometer Appearance Measurement Texture by Mouth Feel H G 8,0001 gram MC 4,000 4 grams H G 8,000 2.5 grams M.C 4,000 2.5 grams H G 8,0004 grams M.C 4,0001 gram fair, slightly rough fair, slightly rough fair, smooth As can be seen from the penatromometer reading, the pieces containing larger amounts of dimethylcellulose ethers were firmer at room temperature than those containing lesser amounts It is believed that by combining binders in this manner, the quality of the product between the time of frying and the time that the consumer actually eats it, will be maintained at any predetermined level.

In one variation of the present process, it is possible to use the solvated binder food mixture prior to gelling, as a food spread product In this case, there would be no extrusion, and the product could be manually spread on to any suitable surface, such as bread, for instance, and heat processed to produce a decorative article Thus, it is possible to have fancy decorations which are food products in themselves and have them maintained in their artistic shape by gelling through heat processing.

40.35 15.10 10.15 crispy, rough outside, mealy moist inside crispy outside, moist mealy inside smooth extrusion from outside, moist, less mealy insideData supplied from the esp@cenet database -

Worldwide

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193.

GB987934 - 3/31/1965

IMPROVEMENTS IN OR RELATING TO PREPARATIONS CONTAINING

LACTULOSE


Applicant(s): TERVALON MIJ VOOR VOEDINGSMIDD (--)

E Class: A23L1/236D; A23L3/46


Priority Number: NL19600250802 (19600422)

Family: GB987934

Abstract:


Dry, lactulose-cointaining infant food preparations for stimulation of intestinal bifidus flora are made by spraying into hot gas, e.g. air, at 135-170 DEG C. an aqueous liquid containing lactose and lactulose, with or without other carbohydrate, which lactulose forms not more than 50% of the solids of the aqueous liquid, and the solids being in not more than 35% concentration, or, if the solids include 2-

8% of gelatinized flour, in not more than 50% concentration. The product may be spherical, aircontaining particles of 2-50 micron size, and may contain: lactulose 30-45%, precooked rice meal 2-

5%, galactose 2.5%, lactose 60-65%, water 0.53%.Description:



NO DRAWINGS 9875934 Date of Applicaition and filing Complete Specification April 24, 1961. e V St/44 @t No 14724/61.

Application made in Netherlands (No 250802) on April 22, 1960.

Complete Specification Published March 31, 1965.


Index at acceptance: -A 2 B( 1 B, 20 A) Int Cl: -A 23 c COMPLETE SPECIFICATION

Improvements in or relating to Preparations Containing Lactulose We, N V TERVALON,

MAATSCHAPPIJ VOOR VOEDINGSMIDDELEN OP WETENSCHAPPELIJKE BASIS, of 151,

Apollolaan, Amsterdam, Holland, a Dutch body corporate organized and existing under the laws of the

Kingdom of the Netherlands, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

THIS INVENTION relates to preparations containing lactulose, and is concerned to provide such preparations in the form of a solid powder which may be conveniently handled.

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It is known that with infants' food which contains a sufficient content of lactulose, a so-called pure bifidus flora can be produced in infants In general, the occurrence of a pure bifidus flora in babies is judged to be favourable since it is a positive indication of a good state of health of the young child.

For this reason, infants' food containing lactulose has found ready acceptance in pediatrics.

For the preparation of lactulose, various methods are available Commonly, lactose, which is used as starting material, is epimerised in aqueous medium at a p H above 5.

Subsequently, unconverted lactose is separated, the residue oxidized with bromine, the acids formed removed and the product freed from acid, crystallised.

It has appeared in practice that obtaining a crystalline product is a very difficult task, and attempts to do so have not as yet resulted in a method usable on a large scale A proposed roundabout way via the octa-esters of lactulose is very cumbrous.

Difficulty has also been encountered in attempting to apply known drying techniques to a concentrated solution or syrup containing the lactulose, in that the product obtained lPrc 6 was more or less sticky and not free-flowing as could be desired.

According to the present invention there is provided a method of preparing a dry product containing lactulose which method comprises spraying an aqueous liquid containing lactulose and lactose, with or without other carbohydrates, into a hot gas having a temperature of from 135 to 170 'C, said liquid having a lactulose content not exceeding 50 % by weight calculated on the total dry substance, and a total dry substance content not exceeding 35 % by weight, or not exceeding 50 % by weight provided that said solid substance includes from 2 to 8 % by weight of gelatinised flour calculated on the total dry substance The invention includes a dry free-flowing powder consisting substantially of lactulose and lactose when produced by that method.

In the ensuing description, the compositions of liquids will be specified in the same manner, namely, giving the total content of dry substance as a weight percentage related to the whole, but giving the content of a particular component as a weight percentage related not to the whole (including water) but to the total dry substance weight content.

The invention embodies our discovery that a sticky product can be avoided provided that the upper limits specified above both for the total solids content and the lactulose content in relation to other constituents, be not exceeded This quantity of lactulose may be limited to a value not exceeding approximately 45 % by weight of the total quantity of solid substance An excessive proportion of lactulose causes a product of a sticky character to result On choosing the lower limit of the quantity of lactulose, no technical limits can be stated; it appears that the lower the lactulose content of the dry substance, the easier a dry and free-flowing product is obtained on spraying, but for economical reasons it is not recommended that the lactulose content of the dry substance be lower than 20 %.

The above implies that no powdered product is formed if the aqueous liquid contains lactulose only

The lactose also present in the aqueous liquid is necessary at the formation of a dry product The remainder of the quantity of dry substance may entirely consist of lactose, but a part may consist of other carbohydrates, provided of course that they do not seriously augment the hygroscopicity of the sprayed product A quantity of 2-5 % of galactose was found to be quite acceptable This is of practical importance since in the normal preparation of lactulose by epimerisation of lactose a small quantity of galactose is formed.

Thus, since the presence of lactose is not disturbing the syrups produced by the epimerisation of lactose at a p H above 5 may be used, with or without addition of further lactose as the aqueous liquid for practising the invention, after required purification measures to remove anions and cations A lactulose/ lactose syrup which after drying yields a product having a lactulose content of 26-29 %,' preferably 27 % 0, has turned out to be particularly suitable A part of the lactose may equally be replaced by sugars other than galactose, if desired, but it is not necessary.

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It is of advantage for the liquid to be sprayed, to contain not more than 8 %, preferably 2-5 %, of gelatinised water-soluble flour, calculated on dry substance, in addition to the lactulose and lactose and for example galactose (Gelatinised flour is obtained by heating flour in water at the gelatinisation temperature for some time, during vwh:ch gelatinisation occurs, and then drying A product obtained in this way is also termed precooked flour).

By using such a flour it is attained that the liquid to be sprayed can easily be dried with lactulose percentages exceeding 30:% calculated on dry substance For exampie, by using from 2-5,-5 % of gelatinised flour, a lactulose syrup may be dried which contains a quantity of from 30 to 45 %',, for exanmple, 400 %, of lactulose calculated on dry substance A liquid having such a high content of lactulose could so far not be obtained at all in a powdered form Of the various usable kinds of flour pre-cooked rice-meal is especially suitable.

It is of importance in addition that the content of dry substance of the syrup to be sprayed be not too large As stated above, the upper limit lies at approximately 35 % except that provided that 2-8 % of pre-cooked fleour be present, this upper limit may be shifted to 45-50 % No special conditions are connected to a lower limit, although this will not be chosen too low either for practical reasons This could not only harmfully influence the heat-economy of the method, but in addition the weight of the sprayed and dried drops will become very low if the concentration of the solid constituents be too low resulting in the drops being easily conducted 70 away from the spray-tower by the drying air.

For this reason it is recommended that the lower limit of the content of dry substance of the aqueous liquid to be sprayed be not below 25-30 % by weight For example, the 75 aqueous liquid may have a total content of dry substance of at least 129 % O by viweght and a lactulose content of at least 20 % calculated on weight of total dry substance.

A conventional drying tower may be em 80 ployed for spraying the aqueous liquid, in conjunction with conventional spraying apparatus Excellent results were obtained with spray apparatus of the spray nozzle or of the disc type Naturally, the temperature of the 85 air blown into the drying tower is not so high that burning of the lactulose and lactose may occur, which would result in brown-colouring of the product The inlet temperature of the drying air may not exceed approxi 90 mately 170 C, and excellent results can be obtained with an inlet temperature of the drying air from 145 to 165 C The lowest possible permissible temperature also is of importance to prevent that insufficient drying 95 occurs, as it would at a temperature lower than 135 C.

At temperatures between 90 and 130 C, important physical changes in lactulose and lactose occur It is better to prevent these 100 changes by ensuring that the dried powder in the tower do not reach temperatures higher than 80 to 90 C Thereby melting of the lactulose, or vitrification or conversion from f/ into a-lactose, can be avoided A check 105 of the temperature of the powder is available in that of the outlet temperature of the drying air should preferably lie between 80 and 95 C.

A product is usually obtained which may 110 contain approximately 2 % of moisture A lower percentage is also possible, but this will as a rule not be lower than 0 5 %, The desired moisture content of the powder may inter elia be controlled by choosing an exact ratio 115 of the quantity of drying air with respect to the quantity of water to be evaporated from the syrup All this depends on the quality of the tower and on the efficiency of the heat transfer which takes place in it, but as 120 a rule satisfactory results will be obtained when 1 kgm of syrup is heated with 30 to kgm of air of the above-mentioned temperature It should be ensured that the product does not contain any more than 4 %/ 125 of water, since otherwise the product starts forming a cake For this reason the dried product should not be stored under moist conditions It has appeared, however, that the product may be stored without objec 130

987,934 syrup was further diluted with water to a dry substance content of 35 %, and the spraying speed was reduced to ly-kgms of syrup per minute The other conditions were the same, and a dry, powdered lactulose-lactose preparation was obtained having a moisture content approximately 2 5 %.

EXAMPLE 3.

250 kgms of lactulose syrup, containing kgms of lactulose, 100 kgms of lactose, 11.75 kgms of galactose and 38 25 kgms of water, were mixed with 158 5 kgms of lactose and 651 5 kgms of water.

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The liquid was sprayed in the above described manner in air of which the inlet temperature was 155 and the outlet temperature 860 C The disc speed of the Lurgisprayer was 7500 r p m.

On spraying the above solution, with a content of dry substance of 35 %, good results were obtained.

EXAMPLE 4.

The procedure described in Example 3 was followed, using a more concentrated syrup having a total solids content of 55 % by weight A satisfactory product was not obtained.

EXAMPLE 5.

439 5 kgms of lactulose syrup, containing 179 8 kgms of lactulose, 196 kgms of anhydrous lactose and 20 7 kgms of galactose, and 43 kgms of water, were mixed with 25 kgms of lactose, 25 kgms of pre-cooked ricemeal and 463 kgms of water This liquid was heated to 90 'C and transferred to a Lurgi spraying tower at this temperature The heating air supplied had a temperature of 1550 C, while the outlet temperature of the air was 850 C The disc speed was 7400 r p m.

The sprayed product had a moisture content of 2 6 %.

tions in air of room temperature of a relative humidity of 25-30 %.

The particles of a product obtained in practising the invention have a spherical shape in which one or more air bubbles are present.

The separate particles are very small and have a size from 2-50,t The product is freeflowing at a moisture content lower than 4 %.

The rate of dissolving in water is very large.

For example, in a tenfold quantity of water, the product will almost entirely dissolve with little agitation with shaking or stirring solution is complete in less than 2 minutes Compared herewith, a lactulose and lactose-containing syrup containing micro-crystalline lactose, dissolves far less rapidly in water.

The invention further includes such a product obtained by a method as described which product is a novel composition, namely, consisting of a dry, free-flowing mixture consisting by weight of 20-45 % of lactulose, 70-45 % of lactose, 0-5 % of sugar other than lactose or lactulose, 0-8 % of a gelatinised flour and 0 5-4 % of water, of which the separate particles have a spherical shape, contain one or more air-bubbles and have a size of from 2-50 p This product preferably contains from 30-45 % of lactulose,

2-5 % of pre-cooked rice-meal, 2-5 % of galactose, 60-55 % of lactose and 0 53 % of water.

In the ensuing specific examples, a number of procedures are described for drying a lactulosecontaining syrup, by way of illustrating the invention and of comparison with procedures differing from the invention in some respect and resulting in an unsatisfactory product More particularly,

Examples 2, 3 and 5 are illustrative embodiments of the invention.

EXAMPLE 1.

An aqueous liquid, having a content of dry substance of 45 %, the dry substance consisting by weight of 27 % of of lactulose, 68 % of lactose (calculated as anhydrous) and % of galactose was heated to 90

'C and, at this temperature, sprayed in a drying tower by means of a so-called Lurgi disc-sprayer which has a normal evaporation of water of 140 litres per hour The warm air passed into the spraying apparatus had a temperature of 1550 C The temperature of the air conducted away was 850 C 3 kgms of the above described syrup were sprayed per minute, the disc speed of the evaporator amounting to

7600 r p m The powder resulting was however unsatisfactory being of a somewhat sticky character and strongly adhering to the wall of the drying tower from which it had to be cleaned.

EXAMPLE 2.

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The procedure described in Example I was followed, using a clean tower, except that theData supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS:-

1 A method of preparing a dry product containing lactulose which method comprises spraying an aqueous liquid containing lactulose and lactose, with or without other carbo 110 hydrates into a hot gas at a temperature of from 135 to 170 'C, said liquid having a lactulose content not exceeding 50 % by weight of the total content of dry substance, and a total content of solid substance not exceed 115 ing

35 % by weight or not exceeding 50 % by weight provided that said solid substance includes 2-8 % by weight of gelatinised flour calculated on weight of total dry substance.

2 A method as claimed in Claim 1 wherein 120 the lactulose content of the aqueous liquid has a value not exceeding 45 % by weight calculated against the total weight of dry substance.

3 A method as claimed in Claim 1 or 125 987,934 Claim 2 wherein the aqueous liquid has a total dry substance content not exceeding % by weight which if exceeding 35 % by weight includes 2-8 % by weight of gelatinised flour.

4 A method as claimed in any one preceding claim, wherein the aqueous liquid has a total content of dry substance of at least 25 %O by weight and a lactulose content of at least 20 % by weight calculated on weight of total dry substance.

A method as claimed in any one preceding claim wherein the aqueous liquid includes from 2-50 % of galactose by dry weight calculated on weight of total dry substance.

6 A method as claimed in any one preceding claim wherein the aqueous liquid consists of the product obtained by epimerising lactose at a p H above 5 after removing anions and cations, with or without subsequent addition of further lactose.

7 A method as claimed in any one preceding Claim, wherein the aqueous liquid contains 2-5 % by weight of a gelatinised flour calculated on weight of total dry substance.

8 A method as claimed in any one preceding claim wherein any gelatinised flour present in the aqueous liquid consists of precooked rice-meal.

9 A method as claimed in any one preceding claim wherein the aqueous liquid has a lactulose content of 26-29 % by weight calculated on weight of dry substance.

A method as claimed in Claim 7 or Claim 8, wherein the aqueous liquid contains 30-45 % by weight of lactulose, calculated on weight of total dry substance.

11 A method as claimed in any one preceding claim wherein the aqueous liquid is sprayed in heated air.

12 A method as claimed in any one preceding claim wherein the highest temperature of the hot gas is from 145 to 1650 C.

13 A method as claimed in any one preceding claim wherein the temperature of the sprayed product does not exceed 80-950 C.

14 A method as claimed in any one preceding claim wherein 30-70 kgms of heated air are used per kgm of liquid to be sprayed.

A method of preparing a dry product containing lactulose substantially as hereinbefore described with reference to any one of the foregoing specific Examples numbered 2, 3 and 5.

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16 A product obtained by the method claimed in any one preceding claim and consisting of a dry, freeflowing powder having a composition by weight of 20-45 P of lactulose, 80-55 % of lactose, 0-5 ,' of a sugar other than lactose and lactulose, 0-8 % O of a gelatinised flour, and 0 5-4 % of water, said powder consisting of separate particles having a spherical shape, containing one or more air bubbles and having a size of 2-50 t.

17 A dry, free-flowing powder as claimed in Claim 16 which contains by weight 304501; of lactulose,

2-5 %,O of pre-cooked ricemeal, 2-50 % of galactose, 60-55 % of lactose and 0 5-3 % of water.

18 A dry free-flowing powder consisting substantially of lactulose and lactose when produced by the method claimed in any one of Claims 1 to 15.

T D THREADGOLD, Chartered Patent Agent, Century House, Shaftesbury Avenue, London, W C 2,

Agent for the Applicants.

Leamington Spa: Printed for Her Majesty's Stationery Office by the Courier Press -1965.

Published at The Patent Office, 25, Southampton Buildings London, W C 2, from which copies may be obtainea, 987,934Data supplied from the esp@cenet database - Worldwide

916/2197

194.

GB990063 - 4/22/1965

PROCESS AND APPARATUS FOR PREPARING RICE PRODUCTS AND RICE

PRODUCTS OF SAID PROCESS


Inventor(s): GOROZPE RAUL DONDE (--)

Applicant(s): CORN PRODUCTS CO (--)

E Class: A23L1/182



Family: GB990063

Abstract:


990,063. Quick-cooking rice. CORN PRODUCTS CO. Jan. 24, 1962, No. 2593/62. Headings A2B and

A2Q. In a process for making quick-cooking rice, rice grains are hydrated in water at a temperature below the gelatinization temperature of the rice, e.g. between 20 and 55 C., until the rice grains attain a water content between 25 and 40% by weight. The hydrated rice gains are passed for a period of 3 to

10 minutes, intermittently through hot water, e.g. in the form of a series of sprays, having a temperature of at least 55 C., e.g. between 80 and 100 C., and an atmosphere of steam and are then passed, for another 3 to 10 minute period, intermittently through water, e.g. in the form of a series of sprays having a temperature below 55 C., and an atmosphere of steam. Cleaned brown or white milled whole rice grains, preferably fissured by pre-treatment with infra-red rays or dry air having a temperature not exceeding 150 C., are fed, from a bin 10, Fig. 1, into a hydrator 20 into which water is fed from a tank 22 through a pipe 24 and a valve 25 controlled by a float 26. The rice grains may remain in the hydrator for 120 minutes. They are discharged through a metering device 30 and an outlet

31, on to the upper flight of a foraminous or reticulated endless wire screen conveyer 32 and may be subjected to a blast of air, from a nozzle 34, as they are discharged. A spreader 46 distributes the hydrated grains evenly on the flight of the conveyer, e.g. in a layer one-half to one inch in thickness.

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Excess water drains off into a tank 36 and a sump 38, from which it is returned to the tank 22 through a pump 40, filter 42 and pipe 43. The hydrated grains are then carried through a gelatinizer 50 comprising an open tank 52 positioned under the upper flight of the conveyer. Perforated steam pipes

54 are disposed in the tank, preferably submerged in water contained therein, to direct steam, preferably wet steam, through the upper flight of the conveyer and the layer of rice grains. The time taken for the rice grains to be conveyed through the gelatinizer is 6 to 20 minutes. Hot water is sprayed on to the rice grains through a series of nozzles 56, preferably depressed downwardly, e.g. at an angle of 45 degrees, in the direction of movement of the layer of rice grains. The nozzles 56 are spaced apart, so that the time taken for rice grains to be conveyed from one hot water spray to the next is 15 seconds.

Cooler water is then sprayed on to the rice grains through a series of similar nozzles 58, which are spaced apart so that the time taken for rice grains to be conveyed from one cool spray to the next is 30 seconds. The rice grains are carried through all the hot water sprays in 3 to 10 minutes and through all the cooler sprays in 3 to 10 minutes. A hood 66 is located over the hot and cooler sprays to direct condensed steam downwardly on to the rice grains. The 85 to 95% gelatinized rice grains emerging from the gelatinizer have a water content between 50 and 65% by weight. They are cooled, if necessary, with water at a temperature between 10 and 55 C., and/or by blasts of cold air from nozzles

68, and are then dried in hot air at a temperature between 80 and 140 C. to yield quick-cooking rice having a moisture content between 10 and 14% by weight. Alternatively, the hydrated rice grains may be gelatinized by being carried, on the upper flight of a reticulated endless belt 32, through a gelatinizing chamber 78, Fig. 5, provided with a cover. The base of the chamber is partitioned to form compartments A, B and C holding water at different levels, so that water overflows from compartment C to B and B to A. Perforated steam coils (not shown) are located in the chamber to heat the water, so that its temperature rises from a temperature below 55 C. in compartment C to a temperature above 55 C., e.g. to 100 C., in compartment A, and to provide an atmosphere of wet steam over the water. The upper flight of the belt 32 is guided by means (not shown) in a zig-zag path through the water and wet steam. The rice grains are sprayed at a location 79 with water at a temperature between 20 and 85 C. The gelatinized rice grains leaving the gelatinizer 78 are subjected to an upward blast of air 80, at a temperature up to 60 C., to cool and loosen the grains and arrest gelatinization. The water for treating the rice may contain tomato powder, onion or garlic flavouring, carotene, vitamins and a vegetable protein, such as soya protein.Description:



DRAWINGS ATTACHED 990.063 0 cD d Date of Application and filing Complete Specification: Jan.

24, 1962.

No. 2593/62.

Complete Specification Published: April 22, 1965.


Index at acceptance:-A2 Q (3A, 3B, 12, 13, 14D, 14X, 16A, 16D, 16X); A2 B (1B, 1J, 1L) Et. Cl.:-A

23 1 1/10 // A 23 b, 1 The inventor of this invention in the sense of being the actual deviser thereof within the meaning of Section 1,6 of the Patents Act 1949 is RAUL DONDE GOROZPE, a Mexican citizen of Calle Rio de la Plata No. 19, Mexico City, Mexico.


Process and apparatus for preparing Rice Products and Rice products of Said Process We, CORN

PRODUCTS COMPANY., a corporation organised and existing under the laws of the States of

Delaware, United States of America, of 717 Fifth Avenue, City of New York, State of New York,

United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

918/2197

This invention relates to a process for preparing a quick-cooking rice product and to the rice product of said process.

There are precooked rice products on the market identified as " quick-cooking rice "; but some, although good products from the standpoint of quick-cooking, are very expensive, costing as much as three times the price of ordinary rice. Others, that are not as quickcooking and are less expensive, nevertheless, cost twice as much as ordinary rice.

The high prices demanded for quickcooking rice products on the market are generally due to the methods of manufacture employed, which methods are inefficient and cause loss of material. Further, these methods involve some loss of nutritive value and require extra large amounts of enrichment materials to restore the original nutritive value thereby increasing the cost of the product.

The present invention provides a process for preparing a quick-cooking rice product which comprises hydrating rice grains with an aqueous medium at a temperature below the gelatinization temperature of the rice until the moisture content is increased to between 25 and 40% by weight, partially gelatinizing the hydrated rice over a period of about 3 to 10 minutes by intermittently continuing hydration of the rice with water having a temperature of at least 550 C and intermittently maintaining the rice in an atmosphere of steam, continuing gelatinization for an additional period of 3 to 10 minutes by intermittently continuing hydration of the partially gelatinized rice with water having a temperature below 550 C and intermittently keeping the rice in an atmosphere of steam, whereby overgelatinization of the portion already gelatinized is avoided.

In order to gelatinize rice, a certain amount of moisture, in addition to that present in hydrated rice, is necessary. If hydrated rice is cooked in a single operation, it is possible for the rice to absorb the necessary moisture for complete gelatinization of the entire grain.

However, such products are sticky because of overgelatinization. In order to, dry them successfully it is necessary to remove the sticky portions and this results in great loss of product. We have discovered that overgelatinization may be prevented by introducing additional moisture into the hydrated rice in several stages while maintaining the temperature of the rice above the gelatinization temperature. For example, the additional moisture may be added in several stages by first immersing the hydrated rice into hot or boiling water, then removing it and keeping it in an atmosphere of steam. This may be repeated several times until the rice is completely gelatinized. The gelatinization starts as soon as the rice grains have absorbed additional moisture and have attained the temperature of the hot or boiling water. During each immersion 4 to 6 per cent by weight of additional moisture is absorbed by the rice.

When the rice is removed from the water and kept in a steam atmosphere, for example, on a screen or mesh wire conveyor, the temperature remains substantially the same or at least above the gelatinization point. The rice starts to sswell during the first immersion and the swelling continues in the steam atmosphere.

While the rice is in the steam atmosphere, the moisture absorbed penetrates the rice grain, further swelling it. This results in the disappearance of the film of free water on the outside of the rice, thereby preventing the excess water from causing overgelatinization.

The loose starch remains in the cooking water thus also preventing stickiness. The immersion and removal steps are repeated until the rice grains are completely gelatinized. If the system is not entirely closed, there may be some evaporation of the free water on the outside of the grains.

A variation of the method of introducing additional moisture into hydrated rice while it is undergoing gelatinization, as for example, in an atmosphere of steam, is to spray hot water having a temperature above 55 ' C., preferably betwveen 800 and 100 C., intermittently on the rice. This permits the rice to absorb additional moisture necessary for gelatinization while maintaining the temperature high enough to gelatinize the rice. It is also permissible to spray cold water (10-15 C.) on the rice after the outer portions are gelatinized to prevent over gelatinization. In this event temperature of the inner portions of the rice grain remains above the gelatinization point.

919/2197

The rice product prepared by tile invention has quick-cooking properties and high nutritive value and can be commercially marketed at a reasonable price only slightly higher than ordinary rice, unprocessed for quick-cooking, but compensating for this small difference in price by saving the purchaser time, fuel and nutritional values.

The process of the invention for making a quick-cooking rice is simple and continuous, and may be automated so that it is economical to perform, thereby greatly reducing the manufacturing cost of the prepared rice.

Any desired additives including flavor, color, minerals and vitamins are easily incorporated in the rice. Such additives may be applied at any time during the process, i.e.

at hydration, during gelatinization or after gelatinization.

By means of the present invention the rice is a uniformly gelatinized product that may be easily cooked for serving, and vwhich with slight changes, not affecting the basic manufacturing process, plus slight differences in the instructions for cooking, will result in a product which will suit the different tastes and particular ways of cooking rice in various countries.

In one mode of practising the invention, whole grain, brown or white milled rice is well dry cleaned and elevated into a bin which is kept filled by automatic means. The rice grain is fed to a hydrator which increases the moisture content of the rice to 30---40 per cent over a period of 120 minutes using water at ambient temperatures. Desirably, enrichment additives are included in the hydrating liquid.

The hydrated rice is fed out of the hydrator and passed through a gelatinizer which quickly and uniformly gelatinizes the rice in two stages, each lasting 3-10 minutes. 75 One stage utilizes wet steam continuously, and hot or warm water sprays intermittently applied to the rice. The second stage utilizes wet steam continuously and water sprays having ambient temperature intermittently 80 applied to the rice. By this means the rice is gelatinized approximately 85 to 95 per cent.

The hydrated rice may be gelatinized by placing a layer of the rice on a reticulated belt which is passed in and out of hot or boiling 85 water bath thus alternately exposing the rice grains to hot water and steam or air at 100 per cent relative humidity. The moving layer of rice grains may then be treated as in accordance with the second stage discussed 90 above or alternately passed through a water bath having a temperature lower than 55 C.

and into an atmosphere of steam or saturated air.

The intermittent exposure of the rice grains 95 to heating and then cooling media or atmospheres serves to uniformly gelatinize the rice grains from their outside surfaces to their interior or centers in a balanced manner. The cooling media act to momentarily lower the 100 temperature of the outer surfaces of the rice grains so that the inside portions and the outer surfaces are gelatinized more or less equally. After gelatinization, the rice is cooled to less than 55 C. and the moisture content 105 is then

40-65 per cent. At this time, more enrichment additives may be applied if so desired. The rice is then dried in several stages by air up to 150 C. to reduce the moisture content to 257/, and finally to approximately 110 10-14%/. The rice is now ready to be classified and packed. During the drying operation various additives, e.g., flavor, nutritional supplements, coloring materials may be added by sprays or blenders. In the automatic 115 process for producing the product, it is possible that the hydrating liquid be salvaged, and accordingly, apparatus may be provided whereby the excess hydrating liquid is decanted or drained from the rice, and run 120 through a filter. The dry substance content thereof may then be recovered.

It is advantageous to pretreat the rice grains before hydration to create fissures in the grains. Fissuring may be accomplished by 125 means of dry air, infrared rays, or other heat ing systems and in the fissuring step the moisture content is reduced by 4-8 Z. The use of drying air having an absolute humidity not exceeding 10 grams per kilogram of bone dry 130 990,063 and preferably fissured before placement in the hydrating liquid, the solution will permeate the rice grain and thus the flavor, vitamins or other additives are soaked into the rice. Vitamins in the skin layers of the rice 70 grain also tend to be carried into the interior and absorbed by the grain during this soaking period. After hydration, the rice is drained to remove the excess liquid and desirably, such liquid is collected and pumped through a

920/2197

filter 75 for re-use in the continuous process. The filter serves to separate loose starch, broken grains, extraneous matter and other impurities from the excess hydrating liquid.

The hydrated rice grains are then gelatinized in two quick stages, each lasting from 3-10 minutes. In the first stage, the rice grain is subjected, while moving;on a reticulated conveyor, to wet steam from below and spaced apart hot water sprays from above. 85 The individual sprays are spaced apart so as to strike the moving rice every 15 seconds.

In the second stage of gelatinization, the moving rice is again continuously subjected to' wet steam from below, but the sprays from above 90 are cold water sprays. These are preferably positioned apart like the hot water sprays, but more widely spaced so as to strike the rice every 30 seconds instead of every 15 seconds.

Thus, in 6-20 minutes, the rice is uniformly 95 gelatinized to 85-95% of completeness.

After the second stage of gelatinization the rice is cooled to ambient temperature and the moisture content is then 45-65%. The rice may then be dried in several stages by 100 forced air at a temperature of, for example, 1500 C. and having, for example, a velocity up to 300 feet per minute. The drying in the first stages lowers the moisture content to 20---25 . At this stage, additional flavoring, 105 coloring or enriching materials may be incorporated in the rice, e.g. by spraying or blending. The rice is finally dried to, a moisture content of 10-14 per cent, allowed to cool and packed. 110 The rice product so produced has the appearance of normal rice or other marketed quick-cooking rices except that under a magnifying glass the rice kernels or grains show a number of minute, irregularly spaced, horizontal and vertical lines or cracks. The number and positioning of these hair lines permit the ready and complete penetration of cooking water and so contribute to the quickcooking properties of the product. The grains 120 from other marketed quick-cooking rices in distinction show horizontally spaced bands in lesser number and more evenly spaced.

Other advantages of the rice product of the present invention are its excellent keeping properties in storage because of the steam sterilization during gelatinization; its very high nutritive value and imroved flavor, very little of the natural nitritive value being lost during the processing and because

130 air for fissuring is a novel feature. The dry air may be at any temperature not exceeding 1500 C. but in practical operations a temperature range of 50-1200 C. will be satisfactory.

The drying air is passed over and around the rice grains.

The fissuring step for producing the rice to be used in the novel method of gelatinizing the rice, produces unexpected results over prior art methods.

One method of cooking the quick-cooking rice for table serving consists in adding a cup of rice to a cup and a half of boiling water and boiling the mixture on a very low fire for only one-half to four minutes. After removal from the fire and standing for ten minutes, the rice is ready to serve. Another method consists in adding an edible oil or fat and flavoring or coloring material to the water prior to boiling and then adding the rice, cooking it two to four minutes and letting it stand for 10 minutes after which the rice is ready to serve.

The invention, both as to its organization and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures and in which:

Figure 1 is a diagrammatic layout of an apparatus for producing a quick-cooking rice product; Figure

2 is a diagrammatic more detailed viewu of the gelatinizer shown in Figure 1; Figure 3 is a plan view of rice kernels after undergoing the present process, a portion of one kernel being highly magnified;

Figure 4 is an enlarged cross-sectional view through a rice kernel and taken on line 4-4 of Figure 3;

Figure 5 is a diagrammatic layout of an apparatus for producing a quick-cooking rice product; Figure 6 is a diagrammatic cross-sectional view of the gelatinizer shown in Figure 5, and Figure 7 is a diagrammatic layout of a drying system for the wet, gelatinized rice.

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The process hereinafter described is that which has been developed with respect to certain varieties of rice.

The steps 'of the process preferably include fissuring of the rice particles as described above followed by hydration of the rice grains at a temperature in the range of 20-550 C.

for a period of from 30 to 120 minutes to obtain a moisture content in the range of 25-40% by weight.

The hydrating liquid is water or an aqueous solution or mixture containing flavoring and water soluble vitamins, minerals and/or other additives which are desirably added to the product. As the grain rice has been husked or milled to remove the shell, well dry cleaned 990,063 of the enrichment materials added; and its capability of being prepared for eating after only one-half to four minutes of boiling at low heat, the aforementioned cracks or fissures enabling rapid moisture penetration and rehydration of the entire kernel. When prepared for table use, the product is practically indistinguishable from first grade large grained, whole rice, whether unprocessed or processed for quick cooking, while the cost is only slightly more than that of ordinary rice, but considerably less than that of other quick-coking rice.

In order to more clearly set forth the invention, several specific examples will now be described in detail with reference to the accompanying drawings.

Referring specifically to Figure 1:

Whole grain rice, brown or white milled, and having a moisture content of 10-14 per cent is well dry cleaned by usual methods and conventional apparatus. The cleaned rice grain is preferably fissured as described above and then elevated or otherwise placed in bin 10.

The bin is kept filled. Limit switches 12, 14, also of conventional design, are employed for automatically controlling the level of the grain in the bin. The bin may be provided with a hopperlike bottom and a discharge spout 16 at the lower end thereof, adjacent to the upper end of the hydrator 20.

Bin 10 feeds the rice to the hydrator by gravity and the discharge spout 16 is selfelosing when the hydrator 20 is filled to the level of the bottom of spout 16.

A supply tank 22 having a water supply pipe 23 and a discharge pipe 24 serves to fill the hydrator 20 with water or an aqueous hydrating solution, dispersion or mixture. The discharge pipe 24 is provided with a discharge valve 25 controlled by a float 26 which operates the valve 25 to control addition of hydrating liquid when the hydrator is filled to the level indicated at 28. Above this level is a drain pipe

29 which prevents overfilling of the hydrator in case of failure of the float 26 to operate properly. The control of the valve 25 by the float 26 thus maintains the level of the solution practically constant in the hydrator 20.

Although plain water may be used for the hydration, it is possible to use an aqueous solution or mixture containing flavoring, water-soluble vitamins, minerals or other additives. This solution permeates the rice grains in the hydrator 20 and thus, the flavoring, vitamins and other additives are soaked into the rice. The strength of the solution may be varied to obtain the best results. It has been found that soaking the rice for a period of 120 minutes at ambient temperature yields very satisfactory results.

At the end of the hydration period, the hydrated rice is fed out of the bottom of the hydrator 20 by means of a device e.g., metering or conveying, 30 and deposited, through outlet 31, on a foraminous or reticulated wire screen conveyor 32. The speed of device 30 is regulated to automatically feed the rice out at the end of the hydrating period and maintain a constant slow flow. In passing from the outlet 31, the stream of hydrated rice may be subjected to an air blast from nozzle 34 which aids in draining the excess hydrating liquid from the rice. The hydrated grains of 75 rice are spread evenly on the conveyor in a layer 12 mm. to 24 mm. (one-half inch to one inch) thick by means of the spreader 46 which is positioned above the conveyor adjacent the area in which the rice is deposited from the 80 outlet 31, and this spreading action also assists in removing excess liquid.

A drain tank 36 is positioned under the hydrator outlet 31 and spreader 46 and beneath the adjacent part of the conveyor 32 to 85 receive the excess hydrating liquid and direct it to a sump 38. An

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automatically controlled pump 40 lifts the excess hydrating liquid from the sump and forces it through a filter 42 which removes loose particles of starch, 90 broken grains, and other foreign material carried with the hydrating liquid. The filtered liquid is pumped through pipe 43 back to the supply tank 22 for re-use in the continuous process for treating the rice. Practically all of 95 the excess solution is taken from the rice which only retains that part of the hydrating solution which has permeated into the interior of the grain.

The moving layer of rice is carried by the 100 conveyor 32 into a gelatinizer 50, more clearly shown in Figure 2. The gelatinizer comprises an open-topped tank 52 positioned under the conveyor screen 32 and having steam pipes 54 disposed therein for its entire 105 area, said pipes preferably being submerged in a water bath. The steam pipes 54 are each perforated or otherwise fashioned to permit steam to escape and rise through the water bath to produce wet steam which rises through 110 the foraminous conveyor 32 and through the layer of moving rice carried thereon. At the entrance end of the gelatinizer are positioned one or more series of hot water spray nozzles 56 disposed above the conveyor 32 and spaced 115 at such intervals, in accordance with the speed of the conveyor, as to direct continuously wvater sprays downwardly upon the rice with a time interval of 15 seconds between sprays during its movement. 120 The nozzles 56 preferably are inclined to direct the sprays downvardly at an angle of and in the direction of movement of the conveyor 32. One or more series of nozzles 58 are similarly positioned over the conveyor 125 at the exit or other end of the gelatinizer 50, and these spray cold water (10.550) upon the rice. These water nozzles are fewer in number and preferably located farther apart so that the rice will be sprayed at this 130 -- 4 990,063 a more efficient action by both sprays and the steam. This, too, results in more uniform gelatinization, and this occurs under both the sprays. In addition, this slight agitation separates the grains or kernels, one from another, and helps to prevent their adherence to each other while in a gelatinized state.

At the completion of the second stage of gelatinization, the rice is cooled by blasts of cold air issuing through nozzles j68 positioned above the conveyor 32. The rice is cooled sufficiently to lower its temperature to 20 to 40 C. and to lower the moisture content of the rice from the 50-65% obtained during gelatinization to 40-55%. The cold air also removes excess liquid from the rice into the drain tank 70. After this partial cooling of the rice, additional enrichment materials in solution or powder form may be sprayed upon the rice from the nozzle 72 if such is desired, or if, for some convenient reason, they have not been added in the hydrator 20.

Alternatively, the rice grains may be cooled at the completion of the second stage of gelatinization with water at a temperature 10 to 55C C. The cooled rice grains may then be drained and/or cold air may be blown through the bed of rice particles to remove excess liquid. The cooled rice grains may then be dried with hot air at a temperature of 801400 C. to a final moisture content in the range of 10-

14%.

Referring to Figure 3, tin. finished rice kernels 76 have the appearance to the naked eye of normal rice or other quick-cooking rice products. However, when examined under a microscope, it will be seen to contain a large number of minute cracks or fissures disposed in both horizontal and vertical directions, and irregularly spaced. The cause of these cracks or fissures is not definitely known but, as shown in

Figure 4, she cracks extend from the surface inwardly toward the heart or core of the kernel.

The kernels or grains are firm and hard, and retain their shape and form until placed in boiling water.

The cracks or fissures in the kernels facilitate rapid moisture penetration and rehydration so that preparation for table use is very quick.

Another embodiment of the invention will now be described. Referring to Figure 5, hydrated rice which has preferably been fissured as described above (moisture content 25 to 40%) is fed into a distributor hopper 77 by which the rice is evenly distributed on a reticulated belt 32. The thickness of the layer of rice may be 12 mm. to 24 mm. (one-half to one inch). Belt 32 is moved by drive wheels and 62 and enters a gelatinizing chamber 78 which may be, for example, 12 meters (40 feet) long, 50 cm (20 inches) high, and 1 meter (39 inches) wide. The chamber is fitted with a dust-tight cover shown in cross-sectional view in Figure 6. The bottom of the chamber stage once every 30 seconds. Both hot and cold water sprays are preferably very fine and in the form of mist. The movement of the conveyor belt 32 is regulated by the speed of S rotation of drive wheels 60 and 62 which are preferably centered

50 feet apart. The rice on the conveyor screen 32 moves through the gelatinizer 50 in a total period of

923/2197

from 6-20 minutes, the two water spray stages each lasting 3-10 minutes The tank 52 is provided with a drain pipe 64 positioned above the level of the steam pipes 54. Preferably the steam pipes are surrounded by water to the level of the drain 64 so that the steam from the pipes rises through this water as wet steam. However, if desired, and under certain conditions, the steam pipes may be operated without surrounding water so that dry steam, rather than wet steam, passes upwardly through the rice during gelatinization. For this purpose, a second drain pipe 65 is provided in the bottom wall of the tank 52 and is controlled by a valve 67.

A vapor-catching hood 66 is positioned above the hot and cold water sprays to re-direct condensed steam and moisture from the water sprays downwardly through the rice and conveyor into the tank 52.

In the first stage of gelatinization, rice on the conveyor 32 is continuously subjected to wet steam from below and hot water sprays every 15 seconds from above, for a period of 3-10 minutes. This provides the rice grains with just enough excess water at an appropriate temperature for proper gelatinization.

Thus the grains acquire the gelatinization temperature first at their outer surfaces and gradually at their inner portions, and are provided with a sufficient amount of excess water at an elevated temperature during the period to permit substantial gelatinization.

In the second stage of gelatinization, the rice is also continuously subjected to steam from below for

3-10 minutes, but the cold water sprays are positioned to contact the rice every 30 seconds. The cold sprays act to momentarily lower the temperature at the outer surface portions of the rice grains, but during the periods in which the rice moves from under one spray to the next, the wet steam imparts heat so that gelatinization temperature is again acquired not only by the surface portions of the grain but also by the whole grain just before another spraying with cold water occurs. By thus intermittently stopping the gelatinization of the outer portions of the grain during the second stage of gelatinization, overgelatinization on the outer surfaces during the first stage is prevented and more uniform gelatinization throughout the grain is obtained.

The inclined direction of the water sprays and the slight pressure of the spray or mist on the bed of moving rice momentarily disturbs and separates the rice grains affording 990,06,3 is partitioned to form compartments A, B and C to hold water at several different levels and constructed in such a way that one level will overflow in a direction substantially opposite to the direction of travel of the upper flight of the conveyor belt 32 to the next and the last to the sewer or solids recovery system.

Means (not shown), for example, perforated steam pipes, are provided to heat the water in the chamber so that the temperature of the water rises gradually in compartments C, B, A to any desired temperature up to boiling and provide an atmosphere of wet steam over the water. Also means, not shown, are provided to move and guide the reticulated belt into and out of each compartment at a given rate of speed, allowing a predetermined immersion time and steaming period.

The hydrated rice on belt 32 is immersed in the first compartment A containing water at a temperature above 550 C., preferably boiling water, where it is held for 15 to 25 seconds. Then the belt is moved upwardly and out of the water into a steam atmosphere, remaining therein for 50 to 90 seconds. This action is repeated four more times in compartments B and C subject to the proviso that water in compartment C has a temperature below 550 C., e.g. between 10 and 550 C. The total time for the gelatinization is 5 to 12 minutes. The intermittent immersion and draining provides the rice grains with sufficient water to gelatinize them and also to gelatinize the inner portions without over gelatinizing the outer portions.

The gelatinized rice is now sprayed at 79, with water having a temperature of 20 to 850 C. to remove loose starch. The moisture content of the rice at this stage is 45-65 ,'.

As belt 32 leaves the gelatinizer 78, a streamof air (temperature up to 600 C.) at 80, is blown underneath and through the bed of rice to loosen up the grains and stop gelatinization.

The moisture content of the rice grains is now 40-60%. The rice grains are now transferred to a conventional drying system shown in Figure 7. The empty returning belt is subjected to an air blast at

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81 to remove adhering particles, then washed at tvo stages at 82 and returned to the head end of gelatinizer 78.

The gelatinized rice now enters a drier 83 shown in Figure 7. This drier may be a travelling belt drier, as shown diagrammatically, wherein hot drying air flows either countercurrently or cocurrently over and also through the reticulated belt conveying the rice. The rice is dried to a moisture content of 15 to

25 per cent to permit further conveying of the rice grains without adhering to each other.

Next the rice is transferred to a classifier 84 wherein the fine material is removed first.

The fine material may be used as a pregelatinized food product. The whole rice grains from the classifier 84 are transferred to a proportioning feeder 85 from which they enter a tumbler mixer 86.

Flavoring and coloring materials and nutritional additives are prepared either in tank 87 or in tank 88.

These materials are metered in metering 70 pump 89 which is regulated by feeder 85 to obtain the desired amount of each to be added to the rice. From the metering pump, the said materials are sprayed in stages upon the rice in tumbler 86, thereby providing a uniform 75 coating or adsorption of the materials on or into the rice, as will be described hereinafter.

The rice now enters another drying system similar to 83 described above where it is dried to a moisture content of 10 to 14 per cent. 80 The agglomerated material or lumps leaving classifier 84 are transferred to a hopper 90, then through a disc separator 91 from which they are returned to the classifier 84.

The finished rice kernels have the same desirable properties heretofore described.

Referring to the addition of flavoring, coloring and enriching materials these, if not already in solution, are dissolved or dispersed in aqueous medium. For example, tomato 90 powder or paste is dissolved in water to a solids content of 14 to 15 per cent. To this is added, as desired, flavoring materials (e.g.

onion or garlic), additional coloring materials (carotene), vitamins, and minerals. It may be 95 desirable, also, to add a protein supplement, for example, a vegetable protein, such as soya protein. The proteins may be in whole or hydrolyzed form. The resultant liquid mixture containing the abovementioned materials 100 is then sprayed, in several stages, upon the rice. The moisture content of the rice is preferably 15 to 25 per cent for this operation but it may be as low as 10 per cent. Between each spraying the rice is allowed a period of time 105 in which to absorb the soluble materials and for the dispersed materials to be imbedded in the surface of the rice grains. The resultant surface coating, upon being dried, sets to a firm coating and does not come off, upon 110 handling for packing and shipping.

Moreover, although the coating is easily penetrated by water upon cooking, it remains substantially on the grain.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS:- 115

1. A process for preparing a quick-cooking rice product which comprises hydrating rice grains with an aqueous medium at a temperature below the gelatinization temperature of the rice until the moisture content is increased 120 to between 25 and 40/, by weight, partially gelatinizing the hydrated rice over a period of 3 to 10 minutes by intermittently continuing hydration of the rice with water having a temperature of at least 550 C and intermittently maintaining the rice in an atmosphere of steam, continuing gelatinization for an additional period of 3 to 10 minutes by intermittently continuing hydration of the partially gelatinized rice with water having a tem990,063 6 tinization of 85 to 95% during a period of 3 to 10 minutes by passing wet steam upwards and continuously through said moving layer while directing spaced apart sprays of cold water upon said layer from above, cooling the rice to a temperature less than 550 C, and drying the rice to a moisture content of 10 to 14%.

6. The process according to claim 4 or 5, wherein the water sprays are applied in the form of a fine mist.

925/2197

7. The process according to claim 5 wherein the gelatinized rice is first dried for approximately five minutes at a temperature of approximately 1050 C to a moisture content of 20 to 25% and finally dried further to a moisture content of 10 to 14%.

8. The process according to claim 5 wherein said moving rice is subjected to hot water sprays spaced apart so as to strike the rice every 15 seconds during said first stage of gelatinizing and to cold water sprays spaced apart so as to strike the rice every 30 seconds during said second stage of gelatinizing.

9. The process according to claim 5 wherein said hot and cold water sprays are directed downwardly in the direction of movement of the rice at an angle of 450.

10. The process for preparing a quickcooking rice product substantially as herein described with particular reference to the examples.

11. A quick-cooking rice product produced by a process according to any of the preceding claim.


Applicants.

perature below 550 C and intermittently keeping the rice in an atmosphert of steam, whereby overgelatinization of the portion already gelatinized is avoided.

2. The process according to claim 1, wherein the rice grains are hydrated at a temperature in the range of 20 to 550 C.

3. The process according to claim 1 or 2, wherein the rice graiis are partially gelatin.

ized by intermittently immersing the hydrated rice in water at a temperature of at least 550 C and in said atmosphere of steam and gelatinization is continued by intermittently immersing thie partially gelatinized rice grains in water having a temperature between 10 and 550 and in said atmosphere of steam.

4. The process of claim 1 or 2, wherein the rice is partially gelatinized by passing steam upward through a layer thereof and intermittently spraying water at a temperature of at least 550 C on the top of the layer and gelatinization is continued by passing steam upward through the layer of the partially gelatinized rice grains and intermittently spraying water thereon having a temperature between and 550

C 5. A process for producing a quick-cooking rice product which comprises hydrating milled grain rice with water at ambient temperature for a period of 30 to 120 minutes to increase its moisture content to between 25 and 40% by weight, partially gelatinizing a moving layer of the hydrated rice in a first stage during a period of 3 to 10 minutes by passing wet steam upwards and continuously through said moving layer while causing said layer intermittently to come into contact with hot water sprayed from above, in a second stage further gelatinizing said rice to a total gelaLeamington Spa: Printed for Her

Majesty's Stationery Office, by the Courier Press (Leamington) Ltd.-1965. Published by The Patent

Office, 25 Southampton Buildings, London, W.C.2, from which copies may be obtained.


926/2197

195.

GB990747 - 4/28/1965

IMPROVEMENTS IN OR RELATING TO CRISP, READY-TO-EAT FOODS


Inventor(s): GERKENS DIRK RENEE D ARNOUD (--)

Applicant(s): NIBB IT PRODUCTS ASS LTD (--)

E Class: A23L1/164E; A23L1/217B



Family: GB990747

Abstract:


Crisp, ready-to-eat, expanded foods are made by extruding, under a pressure of at least 6 atmospheres, strands of a 25-40% water mix of starchy flour, from, e.g. potato, tapioca, rice, which has not less than

30% of the starch not enclosed in cell walls, drying the strands in air to a mean water content of less than 10% with a horny outer layer of water content not more than 85% of the mean water content, breaking the strands, and expanding the pieces by frying in hot fat or oil. Salt or curry powder may be added before the extrusion. The dried intermediate may have 8-18% water content in the centre, and 4-

8% in the horny outer layer. The dried intermediate may be stored, and be re-dried before the frying.

The expanded product has less than 20% fat content. Specification 822,018 is referred to.

927/2197

196.

GB992376 - 5/19/1965

METHOD OF PROCESSING WHEAT


Inventor(s): ROBBINS DEWEY H (--)

Applicant(s): FISHER FLOURING MILLS CO (--)

E Class: A23L1/182



Family: GB992376

Abstract:


In producing a pre-cooked wheat product, wheat grains are cleaned to remove dust, dirt and chaff, treated with water and steam, e.g. in three stages each of several hours duration, until they contain between 40 and 45%, by weight, of moisture and attain a temperature of the order of 200 DEG F., steamed in steam at a pressure between 10 and 30 p.s.i. for 30 to 90 seconds, to gelatinize the starch therein, cooled, e.g. to a temperature between 160 and 170 DEG F., in a current of hot air, dried, e.g. in hot air at 120 to 160 DEG F., until they attain a moisture content of the order of 10%, then pearled, cracked and sifted to remove fines and bran. The product can be prepared for eating in a manner similar to pre-cooked rice.Description:



DRAWINGS ATTACHED.

Inventor: -DEWEY H. ROBBINS.


Jan. 20, 1964. No. 2343/64.

Complete Specification Published: May 19, 1965.


ERRATUM SPECIFICATION NO. 992,376

AENDMENT NO. 1 Page 2, line 125, after "Then delete,tern-"i Page 3, line 42, for "gelatizined" read

"gelatinized" THE PATENT OFFICE, 26th January, 1966 wnicn it is to De pertormea, to De particularly described in and by the following statement:-

This invention relates to a method for processing wheat whereby the processed wheat product can be readily prepared and eaten in a manner similar to pre-cooked rice.

It is an object of this invention to provide a new and improved, continuous method of processing the whole berry or kernel of wheat in a manner which will make it readily consumable and appetizing.

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Another object of this invention is to provide a new and improved method for processing wheat which retains the natural and inherent nutritional properties in the processed wheat product.

The method of processing wheat comprises the following steps: The wheat is first cleaned and the chaff is removed. It is then subjected to a treatment whereby the moisture content of the wheat berry is substantially increased to within a critical range. The wheat is then steamed for a short interval of time and then cooled and dried. After drying, the product is then pearled, cracked, screened and packaged for storage or shipment.

The purpose of the treatment which characterizes this invention, is to gelatinize the starch in the wheat berry and thereby reduce the cooking time required to prepare the product for eating by the consu[Price

4s. 6d.] contameci tnerem will be converted to dextrin, or will be burned in the later stages of the treatment. It is, therefore, a critical step in the method of processing the wheat, to first increase the moisture content so as to permit further processing without destroying the nutritional value or causing other detrimental transformation of the wheat.

The first step in the process, namely, the cleaning of the wheat is accomplished by conventional processes. The wheat berry is first cleaned by a dry process whereby the loose dust, dirt and chaff are removed and after these dry foreign substances have been removed, the wheat berries are washed in tap temperature water to remove remaining dust and dirt.

After the wheat berries have been thoroughly cleaned, they are conveyed to the next stage where the moisture content thereof is substantially increased from a normal moisture content of approximately

10% to within the range of 40% to 45%.

(Percentages are by weight, throughout the specification).

In the method illustrated by way of example in the flow diagram of the accompanying drawings, the wheat is moved through a conveyor and steam is injected into the conveyor to raise the temperature of the wheat to approximately 1250F. From the conveyor, the heated and water-laden wheat is discharged into a large tank. The 992,376 it1 D 60854/9 PATENT SPECIFICATION

DRAWINGS ATTACHED.

Inventor:-DEWEY H. ROBBINS.


Jan. 20, 1964. No. 2343/64.

Complete Specification Published: May 19, 1965.

) Crown Copyright 1965.

Index at Acceptance:-A2 Q(3A, 3B, 13, 14X, 16A, 16D, 17).

Int. CL:-A 23 L 1/10.


Method of Processing Wheat.

We, FISHER FLOURING MILLS Co. a corporation of the State of Washington, United States of

America, of 3235 16th Avenue S.W., Seattle, Washington, United States of America, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

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This invention relates to a method for processing wheat whereby the processed wheat product can be readily prepared and eaten in a manner similar to pre-cooked rice.

It is an object of this invention to provide a new and improved, continuous method of processing the whole berry or kernel of wheat in a manner which will make it readily consumable and appetizing.

Another object of this invention is to provide a new and improved method for processing wheat which retains the natural and inherent nutritional properties in the processed wheat product.

The method of processing wheat comprises the following steps:The wheat is first cleaned and the chaff is removed. It is then subjected to a treatment whereby the moisture content of the wheat berry is substantially increased to within a critical range. The wheat is then steamed for a short interval of time and then cooled and dried. After drying, the product is then pearled, cracked, screened and packaged for storage or shipment.

The purpose of the treatment which characterizes this invention, is to gelatinize the starch in the wheat berry and thereby reduce the cooking time required to prepare the product for eating by the consu[Price

4s. 6d.] mer. To accomplish this result, it has been found that additional moisture must be absorbed, and completely penetrate, into the cleaned wheat berry prior to carrying on subsequent steps or stages.

If the moisture content of the wheat berry is not increased to within the prescribed range, the starch contained therein will be converted to dextrin, or will be burned in the later stages of the treatment. It is, therefore, a critical step in the method of processing the wheat, to first increase the moisture content so as to permit further processing without destroying the nutritional value or causing other detrimental transformation of the wheat.

The first step in the process, namely, the cleaning of the wheat is accomplished by conventional processes. The wheat berry is first cleaned by a dry process whereby the loose dust, dirt and chaff are removed and after these dry foreign substances have been removed, the wheat berries are washed in tap temperature water to remove remaining dust and dirt.

After the wheat berries have been thoroughly cleaned, they are conveyed to the next stage where the moisture content thereof is substantially increased from a normal moisture content of approximately

10% to within the range of 40% to 45%.

(Percentages are by weight, throughout the specification).

In the method illustrated by way of example in the flow diagram of the accompanying drawings, the wheat is moved through a conveyor and steam is injected into the conveyor to raise the temperature of the wheat to approximately 1250F. From the conveyor, the heated and water-laden wheat is discharged into a large tank. The 992,376 wheat enters the tank at the top and is removed by a conveyor from the bottom.

In the apparatus now being utilized, three separate tanks are employed and the wheat progresses from the first tank to the subsequent tanks in a continuous process.

It requires several hours for the wheat to move downwardly in the first tank from top to bottom and then be carried to the second tank. During the treatment in the first tank, the moisture content is increased from approximately 10% to approximately 25%.

The wheat is conveyed by a horizontal conveyor from the bottom of the first tank to the top of the second tank and while in this horizontal conveyor, the wheat is sprayed with water and steam is injected to increase the temperature to approximately 150IF.

In each stage of the multiple tank treatment, the wheat will absorb substantially greater quantities of water. When removed from the second tank, the moisture content of the wheat is raised to between

35% to 40%. It requires several hours for the wheat to progress through the second tank and from this it is conveyed to the third tank.

In the third tank, the temperature is increased to between 160'F and 1650F.

930/2197

Passage of the wheat through this tank takes several hours. When removed from the third tank, the moisture content of the wheat is between 40% and 45 .'. The movement of the wheat from one tank to another is synchronised so as to provide substantially the same quantity of wheat in each tank at all times.

From the third tank, the wheat is conveyed by a screw conveyor in the presence of steam, to the cooker. In the conveyor, the temperature is increased to about 200' F. The wheat remains in the conveyor for 20 to 30 seconds.

When the wheat leaves the conveyor, the moisture has completely penetrated the wheat and it flows by gravity to a continuous process, pressure steamer. It is preferable to use a steamer tunnel which is upwardly inclined at about 25 from a point where the wheat enters. The wheat is advanced through the steamer from the forward, lower end to the upper, discharge end. The steamer presently in use is approximately twelve feet long. At each end of the steamer, is a rotary valve type pressure lock; the wheat is fed into the valve at the receiving end, and the valve revolves to deposit the wheat into the steamer.

The steamer is maintained under a continuous pressure of between 10 psi and psi and the steaming and cooking treatment is carried on from between 30 seconds to 90 seconds. It will be appreciated that

65 if the pressure is increased the time of treatment in the steamer may be decreased and if the pressure is decreased, the time of treatment will be increased. It is desirable to use the lowest possible pressure so as to 70 assure that there will be no burning of the product and it has been found that a better product can be produced when the lower pressure in the neighbourhood of 15 psi is used for approximately 60 seconds. At the 75 upper end of the steamer, a similar pressure lock is employed so that the steamer will be maintained under constant pressure and yet permit ready removal of the wheat.

The wheat discharged from the pressure 80 lock at the upper end of the steamer is conveyed to a cooler. The cooler comprises a long cylinder equipped with a series of internal helical fins or ribbons.

The cylinder is rotated so that the fins cause the wheat 85 to advance. The tumbling of the wheat by the rotation of the cylinder prevents the wheat from becoming stuck together. While the wheat is moving through the cooler, a continuous blast of hot air of approximately 90 400'F is introduced into the cooler at one end. The hot air evaporates some of the moisture from the surface of the wheat, and at the same time the evaporation cools the wheat. The evaporation is such that the 95 wheat leaves the cooler at a temperature of between 1600 F and 170 F.

From the cooler the wheat is conveyed to dryers. It has been found preferable to use columnar dryers through which the 100 wheat is caused to tumble downwardly. Hot air is injected into the dryers and substantially all excess moisture is removed from the wheat. In the preferred method, it has been found most satisfactory to use three 105 dryers, but a single, larger dryer may be used, or two dryers may be used. It has been found preferable to use a time interval in the first dryer of from 60 to 90 minutes at a temperature of approximately 150'F to 110 1600 F.

After the wheat comes from the first dryer, it may be conveyed directly to the second dryer or may move slowly in a conveyor for 20 or 30 minutes. During the interim between dryers, the moisture equalizes between the surface and internal portion of the wheat. The wheat passes through the second dryer in from 60 to 90 minutes. The temperature in the second 120 dryer is 1500 to 1600 F. After the second dryer, there can, if desired, be an equalizing period before the wheat enters the third dryer. The wheat passes through the third dryer in from 90 to 180 minutes. The temtemperature in the third dryer is between 1200 and 1400 F. After the processed wheat has passed through the third dryer, it has a remaining moisture content which is sub992,3,76 in the wheat to be washed is deposited.

Subsequent to its being washed, the wheat is removed from the washer and discharged from the higher end of the upwardly inclined box by a screw conveyor 12. The 70 conveyor discharges the washed wheat into a chute 13 that feeds into a horizontal screw conveyor 15. The conveyor 15 discharges into a settling tank 20. Feeding into the screw conveyor 15 is a steam line 17. 75 Sufficient steam is injected into the conveyor 15 from the line 17 to increase the wheat temperature to approximately 125 F.

931/2197

Wheat received from the conveyor 15 into the top of the tank 20 settles downwardly as wheat is removed from the bottom of the tank; removal being effected by a screw conveyor 21. Water and steam lines 22 and 23, respectively, supply a spray of water and the required steam in conveyor 21. The wheat is discharged from conveyor 21 into the top of settling tank 24.

It is removed from the bottom of this tank by a horizontal conveyor 25 and discharged into the top of the third settling 90 tank 28. Steam and water are admitted by lines 26 and 27 into the conveyor 25.

When the wheat is removed from this tank, its moisture content has been increased to between 40% and 45%. 95 From the tank 28, the wheat is conveyed by means designated by numeral 30, which might be a combination of screw conveyor and bucket conveyor, to a horizontal screw conveyor 31.

Steam is injected into this 100 conveyor 31 through a pipe line 32 so as to further increase the temperature of the wheat.

From the conveyor 31, the wheat passes into and through a pressure steamer designated in its entirety by reference numeral 40. The steamer is upwardly inclined from its lower, receiving end toward the upper discharge end and a screw 41 is provided therein to move the wheat through the 110 steamer.

Pressure locks 42 and 43, preferably of rotary valve type, are provided at the entrance and discharge ends of the steamer so as to permit the receipt and discharge of the wheat and at the same time 115 maintain the required and desired pressure.

A steam supply line 44 is provided for the admission of steam into the steamer and the steam pressure is maintained at between psi and 30 psi. The time required for 120 moving the wheat through the steamer is between 30 seconds and 90 seconds. During the treatment and processing of the wheat through the steamer, the moisture content of the wheat is approximately 45 %. 125 When the wheat is removed from the steamer through the pressure lock 43, it passes to a cooler comprising a rotating cylindrical body 50 and it is conveyed through the cooler. (It should be understantially normal, that is, approximately 10%.

From the third dryer, the wheat is conveyed to a pearler. This is a conventional piece of equipment commonly used in flour mills, for the purpose of removing the loose outside hulls and the fibrous outer bran. The cooled and pearled wheat passes through a two-stage cracking machine. In the first stage the majority of the wheat is cracked and in the second stage, the coarser uncracked wheat is removed by screening so that the finer material may be separated. In the screening process the fines or dust-like particles are removed and the desired end product is packaged for storage or shipment. The total product produced is between 85% and 90% of the original wheat. The remaining 10% to 15%' is the bran and fines and they may be packaged and sold as animal feed.

The product packaged is edible and palatable as rice and may be prepared as a food product in many ways. It may be readily stored and transported in one hundred pound sacks or other containers of desired sizes and kinds. The product is an excellent food substance and a substitute for rice or similar grain products.

It will be appreciated that various types of equipment and alternative methods may be used to increase the moisture content of the wheat prior to its being subjected to the substantial heat or temperature in the steamer. As has been previously stated, it is necessary that the wheat contain a substantial quantity of moisture, at least within the range of 40% to 45%, so that when subjected to heat, the starch, in the presence of the absorbed and completely penetrated moisture in the wheat, will be properly gelatizined and will not be transformed or converted into dextrin, as would be the case if the moisture were not present.

Similarly, the specific treatment may be altered both as to time and temperature without departing from the invention.

The accompanying drawing illustrates in a schematic manner the positioning of the various items of equipment used in carrying on the several steps or stages of the process. As previously stated, this equipment may be altered in design and number of multiple units so long as the required moisture and content and complete penetration is accomplished, prior to the steaming or cooking stage. All of the equipment presently employed is conventional, readily available commercial equipment used in flour mills and other grain processing plants.

932/2197

Referring more in detail to the drawing:

The washer is shown as a whole by 10 and it includes as a part thereof, an upwardly inclined boxlike structure 11 where992,376 stood that the body 50 is shown purely diagrammatically). Hot air is provided by the heater 51 and drawn into the cooler through an inlet 52 at its outlet end, by means of a suction fan 53 located at the other end of the cooler. The rotating cylindrical body includes a series of internal helical fins or ribbons 54 which cause the wheat to be moved forwardly in the cooler as the cylindrical body rotates and at the same time the wheat is tumbled to prevent the wheat berries from becoming stuck together.

After the wheat passes through the cooler 50, it is conveyed to a series of dryers by conveying means

55. The dryers are designated respectively 56, 57 and 58.

The wheat first passes through the dryer 56 and from there is conveyed by a conveyor 60 to the top of the second dryer 57.

If such is desired, the rate or speed of conveyance can be such that the wheat remains in the conveyor

60 for 20 to 30 minutes so as to permit the remaining moisture to equalize throughout the wheat berries. The same can be done in the conveyor 61 between the second and third dryers. Hot air is supplied to the dryers through the air vents 62-62 positioned in vertical spacing along the sidewalls of the dryers. The wheat enters each of the dryers at the top, and baffles 64 are provided therein which cause the wheat to be tumbled as it falls. The dryers are of substantial size and it requires approximately one to three hours for the wheat to pass through each dryer. The hot air blown into the dryers ranges in temperature from 1200 F to 1600 F. When the wheat has been run through the third dryer, its moisture content will have been reduced approximately to normal, that is, to about ten percent. From the third dryer, the wheat is conveyed by conveying means 65 to a pearler or huller 70.

This is merely a conventional machine and in the drawing is merely represented by a rectangular box.

From the pearler, the wheat passes to a grinder or cracker 71 and from the grinder to a sifter 72. In the sifter, the desired product is separated from the fines and is carried away to a packaging station (not shown) by a conveying means 73. The fines and bran are removed through the conveying means

74.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT WE CLAIM IS: -

1. A method of processing wheat comprising cleaning the wheat; simultaneously increasing the temperature of the wheat to approximately 200'F and the absorbed 60 moisture to between 40% and

45%; steaming the moisture laden wheat under a pressure of between 10 psi and 30 psi for between 30 seconds and 90 seconds; cooling the wheat by flowing hot air through 65 the moisture-laden wheat; drying the wheat and thereby reducing the moisture content to approximately 10%; and then pearling, cracking and screening the wheat to separate the fines and bran from the processed wheat product.

2. A method of processing wheat according to Claim 1 wherein the operations are continuous and follow each other without delay. 75 3. A method of processing wheat according to Claim 1 wherein the treatment of the cleaned wheat to increase its moisture content and temperature is in three stages each of several hours duration. 80 4. A method of processing wheat as in Claim 1 wherein the drying is accomplished in multiple dryers and a substantial time interval is provided during the movement of the wheat between the dryers. 85 5. A method of processing wheat as in Claim 1 wherein the steaming of the wheat is accomplished at approximately 15 psi for approximately 60 seconds.

6. A method of processing wheat 90 substantially as herein described, with reference to the accompanying drawing.

WITHERS & SPOONER, Chartered Patent Agents, 148-150, Holborn, London, E.C.1.


933/2197

Abingdon: Printed for Her Majesty's Stationery Office, by Burgess & Son (Abingdon), Ltd.-1965.

Published at The Patent Office, 25 Southampton Buildings, London, W.C.2, from which copies may be obtained.


934/2197

197.

GB993757 - 6/2/1965

A METHOD OF TREATING MATERIAL TO REDUCE THE COUNT OF

ORGANIC LIFE THEREIN


Applicant(s): GRIFFITH LABORATORIES (--)

E Class: A23L1/025B; A23L3/3418; A23L3/3445; A61L2/20E



Family: GB993757


Abstract:


In treating a mass of material having porosity for the passage of gas therethrough in a closed chamber with a gas to reduce the count of organic life in the material, the gas is given a pulsating movement in the chamber by repeatedly changing the overall gaseous pressure in the chamber between higher and lower effective treating pressures. The repeated changing of the overall gaseous pressure may be effected continuously by alternately pumping gas into and out of the chamber, by the movement of a plunger in and out of the chamber, or by operation of an inflatable balloon or metal bellows. Two gas pumps giving an irregular cycle having a greater amplitude than the cycle of each may be operated for a short time at the beginning of a treatment period. Materials specifically mentioned; tobacco, spices such as ground red pepper or paprika, cocoa, flour, rice, grains, starch, dehydrated vegetables, seeds, nuts and nut meats, raisins, prunes and apricots. According to an example ground red pepper is packed in a 300 pound drum, 22 inches in diameter and 36 inches high, lined with two layers of polyethylene film impervious to propylene oxide; the drum so packed is placed alone in a chamber of dimensions 6 x

3,5 X 13 feet. The chamber with a wall temperature of 110 DEG F., is sealed and evacuated to a vacuum of 29 inches of mercury and into the evacuated chamber there is introduced 40 pounds of propylene oxide gas, thereby reducing the negative pressure to 14 inches. Gas is introduced and removed so as to change the pressure in 10-minute regular cycles for three hours, between the limits of

14 and 16 inches of mercury; the chamber is then evacuated to a pressure of 29 inches of mercury, flushed with air and opened. Samples were taken at the top, middle and bottom of the drum for counting the surviving bacteria, yeasts and moulds per gram. In a control experiment the pressure in the chamber is kept static over the three hour treatment period. In other examples, the negative pressure was changed (2) in 30-minute regular cycles between the limits of 12 and 23 inches of mercury, (3) in

7-minute cycles involving departures of 1 to 2 inches from 14 inches of mercury and (4) to give 13 cycles per hour involving pressure changes between 9 and 11 inches of mercury.ALSO:In treating a mass of material having perosity for the passage of gas there-through in a closed chamber with a gas to reduce the count of organic life in the material, the gas is given a pulsating movement in the chamber by repeatedly changing the overall gaseous pressure in the chamber between higher and lower effective treating pressure. The repeated changing of the overall gaseous pressure may be effected continuously by alternately pumping gas into and out of the chamber, by the movement of a plunger in and out of the chamber, or by operation of an inflatable balloon or metal bellows. Two gas pumps giving an irregular cycle having a greater amplitude than the cycle of each may be operated for a short time at the beginning of a treatment period. Materials specifically mentioned: tobacco, spices such as ground red pepper or paprika, cocoa, flour, rice, grains, starch, dehydrated vegetables, seeds, nuts and nut meats, raisins, prunes and apricots. According to an example ground red pepper is packed in a 300 pound drum, 22 inches in diameter and 36 inches high, lined with two layers of polyethylene film impervious

935/2197

to propylene oxide; the drum so packed is placed alone in a chamber of dimensions 6 x 3.5 x 13 feet.

The chamber with a wall temperature of 110 DEG F., is sealed and evacuated to a vacuum of 29 inches of mercury and into the evactuated chamber there is introduced 40 pounds of propylene oxide gas, hereby reducing the negative pressure to 14 inches. Gas is introduced and removed so as to change the pressure in 10-minute regular cycles for three hours, between the limits of 14 and 16 inches of mercury; the chamber is then evacuated to a pressure of 29 inches of mercury, flushed with air and opened. Samples were taken at the top, middle and bottom of the drum for counting the surviving bacteria, yeasts and moulds per gram. In a control experiment the pressure in the chamber is kept static over the three hour treatment period. In other examples, the negative pressure was changed (2) in 30minute regular cycles between the limits of 12 and 23 inches of mercury, (3) in 7-minute cycles involving departures of 1 to 2 inches from 14 inches of mercury and (4) to give 13 cycles per hour involving pressure changes between 9 and 11 inches of mercury.

936/2197

198.

GB994554 - 6/10/1965

METHOD OF AND APPARATUS FOR THE PRODUCTION OF A FOOD FROM

STARCH-CONTAINING MATERIAL


Applicant(s): HEINRICH FLESSNER (--)

E Class: A23L1/18B2; A23P1/14B2; A21C1/06B; B30B11/24


Priority Number: DE1962F037116 (19620620)

Family: GB994554

Equivalent: LU43890; CH413573; DE1217190

Abstract:


994,554. Extrusion apparatus. H. FLESSNER, [trading as HEINZ FLESSNER KOMM.-GES.]. June

18, 1963 [June 20, 1962], No. 24248/63. Heading B5A. [Also in Division A2] In making a food product, starch-containing raw material containing its normal amount, e.g. between 13% and 17% by weight, of moisture is fed, from a hopper 1, into the compression chamber 3 in the body 4 of an extruder and is heated therein and simultaneously compressed by a rotating screw 2, so that the food product emerges from the nozzle 5 of the extruder in a puffed or open, cooked, edible form, e.g. in the shape of a strip or rod, which may be cut into pieces of a desired length and allowed to harden. Speci- fied materials are : tapioca, potatoes and cereals such as maize' rice or wheat particularly in the form of grits or groats. The material may be heated by the heat of compression and, if necessary, by a heating device 7 on the body 4 whose temperature may be measured by devices 11 and 12 and regulated by a cooling device 6. The screw may be cooled by a device 9. The screw may have a polished, e-g. chromium-plated, surface. The inner surface of the chamber 3 may be roughened. It may be provided with longitudinal grooves and, if desired, with one or more grooves, each in the form of a screw thread of coarse pitch. The chamber 3 may have a uniform internal diameter and the diameter of the screw may increase continuously and its pitch may decrease in the direction leading to the outlet of the extruder. As shown in the drawing, the screw 2 and the chamber 3 may each have a curved converging taper in the direction leading to the nozzle 5. In an alternative construction the diameter of the screw increases, then decreases and again increases, in the direction leading to the outlet of the extruder, so that the material is subjected to pressure increments and to decreased pressure between them. When using maize grits containing 15% of moisture, the screw is rotated at 44 r.p.m., the

937/2197

temperature, at point 11, is 165 C. and, at point 12, is 145 C., the nozzle 5 has a diameter of 2 mm. and the puffed rod of extruded food product has a diameter of 8 mm. The extruded food product may be coated, e.g. sprayed, with cheese and/or peanut paste, e.g. containing edible oil or peanut butter, delivered through one or more nozzles located around the nozzle 5. Flavourings such as sugar or fruit essences may be mixed with the raw material or added to the material in the extruder between the screw 2 and the nozzle 5.Description:



DRAWINGS ATTACHED 994,554 Date of Application and filing Complete Specification June 18,

1963.

No 24248/63.

Application made in Germany (No F 37116 I Va/53 k) on June 20, 1962.

Complete Specification Published June 10, 1965.


Index at acceptance: -A 2 B( 1 B, 1 C, 1 J, IV, 1 W, 11); A 2 Q( 21, 22); B 5 A(IG 5 E, l G 9 A, G 10

G, 2 A 1, 2 A 2, 2 M) Int Cl -A 23 1 1/18//B 29 d COMPLETE SPECIFICATION

Method of and Apparatus for the Production of a Food from Starch-Containing Material PATENTS

ACT, 1949 SPECIFICATION NO 994,554

The following corrections were allowed under Section 76 on April 26th, i; 9 ?.

Page 1, delete "I, Heinrich Flessner, of German Nationality, trading as Heinz Flessner KG, a German

Body Cor-c ate of 17-19, Ludw Tigstrasse," insert "we, Red Dot Gesellschaft mit beschrankter

Hafltung a German body corporate of Zeil 23, 6000 Frankfurt/Maine, 1, Germany and Ibu-Rosterei

Gesellschaft mit beschrankter Haftung a German body corporate of Ludwigstrasse 19, 6078 ".

THE PATENT OFFICE, 25th May, 1967 D 86860/11 made from starch-containing material, water and possibly other additives, so as to obtain a fried food.

Another known method is to extrude starchcontaining material at a given moisture content by high pressure into strips of any length, which then have to be fried or grilled, either dry in air or wet in hot oil.

A puffed product has also already been made from starch-containing material by mixing the material for puffing and an evaporable liquid into a plastic state and then applying pressure to this mixture, for example in a cylinder in a hydraulic press This mixture flowing under pressure is then forced into a cylindrical chamber in which the material is heated to temperatures above the boiling point of the liquid and is broken open.

When the material emerges from the cylindrical chamber the overheated evaporable liquid is converted abruptly and instansame with e ancl r peanut pastes prepared approrliatc 17 with edidble oil or peanut 65 butter.

The producc S A,,,n d in the form of a strip or red and >; ' prcfcrably cut into pieces of "'-,r', ? length by a cutting device imnzdia elv fllow;n the nozzle aper 70 ture It has been found that the product prepared according to the invention is still flexible un to about 30 seconds after leaving the cuttina device and does not solidify to its finally hard and ready-cooked form until 75 after that time.

According to a further feature of the invention the material is subiected to pressure decrement between pressure increments.

938/2197

Moisture conrants of 13-170 ' by weight of 80 the m:_terial ar adv ntaecous.

It has l:::':i ver advantageous to use the startin-z:a;tert in the form of grits or g Pa i:r,,uitablestarting a.


DRAWINGS ATTACHED 99)4,554 Date of Application and filing Complete Specification June 18,

1963.

No 24248/63.

Application made in Germany (No F 37116 I Va/53 k) on June 20, 1962.

Complete Specification Published June 10, 1965.


Index at acceptance: -A 2 B( 1 B, IC, If, IV, IW, 11); A 2 Q( 21, 22); B 5 A(LG 5 E, 1 G 9 A, IG 10,

2 A 1, 2 A 2, 2 M) Int Cl: -A 23 1 1/18//B 29 d COMPLETE SPECIFICATION

Method of and Apparatus for the Production of a Food from Starch-Containing Material I,

HEINRICH FLESSNER, of German nationality, trading as Heinz Flessner KG, a German Body

Corporate of 17-19, Ludwigstrasse, Neu-Isenburg, Germany, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a method of and an apparatus for the production of a food from starchcontaining material.

It is known to prepare a dough from flour and water, with special additives if desired, and then to shape the dough by ejecting it from a nozzle, whereafter the product is dried.

Such "pasta", for example vermicelli of macaroni must be cooked or boiled to bring it into an edible form after shaping.

It is also known to fry in oil shaped parts made from starch-containing material, water and possibly other additives, so as to obtain a fried food.

Another known method is to extrude starchcontaining material at a given moisture content by high pressure into strips of any length, which then have to be fried or grilled, either dry in air or wet in hot oil.

A puffed product has also already been made from starch-containing material by mixing the material for puffing and an evaporable liquid into a plastic state and then applying pressure to this mixture, for example in a cylinder in a hydraulic press This mixture flowing under pressure is then forced into a cylindrical chamber in which the material is heated to temperatures above the boiling point of the liquid and is broken open.

When the material emerges from the cylindrical chamber the overheated evaporable __liquid is converted abruptly and instantaneously into vapour, so that the material to which it has been added expands and the volume of this material is enlarged many times.

The present invention is based on the surprising fact that starch-containing raw material of normal moisture content can, very rapidly and simply-and in a very simplified apparatus, be heated in the compression chamber or bush of an extruder and at the same time be subjected to continuously or discontinuously increasing pressure by a compression screw during the passage of the material through the said compression chamber of the extruder to cook the food and give it an edible opened or puffed

939/2197

form immediately it emerges from the extruder The entire preparation process takes less than one minute.

The taste of this product, which is ready for eating, can be varied somewhat by further process steps, for example by spraying the same with cheese and or peanut pastes prepared appropriately with edible oil or peanut butter.

The product is obtained in the form of a strip or rod and is preferably cut into pieces of appropriate length by a cutting device immediately following the nozzle aperture It has been found that the product prepared according to the invention is still flexible up to about 30 seconds after leaving the cutting device and does not solidify to its finally hard and ready-cooked form until after that time.

According to a further feature of the invention the material is subjected to pressure decrement between pressure increments.

Moisture contents of 13-17 % by weight of the material are advantageous.

It has been found very advantageous to use the starting material in the form of grits or g its

Particularly suitable starting materials are maize grits, rice grits, wheat grits and grits of other cereals

The method may however also be applied to starchcontaining tuber material which is advantageously brought into the form of grits or groats (for example) tapioca and potatoes, etc.

To shape the material, the same may be forced through a shaping nozzle after it has passed through the compression chamber of the extruder.

The method according to the invention greatly shortens the preparation and shaping process of foods on a starch-containing basis.

Tests have shown that the material requires, for example, only 40 seconds in the extruder from the time it enters the extruder until it emerges in the ready-cooked state.

To improve the continuous passage of the material through the extruder, it has been found advantageous to use a bush with a roughened inner surface.

It has also been found advantageous to provide the bush with longitudinal grooves open towards the screw, while one or more grooves may also be incorporated in the bush each in the form of a very coarse pitch screw thread.

A number of forms are possible for the screw and the associated bush in order to achieve the increasing pressure applied according to the invention.

For example, a cylindrical bush of uniform diameter may be used, in which operates a screw whose diameter increases continuously towards the outlet of the extruder i e the shaping nozzle.

The compression may also be increased by reducing the screw pitch in the direction of t Ie outlet of the extruder or by convergingly tapering the screw and the interior of the bush curve-wise towards the outlet of the extruder.

The pressure increments interpolated by pressure decrement can be obtained by an initial increase in the screw diameter, followed by a decrease and then another increase in the direction towards the outlet of the extruder.

It has also been found advantageous to make the screw as smooth as possible, i e, for example, with a polished surface, which may be chromium plated.

For appropriate control of the material temperature which is increased by the compression, the extruder is advantageously provided with cooling and heating means.

940/2197

To provide optimum energy conditions, the process may be so controlled that the heat required is drawn completely or practically exclusively from the heat due to compression.

An extruder device advantageously used for the method according to the invention is shown by way of example in the accompanying drawing.

Reference 1 denotes the entry hopper and reference 2 the feed screw which as shown is curved so as to taper towards the outlet of the extruder and operates in the compression chamber or bush 3 which is curved in the same way In the case illustrated, the ratio of the initial to the final compression exerted by the screw on the material is about 1:2 2.

Reference 4 denotes the extruder cylinder or body, 5 the shaping nozzle 6 a cylinder cooling system, 7 a cylinder heating system, 8 another cylinder cooling system and 9 a screw cooling system The screw itself is moved by the drive 10 References 11 and 12 are two temperature measuring stations.

In the case illustrated the screw is 680 mm long and the nozzle aperture has a diameter of 2 mm The inside diameter of the bush at the material inlet is 47 mm and the diameter of the screw is 36 mm The screw turn pitch is 39 mm The bush and the screw are curved to taper to 40 mm and mm respectively at the outlet end of the screw.

EXAMPLE

Maize grits with a moisture content at 15 % were used as starting material with a screw speed of 44 r p m The temperature at measuring station 11 was 165 C and at measuring station 12 was 1450 C.

The finished product was obtained at high speed from the 2 mm nozzle in the form of a rod which assumed a diameter of about 8 mm after leaving the extruder The initially still flexible product solidified after about 30 seconds to a hard ready-cooked state.

The rod was cut into lengths of 5 cm by a rotating cutter.

The finished product may be coated, e g.

sprayed with cheese, peanut or other pastes for example by the use of one or more nozzles disposed around the shaping nozzle which provide the finished product with the appropriate paste after the finished product has emerged from the shaping nozzle.

Flavouring substances, for example sugar or fruit essences, may already be added to the starting product or be added at the end of the compression screw before the material passes through the nozzle.Data supplied from the esp@cenet database - Worldwide Claims:


WHAT I CLAIM IS:-

1 A method of producing a food from starch-containing raw material by the application of heat and pressure, characterised in that the material of normal moisture content 120 is heated in the compression chamber or bush of an extruder and is simultaneously subjected to continuously or discontinuously increasing pressure by a compression screw during the passage of the material through 125 the said compression chamber of the extruder.

2 A method as claimed in claim 1, wherein the material is subjected to pressure decrement between pressure increments.

994,554 to 8, wherein the compression chamber (or bush) and the screw are curved so as to taper towards the end of the screw which is adjacent to the outlet of the extruder.

12 A device as claimed in any of claims to 11, and comprising cooling and heating devices.

941/2197

13 A device as claimed in any of claims to 12, and further comprising one or more nozzles for the delivery of one or more food pastes, such nozzles being disposed around the outside of a shaping nozzle provided at the outlet of the extruder.

14 A method of producing a food from starch-containing raw material by the application of heat and pressure substantially as described herein with reference to the Example.

An extruder device for performance of the method as claimed in any of claims 1-4 or 14 substantially as described herein with reference to and as illustrated in the accompanying drawing.

HEINRICH FLESSNER, Trading as Heinz Flessner K G, Per: Boult, Wade & Tennant, 111/112,

Hatton Garden, London, B C 1, Chartered Patent Agents.

3 A method as claimed in claim 1 or 2, wherein the starting material is used in the form of grits or groats.

4 A method as claimed in any preceding claim wherein after passing through the compression chamber or bush the material is forced through a shaping nozzle.

An extruder device for performance of the method according to claims 1 to 4, comprising a screw in a compression chamber or bush having a roughened inner surface.

6 A device as claimed in claim 5 and comprising longitudinal grooves in the inner surface of the compression chamber or bush.

7 A device as claimed in claim 6, wherein there are one or more grooves each in the form of a coarsepitch screwthread.

8 A device as claimed in any of claims 5 to 7, wherein the screw has a polished, e g. chromium-plated surface.

9 A device as claimed in any of claims to 8, wherein the diameter of the screw increases in the direction of the outlet of the extruder the inside diameter of the compression chamber or bush remaining constant.

A device as claimed in any of claims to 8 wherein the screw pitch decreases in the direction of the outlet of the extruder.

11 A device as chtdmed in any of claims Leamington Spa: Printed for Her Majesty's Stationery Office by the Courier Press -1965.



942/2197

199.

GB995280 - 6/16/1965

MANUFACTURE OF FOOD PRODUCTS CONTAINING DRIED FRUIT



E Class: A23L1/212B



Family: GB995280


Abstract:


Fruit granules are made by mixing 15-60%, by weight of total dry solids, of dried pulverulent applesauce and/or white grapes, p 5-60%. by wt. of total dry solids of powdered sugar, e.g. sucrose, glucose, lactose, 3-25%, by wt. of total dry solids, of an edible filler exemplified by starches and flours of wheat, rye, barley, maize, oats, rice, potato and sweet potato, adding 10-30%, by wt. of total dry solids, of glycerol and stirring. The fruit may have been ground after drying. The granules may contain salt, a flavouring such as orange flavouring or imitation raspberry flavouring, a colouring. The granules are of particular value for incorporation in nut butters and spreads, especially peanut butter. 5-70% of the granules may be incorporated. The nut butter or spread may contain added fat or oil, a sweetening agent such as sucrose, honey or corn syrup, salt.

943/2197

200.

GB995729 - 6/23/1965

IMPROVEMENTS IN OR RELATING TO THE MODIFICATION OF RICE


Inventor(s): WILLOCK JAMES TAYLOR (--)

Applicant(s): ALFRED BIRD and SONS LTD (--)

E Class: A23L1/182



Family: GB995729

Abstract:


In producing modified rice grains which are particularly suitable for rice puddings, the moisture content of milled rice grains is raised, uniformly throughout them at a temeprature below the gelatinizing point of the starch therein, to a value between 18 and 30%, preferably between 22 and

28%, by weight, and the moist grains are then heated to expel moisture rapidly, e.g. to reduce their moisture content to between 10 and 14%, and thus create fissures in the grains and increase their porosity. The milled rice grains may be treated with humid air until they absorb sufficient moisture.

Alternatively, the milled rice grains may be soaked in, or sprayed with, water for 30 minutes at 20 DEG

C. or for 10 minutes at 55 to 60 DEG C., then centrifuged to remove surface moisture and conditioned, as by being contained in a closed space for 30 minutes to 4 hours at 20 DEG C., or retained, for 10 minutes at 55 DEG C., in a current of air having a relative humidity between 80 and 90%. The moist grains may be heated by infra-red or dielectric, e.g. radio-frequency, heating. Alternatively, the moist grains may be heated by passing air or inert gas, having a temperature between 90 DEG and 120 DEG

C., over and/or through them for 2 to 6 minutes, as by carrying a thin (0.75 inch) layer of moist grains on a travelling, permeable, e.g. perforated, belt through a dryer and blowing heated air or inert gas upwardly through the grains on one portion of the belt and then downwardly through the grains on another portion of the belt. The dried grains may then be cooled, as by passing air at room temperature downwardly through them as they are carried on the belt.Claims:


WHAT WE CLAIM IS: -

1. A process for the production of a modified rice in the form of grains, which comprises treating milled rice grains at a temperature below the gelatinisation temperature of the starch content thereof to raise the moisture content uniformly throughout the grains to 18% to 30%, preferably 22% to 28% by weight thereof and thereafter heating the thus treated grains to effect rapid expulsion of moisture therefrom and thus increase porosity and fissure the grains.

2. A process according to claim 1, in which during the heat treatment the moisture content of the grains is reduced to below 14'; preferably 10 to 14% by weight, without effecting more than slight gelatinisation.

3. A process according to either of claims 1 or 2 in which the milled rice grains are soaked in or sprayed with water at a temperature below the gelatinisation point of the starch content thereof, e.g. for

30 minutes at 20TC. or for 10 minutes at 55 to 60TC.

944/2197

4. A process according to claim 3 in whicih surface moisture present on the grains -after soaking or spraying is removed by centrifuging.

5. A process according to either of claims 3 or 4 in which the treated grains are conditioned to ensure substantially uniform distribution of moisture therethrough.

6. A process according to claim 5 in which the conditioning of the treated grains is effected by holding them at a temperature below the gelatinisation point of the starch content thereof either in a closed space or in a current of air having a controlled humidity until the moisture is substantially uniformly distributed throughout the grains.

7. A process according to claim 6 in which (iii) cooling section with downward air flow.

The band speed is adjustable for variation of heating time. Air volume in each section can be adjusted between 600 and 2500 c.ft./min.

by variable speed drives on the fans.

An example of operating conditions:500 Ibs./hour.

110oC.

650C.

93'C.

Room temperature 1 min. 50 secs.

0.75 inch.

)n 160 ft./min. n 140 ft./min.

26.3% by weight.

13.0%, by weight.

the grains are held in a closed space for 30 minutes to 4 hours at a temperature of 200 C.

8. A process according to claim 6 in which the grains are held in a current of air having a relative humidity of 80 to 90% for 10 minutes at a temperature of 550C.

9. A process according to either of claims 1 or 2 in which the milled rice grains are treated with air at a temperature and humidity such that the grains absorb the required amount of moisture.

10. A process according to any one of the preceding claims in which the heating is effected by passing a stream of air or an inert gas at a temperature of 900 to 120TC. over and/or through the treated grains for a period ranging from 2 to 6 minutes.

11. A process according to claim 10 in which the treated grains are placed as a shallow bed on a conveyor belt permeable to air, 90 the conveyor belt traversing a zone in which the heated air or inert gas is blown upwardly through the conveyor belt and through the bed of grains and thereafter traversing a second zone in which heated air or inert gas is blown 95 downwardly through the bed of grains and through the conveyor belt.

12. A process according to claim 11 in which the conveyor belt carrying the bed of grains is passed through a third zone in which con! 100 air is blown downwardly through the grains and the conveyor belt to cool the grains.

945/2197

13. A process according to any one of claims 1 to 9, in which the heating is effected by means of dielectric or infra-red heating. 105 14. A process for the production of a modified rice in the form of grains substantially as hereinbefore described with reference to the Examples.

995,729 15. Modified rice whenever obtained by the process of any of the preceding claims.


Applicants.

Leamington Spa: Printed for Her Majesty's Stationery Office by the Courier Press.-1965.

Published at The Patent Office, 25, Southampton Buildings, London, W.C.2, from which copies may be obtainea or =rData supplied from the esp@cenet database - Worldwide

946/2197

201.

GB996158 - 6/23/1965

PRODUCTION OF GRANULES CONTAINING DRIED FRUIT



E Class: A21D2/36; A23L1/212B; A23B7/08



Family: GB996158


Abstract:


Granules, 1/16 -\ba1/2 inch size, which simulate fruit and are for incorporation in cakes, cookies, muffins, pancakes, sweets and puddings, are composed of 18-71%, by weight of the total dry solids, of dried, pulverulent apple or white grape, 15-70%, by weight of the total dry solids, of sugar, of which at least 50% is sucrose, 3-30%, by weight of the total dry solids, of edible filler e.g. starch or flour of wheat, rye, barley, maize oats, rice potato or sweet potato, and no water or up to 6% of water based on the granule weight.

947/2197

202.

GB998602 - 7/14/1965

IMPROVED CRISPY, EXPANDED FOODSTUFFS, AND PROCESSES FOR THE

PRODUCTION THEREOF




E Class: A23L1/164E; A23L1/217B



Family: GB998602

Abstract:


The production of crispy, expanded food from starchy flour, e.g. potato, tapioca, rice or wheat flour, with 3.5-6% of salt and 28-35% of moisture involves extruding the mixture under pressure to produce strands containing starch not enclosed in cell walls, drying the strands until they possess a horn-like outer layer and are of mean water content 6-10%, and cooking and expanding the so-dried strands in hot fat. The fat content may be less than 25%, the salt content may be 2.6-5.5% and the weight to volume ratio may be 0.18-0.20. On drying before the frying the water content near the surface may be

7% and in the interior 17%, salt beginning to crystallize out at the surface; on frying salt crystals form in layers progressively from the outside to the centre. Cheese, or cheese, tomato or curry powder may be incorporated in the mixture extruded. Specification 822,018 is referred to.Description:


PATENT SPECIFICATION o NO DRAWINGS 99h Inventor: DIRK RENEE d'ARNOUD GERKENS.

Date of Application and filing Complete Specification: Jan. 31, 1962.

No. 3668j'62.



Index at acceptance:-AZ B(1B, 10, 1J, 1L) Int.Cl.:-A231 1/10 COMPLETE SPECIFICATION

Improved Crispy, Expanded Foodstuffs, and processes for the production thereof We, NIBB-IT

PRODUCTS ASSOCiATION LIMITED, a Swiss Company, of Zurich, Switzerland, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: -

This invention relates to a fried crispy food product in an expanded or puffed state, having a low fat content. The said food product is derived from starch-containing flour and preferably from potato flour.

Specifically, it is prepared from a dried intermediate described and claimed in the Complete

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Specification of our copending Application for Letters Patent No. 3648/65 (Serial No. 998603) which is divided out from the present Application.

A number of crispy food products have been developed to take the place of potato chips as snack foods. These products are preferred from the viewpoint of taste. However, they suffer the drawback of a high fat content.

The usual fat content of fat-fried foods, such as potato chips, is about 40%. Foods containing this amount of fat require careful storage and the use of anti-oxidants to avoid having the product turn rancid upon contact with the atmosphere. In addition, this large amount of fat is a detriment in that it contributes a large amount of calories and dietconscious people tend to avoid the use of such highcalorie containing materials.

British Patent Specification No. 822018 describes a food product derived from edible tubers, such as potatoes, which is extruded under pressure and fried to give a crisp expanded product having the taste and aroma of a fried potato product such as potato chips.

This product, however, has a higher weight to volume ratio than desirable and has uncertain frying characteristics and ununiformity in the final product. The present invention represents an improvement over this product and process.

An object of our invention is to produce a fat-fried, crisp foodstuff derived from starch[Price 4s. 6d.] containing flour, preferably, but not necessarily, potato flour, and having a low specific gravity, less than 0.20, as the quotient of weight to volume, and from 2.5 to 5.5%, preferably 3 to 4.5%, based on the weight of crisp foodstuff.

This fried crispy food product is prepared from an intermediate product ready for frying (hereinafter sometimes called "fryready" material) derived from starch-containing flour and containing a mixture of free starch and combined starch, preferably 4 to 5% of salt and 6.5 to 10% of moisture (preferably 8 to

9.5%), the product having a horn-like, hard dry outer layer with uneven protuberances.

By " free starch " we mean starch not enclosed in the cell walls of the cells of the potato and by

"combined starch" we mean starch still surrounded by the original cell walls.

Another object of our invention is a process for the production of a fat-fried crisp foodstuff derived from starch-containing flour and having a low fat content per unit of volume as compared with other fat-fried foods.

These and other objects of our invention will become more apparent as this description proceeds.

We have found that fat-fried, crisp food products having an unexpectedly low specific weight and having a very crisp structure and a fat content of less than 25%, preferably 20 to 22%, can be obtained by frying in hot oil an intermediate product derived from starchcontaining flour as described herein.

This intermediate product contains critical amounts of salt and water. When this intermediate or " fryready " product containing critical amounts of salt and water is fried in hot oil, the product expands greatly, and, at the same time, due to the critical moisture and salt content, little oil penetrates into the interior.

It is believed that to effect this advantageous result the salt content of the intermediate product must be sufficiently high so that crystallization of salt crystals on the surface 3,602 ^1 occurs in the outer layer of the dried intermediate product. This crystallization is greatly increased when the intermediate product is immersed in the hot oil, which may aid moisture transfer out of the product and the heat transfer into the product.

At the same time the moisture imprisoned in the interior of the intermediate product is rapidly heated and driven out, creating rapid expansion of the starchy material and aiding in the prevention of fat penetration into the interior. The product is fried for short periods of time in the range of 6 to 10 seconds and is removed from the fat and drained before the fat can pentrate into the pores of the expanded product.

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The rapid driving of the moisture out of the interior as well as from the surface of the intermediate product may be promoted by the almost instantaneous formation of salt crystals throughout the product when inserted in the hot fat. The rapid expansion or "popping" of the moisture out of the intermediate product produces a low weight to bulk ratio in the finished product, which makes it more filling with less weight and calorie consumption, and the fact that the rapid escape of moisture reduces the pentration of oil into the finished product leads to a crisp, tasty product having a low weight to volume ratio and low fat content as compared with other fried foods, such as potato chips.

We have found that the moisture content and the salt content of the intermediate material derived from starch-containing flour must be very closely controlled to obtain a product which will undergo the above described reactions upon frying in hot oil.

The salt in the ratio of 3.5 to 6%, preferably 4 to 5%, based on the " fry-ready " product having a moisture content of about 10% appears to lower the viscosity of the mix in the extrusion process used to produce the intermediate product and to promote greater expansion of the product both after extrusion and in the final fried state. While other starchcontaining flour can be used in our process, it is preferable to use a flour derived from edible tubers and having present all of the flavor characteristics of the edible tuber, such as the protein, minerals, fibrous material and flavour characteristics of, for example, the potato. Dried potato flour is an excellent source of starch-containing flour because of its taste appeal. The intermediate product is believed to contain from 10 to 30% free starch, as hereinbefore defined, in graduated amounts increasing from the center to the outside surface with the remainder of the starch still contained within unbroken cell walls. It preferably contains from 17% to

7% moisture in graduated amounts decreasing from the centre to the outside surface with an average moisture content of 8 to 10% when sodium chloride is used. There should be present a sufficient concentration of it, so that the salt and moisture is in such a balance on the outer surface of the intermediate product that some salt crystals have formed on the dried outer surface of the intermediate product and in the inside of the intermediate product, the salt is at the point of crystallization. This requires a salt content of between 3.5 and 6%, preferably 4 to 5%, in the intermediate product (moist weight). Other uniunivalent salts may be used provided they meet the required conditions of adaptability to a food product. The intermediate material described, is fried in hot oil at from 1800 to

2100C. for approximately 6 to 10 seconds and is removed from the oil at the moment when it floats to the surface.

The salt content, the moisture content and distribution in the intermediate product are highly critical.

When the extruded moist starch-containing flour product having a free starch content, as hereinbefore defined, on the outer surface is dried, a horn-like outer layer is produced.This layer resists penetration of moisture and of heat and therefore must be quite thin. If it is thick, moisture will be trapped within the product and the product will take too long to dry to a crisp condition, allowing time for fat penetration and burning of the outer layer of the fried product.

If the salt content is sodium chloride and within the critical limits of 3.5 to 6%, preferably 4 to 5%, based on the fry-ready product having a moisture content of about 10%, and the moisture content is distributed so that the centre of the dried intermediate product contains about 17% and the outside surface contains about 7% of water, the salt on the surface of the intermediate product will have partially crystallized in the drying of the intermediate product and the remainder is at the point of crystallization, and, when the dried intermediate product is dropped into the hot fat, more salt is crystallized in the interior.

It is believed that the salt crystals aid in the transfer of heat into the material and the transfer of moisture out of the material. The horn-like outer layer of the material acts at the same time as a fatimpervious layer so that heat may be transferred into the interior of the intermediate product and moisture is transferred out of the interior of the intermediate product while hot fat is substantially excluded from the interior of the cooking product. When the sodium chloride content is below the point of crystallization, the heat transfer is slower and the fried product requires longer to cook and does not expand as much.

It can thus be seen that the product produced by frying an intermediate product with these critical ranges of moisture and salt content is new and distinct from prior art products produced in other

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manners in that the product has a very low specific gravity, less than 0.20 998,602 of moisture from the center to the outer surface since the heavier granules contain less moisture than the lighter granules. At the same time each batch of granules which sinks is separately collected and the free starch content of the batch is determined. The distribution of the free starch can also be determined since the heavier granules contain the least water and are from the exterior of the intermediate product, whereas the lighter granules contain the most water and are from the interior.

The intermediate product when dried can be fried immediately or it can be stored for long periods of time before frying. Since the horn-like outer layer retards changes in the moisture content by evaporation or condensation, this product can be shipped in commerce and fried near the point of consumption and utilized in areas where importation of fatfried products is not allowed, taking care that at the moment of frying the average water content is between 6 and 10%. In making the intermediate product, seasoning materials such as cheese powders, tomato powder, curry powder, may also be added.

While antioxidants are not necessary due to the low fat content of the final product, they may be included to further aid in the shelf life of the product. Any antioxidant suitable for use in connection with fat-fried foods can be used, such as soya flour, butylated hydroxytoluene (B.H.T.), butylated hydroxyanisole (B.H.A.), propyl gallate, organic acid gallates, and mixtures thereof.

The following examples are illustrative of the invention.

EXAMPLE I

A dried potato flour prepared so that it has approximately 10% starch not enclosed in cell walls is added to water containing sodium chloride in such a ratio that the water content is between 28 and 35% and the salt content is between 3 to 5%, preferably 4.2 to 4.6%, of the weight of the potato flour. The dried potato flour may be prepared by blanching potatoes to a negative peroxidase test, drying and grinding to give a flour which passes through a 40 mesh sieve (a sieve having 40 wires per inch) with at least 70% passing through a 50 mesh sieve (a sieve having 50 wires per inch) and at least 50% passing through a 70 mesh sieve (a sieve having 70 wires per inch). The grinding releases some of the starch as free starch, and, when the grind is made as indicated, about 10% of the starch is believed to be in the free state capable of being dissolved in cold water. The mixture of water, salt and potato flour is kneaded in a mixer to obtain as uniform a loose powdery mass as is possible. Presence of small lumps in the powdery mass can be countenanced but large lumps should be reduced as much as possible. The powdery mixture is then fed on a weight to volume basis, and at the same time a fat content of less than

25% and ordinarily from 18 to 23%.

The intermediate product is produced from a powdery mixture of starch-containing ground potato flour and water in which the required amount of salt is dissolved. The moisture content of the ground potato flour is preferably about 10% and water is added so that the mixed flour powder as fed to the extrusion machine is moist to the touch and of such consistency that when squeezed in the hand it will retain the shape it is given by the hand.

During the extrusion under high pressure and the increase in temperature produced by the extrusion it is believed that the outer layers of starch-containing cells are broken down to provide a layer of starch not enclosed in cell walls on the outer surface of the extruded strands. While it is possible to prepare such a material having a greater free starch content on the outside by making several batches of dough, each having a different free starch content, and forming layers, this is difficult and time consuming. We have found that an intermediate product prepared from starchcontaining flour and having a graduated free starch content from the centre to the outside is readily and simply prepared by the process of extruding the ground potato flour containing from 28 to 35% of total moisture and from 3 to 5% of salt, under pressure, through a small opening. The mechanical force required to extrude this powder through the small opening is sufficient to reduce it to a plastic condition and is believed to produce a certain amount of a breakdown of flour particles adjacent to the die surfaces of the extrusion press causing the starch within the particles to be liberated. The extruded product is almost completely homogeneous with respect to moisture content, whereas small lumps may exist in the unextruded powder. This product as extruded contains 27.5 to 35% moisture on a total weight basis and, when slowly dried at room temperature or towards the end of the drying period at temperatures slightly elevated above room

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temperature, forms an intermediate product having the required characteristics of critical salt content, moisture distribution and horn-like outside layer required to produce the final fried food product.

The intermediate product can be readily tested for free starch distribution and moisture distribution by grinding the material to a uniform mesh and suspending it in a high density liquid in which all of the material floats on the surface. Graduated amounts of a low density compatible liquid are introduced and after each addition the percentage of the granules which sink are determined and the granules which sink are separated. After all of the granules have sunk it is possible knowing the average moisture content of the intermediate product, to determine the distribution 998,602 into an extrusion press and is extruded through orifices at a speed of approximately one centimetre per second using orifices of 1 x 3.2 mm. The strands leaving the orifices are elastic and expand to a cross section of about 8 to 10 mm'. The strands in this condition are somewhat elastic, like rubber. When slightly stretched they will tend to return to their original length and they can be stretched to about 120% of their length before rupturing. These strands are dried at room temperature to reduce the moisture content as low as practical and towards the end of the drying period the temperature of the air is raised to about 400C. The water content of the dried intermediate material is reduced to an average of about

9%, the inner layers containing a higher amount and the outer layers containing a lower amount than that specified. The range of moisture distribution varies from about 17% in the center of the intermediate material to about 7% on the surface of the intermediate material. The product in the form of the long strands is broken into convenient pieces and dropped into hot fat maintained at about 1801C to 2100C. The amount of salt with reference to the moisture content is preferably just at the critical point of crystallization so that salt crystals form on the surface of the intermediate product and immediately after the intermediate product is dropped into the hot oil, more crystals form, which salt crystals are believed to provide boiling nuclei promoting the penetration of heat into the interior of the product and the escape of moisture therefrom. The pieces sink in the hot oil, expand rapidly and after 8 to seconds rise to the surface, at which time they are skimmed from the fat and drained.

EXAMPLE II

21 kilograms of dried potato flour containing about 10% starch not enclosed in cell walls and having a range of grain size as follows: all of the material minus 40 mesh, at least 70% minus 50 mesh, and at least 50 / minus 70 mesh, the "mesh" being as indicated in Example I, and a water content of about

9.1%, are thoroughly mixed with 6 kilograms of water containing 1.180 kilograms of pure sodium chloride (equal to about 5%).

To the mass is added 0.21 kilograms of curry powder. The mass is thoroughly mixed into a loose moist powder and passed through an extrusion press having orifices of 3 x 0.5 mm.

at a high pressure producing strands having a breadth of about 5 mm. and a thickness of about 2 mm. and an average moisture content of about 27%. The strands are placed in trays in a room having a circulating air supply and dried for about 6 hours at room temperature.

Thereafter for 2 hours the air temperature is raised to 400C. The dried strands contain about 9% moisture with the greater amount towards the centre and the lesser amount near the surface, and can be stored at this point for periods of several years. The strands are fried in hot oil at 2000C. for 7 to 9 seconds, removed from the oil and drained. The resulting product is expanded to a breadth of about 11 mm. and a thickness of about 3.5 mm., which represents about a fourfold increase in cross section over the cross section of the unfried intermediate strands. It has a yellow to gold color, a fat content of about

20%, a moisture content of 3%, a weight to volume ratio of 0.18 and a salt content of 4.8%. The product remains crisp and non-rancid, even after long exposure to the atmosphere.

EXAMPLE III

The process of Example II was repeated, omitting the curry powder and utilizing respectively (1) no added salt (2) 0.225 kilograms of salt (equal to about 1%) (3) 0.450 kilograms of salt (equal to about

2%) (4) 0.920 kilograms of salt (equal to about 4%.) (5) 1.180 kilograms of salt (equal to about 5%j) as in Example II above, and (6) 1.440 kilograms of salt (equal to about 6%/,) to produce samples numbered 1 to 6 respectively for a comparison. Samples 2 and 3 represent the customary amount of salt

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added for purposes of seasoning, namely about 1 to 2%-/, on a dry weight basis. Comparison of the extruded and dried test samples showed the following results:

In the extrusion press the samples with the higher salt content, samples (4) and (5), had a lower viscosity than samples (1), (2) and (3) and under exactly similar pressing conditions the same press extruded 11 to 25% more of the material of samples (4) and (5) than of the material of samples (1), (2) and (3). The higher salt content lowers the pressing viscosity and increases the transparency of the extruded strands.

998,602 998,602 S TABLE 1

Analysis of intermediate and final products for sodium chloride and water Sample Raw fry-ready product Fried product Salt added: none 1% 2% 4% 5% 6% 7% % Sodium chloride 0.24 1.04 2.12 3.82 4.60 5.98 6.70 8.00 % Water %

Sodium chloride 8.40 9.50 9.45 9.95 9.00 9.95 9.75 10.30 0.14 0.78 1.80 2.94 4.35 5.50 6.30 7.70 %

Water 4.50 4.40 4.25 4.05 4.05 4.75 4.30 4.95 It is to be noted that samples (4) and (5) contain less moisture in the final product than samples (1), (2), (3), and (6).

The extruded strands, dried as described in Example II, were measured in exact lengths and weighed.

The following are the mean results of measuring and weighing each sample four times.

TABLE 2

Fry-ready Sample material (1) (2) (3) (4) (5) (6) (7) (8) no salt 1% 2% 4% 5% 6% 7% The cross section of the extruded strands was measured at the point of emergence from the extrusion orifices and the percentage Mean weight per metre 7.80 gram 8.71 9.40 9.49 10.48 10.70 11.25 10.44 expansion over the size of the orifice was found to be as follows:

TABLE 3

Sample (1) (2) (3) (4) (5) (6) (7) (8) Fry-ready material no salt 1% 2% 4% 5% 6% 7% Expansion 114%

157 191 206 188 (1) (2) (3) (4) (5) (6) (7) (8) It is to be noted that sample (7) has the and salt in the first six samples shows that greatest percentage expansion and that with even in the dried fry-ready strands all the an 8% salt content (Sample 8) the expansion salt in the lower salt samples is in solution, begins to drop off. whereas in the higher salt samples part of the Comparison of the relative amounts of water salt is in the form of crystals.

TABLE 4

Sample Fry-ready % Water % Sodium Water for saturated Water Salt material chloride solution reserve crystals 900 (1) no salt 8.40 0.24 0.7% 0.6% 7.7% (2) 1% 9.50 1.04 2.9 2.7 6.6% (3) 2% 9.45

2.12 5.9 5.4 3.6% (4) 4% 9.95 3.82 10.6 9.8 - 0.24% (5) 5% 9.00 4.60 12.8 11.8 - 1.36% (6) 6% 9.20

5.91 16.4 15.2 - 2.60% The fry-ready material was cooked in hot the quotient of weight to volume was deteroil at 2000C. for 6 to 11 seconds, removed mined and the ratio of total volume to unfrom the hot oil and allowed to drain. This expanded material volume was found to be density of the fried product as determined by as follows:

TABLE 5

Density of fried Ratio of total volume Sample Fry-ready material material Two Samples Mean to material volume no salt 0.3080 0.2210 0.2046 0.1876 0.1866 0.2080 0.2340 0.2790 0.3050 0.307

0.2268 0.224 0.2040 0.204 0.1844 0.186 0.1820 0.184 0.2020 0.205 0.2460 0.240 0.2810 0.280 4.28

5.92 6.13 6.81 7.17 6.70 5.82 5.07 It is to be noted that Samples (4) and (5) have the lowest density and the highest volume expansion and that above 5% of salt content the density again begins to increase and the volume to decrease; also that the product produced by the use of 4 to 5% of salt has a density of less than 0.20, whereas the product produced according to the Example of British Patent Specification

No. 822018 and having a density of 0.22 corresponds to the 1 % salt above tables.

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product of Sample (2) in the EXAMPLE IV

Three batches of dried potato flour were prepared as follows: fresh potatoes were blanched to a negative peroxidase test, and the blanched potatoes were dried under vacuum to a moisture content of about 11% and were ground. The grinding time and the (1) (2) (3) (4) (5) (6) (7) (8) 998,602 the salt contained within the intermediate product to produce crystallization and heat 65 transfer in the intermediate product when the said product is fried. It does not exclude the addition of further salt to the fried and expanded final product, such as by sprinkling salt on the final product to suit the taste of

70 the user.

Other starch-containing flours, such as those derived from tapioca, rice, and wheat, may be used. In like manner combinations of flour derived from various sources may be used. 75 Other seasonings may also be used. Where cheese is used for flavouring, normally about 4.8 parts of cheese are used for every

100 parts of potato flour.Data supplied from the esp@cenet database - Worldwide

Claims:


WHAT WE CLAIM IS:- 80

1. A process for producing an improved crispy, expanded foodstuff from starch-containing flour in which starch-containing flour, water and salt are mixed to an extrudable -nass having a moisture content of 28 to 35% 85 by weight and a salt content of 3.5 to 6% by weight, extruding said mass under pressure to form coherent strands containing starch not enclosed in cell walls, drying these strands until they have a horn-like outer layer and an 90 average moisture content of 6 to 10% by weight, and frying the dried strands in a hot, edible fat for a time sufficient to effect expansion and cooking.

2. A process according to claim 1, wherein 95 the starch-containing flour is potato flour.

3. A process according to claim 1 or 2, in which the salt content of the extrudable mass is 4 to 5% by weight.

4. A process according to any of the foregoing claims, in which seasoning and/or flavouring substances are incorporated in the mixture before the extrusion.

5. A process according to any of the foregoing claims, substantially as described herein. 105 6. A process for producing an improved crispy, expanded foodstuff, substantially as hereinbefore described, particularly with reference to any of the Examples 1 to 4.

7. An improved crispy, expanded foodstuff 110 when produced by a process as claimed in any of claims 1 to 7.

8. A foodstuff according to claim 7, comprising starch, a fat content of less than 25% by weight, a moisture content of less than 115 4.2% by weight, a salt content of from about 2.6 to about 5.5% by weight, and a weightto-volume ratio of less than 0.20.

9. A foodstuff according to claim 8, wherein the salt content is from 4.0 to 5.0% by 120 weight.

10. A foodstuff according to claim 8 or 9, in which the fat content is from 18 to 23% by weight, and the weight-to-volume ratio is s from 0.18 to 0.20. 125 particle size were adjusted so that one batch of potato flour contained 10% starch not enclosed in cell walls, another batch contained 20% starch not enclosed in cell walls, and a third batch contained 30% starch not enclosed in cell walls. The three batches of flour were individually mixed with water and salt in the same proportions as in Example I and a sandwich arrangement of the dough was prepared.

The first layer contained the dough prepared from the 30% free starch flour. The second layer contained the dough prepared from the 20% free starch flour. The third layer contained the dough prepared from the 10% starch flour. The fourth layer contained the dough prepared from the 20% free

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starch flour. The fifth layer contained the dough prepared from the 30% free starch flour. The four outer layers were each about 0.5 mm.

thick. The inner layer was about one mm.

thick. The entire sandwich was approximately 3 mm. thick. This sandwich was cut into strands 6 to 8 mm. wide and dried to a total water content of 9 to 11% to produce a material similar to the "fry-ready" material of the preceding examples. The strands were fried in hot oil and the product produced resembled that produced in Example I.

While a critical salt content of 3.5 to 6%, preferably 4 to 5%, based on the weight of the fry-ready intermediate product has been specified for the production of the improved product of this invention the critical amount of salt to be used can be determined as follows: Pure sodium chloride is soluble in water to the extent of 35.7 to 39.8 parts in parts of water in the temperature range of from 00 to 1000C.

When the salt concentration exceeds this amount, salt crystals begin to form in the solution. By using 4 to 4.5% of sodium chloride in the original composition containing the potato flour having starch not enclosed in cell walls and 30 to 35% of water, all the salt goes readily into solution and is uniformly distributed through the mixture.

When the mixture is extruded and dried to an average moisture content of 9 to 11% and a content of

7% near the surface and 17% at the interior of the intermediate product, the limit of solubility of the salt with reference to water is exceeded at the surface and salt begins to crystallize out evenly on the surface of the intermediate product. More salt crystals form when the intermediate product is introduced into the hot fat, and, as more moisture is evaporated from the interior of the product, salt crystals are formed in progressive layer, nearer and nearer to the centre of the product, thus possibly promoting better heat transfer and more uniform expansion of the product so that completely uniform porosity of the product from the ouside to the centre is pro.

vided. The salt content referred to herein i:

998,602 8 998,602 For the Applicants, SANDERSON & CO., Chartered Patent Agents, 11-13 Bream's

Buildings, London, E.C.4.

Leamington Spa: Printed for Her Majesty's Stationery Office. by the Courier Press (Leamington) Ltd.-

-1965. Published by the Patent Office, 25 Southampton Buildings London, W.C.2, from whicA copies may be obtained.Data supplied from the esp@cenet database - Worldwide

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203.

GB998603 - 7/14/1965

DRIED INTERMEDIATE FOR A FOOD PRODUCT, AND THE PROCESS OF

PRODUCING THE SAME




E Class: A23L1/164E; A23L1/216B; A23L1/00P14B2



Family: GB998603

Abstract:


A dried intermediate for food production, especially by frying and puffing, has a horn-like outer layer with uneven protuberances and comprises a flow containing starch which is not enclosed within cell walls, 3.5-6% of salt and 6-10% of moisture. The flour may be of potato, tapioco, rice or wheat; cheese may be used for flavouring. Specification 822,018 also is referred to.Description:



NO DRAWINGS. 998.603 Inventor: DIRK RENEE d'ARNOUD GERKENS.

: Date of Application and filing Complete Specification: Jan. 31, 1962.

No. 3648/65.

(Divided out of No. 998602).


Ad g) Crown Copyright 1965.

Index at acceptance:-AZ B(1B, 1J, IL) Int. C1.:-A 23 1 1 / 10 COMPLETE SPECIFICATION

Dried Intermediate for a food product, and the process of producing the same We, NIBB-IT

PRODUCTS ASSOCIATION LIMITED, a Swiss Company, of Zurich, Switzerland, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-

This invention relates to an intermediate product for producing a fried crispy food product in an expanded or puffed state, having a low fat content.

The said intermediate product is produced from starch-containing flour, preferably from potato flour, and is obtained in the process for producing an improved crispy, expanded foodstuff from starchcontaining flour in which starch-containing flour, water and salt are mixed to an extrudable mass

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having a moisture content of 28 to 35% by weight and a salt content of 3.5 to 6% by weight, extruding said mass under pressure to form coherent strands containing starch not enclosed in cell walls, drying these strands until they have a horn-like outer layer and an average moisture content of 6 to 10% by weight, and frying the dried strands in a hot, edible fat for a time sufficient to effect expansion and cooking which process is described and claimed in the Complete Specification of our co-pending

Application for Letters Patent No. 3668/62 (Serial No. 998,602) out of which the present Specification is divided. The intermediate product has excellent shipping and storage properties, and is distinguished by a hard outer layer having uneven protruberances and both a critical salt and moisture content.

A number of crispy food products have been developed to take the place of potato chips as snack foods. These products are preferred from the viewpoint of taste. However, they suffer the drawback of a high fat content. The usual fat content of fat-fried foods, such as potato chips, is about 40%. Foods containing this amount of fat require careful storage and the use of anti-oxidants to avoid having the

[Price 4s. 6d.] products turn rancid upon contact with the atmosphere. In addition, this large amount of fat is a detriment in that it contributes a large amount of calories and diet-conscious people tend to avoid the use of such high-calorie containing materials.

British Patent Specification No. 822,018 describes a food product derived from edible tubers, such as potatoes, which is extruded under pressure and fried to give a crisp expanded product having the taste and aroma of a fried potato product such as potato chips.

This product, however, has a higher weight to volume ratio than desirable and has uncertain frying characteristics and ununiformity in the final product. The present invention represents an improvement over this product and process.

An object of our invention is an intermediate product ready for frying (hereinafter sometimes called

"fryready" material) produced from starch-containing flour and containing a mixture of free starch and combined starch, preferably 4 to 5% of salt and 6.5 to 10% of moisture (preferably 8 to 9.5%), the product having a horn-like, hard dry outer layer with uneven protuberances.

By "free starch" we mean starch not enclosed in cell walls, and by "combined starch" we mean starch still surrounded by the original cell walls. In a vegetable product starch granules are enclosed in the cell walls, and by grinding or milling part of the cell walls of the material is broken and thus the starch originally enclosed in the cell walls is liberated.

In extruding under higher pressure a powdery mixture of a flour, obtained by a milling process, and water, other cell walls, especially where the mixture moves along the wall of the die, are broken by friction against the wall, so that further starch is liberated. Therefore generally the outer layer of the strands, obtained by extrusion, contains more starch than the core.

The intermediate product of our invention 1 1 1 on frying produces a fat-fried crispy foodstuff having a low fat content per unit of volume as compared with other fat-fried foods.

We have found that fat-fried, crisp food products having an unexpectedly low specific weight and having a very crisp structure and a fat content of less than 250/, preferably 20 to 22%, can be obtained by frying in hot oil an intermediate product produced from starchcontaining flour as described herein.

When this intermediate or "fryready" product containing critical amounts of salt and water is fried in hot oil, the product expands greatly, and, at the same time, due to the critical moisture and salt content, little oil penetrates into the interior.

At the same time the moisture imprisoned in the interior of the intermediate product is rapidly heated and driven out, creating rapid expansion of the starchy material and aiding in the prevention of fat penetration into the interior. The product is fried for short periods of time in the range of 6 to 10 seconds and is removed from the fat and drained before the fat can penetrate into the pores of the expanded product.

The rapid driving of the moisture out of the interior as well as from the surface of the intermediate product may be promoted by the almost instantaneous formation of salt crystals throughout the product when inserted in the hot fat. The rapid expansion or "popping" of the moisture out of the intermediate

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product produces a low weight to bulk ratio in the finished product, which makes it more filling with less weight and calorie consumption, and the fact that the rapid escape of moisture reduces the penetration of oil into the finished product leads to a crisp, tasty product having a low weight to volume ratio and low fat content as compared with other fried foods, such as potato chips.

We have found that the moisture content and the salt content of the intermediate material derived from starch-containing flour must be very closely controlled to obtain a product which will undergo the above described reactions upon frying in hot oil. The salt in the ratio of 3.5 to 6%, preferably 4 to 5%, based on the "fry-ready" product having a moisture content of about 10% appears to lower the viscosity of the mix in the extrusion process used to produce the intermediate product and to promote greater expansion of the product both after extrusion and in the final fried state.

While other starch-containing flour can be used in our process, it is preferable to use a flour derived from edible tubers and having present all of the flavour characteristics of the edible tuber, such as the proteins, minerals, fibrous material and flavour characteristics of, for example, the potato. Dried potato flour is an excellent source of starch-containing flour because of its taste appeal. The intermediate product is believed to contain from 10 to 30% free starch, as hereinbefore defined, in graduated amounts increasing from the centre to the ouside surface with the remainder of the starch still contained within unbroken cell walls. It preferably contains from 17/, to 7%/ moisture in graduated amounts decreasing from the centre to the outside surface with an average moisture content of 8 to 10W/ when sodium chloride is used. There should be present a sufficient concentration of it, so that the salt and moisture is in such a balance on the outer surface of the intermediate product that some salt crystals have formed on the dried outer surface of the intermediate product, and, in the inside of the intermediate product, the salt is at the point of crysallization. This requires a salt content of between 3.5 to 6 /, preferably 4 to 50/, in the intermediate product (moist weight). The intermediate material described can be fried in hot oil at from 1800 to 2100C. for approximately 6 to 10 seconds and is removed from the oil at the moment when it floats to the surface.

The salt content, the moisture content and distribution in the intermediate product are highly critical.

When the extruded moist starch-containing flour product containing in the outer layer starch not enclosed in cell walls is dried, a horn-like outer layer is produced.

This layer resists penetration of moisture and of heat and therefore must be quite thin. If it is thick, moisture will be trapped within the product and the product will take too long to fry to a crisp condition, allowing time for fat penetration and burning of the outer layer of the fried product.

The horn-like outer layer of the material acts as a fat-impervious layer so that heat may be transferred into the interior of the intermediate product and moisture is transferred out of the interior of the intermediate product while hot fat is substantially excluded from the interior of the cooking product.

When the sodium chloride content is below the point of crystallization, the heat transfer is slower and the fried product requires longer to cook and does not expand as much.

It can thus be seen that the product produced by frying an intermediate product with these critical ranges of moisture and salt content is new and distinct from prior art products produced in other manners in that the product has a very low specific gravity, less than 0.20 on a weight to volume basis, and at the same time a fat content of less than 25% and ordinarily from 18 to 23%.

The intermediate product is produced from a powdery mixture of starch-containing ground potato flour and water in which the required amount of salt is dissolved. The moisture content of the ground potato flour is about 10 / and water is added so that the mixed flour powder as fed to the extrusion machine is moist to the touch and of such consistency that when squeezed in the hand it will retain the

998,603 be fried immediately or it can be stored for long periods of time before frying. Since the hornlike outer layer retards changes in the moisture content by evaporation or condensation, this product can be shipped in commerce and fried near the point of consumption and utilized in areas where importation of fatfried products is not allowed, taking care that at the moment of frying the average water content is between 6 and 10%/. In making the intermediate product, seasoning materials such as cheese powders, tomato powder, curry powder, may also be added.

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While antioxidants are not necessary due to to the low fat content of the final product, they may be included to further aid in the shelf life of the fried product. Any antioxidant suitable for use in connection with fat-fried foods can be used, such as soya flour, butylated hydroxytoluene (B.H.T.) butylated hydroxyanisole (B.H.A.), propyl gallate, organic acid gallates, and mixtures thereof.

The following examples are illustrative of the invention.

EXAMPLE I: A dried potato flour prepared so that it has approximately 10% starch not enclosed in cell walls is added to water containing sodium chloride in such a ratio that the water content is between

28 and 35%/O and the salt content is between 3 to 5%, preferably 4.2 to 4.6%, of the weight of the potato flour. The dried potato flour may be prepared by blanching potatoes to a negative peroxidase test, drying and grinding to give a flour which passes through a 40 mesh sieve (a sieve having wires per inch) with at least 70 /- passing through a 50 mesh sieve (a sieve having 50 wires per inch) and at least

50 / passing through a 70 mesh sieve (a sieve having 70 wires per inch). The grinding released some of the starch as free starch and, when the proper grind is made as indicated, about 10% of the starch is believed to be in the free state capable of being dissolved in cold water. The mixture of water, salt and potato flour is kneaded in a mixer to obtain as uniform a loose powdery mass as is possible. Presence of small lumps in the powdery mass can be countenanced but large lumps should be reduced as much as possible. The powdery mixture is then fed into an extrusion press and is extruded through orifices at a speed of approximately one centimetre per second using orifices of 1 x 3.2 mm. The strands leaving the orifices are elastic and expand to a cross section of about 8 to 10 mm2. The strands in this condition are somewhat elastic, like rubber.

When slightly stretched they will tend to return to their original length and they can be stretched to about 120% of their length before rupturing. These strands are dried at room temperature to reduce the moisture content as low as practical and towards the end of the drying period the temperature of the air is shape it is given by the hand. During the extrusion under high pressure and the increase in temperature produced by the extrusion it is believed that the outer layers of starch cells are broken down to provide a layer of free starch not enclosed in the cell walls on the outer surface of the extruded strands. While it is possible to prepare such a material having a greater free starch content on the outside by making several batches of dough, each having a different free starch content, and forming layers, this is difficult and time consuming. It was found that an intermediate product prepared from starch-containing flour and having a graduated free starch content from the centre to the outside is readily and simply prepared by the process of extruding the ground potato flour containing from 28 to

35% of total moisture and from 3 to 5% of salt, under pressure, through a small opening. The mechanical force required to extrude this powder through the small opening is sufficient to reduce it to a plastic condition and is believed to produce a certain amount of a breakdown of flour partides adjacent to the die surfaces of the extrusion press causing cell walls to be broken so that the starch enclosed therein is liberated.

The extruded products is almost completely homogeneous with respect to moisture content, whereas small lumps may exist in the unextruded powder. This product as extruded contains 27.5 to 35% moisture on a total weight basis and, when slowly dried at room temperature or towards the end of the drying period at temperatures slightly elevated above room temperature, forms an intermediate product having the required characteristics of critical salt content, moisture distribution and horn-like outside layer required to produce the final fried food product.

The intermediate product can be readily tested for free starch distribution and moisture distribution by grinding the material to a uniform mesh and suspending it in a high density liquid in which all of the material floats on the surface. Graduated amounts of a low density compatible liquid are introduced and after each addition the percentage of the granules which sink are determined and the granules which sink are separated. After all of the granules have sunk it is possible, knowing the average moisture content of the intermediate product, to determine the distribution of moisture from the center to the outer surface since the heavier granules contain less moisture than the lighter granules. At the same time each batch of granules which sinks is separately collected and the free starch content of the batch is determined. The distribution of the free starch can also be determined since the heavier granules contain the least water and are from the exterior of the intermediate product whereas the lighter granules contain the most water and are from the interior.

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The intermediate product when dried can 998,603 raised to about 400C. The water content of the dried intermediate material is reduced to an average of about 9%, the inner layers containing a higher amount and the outer layers containing a lower amount than that specified.

The range of moisture distribution varies from about 17% in the centre of the intermediate material to about 7% on the surface of the intermediate material. The product in the form of the long strands can be broken into convenient pieces and dropped into hot fat maintained at about 1800G to 2100C. The amount of salt with reference to the moisture content is preferably just at the critical point of crystallization so that salt crystals form on the surface of the intermediate product and immediately after the intermediate product is dropped into the hot oil, more crystals form, which salt crystals are believed to promote the penetration of heat into the interior of the product and the escape of moisture therefrom. The pieces sink in the hot oil, expand rapidly and after 8 to 10 seconds rise to the surface at which time they are skimmed from the fat and drained.

EXAMPLE II: 21 Kilograms of dried potato flour containing about 10% starch not enclosed in cell walls, and having a range of grain size as follows:

all of the material passing through a 40 mesh sieve, at least 70% through a 50 mesh sieve, and at least

50% through a 70 mesh sieve, the "meshes" being as indicated in Example I, and a water content of about 9.1% are thoroughly mixed with 6 kilograms of water containing 1.180 kilograms of pure sodium chloride (equal to about 5%). To the mass is added 0.21 kilograms of curry powder. The mass is thoroughly mixed into a loose moist powder and passed through an extrusion press having orifices of 3 x 0.5 mm. at a high pressure producing strands having a breadth of about 5 mm and a thickness of about 2 mm and an average moisture content of about 27/.

The strands are placed in trays in a room having a circulating air supply and dried for about 6 hours at room temperature. Thereafter for 2 hours the air temperature is raised to 400C. The dried strands contain about 9%/, moisture with the greater amount towards the centre and the less amount near the surface, and can be stored at this point for periods of several years. The strands can be fried in hot oil at

200C. for 7 to 9 seconds, removed from the oil and drained. The resulting product is expanded to a breadth of about 11 mm and a thickness of about 3.5 mm, which represents about a fourfold increase in cross section over the cross section of the unfried intermediate strands. It has a yellow to gold colour, a fat content of about 20%, a moisture content of 3%., a weight to volume ratio of 0.18 and a salt content of 4.8%. The product remains crisp and non-rancid, even after long exposure to the atmosphere.

EXAMPLE III: The process of Example II was repeated, omitting the curry powder and utilizing respectively (1) no added salt (2) 0.225 kilograms of salt (equal to about 1%) (3) 0.450 kilograms of salt (equal to about 2%) (4) 0.920 kilograms of salt (equal to about 4/:) (5) 1.180 kilograms of salt

(equal to about 5%) as in Example II above, and (6) 1.440 kilograms of salt (equal to about 6/) to produce samples numbered 1 to 6 respectively for a comparison. Samples 2 and 3 represent the customary amount of salt added for purposes of seasoning, namely about 1 to 2% on a dry weight basis. Comparison of the extruded and dried test samples showed the following results:

In the extrusion press the samples with the higher salt content, samples (4) and (5), had a lower viscosity than samples (1), (2) and (3) and under exactly similar pressing conditions the same press extruded 11 to 25%/, more of the material of samples (4) and (5) than of the material of samples (1),

(2) and (3). The higher salt content lowers the pressing viscosity and increases the transparency of the extruded strands.

998,603 TABLE I

Analysis of Intermediate and Final Product for Sodium Chloride and Water Sample Raw Fry-ready

Product Fried Product salt added % sodium chloride (1) (2) (3) (4) (5) (6) (7) (8) none 1% 2% 4% 5%

6% 7% 0.24 1.04 2.12 3.82 4.60 5.98 6.70 8.00 % water 8.40 9.50 9.45 9.95 9.00 9.95 9.75 10.30 % sodium chloride 0.14 0.78 1.80 2.94 4.35 5.50 6.30 7.70 % water 4.50 4.40 4.25 4.05 4.05 4.75 4.30

4.95 It is to be noted that samples (4) and (5) than samples (1), (2), (3) and (6).

contain less moisture in the final product The extruded strands, dried as described in Example II, were measured in exact lengths and weighed. The following are the mean results of measuring four times.

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and weighing each sample TABLE 2

Sample Fry-Ready Mean Weight Material per Metre (1) no salt (2) 1% (3) 2% (4) 4% (5) 5% (6) 6%

(7) 7% (8) 8% 7.80 gram 8.71 9.40 9.49 10.48 10.70 11.25 10.44 The cross section of the extruded strands was measured at the point of emergence from the extrusion orifices and the percentage expansion over the size of the orifices was found to be as follows:

TABLE 3

Sample Fry-Ready Material (1) (2) (3) (4) (5) (6) (7) (8) No salt 1% 2% 4% 5% 6% 7% Expansion

114% 157 191 206 188 998,603 It is to be noted that sample (7) has the and salt in the first six samples shows that even greatest percentage expansion and that with in the dried fry-ready strands all the salt in an 8% salt content (sample 8) the expansion the lower salt samples is in solution, whereas begins to drop off. in the higher salt samples part of the salt is Camparison of the relative amounts of water in the form of crystals.

TABLE 4

Sample Fry-Ready % Water % Sodium Water for Saturated Water Salt Material Chloride Solution

Reserve Crystals 20 900 (1) no salt 8.40 0.24 0.7% 0.6% 7.7% (2) 1% 9.50 1.04 2.9 2.7 6.60 _ (3) 2%

9.45 2.12 5.9 5.4 3.6% (4) 4% 9.95 3.82 10.6 9.8 - 0.24% (5) 5% 9.00 4.60 12.8 11.8 - 1.36% (6) 6%

9.20 5.91 16.4 15.2 - 2.60% The fry-ready material was cooked in hot the quotient of weight to volume was deteroil at 2000C. for 6 to 11 seconds, removed mined and the ratio of total volume to unexfrom the hot oil and allowed to drain. The panded material volume was found to be as density of the fried product as determined by follows:TABLE 5

Sample Fry-Ready Density of Fried Mean Ratio of Total Material Material Two Samples Volume to

Material Volume (1) (2) (3) (4) (5) (6) (7) (8) no salt 1% 2% 4% 5% 6% 7% 0.3080 0.2210 0.2046

0.1876 0.1866 0.2080 0.2340 0.2790 0.3050 0.2268 0.2040 0.1844 0.1820 0.2020 0.2460 0.2810 0.307

0.224 0.204 0.186 0.184 0.205 0.240 0.280 4.28 5.92 6.13 6.81 7.17 6.70 5.82 5.07 It is to be noted that samples (4) and (5) have the lowest density and the highest volume expansion and that above 5% of salt content the density again begins to increase and the volume to decrease; also that the product produced by the use of 4 to 5% of salt has a density of less than 0.20, whereas the product produced according to the Example of British Patent Specification No. 822018 and having a density of 0.22 corresponds to the 1% salt product of Sample (2) in the above tables.

EXAMPLE IV: Three batches of dried potato flour were prepared as follows:

fresh potatoes were blanched to a negative peroxidase test, and the blanched potatoes were dried under vacuum to a moisture content of about 11% and were ground. The grinding time and the particle size were adjusted so that one batch of potato flour contained 10% starch not enclosed in cell walls, another batch contained 20% starch not enclosed in cell walls, and a third batch contained 30% starch not enclosed in cell wals. The three batches of flour were individually mixed with water and salt in the same proportions as in Example I and a sandwich arrangement of the dough was prepared. The first layer contained the dough prepared from the 30% free starch flour. The second layer contained the dough prepared from the 20% free starch flour. The third layer contained the dough prepared from the

10% free starch flour. The fourth layer contained the dough prepared from the 20% free starch flour.

The fifth layer contained the dough prepared from the 30% free starch flour. The four outer layers were each about 0.5 of a mm thick.

The inner layer was about one mm thick. The entire sandwich was approximately 3 mm thick. This sandwich was cut into strands 6 to 8 mm wide and dried to a total water content of 9 to 11% to produce a material similar to the "fry-ready" material of the pre998,603 Other seasonings may also be used.

Where cheese is used for flavouring, normally about 4.8 parts of cheese are used for every 100 parts of potato flour.Data supplied from the esp@cenet database - Worldwide Claims:


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WHAT WE CLAIM IS:-

1. A dried intermediate useful in producing foodstuffs, having a horn-like outer layer with uneven protuberances thereon, comprising starch, water and salt, in which 10 to 30% by weight of the starch is not enclosed in cell walls, and having a salt content of between 3.5 and 6% by weight, and a moisture content of from 6 to 10% by weight.

2. An intermediate according to claim 1, wherein the salt content is from 4.0 to 5.0% by weight.

3. An intermediate according to either of claims 1 and 2, substantially as herein described, particularly with reference to any of the foregoing Examples 1 to IV.

4. A process for producing an intermediate according to any of claims 1 to 3, in which starchcontaining flour, water and salt are mixed to an extrudable mass having a moisture content of 28 to

35% by weight and a salt content of 2.6 to 6% by weight, extruding said mass under pressure to form coherent bands containing starch not enclosed in cell walls, and drying these strands until they have a horn-like outer layer, an average moisture content of 6 to 10% by weight, and a salt content of 3.5 to

6% by weight.

5. A process according to claim 4, wherein the starch-containing flour is potato flour.

6. A process according to either of claims 4 and 5, substantially as hereinbefore described, particularly with reference to any of the foregoing Examples I to IV.

7. A dried intermediate, whenever produced by a process as claimed in any of claims 4 to 6.

For the Applicants SANDERSON & CO., Chartered Patent Agents, 11-13 Bream's Buildings, London,

E.C.4.

ceding examples. The strands were fried in hot oil and the product resembled that produced in

Example I.

While a critical salt content of 3.5 to 6%, preferably 4 to 5%, based on the weight of the fry-ready intermediate product has been specified, the critical amount of salt to be used can be determined as follows:

Pure sodium chloride is soluble in water to the extent of 35.7 to 39.8 parts in 100 parts of water in the temperature range of from 0 to 1000C. When the salt concentration exceeds this amount, salt crystals begin to form in the solution. By using 4 to 4.5% of sodium chloride in the original composition containing the potato flour having starch not enclosed in cell walls and 30 to 35% of water, all the salt goes readily into solution and is uniformly distributed through the mixture.

When the mixture is extruded and dried to an average moisture content of 9 to 11% and a content of approximately 7% near the surface and approximately 17% at the interior of the intermediate product, the limit of solubility of the salt with reference to water is exceeded at the surface and salt begins to crystallize out evenly on the surface of the intermediate product. More salt crystals form when the intermediate product is introduced into the hot fat, and, as more moisture is evaporated from the interior of the product, salt crystals are formed in progressive layers nearer and nearer to the centre of the product, thus possibly promoting better heat transfer and more uniform expansion of the product, so that completely uniform porosity of the product from the outside to the centre is provided. The salt content referred to herein is the salt contained within the intermediate product to produce crystallization and heat transfer in the intermediate product when the said product is fried. It does not exclude the addition of further salt to the fried and expanded final product, such as by sprinkling salt on the final product to suit the taste of the user.

Other starch-containing flours, such as those derived from tapioca, rice and wheat, may be used. In like manner combinations of flour derived from various sources may be used.

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Leamington Spa: Printed for Her Majesty's Stationery Office. by the Courier Press (Leamington) Ltd.-

1965. Published by the Patent Office, 25 Southampton Buildings London, W.C.2, from which copies may be obtained.


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204.

HU9901719 - 2/28/2001

ON THE SURFACE OF ROW-RICE PRODUCT IS FLAVOURED, COMPLETED

WITH NATURAL FOOD COMPONENT AND COLOURED AND PROCESS FOR

THEIR PRODUCTION

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=HU9901719

Inventor(s): GARDONYI ZOLTAN (HU); LEDER FERENCNE (HU)

Applicant(s): INWEST ELELMISZER GYOGYNOEVENY (HU)


IP Class: A23L1/10

E Class: A23L1/182B; A23L1/00P8B8

Application Number: HU19990001719 (19990525)

Priority Number: HU19990001719 (19990525)

Family: HU9901719

Equivalent: WO0070965; EP1191856; HU223329

Abstract:

Abstract not available for HU9901719

Abstract of corresponding document: WO0070965

The invention relates to raw rice products coated with oil/fat and comprising powdered food components or mixtures thereof on the surface of the grains. Optionally, the rice products of the invention also comprise pieces or slices of dried vegetable, fruit or meat. The invention also relates to methods for the preparation of the rice products of the invention. The rice product of the invention can be used for the fast and simple preparation of tasty rice dishes of high nutritive value.Description:

Description of corresponding document: WO0070965

OIL-AND POWDER-COATED RAW RICE AND METHODS FOR THE PREPARATION

THEREOF


The invention relates to raw rice products coated with oil/fat and comprising powdered food components or mixtures thereof on the surface of the grains. The oil/fat used is preferably eating quality mineral oil and/or vegetable oil/fat. The invention also relates to processes for the preparation of the raw rice products of the invention, to the use of the rice products inmulticomponent ready-to-use dish/meal compositions and tomulticomponent, ready-to-use dish compositions.

The invention can be used for the preparation of tasty rice dishes, e. g. onecourse dishes or fast rice garnishes of high nutritive value, supplie with natural food components derived form plants or animals.


As used herein,"powdered food preparation"refers to a mass of particles, said particles having a diameter ofless than 2000zm, and said product being prepared by fine shredding, grinding and/or milling of a main food component.

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Optionally, said preparation also comprises other components, such as spices, flavors and additives which preferably increase the nutritive value of the product.

As used herein, the term"powdered food mixture"refers to powdered food preparations, which comprise two or more food components.

Thecommercially available, flavored, colored rice products of the art aremostly prepared from parboiled rice using a steaming technology where the flavoring or coloring coating components are applied in an aqueous medium. In another large group of ready-to-use rice products theflavoring and coloring components and the dried food components and extracts of plant or animal origin, are simply weighed out and packaged together with the raw or parboiled rice in the same packaging unit.

As starting material, the state of art processes based on rice parboilingtechnology require excellent quality rice. In these technologies the cooking and drying steps are expensive in terms of time and energy. The ratio of thecrumbled (broken) grains in the end product is significant, therefore a subsequent separation step is required.

Other processes for treating the surface of rice are also known in the art and used in practice.In general, the aim of these processes is topolish the surface of the natural, husked, eating rice and to make it more aesthetic. For example, such polishing methods include the water spray polishing method

[Marshall, W. E. and Wadsworth J. I."Rice Science and Technology 242-246 (1994)] and the partial or complete coating of the surface of rice with e. g. dried talc, talc-glucose syrup or glucose solution (see e. g. Bor S.Lun"Rice Production and Utilization"AVI Publishing CompanyInc., Westport,

Connecticut, USA).

Oil-polishing of cereals was performed on millet, as disclosed in Hungarian patent No. HU 21551

(1901); however, because of the rapid rancidification of theedible oil used, prolonge storage of the end product was impossible.

A process for coating raw rice with nutritional supplements (vitamins, minerals, amino acids or othersupplements) is disclosed in US Patent No.

4,765,996. In this process the vitamins, amino acids and various minerals are applied to the surface of rice grains in a water-oil mulsion, using adhesives and relatively high temperatures.

US Patent No. 4,687,669 discloses a process in whichnutritional supplements are applied to the surface of rice and barley by a conventional method in order to increase their nutritive value. In order to protect the added nutrients, the enriched rice is coated with an acqueous mulsion of oil/fat and/or wax. The mulsion is applied in a warm, melted form, which soidifies when cooled down to room temperature.

In US Patent No. 4,767,636 a process for the preparation of dehydrated instant rice and sauce dish made of parboiled rice is taught. In this process the coating is created by applying as many as three layers of oil to the surface of the rice. After the application of the first layer, consisting of a significant quantity of oil, spices and flavors are added.Only in the last step, after the addition of further two layers of oil, are the freeze-dried and/or puffed dried vegetables applied. However, thistechnology is rathercomplicated and expensive due to the use of large quantities of oil and to the high energy consumption of the methods used for the preparation of the rice and vegetable starting materials.

Until recently, however, no fast and simple process wasavailable for the coating of raw, preferably husked rice with essentially any mixtures of food powders and/or powdered, dried vegetables, at low cost. Consequently, no raw rice product coated with mineral oil and/or vegetableoil/fat and comprising powdered food components or mixtures thereof on the surface of the grains was available.

Thus, the object of the invention is to provide a new rice product, which satisfies the above outlined need, and a method for the preparation thereof.

DESCRIPTION OF THE INVENTION

The present invention is based on the unexpected discovery that, without using additives, a durable coating or coloring of powdered food preparations or food mixtures can be applied to the surface of the

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grains of raw, husked white rice or partially husked brown rice comprising at most 16% moisture, by coating the untreated raw, husked or partially husked rice grains with oil/fat, and then sprinkling or dusting the low fat powdered preparation or mixture on the surface of the rotated and whirled rice grains, wherein the powdered preparation or mixture has a moisture contentlower than that of the rice and and appropriate particle size. Preferably, the application of the powdered preparation or mixture is carried out and the product is packaged under low humidity conditions, and anoil/fat unsusceptible to rancidity, i. e. which can be stored atleast for several month, preferably for more than 6 months, is used.

It is known in the art that parboiled rice contains high amounts of hairline cracks on its surface, which is thereby increased. Mostprobably, this is why application of large quantities of oil in US Patent No.

4,767,636 is required.

Furthermore, it can be stated that before the present invention, a person skilled in the art did not use raw rice for the preparation of rice products supplemented with food components on the surface of the grains probably because he could notreasonably expect that a surprisingly large quantity of dry solids could be applied usingsmall quantities of adhered oil, provided that the circumstances disclosed herein are maintained.

Thus, the invention relates to a process for preparing a raw rice product coated with powdered food components said process comprising the steps of coating rice grains of at most 16% moisture content with eating quality mineral oil and/or vegetable oil/fat, and applying a low fat powdered food preparation or mixture to the surface of the oil/fat-coated rice grains, wherein the food preparation or mixture has a moisture contentlower than that of the rice and has an appropriate particle size.

Throughout the description,unless otherwise indicated, % means w/w%, and the ratios of the ingredients of the product are given in % by weight of the rice.

In a preferred embodiment of the invention the surface of raw, husked white rice or partial husked brown rice with at most 16% and atleast about 9%, preferably about 12% to about 15% moisture content is coated with at most 12%, preferably 7.5%, preferablyless than 5%, more preferably 2.1 to

3% eating quality mineral oil and/or vegetable oil/fat or mixture thereof being unsusceptible to rancidity, then applying, depending on the thickness of the oil film layer, at most 20%, preferably about

10%, low fat powdered food mixture which has a moisture content at most 10%, preferably at most 6% and a particle size of at most 2000aum, preferably at most1000 zm, more preferablyless than 500j. m, most preferably m. 99% of the ground powder has a particle size below 250, m.

Prior to further use, the ground powder mixture is stored in a reduced humidity environment, in vapourtight containers. After this the oil-coated rice grains, being rotated in a coatingvessel, are slowly dusted with the homogenized, green powder mixture and further mixed for 5 to 10 minutes in order to obtain an even coating on the rice grains.

The coated rice product is stored in vapourtight containers till packaging.

The above composition of ingredients results in 100 kg of finished product.

Example 2 Rice with spinach (brown rice)

To obtain 100 kg of finished product, brown rice (90.0 kg, 12.0% moisture content) is coated with a mixture of white oil (2.00 kg) and garlic oil (0.09 kg).

Meanwhile, the powdered food mixture for coating is prepared, asfollows:

Spinach powder 2.63 kg

Marinesalt (iodinated) 2.30 kg

Sugar 0.50 kg

Powdered Parmezan cheese 0.90 kg

Powdered Parmezan cheese aroma 0.40 kg

Flavour intensifyer: sodium glutamate 0.09 kg.

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The powdered food mixture is ground, homogenized, applied to the surface of rice, stored and packaged as described in Example 1. Furthermore, the same particle size was used.

Example 3 Rice with spinach

To obtain 100 kg of finished product, husked rice (80.5 kg, 12.7% moisture content) is coated with a mixture of white oil (7.69 kg) and garlic oil (0.08 kg).

Meanwhile, the powdered food mixture for coating is prepared, as follows:

Spinach powder 7.69 kg


Sugar 0.45 kg


Powdered Parmezan cheese aroma 0.41 kg


The powdered food mixture is ground, homogenized, and applied to the surface of rice as described in

Example 1. The particle size of 99% of the powdered mixture isless then 250pm. The higher spinach and oil content results in a darker product with a strong spinach taste.

Products comprising spinach powder are less susceptible to changes in humidity than products coated with tomato powder (see Example 5).

Example 4 Rice with onions

To obtain 100 kg of finished product, husked white rice (91.56 kg, 14.5% moisture content) is coated with a mixture of white mineral oil (1.53 kg) and paprika oil (0.38 kg).Meanwhile, the powdered food mixture for coating is prepared, as follows:

Onion powder 1.00 kg


Sugar 0.46 kg



The powdered food mixture is ground, homogenized, applied to the surface of rice and stored as described in Example 1. Furthermore, the same particle size was used. The coated rice product isyellow or orange in color. Paprika oil is used to provide appropriate color and taste. Substituting a paprika oil of higher coloring power for the paprika oil used herein, its quantity can be reduced to below 0.1 kg paprikaoil/100 kg finished product. The onion flavor can be increased by the addition of 1 to 2% dried onion pieces by weight of the rice.

Example 5 Rice with tomato

To obtain 100 kg of finished product, husked white rice (88.40 kg, 13.0% moisture content) is coated with a mixture of white mineral oil (1.53 kg) and paprika oil (0.38 kg). Meanwhile, the powdered food mixture for coating is prepared, asfollows:

Tomato powder 5.30 kg

Marine salt (iodinated) 0.80 kg



The particle size of more than 90% of the powdered mixture isless then 250zm.

Tomato powders, and thus the above powdered mixtur

After weighing, the powder mixture is homogenized, then distributed on the surface of the oil-coated rice whirled in the coatingvessel. After a further mixing for 5 to 10 minutes an even coating on the rice grains is obtained. The quantity of the instant fruit powder can be varied depending on theflavoring character of the fruit components. As described above, the packaging of the fruit-rice should be vapourtight, flavourtight, and light protecting.

Example 7 Fruit-rice

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The fruit-rice product of this example is largely the same as the product described in Example 6.

However, instead of instant fruit powder dried raisins and fruit pieces are weighed out and packaged together with the coated rice product in the same packaging unit. Composition of the raisins and fruit ingredients (altogether 10 kg in 100 kg finished product) is asfollows:

Dried banana pieces with honey 3.40 kg

Driedapple pieces 2.20 kg

Raisins 4.40 kg.

Examole 8 Cocoa-rice

To obtain 100 kg of finished product, husked white rice (92.28 kg, 14.7 % moisture content) is coated with white oil (2.10 kg). Then, the rice grains,while whirled in a coatingvessel, are evenly coated with the following powdered food mixture:

Sugar 1.00 kg

Instant skimmed milk powder 2.00 kg

Salt 0.50 kg

Crystallinevanilla 0.14 kg

Artificial sweetener 0.50 kg

Instant cocoa drink powder 2-10 kg.

The packaging of the cocoa-rice is the same as described above.

Example 9 Rice with mushrooms

The oil-coated raw rice can be prepared in accordance with any of the above examples. The powdered food mixture comprising sugar, salt, onion powder, driedparsley and spices can be applied to the surface of the processed rice as disclosed in any of Examples 1 to 4. In the next step pieces of dried mushroom or a mushroom mixture are addedseparately, using the same conditions. The size of said pieces is at most 20 mm x 10 mm x 10 mm.

Preferably, the composition of the product is the following:

Rice 87.63 kg

Dried mushroom 5.00 kg

Sugar 0.44 kg

Salt 2.20 kg

White oil 2.20 kg

Spice mixture(Kotányl) 1.14 kg


Driedparsley 0.44 kg

100.00 kg

Example 10"Letchorice"

The oil-coated raw rice can be prepared according to any of the above examples. The powdered food mixture comprising sugar,salt, tomato powder, cheese powder, onion powder, and spices can be applied to the surface of the processed rice as disclosed in Example 5. In the next step pieces of dried paprika, onion and tomato are addedseparately, using the same conditions. The size of said pieces is at most 20 mm x 10 mm x 10 mm. Preferably, said pieces are"leafy" with a thickness of less then 1 mm.

Preferably, the composition of the product is the following:

Rice 84.30 kg

White oil 0.76 kg

Paprika oil 1.52 kg

Tomato powder 1.91 kg

Parmezan cheese powder (FiS) 0.95 kg

Salt 2.10 kg

Sugar 0.76 kg


Sodium glutamate 0.09 kg

Dried paprika 2.34 kg

Dried onion 2.30 kg

Dried tomato 2.20 kg

100.00 kg

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The invention and its preferred embodiments were described above in detail.

In the process used by the presentApplicants the coloring and flavoring components and dried materials of plant or animal origin can be applied to the surface of husked or partially husked raw rice without additives, using a low cost and simple method at normal temperatures.

It should be emphasized that the use of raw rice as starting material is highly advantageous compared with the use of parboiled or instant rice.

Preparation of the latter requires expensive and energy consuming methods, i. e. steamed parboiling and long term (cca. 16 hours) gradual drying to prevent crumbling or breaking of the grains. As aresult, several useful constituents of the rice, such as fibres, vitamins, flavors etc. will decompose. For this reason, and because whitening additives are needed to preserve the original color, theinstant/parboiled rice isless wholesome and its nutritive value is lower,consequently lesspopular among consumers compared to raw rice. Since parboiled rice processed this way is more friable, theloss of grains due to crumbling will be high (cca. 30%) as compared with thenegligible loss found using the process of the invention. Furthermore, a product made of parboiled rice, though really fast to prepare, can easily be overcooked.

Using the process of the invention a durable coating of rice grains can be obtained, provided that the starting materials have an appropriate moisture content, particle size distribution and fat content, the oil and the powder mixtures are applied in the ratios as disclosed in the description. Preferably the finished product is packaged inflavortight, vapourtight and light protecting materials. A further advantage of the process of the invention is that the ratio of the resulting crumbled grains is at most 10% as compared to the starting rice material. (The rice used as starting material should be of an"A"quality husked rice according to the

Hungariandirective"ME 2-61"or an equivalent thereof, comprising at most 1.5% fine debris and at most 9% coarse debris.)

The invention can be used for the preparation of new food products that in turn can be used to prepare tasty rice dishes, e. g. one-course dishes or fast rice garnishes of higher nutritive value compared with rice based dishes of the art. The raw rice products and"one-course rice dishes"can be used advantageously as fast foods or delicacy.

The product range based on coated,fiavored raw rice products of the invention can be further extended, if needed.Data supplied from the esp@cenet database - Worldwide

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205.

IE903186 - 3/13/1991

SHELF-STABLE RICE PRODUCTS AND PROCESSES FOR THEIR

PRODUCTION

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=IE903186

Inventor(s): HOWARD JOHN GEORGE (--); ATHERTON JOHN (--); FIELD ERIC SYDNEY

(--); HAWKINS MICHAEL JOHN (--)

Applicant(s): MARS INC (US)


IP Class: A23L1/182; A23B9/02; A23L3/3508

E Class: A23L1/16D; A23L1/187; A23L3/3508

Application Number: IE19900003186 (19900831)


Family: IE903186

Equivalent: EP0415788; EP0415787; WO9103171; WO9103169; EP0489811; EP0441937;

US5312639; IE903187; IE69383; IE63938; HU214550

Abstract:

Abstract not available for IE903186


The present invention provides shelf-stable, acid-pasteurised rice which, on reheating, does not have any acid flavour notes but has premium quality. This is achieved by use of a polymeric food acceptable acid, such as alginic acid, as the acidulant. There is also disclosed a process for producing such rice.Description:


SHELF-STABLE RICE PRODUCTS AND PROCESSES FOR THEIR PRODUCTION

The present invention relates to acid-pasteurised, shelf-stable, rice products and to processes for their production.

By shelf-stable is meant that the product can be stored at room temperature for long periods of time without being subject to spoilage by microbial action, without its organoleptic properties deteriorating and without it acquiring any undesirable flavour. Typically, food products are considered to be shelfstable if they meet these requirements after at least nine months and preferably after at least twelve or fourteen months of storage at room temperature. The major reason that many food products are not shelf-stable is that the growth of spoilage microorganisms is not inhibited. Therefore, an essential requirement of a shelf-stable food product is that it should not be susceptible to the growth of spoilage microorganisms.

At present, rice is available to the public as raw rice, parboiled rice, frozen rice or canned rice. Both raw and parboiled rice have the advantage that they are generally shelf-stable. Raw and parboiled rice are shelf-stable because they have a low water content, generally in the region of about 12% by weight.

This is too low to support microbial growth.

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Raw rice is generally available as "white" rice, that is the kernel of the rice from which the bran layer and the husk have been removed. Raw rice is also available as "brown" rice, which is the same as

"white" rice except its bran layer has been retained. Raw white rice is cooked by boiling it for about fifteen minutes in salted water. Cooking raw brown rice generally takes somewhat longer.

Raw rice is generally acceptable if it is cooked properly. However, it is very easy to over- or undercook the rice so that an unacceptable product is produced. Moreover, cooked raw rice tends to be very sticky and this has an unacceptable appearance and mouthfeel. Further, raw rice, especially "white" raw rice, has little nutritive value, as most of the nutrients are present in the husk or the bran layer.

Parboiled rice was developed in order to overcome some of the disadvantages of raw rice. The most common method of producing parboiled rice is to soak paddy rice (i.e. rice having the husk and bran layer still present) and then to heat it, for instance by steaming. This causes gelatinisation of the starch in the kernel and also induces many of the nutrients in the husk and bran layer to diffuse into the kernel. A recent development in the production of par-boiled rice is disclosed in EP-A-0 352 939. In the process disclosed in this document, the rice is parboiled by the use of dry heat at a much lower moisture content than is possible using conventional parboiling processes.

Parboiled rice has the advantages that: it is more nutritious than raw rice; on cooking, it does not become sticky; and it is much less susceptible to overcooking than raw rice. It is thus more acceptable both nutritionally and organoleptically and is easier to prepare in acceptable form. However, parboiled rice has the disadvantage that it takes at least twenty minutes, or even longer for brown parboiled rice, to cook. Thus, it cannot readily be used as a convenience food.

In order to overcome the problem of the long cooking times of raw and parboiled rice, frozen rice has been placed on the market. Frozen rice generally comprises raw or, more often, parboiled rice which has been cooked, drained and frozen. As long as it is kept frozen, it is stable for long periods. However, if as it is allowed to warm to room temperature, it will soon spoil. Frozen rice is prepared for eating merely by heating it to the required temperature, for instance in a microwave oven.

Frozen rice has the disadvantage that it requires freezing facilities at the point of production, at the point of sale and at the point of use. It also requires refrigerated transportation. This is very energyintensive and thus makes the product relatively expensive.

There have been many proposals for the production of shelf-stable rice which can be used as a convenience food. One such proposal, which resulted in the production of a dry rice product, required the pre-cooking and then drying of the product under relatively harsh conditions. The product was shelf-stable in that it had a low water content. It could be prepared for eating by soaking in boiling water for a short time. However, it only had limited consumer acceptability because it tended to become sticky and did not have the mouthfeel associated with properly cooked raw or parboiled rice.

Another shelf-stable rice which can be used as a convenience food is canned rice. In producing canned rice, raw or, more often, parboiled rice is cooked, drained, and filled into cans. The cans are then sealed, generally under vacuum or inert gas atmosphere, and sterilized by heating to a temperature of about 122 DEG C for about 38 minutes.

Canned rice can be prepared for eating merely be opening the can and reheating the rice, for instance in a microwave oven. Canned rice when cooked is acceptable to the consumer and has most of the properties of well cooked raw or parboiled rice. However, its texture is not as good since some of the grain structure is destroyed during the sterilization stage, giving a rubbery texture. Moreover, the rice has a browner colour than freshly cooked rice.

Canned rice has a number of other disadvantages. Many consumers associate canned foods with inferior products. For instance, most consumers prefer frozen vegetables to canned vegetables. Canned rice is also relatively expensive. This is because rice is quite corrosive towards metals and therefore high quality cans need to be used to ensure that the cans are not corroded. Moreover, the production process is relatively expensive in that it requires careful control of the canning process and a heat sterilization step.

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There have also been many proposals for the production of acid-pasteurized rice, although to the

Applicant's knowledge none of these proposals has resulted in the production of a commercially available product.

Acid-pasteurisation is a well known process which has been used in connection with a variety of products for some long time. Acid-pasteurisation was developed in order to enable a product to be sterilized at a much lower temperature than is possible if heat sterilization is to be carried out at neutral pH. It is generally recognised that if the pH of a product is reduced to 4.5 or below, it is possible to sterilize a product without needing to heat it above the boiling point of water. This is advantageous because it means that heating can be carried out by steaming at atmospheric pressure or soaking in hot water. Thus, there is no requirement for pressurized systems to accomplish the heating.

It is believed that acid-pasteurisation is effective because the pH destroys or prevents from multiplying many of the microorganisms which could spoil the product. Any microorganisms which are resistant to the acid pH are destroyed or inactivated by the relatively mild heat sterilization.

It has been proposed that pasta products, such as noodles, could be made shelf-stable by treatment with acids. For instance, JP-A-6 307 770 describes the preparation of a noodle which contains an acid preservative. The preservative comprises a mixture of: a conventional food-acceptable organic acid; a salt of such an acid; and a water-soluble macromolecular polysaccharide or chitosan. The organic acid, used as such or as its salt, may be citric, tartaric, malic, fumaric, lactic, acetic or gluconic acid. The polysaccharide may be alginic acid or sodium alginate. It is reported that noodles treated with this preservative mixture were stable for up to ten days. However, ten days is not a commercially acceptable time, especially if the product has to be transported to and stored at its point of sale and then stored at its point of use.Thus, such a product would be unsuitable for use in supermarkets.

It has also been proposed that pasta products could be made shelf-stable by carrying out acidpasteurisation. For instance, US-A-2 434 388 refers to the preparation of shelf-stable macaroni by lightly pickling the macaroni with acetic acid and then pasteurising the product while contained in a can.

US-A-3 886 296 describes a process for producing acid-pasteurised canned spaghetti and other pasta products. The pasta product is blanched in an acid solution to reduce its pH. Thereafter the blanched product is immersed in an acidic liquid medium. The containers are sealed and subjected to a shorthold heat treatment to render the product sterile. Suitable acids for use in the process are acetic, citric, hydrochloric, lactic, malic, phosphoric and tartaric acids. The preferred acid is malic acid.

US-A-4 540 590 discloses a process for producing a rapid cooking pasta product. In the process, the pasta dough is formed from constituents which can include an acidulant.

The dough is formed into shaped products using a particular extrusion process. The shaped products are dried, packaged and heat sterilized at 70 to 95 DEG C. Malic and lactic acids are mentioned as useful acidulants.

US-A-4 552 772 and US-A-4 599 238 disclose the use of a combination of citric and/or lactic acid with table salt in one solution to enhance the preservability of boiled noodle products. Such products can be commercially distributed at ambient temperature. The boiled noodles are treated with the acid solution, packaged and heat sterilized.

US-A-4 597 976 relates to the production of pasta-based ready meals. The ready meals generally have three components, being the pasta, a meat component and a sauce. The pasta, the meat component and, if necessary, the sauce are acidified to a pH of less than 4.6 and are hot filled into containers. The sealed containers are then pasteurised. Acids such as citric, fumaric, lactic, malic, tartaric, sulphuric, hydrochloric and phosphoric acids can be used to acidify the components.

US-A-4 734 291 relates to the production of an "al dente" pasta product having storage stability. The product is produced by cooking freshly extruded pasta with steam or boiling water. The cooked pasta is sealed in a container with sufficient water to complete hydration of the pasta. The water contains

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sufficient acid to reduce the pH to less than 4.6. The sealed container is then sterilised. Fumaric acid is specifically referred to for use as the acidulant.

US-A-4 828 852 relates to a process for producing a precooked pasta product by boiling the raw pasta in acidified water to partially cook the pasta. The partially cooked pasta is soaked in acidified water and then coated with an acidified cream. The coated product is packaged and heat processed to complete the cooking. Acids which can be used include acetic, malic, fumaric, tartaric, phosphoric, adipic, lactic and citric acids.

An early proposal for the acid-pasteurisation of rice is set forth in US-A-1 589 672. The disclosed process comprises blanching or boiling rice in acidulated water, immersing the blanched rice in saline and canning the rice under vacuum. The water is acidulated with phosphoric acid.

US-A-2 187 718 discloses a process for producing a canned rice product which comprises cooking the rice in an acid solution, canning the cooked product and sterilizing the canned product. The acid is supplied as a fruit juice which contains malic, citric, tartaric, lactic or acetic acid.

US-A-2 616 810 discloses a process for producing canned rice which comprises cooking the rice in a saline solution, draining, acidulating the rice, canning the rice and sterilizing the canned rice.

Particularly mentioned acids are lactic and tartaric acids.

US-A-3 647 486 discloses a process in which raw rice is cooked in acidified water at a temperature above the gelatinisation point of starch but below the boiling point of water to achieve a water content of 58 to 65%. The cooked rice is then canned and the cans are sealed and sterilized. The cans are then cooled and the product is aged for a number of days before use. The acids which can be used include acetic, fumaric, malic, tartaric, ascorbic, isoascorbic, succinic, citric and adipic acids.

EP-A-0 322 996 discloses a process for producing a two pack ready meal based on rice. In the first pack is an acid-pasteurized starchy foodstuff, such as rice or pasta, having a pH of below 4.6. In the second pack is an alkalinating agent. Acids used to acidify the rice and pasta include hydrochloric, malic and citric acids. In use, the alkalinating agent is used to neutralise the acid flavour of the rice or pasta product.

It can thus be seen that there have been many proposals for the acid-pasteurisation of rice. It can be seen from the prior art cited above that, in all cases, the acidification has been carried out using recognised food acids. These are generally low molecular weight inorganic or, preferably, organic acids. Such recognised food acids are listed, for example, in the CRC Handbook of Food Additives, edited by Thomas E. Furia, 2nd Edition, Volume 1, 1977, pages 225-270.

The present Applicants have found that, although prior art acid-pasteurised rice products may be acceptable from the point of view of shelf-stability, they have serious drawbacks. The main one is that the acids used to enhance the shelf-stability of the product also endow the product with an acid taste.

This is not surprising as the whole point of adding the acid is to reduce the pH of the product. It would therefore seem to be inevitable that a shelf-stable acid-pasteurised rice product will have an acid taste.

However, from the consumer's point of view, the acid taste is undesirable.

The acid flavour may be masked either by use of an alkalinating agent, as disclosed in EP-A-0 322 996, or by use of strong seasonings. However, the use of an alkalinating agent adds to the expense of the produce and also complicates the preparation of the product. The use of strong seasonings limits the range of products which can be produced.

A further drawback with acid-pasteurisation is that it may adversely affect the other organoleptic properties of the rice. A premium rice product, as prepared for eating, should have certain organoleptic qualities, which are generally classified in the areas of taste, smell, appearance and texture. Premium rice should have the characteristic taste of rice. Some treatments of rice can introduce non-rice flavours, such as metallic or chlorine- derived tastes. Others can remove flavour from rice so that it is bland.

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Premium rice should have the characteristic smell of rice. This can be destroyed by some treatments or masked by non-rice odours introduced by other treatments. For instance, treatments with sulphur dioxide-containing agents can introduce the characteristic smell of sulphur dioxide.

Premium rice should in appearance be white or nearly white and should appear to have grains of approximately the same size. There should preferably be no broken grains or peck. Some treatments introduce yellow or brown colours or cause the rice grains to break up.

The texture of premium rice should be firm, but not hard, rubbery or soft, and should be non-sticky.

The rice should have a moist, but not wet or dry, mouthfeel, should not be oily or slimy and should have grains which generally do not adhere to one another. If the rice grains do adhere to one another, the rice product will have an unacceptable sticky mouthfeel. Some treatments have adverse effects on the texture of rice and in particular prolonged treatments at elevated temperatures can lead to the production of soft, sticky and wet rice product.

It is therefore an object of the present invention to provide premium quality, shelf-stable rice.

It is a further object of the invention to provide a process for producing such premium quality, shelfstable rice.

Therefore, according to the present invention, there is provided shelf-stable, acid-pasteurised rice wherein the acidifying agent is a polymeric food acceptable acid.

Preferably, the rice is contained in a microorganism-impermeable container.

The rice may be "pre-cooked", by which is meant that the rice can be prepared for consumption merely by heating it, for instance in a conventional oven or a microwave oven or by steaming it or immersing it in hot or boiling water, to the required temperature. The rice or pasta will not need any prolonged heat treatment in order to cook it. It can be prepared for eating by heating for a period between 30 seconds and three minutes. It can thus be seen that the rice of the present invention in this form can be used as a convenience food.

Alternatively, the rice may be "partially cooked" by which is meant that the rice cannot be prepared for eating merely by heating it to the required temperature. It will also need to be held at the required temperature for a period of time. Generally, this period of time will be relatively short, of the order of two or three minutes, so that the product can be used as a convenience food.

Preferably, the polymeric acid has a cellulosic or saccharide-derived backbone having pendant carboxyl groups. Particularly preferred polymeric acids are alginic acid, carageenic acid, pectic acid and carboxymethyl cellulose (CMC) acid. Presently, the most preferred polymeric acid is alginic acid.

The pH of the rice should be below 4.5, which is generally recognised as being the maximum pH which ensures that the pasteurized product remains stable. Preferably, the pH of the rice is below 4.2 and most preferably the pH is in the range 3.7 to 3.9. The pH of the rice is determined by macerating

50 g of rice in 150 ml of deionised water and measuring the pH of the supernatant.

The pH may be below 3.5. However, the lower the pH, the more acid must be used and the more likely it is that acid flavour notes will be introduced into the rice. As a practical matter, the skilled person, given the teaching in the present application, will be able to balance the pH level and amount of acid used to ensure that the rice is fully shelf-stable but does not have any acid flavour notes.

Preferably, the rice comprises from 0.01 to 1% by weight of the polymeric acid, where the polymeric acid is used alone. Advantageously, the polymeric acid content of the product is from 0.2 to 0.8% by weight.

It has been found, surprisingly, that the use of a polymeric food acceptable acid enables rice to be acidpasteurised without introducing acid flavour notes into the product. Moreover, the rice of the present invention has organoleptic properties, such as taste, smell, appearance and texture, which make it a premium rice product. It is unexpected, in view of the fact that previously proposed acid-pasteurisation

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procedures have all resulted in products having an acid taste and lower quality, that the rice of the present invention has this combination of no acid taste and premium organoleptic properties.

The rice of the present invention is also advantageous in that, unlike other commercially available rice products, it is easily prepared and stored and has a substantial shelf-life. It thus lends itself to distribution, display and sale in a wide range of commercial settings, for instance both in supermarkets and convenience stores. These advantages accrue without the necessity to sacrifice the organoleptic properties.

The rice of the present invention is also advantageous in that it eliminates the need for specialised delivery and storage means. Unlike frozen rice, the rice of the present invention can be stored at ambient temperatures for long periods without the product deteriorating in quality. The substantial economies resulting from obviating the need for refrigeration make the product appealing from a cost standpoint.

It is to be noted that polymeric food acceptable acids have never before been proposed as acidulants.

The polymeric acids or, more usually, their sodium or calcium salts have found extensive use in the food industry, but not as acidulants. Generally, the polymeric acids and their sodium or calcium salts are used as thickening agents or coatings in food products. CMC in particular is extensively used as a thickener. Alginates are used: as stabilizers in ice cream, water ices, sherbets and cheese; as gelling agents in water dessert gels and milk puddings; as suspending and thickening agents in fruit drinks and beverages; as foam stabilizers in beer; as emulsifiers in salad dressings and as film forming agents in coatings for meat and fish.Thus, the prior art provides no suggestion that such polymeric acids could be used as acidulants, let alone in acid-pasteurisation with the surprising results shown in the present application. In this respect, reference is made to the Chapter on Gums at pages 295 to 360 in the CRC

Handbook of Food Additives cited above.

A further property of these polymeric acids is that they are generally only sparingly soluble in water. It is therefore surprising that they can in fact act as acidulants. It is unexpected that they can produce the required acidification without necessitating the use of large quantities of the acid.

The shelf-stable, acid-pasteurised rice of the present invention may be fully hydrated such that it can be prepared for consumption merely by reheating, for instance in an oven, such as a microwave oven.

Alternatively, the rice may be slightly less than fully hydrated so that it may be prepared for consumption by reheating in boiling water or by steaming. This reheating will also allow the rice to become fully hydrated and ready for serving

The water content of the final product if fully hydrated will generally be in the region of 60 to 70%, depending on the variety of rice used as the starting material. For rice which needs to be partially hydrated during cooking, the water content will be generally in the region of 50 to 55%. At these water contents, normal rice would be susceptible to microbial spoilage, whereas the rice of the present invention is not.

Preferably, the rice of the present invention is not accompanied by free liquid water. This may be achieved by draining the product after cooking and before pasteurisation or by carrying out the cooking and pasteurisation in an amount of water such that all the water is absorbed by the product during processing.

The rice of the present invention, advantageously in the absence of free water, may be contained in a microorganism-impermeable container so as to preserve its shelf-stability. Advantageously, the container is gas-impermeable to prevent the ingress of oxygen which can, in some circumstances, cause browning of the rice. Such containers include cans, jars, bottles, foil trays and pouches. The rice will generally be sealed in the container prior to pasteurisation.

Preferably, the rice of the present invention is contained in a pouch made of plastic material. The plastic material may be a single layer of material or may, preferably, be a laminated material comprising a reinforcing layer, such as a nylon or polyester layer, and a sealing layer, such as a polyethylene, and a barrier layer such as polyvinylidene chloride or ethylene-vinyl alcohol copolymer layer. Such plastic materials are well known in the art. The advantage of packaging the rice of the

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invention in plastics materials is that the product can be reheated in a microwave oven without the need to decant it before reheating.

The rice of the present invention is preferably packed under vacuum or an inert gas atmosphere in order to avoid any discolouration of the product by oxidation during pasteurisation. Packing under an inert gas atmosphere is preferred as this will tend to prevent any flavour changes during processing and storage of the product. The inert gas may be nitrogen.

If desired, the rice of the present invention may be coated with a small quantity of an edible oil, such as sunflower oil, ground nut oil, soya oil or a mixture thereof. The edible oil may be used to alter the mouthfeel of the product and to ensure that it does not stick together or clump during prolonged storage. Preferably, the edible oil comprises from 0.3 to 1% by weight of the product.

The rice of the present invention may, if desired, contain of one or more conventional acidulants in order to potentiate the action of the polymeric acid. The amount of conventional acidulant used should not be so great as to introduce acid flavour notes to the product. Even if a potentiating acidulant is used, it is still the polymeric acid which enables the product to be acid-pasteurised without the introduction of acid flavour notes.

The potentiating acidulants will be used to assist in controlling the pH of the rice of the present invention at the desired level but will not generally be present in sufficient quantity to bring the pH to the desired level themselves. In particular, it should be ensured that the amount of potentiating acidulant used is not so large as to impart acid flavour notes to the rice.

Suitable potentiating acidulants include inorganic acids, such as hydrochloric, sulphuric and phosphoric acids, and organic acids, such as malic, lactic, citric, tartaric, adipic, fumaric, acetic, ascorbic, isoascorbic and succinic acids.

If a potentiating acidulant is used, it will be possible to reduce the amount of polymeric food acceptable acid which is used. However, the amount used should not be such that the addition of the potentiating acidulant leads to the introduction of acid flavour notes into the product.

The rice according to the present invention may be derived from raw brown or white rice or from parboiled brown or white rice. The invention is applicable to short, medium or long grain rice.

However, preferably, long grain rice is used. Any variety of rice may be used. It will be appreciated by those skilled in the art that different varieties of rice will require different treatment regimes. However, determining the appropriate regime will be a matter of routine experiment for the skilled person, given the teaching of the present application.

Preferably, the rice is long grain, parboiled rice produced by conventional "wet" processing or produced by the "dry" process described in EP-A-0 352 939.

According to a second aspect of the present invention, there is provided a process which comprises:

(a) treating rice with an aqueous solution adjusted to a pH of 4.5 or below by use of a polymeric, food acceptable acid; and

(b) pasteurising the rice while it is maintained at said pH of 4.5 or below by use of a polymeric food acceptable acid whereby shelf-stable, acid-pasteurised rice is produced.

Preferably, the process includes a further step of:

(c) either before or after step (a) or after step (b), sealing the rice in a microorganism-impermeable container.

It must be borne in mind that some cooking of the rice will take place during the pasteurisation step (b).

In order to obtain a desired degree of cooking, it will be necessary to control the other steps in the process in dependence on the conditions used in the pasteurisation step (b).

In a first alternative, the treatment step (a) is carried out for such a time and at such a temperature that the rice becomes at least partially cooked and becomes cooked to the desired degree in the acidpasteurisation step (b).

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In a second alternative, the pasteurising step (b) is carried out for such a time and at such a temperature that the rice becomes not only pasteurised but also cooked to the desired degree.

In a third alternative, the process includes a step (d) in which the rice is partially cooked. This partial cooking step (d) may be carried out before or after step (a). If the partial cooking step (d) is carried out after step (a), it must be ensured that, after the partial cooking step (d), the pH of the rice is retained below 4.5 by use of a polymeric food acceptable acid.

In a fourth alternative, the process includes the step (d) and the treatment step (a) is carried out under conditions which cause further partial cooking of the rice. This alternative is similar to the third alternative, except that the partial cooking step (d), the treatment step (a) and the pasteurising step (b) together will provide the necessary required degree of cooking of the rice.

If desired, the rice may be washed in between any of the process stages set forth above. It must be ensured that any such washes do not allow the pH of the rice to rise above 4.5. Thus, it is preferred that the rice be washed in an aqueous solution whose pH has been adjusted to 4.5 or less using a polymeric, food acceptable acid. preferably, the process conditions are adjusted such that the final rice product is not accompanied by any free liquid water. This may be achieved by using in the process only as much water as is required to hydrate the rice to the desired degree. Alternatively, the rice may be drained of all free water, preferably just prior to sealing in a container. In this alternative, it will be necessary to ensure that the rice is hydrated to the desired degree before it is drained.

It is preferred that sealing step (c) is carried out before the pasteurising step (b). Most preferably, the sealing step (c) is carried out immediately prior to the pasteurising step (c).

If the sealing step (c) is carried out after the pasteurising step (b), it will be necessary to carry out the pasteurising and sealing steps under aseptic conditions. This can be disadvantageous as it requires special arrangements to be made for the aseptic steps. This can add to the cost of the process. However, if an aseptic area is already available, packaging and sealing after pasteurisation may enable bulk treatments to be carried out upstream of the pasteurisation step (b), thus allowing cost savings to be made.

Preferably, during the processing of the rice, an edible oil, such as one of the edible oils referred to above, is added so that the rice is coated with the edible oil. Preferably, the edible oil comprises from

0.3 to 1% by weight of the product.

The polymeric food-acceptable acid may be provided as such. Alternatively, it may be generated in situ by reaction between a salt or other derivative of the polymeric acid and an inorganic or organic acid.

For instance, alginic acid may be generated by reacting sodium alginate with hydrochloric acid. This will be particularly advantageous in that the other product of the reaction will be sodium chloride

(common salt) which is generally added to water in which rice is boiled.

Optionally, the polymeric food acceptable acid may be used with a potentiating acid as referred to above. The potentiating acid will be used to assist in controlling the pH of the aqueous solution but will not by itself provide the necessary acidity to reduce the pH to the desired level.

Preferred components and amounts of the components to be used in the process of the present invention are as set forth above in relation to the first aspect of the invention.

It will be appreciated by the skilled person that the conditions used in the process of the present invention will vary depending on the starting material. For instance, it takes longer to cook parboiled white rice than it does to cook raw white rice.

It is, however, essential to ensure that a proper pasteurisation step is carried out. The conditions by which this can be carried out are well known to those of skill in the art. It is generally accepted that the minimum requirements for a pasteurisation step are that the centre temperature of the food should be held at 93 DEG C for five minutes and that the food should have a pH of 4.5. It will be appreciated that if higher temperatures or lower pHs are used, the treatment time may be reduced. However, it is

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preferred that the rice has a pH of 3.7 to 3.9 and that a minimum centre temperature of 93 DEG C is held for at least 5 minutes.

Preferably, the pasteurisation step (b) and, if employed, the cooking step (d) is carried out at a temperature below 100 DEG C. If this is done, then it is not necessary to use pressurised heating systems. The pasteurisation system can in this case be carried out under atmospheric pressure using hot water or steam to heat the product.

If desired, the pasteurisation step (b) may be carried out at a temperature above 100 DEG C. However, this will require the use of a pressurised system to prevent water from being driven off from the rice and causing pressure to build up in the package.

If desired, the process may further include a step (e) of quenching the product after the pasteurisation step (b). The quenching may be accomplished using a solution containing a polymeric food-acceptable acid, optionally in combination with a conventional acidulant. Alternatively quenching may be achieved by spraying or immersing sealed packages in cold water.

Guidance as to suitable conditions to be used can be obtained from a study of the examples set forth below. Given the above disclosure and the examples, the skilled man will be able to determine appropriate conditions for processing any desired rice starting material.

The present invention is further described and illustrated below in the following examples. It will be appreciated that these examples are provided solely for the purposes of illustrating the invention and not for the purpose of limitation. It will further be appreciated that variations and modifications to the product and process may be made by the skilled person without departing from the spirit or scope of the invention as defined in the appended claims.

Example 1

Long grain parboiled white rice made according to the process disclosed in EP-A-0 352 939 was used as the starting material in this example. A stock solution containing 0.12% alginic acid (Protacid F120 supplied by Protan), 0.02% hydrochloric acid and 0.74% salt was made by adding 1.24 g/l of the alginic acid, 0.62 ml/l of 34% hydrochloric acid solution and 7.4 g/l of salt to water and making up to volume. The pH of the stock solution was 3.0.

Half of the stock solution was heated to 95 DEG C with stirring to ensure that the alginic acid dispersed. 70g of the rice per litre of stock solution was added to the heated stock solution and the mixture was maintained at 95 DEG C for 17 minutes. The rice was then drained from the solution and allowed to stand for 5 minutes. The partially cooked rice was then washed in the remaining stock solution for 1 minute and then drained. The pH of a macerate of the washed and drained rice was 3.8.

Sunflower oil was then added to the drained rice to a level of 1% by weight of the drained rice and was distributed thoroughly over the drained rice. Aliquots of the oil coated rice equivalent to 100g of dry rice were then placed in plastics pouches. The pouches were made from a laminate of nylon, polyvinylidene chloride-coated nylon and polyethylene, which is heat sealable, strong and gasimpermeable. The pouches were flushed with nitrogen and sealed. The sealed pouches were then immersed in boiling water for 30 minutes in order to achieve a centre temperature of 95 DEG C for 5 minutes. The pouches were removed from the boiling water and allowed to cool.

Some pouches were opened soon after cooling. The rice in the pouches was found to be free-flowing, of good colour and consisting of individual mainly unbroken grains.

The rice was reheated by immersion in boiling water for five minutes or by microwave heating in a 650

W microwave oven at full power for one minute. The reheated rice was tested by a panel of experienced tasters. It was shown to have the same mouthfeel and flavour as the starting rice which had been cooked in conventional manner. In particular, none of the tasters could detect any acid flavour

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notes in the rice of the present invention. The rice had a good texture, was not sticky and felt moist in the mouth. Thus, the product was of premium quality.

Further pouches were kept at room temperature for up to 3 months. The rice in the pouches showed no signs of microbial spoilage or discolouration. On opening such packages and reheating as described above, no change in the properties of the reheated rice was detectable.

Example 2

Long grain parboiled white rice made by the conventional "wet" process and sold under the trade name

"Uncle Ben's" was used as the starting material in this example.

A stock solution containing 0.1% alginic acid (Protacid F120) and having a pH of 3.9 was made up.

Half of the stock solution was heated to 95 DEG C with stirring to ensure that the alginic acid dispersed. Then 70g of the rice per litre of stock solution was added and the mixture was retained at 95

DEG C for 16 minutes. The rice was drained, allowed to stand for 5 minutes, washed for 1 minute in the other half of the stock solution, drained, coated with 1% sunflower oil and filled into pouches as described in Example 1. The pouches were then retorted for 5 minutes at 110 DEG C under an overpressure of 15 psi in order to effect pasteurisation.

The product was shown to be shelf-stable for at least 6 months. When reheated by boiling in water for

5 minutes or in a 650 W microwave oven for 1 minute, the product could not be distinguished from the same rice prepared by conventional cooking and was thus of premium quality. In particular, no acid notes could be detected.

Example 3

Long grain raw white American rice was used as the starting material in this example. A stock solution containing 0.06% malic acid and 0.025% alginic acid was made up. The pH of this solution was 3.0.

400g of the rice was placed in 5kg of stock solution, boiled at ca. 100 DEG C for 15 minutes and drained. While the rice was still at a temperature of above 90 DEG C, it was transferred aseptically into pouches. The pouches were flushed with nitrogen and sealed.

After storage for 3 months at ambient temperature, the rice was reheated in a 650 W microwave oven for two minutes. The resulting rice was perfectly cooked and organoleptically acceptable with no detectable acid flavour notes and was thus of premium quality.

Example 4

This example illustrates the use of a combined acid treatment, cooking and pasteurisation process.

The parboiled rice referred to in Example 2 was used in this example. A stock solution containing 2.7 g/l of alginic acid, 10 g/l of salt, 20 g/l of sugar and 5 g/l of oil and emulsifier was made up.

54g of the rice and 100g of the stock solution were filled into a pouch which was flushed with nitrogen and sealed. The pouches were of the type described in Example 1. The sealed pouch was heated by steam at atmospheric pressure for minutes and then allowed to cool in cold water.

After storage for 3 months at ambient temperature, the rice was reheated in a 650 W microwave oven for two minutes. The resulting rice was perfectly cooked and organoleptically equivalent to fresh boiled rice. In particular, no acid flavour notes were detectable.

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Example 5

Example 2 was repeated except that the stock solution was made up by adding 1 g/l of sodium alginate and 2.5 ml of 34% aqueous hydrochloric acid solution to water to form alginic acid in situ. There was no difference in the quality or shelf-stability of the final product.

Example 6

Example 1 was repeated, except that the stock solution contained 0.05% of pectic acid in place of the alginic acid. There was no difference in the quality or shelf-stability of the final product. The only noticeable difference was that the rice was slightly yellower due to the yellow colour of the pectic acid.

Example 7

10 g of sodium polygalacturonate (sodium pectate) was dispersed in 340 ml of demineralised water. 17 g of the dispersion was diluted to 1 l with demineralised water. To the diluted dispersion was added 1 ml of 36% HCl solution. The dispersion was agitated. The final solution had a pH of 1.9 and contained

0.05% pectic acid. The final solution was used for the cooking and rinsing steps referred to below.

100 g of Suy rice was added to an excess of the final solution which had previously been brought to the boil. The rice was cooked for 17 minutes, removed from the solution and allowed to drain for 1 minute.

The drained rice was immersed for 45 seconds in an excess of cold final solution, removed from the solution and allowed to drain for 5 minutes. The pH of the cooked and rinsed rice was found to be 3.6.

The rice was filled into a pouch which was flushed with nitrogen and sealed. The sealed pouch was heated in boiling water such that the centre temperature of the rice was at 95 DEG C for 5 minutes.

The rice thus produced had good shelf-stability and organoleptic properties. In particular, its flavour on cooking was excellent.

Example 8

Example 3 was repeated except that the stock solution contained 0.06% alginic acid and 0.025% tartaric acid. There was no difference in the quality or shelf-stability of the final product.

Example 9

Long grain raw white American rice was used as the starting material in this example. A stock solution containing 0.1% carageenic acid having a pH of 3.8 was made up.

400g of the rice was placed in 5kg of water containing 10 g/l of salt and 20 g/l of sugar. The mixture was boiled for 10 minutes at ca. 100 DEG C to partially pre-cook the rice. The rice was drained and washed in cold water. The cooked rice was then soaked in 5kg of stock solution. The soaked rice was drained and placed in a glass jar. The jar was flushed with nitrogen and sealed. The sealed glass jar was retorted under 15 psi over pressure at 110 DEG C for five minutes to effect pasteurisation.

The product was shelf-stable and, on reheating, had good organoleptic properties. It had no acid flavour notes.

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Example 10

Example 4 was repeated except that the stock solution contained 2.5 g/l of CMC acid, 10 g/l of salt, 20 g/l of sugar and 5 g/l rape seed oil. The product was shelf-stable and, on reheating, had good organoleptic properties. It had no acid flavour notes.

Example 11

Example 8 was repeated except that the stock solution contained 0.08% alginic acid and 0.02 citric acid and had a pH of 3.3 and that the cooked and acid-treated rice was placed in an aluminium foil tray which was sealed by crimping. The product was shelf-stable and had good organoleptic properties. It had no acid flavour notes.

Example 12

The parboiled rice referred to in Example 1 was used in this example. A stock solution containing 0.8 g/l alginic acid was adjusted to a pH of 3.5 using phosphoric acid.

400g of the rice was placed in 5kg of the stock solution and heated at 95 DEG C for 15 minutes. The rice was drained and washed for 2 minutes in a further 5kg of stock solution. The washed rice was drained and coated to a level of 1% by weight with sunflower oil. The cooked rice was filled into cans which were flushed with nitrogen and sealed. The sealed cans were heated in boiling water at atmospheric pressure for ten minutes.

The product was shelf-stable and had good organoleptic properties. No acid flavour notes were detectable.Data supplied from the esp@cenet database - Worldwide Claims:


1. Shelf-stable, acid-pasteurised rice wherein the acidifying agent is a polymeric food acceptable acid.

2. The rice of claim 1, wherein the polymeric acid has a cellulosic or saccharide-derived backbone having pendant carboxyl groups.

3. The rice of claim 2, wherein the polymeric acid is alginic acid, pectic acid, carageenic acid or carboxymethylcellulose acid.

4. The rice of claim 3, wherein the polymeric acid is alginic acid.

5. The rice of any one of claims 1 to 4, wherein the pH of the rice is below 4.5.

6. The rice of claim 5, wherein the pH of the rice is below 4.2.

7. The rice of claim 6, wherein the pH of the rice is from 3.7 to 3.9.

8. The rice of any one of claims 1 to 7, which contains from 0.01 to 1% of the polymeric acid.

9. The rice of claim 8, which contains from 0.2 to 0.8% of the polymeric acid.

10.The rice of any one of claims 1 to 9, which is not accompanied by free liquid water.

11. The rice of any one of claims 1 to 10, which is contained in a microorganism-impermeable container.

981/2197

12. The rice of any one of claims 1 to 11, wherein the container is gas-impermeable.

13. The rice of claim 11 or claim 12, wherein the container is a can, a jar, a bottle, a foil tray or a pouch.

14. The rice of claim 13, wherein the container is a plastic pouch.

15. The rice of claim 14, wherein the plastic comprises a laminate of a reinforcing layer and a sealing layer.

16. The rice of any one of claims 11 to 15, wherein the rice or pasta is packaged in the container under vacuum.

17. The rice of any one of claims 11 to 16, wherein the rice is packaged in the container under an inert gas atmosphere.

18.The rice of any one of claims 1 to 17, which is coated with a small quantity of an edible oil.

19. The rice of claim 18, wherein the edible oil is sunflower oil, ground nut oil, soya oil or a mixture thereof.

20. The rice of claim 18 or claim 19, wherein the edible oil comprises from 0.3 to 1% by weight of the rice.

21. The rice of any one of claims 1 to 20, further comprising a potentiating amount of a conventional acidulant.

22. The rice of claim 21, wherein the potentiating acidulant is hydrochloric, sulphuric, phosphoric, malic, lactic, citric, tartaric, adipic, fumaric, acetic, ascorbic, isoascorbic or succinic acid or a mixture thereof.

23. The rice of any one of claims 1 to 22, wherein the rice is prepared from parboiled long grain rice.

24.A process which comprises:

(a) treating rice with an aqueous solution adjusted to a pH of 4.5 or below by use of a polymeric food acceptable acid; and

(b) pasteurising the rice while it is maintained at said pH of 4.5 or below by use of a polymeric food acceptable acid, whereby shelf-stable, acid-pasteurised rice is produced.

25. The process of claim 24, wherein the treatment step (a) is carried out for such a time and at such a temperature as to partially cook the rice, cooking to the desired degree being completed during the pasteurisation step (b).

26. The process of claim 24, wherein the pasteurising step (b) is carried out for such a time and at such a temperature that the rice becomes not only pasteurised but also cooked to the desired degree.

27. The process of claim 24, which includes a step (d) in which the rice is partially cooked.

28.The process of claim 27, wherein the partial cooking step (d) is carried out after step (a), under conditions which retain the pH of the rice below 4.5 by use of a polymeric food acceptable acid.

29. The process of claim 27, wherein the partial cooking step (d) is carried out before step (a).

30. The process of claim 29, wherein the rice is partially cooked in both steps (a) and (d).

31. The process of any one of claims 23 to 30, wherein the rice or pasta is washed after any one of steps (a), (b) and (d).

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32. The process of any one of claims 23 to 31, wherein the process conditions are such that the final rice product is unaccompanied by any free liquid water.

33. The process of claim 32, wherein there is used in the process only as much water as is required to hydrate the rice to the desired degree.

34.The process of claim 32, wherein the rice produced by the process is drained of all the water.

35. The process of any one of claims 24 to 34, wherein an edible oil is added to the rice such that the rice is coated with the edible oil.

36. The process of any one of claims 24 to 35, wherein the polymeric acid is generated in situ by reaction between a salt of the polymeric acid and an inorganic or organic acid.

37. The process of any one of claims 23 to 36, wherein there is used with the polymeric acid a potentiating amount of a conventional acidulant.

38. The process of any one of claims 24 to 37, wherein the pasteurisation step (b) is carried out such that the treatment is at least equivalent to maintaining a minimum centre temperature of 93 DEG C for five minutes while the pH of the rice is below 4.5.

39. The process of any one of claims 24 to 38, wherein the pasteurisation step (b) and, if employed, the cooking step (d) are each carried out at temperatures below 100 DEG C.

40. The process of any one of claims 24 to 39, including the further step of

(c) either before or after step (a) or after step (b), sealing the rice in a microorganism impermeable container.

41. The process of claim 40, wherein the pasteurising step (b) is carried out immediately after the sealing step (c).

42. The process of any one of claims 24 to 40, including the further step of

(e) quenching the rice after the acid-pasteurisation step (b).Data supplied from the esp@cenet database

- Worldwide

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206.

IN171862 - 1/30/1993

PROCESS FOR THE PRODUCTION OF PARBOILED RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=IN171862

Inventor(s): GEBHARDT DR DIPL-LEB-CHEM ERIC (--); LEHRACK DIPL-ING UWE (--)

Applicant(s): NAGEMA VEB K (--)


IP Class: A47J27/00

E Class: A23L1/182

Application Number: IN1989CA00015 (19890105)

Priority Number: DD19870309174 (19871119)

Family: HU50011

Equivalent: JP1148158; DE3830965; DD282613; CH675522; IT1224602; HU200667

Abstract:

Abstract not available for IN171862

Abstract of corresponding document: DE3830965

In the production of white rice, by grinding and polishing husked rice, the germ and the multilayer bran which contains significant contents of vitamins, minerals, protein and fat, are removed. In order to retain these substances in the rice, the parboiling process is carried out. The parboiling process comprises a hydrothermal treatment of the brown rice or paddy rice. The invention is used in the food industry for producing parboiled rice having a high degree of whiteness. The process is suitable for long-grain, medium-grain and round-grain rice.Description:

Description of corresponding document: DE3830965

1. Titel der Erfindung

[0001] Verfahren zur Herstellung von Parboiled Reis

2. Anwendungsgebiet der Erfindung

[0002] Die Erfindung wird in der Lebensmittelindustrie zur Herstellung von Parboiled Reis mit hohem Weissgrad angewendet. Das Verfahren ist sowohl für Langkorn-, Mittelkorn- und

Rundkornreis geeignet.

3. Charakeristik des bekannten Standes der Technik

[0003] Das vom Halm geerntete Reiskorn ist aussen von einer harten, kieselsäurehaltigen Hülle

(Paddy-Hülle) umgeben. In der darunterliegenden vielschichtigen Haut, sie wird als Silberhaut bezeichnet und umschliesst den eigentlichen Kern, sind die wesentlichen Anteile an Vitaminen,

Mineralien, Eiweiss und Fett enthalten. Bei der Herstellung von Weissreis werden durch Schleifen und Polieren des geschälten Reises diese Silberhaut und der Keimling entfernt, damit werden auch die für die Ernährung wichtigen Stoffe entfernt. Um diese Stoffe im Reis zu erhalten, wird der Parboiling

Prozess durchgeführt. Neben der Erhöhung des ernährungsphysiologischen Wertes bewirkt der

Parboiling Prozess auch eine Verbesserung der verfahrenstechnischen Eigenschaften, insbesondere eine Erhöhung der Ganzkornausbeute, und der Kocheigenschaften des Reises. Der Parboiling Prozess besteht in einer hydrothermischen Behandlung des Rohreises oder Paddy Reises. Dabei wandern die

Mineralstoffe und Vitamine aus der Silberhaut in das Kerninnere. Auch führt die hydrothermische

Behandlung zu einer Schalenlockerung sowie zur Härtung bzw. Verhornung des Reiskornes

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(Endospermes) durch Gelatinierung der Stärke. Dies bewirkt eine Verfestigung der gesamten

Reisstruktur und führt zu einer höheren Ausbeute an Ganzkorn beim Schälen, Schleifen und Polieren.

Die beim Parboiling erreichte Gelatinierung des Reises verbessert zwar auch die Kocheigenschaften, der Reis klebt weniger, aber insgesamt ist der Parboiling Prozess nicht zu verwechseln mit einer hydrothermischen Behandlung des geschliffenen und polierten Weissreises zur Herstellung von

Schnellkochreis. Beim Schnellkochreis wird im Gegensatz zum Parboiled Reis eine möglichst stark aufgelockerte und poröse Struktur angestrebt.

[0004] Der Parboiling Prozess besteht aus den Verfahrensschritten Weichen, Dämpfen bzw. Kochen und Trocknen des Paddy Reises. Anschliessend wird der behandelte Reis geschält, geschliffen und poliert.

[0005] Für die einzelnen Prozessschritte sind verschiedene Verfahrenstechnische Lösungen bekannt.

Das Weichen erfolgt vorzugsweise im warmen Wasser bei einer Temperatur von 60 . . . 70 C bis zum

Erreichen einer Feuchte von 25 . . . 35%. In der Regel wird für das Weichen eine Zeit von 2 . . . 4 h benötigt. Es kann auch bei niedrigeren Temperaturen geweicht werden, allerdings erhöht sich dann die Behandlungszeit auf 10 . . . 16 h.

[0006] Nach der US-PS 23 58 251 kann der Prozess verkürzt werden, wenn der Reis bei einem

Druck von 0,1 . . . 0,7 MPa geweicht wird. Die Gelatinierung der Reisstärke wird durch Dämpfen bzw.

Kochen des geweichten Reises erzielt. Nach US-PS 43 61 593 wird der bis auf eine Feuchte von 38% im Vakuum geweichte Reis mit gesättigtem Dampf über einen Zeitraum von 15 min behandelt, der

Reis erreicht eine Temperatur von ca. 90 C. Der Reis mit einer Feuchte von 45% wird dann 6 h bei 45

C gehalten, anschliessend bei 66 C vorgetrocknet und dann bei stufenweiser Absenkung der

Temperatur auf eine Feuchte von 12,5% getrocknet. In der US-PS 25 92 407 wird ein Verfahren beschrieben, bei dem der Reis in dünner Schicht bei einer Temperatur, die 100 C nicht überschreiten soll, und mit einer Wassermenge, die nicht zu einer 100%igen Sättigung des Reiskornes führt, geweicht, anschliessend wird der Reis, ebenfalls in dünner Schicht, einer gesättigten

Wasserdampfatmosphäre ausgesetzt. Die Temperatur soll dabei nahe bei, aber nicht über, 100 C liegen. Während des Dämpfens nimmt der Reis weiteres Wasser bis zum Erreichen des

Sättigungsgrades auf und gleichzeitig wird der Vorgang der Stärkegelatinierung beendet.

Anschliessend wird der Reis im Luftstrom bei 80 C getrocknet. Ein ähnliches, sehr aufwendiges

Verfahren wird in der US-PS 25 71 555 beschrieben. In der US-PS 29 09 114 wird eine Apparatur beschrieben, in der das Dämpfen des Reises unter Druck erfolgt.

[0007] Eine Apparatur zur Herstellung von Parboiled Reis, mit der die Zeiten für das Weichen,

Dämpfen bzw. Kochen und Trocknen des Reises wesentlich verkürzt werden sollen, wird in der US-

PS 36 74 514 beschrieben. Insbesondere die Zeit für das Weichen, die, wenn bei Normaldruck gearbeitet wird, bis zu 10 h betragen kann, soll verkürzt werden durch Vorbehandeln des Reises mit heisser Luft von 150 C. Die Trocknung des gedämpften Reises erfolgt mit heisser Luft von 100 . . .

400 C. Die hohen Temperaturen, insbesondere das Vorbehandeln mit heisser Luft, wirken sich negativ auf die gewünschte Kornstruktur des Reises aus. Die bekannten Verfahren zur Herstellung von

Parboiled Reis haben neben den genannten Vorteilen, insbesondere dem Vorteil der Erhöhung des ernährungsphysiologischen Wertes, den Nachteil, dass der Reiskern im Verlaufe des Parboiling

Prozesses eine gelbliche bis dunkelbraune Farbe annimmt. Ursache für diese unerwünschte

Verfärbung sind enzymatische Bräunungsreaktionen (z. B. durch Phonoloxydasen) bzw. chemische

Reaktionen. Im Verlaufe der hydrothermischen Behandlung bilden sich freie Aminosäuren und reduzierende Zucker, die unter Bildung von gefärbten Maillard-Produkten reagieren.

[0008] Um diese Verfärbungen zu verhindern, wird nach Jayanarayanan (Nahrung, Berlin 8 (1964)

2, S. 129-137) Natriumhydrogensulfit dem Weichwasser zugesetzt. Dies übt aber einen negativen

Einfluss auf die Vitamine des Reises aus, so dass der Wert des Parboiling Prozesses damit sehr in

Frage gestellt wird.

[0009] Ebenfalls nachteilig auf die Qualität des Reises wirkt sich die Verwendung von

Kaliumpermanganat aus, die in dem US-PS 36 60 109 zur Verhinderung von Verfärbungen, hervorgerufen durch in der Schale enthaltene Farbstoffe, beschrieben wird. Ein weiterer Nachteil der bekannten technischen Lösungen zur Erzielung des Parboiling Effektes besteht darin, dass im

Verlaufe der hydrothermischen Behandlung ein Substanzverlust durch teilweises Öffnen der Spelze eintritt. Insbesondere Stärkteilchen werden aus dem Endosperm herausgelöst, was auch zu einer

Erhöhung der Klebrigkeit des Reises führt.

[0010] Zur Herstellung von Schnellkochreis, also hydrothermisch behandeltem Weissreis mit aufgelockerter Endospermstruktur, sind ebenfalls viele Verfahren bekannt. Auf einige sei der

Vollständigkeit halber hingewiesen.

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[0011] Nach DE-AS 26 32 121 wird Schnellkochreis in der Weise hergestellt, dass der Reis zunächst auf das 6- bis 16fache seines ursprünglichen Volumens aufgebläht wird, zum Beispiel durch Erhitzen mit Hochfrequenzwellen, anschliessend mit einem Verdickungsmittel behandelt und danach getrocknet und geschrumpft wird.

[0012] Bei der Herstellung von Schnellkochreis nach der DE-PS 25 38 076 wird der Reis nach dem

Weichen und vor dem Dämpfen mit einem Überzugsstoff gemischt. Nach Entzug des Wassers bis zu einem Feuchteanteil von weniger als 35% wird der Reis gepresst und abschliessend zur

Strukturauflockerung mittels Mikrowellen noch einmal erhitzt. In der DE-PS 35 06 099 wird ein

Verfahren zum Aufschluss von Getreidekörnern beschrieben, das dadurch gekennzeichnet ist, dass verschiedene Getreidearten, auch Reis, mit Feuchteanteilen von 10 . . . 15% einer

Mikrowellenbehandlung unterzogen werden. Der Aufschluss erfolgt im ungeweichten Zustand, so dass das Getreide nach der Behandlung durch die Strukturauflockerung (Puffungseffekt) über ein sehr hohes Wasseraufnahmevermögen verfügt, also auch nicht Parboiled Reis entspricht.

4. Ziel der Erfindung

[0013] Das Ziel der Erfindung besteht in der Herstellung von Parboiled Reis mit sehr guten

Gebrauchseigenschaften, insbesondere mit hohem Weissgrad und geringem Bruchkornanfall beim

Schälen und Polieren. Der Weissgrad soll sich vom Weissreis nicht wesentlich unterscheiden. Ein weiteres Ziel der Erfindung besteht darin, die Prozessdauer gegenüber bekannten Verfahren zu verkürzen.

5. Darlegung des Wesens der Erfindung

[0014] Der Erfindung liegt die Aufgabe zugrunde, Verfahrensbedingungen für die hydrothermische

Behandlung von Rohreis aufzuzeigen, die gegenüber bekannten Verfahren zu einer Verkürzung der

Prozessdauer, aber gleichzeitig zu einem hohen Weissgrad und einer hohen Ausbeute an Ganzkorn beim Schleifen und Polieren führen.

[0015] Erfindungsgemäss wird die Aufgabe dadurch gelöst, dass auf einer Feuchte von 25 . . . 35% geweichter Paddy-Reis in überschüssigem Wasser einer Mikrowellenbehandlung ausgesetzt wird, wobei innerhalb von 1 . . . 10 min eine Produkttemperatur des Reises von 100 C erreicht und diese 1 .

. . 5 min gehalten wird, anschliessend das überschüssige Wasser abgetrennt und die

Mikrowellenbehandlung des Paddy-Reises bis zum Erreichen einer Feuchte von 15 . . . 20% bei der gleichen Temperatur fortgesetzt wird. Danach wird der Reis in bekannter Weise weiterverarbeitet.

[0016] Eine bevorzugte Ausführungsvariante besteht darin, dass der geweichte Reis auf einer

Fördereinrichtung kontinuierlich an einer oder mehreren Mikrowelleneinrichtungen, entsprechend der

Leistung der Einrichtung, vorbeigeführt wird. Die Frequenz der Mikrowellen liegt im Bereich von

2370 . . . 2450 Hz.

[0017] Es wurde gefunden, dass eine hydrothermische Behandlung von Paddy-Reis, wird sie in der

Weise ausgeführt, dass der von Wasser vollständig umgebene Reis einer kurzzeitigen

Mikrowellenbehandlung ausgesetzt wird, nicht zu der für den Parboiling Prozess bekannten

Verfärbung des Reises führt und gleichzeitig den Reis in seiner Struktur so verfestigt, dass beim

Schleifen und Polieren gegenüber bekannten Verfahren eine höhere Ausbeute an Ganzkorn erzielt wird. Die Übertragung der für die Gelatinierung der Stärke benötigten Energie mittels Mikrowellen führt zu einer sehr schnellen, vollständigen Erhitzung des Reiskornes. Dies hat eine Inaktivierung der

Bräunungsenzyme zur Folge, gleichzeitig bilden sich infolge des kurzen Zeitraumes, in dem der Reis auf eine bestimmte Temperatur erhitzt wird, weniger reduzierende Zucker und freie Aminosäuren als

Ausgangsprodukte für eine Maillardreaktion als bei bekannten Verfahren. Darüber hinaus ist aber auch die Zeit für den Ablauf einer Maillard-Reaktion begrenzt. Allein durch die Anwendung von

Mikrowellen ist aber ein Parboiling Effekt bei gleichzeitig hohem Weissgrad des Reises nicht zu erreichen. Nur durch die erfindungsgemässe Verfahrensweise, bei der die Mikrowellen auf geweichten Reis einwirken, der vollständig mit Wasser umgeben ist, wird die Aufgabe der Erfindung gelöst. Die Erzielung eines Parboiling Effektes ohne auftretende Verfärbungen des Reises ist an die

Voraussetzung gebunden, eine Verpuffung, d. h. eine explosionsartige Freisetzung des im Korn enthaltenen Wassers als Wasserdampf, zu verhindern und die damit verbundene Strukturzerstörung zu vermeiden. Das im Überschuss angewandte Wasser wirkt dem sich im Korn aufbauenden Druck entgegen und verhindert das Entweichen von Wasserdampf. Ausserdem bewirkt die erfindungsgemässe Verfahrensweise, dass durch die ansonsten inerte Schale so viel Wasser eindringt, dass die Strukturverkleisterung und die Herbeiführung des Parboiling Effektes garantiert sind. Der

Reis wird also nicht wie bei Schnellkochreis in seiner Struktur stark aufgelockert, sondern die

986/2197

vollständige Gelatinierung der Stärke führt zur Verhärtung der Endospermstruktur in dem von der

Spelze umschlossenen Korn.

[0018] Das erfindungsgemässe Verfahren hat gegenüber bekannten Verfahren zur Herstellung von

Parboiled Reis den weiteren Vorteil, dass sich durch die Mikrowellenbehandlung der Anteil der

Körner mit geöffneten Spelzen nach dem Weichen des Reises nicht weiter erhöht. Ursache dafür ist ebenfalls die stark verkürzte Prozessdauer zum Erreichen einer vollständigen Gelatinierung. Die

Erfindung wird an einigen Ausführungsbeispielen näher erläutert.

6. Ausführungsbeispiele

1. 100 g ungeschälter Langkornreispaddy werden gereinigt, mit 0,2 l Wasser auf eine Temperatur von

70 C erhitzt und bei dieser Temperatur 5 h geweicht. Danach beträgt der Feuchteanteil im Reis 32%.

Der Reis wird mit dem zum Weichen genutzten Wasser in einem auf einem Förderband stehenden oder in einer Fördereinrichtung hängenden Glasbehälter gefüllt. Dabei ist das Getreide vollständig vom Wasser umgeben. Der mit Reis gefüllte Glasbehälter durchläuft anschliessend einen

Mikrowellentunnel. Die Frequenz der zur Behandlung erzeugten Mikrowellen beträgt 2450 Hz. Die

Durchlaufzeit beträgt 4 min. Nach 2 min wird im Reis eine Temperatur von 100 C erreicht. Nach einer weiteren Behandlung von ca. 2 min ist die vollständige Gelatinierung des Reisendosperms erreicht. Nach Durchlaufen des Tunnels wird das überschüssige Wasser vom Reis abgetrennt. Danach durchläuft der vom Wasser getrennte Reis nochmals den Mikrowellentunnel. Dabei wird er innerhalb von 5 min auf eine Feuchte von ca. 20% vorgetrocknet und anschliessend der weiteren Bearbeitung zugeführt.

2. 100 g ungeschälter Rundkornreispaddy werden gereinigt, mit 0,2 l Wasser auf eine Temperatur von

70 C erhitzt und bei dieser Temperatur 4 h geweicht. Dabei wird im Reis ein Feuchteanteil von 28% erreicht. Der Reis wird entsprechend Beispiel 1 mit dem zum Weichen genutzten Wasser einer

Mikrowellenbehandlung ausgesetzt. Dabei ist das Getreide vollständig von Wasser umgeben. Bei einer

Frequenz von 2450 Hz beträgt die Durchlaufzeit durch den Mikrowellentunnel 8 min. Die nach 3 min erzielte Produkttemperatur von 100 C wird durch die Mikrowellenbehandlung 5 min aufrechterhalten.

Nach Abtrennen des Wassers vom Reis wird dieser mittels eines nochmaligen Durchlaufs von 8 min durch den Mikrowellentunnel auf eine Feuche von 15% vorgetrocknet.

3. Entsprechend Beispiel 1 wird Langkornreispaddy auf einen Feuchteanteil von 32% geweicht, jedoch wird der Behälter mit dem vom Wasser vollständig umgebenen Reis in einem Mikrowellenofen mit gleicher Frequenz gegeben und nach 4 min wieder entnommen. Nach dem Abtrennen des Wassers wird der Behälter wiederum 5 min der Mikrowellenbehandlung im Mikrowellenofen zum

Vortrocknen des Reises auf 20% Feuchte ausgesetzt. Anschliessend wird der Reis der weiteren

Bearbeitung zugeführt.Data supplied from the esp@cenet database - Worldwide

Claims:

Claims of corresponding document: DE3830965

1. Verfahren zur Herstellung von Parboiled Reis durch hydrothermische Behandlung, dadurch gekennzeichnet, dass der auf eine Feuchte von 25 . . . 35% geweichte Paddy Reis in überschüssigem

Wasser einer Mikrowellenbehandlung ausgesetzt wird, wobei innerhalb von 1 . . . 10 min eine

Produkttemperatur von 100 C erreicht und diese Temperatur 1 . . . 5 min gehalten wird, anschliessend das überschüssige Wasser abgetrennt und die Mikrowellenbehandlung des Paddy Reises bei der gleichen Temperatur bis zum Erreichen einer Feuchte von 15 . . . 20% fortgesetzt und danach der

Paddy Reis der weiteren Verarbeitung zugeführt wird.

2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der geweichte Paddy Reis auf einer

Fördereinrichtung kontinuierlich an ein oder mehreren Mikrowelleneinrichtungen, entsprechend der

Leistung der Einrichtung, vorbeigeführt wird.

3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass Mikrowellen mit einer Frequenz von

2370-2450 Hz eingesetzt werden.Data supplied from the esp@cenet database - Worldwide

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207.

JP1005461 - 1/10/1989

PRODUCTION OF FOOD OF EXPANDED GRAINS

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=JP1005461

Inventor(s): MITSUI FUMITO (--)

Applicant(s): Q P CORP (--)


IP Class: A23L1/10

E Class: A23L1/18B2; A23L1/00P14B2

Application Number: JP19870159634 (19870629)


Family: JP1005461

Equivalent: US4978552; US4891238; JP2009354

Abstract:

Abstract of JP1005461

PURPOSE:To produce an expanded food of grains providing excellent texture in use as a floating ingredient in soup, by treating a main raw material of grain flour containing an insoluble calcium salt and water by an extruder. CONSTITUTION:A raw material mixture comprising grain flour such as wheat flour or rice flour as a main material, containing about 0.5-20wt.% based on weight of the whole raw materials of an insoluble calcium salt such as eggshell powder having preferably about 2-6mu particle diameter and ;=about 25wt.%, preferably about 30-45wt.% water is fed to an extruder, kneaded and successively heated at ;=100 deg.C, usually about 100-180 deg.C. Then the kneaded blend is pushed out from the extruder, cut into a proper length and further dried under heating.Description:



The present invention relates to a novel process for producing puffed, inflated, or swollen foods

(hereinafter referred to as "swollen" food(s)) and to a specific article of swollen food.

Various attempts have so far been made to obtain swollen foods by heating and pressurizing starchy materials such as flour and cornstarch or proteinous materials such as soybean protein through an extruder and then swelling the same by sudden release of pressure.

While swollen foods can be produced by such conventional methods generally with high efficiency, the swollen foods obtained heretofore have generally been liable to have coarse swollen cells or foam bubbles formed by foaming although depending upon the compositions of the foods. When the swollen cells or foam bubbles are coarse, i.e., large, the cell membranes are generally thick so that the whole swollen food becomes hard, resulting in a hard mouth feel. Consequently, such swollen foods have had the problem, for example, of being unsuitable for infant foods such as baby foods.

Further, in one specific mode of the above method for producing swollen foods in which a food material predominantly comprising a starchy material such as flour is mainly used, the total water content in the starting materials fed to an extruder is maintained at about 40% and the extruder used has

988/2197

a die outlet with a square cross section, the swelling percentage of an extrudate at the die outlet is low since the water content is somewhat higher than in starting materials ordinarily used, so that an extrudate having a square cross section approaching that of the die can be obtained. This extrudate, for example, is then cut to an appropriate length, and water contained therein in excess is removed by drying, whereby it can be expected that crouton-like articles can be obtained as the end product.

Although, when sprinkled over hot soup, the swollen food thus prepared does not soften (or become

"mushy") in a time period as short as about 10 to 30 seconds, it is not crispy and feels so hard in the mouth that it is far from being a crouton from the standpoint of textural feel in the mouth.

Conventional croutons prepared by dicing bread into cubes and drying the so diced bread, on the other hand, can be easily crushed when they are eaten directly but, when sprinkled over hot soup, soften in about 20 to 30 seconds and do not feel crispy, thus losing somewhat their pleasant mouth feel.


In view of the above described situation, the primary and basic object of the present invention is to provide a novel process for producing swollen foods by heating, pressurizing and then swelling through an extruder a food material predominantly comprising a starchy material or a protein, which process ensures the production of swollen foods having a softer mouth feel than might be expected from those obtained by a conventional process.

A second and subsidiary object of the invention is to provide a novel process for producing swollen foods by heating, pressurizing and then swelling through an extruder a food material predominantly comprising a starchy material, which process ensures the production of swollen foods which, when sprinkled over hot soup, do not soften in a time period as short as about 10 to 30 seconds, i.e., do not lose crispiness in a short time period, and yet can be easily crushed (with the teeth), i.e., do not remain too hard.

A third object of the invention is to provide novel swollen foods having the desirable properties of the swollen foods produced by the process described with reference to the second object.

As a result of extensive research efforts expended toward the above objects, we have arrived at the present invention.

Basically, the characteristic feature of the process of the present invention is to heat, pressurize and thereafter swell through an extruder a powder comprising fine particles of porous structure and a food material predominantly comprising a starchy material and/or a protein.


The term "powder comprising fine particles of porous structure" as used herein refers to a powder in the form of fine particles containing numerous micropores, typical examples being powders obtained by pulverization of eggshells, animal bones and the like.

These powders comprise fine particles with a maximum particle size of preferably 100 .mu. or less, and more preferably 50 .mu. or less. Specific examples of such powders are those comprising particles with a maximum particle size of 20 .mu. or less or in the range of from about 2 to 6 .mu., for example, because the smaller the particle size, the less rough mouth feel will the end product have.

The phrase "food material predominantly comprising a starchy material" is intended herein to mean a food comprising, as the principal ingredient thereof, a starch component such as rice, wheat or corn and also to include starches obtained by extracting only starch components from cereals such as rice and wheat. Further, the phrase "food material predominantly comprising a protein" as used herein designates a food comprising, as the principal ingredient thereof, a protein component such as soybeans or soybean protein. While these food materials may be in any form, they are generally in granular or powder form.

989/2197

In the practice of the process of the present invention, a powder comprising fine particles of porous structure and a food material predominantly comprising a starchy material and/or a protein as desired, and, if necessary, seasonings (e.g., sugar, salt and cheese), flavors or spices, colorants, edible oils and pure water in an appropriate amount should first be prepared as starting materials.

A suitable quantity of the powder comprising fine porous particles is about 1 to 20% of the total quantity of the starting materials, for example, in the case of eggshell powder, and similar quantities may apply to powders of other sources. The powder in an excessively small quantity is not sufficiently effective in imparting a soft mouth feel while an excess of the powder tends to give a product which is too soft and unpalatable. Generally, a quantity of about 1 to 10% is preferred.

The total water content in the starting materials fed to an extruder may be about 10 to 18%, at which the materials can be easily swollen, in the case where an increase in swelling percentage is generally intended in order to produce swollen foods having a soft mouth feel and is ordinarily below 25%.

However, in order to also achieve the second object of this invention at the same time, water contents of about 25% or higher are required so that the end product, when used as a garnish for soup, will not turn mushy in a short time but can remain crispy. If the water content is lower than 25% of the total weight of the starting materials, they tend to be swollen excessively when they are extruded and swollen through an extruder, and the end product, when used as a garnish for soup, will turn mushy in the mouth in a short time (20 to 30 seconds). If the water content is excessive, for example, higher than

50%, the swollen product obtained by extrusion will have a hard texture presumably because the product cannot be easily made porous.

Even in the case where the total water content in the starting materials is 25% or higher, however, the end product, while remaining crispy, will become too hard as a whole and feel hard in the core unless pulverized eggshells or bones are added. In order to attain the second object of the present invention, the water content is preferably in the range of from 30 to 45%.

Next, the starting materials described above are fed simultaneously in a given quantity to an extruder through which they are heated and pressurized. The extruder used in the process of this invention may be of any type provided that it can heat and pressurize the starting materials: either of the uniaxial type or of the biaxial type. From the standpoint of easy passage of kneaded materials through the extruder, however, a biaxial extruder which can be applied to a wider range of water content (8 to 95%) is preferable to a uniaxial extruder (10 to 30%).

All of the starting materials may be fed to the extruder from a feeder provided at the starting or upstream end of the screw, or a part of the materials (e.g., water) may be fed from an intermediate part of the barrel covering the screw. Further, the starting materials may either be kneaded together before feeding or be fed at a rate sufficient to obtain a constant ratio of the respective starting materials without kneading.

The starting materials are heated by means both of the frictional heat generated during the passage of the starting materials through the barrel of the extruder and of a heater (100 DEG to 200 DEG C.) provided at the barrel.

The starting materials are pressurized as they are forced to pass through the extruder by the screw.

The food material predominantly comprising a starchy material such as cereals is cooked by heating to

100 DEG C. or higher temperatures whereby the starch component thereof turns pasty (.alpha.-starch).

The heating temperature ordinarily is about 100 DEG to 180 DEG C., preferably about 105 DEG to

150 DEG C. By heating at a temperature in this range, the starch component turns sufficiently pasty while, on the other hand, the food material predominantly comprising a protein turns fluid so that the kneaded materials, when extruded through the extruder, are swollen under atmospheric pressure and made porous at the same time. Since the heating temperature is 100 DEG to 180 DEG C., the pressure within the extruder is maintained ordinarily at about 1 to 40 kg/cm@2. The time for the food materials to pass through the extruder depends on the temperature, pressure and other conditions but may generally be in the range of from about 15 seconds to about 6 minutes.

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The starting materials are thus heated and pressurized through the extruder to convert the starchy material into .alpha.-starch, or to convert the protein into a molten state by thermal denaturation, and further to uniformly disperse fine particles of porous structure in the food materials. The resulting molten starting materials are then forced out abruptly into the air from the die portion of the extruder to obtain a swollen product. The swollen product thus obtained is soft and susceptible to deformation while the temperature thereof is high but, upon cooling in the air for a while, can be solidified into a desired form such as a stick or a sheet according to the shape of the die of the extruder, and the resulting swollen product is generally provided as the end product.

In order to attain the second object of the present invention, however, a food material predominantly comprising a starchy material is principally used as a starting material, and the total water content in the starting materials is maintained at 25% or higher, whereupon the extrudate obtained by the above procedure is cut to an appropriate length and the so cut pieces of the extrudate are then heated and dried. Also in this case, the starting materials are extruded through the die portion of the extruder as set forth above. The shape of the cross section of the extrudate is determined by that of the die, but, when the total water content in the starting materials fed to the extruder or the kneaded starting materials is lower than 25%, especially about 5 to 15%, the materials are swollen to such a great extent at the outlet of the extruder (die portion) that the shape of the cross section of the extrudate is not dependent on that of the die but is substantially circular so as to minimize the cross-sectional area thereof, and further the surface of the extrudate is so uneven that the extrudate of a definite shape is difficult to obtain. The shape of the cross section of the die is suitably selected depending upon the desired shape of the extrudate cross section, for example, a square of sizes of 5 to 8 mm, a circle having a diameter of 5 to

6 mm or a heart shape.

The extrudate is then cut to a size, for example, of 5 to 20 mm in accordance with the desired form of the end product. While any appropriate cutting means may be employed, automatic or hand-operated knives are generally used.

Heat-drying methods are not particularly limited, and hot air-drying or frying is applicable in general.

In a method of drying by hot air, for example, hot air at 80 DEG to 90 DEG C. is used, and heating is carried out for about 20 to 40 minutes. From the standpoint of flavoring the product obtained, heatdrying by frying is preferred. The frying conditions may vary slightly with the moisture content of the extrudate, but frying at a temperature of 150 DEG to 190 DEG C. for about 30 seconds to 5 minutes is generally suitable.

The starting materials heated and pressurized into a molten state in the extruder are extruded into the air through the die portion thereof, whereby the air and moisture contained in the molten starting materials expand explosively all at once to form a swollen product.

In accordance with the process of the present invention, fine particles of porous structure are uniformly dispersed in the molten starting materials, and it is presumed that these fine particles serve to lessen the sizes of the foam bubbles generated in the swollen product when the starting materials are swollen and also disperse the foam bubbles uniformly in the swollen product.

As is apparent from the results of Test Example 1 which will be set forth hereinlater, the cells or foam bubbles formed in the swollen food obtained by the process of the present invention are smaller than those formed according to the conventional process and are dispersed uniformly in the swollen food.

For this reason, a swollen food having a dense surface and cross section can be obtained by the process of the present invention. Further, small cells result in thin cell membranes, whereby the whole swollen food can be made soft.

By applying the process of the present invention, it is therefore possible to facilitate the production of swollen foods for infants including baby foods for which a soft mouth feel is desired.

In the case where a food predominantly comprising a starchy material isused as the food material and eggshell powder or bone powder is used as the fine particulate powder of porous structure while the total water content in the starting materials, including the above mentioned food material, fed to the extruder is maintained at 25% or higher, and the extrudate is cut to an appropriate length, heated and dried in accordance with the process of the present invention, a swollen cereal food obtained as the end

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product is not too soft or too hard and feels adequately crispy when used in various ways, for example, as a garnish for soups. Furthermore, this food can be suitably crushed by chewing and does not feel hard in the core when used as a garnish for a vegetable salad and eaten with a dressing, and hence it can be used in a wider range of foods.

The swollen food which has achieved the third object of the present invention will be described in detail in Test Example 3 set forth hereinlater.

EXPERIMENTAL EXAMPLES

The present invention will now be described in more detail with reference to test examples and specific examples of practice wherein all percentages are "% by weight".

Test Example 1

Eggshell powder (maximum particle size: 20 .mu.), cornstarch and pure water were prepared as starting materials, the quantity of the pure water used being 6% of all the starting materials, and the ratio of the eggshell powder to the cornstarch used being as shown in TABLE 1. Subsequently, all the starting materials of the respective compositions were heated, pressurized and swollen through an extruder under the following conditions to obtain 6 types of swollen food samples of different compositions of starting materials.

For each of the samples thus obtained, the apparent bulk density was measured, and the mouth feel of the sample was tested, while the color tone of the sample and the state of swollen cells were respectively observed. The results obtained are shown in TABLE 1. It is apparent from these results that the swollen food comprising eggshell powder had a softer mouth feel than that comprising no eggshell powder.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Sample 1 2 3 4 5 6

>;tb;__________________________________________________________________________

>;tb;Composition of

>;tb; Quantity of eggshell

>;tb; 0 2 5 10 20 40

>;tb;starting

>;tb; powder (%)

>;tb;material

>;tb; Quantity of cornstarch

>;tb; 94 92 89 84 74 54

>;tb; (%)

>;tb;Properties

>;tb; Apparent bulk density

>;tb; 0.22 0.09 0.07 0.09 0.09 0.08

>;tb;of product

>;tb; Mouth feel hard soft soft soft soft soft but

>;tb;(swollen food) unpalatable

>;tb; State of swollen cell

>;tb; coarse (ca. 8-4

>;tb; fine fine fine(-) &

>;tb; fine(-)

>;tb; microscopic(-)

>;tb; mm) & ununiform

>;tb; (ca. 2-1 mm)

>;tb; (ca. 1-0.5

>;tb; uniform

>;tb; uniform

>;tb; & uniform

>;tb; & uniform

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>;tb; & uniform

>;tb; Color tone Pale yellow

>;tb; White White White White Slightly

>;tb;__________________________________________________________________________

>;tb; gray

Notes:

(1) The figures in the parentheses roughly show the range of the size of the cells, i.e., foam bubbles.

(2) Extruding conditions:

All of the starting materials were fed into a biaxial extruder (supplied by Toshiba Kikai K.K., Model

"TEM-50B", screw rotational speed 150 rpm, barrel temperature 140 DEG C.) simultaneously in a given quantity and pressurized at 20 to 30 kg/cm@2 under heating to convert the materials into a molten state.

Subsequently, the molten starting materials were discharged into the air from the die portion of the extruder to swell the same to obtain a swollen food. The swollen product thus obtained was left standing to cool for 5 minutes at room temperature. Thereafter, the mouth feel and other characteristics of the product were determined.

(3) Similarly, a swollen product was prepared by the above procedure from the starting materials comprising 1% of eggshell powder, 93% of cornstarch and 6% of pure water. The mouth feel and other characteristics of this product were rated substantially between those of Sample 1 and Sample 2.

(4) A similar test was conducted with a sample in which the cornstarch in the starting materials was replaced by soybean protein powder, and the effect of softening the mouth feel of the product due to the addition of eggshell powder was observed to be substantially similar to that in the case where cornstarch was used.

Example 1

10 kg of eggshell powder (maximum particle size 20 .mu.) 90 kg of cornstarch and 6 kg of pure water were fed into a biaxial extruder (supplied by Toshiba Kikai K.K., Model "TEM-50B", screw rotational speed 150 rpm, barrel temperature 140 DEG C.) simultaneously in a given quantity and pressurized at

20 to 30 kg/cm@2 under heating to convert the materials into a molten state.

Subsequently, the molten starting materials were discharged into the air from the die portion of the extruder to swell the same. The swollen product thus obtained was left standing to cool for 5 minutes at room temperature, whereby 95 kg of a swollen food having dense surfaces and moreover a soft mouth feel was obtained.

Example 2

6 kg of bovine bone powder (maximum particle size 50 .mu.), 95 kg of flour (high-gluten flour), 1 kg of table salt, 2 kg of sugar, 0.1 kg of yeast extract and 6 kg of pure water were fed into a biaxial extruder (screw rotational speed 120 rpm, barrel temperature 140 DEG C.) simultaneously in a given quantity and pressurized at 20 to 30 kg/cm@2 under heating to convert the materials into a molten state.

The resultant molten starting materials were discharged into the air from the die portion of the extruder to swell the same. The swollen product obtained was left standing to cool for 5 minutes at room temperature, whereby 92 kg of a snack confection having a dense cross section surface and a soft mouth feel was obtained.

Example 3

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A swollen product was produced as in Example 1 except that the cornstarch was replaced by soybean protein (powder), whereby a swollen food having dense surfaces and moreover a soft mouth feel was obtained.

Test Example 2

In all of the samples of the compositions shown in the following TABLE, the starting materials excluding water were fed into a biaxial extruder (screw rotational speed 280 rpm, barrel temperature

130 DEG C, barrel internal pressure ca. 30 kg/cm@2) from a feeder at a rate of 0.42 kg/min. while water was fed through an inlet provided at the barrel portion. The starting materials in entirety were kneaded and heated in the barrel, and discharged into the air through a die (of approximately 6 .times. 6 mm square cross section). For each sample, the kneaded materials were passed through the extruder for approximately 2 minutes.

Each of the extruded samples (in the form of a bar) was manually cut with a knife at intervals of 6 mm, and the so cut pieces were fried in oil at 170 DEG C. to produce croutons.

The mouth feel of the croutons thus produced from each sample was examined, whereupon the results shown in TABLE 2 below were obtained.

As is apparent from the data in TABLE 2, the croutons obtained by the process of the present invention are excellent in crispiness and shape of the product as compared with those obtained by the control processes.

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb;Conditions Process of the invention

>;tb; Control process I

>;tb; Control process

>;tb;__________________________________________________________________________

>;tb; II

>;tb;Composition of starting material

>;tb;Flour (moisture content: ca. 14%)

>;tb; 68(%) 70(%) 91(%)

>;tb;Eggshell powder (average particle size:

>;tb; 4 0 4

>;tb;2-3.mu.)

>;tb;Water 28 30 5

>;tb;Total water content in starting materials

>;tb; 38 40 18

>;tb;Heating-drying condition

>;tb;Frying temperature &

>;tb; 170 DEG C. 170 DEG C. 170 DEG C.

>;tb;time 2 min. 2 min. 1 min. 20 sec.

>;tb;Moisture content in fried crouton

>;tb; 2.0% 2.2% 1.5%

>;tb;Properties of product

>;tb;Mouth feel of product sprinkled over hot

>;tb; Does not turn mushy and is

>;tb; Does not turn mushy but

>;tb; Turns mushy

>;tb;soup as determined after 3 min.

>;tb; adequately crispy

>;tb; hard in the core

>;tb;Mouth feel of product itself

>;tb; Adequately crispy, easily

>;tb; Hard as a whole and in the

>;tb; Easily crushed and

>;tb; crushed and yet soft to the

>;tb; (so hard as to feel prickly in

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>;tb; yet soft to the core

>;tb; core mouth)

>;tb;Shape of product Substantially dice-shaped

>;tb; Substantially dice-shaped

>;tb; Substantially

>;tb; cylindrical

>;tb; (with no angles

>;tb; character-

>;tb; istic of dice)

>;tb;Apparent bulk density

>;tb; 0.35 0.36 0.11

>;tb;Size of cell ca. 0.5-0.1 mm ca. 1-0.5 mm ca. 1-0.5

>;tb;__________________________________________________________________________

>;tb; mm

Test Example 3

In all of the samples of the compositions shown in the following TABLE, the starting materials excluding water were fed into a biaxial extruder (screw rotational speed 280 rpm, barrel temperature

130 DEG C., barrel internal pressure ca. 30 kg/cm@2) from a feeder at a rate of 0.42 kg/min. while water was fed through an inlet provided at the barrel portion. The starting materials in entirety were kneaded and heated in the barrel, and discharged into the air through a die (of approximately 6x6 mm square cross section). For each sample, the kneaded materials were passed through the extruder for approximately 2 minutes.

Each of the extruded samples (in the form of a bar) was manually cut with a knife at intervals of 6 mm, and the so cut pieces were heated with hot air at 80 DEG to 90 DEG C. for 20 to 30 minutes so that the final moisture content of the product would be 2.0%, thereby to produce croutons.

The mouth feel of the croutons thus produced from each sample was examined. The results obtained are summarized in TABLE 3.

As is apparent from the data in TABLE 3, the product crouton (swollen cereal food) having an apparent bulk density of about 0.22 to 0.39 and a cell size of about 0.7 to 0.08 mm remains appropriately crispy when sprinkled onto a hot soup and yet is not too hard.

It will also be evident that the crouton produced can retain the shape of the die relatively faithfully.

>;tb; TABLE 3

>;tb;__________________________________________________________________________

>;tb; Sample

>;tb;Conditions 1 2 3 4 5 6 7 8

>;tb;__________________________________________________________________________

>;tb;Composition of starting material

>;tb;Flour (moisture content: ca. 14%)

>;tb; 88.3(%)

>;tb; 82.5(%)

>;tb; 76.7(%)

>;tb; 70.9(%)

>;tb; 65.1(%)

>;tb; 59.3(%)

>;tb; 53.4(%)

>;tb; Com-

>;tb;Eggshell (average particle size:

>;tb; 4 4 4 4 4 4 4 mercially

>;tb; -2-3.mu.)

>;tb; 4available

>;tb;Water 7.7 13.5 19.3 25.1 30.9 36.7 42.6 crouton

>;tb;Total water content in starting

>;tb; 20 25 30 35 40 45 50 (prepared

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>;tb;materials from

>;tb; bread)

>;tb;Drying under heating

>;tb;Hot air temperature and

>;tb; 80-90 DEG C.

>;tb; " " " " " " Com-

>;tb;blowing time 20-30 min mercially

>;tb; available

>;tb; crouton

>;tb; (prepared

>;tb; from

>;tb; bread)

>;tb;Moisture content in dried crouton

>;tb; 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0% 2.0%

>;tb;Properties of product

>;tb;Mouth feel of product sprinkled

>;tb; X@(1)

>;tb; .DELTA.@(1)

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .DELTA.@(2)

>;tb; X

>;tb;over hot soup as determined

>;tb;after 3 min. (mouth feel (1))

>;tb;Mouth feel of product itself

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .DELTA.

>;tb; .circle.

>;tb;(mouth feel (2))

>;tb;Shape of product

>;tb; X .DELTA.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb; .circle.

>;tb;Apparent bulk density

>;tb; 0.10 0.16 0.22 0.28 0.34 0.39 0.45 --

>;tb;Size of cell ca. 1-0.5

>;tb; ca. 0.9-

>;tb; ca. 0.7-

>;tb; ca. 0.6-

>;tb; ca. 0.5-

>;tb; ca. 0.3-

>;tb; ca.

>;tb; ca. 1-0.5

>;tb; mm 0.4 mm

>;tb; 0.3 mm

>;tb; 0.2 mm

>;tb; 0.1 mm

>;tb; 0.08 mm

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>;tb; 0.05

>;tb; mm

>;tb;__________________________________________________________________________

Notes:

(1) The symbols O, .DELTA. and X in the TABLE respectively indicate the following characteristics.

Mouth feel (1):

X@(1) softens to turn mushy in 3 to

5 seconds

.DELTA.@(1) turns mushy in 0.5 to 1 minute

O remains moderately hard and feels crispy for about 3 minutes

.DELTA.@(2) remains moderately hard and feels crispy for about 3 minutes, but feels hard in the core

(too hard)

Mouth feel (2):

O feels soft to the core (appropriately crushed)

.DELTA. feels slightly hard in the core (not easily crushed)

Shape of product:

X substantially cylindrical (with no angles characteristic of dice)

.DELTA. while having angles, each edge expanding outwardly in an arch form (swollen)

O substantially dice-shaped

(2) The sizes of the cells in the extrudate were measured with respect to those visible in a cross section perpendicular to the direction of extrusion. Few cells were found on the outer sides of the extrudate in the direction of extrusion.

Example 4

Croutons were produced in accordance with the process of the present invention described in Test

Example 2 above except that the starting materials were used in the following proportions.

>;tb;______________________________________

>;tb;Starting material Proportion (%)

>;tb;______________________________________

>;tb;Flour (moisture cont.: ca. 14%)

>;tb; 64

>;tb;Eggshell powder (av. particle size: 6.mu.)

>;tb; 4

>;tb;Soybean protein powder 4

>;tb;(mositure cont.: ca. 6%)

>;tb;Water 28

>;tb; 100

>;tb;______________________________________

The water content in the overall starting materials was approximately 37%, and the moisture in fried croutons was approximately 1.8%.

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Example 5

Croutons were produced in accordance with the process of the present invention described in Test

Example 2 above except that the starting materials were used in the following proportions.

>;tb;______________________________________

>;tb;Starting material Proportion (%)

>;tb;______________________________________


>;tb; 65

>;tb;Bone powder (av. particle size: 6.mu.)

>;tb; 4

>;tb;Shortening 1

>;tb;Sugar 2

>;tb;Water 28

>;tb; 100

>;tb;______________________________________


Example 6

Croutons were produced as in the process of the present invention described in Test Example 2 above except that the starting materials were used in the following proportions and that the following extruding conditions were employed.

>;tb;______________________________________

>;tb;A: Starting material Proportion (%)

>;tb;______________________________________


>;tb; 64

>;tb;Eggshell powder (av. particle size: 10.mu.)

>;tb; 3

>;tb;Water 33

>;tb; 100

>;tb;______________________________________


>;tb;______________________________________

>;tb;B: Extruding conditions

>;tb;______________________________________

>;tb;Screw rotational speed 250 rpm

>;tb;Barrel temperature 120 DEG C.

>;tb;Barrel internal pressure

>;tb; ca. 35 kg/cm@2

>;tb;Starting material feeding rate

>;tb; 0.60 kg/min.

>;tb;______________________________________

Kneaded materials were passed through the extruder for approximately 2 minutes.

Example 7

Croutons were produced as in the process of the present invention as described in Test Example 2 except that the extrudate cut at intervals of 6 mm was heat-dried with hot air instead of frying

(temperature: 90 DEG C., time 20 minutes). The moisture content in the end product obtained was approximately 3.5%.

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None of the croutons obtained in Examples 4 through 7 described hereinbefore turned mushy in the mouth, but they remained crispy even 1 to 2 minutes after they were sprinkled onto a hot soup as a garnish.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A process for producing swollen foods which comprises heating and pressurizing through an extruder a powder comprising eggshell powder having a maximum particle size of 100 .mu. and a food material predominantly comprising a starchy material or a protein or mixtures thereof and thereafter releasing said powder and food material thereby causing the same to swell.

2. A process as claimed in claim 1, wherein 1 to 20%, based on the total quantity of the starting materials, of eggshell powder is used.

3. A process as claimed in claim 1, wherein a food predominantly comprising a starchy material is used as the food material.

4. A process as claimed in claim 3 wherein the total water content in the starting materials fed to the extruder is maintained at 25% or higher and the resulting extrudate thus caused to swell is cut to an appropriate length, heated and dried.

5. A process as claimed in claim 4, wherein the product obtained after heating and drying is a crouton.

6. A process as claimed in claim 4, wherein the extruder is of the uniaxial or biaxial type.

7. A process as claimed in claim 4, wherein the drying method involves through-flow drying or frying in oil.Data supplied from the esp@cenet database - Worldwide

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208.

JP1010954 - 1/13/1989

MIXTURE OF GERLANGUM AND STARCH


Inventor(s): ROSU SHII KURAAKU (--); DANIERU AARU BAAGAMU (--)

Applicant(s): MERCK and CO INC (--)


IP Class: A23L1/195; A23L1/04

E Class: A23L1/0522; A23L1/054D; C08L3/02



Family: JP1010954


Abstract:


PURPOSE: To obtain a mixture of gellan gum and starch which consists of each specified amt. of gellant gum, starch and water and has improved shear stability and storage stability. CONSTITUTION:

This mixture contains (A) 0.01 to 1wt.% gellan gum which is preferably deacetylated and made transparent, (B) 1.5 to 8wt.% starch which is preferably a starch of corn, waxy maize, tapioca, wheat, potato or rice, (C) water and (D) preferably sugar, animal protein, fat, flavor and/or coloring agent.Description:


GELLAN GUM/STARCH BLENDS


Starch is the most commonly used material to thicken aqueous solutions, especially foods. In a typical application starch is mixed with water, heated to swell the starch granules and solubilize amylose molecules, and the dispersion cooled to form a gel or paste. Chemically modified starches comprise modified starches comprise over 40% of the starches used in the food industry. Chemical modification

(cross-linking) limits the swelling of the granules and produces starches which are more shear stable than unmodified starches. Chemical modification (substitution) controls the way that amylose chains re-associate to form gels.

Combinations of gellan gum and starch have been disclosed in the art. For example, Baird, et al,

Bio/Technology, November 1983, page 781, teach that it may be desirable to use gellan gum in combination with modified starches to obtain optional product texture and stability. Kang, et al, Some

Novel Bacterial Polysaccharides of Recent Development, page 240, teach that gellan gum may be used as a structuring agent to replace of partially replace the starch. Sanderson et al, Food Technology, April

1983, teach at page 66, Table 4, a starch jelly formulation containing 6.56% starch and 0.2% gellan gum; at page 68, Figure 8 an amylograph for a 4.8% starch/0.2% gellan gum blend; and at page 68, the

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advantages of combining starch and gellan gum in pie fillings and puddings. U.S.Patent 4,517,216,

Table 1-1 discloses blends of 0.25% gellan gum and 0.25% corn starch.


It has now been found that blends of gellan gum and starch in the range, by weight, 0.01-1% gellan gum and 1.5-8% starch, the balance being water, optionally with the materials such as sugars, (e.g., sucrose, fructose, etc.) animal or vegetable proteins (e.g., milk or soy), fats, flavorings, colorings, etc., exhibit useful rheological and other physical properties that make them useful in various applications, primarily in food compositions.


By gellan gum is meant deacetylated and partially deacetylated gellan gum and the clarified forms thereof such as are taught in U.S. Patents 4,326,052 (Kang et al,) and 4,503,084 (Baird, et al.), which are incorporated herein by reference. By starch is meant corn, waxy maize, tapioca, wheat, potato, and rice starch. This term is also intended to include native and chemically modified starches, such as cross-linked and substituted starches.

Viscosity Effects

Gellan gum has very little effect on the viscosity of starch pastes during gelatinization. This is important in that it allows for faster heat penetration, i.e., reduced cooking time and allows the use of existing equipment without a change in capacity, etc. This is unexpected as it is known that most hydrocolloids when blended with starch will exhibit a marked increase in viscosity during gelatinization of the starch as compared to the starch sample without gum. The main advantage of gellan gum is at low usage levels (0.1%), where it significantly affects the rheology of the starch paste after hydration. Other gums used at these low levels produce little end effect but do not increase the viscosity during gelatinization. At higher use levels, they do increase gelatinization viscosities and end paste viscosities.

The major parameters governing starch behavior are gelatinization and retrogradation. During gelatinization (heating over a temperature range) the starch granule swells and loses birefringence; the pastes clarify and viscosity increases; amylose molecules are solubilized and leach out. On cooling, retrogradation ("setback") occurs. The amylose molecules re-associate to form a precipitate or gel; the paste becomes cloudy; and syneresis can occur.

To follow the viscosity build of starch while cooking, the Brabender Visco-Amylograph is used. The starch is slurried in either water or water to which an acid or other ingredient has been added, then heated in a revolving cup to a designated temperature and held there for a set length of time. Viscosity is measured through resistance exerted on a paddle suspended in the starch paste. A continuous recording of this resistance is taken on a chart recorder. This resulting curve records the point of gelatinization, the rate of viscosity development, the peak viscosity, and the rate of viscosity breakdown.

The Brabender viscosity curves reveal the comparative viscosity levels and comparative pasting temperatures of starches. The standard method used calls for the starch slurries to be heated rapidly to

50 DEG C, then at a rate of 1.5 DEG C/minute to 95 DEG C. They are held at that temperature for between 15 and 30 minutes then cooled at a rate of 1.5 DEG C/minutes to 50 DEG C. The four major points on the typical curve are:

1) The Pasting Temperature: the temperature at which the viscosity development is first seen. This is the onset of gelatinization.

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2) Pasting Peak: this viscosity is important because in most cases the user must cook through this stage to obtain a usable starch paste.Comparison of the pasting temperature with the temperature at which the pasting peak occurs provides an indication of the gelatinization range of the starch.

3) Viscosity when paste reaches 95 DEG C: The relation of this value to the peak viscosity reflects the ease of cooking the starch. It provides an indication of the fragility of the swollen starch granules.

4) Viscosity after Cooking: an indication of how stable the starch is to further shear. This is the viscosity after the 95 DEG C holding period.

Through the use of the Visco-Amylograph, starches of different varieties, different modification treatments, or gelatinized in different media can be compared. Corn starch heated to 95 DEG C will show a rather rapid increase in viscosity after gelatinization until it reaches a peak. The viscosity gradually decreases during holding then rapidly increases as the paste cools. The waxy starch will increase in viscosity more rapidly than the corn starch, peak sooner and higher, and break down faster and considerably more. On cooling, the waxy corn shows only a very little increase in viscosity after gelatinization with a much higher peak viscosity but it also breaks down faster and considerably more than the corn starch. On cooling it shows a moderate increase in viscosity due to its intermediate amount of amylose present. The effect of various agents and additives on the gelatinization and pasting of starch may also be examined. The addition of a relatively small amount (0.5%) of most hydrocolloids (such as carboxymethyl cellulose and xanthan gum) creates a dramatic increase in viscosity during cooking.

However, the addition of gellan gum to starch prior to gelatinization has only a slight effect on the viscosity of the paste during cook-up. This is in contrast to other hydrocolloids which, because they are used at higher usage levels and/or hold viscosity better at increased temperature than gellan gum, display a marked increase in viscosity during the gelatinization and cooking of the starch. This minimal viscosity effect during gelatinization combined with gellan gum's ability to provide a large effect on the final texture and viscosity after cooling provides an advantage in that it allows for faster heat penetration during cooking, and may allow for a reduction of the level of starch required. This is important in any product which requires high temperature processing such as canned products, or cookup type starch fillings.This is also effective in reducing boil out in pie filling.

Effect on Shear Stability

The reactivity of gellan gum with starch represents a technique which can allow for the extension of the starch, or modification of its texture.

The major parameters governing starch behavior are gelatinization and retrogradation. Important processing variables in food which can effect starch gelatinization are temperature, time, shear, and pH.

The higher the temperature, the more swollen the granule; the more swollen the granule, the more fragile and susceptible it becomes to rupture by shearing, especially after cooling. In order to improve the shear stability of the starch paste, especially after cooling, the starch granule may be chemically modified to limit the swelling of the granule. Today, approximately 100,000 metric tons of the starch used in the food industry is modified. However, current trends in the market are to minimize the use of modified starches, or replace them with non-modified starches.

The blending of gellan gum with starch prior to gelatinization has now been found to improve the shear stability of the starch after cooling. Low levels (approximately 0.1%) of gellan gum have been found to impart a viscosity build following the shearing of the paste. It has been found that the dry blending of gellan gum with either unmodified or modified starches prior to heating improves the viscosity of the pastes following shearing. Also, it has been found that this is true under both neutral and acidic conditions.

A simple blend of starch (approximately 0.3 to 10.0%) and gellan gum (approx 0.1%) can be made prior to heating. The blend must be heated (greater than 85 DEG C) to gelatinize the starch and fully hydrate the gellan gum. The blend or formulation can then be cooled to room temperature. This paste can then be sheared for 5 minutes or longer. Sixty percent or more of the viscosity will be lost during shearing, however, following shearing if the paste is left to stand several hours between 25 to 100% of

1002/2197

the viscosity will rebuild in the paste. This would lend itself to pumpable fillings such as cream fillings, and fruit fillings for fried pies or donuts.

There are several procedures for determining the shear stability of starch samples. See, for example, H.

Klaushofer, "On Determination of Shearing Stability of Starch Pastes" STARCH, June, 1975.

Gellan gum starch blends were tested for shear stability using the following protocol:

1) Measure out water in a 450 ml stainless steel cup.

2) Measure out gum and starch separately. Add the gum to the water with mechanical agitation. Stir for about 5 minutes. Add the starch to the gum solution and mix for an additional 5 minutes.

3) To gelatinize the starch, place the cup in a hot water bath heated to 95 DEG C. Cover the solution with a plastic cover with a hole placed in the center to allow for the shaft of a propeller type stirrer to run through it.Mix the solution continuously at 360 rpm while cooking.

4) The native starches are left in the water bath for 30 minutes; the modified starches for 45 minutes.

5) At the completion of cooking, remove the cups from the bath and allow to cool overnight at room temperature.

6) Take a viscosity reading on the cooled starch paste sample using a Brookfield RVT viscometer with Helipath attachment at 2.5 rpm using an appropriate T-bar type spindle.

7) Using a 3 bladed propeller type mixing blade 2" in diameter, mix the sample at 1800 rpm for 5 minutes.

8) Immediately following mixing, measure the viscosity again using the RVT viscometer.

9) Allow the sample to stand undisturbed overnight. Retake the viscosity using the RVT viscometer.

These trials demonstrated that gellan gum would gel the starch pastes after cooling. In all tests the starch pastes exhibited a gelled matrix with the addition of only 0.1% gellan gum. In most cases the addition of gellan gum did not improve the immediate shear stability of the starch paste as the viscosity generally dropped by more than 60% when measured immediately after shearing. However, it was found that by allowing the starch/gellan gum blend to stand following shearing, a noticeable viscosity increase was observed. This increase in viscosity was more noticeable in the unmodified, and lightly modified starches than in the more highly modified starches. One example was W-13 starch, a lightly cross-linked waxy maize starch, when blended with gellan gum in standard tap water (STW is deionized water containing 0.004M calcium and 0.48M sodium) with vinegar.After shearing this sample blend and allowing it to stand, the viscosity reading was higher than the viscosity before shearing. The highly modified starches displayed very good shear stability. However, the viscosity readings of these pastes, both before and after shearing, were lower than the viscosities of the starch blended with gellan gum after shearing.

These blends of gellan gum and starch may partially replace highly modified starches, and/or enhance their functionality. These blends find application in sauces, soups, and gravies. In addition, they are effective in pumpable type systems such as pumpable jellies, fillings or icings.

The gum starch blend is easily dispersed in cold water, and then can be heated to gelatinize the starch and solubilize the gum. Variations in starch/gellan gum levels effect the final outcome of the product, i.e., change the texture of the product making it more starch like or gelled like depending on the gum:starch ratio.

Storage Stability

The addition of gellan gum to starch prior to gelatinization improves the water holding capacity of the starch. Low levels (about 0.1%) of gellan gum have been found to reduce water migration out of the starch pastes including both unmodified and modified starches under both neutral and acidic conditions. This would have application in any system where water binding is important, such as in puddings and pie fillings.

A simple blend of starch (about 3.0 to 10.0%) and gellan gum (about 0.1%) can be made prior to heating. The blend must be heated to gelatinize the starch and fully hydrate the gellan gum. The blend or formulation can then be cooled to room temperature, and no further processing is required.

1003/2197

Gellan/starch blends were tested for storage stability and water holding capacity using the following protocal:

1) Measure out STW (or STW with 2% 100 grain vinegar) in a 450 ml stainless steel cup.

2) Measure out gum and starch separately. Add the gum to the water with mechanical agitation. Stir for about 5 minutes. Add the starch to the gum solution and mix for an additional 5 minutes.

3) To gelatinize the starch, place the cup in a hot water bath heated to 95 DEG C. Cover the solution with a plastic cover with a hole placed in the center to allow for the shaft of a propeller type stirrer to run through it. Mix the solution continuously at 360 rpm while cooking.

4) The native starches are left in the water bath for 30 minutes; the modified starches for 45 minutes.

5) At the completion of cooking, pour aliquots of the cooked paste into five 50 ml beakers.Allow these samples to cool at room temperature for 30 minutes, then cover with a plastic film (such as Saran

Wrap) and place in the refrigerator set at 2 DEG C. Remove samples as required for testing (1, 2, 6 and

10 days).

6) The samples are removed from the refrigerator at the specified times and allowed to stand at room temperature for several hours. Then viscosities are taken using a Brookfield RVT viscometer with

Helipath, 2.5 rpm spindle 3.

7) A portion of the sample is removed from the 50 ml beaker and placed in a plastic ring, 1 Uml& in diameter and 1/2" in height sitting on a No. 1 18.5 cm Whatman filter paper.The sample is placed in the ring, level to the top of the ring.

8) After one hour has elapsed, the sample is removed and the area dampened by the water migrating out of the paste is traced on the paper.

9) The paper is left to dry overnight.

10) Weigh the filter paper and record the weight (W1). Then cut out and weigh the previously wetted area (W2). W2/W1 x 100 = % wetted area; i.e., a measure of the water retention of the blend.

The results of this test indicate that gellan gum improves the storage stability over a 10 day period as compared to the native starches. Gellan gum's effect in terms of improving the water holding capacity is more noticeable with the raw starches and lesser modified starches (such as W-13, than with the more highly modified starches. From examination of the test results it was found that the syneresis or water migration out of the starch paste is not strictly related to the viscosity of the paste. But gellan gum is effective in improving the water holding capacity of the starch in all samples tested.

This blend of gellan gum and starch may replace modified starches, and/or enhance their functionality in various food products such as puddings, pie fillings, and canned products. The gum/starch blend is easily dispersed in cold water, and then can be heated to gelatinize the starch and solubilize the gum.

Variations in starch/gellan gum levels effect the final outcome of the final product; i.e., change the texture of the final product.

Texture and Rheology Effects

The blending of gellan gum with starch prior to gelatinization has now been found to alter the texture and rheology of both native and lightly modified starches after cooling and shearing.

The addition of low levels (about 0.1%) of gellan gum has been found to gel starch pastes after cooling if sufficient ions are present. The texture of the pastes are basically determined by the concentration of the gellan gum, and the type and concentration of the starch used. Unmodified starches and lightly modified starches blended with gellan gum display a more brittle starch gel matrix, with is rather firm and cutable. Highly modified starches retain more of their starch paste texture which is rather salve-like and less gelled in texture.

If the pastes containing gellan gum are sheared, a noticeable drop in viscosity is observed. However, if these pastes are allowed to stand following shearing, an increase in viscosity is observed. The rheology of these pastes following shearing is changed from the initial cooked and cooled pastes. The unmodified starches lose their gel matrix, and become more pseudoplastic and somewhat resemble a xanthan gum solution. The lightly modified starches loose their firmer, cutable gel matrix, and have a more salve-like appearance, with a rather "chunky", gelled-like flow characteristic. Neither product,

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with either unmodified or modified starch, displays a grainy or pulpy type appearance as would be expected when a gel matrix is broken as during shearing.

The unmodified starch/gellan gum blends have utility in sauces, gravies or salad dressings, as a replacement for more highly modified starch, or other gums. The lightly modified starch gellan gum blends are useful where more highly modified starches are typically used.

Using the protocol described above for measuring shear stability, several starch/gellan gum blends were prepared. After shearing, a sample of gellan gum and (Amioca) native waxy maize starch was found to become rather pseudoplastic and somewhat resembled xanthan gum in its rheology.

A sample of Amioca starch was blended with xanthan gum and compared to an Amioca/gellan gum blend using the shear test procedure. The gellan gum at use levels equal to xanthan gum had a much more dramatic affect on the starch paste viscosity both before and after shearing than the xanthan gum did.

Another example was a lightly cross-linked waxy maize starch (W-13) when blended with gellan gum in standard tap water (STW) with 2%, 100 grain vinegar. After shearing this blend and allowing it to stand, the viscosity reading was higher than the viscosity before shearing. The texture of the blend was changed after this shearing from the initial gelled type matrix which was more brittle and cutable, to a more salve-like, gelled "chunky" flowing consistency.

These blends of gellan gum and starch may partially replace highly modified starches, and/or enhance their functionality. The blends find applications in sauces, soups, gravies, and salad dressings.

Figure 1 shows four Brabender amylographs of 4.5% cross-linked waxy corn starch with and without

0.5% added gum in Standard Tap Water.

Figure 2 shows the shear stability of 5% acetylated, cross-linked waxy cornstarch with and without gellan gum (GELRITE TM ). The starch pastes were cooked and cooled, held for 18 hours, and then sheared at 1800 rpm for 5 minutes.

Figure 3 shows the shear stability of 0.1% gellan gum (GELRITE TM ) gels. The gels were prepared by heating and cooling, and allowed to stand for 18 hours. The gels were then sheared at 1800 rpm for

5 minutes.

Figure 4 shows the storage stability of 5% waxy cornstarch pastes with and without 0.1% gellan gum

(GELRITE TM ). The samples were stored at 2 DEG C.Data supplied from the esp@cenet database -

Worldwide

1005/2197

209.

JP1043162 - 2/15/1989

PRODUCTION OF PRECOOKED PAERIA


Inventor(s): JIYUAN ANTONIO SEGURA KASUTANO (--)

Applicant(s): JIYUAN ANTONIO SEGURA KASUTANO (--)


IP Class: A23L1/10

E Class: A23L1/182; A23L1/182C


Priority Number: ES19870002155 (19870723)

Family: JP1043162

Equivalent: EP0300948; SU1745095; PH26003; MA21335; ES2004149; AR243063; PT88079;

IE882245L; IE62971

Abstract:


PURPOSE: To provide paella which is cooked by simply adding water, by preparing sauce containing seasoning, mixing this sauce with rice, stewing it, adding greens, meat, fish and seafood and packing a product through vacuum and quick freezing. CONSTITUTION: The sauce containing various kinds of seasoning for paella is prepared and this sauce is mixed with rice. Then, the mixed sauce and rice is stewed until all the sauce is absorbed into the rice. Afterwards, components such as greens, meat, fish and seafood selected corresponding to taste suitable for paella are added, the product is packed through vacuum or quick freezing and the purposed paella is provided.Description:


PROCEDURE FOR THE PREPARATION OF PRE-COOKED PAELLA

This invention is about a procedure for the packaging of the pre-cooked paella, meant to be packed fo its sale in such a state that its final consumption can be done through a simple elaboration process which does not require any background or whatsoever cooking skills.

For the preparation of paelleas there are already on the market some products including certain components, such as seafood, greens, etc., in natural and frozen state, with which a certain amount of rations can be prepared. However, until now, there is no product including all the components, the required sauce and rice included.

The aim of this invention is to develop a procedure allowing the preparation of the pre-cooked paellas, including all the precise ingredients and components.

Another aim of this invention is to develop a procedure for the aforesaid aim, through which certain components (e. g. sauce, rice, seafood, and others) are in a pre-cooked stage which allows that at the consumption moment, it will be enough to submit the product to a simple cooking stage, adding water.

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The invention procedure includes the stages of a) preparation of a sauce including the different seasonings for the paella, b) mixing of this sauce with rice in the adequate amount, c) cooking of the rice and sauce mixed until getting all the sauce absorbed by the rice and d) packing of the resulting product through vacuum or deep freezing adding components of greens, meats, fishes, seasood, selected according to the flavour the paella should have.

The preparation of the sauce is to be done on soft fire with ground tomato, vegetal oil, smashed onion, table salt ground garlic, sweet coloured paprika, sugar, ground black pepper and an assortment of natural saffron, parsley, ground garlic, almond, hazelnuts and pine nuts. Those components are to be mixed and par boiled and fried until obtaning an almost thick sauce, adding, if necessary, some vegetal oil in case the sauce was prepared without the necesary amount, The sauce and rice, well mixed, are submitted to cooking in a container at high temperature, preferably between 50 and 260 DEG , until getting all the sauce and added oil to be adsorbed by the rice in a single body, being the rice the carrier of sauce and oil.During the mixing of the different products and its cooking, the elaboration of the rice is carried out until arriving to a refrying stage, the rice grains disentangled the ones from the others.

The aim of the preceeding stage is getting the rice graims to be the carriers of the sauce with its flavour.

In the same time, the rice gets a conservation stage due to the absorbed oil.

To get different flavours in the procedure or method of obtention of the pre-cooked rice, once all the aforesaid stages carried out and before the product is withdrawn from the container it has been cooked in, and keeping it still at high temperature, different flavour dehydratated items can be added, such as meat dehydratateds, seafood or fish dehydratateds, greens dehydratateds and saffron-based colouring agents.

In case the paella is meant to have no special flavour, it won't be precise to add any dehydratated. It the paella is to have fish or seafood flavour, it will be added dehydratated fish or seafood. If the paella is to have greens and vegetables flavour, the greens and vegetables dehydratated is to be added. Combining those dehydratateds can be reached flavours of two or more ingredients. Varying the rate of the dehydratateds added can be reached a prepared product of more or less strong flavours.

After cooling the product prepared in the aforesaid way, it can be packed in rations, adding greens in natural state, refried meats and/or refried seafood and fresh eustaces, depending on the dehydratated/s added before.

During the packaging ca be added mere natural coloured red pepper and natural peas. if the paella was prepared with fish or seafood flavour, during the packagind should be added, let alone the natural coloured red pepper and the natural peas, refried mollusk such as squid, clam, baby-clam, and fresh eustaces such as shrimps, prawns, Norway lobsters and crabs.

It the pre-cooked paella has a flavour of meats, during the packaging will be added natural red coloured pepper and natural peas, meats in refried stage, such as rabbit, chicken, etc. If the paella is to have a greens flavour, during the packaging can be added natural greens such as coloured pepper, peas, artichokes, eggplants, beans, etc., and meats in refried state such as rabbit, chicken, etc.

As for the dehydratateds, also the produts added during the packaging can be mixed to coincide and obtaining the desired flavours.

Once the rice prepared introduced into its container as said and added the products mentioned above, you can proceed to its closing through a vacuum process or a deep freezing system.

When the rice prepared as said is to be consumed, the rice is poured into a container and exposed to low fire, adding, one it reaches a certain temperature, hot water, preferably in boiling stage. When it begins to boil are added the different products packed together with the rice, such as greens, meats, seafood, etc., so that they end up their cooking at the same time, being the paella ready to be consumed, an not requiring to receive any other product or additive.

1007/2197

The base of the invention lies on the fact that the pre-cooked rice is the carrier of the necessary sauce and oil, with the required colour and taste and on the fact that the rice remains also in a refried state and conservation due to the absortion of all the products.

Once the nature of the product thoroughly described, as well as the way of putting it into practice, it must be stated that the aforesaid specifications can undergo certain changes as long as they do not modify its basic principle.Data supplied from the esp@cenet database - Worldwide

Claims:


1.- Procedure for the preparation of pre-cooked paella which includes the stages of: a) preparation of a sauce on low fire, based on smashed tomato, smashed onion, vegetal oil, table salt, smashed garlic, sweet coloured paprika, sugar, ground blank pepper and an assortment of saffron, parsley, smashed garlic, almond, hazelnut and pine nuts,until obtaining quite a thick sauce: b) mixing of the sauce thus prepared with rice in the adequate proportion for the prepared sauce; c) submitting the products, once mixed, to an elaboration process until having all the sauce absorbed by the rice, making a whole body and being the refried rice grains disentangled, adding, finally, whe the product is still warm, saffronbased colouring a gents, in the desired rate and a meat and/or seafood dehydratateds and fish and greens, according to the flavour to be obtained; d) proceed to the packaging of the resulting product, through vacuum or deep freezing, adding greens in natural state, refried meats and/or refried mollusk and fresh eustaces depending on the dehydratated added on the previous stage.

2.- procedure, according claim 1, defined by the fact that the sauce includes for each kilogram, between

340 and 730 grs. of smashed tomato, 1 between 150 and 300 grs. of smashed onion, between 50 and

150 grs.of vegetal oil, between 10 and 40 grs. of fine salt, between 10 and 30 grs. of smashed garlic, sweet red paprika, between 10 and 40 gras, sugar, between 10 and 40 grs., and smashed between 25 and 50 grs.

3.- Procedure, according to claim 1, defined by the fact that for each kilogram of product to be prepared, there are to be mixed 450 and 700 grs. of rice with 250 to 450 gras. of sauce, adding between

25 and 50 grs. of dehydratated and between 25 and 50 grs. of vegetal oil.Data supplied from the esp@cenet database - Worldwide

1008/2197

210.

JP1067158 - 3/13/1989

PRE-HEATED CONVENIENT RICE PRODUCT AND METHOD OF

MANUFACTURING THE SAME


Inventor(s):

RAASON (--)

SHIERIRU AN GUROESUBETSUKU (--); YAU YAN SU (--); GEIRII JIYON



IP Class: A23L1/10

E Class: A23L1/182



Family: EP0306655


Abstract:


PURPOSE: To provide a rice product which improves texture at the time of rehydration, fixes quality and can be rehydrated in hot water, by treating grains of rice through plural processes while regulating the quantity of contained moisture as specified. CONSTITUTION: The grains of rice are heated by adding water so that the quantity of contained moisture can be from 55wt.% to 75wt.%, next dried on standing conditions at the temperature from 140 deg.C to 185 deg.C so that the quantity of contained moisture can be made from 20% to 35% and next dried while being stirred so that the quantity of contained moisture can be from 3% to 15%, and the target rice product, of which the volume density is from 37g/100cc to 42g/100cc, can be provided.Description:


Rice product

The present invention relates to a process for the production of a convenient rice product, more particularly to a pre-cooked rice product that requires no cooking for consumption.

There are basically three kinds of commercial parboiled rice products :

1) Regular parboiled rice : this is prepared for consumption by cooking (simmering) for about 20 minutes and the product has a good texture. However, the time taken to prepare this product for consumption is rather long and depending on the amount of water used and the heating conditions, the texture is not always consistent and, therefore, the product is not particularly convenient to use.

2) Quick cooking parboiled rice : this is 85-95% gelatinised and is produced by partial cooking and drying of regular parboiled rice. This product also requires cooking (simmering) for consumption but, as the time required is only about 5-10 minutes, it is more convenient to use than regular parboiled rice.However, depending on cooking conditions, the water absorption of rice is usually varied and consequently, the rice texture is not consistent. It also requires attention during cooking and, therefore, it is not really convenient.

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3) Instant rice : this is 95-100% gelatinised and is usually produced by complete cooking of the rice followed by low temperature drying (50 DEG -65 DEG C)to a moisture content of about 10% and then high temperature drying (180 DEG -350 DEG C) for a high degree of puffing. This type of rice is more convenient than quick cooking rice because it is reconstituted for consumption by rehydrating in boiled hot water for a period of from only about 1 to 5 minutes.The high degree of puffing is carried out because of the requirement of instant rehydration but, because of this high degree of puffing, the rice structure is usually damaged and, consequently, the texture of the product is not good.

It would be very desirable to produce a convenient rice product which can be reconstituted simply and quickly like instant rice while still possessing the good texture of regular cooked rice. Up to the present time, this has not been achieved because fast rehydration requires a change of the rice structure and texture. In order to maintain the good rice structure, it is important that the rehydration time is at least 8 minutes, preferably at least 9 or 10 minutes.

We have found, surprisingly, that a mildly-puffed convenient rice product, having a good and constant texture when reconstituted to a palatable state by rehydration, can be produced by a process which does not involve a high degree of puffing of low moisture cooked rice and which can be reconstituted for consumption simply by rehydrating in boiled, hot water and allowing to stand for a minimum of about

8 minutes and preferably a minimum of 9 or 10 minutes. Since there is no high puffing step, the rice has a better texture than conventional instant rice. Compared with quick cooking rice, since cooking and attention are not required in the preparation for consumption, not only is it more convenient to use but the texture and quality of the rice product are also more constant.

Puffing can be defined as the expansion of rice grain size and this can be expressed by the bulk density which is measured by weighing the loose weight of dried rice in a 100 ml graduated cylinder. It is essential that the mildly-puffed convenient rice product of the present invention has a bulk density of from 37 to 42 and preferably from 38 to 41 g/100 cc. In addition, to achieve a palatable state on reconstitution, 100 g of the product of the present invention should absorb from 195 to 225 g of water after 10 minutes rehydration in 500 g hot water which has just been boiled without any further heating, which we shall refer to in this invention as "boiled, hot water".In contrast, non-puffed quick cooking rice usually has a bulk density of from 43 to 50 g/100 cc and absorbs less water during rehydration while highly-puffed instant rice usually has a bulk density of from 30 to 36 g/100 cc and absorbs more water after 1 to 5 minutes rehydration.

According to the present invention there is provided a process for the production of a convenient precooked rice product characterised in that rice grains are cooked with water at a temperature and for a time sufficient that their moisture content is from 55% to 75% by weight and dried at a temperature from 140 DEG C to 185 DEG C in two stages firstly under stationary conditions to a moisture content of from 20 to 35% and secondly under agitated conditions to a moisture content of from 3 to 15%, such that the dried rice has a bulk density of from 37 to 42 g/100 cm. For obtaining a palatable product upon rehydration, the dried product is rehydrated in boiled, hot water for a minimum of 8 minutes.

Any type of rice grain can be used, for example, milled white rice (long or short grain), arborio rice, basmati rice but the process of this invention is particularly advantageous for parboiled rice.

In addition to the hereinabove described methods of preparing these rice products for consumption i.e. regular parboiled rice, quick cooking parboiled rice, instant rice and the convenient rice prepared by the process of the present invention, all these rice products can, if desired, be prepared for consumption by microwave cooking. The time required for microwave cooking ranges from about 2 to 20 minutes depending upon the degree of rice gelatinisation, rice puffing, variety of rice and the amount of rice and water used during microwave cooking. For example, to prepare the convenient rice produced by the process of the present invention for consumption in a microwave oven as utilised commonly in the home, it is possible to cook 120 g rice with 230 cc water at high power in 5 minutes and 240 g rice with

460 cc water at high power in 8 minutes.These times are shorter than those required for regular or quick-cooking parboiled rice and the convenient rice produced by the process of the present invention has a better texture than instant rice after preparation for consumption by microwave cooking because of the optimum puffing of the rice.

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The cooking may be carried out by boiling the rice grains in water, steaming,or by a combination of boiling and steaming. Superatmospheric pressure may be used, if desired. The temperature of the cooking may be from 90 DEG C to 110 DEG C and preferably from 95 DEG C to 105 DEG C and the duration of the cooking may be from 5 to 20 minutes. The pH during cooking may conveniently be from 3.0 to 7.5. Preferably, for a product which is to be prepared for consumption by heating in boiled, hot water, the pH during cooking is from 6.5 to 7.5, while for a product which is to be prepared for consumption by microwave cooking the pH during cooking is preferably from 3.0 to 5.5, especially 3.5 to 5.0. Optionally, the rice grains may be soaked in water prior to cooking.

Drying in two stages, first under stationary and then under agitated conditions at from 140 DEG C to

185 DEG C, in each stage, is critical for obtaining the required bulk density which results in the water absorption properties which provide the excellent rehydrated texture of the convenient precooked rice product of the present invention when rehydrated for the stated time. In both drying steps the cooked rice is preferably dried at a temperature from 145 DEG C to 180 DEG C and especially from 150 DEG

C to 175 DEG C.

In the first drying step, the cooked rice is preferably dried to a moisture content of from 23 to 35%. The drying under stationary conditions may be carried out on a regular belt dryer or on a high velocity belt dryer with nozzle tubes that produce hot air. When the rice is dried in a regular, hot air belt dryer, it is conveniently fed onto the dryer in a thin layer. The thickness of the layer of rice grains on the belt may be from 2 to 10 mm and preferably from 3 to 6 mm. The velocity of the hot air is conventional and is usually from 10 to 20 meters per minute. The duration of the first drying step in a regular belt dryer to obtain the required moisture content is usually from 10 to 20 minutes and preferably from 12 to 18 minutes depending on the drying temperature used and velocity of the hot air.When the rice is dried in a high velocity hot air dryer, the cooked rice may be dried by passing the hot air through a layer of cooked rice, which has preferably been dewatered, for instance by suction, to remove some surface moisture. The thickness of the layer of cooked rice is conveniently from 5 to 12 mm thick, and the drying time may be from 2 to 8 minutes, preferably from 3 to 7 minutes. The velocity of the hot air preferably ranges from 100 to 200 metres/min. After the first drying step, the partially dried rice cake is broken and the rice separated. The dewatering step which advantageously precedes the first drying step when using a high velocity hot air dryer can reduce the stickiness of the cooked rice and enables a thicker layer of rice to be dried. In particular, the dewatering step can reduce the sticking of rice cooked at a pH of 6.5 to 7.5.

In the second drying step, the partially dried rice grains are preferably dried to a moisture content of from 6% to 12% by weight. The drying under agitated conditions may be carried out in a vibrating dryer such as a vibrating fluid bed dryer or a high velocity belt dryer with nozzle tubes that produce hot air similar to the one used in the first drying step. The velocity of the hot air generally ranges from 20 to 200 metres/min and the drying time is usually from 30 to 120 seconds. Preferably, the velocity of the hot air in the second drying step is not greater than that in the first drying step.

In both drying steps, the temperature, hot air flow and times are adjusted to create a rice product with the required bulk density, optimum water absorption and texture after about 10 minutes rehydration with boiled, hot water. The duration of the cooking time also affects the bulk density, water absorption and texture and for longer cooking times, the drying temperature and/or hot air velocity are advantageously lower, while for shorter cooking times, the drying temperature and/or hot air velocity are advantageously higher.Compared with conventionally puffed rice which is usually dried at a lower temperature for a longer time (e.g. 50 DEG C for 2 hours) to a moisture content of about 10% and then puffed at a high temperature for a short period of time (e.g. 180 DEG -350 DEG C for a few seconds) the rice prepared by the process of the present invention is only mildly puffed and has good texture. In addition, the rehydration and the water absorption is improved by the longer rehydration time of at least

8, 9 or preferably 10 minutes for conventionally puffed rice.

Another advantage of the present invention is that by drying at a temperature of from 140 DEG C to

185 DEG C instead of at a lower temperature e.g. about 50 DEG C to 60 DEG C as for conventionally puffed rice the rice need not be cooked completely in the boiling step, thus reducing cooking losses which can amount to about 10% or more. The cooking is further completed in the drying step at temperatures from 140 DEG C to 185 DEG C in the present invention.

1011/2197

The present invention also provides a convenient rice product whenever produced by a process hereinbefore described.

It should be understood that although the product of this invention may be reconstituted by rehydrating with boiled, hot water in 8 minutes, the texture of the reconstituted product is superior when the rehydration time is 10 minutes or more. However, reconstitution times appreciably longer than 10 minutes reduce the convenience of the product.


Example 1

1000 g parboiled rice were boiled in water at pH of 7.0 for 15 minutes, rinsed with cold water and drained to give a total weight of 2840 g (68.5% moisture). The rice was then placed in a layer of 5mm on a Proctor & Schwartz's hot air belt dryer with a hot air velocity of 12 metres/min and dried at 175

DEG C for 12 minutes whereupon the moisture content was reduced to 32%, after which the rice grains did not stick together. The partially dried rice was then placed on a Witte's vibrating, fluid bed dryer in a layer of 8 mm and dried at 175 DEG C for 1 minute to a moisture content of 8-10%. The dehydrated rice had a bulk density of 40 g/100 cc. 180 g of this rice product was prepared for consumption by adding to 500 cc boiled, water and allowed to stand for 10 minutes.376 g water was absorbed and the product had a good, tender, firm, even texture.

Comparative Example A

180 g of regular parboiled rice were prepared for consumption by boiling for 20 minutes in 500 cc water. 500 g water were absorbed. Because the cooked rice was not rinsed, it was softer and more starchy than the reconstituted product of Example 1.

Comparative Example B

A quick cooking parboiled rice was prepared by boiling 1000 g parboiled rice for 15 minutes to 68.5% moisture, and then drying at 50 DEG C for 2 hours. The dehydrated rice had a bulk density of 43 g/100 cc.180 g of this product were prepared for consumption by adding to 1000 cc of boiling water and simmering for 10 minutes. 344 g water were absorbed but the product had a more grainy and slightly undercooked texture when compared with the reconstituted product of Example 1.

Comparative Example C

An instant parboiled rice was prepared by boiling 1000 g parboiled rice for 20 minutes to 70% moisture, then drying in a hot air dryer at 50 DEG C for 3 hours and finally puffing at 240 DEG C for

10 seconds. The dehydrated rice had a bulk density of 32 g/100 cc.180 g of this instant parboiled rice were prepared for consumption by adding to 500 cc boiled, hot water and allowing to stand for 5 minutes. 415 g water were absorbed but the product had a broken rice texture and had no structural characteristic of rice.

Example 2

1000 g parboiled rice were boiled in water with pH of 7.0 for 15 minutes, rinsed with cold water and drained to give a total weight of 2840 g (68.5% moisture). The cooked rice was then dewatered for one

1012/2197

minute by placing the rice under force of suction. The rice was then placed in a hot air dryer (12 mm thick) with a jet-tube nozzle (Wolverine's Jetzone dryer), the hot air velocity was 150 meters/min and the temperature was 150 DEG C. After drying for 5 minutes to a moisture content of 25%, the partially dried rice cake was then broken, the rice was separated and dried again at the same temperature and velocity for 45 seconds. The dehydrated rice had a bulk density of 39 g/100 cc.180 g of this rice was added to 500 cc boiled, hot water and allowed to stand for 10 minutes. 374 g water was absorbed and the product had a good, tender firm, even texture.

Comparative Example D

By following a similar procedure to that described in Example 2, but where the velocity of hot air used was 75 meters/min and pre-drying time was 10 minutes, the dehydrated rice had a bulk density of 44 g/100 cc and 180 g of rice absorbed 340 g boiled, hot water after 10 minutes. The rehydrated rice texture was hard and grainy.

Comparative Example E

By following a similar procedure to that described in Example 2, but where the hot air velocity was 450 meters/min and the pre-drying time was 3 min, the dehydrated rice had a bulk density of 36 g/100 cc and 180 g of this rice absorbed 410 g boiled, hot water after 10 minutes. The texture of the rehydrated rice was soft and had no structural characteristics of rice. The same rice was rehydrated for only 7 min, the water absorbed was 317 g but the texture was still soft.

Comparative Example F

By following a similar procedure to that described in Example 2, but where the drying temperature was

190 DEG C and the pre-drying time was 4 min, the dehydrated rice had a bulk density of 35 g/100 cc of this rice absorbed 412 g boiled, hot water after 10 minutes. The texture of the rehydrated rice was soft and had no structural characteristics of rice.

Example 3

By following a similar procedure to that described in Example 2, but using regular long grain, milled rice instead of the parboiled rice (the white rice was boiled for 12 minutes instead of 15 minutes for parboiled rice), the dehydrated rice had a bulk density of 37 g/100 cc and 180 g of this rice absorbed

364 g of boiled, hot water after 10 minutes. The rehydrated rice had a good, tender, firm texture better than some commercial instant white rices which required 5 or 7 minutes rehydration.

Example 4

By following a similar procedure to that described in Example 2, but using arborio rice instead of the parboiled rice (the arborio rice was boiled for 12 min instead of 15 min for parboiled rice), the dehydrated arborio rice had a bulk density of 38 g/100 cc and 180 g of this rice absorbed 365 g of boiled, hot water after 10 minutes. The rehydrated rice had the good, tender texture typical of cooked arborio rice.

Example 5

1013/2197

By following a similar procedure to that described in Example 1 but wherein the pH of the boiling water was 4.0 instead of 7.0 there used, the dehydrated rice produced had a bulk density of 40 g/100 cc.120 g of this rice product was prepared for consumption by cooking with 230 g of water in a microwave oven (high power) for 5 minutes and the product had a good, tender, firm even texture and an attractive white colour.

Example 6

By following a similar procedure to that described in Example 2 but wherein the pH of the boiling water was 4.5 instead of 7.0 there used, the dehydrated rice produced had a bulk density of 39 g/100 cc.240 g of this rice product was prepared for consumption by cooking with 460 g of water in a microwave oven (high power) for 8 minutes and the product had a good tender, firm, even texture and an attractive white colour.Data supplied from the esp@cenet database - Worldwide

Claims:


1. A process for the production of a convenient precooked rice product characterised in that rice grains are cooked with water at a temperature and for a time sufficient that their moisture content is from 55% to 75% by weight and dried at a temperature from 140 DEG C to 185 DEG C in two stages, firstly under stationary conditions to a moisture content of from 20 to 35% and secondly under agitated conditions to a moisture content of from 3% to 15%, such that the dried rice has a bulk density of from

37 to 42 g/100 cm.

2. A process according to claim 1 characterised in that the rice grains used are parboiled rice,milled white rice, brown rice, arborio rice or basmati rice.

3. A process according to claim 1 characterised in that the cooking is carried out by boiling the rice grains in water,steaming or by a combination of boiling and steaming.

4.A process according to claim 1 characterised in that the cooking is carried out at a pH from 3.0 to 7.5.

5. A process according to claim 1 characterised in that the cooking is carried out over a period of from

5 to 20 minutes.

6. A process according to claim 1 characterised in that in the first drying step, the rice grains are dried to a moisture content of from 23% to 33%.

7. A process according to claim 1 characterised in that the first drying step, the drying under stationary conditions is carried out on a regular belt dryer.

8. A process according to claim 7 characterised in that the cooked rice is fed onto the dryer in a layer having a thickness of from 2 to 10 mm.

9. A process according to claim 7 characterised in that the duration of the first drying step is from 10 to

20 minutes.

10.A process according to claim 1 characterised in that in the first drying step, the drying under stationary conditions is carried out in a high velocity hot air dryer.

11. A process according to claim 10 characterised in that before the first drying step, the cooked rice is dewatered to remove some surface moisture.

12. A process according to claim 10 characterised in that the cooked rice is present as a layer having a thickness of from 5 to 12 mm.

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13. A process according to claim 10 characterised in that the duration of the first drying step is from 3 to 7 minutes.

14. A process according to claim 10 characterised in that the velocity of the hot air is from 100 to 200 metres/min.

15. A process according to claim 1 characterised in that in the second drying step, the partially dried rice grains are dried to a moisture content of from 6% to 12% by weight.

16. A process according to claim 1 characterised in that the second drying step, the drying under agitated conditions is carried out in a vibrating fluid bed dryer or a high velocity belt dryer with nozzle tubes that produce hot air.

17. A process according to claim 16 characterised in that the velocity of the hot air is from 20 to 200 metres/min.

18. A process according to claim 16 characterised in that the duration of the second drying step is from

30 to 120 seconds.

19. A convenient rice product having a bulk density of from 37 to 42 g/100 cc and 100 g of which is capable of absorbing from 195 to 225 g of boiled, hot water in 10 minutes whenever produced by the process as hereinbefore defined.Data supplied from the esp@cenet database - Worldwide

1015/2197

211.

JP1144940 - 6/7/1989

RICE OR BARLEY COATED WITH MUSHROOM EXTRACT


Inventor(s): SHIINA SHOJI (--)

Applicant(s): SHIINA SHOJI (--)


IP Class: A23L1/10; A23L1/30; A61K35/84

E Class: A23L1/28



Family: JP1144940

Abstract:


PURPOSE:To obtain the title readily digestible rice and wheat or barley, capable of preventing cancer and providing tasty cooked rice, by blending a mushroom extract with Finetose(R), dipping polished rice or barley or wheat in the mixture solution and drying the rice and barley or wheat.

CONSTITUTION:The aimed rice and wheat or barley obtained by blending a mushroom extract with

10-30% Finetose(R) dipping polished rice or wheat in the resultant mixture liquid, thoroughly stirring and drying the dipped rice and barley or wheat.

1016/2197

212.

JP2002322 - 1/8/1990

FORMED FOOD AND PREPARATION THEREOF


Inventor(s): KONNO AKIRA (--); IIDA ATSUSHI (--)



IP Class: A23L1/10; A23L1/36; A23L1/054

E Class: A23L1/164C; A23L1/054C; A23L1/054; A23L1/20B



Family: JP2002322


Abstract:


PURPOSE:To prepare a formed food resistant to collapse and having the texture of cereal food by mixing a cereal food with curdlan, forming the mixture and bonding and forming the cereal grain with heat. CONSTITUTION:A cereal food such as rice, barley, wheat, millet, corn, soybean or adzuki bean is mixed with a curdlan (preferably as a 2-10% aqueous suspension), formed and heated to effect the bonding and forming of the cereal grains and obtain the objective food. The amount of the curdlan is preferably 0.3-5wt.% based on the final product.Claims:


1. A shaped food, which comprises shaping and binding granules of cereal food with a curdlan.

2. The shaped food according to claim 1, wherein, the granules are foods prepared from cereals, seeds or stones, or pulse.

3. The shaped food according to claim 1, wherein the cereals are rice, barley, wheat, millet, foxtail millet and corn.

4. The shaped food according to claim 2, wherein the pulse are soybeans, aduki beans, peas and broad beans.

5. The shaped food according to claim 1, wherein the curdlan is contained in an amount of 0.2 to 10% by weight based on the final product.

6. A method of producing shaped foods, which comprises mixing a curdlan with granules of a cereal food, shaping the mixture and heating the shaped material for binding cereal grains or granules.

7. The method according to claim 6, wherein the curdlan is mixing in the form of an about 2 to 14% by weight aqueous dispersion.

1017/2197

8. The method according to claim 6, wherein the curdlan is mixed in an amount of 0.2 to 10% by weight based on the final product.

9. The method according to claim 6, wherein the mixture is shaped into a size having a thickness of about 2 to 60 mm.

10. The method according to claim 6, wherein the shaped material is heated above about 55 DEG C.

11. The method according to claim 6, wherein the heating is carried out by the use of mixrowave oven.Data supplied from the esp@cenet database - Worldwide

1018/2197

213.

JP2009347 - 1/12/1990

EXTRUDED PROCESSED FOOD AND PRODUCTION THEREOF


Inventor(s): ROORENSU DABURIYUU UIZUDAMU (--)

Applicant(s): FRITO LAY INC (--)

IP Class 4 Digits: A23L; A23G

IP Class: A23L1/212; A23G3/00; A23L1/214

E Class: A23L1/164E; A23L1/217B; A23L1/212E; A23L1/164



Family: JP2009347

Equivalent: US5132127; GR89100173; ES2012694; IT1232008

Abstract:


PURPOSE: To provide snack food having preservation stability by mixing, extruding and drying a high-moisture cytoplasmic material such as fruits or vegetables and low-moisture starch.

CONSTITUTION: The low-moisture cytoplasmic material such as corns, wheat or rice, for example, is mixed in the high-moisture cytoplasmic material such as fruits or vegetables like apple, orange, banana, lemon, carrot or onion for applying taste to food and moisture is controlled in the range from 25% to

50%. This mixture is extruded and molded in the desired shape and after drying to 8-15%, it is cooked so that snack food can be provided.Description:




The present invention relates to a process for manufacturing a stable food product and to products produced by the process. More particularly, the invention relates to a process for making a snack food product wherein all or substantially all of the moisture is derived from the flavor source; the addition of excess make-up water is avoided, thus improving the retention of natural flavors and textures.

2. Description of the Background Art

A variety of flavored snack food products are available on the market today and are very popular consumer items. Chip-type products flavored with various spices and with different cheeses are especially well-known. Such products are produced both from intact slices, such as potato slices, as well as from extruded pastes or doughs, such as ground corn-based dough. Fruit flavored snack foods typically have been made by dehydrating pieces of fruit, blending them with water and the dry ingredients which will be used to make the chip, and then extruding the blended mixture and further processing the extrudate. Although this process produces an acceptable product, some of the flavor and texture of the fruit pieces is lost in the dehydration-rehydration process. The steps of dehydrating and then rehydrating the fruit also can be time-consuming, and add to the cost of the final product.

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U.S. Pat. No. 4,198,437 (Citti et al.; Apr. 15, 1980), relates to the production of a french fry-like potato product by extruding a potato dough into the desired shape. The potato dough is prepared from a combination of riced, blanched potatoes, dehydrated potatoes (e.g. granulated potato flakes) and an emulsifier in appropriate proportions to arrive at a dough of between about 60 to 75 percent by weight of water.

U.S. Pat. Nos. 3,937,848 (Campbell et al., Feb. 10, 1976) and 3,935,322 (Weiss et al., Jan. 27, 1976) relate to the production of "fabricated" chips from, for example, potato flakes and/or granules and water.

U.S. Pat. No. 4,126,706 (Hilton; Nov. 21, 1978) also relates to the production of snack food products from extruded doughs. The doughs are prepared, for example, from dehydrated potato flakes or granules.

U.S. Pat. No. 4,719,118 (Thomas; Jan. 12, 1988) relates to snack food products made from a mixture of water and low-fat dairy cheese or milk curd. The mixture is sheeted, partially dried and then puffed.

The use of farinaceous ingredients is discouraged.

Many of the prior art snack food products are prepared from doughs produced by rehydrating dehydrated flakes, granules and the like which have been prepared from vegetables, particularly starchy vegetables such as potatoes and corn. As known to those skilled in the art, the production of such flakes and granules includes the step of gently macerating the vegetable. The macerating step must be relatively gentle, substantially avoiding the destruction of the cell walls, so that excessive starch is not released. Excessive starch produces a very gummy, pasty mass which is difficult or impossible to flake or granulate. Unfortunately, this gentle macerating step also fails to release a portion of the flavor of the fruit which, like the starch component, is contained within the walls of individual cells.

The snack food products produced from extruded doughs usually are cooked virtually immediately.

The pre-cooked product is not suitable for transport over long distances to off-site cooking facilities, as the high moisture content tends to promote rapid spoiling. Freezing the pre-cooked product often is the only means for stabilizing the moisture and safely permitting such transport.

Accordingly, it is an object of this invention to provide a simplified process for making a stable snack food product from a high moisture raw material wherein the original pulp, juice or other flavorcontaining component of the high moisture material can be used, rather than dehydrating the component and then recreating the original moisture by adding water to the dehydrated product.

Another object of this invention is to provide a simplified process for making a stable snack food product from a liquid product wherein the liquid product provides the required flavor and moisture. Yet another object of the invention is to provide a process for preparing a stable pre-cooked snack food

"pellet" product which can be shipped over long distances without the need for refrigeration, and then subsequently cooked and packaged.


The present invention relates to a process for preparing a shelf stable snack food product, one component of which is a high moisture material that provides flavor and, optionally, texture, to the product. In one embodiment of the invention the process comprises: a) macerating to a soggy pulp a high moisture material that provides flavor and substantially all of the moisture to the snack food product; b) blending the soggy pulp with one or more low moisture farinaceous base ingredients to produce a dough comprising about 25% to about 50% moisture; c) extruding the dough into a desired shape; and d) drying the extruded product to about 8% to about 15% moisture.

A product so prepared can be cooked immediately, or can be treated as a "pellet" product whereby it is transported off-site for eventual cooking and packaging.

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The high moisture material can be selected from, among others, "cellular" materials such as fruits and vegetables which are vigorously macerated to release natural flavors. In other embodiments, the high moisture material is a liquid over se, such as a solution or suspension, which provides flavor and required moisture to the snack food product and is mixed directly with one or more low moisture, farinaceous base ingredients to produce a blended product comprising about 25% to about 50% moisture; the remaining steps in the process are the same as in the embodiment discussed above. In a second alternative embodiment, the high moisture material is a material which provides flavor to the snack food product but which can be added to the base ingredients without having to undergo an initial maceration step, such as yogurt and other dairy products.


The present invention provides a process for the manufacture of a shelf-stable snack food product wherein one component of the product comprises at least one high moisture material that provides flavor and the required moisture to the final product. It has been discovered that such high moisture materials advantageously can be used directly in a process for making shelf-stable products without first having to dehydrate and subsequently rehydrate them.

The high moisture material imparts flavor and, optionally, textural attributes, to the snack food product.

The term "high moisture" material encompasses both liquids, such as solutions or suspensions, and other materials that comprise at least about 40% moisture and typically comprise about 70% moisture.

Suitable materials include dairy foods such as cottage cheese and yogurt; various fruits, such as apples, bananas, pears, lemons, grapes and tomatoes; and vegetables, including carrots, celery, lettuce, spinach, onions, potatoes and sweet potatoes. Fruits and vegetables are preferred and are macerated into a soggy pulp as described herein. As the process of this invention is low in heat stress, fruits and vegetables which contain high levels of reducing sugars can be used without undesirable browning occurring during processing.

Alternatively, the high moisture material can comprise a liquid, such as a beverage, substantially all the solids of which are soluble, including milk, beer, fruit juices, vegetable juices, wine and carbonated drinks. A number of these beverages, such as milk and juices, can be used to advantage in this process because of the low degree of heat stress placed upon them.

Fruits or vegetables should be washed prior to use. Various types of cleaning or washing equipment can be used, such as a standard potato chip peeler equipped with brushes or abrasive rollers.

The maceration into a soggy pulp of high moisture fruit or vegetable ("cellular") ingredients is conducted in a vigorous manner to release natural flavors contained within the plant cells. For the purposes of this invention, the term "maceration" means such vigorous maceration. Thus, a large proportion of the plant cells will be disrupted by the maceration step. This is in contrast to the gentle maceration process carried out in the production of dehydrated potato flakes and granules, for example, which is a gentler process whereby cells are not disrupted to a great extent. The use of a high speed

Urschel mill is preferred in carrying out the maceration step of the present process.

If the high moisture material is a liquid or a relatively soft material, such as cottage cheese or yogurt, it is not necessary to macerate the material and it simply is blended with the base ingredients to produce a dough.

The high moisture material provides substantially all of the moisture required during processing. By

"substantially all of the moisture" it is meant that although additional moisture may in fact be added, for example for the purpose of providing flavor, or is absorbed from the atmosphere during processing, such additional moisture is not needed in order to process the dough blend. By avoiding the need to add additional moisture, the present process helps preserve (does not dilute) the natural flavors present in the high moisture component and, subsequently, in the finished product.

The high moisture material can be blended with farinaceous base ingredients by any one of several methods. The high moisture material simply can be mixed in a blender such as a standard ribbon blender. Alternatively, depending on the design of the extruder to be used in the following step of the

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process, the blending can take place directly in the extruder. A twin-screw extruder is an example of an extruder wherein the mixing can take place in the extruder bore, the ingredients being injected through various ports and then contacted with co-rotating twin extruder screws in the barrel of the extruder.

Regardless of the precise manner and equipment used to blend the high moisture material and the dry ingredients, the final dough blend desirably will comprise from about 25% to about 50% moisture and preferably about 35% moisture.

The low moisture farinaceous base materials or ingredients that are mixed with the pulp can vary depending upon the source of the high moisture raw material and the nature of the final product desired. Generally, the base ingredients are in granular or powdered form, such as meal, flour, or starch derived from corn, wheat, rice, oats, barley, potatoes, rye, tapioca, and other cereal crops, legumes, tubers, or mixtures thereof. One or more flavoring ingredients, in amounts necessary to provide a desired effect, also can be included. "Low moisture" is defined herein as an edible material or mixture of materials that has a moisture content that does not exceed about 15% by weight of the material.

Although the weight to weight ratio of base ingredients to high moisture material can vary depending upon the water content of the high moisture material, the desired taste attributes of the desired product and the amount of moisture desired in the dough, generally the ratio of base ingredients to high moisture ingredients is about 70:30 to about 50:50 by weight.

The dough blend of high moisture material and dry ingredients undergoes further processing to form it into a desired shape. An appropriate apparatus for accomplishing this step is an extruder which discharges the blend of pulp and dry ingredients through a die. The extruder is capable of generating super-atmospheric pressures and elevated temperatures in the material being extruded.

Depending upon the type of extruder employed, the high moisture and the low moisture base ingredients, either as a blend or individually, are injected into the extruder. As the mixture moves through the barrel of the extruder, the barrel pressure increases. Generally, the extruder is operated to produce a barrel pressure of at least about 200 psi and a temperature of at least 200 DEG F. within the barrel.

The dough mixture exits the extruder barrel through a die which can form the mixture into the desired cross sectional configuration. For example, one can employ a die having an opening that will produce a ribbon or a cylinder of the extrudate, or dies that will produce a tubular or a C-shaped extrudate. If one of the latter types of dies is used, the extruded product can be filled with a flavoring material, such as a paste-like or creamy material (e.g. a cheese-flavored filling or peanut butter), after it has been fully processed.

The hot extrudate emerges from the die into a zone of ambient pressure below the vapor pressure of the water in the mixture; that is, normal atmospheric pressure. Exposure of the extrudate to the reduced pressure environment readily allows a portion of the water in the mixture to vaporize so that the resulting product has a moisture content of about 20% to about 45%. Preferably, the moisture content is about 30%.

As the extrudate exits the die it is stretched. This can be readily accomplished by laying the extrudate on a conveyor. Gravity is sufficient to cause enough frictional force that the weight of the ribbon and a difference between the speed of the conveyor and the speed at which the extrudate exits the die can be sufficient to stretch the extrudate successfully.

The extrudate exiting the extruder is hot and sticky. As it moves along the conveyor, however, it becomes cool enough to touch. An air current can be passed over the cooling extrudate to further firm and harden it for subsequent cutting into the desired final product size and shape.

The extrudate is cut using a conventional commercial cutter and then is further dried to stabilize the cut pieces at about 8% to about 15% by weight moisture. Preferably, the products are dried to about 12% moisture. The drying can be carried out, for example, by passing ambient air over the product pieces.

Depending upon the temperature and relative humidity and the product formula, the drying can be accomplished in about 30 minutes to about 12 hours.

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The dried product, if desired, is transported in its pre-cooked state for off-site cooking and packaging.

The low moisture of the pre-cooked "pellet" renders the product stable and suitable for use in a system of central product preparation followed by transport to a plurality of local or regional cooking and packaging facilities. Such a system provides advantages to the large-volume snack food industry; duplication of processing steps is avoided, while local or regional cooking and packaging ensures product freshness. The stability of the present "pellet" products when stored and transported under ambient conditions provides significant advantages over pellet products which must be refrigerated or frozen.

The product ultimately is cooked, such as by hot oil frying, hot air puffing or other methods, depending upon the end product desired. Frying may be carried out in any edible oil, such as cottonseed, soybean, sesame or peanut oil, at a temperature that is between about 220 DEG F. and the smoking point of the oil. Preferably, the frying temperature is between about 325 DEG F. and about 400 DEG F. The frying time will vary, depending upon the temperature of the oil and the nature of the product, but generally will be in the range of about 10 to about 20 seconds.

Alternatively, the product can be subjected to a hot air puffing cooking process. The product can be puffed using any standard commercial equipment, such as a Wolverine JetZone Dryer. Depending upon the product, the oven typically is heated to between about 400 DEG and 475 DEG F. and the product pieces or pellets are heated until they have popped. The popped product are dried to a desired crisp texture, the entire process typically requiring about 10 to 30 seconds.

The puffed or fried products, following cooking, can be coated with one or more toppings if desired, in manners known in the snack food industry. In one embodiment, the products are sprayed with an edible oil or fat prior to dusting with a flavorful topping, thus enhancing adhesion of the topping to the surface of the products. Vegetable oils having a melting point below about 95 DEG F. are preferred for use during the oil spraying step, with 90 DEG F. melt seasoning oils such as, for example, cottonseed oil, soybean oil, and the like being most preferred.

The invention is further described in the following examples, which are provided for illustrative purposes and are not intended to be limiting.

EXAMPLE 1

Orange Chips

Oranges were peeled and washed, then milled through an Urschel high speed mill equipped with a

0.020 inch millhead to produce a watery fruit pulp. Equal parts by weight of corn meal and rice meal were mixed together and then blended with the orange pulp such that the blended product contained

37% by weight orange pulp, 31.5% by weight rice meal and 31.5% by weight corn meal. The blending was carried out in a standard ribbon blender. The blended product was then fed into a Baker-Perkins twin screw extruder. The feedstock was added at the mid-port of the extruder barrel so that only the last half of the screw was used in the operation. The extruder conditions were as follows:

Screw dimensions: 15/1 length/diameter die: 6" wide Johnson ribbon die adjusted to yield 0.020"-0.030" thick stretched ribbon die temperature: 240 DEG F. die pressure: 200-400 psi barrel temperature: #5-240 DEG F., #4-80 DEG F. screw RPM: 300 residence time: 30-40 seconds in extruder ribbon velocity: 10 ft.-20 ft. per minute.

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The product was extruded through a linear die and stretched to thin the ribbon. This was accomplished by laying the ribbon on a conveyor and moving the conveyor at a faster speed than the speed of the extrudate as it exited the die.

The ribbon exiting the extruder was hot and sticky. Within six feet of the extruder, however, it had cooled to touch. An air current (ambient temperature) was passed over the ribbon to dry it such that it would not stick to the conveyor belt. The air current was passed over the ribbon for a distance of about

30 feet to further dry and harden it so that it could be easily cut. The drying time was about 3-6 minutes.

The ribbon then was cut into rectangular pieces with an Urschel ribbon cutter. The resulting pellets were dried under ambient air currents on trays for several hours until the moisture level of the pellets had been reduced to about 12%. The product then was divided into two batches. One batch was cooked by frying the pellets for 15-20 seconds in oil heated to 375 DEG F. The other batch was cooked in a

JetZone hot air popper for 15-20 seconds at 425 DEG-450 DEG F.

The product resulting from the hot air popping method was sprayed with oil in a tumbler and then both products were dusted with sweet orange seasonings in a tumbler.

The resulting products had similar taste profiles of sweet citrus/orange. The texture of the hot air popped product was crunchier than the fried version; however, both possessed a crisp, crunchy texture.

EXAMPLE 2

Apple Chips

Apples were washed, de-stemmed and milled through an Urschel high speed mill equipped with a

0.020" mill head to produce a watery fruit pulp (approximately 85% moisture).

15.2 pounds of the apple pulp were blended with 15.1 pounds of rice meal, 15.0 pounds of corn meal, and 2.0 pounds of sucrose in a standard ribbon blender for five minutes. The feedstock was then fed into a Baker Perkins 50 mm extruder similar to that used in the procedures of Example 1.

Extruder conditions were essentially the same as in Example 1, and the ribbon handling and pellet drying procedures were similar to those of Example 1.

The resulting dried pellets of about 12% moisture were popped in frying oil heated to 375 DEG F. The fry time to bubble endpoint was 20 seconds. The popped pellets were then coated with a cinnamon sugar seasoning at a 10% level. The resulting product had a pleasant flavor profile dominated by sweet cinnamon. The apple flavor was well rounded but low.

EXAMPLE 3

Apple and Milk Chips

5.2 pounds of apple pulp, prepared as in Example 2, were blended with an equal amount of whole milk.

The resulting mixture (approximately 96% moisture) was blended with 5.1 pounds of rice flour, 5.1 pounds of rice meal, 5.0 pounds of de-germed corn meal, and 5.0 pounds of milled whole corn in a ribbon blender similar to that described in Example 1.

The resulting feedstock ribbon and pellets were handled as described in Example 2.

The pellets then were hot air popped in a pilot plant-sized Wolverine Corporation jet zone oven. The chamber of the oven was 13" high with a 10.25" inside diameter. Nine equally spaced, high velocity, air delivery tubes were positioned 3.5" above the bottom pan of the chamber.

The oven was preheated to 450 DEG F.; the bottom pan of the oven was removed and 100 grams of the apple/milk pellets were quickly added. The pan was then reinserted into the oven for 20 seconds. The

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pellets were completely popped after about 15 seconds and the additional five seconds were used to dry the product to a crisp texture.

The popped pellets then were sprayed with 20% vegetable oil and then coated with a cinnamon/sugar mixture similar to that described in Example 2. The resulting product had a desirable crunchy texture and a strong sweet cinnamon flavor note. The apple and milk flavor notes were well rounded but weak.

EXAMPLE 4

In addition to the foregoing, chips can be made using other high moisture, pulp-containing materials and various liquids in which all, or almost all, of the

>;tb;______________________________________

>;tb;Sweet

>;tb;Potato Tomato Onion Grape Potato

>;tb; Salad

>;tb;Chips Chips Chips Chips Chips Chips*

>;tb;______________________________________

>;tb;high 10.3 10 10 10.2 10.2 10.2

>;tb;moisture

>;tb;material

>;tb;(lbs)

>;tb;rice meal

>;tb; 6.5 9.5 9 10.1 10.1 10.2

>;tb;(lbs)

>;tb;corn meal

>;tb; 6.5 9.5 9 10.0 10.0 10.1

>;tb;(lbs)

>;tb;calcium 100

>;tb;carbonate grams

>;tb;______________________________________

>;tb; *Lettuce, celery, onions, spinach, tomatoes.

To make any of these, or other fruit or vegetable-containing chips, the high moisture raw material is milled to produce a watery pulp. The base ingredients are mixed together and then blended with the soggy pulp. The blended product is fed into an extruder, extruded and stretched to form a thin ribbon.

An air current is passed over the ribbon to dry and harden it so that it can be cut easily.

The ribbon is cut into pieces of a desired size and shape which then are dried until the moisture level is less than about 15%. The pieces then are cooked, by either frying in oil or baking in a hot air popper. If desired, the cooked products can be dusted with seasonings.

EXAMPLE 5

The table below shows suitable content of various base materials and various liquid high moisture materials:

>;tb;______________________________________

>;tb; Milk Pepsi Beer

>;tb;______________________________________

>;tb;high moisture 9.2 10.2 8.2

>;tb;material (lbs)

>;tb;new meal (lbs)

>;tb; 9.1 10.1 8.1

>;tb;corn meal (lbs)

>;tb; 9.0 10.0 8.0

>;tb;wheat flour (lbs)

>;tb; -- -- 6.0

>;tb;milled rice (lbs)

>;tb; 2.0 --

>;tb;rice flour (lbs) 4.0

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>;tb;______________________________________

To make any of these chips, or others wherein the high moisture material is a beverage or other liquid, the liquid is blended with the base ingredients. The blended material is fed into an extruder and processed as described in Example 4.

Although the invention has been described in connection with certain preferred embodiments and specific examples, it is not so limited. Modifications within the scope of the claims will be apparent to those skilled in the art.Data supplied from the esp@cenet database - Worldwide

Claims:


I claim:

1. A process for preparing a stable snack food product which comprises: (a) vigorously macerating to a soggy pulp a high moisture fruit or vegetable material which comprises plant cells and provides a source of flavor and substantially all of the moisture for the snack food product, whereby a substantial proportion of the plant cells are disrupted; (b) blending said soggy pulp with at least one low moisture farinaceous base ingredient to produce a dough comprising from about 25% to about 50% moisture; (c) extruding said dough into a desired shape; and (d) drying said extruded product to about 8% to about

15% moisture.

2. The process of claim 1 wherein said high moisture material comprises at least one fruit or vegetable which has been macerated to disrupt cell walls.

3. The process of claim 2 wherein said high moisture material comprises apples, oranges, bananas, pears, lemons, grapes, tomatoes, carrots, celery, lettuce, spinach, onions, potatoes, sweet potatoes, or combinations thereof.

4. The process of claim 1 wherein said low moisture farinaceous base ingredient comprises at least one material selected from the group consisting of meals, flours and starches derived from corn, wheat, rice, oats, barley, potatoes, rye, tapioca, and other cereal crops, legumes and tubers.

5. The process of claim 1 wherein the dough comprises about 35% moisture.

6. The process of claim 1 wherein said high and low moisture ingredients are blended together by injecting them through one or more ports of an extruder and then contacting them with co-rotating twin extruder screws in the barrel of the extruder.

7. The process of claim 1 wherein the product exiting the extruder has a moisture content of about

30%.

8. The process of claim 7 wherein the product exiting the extruder is cooled, partially dried and then cut into pieces of a desired size prior to being dried to about 8% to about 15% moisture.

9. The process of claim 1 further comprising the step of (e) cooking said dried product to produce a shelf stable snack food product.

10. The process of claim 9 wherein said dried product is cooked under puffed food product cooking conditions to a temperature at which the product puffs.

11. The process of claim 9 wherein the product is cooked by baking at a temperature of about 400 DEG

F. to about 475 DEG F. for about 10 to about 30 seconds.

12. The process of claim 9 wherein said product is cooked by frying it in an edible oil at a temperature that is between about 220 DEG F. and the smoking point of the oil.

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13. The process of claim 9 further comprising the step of coating the cooked product with one or more toppings.

14. The process of claim 1 wherein the high moisture material is oranges, and the low moisture material is a mixture of corn meal and rice meal.

15. The process of claim 14, wherein the blended product of step (a) comprises about 37% by weight orange pulp, about 31.5% by weight rice meal and about 31.5% corn meal.

16. The process of claim 1 wherein the high moisture material is apples and the low moisture base material is a combination of rice meal, corn meal and sucrose.

17. The process of claim 16, wherein the blended product of step (a) comprises about 32% by weight apples, about 32% by weight rice meal, about 32% by weight corn meal and about 4% by weight sucrose.

18. The process according to claim 1 wherein a liquid which provides additional flavor is mixed with said soggy pulp and said base ingredients to provide a dough comprising from about 25% to about 50% moisture.

19. The process of claim 18 wherein said high moisture material comprises macerated apples, said liquid comprises milk, and said low moisture material comprises a combination of rice flour, rice meal, corn meal and milled whole corn.

20. The process of claim 19 wherein the blended product comprises about 17% by weight apples, about

17% by weight milk, about 17% by weight rice meal, about 17% by weight rice flour, about 16 % corn meal, and about 16% milled corn.

21. A process for preparing a snack product, comprising a first stage comprising the steps of: (a) vigorously macerating to a soggy pulp a high moisture fruit or vegetable material which comprises plant cells and provides a source of flavor and substantially all of the moisture for the snack food product, whereby a substantial proportion of the plant cells are disrupted; (b) blending said soggy pulp with at least one low moisture farinaceous base ingredient to product a dough comprising from about

25% to about 50% moisture; (c) extruding the dough into a desired shape; (d) drying said extruded product to about 8% to about 15% moisture to thereby produce a storage-stable pellet; and (e) transporting the pellet to a cooking and packaging site; and a second stage comprising (f) cooking the pellet; and (g) packaging the pellet.Data supplied from the esp@cenet database - Worldwide

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214.

JP2020255 - 1/23/1990

MIXTURE OF HIGHLY ACYLATED GELAN GUM AND STARCH


Inventor(s): ROSU SHII KURAAKU (--); DANIERU AARU BAAGAMU (--)

Applicant(s): MERCK and CO INC (--)

IP Class 4 Digits: A23L; C08L

IP Class: A23L1/195; A23L1/0522; A23L1/04; A23L1/054; C08L3/00

E Class: A23L1/0522; A23L1/054D; C08L3/00



Family: JP2020255

Equivalent: EP0342738; US4869916

Abstract:


PURPOSE: To ensure high shear stability and low strength and to attain rapid gelatinization by incorporating highly acylated gellan gum and starch. CONSTITUTION: Highly acylated gellan gum is mixed with starch selected from among corn, waxed corn, tapioca, wheat, potato and rice starches in a ratio of (0.01-0.50):1 and a liq. carrier such as water and one or more kinds of additives selected from among a flavor, spices, a colorant, a texturing agent, sugar, animal and vegetable proteins are added to

2-10wt.% of the resultant mixture. They are gelatinized by heating and then cooled.Description:


BLENDS OF HIGH ACYL GELLAN GUM WITH STARCH


This invention relates to blends of high acyl gellan and starch having textural and functional properties comparable to those of starch alone. This invention also relates to fast-gelling food products, made with the blends of the invention and at least one food ingredient, which have high shear-stability and low rigidity. Also part of the invention are methods of preparing the native gellan and starch blends of the invention and gelled products containing the blends.

The estimated U.S. consumption of natural and modified thickening and gelling agents used as food additives in 1983 was about 313,000 metric tons, with an average annual growth rate of 3.5% projected for an estimated 1988 consumption of 370,000 metric tons. Starches represent about 70% of the total.

Today, approximately 100,000 metric tons of 43% of the starch used in the food industry is modified.

However, current trends in the market are to minimize the use of modified starches or to replace them with non-modified starches because modified starches are expensive. In addition, several suspect chemicals have been used in the production of modified food starches. Starch is the most commonly used material to thicken liquid edible solutions, especially foods.In a typical application, starch is

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mixed with water, heated to swell the starch granules, and solubilize amylose molecules, and the dispersion is cooled to form a gel or a paste.

Although chemically modified starches comprise a large portion of the starches used in the food industry, chemical modification (cross-linking) limits the swelling of the granules and produces starches which are more shear stable than unmodified starches. Chemical modification (substitution) also controls the way that amylose chains re-associate to form gels.

Other hydrocolloids such as carboxymethyl cellulose (CMC) and xanthan gum have been used to improve the starch paste texture and/or reduce the amount of starch used. However, these hydrocolloids usually also have a detrimental effect on the cook-up viscosity of the starch. Hydrocolloids have also been used to improve the shear stability of starches, and some, such as carrageenan, have proven effective. However, large amounts of carrageenan must be added to attain this effect.

A variety of starch derivatives are known in the art, and some are described below.

Thin boiling starches:

These are starches produced by acid hydrolysis. Usually either hydrochloric or sulfuric acids are used to hydrolyze the starch. They do not swell as much upon cooking as raw starch, but become opaque and form rigid gels on cooling. These starches are useful in gum candies and in applications utilizing the film forming properties of starch.

Cross-linked starches:

These starches can be produced with polyfunctional reagents, i.e., reagents which contain two or more reactive groups to form bridges between polymer chains within the starch granule. Food starches are usually cross-linked using reagents of the phosphate ester type (phosphorous oxychloride or sodium trimetaphosphate). The purpose is to prevent the starch granule from swelling beyond a certain point.

Cross-linking acts mainly on the outer surface of the granule since it is done without gelatinizing the starch. This chemical bonding around the surface inhibits the breakdown or rupturing of the starch granule during processing. This, in turn, reduces the amount of amylose and amylopectin molecules in solution. Cross-linked starches eliminate the elastic or rubbery texture of regular or waxy maize gelatinized starches.They provide a desirable short smooth texture and reduce breakdown of viscosity in retorting of acidic food products. They provide thickening at lower concentrations and decreased shear breakdown in processing. Such starches, however, still suffer from problems of retrogradation since they do not bind water well. For this reason they are not freeze-thaw stable.

Acetate Modified Starches:

Starch acetates are commonly prepared from acidic anhydride in an alkaline starch suspension at low temperatures. The resulting starch has a non-uniform degree of substitution as more acetate groups are found on the outside of the granule than on the inside. These starches are considered more modified than the cross-linked starches. This modification reduces the amount of association between the starch chains after gelatinization. Small amounts of acetyl groups can eliminate the low temperature instability in waxy maize cross linked starches to give stability, texture and clarity in pie fillings, salad dressings and frozen foods. With regular starches (owing to the association of the amylose) the retrograded structure can be minimized to provide products with smooth uniform body.These products are more expensive to produce than native or simple cross-linked starches and are considered more radical than either of these.

Hydroxyalkyl Starches:

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Hydroxyalkyl starch ethers are produced from starch and an alkaline oxide. The modification is carried out at sub-gelatinization temperatures. This modification improves the "water binding" capacity of the starch. This modification is considered more radical than other chemical modifications to starch as many of the impurities remain after the modification is complete. These starches have been suspect due to these impurities. In addition, these starches are the most expensive to produce. Also, these starches usually require a higher use level to achieve a viscosity similar to a lesser modified or non-modified starch. Starch pastes of this modification tend to be more cohesive than simple cross-linked products.

They are more clear and stable to low temperatures and they exhibit good freeze-thaw stability. In addition, the gelatinization temperature is usually lowered significantly.Both of the above described processes are under scrutiny by international regulatory agencies. As a result major food producers are seeking more natural or natural fundamental alternatives to these modifications.

Combinations of deacetylated and partially deacetylated gellan gum and starch are known in the art.

For example, Baird, et al., Bio/Technology, page 781 (November 1983) disclose that it may be desirable to use gellan gum in combination with modified starches to obtain optional product texture and stability. Kang, et al., "Some Novel Bacterial Polysaccharides of Recent Development", page 240, disclose that gellan gum may be used as a structuring agent to replace or partially replace the starch.

Sanderson et al., Food Technology, (April 1983) disclose: in Table 4, page 66, a starch jelly formulation containing 6.56% starch and 0.2% gellan gum; at page 68, Figure 8 an amylograph for a

4.8% starch/0.2% gellan gum blend; and at page 68, the advantages of combining starch and gellan gum in pie fillings and puddings. U.S. Patent 4,517,216, Table 1-1 discloses blends of 0.25% gellan gum and 0.25% corn starch. These blends contain higher amounts of gellan gum than the blends of this invention.

Accordingly, providing a blend of native or modified starch with low amounts of high-acyl gellan gum of reduced cost and equal or improved characteristics such as starch pastiness and flavor would be highly desirable.


This invention relates to a blend of gellan gum and starch in a proportion of about 0.01-0.50:1, optionally with a liquid carrier and additives. These blends exhibit useful rheological and other physical properties which make them useful in various applications, primarily in food compositions.

This invention also relates to a fast gelling food product comprising a gelled matrix having high shearstability and low-rigidity, comprising about 2 to 10% (wt.) of the blend of this invention with respect to the total weight of the product; and at least one food ingredient dispersed in the matrix.

This invention also relates to a method of preparing a fast gelling blend having high shear-stability and low-rigidity, comprising a) mixing gellan and starch in a ratio of about 0.01- 0.05:1; b) admixing the blend with a liquid carrier in a proportion of about 2 to 10% (wt.) of the blend with respect to the total weight of the carrier and the blend; and c) heating and then cooling said admixed blend under conditions effective to gel the blend.

This invention relates as well to a method of preparing a fast-gelling food product having high shear stability and low-rigidity, comprising dispersing at least one food ingredient in a solution of the blend of the invention; and heating and then cooling the solution comprising the blend and the food ingredient under conditions effective to form a gelled matrix containing said food ingredient therewithin.


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The blends of the invention are suitable as substitutes for starches and/or to enhance their functionalities. The present blends are also suitable for use in sauces, soups and gravies as well as in pumpable-type systems such as pumpable jellies, fillings or icings.

The gellan starch blend of the invention is easily dispersable in cold water and can then be heated to gelatinize the starch and solubilize the gellan. By varying the amounts of starch and gellan within the ranges prescribed herein the final consistency of the product may be affected. Thus, different textures can be given the product making it more starch-like or more gel-like, depending on the ratio of the gellan to starch utilized.

The major parameters governing starch behavior are gelatinization and retrogradation. Briefly, during gelatinization (heating over a temperature range) the granule swells and loses birefringence, the pastes clarify and viscosity increases and smaller amylose molecules are solubilized and leach out. Upon cooling retrogradation "setback" occurs, whereby the small amylose molecules reassociate to form a precipitate or gel, the paste becomes cloudy; and syneresis occurs. Some important processing variables which can effect starch gelatinization in food are temperature, time, shear and pH. The higher the temperature, the more the granules swell. The more swollen the granule, the more fragile and susceptible it becomes to rupture by shearing.Acids disrupt the degree of hydrogen bonding to bring about a more rapid swelling of the granule and thus make the swollen granule peak sooner and break down faster. Shearing subsequent to cooling causes a dramatic decrease in viscosity unless the starch has been highly modified.

In the context of this application, gellan gum is defined as native, fully acetylated gellan gum and the clarified forms thereof, which are described in U.S. Patent 4,326,053, which is incorporated herein by reference.

Unexpectedly, the addition of the low amounts of gellan gum to the starch in the blend of the invention has only a minor effect on the viscosity of the paste during the cooking of the blend. This is a clear advantage of the present blends when compared to other hydrocolloids or blends thereof which display marked increases in viscosities during the gelatinization and cooking of the starch blends. The minimal viscosity effect brought about by the addition of low amounts of gellan gum to the starch during the gelatinization step combined with the ability of gellan to provide by itself some viscosity in structure and a rapid set-back on cooling provides a further advantage over starch alone. This is so because this blend allows for faster heat penetration during cooking and affords the product more of a structure thereafter.This even lowers the processing time and allows for a reduction in the amount of starch required for particular purposes.

Moreover, the addition prior to gelatinization of a low amount of gellan to the starch in accordance with this invention has been found to improve the shear stability of the starch and to lower syneresis of the paste after cooling. Moreover, the low levels of gellan added to the starch herein have also been found to impart a viscosity-building capability to the gelled blends which is evident following the shearing of the paste.

When other hydrocolloids are added to starch to reduce the amount of this ingredient required, an undesirable increase is observed in the viscosity of the paste during cooking as well as a slowing of the heat penetration. These two effects lead to increased processing times for the prior art blends.

The blend of the invention consists essentially of gellan and starch in a ratio of about 0.01-0.50:1, more preferably about 0.05-0.25:1, and still more preferably about 0.1:1.

Any starch known to be edible and useful in the food industry may be utilized in the blends of this invention. Examples of such starches are corn, waxy maize, tapioca, wheat, potato and rice starch, among others. Also suitable are mated and chemically-modified starches such as cross-linked and substituted starches.

Also provided herein is a gelling composition comprising the blend of the invention, and optionally an edible carrier such as water. However, other liquid or solid carriers known to be useful in edible gelling compositions known in the art can also be utilized.

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Particularly preferred are compositions where the blend of the invention is present in an amount of about 2 to 10% of the total weight of the carrier, the blend, and any other additives.

The gelling composition may also comprise one or more additives such as flavoring agents, coloring agents, aromatizing agents, texturizing agents, sugars and animal and vegetable proteins, among others.

Other additives known and used in the art can also be utilized with the blends of the invention. The additives are incorporated into the blends in amounts known in the art.

The dried blend of gellan and starch in accordance with this invention affords an improved storage stability with respect to the starch alone by improving the water holding capacity of the paste and thus reducing syneresis. In turn, this characteristic imparts an increased shelf stability to food products containing the gellan-starch blends of this invention.

In another aspect of this invention, the gelling composition may be prepared by a method comprising for forming a blend of gellan and starch in a ratio of about 0.01-0.05:1, admixing the blend with a liquid carrier in a proportion of about 2 to 10% of the blend with respect to the total weight of the carrier and the blend, and heating and then cooling the admixed blend under conditions effective to gel the blend.

The heating may be conducted at a temperature of about 65 to 90 DEG C, preferably at a temperature over 85 DEG C. The heating may be conducted for a period of time sufficient to dissolve the blend components, and preferably about 15 sec. to 10 min., and more preferably about 30 seconds to 5 minutes.

The cooling after the heating step may be conducted at various temperatures, including temperatures such as room temperature or lower, such as refrigerating temperature. The period of time for which the cooling step is conducted depends on the temperature at which the product is allowed to cool as is known in the art.

In a particularly preferred embodiment of the invention, the above method further comprises shearing the gelled blend and allowing the sheared blend to stand to attain a creamy consistency.

Also provided herein is a fast-gelling food product having high shear-stability and low-rigidity, which comprises a gelled matrix comprising about 2 to 10% of the blend of the invention with respect to the total weight of the product and the blend, and at least one food ingredient dispersed within the matrix.

The blends of the invention can be used to prepare any number of food products requiring a creamy or gelled consistency. The food product may be in liquid or solid form, e.g., sauces, soups, baby food, jellies, mousses, fillings, toppings, jams, gelatins, fish, animal and vegetable pastes, and the like. Other foods not described herein are also contemplated within the confines of this invention and may be used as is known in the art.

In another aspect of this invention the fast-gelling food product of the invention having high shearstability and low-rigidity may be prepared by a method comprising dispersing at least one food ingredient in a solution of the blend of this invention, and heating and then cooling the solution under conditions effective to form a gelled matrix containing the food ingredient therewithin.

In a particularly preferred embodiment of the above method, the solution is an aqueous solution. In another preferred embodiment, the blend is present in the food product in an amount of about 5 to 7.5% by weight with respect to the total weight of the food product.

If the food ingredient is in liquid form the dry blend may be admixed with it without a carrier. Suitably, the heating step may be conducted at a temperature of about 65 to 90 DEG C, preferably over about 85

DEG C.

The cooling step may be conducted at a temperature such as room temperature or lower, such as refrigeration temperature. In a particularly preferred embodiment of this invention the above method further comprises cooking the gelled food product and then cooling it. The conditions for conducting the latter two steps are known in the art and need not be described herein.

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The addition of the gellan gum to the starch in accordance with this invention aids in the gelling of the paste after cooling. The texture of this paste is determined by the concentration of the gellan, the type and concentration of the starch, the pH of the paste and the concentration of ions present in the system.

All these are variations contemplated within the context of this invention.

Having now generally described this invention, the same will be better understood by reference to certain specific examples, which are included herein for purposes of illustration only and are not intended to be limiting of the invention or any embodiment thereof, unless so specified. It will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein.

EXAMPLE 1

Comparison of Brabender Amylograph Curves of 5% Starch and Blends of 5% Starch - 0.1% Gellan

Gum (Corn, Waxy Maize, Cross-linked Waxy Maize and Acetylated Cross-linked Waxy Maize

AMYLOGRAPH TEST PROCEDURE

Sample Preparation:

500g samples are prepared for use in the Brabender Visco-amylograph (C.W. Brabender Instruments

Inc.). All samples are run in both standard tap water (STW) and STW with 2% of 100 grain vinegar

(WA) as described below. (STW comprises 1000 ppm NaCl and 143 ppm CaCl2.2H2O dissolved in deionized water.)

1) Water, starch and gum are measured out.

2) The gum is added to 2/3 of the water in a 600 ml beaker with mechanical agitation and stirred for

10 minutes. The measured amount of starch is then added and mixing is continued for several minutes.

3) The dispersion is poured into a Brabender sample cup and the remaining water is used to rinse the beaker and stirrer for most of the sample.This is added to the cup.

4) The cup is placed into the Brabender unit.

Sample Testing Procedure:

1) The machine is set to 75 RPM.

2) With rapid heating to 50 DEG C.

3) Heating is controlled from 50 to 95 DEG C (temperature increased at 1.5 degrees per minute, timer set to 30 minutes).

4) The raw native starches tested are held for 15 minutes at 95 DEG C. The modified starches, being more heat and shear resistant are held for 30 minutes at 95 DEG C.

5) Cooling is done from 95 to 50 DEG C (temperature decreased 1.5 degrees per minute).

Results of Visco-Amylograph Testing:

Test trials conducted on the amylograph indicate the following.

(1) The addition of native gellan gum has little effect on the viscosity of the starch pastes above 85

DEG C, but may increase the paste viscosity in the 68 to 80 DEG C range.

(2) In all the tests it is found that the native gellan gum added aids in gelling the starch pastes after cooling. The texture of the pastes are determined by the concentration of the gum, the type and

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concentration of the starch used, and the pH of the paste.Native gellan gum-starch blends are found to set-back faster than the starch paste alone.

(3) Native gellan gum does not appear to cross-link with the starch during gelatinization since only slight changes in viscosity are observed in the pasting curves run on the Visco-amylograph.

(4) Native gellan gum has only a slight effect on the acid stability of the viscosity of the starch paste during cooking.

(5) Native gellan gum performs similarly to low acyl gellan gum in a blend with starch in that it seems to have only a slight effect on the pasting curves.However, contrary to low-acyl gellan gumstarch blends the gellan-starch blends of this invention have an even greater improving effect on the final texture when low amounts of gellan are added to the starch described herein.

RESULTS OF INDIVIDUAL TRIALS:

EXAMPLE 2

Native Corn Starch With and Without Gellan in Tap Water

When added to native corn starch gellan gum has little effect on the viscosity curve of the starch until well into the cooling cycle. A low peak is observed with gellan gum in the 68 to 80 DEG C range. This corresponds to the hydration of the gellan gum and not to the beginning of starch gelatinization. If the level of gellan gum is increased to 0.5% this peak becomes quite noticeable and may reach 300 to 400

B.U. but then drops almost to 0 before rising again. The gellan gum does not affect the pasting temperature of the native corn starch as may be inferred by the rise and drop observed prior to the second rise.More likely, the first peak is a viscosity build peak created by the hydration of the gellan gum, and the second peak corresponds to the typical gelatinization curve of corn starch.

EXAMPLE 3

Amioca Starch (Native Waxy Maize Starch) With and Without Gellan in Tap Water

The pasting temperature appears to be basically unaffected with the addition of gellan gum to native waxy maize or Amioca. The gellan gum appears to cause the viscosity to increase slightly sooner, but not significantly. The gellan gum-native waxy maize starch blend sets back sooner than the starch alone.

EXAMPLE 4

4.5% Cross-linked Waxy Maize Starch (W-13) With and Without Gellan in Tap Water

The pasting temperature of the starch is slightly lowered by the addition of the gellan gum. However, this is due to the hydration of the gum as discussed earlier. The addition of gellan gum to the starch causes a slight increase in the pasting peak, but otherwise does not affect the viscosity curve until half way through the cooling cycle. The gellan gum-cross-linked waxy maize blend again sets back much faster at a high temperature than starch alone.

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EXAMPLE 5

Acetylated Cross-linked Waxy Maize Starch With and Without Gellan in Tap Water

The results are similar to those of Example 4. The addition of gellan gum has a dramatic effect on the pasting peak of the starch. The viscosity during the 95 DEG C holding period is slightly lower in the samples containing gellan gum. Upon cooling, the samples with the gellan gum-acetylated cross-linked waxy maize starch blend again set back much sooner than the other samples.

EXAMPLE 6

Comparison of Shear Stabilities of Cornstarch, Amioca, Cross-linked Waxy Maize and Acetylated

Cross-Linked Waxy Maize With and Without 0.1wt% Gellan in Tap Water and 2% Vinegar

SHEAR STABILITY PROCEDURE

The procedure used to examine the shear stability of the samples is based on the method of Klaushofer,

H., STARCH, "On Determination of Shearing Stability of Starch Pastes" (June 1975).

Sample Preparation:

250g samples are prepared in STW and in WA for shear stability testing.

1) Water is measured out in a 450 ml stainless steel cup (Type 316, Reading Scientific Co., Reading,

Penn.).

2) Gum and starch are measured out separately. The gum is added to the water with mechanical agitation and stirred for about 5 minutes. The starch is added to the gum solution and mixed for 5 additional minutes.

3) To gelatinize the starch, the cup is placed in a hot water bath heated to 95 DEG C. The solution is covered with a plastic cover with a hole placed in the center to allow for the shaft of a propeller type stirrer to run through it.The solution is then continuously mixed at 360 RPM while cooking.

4) The native starches are left in the water bath for 30 minutes and the modified starches for 45 minutes.

5) At the completion of cooking the cups are removed from the bath and allowed to cool overnight at room temperature.

Sample Testing::

1) A viscosity reading is taken on the cooled starch paste sample using a Brookfield RVT with a

Helipath attachment at 2.5 RPM using an appropriate T-bar type spindle and recorded.

2) The sample is mixed at 1800 RPM for 5 minutes using a 3 bladed propeller type mixing blade which is 2" in diameter.

3) Immediately following mixing, the viscosity is measured again using the RVT viscometer and record.

4) The sample is allowed to stand undisturbed overnight and the viscosity measurement is retaken using the RVT viscometer and record.

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Results of Shear Stability Test:

Gellan when added to a starch increases the viscosity of the starch pastes after cooling. In all tests, the starch pastes exhibited a soft elastic gel matrix with the addition of only about 0.1% gum. When the gellan gum is added to the starch it improves the shear stability of the paste. Generally, the modified starches display better shear stability than the unmodified starches.

A viscosity increase is observed by allowing the starch-gellan gum blends to stand following shearing.

This is an unexpected improvement of the blends of the invention when compared with starch alone.

EXAMPLE 7

Comparison of Storage Stability in Tap Water and 2% Vinegar of 5% Corn Starch, Waxy Maize

Starch, Cross-linked Waxy Maize and Acetylated Cross-linked Waxy Maize With and Without 0.1%

Gellan

RETROGRADATION TEST PROCEDURE

Sample Preparation:

The samples are prepared in the same manner as the samples for the shear stability test procedure except for step 5 which is conducted under the following conditions.

5) At the completion of cooking, aliquots of the cooked paste are poured into five 50 ml beakers

(about 40 ml). The samples are allowed to cool at room temperature for 30 minutes, then covered with plastic Saran Wrap and placed in the refrigerator at 2 DEG C. The samples are later removed as required for testing (0, 2, 6, 10 days).

Sample Testing:

1) The samples are removed from the refrigerator at the specified times. They are allowed to stand at room temperature for several hours.Then viscosity measurements are taken using the Brookfield RVT apparatus with Helipath 2.5 RPM spindle CC.

2) A portion of the sample is removed from the 50 ml beaker and placed in a plastic ring 1" in diameter and 1/2" in height setting in the ring, level to the top of the ring.

3) After one hour the sample is removed and the area dampened by the water migrating out of the paste is traced on the paper.

4) The paper is dried overnight.

5) The filter paper is weighed and recorded (W1). Using scissors, the area traced on the paper which had previously been wetted is cut out. This second piece of paper (W2) is then weighed. W2 is divided by W1 and multiplied by 100 to obtain a percentage value.

Results of Storage Stability Test:

Gellan gum when added to starch improves its storage stability by delaying increases in viscosity with time and by improving the water holding capacity of the starch. For example, an increase in viscosity with time is observed in the control corn starch sample while the water holding capacity of the paste

1036/2197

diminishes. The improving effect of gellan gum on the water holding capacity of the starch paste is more noticeable with the raw starches than with the more highly modified starches.Data supplied from the esp@cenet database - Worldwide Claims:


1. A blend consisting essentially of high acyl gellan gum and starch in a ratio of about 0.01-0.50:1.

2. The blend of Claim 1, wherein the ratio of the gellan gum and the starch is about 0.05-0.25:1.

3. The blend of Claim 1, wherein the starch is selected from the group consisting of corn, waxy maize, tapioca, wheat, potato, and rice starch.

4. The blend of Claim 1, wherein the starch is selected from the group consisting of native and chemically modified starch.

5. A gelling composition, comprising a carrier and 2-10% by weight of the blend of Claim 1.

6. The gelling composition of Claim 5, wherein the carrier is water.

7. The gelling composition of Claim 5, further comprising one or more of an additive selected from the group consisting of flavoring agents, coloring agents, aromatizing agents, texturizing agents, sugars, and animal and vegetable proteins.

8.The gelling composition of Claim 5, prepared by a method comprising:

a) blending gellan gum and starch in a ratio of about 0.01-0.05:1;

b) admixing the blend with a liquid carrier in a proportion of about 2 to 10% of the blend with respect to the total weight of the carrier and the blend; and

c) heating and then cooling said blend under conditions effective to gel the blend.

9. A fast-gelling food product having high shear stability and low-rigidity, comprising a gelled matrix comprising:

a) about 2 to 10% of the blend of Claim 1 with respect to the total weight of the product; and

b) at least one food ingredient dispersed within the matrix.

10. The gelled product of Claim 9, wherein the food ingredient is selected from the group consisting of food fillings, creams, foams, toppings, mousses, soups and sauces.

11.The gelled product of Claim 9, obtained by a method comprising:

a) dispersing at least one food ingredient in a solution of the blend of Claim 1; and

b) heating and then cooling the solution comprising the blend and the food ingredient under conditions effective to form the gelled matrix containing said food ingredient therewithin.

12. A method of preparing a fast-gelling blend having high shear-stability and low-rigidity, comprising:

a) blending gellan and starch in a ratio of about 0.01-0.05:1;

b) admixing the blend with a liquid carrier in a proportion of about 2 to 10% of the blend with respect to the total weight of the carrier and the blend; and

c) heating to about 65 to 95 DEG C for a period of time of about 30 sec. to 5 min. and then cooling said admixed blend under conditions effective to gel the blend.

13. The method of claim 12, further comprising shearing the gelled blend; and allowing the sheared blend to stand for a period effective to attain a creamy consistency.

14. A method of preparing a fast-gelling food product of high shear-stability and low-rigidity, comprising:

a) dispersing at least one food ingredient in a solution of the blend of Claim 1; and

b) heating to about 65-95 DEG C and then cooling the solution comprising the blend and the food ingredient under conditions effective to form a gelled matrix containing said food ingredient therewithin.

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15. The method of Claim 14, wherein the solution is an aqueous solution; and the blend is present in an amount of about 2 to 10% by weight with respect to the total weight of the food product.

16. The method of Claim 14, further comprising cooking the gelled food product; and cooling the cooked product.Data supplied from the esp@cenet database - Worldwide

1038/2197

215.

JP2203757 - 8/13/1990

MAKING OF COLD STORED AND HEATED PRODUCT


Inventor(s):

UEDORARU (--)

JIYAU YAN SU (--); ERUDON CHIENNSHIUNGU RII (--); ERAIN REGINA



IP Class: A23L1/16

E Class: A23L1/16D



Family: JP2203757

Equivalent: EP0369175; NO894517

Abstract:


PURPOSE: To provide a product such as pasta by using a material practically containing no gluten by adding the effective quantity of functional protein into a non-heated starch material, heating the material and cooling it later at a cold storage temperature. CONSTITUTION: The effective quantity of functional protein is added into the non-heated starch material, and the starch material is heated and cooled at the cold storage temperature so that the target product can be provided. In this case, it is preferable to use the starch made from cereal powder, rice, maize or potato as this material and to use gluten as functional protein.Description:


Preparation of a refrigerated product

The present invention relates to a process for the preparation of refrigerated cooked products e.g. pastas from non-conventional starchy materials containing substantially no gluten.

There has recently been an increasing market demand for high quality culinary chilled food products.

However, retrogradation has been a common problem in starch-predominant products, particularly on refrigeration storage and cooked rice used in chilled foods shows this problem which involves firming texture (staling) progressively on refrigeration.

When used in the preparation of pastas, non-conventional starchy materials such as rice, maize and potatoes which contain substantially no gluten, generally require a binder to form a good shape during extrusion and to prevent pasta stickiness during cooking. Binders that have been reported to be suitable for such purposes include gelatinised starch (British Patent No. 1384149), gums such as alginates and certain proteins. However, we have found that the addition of gelatinised starch or alginates to such starchy products does not retard starch retrogradation on refrigerated storage. Chemically modified starches such as certain organic acid derivatives (United States Patent No. 3953616) and certain emulsifiers have also been reported to have a lower staling effect. However, consumers generally prefer natural substances.

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Although pasta formulations containing added proteins have been described in which the proteins are added for protein enrichment or as binding agents, there have been no reports on the use of added proteins to retard starch retrogradation in refrigerated cooked products. We have surprisingly found that the addition of certain functional proteins to the starchy material retards starch retrogradation on refrigerated storage of the cooked product.

Accordingly, the present invention provides a process for the preparation of a refrigerated cooked product from a non-conventional starchy material containing substantially no gluten as hereinafter defined which comprises incorporating an effective amount of a functional protein into the uncooked starchy material, cooking the starchy material and cooling to a refrigeration temperature.

By a non-conventional starchy material containing substantially no gluten we mean a starch or a flour containing substantially low levels of proteins and proteins of lower functionality. The starches contain substantially no gluten/proteins whereas the flours contain some gluten but in substantially low quantities and low functionality.

Examples of non-conventional starchy materials containing substantially no gluten include flours and starches derived from rice, maize and potatoes, reconstituted rice and similar starchy materials. The rice may be regular, parboiled, precooked, brown, long-grain, medium-grain, Basmati (from. India), roasted wild rice and waxy (glutaneous/sweet) rice (from Japan and Taiwan).

By "functional protein" we mean an active protein which possesses its functional properties including binding capability, water absorption and protein-carbohydrate interaction which reduces starch retrogradation. The functional protein is preferably gluten, but other functional proteins may be used such as animal proteins e.g. egg albumen, gelatin or milk protein, plant proteins e.g. soy protein, and microbial proteins e.g. yeast protein. The amount of active protein added to the starchy material may be from 1 to 20% preferably from 2 to 10% and especially from 2.5 to 7.5% by weight based on the weight of the starchy material.

If desired, other additives such as alginate gums may be added to the starchy material.

The starchy material containing the functional protein may be formed into a pasta, for example by extrusion followed by cooking or extrusion/cooking, before cooling. The pastas may be formed by extrusion or by the dough kneading/sheeting process.

By refrigeration temperature we mean above 0 DEG C to about 10 DEG C, usually from about 2 DEG to about 8 DEG C, and the present invention also comprises a refrigerated product prepared by the hereinbefore described process.

The following Examples further illustrate the present invention. Parts are given by weight.

Example 1

81 parts of ungelatinised rice flour and 13 parts of pregelatinised rice flour were mixed with 5 parts of wheat gluten, 0.5 parts of sodium alginate, 0.5 parts of propylene glycol alginate and 40 parts of water until uniform. The dough was then extruded through a low-pressure, pasta-type extruder to form a simulated rice grain shape. The rice pasta was cooked in boiling water for 3 minutes, drained, cooled and placed in a refrigerator at 5 DEG C.

To measure the retrogradation after a period of storage in the refrigerator, a 15 g sample of the pasta was placed in a Kramer shear cell apparatus. The compressibility of the samples was performed with the following parameters:

- full scale load, 100 kg;

- crosshead speed, 50 mm/min;

- chart drive, 50 mm/min;

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The height of peaks was calculated to an equivalent weight load of 15 g sample. The percent of retrogradation after storage was expressed as the percent of the increasing weight load based on the initial sample before storage. The initial Instron Compressibility was 9 kg and after 18 days it was 13 kg which indicates a starch retrogradation of 44%.


Example 1 was repeated except that no gluten was added. The initial Instron Compressibility was 11 kg and after 18 days storage at 5 DEG C was 19.4 kg which indicates a starch retrogradation of 76%.

In the following Examples the tests for retrogradation were carried out as follows:

To measure the retrogradation after a period of storage in the refrigerator at approximately 5 DEG C, a

30g sample of the pasta was placed even in a Kramer shear cell apparatus. The Instron compressibility of the samples was performed with the following parameters: full scale load, 100 Kg; crosshead speed,

50mm/min; chart drive, 50mm/min. The percent of retrogradation after storage was expressed as the percent of the increasing weight-load based on the initial sample before storage.

The thermal characterization for retrograded starch was performed by using differential scanning calorimetry (DSC). The pasta sample after a period of storage was ground to paste form, weighed and encapsulated in a stainless steel pan. The sample pan was scanned from 25 to 150 DEG C at a rate of

10 DEG C/min.

Examples 2 to 6

80 parts of uncooked long grain rice flour, 15 parts of pre-gelatinized long grain rice flour and 41 parts of water were mixed with 5 parts of wheat gluten, egg white, whole egg, sodium caseinate, or Torula yeast, in separate trials, until uniform, and extruded through a low-pressure, pasta type extruder to form a desired pasta shape. The pasta was cooked in boiling water, then cooled and packed under a controlled atmosphere using a gas mixture of carbon dioxide and nitrogen to extend its shelf-life. The results of the retrogradation tests are given in Table 1.

Comparative Example B

A similar procedure to that described for Examples 2 to 6 was carried out except that no functional protein was added. The results of the retrogradation tests are given in Table 1.


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>;tb;Title: II.DSC Analysis: 12 days at 5 DEG C

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>;tb;B>;SEP;Control (none)>;SEP;3.65

>;tb;2>;SEP;Wheat Gluten>;SEP;1.51

>;tb;3>;SEP;Egg White>;SEP;1.90

>;tb;4>;SEP;Whole Egg>;SEP;2.50

>;tb;5>;SEP;Caseinate>;SEP;2.47

>;tb;6>;SEP;Torula Yeast>;SEP;----

>;tb;>;/TABLE; As shown in the TABLE 1, the addition of functional proteins, wheat gluten, egg white, whole egg, sodium caseinate, and Torula yeast showed less retrogradation than the comparative control with no added protein. Wheat gluten demonstrated the most effective protein for minimizing starch retrogradation with stable low Instron compressibility and low enthalpy ( H) of retrograted starch.The endotherm of retrograded starch showed the peak maximum at approximately 50-55 DEG

C.

Examples 7 to 11

55 parts of precooked potato flour from ground potato flake, 40 parts of potato starch and 45 parts of water were mixed with 5 parts of wheat gluten, egg white, whole egg, sodium caseinate or Torula yeast, in separate trials, until uniform, and extruded through a low-pressure, pasta type extruder to form a desired pasta shape. The pasta was cooked in boiling water or steam, then cooled and packed under a controlled atmosphere using a gas mixture of carbon dioxide and nitrogen to extend its shelf life. The results of the retrogradation tests are given in TABLE 2.

Comparative Example C

A similar procedure to that described for Examples 7 to 11 was carried out except that no functional protein was added. The results of the retrogradation tests are given in TABLE 2.


>;tb;Title: I. Instron Compressibility Kg/30g pasta sample in a Kramer shear cell

>;tb;Head Col 1:

>;tb;Head Col 2:


>;tb;Head Col 6: Retrograd., %



>;tb;SubHead Col 3:Initial




>;tb;C>;SEP;Control (none)>;SEP;7.8>;SEP;22.5 >;SEP;22.5>;SEP;188

>;tb;7>;SEP;Wheat Gluten>;SEP;4.0>;SEP;4.8>;SEP;4.8 >;SEP;20

>;tb;8>;SEP;Egg White>;SEP;7.6>;SEP;13.4>;SEP;14.2 >;SEP;76

>;tb;9>;SEP;Whole Egg>;SEP;5.6>;SEP;13.4>;SEP;15.4 >;SEP;139

>;tb;10>;SEP;Caseinate>;SEP;7.2>;SEP;15.0>;SEP;15.2 >;SEP;108

>;tb;11>;SEP;Torula Yeast>;SEP;5.8>;SEP;14.0 >;SEP;15.6>;SEP;141

>;tb;Title: II. DSC Analysis: 20 days at 5 DEG C storage

>;tb;Head Col 1:

>;tb;Head Col 2:


1042/2197



>;tb;SubHead Col 9: DELTA H.J/g

>;tb;C>;SEP;Control (none)>;SEP;4.55





>;tb;11>;SEP;Torula Yeast>;SEP;3.48

>;tb;>;/TABLE; As shown in the TABLE 2, the addition of wheat gluten, egg protein, whole egg, sodium caseinate and Torula yeast showed less retrogradation than the comparative control with no added protein. Wheat gluten demonstrated the most effective functional protein for minimizing starch retrogradation with stable low Instron compressibility and low enthalpy ( H) of retrograded starch.

Examples 12 to 17

60 parts of corn flour, 20 parts of maize starch, 15 parts of pre-cooked corn flour and 41 parts of water were mixed with 5 parts of wheat gluten, egg white, whole egg, sodium caseinate, Torula yeast or gelatin, in separate trials, until uniform, and extruded through a low-pressure, pasta-type extruder to form a desired pasta shape. The pasta was cooked in boiling water, then cooled and packed under a controlled atmosphere using a gas mixture of carbon dioxide and nitrogen to extend its shelf life. The results of the retrogradation tests are given in Table 3.

Comparative Example D

A similar procedure to that described for Examples 12 to 17 was carried out except that no functional protein was added. The results of the retrogradation tests are given in Table 3.


>;tb;Title: I. Instron Compressibility Kg/15g pasta sample in a Kramer shear cell

>;tb;Head Col 1:

>;tb;Head Col 2:


>;tb;Head Col 7: Retrograd., %



>;tb;SubHead Col 3:Initial

>;tb;SubHead Col 4: 1 Day




>;tb;D>;SEP;Control (none)>;SEP;4.2>;SEP;7.7 >;SEP;10.8>;SEP;14.0>;SEP;233

>;tb;12>;SEP;Wheat Gluten>;SEP;2.8>;SEP;4.4>;SEP;4.5 >;SEP;4.6>;SEP;64

>;tb;13>;SEP;Egg White>;SEP;2.8>;SEP;5.8>;SEP;5.8 >;SEP;6.8>;SEP;143

>;tb;14>;SEP;Whole Egg>;SEP;2.7>;SEP;5.6>;SEP;5.8 >;SEP;8.0>;SEP;196

>;tb;15>;SEP;Caseinate>;SEP;3.4>;SEP;7.0>;SEP;7.5 >;SEP;8.2>;SEP;141

>;tb;16>;SEP;Torula Yeast>;SEP;2.7>;SEP;6.2>;SEP;7.6 >;SEP;8.2>;SEP;204

>;tb;17>;SEP;Gelatin>;SEP;2.4>;SEP;5.9>;SEP;7.0 >;SEP;7.2>;SEP;200

>;tb;Title: II. DSC Analysis: 18 days at 5 DEG C storage

>;tb;Head Col 1:

>;tb;Head Col 2:




>;tb;SubHead Col 10: DELTA H.J/g

>;tb;D>;SEP;Control (none)>;SEP;3.76

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>;tb;16>;SEP;Torula Yeast>;SEP;2.68

>;tb;17>;SEP;Gelatin>;SEP;2.70

>;tb;>;/TABLE; As shown in the TABLE 3, the addition of wheat gluten, egg protein, whole egg, sodium caseinate, Torula yeast and gelatin showed less retrogradation than the comparative control with no added protein. Wheat gluten demonstrated the most effective functional protein for minimizing starch retrogradation with stable low Instron compressibility and low enthalpy ( DELTA H) of retrograded starch.Data supplied from the esp@cenet database - Worldwide Claims:


1. A process for the preparation of a refrigerated cooked product from a non-conventional starchy material containing substantially no gluten as hereinbefore defined which comprises incorporating an effective amount of a functional protein into the uncooked starchy material, cooking the starchy material, and cooling to a refrigeration temperature.

2. A process according to claim 1 wherein the starchy material is a flour or starch derived from rice, maize or potatoes.

3. A process according to claim 1 wherein the functional protein is gluten.

4. A process according to claim 1 wherein the amount of active functional protein added to the starchy material is from 1% to 20% by weight based on the weight of the starchy material.

5. A process according to claim 1 wherein the starchy material containing the functional protein is formed into a pasta before cooling.

6. A refrigerated cooked product whenever prepared by a process according to claim 1.Data supplied from the esp@cenet database - Worldwide

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216.

JP2242656 - 9/27/1990

FAT SUBSTITUTE WITH LOW CALORIE


Inventor(s): MAIKERU II HENDORITSUKU (--); ROBAATO EI REIMAA (--)

Applicant(s): PFIZER (--)

IP Class 4 Digits: A23L; C08B; A21D; A23G

IP Class: A23L1/164; A23L1/307; A23L1/24; A23G3/00; A21D13/08; C08B37/00

E Class: A23L1/308; A23L1/308P; A23D9/05; A23L1/00P4B; A23L1/24



Family: JP2242656

Equivalent: EP0380225; PH27047; IE900265L; IE71931

Abstract:


PURPOSE: To obtain a low-calorie fat substitutive consisting of freely flowable microspherical particles by coating low-calorie or non-calorie core materials with digestable solid or semi-solid fat compsns. CONSTITUTION: The core materials selected from polydextrose. nonfibrous cellulose derivatives, erythritol, pulverized rice barn or wax or aq. gel forming compsns., etc., are coated with the digestable solid or semi-solid fat compsns. selected from animal fats, partially or completely hydrolyzed vegetable oils, mono-, di- or triglyceride, phosphorus lipid, etc., by arbitrary means and if desired, layers of intermediate materials, such as cellulose, casein and agar, are formed between the core materials and the fat compsn. coatings. The low- calorie fat substitutive consisting of the nearly spherical particles having an average grain size of >;250mu and more preferably an average grain size of about 2 to 50mu is obtd.Claims:


1. A free-flowing, microparticulate composition comprising an outer shell of a digestible solid or semisolid fat composition surrounding an inner non-caloric or low caloric core material, said composition useful as a low calorie fat substitute, which is substantially insoluble under conditions of food formulation provided that if the core material is cellulose, the cellulose is non-fibrous.

2. The composition of claim 1 wherein said core material is selected from the group consisting of solids, liquids, gel-forming compositions, foams, gases, or combinations thereof.

3. The composition of claim 1 wherein said fat substitute comprises roughly spheroidal particles having a mean diameter of less than 250 microns.

4.The composition of claim 1 wherein said core material is selected from the group consisting of polydextrose, non-fibrous cellulose derivatives, erythritol, micronized bran and waxes.

5. The composition of claim 4 wherein said core material is polydextrose.

6. The composition of claim 1 wherein said core material is an aqueous gel-forming composition.

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7. The composition of claim 6 wherein said aqueous gel-forming composition is formed by combining, in an aqueous medium, a gel-forming polysaccharide selected from the group consisting of alginates, carboxymethylcellulose, succinoglycans, xanthans, gelatin, pectin and scleroglucans with a suitable amount of a salt of a polyvalent metal cation capable of crosslinking said polysaccharide wherein said metal cations is calcium (II) or magneisum (II).

8.The composition of claim 1 further comprising a layer of material between said core material and said shell, said layer of material different from said core material and selected from the group consisting of cellulose, methylcellulose, cellulose acetate phthalate, albumin, casein, zein, agar, gelatin, pectin, and gum arabic.

9. A process for the production of a composition according to any preceding claim comprising encapsulating a low caloric or non caloric, non-fibrous core material with an edible fat composition.

10. The process of claim 9 wherein said coating is accomplished by pan coating, spin disc coating, gas suspension coating, centrifugal coextrusion, rotational suspension, coacervation, inclusion complexation, spray coating, or spray drying. >;/SL;

Claims for the following Contracting States: ES,GR

1.A process for the production of a composition useful as a low caloric fat substitute comprising encapsulating a low caloric or non caloric, non-fibrous core material with an edible fat composition.

2. The process of claim 1 material is selected from the group consisting of solids, liquids, aqueous gel-forming compositions, foams, gases, and gas-filled spheres.

3. The process of claim 1 wherein said coating is accomplished by pan coating, spin disc coating, gas suspension coating, centrifugal coextrusion, rotational suspension, coacervation, inclusion complexation, spray coating, spray drying.

4. The process of claim 1 wherein said core material is selected from the group consisting of polydextrose, non-fibrous cellulose derivatives, erythritol, micronized bran and waxes.

5. The process of claim 4 wherein said core material is polydextrose

6. The process of claim 1 wherein said core material is an aqueous gel-forming composition.

7. The process of claim 1 wherein said aqueous gel-forming composition is formed by combining, in an aqueous medium, a gel-forming polysaccharide selected from the group consisting of alginates, carboxymethylcellulose, succinoglycans, xanthans, gelatin, pectin and scleroglucans with a suitable amount of a salt of a polyvalent metal cation capable of crosslinking said polysaccharide wherein said salt is calcium (II) or magnesium (II).Data supplied from the esp@cenet database - Worldwide

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217.

JP2276547 - 11/13/1990

LOW CALORIE GRANOLA BAR


Inventor(s): JIYOSEFU EDOWAADO KEIZU (--); KAARU UIRIAMU ZABITSUKI (--)



IP Class: A23L1/164; A23L1/18; A23L1/307; A23L1/36

E Class: A23L1/164C; A23L1/18F; A23L1/164; A23L1/308P



Family: JP2276547

Equivalent: EP0348196; DK312289

Abstract:


PURPOSE: To obtain a granola bar as a health food which shows same taste as a bar using triglyceride fat by bonding food chips such as granola and popcorn with a low-calorie fat substitute binder.

CONSTITUTION: Food chips such as granola, popcorn, nuts, fruits and puffed rice are bonded with low calorie fat substitute such as sugar fatty acid polyester, sugar alcohol fatty acid polyester as a binder to obtain a granola bar, popcorn ball, nuts cluster, fruit bar, rice crisp bar, etc. The amt. of the binder is 5 to 100%. preferably 35 to 60wt.%, and especially 5 to 33%.Description:


REDUCED CALORIE GRANOLA BARS

TECHNICAL FIELD

The present invention relates to the field of food products such as granola bars, popcorn balls, nut clusters, and the like, products in which food pieces are held together by a binder. More specifically, the invention relates to foods such as granola bars in which the binder is made with a reduced calorie fat substitute.


Granola products have become increasingly popular as part of a nationwide trend toward more healthoriented foods. They provide a high energy source and contain nutritious ingredients such as grains, seeds, nuts and fruits. Similar food products such as popcorn balls, nut clusters, fruit bars, and rice crisp bars also enjoy wide popularity. These products comprise food pieces of various types and a binder generally made with vegetable oil.

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Unfortunately, the consumption of triglyceride fats (vegetable oils and animal fats) has been linked to various health problems. One of the most common metabolic problems among people today is obesity, primarily caused by ingestion of a greater number of calories than are expended. Triglyceride fat is the most concentrated form of calories in the diet, with each gram of fat supplying approximately 9 calories.

The National Institutes of Health Consensus Development Conference, "Lowering Blood Cholesterol to Prevent Heart Disease," JAMA, Vol. 253, No. 14, pp. 2080-2086 (1985), concluded that elevation of blood cholesterol levels is a major cause of coronary artery disease, and recommended a reduction in the amount of fat eaten in order to reduce blood serum cholesterol levels.

In view of the health concerns associated with triglyceride fats, there is a need for a way to make granola bars and like products in which the amount of triglyceride fat is reduced.

U.S. Patent 3,600,186 of Mattson et al., issued Aug. 17, 1971, discloses low calorie food compositions made by replacing at least a portion of the triglyceride fat with a sugar or sugar alcohol fatty acid ester.

Foods disclosed are frying oils, salad oils, plastic shortening, cakes, breads, prepared culinary mixes

(e.g., for cakes and icings), mayonnaise, and margarine.

U.S. Patent 4,461,782 of Robbins et al., issued July 24, 1984, discloses baked products containing 12-

60% liquid polyol polyester and 25-85% microcrystalline cellulose and flour. Examples given are breads, cakes and wafers.

U.S. Patent 4,034,083 of Mattson, issued July 5, 1977, discloses vitamin-fortified polyol polyesters used in foods or pharmaceutical compositions, and U.S. Patent 4,005,195 of Jandacek, issued Jan. 25,

1977, discloses liquid polyol polyesters combined with anti-anal leakage agents. The polyesters are said to be useful as a partial or complete replacement for normal triglyceride fats in a salad or cooking oil; in plastic shortenings for use in frying, cake making or bread making; or in mayonnaise, margarine, or dairy products.

Fallat et al., "Short Term Study of Sucrose Polyester a Nonabsorbable Fat-Like Material as a Dietary

Agent for Lowering Plasma Cholesterol," The American Journal of Clinical Nutrition 29, pp. 1204-

1215 (Nov. 1976), discloses a study in which the efficacy of sucrose polyester as a cholesterollowering agent was assessed. The polyester was used as a fat component in shortening, margarine, baked and sauteed foods, sauces, frostings and candies.

None of these references discloses granola bars or like products containing reduced calorie fats.

It is, therefore, an object of the present invention to provide food products such as granola bars in which at least a portion of the triglyceride fat in the binder is replaced by a reduced calorie fat.

It is another object of the present invention to provide reduced calorie fat-containing granola bars and like products that taste at least as good as the triglyceride fat-containing products.

These and other objects of the invention will become evident from the disclosures herein.

All parts, percentages, and ratios used herein are by weight unless otherwise indicated.


The present invention relates to food products such as granola bars, popcorn balls, nut clusters, and the like, products in which food pieces are held together by a binder. The binder contains a reduced calorie fat substitute, preferably sucrose fatty acid polyesters. A highly preferred granola bar according to the invention comprises from about 40% to about 65% by weight granola and from about 35% to about

60% by weight binder, where the binder comprises from about 5% to about 33% sucrose polyester.

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This invention relates to food products in which various kinds of food pieces are held together by a binder. A typical example is a granola bar in which the granola pieces are held together by a binder containing a triglyceride fat. In the present invention the binder comprises from about 5% to about

100% reduced calorie fat substitute. It has been discovered that granola bars and such foods can be made that are reduced in calories with at least equal taste compared to products in which the binder contains only triglyceride fat.

Food Products of the Invention

A food product according to the present invention comprises edible food pieces held together by a binder, wherein the binder comprises from about 5% to about 100% reduced calorie fat substitute.

Examples of such food products include granola bars, granola clusters, and other similar granola products. These products comprise pieces of granola held together by a binder of some sort. Musli bars or clusters are made from granola in which the grain is not toasted.

Other examples include various kinds of popcorn balls or popcorn clusters, in which popcorn pieces are held together by a binder. There are a variety of different kinds of popcorn balls and clusters in addition to the standard type comprising popcorn and a binder. For example, crackerjack is a mixture of popcorn and peanuts bound together. Popcorn chop suey is a mixture of popcorn, coconut and peanuts.

Nut popcorn balls are a mixture of popcorn and nuts, for example walnuts, pecans or hickory nuts.

Cereal popcorn balls are a mixture of popcorn and puffed cereal, and raisin popcorn balls are a mixture of popcorn and raisins. The popcorn balls or clusters can be flavored or covered, for example by chocolate, caramel glaze, molasses or candy coating.

Nut clusters are also included within the food products of the present invention. A wide variety of nuts can be used in these products, for example peanuts, almonds, pecans, walnuts, hazelnuts, pine nuts,

Brazils, cashews, chestnuts, filberts, hickory nuts, and pistacchios. The nuts can be raw, roasted, blanched, fried or browned, and chopped, ground, sliced or shredded.

Fruit bars and fruit clusters are another example of food products within the present invention. These products are made with pieces of fruit, usually dried fruit, held together by a binder. The dried fruits most commonly used are raisins, dates, prunes, apricots, and apples, usually in chopped or sliced form.

Other possible fruits include lemons, limes, oranges, cherries, pears, peaches, bananas, pineapple, strawberries, figs, grapes, and grapefruit.

Also within the scope of the present invention are fruit and nut bars or clusters, which contain a mixture of both fruit and nuts, for example walnuts and cherries.

Another example of foods within the present invention are clusters or bars made from puffed rice or other puffed cereal grains, for example "Rice Krispies" bars.

Any combination of the above ingredients can be used, and the foods can be in the form of bars, rolls, balls, clusters, squares, sticks or the like. The products can be in soft or hard form, chewy or crunchy.

Additionally, the products can be covered with various kinds of coatings, for example, chocolate, glaze, candy, or yogurt.

The products can also contain numerous other complimentary ingredients in addition to the food pieces, binder, and any coating. For example, the present products, particularly granola bars, will often contain one or more of the following ingredients: peanut butter or other nut butters, coconut, caramel, chocolate, fudge, graham cracker crumbs, honey, brown sugar, sucrose or other sugars, salt, flavors such as vanillin, spices (e.g., cinnamon, mace, nutmeg, anise, allspice, lemon rinds, coriander, ginger, cloves, or fennel), seeds, flavor chips (e.g., chocolate, butterscotch, peanut butter), soy grits, breadcrumbs, baking soda, baking powder, malt, nonfat dry milk, leavenings, emulsifiers, stabilizers and preservatives.

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The food products of the invention can be baked or unbaked. If baking is not used, typically the ingredients are heated enough to allow mixing, then formed and cooled. The invention is not limited by the processing method.

Granola

Granola is generally defined as a mixture of toasted grains, nuts, seeds, and usually dried fruits. Musli is usually defined the same as granola but containing untoasted grains. Any kind of granola or musli can be used in the present invention.

The typical grain used in granola is rolled oats, which are produced by passing oats through a series of roller mills. Other grains useful in granola include, but are not limited to, cornmeal, corn bran, wheat germ, wheat bran, whole wheat, whole oats, oatmeal, wheat flakes, rye flakes, bran flakes, buckwheat groats, and rice. The grains can be whole, bran, flaked, rolled, or processed in another manner.

The nuts used most often in granola are peanuts, almonds, pecans, walnuts, hazelnuts, and pine nuts, usually in chopped or sliced form. The seeds used in granola are generally sesame seeds, carraway seeds, poppy seeds, sunflower seeds, or pumpkin seeds, although other seeds can be used.

The dried fruits most commonly found in granola are raisins, dates, prunes, apricots, and apples, usually in chopped or sliced form, and shredded coconut.

The Binder

The food pieces that make up the food products of the present invention are held together by a binder.

Vegetable oil or sometimes animal fat generally comprises a large part of ordinary binders. In the present invention, at least a portion of this triglyceride fat is replaced by a reduced calorie fat substitute, described in detail below. Replacement of triglyceride fat allows a reduction in calories, while at the same time the good taste of the food products is maintained.

In addition to the triglyceride fat and reduced calorie fat substitute, the binder can comprise a variety of other ingredients including, but not limited to, the following: sucrose and other sugars, flour, honey, molasses, corn syrup, invert syrup, maple syrup, sorbitol, glycerine, lecithin, water or other fluids, and eggs. The most suitable triglyceride fats are vegetable oils such as corn oil, cottonseed oil, soybean oil, palm oil, rapeseed oil, and peanut oil. The vegetable oils can be partially or fully hydrogenated and can contain stabilizers and emulsifiers, e.g., mono- and diglycerides. The oils can be in the form of shortening or margarine.

Composition Ranges for the Food Products of the Invention

As discussed hereinabove, the food products of the present invention comprise edible food pieces held together by a binder, wherein the binder comprises from about 5% to about 100% by weight reduced calorie fat substitute. Preferably, the binder comprises from about 5% to about 50% fat substitute, more preferably from about 5% to about 33%, and most preferably from about 15% to about 33%.

Granola bars of the present invention preferably comprise from about 25% to about 70% by weight binder and from about 30% to about 75% by weight granola, more preferably from about 35% to about

60% binder and from about 40% to about 65% granola, and most preferably from about 45% to about

50% binder and from about 50% to about 55% granola.

1050/2197

It is also preferred that the granola bars comprise from about 5% to about 33% by weight reduced calorie fat substitute, more preferably from about 5% to about 25%, and most preferably from about

10% to about 20%.

Other food products of the present invention will vary in the amounts of binder and dry food pieces used, depending on the type of food.

Reduced Calorie Fat Substitutes

The reduced calorie fat substitutes used in this invention are edible materials which can replace conventional triglyceride fats. These fat substitutes provide the benefits of triglycerides such as consistency, lubricity and flavor, yet do not add as many calories because they are nondigestible, partially digestible, or are lower in net caloric efficiency compared to triglycerides.

Many classes of reduced calorie fat substitutes, or mixtures thereof, are suitable for use in the present invention. Examples of such materials are: fatty alcohol esters of polycarboxylic acids (U.S. Patent

4,508,746 to Hamm, assigned to CPC International, Inc., issued April 2, 1985); fatty polyethers of polyglycerol (U.S. Patent 3,932,532 of Hunter et al., assigned to ICI United States, Inc., issued January

13, 1976) (food use disclosed in German Patent 207,070, issued February 15, 1984)); ethers and etheresters of polyols containing the neopentyl moiety (U.S. Patent 2,962,419 of Minich, issued November

29, 1960); fatty alcohol diesters of dicarboxylic acids such as malonic and succinic acid (U.S. Patent

4,582,927 of Fulcher, assigned to Frito-Lay, Inc., issued April 15, 1986); triglyceride esters of alpha branched chain-alkyl carboxylic acids (U.S.Patent 3,579,548 of Whyte, assigned to The Procter &

Gamble Co., issued May 18, 1971); fatty acid diglyceride, diesters of dibasic acids (U.S. Patent

2,874,175 to Feuge et al.); polyorganosiloxanes (European Patent Application 205,273 to Frye); alphaacylated glycerides (U.S. Patent 4,582,715 to Volpenhein); and sugar and sugar alcohol fatty acid polyesters (U.S. Patent 3,600,186 of Mattson and Volpenhein, assigned to Procter & Gamble, issued

August 17, 1971), all incorporated herein by reference.Also suitable for use as a fat substitute in the present invention are medium chain triglycerides, highly esterified polyglycerol esters, acetin fats, plant sterol esters, N-Oil, polyoxyethylene esters, jojoba esters, mono/diglycerides of fatty acids, mono/diglycerides of short-chain dibasic acids, silicone oils/siloxanes (see, e.g., European Patent

Application 205,273 of Dow Corp., incorporated by reference herein), and "Olestrin" (Reach Assoc.,

Inc.), made by particle engineering dextrins and adding them to a fat substitute such as polyol fatty acid polyesters.

However, for reasons of cost efficiency, consumer acceptability, and assurance of inherent safety, the preferred class of reduced calorie fat substitute is polyol fatty acid polyesters which comprise sugar fatty acid polyesters, sugar alcohol fatty acid polyesters, glycerol fatty acid polyesters, polyglycerol fatty acid polyesters, and mixtures thereof. More preferably, the fat substitute is selected from the group consisting of sugar fatty acid polyesters and sugar alcohol fatty acid polyesters, and mixtures thereof, the sugars and sugar alcohols containing from 4 to 8 hydroxyl groups.

Sugar or sugar alcohol fatty acid polyesters comprise sugars or sugar alcohols, and fatty acids. The term "sugar" is used herein in its conventional sense as generic to mono- and disaccharides. The term

"sugar alcohol" is also used in its conventional sense as generic to the reduction product of sugars wherein the aldehyde or ketone group has been reduced to an alcohol. The fatty acid ester compounds are prepared by reacting a monosaccharide, disaccharide or sugar alcohol with fatty acids as discussed below.

Examples of suitable monosaccharides are those containing 4 hydroxyl groups such as xylose, arabinose, and ribose; the sugar alcohol derived from xylose, i.e., xylitol, is also suitable. The monosaccharide erythrose is not suitable for the practice of this invention since it only contains 3 hydroxyl groups; however, the sugar alcohol derived from erythrose, i.e. erythritol, contains 4 hydroxyl groups and is thus suitable. Among 5 hydroxyl-containing monosaccharides that are suitable for use herein are glucose, mannose, galactose, fructose, and sorbose. A sugar alcohol derived from sucrose, glucose, or sorbose, e.g., sorbitol, contains 6 hydroxyl groups and is also suitable as the alcohol moiety

1051/2197

of the fatty acid ester compounds. Examples of suitable disaccharides are maltose, lactose, and sucrose, all of which contain eight hydroxyl groups.

Preferred polyols for preparing the polyesters for use in the present invention are selected from the group consisting of erythritol, xylitol, sorbitol, glucose and sucrose. Sucrose is especially preferred.

The polyol starting material having at least four hydroxyl groups must be esterified on at least four of the -OH groups with a fatty acid containing from about 8 to about 22 carbon atoms, and preferably from about 14 to about 18 carbon atoms. Examples of such fatty acids include caprylic, capric, lauric, myristic, myristoleic, palmitic, palmitoleic, stearic, oleic, ricinoleic, linoleic, linolenic, eleostearic, arachidic, arachidonic, behenic, and erucic acid. The fatty acids can be derived from naturally occurring or synthetic fatty acids; they can be saturated or unsaturated, including positional or geometrical isomers.

The polyol fatty acid polyesters useful in this invention must contain at least four fatty acid ester groups. Polyol fatty acid polyester compounds that contain three or less fatty acid ester groups are digested in and the products of digestion are absorbed from the intestinal tract much in the manner of ordinary triglyceride fats, whereas the polyol fatty acid polyester compounds that contain four or more fatty acid ester groups are substantially non-digestible and consequently non-absorbable by the human body. It is not necessary that all of the hydroxyl groups of the polyol be esterified with fatty acid, but it is preferable that the polyol contain no more than three unesterified hydroxyl groups, and more preferable that it contain no more than two unesterified hydroxyl groups.Most preferably, substantially all of the hydroxyl groups of the polyol are esterified with fatty acid, i.e., the compound is substantially completely esterified. The fatty acids esterified to the polyol molecule can be the same or mixed.

The polyol fatty acid polyesters of the present invention can be liquid, solid, semisolid, or mixtures thereof. The liquid polyol fatty acid polyesters are liquids at body temperature, i.e., have a melting point of about 37>;o;C (98.6>;o;) or below. In general, liquid esters are those which are made from unsaturated fatty acids, whereas solid esters are substantially saturated. In order to provide liquid polyol fatty acid polyesters, generally at least about half of the fatty acids incorporated into an ester molecule must be unsaturated. Oleic and linoleic acids, and mixtures thereof, are especially preferred.

The following are non-limiting examples of specific liquid polyol fatty acid polyesters containing at least four fatty acid ester groups suitable for use in the present invention: glucose tetraoleate, the glucose tetraesters of soybean oil fatty acids (unsaturated), the mannose tetraesters of mixed soybean oil fatty acids, the galactose tetraesters of oleic acid, the arabinose tetraesters of linoleic acid, xylose tetralinoleate, galactose pentaoleate, sorbitol tetraoleate, the sorbitol hexaesters of unsaturated soybean oil fatty acids, xylitol pentaoleate, sucrose tetraoleate, sucrose pentaoleate, sucrose hexaoleate, sucrose heptaoleate, sucrose octaoleate, and mixtures thereof. As noted above, highly preferred polyol fatty acid esters are those wherein the fatty acids contain from about 14 to about 18 carbon atoms.

The solid polyol fatty acid polyesters are solids at body temperature, i.e., have a melting point of above about 37>;o;C (98.6>;o;F). Non-limiting examples of specific solid polyol fatty acid esters include sucrose octastearate, sucrose octapalmitate, sucrose heptastearate, xylitol pentastearate, galactose pentapalmitate, and like, saturated polyol polyesters having at least four hydroxyl groups esterified with C10-C22 saturated fatty acids.

It is known that liquid polyol fatty acid polyesters can cause an undesired anal leakage effect. U.S.

Patent 4,005,195 of Jandacek and U.S. Patent 4,005,196 of Jandacek et al., both incorporated by reference herein, disclose a method of avoiding this problem of the addition of anti-anal leakage agents to the liquid polyesters.

Therefore, a preferred embodiment of the present invention is a food product containing a liquid polyol polyester and additionally comprising sufficient anti-anal leakage agent to prevent leakage of the polyol polyester through the anal sphincter. Preferably the food product comprises at least about 5% anti-anal leakage agent by weight of the polyol polyester, more preferably at least about 10%, more preferably at least about 20%, and most preferably from about 20% to about 50%. A preferred anti-anal leakage agent is a solid polyol fatty acid polyester.

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Polyol fatty acid polyesters having a high liquid/solid stability have been found to be highly resistant to anal leakage. By "liquid/solid stability" is meant that the liquid portion of the polyesters does not readily separate from the solid portion. The polyol polyesters preferably have a liquid/solid stability of at least about 50%, more preferably at least about 60%, more preferably at least about 70%, and most preferably at least about 90%. A minimum solids content in the polyol fatty acid polyesters is also preferred for anti-anal leakage control. The polyesters preferably have a solid fat content of at least about 5% at 100>;o;F (37.8>;o;C), more preferably at least about 10%.

These liquid/solid stability and solid fat content properties are preferred for either a physical mixture of different solid and liquid polyol fatty acid polyesters, or a single polyol fatty acid polyester that is partially liquid and partially solid at 100>;o;F (37.8>;o;C).

Also preferred for use in the present invention are polyol fatty acid polyesters, particularly sugar or sugar alcohol polyesters or mixtures thereof, that have a high liquid/solid stability at relatively low solids levels. These polyesters are preferred because the low solids levels give them a less waxy taste.

In particular, the preferred polyesters have the following properties at 100>;o;F (37.8>;o;C): (a) a liquid/solid stability of at least about 50%, preferably at least about 60%; and (b) a solid fat content

(SFC) of not more than about 30%. The solid fat content is preferably between about 5% and about

25%, and more preferably between about 10% and about 20%.It is also preferred that these polyol polyesters have a viscosity of at least about 1 poise after 10 minutes of steady shear at a shear rate of 10 seconds>;-;>;1;, more preferably at least about 5 poise, and most preferably at least about 15 poise. The preferred upper limit of the viscosity of these polyesters is about 10,000 poise after 10 minutes of shear at a shear rate of 10 seconds>;-;>;1;, more preferably about 1,000 poise.

Sucrose fatty acid polyesters are highly preferred polyol polyesters for use as the present reduced calorie fat substitute. The sucrose fatty acid polyesters preferably have the majority of their hydroxyl groups esterified with fatty acids. Preferably at least about 85%, and most preferably at least about

95%, of the sucrose fatty acid esters are selected from the group consisting of octaesters, heptaesters and hexaesters, and mixtures thereof. Preferably, no more than about 35% of the esters are hexaesters or heptaesters, and at least about 60% of the esters are octaesters. Most preferably, at least about 70% of the esters are octaesters. It is also most preferred that the polyesters have a total content of penta- and lower esters of not more than about 3%.

The sucrose fatty acid esters are preferably esterified with particular kinds of fatty acids. Preferably, at least about 80%, and most preferably at least about 90%, of the fatty acids are selected from the group consisting of mixtures of palmitic, stearic, oleic, linoleic, and behenic acids. It is also most preferred that at least about 80% of the fatty acids are selected from the group consisting of mixtures of C16 to

C18 fatty acids.

There are possible advantages associated with the use of sucrose fatty acid polyesters as a replacement for triglyceride oils in the present food products, particularly use of the sucrose polyesters having high viscosity and liquid/solid stability at relatively low solids levels. For example, granola bars made with these sucrose polyesters may be easier to handle during processing in that they are easier to roll and less sticky. The high viscosity at low solids levels also allows the production of food products that are firm yet have a good, non-waxy taste. In general, it is believed that sucrose polyesters may make a better binder than triglyceride oils because the polyesters are comprised of bulkier, less free-flowing molecules. It has also been noted that sucrose polyesters can act to enhance the flavors of certain foods, e.g., the flavor of pecans in granola bars, and dairy flavor in other foods.

The polyol fatty acid polyesters suitable for use herein can be prepared by a variety of methods known to those skilled in the art. These methods include: transesterification of the polyol with methyl, ethyl or glycerol fatty acid esters using a variety of catalysts; acylation of the polyol with a fatty acid chloride; acylation of the polyol with a fatty acid anhydride; and acylation of the polyol with a fatty acid, per se.

As an example, the preparation of polyol fatty acid polyesters is described in U.S. Patent Nos.

2,831,854, 3,600,186, 3,963,699, 4,517,360 and 4,518,772 (all herein incorporated by reference).

Preferred Method for Preparing Sucrose Fatty Acid Polyesters

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Methyl esters of a fully hydrogenated (Iodine Value about 1) soy oil (90.8 kg), and 293 kg. of a 6.8 wt. percent solution of potassium hydroxide in methanol are mixed in a stainless steel batch reactor. This mixture is then heated to about 145>;o;F (63>;o;C) with agitation for 1 to 3 hours at atmospheric pressure. During this time, a portion of the methyl esters are saponified to form soap.

An additional 592.5 kg of methyl esters of a fully hydrogenated soy oil (Iodine Value about 1) and a partially hydrogenated soy oil (Iodine Value about 107), blended in a 57:43 ratio, is then added to the soap mixture. Granular sucrose (136.2 kg.) is added to the soap/ester mixture to give a 5:1 molar ratio of ester to sucrose. Potassium carbonate is then added to the mixture (approx. 0.5 wt. percent of the reaction mix) to catalyze the transesterification. This mixture is agitated and slowly heated at atmospheric pressure until the temperature reaches about 275>;o;F (135>;o;C). This is to remove the methanol. A vacuum is then pulled and the mixture agitated for up to 4 hours to form the mono-, di- and trisucrose esters. Small quantities of tetra- and pentaesters are also formed during this stage.Additional methyl ester (950.7 kg) which has been preheated to 275>;o;F (135>;o;C) is added to bring and maintain the molar ratio of the esters to sucrose to 12:1. Additional potassium carbonate is then added to the mixture (approx. 0.5 wt. percent of the initial reaction mix). When the reaction conditions stabilize at 275>;o;F (135>;o;C), a nitrogen sparge is used to improve agitation and promote methanol stripping. This second reaction stage lasts approximately 4 to 12 hours.

The reaction mixture is then cooled under nitrogen to between 149>;o;F (65>;o;C) and 185>;o;F

(85>;o;C). The crude reaction mixture is agitated with between 2 and 6 wt. percent water. The hydrated crude reaction mixture is passed through a centrifuge to separate a heavy and a light phase. The heavy phase which contains the soaps, excess sugars and potassium carbonate is discarded.

The light phase which contains methyl esters and the sucrose polyester is then dried to remove moisture at 176>;o;F (80>;o;C) under 70 mm Hg or less vacuum for 30 to 60 minutes. Filtrol 105 (1.0 wt. percent) is added and the mix is agitated at 167>;o;F (75>;o;C) to 185>;o;F (85>;o;C). The slurry is separated by filtration or other means until there is less than 0.1 wt. percent fines. The liquid is then passed through a 1 micromillimeter filter.

The refined and bleached reaction mix is then passed through a stainless steel wiped-film evaporator or other suitable equipment to distill off the bulk of the methyl esters. The distillation takes place at

392>;o;F (200>;o;C) to 455>;o;F (235>;o;C) under approximately 3 mm Hg of vacuum.

The sucrose polyester is then deodorized by passing downward through a stainless steel packed column deodorizer or other suitable device at 392>;o;F (200>;o;C) to 482>;o;F (250>;o;C) under a vacuum of about 5 mm Hg or less. Steam is introduced to the bottom of the column and passes counter-currently to the sucrose polyester. Feed rates and temperature are adjusted until the methyl ester content of the sucrose polyester is below 1000 ppm. The mixture is then cooled to between 149>;o;F (65>;o;C) to

185>;o;F (85>;o;C) and passed through a 1 micromillimeter filter. The sucrose polyester is stored in clean stainless steel drums.

Sucrose polyester made according to this procedure has the following composition and properties:


>;tb;Head Col 1: Fatty Acid Composition

>;tb;C16>;SEP;9.8%

>;tb;C16:1>;SEP;-

>;tb;C18>;SEP;50.6

>;tb;C18:1>;SEP;21.6

>;tb;C18:2>;SEP;15.7

>;tb;C18:3>;SEP;1.0

>;tb;Others>;SEP;1.3

>;tb;Iodine Value>;SEP;48.6

>;tb;Head Col 2: Ester Distribution

>;tb;Octa>;SEP;89.1%

>;tb;Hepta>;SEP;10.9

>;tb;Hexa>;SEP;>;0.1

>;tb;Penta>;SEP;>;0.1

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>;tb;Lower>;SEP;>;0.1

>;tb;Head Col 3: SFC Profile

>;tb;50>;o;F (10>;o;C)>;SEP;61.2%

>;tb;70>;o;F (21>;o;C)>;SEP;48.4

>;tb;80>;o;F (27>;o;C)>;SEP;36.2

>;tb;92>;o;F (33>;o;C)>;SEP;19.2

>;tb;105>;o;F (41>;o;C)>;SEP;3.1

>;tb;98.6>;o;F (37>;o;C)>;SEP;11.15

>;tb;100>;o;F (37.8>;o;C)>;SEP;about 10

>;tb;Head Col 4:Viscosity

>;tb;Head Col 5: 25.9 poise

>;tb;After 10 min. steady shear at shear rate of 10 seconds>;-;>;1;

>;tb;Liquid/Solid Stability>;SEP;92.5%

>;tb;>;/TABLE;

Analytical Methods

I. Viscosity Measurement of the Polyol Fatty Acid Polyesters

A. Sample Preparation

The polyol polyester sample is heated until it completely melts and is thoroughly mixed. Ten grams of the melted sample is weighed into a preheated 20 ml glass vial. The sample is then allowed to recrystallize at 100>;o;F +/- 5>;o;F (37.8>;o;C +/- 3>;o;C) for 24 hours. After the 24 hour time period has elapsed, the sample is taken to the viscometer and the viscosity is measured.

B. Ferranti-Shirley Viscometer Operation Procedure

A Ferranti-Shirley viscometer (Ferranti Electric, Inc., 87 Modular Ave., Commack, NY 11725) equipped with a 600 g torque spring is used for the viscosity measurement. A cone is put into place, and the viscometer temperature is adjusted to 100>;o;F (37.8>;o;C). The chart recorder is calibrated, and the gap between the cone and plate is set. The cone speed is checked, and the cone and plate temperatures are equilibrated to 100>;o;F (37.8>;o;C). The panel controls are set. Sufficient sample is placed between the plate and the cone so that the gap is completely filled. The temperature is allowed to stabilize at 100>;o;F (37.8>;o;C) for about 30 seconds. Start the test by selecting the RPM for 10 seconds>;-;>;1; shear rate and record on the strip chart recorder. Record the shear stress at the maximum value for to and then for two 30-second intervals, followed by every minute thereafter until the value at 10 minutes is recorded. Viscosity (poise) = Shear stress (dynes/cm>;2;) divided by shear rate (seconds>;-;>;1;).

II. Liquid/Solid Stability Measurement of the Polyol Fatty Acid Polyesters

A sample is heated until it completely melts and is thoroughly mixed. The sample is then poured into

Beckman #344062 4.4 ml tubes to capacity. The tubes are immediately transferred to a 100>;o;F +/-

5>;o;F (37.8>;o;C +/- 3>;o;C) constant temperature room and allowed to recrystallize undisturbed for

24 hours. The samples are then centrifuged at 60,000 rpm for one hour at 100>;o;F (37.8>;o;C). The force on the samples is 486,000 g's. The percent liquid separated is then measured by comparing the relative heights of the liquid and solid phases. Liquid/solid stability (%) = 100 x (total volume of sample - volume of liquid that separated)/total volume of sample.

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III. Solid Fat Content Measurement

Before determining SFC values, the polyol fatty acid polyester sample is heated to a temperature of

158>;o;C (70>;o;F) or higher for at least 0.5 hours or until the sample is completely melted. The melted sample is then tempered at a temperature of 40>;o;F (4.4>;o;C) for at least 72 hours. After tempering, the SFC value of the sample at a temperature of 100>;o;F (37.8>;o;C) is determined by pulsed nuclear magnetic resonance (PNMR). The method for determining SFC values by PNMR is described in Madison and Hill, J. Amer. Oil Chem. Soc., vol. 55 (1978), pp. 328-31 (herein incorporated by reference). Measurement of SFC by PNMR is also described in A.O.C.S. Official

Method Cd. 16-81, Official Methods and Recommended Practices of The American Oil Chemists

Society, 3rd Ed., 1987 (herein incorporated by reference).

The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims.

EXAMPLE 1

Three varieties of granola bars are made from the following ingredients: EMI20.1

The liquid binder materials are mixed and heated to about 240>;o;F (116>;o;C). To obtain the desired consistency, heating is continued and moisture is allowed to boil off until the final solids content of the mixture is 80-85% by refractometer reading. A working temperature of approximately 165>;o;F

(74>;o;C) is then maintained.

The dry ingredients are placed into a Hobart mixer and then the preheated liquid binder is added. These materials are blended at low speed for one minute.

The blended materials are then placed into the hopper of a Hutt/Bepex G.P. Forming System, 140-300

Series (Bepex Hutt GmbH, Postfach 9, Daimlerstrasse 9, D-7105, Leingarten, West Germany). The system is then warmed as needed to a working temperature of approximately 120>;o;F (49>;o;C). After forming, the granola bars are cooled to make the finished product. Baking is not required.

EXAMPLE 2

Granola bars are made from the following ingredients:



>;tb;Head Col 2: Amount

>;tb;Toasted oats>;SEP;3-1/2 cups

>;tb;Raisins>;SEP;1 cup

>;tb;Chopped nuts>;SEP;1 cup

>;tb;

*

Sucrose polyester shortening >;SEP;2/3 cup

>;tb;Brown sugar>;SEP;1/2 cup

>;tb;Honey>;SEP;1/3 cup

>;tb;Egg, beaten>;SEP;1

>;tb;Vanilla>;SEP;1/2 teaspoon

>;tb;Salt>;SEP;1/2 teaspoon

*The shortening contains 58.5% liquid soybean oil (I.V. 107), 23.0% sucrose fatty acid polyesters prepared as described hereinabove at pp. 14-17, 10.0% sucrose fatty acid polyesters made from nearly

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completely hardened soybean oil methyl esters (I.V. 8), 4.5% mono- and diglyceride emulsifier, and

4.0% nearly completely hardened palm oil (I.V. 3).

>;tb;>;/TABLE;

The ingredients are combined and mixed well. The mixed ingredients are pressed firmly into a well greased 15-1/2 by 10-1/2 inch jelly roll pan, then baked at 350>;o;F (177>;o;C) for about 20 minutes.

After baking, the mixture is allowed to cool, then cut into bars.

Example 3

Popcorn balls are made from the following ingredients:




>;tb;

*

Sucrose fatty acid polyesters >;SEP;2/3 cup

>;tb;Molasses>;SEP;2/3 cup

>;tb;Corn syrup>;SEP;2/3 cup

>;tb;Vinegar>;SEP;1 Tablespoon

>;tb;Popped corn>;SEP;10 cups

*Prepared as described hereinabove at pp. 14-17.

>;tb;>;/TABLE;

The sucrose polyesters, molasses, corn syrup and vinegar are combined and heated to about 250>;o;F

(121>;o;C) to make a binder. The popped corn is placed into a large bowl. The binder is gradually poured into the center of the corn, and the corn is stirred with a fork and gathered, well coated with binder, into balls. The popcorn balls are pressed between the hands to pack hard.

Example 4

Pecan clusters are made from the following ingredients:




>;tb;

*

Sucrose fatty acid polyesters >;SEP;1/2 cup

>;tb;Flour>;SEP;1 cup

>;tb;Finely chopped pecans>;SEP;1 cup

>;tb;Sugar>;SEP;2 Tablespoons

>;tb;Salt>;SEP;1/8 teaspoon

>;tb;Vanilla extract>;SEP;1 teaspoon

>;tb;Confectioner's sugar>;SEP;--

*Prepared as described hereinabove at pp. 14-17.

>;tb;>;/TABLE;

The sucrose polyesters are melted, and then all the ingredients except the confectioners' sugar are combined in a large bowl. The ingredients are mixed until thoroughly blended, then refrigerated 30 minutes.

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Meanwhile, an oven is preheated to 375>;o;F (191>;o;C). The ingredients are rolled by hand into balls

1-1/4 inches in diameter, and then placed 1 inch apart on ungreased cookie sheets.

The pecan clusters are baked 15 to 20 minutes, or until they are set but not brown. The clusters are left standing 1 minute before removing from cookie sheets, then removed to wire racks, and cooled slightly.

The pecan clusters are rolled in confectioners' sugar while still warm, then cooled completely. Just before serving, they are rerolled in sugar.Data supplied from the esp@cenet database - Worldwide

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218.

JP2276801 - 11/13/1990

WATER-SOLUBLE HEMICELLULOSE, ITS PRODUCTION AND HEALTH

FOOD CONTAINING THE SAME


Inventor(s): AOE SEIICHIRO (--); ODA HIROSHI (--); NAKAOKA MASANORI (--);

KUROSAWA SEIJI (--)

Applicant(s): SNOW BRAND MILK PROD CO LTD (--)

IP Class 4 Digits: A23L; C08B; A21D; C12P; A23D; C12S

IP Class: A23L1/308; A21D2/18; A23D7/00; C08B1/00; C12P19/14; C12S3/02

E Class: A23L1/18B2; A23L1/0534; A21D2/18F; A23C9/137; A23C19/082; A23D7/005S;

A23G9/02; A23G9/02K; A23L1/308B; C08B30/10; C08B37/00M7; C12P19/14



Family: US5112964


Abstract:


PURPOSE:To easily obtain the subject compound with a small-sized apparatus by removing starch from cereal bran, etc., with a heat-stable amylase in the presence of hot water, extracting in alkaline state, etc., and neutralizing and desalting the obtained liquid containing the fraction of water-soluble hemicellulose B. CONSTITUTION:A heat-stable amylase is added to a raw material such as rice bran, wheat bran or grain hull in the presence of hot water and subjected to the starch-removing treatment preferably with a homomixer or colloid mill. The treated raw material free from starch is extracted in alkaline or Acidic state preferably with an extruder, colloid mill or homomixer. The obtained liquid containing a fraction of water-soluble hemicellulose B is subjected to neutralizing and desalting treatment preferably with an ultrafiltration membrane, electrodialysis membrane, ionexchange resin or reverse osmosis membrane to obtain the objective hemicellulose.Description:



The present invention relates to a process of producing a water-soluble hemicellulose, in which the B fraction of hemicelluloses contained in rice bran, wheat bran or grain husk and having various kinds of physiological effect is extracted and separated from the bran or the husk, and to the use of watersoluble hemicellulose.

Cellulose, hemicelluloses, pectic substances, lignin, chitin, mucilages (galactomannan, glucomannan and the like), algal polysaccharides, chemically modified polysaccharides (chemically modified starch, carboxymethylcellulose and the like), etc. are designated as dietary fibers, and they are indigestible constituents which are contained in food and indigestible in human digestive enzymes. Recently, it is noted that the ingestion of these dietary fibers shows physiological effects. These dietary fibers are classified into water-soluble fibers and water-insoluble fibers.

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It is reported that the water-soluble dietary fibers have the following advantages: 1) the fibers prevent the absorption of toxic substances or carcinogens present in the intestines and the fibers are excreted with these materials, 2) cholesterol, bile acids and heavy metals adhere to the fibers and these are excreted, and 3) the intestinal surroundings are improved by useful bacterias which are predominantly present in the intestinal micro flora. The insoluble fibers have the following advantages: 1) the fibers stimulate the motility of the large bowel and accelerate large bowel transit in spite of the slower transit time through the stomach and small intestine, and 2) the fecal water content and fecal weight are increased.

The B fraction of hemicelluloses which is a kind of water-soluble fibers has been studied because it has various kinds of physiological effect. A fractionation procedure of the hemicellulose, B fraction has been reported by Southgate, D. A. T. "The Chemistry of Dietary Fiber" in "Fiber in Human Nutrition", edited by Spiller, G. A. and Amen, R. J., pp31, Plenum Press, NY (1976), since then, several fractionation procedures of the hemicellulose B fraction have been reported (Japanese Patent

Publication Numbers 59-1687, 59-1688 and 59-1689, Japanese Laid-Open Patent Publication Number

60-27365). However, the procedure of industrial mass production of hemicellulose B is yet unknown.

As the reason, it is considered that each process cost much money and is time-consuming.

A food which is obtained by adding fibers is described in Japan Laid-Open Patent Application No. 58-

187745. The food is obtained by adding fibers to processed food such as, for example, soy-bean paste, bean-curd, retort foods, pies or bread. The addition aims to obtain characteristics of resistance to age, prevention of water-staining, prevention of concretion, viscosity control, prevention of oil separation and the like. The addition does not aim to obtain food containing the hemicellulose B fraction for the main ingredients. The food contains only a little hemicellulose B fraction which has physiological useful effects. Accordingly, the physiological effect of the hemicellulose B fraction is not noticed in the above application.

In Japanese Laid-Open Patent Application No. 57-21324, it is described that hemicellulose which is extracted in alkaline solution from corn fibers inhibits hypercholesterolemia. However, the present invention is different from the above application, because the obtained hemicellulose in the present invention is separated and extracted from rice bran, wheat bran or grain husk which has effect in the most preferable conditions suitable for drinks and milk powder.

In Japanese Laid-Open Patent Application No. 63-165325, a kind of medicine for intestinal disorders which contains hemicellulose B fraction as an effective ingredient is disclosed. In the separation and extraction process, the removal of protein by using trichloroacetic acid and the purification by using ethanol precipitation are required, and the process is complicated.

In the U.S.A., milk powder in which fiber is mixed in the form of microcrystalline cellulose (MCC) for improving the property of is commercially available. However, since the MCC is a semi-synthesized product compound, its texture is bad. When the MCC was mixed with milk powder and dissolved in water, coagulation of colloids occurs. When it is added to drinks, the obtained drinks taste bad.

Moreover, since the cellulose is a food fiber insoluble in water, it is impossible to expect the physiological effects which the above water-soluble food fiber have.

In Japanese Laid-Open Patent Application No. 61-24251, a low-caloric powder obtained by powdering the mixture of milk powder, beer yeast for food, saccharide which is not absorbed in the intestines and fibers is disclosed. The fibers described in the above invention are psylliun, pectin, guar gum and carrageenan. These fibers are slightly soluble in water and/or have high viscosity, so that when these fibers are added to milk powder, the treatment is troublesome and the obtained drinks containing the food fibers have bad texture.


The present invention has an object to provide a process in which the hemicellulose B fraction contained in rice bran, wheat bran or grain husk and having various kinds of physiological effect can be produced industrially and efficiently. Moreover, the hemicellulose B fraction in the present invention is

1060/2197

added to foods such as yogurt, processed cheese, spread, cookies, sable, ices, bread, puffed snacks and a medicine for constipation and the like, and can be used for healthy foods.

The present invention provides a process of producing a water-soluble hemicellulose comprising a starch removing stage for treating raw material of rice bran, wheat bran or grain husk in which a thermostable amylase is added to the raw material in the presence of hot water and the starch dissolved in the water is removed, an extraction stage in which the starch-free material is extracted under alkaline or acidic conditions with a solution, and a neutralization and desalting stage in which the obtained liquid containing the hemicellulose B fraction is neutralized and desalted to obtain the said watersoluble hemicellulose.

Apparatus and the other elements which are used in other fields can be used in each stage of the process of the present invention. The apparatus introducible in the series of the preparation stages can be used to obtain the water-soluble hemicellulose efficiently.


In the starch removing stage, raw material is treated by adding a thermostable amylase in the presence of hot water (preferably at 70 DEG C. or more) by means of a homomixer or a colloid mill and starch is homogenized and gelatinized. The thermostable amylase functions to accelerate the gelatinization of the starch and to shorten the process time.

In the extraction stage, when the starch-free material is extracted bymeans of a shearing, kneading and grinding device such as an extruder and a colloid mill, or by means of a high speed mixing device such as a stirring-type emulsifier, e.g. a homomixer, the material can be successively treated in a short time.

While the extraction takes a long time, namely ten or more hours in conventional methods, the extraction time in the process of the present invention can be remarkably shortened. Further, the material can be extracted under alkaline or acidic conditions, for example in 2-4% sodium hydroxide solution for several hours. The material can be extracted with an alkali solution having the pH value of

10.0 or more and containing alkali and can be added to food instead of, for example, sodium carbonate or potassium hydroxide. The material can be also extracted with an acid and can be added to food instead of sodium hydroxide. Such an acid is a short-chain fatty acid having the pH value of 5 or less.

Hydrochloric acid, sulfuric acid, phosphoric acid can be exemplified as inorganic acids, and acetic acid, citric acid, gluconic acid, tartaric acid, lactic acid, fumaric acid, malic acid, propionic acid, oxalic acid and the like can be exemplified as organic acids. In the above compounds, hydrochloric acid, oxalic acid, sulfuric acid, phosphoric acid, acetic acid, propionic acid are preferred, and the most preferable acid is acetic acid.

The stages of neutralization, desalting and concentration are conducted by using an ultrafiltration membrane, an electrodialysis membrane, an ion exchange resin or a reverse osmosis membrane or a combination of these means, and the neutralization of material is conducted during desalting or before desalting. For example, the material is desalted by the method of an ultrafiltration membrane which is able to cut the substance having molecular weight millions or less, preferably a hundred thousand or less, and concentrated by the method of a reverse osmosis membrane. The concentration stage is operated with, before or after the neutralization and desalting stage or at the same time.

Morever, the desalted concentrate is treated in a clarification stage by using a micron filter, an adsorbent such as active carbon and an adsorption resin, a centrifugal separator or a combination of these means, and the transparency of the solution can be control led. In this case, it is desirable to use a micron filter 20 having 1.0-0.45 .mu.m hole diameters.

Then, the products can be finally treated in a drying stage by a known method such as spray drying, freeze drying, drum drying and the like. In the drying stage, powder having high water-solubility can be prepared by adding saccharide such as dextrin.

The obtained powder containing the water-soluble hemicellulose can be used medicines, foodstuffs such as yogurt, processed cheese, spread, cookies, sable, ices, bread and puffed snacks, and a healthy food for constipation.

1061/2197

According to the present invention, the physiological effect of the food hemicellulose ingredients derived from grain can be expected. Namely, the hemicellulose is fermented well by Bifidobacterium in intestines and the cholesterol metabolism can be improved by another mechanism than that of the prevention of cholesterol absorption in small intestine.

The merit of the present invention is that the mass-produced water-soluble hemicelluloses can be obtained by using the above series of steps. Whereby water-soluble hemicelluloses contained in rice bran, wheat bran or grain husk can be efficiently extracted and separated, and powder having high water-solublity can be prepared. The water-soluble powder separated from food fibers can be broadly utilized as physiologically functional water-soluble hemicelluloses in industrial fields of medicine, food such as milk powder, margarine, cheese and the like.


The following Examples illustrate the present invention more specifically.

EXAMPLE 1

To ten kg of defatted rice bran of raw material, 50 liters of hot water of about 80 DEG C. and 100 g of thermostable amylase (trade name: Termamyl 120 L, Novo Industry Japan Company) were added and mixed with stirring by using a homomixer. Gelatinized starch isolated in the water solution was filtered to remove and the starch-free residue was collected. In Table 1, the constituents of the rice bran of raw material and the rice bran after removing the starch are tabulated.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; (%)

>;tb; Rice bran of

>;tb; Rice bran after

>;tb; raw material

>;tb; removing the starch

>;tb;______________________________________

>;tb;Moisture 5.09 3.94

>;tb;Crude protein

>;tb; 20.44 24.95

>;tb;Ash 14.14 14.57

>;tb;Total dietary

>;tb; 31.37 42.18

>;tb;fiber* (TDF)

>;tb;______________________________________

>;tb; *Analyzed by a Prosky method.

As shown in Table 1, the content of total dietary fiber is not decreased by the treatment for removing starch, and it is observed that the concentration of the dietary fibers is increased.

Then, 25 liters of 2% sodium hydroxide solution was added to 5 kg of rice bran after removing the starch, and the mixture was stirred and extracted for four hours at 80 DEG C. in a tank. The extracted solution was separated into a solid phase and a liquid phase with a decanter which is operated by centrifugal force of 5,000 r.p.m., and the obtained liquid phase was concentrated to five liters by using a reverse osmosis membrane (trade name: NTR 7450, produced by Nitto Denko Company) The concentrated liquid was desalted with an ultrafiltration membrane which was able to cut the substance having a hundred thousand or less of molecular weight (trade name: GR40PP, produced by DDS

Company). The water which was lost in the desalting was supplemented with a 0.1 N aqueous hydrochloric acid solution, and the neutralization and the desalting was simultaneously conducted.

Furthermore, after the concentrated liquid was passed through a column of active carbon, the liquid was passed through a 45 .mu.m micronfilter to remove proteins causing a turbidity. The liquid was then spray-dried and about 400 g of gray powder was obtained. The powder was redissolved in water to

1062/2197

obtain a 1% aqueous solution, and a brownish transparent solution was obtained. The solution was tastless and had little viscosity.

Table 2 shows the analytical values of the constituents of the hemicellulose prepared by Example 1.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Rice bran hemicellulose

>;tb;______________________________________

>;tb;Cellulose 0.2

>;tb;Noncellulosic polysaccharides

>;tb; 61.3

>;tb;Glucose 4.3

>;tb;Arabinose 26.3

>;tb;Xylose 24.7

>;tb;Galactose 0.3

>;tb;Mannose 0

>;tb;Uronic acid 5.7

>;tb;Lignin 1.8

>;tb;Total nitrogen 4.5

>;tb;Ash 7.1

>;tb;______________________________________

>;tb; (Values are expressed as % of dry matter.)

EXAMPLE 2

Rice bran from which starch was removed by using the same method as described in Example 1 was dried in airing. The repowdered rice bran was used as raw material The raw material was successively extracted with a twin-screw extruder under the conditions of a material feed rate of 9.5 kg/h, a screw speed of 200 r.p.m., a pressure of 0.4 MPa, and a temperature of 85 DEG C. Two kinds of liquid which were extracted by adding 0.5 N sodium hydroxide and by adding 0.5 N acetic acid, respectively, at a rate of 23.9 1/h were prepared.

Each extracted material was a slurry. Hot water was added to the extracted material to dissolve the extracted hemicellulose. Then, the hemicellulose solution was neutralized, desalted, concentrated, clarified and dried in a similar manner as in Example 1, and hemicellulose powder was obtained. When

100 g of rice bran was extracted with acetic acid, about three grams of the hemicellulose, was obtained, while 100 g of rice bran was extracted with sodium hydroxide, 4.5 g of the hemicellulose was obtained.

Accordingly, a good result was obtained in the case of sodium hydroxide However, since the solution was browned by using sodium hydroxide, the kind of solvents should be determined according to food to be used.

EXAMPLE 3

Rice bran was treated by the starch removing stage, the extraction stage, and the neutralization and desalting stage of the present invention to obtain a hemicellulose solution. The solid amount of dextrin

(DE10) equal to that of the obtained hemicellulose was added to dissolve to the hemicellulose solution

The mixture was spray-dried to obtain powder by using the same method as described in Example 1.

The following method was used for examining the solubility of the sample powder. The hemicellulose powder obtained in Example 1 was used as a control.

Three grams of each sample was added to 100 ml of hot water (60 DEG C.) contained in 200 ml of a beaker, the mixture was stirred with a spoon 60 times (two revolutions per second), and the insolubility of each sample was distinguished by the amounts of insoluble substance and undissolved lumps. As the result, the insoluble substance and undissolved lumps in the control were observed in large quantities, while these were little observed in the sample of this Example.

EXAMPLE 4

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Rice bran from which starch was removed by using the same method as described in Example 1 was dried in airing. The repowdered rice bran was used as raw material. The raw material was successively extracted by using a twin-screw extruder under the conditions of a material feed rate of 9.5 kg/h, a screw speed of 200 r.p.m., a pressure of 0.4 MPa and a temperature of 85 DEG C. The liquid which was extracted by adding 0.5 N acetic acid at a rate of 23.9 1/h was prepared.

Hot water was added to the extracted slurry to dissolve hemicelluloses. The mixture was neutralized with 1 N sodium hydroxide and separated into a solid phase and a liquid phase by means of a decanter which was operated by the centrifugal force of 5,000 r.p.m. and the obtained liquid phase was concentrated and desalted by using an ultrafiltration membrane of cut-off molecular weight 100,000 or less (trade name: GR40PP, produced by DDS Company).

Then, the desalted aqueous solution was spray dried to obtain the hemicellulose B fraction powder of rice bran about 300 g.

The following materials containing the obtained powder were combined and sterilized at 100 DEG C. for 30 minutes and then apple juice was prepared.

>;tb;______________________________________

>;tb;Apple Juice (1/5 concentration)

>;tb; 1,000 g

>;tb;Isomerized sugar 1,000 g

>;tb;Citric acid 100 g

>;tb;Water 16,600 g

>;tb;Water-soluble hemicellulose B fraction powder

>;tb; 200 g

>;tb;______________________________________

As regards the flavor and the taste, the obtained apple juice was equal toa drink having no food fibers.

EXAMPLE 5

The following materials containing the water-soluble hemicellulose B fraction powder which was obtained in Example 4 was combined and sterilized at 100 DEG C. for 30 minutes and then a plain drink was prepared.

>;tb;______________________________________

>;tb;Plain syrup 2,000 g

>;tb;Isomerized sugar 1,800 g

>;tb;Citric acid 100 g

>;tb;Water 15,900 g

>;tb;Water-soluble hemicellulose B fraction powder

>;tb; 200 g

>;tb;______________________________________

As regards the flavor and the taste, the obtained plain drink was equal to a drink having no food fibers.


The same ingredients as in Example 4 were used except that guar gum 200 g was used instead of the water-soluble hemicellulose B fraction powder.


The same ingredients as in Example 5 were used except that carrageenan 200 g was used instead of the water-soluble hemicellulose B fraction powder.

Texture of the drinks which were obtained by the above Examples 4 and 5 and Comparative Examples

1 and 2 was estimated. As the result, both drinks which were obtained by Comparative Examples 1 and

2 had high viscosity and the texture was poor. On the other hand, the drinks obtained by Examples 4 and 5 were flavorful and had good taste.

1064/2197

EXAMPLE 6

To ten kg of defatted rice bran of raw material, 50 liters of hot water of about 80 DEG C. and 100 g of thermostable amylase (trade name: Termamyl 120 L, Novo Industry Japan Company) were added and mixed with a homomixer. Gelatinized starch isolated in the water solution was filtered to remove and the residue was collected by separating into a solid phase and a liquid phase by means of filtration.

Then, 25 liters of 2% sodium hydroxide solution was added to five kg of this residue, and the mixture was stirred and extracted for two hours at 80 DEG C. in a tank. The extracted solution was neutralized with 36% hydrochloric acid solution. The precipitated hemicellulose A fraction, the precipitated protein and the extracted residue were separated into a solid phase and a liquid phase by means of a decanter which was operated by centrifugal force of 5,000 r.p.m. and a clarifier of 7,200 r.p.m., and the liquid phase was concentrated and desalted by the method of an ultrafiltration membrane which was able to cut the substance having a hundred thousand or less of molecular weight (trade name: GR40PP, produced by DDS Company) to obtain the water-soluble hemicellulose B fraction.

Then, the obtained water solution was spray-dried and about 400 g of the water-soluble hemicellulose

B fraction powder was obtained.

The obtained powder 400 g was dissolved in 2.0 kg of water at 60 DEG C., the solution was added to

25 kg of fresh milk and the mixture was stirred The mixture was sterilized at 130 DEG C. for two seconds, concentrated and spray dried. 3kg of milk powder containing 10.8% by weight of the hemicellulose B fraction powder of rice bran was obtained. Then, the obtained milk powder was made into granules having grain size of 200-350 .mu.m by using a fluid tank granulator.

EXAMPLE 7

Water-soluble hemicellulose B fraction powder was obtained by using the same method as in Example

6 except that the raw material was changed to corn husk.

The obtained powder was dissolved in 2.0 kg of water at 60 DEG C. The solution was sprayed by using a nozzle for two fluids on 12.5 kg of skimmed milk powder placed in a fluid tank granulator with stirring, and coated granules were obtained. Then, the obtained granules were dried Granulated milk powder having grain size of 250-400 .mu.m and containing the water-soluble hemicellulose B fraction derived from corn husk was obtained

The obtained granulated powder skimmed milk contained 2.9% by weight of the water-soluble hemicellulose B fraction. cl COMPARATIVE EXAMPLE 3

400 g of guar gum was dissolved in 20.0 kg of warmed water. The solution was added to 25 kg of fresh milk with stirring. The milk solution was sterilized at 130 DEG C. for two seconds, concentrated and dried 3 kg of milk powder containing 10.6% by weight of the guar gum was obtained. Then, the obtained milk powder was made into granules having grain size of 200-350 .mu.m by using a fluid tank granulator. Taste and solubility of each milk powder obtained in Examples 6 and 7 and Comparative

Example 3 were estimated. The results are shown in Table 3.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Taste Solubility Total

>;tb;______________________________________

>;tb;Example 6 Excellent, No solids Good

>;tb; creamy and or no

>;tb; good insolubles

>;tb;Example 7 Excellent No solids Good

>;tb; and good or no

>;tb; insolubles

>;tb;Comparative No excellent

>;tb; Solids No good

>;tb;Example 3 and a little

>;tb; and

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>;tb; good insolubles

>;tb;______________________________________

The above taste and solubility were determined by the following method.

1) 10g of a sample was placed in 200 ml of a beaker and 90 ml of warmed water was added. The mixture was dissolved after 60 revolutions of stirring

2) After the dissolution, the solubility was determined by the appeared solids and insolubles.

3) The taste of the solution was estimated.

EXAMPLE 8

157 kg of water was added to 24 kg of skimmed milk powder and the mixture was stirred well. After dissolving, the solution was placed in a nominal 360 liter tank having a jacket and sterilized at 95 DEG

C. for ten minutes by using steam indirect heating Then, the tank was cooled to 42 DEG C. in cooling water. Culture of mixed germ MRC-32 of Lactobacillus bulgaricus and Streptococcus thermophiluswas inoculated in the solution and the solution was fermented at 42 DEG C. for five hours. While stirring the fermented solution, chilled water was circulated in the jacket to cool down the solution to 10 DEG

C.

The other hand, 40 kg of isomerized sugar (S-30 manufactured by Harano Sangyo Company) and 58 kg of water were added to 1 kg of pectin (X-92 manufactured by Unipectin Company) and 1.43 kg

(equivalent to 0.5 parts by weight per total) of hemicellulose. The mixture was dissolved with stirring, sterilized at 90 DEG C. for ten minutes and then cooled to 10 DEG C.

The cooled solution containing the pectin, the isomerized sugar and the hemicellulose was added to the above cooled fermented solution with stirring. The stirred solution was homogenized by using a highpressure homogenizer (manufactured by Sanwa Nyuki Company). The homogenized solution was charged in 550 ml of paper packages for mild and stored in constant temperature room at 10 DEG C. for two weeks.

After two weeks, the solution was tested. As shown in Table 4, the same results as a control no adding hemicellulose were obtained. The texture and the structure satisfied the demand of fluid-type yogurt.

>;tb; TABLE 4

>;tb;______________________________________

>;tb; Adding No adding

>;tb; hemicellulose

>;tb; hemicellulose

>;tb;______________________________________

>;tb;Just after producing

>;tb;pH 4.25 4.24

>;tb;Viscosity 15.0 cp 15.5 cp

>;tb;Texture 9 9

>;tb;Seven days after storage

>;tb;pH 4.15 4.15


>;tb;Texture 9 9

>;tb;14 days after storage

>;tb;pH 4.07 4.06


>;tb;Texture 8 8

>;tb;______________________________________

>;tb; *Viscosity was determined with a B type viscometer (No. 1 rotor).

The taste was judged using a rating of 1 to 10, 10 being the best.

EXAMPLE 9

34 kg of Cheddar cheese and 20 kg of Gouda cheese were pulverized and mixed 1.1 kg of a melted salt

(a complex with 80% sodium polyphosphate and 20% sodium diphosphate) and 1.1 kg of

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hemicellulose were added to the mixture, and the obtained mixture was heated at 85-90 DEG C. in a

Stefan cutter (750 rpm) and dissolved. The obtained processed cheese containing the hemicellulose was packed in packages and cooled. As regards the taste, the structure and the flavor, the obtained cheese was equal to conventional cheese having no hemicellulose.

EXAMPLE 10

To an oil phase 82% by weight comprised of a mixed oil (containing 20 parts by weight of bean oil hydrogenated a little water (melting point:40 DEG C.), 20 parts by weight of palm oil and 42.5 parts by weight of corn oil, melting point:32 DEG C.) of bean oil, palm oil, rapeseed oil and corn oil or processed oil thereof and oil soluble material such as an emulsifying agent and the like, a water phase

16.5% by weight (containing common salt) having 1.0% by weight of hemicellulose were added. By using a conventional method of producing margarine, the oil phase and the water phase were mixed and emulsified. The emulsion was cooled, solidified and milled with a heat transfer of a surface scraping type like a combinator, and W/0 type margarine was obtained.

In view of the latest diet intention, the rate of the oil phase was adjusted to less than 40.0% by weight.

More than 60.0% by weight of the water phase containing 1.0% by weight of the hemicellulose of the present invention and the above oil phase were mixed and treated by the above method and W/0 type fat spread was obtained

As regards the taste, the obtained spread was equal to conventional margarine. 50 mg - 2 g of the hemicellulose per meal (10 g of margarine) could be eaten.

EXAMPLE 11

Cookies (a sheet type)

A small amount of ground vanilla was added to the mixture of 150 parts by weight of butter, 200 parts by weight of granulated sugar and 3 parts by weight of common salt with stirring. 50 parts by weight of whipped egg was added and stirred to form paste. A mixture of 4 parts by weight of sifted baking soda,

450 parts by weight of soft flour and 50 parts by weight of hemicellulose was slowly added to the paste with stirring. The obtained material was placed in a refrigerator for 20 minutes, the cooled material was spread so as to obtain a sheet having a thickness of 3-4 mm on a support powdering a small amount of flour and the obtained sheet was formed with various molds. The formed material was placed on a shallow pan on which a baking sheet was spread and baked in an oven at 180 DEG C. for about 15 minutes. If necessary, a suitable amount of finely chopped nuts (for example, almonds, peanuts or walnuts), raisins or chocolate chips can be added

EXAMPLE 12

Sable (a squeezing out type)

100 parts by weight of butter and 50 parts by weight of shortening were blended, and then 100 parts by weight of sucrose was added with stirring A mixture of 40 parts by weight of whipped eggs and 15 parts by weight of egg yolks was divided into three portions and the mixture was added for three times to the blend. The blend was stirred to form paste. 230 parts by weight of sifted soft flour and 20 parts by weight of hemicellulose were added and lightly mixed to obtain a mass. The mass was squeezed out on a shallow pan on which a baking sheet was spread and baked in an oven at 200 DEG C. for about 15 minutes.

EXAMPLE 13

Using raw materials which were combined as shown in Table 5, ice in cups was prepared.

>;tb; TABLE 5

>;tb;______________________________________

>;tb; (% by weight)

>;tb;______________________________________

>;tb;Raw cream (47%) 20.0

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>;tb;Sweetened skimmed condensed milk

>;tb; 10.0

>;tb;Skimmed milk powder 7.0

>;tb;Granulated sugar 4.0

>;tb;Glucose fractose liquid sugar (13 .times. 75)

>;tb; 2.0

>;tb;Powdered millet jelly (DE30)

>;tb; 5.0

>;tb;Glycerin fatty acid ester

>;tb; 0.2

>;tb;Stabilizer (note) 0.25

>;tb;Hemicellulose 1.0

>;tb;Water 50.35

>;tb;Vanilla extract 0.2

>;tb;______________________________________

>;tb; Note: Stabilizer for ice cream containing locust bean gum, guar gum and

>;tb; carrageenan in a ratio of 5:4:1.

After powders of the granulated sugar, skimmed milk powder, powdered millet jelly, glycerin fatty acid ester and stabilizer were mixed well, the mixture was dispersed in water by using a homomixer

(manufactured by Tokushu Kika Kogyo Company). Raw cream, sweetened skimmed condensed milk, gluose fractose liquid sugar were added to them. The mixture was heated to 85 DEG C. with stirring, maintained for one minute and sterilized, then homogenized at a pressure of 150 kg/cm@2 by using a homogenizer (manufactured by Sanwa Machine), and immediately cooled to 5 DEG C. Vanilla extract was added. After aging, the mixture was foamed to overrun about 60% and freezed by using a soft cream freezer (manufactured by Mitsubishi Heavy Industries, Ltd.), and filled in cups and then hardened and stored at -30 DEG C.

The hardened ice was thawed out at room temperature for several minutes. The ice had good thickness and taste. Moreover, it had the shape retention at room temperature for ten and more minutes.

EXAMPLE 14

Using the following conditions, bread was produced by a sponge dough method.

>;tb;______________________________________

>;tb; Test class

>;tb; Control class

>;tb;______________________________________

>;tb;(sponge dough ingredients)

>;tb;First hard flour 700 g 700 g

>;tb;Yeast (compressed)

>;tb; 25 g 25 g

>;tb;Water 450 g 450 g

>;tb;______________________________________

>;tb;Mixer: two minutes at a low speed, one minute at a

>;tb; middle speed

>;tb; kneading temperature 26 DEG C.

>;tb;Fermentation:

>;tb; two hours and a half at 28 .+-. 1 DEG C.

>;tb;______________________________________

>;tb;(Kneading ingredients)

>;tb;First hard flour 250 g 300 g

>;tb;Hemicellulose* 50 g --

>;tb;Salt 21 g 21 g

>;tb;Granulated sugar 50 g 50 g

>;tb;Skimmed milk powder

>;tb; 20 g 20 g

>;tb;Shortening 40 g 40 g

>;tb;Water 220 g 206 g

1068/2197

>;tb;______________________________________

>;tb;Mixing and kneading:

>;tb; two minutes at a low speed,

>;tb; five minutes at a high speed,

>;tb; after adding the shortening, two

>;tb; minutes at a low speed and three

>;tb; minutes at a high speed

>;tb;Kneading temperature:

>;tb; 28 DEG C.

>;tb;Floor time: 30 minutes at 28 .+-. 1 DEG C.

>;tb;Division: 450 g

>;tb;Bench: 20 minutes

>;tb;Forming: mountain-shaped

>;tb;Drier: 85% RH, for 60 minutes

>;tb; at 38 .+-. 1 DEG C.

>;tb;Baking: 23 minutes at 210 .+-. 5 DEG C.

>;tb;______________________________________

>;tb;Product:

>;tb;Volume 2140 ml 2250 ml

>;tb;Pore Rate 5.49 ml/g 7.55 ml/g

>;tb;______________________________________

>;tb; *Hemicellulose was added and mixed to wheat flour.

As regards the flavor and the taste, the produced bread was equal to the bread of control class.

EXAMPLE 15

Application for puffed snacks

As foodstuffs of Ready To Eat Cereal (R.T.E), puffed snacks which were obtained by extrusion cooking are shown.

>;tb;______________________________________

>;tb;Ingredients

>;tb; Test goods

>;tb; Control goods

>;tb;______________________________________

>;tb;Corn flour 21.57 55.22

>;tb;Wheat flour 35.00 --

>;tb;Corn bran* -- 27.0

>;tb;Hemicellulose 20.7 --

>;tb;Skimmed milk powder

>;tb; 10.0 7.0

>;tb;Granulated sugar 4.5 4.5

>;tb;Sodium ferric citrate

>;tb; 0.3 0.3

>;tb;Calcium carbonate

>;tb; 2.5 2.5

>;tb;Natural calcium agent

>;tb; 1.4 1.4

>;tb;Vitamin C 0.13 0.13

>;tb;Table salt 0.6 0.6

>;tb;Palm oil 3.0 1.0

>;tb;Flavors 0.30 0.35

>;tb;______________________________________

>;tb; *Corn bran was used for food fiber materials insoluble in water.

The above combined powder was treated by a twin-screw extruder under the following conditions.

>;tb;______________________________________

>;tb;Mass feed rate 24 kg/h

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>;tb;Feed moisture content

>;tb; 4 kg/h

>;tb;Screw speed 200 rpm

>;tb;Maximum temperature

>;tb; 150 DEG

>;tb; C.

>;tb;Maximum pressure 0.5 MPa

>;tb;______________________________________

Both treated products were eaten crisp and tasted good.

EXAMPLE 16

Medicine for improving constipation containing tablet type hemicellulose

Using the hemicellulose which was prepared by the process of the present invention, tablets for improving constipation were prepared by blending the following ingredients.

>;tb;______________________________________

>;tb;Ingredients Blending (wt %)

>;tb;______________________________________


>;tb;Cornstarch 40.8

>;tb;Crystallized cellulose

>;tb; 2.5

>;tb;Calcium Carboxymethyl Cellulose

>;tb; 1.7

>;tb;______________________________________

In accordance with the above blending, 2200 g of hemicellulose, 1632 g of cornstarch, 100 g of crystalline cellulose and 68 g of calcium carboxymethyl cellulose were mixed with a kneader and then kneaded by adding dropwise 500 ml of water. The kneaded mixture was granulated with a single axis oscillator on which a 20 mesh screen was set and dried with a fluidized bed dryer. The dried product was ground with a flash mill to obtain uniformed particles. The particles and 80 g of sucrose fatty ester as a smoothing agent were mixed with a V type blender. The mixture was tableted with a tableting machine on which a pestle having a diameter of 11 mm was set. Tablets having an average weight of

0.35 g were obtained.

EXAMPLE 17

Granular foodstuffs containing hemicellulose

Using the hemicellulose prepared by the process of the present invention, granular foodstuffs were prepared by blending the following ingredients.

>;tb;______________________________________

>;tb;Ingredients Blending (wt %)

>;tb;______________________________________


>;tb;Powdered sugar 35.0

>;tb;Lactose 25.0

>;tb;Cornstarch 9.5

>;tb;Flavors 0.5

>;tb;______________________________________

In accordance with the above blending, 1200 g of hemicellulose, 1400 g of powdered sugar, 1000 g of lactose, 300 g of cornstarch and 20 g of flavors were mixed with a kneader and then kneaded by adding dropwise 350 ml of water. The kneaded mixture was granulated with an extruder granulator of a cylinder type equipping screen meshes having a diameter of 11 mm and dried with a fluidized bed dryer. The dried particles were uniformed with a flash mill and sieved to obtain 3400 g of a product.

1070/2197

As regards the taste and the flavor, the obtained product was good. On the other hand, a product containing conventional food-fibers was disagreeable to the taste and the flavor.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A process of producing a water-soluble hemicellulose comprising the steps of: a) adding hot water and thermostable amylase to a raw material selected from the group consisting of rice bran, wheat bran and grain husk to remove starch contained in the raw material, whereby the amylase breaks down the raw material and the starch becomes dissolved in the water and thereby forms a gelatinized starch solution; b) removing the gelatinized starch solution of step a), wherein the amylase remaining in the gelatinized solution breaks down the starch into dextrin or smaller carbohydrates; c) separating the gelatinized solution of step b) into solid and liquid phases; wherein the solid phase contains a watersoluble hemicellulose, cellulose, lignin, protein and minerals, and the liquid phase contains the starch and smaller carbohydrates which are not broken down; d) dissolving the solid phase of step c) with a solvent having an acidic pH of at most 5 or an alkaline pH of at least 10 which forms a second solid and liquid phase, wherein the liquid phase contains the water-soluble hemicellulose; e) separating the liquid phase of step d) from the solid phase; and f) neutralizing and desalting the separated liquid phase of step e) to obtain the water-soluble hemicellulose.

2. A process as claimed in claim 1, wherein a stirring-type emulsifier or a colloid mill is used in the starch removing stage.

3. A process as claimed in claim 1, wherein the extraction is conducted by means of an extruder, a colloid mill, a stirring-type emulsifier or one of these combinations.

4. A process as claimed in claim 1, wherein the neutralization and desalting is conducted by the method of at least one selected from the group of an ultrafiltration membrane, an electrodicalysis membrane, an ion exchange resin, a reverse osmosis membrane and one of these combinations, and the material is neutralized during desalting or before desalting.

5. A process as claimed in claim 1 wherein concentration conducted with, after or before the neutralization and desalting stage or at the same time.

6. A process as claimed in claim 5 wherein an ultrafiltration membrane or a reverse osmosis membrane is used in the concentration stage.

7. A process as claimed in claim 1, further comprising a drying stag e in which the material is dried in the presence of saccharide.

8. A water-soluble hemicellulose which is obtained a process as claimed in claim 1.Data supplied from the esp@cenet database - Worldwide

1071/2197

219.

JP2293054 - 12/4/1990

CONDITIONING AND MILLING RAW MATERIAL FOR EDIBLE CEREALS

AND BEANS


Inventor(s): DOHIYANESHIYUWAA BUFUJIYANGARA (--); KAARUTON JIYOOJI

MERITSUTO (--); RADOWAN HASHIEMU IBURAHIMU (--)

Applicant(s): BORDEN INC (--)

IP Class 4 Digits: A23L; B02B

IP Class: A23L1/10; A23L1/16; A23L1/20; B02B1/04

E Class: A23L1/16; A23L1/20D4; A23L1/10M



Family: JP2293054

Equivalent: EP0394584; US4956190; PT93808; NO901403

Abstract:


PURPOSE: To improve the yield of durum wheat and to improve the color preservable property of milled flour by bringing edible grains and leguminous materials into contact with a reducing agent to temper these materials, then milling the edible grains and the leguminous materials. CONSTITUTION:

The edible grains, such as durum wheat, barley, rye, soybeans, oats and rice, or the leguminous materials are brought into contact with the reducing agent, by which these materials are tempered. The edible grains and the leguminous materials are milled to improve the color preservable property and milling yield of the milled flour. The more adequate examples of the reducing agent include acetic acid, lactic acid, maleic acid, ascorbic acid or the like. More specific, the dulum wheat tempered in the reducing agent-contg. a.q. soln. is milled to produce the edible flour and bran is separated from the resulted edible flour. A method of improving the yield of the edible flour by passing the bran through a mill and recovering an excess amt. of the flour.Description:


TEMPERING AND MILLING OF EDIBLE GRAINS AND LEGUMINOUS MATERIALS


Milling of edible materials, such as grains and legumes, is a grinding and particle size reduction operation, generally designed to produce fine, uniform flour for comestible products. Milling separates the bran and germ from the generally more desirable endosperm portion of the grain. Semolina or semolina flour is the flour obtained from the milling of hard wheat such as the middlings of durum wheat. Semolina comprises a major portion of the milled flour in alimentary pastes because it is highly glutinous and produces a self supporting alimentary pasta.

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It is known to treat pasta dough, or flour being made into pasta dough, with various modifiers, additives and agents for various purposes including color retention, improved nutritive value and greater pasta yield. For example, U.S. 3,762,931, issued October 2, 1973 to Craig, et al. teaches the addition of edible sulfhydryl reducing substances to alimentary paste for the purposes of reducing moisture content, improving surface characteristics and decreasing drying time of the pasta.

Known flour treatment agents include, for example, KBrO3, KIO3, azodicarbonamide

(H2NC(O)N=NC(O)NH2), chlorine dioxide, chlorine gas, benzoyl peroxide, ascorbic acid, and Lcysteine. Of these flour treatment agents, only ascorbic acid and l-cysteine are reducing agents, while the remainder of the agents are oxidizing agents. To the knowledge of the inventors, reducing agents have not been used to treat edible grains and legumes in the tempering step prior to milling.

In "Durum Wheat: Chemistry and Technology", edited by G. Fabriani and C. Lintas, published by The

American Association of Cereal Chemists, Inc., St. Paul, Minnesota, at pages 64-65, it is taught that the use of oxidation inhibitors, such as L-ascorbic acid, can inhibit the destruction of the yellow color in the processing of semolina.

In the commercial production of semolina, it is conventional to use chlorine gas in the tempering solution prior to milling of durum wheat. The chlorine gas is an oxidant and inhibits mold growth during shipping and storage of the flour produced. However, chlorine may be related to adverse effects on the quality of pasta products produced from the semolina. In addition, chlorine is a toxic gas and creates handling and venting problems in the tempering step.

It is also previously known to use sulfur dioxide as a bleaching agent in corn milling and/or in tempering of corn prior to milling for the purpose of reducing color content.

It is therefore an objective of the present invention to increase the yield of durum flour obtained from the milling of durum wheat by the addition of a reducing agent to the tempering step prior to milling.

It is also an object of the present invention to provide a method of improving color retention in milled edible grains and leguminous materials. It is a further object of the present invention to increase the nutritive value of durum flour in general and of semolina flour in particular obtained from the tempering and milling of durum wheat


The invention relates to a method of tempering and milling edible grains and/or leguminous material to produce improvements in the nutritive content, color retention, and yield of edible flour produced thereby. The invention further relates to tempering and milling edible grains or leguminous material to produce a flour comprising: tempering the grains or material in the presence of a reducing agent by contacting the grains or material with the reducing agent in the tempering step; and milling the tempered grains or material to produce a flour. By treating unmilled edible grains and/or leguminous material in a tempering solution containing a sufficient amount of a reducing agent or agents, and subsequently milling the edible material, edible flour is produced which is improved over flour produced when a reducing agent is not present in the tempering solution.

The invention also relates to improved color retention in the semolina fraction obtained from the milling of durum wheat which has been tempered using a reducing agent.

The present invention also relates to a method for improving the yield of high quality, edible flour obtained from wheat whereby the flour retains the desirable grain color comprising the steps of (a) tempering durum wheat in a tempering solution comprising one or more reducing agents; (b) milling the tempered wheat, separating the shorts from the flour produced; (c) milling the shorts to obtain additional flour; and (d) combining the flour from step (b) with the flour from step (c). Additional steps in the method can include, for example, a staged or secondary or tertiary tempering step for the shorts and/or bran, or further milling.The increased yield of edible flour relative to the semolina yield obtained from conventional tempering and milling of wheat is the result of combining the semolina

1073/2197

fraction from step (b) and the additional high quality fraction obtained by milling the shorts separated therefrom. By the method of the instant invention, durum flour is produced possessing, relative to conventional flour, improved color retention, reduced visible bran specks, higher protein content, higher mineral content, and high vitamin content.

The present invention also relates to a method for reducing the fractional portion of milled wheat which results in lower quality product, generally sold as animal feed, while simultaneously increasing the fractional portion of the milled wheat which results in high quality edible flour.

The invention further relates to a method for producing pasta comprising: (a) tempering durum wheat in an aqueous tempering solution comprising a sufficient amount of a reducing agent; (b) milling the tempered durum wheat from step (a) to produce an edible flour; (c) mixing the flour from step (b) with water to produce alimentary paste; (d) extruding or sheeting the alimentary paste; and (e) drying the extruded or sheeted alimentary paste to produce a pasta product. Pasta produced from flour made by the instant invention (1) cooks in a shorter time than does pasta produced from conventional flour (i.e. flour product from wheat tempered in the absence of a reducing agent), (2) can be extruded at higher solids levels, (3) retains more of the natural yellow color, and (4) exhibits cooking losses equal to or less than that of pasta made from conventional tempering.


In one embodiment of the present invention, edible grains or leguminous materials are tempered in an aqueous tempering solution containing a reducing agent. The edible material can be, for example, wheat, barley, rye, soybean, oats, rice, etc., or mixtures thereof. The preferred edible materials are starchy cereal grains and/or farinaceous substances. The most preferred material is durum wheat.

By "tempering" herein is meant any process used to condition the grain or leguminous material to achieve a specific predetermined moisture content. This is often a soaking process wherein the material being tempered absorbs most or all of the tempering solution. By the present invention, the reducing agent is also absorbed by the material being tempered. However, according to the present invention the tempering can also be achieved by atomization of a tempering solution, or by a tempering gas, to which the grain or leguminous material is exposed.

By "tempering" herein the inventors also contemplate the dry blending of various grains or legumes with reducing agents or precursors thereto such that the reducing agent or precursor is absorbed by the grain or legumes whose inherent moisture content is sufficient to thereby produce the desired color retention, vitamin retention, and/or increased yield of edible flour or which upon hydration produces such results. In another embodiment, the grain or legumes which have been dry blended with the reducing agent or agents are subsequently exposed to water or steam sufficient to produce the desired increased yield of edible flour or improved color retention or improved vitamin retention.

Tempering of the unmilled material can be achieved according to the present invention by contacting the edible material with, or exposing it to, a sufficient amount of a reducing agent or agents. The reducing agent can be liquid or solid material dissolved or dispersed in an aqueous solution, or a dry solid material mixed with the unmilled material, or a gaseous or vaporous material bubbled or blown over or through the dry material or an aqueous solution thereof, or a combination of these forms.

The tempering of the edible material in the tempering solution can be performed under any desired or conventional conditions depending on the flour properties sought. The duration, pressure, temperature, pH and other variables of the tempering of the edible material can be varied within the skill of the artisan. For example, tempering can be achieved by exposing the edible material to the tempering solution, gas, or solid for periods of several minutes up to several days, and at temperatures ranging from about 33 DEG F to about 212 DEG F. In a preferred embodiment, the edible material is durum wheat which is tempered in an aqueous tempering solution containing a reducing agent for up to 6 hours at a temperature of about 50-70 DEG F.

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By "reducing agent" herein is meant any compound, chemical, agent, mixture, or substance which is or which produces a material which is, (a) able to chemically reduce and/or reverse the disulfide crosslinking, R-S-S-R, which can result from the oxidative coupling of two sulfhydryl groups, R-SH, on protein(s), or (b) able to donate electrons as in a chemical reduction reaction.

Particularly effective as reducing agents in the present invention are sodium metabisulfite, SO2 or

SO2-generating precursors, or organic acids such as, for example, acetic acid, ascorbic acid, aspartic acid, chloroacetic acid, cysteine, histidine, thioglycolic acid, lactic acid, and maleic acid.

Also effective as reducing agents in the present invention are the anions of certain inorganic acids such as, for example, sulfurous acid, and nitrous acid, and the like.

The presence of the reducing agent also protects the edible material being tempered from chemical or photo degradation of the natural vitamins and coloring agents, including but not limited to carotenoids

(such as beta-carotene), chlorophylls, xanthophylls, and the related lipoxidase-linoleate system. A sulfhydryl reducing agent also plasticizes or otherwise modifies the protein in the outer layers of the grain which produces the flour to thereby facilitate improved flour yields, lower energy consumptions, and increased extrusion rates. The presence of one or more reducing agents in the tempering solution provides a pasta dough extrudable at solids levels higher than pasta dough produced from material tempered in the absence of a reducing agent.This is surprisingly achievable by the viscosity reduction provided to alimentary paste produced by the milling in the presence of a reducing agent. Table I indicates that reduced, pasta dough viscosity (measured as 500 Brabender Units, B.U.) is achieved faster when the flour in the dough was tempered in the presence of a reducing agemt. Reduction in viscosity of the pasta dough is desirable for increasing production rates, reducing extrusion head pressures, reducing energy expeditures, and allowing extrusion at lower moisture levels.Thus moisture levels at extrusion of, for example, 21-27% by weight instead of 30-31% are achievable which reduces drying time, aids in retention of vitamins, and reduces cooking losses.

>;tb;>;TABLE; Columns=3 Brabender Farinograph Viscosity Measurements

>;tb;Head Col 1: Reducing Agent in Tempering Water

>;tb;Head Col 2: Amount (ppm)

>;tb;Head Col 3: Time needed to reach 500 B.U., (Minutes)

>;tb;none>;SEP;>;SEP;10:50

>;tb;Chlorine (Control)>;SEP;10>;SEP;11:00

>;tb;Chlorine (Control)>;SEP;100>;SEP;12:00

>;tb;K2S2O5>;SEP;247>;SEP;11:00

>;tb;>;SEP;300>;SEP;8:25

>;tb;>;SEP;351>;SEP;8:50

>;tb;>;SEP;400>;SEP;8:00

>;tb;>;SEP;1083>;SEP;4:50

>;tb;H2SO3>;SEP;200 (as SO2)>;SEP;9:50

>;tb;Cystiene>;SEP;497>;SEP;7:25

B.U. is an arbitrary scale of Brabender Units recorded on a Brabender Farinograph viscometer.

>;tb;>;/TABLE;

Sulfhydryl compounds are among the effective reducing agents in the present invention. Examples of sulfhydryl reducing agents useful in the process of the present invention include cysteine, water-soluble cysteine salts, such as l-cysteine hydrochloride, hydrogen sulfide and glutathione. Sulfhydryl reducing agents are compounds containing -SH groups or compounds which are capable of initiating reactions which reduce -S-S- bonds in gluten to form -SH groups. Sulfur-containing materials such as the sulfite salts and sulfur dioxide which may not contain a -SH group per se are operative herein as reducing agents if upon exposure to moisture, either liquid or vaporous, a -SH group, such as in sulfurous acid, is produced.Satisfactory reducing agents according to the invention also include compounds related to or homologous with L-cysteine hydrochloride, such as D and DL cysteine hydrochloride, the free bases of L, D and DL cysteine, L-cysteine mono-phosphate, di-L-cysteine sulfite and l-mono-cysteine tartrate. Various sulfite salts such as potassium bisulfite and sodium or potassium sulfite can be used in place of sodium bisulfite. Related compounds such as hydrosulfite and pyrosulfite salts may also be employed as reducing agents in the tempering process. Natural foods and other sources of the above

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compounds may also be used herein. Such a natural food source can include, for example, purified wheat germ fraction which contains glutathione.

It is also believed that nitrogen-containing compounds, such as amines, are also operative herein as reducing agents in the tempering solution. Thus, amides, amines, diamines etc. capable of being oxidized to quaternium compounds will, in turn, act as reducing agents in the present invention.

All of these reducing agents are utilized herein in non-toxic amounts and do not form any known toxic or otherwise objectionable by-products with the other materials, if any, in the tempering solution or with the materials mixed with the flour resulting from milling. The reducing agents have no known detrimental effect upon flavor, nutritional value or other essential properties of the milled flour or subsequent food product, such as pasta. The reducing agents may be utilized in the present invention either singularly or in combination.

The amount of reducing agent present in the tempering solution is an amount sufficient to (a) increase the content of retained protein in the edible material after milling relative to protein content in milled material tempered in the absence of a reducing agent and/or (b) increase the color retention in the milled edible material relative to the odor of milled material tempered in the absence of a reducing agent, and/or (c) increase the content of retained natural vitamins in the milled material relative to vitamin content of milled material tempered in the absence of a reducing agent, and/or (d) increase the yield of semolina obtained from the milling of durum wheat tempered in a solution containing a reducing agent relative to the yield of edible flour obtained from the milling of durum wheat tempered in the absence of a reducing agent.The amount of reducing agent required in the tempering steps of the present invention varies depending on the agent chosen, its solubility, its redox potential, E0, the pH of the solution and the kind and degree of benefit sought. Thus, pH, pressure and temperature can be conventionally controlled to thereby increase the solubilization and thus the effectiveness of the reducing agent in the tempering solution.

It is believed that increasing the pressure during the tempering step will increase the color content of the resulting flour. Thus pressures of 1-2 atmospheres up to several thousand p.s.i. will either enhance the desired properties or reduce the process time, or both. Reduced pressure during tempering can be effective in certain processes by evacuating a container holding the grain and then introducing the reducing agent or an aqueous solution thereof to the partial vacuum. This will facilitate increased and faster penetration of the reducing agent and the moisture into the grain.

The weight percentage of reducing agent in the tempering solution is generally from about 10 parts per million to about 1000 parts per million. A more preferred range is from about 200ppm to 400ppm.

When sodium or potassium metabisulfite is used as the reducing agent, an amount effective in color retention according to the present invention has been found to be in the range of from about 100 to about 1000ppm, and more preferrably from 200 to 500ppm. Sulfhydryl reducing agents, among which are preferred metabisulfite, cysteine and glutathione, are effective reducing agents in the present invention at levels of 100 ppm to 500 ppm, more preferrably at 200 ppm to 400 ppm.

In achieving the increased yield of high quality, edible flour of acceptable color from durum wheat tempered in the presence of a reducing agent, an effective amount of reducing agent can be, for example, 200ppm to 400ppm.

The inventors believe that the presence of the reducing agent(s) serves to plasticize the protein in at least the outer layers of the edible grains and leguminous material. The plasticization of the protein is demonstrated by the viscosity reduction or reduced extrusion pressures which result in increased production rates.

By "plasticizing" the protein herein is meant the softening, loosening, or modification of the protein structure which results from the depolymerization of the gluten. It is believed that the reducing agent(s) plasticizes and solubilizes the protein by disrupting the protein chain shape, which allows the protein to better flow around each discrete starch particle. The result is higher protein extraction in the milled product and a subsequent pasta dough which is softer than conventional dough. As a result, and by the present invention, significant improvements in protein yields of higher functional quality from the milling of the shorts have been achieved due to the use of the reducing agent(s) in the tempering step.

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The softer dough produced can be extruded at either lower pressures or lower moisture content, or both. (See Table IV.)

By "milling" herein is meant the milling, grinding, bolting, shaping, cutting, crushing, conditioning or particle size reduction of the grain or leguminous material. Milling herein can be accomplished by conventional means, such as a ball mill, a Brabender mill, a two roll mill, a three roll mill, rotary mill, and the like.

By "edible flour" herein is meant the flour obtained from the milling of durum wheat, including but not limited to semolina flour. Semolina is the food prepared by grinding and bolting cleaned durum wheat to such fineness that when tested by the method prescribed in 21 CFR section 137.300(b) (2), it passes through a No. 20 sieve, but not more than 3 percent passes through a No. 100 sieve. The semolina is freed from bran coat or bran coat and germ to such extent that the percent of ash therein, calculated to a moisture-free basis, is not more than 0.92 percent. Durum flour has not less than 98 percent passing through the No. 70 sieve. The present invention, however, is not limited to semolina flour and is operative for flours obtained from the tempering and milling of various grains and legumes as described herein.

In conventional milling of durum wheat, several fractions are obtained. The highest value fraction is generally semolina, representing roughly 60% by weight of the milled product. The 40% by weight of the milled product which remains contains a fraction often referred to as "shorts" or bran, which is generally of such color quality and nature that most of it is sold as low value animal feed. The shorts generally include the germ, fine bran and some flour. Conventional chlorine tempering and milling techniques, however, do not render the shorts serviceable as flour for pasta production. A significant feature of the present invention is the ability to recover from the animal feed fraction of the milled product a substantial additional yield of edible flour of sufficient quality to be serviceable in pasta products.

In 1985, the relative values of the semolina fraction to animal feed fraction derived from durum wheat was DOLLAR 10.25 per 100 pounds for semolina to DOLLAR 2.27 per 100 pounds for animal feed.

Thus, semolina is clearly a much higher value-added fraction of the milled durum wheat.

By the present invention, milling of durum wheat which has been tempered in a solution containing a reducing agent, such as sodium metabisulfite, produces a yield of edible flour of approximately 75 to about 80% by weight while reducing the fraction of milled product which goes into animal feed. Using conventional chlorine tempering of wheat, it is common to produce approximately 58% by weight semolina suitable for use in pasta. Using conventional chlorine tempering and collecting the so-called

"straight grade", i.e., whole grain milled to get maximum yield by combining the semolina and the shorts, approximately 78.5% by weight flour is obtained. However, this flour is not acceptable for commercial pasta because of color and texture. However, by the present invention 78.5% by weight edible flour suitable for pasta is produced by combining the flour milled the shorts with the semolina.The increased edible flour yield relative to conventional tempering and milling is the result of combining the semolina fraction and an additional high quality fraction obtained by milling the shorts separated therefrom. Thus by the present invention, the yield of high quality edible flour from the milling of durum wheat tempered in a solution with a reducing agent is approximately 16-20% higher than the conventional yield of semolina alone from durum wheat tempered in the absence of a reducing agent.

Table II shows the total yield of edible flour obtained by the present invention in laboratory experiments when combining the flour from the milling of the shorts with the semolina fraction. In the control sample of Table II, no reducing agent was used in the tempering water. The total yield in that sample was 76.7% but the flour thus obtained was significantly inferior to the quality of the inventive sample.

>;tb;>;TABLE; Columns=5 Laboratory Tempering & Milling Of Wheat

>;tb;Head Col 1: Reducing Agent

>;tb;Head Col 2: Amount,ppm

>;tb;Head Col 3: Total Flour Yield

>;tb;Head Col 4: Color Retention mg/100g as B-carotene

>;tb;Head Col 5:Pasta Quality

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>;tb;none>;SEP;->;SEP;76.7>;SEP;2.51>;SEP;-

>;tb;H2SO3>;SEP;200 SO2>;SEP;79.74>;SEP;2.154>;SEP;+

>;tb;Cystiene-HCl>;SEP;200>;SEP;77.8>;SEP;2.552>;SEP;+

>;tb;K2S2O5>;SEP;1083>;SEP;76.7>;SEP;2.565>;SEP;+

>;tb;Cysteine-HCl>;SEP;767>;SEP;78.8>;SEP;2.640>;SEP;+

>;tb;SnCl2>;SEP;1100>;SEP;78.2>;SEP;2.622>;SEP;+


>;tb;ascorbic acid>;SEP;550>;SEP;75.2>;SEP;2.615>;SEP;+

>;tb;SnCl2>;SEP;1410>;SEP;75.8>;SEP;2.603>;SEP;+



>;tb;gluthione>;SEP;960>;SEP;76.3>;SEP;2.596>;SEP;+

>;tb;>;/TABLE;

In a mill trial, a value of 3.671 mg Betacarotene/100 gms. of semolina was obtained after tempering the wheat with SO2. This represents virtually 100% color retention. The same mill trial using chlorine in the tempering step produced semolina with at best 3.020 mg Betacarotene/100gm.

The additional flour fraction obtained from the milling of the shorts by the present invention is of high food quality because of the desirable color retention, high protein, vitamin and mineral content. The additional fraction obtained thereby is highly suitable for pasta production. Vitamins are generally concentrated in the aleurone or outer part of the grain beneath the bran. This high protein source is generally lost into the shorts and, by conventional technology, would pass to the animal feed fraction.

By the present invention, this valuable fraction can be remilled without increasing the ash content significantly, without significant color loss and without destroying the protein. By tempering in the presence of a reducing agent, the protein in the grain is modified but not destroyed.The flour obtained from the milling of the shorts by the present invention has protein level of about 17% as compared to

13-14% protein of semolina obtained after tempering durum wheat with chlorine. By the present invention, vitamin and mineral content is at least comparable to that obtained by chlorine tempering, and the sulfhydryl tempering does not result in poor texture of pasta produced therefrom.

The invention further relates to a method for improving the yield of durum flour obtained from the tempering and milling of durum wheat comprising the steps of: (a) tempering durum wheat in an aqueous tempering solution comprising a reducing agent; (b) milling the tempered wheat from step (a) to produce flour; (c) separating the shorts from the flour obtained in step (b) and passing the shorts through a mill such as, but not limited to a Brabender mill, whereby the shorts receive further grinding or bolting to thereby produce an additional amount of flour. The flour recovered from the milling, grinding or bolting of the shorts can be combined with the flour from step (b) to thereby increase the total yield of edible flour.This invention thus represents a significant cost savings to millers and/or flour converters by increasing the yields of edible flour with color and protein acceptable for pasta production, by 16% to 20%.

The invention further relates to a method for reducing the ash content of the flour produced. By treating the tempered wheat with water, with or without a reducing agent, immediately prior to milling and following tempering, the bran is maintained as soft and less friable whereby the ash content is minimized. Thus the wheat can be twice or thrice tempered to further improve the color retention and reduce the ash content. Such multiple tempering steps can occur at various times prior to the milling sequence.

The invention also relates to a method for increasing the color retention in semolina by tempering the durum wheat in the presence of a reducing agent. In this manner, close to 100% of the color of the durum wheat is maintained in the semolina, as measured by the AOCC 1250 method, Edition 1964.

By the present invention, straight grade is obtained which when used in spaghetti makes a pasta with improved texture relative to the pasta produced from semolina obtained from tempering with chlorine.

Thus Table III illustrates the results of subjective texture analyses by trained test panelists, wherein the pasta produced from K2S2O5 - tempered wheat was given a value of 4.5 on a scale 1 poor - 5 good while chlorine tempered wheat produced lower quality pasta textures.

>;tb;>;TABLE; Columns=4 Spaghetti Produced From Tempered Wheat

1078/2197

>;tb;Head Col 1: Tempering Agent

>;tb;Head Col 2: Amount, ppm

>;tb;Head Col 3: Product

>;tb;Head Col 4: Texture

>;tb;C12>;SEP;200>;SEP;semolina>;SEP;3.5

>;tb;C12>;SEP;200>;SEP;straight grade>;SEP;4.0

>;tb;K2S2O5>;SEP;400>;SEP;straight grade>;SEP;4.5

>;tb;>;/TABLE;

In the production of pasta (spaghetti and elbow macaroni) from chlorine tempered wheat and SO2 tempered wheat, the inventive product has higher yields per unit time, lower extrusion pressures measured at the diehead, and consumes less energy. Table IV illustrates the results of the pasta production by the inventive SO2 tempering compared to conventional chlorine tempering.

>;tb;>;TABLE; Columns=5 Production Runs Of Pasta From Straight Grade

>;tb;Head Col 1:

>;tb;Head Col 2 to 3 AL=L: Cl2 tempered

>;tb;Head Col 4 to 5 AL=R: SO2 tempered

>;tb;SubHead Col 1;:

>;tb;SubHead Col 2 to 3 RB=3: Spaghetti/Elbow Mac.

>;tb;SubHead Col 4 to 5 RB=3: Spaghetti/Elbow Mac.

>;tb;Pounds product/hr., 12% H2O>;SEP;4859>;SEP;3282>;SEP;5029>;SEP;3799

>;tb;Average diehead pressure, bars>;SEP;102>;SEP;123>;SEP;96>;SEP;130

>;tb;Average amps/trial>;SEP;209>;SEP;-->;SEP;190>;SEP;--

>;tb;>;/TABLE;

The following Example is provided to further demonstrate and illustrate the invention. In the Example and throughout the specification, all temperatures are expressed in degrees Farenheit unless otherwise indicated. The Example is not to be viewed as a limitation of the invention, as it is contemplated that modifications will readily occur to those skilled in the art, which modifications are within the spirit of the invention and the scope of the appended claims.

Example 1 Flour Retention

Clean durum wheat, 500 grams, at 13.1% by weight moisture was tempered to 16% moisture by spraying a mix of 15.52 grams of water and 1.725 grams of sulfurous acid reducing agent into a Colton rotating drum containing the wheat. The water and reducing agent was sprayed in a fine mist onto the wheat while the wheat was continuously tumbled in the rotating drum. After 4-5 minutes, the spraying was completed and the wheat was transferred to a clean glass jar, sealed, and held at 72 DEG - 73

DEG F for one hour. The wheat was then milled 15 minutes using a Chopin Model CD-1 flour mill according to conventional milling practice. This removed the bran from the wheat and two fractions of wheat were obtained. The two fractions obtained were the coarse semolina and break flour. The course semolina was sifted through a #20 and a #30 seive, then milled into flour by passing through reduction rolls, then sifted through a number 70 seive (160 microns). The fractions not passing through the number 70 seive (160 microns) were collected as shorts and remilled. The fraction which did not pass through the #20 seive was bran which was separated out and not used. In this manner were produced final shorts, wheat flour, plus the prior break flour fraction. This represents conventional milling technique but by means of the reducing agent in the tempering solution, the quality of the flour produced from the shorts is significantly improved.Data supplied from the esp@cenet database -

Worldwide Claims:


1. A method for tempering and milling edible grains or leguminous material to produce a flour comprising:

(a) tempering the edible grains or leguminous material in the presence of a reducing agent by contacting the grains or material with the reducing agent;

(b) milling the tempered grains or material to produce a flour.

1079/2197

2. The method of claim 1 wherein the edible grains or leguminous material is selected from the group consisting of wheat, barley, rye, soy bean, oats, and rice.

3. The method of claim 1 wherein the edible grains or leguminous material is a farinaceous cereal grain.

4. The method of claim 1 wherein the edible grain or leguminous material is durum wheat.

5.The method of claim 1 wherein the reducing agent is selected from the group consisting of edible sulfhydryl substances, hydrogen sulfide, sulfur dioxide, acetic acid, lactic acid, maleic acid, histidine, aspartic acid, ascorbic acid, amines, amides, ammonia, and the alkali salts of sulfite, bisulfite, and metabisulfite.

6. The method of claim 4 wherein the edible sulfhydryl substances useful as reducing agents are selected from the group consisting of cysteine, cysteine hydrochloride, sulfur dioxide, hydrogen sulfide, glutathione, thioglycolic acid, and mixtures thereof.

7. The method of claim 1 wherein the reducing agent is dissolved or suspended in an aqueous tempering solution to which the edible grain or leguminous material is exposed.

8.The method of claim 1 wherein the reducing agent is a gas or vapor bubbled through an aqueous tempering solution containing the edible grain or leguminous material.

9. The method of claim 1 wherein the reducing agent is present in the edible grain or leguminous material at a level equal to or greater than 10 parts per million.

10. The method of claim 1 wherein the tempering of step (a) is continued for a period of time and at a temperature and at a pressure sufficient to preserve in the flour produced in step (b) the color of the edible grains or leguminous material.

11. The method of claim 1 wherein the milling of step (b) comprises passing the tempered material obtained from step (a) through at least one particle reducing device, whereby flour is produced.

12. The method of claim 1 wherein the reducing agent is added to an aqueous tempering solution as a powdered solid.

13.The method of claim 1 wherein the reducing agent is at least partially dissolved in water to form a reducing agent solution, which solution is added to an aqueous tempering solution containing the edible grain or leguminous material.

14. The method of claim 1 wherein the tempering is done in a vessel having a positive or negative pressure.

15. A method of improving color retention in milled edible materials comprising:

(a) tempering the edible material in an aqueous tempering solution comprising a reducing agent;

(b) milling the tempered material to produce a flour, whereby a flour is produced which has retained a significant amount of the color of edible material.

16. The method of claim 15 wherein the flour is semolina.

17.A method for improving the yield of edible flour obtained from the tempering and milling of durum wheat material comprising the steps of:

(a) tempering the durum wheat in an aqueous tempering solution comprising a reducing agent;

(b) milling the tempered wheat from step (a) to produce edible flour;

(c) separating the shorts from the edible flour obtained in step (b) and passing the shorts through a mill whereby an additional amount of flour is recovered.

18. A method for producing pasta comprising:

1080/2197

(a) tempering wheat in an aqueous tempering solution comprising a reducing agent;

(b) milling the tempered wheat from step (a) to produce flour;

(c) mixing the flour from step (b) with water to produce an alimentary paste;

(d) extruding or sheeting the alimentary paste; and

(e) drying the alimentary paste to produce a pasta product.

19.A method for producing pasta comprising:

(a) tempering wheat in an aqueous tempering solution comprising a reducing agent;

(b) milling the tempered wheat from step (a) to produce edible flour;

(c) separating the shorts from the flour obtained in step (b);

(d) passing the shorts from step (c) through a mill whereby an additional amount of flour is recovered;

(e) combining the flour from step (b) and the flour from step (d) with water to produce an alimentary paste;

(f) extruding or sheeting the alimentary paste; and

(g) drying the extruded or sheeted alimentary paste to produce a pasta product.

20. The method of claim 17 wherein the reducing agent is selected from the group consisting of edible sulfhydryl substances, hydrogen sulfide, sulfur dioxide, ascorbic acid, and the alkali salts of sulfite, bisulfite, and metabisulfite, and is present in the aqueous tempering solution at a level sufficient to produce from the milling of the shorts a flour fraction essentially equal in color to that of the flour produced in step (b).

21. The method of claim 1 wherein the temperature during the tempering step is 32 DEG to 212 DEG

F and wherein the pressure is above 78 inches of mercury.Data supplied from the esp@cenet database -

Worldwide

1081/2197

220.

JP3083552 - 4/9/1991

METHOD FOR MANUFACTURING RICE BOILED AND DRIED

BEFOREHAND AND FOOD CONTAINING SAID RICE


Inventor(s): MAABIN ROI GODAADO (--)

Applicant(s): UNILEVER NV (--)


IP Class: A23L1/10; A23L1/182

E Class: A23L1/182



Family: JP3083552

Equivalent:

Abstract:

EP0414286; US5098726


PURPOSE: To obtain such rice, that when the rice is hydrated again, it shows desired hardness while each grain of the rice keeps its independent state by dipping cooked rice in a sugar soln., washing the rice, and then freezing and drying with hot air blow. CONSTITUTION: Rice is cooked and dipped in a sugar soln. (20 to 75wt.% and preferably 30 to 60wt.% concn. at 60 to 80 deg.C) for within 7min, preferably 2 to 5min while stirring. The sugar used is sucrose, fructose, glucose, lactose, maltose, dextrose, corn syrup, maltdextrin, etc., and dextrose is preferable. Then the rice is dewatered, washed to remove the cohesive sugar soln., frozen and dried by hot air glow till the water content becomes 5 to

10wt.%. Thus instant rice or a food containing the instant rice can be obtd.Claims:


1. A method of preparing a precooked, dried rice comprising the steps of :

(a) treating the rice during or after cooking with an aqueous solution of a saccharide;

(b) draining and rinsing the treated, cooked rice with water to remove the adherent, aqueous saccharide solution;

(c) freezing the treated, cooked rice, and

(d) drying the frozen, treated, cooked rice to a moisture content between 5% and 10% by weight.

2. A method according to Claim 1, in which the saccharide is selected from the group consisting of sucrose, fructose, glucose, maltose, lactose, dextrose, corn syrup, maltodextrins, and mixtures thereof.

3. A method according to Claim 1, in which the saccharide is dextrose.

4. A method according to Claim 1, in which the rice after cooking is treated with an aqueous solution of a saccharide for a period of up to 7 minutes.

5.A method according to Claim 1, in which the rice after cooking is treated with an aqueous solution of a saccharide for a period of from 2 to 5 minutes.

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6. A method according to Claim 1, in which the rice after cooking is treated with an aqueous solution of a saccharide having a temperature of from 50 DEG C to 80 DEG C.

7. A method according to Claim 1, in which the rice after cooking is treated with an aqueous solution of a saccharide having a concentration of 20% to 75% by weight of the saccharide.

8. A method according to Claim 1, in which the rice is cooked in an aqueous solution of a saccharide having a concentration of 15-30% by weight of the saccharide.

9. A method according to Claim 1, in which in step (d) the drying of the frozen, treated, cooked rice is effected by hot-air drying.

10. A precooked, dried rice whenever prepared by the method claimed in any of Claims 1 to 9.

11. Foodstuffs or ingredients for foodstuffs, at least partially consisting of the precooked, dried rice according to Claim 10.Data supplied from the esp@cenet database - Worldwide

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221.

JP3168066 - 7/19/1991

MAKING OF FLAVOR ADDITIVE


Inventor(s): SANGU HO DATSUKU (--); ROBAATO DASUTAN UTSUDO (--);

ARUFURETSUDO UPEI (--)



IP Class: A23L1/238

E Class: A23L1/238; A23L1/23; A23L1/227; A23J3/34



Family: JP3168066

Equivalent: EP0429760; US5141757; MX171432; CH679542; BR9004522; AR246798;

PT95277; NO179853B

Abstract:


PURPOSE: To produce the flavoring agent having no bitter taste, etc., by preparing an aqueous suspension of a material rich in protein, hydrolyzing the protein at a prescribed pH with a protease to solubilize the protein, subjecting the resulting suspension to heat treatment and ripening the treated suspension with a malted rice enzyme. CONSTITUTION: In this production, an aqueous suspension of a material which is rich in protein and selected from defatted soybeans, powdery peanuts, corn gluten, when protein, etc., is prepared so that the dry matter content of the suspension is about 10 to 40%.

Then, this suspension is hydrolyzed at a pH of 6 to 11 with a protease to solubilize the protein and subsequently, the hydrolyzed suspension is subjected to heat treatment at a pH of 4.6 to 6.5. Thereafter, the treated suspension is cooled and malted rice is added to the cooled suspension in an amount to provide a 2 to 50wt.% concn. of the melted rice in the resulting suspension based on the dry matter content of this suspension, and also, salt is added to this suspension in an amount to provide a 10 to

17wt.% salt content of the resulting suspension. Then, the suspension thus obtained is subjected to ripening at 20 to 40 deg.C for 2 to 20 days with the malted rice enzyme to produce the objective flavoring agent.Description:



This invention relates to a process for the production of a flavouring agent by enzymatic hydrolysis of proteins.

Materials rich in proteins, such as for example oilseed cakes, pulses, cereal gluten or lactic proteins, are widely used in hydrolyzed form as a starting material in the composition of dehydrated or liquid soups, sauces and seasonings.

In this context, a peanut or soybean cake, for example, is normally subjected to hydrolysis with concentrated hydrochloric acid, the hydrolyzate is neutralized with sodium hydroxide, the insoluble

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fractions are removed, the hydrolyzate is optionally subjected to filtration, decoloration, concentration and/or drying and is then used as a flavouring agent as such, or after reaction with reducing sugars, for example.

A process such as this for the production of a flavouring agent by acidic hydrolysis of proteins is attended inter alia by the disadvantage that the amino acids produced during hydrolysis are degraded.

If, for this reason, it is preferred to subject a material rich in proteins to enzymatic hydrolysis, the familiar problem of bitterness of the hydrolyzate caused by bitter peptides produced during hydrolysis is encountered.

Various processes have been proposed with a view to avoiding or eliminating this bitterness, in particular by carrying out the enzymatic hydrolysis under such conditions that the production of bitter peptides is reduced, by extracting the bitter peptides from the hydrolyzate or by degrading the bitter peptides.

EP 223 560, for example, describes a process in which casein or an isolate of soya proteins is hydrolyzed with a proteinase, after which the bitterness of the product obtained is eliminated by rehydrolysis with an aminopeptidase derived from a strain of Streptococcus lactis.


The object of the present invention is to provide a process for the production of a flavouring agent by enzymatic hydrolysis of a material rich in common proteins without having to use purified exopeptidases to eliminate bitterness while at the same time providing the product with remarkable organoleptic qualities.

To this end, the process according to the invention for the production of a flavouring agent is characterized in that an aqueous suspension of a protein-rich material is prepared; the proteins are solubilized by hydrolysis of the suspension with a protease at pH 6.0 to 11.0; the suspension is heat-treated at pH 4.6 to 6.5: and the suspension is ripened with enzymes of koji.

The process according to the invention effectively permits the preparation, from common protein-rich materials such as a defatted soya flour or casein, of a flavouring agent having remarkable organoleptic qualities, namely, in an embodiment involving a relatively short ripening period, a pleasant and relatively neutral taste devoid of bitterness, and in an embodiment involving a longer ripening period, a stronger flavour but still without bitterness.

In the context of the invention, the term "koji" designates the product of fermentation, with a Koji culture, of a mixture of a protein source and a carbohydrate source, more particularly a mixture of a cooked pulse or oilseed and a cooked or roasted cereal, for example a mixture of cooked soya or haricot bean and cooked or roasted wheat or rice.

In the context of the invention, a koji culture is understood to be the culture of koji spores of the type available on the market, particularly in Japan or China, which in particular comprises spores of

Aspergillus oryzae or Aspergillus soyae.

Similarly, in the context of the invention, the expression "halophilic yeast culture" is used in the sense of a culture of yeasts producing aromatic substances and alcohol, such as Saccharomyces rouxii for example, used for the traditional fermentation of a moromi obtained by mixing a koji and a brine in the traditional preparation of soya sauce.

Finally, the enzymatic activity of the protease is characterized in the present specification by the Anson unit (AU), as defined by Anson's analysis method (J. General Physiology 22, 1939, 79-89) modified by

Novo Industri A/S.

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To carry out the process according to the invention, the protein-rich material may be selected from the group consisting of subdivided and defatted oilseeds or pulses, particularly defatted flours or cakes of soybean or peanut oil, cereal gluten, particularly wheat, rice or corn gluten, and lactic proteins, more particularly casein or lactoserum proteins for example. Isolates or concentrates of vegetable or animal proteins, for example, may also be used.

It is preferred to prepare an aqueous suspension of such a material which has a dry matter content of 10 to 40%.

The pH of this suspension is adjusted to a value of 6.0 to 11.0 and preferably to a value of 8.0 to 10.0, for example by addition of sodium hydroxide.

A protease is added to the suspension, the protease having an activity of, for example, 0.2 to 12 AU per

100 g dry matter of the suspension. This protease is preferably selected from the group consisting of neutral or alkaline proteases of bacterial origin (produced for example by B. Licheniformis or B. subtilis) or fungal origin (produced for example by A. oryzae or A. soyae). Enzymes such as these are marketed, for example, under the name of NEUTRASE or ALCALASE by Novo Industri A/S, under the name of MKC-HT PROTEOLYTIC 200 or MKC/Protease/L330 by Miles Kali-Chemie GmbH &

Co KG or under the name of COROLASE N, PN or 7089 by Rohm GmbH.

The suspension may be hydrolyzed for 2 to 8 h and preferably for 3 to 6 h at 50 DEG to 75 DEG C. and preferably at 61 DEG to 68 DEG C.

The pH then is adjusted to 4.6-6.5 and preferably to 4.9-5.9, for example by addition of hydrochloric, lactic, citric, phosphoric or acetic acid. The heat treatment step at this pH plays an important part in regard to the viscosity of the suspension and the solubility of the flavouring agent obtained in a preferred embodiment of the process in which the suspension is pressed after ripening, and the juice obtained is pasteurized and clarified. If the pH is adjusted to a value above 6.5, the flavouring agent shows excessive turbidity when diluted with water. If the pH is adjusted to a value below 4.6, the heattreated suspension has a viscosity which makes it difficult to pump.

The heat treatment may be carried out, for example, in a double-jacketed tank, in a heat exchanger or by injection of steam. Depending on the method of heating selected, the temperature of the heat treatment may be between about 90 DEG and 140 DEG C. and the heat treatment time may be between about 10 s and 30 minutes, the shortest times corresponding to the highest temperatures and vice versa.

The heat-treated suspension then is cooled, for example to a temperature of 20 DEG to 40 DEG C. If the heat treatment is carried out by injection of steam, this cooling may be carried out by flashing which gives the flavouring agent finally obtained a more neutral taste.

Koji may then be added to the cooled suspension in a quantity of 2 to 50% by weight koji, based on dry matter of the suspension, the koji itself having a dry matter content of approximately 60 to 75% for example. The koji may have been prepared, for example, by mixing an oilseed or a cooked pulse, particularly soya or cooked haricot beans, with a cooked or roasted cereal, particularly crushed and roasted rice or wheat, in a quantity of 50 to 90 parts by weight dry matter of optionally defatted oilseed or pulse and 10 to 50 parts by weight cereal, leaving the mixture to cool to 20 DEG-40 DEG C., inoculating it with a koji culture and with a pure culture of A. oryzae or A. soyae spores in a quantity of

1 part by weight spore culture or powder to 1,000 to 10,000 parts by weight mixture and leaving the mixture to ferment for 30 to 50 h at 20 DEG to 40 DEG C. on traditional wattles, on a plate or in a commercial apparatus specially designed for this purpose with intermittment stirring and aeration.

After sodium chloride has been added to the suspension in such a quantity so that the suspension has a sodium chloride content of approximately 10 to 17% by weight for example, the suspension may be left to ripen under the effect of the enzymes in the koji, namely the enzymes which have been produced by the koji culture during fermentation of a mixture of cooked pulse or oilseed and cooked or roasted cereal for example.

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In one embodiment of the process according to the invention, the suspension is left to ripen for 2 to 20 days, after which a flavouring agent having an agreeable and relatively neutral taste is obtained.

Another embodiment of the process according to the invention is characterized in that, after koji and sodium chloride have been added, the suspension is inoculated with a culture of halophilic yeast and left to ripen for 1 to 8 weeks at 20 DEG to 40 DEG C. A flavouring agent having a stronger taste is obtained in this way. In this particular embodiment of the process according to the invention, the suspension has a pH if from 4.9 to 5.9 and is preferably inoculated with 1 to 5% by volume of a culture of Saccharomyces rouxii and/or Torulopsis etchelsii containing approximately 10@7 to 10@8 cells of one or the other microorganism or of a mixture of these microorganisms per ml.

After the ripening step, a clear juice may be extracted from the suspension and may be used as a flavouring agent either as such or after various additional treatments. This juice may also be concentrated, dehydrated and reduced to powder.

To extract the clear juice, the suspension may be pressed after ripening, the insolubles removed and the juice obtained pasteurized and clarified. More particularly, the suspension may be pressed in a press capable of applying an adequate pressure of the order of 10 to 100 bar, such as for example a screw press or hydraulic press. The juice obtained may be pasteurized for 5 s to 30 mins. at a temperature of

75 DEG to 140 DEG C. and may then be clarified by passage through a filter paper or a synthetic membrane for example.

The clarified juice may then be concentrated to a dry matter content of approximately 60 to 85% by weight, for example by evaporation for about 1 to 8 h at a temperature of approximately 40 DEG to 65

DEG C. under a pressure of approximately 10 to 100 mbar.

The concentrated juice may also be dehydrated to a dry matter content of approximately 95 to 99% by weight, for example by drying for about 5 to 10 h at a temperature of approximately 60 DEG to 80

DEG C. under a pressure of 10 to 100 mbar. Finally, the dehydrated juice may be ground, for example in a hammer mill, to reduce it to powder.

The flavouring agent obtained by the process according to the invention in the form of a ripened aqueous suspension, a clear liquid, a concentrate or a powder may either be used as such for flavouring various dishes or as a basic ingredient in the composition of food products or may be used for the preparation of liquid, semi-liquid or dehydrated sauces and soups for example.

EXAMPLES

The process according to the invention is illustrated by the following Examples in which percentages and parts are by weight, unless otherwise stated.

EXAMPLE 1

An aqueous suspension of a defatted soya flour having a dry matter content of 23% is prepared. The pH of the suspension is adjusted to 10.0 by addition of NaOH. 0.6%, based on the dry matter content of the suspension, of a bacterial alkaline protease (produced by B. licheniformis) having an activity of 2.4 AU per g enzyme is added to the suspension. The suspension is then hydrolyzed with continuous stirring for 3 h at 68 DEG C. in a jacketed tank.

The pH value of the hydrolyzed suspension is adjusted to 5.4 by addition of citric acid. The suspension is subjected to a heat treatment by injection of steam at 140 DEG C. for 10 s. The suspension thus treated is cooled to 30 DEG-35 DEG C. by expansion to atmospheric pressure.

In addition, to prepare a koji, 1 part soybean oil cake is mixed with 1 part water, the mixture is cooked in an autoclave for 15 mins. at 120 DEG C. and then cooled to 30 DEG to 35 DEG C. The cooked soya is mixed with crushed roasted wheat in a quantity of 70% soya dry matter to 30% dry matter of the roasted wheat. This mixture is inoculated with a koji culture in a quantity of 1 part spore culture or powder to 5,000 parts mixture. The mixture is left to ferment on wattles for a period of 44 h during which it is stirred twice in all and continuously aerated.

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This koji is added to the suspension cooled to 30 DEG-35 DEG C. in a quantity of 20% koji, based on the dry matter content of the suspension. Sodium chloride is added in such a quantity that the suspension has a sodium chloride content of 14%. The suspension is left to ripen for 15 days at that temperature.

The suspension is pressed in a hydraulio press. The insoluble fractions are removed by sedimentation.

The juice obtained is pasteurized for 30 mins. at 90 DEG C. and then clarified by passage through a filter paper.

The liquid flavouring agent obtained has a dry matter content of approximately 28%, shows good clarity and fluidity and has an agreeable, relatively neutral taste free from any bitterness.

EXAMPLE 2

The procedure is as described in Example 1 up to formation of the cooled suspension containing koji and sodium chloride.

The pH of the suspension is adjusted to 5.4 by addition of citric acid.

The suspension is inoculated with 2% by volume of a mixed culture of Saccharomyces rouxii and

Torulopsis etchelsii containing approximately 5.10@7 cells of each of these microorganisms per ml.

The suspension is then left to ripen for 4 weeks at 33 DEG C.

After ripening, the suspension is pressed in a hydraulic press. The juice is collected, left standing for 3 days and the insoluble fractions which have sedimented are removed. The juice is pasteurized for 15 mins. at 95 DEG C. and then clarified by passage through a filter paper.

The liquid flavouring agent obtained has a dry matter content of approximately 28 to 30%, perfect clarity, good fluidity and a stronger taste free from any bitterness.

EXAMPLE 3

The procedure is as described in Example 2, except that an aqueous suspension of a mixture of 60% defatted soya flour and 40% casein or lactoserum proteins is prepared.

The liquid flavouring agent obtained is comparable in its qualities with the flavouring agent obtained in

Example 2.

EXAMPLE 4

The clarified juice obtained in Example 2 is concentrated at a temperature of approximately 60 DEG C. under a pressure of 20 mbar to a dry matter content of approximately 75%.

The concentrated juice is then dehydrated to a dry matter content of 98% under reduced pressure in a dryer in which it is exposed to a temperature of approximately 70 DEG C. under a pressure of 20 mbar.

The dehydrated juice is ground in a hammer mill provided with a 1 mm square-mesh sieve.

A flavouring agent is obtained in powder form and may be used as a seasoning or may be reconstituted by dispersion in water in a quantity of 1 part powder to 3 parts water for example. The flavouring agent thus reconstituted is comparable in its qualities with the product obtained in Example 1.

This liquid, concentrated or powder-form flavouring agent may be used equally well as such as an ingredient in the composition of food products. It may also be used as a starting material rich in free amino acids capable of reacting with reducing sugars to make bases for the preparation of sauces or soups.Data supplied from the esp@cenet database - Worldwide Claims:


1088/2197

We claim:

1. A process for the production of a flavoring agent comprising hydrolyzing an aqueous suspension of a protein material having a pH of from 6.0 to 11.0 with a protease selected from the group of proteases consisting of neutral and alkaline proteases having an activity of from 0.2 Anson units to 12 Anson units per 100 g dry matter of the suspension to solubilized protein in the suspension, heat-treating the hydrolyzed suspension at a pH of from 4.6 to 6.5 for from about 10 seconds to about 30 minutes at a temperature of from about 90 DEG C. to about 140 DEG C., cooling the heat-treated suspension and then treating the cooled suspension with enzymes obtained from koji to ripen the suspension to obtain a ripened suspension containing a flavoring agent.

2. A process according to claim 1 wherein koji is added to the cooled suspension to provide the enzymes to treat the cooled suspension.

3. A process according to claim 2 wherein the koji is added to the cooled suspension in an amount of from 2% to 50% koji by weight based on dry matter of the suspension.

4. A process according to claim 1 or 2 or 3 wherein the aqueous suspension is hydrolyzed for from 2 hours to 8 hours at a temperature of from 50 DEG C. to 75 DEG C.

5. A process according to claim 1 or 2 or 3 wherein the aqueous suspension of the protein material has a pH of from 8-10 and the hydrolyzed suspension is heat-treated at a pH of from 4.9 to 5.9.

6. A process according to claim 1 further comprising adding sodium chloride to the cooled suspension so that the suspension contains sodium chloride in an amount of from about 10% to 17% by weight.

7. A process according to claim 2 or 3 further comprising adding sodium chloride to the cooled suspension so that the suspension contains sodium chloride in an amount of from about 10% to 17% by weight.

8. A process according to claim 7 wherein the ripening treatment is carried out for form 2 days to 20 days at a temperature of from 20 DEG C. to 40 DEG C.

9. A process according to claim 7 further comprising adding a culture of halophilic yeast to the cooled suspension to treat the ripen the cooled suspension.

10. A process according to claim 9 wherein the cooled suspension has a pH of from 4.9 to 5.9.

11. A process according to claim 9 wherein the culture of the halophilic yeast is selected from the group of yeasts consisting of cultures of Sacchromyces rouzii, Torulopsis etchelsii and mixtures thereof containing from 10@7 to 10@8 cells per ml and is added to the cooled suspension in an amount of from 1% to 5% by volume.

12. A process according to claim 9 wherein the ripening is carried out for from 1 week to 8 weeks at a temperature of from 20 DEG C. to 40 DEG C.

13. A process according to claim 1 or 2 or 3 further comprising pressing the ripened suspension to obtain a juice and then pasteurizing the juice and clarifying the pasteurized juice.

14. A process according to claim 9 further comprising pressing the ripened suspension to obtain a juice and then pasteurizing the juice and clarifying the pasteurized juice.Data supplied from the esp@cenet database - Worldwide

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222.

JP5096187 - 4/20/1993

METHOD FOR POLISHING RICE TO CONTROL ITS COOKING

CHARACTERISTIC


Inventor(s): ROBIN DEII ANDORIYUUZU (--); DEBORA ROTSUKU (--); JIYON EI MAN (--

); JIEEMUZU II SUTOROIKU (--)

Applicant(s): RAISUTETSUKU INC (--)

IP Class 4 Digits: A23L; B02B

IP Class: A23L1/10; B02B3/00

E Class: A23L1/182



Family: JP5096187

Equivalent: EP0505119; US5208063; BR9201066; CA2063094

Abstract:


PURPOSE: To provide an improved method for changing the cooking characteristic of milled white rice and the texture of the cooked rice. CONSTITUTION: This process involves varying only the milling degree to remove either more or less of the aleurone and sub-aleurone layers of the rice grain.

A rice variety or hybrid with one fixed set of physiochemical properties may be milled to produce milled white rice having cooked rice qualities and processing behavior normally associated with a different set of physiochemical properties.Description:



This invention relates to methods for milling rice, and more particularly, processes to control the cooking behavior and cooked rice properties of such rice by varying milling methods alone.


Rice is one of the leading food crops in the world and many different types of rice are consumed.

Quality preferences in various countries and regions are diverse. Preference may originate from naturally occurring local plant types which produce grains with specific properties, or be associated with the utensils available for cooking and eating, or with the nature of local foods which accompany rice and also the availability and convenience of cooking methods. For example, chopsticks are associated with the use of sticky rice, curry eaters prefer dry and fluffy rice, instant rice (precooked, dried and then reconstituted) has different properties but convenience of preparation results in some

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consumers preferring that type of rice.Some consumers prefer highly polished rice which is very white after cooking, other consumers prefer brown rice which has a higher bran and dietary fiber level.

The rice industry, which includes breeders, farmers, processors and marketers, respond to consumer preferences around the world by developing and producing a vast array of varieties and hybrids of rice and products from rice.

Attempts at controlling the cooking characteristics of a rice variety or hybrid deal with determining various physicochemical parameters of breeds of rice and then cross-breeding or hybridization to arrive at proper amylose content, gelatinization temperature, gel consistency, grain dimensions and other such parameters. Broad classifications for amylose are low, medium and high. Classification for gelatinization temperature are low, intermediate and high. Classification for gel consistency are soft, medium and hard. Grain dimensions are used to classify rice as long, medium or short. These tests and classifications are used for milled raw white rice. The tests and classifications are modified when used for parboiled rice. Amylose has been considered as the most important characteristic for predicting rice cooking and processing behavior.The economic value of the rice grain is largely determined by cooking and processing behavior, grade and milling yield.

The breeding into a rice variety of a combination of desirable physicochemical properties, taste, aroma and elongation during cooking results in considerable breeding time, cost and complexity. For the development of hybrid riceit is necessary to add the complexity of breeding in the traits of male sterility and restoration properties. Breeding and parboiling have been the principal way that cooked rice qualities have been imparted to a particular rice in the prior art.

A process or procedure which reduces the need to breed different combinations of physicochemical properties into a rice, and yet obtain differing cooking characteristics normally associated with such differing properties, would significantly improve the efficiency of producing a commercial rice with particular characteristics.


The invention is a process for changing the cooking behavior and cooked rice texture of a given milled rice when cooked in a predetermined way and includes the step of varying only the milling degree of the rice by milling the rice to a greater degree to produce cooked rice which is substantially softer and stickier, or by milling the rice to a lesser degree to produce cooked rice which is substantially fluffier and drier.

One aspect of the invention applied to production control includes the steps of obtaining the milling degree of any acceptable rice when cooked, test milling and cooking a second lot of rice, determining the differences in cooking behavior and rice texture when cooked of the acceptable rice and the second lot, and varying only the milling degree of the second lot to compensate for the differences and yield a uniform production run.

Another aspect of the invention includes the steps of selecting a rice having predetermined cooking behavior and texture when well milled and varying only the milling degree of that rice to produce, after the same cooking procedure, either a substantially fluffier and drier cooked rice by milling said rice to a Satake milling degree ("SMD") of about 78 or less, while producing a rice transparency of about 2.0 or greater, or to produce a substantially softer and stickier cooked rice by milling the rice to a SMD of about 100 or greater.

The invention calls for the use of varying and controlled degrees of milling which supplements, and in some cases overrides, the impact of apparent amylose content and other physicochemical characteristics in determining the cooking and processing behavior of white milled rice and the texture qualities of the cooked product. In accordance with the invention one can, for example, take a variety classified as medium amylose and intermediate gelatinization temperature (which normally produces a somewhat dry and fluffy cooked rice product) and by milling to a very high degree produce a rice

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which cooks sticky and glutinous as if it were produced from a low amylose, low gelatinization temperature class of rice.

In accordance with the invention one can take the same variety, classified as medium amylose and intermediate gel temperature, and by uniformly milling to an unusually low degree produce a white rice product which cooks to produce grains of high integrity and firmness. This product has many of the characteristics of very high amylose rice or parboiled rice. When cooked in excess water, as in the boilinbag cooling process, the product is drier and less mushy than when a regular raw well-milled rice is used. When processed into instant rice, the product has better grain integrity and texture. The low milling degree also increases the amount of aroma and taste compound, 2-acetyl-1-pyrroline, in milled aromatic white rice.This compound is present at higher levels in the bran and surface layers of the rice and low levels of milling retain more of the compound in the milled rice.

Brief Description of the Drawing

Fig. 1 is a graphical representation showing transparency, whiteness and and Satake milling degrees of several samples of rice as determined by the Satake optical milling degree meter and areas corresponding to surface bran remaining on rice classified by the colored bran balance index.

Description of the Preferred Embodiment

One embodiment of the present invention involves varying the milling degree of well milled medium amylose, intermediate gelatinization temperature ("gel") rice so that the rice will cook substantially softer and stickier than the well milled rice when cooked in the same way. To achieve that product, the rice is milled to 100 or greater Satake milling degrees. The same rice may be milled to 78 or less

Satake milling degrees and display the cooking behavior and dry, fluffy cooked rice texture of low gel, low amylose varieties.

Industry conventions describe methods for measuring the degree of milling and classify the techniques into two main groups: (1) those that estimate the quantity of (a) removed bran or (b) residual bran and

(2) those that measure the effects of removal of outer layers of the rice grain on (a) optical characteristics or (b) chemical composition of the final milled product.

The measurement of removed bran can be made by weighing the rice before and after milling. The weights of 1,000 whole grains of rough rice, brown rice and milled rice can be used to measure the percentage by weight of hulls removed to produce brown rice and the percentage by weight of bran removed to produce milled rice. The latter is a measure of degree of milling on a removed bran basis.

Another technique involving the indirect measurement of removed bran utilizes milling efficiency data.

When a sample of rice is tested for milling efficiency on a milling test machine (e.g. a McGill machine) usually for a fixed milling time, the total milling efficiency is measured and also the percentage by weight of whole unbroken grains is measured. The percentage by weight of milled rice produced from a given weight of rough rice is known as the total milling efficiency. It will be evident that if the percentage by weight of hulls is constant then changes in total milling efficiency represent changes in the degree of milling on a removed bran basis.

The measurement of residual bran is usually carried out in the US milling industry by the visual comparison of a milled rice sample against USDA standards arranged in a sample box. Each box contains three standards representing the lower limits for "well milled" (U.S. No. 1 and No. 2),

"reasonably well milled" (U.S. No. 3 and No. 4), and "lightly milled rice" (U.S. No. 5 and No. 6). A sample is compared to the three standards and graded. A separate sample box is provided for long grain, medium grain and short grain rice to prevent grain shape from detracting from the comparison of surface bran levels.

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A more objective evaluation of residual bran utilizes the differential staining of bran and endosperm with May-Grunwald reagent (a mixture of eosin and methylene blue dissoled in methanol) followed by an assessment of the percentage of the grain area (plane image) which is covered by bran. The measurement is known as the Colored Bran Balance (CBB) index. The measurement is made by placing a standard glass plate with an engraved reticle (1 cm grid) over the previously stained grains and the number and percentage of crossover points located on bran is counted. A lower CBB reading indicates a lesser amount of bran on the rice grain surface.

The Satake Milling Meter measures the optical characteristics of the milled rice. In the Satake Milling

Meter (MM-1B, Satake Engineering Co., Ltd., Tokyo, Japan), a halogen lamp provides light which is passed through an intervening filter, center wave length 450nm, and projected onto the grain sample.

The amount of reflected light and transmitted light are measured using a photo diode. The reflected light is displayed as a measure of whiteness (W) and the transmittal light is displayed as a measure of transparency (T) respectively. The two measurements are combined to give a "Satake Milling Degree"

(SMD) measurement. Brown rice has a Satake Milling Degree of zero and the SMD increases progressively as the outer layers of the rice are milled away. The removal of 10% by weight of brown rice by milling might give an SMD of 100, for example.

It is necessary to relate selected measurements of white rice milling degree to normal milled industry standards and practice. The following table shows Satake Milling Degree measurements (SMD; W = whiteness; T = transparency), CBB index and percentage of grains with bran for a typical set of USDA milling standards: EMI6.1

The results show that the well milled standard approximates a 20 CBB index, the reasonably well milled standard approximates a 40 CBB index and the lightly milled standard approximates a 60 CBB index. It can be seen that the test measurements of the USDA standards vary somewhat since several varieties are included in the standards and the samples are used on the basis of visual appearance of surface bran level.

It is believed that the optical measurements of milling degree, such as the Satake milling degree meter, provide meaningful determination of grain surface character and of the amount of outer layers of rice which have been removed in milling. With the use of such testing machines, the milling process can be more closely controlled, and the teachings of the present invention applied with well known milling equipment to measure the effects of the process embodiments set forth herein.

Key results from the practice of this invention can be understood by examining the following tables.

The tables are constructed to summarize the findings from a number of experiments which show the effect of degree of milling, for rices of differing apparent amylose percentage, on cooking behavior and cooked rice qualities.

The range of amylose shown (18% to 30%) covers typical commercial rice varieties excluding waxy rices of extremely low amylose levels. The range of milling degree shown (70 to 115 SMD) extends below normal commercial white rice (abut 85 SMD). A low milling degree level of 70 SMD can be achieved with acceptable grade (U.S. No. 1 or No. 2) using the procedures described herein. The range of milling degree shown extends above that normally used for medium amylose commercial white rice

(80-95 SMD) to a level of 115 SMD. This high level of milling degree is used commercially for low amylose white rice produced for Asian consumers who prefer highly polished and whitened rice with no traces of bran.

The tabulated results represent rices cooked in a Panasonic Rice Cooker using the measured water technique. The cooked rice firmness measurements are from using, a Pabst Texture Tester taking the average shear value of the final two "bites". The stickiness measurements are from experiments where rices of differing properties and cooking conditions but equal firmness are ranked for stickiness and grain integrity. All data has been smoothed statistically to show the primary effects for the cooking procedures and test methods used.

The firmness of cooked rice can be measured using a Pabst Texture Text System. The tester has a one inch cube shear cell which holds 10 gm of cooked rice. The movable cell wall is connected to a force measuring device and has seven teeth which mesh with five stationary teeth, "biting" the cooked rice

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sample. During a test the cell wall moves through a programmed cycle of compression and reversals to yield a shear/displacement curve from a connected computer. The temperature of the sample is measured by a thermocouple in the cell. A typical test cycle involves three "bites", the first bite reduces test cell volume by 34%, the second 55% and the final bite is 100%. The test data profiles can be analyzed in many ways and the profiles of different rice samples precisely compared.In this way, for example, rices of differing starch properties cooked under differing conditions can be evaluated to determine alternative ways of producing rice of identical firmness. The Pabst Texture Test System can utilize different cell designs and compression cycles to explore various characteristics of cooked rice including stickiness.

A simple "cup test" can be used for measuring the grain stickiness of cooked rice. The cooked rice is fluffed with a fork and then carefully spooned into a round flat bottomed cup (height and diameter 2.5 inches). The rice is not pressed into the cup but voids are filled in. A plate is placed over the cup and both are turned over. The cup is carefully removed and the mound of rice is observed for several- minutes. Sticky rice maintains the shape of the cup and eventually sets into a glutinous mass and the height and width of the mound are equal. In this case the rice is rated 1 for stickiness. Less sticky rice immediately falls apart when the cup is removed, the shape of the cup disappears and the maximum diameter and height of the mound of separate grains is in the ratio of about 5 to 1. In this case the rice is rated 5 for stickiness.Intermediate degrees of stickiness are rated, 2, 3, and 4. EMI9.1 EMI9.2

EMI9.3

It will be apparent from the above tables that changes in degree of milling are extremely important relative to cooking behavior and cooked rice properties. Tables 1 and 2 above illustrate that a medium amylose rice with an 85 SMD can be softened and made stickier by milling to a 115 SMD. This product is similar to a low amylose rice at a low milling degree. Table 3 shows that increasing milling degree reduces cooking time in a similar manner to the lowering of amylose. Similarly, medium amylose rice can be milled to a low degree to produce cooking behavior and cooked rice properties more like higher amylose rice.

The significance of these findings can be further illustrated by describing a number of examples in which the cooking qualities of specific varieties are changed by utilizing certain embodiments of this invention.

Example 1.

Rice variety RTA 1002, a medium amylose, intermediate gelatinization temperature rice, was dehulled and then milled using a Satake commercial abrasion milling machine (Satake Engineering Co., Ltd.,

Tokyo, Japan, model RMB). When well-milled, this variety is classified medium amylose (24% apparent amylose by weight) intermediate gel (alkali spreading value 2.4). The machine was adjusted to produce a 68 SMD for Sample 1, and readjusted to produce a 92 SMD for Sample 2. A second pass through the machine of Sample 1 product, milled still longer, produced rice Sample 3 with a 116 SMD.

The amylose percent and the alkali spreading value of each sample was measured.

Cooking behavior was evaluated by bringing 50g. samples of milled rice product in excess water to the boil and simmering for various times. Times of 10 minutes, 15 minutes and 20 minutes were evaluated for each sample. The stickiness of each cooked rice sample was assessed using the "cup test" and the moisture content of each cooked rice sample measured.

The results were as follows: EMI11.1

The results show that milling rice to a higher degree accelerates the rate of moisture absorption during cooking in excess water and that high milling degree rice is stickier at a given moisture content than low milling degree rice. Measurements of amylose and alkali spreading value show slightly higher apparent amylose measurements on the stickier rice. Higher amylose rice, according to prior art, would be expected to give a less sticky rice. The extraction of lipids from a rice sample before conducting the amylose test is known to increase the amylose measurement of medium amylose rice by about 2 percentage points. Measurements of % amylose on rice without lipids extraction is referred to as

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"apparent % amylose." All references to "amylose %" herein refer to apparent percent amylose content by weight.The higher apparent amylose levels measured on the high milling degree rice probably reflects the removal of more of the high lipid content outside layers of the grain at high milling degrees.

The changes in alkali spreading value with milling degree are not considered significant.

Example 2.

A sample of RTA 1002 (24% amylose, 3-5 alkali spreading value) was milled to a high milling degree

(115 SMD) and cooked and compared to a purchased sample of Jasmine 85 rice, produced and marketed by the Douget-Dishman Rice Company. Jasmine 85 (IR841) is a low (17%) amylose, high gelatinization (alkali spreading value 6.5) rice variety available for purchase in the United States.

Samples were cooked in excess water by dropping 50 g. of rice into simmering water for 10 minutes,

15 minutes, 20 minutes and 25 minutes. The moisture content of the cooked rice samples were compared. Cup test measurements of stickiness were made.


The results showed that the high milling degree, medium amylose, intermediate gelatinization rice

(RTA 1002) absorbed water as rapidly as the lower milling degree, low amylose, low gelatinization temperature rice (5-85). Importantly, and contrary to prior art expectations, the medium amylose rice was as sticky as the low amylose rice. The higher milling degree of the medium amylose rice resulted in higher stickiness and a higher rate of cooking than prior art would have suggested.

Example 3.

Dehulled RTA 1002 is fed continuously to an IRM30 Satake Abrasion Milling Machine using a 30 grit stone at 750 RPM with the back pressure adjusted to achieve a 45 SMD. The output from this machine is fed to a KB40 Satake Polishing Machine operating at 850 RPM with the use of a water/air mixture to soften and remove the bran. The output from the process is a low milling degree rice with a 69 SMD

(Whiteness 35, Transparency 2.4). When tested using the May-Grunwald differential dye test the product showed visible bran on 67% of the grains, a Colored Bran Balance index of 8 and the sample was visually determined to surpass the minimum USDA standard for well milled white rice. The cooked rice showed only a small number of grains with bran streaks and was acceptable in overall appearance.

Fig. 1 shows examples of test results using the Satake Milling Degree meter for the USDA standards and various commercial white rice products. Also shown is the product from the process described in this example (P3) and that from Example 2 (P2).

As may be seen by reference to Fig. 1, various commercially available milled white rices were tested for whiteness, transparency and Satake milling degree. Numerals and letters of the rices tested are:

Commercial Brands

1. Texmati Lite Bran, long grain

2. Texmati White Rice, long grain

3. Food Club, long grain

4. Mahatma, long grain

5. Wonder, long grain

6. Seven Star, basmati

7. Al Baari, basmati

8. Super Pari, basmati

9. Rani, basmati

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10. Nishiki, medium grain

11. Watermaid, medium grain

12. Kroger, medium grain

13. Kokuho Rose, medium grain

14. Thai Jasmine, long grain

USDA Long Grain Standards

A-Well milled

B-Reasonably well milled

C-Lightly milled

Example 4.

In this example a rice variety RTA 1002 is milled using three different combinations of abrasion milling and water-polishing steps to produce milled rice of essentially the same degree of milling but with different degrees of polish and surface bran removal. Although elsewhere herein only the term

"milling" is used to describe the bran removal operation, it can include polishing steps of varying lengths of time and other polishing conditions, as is well known in the art. The percentage of the grains with bran was measured using the May-Grunwald dye test. The process descriptions show the change in Satake Milling Degree at each step of each process: EMI14.1

No significant differences in cooking behavior were found between the three samples. Bran streaks were visible on the cooked rice samples in line with the results from the May-Grunwald dye test shown above. However the least polished rice, (which had the highest level of bran streaks), was still acceptable and met the USDA standard for well milled rice.

Example 5.

In this example a very high amylose variety, "LC31", is milled to produce samples of a low milling degree and a high milling degree and compared to samples of a medium amylose variety "Labelle" also milled to a low and high degree.

Samples were cooked in measured water at three water-rice ratios by weight using a Panasonic rice cooker. The cooked rice samples were tested using the Pabst Texture Test System and the Cup Test for stickiness.


The test results showed the importance of water-rice ratio (moisture) and amylose percent in determining cooked rice texture as known in the prior art. However, the results also show that degree of milling is of equal or greater importance to cooked rice texture and that a medium amylose rice can be made to behave more like a high amylose rice by milling to a lower degree.

Example 6.

In this example six different varieties of rice, two of low amylose, two of medium amylose and two of high amylose are milled to a high degree ( 120 SMD) and to a low degree (70 SMD). Samples of each are cooked at three water-rice ratios as in Example 4 above and tested using the Pabst Texture Test

System and the Cup Test. The results of the tests were statistically analyzed using a regression calculation and it was established that cooked rice texture (firmness and stickiness) can be estimated

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from a knowledge of the amylose percent by weight, milling degree, water-rice ratio and the temperature of the cooked rice in the Pabst Test cell.

These same rice varieties were then milled to provide samples of a Satake milling degree of 115, 100,

85 and 70. These samples were then cooked at the water-rice ratios required to produce cooked rice of a uniform Pabst firmness value of 6 kg. This ratio was determined from the regression equation. The cooked rice samples were then ranked in terms of grain integrity and stickiness by a team having no knowledge of the sample identities. The results were analyzed statistically and are shown in Table 4. It is clear that degree of milling has a substantial effect on cooked rice texture for rice products of differing amylose levels cooked to constant firmness. EMI17.1

Table 4 illustrates that by changing water ratio to achieve the same firmness with rices of different amylose and milling degree it is possible to produce high milling degree, 115 SMD, intermediate amylose cooked rice which is perceived to be stickier than low amylose normal, 85 SMD, cooked rice.

The subjective grain integrity and stickiness was judged by human testers applying the standard of 1 for stickiest low integrity rice and 48 for least sticky high integrity rice.

Example 7.

This example demonstrates the manner in which degree of milling can change in the course of the commercial milling of a specific variety and the need to precisely control the milling process and/or the subsequent cooking process to achieve a uniform processed product such as instant rice.

Samples of rice lots of variety RTA 1002 produced from different farms were milled in a McGill laboratory milling machine to isolate samples which differed in Total Milling Yield when milled for the same time. It was to be expected that these samples would differ in degree of milling and this was the case: EMI17.2

Analyses of several lots of this variety, milled at different times over a period of several months, in a commercial mill, using conventional visual milling degree controls, showed that milling degree varied with milling efficiency. Low mill efficiency was associated with high milling degree of the tested rice and high milling efficiency was associated with low milling degree of the tested rice. Changing the milling degree in accordance with this invention has been discovered to cause changes in cooked rice texture when the rice is cooked under constant conditions.By changing the method of operating the commercial rice mill to alter mill machine settings based on the testing of incoming rice for milling efficiency by using a test miller and then supplementing the results with actual measurements of milling degree on product exiting the commercial mill using the Satake Milling DegreeMeter, the range of product milling degree can be narrowed.

Example 8.

This example demonstrates the manner in which degree of milling can be used as a method of improving the uniformity of cooking behavior and cooked rice texture of milled white rice to compensate for variations in the starch properties of rouch rice being used by the mill. Example 7 illustrates the way in which ease of milling and milling degree may vary from lot to lot. These variations can be ameliorated by test milling lots fed to the mill and then modifying milling conditions to maintain constant milling degree. In this example the cooking behavior and cooked rice texture variation between lots of rice being fed to the mill is measured directly or indirectly. The milling conditions are then changed to produce milled rice of varying milling degree but more constant cooking behavior and cooked rice texture.

The amylose levels and alkali spreading values (ASV) of different lots of rice of the same variety will differ as a result of factors such as growing conditions and environment. Amylose content within a variety can vary by as much as 6 percentage points. Temperature during grain ripening has been shown to affect amylose content and ASV with both of those starch properties generally decreasing as the

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mean temperature increases. The following table (from the literature) shows the effect in terms of growing latitude for two varieties: EMI19.1 Similarly the variety RTA 1002, in which two crops are possible from the same planting (first crop and ratoon crop), shows an effect on alkali spreading value due to the cooler temperatures during ripening of the ratoon crop: EMI19.2 These changes in starch properties have an effect on cooking behavior and cooked rice texture.

One embodiment of the present invention may be used to produce a product of more uniform cooking behavior and cooked rice texture from rice of varying starch properties. First, a sample of each lot is test milled to the same milling degree, cooked and tested for product firmness and stickiness. The difference between the results are calculated and then the test milling degree of one or other or both samples is changed to achieve the same desired level of firmness and/or stickiness from the different lots. These milling degree targets may then used by the commercial mill to produce more uniform cooking rice from the two lots.

This technique is illustrated in the following table. Samples from both the first and ratoon crops from

Farm A were tested at the same milling degree and the ratoon crop rice was found to cook to a firmer texure. The samples were tested for firmness after cooking in an electric rice cooker at a below normal water-rice ratio of 2.00 to exaggerate the cooked rice hardness difference between samples. A normal water-rice ratio for this medium amylose rice would be 2.25.

The ratoon crop sample was then laboratory milled to a much higher degree of 113 SMD and retested.

The higher milling degree resulted in a cooked rice firmness reduction of approximately 15% and the texture of the cooked rice sample was more similar to that of the first crop. EMI20.1

To bring the first ratoon crop cooked product textures even more closely in line the commercial mill targets were set at an 80 SMD for the first crop and a 115 SMD for the ratoon crop.

Thus it can be seen that an invention for novel rice milling has been shown. Other embodiments of the process may be utilized without departing from the inventive concept. Steps of certain of the embodiments may be rearranged in order and the invention used to process other varieties and to produce other rice products having special texture characteristics, all as would be apparent to one skilled in the art.Data supplied from the esp@cenet database - Worldwide Claims:


1. In a process for changing the cooking behavior and cooked rice texture of a given milled rice when cooked in a predetermined way, the improvement comprising:

varying only the milling degree of said rice by

milling said rice to a greater degree to produce cooked rice having substantially softer and stickier texture; or,

milling said rice to a lesser degree to produce cooked rice having substantially fluffier and drier texture.

2.In a process for maintaining uniform cooking behavior and cooked rice texture in a production run of a milled rice, the combination of steps comprising:

obtaining the milling degree of a lot of rice conforming to acceptable cooking behavior and cooked rice texture qualities;

test milling a sample of a second lot of rice of the same type in a uniform way;

cooking a sample of said second lot of rice in a uniform manner;

determining the differences in cooking behavior and cooked rice texture of said first lot and said second lot; and

varying only the milling degree of said second lot of rice to compensate for differences in cooking behavior and cooked rice texture between said first lot and said second lot.

3.In a process for milling dehulled rice the steps comprising:

selecting a rice having predetermined cooking behavior and qualities of texture, after cooking by a predetermined cooking procedure, when well-milled;

varying only the milling degree of said rice to produce, after a predetermined cooking procedure, a substantially drier and fluffier rice by milling said rice to a Satake milling degree of about 78 or less

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and a transparency of about 2.0 or greater or to produce a substantially softer and stickier rice when cooked by milling said rice to a Satake milling degree of about 100 or greater.

4. The process as claimed in claim 3, wherein:

The apparent amylose content of said rice milled to more than 100 Satake milling degrees is greater than about 19% by weight.

5.A milled rice produced according to the process of claim 3 and possessing the characteristics selected from the groups consisting essentially of (a) a Satake milling degree of about 100 or greater and having greater than about 19% apparent amylose content by weight, and (b) a Satake milling degree of about

78 or less and a transparency of about 2.0.

6.In a process for milling dehulled rice having predetermined cooking behavior and qualities of texture after cooking by a predetermined cooking procedure when well milled, the improvement comprising:

milling said rice to about 78 Satake milling degrees or less, thereby increasing the dryness and luffiness of the milled rice when cooked, while increasing the transparency of the milled rice above about 2.0;

or milling said rice to about 100 Satake milling degrees or more, thereby increasing the softness and stickiness of the milled rice when cooked.

7. The process as claimed in claim 6, wherein:

the apparent amylose content of said rice milled to about 100 Satake milling degrees or more is greater than about 19% by weight.

8.In a process for changing cooked rice texture and cooking behavior of a given dehulled and milled rice when cooked by a consistent cooking procedure, the step comprising:

varying the Satake milling degree of said milled rice to about 100 or more to produce a softer and more sticky rice or to about 78 or less to produce a firmer and less sticky rice, while increasing transparency of said milled rice to greater than about 2.0.

9. In a process for milling rice, the combination of steps comprising:

selecting a rice type having predetermined qualities of cooking behavior and texture when dehulled, well milled and cooked following a predetermined cooking procedure;

milling said rice to a set of parameters selected from the groups consisting essentially of:

(a) a Satake milling degree of about 100 or greater and an apparent amylose content greater than about 19% by weight; and

(b) a Satake milling degree of about 78 or less and a transparency of 2.0 or greater, thereby producing a softer and stickier cooked rice texture when milled to the parameters of group (a) and firmer and less sticky rice when milled to the parameters of group (b).Data supplied from the esp@cenet database -

Worldwide

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223.

JP52010437 - 1/26/1977

PRODUCTION OF INSTANT RICE


Inventor(s): MIURA CHIAKI (--); UTENA MAKOTO (--); KAMATA EIKI (--)

Applicant(s): KARUPISU SHIYOKUHIN KOUGIYOU K (--)


IP Class: A23L1/18

E Class: A23L1/182; A23L1/18F



Family: JP52010437

Equivalent: US4101683; BE844225

Abstract:

Abstract not available for JP52010437


Fast cooking rice which readily reconstitutes itself into cooked rice is manufactured by a process which comprises causing a specified thickener to be diffused from the surface to the inside center of rice grains puffed in advance to a high degree and subsequently subjecting the treated puffed rice grains to drying and shrinking treatments.Description:



Cooked rice which is a staple food in the countries of East Asia is so-called "steamed and boiled rice".

It is cooked by a time-consuming procedure which comprises the steps of first washing raw rice (which means hulled rice in the instant specification and claims) with water, allowing the washed rice to absorb water amply and thereafter steaming and boiling the water-impregnated rice for a long time.

Ample impregnation with water and an appropriate extent of boiling and steaming are required for preparing the cooked rice of soft texture and agreeable teeth-resistance. Then requirement for rigid control of these conditions prevents a quick cooking. The fact that this cooking consumes much time also constitutes one disadvantage.

Another typical example of cooked rice is pilaf. This is prepared by frying washed rice with oil, whereafter the fried rice is steamed and boiled in the presence of added water. It has the disadvantage that the texture is generally hard. This disadvantage can be overcome by continuing the treatment of steaming and boiling for a relatively long time. Nevertheless, it still has a drawback in that the cooking consumes much time. In view of the above, there is, a need for development of fast cooking rice which readily provides cooked rice of the class described above.

What is called "gelatinized rice" has heretofore been regarded as a kind of fast cooking rice. This is usually prepared by subjecting the rice to the ordinary treatment of steaming and boiling for thereby gelatinizing the rice starch and thereafter drying the starch-gelatinized rice. By mere addition of hot water at a temperature of about 80 DEG C or over, however, the fast cooking rice prepared as

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described above fails to reconstitute itself into cooked rice possessed of desired texture. It is not converted into desirable cooked rice unless it is boiled for several minutes by heating. Such timeconsuming treatment does not befit the fast cooking rice for which the instantaneousness counts strongly.

A method which produces cooked rice by mere addition of hot water has been disclosed by Japanese

Patent Publication No. 5729/1959. The method disclosed therein comprises first steaming and boiling the raw rice to a extent mild enough to pregelatinize the surface layer of the rice grains, then causing the steamed and boiled rice to absorb a paste such as dextrin or sodium carboxymethyl cellulose, subjecting the treated rice to a treatment for regular steaming and boiling for thereby completely gelatinizing the rice grains to the inside center and finally drying the gelatinized rice. The fast cooking rice which is obtained by this method has the disadvantage that, when hot water is added thereto immediately before its consumption, the required reconstitution takes much time or the reconstituted rice has a rather hard texture, possibly because the rice, in the final treatment of drying, suffers partial retrogradation of the rice starch which has once been gelatinized. Furthermore, the process of manufacture is complicated.

Studies have also been continued with a view to producing fast cooking rice which can be reconstituted into as exact an equivalent of regular boiled and steamed rice as practicable. For example, there is a method which utilizes puffed rice, with due consideration of the fact that gelatinized rice is obtained by puffing rice grains. If simply puffed rice is used as a fast cooking rice, it is quickly softened in the presence of hot water added thereto prior to its consumption. Nevertheless, it has the disadvantage that the hot water deprives the rice grains of their shape and renders them quite different from regular boiled and steamed rice in taste, texture, viscoelasticity, etc. Japanese Patent Publication No.

27700/1971 discloses a method which comprises the steps of first puffing raw rice to a slight extent, then immersing the puffed rice in water for thereby heightening the water content thereof, subsequently gelatinizing the puffed rice of increased water content, thereafter drying the gelatinized rice until the water content thereof decreases to a prescribed level and finally re-puffing the dried rice. The fast cooking rice produced by this method, however, suffers from an undesirable spongy texture and poor teeth-resistance. It has the further disadvantages that the process for manufacture is complicated and the yield is consequently low.

As described above, there have been conceived methods for the manufacture of fast cooking rice which combine the treatment of puffing with other treatments. These conventional methods, however, are complicated from the operational point of view because the water content of rice grains must be rigidly regulated in the course of treatments and consequently because the rigid regulation of water content calls for additional treatments, and so on. Methods which involve use of oil and fat are not desirable because the oil and fat incorporated into the rice grains degrade the taste and induce oxidation of said oil and fat to the extent of heavily impairing the quality of fast cooking rice. Also, the removal of excess oil and fat in the course of manufacture demands much time and labor.


The primary object of the present invention is to provide a process for the manufacture of fast cooking rice easily and providing cooked rice which, when served for meals, retains the shape of rice grains unimpaired, and permits the rice grains to remain in their inherent shape and also excels in texture, taste, flavor, etc.

Another object of this invention is to provide a fast cooking rice which is so easily reconstituted that it can be ready for a meal after several minutes of standing in hot water of a temperature of not less than about 80 DEG C.

Still another object of the present invention is to provide a fast cooking rice which is so easily reconstituted that it affords pilaf of a desirable texture after several minutes of cooking such as in a frying pan in the presence of a small amount of water and, by preference, of some oil added thereto.

Yet another object of this invention is to provide a fast cooking rice capable of a wide range of applications such that it readily produces curry-flavored fried rice and many other kinds of cooked rice when cooked in combination with seasoning agents, dry vegetables, dry meat and other foodstuffs.

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It is also an object of this invention to provide a simple process for the manufacture of fast cooking rice without entailing complicated steps of treatment from the operational point of view.


A study continued with a view to materializing the objects of this invention has led to the discovery that a fast cooking rice of excellent quality can be obtained by a simple process by using specific additives. This invention has been accomplished on the basis of this discovery.

In brief this invention comprises the steps of preparing a rice puffed to a high degree and adding to the puffed rice the additives to be described herein below and a step of drying and shrinking the treated puffed rice grains. Thus, this invention is characterized by the combination of the rice puffed in advance to the extent of acquiring an enhanced-porous texture and having incorporated the specific additives. The invention will be described in further detail below.

The first step is to prepare rice puffed to a high degree. The rice grains to be used in making the puffed rice may be of any of the numerous species available. For the purpose of this invention, the puffed rice grains obtained by any methods other than the method resorting to the treatment in heated oil and fat can be used. For example, the puffed rice obtained by first treating rice grains in a closed container kept at elevated temperatures under increased pressure and releasing the rice grains into the atmosphere for thereby allowing them to puff, those puffed by means of heated air, those puffed by having rice grains heated with high-frequency waves and those puffed by having rice grains roasted in conjunction with heated grains such as of common salt, fine sand, ceramic, or those puffed by some other similar puffing method are all usable for this invention. The degree of puffing is desired to be from 6 to 16 times, preferably from 9 to 12 times, as large in volume (hereinafter the degrees of puffing will be expressed in terms of "volume") as the raw rice grains. The degree of puffing of the figures (6 to 16) as used in the instant specification and claims illustrates an average of each rice grain because the size and quality of each rice grain is different. For example, "6 times" includes the degree of puffing of a little bit smaller and also larger than 6 times.

Then the second step is to add a thickener to the puffed rice grains. The term "thickener" as used in the instant specification and also in the claims refers to polysaccharides of plant origin, their derivatives, polysaccharides produced by the use of microorganisms and some of the polymerized substances produced by artificial production including derivation and synthesis. The thickener to be used for the present invention will be concretely described herein below.

There are polysaccharides derived from marine plants: Agar, carrageenin, alginate, alginic acid and furcellaran belong to this class.

There are gums originating in plant seeds of the ground: Locust bean gum, guar gum, tamarind gum, psyllium seed gum, quince seed gum and gaz belong to this class.

There is karaya gum obtained from plant exudate. There is pectin which is derived from fruits. Besides, glucomannan which is contained in Amorphophallus Konjac in a large amount is also usable.

There are artificially produced thickeners: Propylene glycol alginate, low methyl ester pectin, sodium polyacrylate and cellulose derivatives such as carboxylmethylcellulose salt, methylcellulose, hydroxymethylcellulose, methylethylcellulose and hydroxypropylcellulose belong to this class.

There are microorganically produced thickeners: Xanthan gum, cardrun, scleroglucan, succinoglucan and pullulan belong to this class.

The present invention requires the use of at least one of the thickeners enumerated above.

To be more specific, by using a specific thickener selected from the thickeners enumerated above, there can be manufactured a fast cooking rice which produces cooked rice of more excellent texture after several minutes of standing with added hot water of a temperature of not less than about 80 DEG C.

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The fast cooking rice obtained with such a thickener, of course, is suitable for preparation of pilaf and other cooked rice.

The specifically selected thickeners consists of agar, carrageenin, propylene glycol alginate, carboxymethylcellulose salt, methylcellulose and glucomannan.

Now, the method by which the thickener is added to the puffed rice will be described. This addition is accomplished by causing the thickener to penetrate into the puffed rice. As a concrete method, it is desirable to employ one which uses the thickener in the form of an aqueous solution. For example, the addition is effectively carried out by immersing the puffed rice in an aqueous solution containing the thickener or by spraying or sprinkling said aqueous solution on the puffed rice. The advantage of this method is the fact that the individual rice grains can be uniformly treated throughout from the surface to the inside center. In contrast, the method of addition which uses the powdered thickener in its unaltered form fails to attain the object of this invention, because the thickener cannot uniformly penetrate into the interior texture of the rice grains.

Various conditions of treatment such as concentration of the aqueous solution of thickener and temperature will be described. It is natural that the conditions are variable to some extent because the thickeners themselves have properties different from one another. It is generally desirable, however, to avoid heightening the viscosity of the aqueous solution of thickener more than is required. If the viscosity of the aqueous solution is high, there is a danger that the treatment aimed at is obtained only on the surface of the puffed rice and not sufficiently inside the rice grains. Furthermore, the individual rice grains tend to conglomerate into lumps. The increase in viscosity further renders the handling of the aqueous solution itself difficult proportionally. Moreover, after the treatment by the addition of thickener, the required removal of the excess aqueous solution adhering to the puffed rice cannot be fulfilled satisfactorily. The high viscosity also raises a difficulty in immersing the puffed rice having a low specific gravity in the aqueous solution. The ranges of concentration suitable for the use of aqueous solutions of these thickeners are substantially similar and the other treatments such as for addition of thickeners can be carried out under similar conditions. The description, therefore, will be given generally to cover all the thickeners.

The concentration of the thickener in the aqueous solution should fall in the range of from 0.1 w/w percent to 1.0 w/w percent (hereinafter indicated invariably in percent by weight/weight), preferably in the neighborhood of 0.5 percent. The range of concentration, however, is variable slightly from one thickener to another. When the concentration fails to reach the lower limit 0.1 percent, the effect aimed at cannot be obtained satisfactorily. When it exceeds the upper limit 1.0 percent, however, the viscosity of the aqueous solution becomes so high that the solution cannot be handled easily, the individual rice grains tend to adhere mutually to form lumps and the final product has no desirable flavor.

The temperature of the aqueous solution is only required to be such as to permit thorough solution of the thickener. In the case of the aqueous solution of agar, for example, a temperature higher than 40

DEG C is enough. In the immersion of the puffed rice in the aqueous solution of a thickener, the duration of immersion can be decreased in proportion as the temperature of the solution is increased. In the use of 0.4% aqueous solution of agar, for example, the immersion given for ten seconds at 65 DEG or for one minute at 40 DEG C will suffice for the purpose. Where the addition is effected by spraying or sprinkling, the treated rice, as a matter of course, should be left to stand at rest for a while to ensure uniform and thorough penetration of the aqueous solution into the individual grains of puffed rice. No matter whether the addition is effected by immersion, spraying or sprinkling, the purpose of the treatment is attained insofar as the aqueous solution thoroughly penetrates to the inside center of the puffed rice which has a porous texture.

The final third step is to dry, by an ordinary method, the puffed rice with which the thickener has been incorporated as described above. The drying may be carried out under normal atmospheric pressure or under vacuum, either in the absence or in the presence of heating. During the drying, the individual grains of the puffed rice may be kept stationary or may be moved. The method of drying, therefore, can suitably be selected by taking into due consideration the amount of puffed rice, the desired duration of drying time (reflecting readiness of handling), the desired quality of the fast cooking rice to be produced, etc. Where the drying is effected by application of heat, due attention should be paid to avoiding excessive heating which frequently results in the occurrence of burnt rice emitting an

1103/2197

objectionable odor. Concrete examples of the drier well known for this purpose include a tunnel and band dryer, a chamber dryer, an infrared dryer, etc.

In consequence of the gradual vaporization of water, the puffed rice diminishes in volume eventually to approach the volume of raw rice while the incorporated thickener is retained throughout from the surface to the inside center of individual rice grains. To obtain a fast cooking rice which gives a desirable texture when served for a meal and yet is not so bulky as to impair the ease of handling, the process of drying is desirably terminated at the time by which the volume of the treated puffed rice has decreased to less than three times the volume of raw rice.

To the aqueous solution of thickener, to the puffed rice which has incorporated a thickener, or to the fast cooking rice which has undergone the treatment of drying, various seasoning agents, nutrition enriching agents, color-improving agents, etc. may be suitably added and blended therewith. As a result, there can be easily produced a flavored fast cooking rice.

As described in detail up to this point, this invention comprises the first step of puffing rice grains to a high degree for thereby gelatinizing rice starch, inducing cleavage of rice starch micelle, forming a porous texture in the rice grains and causing a specific thickener to be amply entrapped within the rice grains and the subsequent step of drying the treated puffed rice to the extent of allowing the rice grains to dwindle to a prescribed volume. The fast cooking rice which is manufactured as described above provides high yields of production and high preservability and, upon reconstitution, converts itself into a cooked rice excelling in taste, texture and flavor.

Reconstitution of this fast cooking rice, for example, into ordinarily cooked rice can be obtained by adopting a method which is generally practiced in preparing fast cooking rices of this kind. To be specific, the desired reconstitution into cooked rice can be accomplished by allowing this fast cooking rice to stand for one to two minutes in hot water heated in advance to about 80 DEG C or over and added in a volume roughly 1 to 1.5 times the volume of rice, then discarding an excess portion of said hot water and thereafter allowing the rice to be steamed for three to four minutes with the remaining heat. The fast cooking rice can be reconstituted into a soup containing rice grains by following the same procedure except for removal of excess hot water. The fast cooking rice produced by this invention can be also amply reconstituted into a cooked rice of good quality when it is left to stand in water of normal room temperature for about 30 minutes. When the fast cooking rice is reconstituted with milk instead of water of normal room temperature, the resultant cooked rice tastes good. For a user who feels like eating pilaf, a pilaf of mild texture can be obtained by heating the fast cooking rice of this invention such as in a frying pan in the presence of a small amount of oil and fat and a suitable amount of water.

Obviously modifications and variations are possible insofar as they do not depart from the spirit and scope of the present invention. This invention is not limited to the specific embodiments thereof except as defined in the appended claims.

EXAMPLE 1

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 9 times the original.

Two(2.0) Kg of this puffed rice was immersed for 10 - 15 seconds in a 0.4% aqueous solution of agaragar kept at 65 DEG C. It was immediately placed in an electric constant-temperature hot-air dryer at

90 DEG C and dried therein for 2.5 hours to produce 1.9 kg of fast cooking rice having a volume of about twice as large as that of the raw rice. This fast cooking rice was placed in a container provided with a lid. The same volume of hot water at 95 DEG C was poured into the container. The rice and the hot water in the container were left to stand for 90 seconds. Then, the excess hot water was discarded.

Thereafter, the fast cooking rice was left to be steamed for 3 minutes with the remaining heat.

Consequently, there was obtained a cooked rice excellent in taste, texture and flavor.

EXAMPLE 2


Two(2.0) Kg of this puffed rice was sprayed with 5.3 kg of 0.3% aqueous solution of sodium

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carboxymethylcellulose at normal room temperature, then left to stand at normal room temperature for

10 minutes, thereafter placed in a drying oven at 70 DEG C and dried therein for 4 hours to afford 2.0

Kg of fast cooking rice having a volume about twice as large as the volume of raw rice.

A cooked rice of excellent quality was obtained by subjecting the fast cooking rice to treatment by the same procedure as in Example 1.

EXAMPLE 3


One(1.0) Kg of this puffed rice was sprayed with 2.5 Kg of 1.0% aqueous solution of lambda carrageenin at 44 DEG C, then left to stand for ten minutes at normal room temperature, subsequently placed in a vacuum dryer, dried first at 65 DEG C under normal atmospheric pressure for one hour to vaporize the water and then at 65 DEG C under a vacuum of less than 10 mmHg for 3.5 hours. Thus, there was obtained 0.98 Kg of a fast cooking rice having a volume of about 1.7 times the volume of the raw rice. A cooked rice of excellent quality could be obtained by treating this fast cooking rice by the same procedure as in Example 1.

EXAMPLE 4

A raw rice was expanded by use of heated air at 300 DEG C into a puffed rice having a volume of 6 times as large. Three(3.0) Kg of this puffed rice was immersed in 0.45% aqueous solution of guar gum kept at 65 DEG C, then immediately placed in a drying oven at 90 DEG C and dried for three hours to afford 2.9 Kg of a fast cooking rice having a volume of about 1.7 times as large as that of the raw rice.

Two hundred (200) g of this fast cooking rice was placed in a frying pan and heated in the presence of

600 g of water, and a small amount of salad oil was added thereto. There was consequently obtained a cooked rice excellent in taste, texture and flavor.

EXAMPLE 5

A raw rice was expanded by a puffing gun into a puffed rice having a volume of 10 times as large. One and a half (1.5) Kg of this puffed rice was immersed in a seasoning aqueous solution containing 0.5% of propylene glycol alginate, 0.5% of sodium chloride and a small proportion of seasoning agent. After about 15 seconds of immersion in the solution, the puffed rice was immediately placed in a drying oven at 85 DEG C and dried therein for three hours to afford 1.4 Kg of a fast cooking rice having a volume of about 1.9 times as large as that of the raw rice. A curry-flavored cooked rice was obtained by cooking this fast cooking rice in the presence of curry powder and raisin added thereto by a procedure similar to that of Example 4.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. A process for the manufacture of fast cooking rice, consisting essentially of puffing a raw rice into a puffed rice having a volume of 6 to 16 times as large, contacting this puffed rice with a solution of a thickener in a concentration in the range from about 0.1 to about 1.0 weight percent sufficiently to penetrate to the inside center of the puffed rice, and thereafter drying the treated puffed rice to reduce the volume thereof, said thickener being selected from the group consisting of agar, carrageenin, alginate, alginic acid, locust bean gum, guar gum, tamarind gum, psyllium seed gum, quince seed gum, gaz, pectin, glucomannan, propylene glycol alginate, low methyl ester pectin, sodium polyacrylate, carboxymethylcellulose salt, methylcellulose, hydroxymethylcellulose, methylethylcellulose, hydroxypropylcellulose, xanthan gum, cardrun, scleroglucan, succinoglucan and pullulan.

2. A fast cooked rice produced according to the process to claim 1.

3. A process for the manufacture of fast cooking rice, consisting essentially of puffing a raw rice into a puffed rice having a volume of 6 to 16 times as large, contacting this puffed rice with a solution of a thickener in a concentration in the range from about 0.1 to about 1.0 weight percent sufficiently to

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penetrate to the inside center of the puffed rice, and thereafter drying the treated puffed rice to reduce the volume thereof, said thickener being selected from the group consisting of agar, carrageenin, propylene glycol alginate, glucomannan, methylcellulose and carboxymethylcellulose salt.

4. A fast cooked rice produced according to the process of claim 3.Data supplied from the esp@cenet database - Worldwide

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224.

JP55000018 - 1/5/1980

PRODUCTION OF EDIBLE POLLEN


Inventor(s): FURUKOSHI SHIYOUKO (--)

Applicant(s): FURUKOSHI SHIYOUKO (--)


IP Class: A23L1/34

E Class: A23L1/076



Family: JP55000018

Abstract:


PURPOSE:The koji yeast is cultured in a specific medium and pollen is soaked into the extract from the culture, thus producing edible pollen with good storage stability and digestion.

CONSTITUTION:To 100 liters of Fe2(SO4)3 aqueous solution diluted to about 1 deg. Baume are added 1.8-3.6 liters of vinegar and the resulting treating solution, 10-20l, is added to 72 liters of sugar or flour of grain or rice to decompose sufficiently the bark. The product is sterilized by boiling and a koji yeast as Aspergillus oryzae is added and they are cultured. Water or slightly warm water is added to the culture and filtered by pressing. The extract is kept at 25-40 deg.C and pollen is soaked therein for about 48 hours, whereby the effective components in pollen are extracted without being decomposed and other microorganisms disappear and edible pollen harmless against living bodies is obtained.

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225.

JP55003769 - 1/11/1980

ENZYME TREATMENT OF LOWWGRADE RICE FOR FERMENTED FOOD


Inventor(s): TERADA AKIRA (--)

Applicant(s): GUNMA PREFECTURE (--)


IP Class: A23L1/10

E Class: A23L1/105



Family: JP55003769

Abstract:


PURPOSE:To prepare fermented foods such as ''sake'' having excellent aroma and taste, from lowgrade rice, by immersing the low-grade rice in a solution of a specific enzyme, thereby reducing the leucine-content in the unrefined ''sake'', and suppressing the generation of isoamyl alcohol.

CONSTITUTION:Low-grade rice such as crushed rice, unripe rice, etc. is immersed in water containing a protease having leucine-eluting activity and, if necessary, a starch-liquefying enzyme such as amylase, Proteins and their decomposition products such as amino acids, e.g. leucine, etc. can be removed by this treatment. After the treatment, the rice is fermented by conventional process to obtain refined ''sake'', etc.

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226.

JP55009756 - 1/23/1980

LACTIC ACID BEVERAGE FROM RICE AND ITS PREPARATION


Inventor(s): TORIGOE SOUKOU (--); KAWAGUCHI YOSHIFUMI (--); ITABASHI

KATSUHIKO (--); MIZUSAWA TAKAO (--)

Applicant(s): KYOWA HAKKO KOGYO KK (--); SHIKISHIMA SEIPAN KK (--)

IP Class 4 Digits: A23L; A23C

IP Class: A23L1/10; A23L2/38; A23C11/00

E Class: A23L1/105



Family: JP55009756

Abstract:


PURPOSE:To prepare lactic acid beverage having refreshing sourness of yogurt, at low cost, by the use of rice (long-storage rice can be used) in place of animal milk. CONSTITUTION:A medium composed mainly of rice starch [pref. obtained by heating 100 parts by weight of rice or processed rice (broken rice, rice flour, etc.) with water to afford 130-400 parts of alphatized starch], is added with an amylase

(e.g. ''biozyme-A'' ''taka-diastase'', etc. derived from Aspergillus oryzae) or malted rice and lactic bacteria (e.g. Lactobacillus case, Lactobacillus acidophilus, Streptococcus lactis, Lactobacillus sanfrancisco, etc.), and the lactic fermentation is carried out at 25-35 deg.C for 10-24 hours. The concentration of lactic acid can be controlled by adding a proper amount of glucose or sucrose to the medium at a proper time during fermentation.

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227.

JP55039706 - 3/19/1980

METHOD OF CULTURING FILAMENTOUS FUNGUS


Inventor(s): NODA FUMIO (--); HAYASHI KAZUYA (--); MOGI KEITAROU (--); IWAASA

TAKASHI (--); SAKASAI TOSHIO (--); IGUCHI NOBUYOSHI (--)

Applicant(s): KIKKOMAN SHOYU CO LTD (--)

IP Class 4 Digits: C12N; C12R

IP Class: C12N1/14; C12R1/66; C12R1/785; C12R1/80; C12R1/845

E Class: A23L1/238



Family: JP55039706


Abstract:


PURPOSE:Salts of fatty acides of 1-4 carbon atoms, hypochlorous, hyposulforous acids or their salts, hydrogen peroxide, etc. are added during from step for preparing the culture medium to step of culturing to supress the propagation of bacteria groups, thus culturing efficiently filamentous fungus.

CONSTITUTION:In the culture of a jilamentous fungus, at least one of salts of fatty acids of 1-4 carbon atoms and at least one of hypochlorous, chlorous, hyposulfurous, sulforous, prosulforous acids, their salts and hydrogen salts, hydrogen peroxide, bleaching power, chloramine B, chloramine T, halazone and acrylic acid amide are added to the culture medium in any step from the preparation of the culture medium to culturing. The raw materials for culture medium are soybean, rice, wheat, soy grain, etc. The filmentous funga used here are, e.g., Aspergillus oryzae (ATCC20386), Penicilluim fuscum (ATCC10447), which are used in brew of soy and sake or in manufacture of enzymes.Claims:


What we claimed is:

1. In a method for producing a fermentation koji product which comprises inoculating a koji mold in a substrate and cultivating it, the improvement which comprises adding (A) at least one compound selected from the group consisting of alkali metal salts of an acid selected from the group consisting of acetic acid and propionic acid, and (B) at least one compound selected from the group consisting of hypochlorous acid, alkali metal salts of hyposulfurous acid, alkli metal hydrogen sulfite, alkali metal pyrosulfite and hydrogen peroxide, at any time ranging from a step of preparing the substrate to the step of cultivation, the total amount of said compounds (A) and (B) being about 0.01 to about 2% by weight based on the weight of the substrate, and the weight ratio of compound (A) to compound (B) being from 1:4 to 4:1.

2. The method of claim 1 wherein said compounds (A) and (B) are added at any time ranging from the step of preparing the substrate to a time before the step of inoculating the mold.

1110/2197

3. The method of claim 1 wherein said substrate contains a denaturation product or an alpha-form of at least one member selected from the group consisting of soybean, defatted soybean, gluten, rice, wheat, corn, soy sauce lees, mirin lees, sake lees, wheat husk, rice bran and fishmeal.Data supplied from the esp@cenet database - Worldwide

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228.

JP55054864 - 4/22/1980

METHOD OF MAKING FOOD UTILIZING RICE


Inventor(s): TAKEUCHI TAKUYA (--); KANETANI IWAO (--)

Applicant(s): TAKASAGO PERFUMERY CO LTD (--)


IP Class: A23L1/10

E Class: A23L1/105



Family: JP55054864

Abstract:


PURPOSE:Rice is boiled together with water and converted into the alpha-form, cooled, liquefied with

''koji'' or saccharified with an enzyme, subjected to lactic fermentation, treated with heated, then emulsified, thus making a milk-like food with good taste. CONSTITUTION:Rice together with water is boiled to convert the starch into the alpha-form, combined with water to form a slurry, to which koji or an starch saccharification enzyme as amylase is added at 55-60 deg.C and the rice is saccharified at a pH of 4.5-5 for about 12hr. Before the saccharification, fruit or vegetable juice may be added thereto.

Then, a lectobacillus, such as lactobacillus vulgaricus or lactobacillus acidophilus, is inoculated to the product and they are subjected to the fermentation for 2 or 3 days. Then, they are heated over 90 deg.C for over 30min to kill the bacteria and then preemulsified with a homomixer. Further, they are emulsified with a high-pressure homogenizer to give said milk-like food with good taste. When the food is spray-dried, a powdered food is produced.

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229.

JP55127963 - 10/3/1980

FOOD FERMENTED WITH BACILLUS NATTO


Inventor(s): SUZUKI KIICHI (--)

Applicant(s): SUZUKI HISAO (--)


IP Class: A23L1/10; A23L1/20

E Class: A23L1/105



Family: JP55127963

Abstract:


PURPOSE:To prepare a fermented food having high and balanced nutritive value and excellent taste and flavor originated from unmilled rice and soybean extract, by inoculating and culturing Bacillus natto in unmilled rice which is steamed and boiled in soybean soup. CONSTITUTION:Unmilled rice is washed with water, immersed in soybean soup, steamed and boiled under the conventional rice cooking conditions, inoculated with Bacillus natto, placed in a vessel, and fermented in a fermentation chamber under the conditions almost same as that of the preparation of ''natto'' (fermented soybean).

1113/2197

230.

JP55144860 - 11/12/1980

BOILED RICE COVERED WITH EDIBLE COATING


Inventor(s): YAMADA TOSHIHIRO (--)

Applicant(s): YAMADA TOSHIHIRO (--)


IP Class: A23L1/10

E Class: A23L1/182B



Family: JP55144860

Abstract:


PURPOSE:Balls of boiled rice are covered with an edible coating which is made by heating a raw thin film of edible material, thus preventing the rice grains from hardening and increasing the storability.

CONSTITUTION:The edible coating is prepared by kneading wheat flour with water, milling the mixture into thin films, and heating them. Then, balls of boiled rice are covered with the edible coating to give said food product. For example, a powder containing mainly wheat flour and additionally appropriate amounts of powdery germ and powdery rice is kneaded with water or saline solution such as an aqueous alkali, e.g., potassium carbonate, sodium carbonate or sodium bicarbonate. The mixture is milled with a noodle rod into thin films and the films are heated to prepare the flexible and edible coating. Balls of boiled rice are covered with the coating. Boiled rice is, e.g., red rice (containing red beans), sushi or seasoned rice such as rice boiled together with animal meat and subsidiary diet may be put between the coating and the rice.

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231.

JP55149205 - 11/20/1980

AGENT FOR ACCELERATING COLOR DEVELOPMENT AND INCREASING

SACCHARIDE IN CITRUS FRUITS


Inventor(s): IIZUKA CHIYOKICHI (--); MAEDA HIROAKI (--)

Applicant(s): NODA SHIYOTSUKIN KOGYO KK (--)

IP Class 4 Digits: A01G; A01N

IP Class: A01G7/06; A01N65/00

E Class: A23L1/23; A01N63/04; A23L1/275D



Family: JP55149205

Equivalent:

Abstract:

US4281021


PURPOSE:An agent for accelerating color development and increasing the saccharide content in citrus fruits, which is obtained as an extract by extracting the culture mixture of mycelia of an edible mushroom belonging to Basidomycetes and is safe to man and the trees with enabling the earlier shipment of the fruits. CONSTITUTION:The mycelia of an edible mushroom belonging to

Basidomycetes such as shiitake mushroom are cultured in a solid or liquid culture medium and the culture mixture is extracted with an aqueous culture medium and the extract is utilized as said agent.

The culture medium is preferably bagasse culture medium containing 10 parts of bagasse and 1 part of maltose from rice as a solid one because they are inexpensive and readily available. As the liquid culture medium, GPY medium containing glucose, pepton and yeast, MY medium containing powdered malt essence and yeast, and others are recommended. Preferred aqueous solvent is water.Description:



This is an invention to accelerate coloring and improve sweetness of citrus fruits by obtaining extracts containing effective ingredients from water solutions of mycelium nutrient medium and tissue-medium of edible fungus belonging to the genus Basidiomycetes and, after diluting with water, spraying this over the surface of the leaves to accelerate coloring and increasing sugar content. As accelerating coloring of citrus fruits is carried out with the prerequisite or early shipment, which will be advantageous in marketing, it is an important facet in the cultivation of citrus fruits. Not only does it also improve the quality from the standpoint of taste and sweetness, it is also an important process from the viewpoint of preventing deterioration in quality. In the past, several types of chemicals were developed for this purpose. For instance, ethylene was used to accelerate coloring. However, in addition to infuring the tree and increasing defoliation, problems were also involved in relation to safety. There were also examples of sulfur being employed as a sweetening agent but again there were problems in relation to safety and its detrimental effect on the tree. This method is therefore not in

1115/2197

general use. In addition, chemicals capable of accelerating coloring and improving sweetness at the same time have yet to be developed. However, as a result of various research projects carried out over many years in relation to mecelium of edible fungus belonging to the genus Basidiomydetes by the inventor, numerous inventions were made in relation to methods of extracting chemical ingredients contained in the mycelium. On one hand, it was discovered that the extract of mycelium nutrient medium and tissue-medium contained a substance having cytokinin activity. This invention was made when the extract was sprayed over the citrus fruits as in the foregoing and it was accidentally discovered that it was extremely effective in accelerating coloring and increasing sweetness.


The principal purpose of this invention is to offer a method of accelerating coloring and increasing sweetness with superior safety characteristics that means toxicity (L.D. 50) of extract dry matter is Rat

.male. 16.5 g, .female. 15.6 g, Mouse .male. 19.6 g, .female. 17.7 g per kg. (body weight) and, moreover, a method that will not detrimentally affect the tree in any way.

Another purpose of this invention is to offer a low cost method of accelerating coloring and increasing sweetness which would be capable of attaining these two purposes simultaneously. A further purpose of this invention is to make possible early harvesting of citrus fruits and, moreover, enable growing citrus fruits of superior quality.


FIGS. 1A and 1B are graphs showing secular changes of the pigment in the pericarp of sweetish summer oranges (Citrus Natsudaidai) in experiment 1.

In the figures, 445 m.mu. indicates yellowish pigment and 660 m.mu. greenish pigment.

FIGS. 2A and 2B are graphs showing secular changes of the pigment in the pericarp of mandarin oranges in experiment 2.

FIGS. 3A to 3C and 4A to 4C are graphs showing comparisons between this fluid extract undiluted and diluted 100 times particularly in relation to sugar and citric acid content of the analysis results in experiment 3.

Drawings 5A and 5B are graphs showing secular changes of the pigment in the pericarp of sweetish summer oranges in experiment 4.

FIGS. 6A and 6B are graphs showing secular changes of the pigment in the pericarp of mandarin oranges in experiment 5.


In this invention, the mycelium of edible fungus belonging to the genus Basidiomucetes are cultured by means of a culture medium or culture solution and cytoplasm obtained from metabolite and autolysis of the mycelium. Although Shiitake (Lentinus edodes), Hiratake (Pleurotus ostreatus), Nameko (Ploliata nameko), Enokitake (Flammulina Velutipes sing), Shimeji (Lyophyllum aggregatum), Kawaratake

(Coriolus Versicolor), Sarunokoshikake (Rigiooporus ulmarius) and etc. may be used as the

Basidiomycetes in this invention, the most active and superior was that extracted from Shiitake mycelium.

The culture medium employed may be either solid or liquid type culture mediums. The bagasse culture medium (culture medium composed of beet lees 12: rice bran 1), or sawdust culture medium (culture medium composed of sawdust 3: rice bran 1) which is normally used for growing fungus may be used for the former. Of these, as bagasse had no definite usage, it was principally disposed of by incineration in the past. However, it was easily and cheaply procured and was therefore advantageous cost-wise. On the other hand, GPY culture medium (liquid culture medium composed of a mixture of Glucose,

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Peptone and Yeast) and MY culture medium (liquid culture medium composed of a mixture of Malt extract powder and Yeast) may be considered for the latter. There is no particular change in the method of mycelium culture and the same methods as in the past can be used.

A feature of this invention is that mycelium and culture medium do not separate after mycelium of the genus Basidiomycetes is cultured in a solid or liquid culture medium. That is, metabolite of mycelium and the effective ingredients contained in mycelium were extracted from these mixtures of mycelium and culture mediums (hereafter called mycelium nutrient medium and tissue-medium) and results of separating and indentifying the extract confirmed that substances having cytokinin activity were contained as in the foregoing, and it was also determined that polysaccharide were also contained.

However, it may certainly be surmised that other effective ingredients are contained but they have still to be completely clarified. It is also still not clear as to the ingredients contained in the foregoing extracts that act to accelerate coloring and increase sweetness.

The water solvent employed in the extraction process is water or a water solution containing a small amount of water soluble organic solvent, acid and base. Methanol, ethanol or isopropylalcohol is principally used as the organic solvent. Hydrochloric acid, sulphuric acid or acetic acid may be used for the acid and ammonia, caustic soda, caustic potash, and sodium carbonate may be used for the base.

However, water was principally used in this invention.

In this invention as extracted fluids from mycelium nutrient medium and tissue-medium existing in the natural world are used as the effective ingredients, they are absolutely safe for humans and for the trees. Also, as they do not have any ill effects and also contribute to accelerating coloring and increasing sweetness, they are extremely effective and will certainly be highly welcomed by the farmers.

We shall now describe a few examples of applications of this invention.

EXAMPLE 1

A solid culture medium composed of a mixture of 90% bagasse, 5% rice bran and 5% nutrients such as bran is sterilized by the usual method and Shiitake are then inoculated into this medium. Upon completion of inoculation, it is transferred to an air conditioned culture room with a temperature of 18

DEG C. to 20 DEG C. and a relative humidity of 60% to commence culture of mycelium. The culture medium in which mycelium has spread is then transferred and left in the culture room. The culture medium is removed from the culture room at the point where the Shiitake seedlings commence to emerge from the surface of the culture medium and is then crushed into thumb-sized lumps by means of a pulverizer. The crushed culture medium is then placed in a tank with water in the ratio of 5 liters of fresh water to 600 grams of culture medium and is then agitated and mixed for 4 to 5 hours at a temperature of 40 DEG C. to 130 DEG C. The metabolite of the mycelium and the effective ingredients contained in the mycelium fluid will dissolve in the water.

The suspension fluid obtained in this manner is placed in a flannel filter bag and filtered under pressure. The filtered fluid is filtered again by means of a membrane filter to remove fungus and extract the fluid with the effective ingredients contained in the metabolite of mycelium and in the mycelium fluid. Further, as this will be considerably diluted with water in actual usage, in the foregoing example 5 liters of the extract obtained by extracting 600 grams of culture medium dissolved in 5 liters of water shall be used as the undiluted fluid. The powder contained 30 g of effective ingredients is obtained by freezing and drying the above basic undiluted fluid.

The extract in the foregoing manner was used in the following example.

EXPERIMENT 1

Tests on sweetish summer oranges

Test site: Amakusa, Kumamoto Pre.

Test method: The above extract diluted 100 times is sprayed over the leaves at the rate of 450 liters per

10a.

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Spraying period: On Oct. 7 and 14, 1978

Survey in relation to changes in pigment

Samples of the fruit were picked after the elapse of a certain fixed number of days after spraying and measurements were made with a spectrophotometer of the yellow pigment consisting mainly of carotin and xanthophyll, and also the green pigment consisting mainly of chlorophyll.

Adjustment of the Sample

25 Grams of the pericarp is crushed in a mortar with quartz sand and 50 ml of acetone and centrifugation carried out. Extraction is repeated by adding acetone to the residue and repeating the process. After extracting all of the pigment, the extract is transferred to a separating funnel after reduced pressure compression and saponification to 100 ml. Add 50 ml of petroleum ether and 50 ml of water and shake. It will then separate into a yellowish layer of petroleum ether and a greenish layer of water. Light absorption is then measured of a 445 m.mu. layer of petroleum ether and a 660 m.mu. layer of water. Test results are as shown in FIGS. 1A and 1B. As in the foregoing, it was noted that there was a decrease in the green pigments while, on the other hand, there was an increase in the yellow pigment resulting from this treatment which clearly confirmed that this agent was effective in accelerating coloring.

>;tb;______________________________________

>;tb;Analysis results of ripe fruit (fruit juice).

>;tb;Item Sugar Citric Soluble

>;tb;Section (%) Acid (%) Solids (%)

>;tb;______________________________________

>;tb;Treated

>;tb;Section 11.8 1.95 12.5

>;tb;Untreated

>;tb;Section 9.6 1.92 11.5

>;tb;______________________________________

As is clear from the analysis results, the sugar contents in the treated section is approximately 23% higher than that for the untreated section and clearly testifies to the fact that sugar content has increased.

EXPERIMENT 2

Tests on mandarin oranges

Test site: Uto, Kumamoto Pre.

Test method: The above extract diluted 100 times and sprayed over the leaves at the ratio of 450 liters per 10a.

Spraying period: Nov. 2 and 8, 1978

Survey in relation to chages in the pigment

The survey method and the adjustment method of samples used were the same as those used in the previous experiment.

Test results are as shown in FIGS. 2A and 2B.

As in the foregoing, it was noted that the green pigments decreased and the yellow pigments increased sharply as a results of this treatment.

>;tb;______________________________________

>;tb;Analysis results of ripe fruits (fruit juice)

>;tb;Item Sugar Citric Soluble

>;tb;Section (%) Acid (%) Solids (%)

>;tb;______________________________________

>;tb;Treated

1118/2197

>;tb;Section 14.0 0.92 14.8

>;tb;Untreated

>;tb;Section 11.0 0.74 12.4

>;tb;______________________________________

As is clear from the above analysis results, sugar content has increased approximately 26% as compared to the untreated section. This clearly testifies to the fact that sugar content has increased.

EXPERIMENT 3

In view of test results such as in the above, the inventors have entrusted additional tests of this extract with the Kumamoto Pre. Experimental Fruit Laboratory.

Data of the experiments conducted are as follows.

Purpose of the tests: To confirm the effects of spraying Shiitake mycelium extract on accelerating coloring and increasing sugar content of citrus fruits.

Test supervisor: Kumamoto Pre. Experimental Fruit Laboratory

Sample trees: 6 year old Aoshima Mandarin Orange trees

Sample agent: Shiitake mycelium extract

Spraying density, spraying period and number of times.

>;tb;______________________________________

>;tb;Spray Agent

>;tb; Spraying Density

>;tb; Spraying Period

>;tb;______________________________________

>;tb;Extract 100 times Nov. 2, Nov. 11, 1978



>;tb;______________________________________

>;tb;Test Results (Particularly in relation to fruit quality)

>;tb; a b c d e f

>;tb;______________________________________

>;tb; A 69.7 79.1 12.4 13.86 1.193 11.62

>;tb;Dec.1 B 68.6 74.9 10.2 11.17 0.952 11.73

>;tb; C 69.2 75.9 10.6 12.00 0.973 12.33

>;tb; D 69.4 78.1 10.3 11.58 0.970 11.94

>;tb; A 70.3 81.2 12.6 13.77 1.111 12.39

>;tb;Dec.22

>;tb; B 71.5 76.5 10.0 11.28 0.909 12.41

>;tb; C 70.8 76.8 10.1 11.31 0.967 11.70

>;tb; D 69.5 75.2 10.1 11.28 0.955 11.81

>;tb; A 71.4 75.3 13.8 15.03 0.939 16.01

>;tb;Feb.22

>;tb; B 71.4 73.0 11.0 12.37 0.757 16.34

>;tb; C 71.2 75.2 11.7 12.74 0.858 14.85

>;tb; D 71.2 76.0 10.5 11.31 0.760 14.88

>;tb; A 71.4 70.8 14.0 14.81 0.915 16.18

>;tb;Mar.6 B 69.6 74.1 11.3 12.64 0.729 17.34

>;tb; C 70.1 71.9 11.2 12.61 0.851 14.82

>;tb; D 69.2 74.7 11.1 12.37 0.739 16.74

>;tb; A 72.2 72.1 13.5 14.98 0.922 16.25

>;tb;Apr.6 B 66.2 75.4 11.6 12.64 0.694 18.22

>;tb; C 69.8 78.3 11.7 12.93 0.691 18.72

>;tb; D 68.6 78.3 11.3 12.61 0.682 18.50

>;tb;______________________________________

>;tb; A Extract diluted 100 times, 2 spraying

>;tb; B Extract diluted 500 times, 2 spraying

>;tb; C Extract diluted 1,000 times, 2 spraying

>;tb; D Not sprayed

1119/2197

>;tb; a Percentage of sarcocarp

>;tb; b Percentage of fruit juice

>;tb; c Indication of sugar

>;tb; d Soluble solids

>;tb; e Citric Acid

>;tb; f Sweetness ratio

FIGS. 3A to 3C and FIGS. 4A to 4C are graphs showing comparisons between sections sprayed with extract diluted 100 times and sections unsprayed particularly in relation to the amount of sugar and citric acid contained from the above analysis results.

SUMMARY OF TEST RESULTS

(a) Sugar clearly showed a high degree of change in the 100 times section. Although transitions in sugar were high in the 500 times and 1,000 times section, they were lower than that compared to the

100 times section.

(b) The citric acid content was high in the 100 times and 1,000 times 2 sprayings section as compared to the unsprayed section. The transition was particularly high in the 100 times section as compared to the unsprayed section.

(c) Coloring in the 100 times section clearly showed advancement from mid-November.

(d) The above results clearly revealed the tendency for both sugar and citric acid to increase in density by spraying with high density sprays of the extract.

EXAMPLE 2

Place GPY (Glucose-Peptone-Yiest medium) culture medium in a container and place the container in an autoclave for 30 minutes at 121 DEG C. to reduce bacteria. On one hand, the Shiitake seeds are picked up with a platinum roop and planted in the aforementioned culture medium. It is then placed in a culture room at 20 DEG C. and, after shaking for a period of 1 minute at 120 times per minute, it is allowed to culture through its inner portion for a period of 7 to 8 days. The fungi will then spread throughout the culture medium and will gradually take ship to indicate that the fungus were grown sufficiently.

Add 1 liter of water to 1 liter of the fungus culture obtained by the above culture process, homogenize, and obtain the extract by filtering the resulting suspension fluid. After a suitable period of time, filtration concentration is carried out on the extract by means of an ultra-filtration film to obtain fluid extract again and this is further freeze-dried to obtain a brownish powder. Further, the amount of powder obtainable is 10 grams for each liter of extract.

Next, water was added to the forementioned powder and was used to carry out the following experiment.

EXPERIMENT 4

Tests on sweetish summer oranges

Test site: Amakusa, Kumamoto Pre.

Test method: 6 grams of the above powder was dissolved in 1,000 cc of water and this was sprayed over the leaves at the rate of 450 liters per 10a.

Spraying period: 15 and 22 October, 1978

Survey of changes in pigment

Survey method and adjustment method of the samples was the same as in the case of Application

Example 1.

1120/2197

Test results were as shown in FIGS. 5A and 5B. As may be discerned, it was confirmed that the green pigment decreased and the yellow pigment increased as a result of this treatment.

>;tb;______________________________________

>;tb;Analysis results of ripe fruits (fruit juice).

>;tb;Item Sugar Citric Acid

>;tb; Soluble Solids

>;tb;Section (%) (%) (%)

>;tb;______________________________________

>;tb;Treated

>;tb;Section 11.6 1.93 12.3

>;tb;Untreated

>;tb;Section 9.6 1.92 11.5

>;tb;______________________________________

As is clear from the above analysis results, sugar content in the treated section has increased approximately 20% in comparison with the untreated section. It was clearly confirmed that the sugar content had increased.

EXAMPLE 3

After culturing Enokitake mycelium by the same means as in Example 1, fluid extracts containing effective ingredients of mycelium culture was also obtained by the same procedure. Next, this fluid extract was employed to carry out the following experiment.

EXPERIMENT 5

Tests on mandarin oranges

Test site: Uto, Kumamoto Pre.

Test method: The above extract diluted 100 times was sprayed over theleaves at the rate of 450 liters per 10a.

Spraying period: 5 and 12 October, 1978

Survey in relation to changes in pigment

Survey method and adjustment method of the sample was the same as in Example 1.

Test results are as shown in FIGS. 6A and 6B.

As in the foregoing, it was confirmed that the green pigment decreased and the yellow pigments increased by means of this treatment. However, the coloring acceleration effect was slightly less than the extracts obtained from Shiitake mycelium culture.

>;tb;______________________________________

>;tb;Analysis results of ripe fruits (fruit juice).

>;tb;Item Sugar Citric Acid

>;tb; Soluble

>;tb;Section (%) (%) Solids (%)

>;tb;______________________________________

>;tb;Treated

>;tb;Section 13.1 0.90 14.5

>;tb;Untreated

>;tb;Section 11.1 0.74 12.4

>;tb;______________________________________

As is clear from the above analysis results, the sugar content has increased approximately 18% compared to the untreated section and it has been confirmed that the amount of sugar content had increased. However, its accelerating effect on coloring and its effect on increasing sugar content was slightly less compared to that of the Shiitake mycelium extract.

1121/2197

Further, although the inventors carried out various experiments in relation to acceleration of coloring and increase in sugar content of myceliums of fungus other than the edible variety belonging to the foregoing Basidiomycetes such as shimeji, Nameko, Hiratake and Kawaratake and the results of the experiments were generally the same as in Example 4. In all cases they were inferior to that in the case of Shiitake myceliums.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. A method for accelerating the coloration and increasing the sugar content of citrus fruits which comprises applying to the citrus fruit plants a dilute, aqueous solution of the active ingredients obtained by water extraction of the mycelium nutrient medium and tissue medium of an edible fungus of the genus Basidiomycetes, concentrating, and subsequent aqueous dilution thereof to form said dilute, aqueous extract containing said active ingredients.

2. A method according to claim 1 for accelerating the coloration and increasing the sugar content of citrus fruits wherein the dilute, aqueous extract is obtained by diluting 100 times the extract obtained after adding 5 liters of water to 600 grams of solid culture medium.

3. A method according to claim 1 for accelerating the coloration and increasing sugar content of citrus fruits wherein the effective ingredients in the mycelium nutrient medium and tissue-medium are extracted by water.

4. A method according to claim 1 for accelerating the coloration and increasing sugar content of citrus fruits wherein the edible fungus belonging to the genus Basidiomycetes is selected from Shiitake,

Hiratake, Nameko, Enokitake, Shimeji, Kawaratake and Sarunokoshikake.Data supplied from the esp@cenet database - Worldwide

1122/2197

232.

JP55162943 - 12/18/1980

METHOD AND APPARATUS FOR PREPARATION OF JAPANESE CRACKER

FROM GRAIN SUCH AS UNPOLISHED RICE


Inventor(s): HAYASHI GIICHI (--)

Applicant(s): AIRIN KK (--)

IP Class 4 Digits: A23G

IP Class: A23G3/00

E Class: A23L1/18C2; A21B5/02



Family: JP55162943

Equivalent:

Abstract:

US4328741; GB2052240; FR2458219; ES8100759; DE3019798


PURPOSE:To prepare a Japanese cracker soft to the tooth, by placing grains such as rice between an upper and a lower air-tight hot baking molds, pressing and baking for several seconds, releasing the pressure to effect the expansion of the grains, and again pressing the expanded grains with the baking molds. CONSTITUTION:An apparatus for the preparation of Japanses crackers is composed of a lower baking mold 6 having a liftable bottom plate heated with a heater, a vertically movable upper baking mold 14 heated with a heater and engageable air-tightly with the lower baking mold 6 at the lowest position, and a slidable feed plate 18 which transfers a definite amount of grains from the hopper 22 to the lower mold 6. Grains such as unpolished rice are placed between the upper and the lower baking molds 6 and 14 maintained at about 160-180 deg.C, pressed and baked for several minutes, and expanded instantaneously by separating the molds. Steam in the molds is released at the same time.

The expanded grains are again pressed with the upper and the lower baking molds to form the grains to a desired cracker.Description:



The present invention relates to an apparatus for producing crackers or the like from a granular material such as rice, corn or the like.

In the hitherto known production of crackers of rice of the like grain, a bonding agent such as sugar, honey or the like has been used, as the result of which natural taste ascribable to the raw material itself has been remarkably modified.


An object of the invention is to provide an apparatus for producing a cracker from a granular raw material such as rice, corn or the like grain without resorting to the use of bonding agents.

1123/2197

Another object of the invention is to provide an apparatus for carrying out the above-mentioned method which can be implemented inexpensibly in a simplified structure.

The above and other objects, novel features and advantages of the invention will become more apparent from the description on an exemplary embodiment of the invention. The description makes reference to the drawings.


FIG. 1 is a front view of an apparatus according to an embodiment of the invention,

FIG. 2 is a side view of the same,

FIG. 3 is a sectional view of the same taken along the line III--III in FIG. 1,

FIGS. 4 to 7 show enlarged fragmental views of a main portion of the apparatus shown in FIG. 1 to illustrate the operations thereof, and

FIG. 8 is a circuit diagram showing an electrical circuit for controlling the operations of the apparatus.


Referring to FIGS. 1 to 3 which show an apparatus according to the present invention, reference numeral 1 designates a box-like frame having four legs 2. Lateral sides of the box-like frame 1 are all closed by side plates, among which the front one 1a is pivotally mounted on the frame so that it can be opened and closed. Disposed fixedly on the top of the box-like frame 1 is a table 3 which supports a first air cylinder 5 of a disc-like configuration through four supporting columns 4. A lower baking mold

6 of an annular shape is stationarily and coaxially disposed above the table 3 through a plurality of supporting rods 6a and has a bottom plate 7 to which a heat insulating plate 9 incorporating an electric heater 8 therein is fixedly secured, as can be seen more clearly from FIGS. 4 to 6. The heat insulating plate 9 has a lower surface which is connected to a second upstanding air cylinder 11 disposed within the box-like frame 1 through a connecting rod 10. On the other hand, the second air cylinder 11 is suspended by a seat plate 12 which in turn is secured to the lower ends of the lower baking mold supporting rods 6a. It should be noted that the bottom plate 7 can be moved to the level of the upper edge of the lower baking mold 6 through actuation of the air cylinder 11, whereby the lower baking mold 6 as well as the bottom plate 7 can be heated by the heater 8.

Disposed above and in opposition to the lower baking mold 6 is an upper baking mold 14 which is connected to the bottom of the first air cylinder 5 by way of a vertical reciprocatable rod 13. An electric heater 15 is incorporated in the upper baking mold 14 with a heat insulating plate 16 interposed between the heat 15 and the suspending rod 13. The upper baking mold 14 has a protruding press seat

14a formed in the lower surface thereof. It should be noted that the press seat 14a of the upper baking mold 14 is of such shape and dimension as to be snugly received within the lower baking mold 6. The upper baking mold 14 is vertically movable through corresponding actuation of the first air cylinder 5.

When the upper baking mold 14 is moved downwardly, the press seat 14a is snugly received within the lower baking mold 6 so that a chamber closed in a fluid-tight manner is defined within the lower baking mold 6 in cooperation with the press seat 14a of the upper baking mold 14.

A feeding plate 18 is slidably disposed within a casing 17 mounted at a rear side of the lower baking mold 6. A third air cylinder 19 is mounted on the casing 17 at the rear side of the feeding plate 18. The latter is adapted to be slidably moved over a lower plate 20 to thereby effect reciprocating movement over the lower baking mold 6. A through-hole 21 is formed in the feeding plate 18 at an intermediate portion and has an arcuate notch 18a formed at a front end thereof. Reference is to be made to FIG. 3.

At a retracted or withdrawn position of the feeding plate 18, a conduit 22a extending from a hopper 22 is communicated to the casing 17 in an alignment with the through-hole 21. A mass of uncleaned or

1124/2197

brown rice is accommodated within the hopper 22. A chute 23 extends forwardly from the lower baking mold 6.

The baking apparatus of the structure described above is provided with six limit switches in all. More specifically, a limit switch 24 is provided at a position to be actuated by the bottom plate 7 of the lower baking mold 6 upon upward movement thereof. Two limit switches 25 and 26 are actuated when the upper baking mold 14 is moved upwardly. The remaining three limit switches 27, 28 and 29 are adapted to be actuated upon sliding movement of the feeding plate 18. Actuation of the limit switches

25 and 26 is effected upon upward and downward movement of an arm 30 connected to the upper baking mold 14. Operations of these limit switches will be hereinafter described in conjunction with a circuit diagram shown in FIG. 8.

In the drawings, reference numeral 31 denotes a container located below a free end of the chute 23 and disposed on a base frame 32. Numeral 33 denotes a four-way electromagnetic valve of a solenoid type for controlling the operations of the first, second and the third cylinders. Finally, reference numeral 34 designates a switch box.

The raw material or uncleaned rice for producing a rice cracker may be prepared by mixing together some quantity of unhulled or brown rice of more than two kinds or brands, for example. The rice mixture is then cleaned by a rice washing machine and received in a basket to be left for 15 to 20 minutes for removing water. A predetermined quantity of salt is added to the dewatered unhulled rice to be intimately mixed therewith. Thereafter, the raw material is preparatorily dried for a day and then subjected to a primary drying process in a drying machine for two or three hours. After having been dried, the raw material rice mixture is loaded in the hopper 22. An appropriate quantity of laver or sesame seeds may be added, if desired.

Water content of the dried rice mixture provides a meaningful factor for carrying out the invention. The water content should be in the range of 15% to 20% and more preferably in a range of 17 to 18%. By the way, the water content is about 15 to 16% before the washing and about 30% immediately after the washing.

Next, a process for producing an unhulled rice cracker according to the invention will be described in conjunction with FIGS. 5 to 8.

The raw rice mixture loaded in the hopper 22 reaches to the through-hole 21 formed in the feeding plate 18 through the conduit 22a. The upper and the lower baking molds 14 and 6 are heated up to a temperature in a range of 160 DEG C. to 180 DEG C. with the upper baking mold being held at the upper position. At initiation of operation, the feeding plate 18 is moved forwardly to the position where the unhulled rice material G located within the through-hole 21 can be transferred into the lower baking mold 6. When the start switch S is closed at this stage, the air cylinder 5 is operated by the electromagnetic valve 33a through a closed circuit extending from the limit switch 28 (1-3) to the solenoid of the value 33a through a first timer T1 (1-3) and a second timer T2 (8-5), resulting in that the upper baking mold 14 is moved downwardly to be snugly fitted within the lower baking mold 6, whereby the unhulled rice material contained within the lower baking mold 6 is compressed and heated

(refer to FIG. 4). At the same time, operation of the second timer T2 is triggered, as the result of which the timer position is changed over from the output 5 to 6 after the lapse of a preset time, whereupon the electromagnetic valve 33b is electrically energized to move upwardly the first air cylinder 5. As the consequence of the involved upward movement of the upper baking mold 14, the rice material G within the lower baking mold 6 is instantaneously fully expanded, while steam produced within the lower baking mold 6 is exhausted (refer to FIG. 5). Upon upward movement of the upper baking mold 14, the limit switch 25 is changed over from an open position (NO) to a closed position (NC), whereby a relay

R1 is electrically energized through a closed circuit including the limit switch (1-3), the relay R1 (2-7) and the limit switch 29 (1-3). As the consequence of the actuation of the relay R1, relays R2 (1-3) and

R3 (6-8) are changed over from the open or NO position to the close or NC position, whereby the first timer T1 (2-7) is caused to be initiated.

At the same time with the initiation of the first timer T1, the opened path(8-6) is closed. Upon lapse of the time preset at the first timer T1, the upward movement of the upper baking mold 14 is stopped, while the second timer T2 is restored to the position (8-5) from the position (8-6) when the first timer

1125/2197

T1 is started. Consequently, the upper baking mold 14 is again caused to move downwardly to be snugly fitted within the lower baking mold 6. In this manner, the rice material G expanded within the lower baking mold 14 is compressed and shaped to produce a rice cracker G' from the unhulled or brown rice material (refer to FIG. 6).

Subsequently, after lapse of the time preset at the first timer T1, the second timer T2 is initiated and the position (8-5) is changed over to the position (8-6). Then, the electromagnetic valve 33b is energized.

Although the limit switch 25 is closed, the first timer T1 continues to operate, to thereby allow the upper baking mold to be further moved upwardly. The upward movement of the upper baking mold 14 causes the limit switch 26 to change the NO position thereof over to the NC position, whereby the second air cylinder 11 is operated by the electromagnetic valve 33c through the closed path including the limit switch 26 (1-3) and the relay R4 (8-5). Thus, the bottom plate 7 of the lower baking mold is moved upwardly to lift the rice cracker G' to the height of the upper edge of the lower baking mold 6

(refer to FIG. 7).

Simultaneously with the upward movement of the bottom plate 7, the limit switch 24 is changed over to the NC or closed position from the NO position to energize the electromagnetic valve 33d so that the third air cylinder is actuated to move forwardly the feeding plate 18. Consequently, the rice cracker G' is caused to move outwardly through engagement with the arcuate notch 18a formed in the leading end of the feeding plate 18 and drop in the container 31 through the shoot 23. In the meantime, the limit switch 29 is changed over to the position (b) from (a) to thereby open the closed circuit for the relay

R1, resulting in the resetting of the first timer from the position (8-6) to the position (1-3). Further, the limit switch 28 is changed over from the NC or closed position to the NO or open position to terminate the operation of the second timer T2, whereby the electromagnetic valve 33c is deenergized to allow the bottom plate 7 to be moved downwardly, while the feeding plate 18 is withdrawn rearwardly through deenergization of the electromagnetic valve 33d. The limit switch 27 is now in the open or

OFF state, while the limit switch is closed with the limit switch 29 being changed over to the position

(a). The apparatus is now reset to the starting position. It should be noted that when the produced rice cracker G' is moved outwardly from the lower baking mold toward the chute 23, the raw rice material

G contained in the through-hole 24 is transported onto the bottom plate 7 of the lower baking mold 6 to be accommodated therein.

The process for producing the rice cracker has now been completed and the apparatus is now in the position ready to effect the next operation, which is repeated in the manner described above.

By virtue of the fact that the raw rice material is first heated and compressed in the hermetically closed chamber, caused to expand instantaneously by removing the compression and is again subjected to compression, unhulled or brown rice particles will stick to one another under action of moisture and fat contained in unhulled rice to form a rice cracker of a self-sustaining structure. The rice cracker is actually solidified to such a degree of rigidity that it may be softly and tastefully cracked or crunched by teeth. In this connection, it should be noted that a low water content in the raw rice material exhibits a low expansion coefficient unsuitable for shaping a rice cracker, while an excessively high water content brings about degradation in refreshingness of the crunching.

Although the apparatus disclosed herein is especially adapted for producing rice crackers, it will be appreciated that the invention can be applied to production of crackers of other kinds of cereals (corns) or grains. In summary, it is possible according to the teaching of the invention to produce crackers of unhulled rice or other grains exhibiting an improved tastefulness in crunching with a relatively simple structure of a small size apparatus within a relatively short production time. Thus, the invention is suited to be practiced on a large mass production basis with an enhanced efficiency. The products enjoy a high nutritive value.

Although the invention has been described in connection with a preferred embodiment thereof, it will be appreciated that many modifications and variations will readily occur to those skilled in the art without departing from the spirit and scope of the invention.Data supplied from the esp@cenet database - Worldwide Claims:


1126/2197

What is claimed is:

1. An apparatus for producing a cracker from a raw material such as rice or the like, comprising a lower baking mold having a bottom plate which is adapted to be heated and moved upwardly, an upper baking mold adapted to be selectively moved upwardly or downwardly relative to said lower baking mold and received within said lower baking mold in a fluid-tight manner, said upper baking mold being also adapted to be heated, and a slidable feeding plate for transporting a predetermined quantity of said raw material as supplied from a supply source, said feeding plate being adapted to serve both for pushing outwardly a shaped and self-sustaining cracker from said lower baking mold and for feeding said predetermined quantity of raw material into said lower mold when said upper baking mold is at a lifted position.

2. An apparatus for producing a cracker from a raw material such as rice or the like, comprising: a lower baking mold having a bottom plate which is adapted to be heated and moved upwardly; a first heater for heating said bottom plate; an upper baking mold for selectively moving upwardly or downwardly relative to said lower baking mold in a fluid-tight manner, said upper baking mold also suited for heating by a second heater; control means for compressing and heating for a predetermined time said raw material contained within a hermetically closed chamber defined in said upper and lower baking molds, expanding instantaneously said compressed and heated raw material by opening said baking molds and concurrently discharging steam produced within said chamber during said expanded material by means of said baking molds; and a slidable feeding plate for transporting a predetermined quantity of said raw material as supplied from a supply source, said feeding plate suited both for pushing outwardly a shaped and self-sustaining cracker from said lower baking mold and for feeding said predetermined quantity of raw material into said lower mold when said upper baking mold is at a lifted position.Data supplied from the esp@cenet database - Worldwide

1127/2197

233.

JP55162981 - 12/18/1980

PREPARATION OF SOLID KOJI *MALTED RICE*


Inventor(s): NODA FUMIO (--); HAYASHI KAZUYA (--); MOGI KEITAROU (--); IWAASA

TAKASHI (--); SAKASAI TOSHIO (--); MIZUNUMA TAKEJI (--)

Applicant(s): KIKKOMAN SHOYU CO LTD (--)

IP Class 4 Digits: A23L; C12G; C12N; C12R

IP Class: A23L1/238; C12N1/14; C12R1/66; C12R1/785; C12R1/80; C12R1/845; C12G3/08;

C12N1/38; C12R1/665; C12R1/685; C12R1/69

E Class: A23L1/105; A23L1/20F



Family: JP55162981


Abstract:


PURPOSE:To prepare high quality koji having extremely few number of bacteria and extremely high activity of enzyme, e.g., protease, amylase, by inoculating koji with a fungus, and, a given hours later, followed by making the water content of koji not more than a specific weight percentage through dry treatment. CONSTITUTION:Water is addd to a raw material of koji (e.g., protein raw material, such as soybean), if necessary. Koji is conventionally modified or converted to alpha- type koji. The raw material preparing koji is inoculated with a koji fungus, koji preparation control is carried out by ordinary standstill or ventilation koji production 10-20 hours. 10-20 hours after the inoculation of koji fungus, the water content of solid koji fungus is made not more than 35wt.%, preferably not more than

33wt.% by dring. After that, koji preparation is done by conventional koji production. Speaking of drying means, for example, drying is made by ventilation while circulating dried air in the koji preparing chamber. For example, Aspergillus oryzae (ATC 20386) can be cited as the koji fungus.Description:


This invention relates to a process for producing a solid koji which is suitable for use in the manufacture of fermented food products such as soy sauce, miso, sake (Japanese wine from rice) and mirin, and particularly, to an improved process for producing a solid koji, which makes it possible to inhibit growth of contaminating bacteria that adversely affect the quality of koji, and to increase accumulation of enzymes, such as protease and amylase, useful for manufacture of fermented food products.

More specifically, the present invention pertains, in a process for producing a solid koji for fermented food products which comprises inoculating a koji mold in a modified koji substrate and cultivating it at a temperature of about 20 DEG C. to about 40 DEG C. for a time sufficient to produce a solid koji for fermented food products, to the improvement wherein at a certain time during the period of about 10 hours to about 20 hours after the inoculation of the koji mold, the cultivation system is subjected to a drying treatment to adjust its water content to about 30.+-.5%.

1128/2197

According to the conventional practice, koji for fermented food products is produced by inoculating a koji mold or a koji mold in the form of a seed starter in a modified koji substrate, and cultivating it in a microbiologically open system. Hence, there is a fairly high degree of possibility that contaminating bacteria which adversely affect the quality of the koji product will grow and contaminate the cultivation system. Furthermore, modified koji substrates modified by steaming or other known means and/or heat-sterilized, preferably those derived from naturally occurring vegetable or fish proteinous materials and naturally occurring vegetable carbohydrate materials such as soybean, fish meal, wheat, and rice assume a condition in which various contaminating bacteria grow easily. It has been desired therefore to develop an improved method which can more effectively inhibit growth of contaminating bacteria and increase accumulation of enzymes useful for manufacture of fermented food products in the production of koji for fermented food products.

The present inventors have made investigations in order to develop a method which meets such a desire. Consequently, it has been found in accordance with this invention that by subjecting the cultivation system to a drying treatment to adjust its water content to a specified range at a certain time during a specified period of time after inoculation of a koji mold in a koji substrate, preferably by performing the drying treatment while an aliphatic carboxylic acid containing up to 4 carbon atoms or an alkali metal salt thereof and/or an additive selected from the group consisting of chlorous acid, hypochlorous acid, sulfurous acid, hyposulfurous acid, hydrogensulfurous acid, metabisulfurous acid, hydrogen peroxide and bleaching powder is incorporated in the substrate, growth of contaminating bacteria can be effectively inhibited and accumulation of enzymes useful for manufacture of fermented food products increases to give a high quality solid koji for fermented food products.

Specifically, the investigations of the present inventors have shown that the aforesaid improvement can be achieved by inoculating a koji mold in a koji substrate, and at a certain time during a period of about

10 to about 20 hours after the inoculation, subjecting the cultivation system to a drying treatment to adjust its water content to about 30.+-.5% by weight, particularly about 30.+-.3% by weight.

It was previously known that in the production of koji for soy sauce, in order to increase the content of free glutamic acid in a moromi liquid made by using the aforesaid koji, a step is provided of drying the cultivation system for a short period at a time immediately after germination of the spores of the koji mold when heat from growth of the koji mold has not yet been generated (see Japanese Patent

Publication No. 13675/68 published June 10, 1968). This Patent Publication, however, lacks any recognition about the inhibition of contaminating bacteria which adversely affect the quality of koji.

The Publication discloses that drying treatment is carried out during a period of 12 to 16 hours after the inoculation of a koji mold to adjust the water content of the cultivation system to 39.5 to 42.0% by weight, and that by producing soy sauce using this koji, the free glutamic acid contents of soy sauce increased by 7 to 14% over a control.

As shown in Table 1 below, the investigations of the present inventors have shown that by performing the cultivation such that the cultivation system is subjected to a drying treatment to adjust its water content to about 30.+-.5% by weight, particularly about 30.+-.3% by weight, at a time during the specified period after inoculation of a koji mold, the number of contaminating bacteria can be reduced to the order of 10@5 to 10@6 and the specific protease and amylase activities increase by about 20 to

35% as compared with the results in a control in which the cultivation was performed such that the cultivation system has a water content of about 40% by weight (40.2%) and in which the number of contaminating bacteria was on the order of 10@8. This improving effect is quite unexpected.

Furthermore, it has been found surprisingly that according to a preferred embodiment in which the aforesaid drying treatment is performed using a substrate containing the aforesaid carboxylic acid or its salt or the additive, the number of contaminating bacteria further decreases markedly to the order of

10@1 to 10@3 and the specific protease and amylase activities increase by 20 to 70% as compared with a control, as shown in Table 3 below.

It is an object of this invention therefore to provide a markedly improved process for producing a solid koji for fermented food products.

The above and other objects and advantages of this invention will become more apparent from the following description.

1129/2197

According to the process of this invention, a koji mold or a koji mold in the form of a seed starter is inoculated in a modified koji substrate, and then cultivated. During the step of cultivation, the cultivation system is subjected to a drying treatment to adjust its water content to about 30.+-.5% by weight. The drying treatment can be performed at a certain time during a period of about 10 to about 20 hours after the inoculation.

Generally, the modified koji substrate has a water content of about 40 to about 50% by weight. During the cultivation, it is subjected to a drying treatment so that its water content is reduced to about 30.+-

.5% by weight, preferably about 30.+-.3%. The time from the inoculation to the end of the cultivation is generally about 25 to about 300 hours, most usually about 30 to about 100 hours. According to the process of this invention, the drying treatment is performed within a period of about 10 to about 20 hours after the inoculation.

The drying treatment may be carried out by any known means. For example, the water content of the cultivation system can be reduced by passing dry air through the cultivation zone; or passing heated air through the cultivation zone; or passing dried and heated air through the cultivation zone. Or drying may be carried out under reduced pressure. Preferably, the drying treatment is completed within as short a period of time as possible. For example, it is preferred to adjust the water content to about 30.+-

.5% by weight, preferably about 30.+-.3% by weight, within a period of up to about 2 hours.

The known cultivation conditions and means can be used in the process of this invention except for the inclusion of the aforesaid drying step. Preferably, the cultivation is carried out at a temperature of about

20 DEG to about 40 DEG C. The pH of the cultivation system can be varied suitably, but generally it is about 4 to about 7.5.

The modified koji substrates and methods for preparation thereof in this invention are also known. For example, an unmodified koji substrate composed of a material preferably selected from the group consisting of vegetable carbohydrate materials, vegetable proteinous materials, fish proteins and the like is modified by conventional modifying means. These modifying means include, for example, a method of steaming treatment in which water is added to the unmodified koji substrate or raw materials therefor, and it is heated with saturated steam at atmospheric or elevated pressure and then cooled spontaneously or rapidly; a method of roasting treatment in which the materials are dry-heated at a high temperature either directly or after adding water at atmospheric or elevated pressures, and the products are cooled; or a method of puffing treatment in which with or without adding water, the materials are heat-treated with saturated steam or superheated steam at high temperatures, and the product is then rapidly released into the open atmosphere at a lower pressure.

The proteinous materials and carbohydrate materials used as the unmodified koji substrate include, for example, proteinous materials such as soybean, defatted soybean, dehulled soybean, gluten, fish meal and microbial proteins; carbohydrate materials such as wheat, wheat bran, rice, barley, oats and corn; and by-products of fermented food products such as soy sauce lees, mirin lees and sake lees. These byproducts can be used without modification because they are already in the modified state.

The koji molds used in the process of this invention are known, and include, for example, known molds

Aspergillus oryzae (ATCC 20386, ATCC 11866, ATCC 14895, and IFO 5238), Aspergillus phoenicis

(ATCC 14332), Aspergillus niger (ATCC 1004), Aspergillus awamori (ATCC 14331, ATCC 14333,

ATCC 14335), Rhizopus oryzae (ATCC 4858, HUT 1270), Rhizopus oligosporus (ATCC 22959),

Rhizopus japonicus (ATCC 8466), Rhizopus formosaensis (IAM 6245), Mucor circinelloides (ATCC

8770), Penicillium glaucum (AHU 8026), and Penicillium fuscum (ATCC 10447).

These koji molds can be freely obtained from the aforesaid microorganism depositories, namely ATCC

(The American Type Culture Collection, U.S.A.), IFO (Institute for Fermentation, Osaka, Japan), HUT

(Hiroshima University, Faculty of Engineering, Hiroshima, Japan), IAM (Institute of Applied

Microbiology, University of Tokyo, Japan), and AHU (Faculty of Agriculture, Hokkaido University,

Sapporo, Japan).

According to one preferred embodiment of the process of this invention, an aliphatic carboxylic acid containing up to 4 carbon atoms or an alkali metal salt thereof may be included in the modified koji

1130/2197

substrate before the drying step mentioned above, for example during or before the inoculation of the koji mold, by using known means such as those described in U.S. Pat. Nos. 4,028,470 and 4,115,591.

Similarly, in place of, or together with, the aforesaid aliphatic carboxylic acid, at least one additive selected from the group consisting of chlorous acid, hypochlorous acid, sulfurous acid, hyposulfurous acid, hydrogensulfurous acid, metabisulfurous acid, hydrogen peroxide and bleaching powder may be incorporated into the modified koji substrate.

Examples of the aliphatic carboxylic acid and its salts used in the preferred embodiment mentioned above are formic acid, acetic acid, propionic acid and butyric acid, and sodium and potassium salts thereof. Of these, acetic acid, propionic acid and sodium and potassium salts thereof are preferred.

These additives may be incorporated directly to the substrate or raw materials therefor, or may be diluted with powdery diluents such as wheat flour or rice flour or water before addition.

The amounts of these additives may be chosen properly. For example, the amount of the aliphatic carboxylic acid or its salt may be about 0.01 to about 2% by weight, and the amount of the aforesaid additive selected from the group consisting of chlorous acid, hypochlorous acid, sulfurous acid, etc. may be about 0.01 to about 2% by weight. When both of these additives are used together, their total amount is preferably up to about 2% by weight.

The additives used in this invention are mostly or completely assimmilated by koji molds, yeasts and a small number of bacteria. Even if they remain in koji, they will be completely assimilated in a step of fermentation and aging after charging, and therefore, no problem arises with respect to the taste and sanitation of the final product.

The following examples illustrate the process of this invention in more detail.

EXAMPLE 1

One hundred and fifty liters of hot water at 80 DEG C. was added to 110 kg of defatted soybeans, and the mixture was steamed with saturated steam under a pressure of 2 kg/cm@2.G for 10 minutes.

Roasted and crushed wheat obtained by roasting 110 kg of wheat at 180 DEG C. for 40 seconds and then crushing it was mixed with the steamed defatted soybeans to prepare a koji-making substrate having a water content of 45.0%, w/w.

Ten grams of a seed koji mold (the number of available spores: 1.times.10@9 /g), Aspergillus oryzae

(ATCC 14895), was inoculated in each of seven lots of the resulting modified koji-making substrate, and 3 ml of a suspension of various contaminating bacteria separated from an ordinary soy sauce koji

(the number of living cells: 1.times.10@9 /g) was sprayed uniformly on the modified koji substrate.

Each lot was placed in a tray and set in a koji-making incubator at 30 DEG C. and a definite humidity.

Lot No. 1 (control) was subjected to a usual control of koji making for 42 hours. Lots Nos. 2 to 6 were each placed in a separately provided air circulating-type drying chamber to adjust its water content to each of the values shown in Table 1 (the drying time: 15 to 60 minutes) after a lapse of 15 hours from the inoculation of the koji mold. Then, the test lot was returned to the koji-making incubator, and koji making was performed for a total time of 42 hours.

The water content of koji after the end of koji making decreased by about 5 to 6% (w/w) as compared with that after the drying treatment.

The number of contaminating bacteria in the resulting koji and the specific activities of protease and amylase were measured, and the results are shown in Table 1.

A 100-liter tank was charged with 33 kg of the resulting koji and 40 liters of a 22% (w/w) aqueous solution of sodium chloride, and they were subjected to a control of moromi production in a customary manner. The resulting soy sauce moromi was squeezed to obtain a moromi liquid. The moromi liquid was analyzed for composition, and also subjected to an organoleptic test.

1131/2197

The water content and the number of bacteria in the modified koji substrate, the cultivation system and the resulting koji, the specific activities of protease and amylase, and the components and organoleptic properties of a moromi liquid were determined by the following methods.

Water content

A sample (20 g) was placed on a dish of a Kett infrared ray water content meter (manufactured and solid by Kett Kagaku Kenkyusho Kabushiki Kaisha), and heated for 30 minutes. The difference between the weight of the sample before heating and that after heating was measured, and the water content of the sample was calculated.

Number of bacteria

One gram of a sample koji was suspended in 100 ml of aseptic physiological saline, and if desired, the suspension was sequentially diluted. One milliliter of the dilution was added to 7 ml of a culture medium of the following composition, and was incubated at 37 DEG C. for 24 hours. The number of bacterial colonies which consequently appeared was measured.

Composition of the culture medium:

Meat extract--1% (w/v)

Polypeptone--1% (w/v)

Yeast extract--0.5% (w/v)

Glucose--1% (w/v)

Agar--1.5 (w/v) pH--7.0

Specific activities of protease and amylase

Ten grams of a koji sample was mixed with 100 ml of distilled water, and the mixture was allowed to stand for 24 hours at 5 DEG C. The mixture was then filtered, and the filtrate was used as an enzyme solution. The protease and amylase activities of this solution were determined by the method described in the Japanese-language publication "Science of Seasoning," Vol. 22, No. 3, page 14 (1975) published by Japanese Soy Sauce Institute.

The activities obtained were converted to the ratios of these to the activities of the koji in Lot No. 1

(control) by taking the latter as 1.

Analysis of the components of moromi liquid

A sample of moromi liquid was analyzed by the method described in the Japanese-language publication "Analysis Methods in Fermentation" (by Shoichi Yamada, published by Sankyo Tosho

Kabushiki Kaisha). In the following tables, NaCl, T.N., Glu.A., R.S., and Alc. stand respectively for sodium chloride, total nitrogen, glutamic acid, reducing sugars, and ethyl alcohol. T.N.-U.R. shows the percentage of dissolved nitrogen based on total nitrogen in the koji-making substrate.

Organoleptic test on moromi liquid

The taste of each of the moromi liquids in lots Nos. 2 to 7 was compared with that of the moromi liquid in lot No. 1 (control). The results were rated on a scale of 0 (no difference), 1 (some difference), 2

(large difference), and 3 (very large difference). Where the moromi had a better flavor than the moromi of lot No. 1 (control), the sign (+) was attached. The sign (-) thus shows that the flavor of the moromi was inferior to that of the moromi in lot No. 1 (control). These ratings were averages of the results obtained by a panel of 20 well-trained specialists having a differentiating ability. The sign (*) in the column of "Value" shows that the difference was significant at 5% level; the sign (**) shows that the difference was significant at 1% level; and the sign (-) shows that the difference was not significant.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Comparison

>;tb; Comparison

>;tb; Invention

>;tb; Invention

>;tb; Invention

>;tb; Invention

>;tb; Comparison

1132/2197

>;tb;Test 1 (control)

>;tb; 2 3 4 5 6 7

>;tb;__________________________________________________________________________

>;tb;Water content of solid koji

>;tb;after the drying treatment (%)

>;tb; 40.2 37.1 34.0 33.1 30.0 27.2 23.0

>;tb;Number of bacteria in koji

>;tb;per gram 3.8 .times. 10@8

>;tb; 1.1 .times. 10@8

>;tb; 8.8 .times. 10@5

>;tb; 4.1 .times. 10@5

>;tb; 2.6 .times. 10@5

>;tb; 1.3 .times. 10@5

>;tb; 1.0 .times. 10@5

>;tb;Specific enzyme

>;tb; Protease

>;tb; 1.00 1.09 1.27 1.29 1.35 1.28 0.88

>;tb;activity in

>;tb;koji Amylase

>;tb; 1.0 1.1 1.2 1.2 1.3 1.2 0.9

>;tb; NaCl 17.40 17.40 17.35

>;tb; 17.30

>;tb; 17.30

>;tb; 17.35

>;tb; 17.45

>;tb; T.N. 1.73 1.74 1.75 1.75 1.78 1.77 1.70

>;tb;Analysis of the

>;tb; Glu. A.

>;tb; 1.25 1.26 1.31 1.31 1.33 1.31 1.19

>;tb;components of

>;tb;moromi liquid

>;tb; R.S. 2.85 3.05 3.00 3.05 3.25 3.10 2.55

>;tb;(%) Alc. 2.25 2.20 2.20 2.20 2.15 2.20 2.05

>;tb; T.N.-U.R.

>;tb; 84.1 84.6 85.4 85.6 86.6 86.3 82.9

>;tb;Organoleptic test

>;tb; Rating

>;tb; 0 +0.2 +0.6 +0.6 +0.7 +0.6 -0.5

>;tb; Value -- -- * * * * *

>;tb;__________________________________________________________________________

The results in Table 1 show that by reducing the water content of the solid koji to 35% (w/w) or less, especially 33% (w/w) or less, the number of bacteria decreases markedly as compared with the control, and at the same time, the activites of enzymes such as protease and amylase can be markedly increased, and that when soy sauce is produced by using these kojis in accordance with this invention, the ratio of utilization of nitrogen and the contents of useful components such as glutamic acid and sugars increase, and the resulting soy sauce is organoleptically excellent.

When the water content of koji after drying was reduced to less than about 25% (w/w), growth of the koji mold was inhibited, and accumulation of enzymes decreased. Accordingly, drying to such a low water content should desirably be avoided.

EXAMPLE 2

One hundred kilograms of polished rice with a degree of polishing of 10% was washed, soaked and freed of water in a customary manner. It was steamed with saturated steam for 10 minutes under a pressure of 2 kg/cm@2.G, and allowed to cool to make a koji substrate.

1133/2197

Ten grams of a seed koji mold (the number of available spores: 1.times.10@9 /ml), Aspergillus oryzae

(ATCC 11866), was inoculated in each of test lots containing 30 kg of the resulting koji substrate

(water content: 42.5% w/w), and 1 ml of a suspension of various bacteria separated from an ordinary rice koji (the number of living cells: 1.times.10@9 /ml) was sprayed uniformly on the koji substrate.

Each lot was placed in a koji-making tray, and set in a koji-making incubator kept at 30 DEG C. and a definite humidity.

Lot No. 1 (control) was subjected to an ordinary control of Koji making for 48 hours. Test lots Nos. 2 to 6 were dried for 20 minutes in a separately provided air circulating-type drying chamber after a lapse of 8, 10, 15, 20 and 22 hours, respectively, from the inoculation of the koji mold to reduce the water content to 32 to 34% (w/w). Then, each of the lots was returned to the koji-making incubator at 30

DEG C., and subjected to koji making for a total time of 48 hours.

The number of bacteria, and the specific activities of protease and amylase were measured, and the results are shown in Table 2.

A 100-liter tank was charged with 40 kg of soybeans steamed in a customary manner, 9 kg of common salt and 10 kg of the koji obtained in each run. They were subjected to fermentation and aging in a customary manner to obtain a miso moromi liquid. The resulting moromi liquid was analyzed for components, and the results are shown in Table 2.

T.N. (water-soluble) shown in Table 2 was measured as follows: The miso was homogenized, and 1 g of the homogenized miso was suspended in 100 ml of water. The suspension was filtered, and the total amount of nitrogen in the filtrate was measured by the Kjeldahl's method.

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb;Test lot 1(control)

>;tb; 2(comparison)

>;tb; 3 4 5 6(comparison)

>;tb;__________________________________________________________________________

>;tb;Time elapsed until the drying

>;tb;treatment after inoculation (hrs)

>;tb; -- 8 10 15 20 22


>;tb; 3.8 .times. 10@7

>;tb; 1.9 .times. 10@4

>;tb; 2.2 .times. 10@4

>;tb; 3.7 .times. 10@4

>;tb; 6.1 .times. 10@4

>;tb; 2.5 .times. 10@4

>;tb;per gram

>;tb;Specific enzyme activities

>;tb;in koji

>;tb;Protease 1.00 0.85 1.11 1.20 1.15 0.92

>;tb;Amylase 1.0 0.6 1.1 1.2 1.1 1.0

>;tb;Analysis of the components

>;tb;of miso (%)

>;tb;NaCl 10.50 10.75 10.60

>;tb; 10.55

>;tb; 10.50

>;tb; 10.50

>;tb;T.N. 2.20 2.18 2.20 2.18 2.18 2.15

>;tb;R.S. 11.5 10.0 12.1 12.5 12.3 11.8

>;tb;T.N. (Water-soluble)

>;tb; 0.85 0.68 0.93 1.12 0.98 0.90

>;tb; ##STR1## 38.6 31.2 42.3 51.4 45.0 41.9

>;tb;__________________________________________________________________________

1134/2197

The results in Table 2 show that when the drying treatment is performed during a period of about 10 to about 20 hours after inoculation of a koji mold, the number of bacteria in the koji decreases markedly as compared with the control, and at the same time, the protease and amylase activities can be increased greatly, and that when miso is produced by using these kojis, the contents of useful components such as sugars and water-soluble nitrogen increase and the resulting miso is of good quality.

EXAMPLE 3

To 10 kg of defatted soybeans in each test lot was added 13 liters of an aqueous solution of each of the various additives shown in Table 3 in hot water at 80 DEG C. (in each test lot, the amount of the additive was adjusted to 0.5% w/w based on the total amount of the koji substrate). The mixture was steamed with heated saturated steam under a pressure of 2 kg/cm@2.G for 10 minutes. The treated mixture was then mixed with roasted and crushed wheat obtained by roasting 10 kg of wheat at 180

DEG C. for 40 seconds and then crushing it to prepare a koji-making substrate (water content 44.5% w/w).

Fifty grams of a seed koji mold (the number of available spores: 1.times.10@9 /ml), Aspergillus oryzae

(ATCC 20386), was inoculated in 28 kg of the modified koji mold, and 3 ml of a suspension (the number of living cells: 1.times.10@9 /g) of various bacteria separated from an ordinary soy sauce koji was uniformly sprayed onto the substrate. Each test lot was placed in a koji-making tray, and set in a koji-making incubator kept at 30 DEG C. and a definite humidity.

Each of the lots was dried for 20 minutes in a separately provided air circulating-type drying chamber after a lapse of 15 hours from the inoculation of the koji mold to a water content of 32 to 34% (w/w), and then returned to the koji-making incubator. Koji-making was thus performed for a total time of 42 hours.

The number of bacteria and the protease and amylase activities of the resulting koji were determined, and the results are shown in Table 3.

Test lot No. 1 (control) was treated in the same way as above except that no additive was added to the koji-making material but only hot water at 80 DEG C. was added, and during the koji-making process, the drying treatment was not performed.

Twenty kilograms of the koji in each of the lots, and 30 liters of a 22% (w/w) aqueous solution of sodium chloride were charged into a 50-liter tank, and subjected to a usual control of moromi making at 30 DEG C. for 150 days. The resulting soy sauce moromi was squeezed to obtain a moromi liquid.

The moromi liquid was analyzed for components and subjected to an organoleptic test. The results are shown in Table 3.

>;tb; TABLE 3

>;tb;__________________________________________________________________________

>;tb; Number Analysis of the components of

>;tb; bacteria

>;tb; Specific enzyme

>;tb; moromi liquid (%) Organoleptic

>;tb; in koji

>;tb; activities Glu. T.N.-

>;tb; test

>;tb;Test lot

>;tb; Additive per gram

>;tb; Protease

>;tb; Amylase

>;tb; NaCl

>;tb; T.N.

>;tb; A. R.S.

>;tb; Alc.

>;tb; U.R.

>;tb; Rating

1135/2197

>;tb; Value

>;tb;__________________________________________________________________________

>;tb;(control)

>;tb; None 2.1 .times. 10@8

>;tb; 1.0 1.0 17.80

>;tb; 1.72

>;tb; 1.30

>;tb; 4.05

>;tb; 1.95

>;tb; 83.8

>;tb; 0 --

>;tb;2 Acetic acid

>;tb; 4.5 .times. 10@2

>;tb; 1.4 1.2 17.65

>;tb; 1.80

>;tb; 1.45

>;tb; 3.80

>;tb; 2.10

>;tb; 88.4

>;tb; +1.5

>;tb; **

>;tb;3 Sodium acetate

>;tb; 2.1 .times. 10@2

>;tb; 1.6 1.5 17.55

>;tb; 1.80

>;tb; 1.47

>;tb; 3.95

>;tb; 2.15

>;tb; 88.9

>;tb; +1.7

>;tb; **

>;tb;4 Potassium acetate

>;tb; 3.3 .times. 10@2

>;tb; 1.5 1.4 17.55

>;tb; 1.80

>;tb; 1.46

>;tb; 4.05

>;tb; 2.10

>;tb; 88.7

>;tb; +1.6

>;tb; **

>;tb;5 Propionic acid

>;tb; 1.8 .times. 10@2

>;tb; 1.3 1.4 17.60

>;tb; 1.78

>;tb; 1.43

>;tb; 3.95

>;tb; 2.15

>;tb; 87.7

>;tb; +1.4

>;tb; **

>;tb;6 Sodium propionate

>;tb; 1.3 .times. 10@2

>;tb; 1.4 1.5 17.55

>;tb; 1.79

>;tb; 1.45

>;tb; 4.00

>;tb; 2.10

>;tb; 88.4

1136/2197

>;tb; +1.6

>;tb; **

>;tb;7 Sodium formate

>;tb; 1.1 .times. 10@2

>;tb; 1.3 1.4 17.60

>;tb; 1.80

>;tb; 1.43

>;tb; 3.60

>;tb; 2.15

>;tb; 88.6

>;tb; +1.4

>;tb; **

>;tb;8 Sodium butyrate

>;tb; 5.2 .times. 10@2

>;tb; 1.3 1.3 17.60

>;tb; 1.81

>;tb; 1.42

>;tb; 3.70

>;tb; 2.20

>;tb; 89.1

>;tb; +1.3

>;tb; **

>;tb;9 Acetic acid:

>;tb; Sodium acetate

>;tb; 3.0 .times. 10@2

>;tb; 1.4 1.5 17.55

>;tb; 1.80

>;tb; 1.41

>;tb; 3.85

>;tb; 2.20

>;tb; 88.9

>;tb; +1.5

>;tb; **

>;tb; (1:1)

>;tb;10 Chlorous acid

>;tb; 2.5 .times. 10@3

>;tb; 1.2 1.3 17.60

>;tb; 1.76

>;tb; 1.40

>;tb; 4.50

>;tb; 2.10

>;tb; 86.7

>;tb; +1.2

>;tb; **

>;tb;11 Sulfurous acid

>;tb; 3.1 .times. 10@3

>;tb; 1.2 1.2 17.65

>;tb; 1.77

>;tb; 1.40

>;tb; 4.35

>;tb; 2.10

>;tb; 86.9

>;tb; +1.2

>;tb; **

>;tb;12 Hydrogen peroxide

>;tb; 1.8 .times. 10@3

>;tb; 1.2 1.2 17.65

>;tb; 1.78

>;tb; 1.39

1137/2197

>;tb; 3.80

>;tb; 2.15

>;tb; 87.4

>;tb; +1.3

>;tb; **

>;tb;13 Bleaching powder

>;tb; 2.2 .times. 10@2

>;tb; 1.3 1.4 17.55

>;tb; 1.77

>;tb; 1.39

>;tb; 3.75

>;tb; 2.20

>;tb; 87.4

>;tb; +1.5

>;tb; **

>;tb;14 Sulfurous acid:

>;tb; Hydrogen peroxide

>;tb; 2.1 .times. 10@2

>;tb; 1.3 1.3 17.65

>;tb; 1.80

>;tb; 1.40

>;tb; 3.95

>;tb; 2.15

>;tb; 88.4

>;tb; +1.4

>;tb; **

>;tb; (1:1)

>;tb;15 Sodium acetate:

>;tb; Sodium hydrogen-

>;tb; 3.0 .times. 10@1

>;tb; 1.7 1.6 17.50

>;tb; 1.84

>;tb; 1.48

>;tb; 3.60

>;tb; 2.35

>;tb; 90.3

>;tb; +2.1

>;tb; **

>;tb; sulfite (1:1)

>;tb;16 Potassium acetate:

>;tb; Sodium hyposulfite

>;tb; 5.5 .times. 10@1

>;tb; 1.6 1.5 17.50

>;tb; 1.83

>;tb; 1.47

>;tb; 3.50

>;tb; 2.40

>;tb; 89.7

>;tb; +1.9

>;tb; **

>;tb; (1:1)

>;tb;17 Sodium propionate:

>;tb; potassium hyposulfite

>;tb; 1.9 .times. 10@1

>;tb; 1.5 1.5 17.50

>;tb; 1.81

>;tb; 1.45

>;tb; 3.85

>;tb; 2.25

1138/2197

>;tb; 89.2

>;tb; +1.8

>;tb; **

>;tb; (1:1)

>;tb;18 Acetate acid:

>;tb; bleaching powder

>;tb; 3.1 .times. 10@2

>;tb; 1.4 1.3 17.60

>;tb; 1.80

>;tb; 1.41

>;tb; 4.00

>;tb; 2.15

>;tb; 88.3

>;tb; +1.4

>;tb; **

>;tb; (1:1)

>;tb;__________________________________________________________________________

The results in Table 3 show that by adding the various additives in accordance with this invention during the inoculation of a koji mold and drying the cultivation system during a period of 10 to 20 hours after the inoculation of the koji mold to reduce the water content of the solid koji to about 30.+-

.5% (w/w), the number of bacteria in the koji decreases markedly as compared with the control and the protease and amylase activities can be markedly increased, and that when soy sauce is produced by using these kojis, the ratio of utilization of nitrogen and the contents of useful components such as glutamic acid, sugars and ethyl alcohol increase and the soy sauce obtained was organoleptically excellent.

EXAMPLE 4

Warm water (130 liters) at 60 DEG C. was added to 100 kg of defatted soybeans, and the mixture was steamed with saturated steam at 120 DEG C. under a pressure of 1 kg/cm@2.G for 45 minutes. The treated mixture was then mixed with roasted and crushed wheat obtained by roasting 100 kg of wheat at 170 DEG C. for 45 seconds and then crushing it to prepare a koji-making substrate (water content

44.8% w/w).

120 g of a seed koji mold (the number of available spores: 1.2.times.10@9 /g), Aspergillus oryzae

(ATCC 11866), was inoculatted in 150 kg of the koji substrate, and 10 ml of a suspension of various bacteria separated from an ordinary soy sauce koji (the number of living cells: 2.times.10@8 /g) was sprayed uniformly on the koji substrate. The koji substrate was then placed in an air-circulating mechanical koji-making chamber. After a lapse of 14 hours from the inoculation of the koji mold, the koji was dried for 20 minutes in a separately provided air-circulating drying chamber to a water content of 30% (w/w), and then returned to the aforesaid koji-making chamber. Koji-making was performed for a total period of 45 hours.

The control was performed in the same way as above except that the drying treatment of the koji was not performed. The resulting koji (120 kg) was charged into a 300-liter tank together with 180 liters of a 22% (w/w) aqueous solution of sodium chloride, and fermented and aged at 30 DEG C. for 5 months to form a soy sauce moromi.

The results are shown in Table 4.

>;tb; TABLE 4

>;tb;______________________________________

>;tb;Sample Control Invention

>;tb;______________________________________

>;tb;Water content of koji after

>;tb;drying (%) 42.5 30.0


>;tb;per gram 3.7 .times. 10@8

>;tb; 7.5 .times. 10@5

1139/2197

>;tb;Specific enzyme activities

>;tb;Protease 1.0 1.3

>;tb;Amylase 1.0 1.2

>;tb;Analysis of the components of

>;tb;moromi liquid (%)

>;tb;NaCl 17.70 17.55

>;tb;T.N. 1.75 1.78

>;tb;Glu. A. 1.2 1.4

>;tb;R.S. 4.10 3.80

>;tb;Alc. 2.05 2.20

>;tb;T.N.-U.R. 83.5 86.1


>;tb;Rating 0 +2.1

>;tb;Value -- **

>;tb;______________________________________

The results in Table 4 show that the koji in accordance with this invention has a far lesser number of bacteria and much higher protease and amylase activities than the koji in the control, and that when soy sauce is produced by using the resulting koji, the product contains large amounts of useful components such as glutamic acid and ethyl alcohol and has a good flavor.

EXAMPLE 5

In each test lot, 13 kg of polished rice with a degree of polishing of 10% was washed, soaked and freed of water in a customary manner, and steamed with saturated steam for 8 minutes under a pressure of

1.5 kg/cm@2.G. The resulting koji substrate was sprayed uniformly with 0.5 liter of an aqueous solution of each of the additives shown in Table 5 in hot water at 70 DEG C. (the amount of the additive was adjusted to 0.4% w/w based on the total amount of the koji substrate having a water content of 43.1% w/w in lots Nos. 1 to 3). Then, 20 g of a rice seed koji, Aspergillus oryzae (IFO

5238), was uniformly sprayed onto the treated koji substrate. Then, 2 ml of a suspension of various bacteria separated from a rice koji was added. The mixture was placed in a koji-making tray, and then placed in a koji-making incubator kept at 30 DEG and a definite humidity.

After a lapse of 16 hours from the inoculation of the koji mold, the solid koji was dried for 18 minutes in a separately provided air-circulating type drying chamber, and then returned to the koji-making incubator. Thus, koji-making was performed for a total period of 45 hours.

The control was performed in the same way as above except that no additive was incorporated in the koji-making substrate but only hot water at 70 DEG C. was added, and during the koji-making process, the drying treatment was not performed.

Fifteen kilograms of the koji was charged into 200 liter tank together with 100 kg of steamed sticky rice and 50 liters of a 45% (v/v) aqueous solution of ethyl alcohol, and subjected to a control of moromi-making at 25 DEG C. for 60 days in accordance with a usual method of mirin fermentation, and then the product was squeezed. The resulting mirin liquid was analyzed for components and also subjected to an organoleptic test. The results are shown in Table 5.

In Table 5, Baume and amino acids were measured in accordance with the method described in the above-cited "Analysis Methods in Fermentation" as in the analysis of a soy sauce moromi liquid. The ratio of utilization of sugars was measured as follows: The mirin moromi was homogenized, and a predetermined amount of it was filtered on a filter paper. The sugar content of the filtrate was measured, and the percentage of it based on the total amount of sugars in the moromi was determined.

>;tb; TABLE 5

>;tb;__________________________________________________________________________

>;tb;Test lot Control

>;tb; 1 2 3

>;tb;__________________________________________________________________________

>;tb;Additive None Sodium

>;tb; Sulfurous

1140/2197

>;tb; Sodium acetate:

>;tb; acetate

>;tb; acid bleaching powder

>;tb; (1:1)

>;tb;Water content of koji after drying (%)

>;tb; 40.4 33.5 34.0 33.1

>;tb;Number of bacteria in koji per gram

>;tb; 5.6 .times. 10@7

>;tb; 2.5 .times. 10@1

>;tb; 2.0 .times. 10@1

>;tb; 1.0 .times. 10@1

>;tb;Specific enzyme activity

>;tb;Protease 1.0 1.5 1.3 1.4

>;tb;Amylase 1.0 1.4 1.3 1.4

>;tb;Analysis of the components of moromi liquid

>;tb;Baume 19.5 20.5 20.1 20.2

>;tb;Alc. (%) 15.3 15.0 15.1 15.0

>;tb;Amino acids (%) 0.19 0.26 0.23 0.24

>;tb;Sugars (%) 42.5 50.3 48.8 49.5

>;tb;pH 5.4 5.4 5.4 5.3

>;tb;Ratio of utilization of sugars (%)

>;tb; 78.5 82.5 81.8 82.1


>;tb;Rating 0 +1.7 +1.5 +1.5

>;tb;Value -- ** ** **

>;tb;__________________________________________________________________________

The results in Table 5 show that the kojis in accordance with this invention have a far lesser amount of bacteria and much higher protease and amylase activities than the koji in the control, and that when mirin is produced using the resulting koji, the product is of excellent quality with a good flavor and large amounts of useful components such as amino acids and sugars.

As demonstrated hereinabove, the process of this invention makes it possible to inhibit markedly growth of contaminating bacteria in solid kojis for production of fermented food products and to increase greatly the amounts of useful enzymes accumulated in the koji, such as protease and amylase.

Use of these kojis leads to fermented food products containing large amounts of various useful components and a good flavor.Data supplied from the esp@cenet database - Worldwide

Claims:


What we claim is:

1. In a process for producing a solid koji for a fermented food product which comprises inoculating a koji mold in a modified koji substrate having a water content of from about 40% to about 50% by weight and cultivating it at a temperature of about 20 DEG C. to about 40 DEG C. for a time sufficient to produce a solid koji for fermented food products, the improvement wherein at a certain time during a period of about 10 hours to about 20 hours after the inoculation of the koji mold, the cultivation system is subjected to a drying treatment to adjust its water content to about 30.+-.3% and thereafter the cultivation is continued for a total cultivation time of from about 30 to about 100 hours.

2. The process of claim 1 wherein said substrate contains an aliphatic carboxylic acid containing up to

4 carbon atoms or an alkali metal salt thereof.

3. The process of claim 2 wherein said aliphatic carboxylic acid or salt thereof is selected from the group consisting of acetic acid, propionic acid and sodium salts of these.

4. The process of claim 2 or 3 wherein the amount of said aliphatic carboxylic acid or salt thereof is about 0.01 to about 2% by weight based on the weight of the koji substrate.

1141/2197

5. The process of claim 1 wherein said koji substrate contains at least one additive selected from the group consisting of chlorous acid, hypochlorous acid, sulfurous acid, hyposulfurous acid, hydrogensulfurous acid, metabisulfurous acid, hydrogen peroxide and bleaching powder.

6. The process of claim 5 wherein the amount of said additive is about 0.01 to about 2% by weight based on the weight of the koji substrate.

7. The process of claim 1 wherein said drying treatment is carried out using dried air, heated air, or dried and heated air.

8. The process of claim 1 wherein said solid koji is used in the production of a fermented food product which is soy sauce, miso, sake or mirin.Data supplied from the esp@cenet database - Worldwide

1142/2197

234.

JP55165768 - 12/24/1980

PREPARATION OF NOODLE


Inventor(s): FUSHIMI TAKAO (--)

Applicant(s): FUSHIMI TAKAO (--)


IP Class: A23L1/16

E Class: A23L1/16B



Family: JP55165768

Abstract:


PURPOSE:To improve the taste and palatability of noodles, by sandwiching a noodle strip prepared from wheat flour, unpolished rice flour, beans, and table salt, between a pair of noodle strips prepared from wheat flour, etc. and table salt, etc. CONSTITUTION:A noodle strip (A) is sandwiched between a pair of noodle strips (B), and the laminated noodle is pressed and slitted to obtain the objective noodles.

The noodle strip (A) is prepared by kneading wheat flour or a mixture of wheat flour, buckwheat flour or unpolished rice flour, beans, dried bean curd, soybean milk, etc., with water containing table salt or table salt and a noodle improver, etc., and pressing the kneaded dough; and the noodle strip (B) is prepared by kneading wheat flour or a mixture of wheat flour and buckwheat flour with water containing table salt and a noodle improver, and pressing the dough. The noodle improver is, e.g. an emulsifier such as a glycerin fatty acid ester, a sorbitan fatty acid ester, etc., a sizing agent such as sodium arginate, etc.

1143/2197

235.

JP57036947 - 2/27/1982

KENKOINSHOKUHINNOSEIZOHOHO


Inventor(s): KAWAMURA SABURO (--); TAKEUCHI MASAYASU (--)

Applicant(s): JAPAN MAIZE PROD (--)

IP Class 4 Digits: A23L; A21D; A23G

IP Class: A23L1/00; A23L1/30; A23L1/325; A23G3/00; A21D2/18; A23L1/238; A23G1/00;

A23G9/02; A23L1/32; A23L2/26

E Class: A23L1/308B



Family: JP57036947

Abstract:


PURPOSE:To prepre a healthy food having effect to suppress the rise in cholesterol, by adding an edible fiber consisting essentially of hemicellulose extracted from corn fibers to a food.

CONSTITUTION:The husk of corn is treated with an enzyme, starch, lipid, etc. are removed, the prepared matter is treated with an alkali, and an edible fiber consisting essentially of hemicellulose is extracted. The edible fiber is added to ingredients, to prepare a cookie, bread, boiled fish paste, paste bean jam, sponge cake, riceflour dumpling mixed with mugwort, noodles, etc.

1144/2197

236.

JP57039735 - 3/5/1982

PREPARATION OF DRIED SWEET-BOILED JAPANESE CHESTNUT


Inventor(s): YAMASHITA HIROSHI (--); SAITOU TOMIJI (--)

Applicant(s): MEIJI SEIKA CO (--)


IP Class: A23B9/00; A23B7/02; A23B7/08

E Class: A23L1/36B2



Family: JP57039735

Abstract:


PURPOSE:To prepare dried sweet-boiled Japanese chestnuts having good keeping quality and generalpurpose properties as a food material, by draining a sugar solution from sweet-boiled Japanese chestnuts, and reducing the moisture content thereof to 15wt% or less by irradiation with microwaves and through flow drying. CONSTITUTION:Japanese chestnuts are sweet boiled with a sugar solution having a dextrose equivalent of 20-65, and the sugar solution is then drained. The Japanese chestnuts are heated by irradiation with microwaves and dried to a moisture content of 15-25wt%. The dried

Japanese chestnuts are then dried by the through flow drying with hot air at 90 deg.C or below to give the final moisture content of 15wt% or less. Thus, the moisture activity is adjusted to about 0.65 to prevent the deterioration by molds. The resultant Japanese chestnuts are returned to the original sweetboiled Japanese chestnuts by immersing in a concentrated sugar solution, and heating with microwaves.

The resultant dried sweet-boiled Japanese chestnuts are usable as a material for rice boiled with chestnuts, bean jelly with chestnuts mixed up, etc.

1145/2197

237.

JP57086261 - 5/29/1982

PREPARATION OF SNACK FOOD


Inventor(s): MATSUEDA KATSUHARU (--); KOMODA MAMORU (--)

Applicant(s): SUGIYAMA SANGYO KAGAKU KENK (--)


IP Class: A23L1/18; A23G3/00

E Class: A23L1/182C



Family: JP57086261

Abstract:


PURPOSE:To prepare a crisp and short snack food having high expansion ratio, by immersing grains fully in an aqueous ethanol solution, draining, and frying in oil. CONSTITUTION:Grains of corn, rice, wheat, barley, soybean, peanut, etc. optionally ground to 2-8 pieces, are immersed fully in a ;=5wt% aqueous solution of ethanol. Addition of surface-active agents, seasonings, spices, colorants, preservatives, etc. to the solution improves the taste, flavor, color tone, preservability, etc. of the product. The immersed grains are drained and fried in an oil at about 180 deg.C.

1146/2197

238.

JP58051845 - 3/26/1983

PREPARATION OF EXPANDED HOLLOW CAKE


Inventor(s):

-)

MOCHIZUKI KEIZOU (--); KUWADA YUKIO (--); MIZOGUCHI NAGAHIKO (-

Applicant(s): MEIJI SEIKA CO (--)


IP Class: A23G3/00

E Class: A23L1/164B; A23L1/36B2; A23L1/00P8B4; A21D13/08H; A23G3/00M; A23G3/20F12



Family: JP58051845

Equivalent: US4499113; GB2105968; DE3231580

Abstract:


PURPOSE:To prepare an expanded hollow cake having high expansion ratio and excellent feeling to the tooth, palatability, taste and flavor, by coating a core alternately with a mixture of two kinds of starches having different expansion ratio and an aqueous sugar solution, and frying the coated food in oil to effect spontaneous expansion. CONSTITUTION:Nuts, expanded starch, etc. coated with oily cream, chocolate, etc. or formed oily cream, chocolate, etc. is used as a core material, and its surface is coated alternately with (A) a mixture of (a) starch having low expansion ratio and excellent taste and flavor, e.g. mushed potatoes, corn, etc. and (b) alpha-starch having high expansion ratio such as alphaglutinous rice, corn flour, glutinous rice flour, etc. at a ratio of 60:40-30:70, and (B) an aqueous sugar syrup composed of starch syrup and having Brix concentration of 30-40 deg.. The coated product is further coated alternately with (C) a starch mixture obtained by mixing the above component (a) with less than equal amount of the component (b), and (D) an aqueous sugar syrup composed of starch syrup and having Brix concentration of 50-60 deg.. The product is fried in oil to obtain the objective cake.Description:



The present invention relates to a process for preparing snack products having an expanded coating, and more particularly, to snack products twice coated with a mixture of two starchy flours having different degrees of expandability and an aqueous sugar solution in a two layers structure on the surface of a core material selected from nuts, seeds, beans, expanded starchy materials coated with fatty confectionary material and shaped fatty confectionary materials. The process of the present invention does not use a leavening agent and yet provides a snack product with a coating that expands at a desired rate of expansion during frying and is crisp and palatable. As a further advantage, the meltable core material does not flow out of the product during expansion by frying.


1147/2197

A typical Japanese snack product with a coating that is expanded by frying is referred to the name

"Onorokemame". Conventionally, "Onorokemame" is made from a formulation that contains mainly wheat flour and a large amount of expandable pregelatinized starchy flour such as pregelatinized waxy corn flour or pregelatinized glutinous rice flour that expands with heat to provide a fully expanded product. However, there was no use of the starchy flour which is less expandable but provides good savor such as mashed potato flour and corn flour, thus, a fully savory product was not obtained. In accordance with the conventional method of making "Onorokemame", the core material is coated with a layer of starchy flour that has a single degree of expandability. Accordingly, the expansion of the coating during heating is difficult to control, and hence it is difficult to provide a product that has a suitable degree of hardness. Japanese Patent Publication No. 20584/78 (corresponding to U.S. Pat. No.

4,053,650) describes a process that improves and controls the expansion of the coating simultaneously.

The process involves expanding a formulation uniformly within a baking mold without using a large amount of highly expandable starchy flour. However, this process is costly because it requires the use of a special baking mold.


As a result of various studies to eliminate the defects of the conventional process of making snack products with expanded coatings, the present inventors have been able to prepare a snack product that is crisp and palatable. The product can be prepared from a starchy flour formulation that contains a smaller amount of highly expandable pregelatinized starchy flour and 50 to 77.5% by weight, based on the total starchy flour, of less expandable starchy flour such as mashed potato flour and corn flour. The formulation is coated over the core material without a leavening agent. The coated core material is then fried to expand the coating. The snack product prepared in this manner has the same good savor as the less expandable starchy flour. The present inventors have also found that by this method, a snack product containing a core of a shaped fatty confectionary material such as fatty cream or chocolate, can be produced without the core flowing out during frying.


The core material used in the process of the present invention is selected from nuts (for example, almond, hazelnut, groundnut, chestnut, cashew nut, Brazil nut, walnut, Macadamia nut, pecan nut, and so on), seeds, beans, expanded starchy materials coated with fatty confectionary material (for example, expanded rice, popcorn and puffed barley which are coated with fatty cheesy cream or chocolate), and shaped fatty confectionary material (for example, fatty cream and chocolate).

The core material is given a first coating comprising a mixture of two different types of starchy flour.

The first type of starchy flour is comprised of at least one starchy flour that has small expandability but provides good savor, for example, mashed potato flour, corn flour and green pea flour. The second type of starchy flour is comprised of at least one highly expandable pregelatinized starchy flour, for example, pregelatinized waxy corn flour and pregelatinized glutinous rice flour. The mixing ratio of the first type of starchy flour to the second type of pregelatinized starchy flour is 60:40 to 30:70 by weight.

The first coating also includes an aqueous sugar solution that comprises corn syrup (i.e., glucose syrup) or a mixture of corn syrup and sucrose to which water has been added to achieve a refractive Brix value of 30 to 40. This first coating is capable of greatly expanding during frying and is formed by spraying or sprinkling the starchy flour mixture and aqueous sugar solution alternately over the core material in a tumbling coater such as a revolving pan or rotary drum.

The core material is then given a second coating. This coating is comprising a mixture of the less expandable but savory starchy flour with an equal or less amount by weight of the highly expandable pregelatinized starchy flour and an aqueous sugar solution that comprises sucrose or its mixture with corn syrup and/or soluble starch to which water has been added to achieve a refractive Brix value of 50 to 60. The second coating is less expandable than the first coating during frying and is formed by spraying or sprinkling the starchy flour mixture and aqueous sugar solution alternately over the core material in a tumbling coater such as a revolving pan or rotary drum.

To provide a highly expanded snack product that is crisp and palatable, the weight ratio of the first coating to second coating is preferably in the range of from about 50:50 to 60:40. The core material

1148/2197

with the first and second coatings is subjected to a third step where it is fried after optional drying. The result is a desired highly expanded snack product which is crisp and has good palatability.

Preferred examples of the highly expandable pregelatinized starchy flour to be used in the first and second coatings are pregelatinized waxy corn flour and pregelatinized glutinous rice flour, and examples of the less expandable but highly savory starchy flour are mashed potato flour and corn flour.

The preferred mixing ratio of the less expandable but highly savory starchy flour to the highly expandable pregelatinized starchy flour in the first coating is in the range of from 60:40 to 30:70 by weight. If the proportion of the highly expandable pregelatinized starchy flour is less than 40% by weight, the desired expansion of the first coating cannot be achieved, and if the proportion exceeds

70% by weight, the first coating expands too much to provide a uniformly expanded snack product.

The aqueous sugar solution for making the first coating is comprised of corn syrup with a DE of 40 to

50 and a water content of 25% (the term "syrup" as used hereinafter means syrup having this percentage of water) and which has a refractive Brix value of 30 to 40. Alternatively, it may be comprised of a mixture of one part by weight of corn syrup and not more than 2 parts by weight of sucrose to which water has been added to provide a refractive Brix value of 30 to 40. If the refractive

Brix value of the aqueous sugar solution is less than 30, it is difficult to form a uniform first coating on the core material, and if the refractive Brix value exceeds 40, the first coating shrinks during frying and a product with a uniformly expanded coating cannot be obtained. If the proportion of sucrose to corn syrup exceeds 2 parts by weight, the first coating shrinks during frying and a product with a uniformly expanded coating cannot be obtained. Therefore, if a mixture of corn syrup and sucrose is used as an aqueous sugar solution for making the first coating, the mixing ratio must not be more than 2 parts by weight of sucrose to one part by weight of corn syrup and water must be added to provide a refractive

Brix value of from 30 to 40.

The preferred ratio of the thickness of the first coating to that of the second coating is such that the weight proportion of the first coating to the second coating is in the range of from 50:50 to 60:40. In other words, the thickness of the first coating is from 50 to 60% by weight of the total of both coatings.

If the thickness of the first coating is such that its weight exceeds 60% of the weight of the total of both coatings, the coating will rupture during frying and a product with a uniform coating cannot be obtained. If the weight of the first coating is less than 50% of the weight of the total of both coatings, the resulting product will not have an adequately expanded coating.

The first coating is formed and then a second coating is given. A mixture of highly expandable pregelatinized starchy flour and less expandable starchy flour is also used in the second coating. The preferred highly expandable pregelatinized starchy flour is comprised of at least one flour selected from among pregelatinized waxy corn flour and pregelatinized glutinous rice flour. At least one flour selected from among mashed potato flour and corn flour is preferred as the less expandable starchy flour since it also provides good savor. If more savor is necessary, other starchy flours having low expandability (such as non-glutinous rice flour or pea flour) may be used.

In the second coating, the highly expandable pregelatinized starchy flour is preferably used in a weight amount not greater than that of the less expandable starchy flour, namely, the weight ratio of the highly expandable pregelatinized starchy flour to the less expandable starchy flour is in the range of from 5:95 to 50:50. If the weight of the highly expandable pregelatinized starchy flour is less than 5% of the total starchy flour, the surface of the product expanded by frying has a tendency to become coarse.

However, no additional disadvantages result even if less than 5% by weight of the highly expandable pregelatinized starchy flour is used. If the proportion of the highly expandable pregelatinized starchy flour exceeds 50% by weight, the desired crisp product is not obtained.

The preferred aqueous sugar solution for making the second coating comprises sucrose or a mixture of

2 parts by weight of sucrose and not more than one part by weight of corn syrup and/or soluble starch that is given water to provide a refractive Brix value of 50 to 60. If sucrose alone or a mixture of sucrose and corn syrup is not suitable due to being too sweet, a part of the sucrose or a part or all of the corn syrup can be replaced by less sweet soluble starch to reduce its sweetness. If the aqueous sugar solution has a refractive Brix value of less than 50, the second coating does not expand adequately during frying. If the refractive Brix value exceeds 60, it becomes difficult to make the starchy flour

1149/2197

mixture to attach to the first coating uniformly and to form a uniform layer of the starchy flour mixture on the first coating.

The refractive Brix value of the aqueous sugar solution to be added to starchy flour affects the expandability of coatings during frying. Thus, in order to obtain a desired product, the refractive Brix values of the first and the second aqueous sugar solutions must be adjusted to a range of 30 to 40 and a range of 50 to 60, respectively.

The first and second coatings are formed by spraying or sprinkling the aqueous sugar solution and starchy flour mixture alternately over the core material in a tumbling coater such as a revolving pan or rotary drum.

The core material with the first and second coatings formed by the above procedure is subjected to a conventional frying step after optional drying. The frying step is carried out at 160 DEG to 200 DEG

C. for 30 seconds to 3 minutes, preferably at 165 DEG to 175 DEG C. for 1 minute and 30 seconds to 2 minutes and 30 seconds, more preferably at 168 DEG to 173 DEG C. for 100 seconds to 130 seconds.

One advantage of the present invention is that a crisp and highly expanded snack product can be produced even if the proportion of the less expandable starchy flour to be included in the total coating is as great as about 77.5% by weight.

According to the present invention, a crisp and palatable expanded snack product can be obtained without using a leavening agent or other additives that impair the savor of the product or give it an undesired taste. Probably because of the high expandability of the first coating, even if a shaped fatty confectionary material is used as the core material, the first coating on the core material expands before the expansion of the second coating and melting and leakage of the shaped fatty confectionary material.

That is, the expanded first coating provides a space between the core material and the first coating which prevents rapid heat transfer to the core material and helps the entire coating to be expanded during frying without permitting the shaped fatty confectionary material (as core material) to flow out of the coating. Therefore, the process of the present invention requires no special treatment for preventing the leakage of the shaped fatty confectionary material from the coating layer, for example, a treatment of forming a sugar coating on the shaped fatty confectionary material which takes a great deal of time and labor.

According to the present invention, the less expandable starchy flour such as mashed potato flour or corn flour is used in an amount at least half of the total starchy flour used so as to exhibit its savor to the fullest. The maximum amount of the highly expandable starchy flour used in the total starchy flour is reduced to half so as to provide a formulation that can be expanded greatly by frying and give a crisp and palatable hollow snack product without using a leavening agent or other additives that impair or give an undesirable taste to the product. Even if shaped fatty confectionary material such as chocolate or fatty cream is used as the core material, the desired snack product with an expanded coating can be obtained without causing the core material to flow out of the expanded coating as a result of frying.

To show the advantages of the process of the present invention, we prepared snack products according to the process of the present invention and the conventional method of making "Onorokemame" but using the starchy flour formulations of the present invention (i.e., the starchy flour formulations of the present invention is applied to the conventional single coating method). The core material used was expanded rice flour coated with fatty cheesy cream. The core material was coated with starchy flour formulations that were made of pregelatinized waxy corn flour (as highly expandable starchy flour) and mashed potato flour (as less expandable starchy flour) in various weight ratios. The characteristics of the snack products including the weight proportion of mashed potato flour to pregelatinized waxy corn flour in the total coating, the weight ratio of the first to second coatings, the weight proportion of the two starchy flours in each coating, and the degree of expansion of each snack product after frying are listed in Table 1.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Weight Proportion

>;tb; of Two Starchy Proportion of Two Starchy

>;tb; Flours in the Flours in Each Coating

1150/2197

>;tb; Overall Coating

>;tb; Weight Ratio of

>;tb; First Coating

>;tb; Second Coating

>;tb; Mashed

>;tb; Pregelati-

>;tb; the Two Coatings

>;tb; Mashed

>;tb; Pregelati-

>;tb; Mashed

>;tb; Pregelati-

>;tb; Ratio of

>;tb; Potato

>;tb; nized Waxy

>;tb; First Second

>;tb; Potato

>;tb; nized Waxy

>;tb; Potato

>;tb; nized

>;tb; Expansion

>;tb; Flour Corn Flour

>;tb; Coating

>;tb; Coating



>;tb; after

>;tb;Coating Method

>;tb; (%) (%) (%) (%) (%) (%) (%) (%) Frying

>;tb;__________________________________________________________________________

>;tb;Present 50 50 50 50 50 50 50 50 3.86

>;tb;Invention

>;tb; 60 40 50 50 50 50 70 30 3.57

>;tb; 62.5 37.5 50 50 30 70 95 5 4.00

>;tb; 70 30 60 40 60 40 85 15 2.70

>;tb; 74 26 60 40 60 40 95 5 2.40

>;tb; 77.5 22.5 50 50 60 40 95 5 1.85

>;tb;Conventional

>;tb; 70 30 -- -- -- -- -- -- 1.50

>;tb;Method of

>;tb; 60 40 -- -- -- -- -- -- 2.14

>;tb;Making 77.5 22.5 -- -- -- -- -- -- 1.10

>;tb;"Onorokemame"*

>;tb;__________________________________________________________________________

>;tb; *Weight proportion of two starchy flours in the overall coating according

>;tb; to the present invention is applied to conventional method of making

>;tb; "Onorokemame".

In Table 1, the figures in the column "Weight Proportion of Two Starchy Flours in the Overall

Coating" indicate by percentage the weight proportion of mashed potato flour to pregelatinized waxy corn flour in the overall coating on the core material.

The figures in the column "Weight Ratio of the Two Coatings" indicate by weight percentage the thickness of each of the first and second coatings with respect to the overall coating.

The figures in the column "Proportion of Two Starchy Flours in Each Coating" indicate in weight percentage the proportion of highly expandable pregelatinized waxy corn flour to less expandable mashed potato flour contained in each of the first and second coatings.

1151/2197

The figures in the column "Ratio of Expansion after Frying" indicate the degree of expansion as calculated by dividing the volume of the expanded product by that of the unexpanded product made by applying the first and second coatings on the core material.

As shown in Table 1, a snack product prepared by frying a formulation containing 70% of mashed potato flour and 30% of pregelatinized waxy corn flour in the overall coating, using the first and second coatings in a weight ratio of 60:40, and containing 60% of mashed potato flour and 40% of pregelatinized waxy corn flour in the first coating, 85% of mashed potato flour and 15% of pregelatinized waxy corn flour in the second coating had an expansion ratio of 2.70. But the snack product prepared by the conventional method of making "Onorokemame" using a formulation containing 70% of mashed potato flour and 30% of pregelatinized waxy corn flour in the overall coating had an expansion ratio of only 1.50. It is, therefore, clear that the process of the present invention provides a snack product with an expanded coating whose expansion ratio is 1.8 times as much as the ratio achieved by the conventional method.

The snack product prepared by frying a formulation that had the first and second coatings in a weight ratio of 50:50 and used 50% of mashed potato flour and 50% of pregelatinized waxy corn flour in the first coating and 70% of mashed potato flour and 30% of pregelatinized waxy corn flour in the second coating so as to incorporate 60% of mashed potato flour and 40% of pregelatinized waxy corn flour in the overall coating had an expansion ratio of 3.57. But the snack product prepared by the conventional method of making "Onorokemame" using a formulation containing 60% of mashed potato flour and

40% of pregelatinized waxy corn flour in the overall coating had an expansion ratio of 2.14. It is, therefore, clear that the process of the present invention provides (from a formulation with a mashed potato to pregelatinized corn ratio of 60:40 in the overall coating) a snack product with an expanded coating whose expansion ratio is about 1.7 times as much as the ratio achieved by the conventional method. In the above test, the first coating also contained an aqueous sugar solution that contained only corn syrup and which was adjusted to a refractive Brix value of 35, and the second coating also contained an aqueous sugar solution that contained only sucrose and which was adjusted to a refractive

Brix value of 55. In the conventional method of making "Onorokemame", an aqueous sugar solution was used that had the same formulation and Brix value as those of the sum of the aqueous sugar solutions used for the first and second coatings according to the present invention.

The data in Table 1 shows that the process of the present invention is capable of providing a fried snack product with a greatly expanded coating by using a flour formulation containing 50 to 77.5% of less expandable but highly savory starchy flour such as mashed potato flour or corn flour without incorporating a leavening agent or other additives that impair the savor of the product or give it an undesired taste.

The present inventors then measured the strength (hardness) of fried snack products prepared from two formulations, one containing 70% of mashed potato flour and 30% of pregelatinized waxy corn flour in the overall coating, and the other containing 60% of mashed potato flour and 40% of pregelatinized waxy corn flour, by the process of the present invention and the conventional method of making

"Onorokemame". The results are shown in Table 2, wherein the strength of each product is indicated by the weight in grams of the load necessary to rupture the product.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Weight Proportion of

>;tb;Two Starchy Flours

>;tb;in Overall Coating

>;tb;Mashed Strength of Product

>;tb;Potato Pregelatinized

>;tb; Present Conventional

>;tb;Flour Waxy Corn Flour

>;tb; Invention

>;tb; Method

>;tb;(%) (%) (g) (g)

>;tb;______________________________________

>;tb;70 30 1,600 4,000

>;tb;60 40 1,500 3,500

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>;tb;______________________________________

In Table 2, the figures in the colunn "Weight Proportion of Two Starchy Flours in Overall Coating" indicate the proportions of mashed potato flour and pregelatinized waxy corn flour contained in the overall coating on the core material. The figures in the column "Strength of Product" indicate the weight in grams of the load necessary to rupture the fried snack products prepared by the process of the present invention and the conventional method of making "Onorokemame".

The snack product prepared by the present invention from a formulation containing 70% mashed potato flour and 30% pregelatinized waxy corn flour ruptured under a load of 1,600 g, whereas the product made from the same formulation but by the conventional method ruptured under a load of 4,000 g and was at least twice as hard as the product according to the present invention. This indicates the low palatability of the conventional product which was confirmed by an organoleptic test the results of which are listed in Table 3 below.

The snack product prepared by the present invention from a formulation containing 60% mashed potato flour and 40% pregelatinized waxy corn flour in the overall coating ruptured under a load of 1,500 g.

However, the product made from the same formulation but by the conventional method ruptured under a load of 3,500 g and was at least twice as hard as the product of the present invention. This also indicates the low palatability of the conventional product which was confirmed by the same organoleptic test as mentioned above. The load necessary to rupture the snack products was measured with a Kuramochi hardness meter; it comprised a spring scale and a table which compressed the sample until it broke under a certain load that was read on the spring scale.

Two fried snack products were prepared by the process of the present invention and the conventional method of making "Onorokemame" and were subjected to an organoleptic test by a panel consisting of

30 in-house professional tasters. The product of the present invention was prepared from a starchy flour formulation containing 62.5% of mashed potato flour and 37.5% of pregelatinized waxy corn flour in the overall coating. Half of the coating was the first coating made of 30% of mashed potato flour and

70% of pregelatinized waxy corn flour, and the other half was the second coating made of 95% of mashed potato flour and 5% of pregelatinized waxy corn flour. The first coating also contained an aqueous sugar solution comprising one part by weight of corn syrup and the same amount of sucrose that was given water to have a refractive Brix value of 35. The second coating also contained an aqueous sugar solution comprising one part by weight of sucrose and the same amount of soluble starch that was given water to have a refractive Brix value of 55. The product according to the conventional method was also prepared from a starch formulation containing 62.5% of mashed potato flour and 37.5% of pregelatinized waxy corn flour in the overall coating, but it used an aqueous sugar solution which was a mixture of equal amounts of the sugar solutions used for making the first and second coatings of the product of the present invention.

The two products were evaluated for their appearance, crispness, meltability in the mouth, taste and color, and the scores given by the panelists for each factor were averaged and listed in Table 3.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Product

>;tb; Present Conventional

>;tb;Factor Invention

>;tb; Method

>;tb;______________________________________

>;tb;Appearance +2.90 -0.50

>;tb;Crispness +2.80 -1.00

>;tb;Melt in the mouth

>;tb; +2.90 0.00

>;tb;Taste +2.70 +1.05

>;tb;Color +2.00 -1.00

>;tb;______________________________________

>;tb;Criteria of Evaluation

>;tb;______________________________________

>;tb; +3: Best

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>;tb; +2: Good

>;tb; +1: Fairly good

>;tb; 0: Fair

>;tb; -1: Fairly poor

>;tb; -2: Poor

>;tb; -3: Worst

>;tb;______________________________________

As Table 3 shows, the product of the present invention was much preferred over the conventional product with respect to appearance, crispness, melting in the mouth and color, and the taste of the former was evaluated somewhat higher than the latter.

The present invention is now described in greater detail by reference to the following examples which are given here for illustrative purposes only and are by no means intended to limit its scope. All parts in the examples are by weight.

EXAMPLE 1

A mixture of 50 parts of pregelatinized waxy corn flour and 50 parts of mashed potato flour and 100 parts of an aqueous sugar solution comprising corn syrup that was given water to adjust its refractive

Brix value to 35 were used as materials for the first coating. The aqueous sugar solution was sprinkled over 80 parts of core material, in a rotary pan, comprised of expanded rice coated with fatty cheesy cream. When the core material was uniformly coated with the aqueous sugar solution, the starchy flour mixture was then sprinkled. This procedure was repeated until a uniform first coating was formed on the core material. A second coating was thereafter formed on the first coating by alternately sprinkling a mixture comprising 20 parts of pregelatinized waxy corn flour and 47 parts of mashed potato flour and 67 parts of an aqueous sugar solution comprising sucrose that was mixed with water to give a refractive Brix value of 55. The core material with the first and second coatings was taken out of the rotary pan, left at ambient temperature for 30 minutes and deep fried for 1 minute and 50 seconds in a cooking oil that had been heated to 170 DEG C. to thereby produce a crisp snack product with an expanded coating having an expansion ratio of 3.5 and a hardness of 1,600 g.

EXAMPLE 2

150 g of ball-shaped chocolate centers each weighing 1 g were put in a revolving pan and, while being tumbled, each center was given a first coating as in Example 1 using a starchy flour comprising 33.8 parts of pregelatinized waxy corn flour and 50.8 parts of corn flour and 85 parts of an aqueous sugar solution comprising a mixture of 2 parts of corn syrup and 1 part of sucrose that was dissolved in water to give a refractive Brix value of 35. A second coating was thereafter formed on the first coating as in

Example 1 using a starchy flour comprising 8.4 parts of pregelatinized waxy corn flour and 48 parts of corn flour and 56 parts of an aqueous sugar solution comprising a mixture of 2 parts of sucrose and 1 part of corn syrup that was dissolved in water to give a refractive Brix value of 55. The ball-shaped chocolate centers with the first and second coatings were immediately immersed in a cooking oil that had been heated to 170 DEG C. and fried for 2 minutes. Crisp snack products with an expanded coating that had an expansion ratio of 3.3 and a hardness of 1,700 g were obtained. There was no indication of the flowing out of chocolate from the expanded coating.

EXAMPLE 3

150 parts of ball-shaped white cream centers each weighing 1 g were put in a revolving pan and, while being tumbled, each center was given a first coating as in Example 1 using a starchy flour comprising

52.5 parts of pregelatinized waxy corn flour and 22.5 parts of mashed potato flour and an aqueous sugar solution comprising corn syrup that was dissolved in water to give a refractive Brix value of 35.

A second coating was then formed on the first coating as in Example 1 using a starchy flour comprising

7.5 parts of pregelatinized waxy corn flour and 142.5 parts of mashed potato flour and an aqueous sugar solution comprising sucrose that was dissolved in water to give a refractive Brix value of 50, and the ball-shaped white cream centers with the first and second coatings were fried as in Example 1. Ball-

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shaped crisp snack products with an expanded coating that had an expansion ratio of 4.0 and a hardness of 1,300 g were obtained.

EXAMPLE 4

A mixture of 50 parts of glutinous rice flour and 50 parts of pea flour and an aqueous solution of soluble starch comprising 35 parts of solid soluble starch and 65 parts of water were used as materials for the first coating. The aqueous starch solution was sprinkled over 80 parts of a core material in a revolving pan that comprised expanded rice flour coated with a fatty cheesy cream. When the core material was uniformly coated with the aqueous starch solution, the starchy flour mixture was then sprinkled thereon. This procedure was repeated until a uniform first coating was formed on the core material. A second coating was thereafter formed on the first coating by alternately sprinkling a mixture comprising 20 parts of glutinous rice flour and 47 parts of pea flour and 67 parts of an aqueous sugar solution comprising sucrose that was mixed with water to give a refractive Brix value of 55. The core material with the first and second coatings was taken out of the revolving pan, left at ambient temperature for 30 minutes and fried for 1 minute and 50 seconds in a cooking oil that had been heated to 170 DEG C. to thereby produce a crisp snack product with an expanded coating having an expansion ratio of 3.8 and a hardness of 2,000 g.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for producing an edible snack product with an expanded coating, comprising the steps of: providing a core material selected from the group consisting of nuts, beans, an expanded edible starchy material coated with an edible fatty confectionary material and a shaped fatty confectionary material; providing a first flour mixture comprised of 60:40 to 30:70 parts by weight of a starchy flour capable of providing a small degree of expansion and good savor upon frying and a pregelatinized starchy flour capable of providing a high degree of expansion upon frying; providing a first aqueous sugar solution having a refractive Brix value of between 30 and 40; coating said core material with a first coating by alternately applying the first flour mixture and the first aqueous sugar solution to form a uniform coating on the core material; providing a second flour mixture comprised of a starchy flour capable of providing a small degree of expansion and good savor upon frying and an equal or less amount of weight of a pregelatinized starchy flour capable of providing a high degree of expansion upon frying; providing a second aqueous sugar solution having a refractive Brix value of between 50 and 60; coating the first coating with a second coating which is less expandable than the first coating during frying by alternately applying the second flour mixture and the second aqueous sugar solution in order to form a uniform second coating; controlling the thickness of the first coating and the second coating so that the weight ratio of the first coating to the second coating is in the range of from 50:50 to 60:40; and frying the core material with the first and second coatings thereon.

2. A process as claimed in claim 1, wherein the starchy flour capable of providing a small degree of expansion and good savor upon frying in the first flour mixture and in the second flour mixture is at least one starchy flour selected from the group consisting of mashed potato flour and corn flour.

3. A process as claimed in claim 1, wherein the pregelatinized starchy flour in the first flour mixture and in the second flour mixture, is at least one flour selected from the group consisting of pregelatinized waxy corn flour and pregelatinized glutinous rice flour.

4. A process as claimed in claim 1, wherein the weight ratio of the pregelatinized starchy flour to the starchy flour capable of providing a small degree of expansion and good savor upon frying in the second flour mixture is in the range of from 5:95 to 50:50.

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5. A process as claimed in claim 1, wherein the first aqueous sugar solution has a refractive Brix value of 30 to 40 and comprises corn syrup or a mixture of 1 part by weight of corn syrup and not more than

2 parts by weight of sucrose to which a sufficient amount of water is added to adjust the refractive Brix value to 30 to 40.

6. A process as claimed in claim 1, wherein the second aqueous sugar solution has a refractive Brix value of 50 to 60 and comprises sucrose or a mixture of 2 parts by weight of sucrose and not more than

1 part by weight of at least one ingredient selected from the group consisting of corn syrup and soluble starch to which a sufficient amount of water is added to adjust the refractive Brix value to 50 to 60.

7. A process as claimed in claim 1, wherein a weight proportion of the starchy flour capable of providing a small degree of expansion and good savor upon frying to the pregelatinized starchy flour capable of providing a high degree of expansion upon frying in the overall coating is 50:50 to

77.5:22.5.

8. A process according to claim 1, wherein the first flour mixture has a composition which is different from the composition of the second flour mixture.Data supplied from the esp@cenet database -

Worldwide

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239.

JP58111678 - 7/2/1983

POWDERING OF ACETIC ACID-CONTAINING SEASONING SOLUTION


Inventor(s): SATOU JINICHI (--); KURUSU TOSHIROU (--); WATANABE SEIKI (--)

Applicant(s): SATO SHIYOKUHIN KOGYO KK (--)

IP Class 4 Digits: C12J

IP Class: C12J1/00

E Class: A23L1/24; A23L1/22K



Family: JP58111678

Equivalent: GB2112621; FR2518874; DE3226282

Abstract:


PURPOSE:To prepare powder of acetic acid-containing seasoning solution having a high yield of acetic acid, its high content, and high quality, by adding a specific hydrolyzate of starch to the acetic acid-containing seasoning solution, followed by subjecting it to spray drying. CONSTITUTION:A hydrolyzate of starch such as a hydrolyzate of starch consisting of amylopectin or it and amylose which may contain a cyclic oligosaccharide, comprising >;=20wt%, preferably >;=15wt% oligosaccharide having a polymerization degree of glucose of >;=5 and >;=7wt%, preferably >;=5wt% oligosaccharide having a polymerization degree of glucose of >;=3, having a whole polymerization degree of glucose on an average of 6-18 and a viscosity of 50wt% aqueous solution at 40 deg.C of preferably >;=300cps is added to a acetic acid-containing seasoning solution such as rice vinegar, Sake (liquor) vinegar, apple vinegar, synthetic vinegar, etc. in such a way that the amount of the hydrolyzate is 70-200wt% based on the amount of water in the seasoning solution and the resultant substance is subjected to spray drying.Description:


SPECIFICATION

Process for powdering a liquid seasoning containing acetic acid

The present invention relates to a process for powdering a liquid seasoning containing acetic acid as a principal ingredient which produces powder having a high acetic acid content in high acetic acid yield notwithstanding acetic acid is a volatile ingredient and moreover having a good quality.

As a conventional process for powdering a liquid seasoning containing acetic acid, the process of

Japanese Patent No. 929540 is already known. This conventional process comprises dissolving a water soluble substance containing as principal ingredient one or more kinds of starch derivatives such as dextrin, gelatinized oxidized starch etc. in a liquid seasoning containing acetic acid in an amount of not less than 70 % of the amount of the water contained in the liquid seasoning containing acetic acid, which the water soluble substance is selected and used under the condition that the solution obtained by dissolving the water soluble substance in an amount of not less than 70 % as described above is able to be spray-dried, and then spraydrying the resulting solution at as low a temperature as possible.According to this conventional process, it was difficult to produce a quality product worthy of

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calling powder of a liquid seasoning containing acetic acid, because of the defects in various points such as with reference to the process, spray-drying aptitude, acetic acid yield etc., and with reference to the produced powder, caking resistance, acetic acid stability, solubility, viscosity of its solution etc..

Namely, in order to produce the powder, for example, having a high, viz., at least 10 % acetic acid content which does not cause caking, it is good to use a high molecular dextrin or an oxidized starch.However these substances have essentially a high viscosity and the more these substances were dissolved in an aqueous solution of acetic acid in an amount of not less than 70 % of the amount of the water contained in the aqueous solution of acetic acid, the higher the viscosity of each resulting mixture became, and therefore each mixture brought a quite difficult operation on spray-drying. Moreover each aqueous solution of the obtained product had such a high viscosity as was variously an obstacle to its utilization, and the obtained products were not always good in quality in various respects such as acetic acid yield, acetic acid stability, caking resistance etc.. Furthermore, an oxidized starch was very inconvenient to prepare the solution for spray-drying, because of its insolubility in a cold water.

In order to overcome the foregoing defects, the present inventors before tried to produce a high quality powder of a liquid seasoning containing acetic acid in high yield by using a starch hydrolysate (a starch hydrolysate means hydrolysate of starch) having a limited DE value. It is generally considered that a

DE value indicates the properties of the starch hydrolysates prepared variously according to a hydrolyzing extent. However the present inventors could get no satisfactory result by using a starch hydrolysate having a limited DE value, because of the dispersions of acetic acid yield and quality.For example, when various starch hydrolysates having a DE value of about 14, which was considered a preferable DE value from the experience, were prepared and thereby each powder of a liquid seasoning containing acetic acid was produced, not only the dispersion of acetic acid yield but also the despersions of qualities such as acetic acid stability, caking resistance, solubility etc. in the obtained products were recognized, though the starch hydrolysates having the same DE value of about1 4 were used.

With a view to eliminating many defects involved in producing powder of a liquid seasoning containing acetic acid, the present inventors went ahead with the research apart from a DE value.

Resultingly the present inventors found that among starch hydrolysates containing saccharides having by stages a glucose polymerization degree, the starch hydrolysate containing saccharides having a glucose polymerization degree of 1 to 3 does not possess at all the capacity suitable to a powdering carrier (viz., carrier for powdering) in case of drying the solution comprising a powdering carrier, acetic acid and water as three principal ingredients, and that the starch hydrolysate containing saccharides having a glucose polymerization degree of 4 to 5 possesses an extremely insufficient capacity as a powdering carrier, and that in points of drying property, acetic acid yield and quality, the inferior results are recognized in proportion to the increasing of the content ratio which saccharides having a glucose polymerization degree of not more than 5, especially not more than 3, account for in the starch hydrolysate. Moreover the present inventors found that in the case of the starch hydrolysate containing saccharides having a glucose polymerization degree of about 6 or more, the higher the glucose polymerization degree becomes, the better the capacity as a powdering carrier for acetic acid becomes and the better the storage stabilities of the produced powder such as caking resistance etc. become, and however, when said degree becomes too high, the viscosity increases to result in hindrance on spray-drying, and the increase (the increase is actually done by decreasing an amount of the starch hydrolysate per an amount of water) of an amount of water in order to decrease the viscosity causes the lowering of the yield, and therefore the glucose polymerization degree has its limit.

Consequently the present inventors found that the suitable range of glucose polymeriza tion degrees in a starch hydrolysate is approximately from 6 to1 8 as an average glucose polymerization degree.Namely, the present inventors found that when a starch hydrolysate is mixed in a liquid seasoning containing acetic acid and the resulting solution is spray-dried, an acetic acid yield and quality of produced powder of a liquid seasoning containing acetic acid are influenced by a glucose polymerization degree of the starch hydrolysate, and that when a starch hydrolysate containing not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3 and having an average glucose polymerization degree of 6 to1 8 as a whole is selected and used, there is produced effectively powder of liquid seasoning containing acetic acid having a high acetic acid content of at least 10 % in high acetic acid yield of at least 70 %, and moreover which is of good quality.

Furthermore, as the result of the developmental research the present inventors found that it brings a good result that a specifically polymerized oligosaccharide, viz., cyclic oligosaccharide or a starch

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hydrolysate prepared by hydrolyzing slightly starch composed of amylopectin is used alone or together with other starch hydrolysate under the abovementioned conditions concerning the constitution of glucose polymerization degree.

The present invention was completed on the basis of the abovementioned findings. The present invention is a process for powdering a liquid seasoning containing acetic acid, characterized in that a starch hydrolysate containing not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3 is mixed in a liquid seasoning containing acetic acid in an amount of not less than 70 % of the amount of the water contained in the liquid seasoning containing acetic acid, and the resulting mixture is spray-dried.

A preferable starch hydrolysate to use in the present invention is such a starch hydrolysate as has an average glucose polymerization degree of 6 to1 8 and induces a viscosity of not more that 300 cps at40"C in the case of its 50% aqueous solution and contains not more than15% oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 5% oligosaccharides having a glucose polymerization degree of not more than 3. And a starch hydrolysate to use in the present invention is one member or the mixture of two or more members selected from the group consisting of the following a, b, c and d.

a. a starch hydrolysate prepared by hydrolyzing starch composed of amylopectin and amylose,

b. a starch hydrolysate prepared by hydrolyzing starch composed of amylopectin,

c. a starch hydrolysate containing cyclic oligosaccharides and acyclic starch hydrolysate, said a starch hydrolysate being prepared from starch composed of amylopectin and amylose, and

d. a starch hydrolysate containing cyclic oligosaccharides and acylic starch hydrolysate, said a starch hydrolysate being prepared from starch composed of amylopectin.

A starch hydrolysate containing at least one member selected from the group consisting of a a-cyclic oligosaccharide,fl-cyclic oligosaccharide and y-cyclic oligosaccharide, said at least one member being added, is able to be used in the present invention. Saida-cyclic oligosaccharide,fl-cyclic oligosaccharide or y-cyclic oligosaccharide is obtained by separating and purifying from a starch hydrolysate containing cyclic oligosaccharides formed by making a cyclic oligosaccharide-forming enzyme act on a gelatinized or liquefied starch.

The average polymerization degree in the present invention is based on the value obtained by dividing the whole amount of a starch hydrolysate by the amount of the reducing sugar contained in the starch hydrolysate in the case of the starch hydrolysate not containing cyclic oligosaccharide, and in the case of a starch hydrolysate containing cyclic oligosaccharide is based on the total value obtained by adding the value obtained by mulitplying the average polymerization degree of the cyclic oligosaccharides by the content ratio which the cyclic oligosaccharides account for in the starch hydrolysate to the value obtained by multiplying the average polymerization degree of acyclic saccharides, said average polymerization degree being obtained by the abovementioned way, by the content ratio which the acyclic saccharides account for in the starch hydrolysate.And G stands for glucose and the suffix number stands for a polymerization degree. For example,G1, G2 and G3 stand for in due order glucose, maltose and maltotriose, and G4 stands for oligosaccharide having a polymerization degree of

4, andG9 to n stands for saccharides having a polymerization degree of not less than 9.

The starch hydrolysate prepared by hydrolyzing an ordinary starch composed of amylopectin and amylose to use in the present invention, which contains not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3 and at the same time has an average polymerization degree of 6 to 18, is prepared by the undermentioned methods and is used alone or together with two or more kinds of starch hydrolysates prepared by said undermentioned methods. Further starch hydrolysates prepared by other methods can be used so long as the intended powder of the present invention can be produced.

(A) A method comprising subjecting a starch hydrolysate (it is preferable that a starch hydrolysate having a DE value of 6 to 20, which is prepared by hydrolysis with acid or enzyme, is mainly used.) prepared by a usual hydrolysis with acid or enzyme to fractionating with an aqueous alcohol solution

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and separating and removing unnecessary components to obtain the abovementioned constitution of glucose polymerization degree.

(B) A method for preparing a starch hydrolysate by subjecting starch to the specific two-staged liquefaction (when a starch hydrolysate prepared by the first staged hydrolysis has a DE value of not more than 3, the starch hydrolysate is subjected to heating and boiling, and in the second staged hydrolysis the starch hydrolysate is further hydrolyzed with a-amylase added to have a

DE value of 6 to 16.).

(C) A method comprises making a microorganism such as yeast etc. assimilate glucose, maltose and maltotriose contained in a starch hydrolysate (it is preferable that a starch hydrolysate having a DE value of approximately 10 to 20, which is prepared by hydrolysis with enzyme, is mainly used.) prepared by a conventional method.

When in the present invention the starch hydrolysate having an average glucose polymerization degree of 6 to1 8 and containing not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3 is used as a powdering carrier, the undermentioned(II) a starch hydrolysate prepared by hydrolyzing starch composed of amylopectin or(III) a starch hydrolysate prepared by hydrolyzing an ordinary starch is used alone, and moreover the abovementioned use is characterized in that the effects in the production of inteded powder can be more heighten by the specific combined use constituted by selecting members from the group comprising (I) cyclic oligosaccharides having polymerization degree of 6 to 8 which are prepared by hydrolyzing specifically starch, (II) a starch hydrolysate having an average polymerization degree of 6 to 50 which is prepared by hydrolyzing starch composed of amylopectin,(III) a starch hydrolysate having an average polymerization degree of

6 to1 8 which is prepared by hydrolyzing an ordinary starch, and so on, viz., said combined use is(I)

(l)+(lll),(ll)+(lll),(l)+(ll)+(lll)etc..

The abovementioned specified starch hydrolysates are explained in points of each and their combined usings as follows:

(I) Cyclic oligosaccharides:

The starch hydrolysate (viz., mixture of cyclic oligosaccharides (I) and acyclic starch hydrolysate(II)) containing acyclic starch hydrolysate and cyclic oligosaccharide (polymerization degree: 6 to 8) made up by cyclically transforming of oligosaccharides having a glucose polymerization degree of 6, 7 or 8, said cyclic oligosaccharides being formed by making a cyclic oligosaccharide-forming enzyme act on a gelatinized or liquefied starch, can be easily dissolved in an aqueous solution of acetic acid, and the resulting solution has a low viscosity.Therefore by spray-dring the solution obtained by mixing the starch hydrolysate in a aqueous solution of acetic acid, the present inventors found that the spraydrying can be smoothly done because of a low viscosity, and that one of basic techniques of the present invention, which is dissolving a powdering carrier in an aqueous solution of acetic acid in an amount of not less than 70 %, as much as possible, of the amount of the water contained in the aqueous solution of acetic acid, can be more heighten, and that the acetic acid yield of the obtained powder can be heighten and the obtained powder containing acetic acid is very excellent in point of storage stability.

Cyclic oligosaccharide, which has a glucose polymerization degree of 6, 7 or 8 is obtained by separating and purifying from a starch hydrolysate containing cyclic oligosaccharide formed by making a cyclic oligosaccharide-forming enzyme act on a gelatinized or liquefied starch, can not be used alone as a powdering carrier of the low stability in an aqueous solution of acetic acid.

However, so long as said purified cyclic oligosaccharide is used in such an amount that said purified cyclic oligosaccharide can be dissolved and moreover the resulting mixture has an average polymerization degree of 6 to 18, the object of the present invention can be fulfilled by using said purified cyclic oligosaccharide together with one member or more selected from the group consisting of an ordinary starch hydrolysate(III) prepared by hydrolysis according to the object of the present invention, a starch hydrolysate(II) prepared by specifically hydrolyzing starch composed of amylopectin, and mixture (I + II) containing cyclic oligosaccharides and acyclic starch hydrolysate, said mixture being prepared by making a cyclic oligosaccharideforming enzyme act on starch.As a powdering carrier in the present invention, cyclic oligosaccharide is used in such an amount that said cyclic oligosaccharide can be dissolved, and the preferable amount is approximately 5 % or more of a

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whole powdering carrier. In the case of using of plural kinds of cyclic oligosaccharide the preferable amount is the total amount of them.

(II) A starch hydrolysate prepared by hydrolyzing starch compound of amylopectin:

When starch composed of amylopectin such as glutinous corn starch, glutinous rice starch etc. is hydrolyzed with a-amylase, an amylopectin polymer begins to be cut at a-1, 4 glucoside linkage. In that case the hydrolysis begins with the intermediate position of the straight chain of amylopectin at the early stage, and thus the initial polymer changes gradually into still less small polymers, retaining the branched polymeric structure.The starch hydrolysate prepared by hydrolyzing amylopectin with aamylase begins drastically lowering of its velocity when it has an average polymerization degree of approximately 50 to 70, and when said starch hydrolysate has an average polymerization degree of 6 to

50, it has a lower viscosity than that of a starch hydrolysate prepared by hydrolyzing an ordinary starch composed of amylose and amylopectin, and said starch hydrolysate having an average polymerization degree of 6 to 50 can be easily dissolved in an aqueous solution of acetic acid and does not have a retrogradation property.

When the starch hydrolysate(II) having an average polymerization degree of 6 to 50, which is prepared by hydrolyzing starch composed of amylopectin, is used alone as a powdering carrier in the present invention, the starch hydrolysate having an average polymerization degree of 6 to1 8 and containing not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3 is selected and used, and when the starch hydrolysate has said conditions concerning polymerization, the branced structures of amylopectin can be maintained and the spray-drying aptitude is good because of the lower viscosity than that of starch hydrolysate prepared by hydrolyzing starch containing amylose in the same extent as in the case of said starch composed of amylopectin, and moreover because said starch hydrolysate can be mixed in an aqueous solution of acetic acid in a rich amount, the acetic acid yield of the obtained powder is good, and the storage stability of the obtained powder is good.Further, when said starch hydrolysate derived from amylopectin is used together with other starch hydrolysate, said starch hydrolysate derived from amylopectin, having an average polymerization degree of 10 to 50 is mainly used selectively among said starch hydrolysates having an average polymerization degree of 6 to 50, and when said starch hydrolysate derived from amylopectin is used together with at least one member selected from the group consisting of a starch hydrolysate(III) prepared by hydrolyzing an ordinary starch, cyclic oligosaccharides (I) and the mixture of cyclic oligosaccharides (I) and acyclic starch hydrolysate(II), the intended object of the present invention can be fulfilled so long as the resulting mixture has as a powdering carrier an average polymerization degree of 6 to1 8 and contains not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not more than 3.

Furthermore, in the present invention ahigh-molecutar water-soluble substance such as gum arabic, gelatin, CMC etc. can be added.

In the present invention the above-explained starch hydrolysate is mixed in a liquid seasoning containing acetic acid in an amount of 70 to 200 % of the amount of the water contained in said liquid seasoning and thereafter subjected to spray-dring.

A liquid seasoning containing acetic acid to use in the present invention is selected from acid liquid seasonings, in which acetic acid is a principal ingredient, such as rice vinegar, "kasuzu" made by subjecting "sake cake" as a main raw material to an acetic acid fermentation, "shuseizu" prepared by subjecting an aqueous ethyl alcohol solution to an acetic acid fermentation, malt vinegar, wine vinegar, cider vinegar, synthesized vinegar, sauce, aqueous solution of acetic acid, concentrated solution of each abovementioned matter, each abovementioned matter added with acetic acid in addition, processed solution of each abovementioned matter etc..

Further, when a liquid seasoning containing acetic acid is powdered, various aroma ingredients other than acetic acid also powdered at the same time. The yield (aroma remaining ratio) of low boiling aroma ingredients which are contained in the abovementioned brew vinegars etc. is approximately in proportional to an acetic acid yield, and therefore the increase of an acetic acid yield is very important for keeping aroma ingredients.

1161/2197

Hereinafter the tests and examples of the present invention are described.

Test 1:

By using starch hydrolysate (dried matter) A, B, C, D, E, F, G, H and I having respectively analytical values shown in Table 1, the solutions(40"C) comprising 100 parts of starch hydrolysate, 25 parts of acetic acid and the given parts of water are severally prepared and then each resulting solution was spray-dried at a chamber temperature of87"C, being heated up to60"C by a plate heater just before spray-drying. The thus powders containing acetic acid were produced, of which results are shown in

Table 2. And starch hydrolysates used as a sample were respectively prepared by the following methods.

Sample A: the starch hydrolysate having a DE value of1 7.9 prepared by hydrolyzing with acid and enzyme, said starch hydrolysate being an article on the market,

Sample B: the starch hydrolysate having a DE value of1 4.5 prepared by hydrolyzing with enzyme and enzyme, said starch hydrolysate being an article on the market,

Sample C: the starch hydrolysate having a DE value of1 4.1 prepared by the following process: emulsion of a corn starch was added with a-amylase and hydrolyzed till the DE value reached 1.5, and when the DE value reached 1.5 the hydrolysate was heated up to1 30 C and more maintained at1 30 C for 10 minutes, and thereafter the hydrolysate was cooled and added again with a-amylase to proceed with the hydrolysis till the DE value reached 16.8.And by making yeast assimilate glucose, maltose and maltotriose contained in the hydrolysate having a

DE value of 16.8, the starch hydrolysate having a DE value 14.1 was prepared,

Sample D: the starch hydrolysate having a DE value of1 3.9 prepared by hydrolyzing with acid, said starch hydrolysate being an article on the market,

Sample E: the starch hydrolysate having a DE value of 11 prepared from emulsion of a corn starch with a-amylase by the same two-staged liquefaction as in the case of Sample C, viz., hydrolyzing was proceeded till a DE value of 1.5 in the first stage and till a DE value of 11 in the second stage,

Sample F: the starch hydrolysate having a DE value of 8.2 prepared in the same manner as in the case of Sample E excepting that hydrolyzing was proceeded till a DE value of 8.2 in the second stage,

Sample G: the starch hydrolysate having a DE value of 6.4 prepared in the same manner as in the case of Sample E excepting that hydrolyzing was proceeded till a DE value of 6.4 in the second stage,

Sample H: the starch hydrolysate having a DE value of 5.6 prepared in the same manner as in the case of Sample E excepting that hydrolyzing was proceeded till a DE value 5.6 in the second stage,

Sample I: the starch hydrolysate having a DE value of 4.5 prepared in the same manner as in the case of Sample E excepting that hydrolyzing was proceeded till a DE value of 4.5 in the second stage.

By using glucose which was an article on the market, maltose (saccharide composition: 95 % maltose and 5 % glucose) which was an artice on the market, maltotriose (saccharide composition: 90 % maltotriose and 5 % maltohexaose) prepared by hydrolyzing pullulan (pullulan PF-10 supplied by

Hayashibara Co., Ltd.) with pullulanase (CK 20-L supplied by

Amano Pharmaceutical Co., Ltd.) and the starch hydrolysate(0.4 % G1, 1.3 % G2,15.4 % G3,25.2 %

G4, 20.6 %G5, 15.8 %G6, 9.5 % G7, 4.2 % G8 and 7.6 %Ggton) containing mainly maltotetraose and maltopentaose, said starch hydrolysate being prepared as follows: the abovementioned Sample A was subjected to assimilating by yeast and thereby glucose, maltose and maltotriose were assimilated to a certain extent by yeast and the thus treated Sample A was fractionated using an aqueous solution of ethyl alcohol, each mixed solution as shown in Table 3 was prepared and spray-dried at a chamber temperature of87"C. The obtained results are shown in Table 3.

The saccharide composition, the viscosity and the acetic acid yielded in the present invention were determined by the following ways.

Saccharide composition: the saccharide composition was determined qualitatively and quantitatively by the liquid chromatography usingPNH2-10/S2504 (supplied by Shimadzu Corporation) as a column, an acetonitrile-water as a mobile phase and a differential refractometer as a detector.

Viscosity: the viscosity of the aqueous solution of the starch hydrolysate was determined as follows:

500 g of a sample (starch hydrolysate) was dissolved in 500 g water and the resulting solution was

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subjected to measuring its viscosity at40"C by a cylinder-type rotational viscometer And the viscosity of solution before spray-drying also was determined in the same way.

Acetic acid yield: the acetic acid yield was calculated according to the following formula:

Acetic acid yield (remainingratio) % =

B 100XDX

C A wherein A stands for the amount of acetic acid used, B stands for the amount (solid matter) of the starch hydrolysate used, C stands for the solid content (%) of the produced powder containing acetic acid and D stands for the acetic acid content (%) of the produced powder containing acetic acid.

Table 1

Saccharide composition (%) Average Poly

Sample merization Viscosity

G1 G2 G3 G4 G5 G6 G7 G8 G9 to n Degree (cps)

A 4.8 5.7 5.6 5.6 5.4 5.1 4.7 4.1 59.0 5.6 40

B 0.8 5.2 7.0 5.4 4.8 9.8 8.7 5.3 53.0 6.9 42

C trace trace 7.3 6.8 6.6 14.7 12.9 5.7 46.0 7.1 43

D 3.7 4.4 4.3 4.2 3.9 3.2 3.0 3.3 70.0 7.2 71

E trace 2.3 4.6 4.4 4.4 6.5 7.5 6.9 63.4 9.1 63

F trace 1.2 2.7 2.7 2.3 4.4 5.7 5.3 75.7 12.2 145

G trace 1.2 2.6 2.3 1.8 3.5 4.1 2.7 81.8 15.6 180

H trace 0.5 1.3 1.8 1.8 2.9 3.8 2.6 85.3 17.9 200

I trace 0.4 0.6 0.8 0.6 2.0 2.7 2.6 90.3 22.2 420 Table 2

(100 parts of the starch hydrolysate and 25 purts of acetic acid were used.)

Amount of water Sample (parts) Test item A B C D E F G H I

Viscosity of

solution (cps) 37 39 42 59 55 82 104 140 290 100 Acetic acid

content of the 14.3 15.0 16.3 15.8 17.3 17.5 17.2 Note.1. Note 1.

produced powder

(%)

Acetic acid 69.2 73.2 80.8 77.8 86.8 88.0 86.2

yield

Caking resistance -- - # - + + +

of the produced

powder >;RTI Table 2 (continued)

Amount of water Sample (parts) Test item A B C D E F G H I

Viscosity of


contents of the 12.3 12.7 14.2 13.8 15.6 16.3 16.4 16.3 Note 1.

produced powder

(%)

Acetic acid 58.1 60.3 68.6 86.3 76.7 80.8 81.4 80.8

yield

Caking resistance -- - # - + + + +

of the produced

powder >;RTI Table 2 (cont'd)

Amount of water SAMPLE (parts) Test Item A B C D E F G H I

Viscosity of


content of the 9.3 9.7 10.3 10.9 12.0 12.5 12.9 13.4 13.8

produced powder

(%)

Acetic acid 42.4 44.4 47.5 50.6 56.5 59.2 61.4 64.1 66.3

yield (%)

Caking resistance -- - # - + + + + +

of the produced

powder

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Note 1 : Spray-drying was impossible because of high viscosity.

Caking resistance : the caking resistance was determined by the result obtained by the

method comprising enclosing the produced powder in an aluminium

foil pouch aud the treated pouch was allowed to stand for 48 hours

at 40 C for the storage test.

+ stands for no caking, # stands for a slight caking,

- stands for caking and -- stands for a hard caking.>;/RTI;

Table 2 gives the following explanations.

(1) In the case of Sample A, which had a small average polymerization degree, viz., 5.6 and had 16.1

% the total content of G1 and G3 and 27.1 % the total content of G, to G5, the spraydrying aptitude and the powder yield were very poor and moreover the produced powder was very poor at the caking resistance.

(2) Though Sample B, C and D had a DE value of about 14, the comparisons in points of the acetic acid yield and the caking resistance were as follows: the use of Sample B which had 13.0 % the total content of G1 to G3 and 23.2 % the total content of G1 to G5 gave the worst results among three produced powders in both the acetic acid yield and the caking resistance, and

Sample D which had1 2.4 % the total content of G1 toG5 and 20.5 % the total content ofG to G5 secured the acetic acid yield in the case of 100 parts water to 100 parts of the starch hydrolysate, however therein the caking resistance was poor, and Sample C which had 7.3 % the total content of G1 to G3 and 20.7 % the total content ofG1 to G5 gave the better yield of acetic acid and the better caking resistance in comparison with those of Sample D, however therein the caking resistance was still slightly poor.

(3) Sample E, F and G which had in turn an average polymerization degree of 9.1, 12,2 and1 5.6 and had not more than 20 % the total content of G1 to G5 gave good results in all the points such as spraydrying aptitude, acetic acid yield, caking resistance etc. in the case of not more than1 30 parts of water to 100 parts of the starch hydrolysate (viz., 77 parts of the starch hydrolysate to 100 parts of water).

However it is found that when the amount of the starch hydrolysate to the amount of water is decreased, the acetic acid yield is considerable lowered.

(4) Sample H having an average polymerization degree of1 7.9 had a high viscosity.

Therefore the solution obtained by mixing 100 parts of the starch hydrolysate and 100 parts of water could not be mechanically spray-dried because of the high viscosity of the solution. In the case of the solution obtained by mixing 100 parts of the starch hydrolysate and 160 parts of water, said solution being able to be spray-dried, the acetic acid yield was poor, and in the case of the solution obtained by mixing 100 parts of the starch hydrolysate and1 30 parts of water, said solution being able to be spraydried, the acetic acid yield was 80.8 %. Sample I having an average polymerization degree of 22.2 induced a difficult spray-drying and a poor yield of acetic acid.

As shown in Table 3, in the case of maltotriose (G3), not to mention glucose and maltose, the solution had a very poor spray-drying aptitude, viz., the spray-dried matters were adhered to a chamber wall and therefore the powder could not be obtained. This state can be guessed by the fact that maltotriose is dissolved in a 97 % aqueous solution of acetic acid. In the case of the starch hydrolysate containing a small quantity of the saccharides ofG to G3 and about 50 % the saccharides of G4 to G5, the solution had a very poor spray-drying aptitude and the obtained powder was very poor at the acetic acid yield and the caking resistance, and it is understood that the saccharides having a glucose polymerization degree of 4 to 5 is hardly suitable as a powdering carrier for covering and keeping acetic acid.

Table 3

In the case of glucose, maltose, maltotriose and the starch

hydrolysate mainly containing G4 to G5

(Composition of the solution : acetic acid : water : saccharide = 25 : 100 : 100)

Acetic acid Acetic acid Drying state

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Carrier content (%) yield (%)

Glucose (G1) - - All adhered to a chamber wall and

therefore the powder could not

be obtained.

Maltose (G2) - - Ditto

Maltotriose (G3) - - Ditto

Starch hydroly- 8 36 The adherence to a chamber wall was sate mainly con- observed and the obtained powder was taining G4 to G5 poor at caking resistance.>;/RTI;

Consequently, by judging synthetically the present inventors found that the starch hydrolysate, which contains not more than 20 % oligosaccharides having a glucose polymerization degree of not more than

5 and not more than 7 % the total content of glucose, maltose and maltotriose, and has an average glucose polymerization degree of 6 to 18 as a whole, is selected and mixed in an aqueous solution of acetic acid in an amount of approximately 70 % or more of the amount of the water contained in the aqueous solution of acetic acid and the resulting solution is spray-dried at as low a temperature as possible and thereby the powder containing acetic acid, which has a high acetic acid content and a high acetic acid yield, can be produced and moreover the thus obtained powder is very good at caking resistance, moisture proof, keeping or aroma, solubility in water etc..

Test 2:

The starch hydrolysates used and their saccharide compositions are as follows: a-cyclodextrin obtained by separating and purifying from the liquefied solution containing the cyclic oligosaccharides prepared by making a cyclic oligosaccharide-forming enzyme act on a potato starch:

the cyclic oligosaccharide (100%a) -- - - (1)-A,

The mixture containing 50 % the starch hydrolysate (acyclic) having an average polymerization degree of 11.8 and 50 % the cyclic oligosaccharide (mixture of 60 %a, 25 % ss and 15 % y) obtained by making a-amylase act on a potato starch and thereafter by making a cyclic oligosaccharide-forming enzyme act on: the cyclic oligosaccharides (60 %;, 25% ss and 15 %;-----(I-B), the starch hydrolysate having an average polymerization degree of 11.8-----(III)-E,

* the two kinds of starch hydrolysates having respectively an average polymerization degree of 12.5 and 25.0 which were prepared by hydrolyzing a waxy starch (composed of amylopectin)::

the starch hydrolysate having an average polymerization degree of 12.5 which was preparedby hydrolyzing starch composed of amylopectin - - -- - (Il)-A,

the starch hydrolysate having an average polymerization degree of 25.0 which was prepared by hydrolyzing starch composed of amylopectin - - - -- (II)-B,

* the four kinds of starch hydrolysates having respectively an average polymerization degree of 5.0,

7.6, 11.8 and 13.3 which were prepared by hydrolyzing a potato starch (composed of amylose and amylopectin) with a-amylase: :

the starch hydrolysate having an average polymerization degree of 5.0----- (III)-A,

the starch hydrolysate having an average polymerization degree of 7.6----- (III)-B,

the starch hydrolysate having an average polymerization degree of 11.8----- (III)-C,

the starch hydrolysate having an average polymerization degree of 13.3- - - -(lll)-D.

Table 4

Saccharide composition (%)

Powder carrier G1 G2 G3 G4 G5 G6 G7 G8 G9 to n (III)-X 0.6 3.5 5.0 4.5 4.5 6.5 6.0 4.0 65.9 (II)-A trace 1.4 2.2 1.6 2.4 5.0 5.9 4.6 76.5 (II)-B trace 0.3 0.6 0.6 0.5 1.2 1.6 1.8 93.4 (III)-A 4.7 6.5 6.9 6.7

6.5 6.0 5.4 4.8 52.5 (III)-B 1.3 2.3 4.5 4.4 4.1 5.5 5.2 4.6 68.1 (III)-C 0.5 1.2 2.7 2.7 2.3 4.4 5.7 5.3

75.2 (III)-D 0.5 1.0 2.6 2.5 2.1 4.0 5.0 4.6 77.7

At least one member selected from the group of abovementioned starch hydrolysates was mixed in an aqueous 20 % acetic acid solution in an amount of1 25 % of the amount of the water contained in the aqueous 20 % acetic acid solution and the resulting solution was spraydried at a chamber temperature of95 C. In this test, spray-drying state, acetic acid yield, acetic acid stability and caking resistance of the produced powder were observed and the results were shown as in Table 5.

Table 5 teaches as follows:

1) Tests No. 1 to No. 4 which respectively used the starch hydrolysate prepared by hydrolyzing an ordinary starch composed of amylose and amylopectin, are explained as follows.

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In the case of Test No. 1 which used the starch hydrolysate(Ill)-A having a low average polymerization degree and containing not less than 20 % the saccharides of G5 or less, the spray-drying aptitude has not a defect at all because of a low viscosity. However a poor performance in convering acetic acid, adherence to chamber wall during spray-dring and a poor remaining ratio of acetic acid are recognized. In addition the produced powder is very poor at both acetic acid stability and caking resistance.

In the case of Test No. 4 which used the starch hydrolysate (Ill)-D having a high average polymerization degree, the spray-drying is impossible because of a high viscosity when the amount of the powdering carrier is1 25 % of the amount of the water, and therefore the powder can not be produced. In the case of Test No. 3 which used the starch hydrolysate(Ill)-C having a lower viscosity than that of the starch hydrolysate (Ill)-D, a considerably good acetic acid yield, a good caking resistance and a good acetic acid stability are recognized in the produced powder, though the spraydrying aptitude is slightly bad because the viscosity is still slightly high.

However, it is very difficult to secure a higher acetic acid yield than that of Test No. 3, because the starch hydrolysate(lil)-C can not be mixed in an aqueous solution of acetic acid in a higher amount to an amount of the water contained in an aqueous solution of acetic acid than that of

Test No. 3. In the case of Test No. 2 which used the starch hydrolysate(Ill)-B having an average polymerization degree situated between that of the starch hydrolysate(Ill)-A and that of the starch hydrolysate(Ill)-C, the spray-drying aptitude and the acetic acid yield are considerably good, but an inferior caking resistance and an inferior acetic acid stability are recognized.

2) In the cases of Tests No. 5 and No. 6 wherein Test No. 5 used the mixture of the cyclic oligosaccharides(I)-B and the starch hydrolysate (Ill)-E having an average polymerization degree of

11.8 and Test No. 6 used the mixture of the former two (viz.,(I)-B and (Ill)-E and the starch hydrolysate(Ill)-C having a polymerization degree of 11.8, a good spray-drying aptitude, a remarkably heightened acetic acid yield and acetic acid stability, and a good caking resistance are recognized in each Test, because the cyclic oligosaccharides are not viscous and moreover possess a certain combining property to acetic acid.After further examination, a higher acetic acid yield was obtained by increasing more the amount of the powdering carrier to the amount of the water contained in the aqueous solution of acetic acid on condition that the powdering carrier has the same mixing proportion of ingredients in each powdering carrier of Tests No. 5 and No. 6, and the spray-drying can be performed.

3) In the case of Test No. 7 wherein the cyclic oligosaccharide(a-cyclodextrin) (I)-A was used alone on trial as a powdering carrier, the cyclic oligosaccharide was not dissolved to result in settling.

4) Tests No. 8 to No. 10 used the starch hydrolysate having an average polymerization degree of

12.5(Il)-A which was prepared by hydrolyzing a waxy starch. This starch hydrolysate has approximately the same viscosity as that of the starch hydrolysate having an average polymerization degree of 9 prepared by hydrolyzing an ordinary starch composed of amylose and amylopectin and has a low viscosity in spite of a high average polymerization degree and moreover retains the branched polymeric structures peculiar to amylopectin.

All the three uses, viz., the combination use (Test No. 8) of the starch hydrolysate(Il)-A having an average polymerization degree of 12.5 derived from amylopectin and the cyclic oligosaccharide(I)-A, the single use (Test No. 9) of the starch hydrolysate(Il)-A derived from amylopectin and the combination use (Test No. 10) of the starch hydrolysate(Il)-A derived from amylopectin and the starch hydrolysate(Ill)-C having an average polymerization degree of 11.8 which(Ill)-C is the same starch hydrolysate as in Test No. 3, produced the superior results in all points such as spray-drying aptitude, acetic acid yield, acetic acid stability and caking resistance to the results of Tests No. 1 to No.

4.Especially Test No. 8 produced the good results.

Test No. 11 used the starch hydrolysate(Il)-B having an average polymerization degree of 25.0 which was obtained by hydrolyzing a waxy starch. Said starch hydrolysate has a considerably high viscosity and therefore can not be used much. However the combination use of said starch hydrolysate and the

1166/2197

starch hydrolysate(Ill)-B having defects in using alone, produced the good results making up the defects of the starch hydrolysate(III)-B.

In the case of Test No. 12 wherein the abovementioned(Il)-B was used much, the spraydrying could not be done because of the very high viscosity.

5) Test No.1 3 wherein the properties of the cyclic dextrin(I)-B, the starch hydrolysate(llI)-E having the average polymerization degree of 11.8 and the starch hydrolysate(Il)-A derived from amylopectin were effectively incorporated in the composition of the powdering carrier, produced the best results in all the Tests in all points such as spray-drying aptitude, acetic acid yield, acetic acid stability and caking resistance.

* Acetic acid yield is calculated as follows: multipling an acetic acid content ratio of a produced powder by an amount by weight of a produced powder gives a value, viz., an amount by weight of a remaining acetic acid and then which divided by an amount by weight of acetic acid contained in an aqueous acetic acid solution used and moreover multiplied by 100 is the acetic acid yield.

** Acetic acid stability is calculated as follows: 50 g of a produced powder is enclosed in a pouch

(thickness: 0.05 mm) made of polyethylene, said pouch being easily pervious to a gaseous acetic acid, and the pouch is hermetically sealed and then is stored at35"C for 8 days in a constant temperature box and thereafter an amount of acetic acid contained in a stored powder is measured and the acetic acid stability is calculated by the following equation:

Amount of acetic acid contained in powder after storage

X 1 0 = Acetic acid stability

Amount of acetic contained in powder before storage

Caking resistance is judged as follows: a produced powder is enclosed in a pouch made of aluminum foil and the pouch is hermetically sealed and then is stored at40"C for 10 days and thereafter a caking state is observed.

Table 5 Test No.

Powdering carrier 1 2 3 4 (I)-A cyclic dextrin (100%;) - - - (I)-B cyclic dextrin (60%;, 25%ss, 15%;) -

- - (II)-A dextrin having an average polymerization - - -

degree of 12.5 derived from amylopectin (II)-B dextrin having an average polymerization - - -

degree of 25.0 derived from amylopectin (III)-A dextrin having an average polymerization 100 Kg - -

degree of 5.0 (III)-B dextrin having an average polymerization - 100 Kg -

degree of 7.6 (III)-C dextrin having an average polymerization - 50 Kg 100 Kg

degree of 11.8 (III)-D dextrin having an average polymerization - - - 100 Kg

degree of 13.3 (III)-E dextrin having an average polymerization - - -

degree of 11.8

Average polymerization degree of a powdering carrier 5.0 7.6 11.8 13.3

Amount of acetic acid 20 Kg 20 kg 20 kg 20 kg

Amount of water 80 Kg 80 Kg 80 Kg 80 Kg

Solubility of a powdering carrier good good good good

Viscosity of solution cps (40 C) 45 57 147 190

Spray-drying aptitude Note 2 good Note 3 Note 4

Amount of a produced powder (Kg) 101.2 115.4 113.3

Acetic acid content of a produced powder (%) 12.5 15.1 14.8

Acetic acid remaining ratio (yield) * (%) 63.3 87.1 83.8

Acetic acid stability (ratio) ** (%) 60 70 75

Caking resistance *** Note 5 caking Note 6

Note 1 : insoluble and settling Note 4 : impossible

Note 2 : adherence to a chamber wall Note 5 : hard caking

Note 3 : slightly bad because of a high viscosity Note 6 : no caking >;RTI Table 5 (continued) Test

No.

Powdering carrier 5 6 7 8 (I)-A cyclic dextrin (100%;) - - 100 Kg 10 Kg (I)-B cyclic dextrin (60%;,

25%ss, 15%;) 50 Kg 25 Kg - (II)-A dextrin having an average polymerization - - - 90 Kg

degree of 12.5 derived from amylopectin (II)-B dextrin having an average polymerization - - -

1167/2197

degree of 25.0 derived from amylopectin (III)-A dextrin having an average polymerization - - -

degree of 5.0 (III)-B dextrin having an average polymerization - - -

degree of 7.6 (III)-C dextrin having an average polymerization - 50 Kg -

degree of 11.8 (III)-D dextrin having an average polymerization - - -

degree of 13.3 (III)-E dextrin having an average polymerization 50 Kg 25 Kg -

degree of 11.8

Average polymerization degree of a powdering carrier 9.2 10.5 6.0 11.9

Amount of acetic acid 20 Kg 20 Kg 20 Kg 20 Kg

Amount of water 80 Kg 80 Kg 80 Kg 80 Kg

Solubility of a powdering carrier good good Note 1 good

Viscosity of solution cps (40 C) 85 115 - 110

Spray-drying aptitude good good - good

Amount of a produced powder (Kg) 116.7 116.4 - 117.0

Acetic acid content of a produced powder (%) 16.0 15.7 - 16.2

Acetic acid remaining ratio (yield) * (%) 93.4 91.3 - 94.8

Acetic acid stability (ratio) ** (%) 90 85 - 88

Caking resistance *** Note 6 Note 6 - Note 6 >;RTI Table 5 (continued) Test No.

Powdering carrier 9 10 11 12 13 (I)-A cyclic dextrin (100%;) - - - - (I)-B cyclic dextrin (60%;, 25%ss,

15%;) - - - - 25 Kg (II)-A dextrin having an average polymerization 100 Kg 50 Kg - - 50 Kg

degree of 12.5 derived from amylopectin (II)-B dextrin having an average polymerization - - 20 Kg 65

Kg

degree of 25.0 derived from amylopectin (III)-A dextrin having an average polymerization - - - -

degree of 5.0 (III)-B dextrin having an average polymerization - - 80 Kg 35 Kg

degree of 7.6 (III)-C dextrin having an average polymerization - 50 Kg - -

degree of 11.8 (III)-D dextrin having an average polymerization - - - -

degree of 13.3 (III)-E dextrin having an average polymerization - - - - 25 Kg

degree of 11.8

Average polymerization degree of a powdering carrier 12.5 12.2 11.1 18.9 10.8

Amount of acetic acid 20 Kg 20 Kg 20 Kg 20 Kg 20 Kg

Amount of water 80 Kg 80 Kg 80 Kg 80 Kg 80 Kg

Solubility of a powdering carrier good good good good good

Viscosity of solution cps (40 C) 118 131 132 305 105

Spray-drying aptitude good good good Note 4 good

Amount of a produced powder (Kg) 116.7 116.4 116.4 - 117.0

Acetic acid content of a produced powder (%) 16.0 15.8 15.8 - 16.2

Acetic acid remaining ratio (yield) * (%) 93.4 92.0 92.0 - 94.8

Acetic acid stability (ratio) ** (%) 87 83 84 - 89

Caking resistance *** Note 6 Note 6 Note 6 - Note 6>;/RTI;

Example 1

The emulsion of a corn starch was hydrolyzed with a-amylase by the following two-staged hydrolysis.When in the first stage the DE value reached 1.7 by the liquefaction with a-amylase

(Crystase KD supplied by Daiwa Kasel Kabushiki Kaisha), the hydrolysate was heated and boiled for inactivating a-amylase and for swelling and dispersing starch, and in the second stage the resulting hydrolysate was added again with a-amylase (Crystase KD) and further hydrolyzed to have a DE value of 7.2, and thereafter was dried to prepare the starch hydrolysate (moisture : 4) %) which had the saccharide composition comprising trace % G1, 1,4% G2, 2.6% G3, 2,4%

G4, 2.0% G5, 2.3% G6, 3.9% G7, 3.7% G8 and 81.7% G9 to n and had an average polymerization degree of about 14.

100 Kg of the obtained starch hydrolysate was dissolved in an aqueous acetic acid solution prepared by using 90 Kg of water and 30 Kg of acetic acid having a purity of 99% and the resulting mixture was heated up to 55 C by a plate heater and sequentially spray-dried at a chamber temperature of 92 C to result in producing about 125 Kg of the powder having 20.6 % acetic acid content.

As the obtained powder has a high acetic acid content and moreover an excellent caking resistance, the obtained powder is very useful as an acidifying agent for providing an instant seasonings of various sauces or various soups.

1168/2197

Example 2

In 250 Kg of water was dissolved 100 Kg of the starch hydrolysate (saccharide composition : 1.2%

G1, 5.3% G2, 8.2% G3, 5.4% G4. 4.9% G5, 9.3% G6, 9.9% G7, 5.1% G8 and 50.7% G9 to n) having a

DE value of 15, said starch hydrolysate being an article on the market.

To the resultingsolution,10 g of magnesium sulfate,70 9 of primary potassium phosphate, 100 g of yeast extract, 50 g of peptone and 200 g of a baker's yeast were added and dissolved with stirring. The thus obtained solution was subjected to the cultivation which was carried out under the aeration of a sterile air at a rate of 60 ml/min. per liter of the solution at 30+ 1"C for 48 hours. And the pH value of the solution was adjusted to 6.5 and thereafter the solution was heated up to 90 C for sterilization and moreover decolorized, desalted, deodorized and spray-dried to prepare 70 Kg of the starch hydrolysate

(moisture: 3.5 %).This starch hydrolysate had the saccharide composition comprising trace %G1, 0.4

%G2, 5.4 %G3, 6.1 %G4,5.3 G5,10.1 % G6, 10.8%G7, 5.6 %Ge 56.3 % Ggton and had an average polymerization degree of about 8.9.

50 Kg of the obtained starch hydrolysate was mixed in 50 Kg of a wine vinegar (12.0 % acetic acid and 2.0% extract) and the resulting solution was heated up to 50 C by a plate heater and sequentially spray-dried at a chamber temperature of 90 C to result in producing about 55 Kg of the powdery wine vinegar having an acetic acid content of 9.5%. This powdery wine vinegar had flavour peculiar to a wine vinegar and had the good qualities in points of caking resistance, moisture proof, solubility etc..

Example 3

In 200 Kg of an aqueous ethyl alcohol solution having an ethyl alcohol content of 60 w/w % was mixed 50 Kg of the starch hydrolysate (saccharide composition: 4.3 %G1, 5.5 %G2, 5.3 % G3, 5.6%

G4, 6.5% G5, 5.5% G6, 4.9% G7, 4.3% G8 and 58.1% G9to n) having a DE value of 17.5, said starch hydrolysate being an article on the market. The resulting solution was allowed to stand for 24 hours to separate it into upper and lower two transparent layers. By fractionation, there were obtained 180 Kg of the upper layer and 70 Kg of the lower layer. This obtained lower phase (60% solid and 15% alcohol) was subjected to distillation by which alcohol was evaporated and recovered, and then subjected to drying to prepare about 40 Kg of the starch hydrolysate (moisture : 4.0%).The starch hydrolysate had the saccharide composition comprising 1.4% G1, 1.8% G2, 3.4% G3, 4.8% G4, 5.5% G5, 4.6% G6,

5.1% G7, 6.8%

G8 and 66.6% G9to n and had an average polymerization degree of 13.1. 20 Kg of the obtained starch hydrolysate was mixed in 20 Kg of a rice vinegar (20 % acetic acid and 2.7% extract) obtained by freeze-concentrating, and then the resulting mixture was heated up to 50 C by a plate heater and sequentially spray-dried at a chamber temperature of 92 C to result in producing about 24 Kg of the powdery rice vinegar having an acetic acid content of 14.7 %.

The obtained powder has aroma peculiar to a rice vinegar and moreover is of good quality in points of caking resistance, solubility, viscosity of its solution etc.. Therefore the obtained powder is compounded with sugar etc. to provide a very convenient powdery instant "sanbaizu" which is a seasoning comprising vinegar, sugar and salt or soy sauce, or a very convenient "sushinomoto" which is a seasoning for"sushi".

Example 4

The powdering carrier (average polymerization degree: 9.8, saccharide composition: 0.4 %G1, 1.1 %

G2, 2.1 % G3, 2.3 % G4 and 2.7 % G5), which comprising 30 Kg of the starch hydrolysate (an article on the market) having an average polymerization degree of 11 and 80 Kg of the starch hydrolysate containing 50 % the acyclic starch hydrolysate having an average polymerization degree of1 2 and 50

% the cyclic oligosaccharide (mixture of 60 % a, 25 %ss and1 5 % y) obtained by hydrolyzing a potato starch with a-amylase and thereafter making a cyclic oligosaccharide-forming enzyme act on, was mixed in the solution comprising 20 Kg acetic acid having a purity of 99 % and 100 Kg of

"shuseizu" (15.0 % acetic acid, 0.5 % extract and 84.5 % water), and thereby the solution (viscosity:

105 cps at40"C) was obtained.

And then the resulting solution was heated up to60"C by a plate heater and sequentially spray-dried at a chamber temperature of95"C by a spray drier having a nozzle style to result in producing about1 40

Kg of the powdery product.

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The obtained powder was the powdery acetic acid having a high, viz., 23.0 % acetic acid content. The obtained powder is mixed with salt, sugar, a powdery seasoning etc. to provide an instant "sushizu" which is a vinegar for sushi, "nihaizu" which is a seasoning comprising salt or soy sauce and vinegar, or"sanbaizu". By subjecting the hermetically sealed pouches, in which these mixed products being severally enclosed, to a storage test, it was found that each acetic acid stability, viz., antivolatility, caking resistance etc. were superior to those of the products obtained by the conventional method.

Example 5

in 100 Kg of wine vinegar (12.0 % acetic acid, 2.0 % extract and 86.0 % water) was mixed the powdering carrier (average polymerization degree: 14.6 %, and saccharide composition: trace %G1,

1.6 % G2, 3.0 % G3, 3.2% G4 and 3.2 % G5) comprising 80 Kg of the starch hydrolysate (an article on the market) having an average polymerization degree of 10 and 20 Kg of the starch hydrolysate having an average polymerization degree of 33 which was obtained by hydrolyzing a waxy starch with aamylase, and thereby the solution (viscosity:1 20 cps at40"C) was obtained.

And then this solution was heated up and sequentially dried at a chamber temperature of100"C by a spray drier to produce about 110 Kg of the powdery product. This obtained powdery product had an acetic acid content of 10.2 % and was the powder having flavor peculiar to a wine vinegar. This powder can be used as a powdery table vinegar or as a material for various European style seasonings such as a powdery mixed dressing. a powdery mixed sauce etc.. The mixture prepared by mixing the obtained powder with sugar, salt, amino acid etc. was good in an acetic acid stability and showed no caking.

Example 6

In 60 Kg of a cider vinegar (20.0 % acetic acid, 2.5 % extract and 77.5 % water) obtained by freezeconcentrating was dissolved the powdering carrier (average polymerization degree: 12.2, saccharide composition:0.3 % G1, 0.8 % G2,1.8 % G3, 2.1 % G4 and2.4 % G5) comprising 20 Kg of the starch hydrolysate having an average polymerization degree of 18 which was obtained by hydrolyzing a waxy starch with a-amylase and 40 Kg of the starch hydrolysate containing 50 % the acyclic starch hydrolysate having an average polymerization degree of1 2 and 50 % the cyclic oligosaccharides

(average polymerization degree: 6.5) obtained by liquefying a potato starch with a-amylase and thereafter making a cyclic oligosaccharide-forming enzyme act on. The resulting solution (viscosity: 75 cps at60"C) was heated up to60"C by a plate heater and sequentially spray-dried at a chamber temperature of95"C to result in producing about 71 Kg of the powdery product. This obtained powdery product had an acetic acid content of1 5.8 % and the loss of acetic acid caused by drying was very little, viz., the acetic acid remaining ratio was 94 %. This obtained powder is the powdery brew vinegar having aroma peculiar to a cider vinegar and can be used as a material for various instant seasoning or confectionary.

Example 7

In the solution comprising 50 Kg of a cider vinegar (12.0 % acetic acid and 1.5 % extract), 50 Kg of

"shuseizu" (15.0 % acetic acid and 0.5 % extract), 60 Kg of a soy sauce (14.5 % extract and 16.0 % salt) and 20 Kg of a liquid extract (10 % extract) of dried bonito was dissolved 140 Kg of the starch hydrolysate (0 %G1, 2.6 % G2, 2.6 % G3, 2.4 % G4 and 2.2 %

G5) having an average polymerization degree of1 2.5 which was prepared by hydrolyzing a waxy starch with a-amylase. The resulting solution was heated up to65"C and sequentially spraydried at a chamber temperature of 100 C to result in producing about1 70 Kg of the powdery product.

This obtained powder has 7.0 % acetic acid content, 5.6 % salt content and 6.8 % various extracts, and is dissolved in water to provide "ponzu" having flavor peculiar to dried bonito, which "ponzu" is originally a vinegar added with juice of a citrus fruit,

This powdery product contains salt and various extracts besides acetic acid, and is good in keeping acetic acid and other flavors and moreover very good in caking resistance.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1170/2197

1. A process for powdering a liquid seasoning containing acetic acid which comprises mixing a starch hydrolysate containing not more than 20 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 7 % oligosaccharides having a glucose polymerization degree of not not more than 3 in the liquid seasoning containing acetic acid in an amount of not less than 70 % of the amount of the water contained in the liquid seasoning containing acetic acid and spray-drying the resulting solution.

2. A process according to claim 1 wherein the starch hydrolysate having an average polymerization degree of 6 to1 8 and also inducing viscosity of not more than 300 cps at40"C in the case of a 50 % aqueous solution of the starch hydrolysate is used.

3. A process according to claim 1 wherein the starch hydrolysate contains not more than1 5 % oligosaccharides having a glucose polymerization degree of not more than 5 and not more than 5 % oligosaccharides having a glucose polymerization degree of not more than 3.

4. A process according to claim 1 wherein the starch hydrolysate contains at least one member selected from the group consisting of the following a, b, c and d:

a. a starch hydrolysate prepared by hydrolyzing starch composed of amylopectin and amylose,

b. a starch hydrolysate prepared by hydrolyzing starch composed of amylopectin,

c. a starch hydrolysate containing cyclic oligosaccharides and acyclic starch hydrolysate, said a starch hydrolysate being prepared from starch composed of amylopectin and amylose, and

d. a starch hydrolysate containing cyclic oligosaccharides and acyclic starch hydrolysate, said a starch hydrolysate being prepared from starch composed of amylopectin.

5. A process according to claim 1 wherein the starch hydrolysate contains at least one member selected from the group consisting of a-cyclic oligosaccharide,fl-cyclic oligosacchharide and y-cyclic oligosaccharide, said at least one member being added.

6. A process according to claim 1 wherein the liquid seasoning containing acetic acid is selected from the group consisting of rice vinegar, "kasuzu", "shuseizu", malt vinegar, wine vinegar, cider vinegar, synthesized vinegar, aqueous solution of the abovementioned matters, each abovementioned matter added with acetic acid and each processed solution of the abovementioned matters.Data supplied from the esp@cenet database - Worldwide

1171/2197

240.

JP59011166 - 1/20/1984

PREPARATION OF FURIKAKE COMPOSED MAINLY OF DEFATTED BRAN

POWDER


Inventor(s): SATOU YOSHI (--)

Applicant(s): SATO YOSHI (--)


IP Class: A23L1/10; A23L1/34

E Class: A23L1/326



Family: JP59011166

Abstract:


PURPOSE:To prepare FURIKAKE (a mixture of fish meal, powdered laver, etc. to be sprinkled on cooked rice) having excellent taste, flavor and nutritive value, free from the smell of bran and fish, by using defatted bran powder and dried fish powder as raw materials. CONSTITUTION:Defatted bran of rice of barley is partched in a high-pressure rotary oven, etc. preventing the scorching, and pulverized to about 250-300 mesh to obtain defatted bran powder. Separately, the skin, guts, head and tail are removed from a fish having excellent taste and flavor, and the fish meat is boiled, dried and powdered with a mixer, etc. to obtain powdered fish. The defatted bran powder is mixed with the powdered fish at a specific ratio, and parched in a high-pressure rotary oven or in a kettle under dripping of soy, etc. preventing the scorching to effect the drying and seasoning at the same time.

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241.

JP59088045 - 5/21/1984

PRODUCTION OF CORN SNACK FOOD


Inventor(s): ITOU HIDEAKI (--); ITOU HARUO (--)

Applicant(s): ITO SEISEN KOUJIYOU KK (--); ITO SEISENBU HONTEN KK (--)


IP Class: A23L1/18; A23G3/00

E Class: A23L1/164



Family: JP59088045

Abstract:


1173/2197

PURPOSE:To mass produce a nice snack food, by steaming or boiling roughly crushed corn while adding water thereto, rolling the resultant gelatinized rice cakelike material, primarily drying the resultant sheet, winding up the sheet, maturing the wound sheet, homogenizing the moisture, stamping or cutting the wound sheet, drying the resultant material, frying the dried material in oil, roasting the fried material, and seasoning the roasted matrerial. CONSTITUTION:Roughly crushed corn grains

(corn grits) are introduced into a stirred cooker, and water is added thereto while stirring the corn grains. A pH controlling agent and a seasoning are added during the stirring to gelatinize the corn grains, which are changed into a rice cakelike form. The resultant rice cakelike material is then rolled into a sheet, cooled, primarily dried, wound, matured, extended and stamped or cut into a desired form.

The resultant stemped or cut material is then secondarily dried with hot air, and refined to give a dough, which is then subjected to the third drying step in a roasting oven, fried in an oil or baked. The surface of the material is then seasoned to give the aimed corn snack food.

1174/2197

242.

JP59130157 - 7/26/1984

NUTRITIONALLY ENRICHED POLISHED RICE, WHEAT OR BARLEY


Inventor(s): WATANABE HIROHIKO (--); NISHIMURA MOTOYUKI (--); MORITAKA

SHINTAROU (--)

Applicant(s): TAKEDA CHEMICAL INDUSTRIES LTD (--); TAKEDA SHIYOKUHIN

KOGYO KK (--)


IP Class: A23L1/10

E Class: A23L1/10B; A23B9/14



Family: JP59130157


Abstract:


PURPOSE:Polished rice, wheat or barley coated or impregnated with additional nutrients is covered with an emulsion containing fat and oil and wax to produce inexpensively nutritionally enriched polished rice, wheat or barley with nutrients of very little loss on washing. CONSTITUTION:Polished rice, wheat or barley coated or impregnated with nutrients such as vitamins, aminoacids or minerals are covered with an emulsion containing fat, oil and wax which are solid at room temperature and melt on heating such as an emulsion containing 100pts.wt. of fat and oil such as soybean oil, cotton-seed oil or tallow and about 10-100pts.wt., preferably about 5- 80pts.wt. of wax such as carnauba wax or rice bran wax in a usual manner.Claims:


What we claim is:

1. A process for producing enriched polished rice or rice or barley, which comprises incorporating or letting depositing nutrients in or on polished rice or barley grains, and subsequently coating the resultant grains with an aqueous emulsion containing an oil/fat and a wax wherein each of the components melts at about 40 DEG to 80 DEG C.

2. The process according to claim 1, wherein the emulsion contains the wax in a proportion of about 1 to 100 weight parts based on 100 weight parts of the oil/fat.

3. The according to claim 1, wherein the oil/fat is sperm oil, hydrogenated cottonseed oil, hydrogenated beef tallow or hydrogenated rapeseed oil, and the wax is rice bran wax, candellila wax, carnauba wax or bees wax.

4. The process according to claim 1, wherein the coating amount of the oil/fat and the wax is about 2 to

7 weight %, relative to the weight of the finished enriched rice or barley.

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5. The process according to claim 1, wherein the coating of the emulsion is accomplished by a spraycoating procedure.

6. The process according to claim 1, wherein the nutrients are water-soluble vitamins, fat-soluble vitamins, amino acids or minerals.

7. Polished rice or barley enriched with nutrients, said nutrients being fixed in or on the grains by coating the polished rice or barley grains, in or on which the nutrients are incorporated or deposited, with an oil/fat and a wax wherein each of the components melts at about 40 DEG to 80 DEG C.

8. Polished rice or barley enriched with nutrients according to claim 16, wherein the amount of the wax is about 1 to 100 weight parts based on 100 weight parts of the oil/fat.

9. Polished rice, or barley enriched with nutrients according to claim 7, wherein the coating amount of the oil/fat and the wax is about 2 to 7 weight %, relative to the weight of the finished enriched rice or barley.

10. Polished rice or barley enriched with nutrients according to claim 7, wherein the nutrients are water-soluble vitamins, fat-soluble vitamins, amino acids or minerals.

11. Polished rice or barley enriched with nutrients according to claim 7, wherien the oil/fat is sperm oil, hydrogenated cottonseed oil, hydrogenated beef tallow or hydrogenated rapeseed oil, and the wax is rice bran wax, candellila wax, carnauba wax or bees wax.Data supplied from the esp@cenet database -

Worldwide

1176/2197

243.

JP59210850 - 11/29/1984

PREPARATION OF FOOD OR DRINK GOOD FOR HEALTH


Inventor(s): TAKEUCHI MASAYASU (--); KAWAMURA SABUROU (--)

Applicant(s): JAPAN MAIZE PROD (--)


IP Class: A23L1/16; A23L1/00; A23L1/176; A23L1/325; A23L1/32

E Class: A23L1/10E



Family: JP59210850

Abstract:


PURPOSE:To impart a food or drink with a physiological activity, and to improve the physical properties of the food, etc. without deteriorating its palatability, by adding an edible fiber obtained by treating the bran of cereals with an alkaline aqueous solution. CONSTITUTION:The bran of cereals such as rice bran, wheat bran, soybean skin, etc. is optionally cleaned to remove the foreign materials such as starch, protein, lipid, inorganic materials, etc., and immersed in an alkaline aqueous solution having an alkali concentration of 0.05-4.0%, and the obtained edible fiber having an NDF value of

;=50, preferably ;=60 is added to a food or drink.

1177/2197

244.

JP60030650 - 2/16/1985

METHOD AND APPARATUS FOR PRODUCING EASILY COOKABLE

UNPOLISHED RICE


Inventor(s): HIROKAWA TADAHIKO (--); OOKI KATSUMOTO (--); KUMAGAI ISAO (--);

SASAKI HAJIME (--)

Applicant(s): MORINAGA and CO (--); SHIYOKUHIN SANGYO CENTER (--)


IP Class: A23L1/10

E Class: A23L1/182; A23L1/10H2



Family: JP60030650


1178/2197

Abstract:


PURPOSE:To produce easily cookable unpolished rice having uniform quality, by heating unpolished raice under fluidized state with hot air flow, stopping the heating when a specific quantity of thermal energy is absorbed in the rice, and cooling the rice. CONSTITUTION:The present apparatus is composed of the fluidizing heating apparatus 3 for the heating of unpolished rice, the cooling apparatus

11 for cooling the heated unpolished rice, and the transporting apparatus 6 connecting the outlet port of the apparatus 3 and the inlet port of the apparatus 11 and transporting the heated unpolished rice rapidly to the apparatus 11. The apparatus 3 is furnished with the temperature detectors 15, 16 to measure the temperature of the inlet port of the hot air and the exhaust port of exhaust air, and with the flow meter 14 to measure the air flow at the inlet port of the hot air. The data transmitted from the temperature detectors 15, 16 and the flow meter 14 are sent to the computer 12 to calculate the quantity of the thermal energy absorbed in the unpolished rice. When the calculated quantity reaches a preset level, the discharge valve 13 of the apparatus 3 is opened, and the heated unpolished rice is cooled in the apparatus 11.Description:



This invention relates to a process for treating brown rice or unpolished rice, more particularly to a process for treating brown rice, wherein said brown rice is made to develop fissures in the bran layer by cooling immediately after it has been heated, which is characterized in that said heating is controlled by the quantity of heat energy absorbed by said brown rice so that the brown rice treated is always fissured to a prescribed extent.


Since the bran layer (the aleurone layer and all the outer part) of rice is hard, when brown rice as such is cooked in the usual manner, water can hardly penetrate into the interior of the rice grain, so that there is formed half-cooked rice which is hard on account of the fact that the gelatinization cannot completely reach the endosperm. Accordingly, rice is usually cooked in the form of polished rice in which the bran layer has been removed.

However, since the bran layer of rice contains abundantly vitamins, minerals, and fibrous material, it is desirable to use brown rice as such for food, and thus various methods for cooking rice have been developed, such as the method using an autoclave, the method of reboiling, or similar special methods.

However, when using an autoclave, procedures such as adjusting the pressure or controlling the fire, etc. are not easy, and moreover, the loss of the nutrient ingredients may not be ignored, while the method of reboiling not only requires much labor and time but also damages the nutrient ingredients.

Thus, any of the methods of cooking brown rice, which have heretofore been employed, is not desirable, and actually these methods are not utilized much. Especially for the reason that these methods are unsuitable for daily practice in the home, brown rice is rarely consumed.

It is known however that even in such brown rice, if the hard bran layer is fissured, moisture can readily penetrate into the endosperm so that cooking is also readily achieved, and therefore, some methods of developing fissures in the bran layer of brown rice have heretofore been proposed.

One of the most suitable among them is a method in which brown rice is treated in such a manner that immediately after it has been heated while it is in a fluidized state by virture of hot air it is cooled

(Japanese Pat. No. 1077284). This method provides brown rice in uniform quality of which the bran layers of all the rice grains have uniformly several streaks of fissure, brown rice, even when cooked in the usual manner like polished rice, makes nice cooked rice since moisture penetrates through the fissures into the endosperm until the interior of the rice grain is thoroughly gelatinized. Also this treated brown rice can be cooked satisfactorily in admixture with polished rice. Although the above described method is considerably good, it is not possible to ensure that all the brown rice treated even by this method is always of evenly good quality.

1179/2197

That is to say, in some cases too many fissures are formed, but in other cases fissures are insufficient.

And further, treatment using the same conditions in the temperature, heating time, etc. of the hot air resulted in brown rice that differed in quality or in the mode of fissuring from lot to lot on account of the fact that the moisture, ingredients, properties of the bran layer, etc. of the brown rice varied depending on the kind, brand, place of production, year of production, and other characteristics of the brown rice used as raw material, so that the bran layer of the brown rice could not be made to develop fissures to a desired extent.

Thus, when the brown rice treated in quite the same manner is cooked under the same conditions, the cooked rice produced is uneven in hardness owing to the difference in the amount of moisture absorbed by the endosperm in each lot. Therefore, in order to make brown rice pleasantly palatable when cooked, though it may be cooked under almost the same conditions as in polished rice, the amount of the water added in cooking as well as the cooking time, etc. should all be varied according to the lot.

Such a method is too unsatisfactory to be adapted for practical use.

The present inventors made an earnest investigation to develop a process for treating brown rice which can always make the bran layer of brown rice develop fissures to such an extent as desired irrespective of the variation in the kind, brand, etc. of the brown rice used as the raw material and which can prepare the brown rice such that it can always be readily cooked under the same conditions. As it was discovered that when the heat treatment for the brown rice is controlled by the quantity of heat energy absorbed by said brown rice, one can always produce treated brown rice of uniform quality whose bran layer has fissured to a desired extent, this invention was accomplished.


The present invention is directed to a process for treating brown rice to obtain readily cookable brown rice, whereby fissures are developed in the bran layer of rice by heating the brown rice by blowing heated air through the brown rice in a fluidized state and thereafter immediately cooling the heated rice, which process further comprises treating said brown rice to develop the fissures to a desired extent in such a way that said heating is controlled by the quantity of heat energy absorbed by the treated brown rice. The object of this invention is to provide a process for treating brown rice which can convert said brown rice into one which has uniform fissures and can be readily cooked the same manner as in polished rice.

When brown rice is treated maintaining the heat energy absorbed at 60 kcal or more per 1 kg of brown rice, there is obtained brown rice which can be cooked like polished rice in the usual manner.

The present invention is also directed to an apparatus for practicing the above described process, which comprises a heating device of fluidized bed type for heating brown rice, a cooling device for the heated brown rice, a transporting device which links the discharge port of the contents of said heating device with the charge port of the raw material of said cooling device for rapidly transporting the heated brown rice to said cooling device, temperature sensors mounted on said heating device for measuring the temperatures of the heated air passing through the inlet and the outlet of said heated air, a flow meter for measuring the flow rate of the heated air at the inlet, and a means for calculating the quantity of heat energy absorbed by the brown rice in said heating device based on the data received from said temperature sensors as well as said flow meter, and when said quantity of heat energy has reached the pre-established value, stops the blowing of heated air, opens the valve for discharging the contents of said heating device, so as to remove the heated brown rice to said cooling device, and gives instructions to actuate said cooling device.


FIG. 1 illustrates diagrammatically one embodiment of the apparatus of this invention for practicing the process of this invention.

FIG. 2 represents graphically the relation between the quantity of heat energy absorbed and the water content of the cooked rice in Examples 1-19.

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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

The process according to this invention is carried out in such a manner that brown rice is placed in a fluidizing apparatus, for instance, such as a drying apparatus of batchwise fluidized bed type, and heated by blowing heated air thereinto while said brown rice is in a fluidized state, and then, if the data obtained by measuring the quantity of heat energy absorbed by brown rice indicates that it has reached the pre-established value the heating is controlled to be stopped and immediately thereafter cooling is done.

It is most preferable that the quantity of heat energy absorbed by brown rice is found by directly measuring the temperature of said brown rice elevated by the heating and obtaining the product of this temperature and the specific heat of said brown rice.

However, as it is practically impossible to accurately measure the temperature of the brown rice which is being heated in a fluidized state within the apparatus, the quantity of heat energy absorbed by the brown rice may be estimated from the difference between the quantities of heat energy of the air observed at its charge port and discharge port.

That is to say, it may be calculated by subtracting the quantity of heat energy obtained by measuring the flow rate and the temperature of the air effluent from the heating device and the correction values for the quantity of heat energy consumed by the heating device itself from the quantity of heat energy obtained by measuring the flow rate and the temperature of the heated air influent to the heating device, as illustrated by the following calculation. ##EQU1##

The absorbed heat energy is the accumulation, as calculated with elapsed time, of E obtained by correcting CA with the energy loss .DELTA.E proper to each apparatus.

In the above equation .DELTA.E is a correction value for a heating device, and varies from device to device, but such a correction value can be readily calculated by those skilled in the art.

When the quantity of heat energy absorbed by brown rice at the time of heating is controlled to be 60 kcal or more per 1 kg of brown rice, the treated brown rice always can be readily cooked in the usual manner. If the quantity of heat energy absorbed is less than 60 kcal, the fissures formed in the bran layer of the brown rice are so insufficient the the rice cannot be readily cooked. Of course, in the case where less fissure is preferable, the heat energy absorbed may be reduced. Although increasing the quantity of heat energy absorbed does not affect the quality of the treated brown rice, the heat energy increased more than necessary is a mere loss of energy. Usually it will suffice to use up to about 130 kcal.

The temperature of the heated air being blown may be chosen as desired but when it is too high the surface of the brown rice may be scorched before the desired heat energy is absorbed, while when it is too low, the heating takes too much time. Thus, the temperature should preferably be 90 DEG-170

DEG C. Also, the heating time may be calculated by taking into consideration the temperature of the heated air and the actual quantity of energy absorbed, when the heating time is too short, even though the energy absorbed has reached a predetermined quantity calculated, in reality the brown rice cannot absorb that quantity of heat energy, so that the heating time should preferably be 5 minutes or more.

FIG. 1 illustrates diagrammatically the apparatus for practicing the process of this invention. In the figure, 3 is heating device, 11 is cooling device, and 6 is transporting device for transporting heated brown rice from said heating device 3 to said cooling device 5. When brown rice is thrown into heating device 3 through hopper 4, the air heated with heater 2 after passing through filter 1 is sent to heating device 3, in which said heated air heats the brown rice while stirring it in a fluidized state and then is discharged from the top of said heating device. The temperatures of the air blown into heating device 3 and the air discharged from heating device 3 are continually measured by means of temperature sensors

15 and 16 that are respectively mounted at the charge port and the discharge port of the air, and the data thus obtained is sent to computer 12. The flow rate of the heated air to heating device is measured by

1181/2197

orifice-meter 14 mounted at the charge port of the heated air, and the data thus obtained is also sent to computer 12.

By virtue of a program in which the correction values for the heating device have been pre-established, computer 12 calculates the quantity of heat energy absorbed by the treated brown rice within heating device 3 with the passage of time from the data in said program, and when the quantity of heat energy absorbed by the brown rice has reached the pre-established value, gives instructions to stop the operation of blower 5 as well as to open valve 13 for sending the brown rice to cooling device. The brown rice sent to cooling device 11 through cyclone 7 is immediately cooled to below 30 DEG C. by the cooling air sent through blower 10. As the individual devices used in this invention any conventional devices can be used.

This invention will be more fully explained by reference to the following examples which are not intended to limit the scope of the invention.

EXAMPLES 1-19

In the apparatus as shown in FIG. 1, which comprises a heating device of fluidized bed type as a heating device, a blast cooling device of fluidized bed type as a cooling device, a pneumatic conveyor as a transporting device, electric-resistance thermometers as temperature sensors, and an orifice-meter mounted immediately before one of the temperature sensors, brown rices varying in the place of production, kind, and year of production were treated as shown in Table 1.

The quantity of heat energy absorbed was found by the above described calculation formula. Also, the correction value .DELTA.E was found by sending heated air in the absence of brown rice.

The respective brown rices were made to absorb the quantity of heat energy shwon in Table 1 under the heating conditions shown in the same table.

After the heating was complete, the brown rice was immediately transferred to the cooling device, and cooled for 5 minutes by an air current at 20 DEG C. in every case, whereafter the treated brown rice was obtained.

424 parts by weight of each of the brown rices treated in this way was cooked along with 576 parts by weight of water after water washing by the use of an electric cooking-pot for rice (Toshiba RC-10 B), and after the automatic switch was turned off the cooked rice was allowed to settle by its own heat for

20 minutes. The water content of the cooked rice is shown in Table 1.

The cooked rice was also fed to 10 to test whether it has an appetizing taste, and the result of the taste test is shown in Table 1.

The relation between the respective quantities of heat energy absorbed in Examples 1-19 and the water contents is graphically shown in FIG. 2.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Water

>;tb; Temper- content

>;tb;Quantity ature of Results of taste test

>;tb;Exam-

>;tb; of energy

>;tb; of heated

>;tb; Heating cooked

>;tb; Number of persons


>;tb;ple absorbed

>;tb; air time Year of

>;tb; Place of rice

>;tb; who commented

>;tb; who commented

1182/2197

>;tb;No. Kcal/Kg

>;tb; DEGC.

>;tb; min. production

>;tb; production

>;tb; Variety

>;tb; wt. %

>;tb; favorably unfavorably

>;tb;__________________________________________________________________________

>;tb; 1 103 140 10:40

>;tb; 1982 Akita Pref.,

>;tb; Akinishiki

>;tb; 53.2

>;tb; 9 1

>;tb; Japan

>;tb; 2 99 130 14:10

>;tb; 1981 Tochigi Pref.

>;tb; Akinishiki

>;tb; 55.6

>;tb; 10 0

>;tb; Japan

>;tb; 3 94 150 8:20


>;tb; Akinishiki

>;tb; 53.1

>;tb; 7 3

>;tb; Japan

>;tb; 4 91 130 10:10

>;tb; 1981 Niigata Pref.

>;tb; Akihikari

>;tb; 54.4

>;tb; 9 1

>;tb; Japan

>;tb; 5 90 130 20:30


>;tb; Akinishiki

>;tb; 54.1

>;tb; 8 2

>;tb; Japan

>;tb; 6 90 140 14:00

>;tb; 1981 Aomori Pref.,

>;tb; Akihikari

>;tb; 52.7

>;tb; 7 3

>;tb; Japan

>;tb; 7 90 140 17:00


>;tb; Akinishiki

>;tb; 53.6

>;tb; 8 2

>;tb; Japan

>;tb; 8 89 130 12:00


>;tb; Akinishiki

>;tb; 52.5

>;tb; 8 2

>;tb; Japan

>;tb; 9 86 130 7:00

>;tb; 1981 Aomori Pref.,

>;tb; Akihikari

1183/2197

>;tb; 54.5

>;tb; 10 0

>;tb; Japan

>;tb;10 80 140 8:50


>;tb; Akinishiki

>;tb; 51.4

>;tb; 6 4

>;tb; Japan

>;tb;11 78 130 12:30

>;tb; 1981 Yamagata Pref,

>;tb; Sasanishiki

>;tb; 53.4

>;tb; 8 2

>;tb; Japan

>;tb;12 77 130 11:40

>;tb; 1981 Shiga Pref.,

>;tb; Kinpa 53.9

>;tb; 10 0

>;tb; Japan

>;tb;13 76 130 12:00

>;tb; 1981 Chiba Pref.,

>;tb; Toyonishiki

>;tb; 51.0

>;tb; 6 4

>;tb; Japan

>;tb;14 74 130 11:10

>;tb; 1981 Yamagata Pref,

>;tb; Himeno-

>;tb; 52.9

>;tb; 8 2

>;tb; Japan mochi

>;tb;15 73 150 7:00

>;tb; 1981 Niigata Pref.,

>;tb; Hanahikari

>;tb; 52.7

>;tb; 7 3

>;tb; Japan

>;tb;16 72 130 11:10

>;tb; 1981 Iwate Pref.,

>;tb; Yukihikari

>;tb; 52.7

>;tb; 7 3

>;tb; Japan

>;tb;17 69 130 10:40

>;tb; 1981 Iwate Pref.,

>;tb; Nameless

>;tb; 52.1

>;tb; 8 2

>;tb; Japan

>;tb;18 68 140 8:00 1981 Gunma Pref.,

>;tb; Akinishiki

>;tb; 51.7

>;tb; 7 3

>;tb; Japan

>;tb;19 63 140 7:40 1981 Hyogo Pref.,

>;tb; Hounen

>;tb; 50.3

>;tb; 4 6

1184/2197

>;tb; Japan

>;tb;Com-

>;tb; 45 140 9:30 1981 Hyogo Pref.,

>;tb; Kinmaze

>;tb; 44.0

>;tb; 0 10

>;tb;para- Japan

>;tb;tive

>;tb;Exam-

>;tb;ple

>;tb;__________________________________________________________________________

EXAMPLES 20-27

As raw material "Nihon-bare" brown rice produced in Ibaraki-prefecture, Japan, was used and this rice was treated in the same manner as in Example 1 except that the quantity of heat energy absorbed was respectively maintained at 45 kcal, 55 kcal, 65 kcal, 75 kcal, 85 kcal, and 100 kcal. All of these treated brown rices were cooked in the same manner as in Example 1. The water content after the cooking was as shown in Table 2. Also, the taste test of the respective cooked rices was carried out in the same manner as in Example 1, with the result being shown together in Table 2.

The treated brown rices in Examples 20 and 21 were cooked with water added in an amount increased by 30% over the first time. The water contents of the cooked rices then obtained and the result of the taste test are shown in Table 3.

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb;Quantity of

>;tb; Temperature Water content

>;tb; Result of taste test

>;tb; energy

>;tb; of heated of cooked



>;tb;Example

>;tb; absorbed

>;tb; air Heating

>;tb; rice who commented

>;tb; who commented

>;tb;No. Kcal/Kg

>;tb; DEGC.

>;tb; time wt % favorably unfavorably

>;tb;__________________________________________________________________________

>;tb;20 44 110 5'50"

>;tb; 44.8 0 10

>;tb;21 54 110 8'00"

>;tb; 47.8 3 7

>;tb;22 66 120 9'10"

>;tb; 52.1 8 2

>;tb;23 76 120 11'30"

>;tb; 52.9 8 2

>;tb;24 85 130 11'40"

>;tb; 53.2 10 0

>;tb;25 101 130 13'50"

>;tb; 53.6 10 0

>;tb;26 110 140 13'20"

>;tb; 53.9 10 0

>;tb;27 119 150 13'40"

>;tb; 54.4 10 0

>;tb;__________________________________________________________________________

1185/2197

>;tb; TABLE 3

>;tb;______________________________________

>;tb;Example

>;tb;in which

>;tb;the

>;tb;brown Water Result of taste test

>;tb;rice used

>;tb; content Number of persons


>;tb;was of cooked who commented who commented

>;tb;obtained

>;tb; rice % favorably unfavorably

>;tb;______________________________________

>;tb;20 48.3 2 8

>;tb;21 52.3 5 5

>;tb;______________________________________

The above results indicate that by controlling the quantity of heat energy absorbed by brown rice, any brown rice whatever can be made to develop fissures in the bran layer thereof to any desired extent without being affected by the differences in the kind other characteristics of the brown rice. Thus by making the quantity of heat energy absorbed by the treated brown rice larger than 60 kcal, one can obtain brown rice which can be readily cooked in the same manner as in polished rice and is always of evenly good quality.

In addition, as to the brown rice which was treated by maintaining the quantity of heat energy absorbed at less than 60 kcal, when cooked in the usual manner, no matter how much water may be added, it cannot give a cooked rice which is rich in water content and having an appetizing taste like cooked rice obtained from brown rice made to develop fissures in its bran layer by treating at more than 60 kcal of heat energy absorbed.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. In a process for treating brown rice to obtain readily cookable brown rice comprising blowing heated air through brown rice in a heating device so as to fluidize and at the same time heat said brown rice whereby fissures are developed in the bran layer of the brown rice, and thereafter immediately cooling the heated rice, the improvement wherein the quantity of heat energy absorbed by the brown rice is automatically controlled to at least 60 kcal per kilogram of untreated brown rice, said automatic control comprising: (1) continuously monitoring by means of temperature sensors the temperature of the heated air entering said heating device and the temperature of the air discharged from the heating device; (2) measuring the flow rate of heated air entering the heating device; and (3) Continuously calculating the quantity of heat energy absorbed by the brown rice from the monitored temperatures and the measured flow rate, comparing the calculated value with a desired value of at least 60 kcal per kilogram of untreated brown rice, and stopping the operation of blowing heated air on the brown rice when the calculated quantity of heat energy absorbed by the brown rice has reached the desired value.

2. The process as defined in claim 1, wherein said quantity of heat energy absorbed by the brown rice is more than 60 kcal and less than 130 kcal per kg of untreated brown rice.

3. The process as defined in claim 1, wherein the temperature of the heated air entering said heating device is 90 DEG-170 DEG C.

4. The process as defined in claim 1, wherein the heating time is automatically controlled to be at least

5 minutes.

5. The process as defined in claim 1, wherein the temperature of the cooling step is below 30 DEG

C.Data supplied from the esp@cenet database - Worldwide

1186/2197

245.

JP60062940 - 4/11/1985

PREPARATION OF WHOLE SALMON STUFFED WITH SUSHI


Inventor(s): SEKIOKA KUNZOU (--)

Applicant(s): SEKIOKA KUNZOU (--)


IP Class: A23B4/12

E Class: A23L1/325H



Family: JP60062940

Abstract:


PURPOSE:To utilize even a small-sized salmon effectively as a food stuffed with SUSHI (vinegared rice) having the attractive looks of the original salmon, by removing the internals and backbone from a salmon, treating the salmon with vinegar, stuffing the head and belly part of the salmon with a mixture of rice, malted rice, etc., and ripening by the fermentation action of the malted rice.

CONSTITUTION:The internals are removed from a raw salmon, salt is scattered to the surface of the body and in the belly part, and the salmon is left at rest for 20-50hr to effect the salting. the body is incised from the heat to the tail fin, the backbone is removed, the salt is washed out, and the salmon is immersed in a mixture of vinegar and water for 20-40hr to effect the treatment with vinegar. The head and small bones are softened by this treatment. The vinegared raw salmon is drained, a mixture of rice, malted rice and seasoning materials is stuffed in the head part and the belly of the salmon, and the bodies and stacked in a suitable vessel and left at rest for 20-70hr. After fermenting the rice by the action of the malted rice is a state immersed in the liquid exuded from the raw salmon and the mixture, the vessel is opened, and the fermentation is continued by leaving at rest for 20-70hr discharging the exuded liquid by the weight applied to the raw salmon.

1187/2197

246.

JP60062949 - 4/11/1985

METHOD FOR PREVENTING AGING OF FOOD


Inventor(s): USUI TAKAYUKI (--)

Applicant(s): DAIEI YAKUHIN KOGYO KK (--); BEST F KK (--); SHIBATA AKIRA (--);

ARIMURA HAYATO (--); AZUMA KATSUHARU (--)

IP Class 4 Digits: A23L; A21D; A23G

IP Class: A23L1/10; A23L1/16; A23L1/00; A23G3/00; A21D2/36; A21D13/04; A23L1/03

E Class: A23L3/3463; A23L1/0522; A21D2/18



Family: JP60062949

Equivalent: EP0151644; WO8500004; US4690829

Abstract:


PURPOSE:To prevent the aging of a food containing starchy materials, extremely effectively, by using glutinous barley starch as a part of the starchy material. CONSTITUTION:The aging of a food containing starchy material, e.g. rice cake, bun, noodle, bread, sponge cake, etc. is prevented by adding glutinous barley starch as a part of the food material in an amount of 2-50wt% based on the starchy material. The preventive effect can be further promoted and the texture of the food can be improved by adding 0.5-15wt% polymeric polysaccharide (e.g. oligosaccharide, dextrain, etc.) in addition to the above glutinous barley starch. The present process is effective to prevent the aging of foods, and to keep the softness, elasticity, texture, digestibility, etc. of the foods to desirable state.Claims:


What is claimed is:

1. A method of preventing the retrogradation of foodstuffs containing starchy material, wherein waxy barley starch or waxy barley flour having an amount of waxy barley starch within the range of 2 to 50 wt.% of the starchy material, is used as part of said starchy material, and, wherein at least one polysaccharide selected from the group consisting of an oligosaccharide, dextrin, carrageenin, pectin, locust bean gum, guar gum, tamarind tum and xanthane gum is added thereto, wherein the amount of the polysaccharide to be added is within the range of 0.5 to 15 wt.% of the starchy material.Data supplied from the esp@cenet database - Worldwide

1188/2197

247.

JP60186247 - 9/21/1985

PREPARATION OF SALTLESS PICKLE


Inventor(s): HASHINO TOMIKO (--); OOMURA KAZUE (--)

Applicant(s): HASHINO YAKUHIN KK (--); OMURA KAZUE (--)


IP Class: A23B7/10; A23L1/218

E Class: A23B7/10; A23L1/218



Family: JP60186247


Abstract:


PURPOSE:To obtain the titled tasty, saltless pickle useful as a healthy food for diseases of adult people, by adding a pickling agent consisting of strained lees of brewed natural rice vinegar, a sweetening component and an acid neutralizing agent to vegetables, pressing them in a cold place.

CONSTITUTION:A pickling agent consisting of strained lees of brewed natural rice vinegar, a proper amount of sweetening agent (preferably reducing maltose) and a small amount of an acid neutralizing agent (preferably water-soluble calcium salt) is added to vegetables (e.g., Japanese radish carrot, green pepper, etc.), and the vegetables are pressed at about 0-10 deg.C, preferably at 2-5 deg.C in a cold place, to give the desired pickle.Description:




The present invention relates to a process for the preparation of pickled vegetables which are salt-free and pleasing to the taste.


Usually, pickled vegetables are prepared by treating various vegetables with salt (common salt) only, with salt and rice bran, or with salt and fruit vinegar. Thus, in all heretofore known procedures, salt is essential for the preparation of pickled vegetables. Without salt, the pickled vegetables decompose and are of no practical use.

In light of existing circumstances, the present inventors have made various investigations and have now succeeded in preparing salt-free pickled vegetables by using strained lees obtained by brewing natural rice vinegar.


1189/2197

The present invention provides a process for the preparation of salt-free pickled vegetables which comprises adding a pickling agent consisting of strained lees from the brewing of natural rice vinegar, a suitable amount of a sweetening material and a small amount of an acid-neutralizing agent to a vegetable such as radish, cucumber, carrot, sweet pepper, etc. and placing weight on the vegetable at a low temperature.


There is no special limitation on the types of vegetables to be processed into pickled vegetables according to the present invention. As examples of such vegetables, there are included, daikon (radish), beet, turnip, cucumber, baby cucumber with petals, zucchini, carrot, celery, sweet pepper, broccoli, cauliflower, cabbage, chinese cabbage, ginger burdock, lotus rhizoma, bean sprouts and the like.

According to the present invention, it is essential to use strained lees resulting from the brewing of natural rice vinegar, as the pickling agent. The brewing of natural rice vinegar from rice, koji and water is usually effected for about 3 months, and the strained lees obtained thereby have hitherto been thrown away. In the present invention, such strained lees are utilized. A sweetening material is added to the strained lees in a suitable amount. As the sweetening material, reduced maltose also known as maltitol, sorbitol, Stevia sweetening (stevioside) and the like are suitable. However, it has been found that reduced maltose is the most preferable one because it has a pleasant sweetness, it is low in caloric value and no insulin is required for its metabolism. The amount of such sweetening material to be added may be prescribed properly. When reduced maltose is used, it is added, for example, in an amount of 5-15 parts per 100 parts of strained lees.

Further, a small amount of an acid-neutralizing agent is added to the pickling agent of the present invention. By acid-neutralizing agent, is meant an agent which acts to neutralize weak acid ingredients, especially acetic acid, contained in the strained lees from the brewing of rice vinegar. As such acidneutralizing agent, any one which forms a salt by reaction with acetic acid may be used. However, nontoxic agents are generally preferred. More concretely, water soluble inorganic or organic salts, especially, water soluble calcium salts which readily release calcium ion, can be mentioned.

It is desirable to change or vary the amount of the pickling agent to be added to the vegetables, in accordance with the type of vegetable, the pickling time and pickling temperature, and the amounts of sweetening material and acid-neutralizing agents used. For instance, 1 part by weight of the pickling agent is added to 2 parts by weight of radish. The pickling agent may be recycled, with resupplying of any of the components that are consumed, as and when necessary necessary.

It is a characteristic feature of the present invention to effect the pickling in the cold. The temperature is usually about 0 DEG C.-10 DEG C., preferably 2 DEG C.-5 DEG C. The pickling temperature may be somewhat lower than 0 DEG C. or somewhat higher than 10 DEG C. When a temperature lower than 0 DEG is used desirable pickled vegetables may be obtained by somewhat extending the pickling period. Conversely, when a temperature higher than 10 DEG C. is used, desirable pickles may be obtained by somewhat reducing the pickling period. However, pickled vegetables obtained for example by pickling at 18 DEG C. for a short period do not taste mild and readily decompose.

Those vegetables having soft fibrous tissue, such as radish etc., may be used just after being peeled, while those having rather tough fibrous tissue, such as carrot, burdock, etc., are desirably pickled after being sliced.

The pickled vegetables according to the present invention taste very delicious, and are substantially salt-free because they are prepared without using salt. Therefore, they are not only suitable as healthy foodstuffs for those who are required to restrict their intake of salt or calories, or those who are deficient in insulin, such as diabetics, but are also favorable as a relish for drinking sake, whisky and the like or as materials for sandwiches. Pickled vegetables prepared from radish according to the present invention taste delicious.

1190/2197

The present invention is further explained in the following examples, which are not intended to limit the scope of the invention.

EXAMPLE 1

To 2 kg of peeled green-top radish there was added 1 kg of a pickling agent consisting of 1 kg of strained lees obtained brewing natural rice vinegar [which brewing was effected with 2 parts of rice, 1 part of koji (Aspergillus oryzae) and a suitable amount of water for 3 months], 100 g of reduced maltose and 0.5 g of a water soluble calcium salt. Pickling was effected by putting a stone weight on the radish in a refrigerator for 7 days. The pickled radish obtained was very delicious, having a taste just like apple.

EXAMPLE 2

To 2 kg of carrot sliced into 2-3 mm in thickness was added 1 kg of the same pickling agent as used in

Example 1, and the pickling was effected at 2 DEG C.-5 DEG C. for 3 days. The pickled carrot obtained still had some carrot like taste.

After pickling for longer than 3 days, the carrot taste disappeared from the pickled vegetables.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A process for the preparation of salt-free pickled vegetables which comprises adding to a vegetable to be pickled a pickling agent consisting of strained lees obtained by brewing natural rice vinegar, and effective amounts of a sweetening material and an acid-neutralizing agent and placing the vegetable at a temperature of about 0 DEG C.-10 DEG C. for a period of time sufficient to produce a pickled product.

2. A process as claimed in claim 1 wherein the strained lees are obtained from natural rice vinegar brewed from 2 parts of rice, 1 part of koji (Aspergillus oryzae) and a suitable amount of water for about

3 months.

3. A process as claimed in claim 1 wherein the sweetening material is reduced maltose.

4. A process as claimed in claim 1 wherein the acid-neutralizing agent is a water soluble calcium salt.

5. A process as claimed in claim 1 wherein the vegetable is selected from the group consisting of daikon (radish), beet, turnip, cucmber, baby cucmber with petals, zucchini, carrot, celery, sweet pepper, broccoli, cauliflower, cabbage, Chinese cabbage, ginger, burdock, lotus rhizoma and bean sprouts.

6. A process as claimed in claim 1 wherein the temperature is 2 DEG C.-5 DEG C.Data supplied from the esp@cenet database - Worldwide

1191/2197

248.

JP62014751 - 1/23/1987

GELLING AGENT COMPOSITION


Inventor(s): OKONOGI SHIGEO (--); WAKIGUCHI HIROYA (--); MIYAZAKI YUSUKE (--);

MORIMOTO KEIJI (--)

Applicant(s): MORINAGA MILK INDUSTRY CO LTD (--)


IP Class: A23L1/212; A23L1/04

E Class: C08L5/00; A23L1/0528; A23L1/054B



Family: JP62014751


Abstract:


PURPOSE:To improve the water holding property, springiness and adhesive property and make it possible to gelatinize a material within a wide pH range, by incorporating therein xanthan gum and

KONJAK (devil's-tongue) mannan as principal components. CONSTITUTION:A gelling agent composition obtained by uniformly incorporating 30-90pts.wt. xanthan gum with 70-10pts.wt.

KONJAK (devil's-tongue) mannan and, as necessary, a stabilizer and salt. The composition having the above- mentioned composition gels within a range as wide as 3.0-12.0pH range and is useful as a gelling agent for foods, culture medium for plants, water resistance imparter for starch, cold storage material, hardening preventing agent of rice cakes, etc. The above-mentioned composition in an amount of 0.2-4.2wt%, based on the final product is added thereto for use.Description:


S P E C I F I C T A T I I G N

Title of the Invention Gelling Agent

Background of the Invention 1. Field of the Invention

The present invention relates to a novel gelling agent or component suitable for various purposes.

2. Prior Art Description

Ally material or component which Will transform the state of existing material fro sol into gel is generally referred to as a gelling agent. Such gelling agents have been widely used for various purposes, for example, for manufacturing foods,pharmaceuticals and cosmetics, and as culturemedium ofwicroorganism. Various kinds of gelling agents have been proposed, among which suitable one is selected upon demand, taking into consideration physical properties of the objective gel, e.g., pH, water-holding property, thermoreversilbility and elasticity.

Konjakmannan, a kind of glucomannan, is well known as a typical one of the conventional gelling agents (Akio Sotoyama;ZShokuhin-Kako-Yo

Tennenbutsu Binran", 5th edition, pages 293 and 296, published by Shokuhin

1192/2197

To-Kagaku-Sha, Sept.1, 1975).Konjakmannan is gelled into Konjac(Amorphophalus Konjac C. Koch) at alkaline pH, but itforays no gelation in the neutral or acidic pH. The gelled konjakmannan (Konjac) is neverresulted to sol, and has no thermoreversibility Thus, application of konjaknannan has, as a gelling agent, limited and therefore can not always meet the requirements which are expected to be satisfied in various uses.

Xanthan gum is well known as a thickeing assent, a stabilizer and an emulsifying agent, and its use as a gelling agent has also been known.

However, no prior art suggest that a mixture of konjakmannan and xanthan gum be used as a gelling agent, especially in a specific range of mixing ratio thereof.


It is therefore an object of the invention to provide a novel gelling agent or component having high water-holding property, excellent elasticity and thermoreversibility

Another object of the invention is to provide a novel gelling agent which will for a gel not only in alkaline pH but also in neutral and acidic pH.

According to the invention there is provided a gelling agent essentially consisting of xanthan gum and konjakmannan.

A preferred range of mixing ratio of xanthan gum and konjakmannan is 30# 90 parts (by weight; parts and percentages are given by weight throughtout the Specification, unless otherwise specified) of xanthan gum and 10- 70 parts of konjakmannan, and more preferably 40# 80 parts of xanthan gum and

20# 60 parts of konjakmannan.


Xanthanguia and konjakmannan, which are the principal ingredients for the gelling component of the invention, are readily available on the market at moderate prices.

The gelling agent of the invention is manufactured by mixing 30# 90 parts of xanthan gum and 10# 70 parts of konjakmannan. Any suitable type of stabilizer, salt and so on may further be incorporated if necessary. These ingredients may be previously mixed and the mixture be dissolved into water, or alternatively they may be separately dissolved and dispersed into water to prepare solutions which are then mixed together.

A quantity of the gelling component of the invention to be used should be changed to meet the respective requirements but in usual case the quantity will be 0.2# 4.2% of the final product.

The gelling agent of the invention may be used for various purposes, for example, for the gelation of various foods, and may be used as culturemedium of plants and for imparting water-proofness to starch paste and preventing rice cakes fro hardenins and for cooling agent (This term is hereby defined as follows: The cooling agent is packed in pouch and cooled previously in freezer for several hours. It is then placed in adiabatic box to chill within temporary cold storage of food or is used for coooing head in the case of fever.).

The present invention will be described in more detail by means of some exemplifying tests.

Test 1

This test was carried out to examineoptimum proportion in which xanthangum and konjakmannan are mixed.

Raw materials were mixed together to prepare solutions of xanthan sum andkonjakoannan. More partcularly, a mixture of the ingredients was dispersed into water to cause swelling for 10 minutes, and thereafter boiled and dissolved. Each solution of80x: was filled up in a cup and then cooled in a refrigerator of5x: for 5 hours for solidification.

Then, the temperature, hardness & C; State (eppearance) of the resulted sample were measured and observed. The hardness of the resulted sample was measured in the following manner. More

1193/2197

particularly, a conic weight(24M1 in base diameter,32Xx in height and119 in weight) of a penetrometer(Nakakura Ika-Rika Co., Ltd.) was clasped at a definite position at which the pointed end of the weight was just in contact with the gel surface, and then allowed to fall down of itself by 5second unclasping, so that a perpendicular distance (xx) between the gel surface and the position of the pointed end of the weight intruducing into the gel was measured.The gel hardness was defined herein as a figure corresponding to 100 times of a reciprocal of the measured distance. The results are shown in the following Table II.

TABLE I (unit: g)

EMI5.1

raw >;SEP; material\sample >;SEP; No. >;SEP; 1 >;SEP; 2 >;SEP; 3 >;SEP; 4 >;SEP; 5 >;SEP; 6

>;SEP; 7 >;SEP; 8 >;SEP; 9 >;SEP; 10 >;SEP; 11 >;SEP; 12

>;tb; xanthan >;SEP; gum >;SEP; 0.40 >;SEP; 0.38 >;SEP; 0.36 >;SEP; 0.32 >;SEP; 0.28 >;SEP; 0.24

>;SEP; 0.20 >;SEP; 0.16 >;SEP; 0.12 >;SEP; 0.08 >;SEP; 0.04 >;SEP; konjakmannan >;SEP; - >;SEP;

0.02 >;SEP; 0.04 >;SEP; 0.08 >;SEP; 0.12 >;SEP; 0.16 >;SEP; 0.20 >;SEP; 0.24 >;SEP; 0.28 >;SEP;

0.32 >;SEP; 0.36 >;SEP; 0.40

>;tb; sugar >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP;

15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00

>;tb; water >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP;

84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60 >;SEP; 84.60

>;tb; total >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00

>;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00

>;tb; TABLE II

EMI5.2

\sample >;SEP; No. >;SEP; 1 >;SEP; 2 >;SEP; 3 >;SEP; 4 >;SEP; 5 >;SEP; 6 >;SEP; 7 >;SEP; 8

>;SEP; 9 >;SEP; 10 >;SEP; 11 >;SEP; 12

>;tb; temperature >;SEP; ( C) >;SEP; 6.0 >;SEP; 6.5 >;SEP; 7.0 >;SEP; 7.0 >;SEP; 7.0 >;SEP; 7.0

>;SEP; 7.0 >;SEP; 7.0 >;SEP; 6.5 >;SEP; 6.5 >;SEP; 6.5 >;SEP; 6.5

>;tb; hardness >;SEP; of >;SEP; gel >;SEP; - >;SEP; - >;SEP; 8.5 >;SEP; 5.0 >;SEP; 5.6 >;SEP; 5.9

>;SEP; 5.2 >;SEP; 4.8 >;SEP; 3.5 >;SEP; - >;SEP; - >;SEP; state >;SEP; sol >;SEP; sol >;SEP; sol

>;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol

>;tb; Remarks: 1. The mark - in the column of hardness of gel shows the measurement being impossible, i.e.,

the weight fell down beyond the measurable limit (81##) of the penetrometer.

2. In the column of state, when the resulted sample was unmolded from the cup to lie on a dish,

one retaining its cup-shape was contrued to be in gel whereas one whose cup-shape was destroyed

was in sol.>;/RTI;

The results in TableE clearly show that a compositionhaving a proportional range of 30- 90 parts of xanthan gum and 10~ 70 parts of konjakmannan may be effectively used as a gelling component.Especiatly,

Samples 4~ 8 having composition of 40- 80 parts of xanthan gum and 20 60 parts of konjakmannan form gel having satisfactory level of hardness and favorable characteristics. The results with respect to

Samples 1 and 12 show that separate use of xanthan gum or konjakmannan does not form desirable gel.

Combined use of xanthan gum and konjakmannan is essential when used as a gelling agent.

Test 2

This test was carried out to reveal relationship between gelation and pH of the test sample solutions.

The raw material having the same composition as that of Sample 7 in Table I was treated in the same manner as in Test 1 to prepare test samples. To the test samples were added5X sodium hydroxide solution or5X hydrochloric acid solution to thereby adjust pH of the sample solutions to 1.9~ 12.0.

According to the similar method as described in Test 1, these solutions were poured into cups, cooled and solidified so that gelling states were observed. The results are shown in the following

Table m.

1194/2197

Table m

EMI6.1

>;tb; pH >;SEP; 1.9 >;SEP; 2.2 >;SEP; 2.4 >;SEP; 2.7 >;SEP; 3.0 >;SEP; 3.4 >;SEP; 6.2 >;SEP; 8.4

>;SEP; 9.0 >;SEP; 9.8 >;SEP; 10.5 >;SEP; 11.0 >;SEP; 12.0

>;tb; state >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel

>;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel

>;tb;

It can be concluded from the results shown in Table m that the gelling agent of the present invention may form a desirable gelin"a widep11 range of 3.0 to 12.0. This means that the gelling agent of the present invention can be used for various purposes.

Test 3

This test was carried out to comparewater-holding property of gel obtained by using the gelling agent of the invention and the conventional ones.

Table N (unit: g)

EMI7.1

>;tb; >;SEP; raw >;SEP; material\sample >;SEP; No. >;SEP; 13 >;SEP; 14 >;SEP; 15 >;SEP; 16

>;SEP; 17 >;SEP; 18

>;tb; >;SEP; sucrose >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP; 15.00 >;SEP;

15.00

>;tb; >;SEP; gelatin >;SEP; 1.20 >;SEP; - >;SEP; - >;SEP; - >;SEP; - >;SEP;

>;tb; carrageenan >;SEP; - >;SEP; 0.30 >;SEP; - >;SEP; - >;SEP; - >;SEP;

>;tb; >;SEP; agar >;SEP; - >;SEP; - >;SEP; 0.30 >;SEP; - >;SEP; - >;SEP;

>;tb; >;SEP; furcellaran >;SEP; - >;SEP; - >;SEP; - >;SEP; 0.60 >;SEP; - >;SEP;

>;tb; >;SEP; locust >;SEP; bean >;SEP; gum >;SEP; - >;SEP; - >;SEP; - >;SEP; - >;SEP; 0.10 >;SEP;

>;tb; >;SEP; xanthan >;SEP; gum >;SEP; - >;SEP; - >;SEP; - >;SEP; - >;SEP; 0.30 >;SEP; 0.30

>;tb; >;SEP; konjakmannan >;SEP; - >;SEP; - >;SEP; - >;SEP; - >;SEP; - >;SEP; 0.10

>;tb; >;SEP; water >;SEP; 83.80 >;SEP; 84.70 >;SEP; 84.70 >;SEP; 84.40 >;SEP; 84.60 >;SEP; 84.60

>;tb; >;SEP; total >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP;

100.00

>;tb;

The raw materials used in the respective samples were all sold on the market. From these samples were prepared solutions in the same manner as in Test 1, and the solutions were filled up into cups, and cooled and solidified. After allowing them to stand in a refrigerator of 5 C for 1 month, quantities of water separated therefrom were determined by a measuring cylinder, and the average volume was calculated from the results in each 10 samples. The average volume of separated water is shown below inTable V.

Table V

EMI8.1

>;tb; >;SEP; \ >;SEP; sample >;SEP; No. >;SEP; 13 >;SEP; 14 >;SEP; 15 >;SEP; 16 >;SEP; 17

>;SEP; 18

>;tb; separated >;SEP; water >;SEP; quantity >;SEP; (ml) >;SEP; 1.5 >;SEP; 3.0 >;SEP; 3.5 >;SEP;

3.0 >;SEP; 1.0 >;SEP; Iess >;SEP; than >;SEP; 0.5

>;tb;

The volume of separated water in Sample 18, to which was added the gelling agent of the present invention, was extremely lowered in comparison with that of Samples 13#17 to which were added the conventional gelling composition.

Test 4

In this test thermoreversibility of the gelling agents was carried out.

1195/2197

The raw materials having the same composition as that of Sample 7 in Table I was treated to prepare solutions in the same manner as in Test 1.

The solutions were then cooled to form gel. The resulted gel was gradually heated to100X: while observing the remelting states of gel states at each10 C interval, and then again cooled to10x: while observing the solidifying states of gel at each10x: interval. The results of the states during heating and cooling are shown in TableM and TableVB, respectively.

Table Vi

EMI8.2

>;tb; >;SEP; \ >;SEP; temperature >;SEP; (t) >;SEP; 10 >;SEP; 20 >;SEP; 30 >;SEP; 40 >;SEP; 50

>;SEP; 60 >;SEP; 70 >;SEP; 80 >;SEP; 90 >;SEP; 100

>;tb; state >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; sol >;SEP; sol

>;SEP; sol >;SEP; sol

>;tb;

Table VII

EMI9.1

>;tb; >;SEP; \temperature >;SEP; ( C) >;SEP; 100 >;SEP; 90 >;SEP; 80 >;SEP; 70 >;SEP; 60 >;SEP;

50 >;SEP; 40 >;SEP; 30 >;SEP; 20 >;SEP; 10

>;tb; state >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; sol >;SEP; gel >;SEP; gel

>;SEP; gel >;SEP; gel

>;tb;

The results in Table M andVE show that the gelling agent of the present invention consisting essentially of xanthan gum and konjakmannan has definite thremoreversibility.

Test 5

This test was carried out to find the quantity of the gelling agent of this invention to be incorporated.

All of raw materials shown in the following Table VII are available on the market. Sample solutions were prepared from these raw materials in the same manner as in Test 1, then cooled and solidified.

The resulted gels were subjected to the sane tests as in Test 1 to observe the formation of gels in the respective cases. The results are shown in Table IX.

TableVI

EMI9.2

>;tb; >;SEP; am >;SEP; - >;SEP; sample >;SEP; >;SEP; No. >;SEP; 19 >;SEP; 20 >;SEP; 21 >;SEP;

22 >;SEP; 23 >;SEP; 24 >;SEP; 25 >;SEP; 26

>;tb; material

>;tb; xanthan >;SEP; gum >;SEP; 0.05 >;SEP; 0.10 >;SEP; 0.20 >;SEP; 0.40 >;SEP; 1.00 >;SEP; 2.00

>;SEP; 2.50 >;SEP; 3.00

>;tb; konjakmannan >;SEP; 0.05 >;SEP; 0.10 >;SEP; 0.20 >;SEP; 0.40 >;SEP; 1.00 >;SEP; 2.00

>;SEP; 2.50 >;SEP; 3.00

>;tb; water >;SEP; 99.90 >;SEP; 99.80 >;SEP; 99.60 >;SEP; 99.20 >;SEP; 98.00 >;SEP; 96.00 >;SEP;

95.00 >;SEP; 94.00

>;tb; total >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00 >;SEP; 100.00

>;SEP; 100.00 >;SEP; 100.00

>;tb;

TableIX

EMI9.3

>;tb; >;SEP; \sample >;SEP; No. >;SEP; 19 >;SEP; 20 >;SEP; 21 >;SEP; 22 >;SEP; 23 >;SEP; 24

>;SEP; 25 >;SEP; 26

1196/2197

>;tb; \sample >;SEP; sol >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel >;SEP; gel

>;tb;

As shown, it has been found t;iat thegel' agent of this invention should be incorporated in proportion of 0.2# 6.0X. However,

Samples 25 and 26 to which5X or more of the gelling agent of the invention was added were not sufficiently dissolved into water and failed to obtain gel with smoothness and softness peculiar to jelly.

This means that in these samples, not all of the quantity of the gelling component incorporated would contribute to formation of gel. Thus, a preferable range of the gelling agent to be incorporated may be

0.2# 4.0 .

The present invention will be further described by means of some examples thereof and some comparative tests.

Example 1

One point two kilograms (1,2kg) of powdered xanthan gum (Sanei

Kagaku Co., Ltd.) and 0.8ks of konjakmannan (Shimizu Kagaku Co.,Ltd.) were thoroughly mixed to prepare approximately2kg of a powdered gelling agent.

Example 2

Except that the quantities of xanthan gum andkoniakmannan were 1,14kg and 0,86kg, respectively, a powdered gelling agent of approximately2ky was prepared in the same manner as in Example 1.

Example 3

Except that the quantities of xanthan gum and konjakmannan were1.6kS and 1,2kg, respectively, a powdered gelling agent of approximately2.5ks was prepared in the same manner as in Example 1.

Example 4

From 1 kg of xanthan gum and 1 kg of konjakmannan was prepared approximately 2 kg of powdered gelling agent in substantially the same manner as in Example 1.

Example 5

To 2kg of corn starch (Ouji Corn Starch Co., Ltd.) was added0.56kg of the powdered gelling agent obtained in Example 3 and thoroughly mixed to prepare approximately2.5kg of powdered starch material.

Example 6

A mixture having the composition shown in Table X was dispersed into water and swelled for 10 minutes. Then, the solution was heated at 100 C for 10 minutes for sterilization, and thereafter cooled to80t. The solution was poured into a cup and cooled in a refrigerator oft for 4 hours. An arrowroot starch cake containing glutinous flour thus prepared had excellent elasticity andouthfeel.

Table X

EMI11.1

>;tb; raw >;SEP; material >;SEP; composition >;SEP; (kg) >;SEP;

>;tb; sugar >;SEP; 10.00

>;tb; arrowroot >;SEP; starch >;SEP; 2.00

>;tb; glutinous >;SEP; rice >;SEP; flour >;SEP; 1.00

>;tb; gelling >;SEP; agent >;SEP; of >;SEP; Example >;SEP; 1 >;SEP; 0.50

>;tb; flavoring >;SEP; agent >;SEP; 0.10

>;tb; coloring >;SEP; agent >;SEP; 0.05

>;tb; water >;SEP; 86.35

>;tb; total >;SEP; 100.00

>;tb;

Example 7

Five parts of the gelling agent of Example 1 was dispersed into 995 parts of water and swelled for 10 minutes, and then boiled to be dissolved into water. The solution was poured, inSii depth, into a tray

1197/2197

of20c# in depth, and cooled and solidified in a refrigerator.The surface of gel produced was sowed with seed of Kaiware-Daikon (Japanese radish) and allowed to stand in adarkroom of 25x: for 5 days to be germinated and grawn.

After growing, it was placed outdoors for 1 day to be exposed to sunlight, and then harvested. The

Kaiware-Daikon had been grown up rapidly without watering during the period from the sowing to the harvest.

Comparative Test 1

Table XI (unit:s)

EMI12.1

>;tb; raw >;SEP; material >;SEP; \ >;SEP; sample >;SEP; No. >;SEP; 27 >;SEP; 28 >;SEP; 29 >;SEP;

30

>;tb; gelling >;SEP; agent >;SEP; of >;SEP; Example >;SEP; 2 >;SEP; 0.70 >;SEP; - >;SEP; 0.35

>;SEP;

>;tb; product >;SEP; of >;SEP; Example >;SEP; 5 >;SEP; - >;SEP; 2.56 >;SEP; - >;SEP;

>;tb; corn >;SEP; starch >;SEP; - >;SEP; - >;SEP; 5.00 >;SEP; 10.00

>;tb; water >;SEP; 89.30 >;SEP; 97.44 >;SEP; 94.65 >;SEP; 90.00

>;tb;

note: Corn starch was the same raw material as used in Example 5.

The raw materials having the composition shown above in Table XI were dispersed into water, and then boiled and dissolved. The solution was boiled for 10 minutes and then cooled to25t to prepare glue. The sample glue thus prepared and starch paste on the market (Sample 31) were subjected to test for adhesive strength in the following manner.

Thus, two sheets of paper in0.09## thickness were prepared.

To an area of15Xt width fro the end of one sheet was plastered with the sample glue in a quantity ofO.1/cz2 and then the other sheet was super posed thereon while exerting pressure of128/cxf for 10 seconds. After drying indoors for 1 hour, the superposed paper sheets thus bonded together were cut out in a direction perpendicular to the bonded portion, to prepare15## wide test samples. To one group of the test samples were applied external force in a shear direction by means of a tensile test machine

(Toyo Seiki Co., Ltd.) to measure stress of the samples. The other group of the test samples was dipped into water for 24 hours to compare water proofness of glue or paste.Further, glue was applied to a glass sheet to form a3Xx thick coating, and then allowed to stand for 24 hours to compare waterholding property of the glue. The results of these comparative tests are shown in the following Table

XE.

Table XII

EMI14.1

\sample >;SEP; No. >;SEP; 27 >;SEP; 28 >;SEP; 29 >;SEP; 30 >;SEP; 31

>;tb; subject >;SEP; of >;SEP; comparison

>;tb; comparison >;SEP; of >;SEP; adhesiveness >;SEP; all >;SEP; 5 >;SEP; samples >;SEP; bearable

>;SEP; to >;SEP; # >;SEP; # >;SEP; # >;SEP; #

>;tb; (each >;SEP; 5 >;SEP; samples) >;SEP; external >;SEP; force >;SEP; more >;SEP; than >;SEP;

5kg >;SEP; (*)

>;tb; comparison >;SEP; of >;SEP; water >;SEP; proofness >;SEP; all >;SEP; 10 >;SEP; samples

>;SEP; show >;SEP; no >;SEP; peeling >;SEP; # >;SEP; # >;SEP; the >;SEP; portions >;SEP; of

>;SEP; adhesion >;SEP; of >;SEP; #

>;tb; (each >;SEP; 10 >;SEP; samples) >;SEP; aff >;SEP; at >;SEP; the >;SEP; portions >;SEP; of

>;SEP; adhesion >;SEP; # >;SEP; # >;SEP; all >;SEP; 10 >;SEP; samples >;SEP; peeled >;SEP; of

>;tb; comparison >;SEP; of >;SEP; water-holding >;SEP; all >;SEP; 5 >;SEP; samples >;SEP; suitable

>;SEP; for >;SEP; glue >;SEP; # >;SEP; # >;SEP; all >;SEP; 5 >;SEP; samples >;SEP; being >;SEP; dried >;SEP; up, >;SEP; #

1198/2197

>;tb; property >;SEP; (each >;SEP; 5 >;SEP; samples) >;SEP; showing >;SEP; unsuitability >;SEP; for

>;SEP; glue

>;tb; Notes: (*) Papers were broken off at a portion other than that of adhesion, when applied to 5kg external force.

The arrow # shows the same result as in the left column.>;/RTI;

As shown, gel formed by using the gelling agent comprising a mixture of konjakmannan and xanthan gum is usable as glue and its adhesive strength is sufficient. Moreover, by incorporating the gelling agent of the invention waterproof nests and water-holding property of the starch glue may be remarkably improved.

Example8

Cooling agents were prepared from20g of the gelling agent prepared in Example 4, 200g of glycerol on the market and780s of water (Sample 32) and from 20g of the same gelling agent, 150g of sodium chloride on the market and 830g of water (Sample 33). More particularly, the mixtures were heated to100x: and allowed to stand at the same temperature for 10 minutes. Each 200g of the solution was then poured into a pouch (Toyo Seikan Co., Ltd.) and then the pouch was heat-sealed. Thus, each five products were obtained.

Comparative Test 2

The cooling agents having different composition, obtained in

Example 8, and another cooling agent (Sample 34) made by EsurenKako Co.,

Ltd. were put into tests for cooling effect, hardness of the cooling agent and syneresis.

Into a box(200##X175##X135##, 13xr thickness) made by foamed styrol were put two pieces of cooling agent (400g) which had been cooled in a freezer of -20 C for 10 hours, and cooling effect was observed by measuring the temperature change inside the box. Meanwhile, the cooling agents were placed in freezers of -13 C and-20x: for 10 hours, respectively, and thereafter hardness of the cooling agents was observed. More over, hardness and syneresis were observedrafter the cooling agents had been defrosted. The results of these comparative tests are shown in Table XII.

Table XIII

EMI16.1

>;tb; >;SEP; test >;SEP; \ >;SEP; >;SEP; sample >;SEP; No. >;SEP; # >;SEP; 32 >;SEP; 33 >;SEP;

34

>;tb; comparison >;SEP; of

>;tb; cooling >;SEP; effect

>;tb; >;SEP; initial >;SEP; temp >;SEP; 26.4 C >;SEP; 26.4 C >;SEP; 26.4 C

>;tb; >;SEP; temp. >;SEP; after >;SEP; 5 >;SEP; min. >;SEP; 14.5 >;SEP; 14.0 >;SEP; 14.0

>;tb; >;SEP; temp. >;SEP; after >;SEP; 10 >;SEP; in. >;SEP; 14.8 >;SEP; 14.2 >;SEP; 14.5


>;tb; >;SEP; temp. >;SEP; after >;SEP; 30 >;SEP; in. >;SEP; 15.5 >;SEP; 15.0 >;SEP; 15.2

>;tb; >;SEP; temp. >;SEP; after >;SEP; 40 >;SEP; mien. >;SEP; 16.0 >;SEP; 15.5 >;SEP; 15.5


>;tb; >;SEP; temp. >;SEP; after >;SEP; 60 >;SEP; min.>;SEP; 16.5 >;SEP; 16.5 >;SEP; 16.0




>;tb; comparison >;SEP; of

>;tb; hardness >;SEP; & syneresis

>;tb; >;SEP; -15 C >;SEP; in >;SEP; frozen >;SEP; state >;SEP; soft >;SEP; soft >;SEP; hard

>;tb; >;SEP; after >;SEP; defrosting >;SEP; soft >;SEP; soft >;SEP; soft

>;tb; >;SEP; no >;SEP; syneresis >;SEP; no >;SEP; syneresis >;SEP; no >;SEP; suneresis

>;tb; >;SEP; -20 C >;SEP; in >;SEP; frozen >;SEP; state >;SEP; soft >;SEP; soft >;SEP; hard

>;tb; >;SEP; after >;SEP; defrosting >;SEP; soft >;SEP; soft >;SEP; soft

>;tb; >;SEP; no >;SEP; syneresis >;SEP; no >;SEP; syneresis >;SEP; no >;SEP; syneresis

1199/2197

>;tb;

As shown, the cooling effect of Samplesr6e and 33 are comparable with that of the marketed cooling agent (Sample 34) and show nosynerUis after defrost. Moreover, these cooling agents Nos. 32 and 33 have an outstanding characteristic that they are not hardened even in frozen state and are flexible in the shape. These characteristics are not recognized in the conventional cooling agents.

Example 9

A mixture of 8g of the gelling agent in Example 4 and6OOg of glutinous rice flour was added to382s water and the mixture was kneaded in a known manner. The kneaded mass was divided into dumplings each of40e, which were heated in boiled water for 10 minutes, to prepare glutinous rice flour dumplings.

Comparative Test 3 comparative test for hardness of the glutinous rice flour dumplings after preservation in refrigerated states was carried out, with respect to Sample 35, that is a sample of the present invention prepared in

Example 9, and Sample 36 which was prepared in the same manner as in Example 9 except that the raw material was a mixture of 600g glutinous rice flour and400y water. not containing the gelling agent of the invention.

Hore particularly, after the respective samples bad been refriserated in a refrigerator ofSt for 1 week the hardness thereof was measured.

Sample 35 remains soft but Sample 36 was hardened. These results show that it is possible to prevent the glutinous rice flour dumplings from hardening and to have prolonged period of shelf life by using the gelling agent of this invention in the usual method of producing glutinous rice flour dumplings.

Although this invention has been described in conjunction with sone examples thereof, someexemplifing tests and some comparative tests, it is to be noted that many variations and applications thereof may be made without departing from the spirits and scopes of the invention as defined in the appended claims.Data supplied from the esp@cenet database - Worldwide

Claims:


What we claim is:

A A gelling agent, which has atheruoreversible gel-foriing ability anda gel-forzin8 ability in a wide pB range of 3.0 to 12.0, and has properties of high water-holding ability of the resulted gel state and of causing substantially no syneresis in the gel, consisting essentially of xanthan gum and konjakmannan.

2. The gelling agent as claimed in Claim 1, having composition of 30# 90 weight parts of xanthan gum and 10# 70 weight parts of konjakmannan.

3. The gelling agent as claimed inClaim 1, having composition of 40~ 80 weight parts of xanthan gum and 20# 60 weight parts ofkoniakwannan.Data supplied from the esp@cenet database - Worldwide

1200/2197

249.

JP62083861 - 4/17/1987

DELICIOUS SOYBEAN MALT FREE FROM ILL ODOR


Inventor(s): FUKUYAMA TATSUHIKO (--); SAGO TSUTOMU (--)

Applicant(s): BELL SHOKUHIN KK (--)

IP Class 4 Digits: A23L; A21D; A23K; A23C

IP Class: A23L1/16; A23L1/20; A23L1/31; A23K1/14; A23K1/00; A23L1/325; A21D2/36;

A23C19/093; A23C20/00

E Class: A23L1/314B4; A23L1/20F; A23C19/093; A23L1/314D2



Family: JP62083861


Abstract:


PURPOSE:To obtain the titled soybean malt converted its surface with mycelia of aspergillus, having delicious taste and excellent digestibility, absorbability and nutrient value and suitable as a raw material for various processed foods, by mixing streamed or boiled soybean with powdery cellulose, starch, etc., and inoculating the mixture with speed malt and fermenting. CONSTITUTION:Soybean

(e.g. defatted soybean) is washed with water, immersed in water, steamed or boiled and left to cool.

The steamed soybean is mixed with about 2-6% cellulose powder and/or about 10-15% starchy raw material (e.g. corn flour) based on the weight of the steamed soybean. The mixture is inoculated with a small amount of a seed malt for the production of rice malt and fermented. The objective edible soybean malt having delicious taste, low viscosity and free from ill odor and obtained by the above procedure is closely covered with the cellulose powder or starchy raw material containing the mycelia of aspergillus proliferated therein. The edible soybean malt can be suitably used as a raw material for various processed foods such as cheese, sausage, hamburger steak, fish paste product, potage, etc.Description:


EDIBLE SOYBEAN KOJI HAVING NO OFF-FLAVOR AND PROCESS FOR PRODUCING THE

SAME

BACKGROUND OF THE INVENTION:

This invention relates to a non-viscous, edible soybean Koji having no off-flavor covered on the soybean surface with Aspergillus hyphae and having a delicate taste, and to a process for producing the same.

The edible soybean Koji according to the present invention is intended to provide food products having good digestibility, nutrition-supplementation from plant protein, good flavor and testure by using the

1201/2197

edible soybean Koji as it is or after autolysis, grinding, drying, pulverization or the like as materials for various foods.

DESCRIPTION OF THE PRIOR ART

There have heretofore been processed food products obtained by biochemical techniques, for example,

Miso, soy sauce, Tofu and Natto in Japan and tempeh in Southeast Asia. All of them are characteristic proteinaceous foods free from the indigestibility and harmfulness of soybean itself, but are liked only locally and difficult to popularize all over the world.

Kojis used for processing soybeans by a biochemical method include Soy Koji, soybean-bulked Koji for producing soybean Miso and Tamari soy sauce, soybean Koji for "Hama Natto", etc. These conventional techniques comprise inoculating Aspergillus into steamed soybeans. Since large amounts of water and protein contained in the steamed soybeans are not suitable for growth of the Aspergillus, the conventional techniques are mainly composed of a technique for making them suitable. That is to say, in the case of Soy Koji, the total amounts of water and protein are adjusted so as to attain a humidity suitable for growth of the Aspergillus by mixing dried and ground wheat having a low water content with steamed soybeans. In the case of Hama Natto, the water content of the surface of steamed soybeans is adjusted by mixing therewith dried and heated wheat flour or raw wheat flour.In the case of soybean-bulked Koji, growth of the Aspergillus is promoted by grinding steamed soybeans, forming large balls of the ground soybeans to reduce the surface area, thereby facilitating propagation of the

Aspergillus mainly on the surface, and at the same time causing growth of not aerobic harmful bacteria but lactic acid bacteria and the like antagonistic thereto in the soybean ball structure.

These Kojis are used for food via a fermentation or aging step in the presence of water and sodium chloride but the Kojis per se have not been used as a food product.

Furthermore, as a recent prior art, there is a process for producing Koji which comprises, after inoculating Koji in a material for Koji-incubation, effecting the Koji-incubation, by admixing a watercontaining fibrous material therein and maintaining a water content of the inoculated mixture to 25 -

45% Japanese Patents Kokai No. 2l0884/84). However, the purpose thereof is to obtain the Koji having a high level of titer by adjusting the water content of the starting mixture in a certain range with addition of a water-containing fibrous material.

SUMMARY OF THE INVENTION:

In order to produce highly digestible, delicious foods by use of highly nutritious soybeans for the purpose of reducing anxiety about health due to overmuch intake of meats, particularly animal fat which is a serious problem in recent years, the present inventors have conducted various researches and have consequently confirmed that the combination of steamed soybeans and cellulose powder or starch powder which have not heretofore been used for Koji production at all permits a safe progress of Kojiincubation from soybeans and can give delicately tasty, non-viscous, non-off flavoured Koji having good digestibity and excellent nutrition-supplementing property which is very effective as a material for various foods, whereby this invention has been accomplished.

The Soybean Koji obtained according to this invention does not contain a large amount of sodium chloride unlike Miso, does not have any special form, viscosity and off-flavor, unlike Natto, and can be widely used for foods. Furthermore, it can produced in a large amount safely by means of an automatic

Koji-incubation machine, and therefore there can be produced soybean products which can be utilized not only in Japan but all over the world, so that a contribution can be made to human prosperity.

As the soybean used in this invention, any soybeans may be used and defatted soybean may also be used depending on purposes of use.

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The term "cellulose powder" used herein means a pure edible cellulose (for example, Avicel mfd. by

Asahi Kasei Kogyo K.K.), which is not soluble at all in water but have a very high water-absorbing capcity and can be free from adhering undesired bacteria, and hence is the most suitable for such Kojiincubation. Furthermore, as compared with overmuch intake of animal foods, eating of fibrous foods is effective in promoting health, and the combination of the cellulose powder and soybean can impart a function as dietary fiber to the resulting product.

The amount of the cellulose powder used in this invention is preferably 2 to 6% by weight of the steamed soybeans. The powder is very light and has a strong water-absorbing capacity, and therefore even when used in such a small amount, it sufficiently absorbs water on the surface of the steamed soybeans to bring about a state in which an Aspergillus is adhering on the surfaces of the soybeans, and thus it makes Koji-incubation safe and easy. In this case, sufficient absorption of water by the soybeans is not necessary and it is preferable to conduct immersion in water for a short period of time and slight steaming so as to adjust the ratio of the weight of the steamed soybeans to that of the raw soybeans to about l.8.When the weight of the steamed soybeans is larger than such a weight, the powder is preferably used in a larger amount in the range of 2 to 6%, while it is smaller than such a weight, the powder is preferably used in a smaller amount in this range.

There are various commercially available seed Kojis depending on purposes of use, and any

Aspergillus may be used so long as it decomposes protein to a desired degree and a long conidiophore fung bacteria which hardly undergo adhesion of spore, for example, those sold at a market under the name of "Marufukumoyashi", "Shirayuki" is preferred as seed Koji.

When a starch material is used in place of the cellulose, its amount is suitably l0 to l5% or more based on the weight of the steamed soybeans. The starch may be corn starch, potato starch or the like.

The Soybean Koji thus produced is useful as a material for foods rich in flavor and nutritionsupplementing property and is applicable to substantially all of processed food products into which it can be incorporated.

For example, it can be used as it is in cheese, sausage, hamburger and fish-paste products, and it may be incorporated into potage, soybean milk, dressing and the like after grinding, autolysis etc. When made into dried powder, it can be formed into noodles, breads, biscuits and nutritive substance.

Furthermore, when the same Koji production as described above is carried out by using, as a starting material, defatted soybeans prepared by previously defatting soybeans, the resulting product is suitable as an animal foods and pet foods which are easy to digest and absorb.

This invention is further explained below in more detail with reference to Examples.

Example l

(Production of Soybean Koji by use of cellulose powder)

2,000 g of soybeans were sufficiently washed with water, immersed in water for 5 hours, steamed in an autoclave at a pressure of l.2 kg/cm>;2; for l0 minutes, and allowed them to cool at ordinary temperature to obtain 3,650 g of steamed soybeans. The steamed soybeans were divided roughly into two portions each of which was mixed with cellulose powder as shown in the following Table. The mixtures thus obtained were used for Koji-incubation. EMI6.1

Each mixture was inoculated with a small amount of a Seed Koji for rice Koji (Marufuku, Shirayuki) and loaded on a Koji tray, and Koji-incubation was carried out in an incubator for 42 hours by a conventional method. There were thus obtained Soybean Kojis having the following weights.

I l,445 g

II l,460 g

The soybeans Kojis have cellulose powder adhered to the surface, in which Koji hyphae propagated themselves, and the Soybean Koji were suggestive of a kind of confection.

1203/2197

According to observation during the Koji-incubation, the growth and heat generation of the Aspergillus were faster as compared with rice Koji and the like though this is in the nature of things, and the heat generation was also vigorous after the second day but it was relatively easy to control the temperature in a usual range.

During the Koji-incubation, no propagation of undesired bacteria was observed at all and no offensive odor was emitted. The finished Koji thus obtained emitted a sweet aroma stronger than that of rice Koji and was a very strong flavor-enhancer. It is presumed that such a flavor-enhancer is caused by decomposition of soybean protein by the Aspergillus, as shown in the following Table. Accordingly, it can also be inferred that the decomposition of soybean protein results in easy acceleration of digestion and absorption in the body, and the data suggest possibly these facts. EMI8.1 EMI9.1

Example 2

(Production of Soybean Koji by use of corn powder)

In exactly the same manner as in Example l, 3,000 g of soybeans were washed with water, immersed in water, steamed, and allowed to cool to obtain 5,600 g of steamed soybeans. To this were mixed well

650 g of corn powder steamed at atmospheric pressure for 20 minutes and then allowed to cool, after which the resulting mixture was inoculated with a small amount of a seed Koji for rice Koji

(Marufukumoyashi, Shirayuki) and heaped on a Koji tray, and Koji-incubation was carried out in an incubator by a conventional method. Thus, 4,500 g of finished Koji were obtained. It was in no way inferior to the finished Koji obtained by use of cellulose in Example l in the physical properties, aroma and flavor, had an increased sweet taste from starch, and was very tasteful.

Four portions of mixture of the finished Koji 500 g and water 350 ml were prepared by sufficient mixing in a plastic vessel. As samples for drying, two of these portions were taken out, spread in individual shallow boxes as they were, and air-dried at 30 DEG C and 45 DEG C, respectively, for l6 hours. As samples for digestion and drying, the other two portions were subjected to autolysis in an incubator at 45 DEG C for 5 hours, spread in the same manner as described above, and air-dried at 30

DEG C and 45 DEG C, respectively, for l6 hours.

Changes of the respective weights of these samples and their respective contents of amino nitrogen were investigated to obtain the results shown in the following Table. EMI11.1

When the taste of each sample was examined, the samples treated in the manner described above apparently had a stronger and more agreeable flavor, particularly flavor-enhancer than did the untreated finished Koji. In particular, it should be noted that the samples dried as they were after addition of water also had a clearly increased good taste-enhancer.

That is to say, it was confirmed that when the method described above was employed, decomposition of protein and so on by the present Koji enzymes proceeded also during drying, so that good materials for foods which were more excellent in good taste-enhancer could easily be obtained.

This can be supported by calculation of the increased amount of amino nitrogen as shown from the above Table. For example, the weight of the sample for drying at 30 DEG C of 8l0 g became 5l8 g after drying, namely, it decreased to 64% (5l8/8l0 x l00 = 64) of the original weight, and therefore the amount of amino nitrogen of 0.08 g in l00 g of the soybean Koji incorporated with water before drying was increased to 64 g x 0.4/l00 = 0.256 g by air-drying at 30 DEG C.

The increase of the amount of amino nitrogen per l00 g of each portion of water-containing mixture was calculated in the individual steps to obtain the results shown in the following Table. EMI13.1

Example 3

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(Application to cheese)

Cheese was produced by using as a material the soybean Koji obtained in Example 2 by use of corn powder.

In a beaker were placed 270 g of the aforesaid soybean Koji and 900 g of commercially available processed cheese, and heated and mixed. The resulting mixture was placed in a steam oven, steamed at atmospheric pressure for l5 minutes, placed in the same container as those for commercially available cheese, and then cooled to obtain 4.5 containers of cheese containing soybean Koji.

Soybean Koji granules of 20 on the average were present in a 3 cm x 5.5 cm section of the cheese obtained; a section formed by cutting this cheese with a knife was smooth; the yellowish-white color of cheese harmonized agreeably with the light-brown color (circular form) of the soybean Koji in the section; and thus the cheese obtained had a favorable shape as a food.

As to the taste, the cheese obtained emitted a flavor characteristic of cheese more mildly than cheese containing no soybean Koji, had such mouth-feel that the softness of cheese harmonized with the moderate hardness of the soybean Koji, and was judged to be one which did not cloy the palate.

Example 4

(Application to pork sausage)

Pork sausage was produced by using as a material the soybean Koji obtained in Example l.

With 3.500 g of pork sausage emulsion (which had been seasoned and flavored) in the course of preparation were sufficiently mixed 500 g of the aforesaid soybean Koji as it was. The resulting mixed emulsion was placed in an air pressure filling machine and packed in casings under pressure, and the casings were tied up to obtain l2 (exclussive of the residue in the machine) raw sausage of a content of

230 g having a diameter of 4.2 cm. The raw sausages were smoked and boiled in hot water by a conventional method to produce sausages containing soybean Koji.

When sections of the products were examined (20 cases), the number of Koji granules present in the section was 6.0 on the average, the standard deviation was 2.2l, and the scatter of distribution was large. This is probably because the amount of the soybean Koji mixed was small as compared with that of the sausage. In the sections, Koji granules were sufficiently adhered to the sausage, and the sections were even and homogeneous. The sausages had a milder taste than did sausages containing no soybean

Koji, and did not cloy the palate, and its moderate mouth-feel was agreeable.

Since the soybean Koji according to this invention serves as a tasteful material which is easy to digest and absorb and excellent in nutrition-supplementing property, it is applicable also to various processed foods other than the foods shown in the above Examples. Foods to which said soybean Koji is applicable include substantially all Japanese processed foods, for example, dairy and meat products such as not only cheese but also ham, hamburger and shao-mai; fish products such as boiled fish paste, fish sausage and salted fish guts, dainties, breads, confectionary, snacks, Tofu, fried bean curd, etc.

Said soybean Koji is applicable also to various foods of foreign countries and will bring about a great effect. Furthermore, it is considered to be very effective as a nutritive substance.

Now, most of soybeans in the world are subjected to oil expression to give soybean oil and defatted soybeans, and most of the defatted soybeans are consumed as animal feed.

It is anticipated that foods in the world run short with an increase of the population. Therefore, also from the worldwide viewpoint, effective utilization of soybean is useful for preventing such uneconomical use of precious soybean protein that it is used for food after being converted as feed into animal protein and overmuch intake of animal foods, and for acquiring healthy cating habits.Data supplied from the esp@cenet database - Worldwide Claims:

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Claims of corresponding document: EP0218967 l. A non-viscous, edible soybean Koji having no off-flavor of which the surface is covered with

Aspergillus hyphae, and cellulose and/or starch are present in the surface of the soybean Koji.

2. An edible soybean Koji according to Claim l, wherein calcium carbonate is present in the surface of the soybean Koji.

3. An edible soybean Koji according to any one of Claims l or 2, which is in powder form, granular form or flake form.

4. An edible soybean Koji according to Claim l, wherein the soybean is defatted soybean.

5. A process for producing an edible soybean Koji having no off-flavor which comprises mixing and coating steamed soybeans with a suitable amount of powdered cellulose or powdered starch to adjust the water content of surface of the steamed soybeans so as to be suitable for Koji-incubation, and inoculating seed Koji on the surface of the treated soybeans.

6. A process according to Claim 5, wherein the cellulose is Avicel.

7. A process according to Claim 5, wherein the starch is corn starch or potato starch.Data supplied from the esp@cenet database - Worldwide

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250.

JP62208247 - 9/12/1987

PRODUCTION OF GELATINIZED CEREAL


Inventor(s): SAIDA HIDEKAZU (--); MORI SHIGETAKA (--); MORI AKIHIKO (--)

Applicant(s): NIPPON SAITETSUKU KK (--); SAIDA HIDEKAZU (--)


IP Class: A23L1/10; A23L1/18

E Class: A23L1/18C2; A23L1/18B2



Family: JP62208247


Abstract:


PURPOSE:To produce gelatinized cereal having excellent porosity, crispness, flake dispersibility and non-blocking property, by controlling water-content of unexpanded cereal with water, recontrolling the water-content with water after expansion and roughly crushing the cereal. CONSTITUTION:Edible cereal such as rice, barley, corn, etc., is hydrated to adjust the water-content to >;=40%. The cereal is expanded at ;=100 deg.C by continuous extrusion puffing. The expanded cereal is again added with water to a water-content of >;=15% while the cereal is still hot and the obtained expanded cereal is roughly crushed to obtain a crushed product keeping the porous state.Description:



The present invention relates to a process for producing pregelatinized grain without steaming or boiling.

PRIOR ART

Conventionally, grain is used for food or food processing material by gelatinizing or pregelatinizing the grain starch using boiling or steaming. On the other hand, in order to conduct the gelatinization without the boiling or the steaming, techniques of previously pregelatinizing the grain have been employed since very old times. For example, as previously gelatinized products, dried boiled rice and rice cakes can be cited. Recently, there is sold various pregelatinized food as produced from various processes such as products called pregelatinized rice, precooked rice, instant rice, etc.

As a pregelatinization process, there are various processes such as those wherein the grain is heated using the infrared rays, wherein the grain is previously boiled and then the resultant material is packaged under vacuum, and wherein the puffing treatment is employed. Among them, the process using the puffing treatment is advantageous because the resultant material is stable in gelatinized state, good solubility in water, easily digested with an enzyme, and flowable at normal temperature.

1207/2197

As a process for puffing the grain, there have been known various industrial puffing processes such as a home puffing process wherein the grain is heated in fats and oils or on a frying pan, a puffing gun process wherein the grain is heated under pressure in a closed vessel and then is released to an atmosphere at normal tempreature and under normal pressure, a wet process using fats and oils as a heating medium, a dry process using a very hot medium, etc. Recently, a puffing process wherein the grain is puffed by successively extruding it from conditions of high temperature and high pressure according to extrusion puffing, is also known. Among these puffing processes, the extrusion puffing process is most effective in puffing and provides higher degree of gelatinization. As grain to be used for these processes, any kind of grain can be used. In this case, grits have often been used as feet material in order to provide suitable taste.

However, any of the puffed material as produced by the above processes is low in its bulk density, although it is porous and has a considerable degree of gelatinization. Thus, there are several defects in that the puffed material requires much space for its storage; that it takes much time to make the material absorb water since it absorbs water from its surface little by little; and that it becomes sticky while it absorbs water, so that it is difficult to handle the material. Further, since its bulk density is low, it rises and floats on the surface of water when the material is put into water in order to dissolve it in water, so that it takes much time to dissolve the material and the stirring thereof is difficult.

In order to remove these drawbacks, it can be proposed to coarsely pulverize ( crush ) the puff in order to reduce its bulkiness. However, grain having a low protein content such as rice is ready to become fine powder, so that it is not able to collect pulverized grain of suitable size ( flake or grits ). When the fine powder is dissolved in water, it floats on the surface of water and is apt to aggregate, so that its swelling due to water asborption is heterogeneous and it takes much time to dissolve the powder.

On the other hand, light crispy gelatinized food has been commercially available from old times. The food is generally prepared by dissolving the grain powder in water, thinly spreading it on a heated plate to heat and dry the powder so that the powder is slightly roasted, peeling it from the plate, and then coarsely pulverizing it to form flake-like material. Industrially, they are prepared by steaming or boiling grain grits, adjusting the water content to 20% or so, rolling it by a pressure roll, and then roasting and drying it by a drum dryer, etc. However, the flakes as produced by these processes are not generally porous.

Thus, they are not much less fluffy, and their texture as food is not always good because, for example, the flakes become too soft when they are put into milk. On the other hand, the puffed grain is porous and the food texture is hard, and therefore its crispness is sufficient, but it is difficult to handle the puffed grain as stated in the above.


An object of the present invention is to provide a new process for producing pregelatinized grain without steaming or boiling.

Another object of the present invention is to provide a process for producing food or food processing material which can be sufficiently gelatinized, has a taste of crispness while it is maintained porous, has a uniform absorption swelling, it not difficult to aggregate, and has a high solubility in water.

In order to accomplish the above objects, the present inventors have made intensive studies and, as a result, the present invention has been invented.

This invention is a process for producing food or food processing feed material comprising puffing grain, characterized by adjusting the water content of the material before the puffing to 40% or less, puffing the material at 100 DEG C. or above, adding a prescribed amount of water to the puffed material, and then coarsely pulverizing the puffed material, to convert the puffed material into crushed material ( flake or grits ) which is maintained porous.


The present invention will be further explained in detail below.

1208/2197

In the present invention, any kind of edible grain can be used. The grain includes rice (polished or unpolished rice), barley, wheat, rye, oat, foxtail millet, a Deccan grass, adlay, koaliang, corn, etc. The term "puffing" used in this specification means that the feed material is rapidly heated to cause the water content of the feed material to expand and release from the material, so as to form hollow pores ( to be porous ), increase its volume, and harden the tissue ( to be crisp ). The puffing process to be used in the present invention can include any of the conventionally known processes such as the wet process, dry process, puffing gun process, extrusion puffing process, etc. Among them, the extrusion puffing process provides high expansivity and crispness. Further, the degree of the puffing of the extrusion puffed material is 90 % or higher, and its water content is low.

The term "crushed material" used in this specification means processed material in a form of flake or grits. Its dimension is not limited, but it is preferable that the crushed material is 0.1 to 0.5 cm in length and 0.5 cm or less in thickness. The crushed material required in the present invention must have a small thickness or graininess, a high degree of gelatinization, and a good solubility in water.

In the process of the study for producing the pregelatinized material which has merits of both the puffed material having good crispness but heterogeneous water absorption and being difficult to handle, and the flake having homogeneous water absorption and being easy to handle but having bad crispness and texture, various attempts were made. Firstly, the puffed material was coarsely pulverized.

However, fine powder was obtained. Further, when the powder was introduced into water, it easily aggregated, and therefore it was much more difficult to handle than the puffed material before the coarse pulverization. Secondly, the water content of the grain before the puffing treatment was adjusted and then the grain was coarsely pulverized. However, the grain as obtained was fine powder. Thirdly, when water was added to the puffed grain to adjust the water content thereof and then the grain was coarsely pulverized, little large particles were obtained. Lastly, water was added to the grain before the puffing treatment in order to adjust the water content of the grain, the water content of the puffed grain was adjusted by adding water to the puffed grain, and then the puffed grain was coarsely pulverized. As a result, the particles in a flake or grits form were obtained.

From the above attempts, the following knowledge was obtained. When the water content of the grain before the puffing treatment is higher, hard puffed grain having a lower degree of puffing is obtained.

When the water content thereof is lower, brittle puffed grain having a higher degree of puffing is obtained. The degree of gelatinization correlates to the degree of puffing. Namely, the higher the water content is, the lower the degree of gelatinization is. The lower the water content is, the higher the degree of gelatinization is. On the other hand, the higher the water content is, the higher the crispness is. The lower the water content is, the lower the crispness is. Furthermore, it was found that a flakiness related to the water content of the grain before pulverization. This reason seems to be that water contained in the grain gives adhesion to the tissue which easily separates into pieces without water, so that the grain is maintained in a flake or grits form. In this connection, when the water content is too large, the adhesion is too strong and therefore the crispness is lost and the texture is deteriorated.

Therefore, it has been found out that the water content of the grain before puffing has a very big effect on the degree of puffing and degree of gelatinization, while the water content of the grain before pulverization has a very big effect on the flakiness and crispness. Based on this knowledge, the present invention has been completed.

Any of processes of adding water to the grain before puffing can be employed so long as water is uniformly spread over the grain, and it is required that the grain is left to stand or subjected to other suitable treatment until water is sufficiently absorbed so that water does not remain on the surface of the grain. However, a process of immersing the grain in water and then draining off water is not desirable because there is a possibility that the amount of water to be absorbed is beyond the optimum range. A process of immersing the puffed grain in water and then draining off water is not preferable for adjusting the water content of the puffed grain before pulverization, either. In this case, since the grain is puffed and therefore is readily water-absorbable, it is necessary to be cautious so that the water content is not locally high in particular. When the amount of water to be added is low, the grain may be made to absorb water merely by passing it through a steam tunnel.

Any kind of puffing processes can be employed. The continuous extrusion puffing process using a extrusion puffing machine, extruder, wherein a high temperature of 100 DEG C. or above and a high

1209/2197

pressure are employed is desirable, because it provides high degree of puffing and high degree of gelatinization.

The puffed grain is generally subjected to the second adjustment of water content while it is hot, and then coarsely pulverized. It is preferable that the amount of water to be added to the puffed grain be 15

% or lower.

The coarse pulverization ( crushing ) may be conducted just after the water content adjustment, or after it has been left to stand for 1 or 2 hours. Any kind of processes for coarse pulverization may be used so long as they can crush the grain into flakes or grits. The flakers used for producing bread crumb are convenient.

The crushed material in a flake or grits form is dried as it is, and then packaged in a case. Since the water content of the product is 40% or lower, there is little possibility that the product is contaminated with microorganisms such as fungi, etc., even though it is left to stand at normal temperature. However, since the product is vey hygroscopic, it is necessary to store the product so that the product does not contact with humidity.

ADVANTAGE OF THE PRESENT INVENTION

The puffed and crushed grain obtained by the present invention has a very high degree of gelatinization of 90 %, and therefore it is saccharified rapidly and practically completely with a saccharifying enzyme. In addition, the present crushed grain has a degree of puffing 3 times as high as the prior grain, is porous, and has a high air content, so that, when the grain is suspended in water, the grain does not aggregate due to its wide surface contacting with water and is uniformly dispersed. Further, since the air content of the grain is not too much high dislike the grain before crushing, the grain precipitates in water without floating and swelling on the surface of water. Further, the water absorption rate of the grain is equal in all parts, so that the grain absorbs water rapidly and uniformly. In addition, when the present grain is used as feed material for brewage such as sake, vinegar, soy sauce, miso, etc., there yield little less. Therefore, the degree of utilization of the material is high. Further, according to the present invention, even rice lacking maturity ( so-called "shirata-mai") can be also used by no means inferior to matured rice.

When the present flake is used for food, it has high crispness because the puffed grain is suitably roasted at the puffing. Therefore, when the grain is introduced into mil, etc. to eat the grain in a socalled oatmeal milk style, the taste is good ( the food is not sloppy ). In view of the above, the present invention compensates the demerits of both the difficulty in handling of the puffed grain and the low crispness of the conventional flakes, and further produces new crushed grain having merits such as a porosity, crispness, dispersion of flakes, and unadhesivness.

EXAMPLE

The present invention will be explained in detail below with reference to Examples.

REFERENCE EXAMPLE

19 Kg of polished rice was separated into portions each of 1 Kg, water was added to each portion as described in the following Table 1, and then the portion was extruded by a single screw extruder to puff the rice. Water was added to each puffed portion as indicated in Table 1, and the resultant material was coarsely pulverized by a flaker. In the table, the specific volume, degree of gelatinization, crispness, dispersion, and equality of water absorbency of each of the coarsely pulverized materials are listed.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb;Relation between Property of the Coarsely Pulverized

>;tb;Porous Material and Water Content Adjustment

>;tb; 1 2 3 4 5 6 7 8 9 10

>;tb; 11

>;tb; 12

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>;tb; 13

>;tb; 14

>;tb; 15

>;tb; 16

>;tb; 17

>;tb; 18

>;tb; 19

>;tb;__________________________________________________________________________

>;tb;Water content of

>;tb; 14 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb; 14

>;tb;feed rice (%)

>;tb;Amount of water

>;tb; 0 0

>;tb; 5

>;tb; 5

>;tb; 5

>;tb; 5

>;tb; 8

>;tb; 8

>;tb; 8

>;tb; 13

>;tb; 13

>;tb; 13

>;tb; 18

>;tb; 18

>;tb; 18

>;tb; 24

>;tb; 24

>;tb; 28 28

>;tb;added (%)

>;tb;Water content just

>;tb; 7 7

>;tb; 12

>;tb; 12

>;tb; 12

>;tb; 12

>;tb; 15

>;tb; 15

>;tb; 15

>;tb; 20

>;tb; 20

>;tb; 20

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>;tb; 25

>;tb; 25

>;tb; 25

>;tb; 31

>;tb; 31

>;tb; 37 37

>;tb;after the puffing (%)

>;tb;Humidity added (%)

>;tb; 0 10

>;tb; 0

>;tb; 5

>;tb; 10

>;tb; 15

>;tb; 0

>;tb; 10

>;tb; 15

>;tb; 0

>;tb; 10

>;tb; 15

>;tb; 0

>;tb; 10

>;tb; 15

>;tb; 0

>;tb; 10

>;tb; 0 10

>;tb;Total water content

>;tb; 7 17

>;tb; 12

>;tb; 17

>;tb; 22

>;tb; 27

>;tb; 15

>;tb; 25

>;tb; 30

>;tb; 20

>;tb; 30

>;tb; 35

>;tb; 25

>;tb; 35

>;tb; 40

>;tb; 31

>;tb; 41

>;tb; 37 47

>;tb;before coarse

>;tb;pulverization (%)

>;tb;Coarsely

>;tb; Specific

>;tb; 5.4

>;tb; 4.7

>;tb; 5.0

>;tb; 4.5

>;tb; 3.9

>;tb; 3.4

>;tb; 4.4

>;tb; 3.6

>;tb; 3.2

>;tb; 2.9

>;tb; 2.7

>;tb; 2.4

1212/2197

>;tb; 2.0

>;tb; 2.3

>;tb; 2.1

>;tb; 2.0

>;tb; 1.9

>;tb; 1.7

>;tb; 1.5

>;tb;Pulverized

>;tb; volume

>;tb;Material

>;tb; Flakiness

>;tb; X .DELTA.

>;tb; X .circle.

>;tb; .circleincircle.

>;tb; .circle.

>;tb; X .circleincircle.

>;tb; .circle.

>;tb; X .circle.

>;tb; .circle.

>;tb; X .circle.

>;tb; .circle.

>;tb; X .circle.

>;tb; X .circle.

>;tb; Crispness

>;tb; -- X --

>;tb; .circle.


>;tb; .circle.

>;tb; --


>;tb; .circle.

>;tb; --

>;tb; .circle.

>;tb; .circle.

>;tb; --

>;tb; .circle.

>;tb; .circle.

>;tb; --

>;tb; .circle.

>;tb; -- X

>;tb; Dispesion

>;tb; X .DELTA.

>;tb; X .circle.


>;tb; .circle.

>;tb; X .circleincircle.

>;tb; .circle.

>;tb; X .circle.

>;tb; .circle.

>;tb; X .circle.

>;tb; .circle.

>;tb; X .circle.

>;tb; X .circle.

>;tb;__________________________________________________________________________

>;tb; Note:

>;tb; 1. The specific volume was determined by measuring a bulk volume per 100

>;tb; using a measuring cylinder, and calculating the volume rate with respect

>;tb; to that of raw rice.

>;tb; 2. The flakiness was determined as follows:

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>;tb; Uniform big size flakes .circle.

>;tb; Little small size flakes containing powder

>;tb; Flakes containing much powder X

>;tb; These criteria correspond to the followings(a 30 mesh sieve is used):

>;tb; Flakes 50% or more of which were removed X

>;tb; Flakes 30 to 50% of which were removed

>;tb; Flakes 10 to 30% of which were removed

>;tb; Flakes 10% or less of which were removed

>;tb; 3. The crispness was determined by ten panelists. The level of the

>;tb; crispness depends on the number of the panelists who thought the material

>;tb; was crispy as follows:

>;tb; 5 or less X

>;tb; 6 to 7

>;tb; 8 to 9 .circle.

>;tb; 10

>;tb; 4. The dispersion was determined based on the condition of a sample when

>;tb; 100 g of the sample was introduced into 200 g of water.

>;tb; Dispersed without aggregation

>;tb; At first, the sample aggregated, but when stirred for 10 sec. or less, th

>;tb; sample dispersed .circle.

>;tb; At first, the sample aggregated, but, when stirred for 10 to 30 sec., the

>;tb; sample dispersed

>;tb; At first, the sample aggregated, but, when stirred for 30 sec. or more,

>;tb; the sample dispersed X

Table 1 shows that when the water content of the rice before puffing is controlled to 19 to 38 % and the amount of humidity to be added to the puffed rice is controlled to 5 to 15 %, the resultant material is good in flake property, crispness, and dispersion.

EXAMPLE 1

8 liters of water was sprayed to 100 Kg of unpolished rice and the wet rice was left to stand for 2 hours to make the rice sufficiently absorb water. Then, the rice was extruded at a start temperature of 130

DEG C. to puff the rice. 6 liters of water was further sprayed to the puffed rice, and the rice was left to stand for 15 min. and then crushed by a flaker. After the pulverized rice was dried and put into a rice cooker, a seasoning and hot water were added to the cooker, which was left to stand while a cap was placed on the cooker. The resultant instant unpolished rice gruel was nice.

EXAMPLE 2

The crushed material produced in the same manner as Example 1 was added to "furikake" (the furikake is a kind of processed food composed of pulverized cooked fish, toasted laver, etc., and is used to be spread on rice in order that the rice is ate without any special dishes) in an amount of 5 %. The resultant furikake was very nice.

EXAMPLE 3

10 liters of water was sprayed to 100 Kg of unmatured rice "shirata-mai", the rice was left to stand for one hour to make it sufficiently absorb water, and then the rice was extruded at a start temperature of

135 DEG C. in order to puff the rice. 6 liters of water was further sprayed to the rice, the rice was left to stand for 15 min., and then the rice was crushed by a flaker. The resultant crushed material was dried and used for coating fried fish. The taste was plain and nice.

EXAMPLE 4

10 liters of water was sprayed 100 Kg of polished rice, the rice was left to stand for one hour to cause it to absorb water sufficiently, and then the wet rice was extruded at a starting temperature of 125 DEG

C. in order to puff the rice Further, 6 liters of water was sprayed to the puffed rice, the rice was left to stand for 15 min., and then the rice was crushed by a flaker. After the resultant material was dried, a

1214/2197

seasoning and hot water were introduced into a rice cooker, and the cooker was left to stand for one minute with a cap placed on the cooker. As a result, nice instant porridge was obtained.

EXAMPLE 5

Sake was produced by the conventional process using Jozo Kyokai (Brewage Association ) Yeast No.

7, except that 800 Kg of the crushed material obtained from Example 3, 200 Kg of "kome-koji" (the kome-koji is composed of steamed rice on which Koki-mold is grown ), and 1700 liters of water were used. Elegant sake having an alcohol content of 20 % and a soluble solid of 1.5 % was obtained. The alcohol conversion rate was 380 liters / 1000 Kg-rice, and the residual lees rate was 5 % of rice. Thus, these values were very high yields.

EXAMPLE 6

Unrefined sake was produced by the conventional process using Jozo Kyokai Yeast No. 7, except that

800 Kg of the crushed material obtained from Example 3, 200 Kg of the komekoji, and 1400 liters of water were used. 2350 liters of the unrefined sake having an alcohol content of 20 % and a soluble solid of 6 % was obtained. 500 liters of rice vinegar was added to the unrefined sake for denaturation, and then the denatured unrefined sake was pressed and filtered to produce 2600 liters of the filtrate.

The resultant filtrate was diluted with water to form 7100 liters of a feeding material for producing vinegar (rice vinegar ) by an acetic acid-fermentaion. The taste of the products of rice vinegar was mild and nice.

EXAMPLE 7

100 Kg of wheat was partially polished by a rice polished to partially damage it. After 8 liters of water was sprayed to the partially damaged material and then the wet material was left to stand for one hour to cause the material to absorb water, the material was extruded at a start temperature of 140 DEG C. to puff the material. Further, 4 liters of water was sprayed to the puffed material and left to stand for 15 min. Then, the material was crushed by a flaker. The resultant crushed material was dried, which was used as a feed material for soy sauce. The same amounts of the feed material and de-fatted soybeans were used and then the koji culture was made for this mixture. The resultant material was brewed by the conventional process to produce soy sauce. The aging was finished earlier than the conventional material by about one month. The resultant unrefined soy sauce having a total nitrogen content of 1.5

% was obtained. The lees rate of the present soy sauce was 10 %, which was about half of that of the conventional soy sauce. The taste of the resultant soy sauce was the same as that of the conventional one.

EXAMPLE 8

10 liters of water was sprayed to 100 Kg of barley (polished ) and the wet barley was left to stand for one hour to make the barley sufficiently absorb water. The barley was then extruded at a start temperature of 140 DEG C. to puff the barley, to which 4 liters of water was further sprayed and left to stand for 15 min. The resultant material was coarsely pulverized and dried, and then koji culture was made therefor. The resultant material was mixed with the same amount of soy beans and used as a feed for barley miso. The aging was finished earlier than that of the conventional process by two months.

The sugar resolution rate was 83 %, which was higher by 3 % than the conventional one. The resultant miso was glossy and tasty.

EXAMPLE 9

100 Kg of corn (round particle ) was converted into grits. 10 liters of water was sprayed to the grits and the wet grits was left to stand for two hours to cause the grits to sufficiently absorb water. The resultant material was extruded at a start temperature of 140 DEG C. to puff the grits. 6 liters of water was further sprayed to the puffed grits, which was left to stand for 15 min., and then crushed by a flaker.

After the crushed material (flake ) was dried, it was used as a feed for whisky. The resultant flake was mixed with 25 Kg of malt and 650 liters of water to cause the saccharification, yeast was added to the saccharified flake, and then alcohol fermentation was performed by the conventional process. After the resultant material was distilled, 69 liters of the distilate (whisky ) having an alcohol content of 57 %

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was obtained. The alcohol fermentation yield rate of the present process was higher by 7 % than the conventional process. In addition, the taste of the resultant whisky was mild.

EXAMPLE 10

100 Kg of foxtail millet was partially beated by a polisher and 10 liters of water was sprayed to thus partially damaged millet, which was left to stand for two hours in order to cause it to sufficienlty absorb water. The wet millet was extruded at a start temperature of 140 DEG C. to puff the millet. 6 liters of water was sprayed to the puffed millet, which was left to stand for 15 min., and then was coarsely pulverized by a flaker. The resultant flake was dried and used as a feed for shochu (spirits ).

70 Kg of the feed was mixed with 30 Kg of "genmai-koji" (the genmai-koji is composed of unpolished rice on which koji-mold was proliferated.) (black koji) and 160 liters of water and then the resultant mixture was subjected to the conventional alcohol fermentation. After the fermentation, the mixture was distilled by a pot-still to produce 135 liters of 25 % - shochu. The alcohol fermentation yield rate of the present invention was higher by 3 % than that of the conventional process, and its taste was mild.

EFFECT OF THE PRESENT INVENTION

The puffed and crushed grain obtained by puffing grain material whose water content is controlled to

40 % or less, adding a prescribed amount of water to the puffed grain, and then coarsely pulverizing the resultant material, is high in its flakiness crispness, dispersion and porosity, and has a good degree of gelatinization. Since the taste of this crushed material is light, there are many food applications. For example, the material eaten as it is, or as food such as instant gruel, furikake, etc. Further, it can be used for frying coating, confectionery, etc. In addition, the product obtained by the present invention has excellent properties as food for any kind of brewed products as obtained by using fermentation step, such as before-mentioned products in Example of the present invention, beer, shao-hsing rice wine, "mirin" (a sweet sake used for seasoning ), etc. The present invention provides the product with good dispersion when the product is used as a feed, and increases the fermentation efficiency against nitrogen or sugar by 3 to 10 %.

In addition, according to the present invention, unedible grain such as shirota-mai, etc. which has not been used for food can be changed to good edible food, so that the present invention is very advantageous in respect of utilization of resources.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for producing pregelatinized grain comprising puffing said grain to convert the grain into food or material for producing other food, characterized by adjusting the water content of the grain before puffing to 19 to 38%, puffing the grain at 100 DEG C. or higher, adding 5 to 15% of water to the puffed grain, and then coarsely pulverizing the puffed grain, thereby producing the coarsely pulverized porous material.

2. The process of claim 1, wherein the puffing is conducted by an extrusion puffing process.

3. The process of claim 1, wherein said grain is rice.

4. The process of claim 3, wherein said rice is shirota-mai.

5. The process of claim 1, wherein said coarsely pulverized porous material is of a flake or grits form.

6. The process of claim 5, wherein said coarsely pulverized porous material is 0.1 to 0.5 cm in length and 0.5 cm or less in thickness.Data supplied from the esp@cenet database - Worldwide

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251.

JP62210955 - 9/17/1987

METHOD FOR PREVENTING AGING OF FOOD


Inventor(s): KONO TOSHIAKI (--); TOKUNAGA TAKAHISA (--); YAMAGUCHI GOICHI (--

); KITAGAWA HIROYUKI (--); HIRAGA TETSUO (--)

Applicant(s): SHOKUHIN SANGYO BIOREACTOR (--)

IP Class 4 Digits: A23L; A21D

IP Class: A23L1/04; A21D2/18

E Class: A23L1/16; A23L1/0532; A21D2/18



Family: JP62210955


Abstract:


PURPOSE:To prevent aging of food such as deterioration of food, etc., by adding a food to an oligosaccharide derived from agar or carrageenan. CONSTITUTION:A food such as the staple food, e.g. bread, noodles, rice, etc., cakes, e.g. starch paste, cake, etc., is blended with preferably 3-50wt% oligosaccharide (preferably 2-20 polymerization degree) derived from agar and/or carrageenan to prevent aging of food.Description:



This invention relates to a method for preventing deterioration of foods and, more particularly, to a method for preventing deterioration of starch-containing foods by adding a specific oligosaccharide.


Starch is the most important calorie source of foods. Staple foods for humans mainly comprise starch and starch-containing foods are widely used, not only as staple foods but also as subsidiary foods or confections. As starch is usually used in the gelatinized form (.alpha.-starch) made by heating in the presence of water, foods containing starch undergo hardening due to retrogradation of gelatinized starch to .beta.'-starch. As a result, palatability and texture of starch-containing foods deteriorate with time, resulting in reduction of commercial value. Therefore, it is difficult to preserve starch-containing foods for a long period fo time or to deliver them over a long distance.

Many attempts have been made in order to prevent or retard deterioration of foods due to retrogradation of starch. Known methods proposed for this purpose include addition of monosaccharides or oligosaccharide, e.g., sorbitol, glucose, sucrose, maltose, etc., which also serve as sweeteners; addition of polysaccharides of the same type as starch, e.g., dextrin, -limit dextrin, starch of glutinous rice or partial hydrolysates thereof, etc.; addition of natural gum or water-soluble polysaccharides, e.g., sodium alginate, etc.; addition of fats and oils or derivatives thereof; addition of

1217/2197

surface active agents; and the like. These techniques attained their effects to some extent by taking advantage of the characteristics of the respective additive. However, the preventing of deterioration obtained with prior known additives is still insufficient and there has been a demand for a material free from deterioration or an efficient method of preventing deterioration of foods.


As a result of extensive investigation, it has now been found that specific oligosaccharides obtained by hydrolysis of agar or carrageenan with an acid or an enzyme exhibit powerful effects on prevention of retrogradation of .alpha.-starch. The present invention has been completed based on this finding.

The present invention relates to a method for preventing deterioration of foods, which comprises adding an oligosaccharide originating from agar or carrageenan or both agar and carrageenan to foods.


The oligosaccharides of agar origin which can be used in the present invention can be prepared from agar of any form (e.g., rod, band, plate, string, powder, etc.), agarose (i.e., purified agar), and raw materials of agar, e.g., Gelidium amansii Lamouroux, Gracilaria verrucosa, etc. The oligosaccharides of carrageenan origin can be obtained from carrageenans or raw materials of carrageenan, i.e., red algae

(e.g., Chondrum ocellatus).

The oligosaccharides to be used in the invention are suitably prepared by dissolving these materials in water, and by heating and reacting an enzyme to effect enzymatic hydrolysis (cf., e.g., D. Groleu and w. Yaphe, Canadian Journal of Microbiology, 23, 672-679 (1977) and C. Araki, Journal of Chemical

Society of Japan, 65, 533 (1944)). Bydrolases for agar include agarase (e.g., .beta.-agarase originating from Pseudomonas atlantica, sold by Sigma Co.), etc., and those for carrageenans include carrageenase

(e.g., .kappa.-carrageenase originated from Pseudomonas carrageenovora), etc. The conditions for enzymatic hydrolysis are not particularly limited. Oligosaccharide mixtures having an arbitrary molecular weight distribution can be obtained by appropriately controlling the amount of the enzyme used, the reaction temperature, the reaction time, and the like.

Alternatively, the oligosaccharides to be used may also be prepared by hydrolysis of the abovedescribed materials with an acid (cf., e.g., J. Weigh and W. Yaphe, Canadian Journal of Microbiology,

12, 939-947 (1965)). Acids to be employed include sulfuric acid, hydrochloric acid, oxalic acid, etc.

The conditions for acid-hydrolysis are not particularly limited and oligosaccharides having various degrees of decomposition can be obtained by arbitrarily selecting the acid concentration, the reaction temperature, the reaction time, and the like. Substantially the same conditions, e.g., heating at 100 DEG

C. for 1 hour in 1 N sulfuric acid, can be used for hydrolyzing agar and carrageenan.

The oligosaccharides of agar origin are composed of an agarobiose unit, a neoagarobiose unit, and a neoagarotetraose unit having the structures shown below. In general, it is known that enzymatic hydrolysis of agar yields oligosaccharides composed of a neoagarobiose unit and that acid hydrolysis of agar yields oligosaccharides composed of an agarobiose unit. ##STR1##

The oligosaccharides of carrageenan origin are composed of a carrabiose unit, a neocarrabiose unit, and a neocarratetraose unit having the structures shown below. In various carrageenans, one or more of the hydroxyl groups at the 2-, 4- and 6-positions are sulfated or, in some cases, the 2- and 4-hydroxyl groups are methylated. In general, it is known that enzymatic hydrolysis of carrageenans produces oligosaccharides composed of a neocarrabiose unit and that acid hydrolysis yields oligosaccharides composed of a carrabiose unit. ##STR2##

The thus prepared oligosaccharides preferably have a degree of polymerization ranging from 2 to 20. If the degree of polymerization exceeds 20, a sufficient effect to prevent deterioration of foods cannot be obtained.

After the enzyme- or acid-hydrolysis, any insoluble matter is removed from the decomposition mixture, after pH adjustment, if desired, by filtration, centrifugaion, or the like procedure to recover the desired

1218/2197

oligosaccharides. If necessary, the resulting oligosaccharides can be purified by decolorization with activated carbon, desalting with ion-exchange resins, fractionation using a membrane or gel filtration chromatographic column, and the like.

The resulting oligosaccharide solution is concentrated to obtain an oligosaccharide syrup (usually 7 to

75 wt %). The oligosaccharide solution may be converted to a powder by spray-drying, freeze drying, vacuum drying, crystallization, or the like procedure.

The thus prepared oligosaccharides either in the form of syrup or in the form of amorphous or crystalline powder are used in the same manner as sugars commonly employed in foods, such as sucrose, glucose, maltose, starch syrups, lactose, sorbitol, maltitol, etc. When they are used in substitution for these sugars, remarkable effects in preventing deterioration of foods can be assured.

The amount of the oligosaccharide to be added can be decided appropriately depending on the kind and properties of the food of interest and usually ranges from 3 to 50% by weight based on the weight of the food.

The oligosaccharides according to the present invention are sufficiently effective when used alone, but the effect can be further enhanced by a combined use of conventional carbohydrates known to prevent starch retrogradation. Examples of the conventionally employed carbohydrates are sorbitol, glucose, sucrose, maltose, starch syrups, lactose, maltitol, dextrin, .beta.-limit dextrin, starch of glutinous rice or decomposition products thereof, natural gum, sodium alginate, etc. Of these, higher molecular weight carbohydrates such as dextrin, .beta.-limit dextrin, starch of glutinous rice, natural gum, sodium alginate, etc. can be used in an amount of preferably 0.1 to 3 wt % based on the weight of the composition and lower molecular weight hydrocarbons such as sorbitol, glucose, sucrose, etc. can be used in an amount of preferably not lower than 5 wt % based on the weight of the composition.

The variety of foods to which the present invention is applicable is not particularly limited, and preferably include starch-containing foods, such as staple foods (e.g., breads, noodles, rice cakes, etc.) and confections (e.g., sponge cakes, rice pastes, etc.).

The present invention will now be illustrated in greater detail by way of examples, but it should be understood that the present invention is not limited thereto. In these examples, all the parts and percents are by weight unless otherwise indicated.

EXAMPLE 1

To 100 parts of refined rice flour were added sucrose and a powder of an oligosaccharide mixture having a degree of polymerization of from 4 to 6 which was obtained by hydrolysis of agarose with agarase originated from Pseudomonas atlantica in varying amounts as indicated in Table 1 and an adequate amount of water. The mixture was concentrated by heating over an open fire to a water content of about 30% to prepare a rice paste. The rice paste was put in a petri dish, covered with a polyethylene film, and preserved in a refrigerator (about 5 DEG C.) for accelerated deterioration. The degree of deterioration was determined with time by measuring hardness by a rheometer and X-ray diffractometry. As all the samples had substantially the same incipient hardness, the number of days having elapsed until the rheometrical hardness exceeded a level double the incipient hardness is shown in Table 1 as a deterioration period.

As controls, a rice paste prepared by using sucrose alone as a sugar component (Control 1) and a rise paste prepared by replacing the oligosaccharide with maltose (Control 2) were subjected to the same deterioration test as described above.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Control No.

>;tb; Sample No.

>;tb; 1 2 1 2 3 4 5

>;tb;______________________________________

>;tb;Sugar Composition (part):

>;tb;Sucrose 100 30 90 70 45 30 0

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>;tb;Oligosaccharide

>;tb; 0 0 10 30 55 70 100

>;tb;Maltose -- 70 -- -- -- -- --

>;tb;Deterioration Period (day)

>;tb; 0.5 1 2 7 14 27 ;60

>;tb;______________________________________

As can be seen from Table 1, the oligosaccharide according to the present invention exerts a marked effect to prevent deterioration of foods even when used in a small proportion.

The results of X-ray diffractometry also proved that addition of the oligosaccharide of the invention is effective to prevent retrogradation of gelatinizede startch.

EXAMPLE 2

A rise paste was made in the same manner as described in Example 1 except for replacing the sugars with 70 parts sucrose and 30 parts oligosaccharide having a varying degree of polymerization as shown in Table 2. The degree of deterioration, determined in the same manner as in Example 1, is shown in

Table 2. The oligosaccharide used was prepared by hydrolyzing agarose or agar with an enzyme or an acid so as to have the prescribed degree of polymerization. A rice paste made by replacing the sugar used in Example 1 with 100 parts sucrose was used as a control.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Con- Sample No.

>;tb; trol 1 2 3 4 5

>;tb;______________________________________

>;tb;Degree of Polymeriza-

>;tb; -- 2-4 4-6 4-10 10-20 ;20

>;tb;tion of Oligosaccharide

>;tb;Deterioration Period

>;tb; 0.5 10 7 7 4 1

>;tb;(day)

>;tb;______________________________________

Table 2 clearly demonstrates that a sufficient effect or retrogradation of gelatinized starch can be brought about by those oligosaccharides having a degree of polymerization not greater than 20.

EXAMPLE 3

A rice paste was made in the same manner as in Example 2 except for replacing the oligosaccharide as used in Example 2 with an oligosaccharide shown in Table 3. The degree of deterioration, determined in the same manner as in Example 1, is shown in Table 3. As a control, a rice paste made by using sucrose in place of the oligosaccharide was used.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Sample No.

>;tb; Control

>;tb; 1 2 3

>;tb;______________________________________

>;tb;Origin of -- agarose agar carra-

>;tb;Oligosaccharide geenan

>;tb;Process of Hydrolysis

>;tb; -- enzyme acid acid

>;tb;Degree of Polymerization

>;tb; -- 4-6 4-10 2-10

>;tb;of Oligosaccharide

>;tb;Deterioration Period (day)

>;tb; 0.5 7 7 6

>;tb;______________________________________

1220/2197

As is apparent from Table 3, the oligosaccharides of the present invention exhibit a sufficient effect on retrogradation of gelatinized starch irrespective of their origin and the process of hydrolysis.

EXAMPLE 4

A rice paste was made in the same manner as in Example 1 by using 100 parts refined rice flour, 70 parts maltose, 30 parts oligosaccharide of agarose origin having a degree od polymerization of from 4 to 6, and an adequate amount of water. The resulting rice paste exhibited markedly improved preservability as compared with that obtained by using sucrose in place of maltose.

EXAMPLE 5

To 100 parts of wheat flour were added 10 parts of an oligosaccharide (degree of polymerization: 2-10) which was obtained by acid hydrolysis of agar, 2 parts of baker's yeast, and an adequate amount of water to prepare a dough, which as then baked to make a bread. As a control, a bread was made in the same manner except for using sucrose in place of the oligosaccharide. Immediately after baking, both breads has the same palatability. Each of the breads was then separately packaged and preserved at room temperature for 2 days. After two days, the control bread had a hardness greater than the bread of the invention by a factor of 3 or more, was crumbling with poor palatability. On the other hand, the bread according to the present invention still had elasticity without undergoing much change in hardness.

The ability of oligosaccharide addition to prevent retrogradation of gelatinized starch were also revealed by X-ray diffractometry of these breads.

As described above, the addition of oligosaccharides prepared from daily food materials of high safety effectively prevents starch-containing foods from deterioration due to retrogradation of gelatinized starch. The effects obtained by the present invention are superior to those of conventionally employed sugars. In addition, the oligosaccharides according to the present invention exert their effects on a wide variety of foods, thus broadening their application. The present invention, therefore, makes a great contribution to the field of food manufacture.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.Data supplied from the esp@cenet database -

Worldwide Claims:


We claim:

1. A method for preventing deterioration of a starch-containing food due to retrogradation of the starch, comprising adding to the starch-containing food an anit-food deterioration effective amount of an oligosaccharide obtained from hydrolysis of agar, carrageenan or combinations thereof, wherein said oligosaccharide obtained from hydrolysis of agar is an oligo saccharide which consists of units of agarobiose, neoagarobiose and neoagarotetraose and wherein said oligosaccharide obtained from hydrolysis of carrageenan is an oligosaccharide which consists of units of carrabiose, neocarrabiose and neocarratetraose.

2. A method as in claim 1, wherein said oligosaccharide has a degree of polymerization of from 2 to

20.

3. A method as in claim 1, wherein said oligosaccharide is added in an amount of from 3 to 50% by weight based on the weight of the starch-containing food.

4. A method as in claim 1, wherein in the oligosaccharide obtained from hydrolysis of carrageenan, one or more of the hydroxyl groups at the 2-, 4-, and 6- positions are sulfated or one or more of the

1221/2197

hydroxyl groups at the 2- and 4- positions are methylated.Data supplied from the esp@cenet database -

Worldwide

1222/2197

252.

JP63248357 - 10/14/1988

PRODUCTION OF RICE PRODUCT


Inventor(s): MAAKU ERU UENJIYAA (--); GOODON AARU HIYUUBAA (--)

Applicant(s): WENGER MFG (--)


IP Class: A23L1/10

E Class: A23L1/168; A23L1/00P12; A23P1/12



Family: JP63248357


Abstract:

Abstract not available for JP63248357


Quick cooking rice products are manufactured in a low mechanical shear extrusion process by first precooking a rice and water mixture in a preconditioner and then advancing the mixture along the length of an extruder sequentially presenting a cooking zone, a venting zone, a forming zone, and finally an extrusion die to yield an extruded product. Venting of gaseous products removes a significant amount of moisture from the mixture during the time that the latter passes between the cooking zone and the forming zone, and consequently the moisture content of the mixture within the cooking zone can be increased in order to reduce the total mechanical shear imposed on the mixture during the cooking process. The extruded product, once dried, closely resembles rice grain and readily rehydrates without exhibiting slimy or sticky characteristics, and has an increased tolerance to overcooking. A venting device has a rotatable screw for enabling gaseous materials to be discharged from the mixture while substantially preventing the escape of the mixture from the extruder barrel of the extruder.Description:


LOW SHEAR EXTRUSION PROCESS FOR MANUFACTURE OF QUICK COOKING RICE



This invention relates to a method for continuous manufacture of extruded rice products which may be readily rehydrated by immersion of the products in boiling or hot water for 5 to 10 minutes. The method includes the use of a preconditioner to partially pre-cook a rice flour or rice granules and water mixture, and also includes the use of an extruder wherein the rice and water mixture is advanced first through a cooking zone, then through a venting zone and a forming zone, and finally through an

1223/2197

extrusion die to yield the products. The mixture is exposed to a minimum of mechanical shear within the extruder by directly injecting steam into the mixture and then removing a significant amount of moisture from the mixture in the venting zone.The extruder products once dried exhibit the characteristics such as good product integrity after rehydration and good tolerance to overcooking without formation of either a slimy or sticky outer surface.


Rice is a well known and important grain, being a staple and primary food for about one-half of the population of the world. However, whole rice grain, whether cooked with hull intact or initially polished to remove the hull, must be immersed for approximately 30 to 40 minutes in boiling water in order to gelatinize the starch and transform the grain into an edible state. Precooked rice, such as parboiled rice, cooks to an edible state in about fifteen minutes. In addition, rice grains for parboiling which have been broken into pieces are undesirable in the package or container and thus are typically separated out and sold at a discount as granules or for rice flour.

Increased attention in recent years has been directed in more technically advanced societies toward quick cooking rice products which can be conveniently rehydrated in hot or boiling water within a time period of five to ten minutes. Advantageously, such products may also be mixed with other foods and cooked in a microwave or conventional even without the need for precooking the rice on a stove and thereafter draining any excess water. Furthermore, it is known that grinding whole rice grain into rice flour for manufacture of quick cooking rice enables a higher percentage of the grain to be utilized in comparison to the usable percentage of grain that is available after, for example, polishing of the rice for transformation into white rice for cooking by the consumer.

In general, the known processes for manufacture of quick cooking rice include the steps of mixing a rice and water mixture in an extruder and raising the temperature of the mixture during advancement of the same along the length of the extruder in order to gelatinize the rice starch. Unfortunately, known processes impose an excessive amount of shear on the rice and water mixture within the extruder which causes the rehydrated product to have a sticky surface and agglomerate in any unsatisfactory manner when served. An excess of mechanical shear also reduces tolerance of the extruded product to overcooking which in some cases causes the rehydrated rice to have an unattractive, slimy outer surface, or become mushy and full apart.

Excessive shear of the rice and water mixture in the extruder can, under some circumstances, decrease product integrity which is measured by the ability of the rice product to spring back to its original configuration after rehydration. An extreme amount of shear also causes a sliminess or stickiness characteristic that results in poor quality. Also, an extreme amount of shear can lead to increased extruder energy consumption and a variety of mechanical problems due to greater wear at elevated temperatures on the extruder components.

Hence, it would be desirable to provide a process for manufacturing quick cooking rice in such a fashion that mechanical shear imposed upon the rice and water mixture is minimized in order to improve the characteristics of the extruded product as well as to reduce energy consumption and the cost of extruder maintenance. Desirably, the process would enable the use of relatively high amounts of moisture during cooking in order to reduce shear, while ensuring that the extruded product is completely cooked before advancing toward a drying station where the products are dried during relatively short periods of time with air at ambient temperatures or temperatures somewhat above ambient.


The present invention overcomes the disadvantages noted hereinabove by provision of a low shear extrusion process for production of quick cooking rice products which includes the step of passing a rice flour or granules and water mixture through a preconditioner for 20 seconds to three minutes in

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order to partially pre-cook the mixture at temperatures in the range of from about 150 DEG F to 210

DEG F. The mixture is then introduced into an extruder for passage first through a cooking zone, then through a venting zone and a forming zone, and finally through an extrusion die to yield an extruded product. The temperature of the mixture within the cooking zone is in the range of from about 180

DEG F to about 350 DEG F, and preferably within the range of about 235 DEG F to about 265 DEG F.

Pressures within the barrel of the extruder are in the range of 200 psig to 1200 psig.

Importantly, the venting zone provided in the extruder in accordance with the principles of the invention causes significant amounts of moisture in the form of gaseous products to be removed from the rice and water mixture before passage of the latter to the forming zone and subsequently to the die.

As a consequence, the ratio of water to rice in the mixture during advancement to the cooking zone can be increased in order to lower the viscosity of the mixture and thereby cause correspondingly less shear to be imposed upon the same. The extruded product exhibits superior integrity after rehydration with a noticeable absence of a slimy feel and appearance of the product surface; moreover, the product has a substantial tolerance to overcooking without measurable detraction from desirable organoleptic properties. The extrusion process utilizes the less marketable, broken rice granules and/or flour to form a product which, ince rehydrated, has the quality and appearance of parboiled, whole grains of rice.

Exposure of the rice and water mixture to the venting zone in the extruder advantageously cools the mixture before entering the forming zone and the die. As such, the extruded product is substantially easier to handle before arriving at the drying station because the product retains its shape and can be severed by a clean cut without tearing by use of a knife blade held to the face of the die.

It has been found that application of negative pressures to the venting zone of the extruder greatly facilitates removal of moisture from the mixture in order to enhance the quality of the final product, while also allowing the moisture content of the mixture in the cooking zone to be increased so that the forces of mechanical shear are retained at a minimum.Preferably, the venting zone is equipped with a device having a conical housing connected to a vent and an upright screw positioned in the housing, and the screw has flights for biasing any portion of the rice and water mixture entering the housing back toward the extruder in a direction opposite from the flow of the vented gases.

Brief Description of the Drawing

Figure 1 is a fragmentary, side elevational view in somewhat schematic form illustrating an exemplary extruder used for cooking and extruding a rice and water mixture into quick cooking rice products in accordance with the principles of our present invention;

Fig. 2 is an enlarged, fragmentary, plan view of the extruder shown in Fig. 1 with parts broken away in section to reveal twin, flighted screws positioned within a barrel of the extruder; and

Fig. 3 is a typical temperature profile representing the temperature of a rice and water mixture during passage along the length of a preconditioner as well as the extruder shown in Fig. 1.

Detailed Description of the Drawing

Turning initially to Fig. 1, an extrusion apparatus 10 is shown and includes an extruder 12 having a barrel 14 with an inlet 16 located below an outlet of a preconditioner 15; the extruder 12 also has an outlet with a die 18. The barrel 14 as depicted comprises nine barrel sections 20-36, although the number of barrel sections may vary without departing from the principles of the present invention.

As shown in Fig. 2, the extruder barrel 14 has walls defining a chamber 38 which is comprised of two frusto-cylindrical, juxtaposed, intercommunicated chamber sections. Two rotatable, flighted, material advancing screws 40 are received in respective sections of chamber 38 and are intermeshed along the majority of the length of the extruder barrel but diverge at the region of the final barrel section 36 and are received within respective, com- plemental, conical barrel sections in order to split the material being processed into two juxtaposed, noncommunicating streams.

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The twin screw food extruder 12 as illustrated in Fig. 2 is manufactured by Wenger Manufacturing,

Inc., the assignee of the present invention, and is designated as the Wenger TX Extruder depicted in

Wenger Bulletin No. 56-586 which is hereby expressly incorporated into the disclosure herein. The

Wenger TX Extruder is also described in U.S. Patent Application, Serial No. 06/794,252, filed October

30, 1985 (a continuation of S/N 06/603,195, filed April 23, 1984) which is also hereby expressly incorporated into the present disclosure. The Wenger TX Extruder has been found to provide relatively high pressure differentials in the twin head outlet sections, and on the order of 500 psi to 600 psi; this factor is believed to be at least partially significant in obtaining the unique results of the present invention.

Referring again to Fig. 1, a device 42 for venting barrel section 32 includes a housing 44 having a conically configured portion 46 and a cylindrical portion 48 that interconnects the conical portion 46 and the extruder barrel 14. The enclosed housing 44 has structure defining a passage 50 which has a conical configuration within portion 46 and a corresponding cylindrical configuration within portion

48. The passage 50 has an outlet 52 and an inlet 54 which is in communication with a vent opening 56

(see Fig. 2) in barrel section 32. Housing 44 also includes a lower, horizontal flat plate 58 which is received in leak-resistant contact in vent opening 56 and covers a substantial portion of the same except for a region immediately adjacent passage 50 within cylindrical portion 48.

The venting device 42 further includes a screw 60 having flights for biasing material entering the passage 50 through the vent opening 56 in an opposite direction toward the chamber 38 of barrel section 32. The upright venting device screw 60 is axially rotatable within passage 50, including areas adjacent passage inlet 54, and is powered by a motor 62 coupled to right angle drive 64.

The passage outlet 52 is provided by a pipe 66 which extends through a cover 68 of the venting device housing 44, and the pipe 66 is C-shaped within the housing 44 so that the outlet 52 is directly adjacent cover 68. The pipe 66 is vented to the atmosphere, or preferably is coupled to a vacuum source for inducing a negative pressure within passage 50 and for drawing off gaseous products from material being advanced along extruder 12.

In accordance with the present invention, a low shear extrusion process is provided for production of quick cooking rice products, and includes the step of introducing a mixture comprised of rice flour or granules and water into the barrel 14 of extruder 12. The rice and water mixture is initially prepared in the preconditioner 15 by mixing rice with water and elevating the temperature of the mixture to a level of from about 150 DEG F. to about 210 DEG F. for a residence time of 20 seconds to 3 minutes, although a residence time of 1 minute to 2 minutes is preferred. The preconditioning step also may optionally include the step of adding steam to the rice and water mixture during travel of the mixture along the first one-third of the length of the preconditioner 15.

Desirably, the mixture within the extruder chamber 38 ahead of venting barrel section 32 comprises about 80% to 160% by weight of rice and from about 20% to 40% by weight of water. Better results are observed, however, when the mixture ahead of section 32 comprises from about 75% to 70% by weight of rice and from about 25% to 30% by weight of water. Once the rice and water mixture is introduced into the extruder 12 through inlet 16, the mixture is advanced along the length of the barrel

14 by axial rotation of screws 40. The mixture is sequentially advanced first through a cooking zone in the extruder, then through a venting zone and a forming zone, and finally through holes 70 (Fig. 2) in die 18 to yield an extruded product.

Barrel sections 20-30 shown in Figs. 1 and 2 for exemplary purposes represent the cooking zone. The rice and water mixture during advancement through the cooking zone has a temperature in the range of from about 180 DEG F to about 350 DEG F, although preferably the temperature of the mixture in the cooking zone is in the range of from about 210 DEG F to about 300 DEG F. Best results are observed when the temperature of the mixture in the cooking zone is in the range of about 235 DEG F to 265

DEG F. Also, the residence time of materials within the cooking zone including barrel sections 20-30 is within the range of about 10 seconds to about 25 seconds, and preferably is approximately 15 seconds.

Barrel section 32 represents the aforementioned venting zone wherein gaseous products are removed from the rice and water mixture as the latter is advanced by screws 40. As the gaseous products are discharged through vent opening 56 and passage 50, vent device screw 60 is rotated to bias any portion

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of the rice and water mixture that passes from the chamber 38 through vent opening 56 in an opposite direction back toward chamber 38. As can be appreciated by reference to Fig. 1, provision of the upright passage 50 in cooperation with the vertical screw 60 enables the influence of gravity to cause any portion of the mixture within passage 50 to fall toward the screw 60 which, in turn, then advances the same back toward chamber 38.If desired, a wiping element (not shown) may be posi tioned within the conical portion of passage 50 to scrape lodged portions of the rice and water mixture from the internal surface of housing conical portion 46.

Preferably, the outlet 52 of passage 50 communicates with a vacuum source which provides a vacuum from about 5 to 20 in. Hg. Better results are observed, however, when the negative pressure within passage 50 is about 15 in. Hg.

The conical portion of passage 50 enables the face velocity of mixture entering the passage 50 to be reduced to a relatively low level as the mixture approaches cover 68 in order to substantially preclude entry of the mixture into vacuum pipe 66. Location of the vent outlet 52 at an upper corner of passage

50 adjacent cover 68 enables a relatively large quantity of the mixture to temporarily flow into passage

50 without danger of entering pipe 66. At the same time, the conical configuration of portion 46 causes mixture collected therein to fall downwardly toward the passage inlet 50 whereupon the positive rotation of screw 60 by motor 62 causes the same to be forced back into the barrel chamber 38.

Again referring to Fig. 1, barrel sections 34 and 36 represent for exemplary purposes the forming zone through which the rice and water mixture is advanced before being extruded through die holes 70. The residence of time of the mixture in the forming zone is from about 20 seconds to about 60 seconds, and preferably is approximately 45 seconds. Temperatures of the mixture are within the range of about 130

DEG F to about 250 DEG F, and preferably within the range of about 180 DEG F to 220 DEG F.

Additionally, the mixture is subjected to a pressure within the forming zone of from about 200 to about

1200 psig, and preferably the mixture in the forming zone is subjected to a pressure of from about 500 psig to about 600 psig.

Both water and steam may be injected into the mixture as the same is advanced along chamber 38. For example, tap water may be injected into the initial barrel section, or barrel section 20, with a temperature in the range of 50 DEG F. to 65 DEG F., and steam may be added downstream of barrel inlet 16 in regions corresponding to barrel sections 24, 26, 28. As another example, water having a temperature of about 180 DEG F. may be injected into the initial barrel section 20, whereby less steam will be required. Other orientations, of course, are also possible.

The barrel 14 of extruder 12 advantageously is jacketed so that coolant water or oil can circulate in the extruder 12 adjacent chamber 38 for subjecting the rice and water mixture to indirect thermal interchange during advancement thereof along the length of barrel 14. Other expedients such as electrical resistance or induction heating could also be employed. Preferably, the mixture during travel through the entire length of extruder 12 has a temperature in the range from approximately 210 DEG F to approximately 250 DEG F subject, of course, to the temperature ranges in the cooking zone as set forth hereinabove. Optionally, the temperature of the mixture in the forming zone is less than the temperature of the same in the cooking zone.

As the mixture is passed from the forming zone of extruder 12 and through the die holes to yield an extruded product, a knife (not shown) held under compression against the outside face of die 18 severs the extruded product to the desired rice grain-like configuration. Next, the products are advanced to a drying station in order to render the same suitable for storage and transport.

In a preferred forms of the invention, the step of drying the extruded products is carried out until the rice products have a moisture level of about 8% to 14% by weight. However, better results have been observed when the moisture level of the final rice product is in the range of approximately 10% to approximately 12% by weight.

The extruded products during the drying stage are preferably subjected to a temperature of from about ambient, or about 75 DEG F, to about 250 DEG F for a period of from about 60 minutes to about 10 minutes. Better results have been observed, however, when the extruded products during the drying

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step are subjected to a temperature within the range of about 180 DEG F to about 220 DEG F for a period ranging from about 10 minutes to 20 minutes.

Significant amounts of moisture are removed from the rice and water mixture during passage of the mixture through the venting zone in the extruder 12, and as such greater amounts of moisture may be present within the mixture during passage through the cooking zone, thereby reducing the amount of shear that would otherwise be imposed upon the same. Reducing the shear in the cooking zone decreases the tendency of the rehydrated rice product to undesirably agglomerate due to a sticky outer surface. Moreover, reducing the shear imposed on the mixture in the cooking zone lowers overall energy consumption of the extruder 12. The extruded products exhibit increased tolerance to overcooking without becoming either slimy or sticky, and conse quently the quality of the products is superior to products produced by known methods.

Utilization of a vacuum greater than 5 in. Hg. in the venting zone further reduces the amount of mechanical shear imposed on the mixture in the extruder by enabling even higher amounts of moisture, in the form of either tap water or steam, to be added to the mixture during advancement thereof along the cooking zone. The application of a vacuum at the venting zone also substantially prevents formation of air bubbles in the extruded product.

Other ingredients may be added to the rice and water mixture to enhance the characteristics of the extruded product. For example, leavening agents such as calcium phosphate and sodium phosphate may be added to the mixture before the latter enters the cooking zone or, alternatively, the agents may be pumped into the mixture downstream of the venting barrel section 32. These types of additives react with the materials comprising the mixture and cause gaseous bubbles to be formed within the extruded products, thereby slightly expanding the products and facilitating the entry of moisture during rehydration while decreasing the time necessary to accomplish the same. The process is not affected by the type of rice utilized and long grain, short grain or brown rice may all be used, alone or in various combination.

Fig. 3 represents for exemplary purpose a typical temperature profile of the mixture during advancement within the preconditioner 15 as well as along the length of barrel 14. As shown, the temperature of the mixture steadily increases during the travel through the preconditioner 15, and then only slightly increases in temperature during ad vancement through the cooking zone. The temperature of the mixture drops at the venting zone corresponding to barrel section 32, then steadily decreases as the mixture is advanced through the forming zone represented by barrel sections 34, 36, and drops further during passage through the die holes 70.In this example, about 40% of the cooking of the mixture occurs within preconditioner 15, while the remaining percentage of cooking occurs as a result of exposure to temperatures above about 180 DEG F during passage through the extruder 12.

Example 1

In this test, a starting flour mixture of 99.0% by weight long grain rice flour and 1.0% by weight

Myvaplex 600 surfactant was prepared. This dry mixture was then fed to a Wenger TX-80 double screw extruder equipped with a preconditioner and an auger feed hopper and processed to obtain a cooked rice product.

The TX-80 machine is of the type schematically illustrated in Fig. 1 and terminates in a double screw cone nose die head, but had a total of eight tubular heads or barrel sections.

A dry starting rice flour mixture (with a moisture content of 11% by weight) was fed into a preconditioner at the rate of 9.8 lbs. per minute and mixed with water introduced into the preconditioner at a rate of 1.0 lbs. per minute. The water and flour mixture in the preconditioner was raised in temperature by the injection of steam introduced at a rate of 0.40 lbs. per minute 30 psi.

Beaters in the preconditioner which may be pitched at different angles to provide a variety of possible residence times were rotated at a speed of 150 rpm and adjusted to retain the mixture in the preconditioner for 1.5 minutes. The mixture when discharged from the preconditioner had a temperature of 200 DEG F. and a moisture content of 23% by weight.

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Next, the mixture was fed into the inlet of the extruder at the entrance to the cooking zone, and tap water was introduced to the mixture at the rate of 1.45 lbs. per minute. (However, it is alternatively possible to introduce hot water of a temperature of about 180 DEG F. in order to reduce the required mass flow rate of steam.) In addition, 0.66 lbs. per minute of steam was introduced into the extruder at

125 psi, and the screws of the extruder were rotated at a speed of 150 rpm. The load of the extruder was

11.2 KW (kilowatts). The load on the extruder without the mixture present at 150 rpm was about 2.2

KW so that the increased load required by processing of the mixture therein was about 9.9 KW.

Temperatures of the advancing mixture within the twin barrels were maintained at 210 DEG F, 260

DEG F, 255 DEG F and 250 DEG F for the second, third, fourth and fifth barrel section respectively.

The moisture content of the flour and water mixture in the cooking zone of the extruder was about 36 percent by weight. The sixth barrel section included the vent opening which was subjected to a vacuum of 10-15 in. Hg. The forming zone of the extruder corresponded to seventh and eighth barrel sections, where the temperatures of the advancing mixture were 209 DEG F and 216 DEG F respectively.

Product rate through the extruder, including the total amount of water added in the preconditioner and the extruder, was 12.59 lbs. per minute. The pressure at the last barrel section adjacent the die was 500 psi, and moisture of the extruded product immediately downstream of the die was 25% by weight on a wet basis; therefore, the vacuum removes 11% moisture by weight of the extruded product. Total open area of the die was 0.6 square inches. The extruded products were cut by a knife to a length for resembling grains of rice, and advanced to a dryer. The products in the dryer were subjected to a temperature of 205 DEG F for 13 minutes, and the dried, extruded products had a final moisture content of 11% by weight. The product was reconstituted in about 7 to 8 minutes and exhibited good product integrity and palatability with no appearance of darkened, burned specks.

Example 2

A procedure was carried out substantially as in Example 1, except that the dry starting rice flour mixture was fed into the preconditioner at a rate of 8.311 lbs. per minute and mixed with water introduced into the preconditioner at a rate of 0.834 lbs. per minute. The water and flour mixture in the preconditioner was raised in temperature by the injection of steam introduced at a rate of 0.37 lbs. per minute at 30 psi. Beathers in the preconditioner were rotated at 175 rpm and adjusted to retain the mixture in the preconditioner for 1.5 minutes. The mixture when discharged from the precondition had a temperature of 208 DEG F and a moisture content of 26.88% by weight.

The flour and water mixture was then fed into the inlet of the extruder at the entrance to the cooking zone, and tap water was introduced to the mixture at a rate of 0.834 lbs. per minute. Steam was also introduced into the mixture at the cooking zone of the extruder at a flow rate of 0.59 lbs. per minute at

100 psi, and the screws of the extruder were rotated at a speed of 175 rpm. The load of the extruder was

20 KW, and the load on the extruder without the presence of the mixture at 175 rpm was about 2.2 KW so that the increased load required by processing of the mixture within the extruder was about 17.8

KW.

In the cooking zone of the extruder, the temperature of the advancing mixture was maintained at 176

DEG F, 200 DEG F, 200 DEG F, and 200 DEG F for the second, third, fourth and fifth barrel section respectively. The moisture content of the rice flour and water mixture in the cooking zone of the extruder was about 36.4% by weight. A vacuum of 15 in. Hg. was applied to a vent opening in the sixth barrel section. The forming zone of the extruder corresponded to the seventh and eighth barrel sections, and the temperature of the advancing mixture in the eighth barrel section was 169 DEG F.

The rate of product flow through the extruder, including the total amount of water added in the preconditioner and the extruder, was 10.94 lbs. per minute. The pressure at the seventh barrel section was 200 psi, while the pressure at the last barrel section adjacent the die was 500 psi. The moisture content of the extruded product immediately downstream of the die was 26.75% by weight on a wet basis. The extruded, cut products were advanced to a dryer and subjected to temperature of 125 DEG F

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for a totl of 30 minutes, and the dried products had a final moisture content of 12.53% by weight.Data supplied from the esp@cenet database - Worldwide Claims:


1. A low shear process for the production of quick cooking rice products comprising the steps of:

preparing a mixture of rice and water in a preconditioner by mixing said with said water and elevating the temperature of the mixture to a level of from about 150 DEG F to 210 DEG F and retaining said mixture in said preconditioner for a period of time in the range of about 20 seconds to about three minutes;

introducing said rice and water mixture into the barrel of an extruder equipped with a flighted, rotatable screw and an extrusion die;;

rotating said screw to sequentially advance said mixture along the length of said barrel first through a cooking zone, then through a venting zone and a forming zone, and finally through said extrusion die, to yield an extruded product,

said mixture having a temperature in the range of from about 180 DEG F to about 350 DEG F in said cooking zone and being subjected to pressures in the range of from about 200 psig to 1200 psig in the forming zone;

causing gaseous products to be vented in said venting zone; and

drying said extruded product to yield said quick cooking rice products.

2. The process of Claim 1, wherein said temperature of said mixture in said cooking zone is in the range of from about 210 DEG F to about 300 DEG F.

3.The process of Claim 2, wherein said temperature of said mixture in said cooking zone is in the range of from about 235 DEG F to about 265 DEG F.

4. The process of Claim 1, wherein said mixture comprises from about 80 to 60 by weight rice and from about 20 to 40 by weight water.

5. The process of Claim 1, including the step of subjecting said mixture to a vacuum in said venting zone.

6. The process of Claim 5, wherein said vacuum is of a level from about 5in. Hg to 20 in. Hg.

7. The process of Claim 1, said mixture having a temperature in the range of from about 130 DEG F to about 250 DEG F in said forming zone.

8. The process of Claim 7, wherein the temperature of said mixture in said forming zone is in the range of from about 180 DEG F to about 220 DEG F.

9.The process of Claim 1, wherein said drying step comprises the steps of subjecting the extruded product to a temperature in the range of from about 75 DEG F to about 250 DEG F for a period of from about 60 to about 10 minutes.

10. The process of Claim 1, wherein said drying step is carried out until the rice products have a moisture level in the range of from about 10% to about 12% by weight.

11. The process of Claim 1, including the step of injecting steam and/or water into said mixture as said mixture is advanced along the length of said cooking zone.

12. The process of Claim 1, said mixture having a residence time in said cooking zone of from about 10 seconds to about 25 seconds.

13. The process of Claim 1, said mixture having a residence time in said forming zone of from about 20 seconds to about 60 seconds.

14.The process of Claim 1, including the step of subjecting said mixture to indirect thermal interchange during advancement of said mixture along the length of said barrel.

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15. The process of Claim 1, wherein said step of venting said gaseous products includes the step of rotating a venting device screw in a venting passage communicating with said venting zone, said device screw having flights for biasing said mixture toward said barrel while enabling gaseous products to be vented through said passage.

16. The process of Claim 15, wherein said venting device has an area transverse to the rotational axis of said screw which increases in dimension in a direction away from said venting zone of said barrel for reducing the face velocity of any mixture portion flowing in said passage to substantially preclude escape of said mixture portion as said gaseous products are vented.

17. The process of Claim 1, said preconditioning step including the step of adding steam and water to said rice.Data supplied from the esp@cenet database - Worldwide

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253.

JP63287457 - 11/24/1988

PROCESSED 'KONJAK' FOOD AND PREPARATION THEREOF


Inventor(s): OGAWA IKUZO (--)

Applicant(s): MARUZEN SHOKUHIN KK (--)


IP Class: A23L1/212

E Class: A23L1/308; A23L1/0528



Family: JP63287457


Abstract:


PURPOSE:To prepare the titled food having palatability similar to noodles, pastas and cooked rices and free from smell of KONJAK (paste made from starch of devil's tongue), by adding specific amounts of water, soybean flour, proteinase, bittern, refined rice flour and coagulant for KONJAK to

KONJAK powder. CONSTITUTION:Soybean flour is dissolved in water of 30-50 deg.C to obtain a solution like soya milk, which is added with a proteinase and a colorant. The obtained 1st solution is left standing. Separately, bittern and refined rice flour are dissolved in small amounts of water to obtain the 2nd and the 3rd solutions. The 1st-3rd solutions are added to water and stirred. KONJAK powder is mixed to and dissolved in the mixture and the product is left standing when the solution becomes viscous. A coagulant is added to the solution and the mixture is kneaded and formed to a prescribed shape to obtain the objective food containing KONJAK powder, 25-70pts. of water (based on 1pt. of the KONJAK powder), 30-60% of soybean flour (based on the KONJAK powder), 5-15% of proteinase (based on the soybean flour), 0.5-3% of bittern (based on the KONJAK powder), 0.5-7% of refined rice flour (based on the KONJAK powder) and a coagulant.Claims:


What is claimed is:

1. A dietary foodstuff comprising: (a) glucomannan powder; (b) soybean powder, at 30-100% by weight glucomannan powder, that has been reacted with a protein hydrolysis enzyme, at 5-15% by weight soybean powder; (c) bittern, at 0.5-3% by weight glucomannan powder; (d) refined rice flour, at

0.5-7% by weight glucomannan powder; (e) water, at 10-70 times by weight glucomannan powder; and

(f) glucomannan powder coagulant, at 5-10% by weight glucomannan powder, soybean powder, enzyme, bittern, and rice flour.

2. The foodstuff of claim 1 wherein the protein hydrolysis enzyme is bromelain.

3. The foodstuff of claim 1 wherein the soybean powder is present at 30-60% by weight glucomannan powder.

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4. The foodstuff of claim 1 wherein the coagulant is present at 6-10% by weight glucomannan powder, soybean powder, rice flour, enzyme, and bittern.

5. The foodstuff of claim 1 wherein water is present at 25-70 times by weight glucomannan powder.

6. A process for making a dietary foodstuff comprising the steps of: (a) combining a protein hydrolysis enzyme and an aqueous solution of soybean powder and allowing the mixture to stand; (b) combining the mixture from step (a) with an aqueous solution of rice flour and an aqueous solution of bittern; (c) combining the resultant mixture of step (b) with glucomannan powder and allowing the mixture to stand; (d) kneading the resulting mixture of step (c); and (e) combining the kneaded mixture with an aqueous solution of glucomannan coagulant; wherein, based on the weight of glucomannan powder, the soybean flour is used at 30-100%, the rice flour is used at 0.5-7%, and the bittern is used at 0.5-3%, the enzyme is used at 5-15% by weight soybean powder, the coagulant is present at 5-10% by weight glucomannan powder, bittern, rice flour, soybean powder, and coagulant, and water is used at 10-70 times by weight of glucomannan powder.

7. The process of claim 6 wherein soybean powder is used at 30-60% by weight glucomannan powder.

8. The process of claim 6 wherein the coagulant is used at 6-10% by weight glucomannan powder, rice flour, soybean powder, bittern, and enzyme.

9. The process of claim 6 wherein water is used at 25-70 times by weight glucomannan powder.Data supplied from the esp@cenet database - Worldwide

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254.

JP7327628 - 12/19/1995

PRODUCTION OF FORMED POTATO CHIP


Inventor(s): YAMASHITA TETSUO (--); AKI MASATOSHI (--)

Applicant(s): CALBEE FOODS CO (--)


IP Class: A23L1/217

E Class: A23L1/217B



Family: JP7327628

Equivalent: GB2290216

Abstract:


PURPOSE:To obtain a formed potato chip, excellent in flavor and taste and hardly having harshness and bitterness by adding a thermally cooked potato and an oil and a fat, etc., to a dried potato as a main raw material, mixing the raw materials, rolling and forming the resultant mixture and then baking the formed mixture. CONSTITUTION:This method for producing a formed potato chip is to, as necessary, add and mix preferably 5-50wt.% modified starch such as a pregelatinized starch, a seasoning, etc., with preferably 30-90wt.% dried potato such as a potato granule or a potato flake, preferably 0.1-

60wt.% thermally cooked potato such as mashed potato and preferably 0.1-30wt.% oil and fat such as a shortening, add water thereto so as to provide 30-60wt.% moisture content in the final dough, afford a rice caky dough, then roll and form the prepared dough into a sheetlike shape having 0.5-2.0mm thickness and bake the formed dough at 100-300 deg.C for 2-20min.Description:


PROCESS FOR PRODUCING SHAPED POTATO CHIPS

The present invention relates to a process for producing shaped potato chips. More specifically, the present invention relates to a process for producing shaped potato chips by rolling a raw dough containing oils and fats to form a dough sheet, and baking a shaped dough obtained from the dough sheet without employing any frying step used in the conventional process.

Hitherto, potato chips have been produced by slicing raw potatoes in a proper size and frying them for sufficient time to heat them completely. However, the thus-obtained products generally have a high oil content of about 35% by weight since the water in potatoes is replaced by oils during the frying step.

Generally, the shaped potato chips which are now commercially available are those produced by forming a mixture of dried potatoes such as potato flakes and potato granules, and if necessary, additives such as starches and emulsifiers, and seasonings, and then frying this mixture. However, these products also have an oil content of about308 by weight.

Therefore, it has been desired to develop a new process to produce potato chips having a good taste and a good texture. On the other hand, it has been known that the potato chips produced by using dried

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potatoes as a main component have some disadvantages in that they have a dry grass smell, and also they are inferior in terms of inherent taste and flavour of potato itself as compared with potato chips produced by using raw potatoes.

The known processes for overcoming the above-mentioned disadvantages are described below.

For examples, Japanese Patent Publication (JP Kokoku) 61-13787 discloses a process for producing shaped potato chips comprising the steps of mixing potato powder with raw potato and if necessary, other ingredients, forming this mixture into chip and roasting or frying this chip. However, the thusobtained products have a disadvantage in that they have astringent taste and bitter taste since they are produced by using raw potatoes as a component.

Moreover, as a process for overcoming the above-mentioned disadvantages such as astringent taste and bitter taste of final products, Japanese Patent Application Laid-open (JP Kokai) 62-61540 discloses a process for producing shaped potato chips wherein heatcooked potatoes and potato flakes are used as main components.

However, the thus-obtained products have a disadvantage in that they have a high oil content as mentioned above, since this process comprises a frying step.

Furthermore, Japanese Patent Publication (JP Kokoku) 3-12869 discloses a process for producing potato snacks comprising the steps of mixing potato flakes, pregelatinized waxy starch and shortening, rolling this mixture into a sheet, and then baking the shaped small pieces obtained from the sheet.

However, this process has a disadvantage in that the products are inferior in terms of inherent taste of potato itself since potato flakes, pregelatinized waxy starch and shortening are used in this process.

Moreover, this process has other disadvantages in that the permeation of oil into final products is insufficient and that the oil is adhered to hands when picking up them, since the oil is sprayed thereon after baking.In addition, since pregelatinized waxy starch is very sticky, various limitations, such that it is necessary to use pregelatinized waxy starch at a low temperature and that of a low water content, are involved in order to keep certain operational efficiency.

A primary object of the present invention is to provide a process for producing shaped potato chips which makes it possible to produce shaped potato chips having inherent good taste of potatoes and easily control the oil content in final products of shaped potato chips, in particular, to adjust to a low oil content.

This and other objects of the present invention will be apparent from the following description and

Examples.

The present invention has been completed on the inventor's findingthat -there can be produced shaped potato chips having inherent good taste of potatoes wherein the oil content of the said shaped potato chips is easily adjusted, by the employment of the steps of mixing dried potatoes, heat-cooked potatoes and oils and fats as main components to obtain a dough, rolling the thus-obtained dough to form a dough sheet, and baking a shaped dough obtained from the dough sheet, based on the finding that steamed potatoes and oils and fats such as butter are compatible very well.

The present invention provides a process for producing shaped potato chips comprising the steps of mixing dried potatoes, heatcooked potatoes and oils and fats as main components, and moreover, if necessary, processed starches and seasonings, to obtain a dough, rolling the dough to form a dough sheet and baking a shaped dough obtained from the dough sheet.

In the process for producing shaped potato chips according to the present invention, dried potatoes, heat-cooked potatoes and oils and fats are used as main components. In addition, if necessary, additives such as processed starches, seasonings and water may be added thereto.

Examples of the dried potatoes used in the present invention include potato flakes, potato granules and potato flour which can be used in the conventional process for producing shaped potato chips.

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The dried potatoes are used in an amount of about 30 to about 90% by weight, preferably about 40 to about 70% by weight, based on the total weight of all raw materials before addition of water as mentioned below (Hereinafter, "the total weight of raw materials" is referred to as "the total weight of all raw materials before addition ofwater").

The heat-cooked potatoes are preferably mashed potatoes which are obtained by heat-cooking raw potatoes in order to gelatinize the starches of the potatoes and straining the resulting potatoes. More preferred are mashed potatoes obtained by heat-cooking raw potatoes to sufficiently gelatinize the starches thereof, soften the tissue of potatoes and reduce bitter components, and then, straining the resulting potatoes.

One example of the process for producing the heat-cooked potatoes used in the present invention comprises the steps of peeling raw potatoes, slicing them into the thickness of 5 to 25mm, heating them for 5 to 60 minutes with steam or hot water and the like, and straining them. The purpose of using not raw potatoes themselves but heat-cooked potatoes is to get sufficient gelatinization of the starches, to soften the tissue and to reduce astringent and bitter components. Therefore, potatoes may be cut into dice of5mm to 30mm and heat-cooking may be carried out using other means such as a microwave device.

The heat-cooked potatoes are generally used in an amount of about 0.1 to about 60% by weight, preferably about 20 to about 50% by weight based on the total weight of raw materials.

Moreover, a ratio of dried potatoes to heat-cooked potatoes may be suitably adjusted. In this connection, it is preferable that the ratio by weight of dried potatoes/heat-cooked potatoes is generally adjusted in the range of about 99.9/0.1 to about 40/60, more preferably about 80/20 to about 40/60.

Examples of oils and fats include shortening. Though the kinds of oils and fats are not particularly limited, it is preferred to use one which is solid at room temperature, and it is more preferred to use one whose melting point is not lower than30 C .

The oils and fats are generally used in an amount of about 0.1 to about 30% by weight, preferably about 5 to about 15% by weight based on the total weight of raw materials. When more than 30% by weight of oils and fats are added, the binding properties of the dough decreases, whereas when less than 0.1% by weight of oils and fats are added, the potato chips of final products become stiff and powdery.

In the process for producing shaped potato chips according to the present invention, if necessary, processed starches may be added in addition to the main components as mentioned above. The kind and amount of processed starches may be suitably selected depending on properties and amounts of other components and the like.

For example, as compared with the case using potato granules, the use of potato flakes results in the decrease of viscosity of dough sheet at the time of adding oils and fats thereto, which makes it difficult to form the dough sheet. Moreover, the use of heat-cooked potatoes immediately after heat-cooked treatment also results in the decrease of viscosity of sheet at the time of adding oils and fats thereto, which makes it difficult to form the dough sheet. Therefore, when the content of potato flakes and heatcooked potatoes is high, the sheeting can be carried out by adding pregelatinized waxy starch in an amount of about 5 to about 20% by weight based on the total amount of raw materials.On the other hand, when the content of potato granules is high, the decrease of viscosity of dough sheet scarcely occurs as compared in the case of high content of potato flakes or heat-cooked potatoes. In other words, when the content of potato granules is high, if pregelatinized waxy starch is used in the same amount as mentioned above, the dough becomes too sticky. Therefore, it is preferred to use pregelatinized starch of nonwaxy type to form a suitable sheet.

As processed starches, there can be generally used pregelatinized starch and also modified starch derivatives such as acetate, ether or ester. Examples of the pregelatinized waxy starch include pregelatinized waxy-maize starch and pregelatinized waxyglutinous rice starch. The content of processed starch is suitably adjusted depending on the kinds of a selected processed starch and the

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amount of other mixed components and it is generally in the range of about 5 to about 50% by weight, preferably about 5 to about 20% by weight, based on the total weight of raw materials.

Moreover, if necessary, subcomponents, for example, seasonings such as salts and sugar, emulsifiers, expansion agents, spices, coloring agents, may be suitably added. The content of these subcomponents are not particularly limited, and they are generally in the range of about 0.1 to about 10% by weight based on the total amount of raw materials.

Then, these components are mixed. Preferably, before or during mixing, a sufficient amount of water is added so that the water content of the dough becomes in the range of about 30 to about 60% by weight, preferably about 45 to 55% by weight, most preferably about 50% by weight. The amount of water to be added may be suitably adjusted according to the contents of heat-cooked potatoes and dried potatoes. Therefore, as the content of heat-cooked potatoes (whose water content is generally relative high) increases, the amount of water to be added decreases (it can be zero), and as the content of dried potatoes increases, the amount of water to be added increases.

Preferably, the water to be added is cold water. Moreover, preferably, water is added only in the necessary amount since it is desirable to utilize as much water from heat-cooked potatoes as possible.

After mixing the above-mentioned components uniformly, the mixture is kneaded in a mixer for about

5 to about 60 minutes. It is preferred to use a type of mixer wherein strongly kneading can be carried out in order to increase the binding properties of the dough.

Moreover, the kneading process may be preferably carried out with cooling, since the viscosity of sheet unpreferably increases when the temperature of sheet increases to much higher than the melting point of oils and fats such as shortening or the kneading is carried out for a long period of time.

The dough obtained by the foregoing process is rolled into the sheet of the thickness of about0.5mm to about 2.Omm, preferably about 0.8mm to1.5mm, and then, the resulting sheet is subjected to cutting, stamping and/or punching or the like to form pieces of appropriate shape. The sheet can be formed into any shape such as a round, a triangle, a star and a stick shape by means of cutting, stamping or punching.

Then, the thus-obtained shaped products are baked generally at a temperature of about100or to about300"C for about 2 minutes to about 20 minutes, and preferably at a temperature of about1800C to about280"C for about 3 minutes to about 13 minutes.

In this baking process, the expanding and drying of the products are carried out. At the same time, the defects such as warps, cracks and large air bubbles occur in the products. However, these defects can be prevented by putting the pieces of sheet into a desired mold when the pieces are passing through a baking device. Moreover, when the products are on a flat hot plate in an oven, the abovementioned problems can be prevented in some degree by making some pin holes in the pieces of the sheet.

Seasoning after baking is not particularly necessary since oils and fats and seasonings are contained in the sheet. However, if necessary, dusting of chocolate and cheese, and spraying of seasonings and oils and fats may be carried out.

Example

After washing raw potatoes and peeling the potatoes, the potatoes were sliced into the thickness oflOmm. Then, the sliced potatoes were steamed under the atmospheric pressure for 20 minutes and were strained with a masher to obtain heat-cooked mashed potatoes. To 1,750g of a mixture of powdery components which is composed of 1,375g of potato granules (corresponding to 55% by weight of the total weight of the sheet before addition of water) and 375g of pregelatinized starch

(corresponding to 15% by weight of the total weight of the sheet), and 250g of shortening

(corresponding to 10% by weight of the total weight of the sheet), there was added 500g of the aboveobtained heat-cooked mashed potatoes (corresponding to 20% by weight of the total weight of the sheet), mixed and kneaded to obtain a dough.In this connection, during the mixing, 1,500g of cold water was added to adjust the water content of the dough to 50% by weight.

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Then, the dough was rolled with a roller into the thickness of 0.9mm and the resulting sheet was stamped into a round shape. Then, the thus-obtained stamped pieces were baked in an oven to obtain shaped potato chips. The baking was carried out at first at 270"C to expand the chips, and then at19000.

Comparative Example 1

To 1,875g of potato granules (corresponding to 75% by weight of the total weight of the sheet before addition of water), 375g of pregelatinized starch (corresponding to 15% by weight of the total weight of the sheet) and 250g of shortening (corresponding to 10% by weight of the total weight of the sheet), there was added 2,200g of cold water, mixed, kneaded and processed in the same manner as in

Example to obtain shaped potato chips.


After washing raw potatoes and peeling the potatoes, the potatoes were cut into dice of 5mm. The same process as in Example was carried out except that this cut potatoes were used in the same amount instead of the heat-cooked mashed potatoes in Example.

In this case, the blocks of potatoes have remained in the sheet without being perfectly rolled by a roller. As a result, the cracks and holes therefrom occur in the sheet and uniformly sheet can not be obtained.

Moreover, when the thus-obtained non-uniform sheet was baked, uneven baking and cracks occur since the thickness of the sheet is not uniform, and as a result, satisfactory products cannot be obtained.


After washing raw potatoes and peeling the potatoes, the potatoes were grinded. The same process as in Example was carried out except that these potatoes were used in the same amount instead of the heat-cooked mashed potatoes in Example to obtain shaped potato chips.

Sensory Test for taste evaluation

With respect to the above-obtained products (Example,

Comparative Examples 1 and 3), sensory test for taste evaluation was carried out by 10 persons.

The presence of undesirable tastes such as astringent taste or bitter taste and the presence of nasty smell were examined for the products of Example, Comparative Examples 1 and 3. The obtained result was shown in Table 1

Table 1

EMI11.1

>;tb; Example >;SEP; Comparative >;SEP; Example >;SEP; 1 >;SEP; Comparative >;SEP; Example

>;SEP; 3

>;tb; >;SEP; 0 >;SEP; 7 >;SEP; 7

>;tb;

The numbers in the Table 1 represent the number of persons who said that the products have'undesirable tastes or nasty smell.

In this connection, it was pointed out that there were artificial smell and dry grass smell in

Comparative Example 1 and there were bitter taste or astringent taste in Comparative Example 3.

Moreover, in order to compare the product obtained by using heat-cooked potatoes with that obtained by using raw potatoes, (1) the presence of astringent taste or bitter taste, and (2) which product has a more preferred taste of potatoes, were examined for the products of Example and Comparative

Example 3. The obtained result was shown in Table 2.

Table 2

EMI11.2

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>;tb; >;SEP; Example >;SEP; Comparative

>;tb; >;SEP; Example >;SEP; 3

>;tb; (1) >;SEP; Astringent >;SEP; or >;SEP; bitter >;SEP; taste >;SEP; 3 >;SEP; 9

>;tb; (2) >;SEP; More >;SEP; preferred >;SEP; taste >;SEP; of >;SEP; potatoes >;SEP; 8 >;SEP; 2

>;tb;

The results of Tables 1 and 2 demonstrate that the potato chips obtained by the process for producing shaped potato chips according to the present invention have excellent taste properties.

According to the present invention, one can form an uniform dough sheet and produce shaped potato chips having increased taste and flavour of potato itself and decreased astringent and bitter taste and not being powdery, and furthermore, one can control the oil content in final products of shaped potato chips, in particular, to a low oil content.Data supplied from the esp@cenet database - Worldwide

Claims:


CIAIMS

1. A process for producing shaped potato chips comprising the

steps of mixing dried potatoes, heat-cooked potatoes and oils and

fats, and moreover, if necessary, processed starches and

seasonings, to obtain a dough, rolling the dough to form a dough

sheet and baking a shaped dough obtained from the dough sheet.

2. The process of claim 1 wherein the heat-cooked potatoes are

those obtained by heat-cooking raw potatoes to gelatinize the

starches of the potatoes, and then, straining the thus-obtained

potatoes.

3. The process of claim 1 wherein the dried potatoes are one or

more selected from the group consisting of potato granules, potato

flakes and potato flour.

4. The process of claim 1 wherein a sufficient amount of water is

added before: or during mixing so that water content of the dough

becomes in the range of about 30 to about 60% by weight.

5. The process of claim 4 wherein a content of the dried potatoes

is in the range of about 30 to about 90% by weight based on the

total weight of all raw materials before addition of water.

6. The process of claim 4 wherein a content of the heat-cooked

potatoes is in the range of about 0.1 to about 60% by weight based

on the total weight of all raw materials before addition of water.

7. The process of claim 5 wherein the content of the heat-cooked

potatoes is in the range of about 0.1 to about 60% by weight based

on the total weight of all raw materials before addition of water.

8. The process of claim 1 wherein a ratio by weight of dried

potatoes to heat-cooked potatoes is in the range of about 99.9/0.1

to about 40/60.


potatoes to heat-cooked potatoes is in the range of about 99.9/0.1

to about 40/60.


potatoes to cooked potatoes is in the range of about 99.9/0.1 to

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about 40/60.

11. The process of claim 4 wherein a content of oils and fats is

in the range of about 0.1 to about 30% by weight based on the total

weight of all raw materials before addition of water.

12. The process of claim 7 wherein a content of oils and fats is

in the range of aboutO.l to about 30% by weight based on the total

weight of all raw materials before addition of water.

13. The process of claim 1 wherein the processed starch is

pregelatinized starch or modified starch derivatives.

14. The process of. claim 1 wherein the processed starch is

pregelatinized and modified starch derivatives.

15. The process of claim 4 wherein a content of the processed

starch is in the range of about 5 to about 50% by weight based on

the total weight of all raw materials before addition of water.

16. The process of claim 7 wherein a content of the processed

starch is in the range of about 5 to about 50% by weight based on

the total weight of all raw materials before addition of water.

17. The process of claim 1 wherein the dough is rolled into the

thickness of0.5mm to 2.Omm to form a dough sheet and the sheet is

shaped by cutting, stamping or punching.

18. The process of claim 1 wherein the shaped dough is put into a

mold during baking step.

19. The process of claim 1 wherein the baking of a shaped dough is

carried out at100"C to300"C for 2 to 20 minutes.

20. A process for producing shaped potato chips comprising the

steps of mixing dried potatoes, heat-cooked potatoes, oils and fats

and pregelatinized starch with water to obtain a dough, rolling the

dough to form a dough sheet of about 0.5mm to about 2.0mm, cutting

or stamping or punching the dough sheet into shaped pieces and

baking the shaped pieces at 100"C to300"C for 2 to 20 minutues.

21. A process substantially as hereinbefore described.Data supplied from the esp@cenet database -

Worldwide

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255.

JP8214829 - 8/27/1996

PRODUCTION OF POWDERY SEASONING


Inventor(s): NISHINOMIYA TAKESHI (--); YAMAMOTO HIROSHI (--); YAMAURA

TSUTOMU (--); KATAOKA JIRO (--); NANATANE TADAAKI (--)

Applicant(s): AJINOMOTO KK (--)


IP Class: A23L1/238; A23L1/23

E Class: A23L1/238; A23L1/223



Family: JP8214829

Equivalent: EP0727153; US5980957; CN1135853

Abstract:


PURPOSE: To obtain a powdery seasoning capable of preventing caking or deteriorating by reacting a

KOJI (malted rice) cultured product with a vegetable protein, mixing the resultant hydrolyzate with a liquid seasoning and spray-drying the resultant mixture. CONSTITUTION: A cultured product prepared by culturing a KOJI mold in defatted soybeans undergoing puffing heat treatment is kept under oxygen active conditions in a saline solution and a liquid fraction is then separated from the resultant reactional product. The obtained liquid fraction is subsequently mixed with a liquid seasoning and the resultant mixture is spray-dried. Thereby, a favorable taste and flavor can be preserved for a long period and the powdery seasoning is useful as a seasoning, etc., for instant foods.

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256.

JP8289750 - 11/5/1996

MANUFACTURE OF INSTANT RICE NOODLE


Inventor(s): TEIAN SENGU TO (--)



IP Class: A23L1/10; A23L1/16; A23L1/162

E Class: A23L1/16


Priority Number: SG19950000311 (19950422)

Family: JP8289750

Equivalent: EP0738473; US5786018; OA10284; RU2170031; NO961565; ES2164827T;

CN1146294; AU715708

Abstract:


PROBLEM TO BE SOLVED: To provide a title product provided with firm texture and smooth taste, etc., with a strong binding property without using a cooker/extruder and without immersing rice in water for a long time before alpha -ing by a specified method. SOLUTION: The rice (the long grain rice of amylose content 22-27 wt.% preferably) is preliminarily immersed in excessive water, then steamed and partially gelatinized first preferably. Then, after forming preliminarily processed rice powder by the method of performing pulverization and sieving preferably, the small amount of corn starch and ion gelatinizer are added preferably. Then, noodles are formed by extruding dough composed by mixing the rice powder and hot water by a 1-axis extruder preferably, then divided and molded into a nest or a cake preferably. Further, it is steamed for 30-60 minutes preferably and then, branched by the hot water (the one of 90-98 deg.C preferably). Finally, it is dried under the preferable condition at 55-60 deg.C and having relative humidity 30-35% and a moisture content is made >;=15 wt.%.Description:


The present invention relates to a process for the preparation of rice noodles, more particularly instant rice noodles.

The domestic and small-scale production of rice noodles has long been widespread in Eastern riceproducing countries. The processes which are used vary from one region or from one country to another, but they are all based on a small number of basic operations which are linked and/or repeated as dictated by the local traditions and also as a function of the particular qualities of the local types of rice. The fundamental problem is to confer to the rice dough the cohesion which it lacks. The low protein content of the rice on the one hand and the very nature of these proteins on the other hand means that it is impossible to produce a network with rice which is comparable to that formed by wheat gluten in such products as bread or pasta.In order to replace this network in which the starch grains are embedded, it is necessary to either use binders, or to subject the starch grains to treatments, to that they are capable on their own of forming a mass having the necessary cohesion. These problems of cohesion

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are re-encountered at the stage of working the fresh pasta dough as well as at the stage of the reconstitution and consumption of the final product.

The number of conventional and typical basic operations may include for example soaking the grains of rice, wet milling, pre- and post-gelatinisation, cooling and mechanical working of the dough. Thus, a typical, conventional process includes the successive stages of soaking a ground rice over a period of several hours, e.g. 4-6 hours, pre-gelatinisation, cooling, extrusion, post-gelatinisation and drying.

Moreover, the following may be mentioned as conventional binders which have been proposed: egg proteins, soluble proteins of whey, or wheat gluten, for example. In particular, processes are known in which ground rice is used combined with wheat flour, which is not obvious, because if ground rice mixed with wheat flour is pregelatinised, the wheat gluten is denatured and it is no longer possible to shape the dough.

EP-A-105100 describes a process for the production of rice pasta including gelatinisation, extrusion and drying, which comprises mixing a rice flour in a cooker-extruder with soft water and an ionic gelling agent such as an alginate to obtain a dough containing from 35 to 55 % of water, gelatinising the dough by heating and kneading under a pressure of from 70 to 100 bar at a temperature of from 60

DEG to 100 DEG C over a period of 20 to 120 seconds, cooling the dough to a temperature below 100

DEG C, extruding it in the form of pasta, bringing the pasta into contact with water containing a cation such as divalent calcium which forms a gel with the ionic gelling agent, and drying the pasta.

In the process of EP-A-105100 the cation is used to set the ionic gelling agent which forms a network in a similar way to gluten and confers to the rice dough the cohesion that it lacks.

We have now devised a process for the preparation of instant rice noodles in which a cooker-extruder is not required, the rice does not require soaking for several hours before pre-gelatinisation, and the process can be carried out in the substantial or complete absence of an ionic gelling agent and of a cation which forms a gel with the ionic gelling agent.

According to the present invention there is provided a process for the production of instant rice noodles which comprises

a) steaming rice to partially gelatinise the starch and to form a pretreated rice flour

b) mixing the pretreated rice flour with hot water to obtain a dough ,

c) extruding the dough to form the noodles

d) steaming the noodles

e) blanching the steamed noodles in hot water, and

f) drying the noodles to a moisture content below 15 % by weight.

The rice that is used may be rice flour or whole rice. Preferably, the rice used is a long grain rice with a high amylose content, e.g. containing from 21 to 28 % and preferably from 22 to 27 % amylose by weight.

The steaming of the rice should pregelatinise some, but not all, of the starch, e.g. from 20% to 90%, preferably from 60% to 80%. This partial pregelatinisation provides an increase in the water binding capacity of rice flour during dough preparation and reduces the stickiness of the dough during extrusion.

The steaming treatment may be carried out over a period of from 10 minutes to 1 hour and preferably from 20 to 45 minutes. The temperature of the steam may be from 85 DEG to 100 DEG C and preferably from 90 DEG to 100 DEG C. The steaming treatment is preferably carried out in a screw steam blancher to make the pretreatment more continuous in which the rice is steamed in the jacketed housing while being transported along the screw conveyor. Immediately after steaming the rice has an increase of from about 3-6 % moisture, usually from 4-5 % by weight.

If desired, the rice may be presoaked in excess water, e.g. for up to 1 hour, preferably from 15 to 45 minutes, before steaming. The amount of water used is advantageously at least 0.8 parts by weight per part by weight of rice.

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After the steaming treatment the rice is milled and sifted to give a pretreated rice flour. The milling and sifting way be carried out by conventional means. For example the mill used way have a screen opening size of from 0.25 to 0.75 mm, for instance from 0.3 to 0.6 mm. The sifting may be carried out by a centrifugal sifter. If rice flour is used as the starting material, milling is not necessary but sifting may be carried out to eliminate any coarse particles which could block the die holes during extrusion.

After milling and sifting, the moisture content of the pretreated rice flour is usually from 10 to 15% by weight.

The average particle size of the pretreated rice flour after milling and sifting way vary from about 0.1 mm to 0.5 mm depending on the screen opening size of the mill. Within this range, rice noodles made from rice flour having a finer particle size are firmer in bite and smoother in mouthfeel whereas rice noodles made from rice flour having a larger particle size are shorter in bite, rougher in mouthfeel and are more raw in taste.

The pretreated rice flour is advantageously mixed with a minor amount of a starch such as potato starch or corn starch before being made into a dough to give a smoother mouthfeel to the noodle. The amount of the starch may be from 5 to 30 % by weight and preferably from 10 to 25 % by weight based on the total weight of the mixture. Advantageously, a small amount of an ionic gelling agent such as an alginate, e.g propylene glycol alginate may be added for the dough preparation. The amounts added may be from 0.01 to 0.5 %, preferably from 0.025 to 0.25 % and especially from 0.05 to 0.15 % by weight based on the weight of the rice flour. The ionic gelling agent may be premixed with the rice flour or predissolved in hot water before the pretreated rice flour is mixed with the hot water to form the dough.

The amount of hot water added to the pretreated rice flour mixture may be from 25 to 65 % by weight, preferably from 30 to 60 % by weight and more preferably from 35 to 55 % by weight based on the total weight of the dough formed. The temperature of the hot water may be from 80 DEG C to boiling, preferably from 85 DEG to 100 DEG C and especially from 90 DEG to 95 DEG C. The duration of the mixing of the hot water with the pretreated rice flour mixture may be, for example, from 1 to 20 minutes, preferably from 1.5 to 10 minutes and more preferably from 2 to 5 minutes. The use of hot water further gelatinises the starch by from 5% to 30% in order to enhance the binding of the dough for better subsequent extrusion.It should be understood that the starch should not become completely gelatinised, otherwise the dough would become lumpy and difficult to extrude continuously and consistently.

The extrusion of the dough to form the noodle may be carried out in a ram extruder or a double screw extruder but is preferably carried out in a single screw extruder. The diameter of the nozzle may be, for example, from 0.25 to 1.5 mm and preferably from 0.5 to 1.0 mm and especially from 0.6 to 0.9 mm.

The use of a nozzle with a larger diameter enables a better processability because a lower extrusion pressure can be used and there is thus less back flow, less shearing and a higher capacity.

Preferably, after extrusion, the noodle is portioned and formed into a nest or cake. The portioning involves cutting the noodle into strips or strands having a length of from about 7 cm to 50 cm, preferably from 20 to 40 cm. The portioned strands may be formed into a nest by folding and intertwining a plurality of strands into either a roughly spherical shape sowewhat similar to a bird's nest or into a roughly square shape to form a cake. The formation of a nest or cake may be carried out in a perforated tray. The weight of the nest or cake may be from 15 to 100 g, more usually from 20 to 80 g, for example from 25 to 65 g. The volume of the nest or cake may be from about 50 cm>;3; to about

270 cm>;3;.

The steaming of the noodles is performed to firm up the surface and structure and may be carried out for a period of from 5 to 75 minutes, preferably from 20 to 70 minutes and especially from 30 to 60 minutes. The temperature of the steam may be from 85 DEG to 100 DEG C and preferably from 90

DEG to 100 DEG C. Saturated steam or steam at atmospheric condition may conventiently be used, if desired.

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We have found that shorter steaming times, particularly from 5 to 20 minutes, lead to weaker noodle strands which may break up on rehydration. However, when the rice is presoaked in water before steaming or an ionic gelling agent is added to the dough, this disadvantage is avoided.

The blanching of the steamed noodles is carried out to complete or substantially complete the starch gelatinisation. The temperature of the hot water may be from 80 DEG C to boiling, preferably from 85

DEG to 100 DEG C and especially from 90 DEG to 98 DEG C. The duration of the blanching may be from 1 to 60 seconds, preferably from 5 to 45 seconds and more preferably from 10 to 30 seconds.

In the absence of a blanching step, the rehydrated rice noodles are raw in taste and the noodle strands tend to stick together.

After blanching, excess water may be drained away, e.g. by sieving, vibrating or air blowing.

Finally, the noodles are dried to give instant rice noodles, preferably to a moisture content of from 3 to

13 % by weight e.g. from 5 to 10 % by weight. Although the drying may be carried out by any conventional method, moderate drying conditions are preferred to avoid cracking on the noodle strands after drying. Although a temperature from 50 DEG to 80 DEG C for a period of from 30 minutes to 5 hours may be suitable, we have found that lower drying temperatures in humid conditions lead to a better product. The temperature is preferably from 50 DEG to 70 DEG C, more preferably from 55

DEG to 65 DEG C and especially from 55 DEG to 60 DEG C. The relative humidity is preferably from 20 to 50 %, more preferably from 25 to 40 % and especially from 30 to 35 %. The duration of the drying is preferably from 1 to 3 hours and more preferably from 1.5 to 2.5 hours.

The instant rice noodles prepared according to this invention may be reconstituted for consumption by placing in boiling water and soaking with the heat turned off or continuing to boil for from 0.5 to 5 minutes, preferably from 1 to 3 minutes. They may also be reconstituted for consumption by adding to an appropriate amount of water, e.g. boiling water and heating at high power from 1 to 4 minutes, preferably from 2 to 3 minutes or cold tap water at 20 DEG to 25 DEG C and heating in a microwave oven, e.g. at high power from 2 to 5 minutes, preferably from 3 to 4 minutes. Shorter reconstitution times within the above range may be used for thinner noodles.

The solid losses of the reconstituted noodle are acceptable, e.g. from 0.7 to 2.5 % but we have found that the solid losses during reconstitution can be reduced and a firmer bite may be obtained by using rice which has been presoaked in excess water for up to 1 hour before steaming or by adding an ionic gelling agent to the dough as described above.


Example 1

Long grain rice having an amylose content of 23 % by weight and a moisture content of 13 % by weight is steamed at 100 DEG C in a screw steam blancher for 30 minutes at a rate of 1.5 kg per minute after which the moisture content increases by 5 % and the degree of gelatinisation is 22.5%.

The pretreated rice is then milled in a Fitz Mill (a comminuting machine made by the Fitzpatrick

Company with the cutting blades rotating at 4600 rpm) having a screen opening size of 0.31 mm and sifted to give a rice flour having a moisture content of 11 %, 60.3 % of which has a particle size between 0.150 and 0.315 mm and 39.0 % of which has a particle size of less than 0.150 mm.

The pretreated rice flour is mixed with corn starch in a 4:1 ratio and prepared into a dough with a 60 % solids content by mixing with water at 90 DEG C for 3 minutes in a Stephan mixer (Model : UM 40 E-

GNI) which is a vertical single shaft mixer with the shaft turning at 3000rpm. The temperature of the dough after mixing is 65 DEG C.

The dough is extruded into noodle strands through a single screw extruder at 50 bar pressure whose die nozzle diameter is 0.7mm. The noodle strands are cut into 30 cm length and then a plurality of strands are folded and intertwined to form a nest having a weight of 50 g and a volume of 270cm>;3;.

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The nest is steamed with saturated steam for 30 minutes and then blanched in water at 90 DEG C for

20 seconds to complete the gelatinisation of the starch. The blanched nest containing 51 % moisture is drained of excess water by sieving and then dried in a hot air oven for 2 hours at a temperature of 55

DEG to 60 DEG C and at a relative humidity of 30 to 35 % to give the instant rice noodles having a moisture content of 8 % by weight.

On reconstitution for consumption by boiling in water for 1 minute (cooking method), the instant noodles have a firm and clean bite, slightly rough texture, good texture folding, a long strand and slight leaching.

On reconstitution for consumption by soaking in boiling water in a covered vessel for 2 minutes

(soaking method), the instant noodles have a firm, clean and rubbery bite, slightly rough textrure, good texture holding, long strand and no leaching.

Example 2

A similar procedure to that described in Example 1 was followed except that 0.1 % by weight of propylene glycol alginate based on the weight of the pretreated rice flour is added to the dough and steaming of the nest is carried out for only 10 minutes.

On reconstitution for consumption by both the cooking and soaking methods, the instant rice noodles have similar properties to those of Example 1.

Example 3

A similar procedure to that described in Example 1 is followed except that rice flour is used instead of long grain rice and eliminating the milling step.

On reconstitution for consumption by both the cooking and soaking methods the instant rice noodles have similar properties to those of Example 1.

Example 4

A similar procedure to that described in Example 1 is followed except that the long grain rice is presoaked for 30 minutes, drained, and then steamed for 10 minutes instead of 30 minutes in the screw steam blancher at a rate of 2.3 kg per minute to give a degree of gelatinisation of 87.9 %.

On reconstitution for consumption by the cooking method, the instant rice noodles have a firm clean and bouncy bite, smooth mouthfeel, good texture holding, long strand and slight leaching.

On reconstitution for consumption by the soaking method, the instant rice noodles have a firm, clean, bouncy and slightly rubbery bite, smooth mouthfeel, good texture holding, long strand and no leaching)


A similar procedure to that described in Example 1 was followed except that the blanching step was omitted. When the noodles were reconstituted for consumption, they were very sticky and had a raw taste.Data supplied from the esp@cenet database - Worldwide Claims:


1246/2197

1. A process for the production of instant rice noodles which comprises

a) steaming rice to partially gelatinise the starch and to form a pretreated rice flour,

b) mixing the pretreated rice flour with hot water to obtain a dough

c) extruding the dough to form the noodles

d) steaming the noodles

e) blanching the steamed noodles in hot water, and

f) drying the noodles to a moisture content below 15 % by eight.

2. A process according to claim 1 wherein the rice used is a long grain rice containing from 21 to 28 % by weight of amylose.

3. A process according to claim 1 wherein, before steaming, the rice is presoaked in excess water.

4. A process according to claim 1 wherein, after steaming, the rice is milled and sifted to form a pretreated rice flour.

5.A process according to claim 1 wherein the pretreated rice flour is mixed with a minor amount of corn starch before being made into the dough.

6. A process according to claim 1 wherein an ionic gelling agent is premixed with the rice flour or predissolved in hot water before the pretreated rice flour is mixed with the hot water to form the dough.

7. A process according to claim 1 wherein, after extrusion, the noodle is portioned and formed into a nest or cake.

8. A process according to claim 1 wherein the steaming of the noodles is carried out for a period of from 5 to 75 minutes.

9. A process according to claim 1 wherein the blanching of the steamed noodles is carried out to complete or substantially complete the starch gelatinisation.

10. A process according to claim 1 wherein the blanching is carried out in water at a temperature from

80 DEG C to boiling for a period of from 1 to 60 seconds.

11. A process according to claim 1 wherein drying of the noodles is carried out at a temperature from

50 DEG to 70 DEG C at a relative humidity of from 20 to 50 % over a period of from 30 minutes to 5 hours.Data supplied from the esp@cenet database - Worldwide

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257.

KR8900398 - 3/16/1989

FOOD PRODUCT AND METHOD OF MANUFACTURE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=KR8900398

Inventor(s): GALLE EDWARD L (US); ROY G HYLDON (US); EGAR WILLIAM P (US)

Applicant(s): PILLSBURY CO (US)


IP Class: A23L1/195

E Class: A23L1/16; A23L1/168; A23L1/216B

Application Number: KR19820003745 (19820820)


Family: KR8900398


Abstract:

Abstract of KR8900398

A method for preparing starch food is provided. Thus, 1kg of vacuum dried potato (starch content=80%) is ground and hydrated to give 40% H2O content. This blend is pressed at 47[not

>;==]C by standard demaco S-25 laboratory extruder and sliced to give rice-shaped potato followed by steaming at 119[not >;==]C and 15 psig for 3min and drying at 203[not >;==]C for 1.0min to give 10%

H2O content. 40g of the dried granules was placed in a cup contg. boiled H2O to give a final product, which has the same flavor and tissue as potato.Description:


In the rice industry, after the rice is harvested and is being prepared for processing and packaging, many of the rice kernels are broken or otherwise damaged. It has been common practice to separate the good rice kernels from the brokens. The brokens are then sold as rice brokens or brewers grits which bring substantially lower prices than whole kernel rice. Brokens are then used for purposes other than providing consumable rice, such as brewing or rice flour. It would be desirable then to provide a process for utilizing these brokens to upgrade their value.

The present invention provides a rice or other starch based product and a method of manufacture which can utilize rice brokens and make a rice product which is almost identical in appearance and taste of whole kernel rice. It has been found that by practicing the present invention, a rice product can be provided which is equal to and in some regards better than whole kernel rice while still being economical to produce and sell. One advantage provided by the present invention is that the final product is quick cooking, similar to those products referred to as "instant rice".

The processing of rice brokens is discussed in U.S. Pat. No. 3,071,471. In this patent, rice is first crushed to a size of 1/64 to 3/32 of an inch, after which the crushed rice is extruded and cut to form rice-like pieces. Prior to extruding, the pieces are steamed apparently to facilitate extruding. After extrusion, the formed pieces are dried before packaging. The product produced by such a process has attendant problems typical of which are: pasty, non-rice texture (poor eating quality), lack of cooking or steam-table tolerance and inconvenient preparation, requiring special utensils (e.g. "vaporizer") not normally found in a kitchen.

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The present invention so far as it relates to rice provides a rice product and a process of manufacture which overcome the problems attendant with the use of processes such as that disclosed in the cited patent. The rice product unexpectedly has fast cooking properties and steam-table tolerance. The process also produces a rice product which has the following advantages: rice-like texture which can be controlled to simulate any type of rice, e.g. long grain, parboiled or short grain; excellent steam-table tolerance equivalent to parboiled, rice; and convenient, one-step preparation, add to boiling water and let stand for 10 minutes.

The process was designed for utilizing rice brokens and other rice bits which heretofore have been sold at substantially reduced prices as they were not considered consumable since they were broken.

Further, the process is adaptable to high, starch-containing blends and other cereal grains. However, for the sake of expedience, the term "rice" will be used hereinafter and is to be construed to mean rice

(long, medium and short grain), wheat, corn (both white and yellow), millet, oats, triticale, barley, rye, sorghum (milo), and starch-based products such as potatoes and cassava, or mixtures of the above etc.

OBJECT OF THE PRESENT INVENTION

A principal object of the present invention is to provide a process for utilizing rice brokens or whole kernels to produce a rice product of higher value without loss of nutrients. Another object of the present invention is to provide a rice product which is fast cooking, convenient, and tolerant to variations in home preparation. Another object of the present invention is to provide a rice product which has good steam-table tolerance which will permit being held long periods of time before consumption with minimal deleterious effects on the product. A still further object of the present invention is to provide a process which is straighforward and can utilize exiting manufacturing equipment.

Other objects and advantages of the present invention will become apparent from the following detailed description taken in connection with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of the present invention.

DETAILED DESCRIPTION OF INVENTION

Rice brokens or whole kernel rice or both, are used as a starting material. Product color is primarily a result of the color of the starting material. The preferred starting material should be cleaned and polished to meet standards for U.S. No. 1 grade or rice as identified in USDA standards .sctn.68.310,

68.311, 68.312, 68.313.

The term "rice" will be used hereinafter for simplicity. However, it is to be understood that the present invention is applicable to any ground or comminuted material so long as it contains starch in a quantity of at least about 20% by weight, on a dry basis of starch plus filler, if desired, (hereinafter flour), preferably at least about 50% starch and more preferably at least about 70% starch. The filler can be any compatible, edible material such as cellulose, protein, bran, gums, or combinations thereof, or other ground, edible material or materials mixed with the starch to form a mixtures of material hereinafter referred to as flour. Starch without filler can also be used as the flour.

It is preferred in order to obtain the flavor of a starting grain that the flour be a majority by weight of the characterizing grain or starch product. More preferably more than about 75% and most preferably more than about 90% by weight.

The rice is ground sufficiently to provide ease of extrudability and the desired texture. Preferably, it is ground to produce a flour finer than 150.mu. (ASTM 100 mesh); more preferably finer than 106.mu.

(ASTM 140 mesh); and most preferably finer than 75.mu. (ASTM 200 mesh) as analyzed by sifting a

25 gram sample for 3 minutes on an Alpine Model AJS 200 Air-Jet Sieve. Fine grinding of the rice provides good textural quality, i.e. a non-gritty mouthfeel and helps improve down stream processing steps. Other grains or materials may not require such fine grinding, particularly softer grains such as wheat. An 850.mu. (ASTM 20 mesh) grind can be used for wheat.

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Grinding of rice can be accomplished by any suitable grinding process as is known in the art, and preferably, grinding is accomplished by impact milling followed by air classification to separate the flour from oversized material. The oversized material is recycled to the grinder for regrinding.

Grinding of other grains can be done in a similar manner after removal of the desired amount of bran or outer layers. It is also possible to select products from commercial milling operations, such as wheat flour, samolina, rye flour, corn flour etc.

After grinding, the flour is hydrated sufficiently to provide good pressure-forming characteristics preferably by pressure applied through extrusion, molding etc. The flour is hydrated to form a blend of flour and water in a suitable manner whereby the blend has a moisture content in the range of between about 20% and about 40%, more preferably between about 27% and 36%, and most preferably in the range of between about 29% and 31% by weight of blend. The water is absorbed into the flour particles so that the mixture is formable. The hydration can be by any suitable method. Preferably, hydration is conducted in a continuous mixer by metering a controlled amount of water into a controlled amount of flour. Elevated temperatures enhance the forming and stability of the blend in the forming step where hydration is a result of starch granules by increased temperature. It is preferred that the temperature during hydration be between about 120 DEG F. and about 275 DEG F.; more preferable between about

140 DEG F. and about 200 DEG F.; and most preferable between about 150 DEG F. and about 170

DEG F. Lower temperatures can be used for some grains e.g. ambient (70 DEG F.) to 120 DEG F. can be used and is particularly useful for wheat hydration. These lower temperatures can be used for those grains which have functional protein which hydrates to enhance product formation and structure, thus making the higher temperatures required for swelling of starch unnecessary and often undesirable.

Such temperatures, if desired, should be kept below the temperature which would result in protein denaturation, reducing its desired hydration capacity.

It is to be understood that the water and flour can be mixed and subsequently heated as, for example, in the extruder to simplify the hydration step.

Prior to hydration, processing aids and additives can be added to the flour or the blend. For example, substances such as monoglycerides, diglycerides, mono/diglycerides, stearic acid, citric acid or titanium dioxide can be added to the flour before the water addition to improve the properties of the product as, for example, lightness or translucency. Also, reducing agents can be added to the water such as sodium bisulfite which would help inhibit browning in subsequent processing. Also, nutritional additives can be added to the flour or water prior to extrusion so that the nutrients are intimately interspersed within the rice product. Typical nutrients added to cereal grains include vitamins and minerals such as: thiamin, riboflavin, niacin, iron and calcium. Riboflavin and calcium are not presently added to enriched rice because they detract from its appearance. Furthermore, the washing step commonly used in rice preparation removes a large amount of the enrichment. This invention overcomes both of these shortcomings.

After hydration, the blend is pressure-formed into integral particles of a desired shape. Extrusion or other types of molding can be used. Extrusion is preferred to form discrete segments, particles, or granules which can be made to resemble whole kernel product. It is preferred that the extrusion be done in a screw extruder which provides good blend mixing. Extrusion pressure preferably is in the range of between about 400 psi and about 1800 psi; preferably in the range of between about 600 psi and 1200 psi; and most preferably in the range of between about 900 psi and 1100 psi.

The blend can be heated to help hydration. This can be done during the hydration step and/or in the extruder. The temperature of the water/flour mixture in the extruder should be in the range of between about 130 DEG F. and about 200 DEG F.; preferably between about 140 DEG F. and about 180 DEG

F.; and most preferably between about 155 DEG F. and about 170 DEG F. Lower temperatures can be used for some grains as in the initial above described hydration.

The pressurized flour/water mixture can be extruded through a die plate and cut upon exiting from openings in the die plate. For forming rice shaped pieces it is preferred that the die openings be oblong, i.e. the minor axis of the grains are in the direction of extrusion. This has been found to form a more whole kernel appearing product.

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The rice shaped products have been formed using a standard DeMaCo S-25 laboratory extruder with a

440 c stainless steel die plate containing 18 die holes. The inserts are made of Delrin A/F. Each orifice has a major axis dimension of 0.281" and a minor axis of 0.063". Orifice lengths and entrance geometry are varied to equalize linear flow rates at each position on the die face to produce a uniform piece size. The piece cutter is a high speed rotary knife adjusted to cut each piece approximately 0.063" long. The piece length at each orifice can be changed by die geometry to simulate the natural variation in grain size. Other die sizes and shapes can be used depending on the desired end product. Pasta making equipment can be used to produce a variety of pasta type products. Also, product can be made in larger sizes and different shapes.

The blend in the extruder is treated as a pseudo plastic fluid with a flow consistency between 3 and 8 lb in@2 /min.; more preferably between 4 to 7.5 lb in@2 /min.; and most preferably between 5.8 to 7.5 lb in@2 /min. The extrusion rate is important and will be determined by flow consistency of the blend and the extruder design, operating conditions, and die geometry.

After forming into granules or other suitable particles, processing aids can be applied to the granules to help downstream processing steps. For example, the formed granules can be coated with an emulsifier such as a distilled mono/diglyceride to decrease surface stickiness and enhance texture. Such emulsifiers can be applied in a quantity in the range of between about 0.025% and about 0.2% by weight of final product by spraying a dilute dispersion of distilled mono/diglyceride in water onto the formed granules. The emulsifier, such as a mono/diglyceride, can complex with a starch during subsequent processing steps to help reduce stickiness etc. Other processing aids, such as edible oils, lecithin, or emulifiers can be used as is desired.

The formed granules are then subjected to a heating step. Heating is conducted under conditions to substantially, and preferably, to completely and uniformly gelatinize the starch in the granules with minimal or no degradation of the starch. Puffing in rice should be avoided. Preferably, the heating step is conducted such that there will be minimal or no moisture loss from the granules to give the desired density and compactness. The formed granules have moisture content within the ranges as described above for the hydrated flour. The heating step molds the structure of the formed granules and, if used, can react applied emulsifier with the starch.

Preferably, the heating step is an autoclaving step wherein the granules are exposed to steam at super atmospheric pressure. Preferably, the environment is saturated steam in the range of between about 0.5 psig and 75 psig, more preferably between about 3 psig and 35 psig, and most preferably about 5 psig and 20 psig. The time of exposure for heating is generally inversely related to the temperature and pressure of the heating step, i.e. the higher the temperature or pressure, the lower the required time. If the granules are left in too long a period of time, they will have a tendency to brown which is a

Maillard browning reaction. If left in too short of time, the product will become grainy or chalky in texture and have poor integrity. It is preferred that the time of heating be in the range of between about

1 minutes to 30 minutes; more preferably in the range of between about 3 minutes and about 15 minutes; and most preferably in the range of between about 4 minutes and 12 minutes.

The temperature and presssure of saturated steam are directly related (see "Thermodynamic Properties of Steam", by Keenan & Keyes, 1936).

Although not being bound by the following theory it is provided in order to better understand the invention. At atmospheric steam pressue (212 DEG F.) it is not possible to obtain the desired degree of gelatinization no matter how long the product is held, hence this product would have the same characteristics as the "short time" product described above. Results of excessive pressures are not entirely the same as excessive time. Excess pressure causes cell disruption and starch degradation which is characterized by stickiness and solubilization. The extent of this problem is related to the time at the high pressure, e.g. the logical approach of high steam pressure for a very short time can result in a product with a sticky, degraded surface and an underprocessed "short time" type of center. Such a product might not be undesirable if one wants a sticky "Japanese" style rice.

Preferably the heating is done in an autoclave. When the granules have been sufficiently heated to the desired degree of gelatinization of at least about 60% preferably at least about 80% and more

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preferably at least about 95% (as measured by X-ray diffraction), it is preferred that their moisture content be within the ranges as described above for the hydrated flour.

The formed granules can also be heated in a multiple stage process. It has been observed that the granules tend to become somewhat sticky during the autoclaving step. If this step is preceded by a preheating step with steam at sub-atmospheric or atmospheric pressure, the stickiness is substantially decreased. The two-stage process also seems to increase the tolerance of the product to autoclaving, resulting in a more uniform cook in the finished product. The preheating is conducted at a temperature above the gelatinization temperature and preferably above about 180 DEG F. and most preferably at about 212 DEG F. (i.e. at atmospheric pressure). This initial heating step is of some benefit regardless of the heating time; however, maximum benefit seems to require a heating time above about 5 minutes for rice-sized granules.

While the product is normally dried to produce a shelf stable product after the heating step described above, it is also possible to obtain an intermediate or full moisture product at this point of the process.

A full moisture product would be obtained by adding back, after the heating step, sufficient water to obtain a normal cooked moisture content of about 60% by weight (for long grain rice), and freezing or canning the finished product.

Intermediate moisture products are defined as those between the moisture content of dry rice and fullmoisture rice, or about 15% to about 55% moisture by weight. For this purpose, the product should have a water activity (Aw) of less than 0.85, be sterilized and aseptically packed, or at least pasteurized and refrigerated. The Aw can be kept to less than 0.85 either by reducing the final moisture content and/or by the addition of Aw controls such as using glycerine to replace part of the water in the product formulation.

Dry product is defined as having an Aw of less than about 0.65. This is obtained by drying the granules after the previously-described heating step. Aw is normally measured through an equilibrium-testing procedure.

Preferably, the formed granules have a moisture content after drying in the range of between about 6% and 16% by weight; more preferably in the range of between about 8% and about 14%; and most preferably in the range of between about 10% and about 12%. Product can be dried in any suitable manner to remove undesired moisture such as in a continuous-heating oven and is done at an elevated temperature. Preferably, the drying temperature is in the range of between about 150 DEG F. and about

600 DEG F.; more preferably in the range of between about 250 DEG F. and about 450 DEG F.; and most preferably in the range of between about 300 DEG F. and about 400 DEG F. In the case of wheat pasta the drying temperature should be below about 300 DEG F. and preferably between about 150

DEG F. and 250 DEG F. The drying time is adjusted to obtain the desired product moisture level. The time of drying is related to temperature and air flow. The higher the temperature and/or air flow, the lower the required time. Typical drying times have been between 1 and 5 minutes at higher temperatures. At 150 DEG F. drying temperatures can be as long as 3 hours.

Drying provides a formed granule which is easily rehydratable or reconstitutable and has a porous structure of good flavor and texture. Drying also enhances the stability of the formed granule.

The drying condition can be adjusted from very high temperatures which puff the granules, to intermediate temperatures which neither puff nor shrink the granule, but provide a porous structure resulting from moisture loss, to low temperatures which allow the granule to shrink and result in a hard, non-porous, glassy structure. These differences control the rate of rehydration and can affect product texture.

After drying, the formed granules are cooled. The cooling step can also be utilized to stop the drying action. Preferably, the product is cooled to room temperature.

After cooling, the product can be bleached as is known in the art as, for example, using chlorine or peroxide. This will provide the desired degree of whiteness. Bleaching products is well known in the art as disclosed in Cereal Flours and Related Products, F.D.C. Regulations, Part 15.

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The above process can be modified to provide different types of end products, for example, rice bran can be added to the flour so that a quick cooking brown rice can be provided. Also, other flavors, filler, cereal grains or other products can be added prior to the extrusion step to provide homogeneous mixture and homogeneous end product. The present invention provides formed granules which are very close in appearance to the natural-occurring product, are quick cooking and pleasing in flavor. Also, surprisingly, it was found that rice product produced in accordance with the above disclosure was stable on a steam table for several hours, i.e., greater than 4 hours without the product becoming pasty.

This could be due to the limitation of starch gelatinization by controlling the time and temperature or possibly available moisture. Further, by utilization of the above-described process, a product can be produced which has all the natural components of the natural product, or can have in addition thereto additional components which heretofore have not been successfully included in rice, other whole cereal grain, and starch-based products.

The final product is characterized by: uniformity of components, i.e. less than about a 2% variation throughout the granules, exclusive of coating or other materials added after forming; the starch is the predominant binder in those products which have little or no functional protein, i.e. at least about 90% of the binding is due to starch; there is little or no starch degradation, i.e. there is less than about 5% degraded starch and preferably substantially no or no degraded starch; there is greater than about 95% gelatinization and preferably substantially complete gelatinization; and is a precooked, reconstitutable product.

The following are examples showing the operability of the present invention.

EXAMPLE I

1000 grams of vacuum-dried riced potato (80% starch on dry basis) was ground to a fine flour which was then hydrated to a moisture content of about 40%. This blend was extruded in a screw extruder barrel at 120 DEG F. barrel temperature. The extrudate was cut into rice shaped granules. These granules were autoclaved for 3 minutes at 250 DEG F. (15 psig), after which they were dried for 1 minute at 400 DEG F. to a moisture content of 10% by weight.

The dried granules were reconstituted by adding 40 grams of product to 1/3 cup of boiling water and let stand for 10 minutes. The prepared product was judged to have good potato flavor and texture and was neither gummy nor sticky.

EXAMPLE II

Fine-ground rice flour was hydrated to a moisture content of 30% by weight. The hydrated flour was extruded in a pasta press which was at a temperature of 160 DEG F. The extrudate was cut into ricesized pieces. These pieces were coated with a 4% monoglyceride in water dispersion to give a 0.1% level of monoglyceride on the rice pieces. The coated rice pieces were divided into three 1000 gm batches.

These three batches were heated with saturated steam at 212 DEG F. for 15 minutes, 30 minutes and 60 minutes, respectively. Each of the batches was dried at 400 DEG F. for 2 minutes.

75 gms of each dried batch was added to 2/3 cup of boiling water and allowed to stand for 10 minutes.

All reconstituted product was judged to be unacceptable because they were dry, rough and grainy in the mouth, and had raw starchy flavor.

EXAMPLE III

Rice flour was hydrated and extruded, as in Example II. However, the formed pieces were heated in an autoclave with saturated steam at 15 psig, at temperature of 250 DEG F. for 5 minutes.

Upon removal from the autoclave, the rice pieces were loosely matted together. The pieces were allowed to cool and were separated. The separated pieces were dried at 400 DEG F. for 2 minutes.

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75 gms of pieces were added to 2/3 cup of boiling water and allowed to stand for 10 minutes.

The reconstituted product was judged to have excellent texture and flavor.

EXAMPLE IV

Rice flour was hydrated and extruded as in Examples II and III. However, the formed pieces were preheated prior to autoclaving.

The pieces were preheated with atmospheric steam (212 DEG F.) for 10 minutes. They were then autoclaved at 10 psig (240 DEG F.) for 6 minutes. The autoclaved product was only slightly adhered together, i.e. less than the product of Example III.

The pieces were then dried at 400 DEG F. for 2 minutes.

75 gms of product were added to 2/3 cup of boiling water and allowed to stand for 10 minutes. The product was judged to have excellent texture and flavor.

EXAMPLE V

1000 grams of yellow corn flour was hydrated to a moisture content of 32% by weight. The hydrated corn flour was extruded in a pasta press which was at a temperature of 165 DEG F. The extrudate was in the form of elbow macaroni. These elbows were autoclaved at 250 DEG F. for 5 minutes after which they were dried for 5 minutes at 275 DEG F.

The dried "macaroni" was reconstituted by adding the product to boiling water and boiling for 15 minutes. The prepared product was judged to have a good corn flavor and a firm pasta texture.

EXAMPLE VI

White corn meal was ground to a fine flour which was then hydrated to a moisture content of 32% by weight. The hydrated white corn flour was extruded into macaroni elbows, autoclaved and dried as in

Example V.

The reconstituted "macaroni" was judged to have very good mild flavor and a firm texture.

EXAMPLE VII

A sample of pearl millet was debranned to remove 20 % bran and yield 80% millet. The debranned millet was ground to a fine flour which was then hydrated to a 31% moisture. The hydrated flour was extruded in a pasta press at a temperature of 160 DEG F. The extrudate was cut into rice shaped pieces.

These pieces were autoclaved for 8 minutes at 240 DEG F., after which they were dried for 2 minutes at 400 DEG F.

75 grams of the pieces were added to 2/3 cup of boiling water and allowed to stand for 10 minutes.

The reconstituted product was judged to have a strong millet flavor with rice like soft texture.

EXAMPLE VIII

A sample of soft white wheat second clears flour was hydrated to a moisture of 32%. The hydrated flour was extruded in a pasta press which was at a temperature of 116 DEG F. The extrudate was in the form of elbow macaroni. The elbows were autoclaved for 10 minutes at 240 DEG F., after which they were dried for 3 hours at 150 DEG F.

The dried elbows were reconstituted by adding to boiling water and boiling for 9 minutes. The elbows were drained and evaluated. They were judged to have good pasta flavor, "al dente" texture and deep yellow color.

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EXAMPLE IX

A blend of 90% corn starch and 10% yellow corn flour was hydrated to a moisture of 32% moisture.

The hydrated blend was extruded in a pasta press which was at a temperature of 165 DEG F. The extrudate was in the form of elbow macaroni. The elbows were autoclaved for 5 minutes at 250 DEG

F., after which they were dried at 275 DEG F. for 5 minutes.

The dried elbows were reconstituted by adding to boiling water and boiling for 12 minutes. The elbows were drained and evaluated; they were judged to have good mild flavor and pasta texture.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed and desired to be secured by Letters of Patent is:

1. A process of manufacturing a starch-based food item comprising the steps of: providing a mixture of ground material, with said material comprising at least about 20% starch by weight of mixture on a dry basis; hydrating said mixture to form a blend, said mixture being hydrated sufficiently to provide pressure formability to said blend; pressure forming said blend to form individual pieces; and heating the pressure formed pieces by exposing said pieces to substantially saturated steam at a super atmospheric pressure above about 0.5 psig in an autoclave for a time sufficient to gelatinize a major portion of said starch.

2. A process as set forth in claim 1 wherein said heating is done at a pressure in the range of between about 3 psig and about 35 psig in an environment of substantially saturated steam.

3. A process as set forth in claim 2 wherein said heating is done at a pressure in the range of between about 5 psig and about 20 psig.

4. A process as set forth in claim 1, 2 or 3 wherein said forming is done by extrusion.

5. A process as set forth in claim 1, 2, or 3 wherein said mixture is in the form of a flour which has been ground to a fineness of less than about 100 mesh.

6. A process as set forth in claim 5 wherein said flour is ground sufficiently such that at least about

99% is finer than about 140 mesh.

7. A process as set forth in claim 6 wherein said flour is ground to a fineness such that at least about

99% is finer than about 200 mesh.

8. A process as set forth in claim 1, 2, or 3 wherein the mixture is hydrated to form a blend with the blend having a moisture content within the range of between about 20% and about 40% by weight of blend.

9. A process as set forth in claim 8 wherein the blend has a moisture content in the range of between about 27% and about 36% by weight of blend.

10. A process as set forth in claim 9 wherein said blend has a moisture content in the range of between about 29% and about 31% by weight of blend.

11. A process as set forth in claim 1, 2, or 3 wherein the thus heated particles are dried sufficiently to have a water activity level of less than about 0.85.

12. A process as set forth in claim 11 wherein said particles are dried to a water activity level of less than about 0.65.

13. A process as set forth in claim 1, 2, or 3 wherein said formed particles are reconstituted to a higher moisture content by adding back water.

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14. A process as set forth in claim 1, 2, or 3 wherein prior to heating said particles, said particles are preheated at a temperature above the gelatinization temperature of the starch sufficiently to reduce stickiness during heating.

15. A process as set forth in claim 1, 2 or 3 wherein said material includes a majority by weight of rice.

16. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of wheat.

17. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of corn.

18. A process as set forth in claim 1, 2 or 3 wherein said material includes a majority by weight of millet.

19. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of potato.

20. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of sorghum.

21. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of rye.

22. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of barley.

23. A process as set forth in claim 1, 2 or 3 wherein said material includes a majority by weight of triticale.

24. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of oats.

25. A process as set forth in claim 1, 2 or 3 wherein said material include a majority by weight of cassava.

26. A process as set forth in claim 1 wherein said ground material also includes filler and each said heated piece is predominantly bound together by starch and said starch being at least about 95% gelatinized and less than about 5% degraded.

27. A process as set forth in claim 26 wherein substantially all of the starch is gelatinized.

28. A process as set forth in claim 26 wherein there is substantially no degradation of the starch.

29. A process as set forth in claim 26 wherein said ground material includes starch and filler which were ground to a mesh size of less than about 100 prior to pressure forming.

30. A process as set forth in claim 29 wherein the mesh size of said starch and filler prior to pressure forming was less than about 140.

31. A process as set forth in claim 30 wherein the mesh size of said starch and filler prior to pressure forming was less than about 200.

32. A process as set forth in claim 26 wherein said starch is present in an amount of at least about 50% by weight of starch plus filler on a dry basis.

33. A process as set forth in claim 32 wherein said starch is present in an amount of at least about 70% by weight of starch plus filler on a dry basis.

34. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of rice.

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35. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of wheat.

36. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of corn.

37. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of millet.

38. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of potato.

39. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of sorghum.

40. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of rye.

41. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of barley.

42. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of triticale.

43. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of oats.

44. A process as set forth in claim 26, 27 or 28 wherein said filler and starch includes a majority by weight of cassava.Data supplied from the esp@cenet database - Worldwide

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258.

PH18047 - 3/13/1985

RICE PASTA COMPOSITION

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=PH18047

Inventor(s): HSU JAU YANN (--)



IP Class: A21D13/06; A21D2/26; A21D2/16

E Class: A23L1/16; A23L1/0532

Application Number: PH19820028082 (19821102)


Family: KR8900397

Equivalent: EP0081077; US4435435; OA7265; JP58107147; GB2110915; ES8400015

Abstract:

Abstract not available for PH18047


A composition comprising uncooked rice flour and, based on the weight of the uncooked rice flour, from 0 to 40% by weight of precooked rice flour, from 0 to 4% by weight of sodium or potassium alginate or a mixture thereof and from 0 to 4% by weight of propylene glycol alginate with the proviso that when the composition contains less than 5% by weight of precooked rice flour, both the alginates should be present in amounts of at least 1% by weight.Description:


The present invention relates to rice pasta compositions particularly those which can be processed into pasta the same way that regular wheat pasta is manufactured.

Regular wheat pastas i.e. pastas that need cooking for consumption can be made simply by mixing wheat flour with water, then extruding into pasta shapes and drying. The resulting pasta has good strength, with good cooked firmness and low cooking losses. However rice pasta prepared in this way has poor strength with low cooked firmness and high cooking losses.

Therefore rice pasta is prepared by a variety of alternative methods the most common being the conventional Oriental process which requires steam cooking of ground regular or waxy rice to gelatinise the rice starch in order to obtain a firm pasta structure. However, this process is cumbersome, energy consuming and expensive. In another process, wheat flour or wheat gluten is added to rice flour to improve extrusion and formation of the pasta structure but the defect of this approach is the diminution of the characteristics of the rice pasta, such as flavour, texture and appearance. Other newer methods involve either mixing boiled rice with rice flour which enables rice flour to be rolled into the pasta shape, or extrusion cooking of rice flour with water which completely or partially gelatinises the rice flour and forms the pasta structure. Unfortunately, the problems of using partially or completely precooked rice in a regular pasta which requires cooking are the poor cooking qualities, especially the high cooking loss and low cooked firmness.

We have now devised a rice pasta composition which can be made into a rice pasta by mixing dry ingredients with water, extruding and drying as in the regular wheat pasta process and, if desired,

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adding a precooking step to this process. The rice pasta prepared from this composition has good strength with low cooking losses and high cooked firmness.

Accordingly, the present invention provides a composition comprising uncooked rice flour and, based on the weight of the uncooked rice flour, from 0 to 40% by weight of precooked rice flour, from 0 to

4% by weight of sodium or potassium alginate or a mixture thereof and from 0 to 4% by weight of propylene glycol alginate with the proviso that when the composition contains less than 5% by weight of precooked rice flour, both the alginates should be present in amounts of at least 1% by weight.

The present invention also provides a first process for preparing a rice pasta characterised in that a pasta dry mix containing uncooked rice flour and, based on the weight of uncooked rice flour, from 5 to 40% by weight of precooked rice flour, from 0 to 4% by weight of sodium or potassium alginate or a mixture thereof and from 0 to 4% by weight of propylene glycol alginate is mixed with an amount of water sufficient to moisten the dry pasta mix and render it extrudable, extruded into a pasta shape, optionally precooked and finally dried, with the proviso that when the pasta is not precooked both the alginates must be present in amounts of at least 0.1% by weight based on the weight of uncooked rice.

The amount of precooked rice flour used in the first process is preferably from 10 to 35% by weight and especially from 15 to 30% by weight based on the weight of uncooked rice flour.

The amount of sodium or potassium alignate used in the first process is conveniently from 0.1 to 1.5% by weight, preferably from 0.2 to 1.2% by weight, and especially 0.3 to 1.0% by weight based on the weight of uncooked rice flour.

The amount of propylene glycol alginate used in the first process is conveniently from 0.1 to 1.5% by weight, preferably from 0.2 to 1.2% by weight, and especially 0.3 to 1.0% by weight based on the weight of uncooked rice flour.

The present invention also provides a second process for preparing a rice pasta characterised in that a dry pasta mix containing uncooked rice flour and, based on the weight of uncooked rice flour, 0 to 5% of precooked rice flour, at least 1% by weight of sodium or potassium alginate or a mixture thereof and at least 1% by weight of propylene glycol alginate is mixed with an amount of water sufficient to moisten the dry pasta mix and render it extrudable, extruded into a pasta shape, precooked and finally dried.

In the second process of the invention, the sodium or potassium alginate or mixture thereof is conveniently used in an amount of from 1.25 to 4.0% by weight, preferably 1.5 to 3.0% by weight, and especially from 1.75 to 2.25% by weight based on the weight of uncooked rice flour. Similarly, the propylene glycol alginate is conveniently used in an amount of from 1.25 to 4.0% by weight, preferably

1.5 to 3.0% by weight, and especially from 1.75 to 2.25% by weight based on the weight of uncooked rice flour.

In both the first and second process of the present invention, the calcium content of the sodium or potassium alginate is preferably not more than 5% by weight and especially not more than 3% by weight based on the weight of the alginate. The amount of water which is used is conveniently from 25 to 45% by weight, preferably from 28 to 40% by weight, and especially from 30 to 35% by weight based on the weight of the pasta dry mix.

When the processes of the present invention comprise a precooking step before the extruded pasta is dried, the processes may be used to prepare an instant rice pasta. However regular rice pasta may also be prepared by a process employing a precooking step and a precooked pasta is firmer than an uncooked pasta when cooked for consumption.

The precooking may be carried out by either water-boiling or by steam cooking. Steam cooking usually requires from 40 to 50% dough moisture for efficient cooking but at this moisture range the dough is too sticky for extruding. We have developed a technique where rice dough having a moisture content of from 27.5 to 35% is extruded and water is sprayed onto the extruded pasta dough before steaming. The steam temperature is generally from 90 DEG C. to 110 DEG C. and the cooking time is dependent on the pasta's size and the steam temperature.

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The water used in the processes of the present invention may be hard or soft except when sodium or potassium alginate is used in the absence of or in the presence of extremely small amounts of propylene glycol alginate, in which case hard water should be used both for processing and cooking.

In the processes of this invention the uncooked rice flour may be regular rice flour or waxy (glutinous) rice flour, pasta made from the latter being softer than pasta made from the former. Also the firmness of the pasta may be increased by precooking or increasing the amount of propylene glycol alginate.

Moreover if a whiter pasta is desired the amount of sodium or potassium alginate should be reduced and the amount of propylene glycol alginate should be increased. The processes of the two embodiments of the present invention are thus very versatile.

The pasta may be extruded into a variety of conventional shapes including all shapes of macaroni and noodle products which comprise all sizes of spaghetti, vermicelli, linguine, ziti, elbow spaghetti, orzo, shell, elbow macaroni, rigatoni, macaroni twist, rings, alphabets, lasagne, spirals, manicotti, noodles and bows.

The following Examples further illustrate the present invention parts and percentages being given by weight.

EXAMPLE 1

83.2 parts regular rice flour, 15 parts precooked rice flour, 1 part sodium alginate and 0.8 part propylene glycol alginate were premixed until uniform, mixed in regular or hard water (water without a softening treatment) to a total moisture content of 30 to 33%, extruded into noodle shape (1 cm wide,

0.75 cm thick and 5-6 cm long) in a noodle extruder and finally dried at 80-85% humidity and 50 DEG

C. for 3 hours. The moisture content of the dried rice pasta was 9-10%.

The pasta was then tested for dry pasta strength, relative cooking loss, relative cooked weight and cooked firmness by the following methods:

The dry pasta strength was determined by cutting a single strand pasta in an Instron Universal Testing

Instrument. Using a Warner Bratzler meat shear test attachment the peak force required to shear the pasta is recorded (kg/cm@2).

The relative cooking loss was determined by boiling 15 g pasta for 8 minutes and drying at 100 DEG

C. for 4 hours. The dried pasta was weighed and the % loss calculated.

The relative cooked weight was determined by boiling 50 g pasta for 8 minutes and weighing the drained pasta weight (g).

The cooked firmness was determined by boiling 50 g pasta for 8 minutes, weighing out 80 g cooked pasta and recording the peak force required to shear the pasta in an Instron Universal Testing

Instrument using a Kramer Shear Test attachment (kg/cm@2).

The results were as follows:

>;tb;______________________________________

>;tb;Dry pasta strength 3.2 kg/cm@2

>;tb;Relative cooking loss 13.7%

>;tb;Relative cooked weight 114 g

>;tb;Cooked firmness 43 kg/cm@2

>;tb;______________________________________

COMPARATIVE EXAMPLES A TO D

A process similar to that of Example 1 was carried out but using the quantities of ingredients shown in the following Table I.

>;tb; TABLE I

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>;tb;______________________________________

>;tb;Example A B C D

>;tb;______________________________________

>;tb;Regular Rice flour

>;tb; 100 98.2 84.2 84.0

>;tb;Precooked rice flour

>;tb; -- -- 15.0 15.0

>;tb;Sodium alginate -- 1.0 -- 1.0

>;tb;Propylene glycol alginate

>;tb; -- 0.8 0.8 --

>;tb;______________________________________

The dry pasta strength, relative cooking loss, relative cooked weight and cooked firmness were determined by the same methods as used in Example 1.

The dry pasta strength of the pasta of Comparative Example A was only 1.5 kg and that of Example B was only 1.8 kg compared to 3.2 kg of the pasta of Example 1.

The cooking qualities (cooking loss and cooked firmness) of the pastas of Comparative Examples C and D were inferior to those of the pasta of Example 1 as shown in Table II.

>;tb; TABLE II

>;tb;______________________________________

>;tb;Example 1 C D

>;tb;______________________________________

>;tb;Cooking loss 13.7% 26.0% 16.8%

>;tb;Cooked weight 114 g 101 g 122 g

>;tb;Cooked firmness

>;tb; 43 kg 33 kg 26 kg

>;tb;______________________________________

EXAMPLE 2

A similar process to that described in Example 1 was carried out except that soft water was used instead of regular or hard water. The relative cooking loss was 18.8%, the relative cooked weight was

121 g and the cooked firmness was 37 kg/cm@2.

COMPARATIVE EXAMPLES E AND F

A process similar to that described in Example 2 was carried out but using the same ingredients as in

Comparative Examples C and D respectively. The cooking qualities in soft water of the pastas of

Comparative Examples E and F were inferior to those of the pasta of Example 2 as shown in Table III.

>;tb; TABLE III

>;tb;______________________________________

>;tb;Example 2 E F

>;tb;______________________________________

>;tb;Relative cooking loss

>;tb; 18.8% 21.5% 46.5%

>;tb;Relative cooked weight

>;tb; 121 g 130 g 99 g

>;tb;Cooked firmness

>;tb; 37 kg/cm@2

>;tb; 31 kg/cm@2

>;tb; 20 kg/cm@2

>;tb;______________________________________

EXAMPLE 3

A regular type rice pasta that requires cooking for consumption was prepared by mixing and extruding

78 parts of uncooked rice flour, 20 parts of precooked rice flour, 1 part of sodium alginate, 1 part of

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propylene glycol alginate and 38 parts of water. The dough was extruded into Vermicelli shape with 1 mm diameter and dried at 80-85% relative humidity at 50 DEG C. for three hours. The finished rice pasta had a good cooking quality similar to that of regular wheat pasta.

EXAMPLE 4

A procedure similar to that described in Example 3 was carried out but the extruded dough was steam cooked for 4 minutes at 100 DEG C. before being dried. The finished rice pasta after cooking had a firmer texture to that of Example 3 and was very similar to the texture of Oriental rice pasta.

EXAMPLE 5

A procedure similar to that described in Example 4 was carried out but in the absence of propylene glycol alginate and wherein regular or hard water was used for processing and cooking. The firmness of the pasta was between that of the pastas of Examples 3 and 4.

EXAMPLE 6

An instant type rice pasta that requires no cooking (just rehydration with boiling water for 3 minutes) was prepared by mixing and extruding 74 parts of uncooked rice flour, 25 parts precooked rice flour,

0.5 part of propylene glycol alginate, 0.5 part of sodium alginate and 38 parts of water. The dough was extruded into Vermicelli shape with 0.70 mm diameter. Water was sprayed onto the dough which was then steam cooked for 6 minutes at 100 DEG C. and dried at 80-85% humidity at 50 DEG C. for 21/2 hours. The finished pasta after rehydration had a firm texture similar to that of Oriental rice pasta.

EXAMPLE 7

A procedure similar to that described in Example 6 was carried out but in the absence of sodium alginate. The finished pasta after rehydration had a texture similar to that of Oriental rice pasta.

EXAMPLE 8

A procedure similar to that described in Example 6 was carried out but in the absence of alginates. The finished pasta was acceptable although not as firm as that prepared by the process of Example 7.

EXAMPLE 9

A procedure similar to that described in Example 6 was carried out but instead of steam cooking, the pastas were boiled for 3 minutes before drying. The texture of the rice pasta after rehydration was good.

EXAMPLE 10

A procedure similar to that described in Example 6 was carried out but instead of regular rice flour, waxy rice flour was used. The finished rice pasta after rehydration was softer than that prepared by the process of Example 6.

EXAMPLE 11

A procedure similar to that described in Example 6 was carried out except that no precooked rice flour was used and 1.5 part of sodium alginate and 1.5 part of propylene glycol alginate were used. The finished rice pasta after rehydration was acceptable.Data supplied from the esp@cenet database -

Worldwide Claims:


I claim:

1262/2197

1. A composition comprising uncooked rice flour and, based on the weight of the uncooked rice flour, from 0 to 40% by weight of precooked rice flour, from 0.1 to 4% by weight of sodium or potassium alginate or mixture thereof and from 0.1 to 4% by weight of propylene glycol alginate wherein when the composition contains less than 5% by weight of precooked rice flour, each of the said alginates are present in an amount of at least 1% by weight.

2. A process for preparing a rice pasta comprising the steps of formulating a dry pasta mix containing uncooked rice flour and, based on the weight of the uncooked rice flour, from 5 to 40% by weight of precooked rice flour, from 0.1 to 4% by weight of sodium or potassium alginate or a mixture thereof and from 0.1 to 4% by weight of propylene glycol alginate, mixing together an amount of water sufficient to moisten the dry pasta mix and render it extrudable, extruding the mixture into a pasta shape, and drying to a desired moisture content.

3. A process according to claim 2, wherein the amount of precooked rice flour used is from 15 to 30% by weight based on the weight of uncooked rice flour.

4. A process according to claim 2, wherein the amount of sodium or potassium alginate used is from

0.3 to 1.0% by weight based on the weight of the uncooked rice flour.

5. A process according to claim 2, wherein the amount of propylene glycol alginate used is from 0.3 to

1.0% by weight based on the weight of uncooked rice flour.

6. A process for preparing a rice pasta comprising the steps of formulating a dry pasta mix containing uncooked rice flour and, based on the weight of uncooked rice flour, from 0 to 5% of precooked rice flour, at least 1% by weight of sodium or potassium alginate or a mixture thereof and at least 1% by weight of propylene glycol alginate, mixing therewith an amount of water sufficient to moisten the dry pasta mix and render it extrudable, extruding the mixture into a pasta shape, precooking and drying to a desired moisture content.

7. A process according to claim 6, wherein the sodium or potassium alginate or mixture thereof is used in an amount of from 1.5 to 3.0% by weight based on the weight of uncooked rice flour.

8. A process according to claim 6, wherein the propylene glycol alginate is used in an amount of from

1.5 to 3.0% by weight based on the weight of uncooked rice flour.

9. A process according to claim 2 or claim 6, wherein the calcium content of the sodium or potassium alginate is not more than 3% by weight based on the weight of the alginate.

10. A process according to claim 2 or claim 6, wherein the amount of water used is from 28 to 40% by weight based on the weight of the dry pasta mix.

11. A process according to claim 2 or claim 6, wherein the precooking is carried out by spraying water onto the extruded pasta shape and then steaming.

12. A process according to claim 2, wherein after the pasta has been extruded and prior to being dried, the pasta is precooked.Data supplied from the esp@cenet database - Worldwide

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259.

PH24480 - 7/18/1990

RICE GRAIN HUMIDIFYING APPARATUS

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=PH24480

Inventor(s): SATAKE TOSHIHIKO (--)

Applicant(s): SATAKE ENG CO LTD (--)

IP Class 4 Digits: B02B; B02C

IP Class: B02B1/08; B02C11/08

E Class: A23L1/182; A23L1/10H

Application Number: PH19870034951 (19870303)


Family: AU584496

Equivalent: EP0235792; US4829891; MX163426; JP62204858

Abstract:

Abstract not available for PH24480


In an apparatus for humidifying rice grains, a humidifying vessel has defined therewithin a substantially closed space and has a rice supply port and a rice discharge port. Rice grains are supplied into the humidifying vessel through the supply port, while gas is substantially prevented from escaping from the space within the humidifying vessel through the supply port. Rice grains are discharged from the humidifying vessel through the discharge port, while the gas is substantially prevented from escaping from the space within the humidifying vessel through the discharge port. Gas is forcibly delivered into the humidifying vessel to pressurize the space therewithin. Moisture is added to the rice grains within the pressurized space within the humidifying vessel. The moisture is added to the rice grains within the substantially closed space and, simultaneously, the moisture added to each rice grain is penetrated into an interior of the rice grain under pressure.Description:



The present invention relates to apparatuses for humidifying rice grains such as brown rice grains and polished rice grains and, more particularly, to an apparatus for humidifying rice grains up to a predetermined moisture content, without causing cracks to occur therein, to improve taste of boiled and cooked rice.

In general, one of important factors influencing the taste of boiled and cooked rice is a moisture content of polished rice before it is dipped in water for the purpose of being boiled and cooked. If the polished rice having the moisture content of approximately 15% is dipped in water within a cooker, no cracks occur in the surface of the polished rice. Accordingly, the polished rice having the moisture content of approximately 15% can be boiled and cooked in a whole grain configuration. The boiled and cooked rice having such whole grain configuration retains adequate glutinosity and hardness which are factors of taste, and is superior in taste. However, the polished rice having a mixture content less than 14% absorbs moisture at a considerably high rate when the rice is dipped in water. The quick absorption of moisture causes cracks to instantaneously occur in the rice grain surfaces and, soon after, the cracks are developed into the interiors of the rice grains to form splits or fractures. Water penetrates into the splits.

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When the polished rice is boiled and cooked under such condition, gelatinized starch flows out of the splits and adheres to the rice grain surfaces. This renders the rice grains sticky. Moreover, since the boiled and cooked rice grains are broken due to the splits, the rices grains are deteriorated in quality, and have no sufficient biting-resistance and glutinosity. Thus, in order to improve the taste, it is necessary to apply the humidifying treatment to the polished rice grains so as to have the moisture content of approximately 15%, before the polished rice grains are dipped in water for the purpose of being boiled and cooked. It is necessary to bring the moisture content of the polished rice to the level of about 15% in order also to prevent the rice from getting mold and from being decomposed. In the humidifying treatment, however, it is essential to avoid occurrence of cracks in the rice grain surfaces.

The maximum limit of the rate at which the polished rice can absorb moisture under a natural condition, i.e., the maximum moisture adding rate at which the rice grains are humidified without causing cracks to occur therein is 0.3% per one hour. When moisture is added to the polished rice at a rate higher than 0.3% per one hour, the moisture exceeding the natural moisture absorbing rate of the rice grains remains on the rice grain surfaces, to thereby wet the same. If the rice grain surfaces are wetted, the surface layer of each rice grain abruptly absorbs the moisture and is expanded, to cause strain to be developed between the surface layer and the interior of the rice grain. The strain results in the occurrence of cracks in the rice grain surfaces. Even if the moisture adding rate slightly exceeds

0.3% per one hour, cracks occur in the rice grain surfaces, similarly to the case of the dipping of rice grains into water. If the moisture adding rate is considerably high, through cracks occur even in the brown rice covered with pericarp having wax property which prevents penetration of water.

In a conventional rice grain humidifying apparatus as disclosed, for example, in Japanese Patent

Application Laid-Open No. 60-21315, a step of adding moisture to rice grains for a relatively short period of time of about 2 to 3 seconds and a tempering step of adding no moisture to the rice grains for a relatively long period of time of about 15 minutes are alternately repeated. In such conventional humidifying apparatus, it has generally been called that the moisture adding rate is 0.3% per one hour.

Since, however, the time during which the moisture is actually added to the rice grains is 2 to 3 seconds, the net moisture adding rate during the actual addition of moisture is considerably high, i.e., on the order of 0.033% per one second. Consequently, there may be a possibility that such a risky condition occurs instantaneously that the rice grain surfaces are wetted. In view of this, it is usual to operate the humidifying apparatus at a moisture adding rate slightly lower than the desired or target moisture adding rate. This makes it difficult for the conventional humidifying apparatus to enhance the operating efficiency or performance.

In contradistinction to the above-described rice grain humififying apparatus in which the moisture is intermittently added to rice grains, a polished rice humidifying method as disclosed in U.S. Pat. No.

4,450,181 to Satake, for example, comprises the step of continuously adding moisture little by little at a rate not exceeding 0.3% per one hour. In this continuous moisture adding method, the moisture is added to the rice grains at a low rate of 0.0083% per one second and, therefore, the rice grains are humidified at the maximum limit of the natural moisture absorbing rate of rice grains without wetting the rice grain surfaces, so that no cracks occur in the rice grains. Accordingly, the continuous moisture adding method can be said to be a superior humidifying method. Since it is impossible for such humidifying method to add the moisture to the rice grains at a rate exceeding the natural moisture absorbing rate thereof, however, the time of the moisture adding treatment cannot help being prolonged or lengthened. Alternatively, if the apparatus were increased in size and capacity to enable a great amount of rice grains to be subjected at a time to the humififying treatment, the treating capapcity of the apparatus would be able to be enhanced. In such case, however, the cost of equipment would increase.

OBJECT AND SUMMARY OF THE INVENTION

It is an object of the invention to provide a rice grain humidifying apparatus which can add moisture to rice grains at a rate exceeding the natural moisture absorbing rate of the rice grains, to humidify the same.

According to the invention, there is provided an apparatus for humififying rice grains, comprising: a humidifying vessel having defined therewithin a substantially closed space and having a supply port for the rice grains and a discharge port therefor;

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supply means connected to the supply port for supplying the rice grains to the humidifying vessel through said supply port while substantially preventing gas from escaping from the space within the humidifying vessel through the supply port; discharge means connected to the discharge port for discharging the rice grains from the humidifying vessel through the discharge port while substantially preventing the gas from escaping from the space within the humidifying vessel through the discharge port; pressurizing means connected to the humidifying vessel for forcibly delivering the gas into the humidifying vessel, to pressurized the space therewithin; and moisture adding means associated with the humidifying vessel for addingmoisture to the rice grains in the pressurized space within the humidifying vessel.


FIG. 1 is a partially broken-way diagrammatic view showing an entire rice grain humidifying apparatus in accordance with the first embodiment of the invention;

FIG. 2 is a block diagram showing a control system incorporated in the apparatus illustrated in FIG. 1;

FIG. 3 is a flow chart showing the program of the control system illustrated in FIG. 2;

FIG. 4 is a view similar to FIG. 1, but showing a second embodiment of the invention; and

FIG. 5 is a view similar to FIG. 1, but showing a third embodiment of the invention.


Referring to FIG. 1, a rice grain humidifying apparatus in accordance with the first embodiment of the invention comprises a humidifying vessel 1 having defined therewithin a substantially closed space 2.

The humidifying vessel 1 is arranged so as to have a longitudinal axis extending substantially vertically, and is comprised of an upper, generally cylindrical portion and a lower, generally concical portion. The humidifying vessel 1 is formed in its top with a supply port 3 for rice grains and in the bottom with a discharge port 4 therefor.

A rice grain supply device, generally designated by the reference numeral 10, comprises a hopper 11 for temporarily storing the rice grains to be treated such as polished rice grains or brown rice grains, and a supply duct 12 having an upstream end thereof connected to the hopper 11 and a downstream end connected to the supply port 3 in the humidifying vessel 1. The supply duct 12 is provided therein with a rotary valve 13 for allowing the rice grains to be supplied from the supply hopper 11 into the humidifying vessel 1 through the supply duct 12 and the supply port 3 while substantially preventing gas such as, for example, air, inert gas or the like from escaping from the space 2 within the humidifying vessel 1 through the supply port 3 and the supply duct 12. The rotary valve 13 has connected thereto an electric motor 14 which is adjustable in rotational speed, so that the rotary valve

13 is rotated by the motor 14.

A rice grain discharge device, generally designated by the reference numeral 20, comprises a discharge duct 21 having an upstream end thereof connected to the discharge port 4. The discharge duct 21 is provided therein with a rotary valve 23 similar to the rotary valve 13, for allowing the rice grains to be discharged out of the space 2 within the humidifying vessel 1 through the discharge port 4 and the discharge duct 21 while substantially preventing the gas from escaping from the space 2 within the humidifying vessel 1 through the discharge port 4 and the discharge duct 21. The rotary valve 23 has connected thereto an electric motor 24 similar to the electric motor 14, so that the rotary valve 23 is rotated by the motor 24.

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A pair of branching ducts 26 and 27 are connected to the downstream end of the discharge duct 21. A two-way change-over valve 28 is provided at the connection between the downstream end of the discharge duct 21 and the branching ducts 26 and 27, and is movable between a rice discharging position where the discharge duct 21 is brought into communication with one of the pair of branching ducts 26 and a water draining position where the discharge duct 21 is brought into communication with the other branching duct 27. A pneumatic actuator 29 has a piston rod which is connected to the twoway change-over valve 28 through a link, so that the valve 28 is moved by the actuator 29 between the water draining and rice discharging positions.

A branching duct 31 is connected to an intermediate portion of the one branching duct 26, and a damper 32 is provided at the connection between the branching ducts 31 and 26. A pneumatic actuator

33 is connected to the damper 32 through a link, so that the damper 32 is moved by the actuator 33 between a normal position where the branching duct 31 is closed and the branching duct 26 is opened to allow the rice grains to flow toward the downstream end of the branching duct 26, and a position where the branching duct 31 is opened and the branching duct 26 is closed to allow the rice grains to flow toward the downstream end of the branching duct 31. The branching duct 26 has its downstream end connected to a lower or upstream end of a vertical elevator 35. An upper or downstream end of the elevator 35 is connected to the hopper 11 through a duct 36. Thus, a rice grain recirculation path is formed by the ducts 21 and 26, elevator 35 and duct 36. The branching duct 31 has its downstream end connected to a lower or upstream end of a vertical elevator 37 which has its downstream end connected to a subsequent processing step or station. Rice grains to be treated such as brown rice hulled by a hulling machine or rice polished by a polishing machine are adapted to be supplied to the upstream end of the elevator 35 through a duct 38.

A pressurizing device, generally designated by the reference numeral 40, comprises a high pressure turboblower 41 driven by a variable-speed electric motor 42. The turboblower 41 has its discharge port which is connected, through a duct 44, to a gas intake port 43 formed in a lower portion of the humidifying vessel 1 adjacent the discharge port 4. A gas exhaust port 45 is formed in the top of the humidifying vessel 1 adjacent the supply port 3. The gas exhaust port 45 is connected to a suction port of the turboblower 41 through recirculation ducts 46 and 47. The recirculation duct 46 has its downstream end reduced in diameter which, in turn, is inserted into an enlarged upstream end of the recirculation duct 47 to define a fresh-gas intake port 48 between the reduced and enlarged ends. Thus, the recirculation ducts 46 and 47 form a gas recirculation path. The recirculation duct 46 is provided therein with a valve 49 which is actuated by an electric motor 51 to open and close the recirculation duct 46. An exhaust pipe 52 is connected to an intermediate portion of the recirculation duct 46. The exhaust pipe 52 is provided therein with a valve 53 which is actuated by an electric motor 54 between a position where the pipe 52 is closed and a position where the pipe 52 is opened.

A heater 61 for heating the gas flowing through the recirculation duct 47 comprises and electricresistance heating elements wound around the recirculation duct 47. A cooler 62 for cooling the gas flowing through the recirculation duct 47 comprises an evaporator 63 disposed around the recirculation duct 47, and a compressor 64 for compressing refrigerant from the evaporator 63 and delivering the compressed refrigerant thereto.

A moisture adding device, generally designated by the reference numeral 70, comprises a water container 71 located at an upper portion of the space 2 within the humidifying vessel 1. A plurality of supersonic-wave vibrating elements 72 are arranged at a bottom of the water container 71. A perforated tubular member 73 has its lower open end in communication with the top of the water container 71. An upper open end of the perforated tubular member 73 is closed by a conical diffusion member 74. A frusto-conical diffusion member 75 is attached around a portion of the perforated tubular member 73 between its upper and lower ends. A water tank 76 is connected to the water container 71 through a pipe 77 which extends through the peripheral wall of the humidifying vessel 1, to supplement water to the water container 71.

A cleaning device, generally designated by the reference numeral 80, comprises a vertically extending, distribution pipe 81 which is rotatably arranged within the humidifying vessel 1. A plurality of nozzles

82 are connected to the distribution pipe 81 so as to be directed tangentially with respect to the peripheral surface of the distribution pipe 81. The distribution pipe 81 has a lower end thereof rotatably supported by a bracket 83 and an upper end sealingly connected to a downstream end of a pipe 84 by a

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coupling 85 for rotation relative thereto. An upstream end of the pipe 84 is connected to the pipe 77. A compression pipe 86 is provided in the pipe 84 to deliver the pressurized water to the distribution pipe

81.

A moisture sensor 91 mounted to the peripheral wall of the hopper 11detects moisture of the rice grains within the hopper 11 to generate a signal representative thereof. A temperature sensor 92 mounted to the peripheral wall of the hopper 11 detects the temperature of the rice grains therewithin to generate a signal representative thereof. A rice grain sensor 93 mounted to a portion of the supply duct 12 between the rotary valve 13 and the supply port 3 detects whether or not the rice grains are supplied by the rotary valve 13 toward the supply port 3, to generate a signal when the rice grains are supplied toward the supply port 3. A level sensor 94 mounted to an upper portion of the peripheral wall of the humidifying vessel 1 detects whether or not the humidifying vessel 1 is filled with the rice grains up to a predetermined level, to generate a signal when the vessel 1 is filled up to the predetermined level. A pressure gage 95 is in communication with the space 2 within the humidifying vessel 1 through a pipe

96, to indicate the pressure of the space 2. In addition, a pressure sensor 97 is provided in the pipe 96 for detecting the pressure of the space 2 to generate a signal representative thereof. A moisture sensor

98 mounted to a lower portion of the peripheral wall of the humidifying vessel 1 detects moisture of the rice grains humidified within the humidifying vessel 1, to generate a signal representative thereof. A temperature sensor 99 is mounted to the duct 44 extending between the discharge port of the turboblower 41 and the gas intake port 43, for detecting the temperature of the gas passing through the duct 44, to generate a signal representative thereof.

FIG. 2 shows a control system 100 for controlling the operation of the rice grain humidifying apparatus illustrated in FIG. 1. The control system 100 comprises a microcomputer 101 which includes an interface 102, a central processing unit 103 (hereinafter referred to as "CPU") 103 connected to the interface 102, and memory unit 104 and a calculation unit 105 connected to the CPU 103. Connected to an input side of the interface 102 are keyboard 111 with a display, and the various sensors 91, 92, 93,

94, 97, 98 and 99 described with reference to FIG. 1. An output side of the interface 102 is connected, through respective actuators 112 to 120, to the electric motors 14 and 24, supersonic-wave vibrating elements 72, heater 61, cooler 62, variable-speed motor 42, motors 51 and 54, and pneumatic actuator

33.

The operation of the rice grain humidifying apparatus described in connection with FIGS. 1 and 2 will be described with reference to FIG. 3.

Prior to the operation of the rice grain humidifying apparatus, an operator operates the keyboard 111 to input the following set values to the microcomputer 101:

(1) rotational speed (rpm) of rotary valve 23, i.e, rotational speed (rpm) of electric motor 24, which determines flow rate (Kg/s) of rice grains flowing within humidifying vessel 2;

(2) pressure (Kg/cm@2 ; gage pressure) within humidifying vessel 1;

(3) reference temperature range for judging necessity of heating and cooling of rice grains;

(4) maximum limit of humidifying rate per unit time (%/hr); and

(5) desired or target moisture content (%) of rice grains.

After the above set values are inputted, the elevator 35 is operated to supply the rice grains delivered through the duct 38, to the hopper 11 (step S1). Moisture and temperature of the rice grains within the hopper 11 are detected respectively by the moisture sensor 91 and temperature sensor 92 (steps S2 and

S3). These detected values are inputted into the CPU 103 through the interface 102 of the microcomputer 101, and are stored in the memory unit 104. Based on the above-noted set values stored in the memory unit 104 and the detected value from the sensor 91, the calculation unit 105 calculates a time duration during which the moisture is added to the rice grains, and an amount of water added to the rice grains. The calculated value is inputted into the CPU 103 to determine the number of supersonic-wave vibrating elements 72 to be actuated. The determined number is stored in the memory unit 104 and, simultaneously, the CPU 103 outputs respective signals to the actuators 117 and 118

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through the interface 102. The actuator 118 actuates the motor 51 to move the valve 49 to the closed position, to close the recirculation duct 46 (step S4). The actuator 117 starts the operation of the variable speed motor 42 for the high pressure turboblower 41 (step S5). Furthermore, the CPU 103 compares the signal from the temperature sensor 92 representative of the temperature of the rice grains within the hopper 11, with the reference temperature range stored in the memory unit 104. When the temperature of the rice grains within the hopper 11 is within the reference temperature range, the CPU

103 issues no signal, and the operation of the heater 61 and the cooler 62 is unnecessary (step S6). The temperature of the rice grains within the hopper 11 is out of the reference temperature, it is judged whether the temperature of the rice grains within the hopper 11 is higher or lower than the reference temperature range (step S7). When the rice grain temperature is lower than the reference temperature range, the CPU 103 sends a signal to the actuator 115 to actuate the heater 61, to thereby heat the gas flowing through the recirculation duct 47 (step S8). When the rice grain temperature is higher than the reference temperature range, the CPU 103 sends a signal to the actuator 116 to actuate the cooler 62

(step S9). The temperature sensor 99 detects the temperature of the gas within the duct 44 which varies depending upon the actuation of the heater 61 or cooler 62, to send a signal representative of the detected temperature to the CPU 103 (step S10). Based on the signal from the temperature sensor 92 representative of the temperature of the rice grains within the hopper 11, the calculation unit 105 calculates a temperature of the gas which is required to bring the rice grains into the reference temperature range. When the temperature sensor 99 detects that the temperature of the gas flowing through the duct 44 is higher or lower than the calculated temperature, the CPU 103 sends a signal to the actuator 115 or 116, to strengthen or weaken the operation of the cooler 62 or heater 61, or to control the cooler or heater in an ON-oFF manner (step S11).

The purpose of regulation of the rice grain temperature into the reference temperature range is to prevent the moisture from shifting or moving within each rice grain when the rice grains subjected to the humidifying treatment are discharged out of the humidifying vessel 1 and are exposed to the surrounding air.

Subsequently, the pressure within the humidifying vessel 1 is detected by the pressure sensor 97 (step

S12). A signal representative of the detected pressure is sent to the CPU 103 through the interface 102, where the signal is compared with the set pressure value (0.2 to 0.3 Kg/cm@2, for example) stored in the memory unit 104 (step S13). When the pressure within the humidifying vessel 1 reaches the set pressure, the CPU 103 sends respective signals to the actuators 112 and 118. The actuator 118 actuates the motor 51 to move the valuve 49 to the open position, to thereby open the recirculation duct 46 (step

S14). This allows the gas within the humidifying vessel 1 to flow into the recirculation duct 46, so that the gas is recirculated through the gas recirculation path formed by the ducts 46 and 47. The actuator

112 starts the operation of the electric motor 14 to rotate the rotary valve 13, to thereby supply the rice grains from the hopper 11 to the humidifying vessel 1 (step S15).

When the rice grain sensor 93 detects the flow of rice grains supplied to the humidifying vessel 1 (step

S16), the detecting signal from the rice grain sensor 93 is sent to the CPU 103 and is stored in the memory unit 104, and a signal representative of the number of supersonic-wave vibrating elements 72 to be actuated determined by the CPU 103 is sent to the actuator 114. The actuator 114 actuates one or more supersonic-wave vibrating element or elements 72 to generate mist of fine particles. The mist flows from the water container 71 into the perforated tubular member 73 and flows out through a plurality of apertures therein (step S17). The flowing-out mist is diffused by the diffusion members 74 and 75, so that moisture is added to the surfaces of the rice grains flowing down. When the level sensor

94 detects that the humidifying vessel 1 is filled with the supplied rice grains to the predetermined level

(step S18), the signal from the level sensor 94 is sent to the CPU 103 which, in turn, sends a signal to the actuator 113 to start the operation of the motor 24. This causes the rotary valve 23 to be rotated at the set rotational speed, i.e., at the same rotational speed as the rotary valve 13, to discharge the rice grains from the humidifying vessel 1 (step S19). The rotary valve 13 continues to rotate, to continuously supply the rice grains to be treated, into the humidifying vessel 1. The moisture sensor 98 detects the moisture of the rice grains flowing downwardly under gravity within the humidifying vessel

1 (step S20). A signal from the moisture sensor 98 is sent to the CPU 103. If the signal from the moisture sensor 98 indicates that the moisture of the rice grains reaches the target moisture value set in the memory unit 104, the CPU 103 sends a signal to the actuator 120 to actuate the pneumatic actuator

33. The actuator 33 causes the two-way change-over valve 28 to close the branching duct 26 and to open the branching duct 31 (step S21). The rice grains humidified up to the target moisture value are

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delivered to the subsequent processing step by the elevator 37. If the moisture of the rice grains detected by the moisture sensor 98 does not reach the target moisture value, the CPU 103 sends any no signal to the actuator 120. The two-way change-over valve 32 is normally in position where the branching duct 26 is opened and the branching duct 31 is closed and, therefore, the insufficiently humidified rice grains are returned to the hopper 11 through the elevator 35 and the duct 36 which form the rice grain recirculation path. During delivery of the rice grains through the rice grain recirculation path, the gas penetrated into the rice grains is naturally released from the interior of each rice grain.

The above-noted steps S2 to S21 are repeated.

During the period that the rice grains have added thereto the moisture and reach the discharge port 4, the moisture added to the rice grain surfaces is subjected to the pressurization higher than the atmospheric pressure by the operation of the pressurizing device 40. Consequently, the moisture is penetrated into the interior of each rice grain at a rate higher than the natural moisture absorption rate.

Thus, the moisture in the surface layer of each rice grain and the moisture in the interior thereof are equalized with each other for a short period of time, making it possible to increase the humidifying rate without occurrence of cracks in the rice grains. That is to say, since the rice grains are humidified within the humidifying vessel 1 high in pressure, even if the rice grains are humidified at a rate higher than the value equal to or less than 3% per hour which is said to be adequate in the previously discussed conventional humidifying apparatus, the moisture in the rice grain surface layer is penetrated into the rice grain interior under the pressurizing action of gas, for a short period of time unitl the surface layer is expanded by the moisture exceeding the amount which can be absorbed by the surface layer. Thus, the moisture in the rice grains surface layer and the moisture in the rice grain interior are equalized with each other to prevent a strain from being developed due to a moisture difference, to thereby make it possible to enhance the humidifying rate without occurrence of cracks in the rice grains.

When the moisture value of the humidified rice grains does not reach the target moisture value, the rice grains are again returned to the humidifying vessel 1 and are again humidified therewithin. When the value detected by the moisture sensor 98 and the set target moisture value stored in the memory unit

104 are compared with each other, and the moisture difference therebetween is less than the maximum limit of humidifying rate per unit time stored in the memory unit 104, the CPU 103 sends a signal to the actuator 114 to reduce the number of supersonic-wave vibrating elements 72 actuated or the oscillation frequency of the actuated vibrating element or elements 72.

When dirts and dusts contained in the pressurizing gas passing between the rice grains increase in amount with the lapse of operating time of the humidifying apparatus, or when the temperature of the pressurizing gas rises to a level higher than the temperature calculated at the step S11, signals are sent at suitable time intervals from the CPU 103 to the actuator 119 through the interface 102, to actuate the motor 54. The actuation of the motor 54 causes the valve 53 to be opened to allow the contaminated gas to be discharged through the duct 52, and to allow fresh gas to be introduced into the duct 47 through the fresh-gas intake port 48. Alternatively, the valve 53 may be normally closed slightly to always supplement the fresh gas little by little, while always discharging the recirculating gas slightly.

As the contaminated gas is discharged through the duct 52, the pressure within the humidifying vessel

1 decreases to a level lower than the set pressure value. When the pressure sensor 97 detects that the pressure within the humidifying vessel 1 decreases to a level lower than the set pressure value, the CPU

103 sends a signal to the actuator 117 to increase the rotational speed of the variable-speed motor 42 which actuates the high pressure turboblower 41. In this manner, the pressure within the humidifying vessel 1 is maintained at the predetermined pressure.

After the humidifying treatment of some number of lots has been effected, or at the time an exchange is effected to a humidifying treatment of polished rice subsequent to a humidifying treatment of brown rice, it is necessary to clean the inner wall surface of the humidifying vessel 1 so as to remove deposits therefrom. For this purpose, the pneumatic actuator 29 is operated to actuate the two-way change-over valve 28, to bring the discharge duct 21 into communication with the water draining duct 27.

Subsequently, the cleaning device 80 is operated. Specifically, the compression pump 86 is operated and the electric motor 24 is actuated to drive the rotary valve 23. The pressurized water is forcibly delivered to the distribution pipe 81, and is injected through the injection nozzles 82 toward the inner wall surface of the humidifying vessel 1. The water injection from the injection nozzles 82 causes the distribution pipe 81 to be rotated around its own axis. The water which has cleaned the inner wall

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surface of the humidifying vessel 1 flows out of the water draining duct 27. After cleaning, the compression pump 86 and the electric motor 24 are stopped in operation. Subsequently, the variablespeed motor 42 for driving the high pressure turboblower 41 and the heater 61 are actuated to dry the interior of the humidifying vessel 1, in preparation for a subsequent humidifying treatment.

If the humidifying rate does not reach its maximum limit in spite of the fact that an amount of mist generated by the moisture adding device 70 is maximum, the initially set rotational speed of the electric motor 24 may be controlled to adequately adjust the rotational speed of the rotary valve 23 so as to reduce the rice grain flow speed within the humidifying vessel 1, to thereby adjust the humidifying rate.

A compressor may be employed in combination with the high pressure turboblower 41, as the pressurizing device 40. Additionally, the above-described various controls may be effected manually.

FIG. 4 shows a rice grain humidifying apparatus in accordance with a second embodiment of the invention. In FIG. 4, like reference numerals are used to designate parts or components corresponding to those illustrated in FIG. 1, and the description of such corresponding parts or components will be omitted to avoid duplication. The rice grain humidifying apparatus shown in FIG. 4 comprises a moisture adding device generally designated by the reference numeral 270. The moisture adding device

270 has a water container 271 arranged exteriorly of the humidifying vessel 1. The water container 271 is connected to the water tank 76 by a pipe 277. A plurality of supersonic-wave vibrating elements 272 are arranged at the bottom of the water container 271. A duct 273 has open one end thereof in communication with the top of the water container 271. The other end of the duct 273 is connected to the recirculation duct 47 at a location between the evaporator 63 of the cooler 62 and the high pressure turboblower 41. One end of a curved duct 244 arranged within the humidifying vessel 1 is connected to the duct 44 at the gas intake port 43 shown in FIG. 1. The other open end of the curved duct 244, which is directed upwardly, is positioned in facing, but spaced relation to an inner surface of a conical diffusion member 274 disposed at a lower portion of the space 2 within the humidifying vessel 1. The remaining structure of the second embodiment illustrated in FIG. 4 is identical with that of the first embodiment illustrated in FIG. 1.

In operation of the second embodiment shown in FIG. 4, mist generated by the supersonic-wave vibrating elements 272 of the moisture adding device 270 flows into the recirculation duct 47 through the duct 273, and is mixed with the gas flowing through the recirculation duct 47, to form humid gas.

The humid gas flows into the space 2 within the humidifying vessel 1 through a gap between the other open end of the duct 244 and the diffusion member 274. The humid gas flows toward the top of the humidifying vessel 1 while humidifying the rice grains flowing downwardly within the humidifying vessel 1. The gas reaching the top of the humidifying vessel 1 flows into the recirculation duct 46 through the exhaust port 45 shown in FIG. 1, and is again wetted by the mist from the moisture adding device 270 when the gas passes through the recirculation duct 47. In this manner, the second embodiment is arranged such that the humid gas is passed between the rice grains to humidify the same. Operations other than those described above are identical with those of the first embodiment described presviously, and will not be described.

FIG. 5 shows a rice grain humidifying apparatus in accordance with a third embodiment of the invention. In FIG. 5, like reference numerals are used to designate like or similar parts or components illustrated in FIG. 1, and the description of such like or similar parts or components will be omitted.

The rice grain humidifying apparatus illustrated in FIG. 5 comprises a screw conveyor 390 arranged within the humidifying vessel 1. The screw conveyor 390 includes a barrel 391 having a vertical axis coincident with the longitudinal axis of the humidifying vessel 1, a shaft 392 disposed within the barrel

391 in concentric relation thereto, and a screw 393 mounted around the shaft 392. An upper open end of the barrel 391 is located substantially at the same elevation as the level sensor 94. A speed-reduction motor 394 is positioned adjacent the bottom of the space 2 within the humidifying vessel 1, and the motor 394 has an output shaft connected to the lower end of the shaft 392. A moisture adding device, generally designated by the reference numeral 370, comprises a conical diffusion member 371 arranged at the top of the space 2 within the humidifying vessel 1. The diffusion member 371 is disposed in facing, but upwardly spaced relation to the upper open end of the barrel 391. An injection nozzle 372 is positioned at a center of the diffusion member 371. The injection nozzle 372 is connected to the water tank 76 through a pipe 377. The pipe 377 is provided therein with a electromagnetic pump 373 capable

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of adjusting flow rate therethrough. The remaining structure of the third embodiment illustrated in FIG.

5 is substantially identical with that of the first embodiment illustrated in FIG. 1.

In operation of the third embodiment shown in FIG. 5, the rice grains are filled within the humidifying vessel 1 up to a predetermined level and are temporarily stored therein. Subsequently, the space 2 within the humidifying vessel 1 is regulated so that the pressure and temperature of the space 2 reach predetermined respective values. The speed-reduction motor 394 is started in operation to cause the screw conveyor 390 to deliver the rice grains from a position adjacent the discharge port 4 (FIG. 1) to a position adjacent the supply port 3, to recirculate the rice grains within the humidifying vessel 1. Mist is jetted from the injection nozzle 372 of the moisture adding device 370, against the rice grains discharged from the upper open end of the barrel 391. The rice grains are subjected to the pressurizing action within the humidifying vessel 1 in the course of flowing toward the surface layer of the stored rice grains, so that the moisture added to the rice grain surface is penetrated under pressure into the rice grain interior. If the detected value of the moisture sensor 98 reaches the target moisture value at the time the surface layer and interior of each rice grain are humidified up to substantially the same moisture value, the electric motor 24 and the pneumatic actuator 33 are actuated. This causes the humidified rice grains to be discharged from the humidifying vessel 1 into the duct 37 and to be delivered to the subsequent processing step. If the detected value of the moisture sensor 98 does not reach the target moisture value, the conveyor 390 continues to recirculate the rice grains and the moisture is added to the recirculated rice grains. The third embodiment is characterized in that an efficient operation can be effected in case where a considerable difference is present between the moisture value of the rice grains to be treated and the target moisture value, and twice or more humidifications are required even if the operation is effected within the safe range of humidification rate and at the maximum limit of the humidification rate per unit time.

When it is required to continuously repeat a plurality of recirculated humidifying actions in the third embodiment illustrated in FIG. 5, the variable-speed motor 42 of the pressurizing device 40 is temporarily stopped in operation, and the motor 54 is actuated to open the valve 53, so as to permit the gas to escape from the recirculation duct 46 through the duct 52. This causes the pressure within the humidifying vessel 1 to be decreased to the atmospheric pressure, to permit the gas from released from each rice grain interior. Subsequently, the valve 53 is closed, and the variable-speed motor 42 is again started in operation to increase the pressure within the humidifying vessel 1 to the predetermined pressure value. Then, the moisture is added to the rice grains until the moisture of the rice grains reaches the target moisture value.

As described above, the rice grain humidifying apparatus in accordance with the present invention is arranged such that rice grains are humidified in a substantially closed space within a humidifying vessel and, simultaneously, the added moisture is penetrated into the rice grain interior under the pressurizing action. With such arrangement, the moisture is shifted from the rice grain surface toward the rice grain interior at a high speed. Accordingly, it is possible to add the moisture to the rice grains at a rate higher than the natural moisture absorption rate, to humidify the rice grains. This makes it possible to considerably reduce the humidification treating time without occurence of cracks in the rice grains. Moreover, it is possible to reduce the size of the apparatus, making it possible to reduce the cost of equipment of the appartus.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. An apparatus for humidifying rice grains, comprising: a humidifying vessel having defined therewithin a substantially closed space for containing rice grains and gas in pressurized condition therewithin and having a supply port for the rice grains and a discharge port therefor; supply means connected to said supply port for supplying the rice grains to said humidifying vessel through said supply port while substantially preventing such gas from escaping from said closed space within the humidifying vessel through said supply port; discharge means connected to the discharge port for discharging the rice grains from said humidifying vessel through said discharge port while substantially preventing the gas from escaping from said space within said humidifying vessel through said discharge port; pressurizing means connected to said humidifying vessel for forcibly delivering the gas

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into and passing the gas through said humidifying vessel, to pressurize said space therewithin; and moisture adding means, and control means for operating the supply means, discharge means, pressurizing means and moisture adding means, associated with said humidifying vessel and arranged for increasing the moisture-content in the rice grains in said pressurized space within said humidifying vessel, while avoiding substantial occurrence of cracks in the rice grains, at a rate higher than 0.3% per one hour and exceeding the natural moisture absorbing rate of the rice grains.

2. An apparatus as defined in claim 1, including: recirculation path means through which the gas delivered into said humidifying vessel and passed therethrough by said pressurizing means is returned thereto, the returned gas being forcibly delivered into said humidifying vessel by said pressurizing means.

3. An apparatus as defined in claim 2, wherein said recirculation path means comprises at least one duct, a fresh-gas intake port provided in said duct, and a valve located upstream of said fresh-gas intake port with reference to the gas flow passing through said duct, said valve being movable between an open position where the gas is permitted to escape from said duct and a closed position where the gas is prevented from escaping from said duct.

4. An apparatus as defined in claim 3, wherein said supply port and said discharge port are provided respectively in a top and a bottom of said humidifying vessel, said humidifying vessel having a gas intake port provided therein adjacent said discharge port and a gas exhaust port provided in said humidifying vessel adjacent said supply port, the gas pressurized by said pressurizing means being returned thereto through said gas intake port, said humidifying vessel, said gas exhaust port and said recirculation path means.

5. An apparatus as defined in claim 1, wherein said moisture adding means applies mist to the rice grains within said humidifying vessel to humidify the rice grains.

6. An apparatus as defined in claim 5, wherein said moisture adding means comprises a water container arranged within said humidifying vessel, a plurality of sueprsonic-wave vibrating elements disposed at a bottom of said water container for generating the mist, a perforated tubular member having opposed open ends, one said open end thereof being in communication with said water container, and a conical diffusion member provided adjacent said supply port for closing the other said end of said perforated tubular member.

7. An apparatus as defined in claim 1, wherein said moisture adding means mixes mist with the gas delivered into said humidifying vessel by said pressurizing means.

8. An apparatus as defined in claim 7, including: recirculation path means through which the gas delivered into said humidifying vessel and passed therethrough by said pressurizing means is returned thereto, the returned gas being forcibly delivered into said humidifying vessel by said pressurizing means.

9. An apparatus as defined in claim 8, wherein said moisture adding means comrpises a water container arranged exteriorly of said humidifying vessel, a plurality of supersonic-wave vibrating elements disposed at a bottom of said water container for generating the mist, and a duct having one end thereof in communication with said water container and the other end connected to said recirculation path means for introducing the mist generated by said supersonic-wave vibrating elements, into said recirculation path means.

10. An apparatus as defined in claim 9, wherein said recirculation path means comprises at least one duct, a fresh-gas intake port provided in said duct, and a valve located upstream of said fresh-gas intake port with reference to the gas flow passing through said duct, said valve being movable between an open position where the gas is permitted to escape from said duct and a closed position where the gas is prevented from escaping from said duct.

11. An apparatus as defined in claim 10, wherein said supply port and said discharge port are provided respectively in a top and a bottom of said humidifying vessel, said humidifying vessel having a gas intake port provided therein adjacent said discharge port and a gas exhaust port provided in said

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humidifying vessel adjacent said supply port, the gas pressurized by said pressurizing means being returned thereto through said gas intake port, said humidifying vessel, said gas exhaust port and said recirculation path means.

12. An apparatus as defined in claim 11, including: a duct arranged within said humidifying vessel and having one end connected to said gas intake port and the other end opening toward said supply port in a lower portion of said space within said humidifying vessel; and a conical diffusion member positioned in facing relation to the other open end of said duct.

13. An apparatus as defined in claim 1, including: means for heating the gas forcibly delivered into said humidifying vessel by said pressurizing means; and means for cooling the gas forcibly delivered into said humidifying vessel by aid pressurizing means.

14. An apparatus as defined in claim 1, including: recirculation path means for returning the rice grains discharged through said discharge port, to said supply port.

15. An apparatus as defined in claim 1, including: recirculating means arranged within said humidifying vessel for delivering the rice grains from a position adjacent said discharge port to a position adjacent said supply port for recirculating the rice grains within said humidifying vessel.

16. An apparatus as defined in claim 15, wherein said moisture adding means injects mist against the rice grains delivered to said position adjacent said supply port by said recirculating means.

17. An apparatus as defined in claim 16, wherein said recirculating means comprises a screw conveyor including a barrel, a screw disposed within said barrel, and a motor drivingly connected to said screw for rotating the same.

18. An apparatus as defined in claim 1, including:cleaning means for injecting cleaning liquid against an inner wall surface of said humidifying vessel to remove deposits therefrom.

19. An apparatus as defined in claim 18, wherein said cleaning means comprises a pipe having a substantially vertical axis and rotatably supported within said humidifying vessel, a plurality of nozzles connected to said pipe so as to be directed substantially tangentially with respect to a peripheral surface of said pipe, and a pump connected to said pipe for forcibly delivering the cleaning liquid into said pipe.Data supplied from the esp@cenet database - Worldwide

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260.

PL289725 - 11/4/1991

METHOD OF CLARIFYING RICE STARCH DEXTRIN

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=PL289725

Inventor(s): TAO MICHAEL C (US); LITOV RICHARD E (US); EUBER JOHN R (US);

AKRABAWI SALIM S (US); MORAN J ROBERTO (US)

Applicant(s): SQUIBB BRISTOL MYERS CO (US)

IP Class 4 Digits: C08B

IP Class: C08B30/18

E Class: A23L1/09D; A61K31/715; A61K33/14; C08B30/18

Application Number: PL19910289725 (19910403)


Family: AU642483

Equivalent: EP0459108; US5096894; OA9491; MX172924; JP5320054; PT97229; PL165045B

Abstract:

Abstract not available for PL289725


An improved oral rehydration solution comprising a mixture of rice dextrin and required electrolytes is provided. The functionality of the rice dextrin in oral rehydration solutions is superior to glucose in infants with chronic diarrhea resulting in lower stool output and enhanced water retention. Rice dextrin also has a polymer profile which provides more readily available glucose than corn dextrin or rice flour. There is also provided a process for clarifying solutions of rice dextrin which involves a first filtration at 35 DEG C to 50 DEG C and a second filtration at temperatures above 80 DEG C using filter aid and activated carbon.Description:


The development of oral rehydration therapy (ORT) for acute diarrheal diseases of infancy and childhood has significantly reduced related morbidity and mortality, particularly in less developed countries where it constitutes the primary mode of therapy.

Oral rehydration solutions (ORS) used in ORT generally consist of a mixture of electrolytes and a carbohydrate component such as glucose or sucrose. The American Academy of Pediatrics recommends glucose at 2.0 to 2.5% by weight, potassium at 20 mEq/L, anions as chloride and as base

(acetate, lactate, citrate, or bicarbonate), sodium at 75 to 90 mEq/L for acute dehydration and sodium at

40 to 60 mEq/L for the prevention of dehydration or maintenance of hydration (1985, Pediatrics,

75:358). The World Health Organization (WHO)/UNICEF currently recommends that oral rehydration solution contains 90 mEq sodium/liter, 20 mEq potassium/liter, 80 mEq Cl/liter, 30 mEq citrate/liter or

30 mEq bicarbonate/liter and glucose 110 mmol/liter.The WHO formulation has been shown to decrease morbidity and mortality in acute diarrheal disease but the magnitude of diarrhea in terms of volume and frequency of stools and the duration of the illness is not reduced.

Substitution of other carbohydrates for glucose in WHO-type formulations has been investigated.

Lebenthal, et al., J. Pediatrics., 103:29-34 (1983) studied the effect of three corn syrup sugars (dextrins) containing glucose polymers of varying lengths having dextrose equivalents of 10, 15 and 24 and determined they were suitable as the sole carbohydrate source in ORT. It has also been established that

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ORS in which rice and other food sources of starch are substituted for glucose are effective as reported by Carpenter, et al., New England Journal of Medicine, 319:1346-1348 (1988).In particular, rice-based oral rehydration solutions have been found to be effective as reported in the following publications.

Patra, et al Archives of Disease in Childhood, 57:910-912 (1982), "Is Oral Rice Electrolyte Solution

Superior to Glucose Electrolyte Solution in Infantile Diarrhoea?"

Molla, et al The Lancet, 1317-1319 (1982), "Rice-Powder Electrolyte Solution as Oral Therapy in

Diarrhoea Due to Vibrio Cholerae and Escherichia Coli".

El Mougi, et al Journal of Pediatric Gastroenterology and Nutrition, 7:572-576 (1988), "Controlled

Clinical Trial on the Efficacy of Rice Powder-Based Oral Rehydration Solution on the Outcome of

Acute Diarrhea in Infants".

Molla, et al Journal of Gastroenterology and Nutrition, 8:81-84 (1989), "Turning Off The Diarrhea:

The Role of Food and ORS".

The rice-based ORS of the foregoing references contained from 3 to 5% rice and had electrolyte levels corresponding to conventional WHO formations. They were prepared as follows.

Patra, et al supra. - Sufficient powdered rice (prepared by popping unhusked rice on heated sand) was dissolved in rehydration fluid before use to make a 5% ORS.

Molla, et al. (1982) supra. - Rice powder was first dissolved in several hundred milliliters of water and boiled for 1-2 minutes to make a uniform solution and then electrolytes added to make a 3% ORS.

El Mougi, et al supra. - Sufficient rice powder was dissolved in 200 mL of hot water and cooked for

10 minutes until a gel formed to provide a semi-liquid 5% ORS.

Molla, et al (1989) supra. - Sufficient rice flour was boiled in 1.1 liters of water for 5 to 7 minutes forming a homogeneous solution which was mixed with electrolytes to make a 4.5% ORS.

One problem associated with the use of prior art rice-based ORS is that they must be prepared shortly before use because they are not sterile. Another problem with prior art rice ORS relates to the relative insolubility of rice flour which prevents preparation of pharmaceutically elegant crystal (water) clear

ORS.

A primary object of the invention is to provide a stable ready-to-use ORS wherein the carbohydrate component is rice dextrin.

Still another object of the invention is to provide an improved rice based ORS which results in lower stool output and a better water and potassium balance during the rehydration period.


The present invention concerns an improved oral rehydration solution comprising a mixture of required electrolytes combined with rice dextrin. The invention is based on the discovery that ORS rice dextrin functions better than ORS glucose in infants with chronic diarrhea resulting in lower stool output and enhanced water retention. Rice dextrin also has a glucose polymer profile which provides more readily available glucose than corn dextrin or rice flour.


Figure 1 is a schematic diagram of a process for clarification of rice dextrin in accordance with the invention.


The oral rehydration solution of the invention is made by preparing a solution of potassium, sodium, chloride and a base (acetate, lactate, citrate, or bicarbonate) in water. Clarified rice dextrin along with optional flavoring agents are added to the solution which is standardized with purified water to provide

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from 10 to 80 g/L and preferably 10-35 g/L of rice dextrin. Sodium is added at 20-100 mEq/L with a preferred level of from 40-60 mEq/L for formulations for treatment of acute dehydration and 75-90 mEq/L for formulations for prevention of dehydration or maintenance of hydration. Preferred potassium levels are from 20-30 mEq/L with a broad range of 20-100 mEq/L operable. The chloride anion is preferably added at 30-80 mEq/L with a broad range of 25-100 mEq/L operable.The base selected from the group consisting of acetate, lactate, citrate or bicarbonate is preferably added at a range of 25-40 mEq/L with a broad range of 20-50 mEq/L operable.

A most preferred rice dextrin based ORS comprises per liter: sodium - 50 mEq; potassium - 25 mEq; chloride - 45 mEq; citrate - 34 mEq; rice dextrin - 30 g.

The rice dextrin glucose polymer (GP) profile of the instant ORS has a distribution of short chain glucose polymers consisting of 50 to 90% 2 to 6 glucose units and preferably 55 to 80% and most preferably 65 to 75% (Wt./Wt. basis).

Rice dextrin suitable for use in the ORS of the invention can be obtained from the solubilized rice starch of Puski et al U.S. Patent 4,830,861 incorporated in entirety herein. Puski et al describe a procedure whereby the carbohydrate in rice flour is solubilized by amylase enzymes and separated from insoluble rice protein and carbohydrate by centrifugation. The resulting soluble fraction contains about 98% carbohydrate and less than 1% but more than 0.1% protein. This material is not suitable as the carbohydrate component of the instant ORS due to trace amounts of particulate matter and residual protein which contributes to foaming and browning problems during processing and sterilization and the formation of a fine precipitate during storage.

According to the instant invention, the solubilized rice carbohydrate of Puski et al was clarified by a process comprising the steps of:

(a) filtering the solubilized rice carbohydrate fraction obtained from rice flour by enzymatic hydrolysis at neutral pH using filter aid at 35 DEG C to 50 DEG C; and then

(b) subjecting the filtrate to a second filtration using filter aid and activated carbon at temperatures above 80 DEG C.

If desired, the clarified solution can be spray dried following pH adjustment to 4.0-4.8 and preferably

4.5.

Conventional filter aids such as amorphous silica (Silflow) from Sil Flo Corporation, and activated carbon, Darco S-51, from American Norit are used. The clarified rice dextrin of the instant process may be spray dried to provide rice dextrin solids having less than 0.1% protein by weight.

The first filtration essentially reduces the protein to a level where the product can be sterilized without foaming and browning problems. However, the resulting ORS is not acceptable in that it does not have sufficient clarity to meet the requirement of a clear ORS. Subjecting the filtrate from the first filtration to a second filtration with activated carbon at high temperature, preferably at 80-95 DEG C and most preferably at 90-95 DEG C, removes the small particulate precipitate and the haze that forms in the carbohydrate after the first filtration. The results in Table 1 show the improved clarity as a result of the second filtration above 80 DEG C. EMI6.1

The second filtration at a temperature below 80 DEG C does not remove the haze or precipitate formed in the sterilized ORS. The criticality of the second filtration temperature on the clarity of ORS is shown in Table 2 where results of a second filtration at high (90 DEG C) and low (45 DEG C) temperature are set out. EMI7.1

Commercially available rice syrup solids (rice dextrin) are suitable for the instant invention provided they do not contain more than 0.1% by weight protein or other particulate matter and wherein the glucose polymer (GP) profile of GP2 through GP6 is from 50 to 90%. Those that have more than 0.1% by weight protein or other particulate matter are subjected to the instant clarification process.

Table 3 sets out the distribution of glucose polymer found in samples of rice dextrin (RD) and corn dextrin (CD) with similar dextrose equivalents. Rice flour (RF) is also compared. The unclarified rice dextrin (RD-1) was opaque and had poor physical properties. Rice dextrins of the instant invention

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(RD-2, RD-3, RD-4) were very clear syrups. The corn dextrin syrup was also clear while the rice flour sample was insoluble and opaque. EMI8.1

Comparison of Rice Dextrin and Corn Dextrin for Use in Oral Rehydration Solutions.

As previously stated, the World Health Organization (WHO) recommends glucose as the carbohydrate component in oral rehydration solutions (ORS) to aid in replacement of water and electrolytes for infants with serious diarrhea. Glucose enhances the membrane transport of sodium which in turn enables rapid uptake of water.

A clinical comparison of rice dextrin ORS and glucose ORS demonstrated that rice dextrin ORS performed better in infants with diarrhea than the formulation with glucose as the carbohydrate source.

Corn dextrin has also been used as the carbohydrate source in oral rehydration therapy. Lebenthal et al supra. However, as discussed below, rice dextrin provides more readily available glucose than corn dextrin in infants with chronic diarrhea.

Both rice dextrin and corn dextrin are composed of glucose polymers derived by partial hydrolysis of the parent starch. Digestion of these glucose polymers (GP) in infants involves enzymatic breakdown to glucose by amylase enzymes such as intestinal glucoamylase. This enzyme is distributed throughout the small intestinal mucosa and tends to be more resistant to intestinal injury brought about by diarrhea.

Disaccharides and other low molecular weight glucose polymers found in dextrins are the preferred substrate for glucoamylase.

Table 4 shows a glucose polymer (GP) distribution for rice dextrin of the instant ORS and a commercially available corn dextrin with a similar dextrose equivalent. EMI9.1

It is evident from the rice dextrin GP distribution that a greater percentage (65.7%) of the total polymers are short chain polymers consisting of 2-6 glucose units (GP2-GP6) compared to the corn GP distribution (33.6%). Therefore, rice dextrins are preferred substrates over corn dextrins for glucoamylase, the primary digestive enzyme for glucose utilization after episodes of infant diarrhea.

Table 5 sets out the results of enzymatic hydrolysis of rice and corn dextrin by mucosal homogenates.

In this comparison, enzymes obtained from saliva, duodenal aspirates and duodenal mucosal homogenates were obtained from several infants and pooled. Five hundred mL of carbohydrate solution were incubated with 100 mL of duodenal homogenate and incubated for 3 hours with mechanical shaking at 37 DEG C. Following incubation, the mixtures were heated at 100 DEG C for 5 minutes, passed through 4 layers of millipore filters and analyzed on HPLC. The results were combined into two categories GP (2-4) and GP ;/=5. The results are shown in Table 5. EMI10.1

It is evident that rice dextrin produces significantly more glucose and low molecular weight GP than corn dextrin. Correspondingly, the higher molecular weight fraction of rice dextrin (GP ;5) decreased faster compared to the high molecular weight fraction of corn dextrin. These findings illustrate that with human enzyme extracts, rice GP was a better substrate for conversion to glucose and short chain

GP than corn GP.

Carbohydrate Tolerance studies

Table 6 sets out results of carbohydrate tolerance studies with sixteen infants with chronic diarrhea.

The following procedure was used. The patients were fasted for eight hours and then given two grams per kg of a 10% solution of glucose, rice dextrin or corn dextrin in random order on consecutive mornings. All three of the different carbohydrates were well digested and absorbed. EMI11.1

It is evident that the maximal increase in serum glucose is significantly higher with the rice dextrin solution compared to the corn dextrin solution. With respect to peak glucose serum levels, the elapsed time for rice dextrin was significantly shorter than for corn dextrin. Glucose solutions and rice dextrins

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have similar increase in serum glucose. However, glucose solutions have a higher osmotic load compared to dextrin solutions which may be a problem for ORS products.

Serum glucose response curves established that the mean area under the curve of the rice dextrin was significantly greater than corn dextrin during the first 30 and 60 minutes of the tolerance test (p >;0.05) but not at 120 minutes.

Results of this study illustrate that rice dextrin has a greater maximal rise of serum glucose, a shorter elapsed time until the serum glucose peaked and a larger area under the serum glucose response curve during the first 30 to 60 minutes of testing than corn dextrin. These results demonstrate that rice dextrin is more rapidly hydrolyzed and absorbed than corn dextrin. Thus, rice dextrin provides more readily available glucose than corn dextrin to enable the rapid uptake of water and sodium from an oral rehydration solution.

Comparison of Clarified Rice Dextrin, Pop Rice Powder and Rice Flour

As previously mentioned, both popped rice and rice flour have been used in oral rehydration therapy.

However, popped rice and rice flour are not suitable as a carbohydrate component for a clear shelfstable ready-to-use ORS. Oral Rehydration solutions of popped rice and rice flour cannot be sterilized without foaming and browning problems associated with processing and sterilization of the products.

Moreover, clear ready-to-use ORS cannot be prepared because of the relative insolubility of popped rice powder and rice flour. Finally, the organoleptic properties of popped rice or rice flour make them less desirable for ORS than rice dextrin. Comparative results of solutions of rice dextrin, pop rice powder and rice flour at 3% w/w concentration are presented in the following tables. EMI13.1

EMI14.1

It is evident that rice dextrin was completely soluble while only a small fraction of the pop rice or rice flour solids was soluble. The more soluble rice dextrin relative solubility affects clarity as shown in

Tables 7-8. The clarified rice dextrin solution was "water clear" while the pop rice and rice flour solutions were nearly opaque.

In the organoleptic evaluation presented in Table 9, the rice dextrin solution was significantly different from the pop rice powder and rice flour solutions with respect to all attributes examined. Heat treatment (80 DEG C) had little effect except for a slight influence on the mouthfeel of the rice flour solution.

Comparison of Rice Dextrin and Rice Flour Digestion by Intestinal Enzymes

Major enzymes involved in carbohydrate digestion and production of glucose from glucose polymers are intestinal maltase and pancreatic amylase. However, during the first six months of life, pancreatic amylase is absent or extremely low in concentration. Hence, carbohydrate digestion in young infants is primarily dependent on amylase in saliva along with a variety of intestinal amylases.

Gastrointestinal illness in, infants affects carbohydrate digestion because of the loss of enzymes due to infectious disease. However, maltase activity remains high following infectious illness, when other disaccharidases become severely depressed. In addition, carbohydrate breakdown is affected by the low activity of pancreatic amylase in infants up to six months of age.

Table 10 sets out a comparison of maltase digestion of rice dextrin (RD) and rice flour (RF). The maltase digestions were performed by incubating (37 DEG C) 30 mg. of RD or RF with 20 Units of maltase in a total volume of 1.0 mL for various lengths of time. Following incubation, samples were placed in a boiling water bath for 5 minutes to inactivate the test enzyme. Digested samples were centrifuged to separate insoluble materials (e.g., RF) and the concentration of free glucose in the supernatant determined colorimetrically with a Trinder glucose oxidase reagent (Sigma Chemical Co.,

St. Louis, MO). EMI16.1

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It is evident that no glucose was found in RF samples following digestion with maltase for up to 40 minutes. Digestion of RD with maltase, however, led to the immediate production of glucose which increased with increasing incubation times up to 40 minutes. When free glucose in undigested RD was subtracted from total glucose in digested rice dextrins, the amount of glucose liberated as a direct result of maltase digestion ranged from 2.12 to 5.16 mg or 7-17% of the total RD. These results demonstrate that glucose is produced during maltase digestion of RD but not RF.

As previously mentioned, the RD profile for the instant ORS consists of GP of 2 to 6 glucose units with from 65 to 75% preferred. RF has no GP less than 7 GP. When RF and RD are incubated with human pancreatic glucoamylase, proportional increases in GP1 through GP6 content were found for RF and

RD which suggests that RF and RD are comparable in terms of pancreatic amylase digestibility.

However, as pointed out above, pancreatic amylase is not important in the young infant.

Table 11 sets out a comparison of the amount of glucose in solutions of RD and RF before and after digestion with human pancreatic amylase and excess maltase further illustrating that RD provides substantially higher levels of glucose than RF in a comparative test period. Coupled enzyme digestions consisted of incubating 30 mg of RD or RF with 0.28 Units of amylase for desired times, boiling samples for 5 minutes to inactivate the amylase, and subsequent incubation of mixtures with excess maltase (50 Units) to convert available maltose (GP2) and maltotriose (GP3) to free glucose. Digested samples were centrifuged to separate insoluble materials (e.g., RF) and the concentration of free glucose colorimetrically determined. EMI18.1

It is evident that incubation of RD or RF with excessive levels of maltase alone (amylase blank) resulted in production of large amounts of glucose in RD samples (7 mg/30 mg RD), 23% of total RD but no glucose in maltase digested RF. This glucose is the result of maltase digestion of GP2 (maltose) and GP3 (maltotriose) which is present in RD but not RF. Digestion of RD or RF with both pancreatic amylase and excess maltase led to higher amounts of glucose in RD samples than in RF samples. The total glucose produced in samples of RD or RF increased with increasing time of incubation with amylase.

The results from the intestinal digestion study indicate that higher levels of glucose are produced from

RD than RF during digestion by both amylase and maltase. Further, the results also demonstrate that glucose is produced during maltase digestion of RD but not RF indicating that free glucose would continue to be available from RD but not RF during periods of pancreatic amylase insufficiency. Thus,

"in vitro" digestion of RD but not RF appears to provide the glucose required in the management of acute diarrhoeal dehydration in infants.

The following examples illustrate the invention.

EXAMPLE 1

Clarification of Rice Dextrin - Lab Scale

In this example, 300 g of a solution containing 30% crude rice dextrin carbohydrate is warmed to 45

DEG C and the pH adjusted to 6.0 with KOH. A first filtration is carried out with a Buckner filtration funnel precoated with filter aid after the addition of 6.2 g filter aid, Sil Flo.

The filtrate is prepared for a second filtration by the addition of 2.75 g of filter aid and 8.1 g of carbon powder, American Norit. The mixture is heated to 90 DEG C before being filtered on a Buchner filtration funnel coated with filter aid.

The resulting filtrate is cooled to 30 DEG C and the pH is adjusted to 4.0-4.5 with 0.1N HCl. This clear filtrate is used in ORS products. The processed carbohydrate solutions are clear and colorless at 20% solids and the protein content is >;0.1% on a solids basis.

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EXAMPLE 2

Clarification of Rice Dextrin - Production Scale

Crude rice dextrins, a by-product of the high protein rice flour process, require clarification prior to utilization in a commercial ORS product. In this production scale clarification example, 4500 pounds of crude rice dextrins are blended into an open tank containing 1250 gallons of defluoridated tap water.

The mixture is agitated and heated to 112-122 DEG F.

The pH is adjusted to 5.9 with a 10% solution of KOH. In this case, the initial pH was 4.5 and 6 pounds of KOH was required to bring the pH to 5.98. Approximately 300 pounds of Silflo filter aid was added to the water and rice dextrin mixture in the open tank. A plate and frame filter press is assembled with about 50 pounds of Silflo filter aid used to coat the filters. The rice dextrin solution is pumped through the filter press into a second open tank. The agitator is started in the second tank containing the first filtrate at about 25% solids and this filtrate is heated to 185 DEG F.

After the first filtrate reaches the desired temperature, 84 pounds of Silflo filter aid and 253 pounds of activated carbon are added. This solution is pumped through a properly assembled plate and frame filter coated with filter aid to a third tank where the second filtrate is first cooled to 100 DEG F in the tank, then to 45 DEG F through a plate cooler. The cooled second filtrate at 17.91% total solids is adjusted to pH 4.5 with a 10% solution of HCl. This second filtrate is concentrated and spray dried to produce a white powder with about 2.3% moisture, less than 0.1% protein and a 24.6 dextrose equivalent (DE). When reconstituted, it is crystal (water) clear.

EXAMPLE 3

Preparation of Rice Dextrin Oral Rehydration Solution

Oral Rehydration Solution (ORS) is formulated and manufactured on a production scale using the following procedure for a 2000 gallon batch.

Initially, 1800 gallons of deionized water is heated to 130 DEG F and pumped into a blending tank.

Then, the dry ingredients, 19.7 kg sodium chloride, 3710 g sodium citrate, 1920 g citric acid, 18.6 kg potassium citrate and 233.5 kg dry, clarified rice syrup solids are added to the water through a Tri-

Blender.

After the dry ingredients are added, 21.2 kg of Natural Tropical Flavor liquid is added to the product in the blending tank. The blended product is then pumped through the cooler at 40 DEG F. The product is standardized with purified water to an optimum total solids of 3.49%. Approximately 200 gallons of water is required to standardize the product.

The liquid product is filled into containers for sterilization. The nutrient claims per liter are listed as follows: EMI21.1

EXAMPLE 4

Clinical Comparison of Rice Dextrin ORS and Glucose ORS

A clinical study was carried out to evaluate the efficacy of the rice dextrin ORS of the instant invention compared to the conventional glucose-based ORS as follows.

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Male infants, 3-18 months of age, with mild to moderate dehydration secondary to acute diarrhea were selected as candidates for ORT and randomLy divided into two groups. Initial information obtained on all patients was age, sex, weight, initial degree of dehydration, days of diarrhea prior to enrollment, and presence or absence of vomiting. Baseline blood samples were collected for determinations of serum sodium, potassium, chloride, bicarbonate, pH, pCO2, glucose, urea, creatinine, and osmolality.

Additional determinations were performed at 6, 12, 24, and 48 hours after admission. During the study period, stool and urine were collected separately, weighed, and stored for determination of sodium and potassium; stool for osmolality, and urine for specific gravity. Collection periods of stool and urine were from 0-6 hours, 6-12 hours, and 12-24 hours.Vomitus weights were estimated by determining the difference between the dry and wet weights of diapers utilized to collect the vomitus.

On admission to the study, the infants total fluid deficit was determined by multiplying estimated percentage of dehydration by the admission weight. During the ensuing 6-12 hours, infants received the

ORS in a volume equivalent to twice the calculated fluid deficit. When clinically indicated, such as in infants reluctant to drink or who vomited frequently, the ORS was given by means of a nasogastric tube. After the administration of the calculated volume of fluid, the infants were reassessed by clinical examination. If rehydration was not achieved, a volume of rehydration solution was given again, calculated according to the more recent estimate of fluid deficit with intake recorded throughout the period of rehydration.

Upon completion of rehydration, the patients were weighed and the percentage of weight gain for each infant was calculated as follows: ((rehydration weight-admission weight)/rehydration weight) times

100.

Non-parametric data was analyzed by the chi-square test. Continuous data was analyzed by ANOVA or repeated measure analysis of varients for treatment differences over time. A level of significance was set at p >; 0.05. Results are expressed as mean +/- one standard deviation (SD) unless otherwise indicated.

Table 12 below sets out the composition of the oral rehydration solution used in this study. EMI23.1

Table 13 illustrates there were no significant differences in the clinical features and nutritional status of the study groups. EMI24.1

Table 14 sets out results of balance studies for fluid and sodium intake. Both groups of patients were comparable with respect to ORS intake over the study period. Glucose ORS patients received an ORS with higher concentration of sodium. Thus, their net sodium intake was significantly higher than the intake of patients given rice dextrin ORS. EMI24.2

Table 15 sets out the stool output. During the first six hours of treatment, the mean stool output was lower in rice dextrin ORS patients. The mean stool output over the entire study period for rice dextrin group was 49.9 g/kg compared to 65.9 g/kg for the glucose ORS group. Stool output of sodium and potassium was significantly lower in the rice dextrin ORS group when compared to the glucose group during the first six hours of treatment.

There was a trend towards lower stool weight and Na output at the later time periods of 6-12, 12-24, and 24-48 hours for the rice dextrin ORS group. EMI25.1

Table 16 sets out the net gut balance calculated by subtracting stool output from net intake. EMI26.1

Fluid gut balance was significantly greater in the rice dextrin ORS group during the first six hours of the rehydration phase. When analyzed across the different periods of study, the mean fluid balance for the rice dextrin ORS group was greater (55.2 +/- 3.1 mL/kg) than the glucose ORS group (41.4 +/- 3.2 mL/kg).

Although the sodium content of the glucose ORS was higher, there was no difference in net sodium gut balance between the groups during any of the four time periods over 0-48 hours. Surprisingly, mean

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balance was higher in the rice dextrin ORS group when that parameter was evaluated across the duration of the study.

Potassium gut balance in the rice dextrin ORS group was statistically greater than the glucose ORS group during the first six hours of therapy. Throughout the remaining three time periods of the study there was a trend of greater gut balance in the rice dextrin ORS group compared to the glucose ORS group.

The results of the foregoing rice dextrin ORS and glucose ORS study indicate that both formulations were effective in restoring hydration. However, the balance studies demonstrate that the rice dextrin

ORS of the instant invention was more effective than glucose ORS in treating diarrhea inasmuch as infants fed rice dextrin ORS had significantly lower stool output (Table 15) and greater water and potassium balance (Table 16) during the initial six hour rehydration period than glucose ORS with a trend in this direction continuing through the three time periods up to 48 hours. Sodium balance was not different between the two groups (Table 16) indicating that the rice dextrin ORS, although containing lower sodium levels, was nevertheless as efficient in promoting sodium absorption as the glucose ORS which had a higher sodium level (Table 12).Data supplied from the esp@cenet database -

Worldwide

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261.

PL309049 - 9/18/1995

STEAMED RICE PRODUCT AND METHOD OF MAKING SAME

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=PL309049

Inventor(s):

JOSEPH (US)

KRATOCHVIL CYNTHIA P (US); LIN YAH HWA E (US); NOVAK THOMAS

Applicant(s): UNCLE BEN S (US)


IP Class: A23L1/182

E Class: A23L1/182

Application Number: PL19930309049 (19931028)

Priority Number: WO1993US10393 (19931028); US19920979809 (19921120)

Family: BG99719

Equivalent: WO9412056; EP0669810; US5316783; OA10159; BR9307483; RO114544;

PL172859B; HU223060; BG61988

Abstract:

Abstract not available for PL309049


Parboiled rice having the beneficial properties of parboiled rice, such as intact grain structure and texture, and having improved color vis-a-vis a typical parboiled rice, and further in the case of a brown rice starting material being substantially without the characteristic parboiled flavor and color, and methods of making same.Description:



The present invention relates to parboiled rice and to processes for its preparation.


Parboiled rice is usually defined as rice which has been steeped, heat treated and dried. During the heat treatment step of parboiling, the starch in the endosperm of the rice is substantially gelatinized. The parboiling process and the resulting gelatinization of the starch have several beneficial effects.

First, rice is routinely parboiled to achieve a better milling yield (less broken rice). Less broken rice has significant economic and quality consequences; whole rice commands a higher price because whole grains are valued by consumers of rice as high quality. Upon cooking, a rice with less brokens is generally accepted world-wide as having a more pleasing appearance.

Parboiling also causes a very important second quality change, which becomes evident upon cooking.

Cooked parboiled rice grains are significantly more intact and retain their natural shape as compared to non-parboiled rice. In selected rice eating cultures of the world, this is viewed as a quality improvement over non-parboiled rice.

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Also, during the parboiling process, the rice grain is strengthened to impart increased resistance to the rigors of abrasive milling. (Unparboiled rice easily shatters.) The strengthening of the grain is manifest in the cooked finished product. The rice is so strengthened by parboiling that it typically takes somewhat longer to cook during preparation by consumers than does unparboiled rice. Furthermore, parboiled rice often has a firmer texture and is less sticky than unparboiled rice. Even with the cooktime increase, these changes make parboiled rice more attractive than unparboiled rice in selected cultures around the world.

Parboiling of rice apparently originated, principally, in India. In the early history of parboiling, the rough (paddy) rice was simply soaked in warm water overnight and then dried in the sun. The perceived benefit was that the rice hulls were split open and were thus easily removed from the rice kernel. In modern times, it has been realized that parboiling also provides a more nutritional rice as thiamine and other essential nutrients, which are normally present in the rice bran, migrate to the rice endosperm during the water steeping or soaking step. Since almost all rice is milled to remove the bran, this migration preserves at least some of the nutritional value initially contained in the bran. Parboiling is also beneficial since the starch in the rice endosperm is changed from a partially crystalline-partially amorphous state to a substantially amorphous state. With the starch in the amorphous state, the kernel is tougher, resulting in a higher yield of whole rice kernels after milling. As mentioned earlier, unparboiled (crystalline) rice easily shatters. Gelatinization via parboiling, simply put, is the waterassisted melting of starch granules upon heat treatment. The presence of too much or too little water when heat is applied to the starch can have beneficial or deleterious results. Another significant benefit of parboiling is that the lipase in the bran layer of brown rice becomes inactivated due to the heat treatment. This improves the shelf life of parboiled brown rice by reducing the tendency for oxidative rancidity.

As a rule of thumb, prior parboiling practices can be divided into three broad categories: the

"atmospheric steaming" method, the "dry-heat" method and the "pressure-steaming" method. The atmospheric steaming method comprises soaking, draining, and steaming at atmospheric pressure, followed by drying and milling stages. The dry-heat method replaces the steaming step of the conventional method with a heating stage in which the rice is cooked in dry-hot air, hot non-aqueous liquids or hot sand prior to drying. Sometimes, the hot dry heat media are replaced by electromagnetic energy heating, such as microwave heating. In all cases with the dry heat method, the use of water or steam is avoided. The consequences of avoiding the use of water will become apparent later in the text.

Finally, the pressure-steaming method comprises a low-moisture initial soak followed by pressurized steaming prior to drying and milling.

Today, commercial parboiling processes generally include the steps of: (I) soaking rough (or paddy) rice in 50 DEG-70 DEG C. water for 3-4 hours to yield a rough rice having a 30 weight percent water content; (2) draining the free water from the soaked rice; (3) applying steam heat under pressure for 10 to 20 minutes to effect gelatinization; and (4) drying the steamed rice with hot air to reduce its water content to about 14 weight percent water. The dried, parboiled rough rice is then ready for shelling (to remove the hull) and milling to remove the bran.

Parboiling has been an active topic in the patent literature. There have been numerous efforts to improve upon the basic technology. For example, U.S. Pat. No. 5,017,395 teaches an extra predrying step at an elevated temperature. U.S. Pat. No. 4,810,511 prescribes use of microwave energy for partial gelatinization. According to U.S. Pat. No. 4,361,593, the rice starch is not completely gelatinized during steaming, and a tempering step is performed under non-gelatinizing conditions to reduce subsequent rupturing. In U.S. Pat. No. 4,338,344, there is disclosed an inclined enclosed chamber where rice is cooked in hot water in a first zone at a lower end, and then is steamed in a second zone at an upper end.

Unfortunately, despite these treatments, two undesirable conditions persist: conventional processes cause parboiled rice to be yellow and to develop a characteristic "parboiled" flavor in appreciable part due to Maillard-browning effects (and also in part as a result of the effects of agents contained in the rice hull when using paddy rice). To many cultures and consumers, these conditions are objectionable.

In fact, many consumers believe that the yellow color and parboiled flavor signify that the rice is old and stale. This is important because, as widely accepted in culinary arts, the first impression of a food is generally visual. That is, the willingness of a person to eat a particular food depends largely on

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preconceptions as to appealing color and other visual cues. Color is an influential quality attribute presupposed by people to be an indicator of deteriorative changes undergone by food. Aroma and flavor can also be influential upon smelling and tasting. Thus, an off-color, increases the likelihood that a food will be rejected, and this phenomenon jeopardizes the acceptability of parboiled rice amongst the majority of rice eating cultures around the world. This is so to an even greater extent if the rice has a foreign flavor. It is desired that rice color be near-white and that rice flavor be near bland and subtle.

Only a relatively small group of consumers of conventional parboiled rice accept its appearance and flavor. Indeed, the overwhelming majority of rice consumers, worldwide, eat non-parboiled rice. To our knowledge, none of the prior parboiling practices has resulted in a rice which combines the beneficial features of parboiled rice such as intact grain structure with an improved color vis-a-vis that exhibited by typical parboiled rice. This is especially true of such a rice having those advantages and being substantially free from typical parboiled flavor and color. Provision of a parboiled rice product having a full complement of advantageous features without one or more of the common shortcomings would be a substantial advance over the technology discussed heretofore.

OBJECTS OF THE INVENTION

Accordingly, it is an object of the invention to provide an improved parboiled rice product.

It is an additional object of the invention to provide a parboiled rice product which has all the advantages of conventional parboiled rice.

It is another object of the invention to provide a parboiled rice product which has improved color vis-avis that of typical parboiled rice.

It is yet another object of the invention to provide a parboiled rice product which has improved flavor vis-a-vis that of typical parboiled rice.

It is still another object of the invention to provide a method for the preparation of the above-mentioned parboiled product.

These and other objects of the invention will be readily apparent from the following description and claims.


In one aspect, the invention is a parboiled rice product which comprises a rice grain having an intact grain structure and a gelatinous kernel which is substantially non-crystalline, said rice product being substantially free of Maillard-browning effects, without the need for the rice grain's exposure to counterbrowning agents or counterbrowning measures to effect said freedom from Maillard-browning effects.

In another aspect, the invention is a method for the preparation of parboiled rice, which comprises (a) steeping brown rice to a moisture content sufficiently high that the rice starch is capable of being substantially fully gelatinized; and (b) exposing the rice to a hot gaseous medium flow at a temperature and for a time such that the rice starch is gelatinized and the surface of the rice is dried in substantial part.

As described, the rice of the invention has the beneficial properties of parboiled rice, such as intact grain structure and texture, and further has improved color vis-a-vis that of typical parboiled rice.

Furthermore, in the case of a rice product made from a brown rice starting material, the rice product is substantially free of browning effects and parboiled flavor. This is achieved with the present invention because gelatinization is effected so rapidly that those agents which cause Maillard-browning, and in the case of brown rice those agents which cause other browning effects also and/or which impart parboiled flavor, do not have a chance to develop to any substantial extent. In particular, the use of brown rice avoids the transfer of paddy-hull solubles, which cause both undesirable color and flavor.

DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

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In accordance with the present invention, then, a parboiled rice product is obtained from paddy rice or brown rice. Even with paddy rice, the invention confers substantial property benefits, such as intact grain structure, substantial gelatinization and substantial freedom from Maillard-browning effects.

However, the use of brown rice for parboiling, rather than paddy rice, offers yet additional and substantial advantages. It is an important feature of the invention that its practitioner, while utilizing brown rice, can simultaneously achieve intact grain structure and a gelatinous kernel which is substantially non-crystalline, with substantial freedom from paddy hull solubles and browning effects, without the need for the rice's exposure to counterbrowning agents or counterbrowning measures to effect said freedom from browning effects.

Importantly, it is an additional feature of the invention that brown rice can be parboiled using hot air or steam. This is surprising, as one would have expected brown rice to be an unfavorable starting material for several reasons. By way of explanation, paddy rice is normally used in parboiling since the rice hull acts like a pressure vessel and a moisture barrier Brown rice has no hull When parboiling with hot air, there is no moisture loss barrier to retain moisture during gelatinization, which would tend to discourage its use as a starting material especially with hot air at atmospheric pressure. When parboiling with steam, since brown rice has no hull, there is no moisture pick-up barrier which would tend to discourage its use as a starting material with steam. This moisture pick-up can result in severe handleability problems and render the process impractical.

The maintenance of "intact grain structure" is of great importance. The term refers to that condition in which, upon hydration, as in cooking, the rice grain is capable of maintaining its natural shape and structural integrity. This minimizes or eliminates two major defects which non-intact cooked grains can have, to varying degrees. These are split grain appearance and ragged surface appearance. A rice grain or kernel after hydration, as in cooking, is considered as not having an intact structure when the dorsal and ventral sides are swollen and/or essentially split open such that the surfaces and edges appear curly and ragged. Eventually, if the grain is allowed to hydrate more and more, it assumes an almost xshaped structure, sometimes referred to as being "butterflied". A grain which does not have intact structure may also be characterized simply as a grain having either of its two tips swell open partially or completely, or as grains which developed an unnatural square grain tip, rather than the natural rounded tips. Rather than a split appearance, a desirable intact cooked grain has a cooked shape such that the dorsal (back) and ventral (belly, where the embryo is located) sides of the grain remain essentially fused together even if considerable stretching or expansion is noticeable, and the inner endosperm starchy region becomes visible Further, instead of being ragged or fuzzy like a cottonball, the overall surface appearance characterizing intact grain structure is smooth.

Another measure of whether or not the rice grain has an intact structure is to assess the final dry rice product for degree of fissuring. Fissured grains are characterized as having transverse lines running either partially or totally across the width of the grain. No fissuring or minimal (less than 10%) fissuring is preferable, and more preferably, less than 2%.

Fissured rice is undesirable because it can result in breakage of grains during milling or later during cooking, and "brokens" are economically unattractive Moreover, depending upon the extent of the fissures, fissured grains can become "brokens" prior to milling. Broken grains are undesirable because they result in poor milling yields. Multiply-fissured grains can result in multiply fragmented grains, which fragments are smaller and even more difficult to recover in milling. Highly fissured grains also tend to cook-up as non-intact grains, with the resulting cooked rice being fragmented into pieces.

Many analytical techniques are used to assess the quality of the resulting milled rice. The amount of fissuring can be measured as follows: 5 to 10 grams of milled rice are weighed. Fissured grains are identified by visual inspection, segregated and separately weighed. The degree of fissuring is calculated as follows: ##EQU1##

Percent broken grains, which is also a measure of intact grain structure, can be determined either by hand-sorting a given weight of sample obtained from a sample splitter, or by placing 100 grams of milled rice or brown rice in a grain sizing device equipped with two #12/64 indent plates. The plates are positioned at an incline so that upon lateral shaking, the grains roll down the plates. The brokens

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become trapped in the indents while the whole grains are collected at the bottom of the two plates.

Accordingly: ##EQU2##

Measurement of solids loss upon cooking gives an indication of the amount of soluble and particulate starch removed from the rice grain during cooking in excess water for a given period of time. It is a reflection of the ability of the grain to maintain its intact structure while being subjected to heat in the presence of excess water. Raw or non-parboiled rice normally yields about 1.5 to 2 times the amount of solids loss which do parboiled rice and rice in accordance with the invention. Rice in accordance with the invention, depending upon the variety and retrogradation state, will yield solids loss values about equal to that of conventionally, dry heat-parboiled or steam-parboiled rice.

For instance, in one method to measure solids loss, 25 grams of a rice sample is placed in 250 ml of boiling deionized water. It is simmered for 20 minutes, drained and placed through a sieve. The water is retained. The rice is rinsed with an extra 100 ml. of water. All rinse water is collected including a 25 ml rinse of the cooker pot. The total rinse water is dried to capture all solids. The percent solids is then calculated as follows: ##EQU3##

Gelatinization is another important feature of the invention. When rice is gelatinized due to parboiling, a tougher rice grain is achieved. By "gelatinization", we mean an irreversible physical change that native starch granules undergo when exposed to water and heat. For the starch chemist skilled in the art, it is the process whereby starch granules in contact with water cease to exhibit a birefringence pattern under polarized light when the mixture reaches a critical temperature called the gelatinization temperature (GT). This can be detected by viewing the starch-water sample under a polarizing microscope. The non-gelatinized, native or raw starch granule will show a characteristic light pattern with a dark cross. Upon absorption of water and heating to the gelatinization temperature, the cross disappears. At this point, the granule is said to have lost birefringence and is gelatinized. The starch granules appear swollen and their size or diameter is much bigger than the size or diameter of the native granules.

Starch gelatinization is also manifest in the physical structure of the granules. Native starch granules consist of amorphous and crystalline regions made up of molecules of glucose polymers. When the starch granules absorb water and are exposed to heat, the amorphous regions swell causing instability in the crystalline regions of the granule. This eventually weakens the crystalline regions to the point that they break up and the whole granule becomes amorphous. The starch granule appears very swollen and, at this point, is said to have undergone gelatinization. Gelatinization is an irreversible process.

Once it occurs, the starch molecules cannot revert to their original or native amorphous and crystalline configuration.

Thus, gelatinization of rice kernels is typically viewed as the irreversible swelling of starch granules due to the effects of water and heat, resulting in loss of birefringence under polarized light. Such gelatinization can be considered a melting process consisting of three basic steps, namely, (1) diffusion of water into the starch granule, (2) a phase transition of the starch molecule requiring varying levels of moisture and energy, and (3) swelling of the granules. Gelatinization in the context of this invention refers to the disruption of the crystalline structure of the rice starch, usually as a result of steeping in water and heat treating. In effect, gelatinized starch granules are melted together into an amorphous state.

In the practice of the present invention, it is advantageous that the rice kernel be substantially noncrystalline and gelatinous, i.e., appreciably gelatinized. But, this condition does not exclude the continued existence of some of the original crystalline regions. The degree of gelatinization of the rice sample is typically at least about 35% (and conversely 65% still crystalline), preferably about 95% and especially 100%.

It should be noted that retrogradation can follow gelatinization, and is a phenomenon which is advantageously avoided or, at minimum, controlled. The term refers to the reassociation of gelatinized starch molecules, within a granule in an intact structure (such as a rice grain), into tight bundles that renders the molecules less soluble in water. Retrogradation reflects the slow and progressive tendency of starch molecules to come together or associate in cooked foods. The practice of the present invention typically provides a rice product having minimal retrogradation as compared to conventional steam-

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parboiled rice. This is desirable as minimal retrogradation effectuates a faster cooking rice, all other things being equal, because non-retrograded starch is less resistant to water absorption than highly retrograded rice upon cooking.

Equilibrated moisture content of milled rice upon soaking in water is a test which is used to obtain a rough measurement of the degree of gelatinization of parboiled rice. It is based on the phenomenon that gelatinized starch granules can absorb much more water at room temperature than non-gelatinized starch granules. For example, raw or nonparboiled rice typically has an equilibrated moisture content of about 40 percent dry basis, but parboiled rice from the same variety will yield an equilibrated moisture content of about 100 to 200 percent depending upon processing conditions. While determining equilibrated moisture content is a convenient and useful way of determining the degree of gelatinization, it is not an absolute measure of that parameter. This is because the equilibrated moisture content is affected by the extent of retrogradation which gelatinized starch undergoes during cooling and drying. For instance, non-retrograded rice can have an equilibrated moisture content of 180, but if it is allowed to undergo extensive retrogradation, for example, as a result of tempering the partially dried rice for two hours at 75 DEG C., the equilibrated moisture content of the final product can be as low as 100. Thus, when utilized, equilibrated moisture content should not be accepted uncritically, but rather in the context of the conditions prevailing at the time of testing.

The following example will illustrate how to measure the equilibrated moisture content. Four grams of rice are weighed and then soaked in 100 milliliters deionized water for 24 hours at room temperature.

The soaked rice is drained and patted dry with tissue paper and then weighed again. The wet rice is dried at 100 DEG C. for 24 hours, desiccated and weighed. The equilibrated moisture content is calculated as set forth below: ##EQU4##

Measuring moisture absorption is useful. Percent water absorption represents the total amount of moisture in cooked rice after cooking in excess water for a given period of time. In a 100 gram sample of rice, percent water absorption can be calculated as follows: ##EQU5##

Also, the firmness or softness of rice can be measured by a shear-testing device. Shear of cooked rice is inversely related to water absorption. The higher the water absorption, the softer the rice is, and vice versa. Thus, cooked rice shear can also be determined as a measure of the softness or firmness of the cooked rice, and indirectly the amount of water absorption.

In one useful way of measuring shear value, 250 grams cooked rice is placed in mason jars and allowed to cool for 2 hours at room temperature. Then 100 grams of the cooked rice is placed in a shear press cell. The force (in kilograms) required to extrude the rice through the cell by shear blades is equal to the shear of the cooked rice. Shear value is read from a meter.

Another advantage, which flows particularly from the use of brown rice as a starting material, is that the parboiled rice product made from it is substantially free of "paddy hull solubles". These solubles include any species such as ions, molecules, color bodies, proteins, residual pesticides, etc., that normally resides in paddy rice hulls, or that normally comprises a contaminant rendered soluble in water during the process of steeping of the paddy rice at a temperature ranging from ambient to that conventionally viewed as a steeping temperature, i.e., 55 DEG-75 DEG C. Paddy hull solubles are substances capable of migrating into the inner endosperm of the rice grain through bran layers during the steeping process. They cause various types of browning effects other than Maillard-browning, and also impart typical "parboiled" flavor notes. Such substances are typically detectable in the spent steeping water some time during, and at the end of, steeping cycles Substantial freedom from paddy hull solubles reduces to a negligible level the possibility that extraneous materials will be deposited in the rice product and adversely affect the beneficial features otherwise imparted by the practice of the invention.

An especially important feature of a rice product in accordance with the invention is the substantial freedom from Maillard-browning effects, and in the case of brown rice other types of browning effects as well. The expression Maillard-browning effects refers to darkening or discoloration of the rice grains or kernels due to the formation of colored substances brought about by the Maillard reaction; similarly, other types of browning effects are caused by pigment absorption or adsorption, by oxidation or polymerization of colorless phenolic compounds in the rice to produce colored pigments, or by

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enzymatic browning reactions in conventional parboiling practices, the resulting milled rice exhibits colors ranging from yellow to light brown, to orange brown, to dark brown or even to almost black. As previously mentioned, the typical color of parboiled rice is darker than the majority of global consumers find acceptable. This unacceptable color leads to consumer rejection of conventionally parboiled rice. In contrast, the substantial freedom from Maillard-browning effects, and especially from other types of browning effects as well, confers upon the rice product of the invention a corresponding color improvement. It follows that this should increase consumer-acceptance.

The expression "substantially free of browning effects" (whether Maillard-browning or some other type) refers to that condition in which milled rice obtained in accordance with the present invention is whiter or lighter in color relative to a typical specimen of conventionally parboiled rice. It should be noted that rice which is substantially free of browning effects may nonetheless darken in color if subjected to prolonged heat treatment such as in long-drying times at high temperatures.

ASTM E 313-73 (Reapproved 1979), entitled "Indexes of Whiteness and Yellowness of Near-White,

Opaque Materials" promulgated by the American Society for Testing and Materials (1916 Race Street,

Philadelphia, Pa., USA) provides a suitable test by which the color of the rice product of the present invention, vis-a-vis that of typical parboiled rice, can be evaluated. Generally speaking, the ASTM standard prescribes a yellowness index which can be used to arrive at a single number characterizing the deviation from the preferred white color. Using the yellowness index, commercially purchased unparboiled rices range from 35.1 to 39.2, commercially purchased parboiled rices range from 59.4 to

67.0, and the product of this invention preferably ranges up to 54.5. In particular, the product of this invention has a maximum yellowness index of 55.0.

In carrying out an analysis according to the aforementioned ASTM standard, the color of each rice product can be measured using a Hunter Colorimeter, from Hunter Associates Laboratory, Inc. (11495

Sunset Hills Road, Reston, Va., USA). The meter is a tri-stimulus response device which yields the three traditional color value readings (L, a, b). The "L" scale ranges from 0 to 100, from pure black to pure white, respectively. The "a" value can either be positive or negative, indicating intensity of the red and the green hues, respectively. The "b" value indicates the strength of yellow hue when positive, and the blue hue when negative.

When rice is thermally abused, it darkens such that the "L" value gets lower. It also gets more yellow such that the "b" value increases. And, it also gets more red, such that the "a" value increases. These changes do not happen in unison; and, so, reliance only on one of the three values alone as a measure of deviation from natural white color is not advisable.

The above-mentioned standard specifies a yellowness index as follows: ##EQU6## As the yellowness index value increases, the sample is judged to be further away from white, and increasing in perceived yellowness. The tri-stimulus X, Y, Z values are known to those skilled in the art as the CIE X, Y, Z scale for the CIE 1931 2@0 Standard Observer The relationships between the Hunter L, a, b scale and the CIE X, Y, Z scale are as follows: ##EQU7##

The ASTM standard states, in relevant part, "1.2 For complete analyses, white colors must be measured, as must all other colors, by some three-number system. Frequently, graphical relationships between white colors are shown on a two-dimension lightness ["L" value] yellowness ["b" value] diagram in which the generally unimportant (for whites) red-green dimension is omitted For many problems involving color quality evaluations of white materials, one does not require either three- or two-dimensional analysis of white colors Rather, one needs for each such problem to measure only the single specific attribute important to him . . ."

By using the yellowness index, which appropriately combines contributions from all three tri-stimulus values, we can arrive at a single number which describes deviation from the preferred white The

ASTM standard further states, "5.2 This is a psychophysical test method; that is, the procedures specified [i.e., the equations] are designed to yield numbers correlating with visual estimates made under one set of typical observing conditions . . ." An examination of the numerical ratings, set forth heretofore regarding commercially purchased unparboiled rices (35.1-39.2), commercially purchased parboiled rices (59.4-67.0), and the rice product of the present invention (up to 54.5), shows that commercially purchased unparboiled rice is closest to white--though it suffers from other shortcomings

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such as broken grains and non-intact cooked appearance. Commercially purchased parboiled rice, while exhibiting intact grain structure, is furthest from white. A rice product of the invention made from a brown rice starting material combines the strengths of both of the foregoing insofar as it exhibits intact grain structure, is free from characteristic parboiled taste and has a color which approaches the near-whiteness of unparboiled rice.

The foregoing assumes that, for purposes of comparison, each of the heat-treated products is processed to a "degree of milling" loss of about 10% of original rice feed (to the mill). This is because browning effects in heat-treated milled rice can be altered by varying the amount of milling. Milling, sometimes referred to as whitening, abrasively (and/or through friction) removes layers of matter from the surface of rice. When milling first begins on brown rice, whether it is heat-treated or not, a rapid change in the whiteness of the rice occurs, as most of the bran is removed at first. Since the division between where the darker bran stops and the whiter starchy endosperm starts is not easy to separate cleanly, there is a transition zone or color gradient Further, other color gradients are present, including presence of otherthan-starch materials, such as protein and fat. Also, during steeping in the parboiling process, it is widely accepted that sugars, coloring matter, pigments and other soluble substances (called "bran solubles") are moved somewhat from the bran into the upper layers of the endosperm; some of these substances actually have a higher tendency to brown than the native endosperm. The upper, darker layers can be reduced with deeper milling, allowing the rice to be whiter. Thus, the miller can undermill and increase his milling yield (improving economics), but get a darker product. Conversely, the miller can overmill or deep mill, and lose yield but whiten the product. As will be appreciated, normalizing the degree of milling standardizes the whitening effect contributed by that measure, so as to ensure the integrity of the comparison.

A principal benefit of the invention is the minimization of browning effects without the need for use of counterbrowning agents or counterbrowning measures. Typically, in practicing the invention, the skilled worker can eliminate all need for intentional introduction of counterbrowning agents, and though some may be present in incidental amounts (on the order of say, 0.1 weight % or so) as a result of extraneous processing considerations or the like, the amount is zero or close to zero. Similarly, there is typically no need for counterbrowning measures of the type discussed above, and typically none is carried out. Nevertheless, it may be that other processing steps entail performance of acts which are also counterbrowning measures, and rice product made using these steps but which would be free of browning effects even if they were not performed, will still fall within the broad invention.

Counterbrowning agents are substances that inhibit browning reactions, or mask browning effects, in the rice completely or at least to an appreciable extent. Examples include sulphites and ascorbic acid. A counterbrowning measure is any condition or set of conditions which, when the rice is exposed thereto, leads to the destruction, inactivation or blocking of one or more enzymes or compounds that otherwise participate in a browning reaction, or one or more precursors of such enzyme(s) or compound(s). For example, a piece of biological material including an enzyme may be exposed to sufficient heat to render the enzyme denatured, or rough rice may be steeped in a highly acidic environment that disfavors the Maillard reaction. The obviation of the need for counterbrowning agents and/or measures is beneficial because it reduces expense due to material or processing economics, and further eliminates the presence of extraneous substances which may affect flavor, aroma, nutritional or other properties of the rice adversely.

The inventive product is prepared by steeping brown rice in water to impart a moisture content sufficiently high that the rice starch is capable of being fully gelatinized. Steeping can be carried out in any suitable manner, and conventional methods will suffice. Receptacles such as tanks and screw-type steepers can be utilized, but the invention can be practiced with any receptacle sufficiently large to accommodate the amount of rice and water desired. The water may contain various vitamins or other desirable additives which are sought to be incorporated in the rice, but this is not essential. After steeping, the rice can be allowed to drain--for instance, on a screen of appropriate mesh size (such as

U.S. #10 mesh) - for a time period, say, 2-5 minutes, which is sufficient for the removal of excess water. Preferably the moisture content after steeping is about 30-38 percent, wet basis. To measure the percent water content of a sample of rice grains, any suitable method can be employed. In a preferred method used for steeped rice (as well as steamed rice and final rice moisture), a given weight of wet rice is oven dried at 100 DEG C. The initial weight loss is calculated. The oven dried sample is then ground in a mill and a ten gram sample is collected in a metal cup, weighed and dried in an oven for final moisture determination. The moisture content is calculated as follows: ##EQU8##

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The value of the moisture content as measured above reflects the total moisture content. If the rice is patted-dry with a tissue or other absorbent material prior to measurement, a moisture content minus surface water results.

The rice is gelatinized by exposure to a hot gaseous medium flow. This flow is at a temperature, and the rice is exposed to it for a time, such that not only is the rice starch gelatinized, but further, the surface of the rice is dried in substantial part. After it is exposed to the hot gaseous medium flow, the rice preferably has a moisture content of about 20-30 percent, wet basis.

The hot gaseous medium flow is preferably such that any free water on the exterior of the rice remaining from steeping, or condensed upon the surface of the rice during the gaseous medium contact, is substantially removed by drying, by the physical removal action of the gaseous flow, or both.

Hot gaseous medium flow generally can be characterized by its velocity, temperature, flow pattern, flow rate, and pressure. The hot gaseous medium is preferably hot air or steam, but can be any other suitable gas or gas mixture (including air and steam) which is sufficient to perform the functions identified above but which is inert to (i.e., does not adversely affect the properties of) the rice product of the invention. Advantageously, when the hot gaseous medium is hot air, it is at a temperature of 150

DEG-200 DEG C., the flow at a superficial velocity of 100-300 meters per minute, and the rice exposed to the flow for 15-40 seconds under a pressure of 0-380 kpag. When the hot gaseous medium is steam, it is advantageously at a temperature of 105 DEG-200 DEG C., the flow at a superficial velocity of 1-100 meters per minute, and the rice preferably exposed to the flow for 5-40 seconds under a pressure of 0-380 kpag.

The "flow" of "hot gaseous medium" is the continuous movement of gaseous molecules (e.g., steam, air, or steam and air) around an individual rice grain or a mass or plug of rice grains. Flow implies velocity and, in certain embodiments, when the velocity of the hot gaseous medium flow is increased such that the entire bed of rice is suspended, and every particle is surrounded by gas, then there is fluidization. However, fluidization is not necessary for the practice of the invention. In general, fluidized behavior is used in the hot air approach whereas packed beds are used in the steaming approach.

The hot gaseous medium flow can be co-current, counter-current or mixed flow vis-a-vis the rice flow, as well as the steam which is liberated from the rice during gelatinization, depressurization and drying.

The flow can be laminar or turbulent, but preferably turbulent, and is specifically characterized by an engineering index called the Reynolds Number (Re). It is a dimensionless number which increases as turbulence increases. In general, the hot gaseous medium flow falls into one of two categories: either hot air flow (i.e., hot air drying) used in atmospheric processing, or hot steam flow (or flow of a hot steam/air mixture) used in pressurized processing.

Especially when utilizing brown rice, it is noteworthy that in atmospheric processing, because of the presence of intact bran layers, a certain amount of gaseous water molecules remain trapped in the endosperm and starch granules Pressure builds up inside the grain. However, the pressure is such that it does not exceed the rupture point of the bran layer. The pressure build-up indicates enough moisture is available to the starch granules to effect gelatinization. This happens in a matter of 5 to 40 seconds.

Internal grain pressure gradually releases when the rice is removed from the flow of hot air, or when the rice is allowed to dry.

In pressurized processing (typically steaming) of brown rice, a somewhat different dynamic pertains.

During steaming, the steam first condenses on the surface of the rice, releasing its heat of condensation.

The rice will warm, typically to a temperature of from 50 DEG C. to 200 DEG C.; the amount of steam required to warm the rice can be easily calculated using conventional thermodynamic equations. But, the wet condensate on the surface of the rice can have a severely deleterious effect on the

"handleability" of the rice if the condensate is absorbed. The absorbed condensate swells the upper layers of starch, eventually causing the bran layer to burst and the starch to exude from the grain. This can cause equipment shut-down (from starch build-up on equipment surfaces, etc.). Therefore, it is important for the steaming process to be conducted in a sufficiently brief amount of time (about 10-30 seconds as opposed to normal parboiling time for paddy rice, about 10 minutes) that the condensate

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does not have time enough to absorb into the grain A further precaution which can be employed is to conduct the steaming process in such manner as to sweep away any condensate formed. In this case, the rice, which has been heated to the processed temperature, has no condensate on its surface. When pressure is released to the atmosphere, the rice cools down to 100 DEG C. (i.e., the boiling point of water at atmospheric pressure). For this to happen, some heat energy is transferred to the steeped moisture contained in the rice, which is vaporized and escapes. Thus, not only is the possibility of undesirable excess absorbed moisture thwarted, but, in addition, the rice beneficially dries itself, especially on its surface.

Surface drying is quite beneficial when brown rice is the starting feed for parboiling using steam as the gaseous media. Surface drying results in the absence of surface moisture thereby curtailing

"uncontrolled gelatinization" especially of the starch granules on the outer endosperm. Uncontrolled gelatinization is often accompanied by rupture or breakdown of the starch granule. The bran layers are ruptured and intragranular starch material is exposed. Surface drying of brown rice minimizes such damage and allows for smoother material flow of the heat-treated grains through the heat treating device and through further equipment.

The temperature of the hot gaseous medium is measured using an appropriate thermocouple. The thermocouple can be held in place by a small conduit communicating with the pipes of the vessel in which the parboiling occurs. It will be appreciated that temperature is also a function of prevailing pressure, and that it is accordingly desirable to monitor pressure during pressurized processing embodiments of the present invention. For instance, if saturated steam is used as the medium in a pressurized steaming operation, then pressure gauges can be installed at appropriate locations in the apparatus as known to those skilled in the art. Another factor which may influence measurements of temperature of the hot gaseous medium is heat radiating from external sources. For example, an unshielded thermometer or thermocouple in a gas stream, in the proximity of a surface having a temperature higher than that of the gas stream, will signal a higher temperature then the true gas stream temperature. Therefore, to compensate for the effects of radiated heat, shielding of the measuring elements is preferably employed to promote accurate measurements of gas temperatures. To measure the temperature of the rice grain or the temperature of the wall of the vessel, an appropriate thermal probe can be used as known to those skilled in the art.

The flow conditions of the gaseous medium, such as pressure and velocity, can be measured with a pilot tube or with an anemometer. One way of determining velocity is to calculate a "superficial velocity" in which the flow (in volume units per time, e.g., cubic feet per second or ft@3 /sec) is divided by the area through which the flow occurs (e.g., square feet or ft@2).

Of course, additional processing steps may be incorporated in the practice of the invention. For example, the heat-treated rice can be subsequently tempered at about 70 DEG-110 DEG C. for about

15-120 minutes. Additionally, the rice can be further dried, for instance, to a moisture content of about

11-13 percent, wet basis. Also, the rice can be conditioned after these treatments, at about ambient temperature to about 45 DEG C. for about 3-6 hours, if desired. As is customary with rice, it can then be milled.

The present invention is further described and illustrated in the following examples It will be appreciated that these examples are provided solely for illustrating the invention and not for the purpose of limitation. It will further be appreciated that variations and modifications to the product and process can be made by the skilled worker without departing from the spirit or scope of the invention as defined in the appended claims.

EXAMPLES

A sample of brown rice, Lemont variety, was steeped in water at 70 DEG C. for 90 minutes. The EMC of the brown rice was measured and found to be 39.3. The steeped rice was dewatered by allowing the rice to drain for 2 minutes on a mesh screen. In this wet state, the rice was not free-flowing and was relatively difficult to handle. The moisture minus surface water of the rice was measured and found to be 31.4%. The dewatered rice was then split into four portions.

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Example 1 (not in accordance with the invention):

A first portion of rice was placed into a hot air dryer. The rice was exposed to a flow of hot air such that the rice became fully fluidized. The temperature of the inlet air to the rice drying section was set at

95 DEG C. The exhaust from the section was 90 DEG C. The treatment was conducted for twenty seconds. At the end of the treatment, the rice was removed from the dryer. The rice was free of clumps and flowed easily. The average total moisture of the rice was about 26.4%. However, it was not gelatinized, as indicated by its EMC value which was found to be 43.6, essentially equal to that of the initial raw rice. The rice was then dried, milled and cooked for consumption. The cooked grains were found to be non-intact. The color of the milled rice was white. The flavor was free of characteristic parboiled taste.

Example 2 (in accordance with the invention):

A second portion of the steeped rice described above was placed into the same hot air dryer as in

Example 1 The rice was then exposed to hot air, which had an inlet temperature of 190 DEG C. and an exhaust temperature of 180 DEG C., and full fluidization of the rice grains was attained. The exposure time was twenty seconds. At the end of the treatment, the rice was essentially 100% gelatinized as evidenced by an EMC value of 209. No clumps were found in the rice. The moisture content after exposure was found to be 21.6%. The rice was then dried, milled and cooked for consumption. The color of the milled rice was white. The flavor was free of characteristic parboiled taste. The cooked grains were intact.

Example 3 (not in accordance with the invention):

A third portion of steeped rice described above was placed into a steaming vessel equipped for pressure control. The steamer was designed such that the amount of liquid water formed from condensation of steam on the vessel walls is minimized. Steam was applied at a saturated steam pressure of 10 psig for

10 minutes. During the initial pressurization, the flow of steam was considerable due to the need to heat both the rice and the vessel to the temperature of the saturated steam. After the targeted pressure of 10 psig was achieved, the flow of steam was decreased to a negligible rate, with additional steam being introduced only to maintain the target pressure. After the ten-minute period, the pressure was released and the rice was removed from the steaming vessel. The grains were gelatinized as evidenced by an

EMC of 114.9. The percent of clumped grains is counted as a measure of grain damage and of flowability/handleability. The count indicated that about 17.2% of the grains were in the clumped condition. A clumped condition is defined as two or more rice grains which are stuck together and do not break apart easily. The moisture content of the rice was measured and was about 32.8%. The rice was dried, milled and then cooked for consumption. The grain structure was found to be intact. The flavor was free of characteristic parboiled taste. The color of the milled rice was white.

Example 4 (in accordance with the invention):

A fourth portion of rice described above was placed into the steaming vessel described above in

Example 3. In this instance, the targeted pressure was 30 psig to be applied for a time period of 20 seconds. The steamer was operated such that a considerable amount of steam was allowed to flow through the packed bed of rice. After twenty seconds, the rice was removed from the vessel. The grains were substantially 100% gelatinized as evidenced by an EMC of 192.1. Grain clumps were measured.

The count indicated that about 1.2% of the grains were in the clumped condition. The moisture of the rice was measured and found to be 29.5%. The rice was then dried, milled and cooked for consumption. The color of the milled rice was white. The cooked grains were intact. The flavor of the rice was free of characteristic parboiled flavor.

DISCUSSION

* The purpose of Example 1 is to illustrate that the steeped rice can be dried so that it is free flowing but not gelatinized. The color of the milled rice is white, but it has a poor cooked grain structure.

* By way of contrast, in Example 2, gelatinization is achieved when the drying conditions are in accordance with the present invention. The color of the milled rice is white and it has an intact cooked grain structure.

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* In Example 3, it is shown that steaming can effect gelatinization, but that poor "handleability" can result. The color of the rice is white and it has an intact cooked grain structure.

* In Example 4, it is shown that steaming in accordance with the invention can yield rice which is both gelatinized and free flowing. The color of the rice is white and it has an intact cooked grain structure.

>;tb;______________________________________

>;tb;Brown Rice Feedstock

>;tb;Ex- Gela- Free White Intact-

>;tb; Free of

>;tb;ample tinized? Flowing? Color?

>;tb; ness Parboiled Flavor

>;tb;______________________________________

>;tb;1 NO YES YES NO YES

>;tb;2 YES YES YES YES YES

>;tb;3 YES NO YES YES YES

>;tb;4 YES YES YES YES YES

>;tb;______________________________________

The terms and expressions utilized herein are intended as terms of description, not limitation, and there is no intention in the use of such terms or expressions of excluding any equivalents of the features shown and described as portions thereof, its being recognized that various modifications are possible within the scope of the invention.Data supplied from the esp@cenet database - Worldwide

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262.

SU1102481 - 7/7/1984

METHOD FOR PREPARING INSTANT RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=SU1102481

Inventor(s): ANDO MOMOFUKU (--); TAKATSU MITSUMUNE (--); MINAMI YUNICHI (--

); ONISI FUMIO (--); KAVAMOTO SIYUNICHI (--)

Applicant(s): MOMOFUKU ANDO (JP)


IP Class: A23L1/10

E Class: A23L1/182

Application Number: SU19752171011 (19750905)


Family: SU1102481

Equivalent: US4233327; NL7510157; FR2283635; ES440699; DE2538076; SE7509376;

SE422399; NL171219C

Abstract:

Abstract not available for SU1102481


Process for producing instant-cooking rice which includes soaking rice in water, gelatinizing the soaked rice, reducing its water content 25-35% by weight, pressing the rice, reducing the water content of the pressed rice to 8-25% by weight, aging the rice and then puffing and drying the rice by hot air or high frequency dielectric heating.Description:



This invention relates to a process for manufacturing instant-cooking rice, which is storable over a long period of time, and which can be reconstituted into a food preparation as palatable as home-cooked rice a few minutes after hot water is poured thereon.

Although studies and developments have been made in the field of instant-cooking rice and these rice products are now on the market, they have not yet gained popularity in Japan.

The following may be considered as the main reasons thereof:

(a) Individual rice kernels, even if they are of the same kind, differ in size, composition or ingredients, etc. These differences affect heat transfer and water permeation, resulting in half-cooked rice and mixed kernels each having a different taste or feeling.

(b) Prior instant-cooking rice is reconstituted or restored by either boiling in a pan or a cookpot for few minutes, or by pouring hot water thereon and leaving it as it is for more than 10 minutes. The prior products which are restored by boiling in a pan or a cookpot may not be always restored in a constant state, even if they are the same products, due to slight differences in pan size, water amount, fire

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intensity, etc. On the other hand, the prior products which are restored with hot water may require a period of time longer than ten minutes for restoration.


A main object of the present invention is to provide a process for producing instant-cooking rice, which may be processed at lower temperatures and in less complicated steps as compared with the prior art, and which can be restored to rice as palatable as home-cooked rice a few minutes after hot water is poured thereon.

Another object thereof is to provide instant-cooking rice which is storable over a long period of time, which will permit hot water to permeate the interior of the rice tissue a few minutes after hot water is poured thereon, which will have no core, and when restored will be as palatable as the home-cooked rice.

A further object thereof is to provide instant-cooking rice which can be prepared by a very simple method of pouring hot water thereon, thus requiring no cooking means such as pans or cooking pots for preparation or consumption, and which will always turn out the same, no matter who cooks it, therefore palatable rice can be obtained wherever hot water is available.

A further object thereof is to provide instant-cooking rice which is preferably packed in a heatinsulating container, is portable, and is widely applicable for emergency and leisure use.

These and other objects will be understood from the following detailed description of the specific embodiment of this invention.

BRIEF EXPLANATION OF THE DRAWINGS

FIGS. 1A to 1B(1-4) are perspective and cross-sectional views of the rice grains before pressing (A) and the pressed rice grains (B) which have been dried to various extent before the pressing;

FIG. 2 is a graphical representation of the cracked grains on pressing similar to FIGS. 1A and 1B(1-4); and

FIGS. 3A to 3D are graphical representations showing various results of aging.


Any kind of rice may be treated in accordance with the present invention.

First, after the rice is washed in water, it is soaked in water or seasoning liquid, so that its water content is adjusted to 20-35%, preferably 30-34% by weight, and it is preferably then mixed with surfactants such as glycerine fatty acid esters, sugar esters and sorbitan ester or edible oil or However, the mixation of surfactants etc. is not essential. Finally, the rice is gelatinized by steaming or boiling. Since the surfactant, edible oil or talc is added to prevent the rice grains from sticking to each other during the steaming and pressing processes, a small quantity, for example 0.1-1.0% by weight, of such additives will suffice for this purpose. The grains are completely gelatinized by being treated for 0.5-6 minutes with steam of a temperature within the range from 100 DEG at pressure of 1.03 Kg/cm@2 to 140 DEG

C. at a pressure of 3.68 Kg/cm.

Next, the gelatinized rice is exposed to air at a temperature of preferably 40 DEG-120 DEG C., so that the water content of the rice is reduced to 25-35% by weight before it is pressed. The reduction of the water content may, instead of being done by such ventilation, be done by adding cereal flour such as dry wheat flour, rice flour or starch etc., cellulose powder or talc to the rice to absorb excess water.

Since steamed grains, if immediately fed into a pressing machine, will adhere to each other as well as to the walls of the machine, they should be dehydrated to a moisture content of preferably less than

35% by weight before being pressed.

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It is essential that the grains be pressed without producing cracks and fissures therein since the cracked grains may break into small pieces when puffed, thereby reducing the commercial value as rice products. If the moisture has been reduced to 25% or less by weight before pressing, the pressed grains will have cracks and fissures as shown in FIGS. 1 and 2, the results of which were obtained with rice processed up to pressing according to Example 1 which will be disclosed later. The conditions of drying before the pressing were the parameters of rice shown in FIGS. 1 and 2. U.S. Pat. No. 2,733,147 discloses soaking, gelatinizing, drying, compressing and drying rice, but also discloses that the compression results in the formation of cracks and fissures within the grains at column 5, lines 10-12.

As for pressing rice grains, any type of compressing apparatus may be applied. The pressing method includes a method of pressing the rice grains in two directions, such as by passing them between rolls or by means of metal plates, and a method of pressing the rice grains in all directions, such as by means of a rice sweeper, an extruding machine or a mixer. In a rice sweeper, the rice grains, after being fed into the machine, are pressed in all directions and moved for discharge while turning and spinning. The distance between the rolls is preferably 0.1-1.0 mm.

When pressed, the starch tissues in secure or fixed relation in the rice are loosened, thus resulting in a slide between the tissues so that the starch tissues become resilient and soft in structure, thereby causing slight gaps between the tissues. In other words, a number of small particles are formed within the tissue of each rice grain so that the rice becomes resilient enough to easily expand and contract when force is exerted thereagainst and so that it will restore almost to its original shape when the force is removed, like rubber. Accordingly, no core is created in the pressed rice, so heat transfer and water permeation will be improved, thus enabling its quick and uniform restoration when cooked, with hot water, and permitting the puffing and drying process to proceed at a relatively low temperature after the pressing process.

The pressed rice grains are then put through the final process, namely puffing or drying. In order to facilitate the puffing, it is preferred to expose the grains to air at a temperature of 20 DEG to 100 DEG

C. to preliminarily dry them to reduce the water content, preferably to 8 to 25% before puffing.

Since each of the preliminarily dried grains has a moisture distribution which tends to be moister toward its cent the grains are aged to unify or equalize the moisture distribution. It is preferable that the aging be carried out within a closed chamber to prevent natural or atmospheric dehydration of the grains. The aging time and temperature depend on each other as shown in Table 1. For example, aging at a temperature above 80 DEG C. for longer than 17 hours causes the grains to turn yellow while aging below 5 DEG C. or for shorter than 30 minutes has no effect. The most preferable temperatures range from 15 DEG C. to 35 DEG C.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Aging Temperature ( DEGC.)

>;tb; Aging Time (hour)

>;tb;______________________________________

>;tb;5-15 longer than 3

>;tb;25 longer than 2

>;tb;37 longer than 1

>;tb;80 0.5-17

>;tb;______________________________________

The properly aged grains can be puffed into a greater size (FIGS. 3A and 3B) with uniformity across each grain in the subsequent puffing process. Such well aged puffed rice will absorb a greater amount of hot water on subsequent cooking (FIG. 3C) and therefore be cooked to be viscous textured (FIG.

3D). The results of FIGS. 3A-D were obtained with rice processed up to puffing according to Example

1 except conditions of aging which are the parameters of the graphs.

The final puffing or drying is carried out with a hot air blast at a temperature of preferably 160 DEG to

450 DEG C., or by dielectric heating at a high frequency within the range of preferably 300 to 3000

Mc/s. The temperature of the hot air, electric power, frequency, period etc. for the process are adjusted relative to the amount of pressed rice and its water content.

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The instant-cooking rice manufactured in accordance with the invention is packaged into a heatinsulating container with powdered soup or dried food materials such as vegetable or meat, etc. added as necessary for each of the various foodstuffs to be prepared, e.g., pilaf, curried rice, or "chicken and rice" etc. which will be prepared 3-5 minutes after hot water is poured thereon.

EXAMPLE 1

Two kilograms of rice is washed and soaked in water for 4 hours. After the water is drained off, the wet rice is mixed with 8 g of sugar ester and steamed at a steam pressure of 1.4 Kg/cm@2 for 7 minutes.

The steamed rice is dried with 60 DEG-80 DEG C. hot air to a water content of 27% by weight and is then pressed between rolls spaced a distance of 0.2 mm apart. The pressed rice is dried with 60 DEG-

80 DEG C. hot air to a water content of 17%, and then, the dried rice is aged at 20 DEG C. for 15 hours in a closed chamber. This aged rice is finally processed in a puffing or drying process with a 235 DEG

C. hot air blast at a velocity of 8 meters/sec. for 23 seconds, thereby forming the instant-cooking rice.

EXAMPLE 2

Two kilograms of rice is washed and soaked in seasoning liquid for 15 hours. After draining the water, the rice with a water content of 30% by weight is mixed with 20 g of monoglyceride and steamed under a steam pressure of 1 kg/cm@2 for 10 minutes. The steamed rice is dried with 60 DEG-80 DEG C. hot air to a water content of 28% by weight and pressed between rolls spaced a distance of 0.4 mm apart.

This pressed rice is dried with 60 DEG-80 DEG C. hot air to a water content of 12%, and the dried rice is aged at 30 DEG C. for 5 hours in a closed chamber. Finally, the aged rice is puffed by dielectric heating with a microwave (600 W, 2450 Mc/s) for 60 seconds, thereby forming the instant-cooking rice.

The thus produced instant-cooking rice, which, for marketing, may be packaged in an envelope or a heat-insulating container, will be reconstituted into a food preparation, for example, as follows:

ORDINARY RICE

300 cc of hot water is poured directly over 80 grams of the rice product having been packed in a 500 cc foamed styrene container. Palatable rice is ready to eat five minutes after quickly removing the water.

SHRIMP PILAF

300 cc of hot water is mixed with 100 g of the rice product, 2 g of freeze-dried shrimps, 1 g of freezedried carrot, 2 g of freeze-dried green peas and 1 g of freeze-dried onion having been packaged together in a 500 cc foamed styrene container. Five minutes after the water is removed, 8 g of rice oil and 4 g of powdered seasoning respectively wrapped with plastic film are then mixed thereinto and stirred using a spoon, thus preparing palatable "shrimp pilaf".

CHICKEN AND RICE

300 cc of hot water is mixed with 100 g of the rice product, 2 g of freeze-dried chicken meat, 5 g of freeze-dried carrot, 1.5 g of freeze-dried onion and 2.5 g of freeze-dried green peas having been packaged together in a 500 cc foamed styrene container. Four minutes after the water is removed, 10 g of rice oil and 15 g of powdered seasoning respectively wrapped with plastic film are then mixed therewith and stirred using a spoon, thus preparing palatable "chicken and rice".

CREAM STEW AND RICE

230 cc of hot water is mixed with 65 g of the rice product, 4 g of freeze-dried pork, 1.5 g of freezedried onion, 2.5 g of freeze-dried green peas, 10 g of gelatinized flour, 10 g of dextrin and 10 g of powdered seasoning having been packaged together in a 400 cc foamed styrene container. Palatable

"cream stew and rice" is prepared 4 minutes after the mixture is stirred.Data supplied from the esp@cenet database - Worldwide Claims:


1299/2197

What is claimed is:

1. A process for preparing instant-cooking rice consisting essentially of the steps of: (a) soaking rice in water or seasoning liquid so that its water content is 20-35% by weight; (b) mixing the soaked rice with

0.1-1.0% by weight of a surfactant, edible oil or talc; (c) completely gelatinizing the soaked rice with steam at a temperature of 100 DEG-140 DEG C.; (d) reducing the moisture content of the gelatinized rice to 25-35% by weight by exposing it to air at a temperature of 40 DEG-120 DEG C.; (e) pressing the reduced-moisture containing gelatinized rice between rolls spaced from 0.1-1.0 mm apart without producing cracks and fissures therein; (f) drying the pressed rice to 8-25% by weight be exposing it to air at a temperature of 20 DEG-100 DEG C.; (g) aging the dried rice in a closed chamber at a temperature of 15 DEG-35 DEG C. for at least 30 minutes to equalize the moisture distribution within the grains; and (h) puffing the aged rice with hot air at a temperature of 160 DEG-450 DEG C.

2. A process for preparing instant-cooking rice consisting essentially of the steps of: (a) soaking rice in water or seasoning liquid so that its water content is 20-35% by weight; (b) mixing the soaked rice with

0.1-1.0% by weight of a surfactant, edible oil or talc; (c) completely gelatinizing the soaked rice with steam at a temperature of 100 DEG-140 DEG C.; (d) reducing the moisture content of the gelatinized rice to 25-35% by weight by exposing it to air at a temperature of 40 DEG-120 DEG C.; (e) pressing the reduced-moisture containing gelatinized rice between rolls spaced from 0.1-1.0 mm apart without producing cracks and fissures therein; (f) drying the pressed rice to 8-25% by weight by exposing it to air at a temperature of 20 DEG-100 DEG C.; (g) aging the dried rice in a closed chamber at a temperature of 15 DEG-35 DEG C. for at least 30 minutes to equalize the moisture distribution within the grains; and (h) puffing the aged rice by high frequency dielectric heating at a frequency of 300-

3000 Mc/s.

3. A process as claimed in claim 1 or 2, wherein the gelatinization is carried out under conditions ranging from steaming at a temperature of 100 DEG C. and pressure of 1.03 kg/cm@2 to steaming at a temperature of 140 DEG C. and pressure of 3.68 kg/cm.

4. A process as claimed in claim 2, wherein the gelatinization is carried out for 0.5-60 minutes.

5. A process as claimed in claim 1 or 2, wherein the aging is performed for 0.5-17 hours.Data supplied from the esp@cenet database - Worldwide

1300/2197

263.

SU651654 - 3/5/1979

METHOD OF PREPARING INSTANT RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=SU651654

Inventor(s): ANDO MOMOFUKU (--); TAKATSU MITSUMUNE (--); MINAMI YUNICHI (--

); ONISI FUMIO (--); SAVADA MAKOTO (--)

Applicant(s): MOMOFUKU ANDO (JP); ANDO GIKEN KK (--); MITSUMUNE TAKATSU (--

); FUMIO ONISI (--); MAKOTO SAVADA (--)


IP Class: A23L1/10; A23L1/18

E Class: A23L1/182

Application Number: SU19752115493 (19750320)


Family: SU651654

Equivalent: NL7416833; JP51001669; SE410547

Abstract:

Abstract not available for SU651654

1301/2197

264.

TW448040 - 8/1/2001

GRAIN CONFECTIONERIES AND ITS MANUFACTURING INSTALLATION

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=TW448040

Inventor(s): TAKAOKA TERUMI (JP)

Applicant(s): ENSEKI AOJIRU CO LTD (JP)


IP Class: A23L1/10; A23P1/10

E Class: A23L1/185; A23L1/164C; A23L1/18C2; A23L1/172; A23L1/00P14B4; A23P1/14B4

Application Number: TW20000112082 (20000620)


Family: TW448040

Equivalent: EP1066760; JP2001017065

Abstract:

Abstract of TW448040

The object of this invention is about one kind of grain confectionery and it's manufacturing installation.

We use germinant brown rice and other germinant grain as materials of the grain confectionery, then heat, welding pressure the germinant grain to form a regular shape. Be caused by germinating can increase grain's natural sweet taste and it's component become easy to be absorbed by human body.

The manufacturing method of grain confectionery contain process portion and received portion that receive the product. The two portion put in a moving workcar that has wheels to stick on it and all the manufacturing process can be completed in the one installation. So, not only in department but also in various event place, the installation can produce and sale very well.Description:


[0001] This invention relates to cereal cakes using germinating unhulled rice and other germinating grains as the main constituent material and a device and process for manufacturing them.

[0002] Some conventional cereal cakes are made in circular form approximately 5 to 10 mm thick.

Each cake is heat processed and pressed by upper and lower mould parts after cereal, originally from unhulled rice, white rice, barn millets and other millets has been put into a forming position of a rice cake manufacturing machine.

[0003] Since a conventional cereal cake is made using raw grain without any processing, it bars digestion of protein and the absorption of minerals by phytic acid, a type of acid contained in cereals, and its nutrition is excreted without getting absorbed into the body even when eaten as it is.

[0004] Conventional manufacturing devices for cereal cakes are generally large and designed to be installed in a factory. Their constituent elements are separate so it is not easily possible to use them in vending shows which demonstrate the steps involved in making a finished cereal cake product from raw materials. There are no devices which are as convenient as the device according to the present invention, with which it is possible to wrap and sell a cake, immediately after it has been made. Such devices are useful at festivals and like events and at parks such as theme parks. In the cereal cake according to the invention, germinating grains are heated and pressed to form a predetermined shape in

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such a way that germination of the cereals provides phosphorous and by the effect of phosphoric acid enzyme, phytic acid gets dissolved into phosphoric acid and inositol whereas protein present turns into amino acid, fat present turns into an essential fatty acid, starch turns into sugar and minerals present get combined with amino acid, becoming easier to absorb. The cereal cake provided is characterised by a distinctive natural sweetness typical of the cereal itself.

[0005] Another object of this invention is to provide a cereal cake which feels good on the tongue and is easy for infants and aged people to eat. The cake is made by forming a cereal cake of predetermined form after geminating cereals have been irradiated by far infra-red radiation, heated and pressed. The product is characterised in that it is easy to be sufficiently absorbed into the body as a consequence of making the best of the nutrition typical of the cereals by the use of far infra-red radiation.

[0006] A still further preferable object is to provide a cereal cake including at least one additional food like black soya beans, black sesames and Hijiki (a kind of edible marine product) mixed with the above-mentioned germinating grains and producing nutritional elements from those additional foods.

[0007] According to a further aspect of the invention there is provided a manufacturing device for the cereal cakes. With the device, it is possible for all processing of the materials through to the finished product to be accommodated in one system mounted on a moving platform with wheels. Processing apparatus which processes the grains into cakes and a receipt part which receives the processed cakes are installed together. Consequently, the device is very effective in promoting the sale of the cakes.

Manufacturing of products according to the invention is convenient not only inside building like department stores but also at various other venues such as in event halls.

[0008] In the processing apparatus, cereals are dispensed from a hopper by a dispensing device and heat-pressed between upper and lower moulds so that it is possible to process the cereal by expansion and frying. Furthermore, since operation of the device involves elevating and bringing down the upper and lower moulds, its construction is simple and suitable for use as a moving device.

[0009] Furthermore, another preferred object of this invention is to form more than one operating space surrounded by transparent plates or panels so that it is possible to limit contact with outside agents. As the processing apparatus and the cake recipient region are situated inside the operating spaces, the device is hygienic. Furthermore, viewers watching the cakes being made and those who want to buy the cakes can easily enjoy watching how the cakes are being made from the outside of the device.

[0010] A preferred feature of this invention is to provide a wrapping space in the recipient region of the device or in the processing region so that it is possible not only to exhibit the way the cakes are manufactured but also make use of one device for selling the cakes immediately after they have been baked and wrapped.

[0011] According to a further preferred feature of the present invention it is possible to make the environment of the recipient region appropriate for cakes. Material constituting the bottom of the recipient region of the device is formed of a material of high heat conductivity. By putting an air compressor for driving an air cylinder for driving the moulds of the heat-pressing means underneath this bottom, it is not necessary to supply additional heating means. Accordingly it is possible to make use of the high heat generated by the compression of air in the compressor.

[0012] The invention will now be described by way of example with reference to the accompanying

Figures in which:

Figure 1 is a perspective view of a cereal cake of the present invention;

Figure 2 is a perspective view of a manufacturing device according to the invention for manufacturing a cereal cake;

Figure 3 is a vertical section of the manufacturing device shown in Figure 2;

Figure 4 is a transverse cross-section of the manufacturing device shown in Figure 2;

Figure 5 is a vertical cross-section of the processing part of the device shown in Figure 2;

Figures 6 to 9 are views similar to Figure 5 showing different stages in the operation of the device.

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[0013] The Figures show a cereal cake and a device for manufacturing it. Figure 1 shows the finished grain cake B of thin meat made by the present manufacturing device which has an uneven surface, it is approximately 1 to 2 mm thick and has a diameter of 3 to 6 cm. Depending on the size of the upper and lower pressing moulds and the pressure applied thereto, different thickness and grain cake diameters can be achieved.

[0014] Figure 2 is a perspective view of the manufacturing device 1 (which will be called the device from hereon) for making the grain cake B. The device comprises a movable platform which can be used anywhere. The device 1 is one on/in which necessary sub-devices are installed inside a rectangular parallelpiped case body 3 which has wheels 2 (e.g. castors) thereunder.

[0015] Figure 3 is a vertical section of the device 1 and Figure 4 is a transverse cross-section of the upper part of the device 1. As is clear from these Figures, the device 1 is provided with two adjacent surrounded or enclosed spaces 4 and 5 in an upper part thereof. One space 4 is equipped with processing apparatus 6 which manufactures cakes by processing cereal and the space 5 comprises a recipient region for receiving the cakes B which have just been made. The lower part of the device is provided with a machine which is necessary for driving the processing apparatus or mechanical part 6.

[0016] The device 1 has a ceiling 3a covering the operating spaces 4 and 5. The operating space 4 is cut off from the outside on two adjacent side surfaces which are provided with transparent plates 4a and 4b (e.g. acrylic plates). Furthermore, the operating space 5, called the cake recipient region 7, is surrounded by transparent plates 5a and 5b, but on the same side as an opening side of the operating space 4 an openable and closable door 5c is provided. A division between the operating space and the cake recipient region 7 is provided by a transparent plate 8 which is provided with a communicating hole 8a which connects the spaces 4 and 5 with each other in a predetermined position and a cake B which has been produced by the processing apparatus 6 is received through this communicating hole 8a into the cake receiving region 7.

[0017] The processing apparatus 6, as shown in Figure 5, comprises: a hopper 9 which contains cereal A; a means of dispensing a determined quantity of the grain A from the hopper 9; a means of heat-pressing the cereal A which has been so dispensed by means of an upper mould 10 and a lower mould 11; and a means of pushing cereal cakes B which have been made by the above means of heatpressing into the cake recipient region 7.

[0018] The hopper 9 facilitates charging of the device with cereal A by protruding a little upwardly from the upper surface of the ceiling 3a of the case body 3. The lower part of the hopper 9 constitutes a narrow funnel-like passage. A rack 12 connected to a slider 14 and moved by a pinion 13 is situated below the hopper 9.

[0019] The slider 14 serves as a means of dispensing the cereal A as well as means of displacing grain cakes B which have been made. In other words, while a motor (not shown in the drawings) drives the slider 14 forwardly, cereal A is dispensed from the hopper and at the same time cakes already made are pushed out from the processing apparatus into the cake recipient region 7.

[0020] The slider is provided with four round vertical through feeding holes 14a (see Figures 4 and

5). At one end, the slider 14 is provided with limitative guide protrusions 15a which prevent cakes being pushed towards the recipient region 7 from falling off the sides and a part 15 for pushing the cakes towards the recipient region 7. On the underside of the slider 14, below the hopper 9, there is provided a guiding plate 16 which prevents grain A, which has entered the feeding holes 14a, from falling through the slider.

[0021] The four feeding holes 14a are configured so as to correspond with a processing surface of the upper mould 10 and the lower mould 11 for heat-pressing the cereal A. The amount of grain A to be provided is determined by the thickness of the slider 14 and the size of the feeding holes 14a.

[0022] According to the embodiment shown, four cakes are made at one time by heat-pressing.

However the number of cakes made may be 1, 5, 6 or any convenient number.

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[0023] The upper mould 10 is provided with a heater 17 which is maintained at a determined temperature. Four cylindrical parts 10a protrude vertically downwardly from a lower surface of the upper mould 10.

[0024] The lower mould 11 is provided with an inner part 19 and an outer part 18 having four upwardly open round holes 18a. The inner part 19 moves up and down inside the holes 18a in the outer part. The outer part 18 is fixed inside a supporting plate 21 positioned at a given height on a base 20.

The above-mentioned guiding plate 16 and the upper surface of the outer part 18 are set at the same level and co-planar. The inner part 19 is provided with heaters 22 and has four cylindrical parts 19a protruding upwardly therefrom.

[0025] The upper mould 10 and the inner part 19 of the lower mould 11 are moved up and down by air cylinders.

[0026] The upper mould 10 is connected to the lower side of an upper support plate 23 which is supported by right hand and left hand guide rods 24 which extend below the base 20 where they connect to a lower support plate 25 in a lower region of the operating space 4. The lower support plate

25 is fixed to the end of a piston rod 26a of an upper mould air cylinder 26, actuation of which causes the upper mould 10 to move up and down.

[0027] The inner part 19 of the lower mould 11 is fixed to the end of a piston rod 27a of a lower mould air cylinder 27 situated vertically under the base 20 in such a way as to move it up and down. A stopper 27b is fixed on the piston rod 27a.

[0028] Fixed diagonally between the supporting plate 21 and the outer part 18 of the lower mould 11, and fixed on the supporting plate 21 is a slide-like plate or chute 28 down which formed cakes can slide. Consequently, the cereal cakes pass through the communicating hole 8a of the transparent plate 8 between the spaces 4 and 5 and slide down the plate 28 into the cake recipient region.

[0029] The cake recipient region 7 has a base part 29 which is made of a material of good heat conductivity such as steel and there is formed therein a hole 29a through which small debris and powder from the cakes B can fall. On the top of the hole 29 there is fixed a net or grille 30 and a removable powder collector 31 is installed below it.

[0030] Under the base part 29, an air compressor 32 is situated which is designed to drive the upper and lower mould air cylinders 26 and 27. An exhaust duct 32a is situated above the compressor so as to touch or be adjacent to the base part 29. Therefore, the base part 29 will receive heat from the air compressor 22 by means of gas exhausted therefrom which has been heated as a consequence of compression. Accordingly, the environment of the inner part of the cake recipient region 7 will be dried, thus providing an excellent environment for the prepared cakes without having to provide an additional drying or heating device specifically for this purpose. Figure 3 shows a receiver tank 33.

[0031] As shown in Figure 4, in the operating space 4, having the above mentioned processing apparatus 6, there is a wrapping space 34 for wrapping cakes B obtained from the cake recipient region

7 at a marginal region on the open side of space 4. More specifically, on the open side of the operating space 4, a wrapper container 34a for accommodating wrappers or bags, a balance 34b and a sealing machine 34c to seal the wrappers or bags are provided. An operating panel 35, for operating the device

1 is also shown.

[0032] The wrapping space 34 as described may be provided in the cake recipient region 7 or provided in another operating space of the device.

[0033] The device 1 functions as follows during the manufacture of cereal cakes.

[0034] The making of a thin rice cake B which gives a crispy feeling to the teeth and which is made using millet or germinating millet selected from various cereals will be described as an example. The nutritional components of germinating millet are easily absorbed into the body because of the

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germination process. If irradiated by far infra-red rays, nutrition from millet is absorbed best since this process makes it easier to absorb its nutrition into the body.

[0035] As a first step in the manufacturing process millet, as the grain A, is placed in the hopper 9.

Other marine and/or mountain products like beans (e.g. soya beans), other cereals, sesame products

(e.g. sesame seeds), Hijiki (a kind of edible marine product) or small fishes may be mixed with the millet. In this way, as shown in Figure 5, the cereal A will be fed into the feeding holes 14a of the slider 14.

[0036] A water content of approximately 14-15% should be maintained in the millet. In the upper mould and the lower mould, electricity is supplied to the heaters 17 and 22 to maintain a specific temperature. In the case of millet only, this temperature might be about 240 DEG C.

[0037] The pinion 13 is rotated by the motor and other devices (not shown in the Figures) sending the rack forwards. The slider 14 is accordingly moved towards the lower mould 11 until each feeding hole of the slider 14 is positioned above one of the cylindrical parts 19a of the lower mould 11.

Subsequently, the inner part 19 of the lower mould 11, as shown in Figure 6 with a dashed line is brought down by the lower mould air cylinder 27. This lowering movement stroke continues until the stopper 27b touches the base 20. Furthermore, the slider 14 is returned by rotation of the motor, pinion

13 and other devices, allowing refilling of the feeding holes 14a with cereal A to occur and positioning the slider 4 for pushing the formed cereal cakes forward.

[0038] The upper mould 10 is then brought down as shown in Figure 7, for heat-pressing of the cereal cakes. In other words, as the upper mould air cylinder 6 is driven to bring the upper mould 10 down, the protruding parts 10a of the upper mould 10 heat-press the cereal inside the cavities defined by the outer part 18 and the inner part 19 of the lower mould 11.

[0039] In the manufacture of a cake B of a crispy thin material, such as a rice cake, as described above, at a temperature of approximately 240 DEG C, a pressure of approximately 6 kg/cm>;2; is applied for about 2 minutes. After a certain period of time has passed, the upper mould 10 is brought up at a high speed by the upper mould air cylinder 26. As result of this procedure, the cereal A swells and looses its water.

[0040] After this, the upper mould air cylinder 26 is driven to bring the upper mould 10 down to heat press the grain A which will have swollen. This heat pressure may last for about two minutes at about

240 DEG C and with a pressure of about 6 kg/cm>;2;. By this reapplication of heat pressure, the cereal

A, which has been swollen gets an uneven surface as a whole after being fried and becomes crispy and delicious in a stereoscopic or three-dimensional form. Then, as the upper mould 10 is raised, the inner part 19 of the lower mould 11 is also raised. Consequently, the cakes formed move to the position as shown in Figure 8 and become level with the guiding plate 16 supporting the slider 14. At this point, as at the beginning of the process, the slider 14 is advanced and the cakes B, as shown in Figure 9, are pushed out into the cake recipient region 7 down the shute 28. At the same time, further cereal A, which has refilled the feeding holes 14A of the slider 14, is moved to a position above the inner part 19 of the lower mould 11. After this, when the inner part 19 of the lower mould 11 is lowered, as is shown by the broken line in Figure 9, the further cereal A falls into the cavities defined by the outer part 18 and the inner part 19 of the lower mould 11. Consequently, each time the slider 14 is moved back to the position shown in Figure 5, cereal A for the next batch of cakes is charged into the feeding holes 14a.

The cakes B which have been made and delivered to the cake recipient region 7 are kept dry by heat from the air compressor 32 and retain their crispy texture. Furthermore, as no other special devices are required to achieve this, the construction of the device is simple and compact.

[0041] Accumulated superfluous debris or powder drops through the hole 29a of the base part 29.

After opening the door 5c, and extracting the prepared cakes, the wrapping space 34 is utilised for wrapping the cakes.

[0042] As the processing apparatus 6 which processes the cereal A into the cakes B and the recipient region 7 which receives the processed cakes B are installed together within the case body 3 with wheels

2, all processing from the raw material through to the finished product can be achieved within one device. Therefore, in places like department stores as well as at indoor and outdoor events such devices

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are very useful for exhibiting and sale purposes. Furthermore, as the device constitutes a moving base with wheels, it is easy to move.

[0043] In the processing apparatus 6, the cereal A which is provided from the hopper 9, is heatpressed by the upper mould 10 and the lower mould 11 so that a swelling process as well as a frying process is possible. In the above example, there is described a process of heat-pressing twice. However, in a process of single heat-pressing, in which the upper mould 10 is elevated at a high speed, it is possible to obtain a grain cake B which is soft and swollen as a result of the swelling process.

[0044] As it is merely necessary to elevate and bring down the upper and lower moulds 10 and 11, the structure can be simple and suitable for incorporation into the moving device.

[0045] As a consequence of the transparent plates 4a, 4b, 5a, 5b and the doors which surround the two operating spaces 4 and 5, where the processing apparatus 6 and the cake recipient region 7 are respectively situated, it is possible to maintain hygienic conditions as it is possible to limit contact with outside agents. This makes it possible for people who want to buy the product or mere onlookers to enjoy watching the exhibition provided by the cakes being produced since they can see this from the outside of the device.

[0046] As a wrapping space 34 for wrapping the product is provided, it is possible to wrap and sell the cakes immediately after they have been made in addition to exhibiting the process of making the product.

[0047] In the above example the case body 3 corresponds to the moving base.Data supplied from the esp@cenet database - Worldwide

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265.

US1490018 - 4/8/1924

METHOD OF PREPARING RICE

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=US1490018

Inventor(s): MIYATAKA MIYA (--)

E Class: A23L1/182

Application Number: US19230676627 (19231123)


Family: US1490018

Abstract:

Abstract not available for US1490018

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266.

US1589672 - 6/22/1926

METHOD OF PREPARING RICE FOR CANNING


Inventor(s): WILLISON WALTER W (--)

Applicant(s): THERMOKEPT CORP (--)

E Class: A23L1/182



Family: US1589672

Abstract:


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267.

US1621763 - 3/22/1927

PROCESS OF MAKING FRIED RICE FOOD


Inventor(s): BUNKICHI YOKOYAMA (--)

E Class: A23L1/164E



Family: US1621763

Abstract:


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268.

US2001011657 - 8/9/2001

TRAY FOR PREPARING SUSHI AND PROCESS FOR PREPARING SUSHI

USING SAID TRAY


Inventor(s): AOKI MINORU (JP)

IP Class 4 Digits: B65D; A47G

IP Class: A47G19/00; B65D21/02

E Class: A23L1/182; A47J43/20; B65D21/02E5; B65D81/26C1



Family: US2001011657


Abstract:

Abstract of US2001011657

A ray set composed of a first tray and a second tray, wherein the first tray having a plurality of depressed portions in which sushi toppings can be placed and which each has a shape having a depth so as to fill it with the sushi topping and a portion of a lump of rice seasoned with vinegar. The first tray is provided with a plurality of holes on the bottom so as for liquid dropped or oozed out from the toppings to be discharged therethrough. The second tray is arranged such that it can be laid under the first tray and the liquid discharged from the first tray can be received by a depressed face, and a plurality of projections are formed continually and integrally with the depressed face and the plurality of the projections are disposed so as to be engageable with the holes of the first tray and to project through the holes inside the first tray, when the second tray is laid under the first tray. The projections assist in separating the sushi from the tray. The tray set and the process for preparing sushi by using the tray sets do not require any experience and skills for preparing sushi and can prepare a number of sushi with high efficiency and at cheaper costs in a short time.Description:

Description of US2001011657



[0002] The present invention relates to a tray set for use in preparing sushi and to a process for preparing sushi using the tray set.

[0003] 2. Description of the Related Art

[0004] Typically, "sushi" referred to herein is a lump of boiled rice seasoned with vinegar and having a sushi topping such as a piece of sliced fish flesh or any other topping placed on top. Generally, handmade sushi may be prepared by a cook having skills and prolonged experience. On the other hand, a tray for preparing rolled sushi is used as a frame to prepare rolled sushi. The process for preparing rolled sushi by using such a sushi-preparing tray does not require skilled cooks and can provide rolled sushi of a uniform quality and shape and in a short time. The sushi-preparing tray as a frame is provided with a plurality of depressed portions each having a rectangular shape corresponding to a shape of sushi. A predetermined amount of boiled rice is placed in the form of a lump into each depressed portion of the sushi-preparing frame, and then a topping such as, for example, a piece of fish or shellfish, e.g., a slice of tuna, sea bream, bonito or cuttlefish, shrimp, oyster, sea urchin or otherwise,

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vegetables or sea weed, such as horse radish sprouts or otherwise, etc. is placed on the rice lump placed in each depressed portion. The rice lump with the topping on top thereof is then pressed into a piece of rolled sushi that allows the topping to loosely attach to the rice lump, and the piece of the rolled sushi is then removed from the sushi-preparing frame. The sushi-preparing frame can prepare plural pieces of rolled sushi at one time.

[0005] The use of such a sushi-preparing frame allows rolled sushi to be prepared readily and quickly at a sushi corner in a super market or department store or any appropriate place without using the hands of a cook having long-experienced skills. Further, such a sushi-preparing frame can prepare a number of pieces of rolled sushi at one time which otherwise have to be prepared by plural sushi cooks.

[0006] Such a conventional frame for use in preparing rolled sushi, however, carries some problems.

The toppings such as a slice of fish flesh, sea weed, vegetables or the like may contain a lot of water or juices so that, when they are allowed to stand for a while, liquid is allowed to drop or ooze out from the toppings, resulting in sushi becoming too watery and spoiling a quality of sushi and eventually a value of sushi as goods.

[0007] Further, when sushi is prepared by means of a conventional sushi-preparing tray, a piece of pressed sushi is often unlikely to be taken out from the tray or some grains of boiled rice are left attached on the surface of the tray resulting in the breakdown of a shape of sushi and losing the value of v sushi as goods. Such a piece of sushi cannot be solid as goods any more. Further, if time would be spent to take pieces of pressed sushi out from the tray, labor efficiency will be decreased as a matter of course.

[0008] As a matter of course, labor is required for preparing sushi by using a sushi-preparing tray. If, however, labor would be used over the entire course or a majority of the course of the preparation of sushi even if using such a sushi-preparing tray, labor efficiency will be decreased greatly.


[0009] Therefore, the present invention has an object to overcome the problems inherent in conventional sushi-preparing technology and to provide a sushi-preparing tray suitable for use in preparing sushi.

[0010] The present invention has another object to provide a method for preparing sushi using a sushipreparing tray.

[0011] In order to achieve the object, the present invention in an aspect provides a sushi-preparing tray set comprising a first tray and a second tray; the first tray comprising a plurality of depressed portions each having a depth that can receive a slice of fish flesh or any other topping and a lump of boiled rice seasoned with vinegar placed thereon and having a small aperture through which drips or water from the sliced fish flesh or other topping can be removed from the depressed portion, and the second tray having a depressed face that receives drips or water discharged through the small aperture of the first tray, when the second tray is laid underneath the first tray, and having a plurality of raised portions formed continually and integrally with the depressed face and so adapted as to protrude inside the first tray through the small aperture thereof in a state in which the second tray is laid under first tray.

[0012] In a preferred mode of this aspect of the present invention, the sushi-preparing tray set is configured such that a row of depressed portions are disposed in the transverse direction of the first tray by locating a plurality of depressed portions in a spaced relationship apart at a predetermined interval and a plurality of rows of depressed portions are disposed in a spaced relationship apart in a predetermined interval in the longitudinal direction of the first tray; and such that each depressed portion in each row is formed at a predetermined angle with respect to virtual longitudinal coordinate of the first tray, when looked in section, that is, each depressed portion is formed so as to become gradually narrower from the top toward the bottom.

[0013] In another aspect according to the present invention, there is provided a method for preparing sushi by using the sushi-preparing tray set as disclosed in the one aspect, which comprises: the first step of placing a slice of fish flesh or any other topping in each depressed portion of the first tray of the sushi-preparing tray set as described above; the second step of placing a lump of boiled rice seasoned with vinegar onto the slice of fish flesh or any other topping placed in each depressed portion; the third step of pressing the lump of rice from top so as to attach the rice lump to the topping; the fourth step of covering pieces of sushi formed on the sushi-preparing tray set with a packaging material and turning the sushi-preparing tray set upside down to allow the pieces of sushi to be detached from each depressed portion of the first tray; and the fifth step of detaching the sushi-preparing tray set from the pieces of sushi and wrapping the piece of sushi with a packaging material to yield a sushi pack.

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[0014] In a preferred mode of this aspect of the present invention, the work of locating a lump of boiled rice seasoned with vinegar into each depressed portion of the first tray with the topping such as sliced fish flesh or other topping placed therein is carried out by a robot having required functions.

[0015] In another preferred mode of this aspect of the present invention, a small amount of a seasoning, such as spice, e.g., wasabi, i.e., Japanese horseradish, is coated on the bottom surface of the topping placed in a first depressed portion of the first tray as another lump of rice is placed into a second depressed portion of the same tray disposed adjacent the first depressed portion thereof.


[0016] FIG. 1 is a view explaining a line carrying out a method for preparing sushi in accordance with an embodiment of the present invention, when looked from top.

[0017] FIG. 2 is a side view showing an outline of a sushi-preparing tray set according to an embodiment of the present invention.

[0018] FIG. 3 is a plan view showing a top tray of the sushi-preparing tray set according to the embodiment of the present invention.

[0019] FIG. 4 is a side view showing the top tray of the sushi-preparing tray set according to the embodiment of the present invention.

[0020] FIG. 5 is a plan view showing a bottom tray of the sushi-preparing tray set according to the embodiment of the present invention.

[0021] FIG. 6 is a side view showing the bottom tray of the sushi-preparing tray set according to the embodiment of the present invention.

[0022] FIG. 7 is a view explaining the top and bottom trays of the sushi-preparing tray set according to the embodiment of the present invention, when the top tray is superimposed over the bottom tray thereof.

[0023] FIG. 8 is an enlarged side view in section showing a depressed portion of the top tray and a raised portion of the bottom tray.

[0024] FIG. 9 is a view explaining a portion of the method for preparing sushi according to an embodiment of the present invention.





[0028] The sushi-preparing tray set for preparing sushi according to an embodiment of the present invention is of a double tray structure consisting of a first tray as a top tray and a second tray as a bottom tray to be disposed underneath the first tray, the first tray being provided with a plurality of depressed portions in each of which a topping, such as a slice of fish flesh or any other topping, is placed therein and a lump of boiled rice seasoned with vinegar is superimposed over the topping and the second tray being laid under the first tray.

[0029] Each of the plural depressed portions formed in the first tray may be in a generally rectangular shape and have a depth that can receive a slice of fish flesh or any other topping and a lump of rice seasoned with vinegar superimposed over the slice of fish flesh or another topping. Further, each of the depressed portions may be provided in its bottom portion with a small aperture through which drips or other liquid dropped or oozed out from the topping, i.e., the slice of fish flesh or any other topping disposed in the depressed portion thereof can be discharged outside from the first tray into the second tray. And each depressed portion of the first tray may preferably be configured such that it can accommodate the rice lump placed on the topping so as for the top surface of each rice lump to become higher than the top surface of the first tray yet lower than the bottom surface of the second tray so as for the top surface of each rice lump to fail to come into touch with the bottom surface of the second tray after the rice lump has been pressed into a piece of sushi when the second tray is laid under the first tray.

[0030] A plural number of the depressed portions may be arranged in a row in an equally spaced relationship in the transverse direction of the first tray. Likewise, a row of the depressed portions may

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be arranged in plural numbers in an equally spaced relationship parallel to the row, that is, in a longitudinal direction of the first tray.

[0031] Furthermore, each of the depressed portions may be formed as an opening that in turn may be configured such that the opening in section is tapered at a constant angle so as for each side to become gradually narrower toward the bottom. A number of the depressed portions can be arranged effectively in a constant area of the first tray. For instance, eight to twelve depressed portions may be formed in the first tray and eight to twelve pieces of sushi can be prepared at one time. It is to be noted herein, however, that the number of the depressed portions is not restricted to those particular numbers and may be varied.

[0032] On the other hand, the second tray may be formed so as to receive the first tray disposed on top so that the first tray can be laid over the second tray. Therefore, when the first tray is superimposed over the second tray, the first and second trays may be formed integrally as one tray. More specifically, the second tray comprises a flat depressed bottom face that can receive and gather drips and any liquid dropped or oozed out from the apertures disposed in the depressed portions of the first tray through which the drips and the liquid are discharged from the first tray. The second tray is further provided with raised portions that correspond to the apertures formed in the depressed portions of the first tray and that can penetrate through the corresponding apertures and protrude inside the first tray through the apertures thereof, when the first tray is superimposed over the second tray.

[0033] The raised portions may be disposed so as for their upper portions to be inserted through the corresponding apertures formed in the first tray and to protrude therethrough upwardly to some extent inside the corresponding depressed portions of the first tray, when the first tray is laid over the second tray. When the first tray is superimposed over the second tray so as for the raised portion s of the second tray to be inserted into the apertures of the depressed portions formed in the first tray and to protrude upwardly inside the depressed portions of the first tray, the contents of the depressed portions of the first tray are allowed to come into contact with the top sections of the raised portions of the second tray protruding from the bottom of the depressed portions of the first tray and to be raised to some extent therefrom. Therefore, this configuration of the sushi-preparing tray set according to the present invention can assist in detaching pieces of sushi from the bottom of the depressed portions of the first tray without breaking the entire shape of sushi.

[0034] Now, a brief description will be given regarding the method for the preparation of sushi using the sushi-preparing tray set according to the present invention.

[0035] The method for the preparation of sushi according to the present invention may comprise combining the first and second trays into the sushi-preparing tray set according to the present invention, boiling a given amount of rice and seasoning boiled rice with vinegar and other seasonings, preparing lumps of boiled rice seasoned with vinegar and other seasonings, placing a topping such as a slice of fish flesh or other topping in each of the depressed potions of the first tray, placing a lump of rice onto the topping placed in the depressed portion of the first tray, placing or supplying a small amount of a seasoning, such as spice, e.g., wasabi, as needed, on the topping placed in the depressed portion of the first tray, pressing the rice lump onto the topping placed in the depressed portion of the first tray so as to allow the rice lump to loosely attach to the topping, turning the tray set upside down, together with a set of pieces of sushi located on the first tray, and removing the tray set from the set of pieces of sushi.

[0036] As a preparatory work, the first tray and the second tray are combined together to form the sushi-preparing tray set according to the present invention. The first and second trays may be combined immediately before preparing sushi upon order or may be stored in a refrigerator after placing the topping including, e.g., a slice of fish flesh or other topping in the first tray.

[0037] The depressed portions of the first tray of the tray set is then filled with toppings such as slices of fish flesh and any other suitable toppings, as preset or requested, manually by hand or automatically by a robot. Typically, different kinds of toppings are used for all pieces of sushi arranged on one tray. It is possible to set a robot so as to arrange all different kinds of toppings in the depressed portions in one tray, however, the use of such a robot for an automatic sushi making machine may require a large amount of investment for machinery and eventually raise costs of pieces of sushi. In a majority of cases, it may be better to place the different toppings in the depressed portions of the first tray by hand so as to comply with a consumer's request and so on, in order to save costs of investment for machinery or plant and reduce costs of preparation of pieces of sushi.

[0038] On the other hand, lumps of boiled rice may be prepared by means of a conventional rice-lump preparing machine that can prepare a number of rice lumps at one time. This kind of the machine is suitable for preparing a number of rice lumps in a short time although such boiled rice lumps can be prepared by hand. The use of such an automated rice-lump preparing machine is preferably suitable for

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automation of the preparation of sushi and, as a matter of course, this can save a lot of labor and time, improving efficiency and workability to a great extent.

[0039] Then, the rice lumps so prepared are transferred to a sushi-preparing tray set by hand or with a robot and a rice lump is placed onto the topping placed in each of the depressed portion of the first tray of the tray set one after another. For the work of placing rice lumps in the depressed portions thereof, the robot is particularly suitable for preparing sushi in a large number in a short time. The manual work can also be conducted particularly to prepare sushi in a small number in a very short time.

[0040] The robot for use in transferring the rice lumps from the rice-lump preparing machine to the tray sets and placing them in the depressed portions of the first tray may comprise a hand section that can clamp a rice lump at the rice-lump preparing machine and transfer it to a predetermined position of the depressed portion of the first tray. As the rice lump has been transferred to the predetermined depressed portion thereof, the hand section of the robot releases the rice lump on the topping in the depressed portion. This work is repeated to fill the tray set with a predetermined number of rice lumps, that is, to fill a required number of the depressed portions with the rice lumps.

[0041] In accordance with the embodiment of this invention, the seasoning such as spice, e.g., wasabi, i.e., Japanese horseradish, may be placed or coated, as requested, on the topping placed in the depressed portion thereof, for example, by means of a seasoning supply unit, as the rice lump is placed in each of the depressed portions of the first tray. In a preferred mode of this embodiment, a seasoning supply unit may be installed to the robot for placing the rice lump in each of the depressed portions of the first tray so as to enable placing or supplying a small amount of a seasoning, such as spice, e.g., wasabi, on the topping placed in the depressed portion thereof. In this mode of the embodiment, the seasoning supply unit is disposed nearby the hand section of the robot and arranged so as to place or coat the seasoning on the topping as the hand section of the robot is being placing a rice lump into another depressed portion of the first tray. In this case, it is better to set the interval between the seasoning supply unit and the hand section of the robot to comply with the interval between the adjacent depressed portions of the first tray. In order to conduct a series of this work effectively and efficiently, the robot is preferably arranged so as to operate the hand section to conduct the first stroke without clamping any rice lump simply by allowing the seasoning supply unit to supply a given amount of a seasoning, such as spice, e.g., wasabi, to the topping placed in the first depressed portion of the first tray. At the second stroke of transferring a rice lump from the rice-lump preparing machine to the tray set, the hand section of the robot clamps another rice lump at the rice-lump preparing machine and carries it to the first depressed portion where the topping has already been supplied with the seasoning.

At this time, the seasoning supply unit is located above the second depressed portion of the first tray.

As the hand section of the robot then releases the rice lump on the topping in the first depressed portion, the seasoning supply unit supplies a small amount of the seasonings onto the topping placed in the second depressed portion thereof. This operation is repeated to allow all the depressed portions of the tray set to be filled with the rice lumps. At the last stroke of the hand section of the robot, the seasonings supply unit is set to fail to supply any amount of the seasonings because it is located outside the tray set at this time. If no seasoning is requested, the seasonings supply unit can be set so as to supply no seasoning to the first tray. The concurrent operations of placing rice lumps on the tray set and supplying the seasoning thereon can remarkably improve the efficiency of preparing sushi.

[0042] After the rice lumps have been placed in all the depressed portions of the first tray, then they are pressed somewhat to allow the rice lumps and the toppings placed thereunder and in the depressed portions thereof to loosely attach to each other yet for each piece of sushi to fail to easily separate the topping from the rice lump. The pressing may be effected by means of a device with a special type of a mold having substantially the same size of the upper portion of each piece of sushi located on the first tray of the tray set, thereby shaping each piece of sushi.

[0043] The tray set with the pieces of sushi located thereon is covered with a packaging material such as a package that may function as a bottom package section, and then turned upside down, and the tray set is detached leaving the pieces of sushi on the packaging material. The pieces of sushi located on the packaging material are then covered with another packaging material, e.g., a top package section, to produce a sushi pack containing plural pieces of sushi with different kinds of toppings on top.

[0044] With the arrangement as described above, a large number of sushi with the topping placed thereon can be prepared efficiently in a short time in a generally automated manner even without skilled cooks, while maintaining a uniform yet high quality.

[0045] The present invention will be described in more detail by way of examples with reference to the accompanying drawings.

1315/2197

[0046] FIG. 1 shows a sushi production line for carrying out the method for the preparation of sushi by using a tray set in accordance with the present invention. The sushi production line L may comprise a tray carrying line L1 for transferring tray sets, a rice lump filling line L2, and a press-turning line L3.

[0047] The tray carrying line L1 comprises a belt conveyor 10 to carry a tray set 1 to a robot 2 after the tray sets have been pre-prepared. The tray set 1 for use in preparing sushi according to this embodiment of the present invention will be described later in more detail. The robot 2 is disposed on the last end side of the belt conveyor 10. The tray set 1 is first filled with toppings S1 while it is being carried on the belt conveyor 10, although this operation will be described later in more detail.

[0048] The rice lump filling line L2 is provided with a robot 2 that can fill rice lumps S2 in the depressed portions of the tray set 1 which have already been filled with the toppings S1, while the tray set 1 is being conveyed by means of the tray carrying line L1 in the direction crossing the rice lump filling line L2.

[0049] In this embodiment, a rice-lump preparing machine 3 is disposed nearby behind the robot 2 to produce rice lumps S2. The rice-lump preparing machine 3 is provided with a group of rollers having a pair of rollers per row disposed in plural rows and with a shaping mold disposed under the group of the rollers, the machine having a rice box or container 30 disposed on top which is filled with boiled rice.

The boiled rice is supplied downwards from the rice box or container 30 and expanded in the form of a belt by means of the rollers. The rice in the belt form is further transferred downwards, followed cutting the rice into a predetermined size with a cutter section disposed on the shaping mold and then shaping the cut amount of rice into a rice lump S2. The shaped rice lumps S2 are then transferred to a predetermined position by means of a conveyor section 31. The rice-lump preparing machine 3 may be provided with a pair of the rollers groups and the shaping molds, and with a rice dividing section for dividing the rice supplied from the rice box or container into two streams each in the form of a belt.

The divided streams of rice are processed in substantially the same manner as described immediately above, so that two lumps S2 of boiled rice can be prepared at the same time.

[0050] The press-turning line L3 contains a pressing unit 4 (see FIG. 11) and a turning unit 5, and the pressing unit 4 is of a shape corresponding to a shape of sushi so as to press the rice lump from top and shape the rice lump to a piece of sushi. The turning unit 5 is arranged to turn the tray set 1 with the pressed sushi rolls filled therein upside down after covering the pressed sushi lumps in the tray set 1 with a package P functioning as a sushi container. In FIG. 1, reference symbol C refers to a refrigerator accommodating the tray sets 1 with toppings, such as slices of fish flesh or other toppings inserted in the depressed portions of the first tray, reference symbol M refers to an operator, and reference symbol

S refers to completed sushi lumps.

[0051] Now, a description will be given below regarding the configuration of the tray set 1 according to the present invention with reference to FIGS. 2 to 8. In this embodiment, the tray set 1 is made of a synthetic resin although the material for the tray set is not restricted to a particular one and a metallic material such as aluminum foil may also be used. Further, the surface of the tray set1 may be processed by antibacterial coating procedures.

[0052] As shown in FIG. 2, the tray set 1 may comprise a top tray 6 as a first tray and a bottom tray 7 as a second tray, and the top tray 6 is superimposed over the bottom tray 7 and assembled therewith.

Moreover, the tray set 1 can be laid on another tray set one after another in plural rows.

[0053] As shown in FIGS. 3 and 4, the top tray 6 comprises an area 61 where a plurality of depressed portions 60 are disposed, a flange section 62 disposed integrally around the area 61, and footaccommodation depressed portions 62a disposed inside the flange section 62 at which corresponding foot portions 72 disposed on the bottom tray 7 are to be accommodated. Further, the top tray 6 is provided with cut-away portions 62b on the outer hanging edge section of the flange section 62. Upon superimposing the top tray 6 over the bottom tray 7, an engaging section 70b provided on the bottom tray 7 can be engaged tightly with the corresponding cutaway portion 62b so as to allow a ready superimposition of the first tray over the second tray.

[0054] The top tray 6 is provided with the plural depressed portions 60 on the area 61, and each depressed portion 60 is shaped in a generally rectangular form so as to accommodate a topping S1 such as a slice of fish flesh or any other topping, as requested. Each of the depressed portions 60 is rendered gradually narrower from the top opening area toward the bottom area and has a depth in which the rice lump S2 can be placed on the topping S1, as shown in FIG. 4. Further, each depressed portion 60 is provided on the bottom with a plurality of holes 63 through which liquid dropped or derived from the topping S1 and so on can be discharged, as shown in FIG. 3. The holes 63 are composed of small openings through which blood or other liquid oozed out from the toppings such as fish flesh and so on is discharged from the depressed portion 60. The holes 63 can prevent sushi from becoming too watery and sustain a high quality as sushi.

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[0055] Moreover, the area 61 of the top tray 6 is provided with a predetermined number of the depressed portions 60 in a row 6a (in this embodiment, five depressed portions per row being disposed in two rows) in a spaced relationship apart at a constant distance in the lengthwise direction. The row

6a of the depressed portions 60 is disposed in plural numbers at a constant interval in the widthwise direction (in this embodiment, two rows are depicted). In addition, in this embodiment, each row 6a of the depressed portion 60 is disposed at a constant angle with respect to the parallel sides of the top tray

6, when looked in a plane. This allows an efficient arrangement of the plural depressed portions 60 on the top tray 6 so as to prepare plural pieces of sushi.

[0056] On the other hand, the bottom tray 7 is in a generally rectangular form, when looked in a plane, as shown in FIGS. 5 and 6, so as to be tightly engaged with the top tray 6, as shown in FIGS. 2 and 7.

The bottom tray 7 has a depressed area 70 that receives the liquid penetrated from the holes 63 of the top tray 6. The depressed area 70 of the bottom tray 7 is integrally provided with raised sections 71 so as to engage with the corresponding holes 63 and project inside the top tray 6 therethrough, when the top tray 6 is superimposed over the bottom tray 7, as shown in FIGS. 7 and 8. The raised sections 71 can assist in readily separating the pieces of sushi S from the corresponding depressed portions 60 of the top tray 6. The bottom tray 7 also comprises a flange section 70a with engagement pieces 70b formed projecting in a semi-circular shape from the flange section 70a so as to engage with the cutaway portion 62b of the top tray 6 in a manner as described above. After the pieces of sushi S have been separated from the tray set 1, the tray set 1 is divided into the top and bottom trays 6 and 7 and the liquid collected in the bottom tray 7 is discharged, followed by washing them with water for re-use.

[0057] Now, a description will be give below regarding the process for the preparation of sushi by using the tray set 1 having the above configuration with reference to FIGS. 1 and 9-12. In this embodiment, sushi may be prepared for example in a take-out sushi shop.

[0058] As shown in FIG. 9, the top tray 6 is in advance assembled with the bottom tray 7 by superimposing the top tray 6 over the bottom tray 7. Then, a topping S1 such as a piece of fish flesh or any other topping is placed in each depressed portion 60 of the top tray 6. At this case, a different kind of a topping S1 may be placed in each of the depressed portions 60 of the tray set 1, as shown in FIGS.

9(a) and 9(b). In this case, different toppings S1 are inserted in all the depressed portions 60. The tray set 1 with the toppings S1 arranged thereon is then placed and stored in a refrigerator C, as shown in

FIG. 9(c), in order to be ready for preparation any time when an order is placed. At this time, a plurality of the tray sets 1 with the identical or different toppings S1 so arranged thereon can be superimposed over another tray set 1 with the toppings S1 so arranged thereon, as described above, in order to save a space within the refrigerator C and allow a ready storage therein.

[0059] Once an order is placed from a take-out counter of the sushi shop, for example, the sushi production line L is started and the number of the tray sets 1 are taken out from the refrigerator C, as ordered and placed on the tray transfer line L1. The tray sets 1 are then transferred to the position of the robot 2 where rice lumps are placed in the depressed portions 60 thereof (FIG. 1).

[0060] As the sushi production line L has been started, the robot 2 and the rice-lump preparing machine

3 are also ready for starting operation. The rice-lump preparing machine 3 prepares rice lumps S2 continually, and the rice lumps S2 are transferred to an operating region of the hand section 20 of the robot 2 by means of the conveyor section 31, as shown in FIG. 10.

[0061] As shown in FIG. 10, the robot 2 comprises a hand section 20 for clamping rice lumps S2, a horizontal transfer device 21 for horizontally transferring the hand section 20, and a lift device 22 for moving the hand section 20 vertically. The hand section 20 is disposed at the top edge of the conveyor section 31 of the rice-lump preparing machine 3 and also provided with a finger portion 23 at the top thereof, which can clamp the rice lump S2 by closing it and release it by opening it to fill the depressed portions 60 of the tray set 1 with the rice lumps S2 one after another from a one side to another side of the tray set 1.

[0062] FIG. 10 also shows a seasonings supply unit 8 disposed on the hand section 20 for supplying a small amount of a seasoning, such as spice, e.g., wasabi, i.e, Japanese horseradish or the like. In this embodiment, the seasonings supply unit 8 is of a nozzle type and mounted in front of the finger portion

23 of the hand section 20 of the robot, the seasonings supply unit 8 comprising a nozzle part 81 for supplying a predetermined amount of a seasoning on the sushi topping S1 upon contact with the topping. Further, the distance D between the center of the nozzle part 81 and the center of the finger portion 23 is set so as to become equal to a pitch d between one depressed portion 60 and the adjacent depressed portion 60 of the tray set 1.

[0063] Therefore, at the first stroke of supplying the tray with the rice lump S2, the horizontal transfer device 21, the lift device 22 and the finger part 23 are controlled so as for the finger part 23 to be located in front of the tray set 1 without clamping any rice lump S2. At this time, the nozzle part 80 of

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the seasonings supply unit 8 is arranged so as to be located at the position of the first depressed portion

60 of the tray set 1 and to come into contact with the sushi topping SI within the first depressed portion

60 to supply wasabi 80 or other seasoning onto the sushi topping S1.

[0064] Then, at the second stroke of placing a rice lump S2, the finger part 23 of the hand section 20 clamps a rice lump S2 and then carries it to the first depressed portion 60 of the tray set 1. At this time, the nozzle part 80 of the seasonings supply unit 8 is located above the topping S1 placed in the second depressed portion adjacent the first depressed portion being supplied with the rice lump S2. Then, the finger part 23 is lowered to allow the rice lump S2 to come into contact with the sushi topping S1 located therein and releases it on the sushi topping S1. Concurrently with the lowering of the finger part 23, the nozzle part 81 of the seasonings supply unit 8 is lowered to supply the second depressed portion 60 with a small amount of the seasoning. At the strokes et seq., this procedure is repeated to supply the seasoning 80 onto the topping S1 placed in the last depressed portion 60 of the tray set 1 and to supply a rice lump S2 in the last second depressed portion 60 thereof. Then, at the last stroke for filling the rice lumps in the tray set 1, the finger part 23 of the hand section 20 is transferred to the position of the last depressed portion 60 of the tray set 1 and supplies a rice lump S2 onto the sushi topping S1 with wasabi or other seasoning already supplied thereto in the last depressed portion 60 thereof. At this time, the nozzle part 81 is located outside the tray set 1 so that the seasonings supply unit 8 is controlled so as to supply no amount of the seasoning.

[0065] After all the depressed portions 60 of the tray set 1 (the top tray 6) have been filled with the sushi toppings S1 and the rice lumps S2, the tray set 1 is then transferred to the press-turn line L3. In the press-turn line L3, the pressing unit 4 with a depressed portion 40 is lowered to the rice lump S2, as shown in FIG. 11(a). The depressed portion 40 is formed so as to adapt to the shape of a piece of sushi and to arrange the piece of sushi for a better shape as goods. As the pressing unit 4 is lowered to cover the rice lump S2 from top, the rice lump S2 is pressed toward the sushi topping S1 to re-shaped the rice lump S2 into a piece of sushi having a quality as high as goods. After having pressed, the pressing unit

4 is moved upward from the tray set 1 to release the rice lump S2, as shown in FIG. 11(b).

[0066] Then, the tray set 1 is transferred to the location where a turning unit 5 is disposed. The turning unit 5 comprises a first pressing plate 51 for pressing the tray set 1 from the side of the top tray 6 and a second pressing plate 52 for pressing it from the side of the bottom tray 7. Before pressing the tray set 1 by the first and second pressing plates, the tray set 1 is covered with a package P on top and the tray set

1 is interposed and pressed between the first and second pressing plates 51 and 52 from top and bottom, respectively, as shown in FIG. 12(a). Then, the tray set 1 is turned upside down in the state that it is sandwiched between them.

[0067] After it has been turned upside down, the second pressing plate 52 now located on top is detached from the tray set 1 and then the tray set 1 is removed to release the pieces of sushi S, as shown in FIG. 12(b). Upon removing the tray set 1, the raised portions 71 disposed on the bottom tray 7 of the tray set 1 acts to release the piece of sushi S from the top tray 6 thereof. Thereafter, the package P with the pieces of sushi S filled therein is covered with a lid P1 to form a sushi pack, as shown in FIG. 12(c).

Such a sushi pack is wrapped and ready for delivery to a customer.

[0068] The steps of preparing such a sushi pack as described above are continually repeated to prepare a number of sushi packs.

[0069] The above method for the preparation of sushi by means of the sushi-preparing machine requires no experienced skill and no laborious work and can be carried out by only one person M without any experienced skill. Further, the above method is suitable for continually preparing a large number of sushi packs with pieces of sushi arranged therein.

EFFECTS OF THE INVENTION

[0070] The present invention can be practiced in the manner as described above and achieve the following effects.

[0071] As described above, the present invention in an aspect provides the tray set for use in the preparation of pieces of sushi, each piece being composed of a sushi topping and a rice lump with the sushi topping placed thereon and, as needed, a small amount of a seasoning interposed between the sushi topping and the rice lump, wherein the tray comprises the first tray and the second tray, the first tray being provided with a plurality of depressed portions, each having a shape corresponding to the shape of a piece of sushi, and with holes through to discharge liquid dropped or derived from the sushi topping; and the second tray arranged so as to be laid under the first tray and having a depressed face so as to receive the liquid discharged from the holes disposed in the first tray, and having a plurality of raised sections formed continually and integrally with the depressed face so as to enter through the corresponding holes and project inside the first tray when the second tray is laid under the first tray.

1318/2197

The tray set of this type for preparing sushi does require experienced skills, unlike sushi shops or restaurants where cooks with experienced skills are usually required, so that a person having no experienced skills can prepare sushi having a quality as high as sushi prepared by cooks with skills and experience. The present invention can prepare sushi containing less amount of liquid and preventing it becoming too watery (reducing the quality as sushi) as well as less breakage of the shape of sushi, thereby sustaining a high quality of sushi as goods.

[0072] In a preferred aspect, the present invention provides the tray set for use in the preparation of sushi wherein the depressed portions for preparing pieces of sushi are provided in plural rows, each row being composed of a predetermined number of the plural depressed portions. This can allow a plurality of pieces of sushi to be prepared on a tray in a continuous manner.

[0073] In another preferred aspect of the present invention, each of the plural depressed portions of the first tray is arranged so as to have a shape corresponding to each piece of sushi and having a space narrowed gradually from the top to the bottom. This shape of the depressed portion allows the piece of sushi to be released easily from the first tray of the tray set.

[0074] The present invention in another aspect provides the process for the preparation of sushi by using a tray set as described above. This process can prepare a sushi pack containing different kinds of pieces of sushi having different sushi toppings. Further, this process does not require any experienced skills and can efficiently prepare sushi of a high quality, which contains less amount of liquid by preventing it becoming too watery. Moreover, this process allows the preparation of pieces of sushi at lower costs while sustaining a high quality as sushi.

[0075] In a preferred aspect of this invention, the work of filling the depressed portions of the first tray with sushi toppings and rice lumps is carried out by the robot, so that a number of pieces of sushi can be prepared with high efficiency and at lower costs.Data supplied from the esp@cenet database -

Worldwide Claims:

Claims of US2001011657

What is claimed is:

1. A tray set for use in the preparation of pieces of sushi composed of a sushi topping and a rice lump with the sushi topping placed thereon and, as needed, a small amount of a seasoning interposed between the sushi topping and the rice lump, comprising: a first tray with a plurality of depressed portions each having a shape corresponding to a piece of sushi and a depth approximately corresponding to a thickness of the topping and a portion of a thickness of a rice lump and with holes through to discharge liquid dropped or derived from the topping; and a second tray arranged so as to be laid under the first tray and having a depressed face so as to receive liquid discharged from the holes disposed in the first tray, and having a plurality of raised sections formed continually and integrally with the depressed face so as to enter through the corresponding holes and project inside the depressed portions of the first tray, when the second tray is laid under the first tray.

2. The tray set as claimed in claim 1, wherein the first tray is provided with the plurality of the depressed portions at a constant interval in a row in a transverse direction of the first tray; and a plurality of rows, each row composed of the plurality of the depressed portions disposed in the transverse direction of the first tray, are provided at a constant interval in a longitudinal direction of the first tray.

3. The tray set as claimed in claim 1, wherein each of the depressed portions is formed in such a shape in section that becomes gradually narrower in width from the top to the bottom at a constant angle with respect to the virtually perpendicular coordinate of the first tray.

4. The tray set as claimed in claim 1, wherein the first tray is provided with a depressed section on top; the second tray is provided with a leg section on the bottom; and the depressed section of the first tray of a one tray set composed of the first and second trays is engageable with the leg section of the second tray of another tray set composed of the first and second trays, when the another tray set is laid on the one tray set.

1319/2197

5. The tray set as claimed in claim 2, wherein the first tray is provided with a depressed section on top; the second tray is provided with a leg section on the bottom; and the depressed section of the first tray of a one tray set composed of the first and second trays is engageable with the leg section of the second tray set composed of another set composed of the first and second trays, when the another tray set is laid on the one tray set.

6. The tray set as claimed in claim 1, wherein the first tray is provided with a flange part on top, the flange part having a cut-away section on an outer edge portion thereof; and the second tray is provided with an engagement projection that is engageable with the cut-away section of the flange part of the first tray, when the first tray is laid on the second tray.

7. The tray set as claimed in claim 2, wherein the first tray is provided with a flange part on top, the flange part having a cut-away section on an outer edge portion; and the second tray is provided with an engagement projection that is engageable with the cut-away section of the flange part of the first tray, when the first tray is laid on the second tray.

8. A process for the preparation of pieces of sushi by using a tray set for use in the preparation of pieces of sushi each composed of a sushi topping and a rice lump with the sushi topping placed thereon and, as needed, a small amount of a seasoning interposed between the sushi topping and the rice lump, having: a first tray with a plurality of depressed portions each having a shape corresponding to a piece of sushi and a depth approximately corresponding to a thickness of the sushi topping and a portion of a thickness of a rice lump and with holes through to discharge liquid dropped or derived from the sushi topping; and a second tray arranged so as to be laid under the first tray and having a depressed face so as to receive liquid discharged from the holes disposed in the first tray, and having a plurality of raised sections formed continually and integrally with the depressed face so as to enter through the corresponding holes and project inside the first tray when the second tray is laid under the first tray, comprising: the step of placing a topping in each of the plurality of the depressed portions of the first tray; the step of a rice lump on the sushi topping placed in each of the depressed portions of the first tray by the first step; the step of pressing the rice lump and the sushi topping so as to attach the rice lump to the topping; the step of covering the first tray with a packaging material and turning the tray set upside down; and the step of releasing the tray set to leave the pieces of sushi on the packaging material.

9. The process as claimed in claim 8, wherein a topping is placed in each of the plurality of the depressed portions disposed on the first tray in a transverse direction of the first tray at a constant interval in a row and disposed in a plurality of rows at a constant interval in a longitudinal direction of the first tray; and a rice lump is placed onto the topping previously placed in each of the plurality of the depressed portions of the first tray.

10. The process as claimed in claim 8, wherein the rice lump is inserted by a robot onto the topping placed in advance in each of the depressed portions of the first tray.

11. The process as claimed in claim 9, wherein the rice lump is inserted by a robot onto the topping placed in advance in each of the depressed portions of the first tray.

12. The process as claimed in claim 8, wherein a seasoning is added to the topping placed in one depressed portion of the first tray while another rice lump is being inserted into another depressed portion of the first tray.

13. The process as claimed in

1320/2197

claim 9, wherein a seasoning is added to the topping placed in one depressed portion of the first tray while another rice lump is being inserted into another depressed portion of the first tray.

14. The process as claimed in claim 12, wherein the topping placed in a depressed portion of the first tray is supplied with the seasoning while the rice lump is placed in another depressed portion thereof located in the position adjacent the depressed portion in which the topping in process of supplying with the seasoning is placed.

15. The process as claimed in claim 13, wherein the topping placed in a depressed portion of the first tray is coated with the seasoning while the rice lump is placed in another depressed portion thereof located in the position adjacent the depressed portion in which the topping in process of supplying with the seasoning is placed.Data supplied from the esp@cenet database - Worldwide

1321/2197

269.

US2001012533 - 8/9/2001

METHOD FOR PREPARING COOKED RICE


Inventor(s): NAKAMURA RYOJI (JP); SANO FUMIHIKO (JP); OGATA YOSHIO (JP);

NISHINOMIYA TAKESHI (JP); TOBA SHIGERU (JP)

Applicant(s): AJINOMOTO KK (JP)


IP Class: A23L1/182

E Class: A23L1/182



(20000706)



Abstract:


The invention relates to a method of preparing cooked rice, comprising steaming raw rice having a water content of less than 30% by weight and then boiling the steamed rice, to cooked rice prepared according to the present method, and to cooked rice types comprising the cooked rice.Description:




[0002] The invention relates to a method of preparing cooked rice, to cooked rice prepared according to the method, and to cooked rice types comprising the cooked rice.

[0003] 2. Discussion of the Background

[0004] Cooked rice has traditionally been prepared by various methods. In one method, raw rice is first washed and then soaked in water, and the soaked rice is then placed in a rice cooker and cooked in water by heating (cooker cooking). In another method, raw rice is first washed and soaked in water, the soaked rice steamed and then soaked in hot water, followed by steaming the resulting rice (steam cooking; see for example Japanese Patent Laid-open No. 224661/1984). In yet another method, raw rice is first washed and soaked in water and then steamed, and the steamed rice is then heated with warm water or water in a rice cooker (hybrid cooking; see Japanese Patent Laid-open No.

195465/1991).

[0005] Also according to traditional rice cooking methods, washed raw rice is soaked in water for 1-2 hours. When raw rice is not soaked, or soaked for only a short period of time, the resulting cooked rice is not sticky and has a hard core and very poor taste. Such a phenomenon is distinctive of rice cooked in a cooker. Thus, traditionally, a soaking step has been used in rice cooking methods. To prepare cooked rice with a desirable taste and texture, therefore, soaking of the rice in water for a sufficient period of time is carried out. However, since the soaking step lengthens the total preparation time of the cooked rice product, poor production efficiency results when rice is cooked on an industrial scale.

[0006] To increase the production efficiency of the rice cooking process, therefore, it is desirable to decrease the total preparation time of the cooked rice, especially when rice is cooked on an industrial

1322/2197

scale. This is especially important when frozen rice food products, such as frozen pilaf and Chinese fried rice products suitable for microwave or oven cooking, are prepared on an industrially large scale.

[0007] The cooking time of the rice may be shortened by cooking the rice under pressure, or by omitting the soaking step of raw rice in water (non-soak steam cooking; see Japanese Patent Laid-open

No. 327617/1995). However, cooking the rice under pressure results in a cooked rice which is excessively sticky, while non-soak steam cooking results in a rice type which is too poorly sticky.

Cooked rice having a desirable taste and texture which is suitable for western-style and Chinese-style cooked rice types has not been prepared according to any of the known methods, which is a disadvantage in this industry.

[0008] The inventors have overcome the aforementioned disadvantages in the rice cooking industry by omitting the soaking process of raw rice in water. In the present method, raw rice is washed and steamed, preferably immediately after washing, and the steamed rice is then boiled in water. The washing step may be omitted if the rice used is of a type which does not need to be washed (referred to as a wash-free milled rice type hereinafter). The inventors have found that excellent cooked rice suitable for the preparation of western-style and Chinese-style cooked rice types can be prepared by their method. The inventors have also found that cooked rice type having a dry crispness and being suitable for pilaf rice can be recovered by suppressing stickiness essentially required for general plain cooked white rice.

[0009] Some advantages associated with the present method are that large-scale soaking equipment is unnecessary, resulting in a saving of space in the rice production facility, as well as a reduction in the amount of water discharged from the facility.

[0010] Prior to the present invention, there were no known methods for preparing cooked rice having the desired stickiness and fluffiness and a texture (crispness) suitable for the preparation of westernstyle and Chinese-style cooked rice types such as pilaf, Chinese fried rice, dry curry, paella, and buttered rice with chicken (chicken rice), on an industrially large scale and with a short cooking time.

[0011] In such circumstances, there has been a need for the development of a method for preparing cooked rice suitable for use in the preparation of the aforementioned cooked rice types.


[0012] Accordingly, it is an object of this invention to overcome the disadvantages of the known methods of preparing cooked rice which is suitable for western-style and Chinese-style cooked rice types. More specifically, the present invention provides an efficient method for cooking rice which omits the time-consuming step of soaking the rice in water, and which provides cooked rice having grains which adhere weakly to each other and a stickiness and fluffiness which are suitable for the preparation of western-style and Chinese-style cooked rice types.

[0013] In one embodiment of the invention, a method of preparing cooked rice comprising steaming raw rice having a water content of less than 30% by weight and then boiling the steamed rice is described.

[0014] In an alternative embodiment, cooked rice prepared by the present method is described.

[0015] In an alternative embodiment, a cooked rice type comprising the cooked rice prepared by the present method is described.


[0016] In accordance with the invention, cooked rice having the desired quality for the preparation of western-style and Chinese-style cooked rice types such as pilaf, Chinese fried rice, dry curry, paella and chicken rice, can be prepared on an industrially large scale in a short period of time by omitting the soaking process of raw rice.

[0017] In accordance with the invention, raw rice is washed and steamed, preferably immediately after washing, and the steamed rice is then boiled in water. The washing step may be omitted if wash-free milled rice is used. The rice grains of the resulting cooked rice have poor adhesivity to each other, and are therefore dry and crisp but appropriately sticky.

[0018] As used herein, the term "wash rice" means a type of rice which needs to be washed.

[0019] As used herein, the term "wash-free milled rice" means a type of rice which does not need to be washed.

[0020] As used herein, the term "raw rice" means milled rice (raw material rice) washed under agitation in sufficient volume of water or warm water to a final state with no rice bran or contaminants therein, and which is not yet steamed or boiled. Further, the raw rice may include the wash-free milled rice described above.

1323/2197

[0021] In accordance with the invention, any cultivars of rice can be used without specific limitation, and includes any nonglutinous rice, glutinous rice, low amylose rice or high amylose rice. The water content of the rice used is from 12 to 17% by weight. This range includes all specific values and subranges there between, such as, but not limited to, 12.5, 13, 13.5, 14, 14.5, 15 and 16% by weight. If necessary, additionally, appropriate amounts of barley and the like may satisfactorily be mixed with such rice for use.

[0022] As used herein, the term "water content" means a ratio (% by weight) determined by heating a rice sample and vaporizing water therein at drying process under heating at atmospheric pressure, measuring the difference in weight between prior to and after drying to calculate the volume of water in the sample and calculating the ratio of the volume to the sample prior to drying. To prevent the sample from turning heterogeneous, the sample was sufficiently mixed together under agitation and then collected.

[0023] The water content of the raw rice is less than 30% by weight, preferably 14 to 29% by weight, more preferably 20 to 26% by weight, still more preferably 21 to 24% by weight. These ranges include all specific values and subranges there between, such as, but not limited to, 14.5, 14.75, 15, 16, 18, 20,

22, 25 and 27% by weight. When the water content of raw rice is more than 30% by weight, the adhesivity of the resulting cooked rice is enhanced. To avoid the enhancement, the water content should be selected to be less than 30% by weight. To prepare cooked rice which is not too hard, a water content of more than 14% by weight is preferably selected.

[0024] As used herein, the term "soaking process" means a process of soaking raw rice in water or warm water for one to 2 hours to allow the raw rice to absorb water sufficiently to a final water content of 30 to 36% by weight.

[0025] Appropriate conditions for the steaming process (temperature, length of steaming, etc.) can be selected by those of ordinary skill in the art without undue experimentation. For example, a steam temperature of from 90 to 100[deg.] C. can be used, while the steaming time varies depending on the steaming temperature. This temperature range includes all specific values and subranges there between, such as, but not limited to 91, 91.5, 92, 93, 94, 95, 97 and 99[deg.] C. The steaming time is generally about 10 to 30 minutes. This range includes all specific values and subranges there between, such as, but not limited to 11, 12, 13, 14, 16, 18, 20, 22, 23, 26 and 29 minutes. The steamed rice is preferably at a water content of 20 to 30% by weight and with a gelatinization degree of 15 to 35%, more preferably at a water content of 25 to 30% by weight and with a gelatinization degree of 18 to 30%.

These water content ranges includes all specific values and subranges there between, such as, but not limited to 21, 22, 23, 24, 25, 26, 27, 28 and 29% by weight. These ranges of gelatinization degree include all specific values and subranges there between, such as, but not limited to 16, 17, 18, 19, 20,

22, 24, 26, 27, 27, 31 and 33%. The gelatinization degree was measured according to the P-amylase pullulanase method (see J. Jpn. Soc. Starch Sci., 28, 235 (1981)).

[0026] Appropriate conditions for cooking the rice (temperature, water volume, etc.) can be selected by those of ordinary skill in the art without undue experimentation. Methods generally used for cooking rice including heating conditions may satisfactorily be used. For cooking the rice, water (preferably water at for example 50[deg.] C. or more, more preferably at about 70 to 80[deg.] C.) is then added at a volume ratio to rice to be cooked according to general rice cooking methods This temperature range includes all specific values and subranges there between, such as, but not limited to 55, 58, 60, 65, 75 and 78[deg.] C. Otherwise, the water is at a slightly less volume or at a slightly more volume.

Depending on the rice species or the final product type, the volume of water can appropriately be selected. Per 100 parts by weight of rice (raw rice or wash-free milled rice if used), water is additionally added preferably at about 100 to 140 parts by weight (water content of cooked rice at 56 to

67% by weight) and more preferably at about 120 to 130 parts by weight (water content of cooked rice at 60 to 64% by weight) to the steamed rice. These ranges include all specific values and subranges there between, such as, but not limited to 101, 105, 110, 115, 125 and 135 parts by weight. In accordance with the invention, cooked rice with appropriate stickiness and fluffiness and a texture suitable for western-style and Chinese-style cooked rice types such as pilaf, Chinese fried rice, dry curry, paella and chicken rice, even when the volume of water added is at 140 parts by weight (water content of cooked rice at 67% by weight), can be prepared in an efficient way and with increased yield compared to traditional rice cooking methods.

[0027] The container for rice cooking is with no specific limitation but a rice cooker can be used as the container. Rice cooking in water is satisfactorily performed in a rice cooker. Herein, the rice cooking process comprises a boiling step of swelling the rice under heating in a rice cooker thereby gelatinizing the rice and simultaneously changing the starch in the rice into [alpha]-type, a baking step of additionally heating the rice when water in the cooker is absorbed in the rice, and a subsequent

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steaming step of leaving the rice to stand alone while the lid of the cooker remains on. Any means or any known methods routinely used as rice cooking methods can be used therefor. More specifically, the time required for the elevation of the temperature of the product to 100[deg.] C. at the boiling process can be set at 5 minutes to 20 minutes. This range includes all specific values and subranges there between, such as, but not limited to 6, 7, 9, 10, 12, 15, 17 and 19 minutes.

[0028] The cooked rice produced by the present method is dry and crisp because of poor adhesion between rice grains, and having a particularly suitable texture for western-style and Chinese-style cooked rice types such as pilaf, Chinese fried rice, dry curry, paella and chicken rice and still having appropriate stickiness and fluffiness.

[0029] To prepare pilaf, Chinese fried rice, dry curry, paella and chicken rice, the necessary cooking materials and seasonings are added at any of the steps during the rice cooking process, or after the rice is boiled. For example, rice is steamed and boiled according to the present method and, subsequently, appropriate seasonings for the desired cooked rice type are added. For pilaf, for example, necessary ingredients are added to the cooked rice to generate the pilaf taste. In such manner, pilaf can completely be prepared.

[0030] The various western-style and Chinese-style cooked products such as pilaf, Chinese fried rice, dry curry, paella and chicken rice, made using rice prepared by the present invention, are also encompassed within the cooked rice types prepared in accordance with the invention.

[0031] The pilaf, Chinese fried rice, dry curry, paella and chicken rice thus prepared have particularly highly dry and crisp touch on the tongue. Because the inventive method comprises cooking after an optional rice washing process (the process can be omitted for wash-free milled rice) (the soaking process can substantially be omitted) and a subsequent steaming process, foods produced by methods for preparing cooked rice types, at least comprising the two processes, namely the steaming process and the boiling process, in this sequence, are all encompassed within the products prepared by the inventive method, namely the inventive products. Furthermore, fats and oils may satisfactorily be added during these two processes according to the methods described in Japanese Patent Laid-open

Nos. 55167/1981, 275437/1984 and 91844/1993. Preferably, fats and oils are added after the steaming process. Products necessary for intermediate products and final products (foods in final forms), which are produced by a processing process and a cooking process and the like in addition to the two processes essential for the invention, are also encompassed within the products produced by the inventive method, as long as the products have no adverse influence on the advantages or purposes of the invention. Therefore, cooked rice types recovered in accordance with the invention can be used for preparing various cooked products and foods or can be contained in such various cooked products and foods. It is needless to say that the resulting cooked products and foods are also encompassed within the scope of the invention.

[0032] Because the cooked rice types prepared in accordance with the present invention are suitable for frozen foods, the cooked rice types can be stored in such frozen states for use. As the freezing method in such case, general methods for preparing frozen foods including individuated quick-freezing methods described in for example Japanese Patent Laid-open Nos. 105847/1975 and 44857/1988 can be used.

EXAMPLES

[0033] Having generally described this invention, a further understanding can be obtained by reference to specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.

Example 1

[0034] Milled raw rice (3 kg) prepared by milling the brown rice of the brand Mutsuhomare produced in 1998 (cultivated region: Aomori in Japan) was weighed and washed for 2.5 minutes according to a conventional methods, followed by water draining for 10 minutes. The water content of the rice (raw rice) after water draining was measured as 22.1% by weight. Subsequently, the rice after water draining was charged in a Chinese-style steamer (square type of 400 mm*400 mm), under purging of steam at about 100[deg.] C. from the underneath for steaming for 20 minutes. The steamed rice was at a water content of 27.2% by weight. Subsequently, the steamed rice [about 600 g (500 g on a milled rice weight basis)] was weighed, followed by addition of 120 parts by weight of water at 80[deg.] C. per

100 parts by weight on a milled rice basis, 1.8 parts by weight of edible salt, 0.14 part by weight of pepper, 0.26 part by weight of sodium glutamate and 0.9 part by weight of consommé as pilaf seasoning per 100 parts by weight on a milled rice basis, and 2.3 parts by weight of salad oil per 100

1325/2197

parts by weight on a milled rice basis; and the resulting mixture was boiled in an electric rice cooker for 20 minutes. Subsequently, the rice was steamed for 15 minutes, while the rice was retained at

90[deg.] C. or more. The cooked rice after completion of steaming was at a water content of 62.1% by weight.

Example 2

[0035] Wash-free milled rice (at water content of 15.6% by weight; 3 kg) prepared from the rice of the brand Mutsuhomare produced in 1998 (cultivated region: Aomori in Japan) was weighed and charged in a Chinese steamer (square type; 400 mm*400 mm), under purging of steam at about 100[deg.] C. from the underneath for steaming for 20 minutes. The steamed rice (steamed rice) was at a water content of 20.1% by weight. Subsequently, the steamed rice [about 540 g (500 g on a milled rice weight basis)] was weighed, followed by addition of 140 parts by weight of water at 80[deg.] C. per

100 parts by weight on a (milled) rice basis, 1.8 parts by weight of edible salt, 0.14 part by weight of pepper, 0.26 part by weight of sodium glutamate and 0.9 part by weight of consommé as pilaf seasoning per 100 parts by weight on a milled rice basis, and 2.3 parts by weight of salad oil per 100 parts by weight on a milled rice basis; and the resulting mixture was boiled in an electric rice cooker for 20 minutes. Subsequently, the rice was steamed for 15 minutes while the rice was retained at

90[deg.] C. or more. The cooked rice after completion of steaming was at a water content of 60.0% by weight.

[0036] The properties of the rice types recovered above were determined, using a tensipressor ("My

Boy" manufactured by Taketomo Electric Machine, Co., Ltd.). The method for determining the properties comprised placing one grain of cooked rice on a sample table, measuring the thickness of the grain of cooked rice with a plunger (18 mm[phi]) each time, and then measuring the load required for compressing the thickness to 25% (low-pressure compression one byte) and 85% (high-pressure compression two byte) thereof. Based on the resulting chart (see Table 1), the adhesion (-H2) and stickiness (A6) were determined. The mean values thereof concerning 30 cooked rice grains are shown in Table 2.

>;tb;>;sep;TABLE 1

>;tb;>;sep;A chart (an example of one grain method pattern) of the load

>;tb;>;sep;on the cooked rice grain used in Example 1, and shows an analysis

>;tb;>;sep;of cooked rice with low-pressure compression (25% compression) and

>;tb;>;sep;high-pressure compression (85% compression) by a 2-byte method:

>;tb;>;sep;Items>;sep;Indicators>;sep;Note

>;tb;>;sep;Hardness>;sep;H2>;sep;harder at a larger value

>;tb;>;sep;Elasticity>;sep;(A4 + A5)/(A1 + A2)>;sep;stronger at a larger value

>;tb;>;sep;Flexibility>;sep;H2/H1>;sep;flexible at a larger value

>;tb;>;sep;Adhesion>;sep;-H2>;sep;stronger at a larger value

>;tb;>;sep;Stickiness>;sep;A6>;sep;stronger at a larger value

>;tb;>;sep;Fragile property>;sep;A4/A5>;sep;fragile at a larger value

>;tb;>;sep;H1, H2, -H1, -H2: peak values

>;tb;>;sep;A1 to A6: area

>;tb;>;sep;L1 to L6: distortion level (mm)

[0037] In the same manner as in Example 1, without any modification, except that rice washed and soaked for 2 hours was steamed to weigh and use the resulting rice of about 670 g (500 g on a milled rice basis) and that 100 parts by weight of warm water were used per 100 parts by weight on a milled rice basis, cooked rice (Comparative Example 1) was prepared. The properties thereof were determined in the same manner as described above. The results are shown in Table 2.

>;tb;>;sep;TABLE 2

>;tb;>;sep;Samples>;sep;Adhesivity (dyn)>;sep;Stickiness (erg)

>;tb;>;sep;Example 1>;sep;1.20 * 10>;5;>;sep;1.51 * 10>;5;

>;tb;>;sep;Example 2>;sep;0.68 * 10>;5;>;sep;0.53 * 10>;5;

>;tb;>;sep;Comparative Example 1>;sep;1.75 * 10>;5;>;sep;2.26 * 10>;5;

[0038] As shown in Table 2, the inventive product was at far lower degrees of adhesivity and stickiness, compared with the comparative product. It was verified that compared with the comparative product, the inventive product was very tasty with excellent texture, when materials necessary for pilaf were added to the inventive product to prepare pilaf.

Example 3

1326/2197

[0039] Cooked rice prepared by cooking according to the inventive method (Example 1) was mixed with dry ice pulverized into powder under agitation, for individuated quick-freezing to recover a product (Example 3). Alternatively, cooked rice prepared by cooking according to the method disclosed in Japanese Patent Laid-open No. 327617/1995 was subjected to individuated quick-freezing in the same manner, to recover a product (Comparative Example 2). Specifically, the comparative product was prepared by subjecting raw rice to steaming for 12 minutes in the same manner as in

Example 1, subsequently soaking the total volume of the steamed rice in hot water at 90[deg.] C. for 4 minutes, draining water for about 15 seconds, charging again and steaming the resulting rice in the same steamer for 12 minutes, adding the same kind and quantity of pilaf seasonings as in Example 1 and salad oil to recover cooked rice (Comparative Example 2 prior to freezing), mixing the cooked rice with dry ice pulverized into powder under agitation and subjecting the mixture to individuated quickfreezing (Comparative Example 2).

[0040] Individual samples (250 g each) of the frozen products were placed in a microwave oven for heating at 600 W for 5 minutes, from which the samples were taken out and left to stand at ambient temperature for 3 minutes. In a sensory test (n=8), dry crispness as well as stickiness were evaluated to assess the preference of the resulting samples for western-style cooked rice, concerning stickiness and fluffiness suitable for pilaf. As a control in the sensory test, the cooked rice of Comparative Example I was used, after freezing and heating in a microwave oven. The results are shown in Table 3.

[0041] The assessment was carried out by eight panelists, and the properties of the rice were ranked in

5 grades as shown on average score, while the control was defined as score 0. Concerning the degrees of dry crispness and stickiness, the assessment scores were defined as follows:

[0042] score 2: strong

[0043] score 0: identical to control

[0044] score -2: weak.

[0045] Concerning the preference of overall texture, the assessment scores were defined as follows:

[0046] score 2: preferable

[0047] score 0: identical to control

[0048] score -2: not preferable.

[0049] As shown in Table 3, the inventive product (Example 3) had preferable texture, but the product of Comparative Example 2 was too poorly sticky, with the resulting absence of preferable texture.


>;tb;>;sep;>;sep;>;sep;Dry crispness>;sep;Stickiness>;sep;Preference of

>;tb;>;sep;>;sep;Samples>;sep;degree>;sep;degree>;sep;overall texture

>;tb;>;sep;>;sep;Example 3>;sep;0.5>;sep;-0.1>;sep;0.3

>;tb;>;sep;>;sep;(invention)

>;tb;>;sep;>;sep;Comparative>;sep;1.5>;sep;-1.3>;sep;-0.3

>;tb;>;sep;>;sep;Example 2

>;tb;>;sep;>;sep;Control Product>;sep;0.0>;sep;0.0>;sep;0.0

Example 4

[0050] Pilaf was produced according to the following method:

[0051] To the cooked rice recovered in Example 1 were added 54 parts by weight in total of preliminarily prepared shrimp and vegetables (onion, carrot, kidney bean, green pepper, sweet corn and mushroom) per 100 parts by weight on a milled rice basis, to prepare shrimp pilaf. With or without individuated quick-freezing, the resulting shrimp pilaf was dry and crisp, with weak adhesivity of rice grain to each other, and the resultant preferable texture.

[0052] Having now fully described this invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein.

[0053] This application is based on (a) Japanese Patent Application No. 13282/2000, filed Jan. 21,

2000, (b) Japanese Patent Application No. 84845/2000, filed Mar. 24, 2000, and (c) Japanese Patent

Application No. 205653/2000, filed Jul. 6, 2000, the entire contents of which are hereby incorporated by reference herein, the same as if they were fully set forth at length.Data supplied from the esp@cenet database - Worldwide Claims:

Claims of US2001012533

What is claimed as new and desired to be secured by Letters Patent of the United States is:

1327/2197

1. A method of preparing cooked rice, comprising steaming raw rice having a water content of less than

30% by weight and then boiling the steamed rice.

2. A method according to claim 1, wherein the raw rice has a water content of from 14 to 29% by weight.



5. A method according to claim 1, wherein the raw rice is a wash rice type.

6. A method according to claim 1, wherein the raw rice is a wash-free milled rice type.

7. A method according to claim 1, wherein the raw rice is steamed for a period of from 10 to 30 minutes.

8. A method according to claim 1, wherein the raw rice is steamed at a temperature of from 90 to 100[deg.] C.

9. A method according to claim 1, wherein water at a temperature of 50[deg.] C. or more is added to the steamed rice before boiling.

10. A method according to claim 1, wherein water at a temperature of from 70 to 80[deg.] C. is added to the steamed rice before boiling.

11. A method according to claim 1, further comprising adding a seasoning to the rice during steaming or boiling, or during both steaming and boiling, or to the boiled rice.

12. A method according to claim 11, wherein the seasoning is a seasoning used in pilaf, Chinese fried rice, dry curry, paella or buttered rice with chicken.

13. A method according to claim 1, further comprising steaming the rice after boiling.

14. A method according to claim 13, wherein the boiled rice is steamed at a temperature of 90[deg.] C. or more.

15. A method according to claim 1, wherein the steamed rice before boiling has a gelatinization degree of from 15 to 35%.

16. A method according to claim 1, wherein the steamed rice before boiling has a gelatinization degree of from 18 to 30%.

17. Cooked rice prepared according to the method of claim 1.

18. A cooked rice type comprising the cooked rice of claim 17.

19. A cooked rice type according to

1328/2197

claim 18 which is selected from the group consisting of pilaf, Chinese fried rice, dry curry, paella and buttered rice with chicken.Data supplied from the esp@cenet database - Worldwide

1329/2197

270.

US2001012535 - 8/9/2001

RECONSTITUTABLE RICE GRAINS


Inventor(s):

ERNST H (CH)

DUPART PIERRE (CH); MOHAMAD YUSSOF OTHMAN (MY); REIMERDES

Applicant(s): PIERRE DUPART (US)


IP Class: A23L1/201

E Class: A23L1/168




Equivalent: EP0913096; DE69720220T; DE69720220D; CN1216687; AU751378

Abstract:


A process for making reconstitutable rice grains by cooking a mixture of rice flour, water and hydrogenated oil in a cooker-extruder to produce a partly gelatinized mixture, forming the partly gelatinized mixture into rice-grain shaped pieces and then drying and cooling the pieces to room temperature to provide the reconstitutable rice grains. Also, the resulting reconstitutable rice grain product.Description:


TECHNICAL FIELD

[0001] The subject of the present invention relates to process for the preparation of rice grains which may be rapidly reconstituted. The invention also relates to the resultant rapidly reconstitutable rice grains.

BACKGROUND ART

[0002] Usually, quick-cooking reconstitutable rice grains are produced by gelatinizing rice flour and then forming the gelatinized flour into grain shaped pieces.

[0003] U.S. Pat. No. 4,769,251 describes in particular a process for the manufacture of quick-cooking rice products in which a mixture comprising 60-80% of rice flour or granules and 20-40% of water is cooked for 20 seconds to 3 minutes by adding steam, in order to increase its temperature from about

150[deg.] F. to 210[deg.] F. After this preconditioning step, the mixture is introduced into an extruder in which it is sequentially advanced first through a cooking zone, then through a venting zone and a forming zone.

[0004] One problem with this process is that a venting zone is necessary to decrease the water content of the mixture which is added at the beginning to decrease the mechanical energy. Also, the final product requires cooking before it can be reconstituted.

[0005] European patent application 0226375 describes a process for the preparation of a quick-cooking rice-like product in which rice flour and water are first mixed to form a dough. This dough is then treated in a section of a single or twin screw extruder, preferably in a twin screw extruder, at a temperature below the cooking range of the ingredients. The cooking section of the extruder has four

1330/2197

cooking zones of progressively increasing temperature, between 29.4[deg.] C. and 104[deg.] C., and operates at a pressure of between 6205 kPa and 10342 kPa. The dough is then treated in order to totally gelatinize the starch molecules and to denaturate the proteins. After that the dough is treated in a cooling zone at a temperature between 32.2[deg.] C. and 40.5[deg.] C., and then sized into dimensions to simulate rice grains which are dried.

[0006] One problem with this process is that a large amount of mechanical energy is required to totally gelatinize the starch molecules. Further, the quick-cooking rice-like product is soft after rehydration and does not have the texture of rice grains.


[0007] The aim of this invention is to provide a simple and rapid process which makes it possible to produce reconstitutable rice grains which keep their grain shape after rehydration without becoming soft. Another aim is to produce rice grains that can rehydrate rapidly and which have a good texture.

[0008] Accordingly, in one aspect, the invention provides a process for making reconstitutable rice grains, comprising cooking a mixture of rice flour, water and hydrogenated oil in a cooker-extruder operated at about 100-500 rpm and at a temperature of about 70-150[deg.] C., to produce a partly gelatinized mixture, forming the partly gelatinized mixture into rice grain shaped pieces and then drying and cooling the pieces to room temperature to provide reconstitutable rice grains.


[0009] It was surprisingly found that this process makes it possible to produce rapidly reconstitutable rice grains without requiring a large amount of energy. These reconstitutable rice grains have the advantage of having pores but not cracks on their surface to allow a quick rehydration with good texture. Furthermore, the reconstitutable rice grains of the invention have the advantage of being resistant to bacteriological contamination.

[0010] In order to make use of invention, the extruder cooker is preferably operated at about 120-200 rpm and at a pressure equal or more than 20 bar. Preferably the pressure is about 80-160 bar.

[0011] Before extrusion cooking, the rice flour can be treated to decrease bacteriological contamination, especially Bacillus cereus.

[0012] In the present invention, the mixture can contain different qualities of rice flour. This permits a larger range of final textures of the instantly reconstitutable rice grains.

[0013] The mixture can also contain about 2-11% hydrogenated oil, with respect to the total weight content of the rice flour. It is possible to use, as the hydrogenated oil, coconut oil, soybean oil, cottonseed oil, palm oil or palm kernel oil, so as to decrease the friction during the extrusion-cooking and to control the water absorption of the reconstituted rice grains. If too much oil is added in the mixture, the reconstitutable rice grains do not absorb water very well during rehydration.

[0014] In the invention the mixture can also contain 12-25% water. If the amount of water is more than

25%, the mixture is likely to stick in the extruder-cooker. If the amount of water is below 12%, there is too much mechanical energy during the extrusion-cooking and the mixture gelatinizes totally.

[0015] According to the invention the mechanical energy used during the extrusion-cooking is preferably less than or equal to 115 watt per kilogram of the mixture, in order not to gelatinize the starch fraction of the rice flour to more than 85% and to form extrudates in a shape of rice grains.

During the extrusion-cooking, the level of mechanical energy used is very low owing to the quantity of water and the quantity of oil contained in the mixture.

[0016] A desirable extruder-cooker for the practice of the process of this invention is a twin screw extruder-cooker in which the processing section can be made up of two identical intermeshing screws, rotating in the same direction in the bore of a fixed barrel to produce different amount of compression and rates of flow of the ingredients within the extruder barrel.

[0017] In preferred embodiments, the extruder-cooker has a 600 to 1700 millimeter diameter barrel with 3 to 8 heating zones, a mixing zone, and 1 to 3 cooling zones.

[0018] The mixture is forced through the barrel where the ingredients are mixed, compressed and cooked. The mixture is formed at the end of the barrel and exits as instantly reconstitutable rice grains with pores on their surface.

[0019] At the end of the barrel, an excess of steam is released so as to increase the porosity of the instantly reconstitutable rice grains.

[0020] On account of the conditions of the extrusion-cooking, bacteriological contamination is reduced during this stage.

1331/2197

[0021] If desired, it is possible to add to the mixture aroma, spices and/or coloring agents before or after the extrusion-cooking. It is possible to use as the aroma, chicken, beef, pork, tomato, red pepper, green pepper and/or mushroom. It is possible to use paprika, pepper and/or curry as the spices.

[0022] It is possible to add about 0.2 to 2.5% of hydrocolloids, such as alginates, guar or xanthan gum, to the mixture before or after the extrusion-cooking. This increases the quality of the texture of the instantly reconstitutable rice grains. Preferably, alginates which can be extracted from seaweed, such as

Laminaria hyperborea or Laminaria digita.

[0023] It is possible to fry the pieces before drying them to increase the amount of oil in the final product. This delays the rehydration of the reconstitutable rice grains in food products, such as soup. In this case, the rice will be not an instantly reconstitutable rice.

[0024] The instantly reconstitutable rice grains are dried before being cooled to room temperature. The instantly reconstitutable rice grains are preferably dried to reduce their moisture content to below 11%.

[0025] In another aspect, this invention provides rapidly reconstitutable rice grains comprising a partly gelatinized matrix of a rice flour which contains a hydrogenated oil. The rice grains reconstitute instantly in hot water and have a good texture. Preferably the rice grains are instantly reconstitutable in hot water.

[0026] The instantly reconstitutable rice grains according to the invention have pores on their surface to allow quick rehydration.

[0027] The density of the instantly reconstitutable rice grains is about 0.3-0.7 kg/1. The lower the density, the higher the porosity and the faster the rehydration. The value of water uptake after about 2 to 6 mm of rehydration is about 0.70-3.2 g per g of reconstitutable rice grains. The lower the mechanical energy, the lower the water uptake during rehydration and the harder the reconstitutable rice grains.

EXAMPLES

[0028] The preparation process and the rice grains according to the invention are described in more detail in the examples below where the percentages are given by weight, except when otherwise indicated.

Example 1

[0029] A mixture containing 74 kg of rice flour, 0.8 kg of salt, 12.9 kg of water and 3.4 kg of soybean oil is extrusion-cooked in twin screw extruder of 1200 millimeters in length. The extrusion-cooker is operated at 180 rpm and the pressure in the extruder-cooker is 154 bar.

[0030] During the extrusion-cooking, the mixture is heated in 3 zones at 50[deg.] C., 110[deg.] C. and

115[deg.] C., mixed and then cooled in 2 zones at 50[deg.] C. and 60[deg.] C. The mixture is then extruded in the shape of rice grains.

[0031] After the extrusion-cooking, the instantly reconstitutable rice grains are dried until their moisture content decreases to 5%. The density of the instantly reconstitutable rice grain is 0.58 kg/1.

[0032] The instantly reconstitutable rice grains are then cooled to room temperature before being packaged in a hermetically closed plastic sachet and then stored at room temperature.

Example 2

[0033] A mixture containing 125.65 kg of rice flour, 0.63 kg of salt, 0.4 kg of sodium biphosphate, 29 kg of water and 12.48 kg of soybean oil is extrusion-cooked in twin screw extruder of 1500 millimeters in length. The extrusion-cooker is operated at 217 rpm and the pressure in the extrusion-cooker is 166 bar.

[0034] During the extrusion-cooking, the mixture is heated in 2 zones at 80[deg.] C. and 100[deg.] C., mixed and then cooled in 2 zones at 15[deg.] C. and 10[deg.] C. The mixture is then extruded in the shape of rice grains.

[0035] After the extrusion-cooking, the rice grains are dried and cooled as described in Example 1.

[0036] The density of the reconstitutable rice grain is 0.38 kg/1.

Example 3

[0037] A mixture containing 122.34 kg of rice flour, 0.62 kg of salt, 0.4 kg of sodium biphosphate,

1.24 kg of alginate, 29 kg of water and 12.49 kg of soybean oil is extrusion-cooked in twin screw extruder of 1500 millimeters in length. The extrusion-cooker is operated at 218 rpm and the pressure in the extruder-cooker is 126 bar.

1332/2197

[0038] During the extrusion-cooking, the mixture is heated in 2 zones at 80[deg.] C., mixed and then cooled in 2 zones at 50[deg.] C. and 40[deg.] C. The mixture is then extruded in the shape of rice grains.

[0039] After the extrusion-cooking, the rice grains are dried and cooled as described in Example 1.

[0040] The density of the instantly reconstitutable rice grain is 0.53 kg/1.

Example 4

[0041] A mixture containing 100 kg of rice flour, 0.5 kg of salt, 11.8 kg of water and 2.4 kg of palm oil is extrusion-cooked in twin screw cooker extruder of 1200 millimeters in length. The extrusion-cooker is operated at 160 rpm.

[0042] During the extrusion-cooking, the mixture is heated in 3 zones at 80[deg.] C., 110[deg.] C. and

120[deg.] C., mixed and then cooled in 2 zones at 50[deg.] C. and 46[deg.] C. The mixture is then extruded in the shape of rice grains.

[0043] After the extrusion-cooking, the reconstitutable rice grains are dried until their moisture content decreases to 5%.

[0044] The reconstitutable rice grains are then cooled to room temperature before being packaged in a hermetically closed plastic sachet and then stored at room temperature.

Example 5

[0045] A curried rice dish is produced using instant reconstitutable rice grains prepared in a manner similar to that described in Example 1.

[0046] To do this, 73% of rice grains according to the invention, 12% of maltodextrin, 10% of dried vegetables, 3.6% of curry powder, 0.4% of yeast extract and 1% of salt are mixed together.

[0047] This mixture is poured into a cup to which hot water is added. The rice grains reconstitute instantly to provide a curried rice dish with a good taste and a nice texture. After 2 to 5 min of soaking, this food preparation can be eaten.

Example 6

[0048] Vegetable porridge is produced using instantly reconstitutable rice grains prepared in a manner similar to that described in Example 1.

[0049] 50 g of instantly reconstitutable rice grains and 15 g of a spice mixture are mixed together. The spice mixture contains 11.8% of salt, 0.02% of garlic, 0.08% of pepper powder, 3.3% of sodium monoglutamate, 4.5% of corn starch, 3.8% of sugar, 2% of onion powder, 65.5% of potato flakes, 5% of dehydrated carrots, 2% of dehydrated onions and 2% of dehydrated parsley.

[0050] Boiling water is added to this preparation which is soaked for 2 to 5 mm, before the consumption. The instantly reconstitutable rice grains in this vegetable porridge have a nice texture and a good taste.Data supplied from the esp@cenet database - Worldwide

1333/2197

271.

US2001033885 - 10/25/2001

METHOD OF AND APPARATUS FOR MANUFACTURING NO-BRAN CEREAL


Inventor(s): SATAKE SATORU (JP); MATSUMOTO NOBUHIRO (JP); MUNESADA

TAKESHI (JP); KAWANO YUKIHIRO (JP); KATO AKIHIKO (JP); NONAKA KAZUTO (JP);

CHIKAMUNE KATSUNORI (JP); INOMOTO YOSUKE (JP); SHITADERA KAORU (JP)


IP Class: A23L1/182

E Class: A23L1/182; B02B1/04; B02B3/00; B02B3/04C; B02B3/06; B02B5/02



(20000324); JP20000182350 (20000616); JP20000218854 (20000719); JP20000317219 (20001017)


Equivalent: US6610345; CN1167510C

Abstract:


A method of and an apparatus for manufacturing no-bran cereal such as no-bran rice which require no washing before cooking. With the method and the apparatus, bran stuck on a surface of a grain of the polished cereal is easily removed without imparting any damage on the surface, and further moisture in the grain is maintained to increase taste of the cereal. Moisture is added to the polished cereal and granular material is mixed and stirred with the moistened polished cereal to polish a surface of each grain of the polished cereal and remove bran stuck on the surface of the polished cereal. Then, the polished cereal is separated from the granular material to obtain the no-bran rice.Claims:

Claims of US2001033885

What is claimed is:

1. A method of manufacturing no-bran cereal comprising the steps of:

(a) adding moisture to polished cereal;

(b) mixing and stirring granular material with the moistened polished cereal so as to remove bran stuck on a surface each grain of the polished cereal; and

(c) separating the polished cereal from the granular material.

2. A method of manufacturing no-bran cereal according to claim 1, wherein said cereal comprises rice.

3. A method of manufacturing no-bran cereal according to claim 1, wherein said cereal comprises wheat or barely corn.

4. A method of manufacturing no-bran cereal according to claim 1, wherein said granular material comprises an edible grinded cereal.

5. A method of manufacturing no-bran cereal according to claim 4, wherein said granular material comprises grinded rice.

1334/2197

6. A method of manufacturing no-bran cereal according to claim 5, wherein said granular material comprises pre-gelatinized grinded rice.

7. A method of manufacturing no-bran cereal according to claim 4, wherein said granular material is selected from the group consisting of grinded wheat, grinded barleycorn, grinded millet, grinded buckwheat, and grinded kaoliang.

8. A method of manufacturing no-bran cereal according to claim 1, wherein said granular material comprises pearl tapioca.

9. A method of manufacturing no-bran cereal according to claim 1, wherein said granular material has granularity of 1.0 mm-1.7 mm and moisture not higher than

5% in weight.

10. A method of manufacturing no-bran cereal according to claim 1, further comprising a step of heating said granular material before said step (b).

11. A method of manufacturing no-bran cereal according to claim 10, wherein said granular material is heated to a temperature not lower than 60[deg.] C.

12. A method of manufacturing no-bran cereal according to claim 11, wherein said granular material is heated to a temperature in the range between 60[deg.] C. and 80[deg.] C.

13. A method of manufacturing no-bran cereal according to claim 1, the polished cereal is mixed with the granular material of 50% of the polished cereal in weight and stirred at a pressure of approximately 20 gf/cm>;2 ;in said step (b).

14. A method of manufacturing no-bran cereal according to claim 1, further comprising a step of processing hulled cereal by passing the hulled cereal through a pair of rollers coated by elastic material by a plurality of times to obtain the polished cereal before said step (a).

15. A method of manufacturing no-bran cereal according to claim 14, wherein the hulled cereal is processed to the polished cereal at polishing yield of approximately 92% in said step of processing hulled cereal and the polished cereal is polished at polishing yield of approximately 91% in said step (b).

16. A method of manufacturing no-bran cereal according to claim 14, wherein moisture is added to the hulled cereal in said step of processing hulled cereal.

17. A method of manufacturing no-bran cereal according to claim 1, wherein moisture of 3%-5% of the polished grain in weight is added to the polished grain in said step (a).

18. A method of manufacturing no-bran cereal according to claim 1, said step (a) including spraying the polished cereal with water and stirring the polished cereal.

19. A method of manufacturing no-bran cereal according to claim 18, wherein the polished cereal is sprayed with water of 5% of the polished cereal in weight.

20. A method of manufacturing no-bran cereal according to claim 1, wherein said steps (b) and (c) are repeatedly performed after performing said step (a).

21. A method of manufacturing no-bran cereal according to claim 1, further comprising a step of wet-polishing the polished cereal after said step (c).

22. A method of manufacturing no-bran cereal according to

1335/2197

claim 1, wherein said step (a) is performed immediately after finishing a polishing process of hulled cereal.

23. An apparatus for manufacturing no-bran cereal comprising: moisture adding means for adding moisture to polished cereal; mixing/stirring means for mixing and stirring granular material with the moistened polished cereal to remove bran stuck on a surface of each grain of the polished cereal; and separating means for separating the polished cereal from the granular material.

24. An apparatus for manufacturing no-bran cereal according to claim 23, further comprising heating means for heating the granular material before being fed to said mixing/stirring means.

25. An apparatus for manufacturing no-bran cereal according to claim 24, wherein said granular material is heated to have a temperature not lower than 60[deg.] C.

26. An apparatus for manufacturing no-bran cereal according to claim 25, wherein said granular material is heated to have a temperature in a range between 60[deg.] C. and 80[deg.] C.

27. An apparatus for manufacturing no-bran cereal according to claim 23, further comprising a polishing means for polishing hulled cereal to obtain the polished cereal.

28. An apparatus for manufacturing no-bran cereal according to claim 27, wherein said polishing means comprises a pair of rollers coated by elastic material through which the hulled cereal is passed by a plurality of times.

29. An apparatus for manufacturing no-bran cereal according to claim 23, wherein said moisture adding means includes a sprayer for spraying the polished cereal with water and a stirrer for stirring the polished cereal.

30. An apparatus for manufacturing no-bran cereal according to claim 23, further comprising an additional mixing/stirring means for mixing and stirring the polished cereal separated by said separating means and granular material; and an additional separating means for separating the polished rice from the granular material.

31. An apparatus for manufacturing no-bran cereal according to claim 23, further comprising a wet-polishing means for wet-polishing the polished cereal separated by said separating means.

32. An apparatus for manufacturing no-bran cereal according to claim 23, wherein said moisture adding means includes a first horizontal screw cylinder, a first screw shaft with stirring vanes arranged in said first screw cylinder and a spray nozzle for spraying water on the polished cereal at a feeding start portion of the screw cylinder; said mixing/stirring means is arranged under said moisture adding means and includes a second horizontal screw cylinder having substantially the same size as said first screw cylinder, a second screw shaft with stirring vanes arranged in said second screw cylinder and a hopper for supplying the granular material into the second cylinder arranged at a feeding starting end of the second screw cylinder, said separating means is arranged under said mixing/stirring means and includes a screen cylinder with a number of slits, a rotary shaft with stirring vanes arranged in said screen cylinder, a blowing inlet arranged at an upper side of said screen cylinder, an outer casing cylinder for covering said screen cylinder, a blowing discharge duct connected on lower side of said screen cylinder and a processed cereal outlet at a feeding end of said screen cylinder.

33. An apparatus for manufacturing no-bran cereal according to claim 23, wherein water of approximately 5% of the polished cereal in weight is sprayed on the polished cereal from said spray nozzle and the polished cereal is stirred at 500 revolutions per minute in said first screw cylinder, the polished cereal and the granular material are stirred at approximately

600 revolutions per minute under a pressure of approximately 20 gf/cm>;2 ;in said second screw cylinder, and the polished cereal and the granular material are stirred at approximately 280 revolutions

1336/2197

per minute and surface of each grain of the polished cereal is dried by an air blow from said blowing inlet in said screen cylinder.Data supplied from the esp@cenet database - Worldwide

1337/2197

272.

US2001043969 - 11/22/2001

EDIBLE COLORED COOKIE, METHOD FOR COLORING SAME, COLORING

TOOL AND A KIT CONTAINING A COOKIE AND A COLORING TOOL


Inventor(s): WILD DAVID (US)


IP Class: A23L1/27

E Class: A23G3/00; A21D13/08B; A23G3/28; A23L1/275


Priority Number: US20010837768 (20010418); US20000198048P (20000418)


Abstract:


An edible confection includes a cookie having white icing imprinted with a black edible ink outline of an image suitable for coloring. According to the invention, the cookies are distributed with one or more fruit flavored alcohol based ink markers. According to the presently preferred embodiment, the cookies are shaped to conform to the general outline of the image borne thereon. The presently preferred ink markers contain a mixture of water, glycerine, ethyl alcohol, flavoring, and food dyes. The cookies of the invention are preferably distributed in groups of thematically related images. Some thematic images contemplated by the invention include farm animals, zoo animals, reptiles, fish, holiday themes, licensed characters, etc. According to one embodiment, indicia are provided on the icing of the cookie

1338/2197

to indicate what colors should be used to color each portion of the image. According to another embodiment, the edible ink markers can be used to color other edible items such as cakes, fondants, fruits, glazes, gum or rice paper. According to still other embodiments, colorable confections are provided in the form of greeting cards, post cards, and holiday ornaments.Description:


[0001] This application claims the benefit of provisional application Ser. No. 60/198,048 filed Apr. 18,

2000, the complete disclosure of which is hereby incorporated by reference herein and provisional application Ser. No. ______ filed Mar. 19, 2001.



[0003] The invention relates to edible confections and to childhood amusements. More particularly, the invention relates to an edible cookie bearing a colorable image and kits containing such cookies with edible ink coloring markers.

[0004] 2. State of the Art

[0005] It is generally known in the art of confections to provide cookies which bear images. Images are applied by the baker using edible coloring agents. It is also know in the art childhood amusements to provide "coloring books" which contain black and white outline images to be colored in with crayons, colored pencils, or ink markers, Children are amused by the process or coloring in the images.

[0006] Heretofore, it has not been known or suggested to combine features of edible confections with childhood amusements. More particularly, it has not been known or suggested to combine features of cookies with features of coloring books.


[0007] It is therefore an object of the invention to provide an edible confection.

[0008] It is also an object of the invention to provide a childhood amusement.

[0009] It is another object of the invention to provide an amusing activity for children.

[0010] It is still another object of the invention to provide a kit containing an edible confection and a coloring tool.

[0011] In accord with these objects which will be discussed in detail below, the edible confection of the present invention includes a cookie preferably having white icing imprinted with a black edible ink outline of an image suitable for coloring. According to the invention, the cookies are distributed with one or more fruit flavored alcohol based ink markers. According to the presently preferred embodiment, the cookies are shaped to conform to the general outline of the image borne thereon. The presently preferred ink markers contain a mixture of water, glycerine, ethyl alcohol, flavoring, and food dyes. The cookies of the invention are preferably distributed in groups of thematically related images.

Some thematic images contemplated by the invention include farm animals, zoo animals, reptiles, fish, holiday themes, licensed characters, etc. Moreover, cookies bearing corporate logos make suitable gifts for children of employees.

[0012] The methods of coloring the cookie ray be undertaken as an individual or group activity.

According to one embodiment, indicia are provided on the icing of the cookie to indicate what colors should be used to color each portion of the image. According to another embodiment, the edible ink markers can be used to color other edible items such as cakes, fondants, fruits, glazes, gum or rice paper. According to still other embodiments, colorable confections are provided in the form of greeting cards, pout cards, and holiday ornaments.

[0013] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.


[0014] FIG. 1 is a plan view of an exemplary embodiment of a cookie according to the invention; and

[0015] FIG. 2 is a plan view of a kit according to the invention.


1339/2197

[0016] Referring now to FIG. 1, an edible confection 10 according to the invention includes a top surface 12 which is imprinted with an outline image 14. According to the presently preferred embodiment, the top surface 12 includes a white icing and the image 14 is imprinted on the icing with an edible black ink. The white icing is adapted to receive thereon edible inks of other color than black.

[0017] According to one embodiment of the invention, the image 14 is provided with indicia 16, 18,

20, 22 indicating color codes; alternatively, the color codes could be identified in the packaging for the cookie. According to the presently preferred embodiment, the edible confection is a cookie and is shaped to conform to the general outline of the image 14 borne thereon. The cookies are preferably distributed in groups of thematically related images. Some thematic images contemplated by the invention include farm animals, zoo animals, reptiles, fish, holiday themes, licensed characters, etc.

Moreover, cookies bearing corporate logos make suitable gifts for children or employees.

[0018] Referring now to FIG. 2, according to the invention, a kit 30 is provided containing one or more cookies 32 with one or more fruit flavrored alcohol based ink markers 34, 36, 38.

[0019] The presently preferred ink markers contain a mixture or water, glycerine, ethyl alcohol, flavoring, and food dyes.

[0020] A first example of an edible ink according to the invention in set forth in Table 1. below.


>;tb;>;sep;>;sep;Ingredient>;sep;Relative Amount

>;tb;>;sep;>;sep;Water>;sep;36.59%

>;tb;>;sep;>;sep;Glycerine>;sep;30.96%

>;tb;>;sep;>;sep;Ethyl Alcohol>;sep;28.14%

>;tb;>;sep;>;sep;FDC Coloring>;sep;2.81%

>;tb;>;sep;>;sep;Flavoring>;sep;2.5%

[0021] According to the invention, the FDC coloring includes one or more of the following edible dyes: FDC yellow #5, FDC blue #1, FDC red #40, and FDC red #3.

[0022] Another formulation of an edible ink according to the invention is set forth in Table 2, below.


>;tb;>;sep;>;sep;Ingredient>;sep;Quantity

>;tb;>;sep;>;sep;Water>;sep;27,300 grams

>;tb;>;sep;>;sep;Glycerine>;sep;23,100 grams

>;tb;>;sep;>;sep;Ethyl Alcohol>;sep;21,000 grams

>;tb;>;sep;>;sep;Flavoring>;sep;1,070 grams

>;tb;>;sep;>;sep;Food Dyes>;sep;according to color

[0023] According to the invention, the flavoring is preferably a natural or artificial fruit flavoring. The edible ink is preferably dispensed from a conventional felt or porous plastic tip marker 34, 36, 38 having felt or porous plastic tip applicators 35 normally covered by caps 37. The ink is fast drying when applied, but slow drying in the marker. According to the invention, a marker containing ink according to the invention can be left uncovered for six hours without drying out. Alternatively, conventional paint markers could be used.

[0024] The methods of coloring the cookie may be undertaken as an individual or group activity.

According to another embodiment, the edible ink markers can be used to color other edible items such as cakes, fondants, fruits, glazes, gum or rice paper. According to still other embodiments, colorable confections are provided in the form of greeting cards, post cards, and holiday ornaments.

[0025] There have been described and illustrated herein several embodiments of an edible confection, methods for coloring it, and a kit containing an edible confection and coloring tools. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.Data supplied from the esp@cenet database - Worldwide

1340/2197

273.

US2021721 - 11/19/1935

TREATMENT OF RICE, RICE OFFALS OR PADDY, AND THE LIKE


Inventor(s): HARRISON GIBBON SAM (--)

Applicant(s): STEEL BROTHERS and COMPANY LTD (--)

E Class: A23L1/182


Priority Number: GBX2021721 (19330714)

Family: US2021721

Abstract:


1341/2197

274.

US2055120 - 9/22/1936

PROCESS OF CANNING RICE


Inventor(s): TAKANOSHIN DOMOTO (--)

E Class: A23L1/182



Family: US2055120

Abstract:


1342/2197

275.

US2064701 - 12/15/1936

MANUFACTURE OF RICE FLAKES


Inventor(s): STOKKEBYE EINAR O (--)

E Class: A23L1/168B


Priority Number: SEX2064701 (19341110)

Family: US2064701

Abstract:


1343/2197

276.

US2161119 - 6/6/1939

RICE CANNING PROCESS


Inventor(s): COAN NICHOLAS C (--)

E Class: A23L1/182



Family: US2161119

Abstract:


1344/2197

277.

US2187718 - 1/23/1940

RICE PRODUCT AND PROCESS


Inventor(s): WILBUR PAUL C (--)

E Class: A23L1/212E; A23L1/187B



Family: US2187718

Abstract:


1345/2197

278.

US2195165 - 3/26/1940

METHOD OF COOKING RICE


Inventor(s): CHOPPIN ARTHUR R (--); WINBORN ELEANOR L (--)

Applicant(s): RICE MILLERS ASS (--)

E Class: A23L1/182; A47J27/04



Family: US2195165

Abstract:


1346/2197

279.

US2282805 - 5/12/1942

STABILIZED COMBINATIONS OF RICE AND SIMILAR POLISHINGS AND

WHEY OR SIMILAR MILK-SOLIDS-NOT-FAT


Inventor(s): SIDNEY MUSHER (--)

Applicant(s): MUSHER FOUNDATION INC (--)

E Class: A23L1/10E



Family: US2282805

Abstract:


1347/2197

280.

US2292431 - 8/11/1942

RICE CANNING PROCESS


Inventor(s): COAN NICHOLAS C (--)

E Class: A23L1/182



Family: US2292431

Abstract:


1348/2197

281.

US2295116 - 9/8/1942

PROCESS FOR THE PRODUCTION OF A COOKED AND PUFFED RICE

PRODUCT


Applicant(s): MARY M KELLOGG (--); HELEN L KELLOGG (--)

E Class: A23L1/18C2



Family: US2295116

Abstract:


1349/2197

282.

US2358251 - 9/12/1944

PROCESS FOR THE TREATMENT OF RICE AND OTHER CEREALS


Inventor(s): GUSTAV HUZENLAUB ERICH (--); HERON ROGERS FRANCIS (--)

E Class: A23L1/182


Priority Number: GBX2358251 (19391130)

Family: US2358251

Abstract:


1350/2197

283.

US2381343 - 8/7/1945

MANUFACTURE OF IMPROVED HULLED RICE


Inventor(s): FRANK FURTER MAX (--)


E Class: A23L1/10B



Family: US2381343

Abstract:


1351/2197

284.

US2390210 - 12/4/1945

FORTIFICATION OF RICE


Inventor(s): FIEGER ERNEST A (--); WILLIAMS VIRGINIA R (--)

Applicant(s): UNIV LOUISIANA STATE (--); AGRICULTURAL AND MECHANICAL CO (--)

E Class: A23L1/10B



Family: US2390210

Abstract:


1352/2197

285.

US2585036 - 2/12/1952

PREPARATION OF NOVEL FOOD PRODUCTS FROM RICE


Inventor(s): ROBERTS ROBERT L (--)

E Class: A23L1/164E



Family: US2585036

Abstract:


1353/2197

286.

US2592407 - 4/8/1952

METHOD OF PROCESSING RICE FOR PRESERVING THE VITAMIN

CONTENTS THEREOF


Inventor(s): FERNANDES DANIEL S (--)

E Class: A23L1/182



Family: US2592407

Abstract:


1354/2197

287.

US2610124 - 9/9/1952

PRODUCTION OF QUICK-COOKING RICE



E Class: A23L1/182



Family: US2610124

Abstract:


1355/2197

288.

US2610914 - 9/16/1952

METHOD FOR TREATING RICE BRAN AND RICE POLISH


Inventor(s): MIKE CASSIDY MILLARD (--); BURNS NAWRY HARRIET LOUISE (--)

Applicant(s): AMERICAN RICE GROWERS COOPERAT (--)

E Class: A23L1/10E; C11B5/00



Family: US2610914

Abstract:


1356/2197

289.

US2616808 - 11/4/1952

PRODUCTION OF EXPANDED RICE PRODUCTS



E Class: A23L1/18C6



Family: US2616808

Abstract:


1357/2197

290.

US2616810 - 11/4/1952

PROCESS FOR CANNING RICE


Inventor(s): BENTON GALLENKAMP NORMA (--)

E Class: A23L1/182



Family: US2616810

Abstract:


1358/2197

291.

US2653100 - 9/22/1953

PRECOOKED RICE


Inventor(s): ALLISON JIM E (--); CARMAN CHARLES R (--)


E Class: A23L1/182; A23L1/18C2



Family: US2653100

Abstract:


1359/2197

292.

US2696156 - 12/7/1954

PROCESS OF PREPARING QUICK-COOKING RICE


Inventor(s): CAMPBELL HAROLD A (--); HOLLIS JR FRANK (--)


E Class: A23L1/182



Family: US2696156

Abstract:


1360/2197

293.

US2715579 - 8/16/1955

PREPARATION OF PRE-COOKED RICE



E Class: A23L1/18C; A23L1/18C6



Family: US2715579

Abstract:


1361/2197

294.

US2720460 - 10/11/1955

PRODUCTION OF QUICK-COOKING RICE


Inventor(s): HOLLIS JR FRANK (--); FLYNN CHARLES E (--)


E Class: A23L1/182



Family: US2720460

Abstract:


1362/2197

295.

US2740719 - 4/3/1956

QUICK COOKING RICE AND PROCESS THEREFOR


Inventor(s): OZAI-DURRANI ATAULLAH K (--)

E Class: A23L1/182



Family: US2740719

Abstract:


1363/2197

296.

US2752247 - 6/26/1956

RICE PROCESSING


Inventor(s): CHANDLER RAY C (--)

E Class: A23L1/182



Family: US2752247

Abstract:


1364/2197

297.

US2758031 - 8/7/1956

METHOD FOR PROCESSING RICE PADDY


Inventor(s): OZAI-DURRANI ATAULLAH K (--)

E Class: A23L1/182



Family: US2758031

Abstract:


1365/2197

298.

US2785070 - 3/12/1957

METHOD OF PREPARING PRE-COOKED PUFFED BROWN RICE CEREAL


Inventor(s): KESTER ERNEST B (--); FERREL ROBERT E (--)

E Class: A23L1/182; A23L1/18C6



Family: US2785070

Abstract:


1366/2197

299.

US2808333 - 10/1/1957

RICE TREATING PROCESS


Inventor(s): MICKUS ROBERT R (--); BREWER GEORGE W (--)

Applicant(s): RICE GROWERS ASS OF CALIFORNIA (--)

E Class: A23L1/182



Family: US2808333

Abstract:


1367/2197

300.

US2813796 - 11/19/1957

PROCESS FOR PRODUCING A QUICK-COOKING PRODUCT OF RICE OR

OTHER STARCHY VEGETABLE


Inventor(s): KENEASTER KENNETH K (--); NEWLIN HARRISON E (--)

Applicant(s): CONVERTED RICE INC (--)

E Class: A23L1/182; A23L1/201



Family: US2813796

Abstract:


1368/2197

301.

US2828209 - 3/25/1958

PROCESS OF PREPARING A QUICK COOKING RICE


Inventor(s): HOLLIS JR FRANK (--); MILLER FRANK G (--); MILLER FREDERICK J (--)


E Class: A23L1/182



Family: US2828209

Abstract:


1369/2197

302.

US2890957 - 6/16/1959

PROCESS FOR PREPARING QUICK-COOKING RICE


Inventor(s): EDWARD SELTZER (--)

Applicant(s): LIPTON INC THOMAS J (--)

E Class: A23L1/182



Family: US2890957

Abstract:


1370/2197

303.

US2898214 - 8/4/1959

PROCEDURE FOR PREPARING CANNED RICE


Inventor(s): FERREL ROBERT E (--)

E Class: A23L1/182B; B65B25/00A



Family: US2898214

Abstract:


1371/2197

304.

US2898215 - 8/4/1959

METHOD OF CANNING RICE


Inventor(s): FERREL ROBERT E (--)

E Class: A23L1/182B; B65B25/00A



Family: US2898215

Abstract:


1372/2197

305.

US2969288 - 1/24/1961

METHOD FOR PREPARING QUICK-COOKING RICE


Inventor(s): FLYNN CHARLES E (--); RICKER MILLARD O (--)


E Class: A23L1/18C2



Family: US2969288

Abstract:


1373/2197

306.

US2975058 - 3/14/1961

METHOD OF PRODUCING RICE FOODS


Inventor(s): COLARUSSO AUGUSTINE L (--)

Applicant(s): BRODE MILLING CO INC VAN (--)

E Class: A23L1/18C6



Family: US2975058

Abstract:


1374/2197

307.

US2992921 - 7/18/1961

PROCESSING OF BROWN RICE


Inventor(s): BARDET GEORGE V (--); GIESSE ROBERT C (--)

Applicant(s): M J B (--)

E Class: A23L1/182; A23L1/18C6



Family: US2992921

Abstract:


1375/2197

308.

US3006269 - 10/31/1961

RICE PROCESSING MACHINE


Inventor(s): BARDET GEORGE V (--); GIESSE ROBERT C (--)

Applicant(s): M J B CO (--)

E Class: A23L1/18C6; B02B1/08



Family: US3006269

Abstract:


1376/2197

309.

US3157514 - 11/17/1964

METHOD FOR PREPARING QUICKCOOKING RICE


Inventor(s): DONDE GOROZPE RAUL (--)

Applicant(s): CORN PRODUCTS CO (--)

E Class: A23L1/182



Family: US3157514

Abstract:


1377/2197

310.

US3164475 - 1/5/1965

RICE PROCESS


Inventor(s): TAYLOR WILLOCK JAMES (--)


E Class: A23L1/182



Family: US3164475

Abstract:


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311.

US3189461 - 6/15/1965

PROCESS FOR PRODUCING QUICK-COOKING RICE


Inventor(s): CHERRY JAMES R (--); MANHATTAN BANK THE CHASE (--)

E Class: A23L1/182



Family: US3189461

Abstract:


1379/2197

312.

US3189462 - 6/15/1965

PROCESS FOR THE PREPARATION OF PRECOOKED RICE


Inventor(s): AUTREY HARRY S (--); LAWRENCE LYNN (--)

Applicant(s): RIVER BRAND RICE MILLS INC (--)

E Class: A23L1/182



Family: US3189462

Abstract:


1380/2197

313.

US3647486 - 3/7/1972

METHOD OF PREPARING CANNED COOKED RICE


Inventor(s): TOLLEFSON CHARLES I (--); BICE CLAUDE W (--)

Applicant(s): FRENCH CO R T (--)


IP Class: A23B7/00

E Class: A23L1/182; A23B5/02

Application Number: USD3647486 (19680403)


Family: US3647486

Abstract:


Raw rice is cooked in acidified water at a temperature above the gelatinization point of starch but below the boiling point of water for a sufficient period to achieve a moisture content between 58 and

65 percent. The cooked rice is then canned and the cans sealed and sterilized. Then the cans are cooled and the product is allowed to remain in the cans ("aged") for several days before consumption.Description:


The present invention relates to the canning of foodstuffs, and more particularly to the canning of rice.

In a still more specific aspect, it relates to the canning of parboiled rice, to obtain a product that can be prepared for consumption by merely heating it in a skillet.

Canning of cooked rice has not generally been successful heretofore because of the tendency of the cooked rice kernels to cohere, which makes it difficult to remove the rice from the can and separate the individual kernels when the can is opened. Another disadvantage with prior methods of preparing canned cooked rice is that the kernels are usually ruptured and ragged.

One suggested method for overcoming these difficulties involves soaking the raw rice in water at a temperature below the gelatinization point of starch prior to cooking the rice in boiling water. Soaking at a temperature below the gelatinization point allows the moisture to penetrate to the centers of the kernels so that, when the soaked rice is cooked in boiling water, gelatinization can be obtained at the centers of the kernels with a minimum of overcooking at the surface. Accordingly, fewer cells are ruptured and starch losses are minimized. It has been considered critical to restrict the cooking operation so that the kernels contain not more than 45 to 60 percent moisture, preferably about 55 percent. Since the product is not considered edible at this moisture level, it is prepared for consumption, after removal from the can, by immersing the rice in boiling water to increase its moisture level while at the same time heating it. However, even with this method, an undesirable degree of cohesiveness remains; and the product requires heating in water and draining to prepare it for consumption.

Another prior process, generally similar to the above process, in that soaking and cooking steps are involved, requires an additional step of freezing the canned rice after retorting. The freezing is believed

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to cause retrogradation of starch. However, this process is costly; and the results are not uniformly dependable since the rate of freezing and/or thawing has an important bearing on the degree of starch retrogradation obtained. Moreover, the rate of freezing affects not only the ease of separation of the kernels, but also the textural properties of the final product.

The primary object of the present invention is to provide a method for preparing canned parboiled rice which will enable the canned product to be readily removed from the can and separated into individual kernels.

Another object of the invention is to provide a method of producing canned cooked rice which can quickly and easily be prepared for consumption, either as a fried rice, or as a component of casseroles, puddings, or other dishes in which cooked rice is used.

Another object of the invention is to provide a method for canning parboiled rice which will produce kernels that are plump, smooth and attractive in appearance, and not ruptured and ragged like the product obtained by other methods.

Another object of the invention is to provide a method for preparing canned rice which will eliminate the soaking step previously required.

Another object of the invention is to provide a method for preparing canned parboiled rice which will have a moisture level high enough so that the product does not require further cooking in water.

Still another object of the invention is to provide a method for preparing canned parboiled rice which will ensure a texture and flavor in the product, when fried, equal to or better than that of the finest quality of fried rice prepared by other methods.

A still further object of the invention is to provide a simplified and economical process for achieving the above-mentioned goals.

Other objects of the invention will be apparent hereinafter from the specification and from the recital of the appended claims.

In the method of the present invention the rice, which is to be canned, is cooked in acidified water, at a temperature above the gelatinization point of starch (65 DEG to 75 DEG C.) but below the boiling point of water, for a sufficient period that the moisture content of the final product will be between 58 and 65 percent, and rupture of surface cells will be minimized, then draining the rice, packing it in cans, sealing the cans, subjecting the sealed cans to a sufficient heat to sterilize the cans and their contents, then cooling the cans and their contents, and aging the product in the cans for several days before consumption.

Additionally, the rice may be cooked in the presence of an edible starch-modifying agent, such as a mixture of mono- and diglycerides, which complexes any free starch and thus reduces cohesiveness.

By controlling the amount of free starch, a product with desirable characteristics is obtained, that is, a product which is readily removable from the can and easily separated into individual kernels.

Furthermore, a product with desirable textural properties can be achieved with moisture levels in the range 58 to 65 percent, preferably about 62 percent.

The product of the present invention does not require heating in boiling water to further increase the moisture level for consumption. Since cooking is accomplished at temperatures below the boiling point of water, a longer cooking time is required than if the product were cooked in boiling water, but the cooking time is less than the combined soaking and cooking time of prior methods. This has advantage in that precise control of the cooking time is less critical than in other methods.

It has been discovered quite unexpectedly that the canned product improves with storage at ambient temperatures (70 DEG to 75 DEG F). Thus, the kernels of rice canned by the process of the present invention separate much more readily a week or so after retorting than the day after retorting. This effect, which may result from starch retrogradation, is called "aging."

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To illustrate the invention, several examples are given below: EXAMPLE 1

Two pounds of parboiled Belle Patna rice were steeped for 25 minutes with agitation at 165 DEG F. in

1 gallon of water containing 0.15 ml. glacial acetic acid and 15 g. edible monodiglyceride (52 percent alpha monester content). At the end of the steeping (or cooking) period, the rice was drained for 2 minutes, packed in cans (11 ounces per 300.times.407 can), and processed in a retort for 60 minutes at

240 DEG F. to achieve sterilization. The cans were then cooled in water to an internal temperature of about 120 DEG F. Upon opening the cans, the rice was found to separate fairly readily. The rice was prepared for consumption as fried rice by heating the contents of a can in a skillet at 325 DEG F. with one tablespoonful of cooking oil. The texture of the fried rice was considered acceptable although slightly tough, but this was not unexpected since the moisture content of the cooked rice was only 58 percent.

EXAMPLE 2

Parboiled rice was processed as in example 1 except that the steeping time was increased to 30 minutes. The moisture level of the canned rice was 60.9 percent. When a can was opened immediately after cooling, the rice seemed somewhat more sticky than that produced in example 1. However, when the canned product was "aged" for several days after processing, and before opening a can, the kernels separated very readily, and the texture of the fried product was rated as very good.

EXAMPLE 3

Parboiled rice was processed as in example 1 except that the steeping time was decreased to 20 minutes. The moisture level of the canned rice was 55.5 percent, and the texture of the fried product was considered undesirably tough.

EXAMPLE 4

Parboiled rice was prepared as in example 1 except that the steeping temperature was 175 DEG F. and times of 20, 25, and 30 minutes were employed. The results were as follows: -------------------------------

--------- -

>;tb; Texture of

>;tb; Steeping Time Percent Moisture Fried Product

>;tb;__________________________________________________________________________

>;tb; 20 minutes 58.9 Slightly dry

>;tb; and tough

>;tb; 25 minutes 62.1 Excellent

>;tb; 30 minutes 64.5 Acceptable,

>;tb; slightly soft

>;tb;__________________________________________________________________________

EXAMPLE 5

Parboiled rice was processed as in example 4 except that the steeping temperature was 185 DEG F. and times of 15, 20 and 25 minutes were employed. Results were as follows: ------------------------------------

---- -

>;tb; Texture of


>;tb;__________________________________________________________________________


>;tb; slightly dry

>;tb; 20 minutes 63.4 Very good

>;tb; 25 minutes 66.2 Somewhat too soft

>;tb;__________________________________________________________________________

EXAMPLE 6

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Parboiled rice was processed as in example 1 except that the rice was steeped in boiling water for periods ranging from 7 to 15 minutes. Results were as follows: ----------------------------------------

-

>;tb; Texture of


>;tb;__________________________________________________________________________

>;tb; 7 minutes 53.7 Firm, dry




>;tb; somewhat dry


>;tb; somewhat dry

>;tb; 12 minutes 61.6 Acceptable


>;tb; somewhat soft

>;tb; 14 minutes 64.5 Too soft for

>;tb; fried rice

>;tb; 15 minutes 65.8 Too soft for

>;tb; fried rice

>;tb;__________________________________________________________________________

When compared with the products of comparable moisture levels obtained by steeping at lower temperatures (such as 175 DEG F.), it was found that the product obtained from cooking in boiling water while perhaps acceptable in a general sense, was inferior in quality to the product obtained when the rice was steeped in water at a temperature below the boiling point of water. Thus, in comparing products of equivalent moisture content, it was found that the product obtained using a steeping temperature of 175` F., for example, was superior to the product obtained using boiling water in the following respects: a. The rice grains were less cohesive. b. There was less rupturing of kernels: hence solids losses were reduced. c. The color was somewhat lighter and brighter. d. The fried product had firmer texture which is highly desirable in oriental-type fried rice.

Moreover, processing in boiling water requires precise control of cooking time since small changes in cooking time result in relatively large changes in moisture content, thus making it difficult to obtain consistently a product having the desired moisture content.

EXAMPLE 7

Parboiled rice was processed as in examples 1 through 5 except that no monodiglyceride was added to the steeping water. Immediately after processing, the canned rice was somewhat more sticky than canned rice processed with monodiglyceride. However, after aging the product in the can for 2 to 3 weeks at room temperature (about 70 DEG F.), cohesiveness had decreased so that differences in ease of separating kernels, as related to presence or absence of monodiglyceride, were hard to demonstrate.

Besides mono- and diglycerides, other starch-complexing agents, such as sodium stearyl fumarate and calcium stearyl-2- lactylate were also investigated. All these starch-complexing agents were found to provide similar benefits with regard to ease of separating kernels of rice immediately after processing.

Several acidulants, other than glacial acetic acid, were also investigated, including fumaric acid, malic acid, tartaric acid, ascorbic acid, isoascorbic acid, succinic acid, citric acid, and adipic acid. All of these acids were found satisfactory for this purpose.

While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification, and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and as may be applied to the essential features hereinbefore

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set forth, and as fall within the scope of the invention or the limits of the appended claims.Data supplied from the esp@cenet database - Worldwide

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314.

US3655400 - 4/11/1972

PRODUCTION OF SHELF STABLE REHYDRATABLE RICE


Inventor(s): CSERI JOSEPH (--); HALIK JOSEPH JOHN (--); KAPLOW MILTON (--)



IP Class: A23L1/10

E Class: A23L1/182; D03C3/40



Family: US3655400

Abstract:


Production of shelf stable dehydrated rehydratable rice having greater than usual moisture contents by cooking rice in a solution comprising polyhydric alcohols salts, and an antimycotic agent.Claims:

Claims of US3655400

What is claimed is:

1. A process for producing shelf stable rehydratable rice having a polyhydric alcohol content of about 7 percent, comprising immersion cooking said rice in excess stabilizing solution for a period sufficient to thermally inactivate the enzymatic and pathogenic activity, removing excess stabilizing solution, and partially drying said rice to a moisture content between about 17 to 35 percent; said stabilizing solution containing from about 3 to about 7 percent of polyhydric alcohol, salt, and sufficient antimycotic to prevent mold growth.

2. The process of claim 1 wherein the rice is immersion cooked in the solution at a temperature in excess of 160 DEG F. for a period in excess of 10 minutes.

3. The process of claim 1 wherein the salt solutes present in the solution are selected from the class of readily ionizable salts.

4. The process of claim 1 wherein the rice treated is washed raw rice.

5. The process of claim 1, wherein said cooked rice is air dried at temperatures of at least 110 DEG F. for at least 10 minutes.

6. The shelf stable rehydratable rice produced by the process of claim 1.Data supplied from the esp@cenet database - Worldwide

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315.

US3656966 - 4/18/1972

FOOD CHIP AND PROCESS FOR MAKING IT


Inventor(s): BALL MURRAY E (--); DEMENY LEROY M (--)



IP Class: A23L1/10; A23L1/18

E Class: A23L1/164E



Family: US3656966

Abstract:


A process for making a ready-to-eat food chip from cereal grain such as wheat or rye, by cooking a mixture of whole wheat, or whole rye, which has been cut into pieces, water, flavoring ingredients, and a small amount of another grain such as rice if desired, thereby forming a dough, shaping the dough into pieces or chips, drying the pieces, expanding or puffing the pieces by deep fat frying them in oil, and dusting the resulting chips with salt.Description:


The present invention relates to a process for making a food product, and the resulting product. More specifically, it pertains to the preparation of a ready-to-eat food chip which includes wheat or rye as its major ingredient.

Numerous apparatus and processes have been devised for forming a variety of edible snack food products from starch containing ingredients such as cereal grains and vegetables. Such products have been formed in a number of different shapes and sizes in order to effect and improve their physical characteristics, their taste and texture, their convenience of use, as well as their marketability. A popular form of snack product is provided in chip form, as exemplified by the potato chip. Efforts have been made from time to time to form chip products from other ingredients as well, such as corn. To the best of applicants' knowledge, efforts to form an edible chip from wheat or rye have not been successful; the resulting product has lacked the desirable flavor, texture, and appearance characteristics necessary to warrant its production and subsequent marketing.

Accordingly, one object of the present invention is to provide a novel process for making an edible food product.

Another object is to provide a process for forming an improved edible food snack having wheat as its major ingredient.

Another object is to provide a process for forming an improved edible food snack having rye as its major ingredient.

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A further object is to provide an improved process for making a wheat chip or a rye chip having excellent flavor, texture, and appearance characteristics.

A still further object is to provide an improved edible wheat containing chip.

Another object is to provide an improved edible rye containing chip.

Other objects and advantages will become apparent from a consideration of the following specification and accompanying drawings.

Generally, the invention involves cutting kernels of cereal grain, such as whole wheat or whole rye, into slices or pieces, and combining the pieces with a small amount of rice or other grain if desired, which has likewise been reduced in size. The cereal grains are combined and mixed with water and flavoring ingredients, and formed into a dough or mass by pressure cooking the mixture. The dough is cooled if desired, formed into pieces having a prescribed size and shape and dried to a prescribed moisture content. The pieces are thereafter deep fat fried in oil and salted to form the final chip.

The invention will be better understood by reference to the following drawings wherein:

FIG. 1 is a perspective view of a snack chip formed according to the present invention;

FIG. 2 is a top plan view of the chip illustrated in FIG. 1;

FIG. 3 is a side elevational view of the chip;

FIG. 4 is an enlarged sectional view taken along line 4--4 of FIG. 2; and

FIG. 5 is an enlarged partial view taken along line 5--5 of FIG. 4.

Since the product formed in accordance with the present invention is comprised primarily of wheat or rye as the cereal base, one of the first factors to be considered is the type of wheat or rye to be used.

When wheat is used, it has been found that either soft or hard wheat can be used with satisfactory results. When rye is used, whole, clean, dry rye should preferably be used. Another factor to be considered is whether a certain amount of another cereal grain should be included in the formulation. It has been discovered that inclusion of a certain amount of rice in either the wheat product formulation or the rye product formulation, results in a product having a different texture because the resulting product seems to puff or expand better, it has a different appearance because it is somewhat bubbly or irregular, and it changes the flavor and palatability characteristics of the product. Generally, the ratio of wheat or rye to rice should range from about 1-5 parts of wheat or rye to about 1 part of rice. More specifically, when wheat and rice are combined, preferably about 5 parts of wheat to about 1 part of rice are used; when rye and rice are combined on the other hand, preferably about 3 parts of rye to about 1 part of rice are used. In addition, in some instances, it might be preferred to use a combination of other cereal grains such as rye and barley, in varying ranges of each. Moreover, it might be desirable to combine wheat and rye in varying amounts with each other, to form a product having somewhat different features and characteristics.

The first step in preparing the product after selecting the wheat or rye to be used, is to subject the individual kernels to a cutting operation so as to reduce their size, to increase the total surface area, and to expose the endosperm, thereby improving the absorption of moisture capabilities of the kernels when they are combined with water. As known, the outer layer, or bran, of a kernel such as wheat or rye, is quite tough and relatively difficult to penetrate with water; cutting the kernels into pieces or slices improves the overall process. Cutting devices are known in the art and are commercially available for slicing the kernels into a plurality of slices or pieces having a thickness ranging from about 0.030-0.055 inch. Urschel Laboratories, Inc., Valparaiso, Indiana, for example, manufactures cutting devices which have been used with satisfactory results. For optimum results, it is preferred that a minimum amount of fine particles (i.e., flour-sized particles) be obtained during the cutting operation. The rice kernels are likewise subjected to a cutting or comminuting operation; in this instance, the kernels can be reduced to

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a relatively small particle size by using one of various well known and commercially available reduction mills, such as Fitzpatrick Mills, Raymond Vertical Mills, or the like. In certain instances it might be preferred to use broken kernels of rice, rather that subjecting whole kernels to a cutting or comminuting operation. As known to those familiar with the art, such a product is ofttimes referred to as "second heads."

After the individual kernels have been reduced in size, a mixture is formed by combining a predetermined amount of the cut wheat or rye kernels with a prescribed amount of the rice, flavoring ingredients such as sugar, salt, bicarbonate of soda, and malt flavoring, and enough water to raise the moisture content of the mixture to about 25-40 percent, and preferably about 30 percent. In this regard additional flavoring ingredients, such as onion flavoring, might be used to impart a specific flavor to the product. Moreover, if desired, one or more artificial colorants might be included so as to give the product a certain hue. Generally, a good chip can be formed by using about 45-80 parts of the cut wheat or rye kernels, about 0-25 parts ground rice, about 15-30 parts water, about 0-10 parts sugar, about 0-4 parts malt syrup, about 0-5 parts salt, and about 0-1 part sodium bicarbonate. The resulting mixture is then permitted to steep at room temperature for about one hour, during which time the moisture soaks into the cut pieces, and the flavoring ingredients penetrate the pieces. Furthermore, the tempering, while not essential, shortens the subsequent cooking time required.

After the mixture has been tempered, the ingredients are cooked in a pressure cooker until the starch is gelatinized. It is preferred that the cooking be accomplished without completely mashing or crushing the cut wheat or rye pieces; in other words, the resulting dough should retain discrete particles of the wheat or rye bran after the cooking operation has been completed. The pressure cooking can be accomplished in a batch cooker, or if desired a continuous type pressure cooker might be used. Both types of cookers are well known in the art and will not be described in detail. In both types of cookers, the relative conditions of time, temperature, and pressure can be controlled depending upon the type of product being cooked, the amount of gelatinization desired, and the like.

Generally, it has been found that the ingredients should be cooked for about one hour at a pressure of about 20 psig., although the pressure might vary within a range from about 15-30 psig.; and at a temperature which ranges from about 250 DEG-280 DEG F., depending upon the pressure used.

Cooking pressures above or below the above range might also be used, but in a commercial operation there is no particular advantage in using a higher pressure, and lower pressures might result in inadequate cooking.

The cooked mass or dough is discharged from the cooker having a temperature of about 250 DEG F. or higher. At such temperatures, the dough is relatively sticky and often difficult to handle; therefore, it has been found advisable to cool the dough before it is processed further. For best results, the dough should be cooled to a temperature below about 140 DEG F. and preferably to a range of about 100

DEG-120 DEG F. Adequate cooling can be achieved by spreading the dough over a surface and permitting the dough to cool at room temperature for a desired period of time, e.g., 15-30 minutes, or by blowing cool air over or through the dough. In some instances, it might be desirable or necessary to de-lump, or break down, the dough in a hammer mill after it has been cooled. It should be recognized of course, that in some instances it might not be necessary or desirable to cool the dough.

After cooling, the cooked dough which is quite pliable, is formed into chips. This operation can be performed by rolling or extruding the mass into a sheet or sheets, having a thickness ranging from about 0.020 to 0.060 inch. The relative thickness of the sheet can vary depending upon the type of ingredients used, the type of rolls used, e.g., whether smooth or corrugated or a combination thereof, and the like. The sheet is then cut and formed into chips having a prescribed shape. Another shaping technique might involve extruding the dough into a rope which is cut into pellets, which are then flaked between rolls to form chips or flakes having a prescribed thickness. Generally, it has been found that if the chips are too thin, the resulting product is quite fragile and easily broken; on the other hand, if the chip is too thick, it will not cook properly during the frying operation. The chips thus formed, have a moisture level ranging from about 18-35 percent, and preferably the moisture level should be about 28 percent.

After the dough is formed into pieces or chips, the chips are dried in order to reduce their moisture content to about 8-14 percent, preferably about 11 percent. It has been found that if the chips are either

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too moist or too dry, they will not puff properly when subsequently subjected to intense heating.

Various drying procedures and techniques might be employed. A suitable product can be obtained by drying at room temperature for a prescribed period of time; if time is important however, the pieces can be dried at an elevated temperature, e.g., 100 DEG F. by appropriate means. It has been found that if the chips are dried by using too high a temperature, e.g., 200 DEG F., they do not puff as well when subsequently subjected to intense heat.

After the chips have been dried, they are puffed or expanded by subjecting them to intense heat for a short period of time. Although a number of methods might satisfactorily be used, such as salt puffing, it is preferred that the chip be deep fat fried in oil having a temperature ranging from about 350 DEG-400

DEG F. for about 5-40 seconds. This step normally reduces the moisture content of the chips to about

0.2-3.0 percent, and causes the product to increase somewhat in size. The product is then removed from the fryer, dusted with salt so that about 0.5 to 3.0 percent by weight of salt is added, and the product allowed to cool. The oil content of the final product might range from about 25-40 percent, and preferably about 30 percent. After cooling, the product is either packaged immediately, or stored for future packaging.

FIGS. 1-5 illustrate a chip 10 formed in accordance with the present invention. In general, the appearance of such a chip is substantially the same when either wheat or rye is used as the cereal grain; generally, the rye chip will have a darker color however. For purposes of illustration, the chip 10 will be described as being comprised of wheat and rice. As illustrated, the chip 10 has a somewhat uneven outline and a bubbly, irregular surface. As shown more fully in FIG. 4, the chip 10 includes an expanded starch matrix or structure 12 formed from the cooked gelatinized rice, a certain amount of the cooked wheat, the water, and the flavoring ingredients. Pieces of the cut wheat kernels or bran, are shown at 14. Chips of this type, whether formed from wheat or rye, have a unique texture because they contain discrete pieces of bran separated from each other by the gelatinized starch; moreover, the chips have a flavorful and delectable taste which is quite different from food products presently known.

The invention will be better understood by reference to the following examples:

EXAMPLE I

One hundred pounds of soft white wheat having a moisture content of about 12% were fed into a cutting apparatus, manufactured by Urschel Laboratories, Inc., so that the kernels were cut into a plurality of slices or pieces having a thickness of about 0.040 inch; less than 10 percent fines were produced which passed through a 20-mesh screen. About 11,300 grams of the cut wheat were combined and mixed with about 3,600 milliliters of water, 300 grams of salt, 225 grams of malt syrup, and about 60 grams of sodium bicarbonate. The resulting mixture was permitted to stand at room temperature for about 60 minutes, thus permitting the cut pieces to absorb at least part of the water, and permitting the flavoring ingredients to penetrate into the cut pieces. A dough having a moisture content of about 30 percent was then prepared by pressure cooking the mixture for about 1 hour at 20 psig.

After cooking, the dough was cooled at room temperature until its temperature was lowered to about

120 DEG F. The dough was then formed into a sheet about 0.032-0.035 inch thick by running it through a pair of sheeting rolls, and cut into chips about 1-2 inches in diameter. The chips were air dried at room temperature for 24 hours to a moisture content of about 11 percent. The dried chips were then deep fat fried in coconut oil having a temperature of 375 DEG F. for about 15 seconds. The chips expanded in thickness, as well as in diameter during the frying step; their moisture content was reduced to about 1.5 percent; and their oil content was about 35 percent. The chips were then dusted with salt so that an additional 1 percent by weight was added. The resulting chips were considered very good.

EXAMPLE II

Twenty-five pounds of white rice having a moisture content of about 11 percent were milled in a Fitz

Mill operated at medium speed and using a No. 5 screen. One thousand eight hundred grams of the milled rice were combined and mixed with about 9,500 grams of the cut wheat formed in Example I,

3,600 milliliters of water, 225 grams of salt, 225 grams of malt syrup, and about 70 grams of sodium bicarbonate. This mixture was permitted to steep for about 1 hour, after which a dough was formed by pressure cooking the mixture for about 1 hour at 20 psig. After cooking, the dough was tempered by blowing cool air over the mass, and then sheeted to a thickness of about 0.035 inch. Chips which were

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cut from the sheet were dried to a moisture content of about 10 percent, deep fat fried in coconut oil for

10 seconds at a temperature of 375 DEG F., and dusted with salt. The resulting chips had a crispy, crunchy texture, an appetizing appearance, and a delicious flavor.

EXAMPLE III

A mixture was formed by combining and mixing about 7,700 grams of cut wheat with about 3,600 grams of ground rice, 3,600 milliliters of water, 300 grams of salt, 225 grams of malt syrup, and about

70 grams soda; thus the ratio of wheat to rice was a little over 2:1, rather than about 5:1, as set forth in

Example II. The mixture was steeped for about 1 hour, and cooked in a pressure cooker for 1 hour at 20 psig. to form a dough. The dough was immediately formed into a rope by extruding it through a die opening in a piston-type extruder. The rope was formed into pellets having a diameter of about fivesixteenths inch, and a length of about three-fourths of an inch. The pellets were then flaked or flattened by passing them through a set of shred rolls to a thickness ranging from about 0.025-0.030 inch. After drying to a moisture content of about 9.5 percent, the chips were deep fat fried in coconut oil at 375

DEG F. for about 10 seconds, and dusted with salt. The final product had an oil content of about 28 percent, and a good flavor.

EXAMPLE IV

A mixture was formed by combining 9,070 grams of cut wheat with about 2,175 milliliters of water, and permitting it to temper for about 1 hour at room temperature. A dough was formed by pressure cooking the mixture for about 1 hour at 20 psig. The cooked dough was cooled, sheeted between a pair of corrugated rollers to a thickness of about 0.046-0,048 inch, and cut into chips. The chips were dried to a moisture level of about 11 percent, after which they were deep fat fried in coconut oil for about 27 seconds at 390 DEG F; the moisture content of such fried chips being reduced to about 1 percent after frying. After frying, the chips were dusted with salt so that about 2 percent by weight was applied.

While the cooked dough was comprised only of cut wheat and water, it nevertheless resulted in a wheat chip, which when dusted with salt, had very favorable characteristics as to flavor, texture, and appearance.

EXAMPLE V

One hundred pounds of whole, clean rye having a moisture content of about 12.5 percent were fed into the cutting apparatus identified in Example I, so that the individual rye kernels were cut into slices about 0.040 inch thick. About 9,000 grams of the cut rye were combined and mixed with about 2,400 milliliters of water, 450 grams of sugar, and 90 grams of salt. This mixture was tempered for about 1 hour at room temperature, after which a dough was formed by pressure cooking the ingredients for about 1 hour at 20 psig. The resulting dough was cooled, formed into a sheet about 0.052 inch thick, and cut into chips. The chips were then air dried to a moisture content of about 11.0 percent, deep fat fried in coconut oil for about 12 seconds at 400 DEG F; and then dusted with salt. The resulting product, while similar to the wheat chip product formed in Example I, had a somewhat more pronounced and distinguished flavor and its color was somewhat darker; in most respects however, it compared favorably to the wheat chip.

EXAMPLE VI

A mixture containing about 6,800 grams of the cut rye formed in Example V, 2,270 grams of broken kernels of white rice, referred to as "second heads," 450 grams of sucrose and 90 grams of salt, were combined with about 2,270 milliliters of water, and permitted to steep for about 1 hour. A dough was formed by pressure cooking the ingredients for about 1 hour at 20 psig, after which the dough was cooled, sheeted to a thickness of about 0.052 inch, cut into chips, and dried to a moisture content of about 11 percent. The dried chips were then deep fat fried in coconut oil at 400 DEG F. for about 12 seconds, and dusted with salt.

EXAMPLE VII

The general procedure set forth in Example V was followed by permitting a mixture of 9,070 grams of cut rye kernels and about 2,040 milliliters of water to temper for about 1 hour. After cooking, the

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resulting dough was cooled, sheeted to a thickness of about 0.052 inch, cut into chips, dried, deep fat fried for about 12 seconds at 400 DEG F., and dusted with salt so that about 2 percent by weight was applied. The rye chip which resulted compared favorably to the chip formed in Examples V and VI.

The products formed in accordance with the present invention result in a chip which is quite different from the conventional chip-type products presently available on the market. Not only do the chips exhibit a flavor substantially different from known products, but they also have a texture and appearance which is not the same as existing products. As illustrated in the drawings and as described in the examples, the resulting chip contains a plurality of discrete pieces or particles which give the product uniquely different flavor, texture, and appearance characteristics.

In the above description, a disclosure of the principles of this invention is presented, together with some of the specific examples by which the invention might be carried out.Data supplied from the esp@cenet database - Worldwide Claims:


1.

1. A process for making a ready-to-eat food product which comprises subjecting individual kernels of grain selected from the group consisting of whole wheat and whole rye, and mixtures thereof, to a slicing operation to reduce their size and expose the endosperm, forming a mixture by combining the sliced grain kernels with flavoring ingredients and enough water to raise the moisture content of the mixture to about 25-40 percent, pressure cooking said mixture to gelatinize the starch contained in the kernels and form a dough having discrete particles of bran retained in the dough, forming the dough into pieces having a prescribed size and shape, drying said pieces to a moisture content of about 8-14 percent, and puffing and expanding said pieces by subjecting them to intense heat for a prescribed period of time, said puffed pieces having discrete particles of bran retained therein which are separated from each other by the

2. The process of claim 1 which includes combining rice kernels which have been reduced in size with said mixture, the ratio of sliced grain kernels to rice ranging from about 1-5 parts of said grain kernels to one part of

3. The process of claim 1 wherein the grain kernels are sliced so that less

4. The process of claim 1 which includes steeping the mixture for about one hour at room temperature before the mixture is introduced into the cooker.

5. The process of claim 4 which includes cooling the dough to a temperature below 140 DEG F. after it is discharged from the cooker and before it

6. The process of claim 5 which includes forming the dough into sheets after the dough has been cooled, said sheets having a thickness ranging from about 0.025 to 0.060 inch, and cutting the sheets into chips having a

7. The process of claim 1 wherein the pieces are puffed by deep fat frying them in oil at about 350

DEG-400 DEG F. for about 10-40 seconds

8. The process of claim 7 which includes dusting the fried pieces with salt so that about 0.5-3.0 percent by weight of salt is added, the oil content

9. A process for making a ready-to-eat wheat chip which comprises slicing individual kernels of whole wheat into slices having a thickness ranging from about 0.030-0.055 inch to reduce their size and expose the endosperm, milling kernels of rice into flour, combining about 1-5 parts of said sliced wheat and about 1 part of said rice with water, sodium bicarbonate, salt, and malt syrup, thereby forming a mixture, steeping said mixture for about 1 hour, pressure cooking said mixture to gelatinize the starch contained in the kernels and form a dough having a moisture content of about 25-40 percent and discrete particles of bran in the dough, cooling said dough to a temperature ranging from about 100

DEG-120 DEG F., forming said dough into a sheet about 0.020-0.060 inch thick, cutting said sheet into

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chips, drying said chips to a moisture level of about 8-14 percent, deep fat frying said chips in oil at

350 DEG-400 DEG F. for 10-40 seconds, and applying salt to the chips after frying so that about 1-3 percent by weight is applied to said chips, said chips having discrete particles of bran retained therein which are separated from each

10. A process for making a ready-to-eat rye chip which comprises slicing individual kernels of whole rye into slices having a thickness ranging from about 0.030-0.055 inch, to reduce their size and expose the endosperm, combining about 1-3 parts of said sliced rye with about 1 part of rice kernels which have been reduced in size, water, sugar, and salt, thereby forming a mixture, steeping said mixture for about one hour, pressure cooking said mixture to gelatinize the starch and form a dough having a moisture content of about 25- 40 percent and discrete particles of bran in the dough, cooling said dough to a temperature ranging from about 100 DEG-120 DEG F., forming said dough into a sheet about

0.020-0.060 inch thick, cutting said sheet into chips, drying said chips to a moisture level of about 8-14 percent, deep fat frying said chips in oil at 350 DEG-400 DEG F. for 5-40 seconds, and applying salt to the chips after frying so that about 1-3 percent by weight is applied to said chips, said chips having discrete particles of bran retained therein

11. A ready to eat food product made by the process of claim 1.Data supplied from the esp@cenet database - Worldwide

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316.

US3660109 - 5/2/1972

PRODUCTION OF PARBOILED RICE


Inventor(s): LAY WILLIAM A (--)

Applicant(s): CARUS CHEMICAL CO INC (--)


IP Class: A23L1/10

E Class: A23L1/182



Family: US3660109

Abstract:


Treating of rice grain, while still covered by its hull, with aqueous potassium permanganate prior to steaming of the rice in processes for producing parboiled rice. The permanganate treatment has the effect of fixing or destroying color bodies in the hull to prevent their migration onto the surface of the starchy endosperm in the subsequent steaming and drying steps and thus prevent color impartation to the parboiled rice.Description:


INTRODUCTION

The parboiling of rice as it is practiced in the U.S. today is an involved manufacturing process but it is basically similar to the open kettle, hand operations that have been carried out in the Orient for centuries. The mechanized process of the U.S. has been adopted by other countries only recently.

Almost all methods of parboiling, from the most primitive village operation to the most complex manufacturing plant, have similar steps of soaking rough rice, steaming, drying, and milling. Each manufacturer has his own variations of these basic operations.

Parboiled rice is a fully precooked product in a dense form that does not allow the starch granules to take up water rapidly. Cooking time for food preparation remains about the same as raw rice. Even through it is not an instant or even a quick-cooking product, parboiled rice has the advantage of being more nutritious, more resistant to insect infestation, more stable in shape and less likely to be sticky or mushy after cooking. Prior to the milling step it has a slightly flexible quality which lends toward less breakage of individual grains in the milling process. This results in yield increases over raw rice that almost completely offset the cost of the parboiling operation and places the cost of parboiled rice approximately on an equal basis with raw rice. Relative cost also leans in favor of parboiled rice for processed food items because of the definitely greater volume per unit weight realized by parboiled rice as compared to raw rice.

There are two notable disadvantages to parboiled rice. The small mount of fat present is quite easily oxidized to produce strong rancidity. This has been overcome with the addition of anti-oxidants. A more serious problem is encountered in the color change during parboiling. Some of the colorants present in the hull and bran of rough rice migrate during parboiling to the outer part of the starchy rice

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grain to produce a slightly different flavor and the formation of a light tan color. This change in color has been an adverse factor in those rice consuming areas where whiteness of rice is the criterion of quality.

One technique in common practice is the bleaching of the rough rice with sodium bisulfite solution to inhibit discoloration of the starchy endosperm of the parboiled rice. The sodium bisulfite solution is relatively dilute, e.g., in the order of 0.1 to 0.6 percent. This technique inhibits the discoloration, but it is not entirely satisfactory due to inconsistent whiteness of the parboiled rice and the imparting of an aftertaste to the finished rice if the bisulfite is used in excess.

Another technique which has been tried for rice bleaching in the production of parboiled rice is the use of sulfur dioxide. In terms of bleaching results, the sulfur dioxide functions well, but it imparts an objectionable taste to the rice. A rancidity problem can also arise if the rice bran is disturbed and the bleaching action begins to form peroxide aldehyde type compounds.

THE INVENTION HEREIN

The generally employed commercial techniques for producing parboiled rice embody a series of steps in the following sequence: (1) steeping of the rough rice in water for several hours at elevated temperature, e.g., 3 to 4 hours at 140 DEG to 160 DEG F.; (2) steaming; (3) drying; (4) milling of the dried rice grains to remove the hull; (5) grinding the milled grains to remove the bran; and (6) polishing the rice grain endosperm.

The subject invention concerns this in the production of parboiled rice wherein a dilute, preferably neutral or alkaline solution of an alkali metal permanganate, preferably potassium permanganate, is used in the first stages of the process to bring the alkali metal permanganate into contact with the hulls of the rice grains to provide a fixation or oxidation of the color bodies contained mainly within the intensely colored hull. This treatment may be carried out during a part of the whole of the steeping of the rough rice in water or it may be carried out in a separate step either preceding or following the steeping operation. In general, the solution has an alkali metal permanganate concentration in the range of 0.5 to 10 grams per liter with an optimum concentration of 1.5 to 3.5 grams per liter. The pH of the permanganate solution may be acid, neutral or alkaline over the broad range of 1.5 to 11 with a preferred range in terms of best overall results of pH3 to 9.5. As a practical matter, however, alkaline solutions produce a faster reaction between the permanganate and the color bodies than do acid solutions. Also from an equipment corrosion viewpoint, the alkaline solutions are preferred.

Accordingly the optimal preferred pH range for the aqueous permanganate solutions is from about 7 to

9.5.

The rough rice grains are steeped in the permanganate solution at elevated temperature, preferably in the range of about 40 DEG to 70 DEG C. with an optimum in the order of 50 DEG C. The steeping time is sufficient to permit substantially complete consumption of the permanganate and may range over a period of 20 minutes to 4 hours. In general 30 to 60 minutes is sufficient for substantially complete permanganate consumption. The permanganate consumption is by way of oxidation of the organic substrate, i.e., the rice hulls and can be expressed by the following general equation

2 KMn04 + H2 0 + (organic substrate) .fwdarw. 2 KOH + 2 MnO2 + 30*

*chemically combined with substrate

The byproduct of these permanganate reactions is a hydrous form of a dark-colored manganese dioxide which is water insoluble and possesses a significant sorptive capacity.

At the completion of the permanganate steeping step, the hulls of the rice grains assume a darker brown color caused by deposits of hydrous manganese dioxide. The brown-colored steeping solution is drained from the rice grains, whereafter that they may be washed to remove residual steeping solution and any manganese dioxide loosely adhered to the hulls of the rice grain.

As an alternative, the manganese dioxide may be chemically removed from the rice grain hulls by treatment with sodium bisulfite or sulfur dioxide in aqueous solution. It is advantageous to first drain

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the manganese dioxide-containing steeping solution to thus eliminate the major part of the manganese dioxide without treating chemical cost. Thereafter acidified sodium bisulfite solution or sulfur dioxide in aqueous solution is added to the steeped rice grains. The brown hydrous manganese dioxide is converted within a few minutes into water soluble, almost colorless, divalent manganese sulfate. This solution can then be drained, whereafter the rice grains may then be washed with water to remove residual soluble manganese sulfate.

The steaming, drying, milling, grinding and polishing steps do not per se constitute a part of the subject invention. The conventional procedures may be used for these steps, e.g., a steaming time in the order of 5 to 30 minutes at 104 DEG to 127 DEG C. and a drying time in the order of 45 to 120 minutes at 45 to 90 DEG C. Milling, grinding and polishing are well known mechanical operations and need not be described herein in detail.

The invention heretofore described and the advantages accruing therefrom will be further appreciated from the following specific examples.

EXAMPLE 1

A steeping solution containing 16.3 grams of KMnO4 in 2.5 gallons of water is heated to approximately 160 DEG F. and applied to 18 lbs. of rice in a steeping vat. The initially dark purple color of the steeping solution changes gradually to brown, indicating the progress of the oxidation reaction. The reaction is completed (i.e., essentially all of the KMn04 is consumed) after approximately

30 minutes, leaving the hulls of the rice grains with a darker brown color caused by deposits of hydrous manganese dioxide. Under proper circumstances, the permanganate action is confined to the hull only with no obvious evidence of KMnO4 attack on the grain. At this point the brown-colored steeping solution may be drained and the rice may be washed with water to remove the suspended MnO2. This wash may also remove any Mn02 which may be loosely adhering to the rice grains.

As an alternate, the MnO2 can be chemically removed by treatment with sodium bisulfite (NaHSO3) or

SO2 in aqueous solution. If this is desired, the MnO2 -containing steeping solution is acidified with sulfuric acid to a pH of 3.2, and 32 grams of NaHSO3 is added. The brown Mn02 is converted within minutes to soluble, almost colorless, divalent manganese sulfate. This solution can then be drained and the product washed with water to remove the soluble Mn.

The above method can be advantageously modified by first draining the MnO2 -containing steeping solution, thus eliminating the major part of the MnO2 without chemical cost. Then, acidified NaHSO3 solution (pH 3.2) is applied, with only about one-third of the above quantity of NaHSO3 required

(approximately 10 grams NaHSO3 in 2 gallons of water). Removal of the solubilized Mn can be effected by washing with water as mentioned above. The rice is then steamed and dried under optimum conditions. The remaining steps in the customary production process for the parboiled rice (milling, grinding and polishing) are carried out as usual.

EXAMPLE 2

Laboratory tests were run with both alkaline and acid potassium permanganate solutions in which rough rice grains were immersed to ascertain the respective reaction times as measured by substantially complete consumption of the permanganate. In each of these tests 250 grams of rough rice were treated with 250 milliliters of the respective solutions listed below until substantially all of the potassium permanganate was reduced. The treating temperature in each case was 60 DEG C. The hydrous manganese dioxide formed was removed by adding dry sodium bisulfite to the liquor at the end of the reaction, after which the liquor was drained off the rice grains. The rice grains were then washed three times with water and dried in an oven at 50 DEG C.

The tests conducted are listed in the table below. ##SPC1##

EXAMPLE 3

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Potassium permanganate was added to water in the ratio of 16.3 grams KMnO4 per 25 gallons of water. After heating to about 160 DEG F., the solution was recycled through three parallel cookers, each containing 6 lbs. of rough rice. All KMnO4 was reduced after approximately one-half hour of reaction time. After steaming, a part of the rice was dried. The bleaching results observed were very satisfactory. The potassium permanganate did not appear to have penetrated beyond the hulls. Hydrous manganese dioxide deposits were noted only on the outer hull surface.

It is thought that the invention and its numerous attendant advantages will be fully understood from the foregoing description, and it is obvious that numerous changes may be made in the form, construction and arrangement of the several parts without departing from the spirit or scope of the invention, or sacrificing any of its attendant advantages, the forms herein disclosed being preferred embodiments for the purpose of illustrating the invention.Data supplied from the esp@cenet database - Worldwide

Claims:


1.

1. In a process for producing parboiled rice wherein rough rice is subjected to soaking, steaming and milling, the improvement which comprises treating rough rice prior to dehulling thereof with an aqueous solution of an alkali metal permanganate, said solution having an alkali metal permanganate concentration in the range of 0.5 to 10 grams per liter, for a period of at least 20 minutes under conditions effecting oxidation by said alkali metal permanganate of the color bodies in the

2. The improvement as claimed in claim 1, wherein said solution is in

3. The improvement as claimed in claim 2, wherein the temperature of said

4. The improvement as claimed in claim 3, wherein said solution has an alkali metal permanganate concentration of 1.5 to 3.5 grams per liter and

5. The improvement as claimed in claim 1, wherein said rough rice, after said contact with said alkali metal permanganate solution, is subjected to steaming, drying, and milling to remove said hulls to yield white rice grains substantially free from discoloration.Data supplied from the esp@cenet database -

Worldwide

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317.

US3674514 - 7/4/1972

SYSTEM FOR PREPARING PARBOILED ROUGH RICE


Inventor(s): SATAKE TOSHIHIKO (--)

Applicant(s): TOSHIHIKO SATAKE (--)


IP Class: A23B9/00

E Class: A23L1/182



Family: US3674514

Abstract:


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318.

US3690894 - 9/12/1972

PROCESS FOR PREPARING A DRIED RICE CEREAL PRODUCT


Inventor(s): KELLY VINCENT J (--); SMALLIGAN WAYNE J (--); CLOUD LARRY L (--)

Applicant(s): GERBER PROD (--)


IP Class: A23L1/10

E Class: A23L1/164F



Family: US3690894

Abstract:


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319.

US3692533 - 9/19/1972

MODIFICATION OF THE PHYSICAL PROPERTIES OF FREEZE-DRIED RICE


Inventor(s): HUBER CLAYTON S (--)

Applicant(s): NASA (--)


IP Class: A23L1/10

E Class: A23L1/182; A23L3/44



Family: AU3279971

Equivalent: GB1302314; FR2102021; CH551758

Abstract:


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320.

US3694226 - 9/26/1972

QUICK-COOKING RICE PRODUCT AND PROCESS FOR PREPARING SAME


Inventor(s): HOWLAND ROBERT F (--); HAIGH JOSEPH B (--); FUSI ROBERT W (--)



IP Class: A23L1/10

E Class: A23L1/182



Family: US3694226

Abstract:


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321.

US3701667 - 10/31/1972

METHOD FOR PUFFING GELATINIZED RICE GRAINS


Inventor(s): HEKI TAKAO (--); YASUMATSU KATSUHARU (--); SAWADA KOSHICHI (--);

FUNAKOSHI YOSHIRO (--)



IP Class: A23L1/18

E Class: A23L1/18C6



Family: US3701667

Abstract:


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322.

US3706573 - 12/19/1972

FRIED RICE PRODUCT AND PROCESS FOR PRODUCING SAME


Inventor(s): TOLSON RAYMOND C SR (--); TOLSON RAYMOND C JR (--)

Applicant(s): GT PROD INC (--)


IP Class: A23L1/10; A23L1/18

E Class: A23L1/182C



Family: CA936040

Abstract:


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323.

US3711295 - 1/16/1973

SHAPED RICE PRODUCT AND METHOD FOR PRODUCING SAME


Inventor(s): ZUKERMAN H (--)

Applicant(s): ZUKERMAN H (--)


IP Class: A23L1/10

E Class: A23L1/182; A23L1/182C; A23L1/10



Family: US3711295

Abstract:


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324.

US3753727 - 8/21/1973

METHOD OF RESTRUCTURING RICE


Inventor(s): WHELAN J (--)

Applicant(s): ADAMS and WHELAN (--)


IP Class: A23L1/10; A23L1/18

E Class: A23L1/182; A23L1/18C



Family: US3753727

Abstract:


Rice is restructured by quickly heating a mass of natural rice at substantially atmospheric pressure to a temperature of about 300 DEG F and then passing the rice mass while so heated between rotating rolls, preferably metal, and yieldably pressed together, so that the heated rice is mechanically squeezed and then is discharged, preferably by gravity, whereupon the rice grains enlarge in all dimensions.Description:


In the handling of rice it is sometimes advantageous to alter the rice grains in some fashion so that they can easily be recognized as distinct from other naturally occurring and untreated rice grains. Sometimes this is attempted by dyes, superficial coloring matter of various sorts and the like. In most instances colors or dyes are disadvantageous for many reasons, either because they are readily removed or are not sufficiently distinct or may, in some instances, result in adverse reactions. It is also often desired to change the cellular constituency of rice in order to make it more readily acceptable for feeding, either human or animal, and sometimes also for the purpose of altering its available nutritional value. It is likewise sometimes advantageous to change the bulk of the rice so that it is greater than that of natural rice for various different commerical purposes.

Heretofore it has been the custom to heat rice with normal or extra moisture and at a substantially elevated pressure, so that the rice is simultaneously subject to heating and pressurizing. Thereupon the pressure is quite suddenly relieved. As a result the rice puffs or enlarges substantially. This is an effective way of changing the appearance and the structure of the rice, but it is likewise not only a relatively expensive process because of the necessary pressure vessels but also tends to be feasible only in a batch process rather than in a continuous process.

It is therefore an object of the invention to provide an improved method of restructuring rice.

A further object of the invention is to provide a method of restructuring rice not involving heavy pressure vessels.

A further object of the invention is to provide a method of restructuring rice which readily lends itself to a continuous type of operation.

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A further object of the invention is to provide a method of restructuring rice which can readily be accomplished without any heavy or special equipment and can readily be carried out in most milling or feed handling establishments with only minor variations in or rearrangement of the machinery.

A further object of the invention is to provide a method of restructuring rice in which the controls necessary for consistent operation are exceedingly simple and straightforward.

A further object of the invention is in general to provide an improved method of restructuring rice.

In the conduct of the present method, the starting material is referred to as natural rice. By this is meant a rice grain as it naturally occurs and as it has been removed from the rest of the rice plant. It may or may not have been treated to remove the hull. The rice grain may or may not be polished. In any event, it is received in an uncooked or previously untreated condition except for the possible hull removal and possible polishing. While there may be some other locally unusual grains that act similarly to rice under the practice of this process and so can be considered as equivalents to rice, the usual, other commercial grains, such as corn, oats, wheat and barley, have not responded to the practice of the present process, do not develop the same or a similar restructuring under this process and so are not herein considered as equivalent to rice.

To carry out the process, a mass of natural rice grains is assembled in a suitable container at atmospheric pressure and under ambient atmospheric conditions as to humidity and temperature and then is subject to a heating step. Heat is applied quickly to the assembled mass of rice grains, so that they are promptly raised in temperature from the normal ambient temperature to a temperature value in excess of the atmospheric boiling point of water and preferably in the neighborhood of 300 DEG F.

Reference to quickly heating the rice mass means that each rice grain is subject to hot air and is brought up through the temperature gradient in a matter of 2 minutes.

When heated in this fashion, the resulting appearance of the mass of grain so heated is not appreciably different from the initial visual appearance of the mass of starting material. But if the heating is done relatively slowly, the rice tends to lose its moisture; that is, to dry out and shrink or distort and likewise to change its color by darkening. Also, some of the grains, particularly if there is a very small mass of grains involved, may tend to enlarge slightly. If a substantial quantity or mass of grains is processed quickly, then the color during the quick heating does not appreciably change nor do any of the grains appreciably change their shape or volume.

In accordance with the process, the mass of rice quickly heated to approximately 300 DEG F is immediately passed while warm between the abutting surfaces of a pair of rollers. These are the customary parallel, metal rollers normally smooth and circular cylindrical. They are not initially heated but after some use become heated to approximately the same temperature as the passing rice. The rollers are mounted in such a fashion that they can yield with respect to each other. While they may abut initially they yield against spring pressure as rice quantities pass between them. AS an example, rolls approximately 16 inches in diameter and 18 inches long are pressed together with springs exerting a total force of approximately 2,000 pounds. The force per inch of roll length is about 110 pounds. The mass of heated rice is fed, preferably by gravity, between the generally horizontal rolls from the upper, converging sides thereof and passes down between the rolls to discharge by gravity. The rolls, of course, yield as the mass of rice passing between them varies slightly in bulk but the unit pressure is always substantially the same. Some warm air is entrained by the rice flow.

It might be expected that this amount of force on the heated rice would tend permanently to flatten and crush the rice grains and result in a product resembling flakes or plates. This is not the case. The rice grains in passing between the rolls are momentarily flattened or deformed, but as they emerge on the downstream or discharge side of the rolls and fall by gravity they immediately enlarge into a volume substantially greater than the initial volume. This in effect is a puffing of the rice grains. The appearance of the rice grains and of the rice mass on the downstream side of the rolls is entirely different from that on the upstream side of the rolls. The treated rice is readily distinguished by appearance from untreated rice. Furthermore, the product has the attributes of a rice grain that has been substantially restructured.

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What is believed to occur is that during the quick heating of the natural rice grains the moisture within the cells is brought above its boiling point and would form steam except for the fact that the cell walls are intact and retain the hot moisture in place under internal cell pressure. In passing through the rolls, the cell wall structure is substantially reoriented and in many places mechanically interrupted or broken. The pressure within the cells resulting from the initial heating is rather abruptly released into adjacent grain volumes, enlarging the grains. The moisture within the cells is such as to render their walls fairly spongy or resilient or plastic, so that no permanent crushing occurs as the rice grains go between the rolls, yet as soon as the roll pressure is relieved the internal pressure due to the heated moisture is sufficient to move the disrupted cells and to travel to others and thus distort or enlarge the volume of the so-treated rice.

As it emerges from the rolls on the discharge side, the rice falls by gravity and is simply collected and permitted to cool to ambient or atmospheric value. The mass of treated rice is then removed from the structure and is ready for subsequent operations.

As described, it will be appreciated that the process can be operated virtually as a batch process in that a definite, small quantity of rice can be put through at any one time. It will also be appreciated that rice going through the heating zone and through the subsequent rolling zone to the discharge zone can likewise continue uninterruptedly for an indefinite period, and thus may be a continuous process.

As an example of what occurs under the conditions mentioned, a representative batch of natural rice going into tthe process but being merely heated therein has a mean or representative grain of a length of 5.62 millimeters, a width of 2.77 millimeters and a thickness of 2.03 millimeters. The same representative or mean grain sample at the discharge side of the process, after passing between the rolls, shows a length of 8.26 millimeters, a width of 4.70 millimeters and a thickness of 3.10 millimeters. This amounts to an increase of 47 per cent in length, of 70 per cent in width and of 53 per cent in thickness. Thus, simply as a distinguishing or marking arrangement, the process presents a product which is markedly different in appearance becasue of its increased size. Furthermore, the exterior surface of the rice is somewhat irregular and the normal rice grain shape is substantially distorted. Also, the internal, cellular structure of the rice is mechanically altered substantially to attain the benefits, such as better nutrient availabiliy, accompanying grain puffing.

The regulation of the process is extremely simple in that the only factor of consequence is to maintain the quick heating during a time of about 2 minutes and at a value of approximately 300 DEG F. This time and this value are not absolutely critical, but something in the immediate range is satisfactory and can readily be controlled by ordinary commerical equipment. The pressure on the rolls is a matter of initial machine design, and once it has been established and set usually requires no regulation, adjustment or supervision. Thus the process can be carried out, once started, with no supervision whatsoever and under fully automatic control.Data supplied from the esp@cenet database - Worldwide

Claims:


1.

1. A method of restructuring rice consisting essentially in the steps of quickly heating natural uncooked rice from its natural ambient temperature and substantially at atmospheric pressure to a temperature above the atmospheric boiling point of water, then mechanically deforming said rice while at said temperature by subjecting said rice to a predetermined compressive force, then promptly relieving said rice from said force whereby said rice immediately enlarges into a volume substantially greater than the initial volume, and collecting said deformed rice at

2. A method as in claim 1 in which the heating period of said rice is about

3. A method as in claim 1 in which the heating temperature of said rice is

4. A method as in claim 1 in which said rice is subject only momentarily to

1407/2197

5. A method as in claim 1 in which said force is equivalent to that exerted on said rice in passing between cylindrical rolls yieldingly urged together with a pressure of about 110 pounds per axial inch of roll

6. A method as in claim 1 in which said deforming step quickly follows the attainment of the temperature above the atmospheric boiling point of water

7. A method as in claim 1 in which said heating step is performed by air.

8. A method as in claim 1 in which said rice advances in a continuous stream while being heated, then while being subjected to said force, and

9. A method as in claim 8 in which said rice advances largely by gravity.Data supplied from the esp@cenet database - Worldwide

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325.

US3803334 - 4/9/1974

PARBOILED RICE PRODUCT


Inventor(s): HUNNELL J (--)

Applicant(s): RIVIANA FOODS INC (--)


IP Class: A23L1/10

E Class: A23L1/182



Family: US3803334

Abstract:


1409/2197

326.

US3852504 - 12/3/1974

PROCESS FOR COMPLETE SEPARATION OF CONSTITUENTS OF RICE-

BRAN AND THE LIKE


Inventor(s): YASUI E (--); TACHIBANA K (--); ENDO T (--); MIHARA S (--); INABA Y (--)

Applicant(s): NAKATAKI PHARM IND CO LTD (--)


IP Class: A23J1/14

E Class: A23L1/10E; C11B1/10; C08B30/04B; A23J1/12


Priority Number: US19720286602 (19720905); JP19690027363 (19690409); US19700026089

(19700406)

Family: US3852504

Abstract:


All the constituents of seeds and brans of cereal grains, especially rice bran, are recovered by mixing the same with an excess of an aqueous acid solution, pulverizing the mixture, separating an emulsified solution of the dissolved phytin and the protein bonded with the oil dispersed in the acid solution from the solid residue, and screening the solid residue to separate crude fiber-containing substances from a starch-rice fraction.Description:




The present invention relates to a process for the complete separation of the major constituents of seeds and brans of cereal grains, particularly rice-bran.

The production of rice has increased year by year, but rice-bran is being used primarily as a raw material of oil or as an animal feed. Although the protein and the starch of rice-bran are of excellent quality and highly nutritive, these ingredients are hitherto not been fully utilized, as foods because the contents of the respective components of rice-bran are rather close to each other and, therefore, there is no suitable means for isolating and concentrating each of the respective components. It is impossible to separate them effectively by applying any known separation method which can be used for other plant constituents. The composition of rice-bran is generally 11 - 13 percent (percent is by weight, here and hereinafter) of water, 18 - 21 percent of crude fat and oil (or fatty oil, which will be collectively referred to only as "oil" hereinafter), 14 - 16 percent of crude protein, 8 - 10 percent of crude fiber, 9 -

12 percent of ash, and 33 - 36 percent of carbohydrates. The content of starch in the carbohydrates is about 40 percent which corresponds to about 10 percent of rice-bran, whereas most of the ash exists as

Phytin. Usually, in order to separate the protein from rice-bran, the starting material is dehydrated and extracted of oil and the residues after the extraction of oil are extracted with an alkaline solution and then subjected to a coagulation treatment with an acid to precipitate and obtain the protein. However,

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the protein in rice-bran undergoes a severe denaturation during the oil extraction treatment and is mixed closely with the starch which makes the extraction with an alkaline solution much more difficult. Accordingly, few successful examples of such extraction of protein from rice-bran have been reported.

2. Summary of the Invention

The present invention provides a process for separating all of the constituents of seeds and brans of cereal grains, particularly rice-bran, by a simple means and in a short time, without using such difficult separation steps as mentioned above.

According to the present invention, rice-bran is pulverized in an aqueous acid solution. If rice-bran alone is pulverized as it is or after it has been dried, the crude fiber and other impurities such as cellmembrane (which will be referred to only as "crude fiber containing substances" hereinafter) are also finely divided, mixed closely with the starch and are difficult to remove, thus lowering the quality of the starch. On the contrary, when rice-bran is pulverized in an aqueous acid solution, the pulverized particle size of the crude fiber containing substances is greatly different from that of the starch, which enables the separation of the more coarse particles of the crude fiber containing substances from the finely divided particles of the starch by screening them with a sieve.

The process of the present invention is explained in further detail below:

The starting materials (rice-bran or oil-containing seeds such as soy bean) are mixed with several times as much as by weight, usually two to 10 times (wt./wt.), preferably four to eight times, of an aqueous acid solution and are pulverized for a short time, for example, a few minutes, in a pulverizer (wet pulverizer such as a mixer, a homogenizer, a desper mill or a supersonic disperser). A time of pulverization of 10-15 minutes will be usually sufficient.

As the aqueous acid solution, a mineral acid such as hydrochloric acid and sulphuric acid or an organic acid such as acetic acid can be used and it is advantageous to adjust the pH value of said acid solution within the range of 1 - 6 at which pH the protein is coagulated. If the pH of the said acid solution is made less than 1, such a low pH will make the consequent filtration operation difficult and will solubilize a portion of the protein to lower the yield of the protein. On the other hand, if the pH is more than 6 or water alone is used instead of an aqueous acid solution, only half the amount of the Phytin contained in the rice-bran is transferred into the water and the remainder of the Phytin is mixed with the starch and the crude fiber containing substances, thus decreasing the purity of the starch and the yield of the Phytin, unless it is not recovered from said mixture. On the contrary, if the starting material is pulverized in an aqueous acid solution of pH 1 to 6 according to the process of the present invention, the Phytin in the rice-bran is transferred completely into the aqueous solution. In addition, the liquid thus obtained by the pulverization is in an emulsified state, in which the protein is bonded with the oil and thus it is not precipitated upon its coagulation. Then, the crude fiber-containing substances of a large particle size are separated from the aqueous solution by screening, or the starch and the crude fiber-containing substances are separated from the aqueous solution by a centrifugal machine. In case the liquid was first treated by screening to remove the crude fiber-containing substances, the obtained aqueous solution is further treated by centrifugation, thus separating the starch from the aqueous solution. On the other hand, in case the liquid was first treated in a centrifugal machine, the obtained mixture consisting of the starch and the crude fiber containing substances is then screened, thus separating the starch and the crude fiber containing substances easily from each other. In separating the crude fiber-containing substances from the starch by screening, the screening operation is carried out in a wet state, usually by using a 200 to 400 mesh sieve, since the average particle size of the pulverized crude fiber-containing substances will be about 110 mesh, whereas the particle size of the carbohydrates (starch) will be about 5 to 10 .mu., which will easily pass a 200 to 400 mesh sieve.

Accordingly, the use of a 200 mesh sieve is preferable to separate the crude fiber-containing substances. The aqueous solution obtained after the above mentioned centrifugation or screening treatments may be separated into the oil-bonded protein fraction and the liquid fraction by a filtration treatment. The oil-bonded protein fraction (water content of 40 to 50 percent) is then treated with a water miscible solvent (for example, methanol, ethanol and acetone) to separate the protein and the oil from each other. Otherwise, the fraction is dried to a water content less than 5 percent and then, it is

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treated with an oil extracting organic solvent such as hexane, benzene and toluene to separate the oil and the protein.

The liquid fraction is then made alkaline by the addition of an alkali such as sodium hydroxide, potassium hydroxide and ammonia to precipitate the Phytin therefrom. In this case, the pH of the liquid will be adjusted to the isoelectric point of the Phytin in the range of pH 8 to 10 to precipitate the Phytin as a salt. The precipitated Phytin is separated by filtration or centrifugation for the solution. The remaining solution is a highly nutritious solution containing much vitamin, sugars and soluble protein.

The products of the respective ingredients thus separated according to the process of the present invention are oil, protein, starch, Phytin, crude fiber containing substances and a vitamin-rich solution, respectively. The protein thus obtained has a purity of not less than 85 percent and the amino acid composition thereof was similar to that of an egg. The starch thus obtained has excellent properties close to those of rice starch. The crude fiber containing substances thus obtained contain some carbohydrates, starch, protein and oil and can be satisfactorily utilized as an animal feed, which is free of a rice-bran-like odor and even tastes sweet.

In the above, the present invention has been described mainly with reference to the treatment of ricebran, but the process of the present invention may be applied not only to rice-bran but also to an oilcontaining seeds such as soy bean and sesame.

The followings are the specific, nonlimiting examples of the present invention.

All percentages are percent by weight.

EXAMPLE 1

100 g. of commercially available rice-bran containing crushed rice, 10 percent of water, 20 percent of oil, 13 percent of crude protein, 10 percent of crude fiber, 9 percent of ash, 37 percent carbohydrates was pulverized in 400 ml. of an aqueous acid solution acidified with hydrochloric acid to pH of 2.0 and the thus treated aqueous solution was separated into a precipitate and a solution (A) by a centrifugal machine; to the precipitate, 500 ml. of water was added and screened with a 200 mesh-sieve to separate the crude fiber containing substances remained on the sieve from the solution (B). The solution (B) was centrifuged to separate the starch as a precipitate. The amount of the thus separated starch was 14.5 g. after drying. Next, the above solution (A) was filtered to separate the oil-bonded protein and the solution (C). The oil-bonded protein was then treated with 200 ml. of acetone to separate the protein from the solution and acetone was distilled off from the solution to obtain 16.5 g. of the oil and 9 g. of the dried and finely divided powder of protein (purity 86 percent). The above solution (C) was added with an alkali to make the pH of the solution to 9.0 at which pH the Phytin was precipitated, giving 8 g. of the same after drying. On neutralizing the solution after the separation of the Phytin with an acid followed by the evaporation of water, 22 g. of a glutinous solid substance containing vitamin, saccharose and soluble protein was obtained. The amount of the above crude fiber containing substances remained on the sieve was 25 g. after drying and they were found to be composed of 2.2 percent of water, 13 percent of the crude protein, 6 percent of the oil content, 3 percent of the ash content and 27 percent of the crude fiber, which were sufficiently nutritious to be used as an animal feed.

EXAMPLE 2

100 g. of soy bean (water--11 percent, oil content--20 percent, crude fiber--4 percent, ash--5 percent, crude protein--37 percent, carbohydrates--23 percent) was pulverized in an aqueous acid solution acidified with acetic acid to pH of 4.0. After that, the thus treated solution was further treated in the same manner as in Example 1 and 31 g. of protein (purity 85 percent), 16 g. of oil, 2 g. of Phytin, and

18.5 g. of the crude fiber containing substances (cell-membrance and crude fiber) remained on the sieve were obtained.Data supplied from the esp@cenet database - Worldwide

Claims:


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The embodiments of the invention in which an exclusive property or

1. A process for separating and recovering the constituents of a starting material consisting of nondeoiled seeds or brans of cereal grains, said starting material containing the naturally occurring amount of oil of said seeds or bran together with protein, crude fiber, starch, Phytin, water soluble carbohydrates and water, which consists of the steps of 1. mixing said starting material with an aqeuous acid solution having a pH in the range of from 1 to 6, the amount of said aqueous acid solution being from two to 10 times by weight, of the starting material, and mechanically pulverizing the mixture consisting of said starting material and said aqueous acid solution to obtain a pulverized mixture of components consisting essentially of a. a solid phase consisting essentially of large size crude fibers and small size starch particles b. a liquid phase consisting essentially of i. protein bonded with oil, emulsified in ii. an aqueous phase containing dissolved therein Phytin and water soluble carbohydrates;

2. separating from the mixture and recovering separately the large size crude fibers and small size starch particles; 3. filtering component (b) and recovering separately constituents (i) and (ii); 4. then treating constituent (i) with a solvent to recover separately said protein and said oil, and 5. adjusting the pH of constituent (ii) in the range of 8 to 10 to precipitate Phytin and then separating the precipitated

Phytin from the aqueous solution containing dissolved therein the water soluble

2. A process according to claim 1, in which the seeds or brans are

3. A process according to claim 1, in which the solids are screened by passing same in a wet state through a screen having a mesh size in the

4. A process according to claim 1, in which step (2) comprises screening the pulverized mixture with a screen having a mesh size in the range of 200 to 400 mesh to separate the large size crude fibers and then centrifuging the remainder of the mixture to separate therefrom the small

5. A process according to claim 1, in which step (2) comprises centrifuging the pulverized mixture to separate component (a) from component (b) and then screening component (a) using a screen having a mesh size in the range of 200 to 400 mesh to separate the large size crude fibers from the

6. A process according to claim 1, in which step (4) comprises adding a

7. A process according to claim 1, in which step (4) comprises drying constituent (i) to a water content of less than 5 percent and then treating same with an oil-extracting solvent.Data supplied from the esp@cenet database - Worldwide

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327.

US3860735 - 1/14/1975

METHOD OF MANUFACTURING NON-GLUTINOUS RICE CRACKERS


Inventor(s): HOSHINO HIROSHI (--)

Applicant(s): HOSHINO HIROSHI (--)


IP Class: A23L1/10

E Class: A23L1/164



Family: US3860735

Abstract:


A method of manufacturing non-glutinous rice crackers by milling non-glutinous rice, adding water to the resultant rice powder, kneading and smothering the mixture, treating the smothered paste with water, rolling the resultant paste into a strip-like form, feeding the strip-like paste into a dehydrator at a temperature of 60 DEG to 90 DEG C to reduce the water content in the paste down to 14 to 30 percent, adjusting, if necessary, the dehydrated paste to a hardness suited to high speed cutting, cutting the dehydrated paste in a continuous high-speed cutting process, and drying and baking the resultant material.

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328.

US3879566 - 4/22/1975

PROCESS FOR PREPARING A QUICK-COOKING RICE


Inventor(s): COX JAMES PATRICK (--); COX JEANNE MARIE (--)

Applicant(s): MARTIN ROBERTSON and BAIN LTD (--)

IP Class 4 Digits: A23C

IP Class: A23C1/00

E Class: A23L1/182; A23L1/182B; A23B9/30



Family: US3879566

Abstract:


Various varieties of rice are subjected to heat treatment either by torrefaction in the presence of some water, by steaming, or by boiling, the water in each instance containing dissolved chemicals, for the purpose of modifying the protein content and the starch content to condition the product for subsequent accelerated water imbibation during final cooking for eating. After the heat and chemical treatment the rice product is rinsed to remove chemical residue and to eliminate clumping. The rice is then dried.Description:


A principal object of this invention is to provide a quick-cooking rice having whole grains which are strong and not fractured or mutilated, having good color both before and after cooking and having no objectionable odor or taste. Avoidance of mutiliation of the rice grains minimizes loss of starch and nutrients during cooking and rinsing in the process of preparing the quick-cooking rice.

More specifically it is an object to produce such a quick-cooking rice which, before final cooking, looks like the usual commercial rice product, the grains of which will not be appreciably different in size from unmodified rice, which will have substantially the same characteristics of swelling as natural rice and, when finally cooked, will have odor, texture, taste and appearance very similar to ideally cooked conventional milled rice.

Still more specifically, it is an object to modify the protein component of the rice so that water will be more available to the starch component for imbibation, and to modify the starch component of the rice to increase its hydrophilic characteristics.

Another object is to accomplish the modification of the rice by heating and chemical treatment which can be performed by simple procedures and with simple equipment.

It is also an object to provide a process which can be used for treating various types and varieties of rice including long grain rice, short grain rice, pearl rice and brown rice, and which can be used to produce finally cooked rice having different physical qualities.

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In processing the rice so that it will have quick-cooking characteristics it is an object to minimize loss of rice quantity as well as of various nutrient components of the rice itself.

A further object is to provide a rice product which can be prepared for eating by final cooking sufficiently quickly so that coatings carried by the rice grains to make special rice dishes, such as rice pudding, Chinese rice, curried rice, Italian rice, Spanish rice, rice with cheese sauce or rice with buttertype sauce, will not be overheated or overcooked.

Such quick-cooking rice can also be combined with other food components capable of being cooked in the same period of time as required for final cooking of the quick-cooking rice, such as spun soya protein chunks and dry beans in chili-rice, an alimentary paste product and bread chunks in dressing.

Another object is to deter loss of moisture from quick-cooking rice or from conventional milled rice to reduce weight loss during storage.

An additional object is to provide chemical treatment to facilitate the final cooking of quick-cooking rice for eating which will utilize chemicals that nutritionally fortify the rice product, particularly such chemicals that will increase its calcium, phosphorous and citrate content.

Various types of quick-cooking rice have been produced heretofore, but the theories followed in preparing such rice have been different from that of the present invention. By some processes the physical characteristics of the rice grains are altered, such as by fracturing them without disintegration in an effort to facilitate penetration of water into the interior of the grain for imbibation during final cooking. Such physical modification of rice grains detracts from the appearance of the rice, results in loss of nutrient values and is a comparatively expensive process to perform. Another proposal for preparation of quick-cooking rice is that of pregelatinization and expanded grain fixation, which process includes cooking rice at the factory to a condition of virtually complete gelatinization, followed by a drying operation by which a major portion of the imbibed water used for gelatinization is removed coupled with a puffing effect or an attempt to maintain the grains in expanded condition. The theory of such a pregelatinizing operation apparently is that after rice grains have once been expanded by gelatinization they will imbibe water more readily during the final cooking operation if the expanded condition produced can be retained. Such process requires the use of expensive equipment.

In preparing quick-cooking rice according to the present invention the rice grains are not subjected to mechanical action to modify their physical structure. Neither is reliance placed on bloating the rice grains followed by drying them in a manner to retain their expanded condition so as to facilitate subsequent water imbibation during final cooking. Instead, the present invention relies on molecular or internal structural modification of the rice grain chemical components accomplished by the use of chemicals and heat treatment to facilitate penetration of water into the rice grains and to expedite imbibation of the water during preparation of the quick-cooking rice and also during its final cooking to palatable condition.

In the textbook entitled, Starch, Chemistry and Technology, by Roy L. Whistler and Eugene F. Pascal,

Vol. 2, Industrial Aspects, published in 1967 by Academic Press, Inc., at page 73, it is stated that, "Rice starch granules are bound into a rigid structure by proteins in close association with the starch (18).

Chemical treatment is necessary to separate this protein fraction from the starch in the manufacturing process." Descriptions of various processes of manufacturing starch from rice then follow, all of which processes include the step of grinding the rice grains or physically disintegrating them in some fashion.

It is believed that the internal structure of a rice grain may include an integumental web formed by the protein component which sequesters the starch to deter imbibation of water by the starch to gelatinize it. Such theory could be responsible for the long time ordinarily required to cook rice in boiling water, for example. According to the present invention heat treatment of the rice with aqueous chemical apparently modifies the protein component and/or the starch component to facilitate penetration of water into the interior of the rice grains and to expedite imbibation of such water by the starch during gelatinization.

The heat treatment can be effected either by the rice being processed in hot, preferably boiling, water at atmospheric or higher pressure, or by the rice being steamed at atmospheric pressure or

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superatmospheric pressure, or by torrefaction of the rice in an autoclave in the presence of a small amount of water, or the rice can be subjected to a plurality of such heat treatment steps, either of the same type or of different types, in succession.

If the rice has been milled before being subjected to the process of the present invention, it is desirable, although not necessary, to rinse the rice initially in water, which preferably is warm, such as within the range of 85 DEG F. to 95 DEG F., to remove talc, glucose and free starch from its surface. The rinse water preferably is a mildly alkaline solution, such as being a solution of 0.001% of sodium bicarbonate having a pH of 7 to 8. Rinse water having a pH range of 5 to 9 can, however, be used.

Rinse water having a pH of less than 6.8 will tend to produce a whiter product, whereas considerably higher pH will produce a yellow or greenish yellow tint. Rinse water having higher pH, such as above

7.5, will increase the hydrophilic character of the rice. Successive rinse waters can be used until the rinse water is clear.

The rinsing preferably should not be continued for more than 3 minutes to 5 minutes if the rice is to be subjected to dry steam heat treatment subsequently. Otherwise, the rice may remain in the rinse water for a considerable period of time, such as 10 minutes to 30 minutes, to increase the depth and uniformity of penetration of the water into the rice kernels. Such penetration reduces the tendency of the rice kernels to disintegrate or to become mutilated from the action of internal osmotic pressure acting to burst the rice grains during subsequent boiling, which results in starch being lost to the cooking water. A brief after-rinse in calcium chloride brine deters adhesion between grains which adhesion would cause mutilation if the grains were forced apart.

Heat treatment of the rice is effected in the presence of the aqueous chemical or chemical solution. An aqueous solution can be used which initially is either cold or hot. Such chemical may be alkali metal phosphate, i.e. phosphate of sodium or potassium including orthophosphates, pyrophosphates and metaphosphates. Specific examples are monosodium phosphate, NaH2 PO4, disodium phosphate, Na2

HPO4, sodium trimetaphosphate, (NaPO3)3, disodium dihydrogen pyrophosphate, Na2 H2 P2 O7, and tetrasodium pyrophosphate, Na4 P2 O7. It is believed that alkali metal phosphates act principally to modify the starch of the rice for increasing its hydrophilic character, but may also modify the protein of the rice to reduce its protection of the starch from water absorption. Trisodium phosphate, Na3 PO4, is undesirable because of its adverse cross-linking characteristics which may actually deter absorption of water by the rice and prevent its gelatinization.

Chemicals believed to act principally to modify the protein structure of the rice by attenuation, disruption and/or disintegration are citrates, including magnesium citrate, sodium citrate, Na3 C6 H5

O7, and calcium citrate, Ca3 (C6 H5 O7)2 .4H2 O. Such citrates are not sufficiently effective alone to produce a desirable quick-cooking rice product in conjunction with heat treatment. Such a citrate should be used either with alkali metal phosphate as specified above or with calcium chloride, CaCl2.

Calcium chloride and alkali metal phosphate should not be used together in the heat treatment aqueous chemical, however, because they react with each other to prevent effective action of either to modify the rice protein. A beneficial effect of the calcium chloride is to reduce the temperature of heat treatment required in preparing the quick-cooking rice product. Calcium chloride provides the further benefit of serving as a desiccant to deter loss of moisture from rice grains and thus reduce weight loss of the rice during storage. For this purpose the calcium chloride can be supplied to rice grain either during a rinsing operation or a precooking operation or, by addition to rice grain which has not been treated to reduce its final cooking time, by mixing the calcium chloride with glucose and talc for coating the rice grains during the milling process.

Auxiliary chemicals having beneficial effects are fatty acid glycerides, i.e. glyceryl monostearate, monooleate, monopalmitate, distearate, dioleate, diplamitate, tristearate, trioleate or tripalmitate and silicones, which deter adhesion, and primary calcium phosphate, CaH4 (PO4)2, or secondary calcium phosphate, CaHPO4, which facilitates absorption of water by the starch and enhances the whiteness of the rice product. Any or all of such auxiliary chemicals can be used in combination with alkali metal phosphate as specified above, or with an alkali metal phosphate and citrate combination, or with a citrate and calcium chloride combination.

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The proportions by weight of the various chemicals as compared to the dry rice to be treated, usable in a rice-treating solution in which rice may be heated or which can be sprayed on rice to be heated, or which can be mixed with the rice, are as follows:

>;tb;Chemical Range Preferred

>;tb;______________________________________

>;tb;Alkali metal phosphate

>;tb; .001%-7% 0.3% to 1.5%

>;tb;Citrate .001%-7% 0.2% to 1.5%

>;tb;Calcium chloride

>;tb; .001%-7% 0.3% to 1.5%

>;tb;Fatty acid glyceride

>;tb; .05%-9% 0.5% to 1%

>;tb;Silicones .001%-5% 0.3% to 1.5%

>;tb;Calcium phosphate

>;tb; .001%-5% 0.1% to 0.8%

>;tb;______________________________________

Heat treatment is required for reaction between the chemicals and the rice to produce quick-cooking rice. The rice can be heated in an abundance of water containing the desired chemicals in solution for a period of 3 minutes to 60 minutes, depending upon the chemicals used and the concentration of the solution of the various chemicals. The treatment time should be increased if the rice is placed in cold water which must be brought to a boil. The processing time can be shortened by increasing the temperature of the water in the range of 212 DEG F. up to as much as 280 DEG F. by maintaining the heat-treating vessel under pressure.

An alternative type of heat treatment can be effected by subjecting the rice to steam. In such process ample chemical solution of the type described above is sprayed onto or mixed with the rice intermittently during the steaming process. The rice is then subjected to live steam at a temperature of

212 DEG F. to 280 DEG F. for a period of 5 minutes to 45 minutes. Again the time of heat treatment is dependent upon the amount of chemical solution used, the temperature of the steam, the concentration of the chemical solution, the duration of presoaking and the type of rice. A longer treatment time is required where the steam is at a lower temperature and/or the solutions are less concentrated.

A third type of treatment is torrefaction. For such treatment the rice is sprayed or mixed with a chemical solution of the type described above in the amount of 5 pounds to 50 pounds of solution per

100 pounds of rice or mixed with an equivalent amount of dry chemical powder. Such heating may be accomplished in an autoclave within a temperature range of 212 DEG F. to 285 DEGF. and under a pressure of 1 pound per square inch to 40 pounds per square inch.

Following the heat treatment the rice is rinsed to remove excess chemical solution and exudates and to eliminate clumping. The rinsing may be effected in calcium chloride brine for this purpose. The rice is then dried, such as by a steady current of warm air not exceeding about 160 DEG F. or by intermittent blasts of hotter air. The resulting product will be ready to be packaged for sale as quick-cooking rice.

The grains of such product will be unmutilated and strong. The rice will be approximately as white as the rice was before being subjected to the treatment, and the grains will be of generally the same size as the grains of the initial rice.

While the general type of rice treatment to produce quick-cooking rice has been described above, the following representative specific examples of such treatment have been found to be satisfactory.

EXAMPLE 1

>;tb;______________________________________

>;tb;Initial rinsing optional.

>;tb;Treating chemical aqueous solution:

>;tb;Monosodium phosphate

>;tb; 0.75% by weight of

>;tb; the dry rice.

>;tb;Calcium citrate 0.5 % by weight of

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>;tb; the dry rice.

>;tb;______________________________________

Cook the rice in ample chemical solution under atmospheric or higher pressure at a temperature of 185

DEGF. to 280 DEGF. until the rice has been substantially completely cooked. Time required 1 minute to 50 minutes. At boiling the usual time required is about 17 minutes.

Rinse the rice in water to remove chemical residue and separate the grains.

Air dry the rice to a moisture content of 13% to 17%.

The quick-cooking rice product can be cooked finally to a palatable state by boiling in water at atmospheric pressure for a period of 4 minutes to 8 minutes.

EXAMPLE 2

Same as Example 1 except that either during the step of boiling the rice in chemical solution or in the rinsing step after boiling calcium phosphate is provided to increase the ability of the rice to absorb water. If the calcium phosphate is provided in the rinse water, it should contain calcium phosphate in the proportion of a 0.001% to 0.5% by weight of the dry rice.

EXAMPLE 3

Same as Example 1 or Example 2, except that the chemical solution contains sodium citrate instead of calcium citrate in the proportion of 0.6% by weight of the dry rice.

EXAMPLE 4

Same as Example 1, Example 2 or Example 3, except that the chemical solution contains disodium phosphate instead of monosodium phosphate, in the proportion of 0.8% by weight of the dry rice.

EXAMPLE 5

Same as Example 1, Example 2, Example 3 or Example 4, except that after the cooking of the rice has been completed glyceryl monostearate or silicone is added to the solution in the proportion of 0.5% by weight of the dry rice to coat the rice grains to deter their adhesion to each other.

EXAMPLE 6

Rinse in water (80 DEGF. to 85 DEGF.) for 3 minutes to 5 minutes.

Treating chemical aqueous solution:

Calcium chloride 0.75% by weight of the dry rice.

Sodium citrate 0.5% by weight of the dry rice.

Boil the rice in the chemical solution under pressure at a temperature of 245 DEGF. to 250 DEGF. for a period of 10 minutes to 20 minutes.

Air dry the heat-treated rice to a moisture content of 13% to 17%.

The resulting quick-cooking rice product can be cooked finally to a palatable state by boiling in water at atmospheric pressure for a period of 5 minutes to 8 minutes.

EXAMPLE 7

Same as Example 6, except that the rice is boiled in the chemical solution at a temperature of 250

DEGF. for a period of 20 minutes to 40 minutes.


EXAMPLE 8

Same as Example 6, except that, following boiling of the rice in the chemical solution at a temperature of 245 DEGF. to 250 DEGF. for a period of 15 minutes to 20 minutes, the rice is further boiled in water at atmospheric pressure at a temperature of 212 DEGF. for a period of 3 minutes to 7 minutes.

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EXAMPLE 9

Rinse for 3 minutes to 5 minutes in water at a temperature of 80 DEGF. to 85 DEGF.

Treating chemical aqueous solution:

Monosodium phosphate 0.75% by weight of the dry rice.

Boil the rice in the chemical solution under pressure at a temperature of 250 DEGF. for 30 minutes.

Boil in water at atmospheric pressure at a temperature of 212 DEGF. for a period of 3 minutes to 12 minutes until the grains have been approximately 75% cooked.

Air dry the heat-treated rice to a moisture content of 13% to 17%.


EXAMPLE 10

>;tb;______________________________________

>;tb;Initial rinsing optional.

>;tb;Treating chemical aqueous solution:

>;tb;Disodium phosphate

>;tb; 0.75% by weight of the

>;tb; dry rice.

>;tb;Glyceryl monostearate

>;tb; 0.5 % by weight of the

>;tb; dry rice.

>;tb;______________________________________

Spray from 15 pounds to 75 pounds of the chemical solution onto the rice for each 100 pounds of rice and project live steam onto the rice on a continuous belt for a period of 3 minutes to 5 minutes at a temperature of approximately 212 DEGF.

Rinse in warm water.

Spray onto the rice 15 pounds to 30 pounds of the chemical solution for each 100 pounds of rice and steam the rice at a temperature of approximately 212 DEGF. for a period of 3 minutes to 5 minutes.

Rinse as above.

Spray onto the rice from 15 pounds to 30 pounds of water per 100 pounds of rice and steam the rice at a temperature of approximately 212 DEGF. for a period of 3 minutes to 5 minutes.

Rinse in water at a temperature of 35 DEGF to 50 DEG F.

Air dry to a moisture content of 13% to 17% moisture.


EXAMPLE 11

Initial rinsing optional.

Treating chemical aqueous solution or dry chemical: Disodium phosphate 0.75% by weight of the dry rice.

Permeate the rice with the chemical solution until thoroughly surface-coated, or mix with dry chemical and spray lightly with water.

Roast in pressure cooker at a temperature of 165 DEGF to a temperature of 285 DEGF., preferably at an average temperature of 240 DEG F. to 250 DEG F., for a period of 50 minutes to 70 minutes.

Spray or rinse in warm water.

Dry to a moisture content of 13% to 17% by weight.

The resulting quick-cooking rice product can be cooked finally to a palatable state by boiling in water at atmospheric pressure of a period of 3 minutes to 8 minutes.

The various processes described are generally suitable for long grain rice, short grain rice, pearl rice or brown rice, except that steam cooking is not preferred for treating short grain rice or pearl rice. In the

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examples given above the amount of chemicals specified and the times of treatment apply to the processing of long grain rice. For processing natural or brown rice the concentration of the various chemicals should be approximately twice as great as used for long grain rice and the cooking times should be extended to approximately three times as long. For treating short grain rice or pearl rice the proportion of chemicals used in the treating liquid can be approximately the same as for treating long grain rice, except taht approximately twice as much alkali metal phosphate should be used as for treating long grain rice and the treating time should be approximately two-thirds as great as for treating long grain rice.

Generally it is immaterial to what extent the original rice expands during preparation of the quickcooking rice or how much of the expansion is retained following the drying step. The important consideration is that the rice protein and/or starch components be modified by the chemical and heating treatment so that during the final cooking operation the rice will imbibe water quickly and be expanded fully to yield a product having an appearance, odor, texture and taste substantially comparable to conventionally milled rice which has been cooked competently.

Since quick-cooking rice prepared in accordance with the processes described above can be cooked finally by the consumer by being heated in water for a period of 2 minutes to 8 minutes, depending upon the particular process used, such rice can be coated with any of a variety of coatings prior to being marketed to make special rice dishes. Such coatings may, for example, be used to produce rice with cheese sauce, Spanish rice, curried rice, Italian rice, Chinese rice, rice pudding or rice with buttertype sauce.

Such coatings may have the following ingredients in the proportions given by weight:

>;tb;Ingredients Range Preferred

>;tb;______________________________________

>;tb;Fatty acid glyceride

>;tb; base 1% to 25% 10%

>;tb;Powdered whey 1% to 15% 5% to 10%

>;tb;Characterizing

>;tb; ingredients 60% to 95% 60% to 80%

>;tb;______________________________________

Preservatives can be added as needed. The type of characterizing ingredients will depend upon the type of coating desired.

In preparing the coating, which may be any of those previously listed above, the fat base, i.e. the fatty acid glyceride, which is solid at ordinary temperatures, is heated until it is melted. In some instances the rice is mixed into the melted fatty acid glyceride until it has been coated with the fat base. The other ingredients of the sauce are then mixed together in powdered form and the rice is stirred with the powder which adheres to the rice grains coated with the melted fatty acid glyceride. In other instances the dry ingredients of the coating can be mixed with the melted fatty acid glyceride and the uncoated dry rice is then stirred into and mixed with the total coating preparation. The coated rice grains are then cooled quickly to room temperature so that the fat in the coating becomes solid again. The proportion of coating preparation to rice may be within the range of 1 pound to 10 pounds of coating per 100 pounds of dry rice.

For cheese coating the characterizing ingredients can be powdered cheese, powdered milk and cooking fat. These ingredients can, for example, be provided in equal proportions by weight, such as each of the characterizing ingredients being 25% by weight of the coating mixture. In this instance the cooking fat is melted with the fatty acid glyceride, and the powdered spices, whey, cheese and milk are mixed into the liquid fat before the rice is mixed with the coating material.

For preparing Spanish rice the characterizing ingredients can include, for example, by weight: tomato powder 50%, comminuted peppers (red and green) 13%, and citric acid powder 2%. In this instance the rice is first mixed into the melted fatty acid glyceride until it has been coated. The dry ingredients of the coating are mixed together and the rice is stirred with the dry mixture which adheres to the rice grains coated with the melted fatty acid glyceride.

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For curried rice the characterizing ingredients may include, for example, by weight: curry powder 20%, onion powder or flakes 15%, parsley flakes 7%, powdered starch 10%, cooking fat 20%, chicken or beef extracts or hydrolized plant proteins 15%. The cooking fat is melted with the fatty acid glyceride, and the other ingredients of the coating are mixed into the liquid fat before the rice is mixed with the coating material.

For Italian rice the characterizing ingredients may include, for example, by weight: powdered Romano or parmesan cheese 15%, tomato powder 45%, caramel 5%, oregano flakes 3%, thyme flakes or powder 2%, sweet basil flakes 3%, garlic powder 1%, onion flakes or powder 5%, citric acid 1%. In this instance the rice is first mixed into the melted fatty acid glyceride until it has been coated. The dry ingredients of the coating are mixed together and the rice is stirred with the dry mixture which adheres to the rice grains coated with the melted fatty acid glyceride.

For Chinese rice the characterizing ingredients may include, for example, by weight: monosodium glutamate powder 2%, onion powder or flakes 7%, cumin powder 6%, beef extract or yeast hydrolysate

22%, powdered mushrooms 16%, garlic powder 2%, citric acid powder 1%, celery salt 5%. The rice is first mixed into the melted fatty acid glyceride until it has been coated. The dry ingredients of the coating are mixed together and the rice is stirred with the dry mixture which adheres to the rice grains coated with the melted fatty acid glyceride.

For rice pudding the characterizing ingredients may be, for example, by weight: powdered custard mix

20%, caramel 16%, spices 4%, raisins 3%, pudding starch powder 30%, vanilla, cinnamon and/or fruit flavoring 3%, powdered milk 4%. The rice is mixed into the melted fatty acid glyceride and liquid ingredients until it has been coated. The dry ingredients of the coating are mixed together and the rice is stirred with the dry mixture which adheres to the rice grains coated with the melted fatty acid glyceride and liquid ingredients.

For the cooked rice to be in a butter-type sauce the following characterizing ingredients can be included, for example, by weight: cooking fat, e.g. butter, 40%, pudding starch powder 15%, powdered milk 15%, diacetyl .05%. The cooking fat is melted with the fatty acid glyceride and the powdered ingredients are mixed into the liquid fat before the rice is mixed with the coating material.

To provide a combination of rice and an alimentary paste product such as macaroni, spaghetti, vermicelli or noodles, the following characterizing ingredients may be used, for example, by weight: chopped or short-length paste product 50% and powdered beef or chicken extracts 10%. The rice is first mixed into the melted fatty acid glyceride until it has been coated. The dry ingredients of the coating are mixed together and the rice is stirred with the dry mixture, the powdered portions of which adhere to the rice grains coated with the melted fatty acid glyceride.

Alternatively, a marketable product is composed of quick-cooking rice alone mixed with a chopped or short-length alimentary paste product without additional ingredients in proportions, by weight, within the range of 20% to 80% of either component. Preferably the rice and paste product should be in approximately equal proportions by weight.

A chili-rice dish can be provided by use of the following characterizing ingredients, for example, by weight: hydrolized plant protein up to 20%, beef extract up to 10%, spun soya protein chunks 30%, dry beans or bean powder 20%, tomato powder up to 20%, onion powder 1%, chili powder 2%. The rice is first mixed into the melted fatty acid glyceride until it has been coated. The dry ingredients of the coating are mixed together, and the rice is stirred with the dry mixture so that the powder adheres to the rice grains coated with the melted fatty acid glyceride.

To make dressing the following characterizing ingredients may be used, for example, by weight: bread crumbs or chunks or both up to 50%, sage powder 2%, celery salt 2%, onion salt 2%, monosodium glutamate 2%, comminuted mushrooms 10%, cooking fat 10%. The cooking fat is melted with the fatty acid glyceride and the powdered dry material is mixed into the liquid fat before the rice is mixed with the coating material. The coating material, bread and rice are then mixed together.

The coated rice products and the mixture of rice with other components described above will all be in dry form and may be packaged in cardboard boxes. No special technique is required for preserving

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their shelf life for reasonable periods of time. In preparing the rice dish it is merely necessary to cook the coated rice or rice combination mixture for the same period of time and in the same manner in hot water as would be required for cooking the rice alone.Data supplied from the esp@cenet database -

Worldwide Claims:


We claim:

1. The method of preparing a quick-cooking rice product consisting essentially in the steps of increasing the water absorptivity of rice by heating rice to a temperature within the range of 185 DEG

F. to 280 DEG F. at a pressure at least as great as atmospheric pressure for a period of 2 minutes to 70 minutes and simultaneously treating such rice with aqueous chemical solution consisting of alkali metal phosphate, excluding trisodium phosphate, said solution containing said alkali metal phosphate in the proportion of 0.001% to 7% by weight of the dry rice to be treated, and thereafter drying the rice.

2. The method defined in claim 1, including rinsing rice in a mildly alkaline solution prior to the application to it of the aqueous chemical solution.

3. The method defined in claim 1, including heating the rice in ample aqueous chemical solution.

4. The method defined in claim 1, including heating the rice and aqueous chemical solution in an atmosphere of live steam.

5. The method defined in claim 1, including heating the rice and aqueous chemical solution by torrefaction.

6. The method defined in claim 1, including rinsing the rice following the heating step to remove aqueous chemical solution residue and to deter clumping.

7. The method defined in claim 1, including rinsing the rice in calcium chloride brine following the heating step to remove aqueous chemical solution residue and to deter clumping.

8. The method defined in claim 1, in which the aqueous chemical solution includes calcium phosphate in the proportion of up to 5% by weight of the dry rice.

9. The method defined in claim 1, in which the aqueous chemical solution contains, in the proportion of

0.001% to 7% by weight of the dry rice to be treated, at least one citrate selected from the group consisting of sodium citrate, calcium citrate and magnesium citrate.

10. The method defined in claim 9, in which the citrate is sodium citrate.

11. The method defined in claim 9, in which the citrate is calcium citrate.

12. The method defined in claim 9, in which the citrate is magnesium citrate.

13. The method of preparing a quick-cooking rice product consisting essentially in the steps of increasing the water absorptivity of rice by heating rice to a temperature within the range of 185 DEG to 280 DEG F. at a pressure at least as great as atmospheric pressure for a period of 2 minutes to 70 minutes and simultaneously treating such rice with aqueous solution of calcium chloride in the proportion of 0.001% to 7% by weight of the dry rice to be treated and, in the proportion of .001% to

7% by weight of the dry rice to be treated, of at least one citrate selected from the group consisting of sodium citrate, calcium citrate and magnesium citrate, and thereafter drying the rice.

14. The method of preparing quick-cooking rice which comprises heating rice to a temperature within the range of 185 DEG F. to 280 DEG F. for a period of 2 minutes to 70 minutes while being treated with aqueous chemical solution containing, a. in the proportion of 0.001% to 7% by weight of the dry rice, at least one citrate selected from the group consisting of sodium citrate, calcium citrate and

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magnesium citrate, and, b. in the proportion of 0.001% to 7% by weight of the dry rice, calcium chloride or alkali metal phosphate, excluding trisodium phosphate, and thereafter drying the rice.

15. The method defined in claim 13, in which the citrate is sodium citrate.

16. The method defined in claim 13, in which the citrate is calcium citrate.

17. The method defined in claim 13, in which the citrate is magnesium citrate.

18. A method for producing a cooked rice product which comprises applying to the dried rice grains resulting from the process defined in claim 1 a fat base coating which is solid at ordinary temperatures, and cooking the coated rice in the presence of moisture until the rice and coating material are cooked to a palatable state.

19. A method for producing a cooked rice product which comprises applying to the dried rice grains resulting from the process defined in claim 13 a fat base coating which is solid at ordinary temperatures, and cooking the coated rice in the presence of moisture until the rice and coating material are cooked to a palatable state.Data supplied from the esp@cenet database - Worldwide

1424/2197

329.

US3922370 - 11/25/1975

FOOD PRODUCT AND PROCESS FOR PREPARING SAME


Inventor(s): PRAKASH VINOD (--)



IP Class: A23L1/18

E Class: A23L1/164E


Priority Number: CH19710005639 (19710419); US19740495416 (19740807); US19720244289

(19720414)

Family: US3922370

Abstract:


A crisp snack product, in the form of pieces puffed by deep-frying, comprising 25 to 40% by weight of fat, 50 to 75% by weight of gelatinised rice flour and 0 to 10% of flavourings and/or colouring and having a density between 50 and 90 g/liter. A process for preparing the product is also disclosed.

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330.

US4031250 - 6/21/1977

METHOD FOR IMPARTING RED COLOR TO ANIMAL FOOD


Inventor(s): HAAS GERHARD JULIUS (--); HERMAN EDWIN BERNARD (--); LUGAY

JOAQUIN CASTRO (--)


IP Class 4 Digits: A21D; A23K

IP Class: A23K1/18; A21D2/00

E Class: A23K1/16C; A23K1/18N; A23L1/275D; C09B61/00



Family: US4031250

Abstract:


An animal or pet food is prepared wherein a red, meaty color is imparted thereto by incorporation of an effective amount of the pigments produced by growth of Monascus purpureus on rice or corn.Description:



This invention relates to animal or pet foods and more particularly to the coloring of such foods to obtain a meaty, red color.

Animal or pet foods, whether they be of the dry; shelfstable intermediate-moisture; or canned variety are typically formulated so as to give the appearance of real meat in both color and texture. To achieve a meaty red color resort has been had to artificial coloring materials such as FDC Red No. 2 or more recently FDC Red No. 40 or Red No. 3. Consumer skepticism regarding such materials has led us to investigate other sources of raw meaty colors.

It is known in the prior art that rice acted upon by the mold Monascus purpureus becomes stained red by the mold. See, e.g., Hesseltine, A Millennium of Fungi, Food, and Fermentation, Mycologia, Vol.

LVII, No. 2, 179-81 (1965); Lin, Isolation and Cultural Conditions of Monascus Sp. for the Production of Pigment in a Submerged Culture, J. Ferment. Technol., Vol 51, No. 6, 407-414 (1973). See also,

U.S. Pat. No. 3,765,906. The thus stained rice has been used in the Orient for preparation of red rice wine. The use of a corn medium has also been tried. Palo, et al., A study on Ang-kak and its

Production, Philippine J. Sci. 89: 1-22 (1961).


We have found that the pigments produced by the growth of Monascus purpureus on a material selected from the group consisting of rice, corn and mixtures thereof when added to an animal or pet food results in a surprisingly good raw meaty red color being imparted to the animal food. The use of such pigments is especially beneficial in a preferred embodiment wherein the treated rice or corn is

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finely-subdivided and used "as is" as the coloring material. The corn or rice thereby serves as a nutrient for the animal as well as a colorant.

In an alternate embodiment of the invention, the pigments produced are extracted from the corn or rice with a suitable organic solvent. Where the solvent is one having utility in pet foods such as propylene or butylene glycol or glycerol, this embodiment is especially unique in that the pigments can be added with the solvent to the animal food without the need for separation thereof.


The primary object of this invention, namely, to impart a red meaty color to pet food through the use of natural coloring components is achieved in the following manner.

The basic starting material in the attainment of the natural coloring is a culture of the mold Monascus purpureus obtainable, for example, from the Western Regional Research Laboratories of the United

States Department of Agriculture at Peoria, Ill. As obtained, the culture is typically carried on

Sabourands agar slants. Potato dextrose agar is another suitable medium.

The mold is then used to inoculate either rice or corn. Preferably, the rice or corn is heated in a pretreatment step to temperatures sufficient to inactivate or kill microorganisms possibly present.

Preferred in this respect is a simple autoclave process with temperatures typically in excess of 100

DEG C, generally 121 DEG C at 15 psi pressure for about 15 minutes. The amount of mold needed to stain a given batch of rice or corn a deep red color is not per se critical and is easily determinable by skilled art workers. Typically, a suspension of the mold in a liquid medium, for example water or isotonic saline, is first formed and then a suitable amount thereof is used to inoculate the rice or corn.

By way of example, slants on which the organism has been grown are washed with about 9-10 mls. of water insuring that an adequate amount of mold material is brought into a visually turbid suspension.

This suspension is added to a 50 gram batch of rice. As with other microorganisms, a preferred commercial embodiment utilizes the so treated rice or corn to inoculate further batches of such material.

A critical parameter in the inoculation process is the moisture present in the rice or corn/mold mixture.

The preferred condition is to have water present in an amount sufficient to keep the rice or corn moist to the eye but not such that free excess water is apparent. Excess water has the effect of facilitating the growth of other molds and even bacteria, a particularly undesirable result. Utilization of less moisture than above-described is not detrimental to the growth except to prolong the time needed to fully stain the rice or corn or to inhibit the growth altogether. The presence of at least some moisture is, however, necessary.

Depending upon the amount of moisture, mold and the inoculation conditions, the thorough staining may take anywhere from a few days to 3 weeks. The conditions of temperature are not per se believed to be critical except insofar as affecting the rate of growth. The temperature should not be so excessive as to substantially inhibit growth of the microorganism or so high as to completely kill it. Preferred temperatures are in the ambient range, typically 20 DEG to 25 DEG C. The outer extremes for temperature conditions are believed well within the skill of the art.

The moisture requirement will typically require the intermittent addition of water to the rice or corn/mold mixture. In the initial stages of inoculation, heat-producing fermentation will be very active resulting in evaporation of the water. Hence, care must be taken at these early stages to retain moisture in the mix. As fermentation slows in the latter stages of inoculation, the moisture loss becomes less significant.

When the rice or corn has been suitably stained, it is heated to temperatures sufficient to kill the mold such temperatures typically in excess of about 100 DEG C, more typically above 120 DEG C. Again, an autoclave procedure is particularly suitable for this process.

The process from this point may take two different routes. In one especially suitable embodiment, the thus colored corn or rice is used as is to impart color to a pet or animal food. Thus an added advantage

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herein is that the coloring material makes a nutritional contribution to the food. In order to be compatible with the various food systems and to achieve as wide a dispersement of coloring material, the rice or corn is finely-divided prior to incorporation into the food. Any method of sub-division such as crushing, grinding, flaking may be used. A preferred particle size is smaller than about 40 microns typically achieved by pulverizing the rice or corn in a mill having a 40 micron screen. The amount of this finely-divided material is not critical and rather depends only upon the degree of color needed or desired. A typical amount for a meat-containing animal food is about 1-5% by weight. Larger amounts may be necessary where the animal food contains little or no meat as described hereinafter.

In an alternate embodiment, the red pigments of the rice or corn are extracted therefrom with a suitable solvent, preferably an organic solvent such as ethanol, propylene glycol, butylene glycol and the like. It is preferred though not essential to sub-divide the corn or rice as described above prior to extraction.

The resultant solution of pigments may then be exaporated to dryness for use in the particular food formulation. Alternatively, where such solvents as propylene or butylene glycol are used, the pigment solution may be added with said materials, a particularly preferred embodiment where the glycols or other extracting material will comprise a portion of the final food product.

The present invention is applicable to the coloring of any animal food be it dry, soft-moist, or canned.

Such foods are extremely well-known in the art as exemplified by the following patents:

Dry:

U.s. pat. No. 3,119,691 to Ludington et al.

U.s. pat. No. 3,365,297 to Burgess et al.

British Pat. No. 1,312,910 to Baker et al. Complete Specification published Apr. 11, 1973

Intermediate-Moisture:

U.s. pat. No. 3,202,514 to Burgess et al.

U.s. pat. No. 3,380,832 to Bone

British Pat. No. 1,290,811. Complete Specification published Sept. 27, 1972.

U.s. pat. No. 3,653,908 to Buck et al.

Canned:

U.s. pat. No. 3,574,633 to Flier

The dry foods will typically have a moisture content below about 12% by weight, soft-moist or intermediate-moisture feeds between about 15 to 60% water; canned typically above 60 to 75% water.

Various categories such as "semi-dry" or "soft-dry" have been used to describe products in the 10 to

25% moisture range.

The above-recited patents typically involve the use of meat, meat by-products or meat meal as a source component. However, the present invention is also applicable to and indeed is particularly applicable to products containing no meat since the coloring requirements are more pronounced in such foods.

Typical of such products are totally grain-based products or products prepared from textured vegetable protein such as described in U.S. Pat. Nos. 3,488,770 to Atkinson; 3,496,858 to Jenkins.

The particular point at which the coloring material of this invention is incorporated with the animal food is not critical nor is the particular type food itself. Typically, the coloring material will be added as a source ingredient to the food mixture which may then be further processed such as by extrusion/cooking, forming, and the like. Where textured vegetable protein prepared by extrusion/expansion is used as a component of the foodstuff, it may be more desirable to add the coloring after extrusion, e.g. by infusion of a pigment solution or coating with the pigments. Dry foods prepared from farinaceous and proteinaceous materials are particularly suitable for use of the stained corn or rice "as is" where a meaty color is desired as well as soft-moist or canned products desirably containing a farinaceous ingredient.

A particularly preferred embodiment of this invention involves those foods where an organic solvent such a glycerol, other polyhydric alcohols, propylene or butylene glycol is employed as an ingredient thereof. In dry or semi-dry foods these solvents are particularly useful as texturizing humectants to obtain a moist/dry appearance and texture as well as to impart shelf-stability or microbiostasis to such

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products. Intermediate-moisture products make especial use of such materials as microbiostatic agents designed to lower the Aw of such products (a measure of water availability for growth of microorganisms) to impart or aid shelf-stability. Use is typically in the 1 to 20% by weight range.

Canned products may employ such ingredients to retain a moist texture and appearance. Textured protein products make use of such materials to impart plasticity to the protein mix and to aid or confer resistance to microbial contamination.

Where such products are to be colored, the stained rice or corn can be extracted with such solvents to remove the pigments therefrom and the pigment/solvent solution with or without dilution if needed is added as is to the particular formulation. Solvents not desirably present in the formula or not compatible with such formulas require evaporation prior to incorporation of the pigments to a food.

The following example illustrates the best mode of practicing this invention.

A culture of Monascus purpureus (Culture No. NRRL-2897) was obtained from the USDA Lab earlier mentioned. The culture was carried on Sabourauds agar slants (Difco). Nine mls. of water was used to wash the slant and the suspension was used to inoculate 50 grams of autoclaved (121 DEG C) rice at room temperature (about 23 DEG C). The rice was stained a deep red after about 16 days. This batch of rice was used to inoculate 500 grams of rice at room temperature, 300 mls. of water being added thereto. Water was added intermittently to keep the rice moist to the eye, yet avoiding excess water.

After about 2 weeks the red rice was autoclaved (15 psig/121 DEG C) and dried at about 100 DEG C.

The rice was pulverized in a mill with a 40 micron screen.

To an uncolored intermediate-moisture animal food made substantially in accordance with Example X of U.S. Pat. No. 3,202,514 to Burgess et al., was added about 3% by weight of the ground powders to color the product a meaty red color of approximately the same color and intensity as a control sample colored using FDC colors.

In another example, 20 grams of the pulverized rice was extracted in a Soxhlet laboratory extraction apparatus using ethanol as the solvent. When evaporated to dryness, 3 grams of pigment were obtained having about 10% the color intensity of FDC Red No. 3.

It will be appreciated that the various examples, conditions and the like are intended for illustrative purposes and that obvious variations and modifications may be made without departing from the scope and spirit of the invention as defined in the appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


Having thus described our invention, what is claimed is:

1. A method for imparting a meaty red color to an animal food comprising culturing Monascus

Purpureus on a material selected from the group consisting of rice, corn, and mixtures thereof to obtain red pigments thereon, subdividing said material containing said pigment to a finely-divided form, and adding said finely-divided material to an animal food in an amount effective to impart a red color to said food.

2. The method of claim 1 wherein the particle size of said finely-divided material is about 40 microns or less.

3. The method of claim 2 wherein said animal food is an intermediate-moisture, shelf-stable animal food.

4. The method of claim 2 wherein said animal food has a moisture content below about 12% by weight.

5. The method of claim 2 wherein said material is added to said food in an amount between about 1 to

5% by weight.

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6. A method of imparting a meaty red color to intermediate-moisture animal foods comprising culturing Monascus Purpureus, a material selected from the group consisting of rice, corn and mixtures thereof to obtain red pigments thereon, extracting said pigments with an organic solvent selected from the group consisting of glycerol, proplyene glycol and butylene glycol, and adding said pigments with said organic solvent to an animal food in an amount sufficient to impart a red color to said food.

7. The method of claim 6 wherein the amount of said solvent added with said pigments is between about 1 to 20% by weight of said food.

8. The method of claim 7 wherein said solvent is propylene glycol.

9. A red meaty colored animal food comprised of edible nutritionally balanced ingredients selected from the group consisting of farinaceous material, proteinaceous material, and mixtures thereof, said farinaceous material comprising a finely-divided coloring material selected from the group consisting of rice, corn and mixtures thereof, which has been cultured with Monascus purpureus to impart a deep red coloration thereto, said finely-divided coloring material being present in an amount effective to impart a meaty red color to said animal food.Data supplied from the esp@cenet database - Worldwide

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331.

US4073958 - 2/14/1978

RICE FLAVORED SNACK FOOD


Inventor(s): ABE SHUNJI (--)

Applicant(s): ABE SHUNJI (--)


IP Class: A21D10/00

E Class: A23L1/164E; A23L1/164



Family: US4073958

Abstract:


A novel snack food product can be obtained by preparing a corn dough cake by kneading finely divided corn materials with water, if desired with the addition of rice bran materials derived from Japanese rice wine production and/or defatted soybeans, followed by shaping, drying, baking and seasoning.Description:


This invention relates to a novel snack food having rice crackers flavor achieved by incorporating rice bran materials and/or defatted soybeans into finely divided corn materials and the process therefor.

More particularly, the invention relates to a novel snack food essentially consisting of corn materials that are inexpensive and provide a controlled superior swelling quality and the process therefor.

As is well known, rice crackers have unique flavour due to the contents of amino acids based on lysine hydrochloride, arginine hydrochloride, alanine, etc., and insufficient content of the above amino acids causes deterioration of the product flavour.

Accordingly, in prior art, the starch materials other than rice materials can be used for the production of rice crackers only with the addition of amino acid preparations. Many additives for this purpose are available commercially. However, it is known that the conventional amino acid preparations are only effective for up to 40% content of such substitution materials as corn materials, and thus, substantial replacement by other substitution materials than rice can not be expected by means of such conventional amino acid additives.

Accordingly, the main object of the present invention is to provide a novel process for producing a rice-flavoured product from the starch substitution materials other than rice and to provide a novel snack food obtained therefrom.

Recently, the inventor of the present invention has found that a novel product can be obtained by preparing a corn dough cake by kneading finely divided corn materials with steam, followed by shaping, drying, baking and seasoning, without any addition of rice materials. However, the products obtained have some unpleasant and strange smells that must be overcome for successful marketing.

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The inventor has also found that rice bran materials derived from the Japanese rice wine production can be used to impart rice flavour to the corn dough cake quite conveniently and satisfactorily. The products obtained by mixing it with such corn materials as finely divided waxy corn (corn grits) or waxy starch have proved to have satisfactory rice flavour and desirable soft texture.

The rice bran materials obtained from Japanese rice wine production is generally contain a larger amount of proteins, fats, vitamins, etc. than that of the polished grain rices and generally are white to red colored depending on the degrees of refined rice wines.

In the course of Japanese rice wine production, surface portions of rice grains should be removed by polishing, the amount depending on the desired level of rice wine refining. The amount to be polished usually reaches up to approximately 60% of original weight of the rice grains. This amount is much more than that of grained rice polishing used in conventional rice industries.

Thus, the rice bran materials obtained from Japanese rice wine production are usually white colored and have slightly more odor due to the higher content of crude protein, crude fat, ash, etc. than those of inner portions of polished rice grains. Because of their unpleasant smells and their swell-disturbing characteristics, they could not be used in the conventional rice cracker industries in the prior art and sold as industrial waste very cheaply.

In the following tables, compositions of corn grits and waxy corn starch, and white rice bran materials and polished rice grains are shown for comparison.

>;tb; Table 1.

>;tb;__________________________________________________________________________

>;tb; Deodorized Waxy corn

>;tb;Material grits Grits starch

>;tb;__________________________________________________________________________

>;tb;Composition, Property

>;tb; Water % 9.3 12.4 13.5

>;tb;Amylography

>;tb; Gelatinizing DEG C

>;tb; 61.0 65.5 67.0

>;tb; temperature

>;tb; Max. viscosity Bu

>;tb; 460 180 900

>;tb; Min. viscosity Bu

>;tb; 73 180 250

>;tb; Final viscosity Bu

>;tb; 200 290 500

>;tb; pH 3.90 5.03 4.5

>;tb;Color Blue filter 85.0

>;tb; 83.2 76.5 90

>;tb; Green filter 85.5

>;tb; 90.5 86.0 --

>;tb; Ash % 0.25 0.36 0.04

>;tb; Crude protein %

>;tb; 9.0 9.0 0.35

>;tb; Reducing sugar %

>;tb; 2.51 2.26 0

>;tb;__________________________________________________________________________

>;tb; Note: Sampled grits are subjected to soak in water at 60 DEG C for 3

>;tb; hours, ground by an atomizer (made by Fuji Electric Co.), and then dried

>;tb; at 50 DEG C for 24 hours.

>;tb; Table 2.

>;tb;______________________________________

>;tb; Water Fat Nitrogen

>;tb; Crude

>;tb;Composition

>;tb; (%) (mg/100g) (mg/g) protein (%)

1432/2197

>;tb;______________________________________

>;tb;Material

>;tb;White rice bran

>;tb; 12 1.0-3.1 22 13.2

>;tb;Polished 14 0.77 13 7.7

>;tb;rice grains

>;tb;______________________________________

As can be clearly understood from the tables, polished rice grains may be substituted by white rice bran materials in view of the compositions.

Further, the inventor has found that defatted soybean powders can be used for eliminating unpleasant smells and imparting much higher protein content to the corn dough cake together with white rice bran materials. The addition of defatted soybean powders also serves to omit the evacuation step during steam kneading, and gives the product more nutrition than conventional rice crackers.

The present invention is thus based on the facts above described, and it relates to a process for obtaining rice-flavoured novel snack food from finely powdered corn materials which comprises mixing finely divided corn materials with finely powdered white rice bran materials or powdered rice grains and kneading them with steam under evacuation. It relates further to a process for eliminating the vapor evacuating step by the addition of defatted soybean or defatted peanut and to the products therefrom.

The white rice bran materials obtained from Japanese rice wine production usually range from 100 to

300 mesh particle size. According to the process of the present invention, particle size of rice bran materials should be in a range miscible with other starch materials. Homogeneous mixing of the raw materials, which is usually include at least two types of powders, is particularly important for the present invention. When homogeneous mixing is not attained, homogeneous water distribution in a dough cake texture can not be expected, thus causing differences in drying speeds in the dough texture and disturbing homogeneous swelling of the dough cake, resulting in deteriorated products with cracks or irregular swelling.

After homogeneous mixing of the raw materials, the mixture is subjected to steam kneading through a kneader for about 10 minutes at a pressure from 0.3 - 0.7 kg and then shaped and baked into the product. The product may be seasoned, such as with soysauce.

An important thing to be noted according to the process of the present invention is the swelling characteristics, that is the essential matter of the process according to the present invention. Swelling characteristics depend on the hardness of the surface films formed on the dough cake during drying.

Thus, the hardness can be determined by means of amylography. Swelling level, therefore, depends mainly on the characteristics of the additives in the corn materials.

Accordingly, from the view point of swelling level regulation, special care should be paid to the selection and the characteristics of the additives. It is obvious that incorporation of rice bran materials into corn dough cake influences the swelling characteristics of the product obtained.

From the view point of flavour, it is important to increase the amount of rice bran materials to be added. On the other hand, from the view point of the swelling characteristics and the protein content, up to 30% of rice bran materials may be added to corn materials.

It is also noted that higher drying temperature not only accelerates much film formation on the surface, but also causes amino acid consumption due to the reactions between saccharides, thereby giving a flavour-deteriorated product.

The embodiments of the invention will be clarified in greater detail by the following examples.

EXAMPLE 1

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80 kg of a mixture of waxy corn starch containing 100% of amylopectin and white rice bran materials of 300 mesh particle size (mixing ratio 60 : 40) was put into a steam kneader. After mixing it with 50 l of water for 1 minute, the mixture was kneaded with steam for 10 minutes under the a steam pressure of 0.4 kg/cm@2 while stirring at 47 r.p.m., thereby producing a dough cake. When 80% of kneading time had passed, the cover of the steam kneader was taken off and steam was discharged therefrom.

The dough cake thus produced was further passed through the kneader to make a homogeneous dough cake.

The dough cake was extruded by an extruder into a stick of 2 cm in diameter, and taken out on a plate spread with flour, and then immediately put into a refrigerator at 5 DEG C. After about 4 hours the temperature of the dough cake fell to about 5 DEG C and the cake was left in the refrigerator for 18 hours to be cooled and solidified. The solidified cake was cut into desired pieces of 1.7 mm in thickness and dried for 2 hours at 45 DEG - 50 DEG C in a ventilating drier until the water content was reduced to 30 - 32%. The dried cake was allowed to stand for 20 hours at a room temperature to adjust the water-content uniformly (aging). After aging the cake was baked at 150 DEG C for 3 minutes, at

160 DEG C for 3 minutes and at 180 DEG C for 2 minutes in a baking oven at 94 r.p.m.. The baked cake was seasoned with desired relish and dried to obtain a product.

EXAMPLE 2

80 kg of a mixture of waxy corn starch and white rice bran materials of 300 mesh particle size (mixing ratio 60 : 40) was put into a steam kneader and 48 l of water was added thereto. After mixing for 1 minute the mixture was kneaded with steam for 10 minutes under a steam pressure of 0.4 kg/cm@2 while stirring at 47 r.p.m. to produce a dough cake. When 80% of kneading time had passed, unpleasant smells of waxy corn starch and white rice bran materials were removed with steam.

The dough cake thus produced was extruded by an extruder and soaked in cold water to be cooled to about 45 DEG C. The cooled dough cake was further extruded by the extruder to prepare a homogeneous dough cake. The homogeneous dough cake was rolled by a rolling machine to a sheet of

2.5 mm in thickness and shaped into desired pieces. The shaped dough cake was immediately dried at

40 DEG C for 2.7 hours by a ventilating drier, thereby adjusting the water-content of the cake to 20 -

22%. Then it was put into a preheating drier and dried at 50 DEG C for 2 hours and baked at 250 DEG

- 300 DEG C for 2 minutes in a baking oven. The baked cake was seasoned with a desired liquid relish and dried to obtain a product.

EXAMPLE 3

65 kg of a mixture of waxy corn starch (56%), rice bran materials (14%) and defatted soybean (30%) was put into a steam kneader and 35 l of water was added thereto. The mixture was kneaded with steam for 5 minutes under a steam pressure of 0.4 kg/cm@2 under stirring. During kneading .beta.-starch included in the mixture was converted into .alpha.-starch and a homogeneous dough cake was obtained.

The dough cake was extruded by an extruder into a stick of a desired diameter and cooled in a refrigerator at 2 DEG C, thereby lowering the temperature of the cake to 5 DEG C. The cooled cake was cut into desired pieces and dried. The product thus prepared with no relish, was fried in an oil bath for 2 minutes at 180 DEG C and seasoned with desired relish to obtain a fried snack food.

EXAMPLE 4

The product with no relish obtained in Example 3 was baked at 200 DEG C for 3 minutes in a baking oven. The baked product was spread with liquid relish and dried to obtain a crunchy snack food having good smells of soybean.

EXAMPLE 5

Examples 1 - 4 were carried out by using waxy grits (deodorized), soaked in water for 4 - 6 hours and drained, as the main raw material, and the same products as obtained in Examples 1 - 4 were obtained.

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As mentioned above, according to the present invention, rice-flavoured snack food can be obtained by mixing rice bran materials and/or defatted soybean.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for preparing a snack food which comprises: a. homogeneously mixing finely divided corn material selected from the group consisting of waxy corn starch and waxy grits with a sufficent amount of finely divided rice bran having a particle size in the range of 100 to 300 mesh to impart a rice flavor and water, b. kneading the mixture with steam for about 10 minutes at a pressure of 0.3 to 0.7 kg/cm@2 to produce a dough cake, c. further kneading said dough cake in the absence of steam, d. shaping said dough cake, e. cooling said shaped dough cake, f. drying said cooled dough cake for about

2 to 5 hours at about 40 to 50 DEG C, g. swelling said dried dough cake by baking or frying in oil at

150 to 300 DEG C for 2 to 8 minutes, and h. seasoning said swelled dough cake.

2. The process of claim 1, wherein seasoning is effected by means of soy sauce.

3. The process of claim 1, wherein said rice bran is industrial waste derived from Japanese rice wine production.

4. The process of claim 1, wherein said corn materials constitute the major ingredient of said mixture.

5. The process of claim 1, wherein the mixing step produces a mixture consisting essentially of said corn materials, rice bran, and water.

6. A snack food obtained by the process of claim 1.

7. The snack food of claim 6, wherein the finely divided corn material is defatted waxy corn starch or deodorized waxy grits.

8. The snack food of claim 6, wherein the mixture is heated with steam under evacuation during kneading.

9. The snack food of claim 8, wherein said rice bran is industrial waste derived from Japanese rice wine production.

10. The snack food of claim 8, wherein said corn materials constitute the major ingredient of said mixture.

11. The snack food of claim 8, wherein said mixture consists essentially of said corn materials, rice bran, and water.

12. A process for preparing a snack food, which comprises: a. homogeneously mixing finely divided corn material selected from the group consisting of waxy corn starch and waxy grits with a sufficient amount of finely divided rice bran having a particle size in the range of 100 to 300 mesh to impart a rice flavor, finely divided defatted soybean or defatted peanut, and water while kneading with steam for about 5 minutes at a pressure of 0.3 to 0.7 kg/cm@2 to produce a dough cake, b. shaping said dough cake, c. cooling said shaped dough cake, d. drying said cooled dough cake for about 2 to 5 hours at about 40 DEG to 50 DEG C, e. swelling said dried dough cake by baking or frying in oil at 150 DEG to

300 DEG C for 2 to 8 minutes, and f. seasoning said swelled dough cake.

13. The process of claim 12, wherein said rice bran is industrial waste derived from Japanese rice wine production.

14. The process of claim 12, wherein said corn materials constitute the major ingredient of said mixture.

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15. The process of claim 12, wherein said mixture consists essentially of said corn materials, rice bran, defatted soybean or peanut, and water.

16. A snack food obtained by the process of claim 12.

17. The snack food of claim 16, wherein said rice bran is industrial waste derived from Japanese rice wine production.

18. The snack food of claim 16, wherein said corn materials constitute the major ingredient of said mixture.

19. The snack food of claim 16, wherein said mixture consists essentially of said corn materials, rice bran, defatted soybean or peanut, and water.Data supplied from the esp@cenet database - Worldwide

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332.

US4085234 - 4/18/1978

PROCESS FOR MANUFACTURING FAST COOKING RICE


Inventor(s): KAMADA HIDEMOTO (--); MIURA CHIAKI (--); KANO ETSUO (--)

Applicant(s): CALPIS FOOD IND CO LTD (--)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/18F



Family: JP52010438


Abstract:


Fast cooking rice which readily reconstitutes itself into cooked rice is manufactured by a process which comprises forming gel on the surface and to the inside center of rice grains puffed in advance to a high degree and subsequently subjecting the treated puffed rice grains to drying and shrinking treatments.Description:



Cooked rice which is a staple food in the countries of East Asia is so-called "steamed and boiled rice. "

It is cooked by a time-consuming procedure which comprises the steps of first washing raw rice (which means hulled rice in the instant specification and claims) with water, allowing the washed rice to absorb water amply and thereafter steaming and boiling the water-impregnated rice for a long time.

Ample impregnation with water and an appropriate extent of boiling and steaming are required for preparing the cooked rice of soft texture and agreeable teeth-resistance. The requirement for rigid control of these conditions prevents quick cooking. The fact that this cooking consumes much time also constitutes one disadvantage.

Another typical example of cooked rice is pilaf. This is prepared by frying washed rice with oil, whereafter the fried rice is steamed and boiled in the presence of added water. It has the disadvantage that the texture is generally hard. This disadvantage can be overcome by continuing the treatment of steaming and boiling for a relatively long time. Nevertheless, it still has a drawback in that the cooking consumes much time. In view of the above, there is a need for development of fast cooking rice which readily provides cooked rice of the class described above.

What is called "gelatinized rice" has heretofore been regarded as a kind of fast cooking rice. This is usually prepared by subjecting the rice to the ordinary treatment of steaming and boiling for thereby gelatinizing the rice starch and thereafter drying the starch-gelatinized rice. By mere addition of hot water at a temperature of about 80 DEG C or over, however, the fast cooking rice prepared as described above fails to reconstitute itself into cooked rice possessed of the desired texture. It is not

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converted into desirable cooked rice unless it is boiled for several minutes by heating. Such timeconsuming treatment does not befit the fast cooking rice for which instantaneousness counts strongly.

There is Japanese Patent Publication No. 1581/1958 which employs substances similar to those used in the present invention for treating rice grains. But, this publication aims to prepare highly nutritious rice grains by coating raw rice grains with sodium alginate, cow's milk and powdered milk. As this rice grain is quite raw, it requires the ordinary treatment of steaming and boiling for providing a cooked rice. Therefore, this prior art is obviously different from the present invention in the object and the product to be prepared.

A method which produces cooked rice by mere addition of hot water has been disclosed by Japanese

Patent Publication No. 5729/1959. The method disclosed therin comprises first steaming and boiling the raw rice to a extent mild enough to pregelatinize the surface layer of the rice grains, then causing the steamed and boiled rice to absorb a paste such as dextrin or sodium carboxymethyl cellulose, subjecting the treated rice to a treatment for regular steaming and boiling for thereby completely gelatinizing the rice grains to the inside center and finally drying the gelatinized rice. The fast cooking rice which is obtained by this method has the disadvantage that, when hot water is added thereto immediately before its consumption, the required reconstitution takes much time or the reconstituted rice has a rather hard texture, possibly because the rice, in the final treatment of drying, suffers partial retrogradation of the rice starch which has once been gelatinized. Furthermore, the process of manufacture is complicated.

Studies have also been continued with a view to producing fast cooking rice which can be reconstituted into as exact an equivalent of regular boiled and steamed rice as practicable. For example, there is a method which utilizes puffed rice, with due consideration of the fact that gelatinized rice is obtained by puffing rice grains. If simply puffed rice is used as a fast cooking rice, it is quickly softened in the presence of hot water added thereto prior to its consumption. Nevertheless, it has the disadvantage that the hot water deprives the rice grains of their shape and renders them quite different from regular boiled and steamed rice in taste, texture, viscoelasticity, etc. Japanese Patent Publication No.

27700/1971 discloses a method which comprises the steps of first puffing raw rice to a slight extent, then immersing the puffed rice in water for thereby heightening the water content thereof, subsequently gelatinizing the puffed rice of increased water content, thereafter drying the gelatinized rice until the water content thereof decreases to a prescribed level and finally re-puffing the dried rice. The fast cooking rice produced by this method, however, suffers from an undesirable spongy texture and poor teeth-resistance. It has the further disadvantages that the process for manufacture is complicated and the yield is consequently low.

As described above, there have been conceived methods for the manufacture of fast cooking rice which combine the treatment of puffing with other treatments. These conventional methods, however, are complicated from the operational point of view because the water content of rice grains must be rigidly regulated in the course of treatments and consequently because the rigid regulation of water content calls for additional treatments, and so on. Methods which involve use of oil and fat are not desirable because the oil and fat incorporated into the rice grains degrade the taste and induce oxidation of itself to the extent of heavily impairing the quality of fast cooking rice. Also the removal of excess oil and fat in the course of manufacture demands much time and labor.


The primary object of the present invention is to provide a process for the manufacture of fast cooking rice easily, and providing cooked rice which, when served for meals, retains the shape of rice grains unimpaired, and permits the rice grains to remain in their inherent shape which excel in texture, taste, flavor, etc.

Another object of this invention is to provide a fast cooking rice which is so easily reconstituted that it can be ready for a meal after several minutes of standing in hot water of a temperature of not less than about 80 DEG C.

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Still another object of the present invention is to provide a fast cooking rice which is so easily reconstituted that it affords pilaf of a desirable texture after several minutes of cooking such as in a frying pan in the presence of a small amount of water and, by preference, of some oil added thereto.

Yet another object of this invention is to provide a fast cooking rice capable of a wide range of applications such that it readily produces curry-flavored fried rice and many other kinds of cooked rice when cooked in combination with seasoning agents, dry vegetables, dry meat and other foodstuffs.

It is also an object of this invention to provide a simple process for the manufacture of fast cooking rice without entailing complicated steps of treatment from the operational point of view.


This invention has been accomplished on the basis of a study continued with a view to obtaining a fast cooking rice of excellent quality by a process as simple as possible. In brief this invention comprises preparing a rice puffed to a high degree, adding onto the surface and also to the inside center of the puffed rice a thickener to be gelled by metallic ions and said metallic ion, drying and shrinking the treated puffed rice grains. The invention will be described in futher detail below.

The first step is to prepare rice puffed to a high degree. The rice grains to be used in making the puffed rice may be of any of the numerous species available. For the purpose of this invention, the puffed rice grains obtained by any methods other than the method resorting to the treatment in heated oil and fat can be used. For example, the puffed rice obtained by first treating rice grains in a closed container kept at elevated temperatures under increased pressure and releasing the rice grains into the atmosphere for thereby allowing them to puff, those puffed by means of heated air, those puffed by having rice grains heated with high-frequency waves and those puffed by having rice grains roasted in conjunction with heated grains such as of common salt, fine sand, ceramic, or those puffed by some other similar puffing method are all usable for this invention. The degree of puffing is desired to be from 6 to 16 times, preferably from 10 to 12 times, as large in volume (hereinafter the degrees of puffing will be expressed in terms of "volume") as the raw rice grains. The degree of puffing of the figures (6 to 16 ) as used in the instant specification and claims illustrates an average of each rice grain because the size and quality of each rice grain is different. For example, "6 times" includes the degree of puffing of a little bit smaller and also larger than 6 times.

The second step is to immerse the puffed rice in an aqueous solution containing at least one thickener to be gelled by metallic ions or to spray or sprinkle said aqueous solution on the puffed rice. The term

"thickener to be gelled by the metallic ions" as used in the instant specification and also the claims refers to polysaccharides of plant origin, their derivatives, and polysaccharides produced by the fermentation of microorganisms. Concrete examples of the polysaccharides which are gelled by the metallic ions are alginic acid, its salt, carrgeenin, pectin, etc.

The concentration of the aqueous solution of a thickener involving formation of a gel by metallic ions should generally fall in the range of from 0.2 w/w to 3.0 w/w percent (hereinafter indicated invariably in percent by weight/weight). This range is variable to some extent with the particular kinds of thickeners to be used. To attain the effect aimed at in a short time, a concentration below the lower limit 0.2 percent does not suffice. When the concentration exceeds the upper limit 3.0 percent, however, the viscosity of the aqueous solution increases to an extent such that the solution will not permit ready penetration into the puffed rice nor easy handling, the individual rice grains tend to adhere mutually and the final product gives an undesirable taste. The temperature of the aqueous solution and the duration of immersion in this aqueous solution are not specifically limited by the present invention.

The purpose of the immersion is amply attained when the immersion is for a brief period of about 30 seconds at a temperature falling within the range extending from normal rool temperature to 90 DEG

C, for example. Where the addition is effected by spraying or sprinkling, the treated rice, as a matter of course, should be left to stand at rest for a while to ensure uniform and thorough penetration of the aqueous solution into the puffed rice. Consequently, the thickener to be gelled by the metallic ions thoroughly penetrates from the surface to the inside center of the puffed rice having a porous texture.

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The third step is to immerse the above treated puffed rice in an aqueous solution containing metallic ions capable of inducing gelation of the thickener or to spray or sprinkle the aqueous solution on the puffed rice. In the conventional prior art, there are methods for producing a fast cooking rice by immersing the rice grains or spraying on the rice grains using a thickener. But, these are treatments only on the surface of the rice grains. The method of the present invention differs from these methods on this point and is characterized by the ample gelation also in the inside center of the rice grain.

The expression "aqueous solution containing metallic ions" as used in the present invention refers to an aqueous solution containing free metallic ions. Examples of the aqueous solution satisfying this definition include aqueous solutions prepared by addition of metallic salts, solutions prepared by an ion exchange treatment, naturally occurring mineral waters containing metallic ions and natural aqueous solutions which originate in animals and plants. Of the various aqueous solutions described above, the aqueous solutions prepared by addition of metallic salts will be described by way of exemplification.

In the preparation of aqueous solutions containing metallic salts, examples of the metallic salts usable for this purpuse include calcium salts, potassium salts, magnesium salts and other similar metallic salts of carbonic acid, hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid, lactic acid, citric acid, ascorbic acid, glycerophosphoric acid and other similar acids.

In the solution containing metallic ions capable of acting upon the thickener to be gelled by the metallic ions and consequently inducing gelation, the concentration of the metallic ions is only required to be such that the absolute amount of metallic ion present therein is enough to bring about the effect of gelation. Whether the combination of the respective kinds of the aqueous solutions containing the thickener and the metallic ions separately and the combination of their respective concentrations are proper or not for the purpose of this invention can be confirmed by mixing the two aqueous solutions in the absence of puffed rice and examining the resultant mixture to find the presence or absence of the ensuing reaction of gelation. Thus the selection of a proper combination can easily be accomplished.

The contact time between the thickener and the metallic ions has some bearing on the strength of the gel to be consequently formed. For example, a strong gel is formed by allowing an ample contact time, so that the finally produced fast cooking rice provides enhanced teeth resistance when it is reconstituted with hot water and served for a meal. Thus, the degree of resistance to the teeth can be controlled by suitably selecting the length of contact time for gelation. The kinds and concentrations of the aqueous solutions, the temperature, contact time and pH status involved in the treatment can be suitably selected from conditions generally practiced in most treatments for gelation. Further and more specific information thereon is made apparent in several examples to be cited afterward. The object of the present invention is also accomplished by conversely performing the second step and the third step.

The final fourth step is to dry, by an ordinary method, the puffed rice in to which the thickener or the gelled thickener has been incorporated as described above. The drying may be carried out under normal atmospheric pressure or under vacuum, either in the absence or in the presence of heating. During the drying, the individual grains of the puffed rice may be kept stationary or may be moved. The method of drying, therefore, can suitable be selected by taking into due consideration the amount of puffed rice, the desired duration of drying time (reflecting readiness of handling), the desired quality of the fast cooking rice to be produced, etc. Where the drying is effected by application of heat, due attention should be paid to avoiding excessive heating which frequently results in the occurrence of burnt rice emitting an objectionable odor. Concrete examples of driers well known for this purpose include a tunnel and band dryer, a chamber dryer, and an infared dryer, etc.

In consequence of the gradual vaporization of water, the puffed rice diminishes in volume eventually to approach the volume of raw rice while the incorporated gelled thickener is retained throughout from the surface to the inside center of individual rice grains. To obtain a fast cooking rice which gives a desirable texture when served for a meal and yet is not so bulky as to impair the ease of handling, the process of drying is desirably terminated at the time by which the volume of the treated puffed rice has decreased to less than three times the volume of raw rice.

To the aqueous solution of thickener, to the aqueous solution of metallic ions, to the puffed rice which has incorporated a gelled thickener, or to the fast cooking rice which has undergone the treatment of drying, various seasoning agents, nutrition enriching agents, color-improving agents, etc., may be

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suitably added and blended therewith. As a result, there can easily be produced a flavored fast cooking rice.

As described in detail up to this point, this invention comprises the first step of puffing rice grains to a high degree for thereby gelatinizing rice starch, inducing cleavage of rice starch micelle, forming a porous texture in the rice grains and causing a specific thickener in a gelled form to be amply entrapped within the rice grains and the subsequent step of drying the treated puffed rice to the extent of allowing the rice grains to dwindle to a prescribed volume. The fast cooking rice which is manufactured as described above provides high yields of production and high preservability and, upon reconstitution, converts itself into a cooked rice excelling in taste, texture and flavor.

Reconstitution of this fast cooking rice, for example, into ordinarily cooked rice can be obtained by adopting a method which is generally practiced in preparing fast cooking rices of this kind. To be specific, the desired reconstitution into cooked rice can be accomplished by allowing this fast cooking rice to stand for 1 to 2 minutes in hot water heated in advance to about 80 DEG C or over and added in a volume roughly 1 to 1.5 times the volume of rice, then discarding an excess portion of said hot water and thereafter allowing the rice to be steamed for 3 to 4 minutes with the remaining heat. The fast cooking rice can be reconstituted into a soup containing rice grains by following the same procedure except for removal of excess hot water. The fast cooking rice produced by this invention can be also amply reconstituted into a cooked rice of good quality when it is left to stand in water of normal room temperature for about 30 minutes. When the fast cooking rice is reconstituted with milk instead of water of normal room temperature, the resultant cooked rice tastes good. For a user who feels like eating pilaf, a pilaf of mild texture can be obtained by heating the fast cooking rice of this invention such as in a frying pan in the presence of a small amount of oil and fat and a suitable amount of water.

Obviously modifications and variations are possible insofar as they do not depart from the spirit and scope of the present invention. This invention is not limited to the specific embodiments thereof except as defined in the appended claim.

EXAMPLE 1

A raw rice was expaned by use of heated air at 300 DEG C into a puffed rice having a volume of six times as large. One (1.00) kg of this puffed rice was sprayed with 1.86 kg of 0.2% aqueous solution of sodium alginate at normal room temperature, then left to stand for about 10 minutes and then sprayed with 0.64 kg of 2.0% aqueous solution of calcium lactate at room temperature, then left to stand for about 10 minutes and thereafter dried in a drying oven at 80 DEG C for 3 hours. There was consequently obtained 0.96 kg of a fast cooking rice having a volume of about 2.4 times that of the raw rice. This fast cooking rice was placed in a container provided with a lid. The same volume of hot water at 95 DEG C was poured into the container. The rice and the hot water in the container were left to stand for 90 seconds. Then, the excess hot water was discarded. Thereafter, the fast cooking rice was left to be steamed for 3 minutes with the remaining heat. consequently, there was obtained a cooked rice excellent in taste, texture and flavor.

EXAMPLE 2


(1.00) kg of this puffed rice was immersed in 0.5% aqueous solution of a low methyl ester pectin at normal room temperature for 60 seconds and then immersed again in 0.5% aqueous solution of calcium chloride at 60 DEG C for 60 seconds. The puffed rice thus treated was dired in a drying oven at 60

DEG C for 4 hours to afford 0.98 kg of a fast cooking rice having a volume of 2.4 times as large as that of the raw rice. A cooked rice of excellent taste, flavor and texture was obtained by subjecting 200 g of this fast cooking rice to heating in a frying pan in the presence of 600 g of water and a small amount of salad oil added thereto.

EXAMPLE 3


(1.00) kg of this puffed rice was immersed in an aqueous solution of 0.5% sodium alginate and 0.5% low methyl ester pectin at 60 DEG C for 30 seconds, then immersed again in an aqueous solution

1441/2197

containing 3.0% of calcium lactate, 3.0% of chicken soup, 0.5% of sodium chloride and 0.03% of seasoning agent at normal room temperature for 45 seconds, and thereafter dried in a drying oven at 95

DEG C for 2.5 hours. Consequently, there was obtained 0.99 kg of fast cooking rice having a volume of 2.9 times as large as that of the raw rice. A flavored cooked rice of excellent taste was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

EXAMPLE 4

A raw rice was expanded by puffing gun into a puffed rice having a volume of 15 times as large. One

(1.00) kg of this puffed rice was immersed in 2.0% aqueous solution of calcium and potassiumsensitive carrageenin at 80 DEG C for 30 seconds, and then immersed again in an aqueous solution containing 1.0% of calcium lactate and 1.0% of potassium monohydrogenphosphate at 80 DEG C for

60 seconds. When the treated rice was dried for 5 hours under conditions of 45 DEG .+-. 5 DEG C and a vacuum of less than 10 mmHg, there was obtained 1.0 kg of fast cooking rice having a volume of 1.6 times that of the raw rice. A cooked rice of excellent quality was obtained by subjecting this fast cooking rice to a treatment similar to that of Example 1.

EXAMPLE 5


(1.00) kg of this puffed rice was immersed in 1.0% aqueous solution of calcium chloride at 40 DEG C for 15 seconds, then immersed again in 0.5% aqueous solution of sodium alginate at 40 DEG C for 120 seconds, and thereafter dried in a drying oven at 80 DEG C for 3 hours. Consequently, there was obtained 0.94 kg of fast cooking rice having a volume of 2.6 times as large as that of the raw rice. A flavored steeped rice of excellent taste was obtained by adding to this fast cooking rice small amounts of powdered sea weed and powdered green tea, a suitable amount of sodium chloride and a small amount of dried salmon flakes and allowing the resulting mixture to stand in hot water at 90 DEG C for

3 minutes.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A process for the manufacture of fast cooking rice, consisting essentially of puffing raw rice into a puffed rice having a volume of 6 to 16 times as large, contacting said puffed rice with a solution of at least one thickener susceptible to gelling by metallic ions, in a concentration of about 0.2 to about 3.0% by weight sufficiently to penetrate to the inside center of the puffed rice, then contacting said rice with a solution of said metallic ions to thereby gell said thickener and subsequently drying the treated puffed rice whereby it is reduced in volume.

2. A process according to claim 1 wherein said thickener is a polysaccharide or a derivative thereof.

3. A process according to claim 1 wherein said thickener is alginic, acid, salts thereof carrgeenin, or a low methyl ester pectin.

4. A fast cooking rice produced according to the process of claim 1.

5. A process for the manufacture of fast cooking rice, consisting essentially of puffing raw rice into a puffed rice having a volume of 6 to 16 times as large, contacting the puffed rice with a solution of metallic ions, then contacting said rice with a solution of a thickener susceptible to gelling by said metallic ions to thereby gell said thickener and subsequently drying the treated puffed rice to reduce the volume thereof, the concentration of the solution of the thickener being about 0.2 to about 3.0% by weight and the contacting of the puffed rice therewith being sufficient to penetrate to the inside center of the puffed rice, the concentration of the solution of metallic ions being sufficient to cause gellation of said thickener.

6. A process according to claim 5 wherein said thickener is a polysaccharide or a derivative thereof.

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7. A process according to claim 5 wherein said thickener is alginic acid salts thereof, carrageenin, or a low methyl ester pectin.

8. A fast cooking rice produced according to the process of claim 5.Data supplied from the esp@cenet database - Worldwide

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333.

US4119734 - 10/10/1978

HIGH PROTEIN RICE MIXTURE


Inventor(s): SPIEL ALBERT (--)

Applicant(s): NABISCO INC (--)


IP Class: A23L1/20

E Class: A23L1/182; A23L1/20D4



Family: CA1075965

Abstract:


A protein-enriched rice food product of substantially uniform density in the dry state composed of particulate soy protein and rice grains wherein the particulate soy protein particles have a density substantially equivalent to that of rice whereby the protein-rice product can be packaged without segregation of the product mix. The soy protein particles have suitable hydration properties such that the subsequent preparation of the particulate protein-rice food product resembles that of rice.Description:



The present invention relates to a novel soy protein-enriched rice food product of substantially uniform density which is composed of particulate soy protein and rice grains wherein the particulate soy protein particles have a density substantially equivalent to that of rice whereby the protein-rice product can be packaged and shipped without segregation of the soy particles and the rice.

As is well known there is a critical shortage of rice which is the primary staple of the diet of many peoples, particularly the people of Asia. Additionally, it is well known that rice is primarily a carbohydrate type of food and thus is lacking in protein.

Previous attempts to fortify rice or produce an enriched artificial rice have not been too successful in that fortification procedures tend to produce objectionable discolorations of the rice and processes for the production of an enriched artificial rice fails to produce a product having suitable hydration properties such that preparation of the product is uniform and resembles that of rice.

Accordingly, it is a primary object of this invention to produce a protein-enriched rice food product of substantially uniform density, in the dry state, composed of particulate soy protein and rice grains wherein the particles of soy protein have a density substantially equivalent to that of rice whereby the protein-rice product can be packaged and transported without segregation of the product mix and wherein the soy protein particles possess suitable hydration properties such that the subsequent preparation of protein-enriched rice food product resembles that of rice.

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Another object of the invention resides in the provision of an improved process which increases the protein nutrition of rice.

Yet another object of the invention resides in the provision of a protein-enriched rice food product which permits vitamin and mineral fortification of rice without any objectionable discolorations of the rice.

Still another object of the invention resides in the provision of an improved protein-enriched rice food product which permits the incorporation of protein supplements into rice, in the dry state, without segregation in the package.

Still further objects of the invention will become more immediately apparent as the following description of the invention proceeds.

In accordance with the present invention the aforementioned objects of the invention are readily accomplished by incorporating or blending with rice a particulate soy protein of substantially the same density as rice, said particulate soy protein having hydration properties such that subsequent preparation of the soy protein-rice food product for consumption is uniform and resembles that of rice.

The soybeans which can be converted to soybean particulates having desired densities and hydration properties can be any of the several varieties of soybeans such as Lincoln soybeans and the like.

Soybeans contain small amounts of enzymes, for example, urease and lipoxidase, and inhibitors, such as hemaglutin and antitrypsins. All are inactivated by the moist heat used in the processing steps herein. Also, the proteinaceous plant (soybean) material used herein usually contains such amino acids as arginine, histidine, lysine, tyrosine, tryptophane, phenylalanine, threonine, methionine, cystine, leucine, isoleucine, valine, glycine, and/or glutamic acid. The primary protein of soybean is glycinin, which is a mixture of short and long molecules made up in part of various amino acids. The soybean material also contain carbohydrates, ash, fibrous and pulpy constituents and associated flavoring ingredients.

The soybeans are usually processed to prepare soybean meal by the following sequence of steps, all of which are within the skill of those ordinarily skilled in the art: magnetic separation; bean cleaning, been cracking (cracking rolls); dehulling, but the hulls can then be used as part of the feed; tempering, flaking; oil-extraction; and grinding. (Hulled or dehulled soybeans can be used in this invention. Also, defatted or full-fat soybean flour can be used as feed in this invention). The soybeans used as feed in the screw press are first conventionally particulated into meal, grits, flour, flakes or similar material, and the particulated material is conventionally processed using conventional solvent-extraction schemes to remove the oil. The most frequently used solvent is hexane, but examples of other volatile, nonpolar, oil solvents which can be used are pentane, heptane and benzene. Also, mixed solvents can be used, such as volatile, nonpolar, oil solvents, 1 to 10 percent water and volatile, polar organic solvents, such as acetone, the lower alcohols (like methanol, ethanol and propanol).

The particulated material is desolventized and/or deodorized by known techniques involving the application of heat, the degree of which affects the protein solubility range usually expressed in NSI or

PDI, respectively. Nitrogen Solubility Index and Protein Dispersability Index (AOCS Test BA 10-65) which are standard tests of the American Oil Chemists Society. A suitable range of NSI for the particulated material used herein extends from about 30 to about 70, preferably 45 to 60. Too low of an

NSI or PDI provides a mass which is too loose for suitable compaction and leaching and too high of an

NSI results in a highly compacted chunk which is relatively difficult to hydrate and/or rehydrate.

The particulated material (preferably flakes) which contains some moisture, is then subjected to a pressure of at least 1,800 pounds per square inch for a time and at a temperature sufficient to convert moisture into steam. The material is partially disembittered, toasted without scorching, and compacted into a hard and substantially fused mass.

The pressure used is at least 1800 p.s.i., generally between about 2000 and about 5000 p.s.i. and preferably between about 2000 and 3000 p.s.i. (The vast majority of the oil has been already removed from the soybean, so usually less than one percent by weight of oil remains in the soybean feed.) One reason why pressures between 2000 and 3000 pounds per square inch are preferred is that less energy is

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generated which results in less chance of scorching the product. Pressures below those specified result in chunks that are too loosely compacted, require extremely long times to achieve any degree of disembittering. Pressures in the above range result in a compacting and plasticizing of the material whereby a cake is formed in which the dust and any hulls are uniformly combined with the rest of the material. The plasticizing action during the pressure and heat treatment causes the cake to be substantially uniform, in which the fines and hulls are intimately held. The cake can therefore be fragmented into chunks which remain cohesive enough to be a commercial product which retains its size and shape even though subjected to boiling water and stirring.

The hydration properties of the chunks of this invention can be controlled by controlling the compaction process. In general, the higher the degree of compaction, the slower the rate of hydration and the higher the density. The reverse is also true, i.e., the lower the degree of compaction the faster the rate of hydration and the lower the density. The rate of hydration can be further increased and the density decreased by extracting the chunks with water and drying before mixing with rice. Insufficient compaction, e.g., at pressures below about 1800 p.s.i., or too low protein solubility, produces chunks that tend to form a mush or gruel upon hydration.

The moisture content of the material should be between about 5 and about 10 percent when it is fed into the equipment wherein it will be subjected to at least 1800 pounds per square inch. The reason for this is that that much moisture is necessary to obtain partial or substantial disembittering by steaming in such equipment (i.e., the moisture is converted therein into steam). If too much moisture is present, scorching of the product will occur or uneven toasting will result. If the moisture content of the soybean material is too high, the portions of the meal away from the source of the heat will not be toasted, or if sufficient heat and pressure are applied to toast the portions away from the source of heat, those portions in juxtaposition to the source of heat will be scorched or burned.

The period of time of processing the soybean material at the stated pressure is normally between about

1.5 and about 5 minutes to obtain the desired results. Preferably the time period is 3 minutes.

The soybean material can be treated by any conventional means which will produce the desired results.

For example, a press plate having heated plates can be used.

The desired results are preferably obtained by the use of a modification of a screw press of the type disclosed in U.S. Pat. No. 731,737 (incorporated herein by reference) and customarily referred to in the art as an "Anderson expeller." The outer casing surrounding the screw does not contain the series of holes, as for example the oil has already been removed from the particulate soybean feed by an appropriate method. The modified Anderson expeller includes a preconditioning chamber which is, for example a 14 inch wide by 14 feet long steamjacketed continous ribbon blender. Next in the process line is a vertical force feeder which conveys the particulate soybean material to the main horizontal pressing chamber. The main horizontal pressing chamber has been modified by replacing the barrel spacing bars with solid polished plates. Also the main press worm (screw) has been modified by sliding a tapered cone along the shaft into the pressed cake outlet space to increase the internal pressure along the press worm and to obtain uniform, thin, compacted material (usually about 3/8 inch thick). All internal surfaces of the press subjected to contact with the soy material or compacted material are hardened and highly polished for smooth flow of the material through the press.

The press is normally set so that the thickness of the resulting cake (mass) is about one-fourth to threeeighth inch, but this thickness is not critical and is only desirable.

The screw press can be modified by the addition of heating coils around the outer wall of the screw press casing housing the rotatable screw as to uniformly heat the casing in such regions. This is normally not done when the soybean particles have been preheated in a preconditioning chamber. (Any other heating arrangement can be used.)

The desired temperature of the soybean material during the pressing is about 150 DEG to about 200

DEG C. (about 302 DEG to about 392 DEG F.), so the inner casing wall should not have a temperature which will cause the temperature of the soybean material to rise above about 200 DEG C. or else the soybean material will become scorched. The pressure in the press will convert the moisture into steam, but not all of the energy produced will be used in vaporizing the moisture--some will go to generally

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raising the temperature of the soybean material. If properly done within the limits set forth herein the resulting cake (mass) will not be scorched. Some degree of disembittering is obtained by the steam thusly produced, but the cake (mass) still has a degree of bitterness or beany flavor and has a nutty flavor. The look, taste, chewability, blandness, meatlike texture and general characteristics of the meatlike product have not been obtained at this point in the processing of the soybeans.

As previously stated, the temperature of the soybean material should be between about 150 DEG and about 200 DEG C., and preferably 165 DEG to 180 DEG C. This assures partial or substantial disembitterment without scorching. The soybean material can be preheated, before being fed into the pressure-treated equipment, to a temperature between about 160 DEG and 200 DEG F. Soybean material which contains too high of a moisture content can be preheated and dried to the proper moisture content in a tempering chamber before being fed into the pressure equipment. When equipment like a press plate having heated plates is used, the soybean material is first placed therein and allowed to stand in order to preheat the material.

The mass obtained from the screw press or other equivalent processing equipment is fragmented by any convenient means. Examples of such means are chopping blades and crushers. The resulting chunks are sized so that they have a more uniform size range. For example, four suitable portions of different but individually uniform size ranges include chunks that:

>;tb;______________________________________

>;tb;Pass through a screen

>;tb; But are retained on a screen

>;tb;having openings of

>;tb; having openings of

>;tb;______________________________________

>;tb;1 inch 1/2 inch

>;tb;1/2 inch No. 4*

>;tb;No. 4* No. 10*

>;tb;No. 8* No. 20*

>;tb;______________________________________

>;tb; *U. S. Mesh sizes

Preferred chunks pass through a 1 inch opening screen and stay on a 1/2 inch opening screen. The over and under sized material can be removed. The resulting chunks are light yellowish brown or buff in color and are relatively nonporous.

The soy protein particulate material produced in accordance with above described process can also be shaped to resemble known food components commonly used with rice around the world. These shapes can resemble the rice grains themselves, wheat, barley, soybeans, corn, meat, poultry or fish granules and other components indigenous to various countries around the world.

The soy protein-rice particulate ratio is not necessarily a critical feature of the invention and can be varied over a wide range and tailor made to meet or satisfy specific protein requirements of various nutritional food recipes or satisfy specific protein requirements of various peoples. In general the amount of soy protein to rice grains can be varied from about 5.0 to 100 percent by weight of soy protein based on the weight of the rice grain.

If desired, flavoring systems including flavor enhancers and/or agents can be added to the soy protein particulates prior to their combination with rice granules. In general, such flavoring systems are not necessary, but, if desired, such flavoring systems are employed in amounts of from about 0.1 to 2.0 percent by weight of the soy protein particulate matter. Examples of such flavor enhancers are monosodium glutamate, disodium inosinate and disodium quanylate. Also, if desired, flavoring agents in the amount of from 10 to 20 percent by weight based on the weight of the soy protein can be added.

The soy protein-enriched rice can be readily nutritionally enhanced by the fortification of the soy protein being compacted in the compactor or modified Anderson screw press or expeller with vitamins and/or minerals to provide specific fortification levels depending upon the intended use before mixing the compacted soy particles or chunks with the rice. This means of fortification of the soy protein particulates is quite advantageous since any color effects induced by such fortification can be more

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suitably masked in the soy protein particulates than in the rice granules, particularly white rice granules. The amounts of vitamin or mineral supplements which can be normally employed are amounts which are recognized in the art with respect to other fortified materials such as cereals, breaks and the like.

As pointed out above the control of the density of the textured soy protein particles to be substantially that of the rice granules is of utmost importance in achieving soy protein-enriched rice food product mix which can be supplied in multiwall bags or fiber drums and which will withstand prolonged transportation without segregation of either of the ingredients, that is the soy protein particulate material and the rice granules. Density control is achieved by the choke or tapered cone mounted in the pressed cake outlet. Movement of the cone in one direction reduces the outlet size and increases the pressure in the press, thus increasing the density of the compacted soy, whereas movement in the opposite direction increases the outlet size and decreases pressure thus providing compacted soy of less density.

In order to determine the suitability of various blends of soy protein and rice grains as to their suitability for transportation without separation of ingredients various uniformly blended premixes of same are subjected to a simulated transportation test to determine densification and determine the distribution of the soy protein in the soy-protein-rice mixture. The densification test includes filling a

100 ml graduated cylinder with a blended mixture of soy protein particulate matter and rice grains. The cylinder is tamped gently 50 times. Observations are then made of the distribution patterns of the mixture of materials. If it is observed that no separation occurs between the soy protein and the rice grains it illustrates that the substantially equal densities of the soy protein particulates and the rice granules achieve one of the primary objects of the invention. Thus, by choosing the proper density of the soy protein particulate matter and combining it with specific types of rice such as long grain, medium or short grain, brown, unpolished or white rice, the combined ingredients are held in suspension without segregation until consumer use.

Unless otherwise stated or indicated in the following examples and throughout are rest of the specification and in the claims, all percentages, parts and portions are expressed on a weight basis, based on total composition. The following examples are intended to be further illustrative of the invention and not limitative thereof.

EXAMPLE 1

The starting material is flakes of dehulled, solvent-extracted, soybean having a moisture content of 7.5 percent and an NSI of about 50 percent. The soybean flakes are processed in a "modified Anderson expeller" as described above.

The soybean flakes are preheated to about 180 DEG F. in the preconditioning chamber. The retention time in the preconditioning chamber is 1 minute, and steam having a pressure of 65 p.s.i.g. is used in the steam jacket. The soybean flakes have a moisture content of 6.8 percent upon exiting from the preconditioning chamber and are passed through the vertical force feeder into the main horizontal pressing chamber. The processing retention time (time during which the pressure is applied) is 2 minutes: the pressure applied is 2000 p.s.i. and the thickness of the cake is about 3/8 inch. The cake during the pressing has a temperature of 305 DEG F. The exiting cake has a moisture content of 5.5 percent, is allowed to cool and is fragmented by means of chopping blades into chunks. The chunks have a light yellowish brown or buff color and are not porous in appearance.

The chunks are separated by screens to give retained chunks having a chunk size that passes through a

1-inch screen and stays on a 1/2 inch screen. The compacted chunks have an analysis (weight percent on a dry basis) as follows:

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Compacted chunks

>;tb;______________________________________

>;tb;Protein (N.times.6.25)

>;tb; 53.5

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>;tb;Fat 1.2

>;tb;Fiber 4.0

>;tb;Ash 6.7

>;tb;Carbohydrate (difference)

>;tb; 34.6

>;tb;______________________________________

The noted calculation basis for the protein is N.times.6.25, wherein N is the value obtained by an analysis for protein nitrogen using the Kjeldahl Test and 6.25 is the standard factor for soy to get total protein.

The following is the amino acid profile for the compacted soybean chunks:

>;tb;______________________________________

>;tb;Amino Acid Percent

>;tb;______________________________________

>;tb;Lysine 4.798

>;tb;Available Lysine 4.421

>;tb;Histidine 2.016

>;tb;Arginine 5.664

>;tb;Aspartic Acid 9.142

>;tb;Threonine 2.882

>;tb;Scrine 3.977

>;tb;Glutamic Acid 14.230

>;tb;Proline 3.996

>;tb;Glycine 3.293

>;tb;Alanine 3.546

>;tb;Cystine, Half Trace

>;tb;Valine 3.038

>;tb;Methionine 1.281

>;tb;Isoleucine 2.732

>;tb;Leucine 4.858

>;tb;Tyrosine 2.455

>;tb;Phenylalanine 3.614

>;tb;______________________________________

The following is the vitamin analysis for the compacted soybean chunks:

>;tb;______________________________________

>;tb;Vitamins Amounts

>;tb;______________________________________

>;tb;Thiamin 3.49 mgs per lb.

>;tb;Riboflavin 2.18 mgs per lb.

>;tb;Niacin 8.17 mgs per lb.

>;tb;Vitamin B6 2.27 mgs per lb.

>;tb;Vitamin B12 None detected

>;tb;______________________________________

The protein efficiency ratio of the compacted chunks is 87 percent of that for casein.

The following is the mineral analysis for the compacted soybean chunks:

>;tb;______________________________________

>;tb;Mineral Amount

>;tb;______________________________________

>;tb;Calcium 0.216 percent

>;tb;Phosphorous 0.660 percent

>;tb;Potassium 0.230 percent

>;tb;Magnesium 0.280 percent

>;tb;Iron 90.5 ppm

>;tb;Copper 15.0 ppm

>;tb;Manganese 20.0 ppm

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>;tb;Zinc 81.0 ppm

>;tb;Sodium Chloride 0.222 percent

>;tb;Cobalt 0.033 ppm

>;tb;Iodine Less than 0.14 ppm

>;tb;______________________________________

The density of the soy protein was controlled by varying the degree of compactness in the "modified

Anderson expeller." The degree of compactness is accomplished by controlling the choke mechanism of the expeller which is mounted on the cake outlet space to increase or decrease the internal pressure along the expeller screw. The degree of compactness can be adjusted to provide a bulk density of the cake of substantially that of rice.

Subsequently, a mixture can be prepared of rice and soy protein in a ratio of about 4:1 by placing the ingredients in a Hobart mixer equipped with an anchor type agitator.

After mixing is complete a sample of the mixture is subjected to a densification test which is accomplished by filling a 100 ml graduated cylinder therewith and tamping fifty times. Visual observations of the distribution patterns of the ingredients of the mixture will indicate no separation of the soy protein granules from the rice granules.

EXAMPLE 2

Solvent-extracted soy flakes are processed in a "modified Anderson expeller" under a series of preestablished operations to obtain the desired cake as an exit product from the expeller. The cake is allowed to cool and is fragmented by means of chopping blades into granules. The granules are further separated using a sifter to give retained granules having a size that passes through a U.S. S/S #5 screen and remains on a U.S. S/S #16 screen.

The bulk density of the soy protein was obtained by varying the degree of compactness in the

"modified Anderson expeller." The degree of compactness is accomplished by controlling the choke mechanism of the expeller which is mounted on the cake outlet space to increase or decrease the internal pressure along the expeller screw.

The bulk density of the soy protein granules obtained was 36.0 lbs. per cu. ft.

A mixture of 15.0 pounds of rice having a density of 32 lbs. per cu. ft. and 5.0 lbs. of the soy protein granules having a size and shape similar to rice were mixed in a Hobart mixer with an anchor type agitator. After mixing was complete a sample of the mixture was subjected to a densification test by filling a 100 ml graduated cylinder therewith and tamping gently fifty times. Visual observations were made on the distribution patterns of the ingredients of the mixture. No separation of the soy protein granules from the rice granules was observed.

The present invention is equally applicable to the protein enrichment and fortification of other grain materials, such as wheat, barley, buckwheat, bulgar, groat, hominy grits, cassava, tapioca and the like.

EXAMPLE 3

Soy protein granules were prepared in the manner as described in Example 1 having a density of 44 lbs. per cubic foot. The granules were of a size and shape of wheat granules and were mixed at the rate of 5 lbs. of the soy protein granules with 15 lbs. of wheat having a density of 48 lbs. per cubic foot. After mixing was complete, a sample of the mixture was subjected to a densification test as described above.

Visual observations were made on the distribution patterns of the ingredients of the mixture. No separation of soy protein granules from the wheat granules was observed.

EXAMPLE 4

Soy protein granules were prepared in the manner as described in Example 1having a density of 40 lbs. per cubic foot. The granules were of a size and shape of barley granules and were mixed at the rate of 5 lbs. of the soy protein granules with 15 lbs. of barley having a density of 39 lbs. per cubic foot. After

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mixing was complete, a sample of the mixture was subjected to a densification test as described above.

Visual observations were made on the distribution patterns of the ingredients of the mixture. No separation of soy protein granules from the barley granules were observed.

EXAMPLE 5

Soy protein granules were prepared in the manner as described in Example 1 having a density of 40 lbs. per cubic foot. The granules were of a size and shape of buckwheat granules and were mixed at the rate of 5 lbs. of the soy protein granules with 15 lbs. of buckwheat having a density of 40 lbs. per cubic foot. After mixing was complete, a sample of the mixture was subjected to a densification test as described above. Visual observations were made on the distribution patterns of the ingredients of the mixture. No separation of soy protein granules from the buckwheat granules was observed.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method of preparing a protein-enriched grain food product of substantially uniform density and hydration properties in the dry state composed of particulate soy protein and grain wherein the particulate soy protein particles have a density substantially equivalent to that of the grain whereby the protein-grain product can be packaged and transported without segregation of the product mix and hydration properties whereby preparation of the product for consumption is uniform and resembles that of said grain, said method comprising the steps of: (a) subjecting a soybean feed material selected from the class consisting of solvent-extracted meal, grits and flakes of soybean material having an NSI of about 30 to about 70 and containing moisture, to a mechanical pressure of at least 1800 pounds per square inch for a time and at a temperature sufficient to convert said moisture into steam whereby said soybean feed is partially disembittered, toasted without scorching and is compacted at a degree of compactness sufficient to compact said feed into a hard and substantially fused mass having a density and hydration properties substantially equivalent to that of the grain; (b) fragmenting said mass into chunks and (c) mixing said chunks with the grain whereby there is obtained a soy protein enrichedgrain food product of substantially uniform density and hydration properties.

2. The method of claim 1 wherein the grain is rice.

3. The method of claim 1 wherein the soybean feed material is heated before step (a) so that the moisture content thereof is reduced to between about 6 and about 8 percent by weight.

4. The method of claim 1 wherein the soybean feed material has a protein content of 30 weight percent or more.

5. The method of claim 4 wherein the soybean feed material has an NSI of 45-60.

6. The method according to claim 1 wherein a pressure between 2000 and 5000 pounds per square inch is applied in step (a) at a temperature between about 150 DEG and about 200 DEG C.

7. The method according to claim 1 wherein the soybean feed material is subjected to heat and pressure in step (a) from 1.5 to 5 minutes.

8. The method according to claim 1 wherein said mass is fragmented in step (b) into chunks which will pass through a 1-inch opening screen and be retained on a 1/2 inch opening screen.

9. The method according to claim 1 wherein said mass is fragmented in step (b) into chunks which will pass through a U.S. S/S #5 screen and be retained on a U.S. S/S #16 screen.

10. The method according to claim 2 wherein said mass in step (b) is fragmented into chunks simulating the size and shape of rice.

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11. A protein-enriched rice food product of substantially uniform density and hydration properties in the dry state composed of particulate soy protein and rice wherein the particulate soy protein particles have a density substantially equivalent to that of rice whereby the protein-rice product can be packaged and transported without segregation of the ingredients of the product mix and hydration properties whereby preparation of the product for consumption is uniform and resembles that of rice and produced by the process of claim 1.

12. The product according to claim 11 wherein the soy protein particles simulate rice as to size and shape.

13. A protein-enriched grain food product of substantially uniform density and hydration properties in the dry state composed of particulate soy protein and a grain wherein the particulate soy protein particles have a size, shape and density substantially equivalent to that of the grain whereby the protein-grain product can be packaged and transported without segregation of the ingredients of the product mix and hydration properties whereby preparation of the product for consumption is uniform and resembles that of said grain and produced by the process of claim 1.

14. The product according to claim 13 wherein said grain is wheat.

15. The product according to claim 13 wherein said grain is buckwheat.

16. The product according to claim 13 wherein said grain is barley.

17. The method of claim 1 wherein the soybean feed material in step (a) is fortified by addition of a supplement selected from the group consisting of vitamins, minerals and mixtures thereof.

18. The product according to claim 11 wherein said soy protein particles are fortified with a supplement selected from the group consisting of vitamins, minerals and mixtures thereof.

19. The product according to claim 13 wherein said soy protein particles are fortified with a supplement selected from the group consisting of vitamins, minerals and mixtures thereof.Data supplied from the esp@cenet database - Worldwide

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334.

US4166868 - 9/4/1979

MANUFACTURE OF READY-TO-EAT RICE


Inventor(s): ANDO MOMOFUKU (JP); MINAMI JUNICHI (JP); OHNISHI FUMIO (JP);

SAWADA MAKOTO (JP); TAKATSU MITSUMUNE (JP)

Applicant(s): ANDO MOMOFUKU (JP); MINAMI JUNICHI (JP); OHNISHI FUMIO (JP);

SAWADA MAKOTO (JP); TAKATSU MITSUMUNE (JP)


IP Class: A23L1/182; A23B7/02

E Class: A23L1/182C



Family: US4166868

Abstract:


Manufacture of ready-to-eat rice comprises soaking rice in water, gelatinizing the wet rice, pressing the gelatinized rice between rollers to alter the grain structure (to permit easier puffing during frying), adjusting its water content to 8-25% by weight and frying the rice at a temperature of 130 DEG -200

DEG C.Description:



The present invention relates to a process for manufacturing ready-to-eat rice, which can be reconstituted into a food preparation with its original shape, good taste and flavor or pleasant sensation to the tongue in a very short time, merely by being mixed with boiling water.

The study and development of the so-called ready-to-eat rice, such as pre-cooked boiled rice, rice gruel, porridge of rice and vegetables and so on, have been known, and these foodstuffs have been on the market. However, such foodstuffs have many defects concerning their precooking and preparation or reconstitution and quality, and no satisfactory product has yet been developed.

The conventional manufacturing process of ready-to-eat rice is divided broadly into three categories as follows:

(1) Rice is boiled and then dried.

(2) Rice is boiled and then fried in oil.

(3) Rice is boiled, flattened and then dried.

However, the rice made by the first process as mentioned above in (1) needs a longer time for restoration to its original shape and lacks stickiness peculiar to boiled rice and pleasant texture to the tongue.

The second process as mentioned above in (2) requires a high oil temperature for frying the rice after boiling, and it is therefore rather difficult to maintain the good quality of the boiled rice. Furthermore,

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the rice made by this process has the defect of not being easily restored to its original shape by merely pouring boiling water on it.

The rice made by the third process as mentioned above in (3) can not be restored to its original shape peculiar to rice, but rather remains in a flattened state, and is far removed from boiled rice in flavor and feel of eating.


The present invention overcomes such defects of the prior art.

It is a general object of the present invention to provide rice foodstuffs such as pilaf and curried rice which can be made ready to eat a few minutes after simply mixing them with hot water.

It is another object thereof to provide rice foodstuffs which can be prepared as viscous and elastic with hot water as home cooked rice.

It is a further object to provide rice foodstuffs which can be reconstituted into food preparations with their completely original shape.

It is a further object to provide rice foodstuffs which can be prepared for consumption without cooking means such as pans.

It is a further object to provide rice foodstuffs which can be prepared for consumption whenever and wherever hot water is available.


The manufacturing process in this invention is described in detail below.

Any edible rice, irrespective of kind and quality, including imported and home-grown rice, can be used for the material to be processed in accordance with this invention.

The grains of rice are first washed with water and soaked in water or liquid seasoning. The water or liquid temperature is preferably lower than 70 DEG C., and the soaking time depends on the water or liquid temperature, with higher temperatures requiring less soaking time. Furthermore, it is preferably that the water content of the soaked rice be 25-40%, more preferably 30-34%, by weight of the rice.

Then, surfactants, e.g. glycerine fatty acid esters, sugar esters, fatty acid monoglycerides, fatty acid sucrose esters, soybean lecithins and yolk lecithins, or edible oil, e.g. palm oil, rice-bran oil, soybean oil, rape seed oil, cottonseed oil, sesame oil, olive oil, coconut oil, lard and tallow, or talc are mixed therewith, preferably in an amount of 0.1-1.0% by weight of the rice. The resultant rice grains are then gelatinized by boiling in water or steaming.

Since the surfactant, edible oil or talc is added in order to prevent the subsequently gelatinized rice grains from sticking to one another and the roll surface used during the pressing steps, a small quantity of such additives will suffice for this purpose.

The rice should be gelatinized to the heart by proper means, such as the usual steam cooking or pressure steam cooking means. The period of steaming depends on the pressure employed. Generally, the conditions range from steaming for 30 minutes at atmospheric pressure to steaming for 4 minutes at a pressure of 3 kg/cm@2 above atmospheric pressure.

If the rice is steamed for gelatinization, it is then exposed to air at a temperature of, for example, 20

DEG-100 DEG C. to adjust its water content to 18-35% by weight. If the rice is boiled in water, it will be wetter than the steamed rice. Therefore, excess water of the boiled rice may be absorbed by cereal flour such as dry wheat flour, rice flour, starch, etc., cellulose powder or talc, before being dried to a water content of 18-70% with, for example, hot air.

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The gelatinized rice is forcibly passed through a slit between rolls or pressed between flat plates of metal or plastic, etc. From the viewpoint of productivity and economics, pressing by rolls is preferable.

In case of pressing by rolls, if the gelatinized rice is forcibly passed between metal rolls as it is, the grains join with one another and stick to the rolls. Therefore, it is desirable to dry the boiled rice beforehand so that its moisture content is no more than 70% by weight. If over 70%, it is necessary to lower the temperature of the grain surfaces to some extent. If the rice is dried to less than 18% moisture, it becomes stiff and is broken when pressed. Therefore, in general the most suitable moisture content prior to pressing by rolls is 18-70% for the boiled rice and 18-35% for the steamed rice.

The diameter of the rolls is preferably greater than 50 mm and the rotational speed thereof is preferably less than 25 m/min.

The pressing degree may be adjusted by changing the distance between the rolls through which the gelatinized rice is forcibly passed. If too much pressure is exerted on the gelatinized rice, cracks are produced in the rice resulting in loss of ability for restoration to the original shape of the gelatinized rice. However, if the pressing is too weak, it has no effect. In such instances, it is necessary to adjust the slit between the rolls.

Generally speaking, when the moisture content is high, it is necessary to make the slit between the rolls wider, and vice versa.

As a result of experiments, it has been found desirable that the slit between the rolls be adjusted to 0.1-

1.0 mm, as shown in Table 1 under the conditions therein.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Pressing degree for boiled rice and quality after restoration

>;tb;Pressing Time required

>;tb;degree for restoration

>;tb;(Distance Apparent after pouring

>;tb;between specific boiling water

>;tb; Quality after

>;tb;rolls in mm)

>;tb; gravity (min) restoration

>;tb;______________________________________

>;tb;No pressing

>;tb; 0.34 7 Undercooked. Un-

>;tb; pleasant feel of

>;tb; eating.

>;tb;(*) 0.20 5 No elasticity.

>;tb; Unpleasant feel

>;tb; of eating.

>;tb;1.8 0.34 7 Undercooked.


>;tb; of eating.

>;tb;1.6 0.33 6 Undercooked.


>;tb; of eating.

>;tb;1.4 0.32 5 Partly undercooked.

>;tb; Inferior feel of

>;tb;1.2 0.28 4 eating.

>;tb;1.0 0.27 3

>;tb;0.8 0.26 3

>;tb;0.4 0.28 3 As pleasant feel

>;tb; of eating as boiled

>;tb;0.2 0.24 1.5 rice.

>;tb;0.1 0.23 1.5

>;tb; 0.05 0.22 1.0 Not restored to the

1455/2197

>;tb; original granular

>;tb; shape. No elasticity

>;tb;______________________________________

Remarks:

(1) Home-grown rice made into gelatinized starch and dried to a moisture content of 26% by weight was passed through the fixed slit between the rolls.

(2) Apparent specific gravity was for puffed rice fried in palm oil at a temperature of 160 DEG C. after adjusting the moisture content of the pressed boiled rice to 13% by weight.

(3) Diameter of the rolls was approximately 200 mm and the revolving speed of the rolls was 10 r.p.m.

(*) Conventional non-flattened puffed boiled rice fried in oil at a temperature of 200 DEG C. for 15 seconds was used.

Japanese Patent Publication No. 46-21770 describes a process of flattening boiled rice to a width of

1.5-2.0 mm, and indicates that flattening to less than 1.5 mm results in flaking of the boiled rice. This is because, in accordance with this publication, free water in boiled rice is evaporated and the boiled rice loses its elasticity as it is flattened by heat rolls whereby the free water is evaporated.

In the present invention, however, it is desirable that the slit between the rolls should be considerably narrower as compared with that used in the Japanese publication process, since puffing of the boiled rice by frying will take place later.

Besides, the present invention differs in the pressing method from that employed in the cited process.

Pressing in the present invention does not cause evaporation of free water. It aims at partial destruction or slipping of the internal construction of boiled rice so that puffing by frying is easily accomplished.

The pressed rice is then dried so that its moisture content becomes 8-25% by weight in order to render puffing of the pressed rice easier, and then the frying process is carried out in previously heated edible oil. As shown in Table 2, gelatinized rice which has been pressed can be processed at a lower temperature within a shorter time period as compared with non-pressed gelatinized rice.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Time

>;tb;Frying oil

>;tb; Oil content required for

>;tb;temperature

>;tb; after deoiling

>;tb; restoration

>;tb; Quality after

>;tb;( DEG C.)

>;tb; (%) (sec) restoration

>;tb;______________________________________

>;tb; a. 19 100 Partially scorched

>;tb;220

>;tb; b. 17 5 Scorched

>;tb; a. 16 180 No elasticity

>;tb;200

>;tb; b. 15 15 Good, but slightly

>;tb; low elasticity

>;tb; a. 14 240 Insufficient

>;tb;190 elasticity

>;tb; b. 13 25 Good

>;tb; a. 12 360 Undercooked

>;tb;170

>;tb; b. 8 30 Good

1456/2197

>;tb; a. 10 -- Undercooked; No

>;tb;150 good

>;tb; b. 4 120 Good

>;tb; a. -- Impossible to fry in oil

>;tb;130

>;tb; b. 3 180 Good, but slightly

>;tb; undercooked

>;tb;120 Impossible to fry in oil

>;tb;______________________________________

Remarks: a.=Non-pressed boiled rice b.=Pressed boiled rice

Moisture content of rice=13.5% by weight

Distance between the rolls=0.1 mm

The oil content of the fried rice following deoiling is preferably less than 16.5% by weight of the rice.

The effective oil temperature used in the present invention ranges from about 130 DEG C. to about 200

DEG C., while non-pressed boiled rice requires 170 DEG-220 DEG C. Thus, flattened boiled rice can be processed at a comparatively lower temperature and this avoids oil from rancidification and lowering of the quality of the products by scorching or other causes.

Frying is generally carried out for a period of 4-25 seconds.

It is remarkable that rice having excellent ability of restoration is obtained in this invention, even when processing at lower temperatures of 130 DEG-170 DEG C.

The function of adequate pressing can be considered as follows:

The gelatinized rice with its adjusted moisture content, adequate plasticity and elasticity is forcibly passed between the rolls so that the grains are pressed and flattened. When it is pressed through an adequately sized slit between the rolls, it is restored to almost its original shape.

When the gelatinized rice is pressed, the internal construction of the rice is partly broken or slipped, causing formation of a number of particles in the interior of the rice. In other words, each grain of rice is converted into a great number of particles which can be easily puffed by frying. As a result, the entire construction of the rice can be heated uniformly and simultaneously, as well as promptly, in the frying process. Therefore, the rice can be fried in oil at a lower temperature in a shorter time compared with non-pressed gelatinized rice, and the entire grain of rice is easily puffed.

Boiling water soaks into the interior of the puffed boiled rice completely as soon as it is poured thereon, and the boiled rice is restored to its original shape uniformly, without any hard core.

Since the construction of the rice is not completely destroyed, but only compressed and slipped, the boiling water will permeate the fried rice sufficiently and promptly to restored it to a complete granular shape.

The fried rice obtained in this invention is far superior to conventional non-pressed gelatinized rice in terms of the time required for restoration, and in flavor and feel of eating after restoration, as shown in

Table 1 above.

Pre-cooked rice foodstuffs having as pleasant a feel of eating as boiled rice may be obtained merely by pouring boiling water in the bowl containing the fried rice mixed with powdered soup and a mixture of desiccated vegetables, eggs, meat and the like as desired, for instance, pilaf, frizzled rice, chicken and rice, rice cooked together with various vegetables, meat, shrimps, etc., stew and so on.

As shown in Table 3, the rice fried in oil after being pressed has a better effect on removing oil therefrom and also more uses than non-pressed fried rice.

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Rice gruel, baby food, relishes, cakes, etc. can also be made by adjusting the pressing degree and the temperature of the frying oil.

>;tb; TABLE 3

>;tb;______________________________________

>;tb;Pressing degree, amount of oil removed and quality after

>;tb;restoration

>;tb;(Fried at a temperature of 165 DEG C.)

>;tb;Distance between

>;tb; Oil content Oil content

>;tb;the rolls before deoiling

>;tb; after deoiling

>;tb;(mm) (%) (%)

>;tb;______________________________________

>;tb;No pressing 25.0 12.1

>;tb; 21.3(*) 14.3

>;tb;0.8 23.0 7.3

>;tb;0.4 21.2 5.1

>;tb;0.1 23.1 7.1

>;tb;______________________________________

>;tb; (*)In case of deep frying at a temperature of 200 DEG C. for 15

>;tb; seconds

As the rice processed by frying usually contains 20-30% by weight of oil, it is suitable for foodstuffs such as frizzled rice, pilaf, etc.

However, by removing oil from this fried boiled rice, for example by physical means such as applying centrifugal force or blasting with hot air, or by chemical means such as applying a solvent like ethyl alcohol as mentioned in Japanese Patent Application Nos. 48-68410, 48-68411 and 48-68412, precooked rice foodstuffs suitable for sushi (vinegared fish and rice), boiled rice with tea, white-polished rice, etc. can be obtained.

EXAMPLE 1

2.0 kg of rice grains were washed with water and soaked in water for 15 hours.

After draining off the water, 20 g of monoglyceride was uniformly mixed with the water-soaked grains of rice. Then they were put in a pot and steamed for 25 minutes at a steam pressure of 1 kg/cm@2.

The thus gelatinized rice was exposed to a hot air blast of 60 DEG-80 DEG C. so that the moisture content of the rice became 26% by weight, and such partially dried gelatinized rice was forcibly passed through a slit of 1.0 mm between two rolls to obtain pressed rice.

This pressed rice was exposed to hot air having a temperature of 60 DEG-80 DEG C. to reduce its moisture content to 13% by weight. It was then processed in palm oil heated to a temperature of 190

DEG C. for 10 seconds to obtain the ready-to-eat rice.

Furthermore, the following ingredients were placed in a polystyrene bowl:

>;tb;______________________________________

>;tb;Powdered soup 6.0 g

>;tb;Freeze-dried mushroom 0.5 g

>;tb;Freeze-dried shrimp 1.0 g

>;tb;Freeze-dried egg 1.0 g

>;tb;Freeze-dried parsley 0.3 g

>;tb;Freeze-dried green peas 1.0 g

>;tb;______________________________________

1458/2197

Then 100 g of the ready-to-eat rice was added to and mixed with these ingredients. 150 cc of boiling water was poured into the bowl, which was then covered and left standing for three minutes. Thus, pilaf having good flavor and pleasant feel of eating was obtained.

EXAMPLE 2

2.0 kg of rice grains were washed with water and soaked in water for 15 hours.

After draining off the water, 20 g of monoglyceride was uniformly mixed with the water-soaked grains of rice. Then they were placed in a pot and boiled for 25 minutes at a steam pressure of 1 kg/cm@2.

The gelatinized rice was then exposed to a hot air blast of 60 DEG-80 DEG C. so that the moisture content of the rice became 30% by weight, and such partially dried gelatinized rice was forcibly passed through a slit of 0.1 mm between two rolls to obtain pressed rice.

This pressed rice was exposed to hot air having a temperature of 60 DEG-80 DEG C. to reduce its moisture content to 24% by weight. It was then processed in palm oil previously heated to a temperature of 140 DEG C. for 10 seconds.

The resultant puffed boiled rice was introduced into a basket-type centrifuge having a diameter of 230 mm and processed therein for 30 seconds at 1,200 r.p.m., maintaining a temperature of 60 DEG C.

Thus, puffed boiled rice having an oil content of 5% by weight was obtained.

80 g of the resultant puffed and deoiled rice was placed in a polystyrene bowl. The, the following ingredients were mixed therewith:

>;tb;______________________________________

>;tb;Powdered soup 5.0 g

>;tb;Laver 0.5 g

>;tb;Rice-cake cubes 2.0 g

>;tb;______________________________________

300 cc. of boiling water was poured into the bowl, which was the covered and left standing for three minutes. Thus, a product of boiled rice with tea having as pleasant a feel of eating as boiled rice was obtained.

EXAMPLE 3

Fried rice obtained by the process applied in Example 1 was processed to remove oil in such a way as mentioned in Example 2, and ready-to-eat rice suitable for sushi and which is restored to its original shape with boiling water in three minutes was obtained.

EXAMPLE 4

By changing the temperature of the palm oil to 180 DEG C. instead of 140 DEG C. in the same process as mentioned in Example 2, rice gruel which can be restored to its original shape in 30 seconds with boiling water was obtained.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. A process for preparing ready-to-eat rice which can be reconstituted into a foodstuff essentially in the form of original rice grains, said process consisting essentially of (1) soaking grains of an edible rice in water or liquid seasoning, said water or said liquid seasoning having a temperature lower than

70 DEG C. to result in soaked rice having a water content of 30-34% by weight, (2) gelatinizing the soaked rice, (3) reducing the moisture content of the gelatinized rice to 18-70% by weight, (4) forcibly passing the resultant rice grains between rolls spaced 0.1-1.0 mm apart from each other so that the grains are pressed and flattened and the internal structure of the grain is irreversibly changed but the

1459/2197

grains are not cracked, (5) reducing the moisture content of the pressed and flattened rice grains to 8-

25% by weight, and (6) frying the thus obtained rice grains in oil at a temperature of 130 DEG-200

DEG C. so as to puff the grains, such that they reconstitute to said form of original rice grains upon adding boiling water.

2. The process according to claim 1, wherein the moisture content of the gelatinized rice is adjusted in step (3) to about 25-35% by weight.

3. The process according to claim 1, wherein the gelatinization is carried out by steaming the soaked rice and wherein the moisture content of the gelatinized rice is adjusted in step (3) to 18-35% by weight.

4. The process according to claim 1, wherein the gelatinization is carried out by means of boiling water.

5. The process according to claim 1, wherein the gelatinization is carried out by steaming the soaked rice under conditions ranging from atmospheric pressure for 30 minutes to a pressure of 3 kg/cm@2 for

4 minutes.

6. The process according to claim 1, wherein the moisture content of the gelatinized rice is adjusted in step (3) to 18-35% by weight.

7. The process according to claim 1, wherein the gelatinized rice is dehydrated in step (3) with cereal flour, cellulose powder or talc.

8. The process according to claim 1, wherein a surfactant, edible oil or talc is mixed with the soaked rice prior to gelatinizing.

9. The process according to claim 1, wherein the oil content of the fried rice is less than 16.5% by weight.Data supplied from the esp@cenet database - Worldwide

1460/2197

335.

US4208260 - 6/17/1980

TREATMENT OF COMMINUTED PROTEINACEOUS MATERIAL UNDER THE

INFLUENCE OF AN ELECTRIC FIELD


Inventor(s): OUGHTON RICHARD W (CA)

Applicant(s): DU PONT CANADA (CA)

IP Class 4 Digits: A23J; B03C

IP Class: A23J1/12; B03C5/00

E Class: A23J1/12; A23J1/00F; A23J1/14C; A23J1/20C; A23L1/025; B01D57/02; B03C5/00



Family: US4208260

Abstract:


A process for the separation of comminuted proteinaceous material from an admixture thereof with solvent is disclosed. An admixture of the material and the solvent is subjected to a high voltage electric field between an anode and a cathode, thereby depositing at least part of the material on at least the anode. The solvent is an aliphatic hydrocarbon containing from 5 to 8 carbon atoms or a normally liquid chlorofluorocarbon containing 1 or 2 carbon atoms. The proteinaceous material may be wheat, rye, barley, triticale, rice, peas, beans, soya beans, sesame seeds, peanuts, sunflower seeds, whey powder, corn, rapeseed, sorghum, flax and buckwheat. In an embodiment the fraction is in the form of a dispersion, e.g. fines, in the solvent.Description:


The present invention relates to a process for the treatment of comminuted proteinaceous material and especially to a process for the treatment of comminuted proteinaceous material under the influence of an electric field. In particular the invention relates to the treatment of admixtures of comminuted proteinaceous material and a solvent, especially a hydrocarbon solvent, for oil in the proteinaceous material, such admixtures being treated under the influence of an electric field.

As used herein proteinaceous material consists of wheat, rye, barley, triticale, rice, peas, beans, soya beans, sesame seeds, peanuts, sunflower seeds, whey powder, corn, rapeseed, sorghum, flax and buckwheat. The outer coat of the cereal grains viz wheat, rye, barley and triticale is also known as bran, such bran may have endosperm attached thereto, whereas the outer coat of peas, beans and buckwheat is also known as the seed coat. The endosperm of peas and beans is also known as the cotyledon. For the cereal grains and buckwheat the endosperm may include the germ. The expression "gum" used herein refers in particular to water-soluble gums, if present in the particular proteinaceous material.

The proteinaceous materials are a potential source of a wide variety of useful products. Examples of such products are flour, starch, protein-enriched and protein-depleted products, bran, gum and oil, depending on the particular proteinaceous material. Traditional techniques used in the food processing industry, if available, for the treatment of proteinaceous material so as to effect the separation of the proteinaceous material into fractions of differing composition are capable of improvement, for example

1461/2197

with respect to energy requirements, potential pollution problems and the taste and/or colour of products. In other instances techniques may not be available for the conversion of the proteinaceous material into commercially viable products for example products of increased protein content.

A process for the separation of a flour fraction, a bran fraction and oil from comminuted oats in which gum does not cause significant process problems and in which the flour is essentially free of gum is disclosed in U.S. patent application Ser. No. 695,206 of R. W. Oughton, filed June 11, 1976 now abandoned. A process for the separation of comminuted oats, especially flour fractions, into fractions differing in composition in which the separation occurs under the influence of centrifugal force is disclosed in U.S. patent application Ser. No. 747,734 of R. W. Oughton, filed Dec. 6, 1976. Processes for the separation of proteinaceous materials into fractions differing in composition are disclosed in

U.S. patent application Ser. No. 747,733 of R. W. Oughton, filed Dec. 6, 1976 now U.S. Pat. No.

4,154,728.

A process for isolating protein from a pulverized oil seed using liquid fluorocarbons is disclosed in

U.S. Pat. No. 3,869,438 of J. W. Finley et al, which issued Mar. 4, 1975. The density separation of protein and carbohydrates from wheat flour, soya beans, green peas and dried acid whey using a nonaqueous solvent system is described by J. W. Finley in Journal of Food Science, 41, 882-885 (1976).

Processes for the solvent-extractive milling of maize or corn, wheat, rye and the sorghum grains to remove the bran coat from whole kernels of such grains followed by comminution of the whole milled kernels and for the separation of so-called fibrous, proteinaceous, endosperm and/or starch fractions derived from such grains are disclosed by T. B. Wayne in Canadian Pat. Nos. 864,538, which issued

Feb. 23, 1971, and 905,909 and 905,910, both of which issued July 25, 1972.

Techniques for the separation of solid particles from an organic liquid e.g. for the separation of solid particles from a dispersion thereof in organic solvent, are known. For example in U.S. Pat. No.

3,304,251, which issued Feb. 14, 1967, J. Walker et al describe a process for the separation of wax from a dispersion thereof in oil in which the separation involves the use of a non-uniform electric field.

The separation is referred to in the patent as dielectrophoresis. It is stated that in order to obtain the separation of the solid particles of wax, the solid particles must have a dielectric constant higher than that of the continuous phase of the dispersion.

Processes for removing electrically conductive materials from hot liquid hydrocarbon feed stock are disclosed in U.S. Pat. Nos. 3,928,158 of G. R. Fritsche et al, which issued Dec. 23, 1975; 4,009,089 of

J. H. Crissman et al, which issued Feb. 22, 1977; and 4,022,675 of J. D. Chachere, which issued May

10, 1977. Such processes for removing electrically conductive materials involve passing the feed stock through interstitial spaces defined by non-conducting spherical particles, for example, of glass or ceramics. The spherical particles are located between electrodes across which an electric field is applied. The electrically conductive materials in the feed stock become deposited on the spherical particles from which they may be removed by back-flushing.

The separation of comminuted proteinaceous material, or fractions thereof, from an admixture of such proteinaceous material and hydrocarbon solvent may in general be accomplished by, for example, centrifuging the admixture. However such separation techniques are capable of improvement especially with regard to separation of products in a form that is essentially free from contamination with for example oil of the proteinaceous material in the solvent and/or so that the remaining hydrocarbon solvent miscella has a low level of fines. The presence of fines in a miscella has traditionally been a problem in the processing of oil seeds.

It has now been found that comminuted proteinaceous material, and especially fractions thereof, may be separated from an admixture of such proteinaceous material and an aliphatic hydrocarbon containing

5 to 8 carbon atoms or chlorofluorocarbon containing 1 or 2 carbons as the solvent under the influence of a d.c. electric field and that such separation techniques are capable of providing comminuted proteinaceous material essentially free from contamination with oil of the proteinaceous material and/or with low levels of fines.

Accordingly the present invention provides a process for the separation of a comminuted fraction of proteinaceous material from an admixture thereof with a hydrocarbon or chlorofluorocarbon solvent, said proteinaceous material being selected from the group consisting of wheat, rye, barley, triticale,

1462/2197

rice, peas, beans, soya beans, sesame seeds, peanuts, sunflower seed, whey powder, corn, rapeseed, sorghum, flax and buckwheat and said solvent being capable of extracting oil from said proteinaceous material, comprising the steps of:

(a) subjecting the admixture to the influence of a high voltage electric field, said admixture being in the form of a slurry and said electric field being formed between an anode and a cathode, and thereby depositing at least part of the comminuted fraction of proteinaceous material on at least the anode, and

(b) separating the part so deposited from said admixture.

In a preferred embodiment of the process of the present invention, the admixture of the comminuted fraction of proteinaceous material and the solvent is a dispersion of said fraction in the solvent.

In another embodiment step (b) is followed by step (c) in which the part so deposited in contacted with solvent essentially free of oil.

In the process of the present invention the comminuted fraction ofproteinaceous material that is to be separated is in admixture with a solvent, especially a hydrocarbon solvent, for any oil of the material.

Such a solvent will facilitate extraction of oil, if present, from the comminuted fraction of proteinaceous material i.e. the de-oiling of the fraction. The solvent used must be acceptable for use with foodstuffs e.g. be nontoxic at the levels remaining in the products subsequently produced, and not cause the formation of toxic materials in the product and not have a significant deleterious effect on the nutritional value of the product. The amount and type of solvent remaining in products offered for sale must be acceptable to the appropriate health authorities, as will be understood by those skilled in the art. Suitable hydrocarbon solvents are the aliphatic hydrocarbons containing from 5 to 8 carbon atoms.

Examples of solvents are pentane, hexane, heptane and cyclohexane, and mixtures thereof; as used herein the solvents hexane and heptane include those solvents referred to in the food industry as hexane and heptane. The preferred solvent is hexane. The present invention will generally be described hereinafter with reference to hexane as the solvent.

Although the process of the present invention is particularly described herein with reference to hydrocarbon solvents, especially hexane, the process may also be operated with normally liquid chlorofluorocarbon solvents containing 1 or 2 carbon atoms, for example, trifluorotrichloroethane which is available under the trademark FREON 113. Such fluorocarbons must be liquid under the conditions at which the process is operated.

In the process of the present invention the proteinaceous materials that are cereal grains or buckwheat are preferably dehulled, if necessary, prior to comminution. Techniques for dehulling cereal grains and buckwheat are known. In addition peas and beans should be separated from their pods. The proteinaceous materials are comminuted in order to facilitate extraction of any oil and to faciliatate separation of a subsequently formed admixture of comminuted proteinaceous material and solvent into fractions differing in composition. The particle size of the comminuted proteinaceous material will depend in particular on the technique to be used to separate the comminuted proteinaceous material in the admixture into fractions and may effect the segregation of protein in the material. Conventional techniques, for example, pinmilling, hammer milling and other shearing techniques would appear to produce an acceptable comminuted proteinaceous material, the preferred techniques depending in particular on the actual separation techniques to be used.

In embodiments of the present invention the admixture of comminuted fraction of proteinaceous material and hexane subjected to the influence of an electric field may be obtained from a variety of sources. For example the admixture may be formed from comminuted proteinaceous material and hexane. In such admixtures the comminuted proteinaceous material may be material that has been comminuted in order to facilitate extraction of oil. The required particle size of the comminuted proteinaceous material will depend primarily on the requirements of other processes to which the comminuted proteinaceous material is to be subjected and on any requirements with respect to the deoiling of the material.

The admixture may also be an admixture of a comminuted fraction of proteinaceous material and hexane that has been obtained from a step of a process disclosed in the aforementioned U.S. patent

1463/2197

application Ser. No. 747,733 of R. W. Oughton. Such an admixture may be for example an admixture of hexane and a fraction of proteinaceous material having a high protein content or an admixture in the form of a dispersion of particles of proteinaceous material in hexane that remains after a slurry of a comminuted fraction of proteinaceous material and hexane has been centrifuged so as to separate the fraction from the hexane.

In the process of the present invention the admixture is usually in the form of a slurry when it is subjected to the influence of the electric field. In particular embodiments of the process the slurry is, in whole or in part, a dispersion of the comminuted fraction of proteinaceous material in hexane.

In the process of the present invention the fraction of proteinaceous material may become deposited on the anode or on both the anode and the cathode while under the influence of the electric field. When the electric field is discontinued the deposited comminuted fraction may or may not remain deposited on the electrode. There appear to be a number of important factors in the deposition of fractions of proteinaceous material on the electrode(s). One factor is the shape of the electrodes. If the electrode is plate-like and in a vertical position the influence of gravity alone will tend to make a deposit less likely to remain on the electrode. Similarly a deposit will have a relative tendency to remain on a sloping electrode, especially an electrode having a lip or the like at the lower edge thereof, or on a horizontal electrode.

Another factor is the nature of the comminuted fraction of proteinaceous material. If the comminuted fraction is for example endosperm, the fraction will tend to become deposited on both electrodes under the influence of the electric field and at least the deposit on the cathode will tend to separate from that electrode when the electric field is discontinued. In contrast comminuted fractions of high protein content may tend to deposit on the anode only and remain on the anode when the influence of the electric field is discontinued. Other factors in the formation and properties of the deposit include the source and preparation of the comminuted fraction, particle size, voltage applied, agitation of the admixture of comminuted fraction and hydrocarbon solvent and nature of the electrodes.

As exemplified hereinafter the electric field to which the admixture is subjected according to the present invention is a high voltage d.c. electric field for example, 1-20 kV/cm and especially 5-15 kV/cm. The d.c. electric field may be a steady or pulsating d.c. electric field. Higher or lower voltages may however be used.

In one embodiment of the present invention a comminuted fraction of proteinaceous material may be de-oiled. For example, an admixture of such a fraction and hexane, in which the fraction and/or the hexane contain oil from the proteinaceous material, may be subjected to the influence of an electric field in a continuous or batch process. The preferred type of process may depend on the nature of the protein fraction. In a batch process all or part of the comminuted fraction could be deposited on the anode, or anode and cathode, and subsequently the remaining oil-containing solution may be replaced with oil-free hexane to wash the deposit. The technique of replacing the solution with oil-free hexane will depend to some extent on the nature of the deposit, as will be understood by those skilled in the art. In a continuous process the anode could be a moving electrode e.g. a rotating drum or a moving inclined belt, from which the deposit could be removed continuously. The deposit could be washed e.g. by spraying with oil-free hexane prior to being separated from the moving electrode. By judicious choice of, for example, technique, method and amount of washing and repetition of the deposition/washing procedure, the oil content of a comminuted fraction of proteinaceous material may be reduced by substantial amounts.

In another embodiment, fines of proteinaceous material may be removed from an admixture of hexane and a comminuted fraction of proteinaceous material remaining in the form of fines. For example, such an admixture could be in the form of a miscella obtained from a continuous centrifuge in which a comminuted fraction is being separated from hexane. In a centrifugal separation process it is difficult to remove fines effectively from an admixture of hexane and a comminuted fraction of proteinaceous material and, thus, the miscella discharged from the centrifuge usually contains fines. Such a miscella may be subjected to the influence of an electric field according to the present invention in order to remove part or even effectively all of the fines in the miscella. Apart from clarification, the separation of fines from the miscella may be beneficial in subsequent treatment of the miscella e.g. in the recovery of any oil in the miscella and/or in the recovery of hexane for further use.

1464/2197

In a further embodiment of the present invention, a fraction of proteinaceous material having a high protein content may be recovered from an admixture of hexane and a comminuted fraction of proteinaceous material having a high protein content. Such an admixture may be obtained from a variety of sources, for example, using processes disclosed in the aforementioned U.S. patent application Ser. No. 747,733 of R. W. Oughton. Under the influence of the electric field on the admixture, a fraction of high protein content may become deposited on the anode and the cathode may be free of deposit. While the recovery of such a fraction may be operated as a batch or continuous process, the latter is preferred. Preferably, the anode is adapted for the continuous recovery of deposit e.g. it is a rotating drum or moving belt electrode. Recovery of the fraction of proteinaceous material, washed if necessary to remove any adsorbed oil, so as to obtain a clear hexane solution is possible.

In the processes of the present invention the space between electrodes does not contain matter other than the admixture thereby permitting free flow of the admixture between the electrodes. As discussed hereinabove the admixture is usually in the form of a slurry. In specific embodiments, the slurry may be in the form of a dispersion. Extraneous matter between the electrodes may lead to plugging of the apparatus and hence to process problems.

The various processes embodied by the present invention are useful in a variety of ways in the treatment of admixtures of hexane and comminuted fractions of proteinaceous material, as described herein.

The present invention is illustrated by the following examples.

EXAMPLE I

25 g of comminuted preteinaceous material, de-hulled where necessary, were admixed with 250 g of hexane for 3 minutes in a WARING.TM. blender. The resultant admixture was then decanted into a

400 ml beaker. A cylindrical aluminum foil electrode (cathode) and a centrally located rod anode were placed in the admixture in the beaker. A d.c. electric field of 15 kV (5 kV/cm) was applied across the electrodes.

In all cases proteinaceous material was primarily attracted to the anode. However the deposit formed did not remain on the anode when the electric field was discontinued. In general proteinaceous material was also attracted to the cathode.

Further comments are as follows:

>;tb;______________________________________

>;tb;Proteinaceous

>;tb; Current

>;tb;Material (mA) Comments

>;tb;______________________________________

>;tb;Soya Beans

>;tb; 0.8 Clear miscella formed but

>;tb; cloudy between electrodes.

>;tb;Sesame Seeds

>;tb; 0 Clear miscella formed.

>;tb;Peanuts 0.05 Clear miscella formed.

>;tb;Sunflower 0.55 Clear miscella formed. "Spokes"

>;tb;Seeds of material formed between the

>;tb; electrodes.

>;tb;Whey 0 Miscella not clear. Some

>;tb; "spokes" formed. Large part of

>;tb; material settled to bottom of

>;tb; beaker.

>;tb;Barley 0.1 "Spokes" between electrodes.

>;tb;Buckwheat 0 Clear miscella formed. All

>;tb; material on anode.

1465/2197

>;tb;Corn 0 Miscella cloudy. "Spokes"

>;tb; formed between electrodes.

>;tb;Wheat 0 Miscella cloudy. "Spokes",

>;tb; mainly on anode, were formed.

>;tb; Large part of material settled

>;tb; to bottom of beaker.

>;tb;Rapeseed 0 Clear miscella formed. "Spokes"

>;tb; formed. On repetition of run on

>;tb; same material, material tended

>;tb; to go to anode only with no

>;tb; "spokes".

>;tb;Rice 0 "Spokes" between electrodes.

>;tb;Sorghum -- Some material attracted to

>;tb; anode, most material settled

>;tb; to bottom of beaker.

>;tb;______________________________________

This example illustrates that the process of the present invention is capable of being used to separate proteinaceous material from an admixture thereof with hexane.

EXAMPLE II

100 g of soya beans were admixed with 250 g of hexane for 3 minutes in a WARING blender. A further 750 g of hexane were then added. The resulting admixture was pumped through a glass cylinder equipped with a centrally located rod cathode and a cylindrical wire mesh anode at the circumference of the cylinder. A d.c. electric field of 15 kV (7.5 kV/cm) was applied across the electrodes while the admixture was pumped through the cylinder.

The material in the admixture became deposited, mostly on the anode. The hexane miscella, which contained the oil in soya beans, passing from the cylinder was substantially clear.

The hexane miscella was passed through the cylinder again while the material was still deposited on the anode. The hexane miscella thus treated that passed from the cylinder was very clear.

This example illustrates a method of de-oiling soya beans and of separating soya bean material from solution.

EXAMPLE III

100 g of dehulled soya beans were admixed with 300 g of hexane for 2 minutes in a WARING blender and then sieved through a 80 mesh TYLER.TM. screen. The undersized material i.e. that passing through the screen, was pumped through a glass cylinder equipped with a centrally located rod cathode and a cylindrical wire mesh anode at the circumference of the cylinder. A d.c. electric field of 15 kV

(7.5 kV/cm) was applied across the electrodes. The hexane miscella passing through the cylinder was fed to the screen and recycled back through the cylinder.

The undersized material became deposited on the anode. The oversized material, which was retained on the screen, became very clean in appearance. The miscella became clear and free of visible particles in about one minute. After a period of time the hexane miscella was replaced with fresh hexane so as to wash the undersized material on the anode.

At the end of the run the hexane in the cylinder was drained off. The deposite of undersized material flowed out of the cylinder with the hexane.

The above procedure was repeated except that the admixture was formed from 100 g of rapeseed and

300 g of hexane which were admixed for 2 minutes in a WARING blender. A similar result was obtained.

EXAMPLE IV

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A sample of proteinaceous material, dehulled if necessary, was comminuted in a knife mill using a 1 mm screen. A 25 g sample of the comminuted material was admixed with 250 g of FREON.RTM. 113 fluorocarbon solvent (trichlorotrifluoroethane) in a 400 ml beaker fitted with two electrodes. The electrodes were a cylindrical aluminum foil electrode and a centrally located electrode, of rolled aluminum foil, approximately 1 cm in diameter. A d.c. electric field of 20 kV (6.7 kV/cm) was applied across the electrodes.

When the proteinaceous material was sunflower seeds the material was attracted to the anode especially when the central electrode was the anode. In the latter case when the anode was withdrawn from the solvent the material remained adhered to the electrode. However when the cylindrical electrode was the anode the material did not remain adhered to the electrode when the electric field was discontinued.

When the proteinaceous material was soya beans, the so-called "spokes" were observed between the electrodes. When the cental electrode was the anode the material remained adhered to the electrode as the anode was withdrawn from the solvent.

This example illustrates that the process of the present invention is capable of being used with a liquid fluorocarbon as the solvent.Data supplied from the esp@cenet database - Worldwide

Claims:


I claim:

1. A process for the separation of a comminuted fraction of proteinaceous material from an admixture thereof with an aliphatic hydrocarbon containing 5 to 8 carbon atoms or a normally liquid chlorofluorocarbon containing 1 or 2 carbon atoms, said proteinaceous material being selected from the group consisting of wheat, rye, barley, triticale, rice, peas, beans, soya beans, sesame seeds, peanuts, sunflower seed, whey powder, corn, rapeseed, sorghum, flax and buckwheat, comprising the steps of:

(a) subjecting the admixture to the influence of a high voltage electric field, said admixture being in the form of a slurry and said electric field being formed between an anode and a cathode, and thereby depositing at least part of the comminuted fraction of proteinaceous material on at least the anode, and

(b) separating the part so deposited from said admixture.

2. The process of claim 1 in which the high voltage electric field has an intensity in the range of about

1-20 kV/cm.

3. The process of claim 1 in which proteinaceous material is deposited on both the anode and the cathode.

4. The process of claim 1 in which proteinaceous material is only deposited on the anode.

5. The process of claim 2 in which the admixture of proteinaceous material and solvent is in the form of a slurry.

6. The process of claim 2 in which the proteinaceous material is admixed with the solvent in the form of a dispersion.

7. The process of claim 4 in which step (b) is followed by a step (c) in which the fraction deposited on the anode is contacted with solvent essentially free of oil.

8. The process of claim 1 in which the solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane and chlorofluorocarbons, and mixtures thereof.

9. The process of claim 2 in which the solvent is selected from the group consisting of pentane, hexane, heptane and cyclohexane, and mixtures thereof.

1467/2197

10. The process of claim 2 in which the solvent is a chlorofluorocarbon.

11. The process of claim 8 in which the high voltage electric field has an intensity in the range of about

5-15 kV/cm.

12. The process of claim 1 in which the proteinaceous material is soya beans.

13. The process of claim 1 in which the proteinaceous material is sunflower seeds.

14. The process of claim 1 in which the proteinaceous material is sesame seeds.

15. The process of claim 1 in which the proteinaceous material is peanuts.

16. The process of claim 1 in which the proteinaceous material is whey.

17. The process of claim 1 in which the proteinaceous material is barley.

18. The process of claim in which the proteinaceous material is buckwheat.

19. The process of claim 1 in which the proteinaceous material is corn.

20. The process of claim 1 in which the proteinaceous material is wheat.

21. The process of claim 1 in which the proteinaceous material is rapeseed.

22. The process of claim 1 in which the proteinaceous material is rice.

23. The process of claim 1 in which the proteinaceous material is sorghum.Data supplied from the esp@cenet database - Worldwide

1468/2197

336.

US4238514 - 12/9/1980

RICE CEREAL AND PROCESS


Inventor(s): CLAUSI ADOLPH S (US); MARTIN THOM O (US)



IP Class: A23L1/18

E Class: A23L1/18F; A23L1/18C



Family: CA1118632

Abstract:


Disclosed is an improvement in a process for preparing a puffed ready-to-eat cereal product from rice.

Nato rice typically sticks and clumps during processing. The present invention reduces this problem. In a preferred embodiment, milled rice is admixed with spray dried torula yeast which has been cultured in ethanol, prior to cooking the rice in a sugar solution, and drying, tempering, bumping, puffing and toasting.Description:


DESCRIPTION

1. Technical Field

Our invention relates ready-to-eat cereal products, and particularly to an improved process for preparing a puffed cereal product from milled rice.

In the the preparation of puffed cereal products from milled Nato rice, it is necessary to first cook the rice in a flavoring solution which usually contains sugars, salt and the like. The processing of Nato rice in this manner has been difficult in the past because the rice tends to stick together after cooking and again after drying. The present invention provides a new process which decreases sticking and clumping.

2. Background Art

Nato rice is attractive economically, but has found limited use in ready-to-eat cereals because of its inherent processing difficulties. The prior art has determined that the sticking and clumping of cooked, milled Nato rice can be decreased by employing glycerol monostearate, particularly as sold under the trademark Myvaplex. As available, the Myvaplex glycerol monostearate is a mixture with several other synthesized chemicals. The use of this processing aid, however, was not wholly advantageous from a nutritional standpoint. It was added for the sole purpose of improving the processability of the product and provided no nutritional value. Thus, it was inert in the food sense. Moreover, government regulations prevent calling a cereal product "natural" if it contains such synthesized chemical compounds. Accordingly, when it has been desired to produce natural-appearing products, such as

1469/2197

disclosed in the U.S. Pat. No. 4,038,427, which could be legally called "natural", it has been the practice to avoid using Nato rice, regardless of the fact that an effective processing aid was known which was safe and food-approved.

DISCLOSURE OF INVENTION

In accordance with the present invention, we provide an improvement in a process for preparing a puffed product from rice by cooking milled rice in an aqueous flavoring solution, drying the resulting cooked rice to a moisture content effective for puffing, tempering the resulting dried rice to a degree effective to provide satisfactory puffing, and heating the rice under conditions effective to puff the rice, wherein the improvement comprises: prior to cooking the rice, admixing with it, dried torula yeast in the amount effective to reduce the tendency of the cooked rice to stick and clump. Alternatively cooked and extruded rice products can be similarly improved with torula yeast prior to puffing.

Thus, the present invention improves the known process for producing puffed Nato rice for use in cereal products by the use of a specially prepared torula yeast which decreases sticking and clumping after cooking and drying of the rice. The rice prepared in this manner can be used as a cereal product in the form produced, or can be combined with various cereal or food components to form pre-sweetened, agglomerated, fruit and cereal, or other ready-to-eat ceral products. As with prior art ready-to-eat cereal products of this type, they can be comsumed with milk, by themselves as snack products, or as ingredients in or garnishes in other food products.

In preparing the puffed products, milled Nato rice is mixed with spray-dried torula yeast which has been prepared by culturing on food grade ethanol. The spray-dried torula yeast is inactive by virtue of the conditions of spray-drying, but yet provides proper functionality for the purpose of decreasing sticking and clumping after cooking and drying. The torula yeast in its preferred form is a bland-tasting cream-colored powder. It will typically have a protein content of above approximately 45% and a fat content of no greater than about 9%. It is spray-dried to a moisture content of lower than 7% under conditions effective to provide a near-neutral to slightly-alkaline pH, preferably within the range of from about 7 to 8. Those spray-dried torula yeast products sold under the trademark "Torutein", and particularly those sold under the numerical designations 94, 50 and 10, have been found effective for use according to the present invention.

The spray-dried torula yeast can be employed according to the present invention in any amount effective to obtain a reduction in the degree of stocking and clumping of the milled Nato rice. The exact amount employed will be a function not only of the type of rice employed, but also of the ability of the processing equipment to handle a degree of sticking and clumping, as well as the functionality of a particular lot or grade of the torula yeast, as well as other variables which are beyond the scope of our present investigation. It has been found in practice, however, that a level of about 1% based on the weight of the rice will be effective under most conditions. It will be understood, however, that amounts less than this, say on the order of about 0.25%, and greater than this, say up to about 5% by weight can be employed so long as it is recognized that at the lower end of the range, less reduction in sticking and clumping will be obtained, and at the upper end of the range, there may be some minor flavor problems. It is fully within the contemplation of the present invention, however, to employ whatever level is effective for the intended purpose and which is not otherwise detrimental to the particular food product intended.

The spray-dried torula yeast is admixed with the milled Nato rice prior to cooking in the aqueous flavoring solution. The Nato rice is preferably what is known in the art as dehulled, polished Nato rice.

In this form it is mixed dry with the spray-dried torula yeast for a period of time sufficient to uniformly distribute the smaller torula yeast particles among and around the larger rice grains. Typically, this is conducted in a conventional rotary pressure cooker prior to introduction of the aqueous flavoring solution thereto.

After adequate admixing of the Nato rice and the spray-dried torula yeast in the dry state, and aqueous flavoring syrup is added thereto in an amount effective to provide enough water for complete cooking of the rice as well as enough flavoring for the intended end use of the product. While it is possible to employ water alone, or water with salt, it is typical to employ various sugars such as sucrose, corn syrup solids, dextrose, and the like as well as flavoring materials such as malt extract and other cereal-

1470/2197

compatable flavors. It is typical to employ a cooking syrup in an amount of from about 30% to about

50% based upon the weight of the rice wherein the syrup contains approximately 30% to 50% solids by weight.

After admixing the Nato rice and the spray-dried torula yeast with the aqueous flavoring solution, but prior to actually cooking the admixture, the admixture is preferably mixed in the rotary cooker for a period of up to about 15 to 30 minutes.

The cooking is preferably carried out in a conventional rotary pressure cooker which after addition of the ingredients, is sealed and heated for a time and under a steam pressure effective to fully cook the rice. Typically the rice will be cooked for a period of time of from about 30 to 60 minutes at a steam pressure of from about 10 to about 25 psig. According to preferred embodiment, the rice will be cooked for about 45 minutes at about 18 psig. During the entire period of cooking, the pressure cooker is rotated about its horizontal axis to provide good liquid-solid contact and to minimize sticking and clumping as would happen if the material remained stationary. After obtaining the desired degree of cook, the pressure cooker is depressurized and cooking air is admitted to at least partially cook and cooked Nato rice prior to unloading. According to the preferred embodiment, the rice is cooled during the unloading of the cooked rice from the rotating cooker with ambient air.

The resulting cooked Nato rice is then dried to a moisture content effective for puffing. Typically, the moisture content will be reduced to within the range of from about 12% to about 20% based upon the weight of the total cooked rice product. Drying can be accomplished by any suitable means. Typical of the equipment which can be employed are the well known cereal and macaroni dryers which find extensive use in the cereal art. The drying temperature will typically be sufficiently above 100 DEG C. to obtain an adequate rate of drying. Typical drying temperatures will be within the range of from about 100 DEG C. to about 110 DEG C. As is known in the art, lower drying temperatures are not preferred because they require extensively long periods of time to obtain the proper moisture content, while higher drying temperatures are not preferred because they can cause uneven drying and caramelization which interfere with the puffing process.

After the drying, it is necessary to temper the rice for a period effective to substantially equalize the moisture content throughout the individual grains to improve its puffing characteristics. Typically, the tempering will take from about 3 to about 24, preferably from 4 to 6 hours. During tempering the rice can be maintained in mild agitation if, desired, however, this is not necessary.

Prior to puffing, the tempered Nato rice can be bumped by passing it between a pair of spaced rollers or other means suitable for flattening the rice into non-resillient pieces of diminished thickness.

According to a preferred embodiment, the rice will be decreased to about 40% to about 75% of its original thickness. In this embodiment the rice will expand upon puffing into a gently cupped and puffed flake. If desired, it is possible to bump the rice to a greater degree to obtain a more-flattened, flake-like product.

After tempering and bumping if desired, the rice will be charged to a puffing device for forming the puffed flake. Typically a puffing oven can be employed where the Nato rice will be blasted with heated air at a temperature of from about 200 DEG to about 250 DEG C. at atmospheric conditions for a period from about 10 to about 120 seconds to product the desired puffed flake. Preferably the temperature within the puffing oven is sufficiently high to toast the rice simultaneously with puffing.

BEST MODE FOR CARRYING OUT THE INVENTION

The following example sets forth the best mode for carrying out the invention. This example is for the purpose of further describing and explaining the invention to those skilled in the art and is not meant to be limiting in any regard. Unless otherwise indicated, all parts and percentages given below are by weight.

EXAMPLE

1471/2197

To prepare a batch of cereal according to the process of the present invention, 634 kilograms of Nato rice and 6.5 kilograms of Torutein-94 (TM) spary-dried torula yeast is added to a rotary pressure cooker and admixed therein by rotating the cooker. After 5 minutes of mixing, 240 kilograms of an aqueous flavoring syrup solution containing about 50.3% water and about 40.7% solids is added to the cooker and mixed with the rice and spray-dried torula yeast for about 20 minutes prior to heating under pressure. The flavoring solution contains about 145 kilograms of aqueous sucrose containing 32.5% water, about 10 kilograms corn syrup containing about 19.5% water, and about 85 Kilograms of salt brine containing about 73.5% water. At the end of 20 minutes of mixing, the cooker is heated under a pressure of 18 psig for 45 minutes with continued rotation. After this priod of time the cooker is exhausted to 0 psig. The cooled Nato rice is then cooled in the cooker, still under rotation, for 2 hours.

The cooked and cooked Nato rice is then unloaded onto the wire mesh belt of a two-stage Proctor and

Schwartz dryer. The drying air passing through both stages of the dryer is at a temperature of about 110

DEG C. and reduces the moisture content of the cooked rice from the value of about 26% at the end of the cooking, to about 18% at the end of zone 1, and about 14% at the end of zone 2. Clumps are diminished by employing a pinbreaker within the dryer and employing a vibrating grading screen at the dryer discharge. The screen has about 41% net open area with opening sizes being 0.9.times.0.9 mm.

The dried, cooked Nato rice is passed to a bin wherein it is tempered for about 1 to 6 hours and is then passed between bumping rolls spaced at a distance of about 50% of the thickness of an average grain and rotated at a speed of about 160 rpm. The bumbed Nato rice is then toasted in a conventional toasting oven operated at a temperature of about 240 DEG C. for about 90 seconds to finally puff and toast the flake.

The above described puffed and toasted Nato rice flakes are desirably employed to prepare an agglomerated, natural cereal product. To accomplish this, the following dry fraction ingredients are weighed and added to a multi-flighted coating reel approximately 3 feet in diameter:

Rolled oats (8% moisture)--8 Killogram (KG)

Rolled wheat (8% moisture)--1.68 KG

Torula treated Nato rice flakes (2.5% moisture)--4.12 KG

Almonds, diced (4% moisture)--1.4 KG

Unsweetened, dried coconut (4% moisture)--1.31 KG

Non-fat Dry Milk (3% moisture)--1.04 KG

The dry fraction ingredients are mixed in a coating reel which is operated at 30-60 rpm's for 5 minutes.

Pure coconut oil (3.8 Kilograms) at 43 DEG C. is poured or sprayed onto the pre-blended dry fraction ingredients in the rotating reel, and the resulting oil-coated dry fraction is allowed to tumble in the reel for an additional five minutes at the same rpm to insure distribution of oil on the surface of the ingredients and impregnation thereof.

Spearately, a coating syrup having the following ingredients is prepared:

Brown sugar (granular, 2% moisture)--5.57 KG

Corn syrup (42 D.E. 80% solids)--0.54 KG

Honey solids--0.32 KG

Pure caramel power (1% moisture) 0.27 KG Water--2.6 KG

The foregoing coating ingredients are dissolved in water at 65 DEG C. and sprayed or poured at this temperature onto the oil-coated dry ingredients fraction in the rotating reel, the reel being operated at a range of 30-60 rpm's for an additional 5 minutes of tumbling so as to promote uniform coating of the material and particle aggregation.

The oil/syrup coated aggregates are then removed from the coating reel at a moisture content of 13% and dried. The dried agglomerates have a final moisture content of 1.5% to 3%. The material is broken apart while still in a warm, plastic state, cooled and sized by pressing through wire screen having .chi.inch openings. The sized, cooled agglomerate is then bulk-bagged for packaging.

The above description has been for the purpose of explaining the present invention of those of ordinary skill and is not intended to detail all those obvious modifications and variations of it which will become apparent upon reading. It is intended, however, to include all such obvious modifications and variations within the scope of the invention which is defined in the following claims.Data supplied from the esp@cenet database - Worldwide

1472/2197

337.

US4325976 - 4/20/1982

REFORMED RICE PRODUCT


Inventor(s): HARROW ALASTAIR D (--); MARTIN JOHN W (--)

Applicant(s): LIPTON INC THOMAS J (--)


IP Class: A23L1/10; A21D2/00; A21D10/00

E Class: A23L1/168



Family: US4325976

Equivalent: EP0016649; IE800585L; IE49325

Abstract:


A reformed rice product is made by extruding a dough through a low-pressure, pasta-type extruder to form simulated rice grains which are then dried at a temperature of up to 150 DEG C. to a final moisture content not exceeding 15% of the product. The dough is made by adding water to a dry composition comprising a mixture of pregelatinized and ungelatinized flour, sodium chloride and fat in powder form.Claims:


What is claimed is:

1. A dry composition for use in the production of a reformed rice product, which comprises: (a) a mixture of pregelatinised and ungelatinised flour in which the proportion of the pregelatinised flour is from 30% to 70% by weight of the mixture and in which the flour is at least partly rice flour, (b) at least 3.0% sodium chloride by weight of the composition, and (c) an amount up to 10% of fat in powder form by weight of the composition.

2. A composition according to claim 1, in which the flour comprises a major proportion of rice flour.

3. A composition according to claim 1 in which the amount of sodium chloride is from 4% to 12% by weight of the composition.

4. A composition according to claim 1 which additionally comprises from 1% to 3% by weight of a puffing aid.

5. A composition according to claim 1, in which the fat in powder form is a spray-dried fat.

6. A composition according to claim 5, in which the amount of spray-dried fat is from 1% to 10% by weight of the composition.

1473/2197

7. A composition according to claim 6, in which the amount of the spray-dried fat is from 3% to 6% by weight of the composition.

8. A composition according to claim 1 in which the fat in powder form is present as whole egg or egg yolk powder.

9. A composition according to claim 8, in which the amount of whole egg or egg yolk powder is from

1% to 7% by weight of the composition.

10. A composition according to claim 1, which additionally comprises from 0.5% to 2% by weight of lecithin.

11. A process for producing a reformed rice product which comprises the steps of: (a) mixing the composition of claim 1 with a proportion of water sufficient to produce an extrudable dough containing

20% to 30% water by weight of the dough, (b) extruding the dough into a form so as to obtain simulated rice grainsand (c) drying the simulated rice grains at an elevated temperature up to 150 DEG

C., to a moisture content not exceeding 15% by weight of the dried product.

12. A process according to claim 11, in which the dough is extruded through a die having generally elliptical apertures having a long axis length of from 4 mm to 8 mm and a short axis length of from 0.5 mm to 3 mm.

13. A process according to claim 11, in which the extruded dough is cut adjacent to the die face such that the cut thickness of the simulated rice grains is from 0.5 mm to 3 mm.

14. A process according to claim 11, in which the dough is extruded through a die having generally elliptical apertures having a long axis length of from 4 mm to 7 mm and a short axis length of from 1 mm to 1.6 mm and the extruded dough is cut adjacent to the die face such that the cut thickness of the simulated rice grains is not more than 1.6 mm.

15. A process according to claim 11, in which the extruded dough is cut using a knife coated with a synthetic polymer.

16. A process according to claim 15, in which the synthetic polymer is polytetrafluoroethylene.

17. A process according to claim 11 in which the simulated rice grains are dried in a fluidised bed air drier.

18. A process according to claim 11 wherein the simulated rice grains are dried at a temperature of from 130 DEG to 150 DEG C.

19. A reformed rice product in the form of simulated rice grains made by the process according to claim 11.Data supplied from the esp@cenet database - Worldwide

1474/2197

338.

US4333960 - 6/8/1982

PROCESS FOR PRODUCING DEHYDRATED RICE AND PRODUCT FROM

PARBOILED RICE


Inventor(s): BARRY JAMES A (--); MCGARRY JAMES (--)

Applicant(s): COMHLUCHT SIUICRE EIREANN (--)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/18C6


Priority Number: IE19790000474 (19790703); IE19800001032 (19800516)

Family: CA1144812

Equivalent:

Abstract:

EP0021855; IE790474L; IE49456


The invention concerns a process for the production of "no-cook" dehydrated rice which can be rehydrated and rendered palatable in a few minutes by the addition of boiling water thereto. The process comprises soaking parboiled rice, cooking it, drying it to a moisture content of 2-20% by weight, and puffing the rice at a temperature in the range 150 DEG -350 DEG C. In a preferred embodiment, the parboiled rice is soaked to a moisture content of about 50%, washed, drained, allowed to stand for at least 1/2 hour, cooked in dry steam, washed, cooled, dried to a moisture content around

10%, allowed to stand for at least 1/2 hour, and puffed in a stream of hot air for 13-20 seconds at 240

DEG -270 DEG C.Description:




This invention relates to the processing of rice to produce dehydrated rice, particularly for use in dehydrated foodstuffs such as soups and so-called "instant" foods or "no-cook" foods.

There is increasing commercial interest in dehydrated food preparations which can be rehydrated by the consumer in a few minutes by the addition of boiling water and which do not require any further cooking. Such food preparations can be sold in a container which also acts as a dish. The consumer adds boiling water to the food preparation and obtains a warm, cooked, palatable food which can be eaten after a few minutes. The necessary boiling water can be obtained from a kettle and there is no need for a cooker or a saucepan.


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However there has not hitherto been any process available for the reliable production of rice which is suitable for use in "no-cook" food preparations and which is capable of rehydration to a palatable state in 2-3 minutes by the addition of boiling water therein, without additional cooking. Much work has been done in the field of quick-cooking rice (see "Technology of Quick-Cooking Rice" by B. P. Bhat,

T. K. Chakrabarty and B. P. Bhatia in "Indian Food Packer", September-October 1972) but processes such as those of A. K. Ozai Durrani in U.S. Pat. Nos. 2,438,939 and 2,733,147 require the product to be further cooked by immersion in boiling water for 2-3 minutes (i.e. heating must be carried out to keep the water boiling) or by bringing the water back to the boil after the rice has been added to it.

Disadvantages of the process of U.S. Pat. No. 2,438,939 are set out in Ozai Durrani's later U.S. Pat. No.

2,937,946. U.S. Pat. No. 2,733,147 and Ozai Durrani's British Pat. Nos. 657,691, 737,372 and 737,450 describe processes involving mechanical compression of the rice grain, which is difficult to carry out in large-scale production. British Pat. No. 437,446, also of Ozai Durrani, describes a process involving steaming and drying rice grains. The fact that so many proposals originated from the same inventor illustrates the problem in finding a satisfactory process for the production of a rice product which could be described as quick-cooking.

U.S. Pat. No. 2,715,579 of R. L. Roberts describes the preparation of a rice product which is said to be pre-cooked and whose preparation for the table involves absorption of boiling water without additional cooking. The Roberts' process involves soaking raw white rice in water until its moisture content is about 25 to 35%, heating the soaked rice to completely gelatinize the starch content of the grain without substantial increase in the moisture content thereof, drying the gelatinized grains to a moisture content from about 8 to 14%, and then expanding the dried grains in hot air at 200 DEG-260 DEG C.

The present inventors have carried out tests on commercially available raw white rice and have found it to be an unsatisfactory starting material for the production of a "no-cook" rice by expansion or

"puffing". When raw white rice of commerce is soaked, the present inventors have observed that a substantial proportion of grains have surface cracks which make the rice difficult to handle in subsequent processing. Also it has been observed that grains of raw white rice do not absorb water in a satisfactory manner in the soaking step.

In an earlier U.S. Pat. No. 2,616,808, R. L. Roberts described the use of parboiled rice in an expansion process to produce a ready-to-eat cereal product i.e. a product not intended to be rehydrated. However,

Roberts did not suggest the use of parboiled rice for preparation of pre-cooked rice in the process of

U.S. Pat. No. 2,715,579.


It is an object of the present invention to provide a process for the production of a "no-cook" rice product which does not involve mechanical compression and which can be carried out reliably in large scale production in order to prepare rice capable of rehydration to an acceptable palatable state in 2-3 minutes by the addition of boiling water thereto.

The present invention provides a process for the production of dehydrated rice which comprises soaking paraboiled rice, cooking it, drying the rice to a moisture content in the range 2 to 20% by weight and puffing the rice at a temperature in the range 150 DEG-350 DEG C. The percentages mentioned herein are calculated on the total weight.

Parboiled rice is readily available on a commercial scale. It differs from raw rice in that the rough rice has been treated, e.g. with water and steam, before it is milled to separate the husk from the grain. The parboiling treatment causes partial gelatinization in outer layers of the grain and an absorption of valuable minerals and vitamins into the kernel. In the manufacture of dehydrated foodstuffs in accordance with the present invention, the rice normally used is parboiled long grain rice.

Preferably, in the process of the present invention, parboiled rice of commerce is soaked in water until it has a moisture content in the range 20 to 60% by weight. The aim of the soaking step is to distribute moisture throughout each grain of rice, and more particularly to distribute the moisture evenly. The soaking procedure may involve soaking the rice over a relatively long period e (e.g. for 21/2-31/2 hours, particularly about 3 hours), or it may involve a relatively short soaking time, preferably 1-2 hours, followed by a tempering period in which the soaked rice is allowed to stand for a minimum of

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1/2 hour, preferably at least 1 hour, so that the moisture content becomes uniformly spread through the rice.

In the preferred process of the present invention, after the soaking step, the rice is washed to remove starch which has soaked out of the grain. This washing step helps in overcoming sticking during the subsequent processing. After washing, the rice is normally drained.

The soaking is most suitably carried out in water at 15 DEG-30 DEG C., preferably 20 DEG-25 DEG

C., particularly about 22 DEG C. However, the temperature of soaking can be varied outside the above limits, with the time being adjusted accordingly. Soaking at a higher temperature will result in diffusion of moisture into the centre of the grain more rapidly. However, it is preferred to carry out soaking at a temperature at which no appreciable gelatinization of starch occurs, i.e. below 65 DEG C.

The preferred product at the end of the soaking step has a moisture content of 40-55% by weight, preferably of the order of 50% by weight.

The cooking step is preferably carried out in dry steam, suitably for about 2-10 minutes, more preferably for 3-5 minutes, particularly about 4 minutes. The steam cooking process is essentially a dry blanching process, so that the grains of rice remain substantially dry on the surface (the moisture being distributed through the grain). If the surface were wet during steam cooking, or if cooking in water for more than a short period were used, excess water would be absorbed into the surface layers of the grain, leading to an undesirable release of starch. It has been found that steam blanching is satisfactory without the application of increased pressure. However, cooking can alternatively be carried out in steam at a pressure up to about 30 pounds per sq. inch gauge (207 kN/m@2), or a short period of cooking in water can be followed by pressure cooking.

The cooked rice is preferably washed and cooled so as to stop the cooking process and to wash off any starch which has come out of the grains during cooking. The washing step is suitably carried out in cold or warm water, e.g. at 10 DEG-45 DEG C.

It is usual to dry the cooked rice to a moisture content in the range of 5-20% by weight, more preferably 7-14%, particularly about 10% moisture by weight. This drying step is suitably carried out with air at a temperature of about 50 DEG-65 DEG C., drying being controlled so that the rice is not heated to a temperature above about 55 DEG C.

Drying in a conventional air-dryer such as a Schilde dryer can result in non-uniform drying of the rice.

It is preferred therefore to temper the dried rice by allowing it to stand for a minimum of 1/2 hour, preferably at least one hour to allow residual moisture in the rice to become evenly distributed through the mass of the rice.

The puffing procedure to expand the rice grains is preferably carried out in a current of hot gas particularly air or superheated steam. It is preferred to use dry air at this stage rather than steam in order to avoid condensation which could result in extraction of starch. "Gunpuffung", involving the use of super atmospheric pressure, is not necessary. The puffing temperature is preferably in the range 180

DEG-300 DEG C., more preferably 240 DEG-270 DEG C. The puffing time may suitably be 5-45 seconds, although the time required for puffing is dependent on the temperature used and also on the moisture content of the dried rice grains. It is particularly preferred to carry out the puffing step on rice having a moisture content of about 10% by weight for 13-20 seconds at about 250 DEG C. At lower temperatures (e.g. below 190 DEG C.) puffing must be carried out over longer time periods and care must be taken to ensure that heat is transmitted into the rice grains before the moisture has diffused out.

At higher temperatures (above 280 DEG C.) there is a risk of scorching.

The combination of using parboiled rice as the starting material and processing it in accordance with the invention results in a "no-cook" rice which can be reconstituted satisfactorily by addition of boiling water thereto and which can then be eaten as part of a "cooked" foodstuff without any further cooking.

It is believed that parboiled rice is advantageous compared to raw white rice because the outer layers of the grain of parboiled rice maintain the structure of the grain and restrict loss of starch during the processing steps so that the grains presented at the puffing stage will expand in a reliable and consistent manner. The preferred embodiment of the invention, involving even distribution of moisture through

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the grains and two tempering steps to allow moisture to equilibrate after soaking and drying, improves the consistency of the product.

Two embodiments of the invention will now be described by way of Example, the first Example being the preferred embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENT

EXAMPLE 1

Parboiled long grain rice was soaked for 90 minutes in water at 22 DEG C., resulting in a moisture content of about 50% by weight. The soaked rice was washed in water at ambient temperature (20

DEG C.) to remove surplus starch. The water was then drained off. The rice was tempered by being allowed to lie in a large bin for 11/2 hours at ambient temperature (20 DEG C.), during which time any excess water drained off and the remaining moisture content equilibrated i.e. spread uniformly through the rice.

The rice was cooked in dry steam at atmospheric pressure for 4 minutes.

Immediately after cooking, the rice was washed in water at 34 DEG C. to stop further cooking and to remove surplus starch. Surplus water was drained off.

The cooked rice was dried in a Schilde air dryer supplied with air in the range 50 DEG-60 DEG C. for

21/4 hours, resulting in a moisture content of about 10% by weight. The rice was allowed to stand for 1 hour at ambient temperature again to allow the moisture to equilibrate. The dried rice was puffed in a current of air at 250 DEG C. for 20 seconds, a layer of rice generally one grain deep being passed on a stainless steel mesh belt moving through a cabinet in which the first half was supplied from above with a current of air at 250 DEG C. and the second half was supplied with a current of air at ambient temperature. The forwarding speed of the belt was controlled so that the dwell time of the rice in the heated half of the cabinet did not exceed 20 seconds.

In a test of rehydration, 2 gm of the puffed rice was covered with 6 fl. oz (170 cm@3) of boiling water, the vessel was covered and allowed to stand for 2 minutes. No additional heating was carried out. The sample was then drained and re-weighed.

The reconstitution ratio was then determined by comparison of the weight of the rehydrated sample with the weight of the dehydrated sample.

Reconstitution ratios in the range 1:2.5 to 1:3.5 were obtained, which indicate satisfactory rehydration in the very short time of 2 minutes. Further tests carried out to test rehydration in a thickened liquid medium comparable to that of soup resulted in satisfactory reconstitution in 3 minutes. In a formulation comparable to that of a prepared meal, satisfactory reconstitution was obtained in 3-5 minutes, particularly about 4 minutes.

Inspection of the puffed rice showed that it was internally porous with a multitude of small pores but no major cavities. The average volume of the puffed rice grain was about 2-4 times the volume of the unpuffed grain.

EXAMPLE 2

1 kg of parboiled long grain rice was soaked for 1 hour in water at ambient temperature, resulting in an added moisture content of about 30% by weight, (total moisture content about 40% by weight). The soaked rice was washed in water at ambient temperature to remove surplus starch.

The rice was pressure cooked for 22 minutes at 15 pounds per square inch gauge (103 kN/m@2 above atmospheric pressure) in a layer 1/2 inch to 21/2 inches (1.27-6.35 cm) in depth.

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Immediately after cooking, the rice was washed in cold water to stop further cooking and to remove surplus starch.

The cooked rice was dried for 23/4 hours at 52 DEG C., resulting in a moisture content of about 10% by weight. The dried sample was puffed by placing it in a current of air at 250 DEG C. for 20 seconds.

In a test of rehydration, 2 gm of the puffed rice was covered with 6 fl. oz (170 cm@3) of boiling water, the vessel was covered and allowed to stand for 2 minutes. The sample was then drained and reweighed.

The reconstitution ratio was then determined by comparison of the weight of the rehydrated sample with the weight of the dehydrated sample.

Reconstitution ratios in the range 1:2.3 to 1:2.5 were obtained, which indicate satisfactory rehydration in the very short time of 2 minutes.

Further tests carried out to test rehydration in a thickened liquid medium comparable to that of soup resulted in satisfactory reconstitution in 3 minutes.

Inspection of the puffed rice showed that it was internally porous. The average volume of the puffed rice grain was about twice the volume of the unpuffed grain.Data supplied from the esp@cenet database - Worldwide

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339.

US4338339 - 7/6/1982

CO-CRYSTALLIZATION OF DEXTROSE AND SUCROSE ON CEREAL

PRODUCTS


Inventor(s): EDWARDS LARRY W (--)

Applicant(s): CPC INTERNATIONAL INC (--)


IP Class: A23L1/164; A23L1/18

E Class: A23L1/164B



Family: US4338339

Abstract:


Dextrose and sucrose are co-crystallized onto the surface of breakfast cereal products such as corn flakes, puffed wheat or puffed rice, by applying to the surface of said cereal product a powdered crystalline material comprising any of sucrose, dextrose or mixtures thereof, and coating the surface with a layer of a concentrated aqueous solution of dextrose and sucrose. The coated cereal product is then dried at a temperature below the browning temperature of the product. The resulting coated cereal product has a desirable frosted appearance.Claims:


What is claimed is:

1. A presweetened coated breakfast cereal product having a frosted appearance wherein the coating consists essentially of a thin, uniform layer of co-crystallized dextrose and sucrose.

2. A product in accordance with claim 1 wherein the quantity of coating material is in the range of about 25% to about 45%, dry basis, based on weight of the cereal material.

3. A product in accordance with claim 1, wherein said cereal material is corn flakes.Data supplied from the esp@cenet database - Worldwide

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340.

US4338344 - 7/6/1982

PROCESS FOR PRODUCING A QUICK-COOKING RICE


Inventor(s):

)

BROOKS ARTHUR W (--); STEVENSON RICHARD B (--); BELL LEONARD (--



IP Class: A23B9/00; A23L1/10

E Class: A23L1/182; A23L1/10H2



Family: CA1160896

Abstract:


The object of the invention is to provide an improved process for preparing a fully gelatinized rice.

FIG. 1 shows an inclined enclosed chamber 10 wherein rice is cooked in hot water in a first zone at low end 12 and is steamed in a second zone at raised end 14. Locks 32 and 34 permit continuous pressure operation. The rice removed from lock 34 has a moisture content of 30 to 75% and its starch is substantially completely gelatinized. The cooked rice is preferably drived in conventional manner such as in drier 40. The invention enables the preparation of a high quality fully gelatinized rice with less energy consumption, less loss of product weight and decreased effluents in need of treatment than conventional processes.Description:


TECHNICAL FIELD

This invention relates to the production of a fully gelatinized rice, and more particularly to an improved process and an improved apparatus for producing fully gelatinized rice which preferably is dry and quick-rehydrating.

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Known processes and apparatus for cooking rice in the preparation of a fully gelatinized rice provide good quality products, but are less efficient in a number of regards and more costly than desired. It would be desirable to have, and this invention provides, processes and apparatus which produce a high quality product with less energy consumption, less water consumption, less product weight loss and less effluents in need of treatment, and which can accomplish this in reduced processing time than conventional processes which water cook or water cook and steam the rice.

BACKGROUND ART

The basic process for preparing quick-rehydrating rice products is described in U.S. Pat. No. 2,438,939 to Ozai-Durrani. According to that disclosure, rice is first cooked in water to substantially gelatinize the starch and raise the moisture content of the rice grains to cause substantial swelling of the grains. The swollen grains are then dried by circulating air at a temperature of up to about 140 DEG C., through the grains. The hot air dries the grains in their enlarged condition by causing the exterior to dry first and harden. The enlarged or swollen rice grains are easier to hydrate. Products made by this process have enjoyed substantial commercial success, but are costly to produce.

In United Kingdom Patent Specification No. 563,792, there is described a process for cooking cereals, such as rice, for the preparation of a quick-rehydrating product. According to this disclosure, the cereal is steeped and steamed in a single vessel; however, this is a batch process. There is no recognition therein that decreased energy usage, decreased product solids losses, and time savings could be achieved in preparing a fully gelatinized rice of high quality, by continuously moving the rice through cooking and steaming zones simultaneously maintained within the same enclosed vessel.

There have been efforts to run various processes and unit operations continuously in a variety of rice processes. For example, U.S. Pat. No. 3,261,690 to Wayne, employs screw conveyors to mill rice as well as convey it to various processing units. Also, U.S. Pat. Nos. 2,498,573, 2,525,137, 2,592,407,

2,758,031, 2,801,176, and 3,085,011 disclose employing separate screw conveyors for each of the processing steps of soaking, steaming and drying the rice. Simple conveying of rice by screw conveyor is also disclosed. However, none of these references recognized that substantial efficiencies and savings could be obtained in the preparation of a fully gelatinized rice by carrying out both the cooking and steaming steps in the same vessel with continuous movement of the rice from a water cooking zone to a steaming zone.

The use of pressure cookers employing continuous screw conveyors is known for steam peeling potatoes, steaming oysters, and the like processes; however, their use with water in a first zone to cook a potentially sticky product such as rice and then steam in a second zone within the same enclosed chamber is unknown.


In accordance with the present invention, there is now provided an improved process and apparatus for preparing a fully gelatinized rice product by cooking the rice in water in a first zone under conditions effective to raise the moisture content to within the range of from 30 to 75% by weight and to partially gelatinize the rice, then subjecting the rice to steam cooking in a second zone to substantially complete gelatinization of the starch in the rice, and then preferably drying the rice. The improvement in the process comprises maintaining said first and second zones within the same enclosed vessel and continuously advancing rice from said first zone to said second zone.

The improvement in the apparatus comprises the combination of: an inclined chamber enclosing the first and second zones comprising an inlet at the low end for continuously adding rice thereto and an outlet for continuously withdrawing cooked rice therefrom; a means for continuously advancing rice through the chamber; preferably a means for agitating rice as said rice is conveyed from said inlet to said outlet; a means for supplying water to said low end of said chamber to form said first zone; and a means for controlling the water level in said low end such that the water will cover from about 40 to

90% of the length of the path of travel of the rice through the chamber.


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The invention will be better understood and its advantages will become more apparent from the following detailed description, especially when read in light of the attached drawings wherein:

FIG. 1 is a schematic representation of a preferred embodiment of the process and the apparatus of the present invention; and

FIG. 2 is a schematic representation of an alternative embodiment of a single-chamber cooking and steaming vessel according to the present invention.


The apparatus and method of the present invention enable the production of a high quality fully gelatinized rice product in less time and with less energy consumption, less water consumption and less loss of rice solids to the cooking water than has been possible with conventional processes which water cook or water cook and steam the rice.

Referring to FIG. 1, there is seen an inclined enclosed cylindrical chamber 10 as the cooking vessel which has a low end 12 and a raised end 14. Water is fed to the chamber 10 by line 16 and collects at the low end 12 to form a first zone within the chamber 10 wherein rice is cooked to an extent effective to raise its moisture content to within the range of from 30 to 75%, preferably 60 to 75%, by weight of the cooked rice and to partially gelatinize the rice. The water is removed from the chamber 10 at water outlet 18 which is positioned to maintain the water at the desired level. Steam is introduced at steam inlet 20 to maintain a steam atmosphere in the raised end 14 to form a second zone within the enclosed chamber 10 to further cook the rice and substantially complete gelatinization of the starch in the rice.

By enclosed, what is meant is that the chamber 10 is not substantially open to the atmosphere to allow significant heat or moisture loss.

The enclosed chamber 10, or other suitable enclosed vessel maintaining first and second zones 12 and

14, is provided with means for feeding rice at the low end 12 and for withdrawing cooked rice at the raised end 14. FIG. 1 schematically shows rice inlet 22 and outlet 24. It is preferred to provide means to agitate the rice as it is continuously conveyed from the inlet 22 at the low end 12 of chamber 10 to the outlet 24 at the raised end 14 of the chamber 10. FIG. 1 shows screw conveyor 26 which agitates the rice as it is being conveyed. Agitation of the rice becomes important when more than a mono layer of rice is to be processed (i.e. multi-layers of rice) to ensure uniform hydration and gelatinization of the rice in the first and second zones.

FIG. 2 shows an alternative embodiment of an enclosed vessel containing first and second zones for continuously cooking and steaming rice. According to this embodiment, an open mesh conveyor belt

126 conveys rice from the inlet 122 to the outlet 124 of vessel 110. Agitation of the rice as it is conveyed is provided by a plurality of downwardly depending pins 128. The remainder of the means which are equivalent to those in FIG. 1, starting with identification number 110, have the same last two digits of the corresponding identification number used in FIG. 1.

The rice can be raw, parboiled, brown or wild rice. It can be untreated, or pretreated, such as by presoaking or preheating. Preferably the rice will be raw white rice or parboiled rice. The water employed to cook the rice in the first zone is preferably acidified by a suitable acidulant, such as phosphoric acid, adipic acid, citric acid, or hydrochloric acid, to bring the pH within the range of from

3 to 7, preferably about 5.

Chamber 10, which encloses the first and second zones for cooking and steaming the rice, has means associated with it for controlling the level of water in the low end 12 such that the water will cover from about 40 to 90% of the length of the path of travel of the rice through the chamber. In the apparatus shown in FIG. 1, the water level is a function of a number of factors including the diameterto-length ratio of the chamber 10, the quantity of water required, and the angle of incline of the chamber 10. Where any two of these factors are held constant, means for varying the third can control the level of water and the proportion which the water covers the path of travel of the rice through the chamber 10. The angle of incline can be adjusted by suitable means such as jack 30, which can be

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screw operated and is preferably fitted with a locking device. The quantity of water in the enclosed chamber 10 will preferably be controlled by suitable means such that the upper surface of the water closely approaches the upper surface of the chamber 10 at the low side 12 of the chamber. The means for controlling the level at this point can simply be water outlet 18, or means external to the outlet 18 can be employed. The diameter to length ratio of the chamber 10 of an enclosed screw conveyor will preferably be within the range of from 0.10 to 0.25, and most preferably from 0.13 to 0.17.

The water level is desirably controlled such that from about 40 to 90% of the path of the rice through the enclosed chamber 10 is covered with water. Preferably, the water will cover from about 50 to 80% of the path of the rice through the chamber 10. By varying the longitudinal extent of the water and the relative sizes of the first and second zones, the time the rice is within each zone can therefore be controlled to provide the optimum hydration and gelatinization. Additionally, a variable pitch screw can be employed in the screw conveyor, wherein the distance between the flights of the screw are varied to control the rate of advance of the rice and therefore the amount of time the rice is within each zone.

The chamber 10 can be operated at atmospheric pressure, but is preferably adapted to operate at superatmospheric pressure and is fitted with pressure locks 32 and 34 (e.g. rotary pressure locks) at the rice inlet 22 and at the rice outlet 24, respectively. The use of superatmospheric pressure enables more rapid hydration and gelatinization due to the higher temperatures which are achieved. Preferably, pressures of up to about 10 psi (520 mm of mercury) above atmospheric pressure are employed, with higher pressure being generally undesireable as excessive dextrinization occurs. The construction of the pressure locks is conventional, as is their use to permit continuous addition and withdrawal of rice while operating under pressure. In general, the temperature of the water in the first zone will be maintained within the range of from about 80 DEG C. (175 DEG F.) to 110 DEG C. (230 DEG F.)

Care should be exercised with temperatures higher than about 110 DEG C. as dextrinization of the starch can occur.

For atmospheric operation, the temperature will vary up to about 100 DEG C. (212 DEG F.) and will preferably be within the range of from about 95 DEG C. (200 DEG F.) to 100 DEG C. (212 DEG F.).

To raise the moisture content of the rice to the requisite 30 to 75%, preferably 60 to 75%, cooking times in the first zone will typically be within the range of from about 10 to 50 minutes, and preferably from about 10 to 30 minutes. The length of cooking time can be varied by varying the length of chamber 10, the longitudinal extent therein of the water comprising the first zone 12, or the rate of advance of the rice through the water. Steam will be supplied at the rate necessary to maintain a steam atmosphere in the second zone to substantially complete gelatinization of the rice as it passes therethrough. This will take about 1 to 30 minutes, with steaming times of from about 10 to 25 minutes being preferred.

For superatmospheric operation, the temperature of the water in said first zone will typically be in the range of from about 100 DEG C. (212 DEG F.) to 110 DEG C. (230 DEG F.), and preferably will be within the range of from about 103 DEG C. (217 DEG F.) to 110 DEG C. (230 DEG F.). Steam pressures in the range of from about 150 to 260 mm of mercury (3 to 5 psi) above atmospheric pressure will generally be preferred. The cooking times of the rice in the first zone for superatmospheric processing will typically be within the range of from about 2 to 30 minutes, and will preferably be from about 8 to 18 minutes. Retention times of the rice in the steam in the second zone will be from about 1 to 30 minutes, with about 5 to 15 minutes being preferred.

The fully cooked rice upon exiting the chamber is preferably washed to remove excess surface starch and to cool the rice. This can be accomplished with a spray of water or, as shown in the Figures, in a flume 36 of moderately heated water to cool the rice to a temperature below about 77 DEG C. (170

DEG F.), the gelatinization temperature of the rice starch. The rice is then drained such as by belt drainer 38 which conveys the rice to drier 40. The details of drying are conventional in the art.

Typically, drying can be accomplished in a belt drier 40 wherein air at a temperature within the range of from about 150 DEG C. (300 DEG F.) to 180 DEG C. (360 DEG F.) is circulated through the rice for a period of from about 5 to 15 minutes. These or other suitable drying conditions can be employed to reduce the moisture content of the rice to a level effective to permit stable storage. Typically, the moisture content will be about 12% or less, and will preferably be reduced to about 9%, based on the

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total weight of the rice product. Alternatively, instead of drying, the rice can be frozen to permit stable storage.

The preferred dry quick-rehydrating fully gelatinized rice product prepared in this manner is easily rehydrated for serving by preferably adding the rice product to boiling water and then removing from the heat and allowing the rice to stand for about 3 to 10 minutes. Other means of rehydrating the dry rice product can be employed depending upon the particular dry rice product produced, but preferably the rice is quick rehydrating, i.e. rehydrates in 5 to 10 minutes by either simmering, standing, and/or boiling. The water can be salted and seasoned or flavored as desired. The frozen fully gelatinized rice product can be prepared simply by reheating.

The following examples are presented for the purpose of further illustrating and explaining the invention and are not to be taken as limiting in any regard. Unless otherwise indicated, all parts and percentages are by weight.

EXAMPLE I

This example describes the preparation of a dry quick-rehydrating fully gelatinized rice according to the invention, wherein cooking is conducted in an apparatus as in FIG. 1 at atmospheric pressure.

Raw, milled white rice was introduced at a rate of 82 kilograms (180 lbs) per hour through a rotary inlet lock at the low end of an enclosed continuous screw cooker which was inclined at an angle of 11.3

DEG. The cooker had a cylindrical chamber 0.36 meters (14 inches) in diameter and 2.74 meters (9 feet) long. A screw conveyor was rotated within the chamber at a rate effective to continuously advance the rice from the inlet to a like rotary lock at the outlet at a linear rate of 6.85 meters per hour.

Water at a temperature of 110 DEG C. (230 DEG F.) and a pH of 5.0 (adjusted with phosphoric acid) was added from the top of the chamber, about three forths of the distance from the inlet to the outlet, at a rate of about 450 liters per hour. The water filled the low end of the chamber to a depth of 0.36 meters at its deepest point and covered 66% of the bottom surface of the chamber from the low end thereof to the outlet rotary lock. The water was constantly removed at the low-end of the chamber to maintain this quantity of water.

In the first zone, the water at the low end of the chamber was maintained at a temperature of about 95

DEG C. (203 DEG F.), and saturated steam was supplied to the raised end of the chamber at a rate of

40 kg per hour. The rice was cooked in the water which forms the first zone in the chamber for about

16 minutes, during which time its moisture content was raised to about 70%. The screw conveyor continuously moved the rice out of the first zone into the steam in the raised end of the chamber which formed the second zone. The rice was steamed in the second zone until the starch within the rice grains, which was partially gelatinized in the first zone, became substantially completely gelatinized. This stage of the process took about 8 minutes.

The cooked rice was continuously removed from the chamber through a rotary lock and immersed in a flume wherein the water was maintained at a temperature of about 38 DEG C. (100 DEG F.). The flume carried the rice to a draining belt which then conveyed the rice to a multiple zone conventional continuous belt drier operated at an air temperatures of 135 DEG C. to 180 DEG C. wherein the rice was dried to a moisture content of about 9% in about 10 minutes.

The rice product produced in this manner was judged to be of excellent quality. The average starch loss was within the range of from about 6% to 8%, depending principally on the nature of the starting material. For example, rice from crops near the end of the growing season tended to lose less solids than rice from crops harvested near the beginning of the season. Energy consumption for the entire process was within the range of from 750 to 1200 kilocalories per kilogram of rice product. Water required for the process was found to range from 11 to 13.5 kilograms per kilogram of rice product.

EXAMPLE II

This example describes the preparation of a dry quick-rehydrating fully gelatinized rice product according to the invention wherein the rice was cooked and steamed under a steam pressure of about

200 millimeters of mercury (4 psi) above atmospheric pressure. The basic process remains the same as

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described in Example I, except that the screw cooker was pressurized with steam and the water temperature in the first cooking zone was maintained at about 110 DEG C. (230 DEG F.). Because of the higher operating temperatures, retention time in the first zone (water) was about 13 minutes and in the second zone (steam) was about 7 minutes.

The quality of the rice was judged to be the same as in Example I, as was the usage of water. However, the rice solids losses were reduced to the range of from about 5 to 7%, and the energy required was reduced to the range of from 500 to 930 kilocalories per kilogram of rice product.

EXAMPLE III

This example describes the preparation of dry quick-rehydrating rice by a conventional process, which water cooks then steams the rice to produce a high quality quick-rehydrating, fully gelatinized rice product.

Raw milled white rice was totally immersed into 98 DEG C. water in a reel type blancher for 12 minutes to partially gelatinize the rice and increase its moisture content to about 63%. The rice was then deposited into a hot water (93 DEG C.) flume and pumped to a continuous screw pressure cooker.

As the rice entered the screw cooker its moisture content was raised to about 67%. The rice was steamed under a steam pressure of 3 psi (150 mm of mercury) above atmospheric pressure for 10 minutes to fully gelatinize the starch of the rice. The final moisture content of the rice was 72%. From this point, the rice was processed as in Example I, i.e. the rice was continuously removed from the screw cooker and immersed into a cold water (38 DEG C.) flume, by which it was conveyed to a draining belt and then to a conventional dryer.

The quality of the product was judged to be the same as in Example I. However, the water required from the process increased to about 18.5 kilograms per kilogram of rice product, the energy consumption increased to about 4200 kilocalories per kilogram of rice product, and the rice solids losses increased to about 10%.

The above description is for the purpose of teaching the person skilled in the art how to practice the present invention. This description is not intended to detail all of the obvious modifications and variations of the invention which will become apparent upon reading. However, applicants do intend to include all such obvious modifications and variations within the scope of their invention which is defined by the following claims.Data supplied from the esp@cenet database - Worldwide

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341.

US4361593 - 11/30/1982

PROCESS FOR PREPARING DRY QUICK-COOKING PARBOILED RICE AND

PRODUCT THEREOF


Inventor(s): BROOKS ARTHUR W (--); GARIBIAN VAHAN M (--); SARMA MONOJ K (--)



IP Class: A23L1/182

E Class: A23L1/182



Family: US4361593

Abstract:


The principal objects of the present invention are to provide an improved dry parboiled rice product and a process for preparing it, wherein the rice can be rapidly rehydrated for consumption, but yet is relatively non-starchy. This is achieved by modifying prior art parboiled rice procedures by less than completely gelatinizing the starch during steaming, and then tempering the rice under non-gelatinizing conditions for a period of time effective to reduce subsequent rupturing of the starch granules upon rehydration.Description:



Technical Field

This invention relates to an improved form of parboiled rice and a process for preparing it. In particular, the parboiled rice of the invention cooks rapidly, and yet is free of starchiness.

There are many recipes and occasions for which rice is so highly preferred that it seems indispensable.

The art has long endeavored to improve upon natural raw rice in terms of its cooking and eating qualities. Up to the present time, however, it has not been possible to produce a rapidly cooking rice which is non-starchy and yet has a texture comparable to parboiled rice.

Parboiled rice is typically prepared by soaking rough rice paddy (unhulled rice, substantially as it comes from the field) in cold, warm or hot water for a substantial period of time, until the rice kernels have increased their moisture content, generally to at least above 20%; steaming the rice, generally at super-atmospheric pressure, to gelatinize the rice; and then drying the rice. The steaming partially opens the hulls and subsequent to steaming the kernels are dried and then milled.

Raw rice which is not parboiled, but is milled in the dry raw state, is generally quite rapidly cooked.

Typically, cooking times of around 10 to 15 minutes will be achieved; however, the rice resulting from this process is extremely starchy tasting. It is believed that water enters the individual starch granules

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within the rice kernels and causes them to swell, then burst releasing free molecular starch and yielding a very starchy, pasty feel in the mouth. The starch in the raw milled rice, as stated in the name, is essentially ungelatinized (raw). When the rice is ground and tested by amylograph analysis on a

Brabender Viscometer in standard fashion, the ground rice will show a breakdown value of within the range of from about 250 to 500 brabender units. The amylograph breakdown value is the difference in viscosity, as recorded on the amylograph curve, between the peak viscosity and viscosity after a hold time, which is believed indicative of the amount of starch granules which have ruptured causing the reduction in viscosity. The free molecular starch released as the starch granules rupture causes starchiness, thus the breakdown value is directly proportional to the starchiness of the hydrated rice.

This test is carried out by: grinding 50 grams of milled rice and blending with 450 ml. of distilled water; placing the sample in the Brabender Viscometer which is set at a starting temperature of 30

DEG C.; and then heating and holding in the standard fashion (see Halick and Kelly, Cereal Chem. 36

(1), 1959 and Ferrel and Pence, Cereal Chem. 41 (1), 1964).

Parboiled rice, shows a great degree of improvement in its freedom from starchiness as evidenced by amylograph breakdown values of around 0 brabender units or even a slightly negative value (indicating an increase in viscosity after hold time). In the case of a negative amylograph breakdown value not only are starch granules remaining unbroken, but they continue to swell. This advantage in organoleptic improvement is, however, offset to a degree by the increased cooking time required to fully rehydrate the dry parboiled rice to achieve a cooked product. Typically, parboiled rice will require from 20 to 25 minutes to reach full hydration.

A quicker-cooking parboiled rice on the order of about 15 minutes can be achieved by reducing the severety of the parboiling procedure, however, the ultimately cooked parboiled rice becomes starchy.

Typically, the quicker cooking parboiled rice prepared in this manner shows very high amylograph breakdown values, being at least 150 brabender units and typically being around 200 brabender units and higher.

BACKGROUND ART

In an alternative to parboiled rice, a major advance was taught by Durrani in U.S. Pat. No. 2,438,939.

According to that process, a dry precooked quick-cooking rice was prepared which could be rehydrated for consumption by the consumer in as little as 10 minutes. The rice was precooked by subjecting a milled rice to heat and moisture to increase the moisture content to about 65 to 80% and to gelatinize the starch granules. Thereafter, the grains were dried to set them in their enlarged condition.

Despite the advantages of quick-cooking precooked rice, many consumers still prefer the eating consistency produced by parboiled rice. The precooked rice as prepared by these procedures, while being quick cooking, is very light and fluffy in texture. This precooked rice is not starchy as the free molecular starch is generally washed out in the precooking process. Raw white milled rice is very starchy, but is also suitably dense and relatively quick cooking. Parboiled rice is desirably dense and non-starchy, but takes a relatively long period of time to finally cook.

Typically, in parboiled rice the starch granules therein are at least 80% gelatinized and will show an absence of birefringent crosses as measured under polarized light. The percent of gelatinization of rice, as referred to herein, can be measured indirectly through percent alkali soluble starch according to the procedure set forth by Birch and Priestley in the publication Die Starke, 25, Jahrg. 1973, Nr. 3, pages

98-100.

In a paper by Bhattacharya and Rao in the Journal of Agricultural Food Chemistry, Vol. 14, No. 5,

1966, at pages 476-479, the effect of various conditions of soaking and steaming of paddy (rough rice) during parboiling are studied for their effect upon the cooking quality and the color of parboiled rice. It was concluded therein that the greater the severety of heat treatment during soaking and steaming, the lower the water uptake and the darker the color of the rice. While not supplying any data to the effect, the article states that it was observed that heaping of hot parboiled paddy in bulk prior to drying was similar in effect of continued steaming.

According to the disclosure of the Bhattacharya and Rao reference, where a soft cooking quality and low color is desired, quick cooling after parboiling may be the most important factor in industrial

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operations. Where the reverse of this is desired, this could be achieved by either prolonging the steaming step or heaping the parboiled paddy in bulk prior to drying. There is no discussion, however, of the relative importance of the various processing conditions on the preparation time of the dried rice products, or of their relative organoleptic qualities such as starchiness.


Briefly, the present invention prepares a dry parboiled rice which upon rehydration is both quick cooking and has reduced starchiness. This dry quick-cooking parboiled rice is prepared by soaking rough rice, steaming the soaked rice to partially gelatinize the starch granules, then tempering the steamed rice at a moisture content, temperature and for a period of time effective to reduce starchiness of the rice upon rehydration. After tempering, the rice is dried and milled.


In accordance with the present invention, there is provided an improved dry, quick cooking, parboiled rice product and a process for preparing it.

The dry parboiled rice product of the present invention is characterized in that substantially all of the starch granules in the rice kernels are at least partially but less than fully gelatinized, and the dry parboiled rice product can be fully cooked in less than 20 minutes in water boiling at atmospheric pressure, and yet with reduced starchiness in the rehydrated parboiled rice, as evidenced by amylographic analysis of the parboiled rice exhibiting a reduced breakdown value of typically less than

100 brabender units.

The process according to the present invention enables the preparation of a dry parboiled rice product which requires a reduced rehydration time while producing a rehydrated rice with decreased starchiness and comprises: (a) soaking rough rice in water to increase the moisture content to 30 to 45% by weight but without effecting substantial gelatinization; (b) steaming the hydrated rice to partially gelatinize substantially all starch granules in the rice kernel but without fully gelatinizing said granules; (c) tempering the partially-gelatinized rice for a period of time, at a temperature below the gelatinization temperature of the starch, and maintaining a level of moisture above 20%, effective to reduce subsequent rupturing of the starch granules upon rehydration; (d) drying the rice to a moisture content of less than 15%; and (e) milling the rice.

Conventional parboiling will typically include a steeping step wherein the rice is soaked in hot water sufficiently to hydrate it to from about 30 to about 45%, then steamed under conditions effective to gelatinize the starch and then rapidly cooled prior to drying. The present invention is based upon the discovery that quickly-cooking dry parboiled rice products, capable of producing a non-starchy cooked product, can be obtained where the rice critically is both partially gelatinized and tempered under moist, non-gelatinizing conditions after steaming, but prior to drying.

The tempering step according to the present invention has been found to dramatically reduce the starchiness of the final product even though final cooking is reduced to less than 20 minutes, typically about 15 minutes. The degree of reduction in starchiness is evidenced by the amylograph breakdown which will show values of less than 100 brabender units and, more typically, in the 0 to 50 brabender unit range. While not wanting to be bound to any particular theory, it is believed that the tempering of the partially gelatinized rice in a hydrated and energized state allows the formation of associative bonding between adjacent starch molecules within individual starch granules, rendering the starch granules of the dry parboiled rice upon rehydration more resistant to penetration of water into the starch granules which would tend to swell and subsequently rupture the granules, producing starchiness. This dry tempered parboiled rice is thereby able to hydrate more uniformly, avoiding rupturing of starch granules which causes starchiness. In comparison, a dry parboiled rice which is quick cooking (i.e. by being partially gelatinized) but without the tempering step, upon hydration results in a substantial amount of the starch granules rupturing rendering the rice very starchy, as evidenced by amylograph breakdown values of about 150 to 250 brabender units.

Aside from the combination of the steaming and tempering steps of the present invention which render the dry parboiled rice both quick cooking and non-starchy upon rehydration, the remainder of

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processing to achieve a dry parboiled rice product is similar to that practice by the prior art. Thus, as with the prior art, the rough rice is preferably treated to either remove the air which is trapped under the rice husks by subjecting the rice to a partial vacuum prior to steeping the rice under atmospheric pressure, or the rice can be steeped under elevated pressure to displace the air. For example, a vacuum of at least 25 inches of mercury (0.9 Kg per cm@2) will be employed for about 30 minutes to remove entrapped air and aid soaking of the rice.

During the soaking or steeping step the water is introduced into the chamber and is steeped below the gelatinization temperature of rice for a period of time effective to raise the moisture content thereof to within the range of from about 30 to about 45%, preferably from about 35 to about 40%. The temperature of the water will typically be within the range of from about 140 DEG to about 170 DEG

F. (about 60 DEG to about 73 DEG C.), and preferably from about 155 DEG to about 165 DEG F.

(about 68 DEG to 74 DEG C.). The soaking is preferably carried out under atmospheric pressure for a time of from about 1 to about 4 hours, with about 2 to about 3 hours being preferred.

When a vacuum is used prior to soaking the water can be introduced while still under vacuum. Where it is desired to eliminate the vacuum step, the steeping may be done under imposed air pressure at the same time and temperature ranges given above, but at pressures of from about 50 to 150 psig (about 3.5 to 10.5 Kg per cm@2).

To increase the whiteness of the resultant parboiled rice product, it may be desirable to acidify the steep water by adding an acid, such as adipic or phosphoric acid, to achieve a pH of from about 3 to 7, preferably about 4 to 5. The acid may bleach the rice somewhat and reduce browning enzymes to achieve the lightest product color.

Upon attainment of the desired moisture content, the hydrated rice is removed from the steep water and steamed to partially gelatinize substantially all starch granules in the rice kernels but without fully gelatinizing said starch granules. The steam is preferably low pressure saturated steam, and is preferably supplied under conditions effective to maintain the hydrated rice at a temperature of from about 170 DEG to about 210 DEG F. (about 77 DEG to about 100 DEG C.), preferably from about 180

DEG to about 190 DEG F. (about 80 DEG to 90 DEG C.), for a period of time effective to partially gelatinize the rice starch. Steaming times will typically be within the range of from about 5 minutes to about 1 hour, and preferably within the range of from about 10 minutes to about 20 minutes. The percent of gelatinization in the partially gelatinized rice, as measured indirectly through percent alkali soluble starch, will be from about 20 to about 70%, and preferably from about 30 to about 55%, as compared to a fully gelatinized rice in which the rice starch will be gelatinized to at least 80%. Stated another way, a fully gelatinized rice will not have any birefringent crosses remaining when observed under polarized light, while a partially gelatinized rice will have some birefringent crosses remaining.

It is important to restrict the degree of starch gelatinization which occurs according to the invention.

Where the rice starch is fully gelatinized beyond the degree indicated, the rice will require the lengthy cooking (rehydration) times of about 25 minutes of conventional parboiled rice. To achieve the rapid cooking times (e.g. less than 20 minutes) desired according to the present invention, it is necessary to partially gelatinize the rice starch by stopping the gelatinization short of completion.

The partially gelatinized rice is then tempered under conditions of time and temperature, below the gelatinization temperature, effective to reduce the subsequent rupturing of the starch granules and resultant starchiness upon rehydration. By restricting the degree of gelatinization, a quicker-cooking dry parboiled rice is obtained; however, this also will increase the undesireable starchiness of the rice upon rehydration. The tempering step will reduce this starchiness in the rehydrated quick cooking parboiled rice.

In order to achieve a practical degree of reduction of subsequent rupturing of the starch granules, the moisture content of the rice should be maintained at a level of at least about 20% during the tempering process. The temperature during the tempering step will typically be within the range of from about 70

DEG to about 150 DEG F. (about 20 DEG to about 65 DEG C.), and will preferably be within the range of from about 125 DEG to about 135 DEG F. (about 50 DEG to about 57 DEG C.) to reduce starchiness. At temperatures over about 135 DEG F. (about 57 DEG C.), the resultant dry parboiled rice product will, in addition to having an increased reduction of starchiness, tend to take longer to

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rehydrate. Tempering times as short as about 2 hours will provide some measurable reduction in starchiness; however, times of at least 3 hours are preferred, with times within the range of from about

6 hours to about 24 hours being most preferred to reduce starchiness in the rehydrated parboiled rice.

The optimum set of conditions is presently believed to be at a temperature of about 130 DEG F. (about

54 DEG C.) for about 24 hours. Longer periods of time can also be employed, but are generally not considered economic.

During the tempering operation, the moisture content of the hydrated rice is preferably maintained at a level of from about 35 to about 45%. However, the moisture level may be slowly reduced during the tempering operation so long as it is not allowed to decrease below about 20%. Where the moisture content is reduced too rapidly to too great an extent, as in conventional drying procedures, the tempering will not proceed to the proper degree and the product will tend to be relatively more starchy.

Upon completion of the tempering step, the product can then be dried in a conventional manner.

Beneficially, the rice can also be held between drying stages to allow the moisture to be removed without excessive stress on the rice structure. Typically, this might comprise forced convection drying at about 150 DEG F. (about 66 DEG C.) for about 2 hours, then letting the product stand for about 1 to

11/4 hours before resuming drying at about 100 DEG F. (about 38 DEG C.) for another 3/4 of an hour, and again letting the product stand for 3/4 of an hour before resuming drying for 3/4 hour at 100 DEG

F. (about 38 DEG C.), and recycling the rice at these last stated conditions one or more further times to achieve a preferred final moisture content of from about 8 to about 14%. After drying, the product is permitted to temper for from about 24 to about 48 hours to relieve any mechanical stresses within the rice kernels prior to milling under conventional conditions. Following drying the rice is milled.

According to an alternate embodiment, the milled rice can be washed of surface starch and then dried prior to packaging. The washing is typically performed by immersing the rice in water maintained at a temperature of about 200 DEG to about 210 DEG F. (about 93 DEG to about 100 DEG C.) and agitating for from about 0.5 to about 2 minutes. The rice can then be dried in a conventional belt dryer at 275 DEG F. (135 DEG C.) for 7 to 10 minutes to reduce the moisture content to about 8 to about

14%.


The following examples are presented for the purpose of describing what is presently considered the best mode for carrying out the invention, and are not intended to be limiting in any regard. Unless otherwise indicated, all parts and percentages are by weight.

EXAMPLE I

Five pounds (2.3 Kg) of paddy rice is placed in a vacuum chamber which is evacuated to a pressure of

27 inches of mercury (0.93 Kg per cm@2) where it is maintained for about 30 minutes. While the partial vacuum is maintained, fifteen pounds (6.8 Kg) of water, acidified to a pH of about 7 with phosphoric acid and heated to a temperature of about 160 DEG F. (71 DEG C.), is introduced into the vacuum chamber. The vacuum is released and the rice is steeped in the water for about 21/2 hours. At the end of this time period, the rice has a moisture content of about 38%. The hydrated rice is then drained and exposed to saturated steam in an atmospheric belt steamer to partially gelatinize the starch.

The saturated steam subjects the rice to a temperature of about 195 DEG F. (91 DEG C.) for about fifteen minutes. The resulting, partially gelatinized rice is then removed from the steaming chamber and held in a sealed container at 45 % moisture, for 6 hours at a temperature which is maintained at about 130 DEG F. (54 DEG C.) to temper the rice. The tempered rice is then forced convection dried at

150 DEG F. (66 DEG C.) for 2 hours, held at ambient temperature for 11/4 hours, dried at 100 DEG F.

(38 DEG C.) for 3/4 hour, held at ambient for 3/4 hour, dried for 3/4 hour at 100 DEG F. (38 DEG C.), held at ambient for 3/4 hour, and finally dried for another 3/4 hour at 100 DEG F. (38 DEG C.). The resulting quick cooking parboiled rice product has a moisture content of 12.5%. As measured by percent of alkali soluble starch the parboiled rice starch has been gelatinized to about 39%. This parboiled rice shows an amylograph breakdown value of 10 brabender units and can be rehydrated fully by cooking in boiling water at atmospheric pressure for 15 minutes. Upon rehydration the

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parboiled rice exhibits the desireable dense, rubbery, non-starchy texture characteristics of conventional parboiled rice.

EXAMPLE II

This example presents a comparison between a rice product prepared in accordance with the conditions of Example I (identified as the Experiment 1 sample) and two products prepared in essentially the same manner, except that in the Control 1 sample the steaming step is conducted for a period of time sufficient to completely gelatinize the starch therein (no tempering step needed), and in the Control 2 sample the tempering step after steaming but prior drying is eliminated. The results are shown in the following table:

>;tb;______________________________________

>;tb; Amylograph

>;tb; Breakdown Rehydration

>;tb; Gelati- Value Time

>;tb;Sample nization (%)

>;tb; (Brabender Units)

>;tb; (Minutes)

>;tb;______________________________________

>;tb;Exp. 1 39% 10 15

>;tb;Con. 1 100% -50 25

>;tb;Con. 2 37% 270 15

>;tb;______________________________________

The samples of Experiment 1 and Control 1 upon rehydration exhibited a desireable dense, non-starchy texture. The sample of Control 2 upon rehydration was desireably dense, but had a starchy texture and taste. This direct comparison demonstrates the desireable effect which the tempering step has upon the quick-cooking parboiled rice.

The above description is for the purpose of teaching those skilled in the art how to practice the present invention and is not intended to recite all the possible modifications and variations thereof which will become apparent to the skilled worker upon reading. It is intended, however, that all such modifications and variations be included within the scope of invention which is defined by the following claims.Data supplied from the esp@cenet database - Worldwide

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342.

US4377602 - 3/22/1983

PROCESS FOR THE PREPARATION OF A HYDROLYZED PRODUCT FROM

WHOLE GRAIN AND SUCH A PRODUCT


Inventor(s): CONRAD ERNST (SE)

Applicant(s): NORDSTJERNAN AB (SE)


IP Class: A23J1/12; A23L1/195

E Class: A21D13/02; A23C21/02; A23J3/34B4; A23L1/105B; C12C9/00; C12G3/02; C13K1/06


Priority Number: SE19770011742 (19771018)

Family: US4377602

Abstract:


The present invention relates to a process for the preparation of hydrolyzed products from whole grain, and such derived products. The invention solves the problem of obtaining a protein and sugar containing product able to be filtrated whereby this is achieved by treating whole grain, as wheat, maize, rye, barley, oat, and rice, with a proteolytic enzyme to transform waterinsoluble proteins into watersoluble products, and further to treat the starch contents with an amylase free from other carbohydrate hydrolyzing enzymes to form watersoluble starch products, as mono and disaccharides, removing the bran fraction and removing water to obtain a dry, semimoist, or liquid but concentrated derived product. The product is to be added as a sweetening agent in food products as bread, drinks, and cereal products, whereby the bran obtained can be used in bread as fiber additive.Description:


The present invention relates to a process for the preparation of a product and/or products from whole grain by means of enzymatic hydrolysis and such product and/or products.

It is known to use grain, preferably rice, maize, and wheat, (besides the common use as flour, grain, flakes and the like) for preparation of products from their main components, starch and proteins or to use them as such. Isolated starch is used in preparation of starch syrup or starch sugar by means of hydrolysis in acidic environment and/or by means of enzymatic treatment. Water soluble proteins present were originally used in preparation of glue but have today, due to better refining methods, to higher qualities also been used in food industry.

It is thus known from the Swiss Pat. No. 514.674 to produce a product to be used in beer preparation, whereby a starch containing material is mixed with water, pH is adjusted in such a way that proteolytic enzymes present in the material is released and peptisation occurs, pH is further adjusted and a heat stable proteolytic enzyme is added to further hydrolyse the material. The material thus obtained is then further treated to give a partial amylolysis and then a complete amylolysis by means of an amylolytic enzyme.

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However, a product prepared according to said patent will not contain all the proteins and/or proteolytic products present from the beginning. After filtration, to produce a clear filtrate, it will loose most of its proteins. Such a product in unfiltrated state cannot be used in the preparation of clear products as for example stilldrinks and carbonated soft drinks.

An object of the present invention is to obtain a process for the preparation of product and/or products from whole grain, whereby especially substantially all the essential, nutritionally important proteins of the grain are present in water soluble state substantially as peptides, preferably together with the watersoluble starch hydrolysis products. These water soluble ingredients may in some products also contain all or part of the water insoluble bran parts of the whole grain and starch not converted.

However, another object of the invention is to obtain a clean bran fraction, substantially free from starch.

It is understood that also other substances present in the grain as fats, minerals and vitamins are present in the end product/products.

Grain consists substantially of starch, but also about 10-12 percent of proteins.

Conventional isolation of starch from grain involves great technical problems mainly due to the tendency of proteins, bran, germs and starch granules of gluing together. In order to separate the different parts, manufacturers therefor generally have to use a lot of water. Water which later will carry small parts from the corn and causes increased tendency of growing recipients.

According to the present invention all proteins and starch ingredients are recovered as water soluble hydrolysis products whereby mentioned problems are eliminated. Fats, salts, vitamins and minerals are recovered as well, and as a "byproduct" a fibre rich and almost starch free bran is obtained which is very suitable to stimulate a normal gastro intestinal function.

In order to increase the proteinaceous value of the end product/products, as well as the improved taste derived from hydrolyzed lactose another object of the present invention is to use an aqueous medium in the process, which medium consists of whey.

The present invention is based on the fundamental idea that instead of preparing the waterinsoluble protein and starch, these main components are subjected to a process in situ, i.e. when still present in the corn mass. It is understood that the corn has to be crushed in order to make the starch and proteins available to the aqueous solution in which the treatment is to be carried out. As the crushing of the grain is made only to open the grain to make the starch and proteins available the degree of crushing is of minor importance. One can thus crush or grind eg between rollers to coarse flakes and grains down to flour and to make it as wet or dry milling.

All types of corn may be used as wheat, rye, barley, oat, maize, rice and the like, whereby however, wheat is preferred.

In dry milling the bran may be sieved off, whereby, however, as will be evident from below it may be preferred to let them be present during processing.

The treatment gives also a possibility of obtaining different end products. Thus one can recover the water solubilized proteins and the water insoluble starch fraction. One may also recover the watersolubilized starch fraction per se and then the bran and waterinsoluble protein fraction per se, which latter fraction then is made water soluble.

The process of the invention thus relates to the preparation of product totally enzymatically hydrolysed from whole grain whereby substantially all of the nutritionally important protein ingredients of the grain are present in water soluble state, and, possibly, substantially all of the starch of the grain is present in water soluble form in the form of degraded products of starch, as well as fats, salts, vitamins and minerals, whereby the invention is characterized in that one crushes the grains and in any order or simultaneously subjects the material thus crushed to

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(a) on one hand an enzymatic treatment with a proteolytic enzyme for the transformation of water insoluble proteins to water soluble degraded products whereby the enzymatic treatment is carried out using an endopeptidase to give a protein hydrolysate containing 50-60% of peptides having at least 25 amino acid residues, 35-45% of peptides having 5-20 amino acid residues and 4-8% of peptides having up to 4 amino acid residues, the protein fraction being substantially recovered in the filtrate after clear filtration

(b) on the other hand an enzymatic treatment using a starch hydrolyzing enzyme for the transformation of water insoluble starch to water soluble degraded products of starch, preferably mono and disaccharides, the enzymatic treatment being carried out using a specific amylase substantially free from other carbohydrate hydrolysing enzymes

(c) and further separating off water insoluble bran ingredients and, if present, water insoluble starch components; and

(d) further, if desired, completely or partly evaporate the solution of products thus obtaining these in dry, semimoist, or liquid but concentrated form.

A preferred embodiment of the invention is characterized in that process step (a) is carried out prior to or simultaneously with process step (b).

Another preferred embodiment of the invention is characterized in that the process is carried out at a temperature below the gelatinization temperature of the grain used.

A further preferred embodiment of the invention is characterized in that process step (b) is carried out using an .alpha.-amylase and then and/or simultaneously using an amyloglucosidase.

Another preferred embodiment of the invention is characterized in that one uses amyloglucosidase at pH 4-4.5 to transformation of starch to glucose.

A further preferred embodiment of the invention is characterized in that one uses amyloglucosidase at pH 6 for the transformation of starch to mainly maltose.

A preferred embodiment of the invention is characterized in that one moreover adds an isomerase for the partial transformation of glucose formed to fructose.

Another preferred embodiment of the invention is characterized in that the water insoluble bran components are isolated in process step (c), which components, if desired, are washed, whereby the components contain at least 60% by weight of fibres, and at most 2% by weight of residual starch.

According to another aspect the invention comprises a grain product obtained in accordance with the process, whereby it is characterized in that the proteins are present as a protein hydrolysate enzymatically obtained by an endopeptidase, whereby 50-60% of the peptides present have more than

25 amino acid residues, 35-45% of the peptides have 5-20 amino acid residues and 4-8% of the peptides have up to 4 amino acid residues, which protein hydrolysate is water soluble and capable of being substantially recovered after clear filtration, that the starch is present as enzymatically present starch hydrolysate obtained by a specific amylas substantially free from other carbohydrate hydrolysing enzymes whereby the product is present as powder, syrup or liquid in unconcentrated or concentrated form.

According to another aspect the invention comprises a bran fraction, whereby it is characterized i.e. that it consists of the bran fraction isolated from an enzymatically hydrolyzed grain, which bran fraction contains at least 60% by weight of fibres, and at most 2% by weight of starch residues.

According to a further aspect of the invention the invention comprises food products containing a grain product obtained in accordance with the process and defined in process and product definitions herein.

Process steps (a) and (b) above may be carried out simultaneously, if so desired, but may also be carried out separately, whereby the different fractions are recovered as separate products. The enzymes

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used are commercially available. The transformation of water insoluble protein to water soluble products is thereby carried out using an endopeptidase and the transformation of starch to water soluble oligosaccharides is carried out using amylases, preferably .alpha.-amylas, possibly together with amyloglucosidase, whereby a high content of glucose is obtained. However, as given above, if a certain pH is selected, pH 6, a high content of maltose is obtained which is preferred in certain cases to improve flavour. Isomerase may be used in another preferred embodiment to transform part of the glucose content to fructose, whereby a crystallization of the end product is inhibited. The starch may under certain circumstances be isolated as such.

Suitable enzymes are manufactured industrially and are marketed e.g. by Novo A/S, Copenhagen, and

Miles Kalichemi, BRD. Suitable proteolytic enzymes are "Neutrase" (Novo A/S) and "HT Proteolytic"

(Miles Kalichemi). .alpha.-amylases used are "BANL 120" (Novo A/S) and "Optiamyl-L" (Miles

Kalichemi). A suitable .beta.-amylase and maltose forming enzyme, respectively is e.g. "Fungamyl

1600" (Novo A/S) and suitable amyloglucosidases are e.g. "AMG 150" (Novo A/S) and "Optidex-L"

(Miles Kalichemi). A useful isomerase is e.g. "Optisweet P" (Miles Kalichemi).

Malted grain may be used to carry out the transformation of a starch to water soluble derivatives. In this case the grains are malted as known per se in beer and liquor production. The malted grain is mixed with water, whereupon a proteolytic enzyme is added. After protein hydrolysis transformation to water soluble starch derivatives is carried out.

According to the invention one may thus obtain a product which, after transformation in situ, contains different nutritionally important components, possibly with or without the bran fraction. According to the invention it is also possible to obtain a product which substantially consists of water soluble protein products whereby the water insoluble protein fraction is isolated and transformated per se. Thus a bran fraction containing ;30% of protein is possible to obtain, as well as protein hydrolysate containing 80-

90% of protein.

Such a protein hydrolysate may be mixed with bran and be used in the preparation of soups. Further a pure starch fraction can be obtained, and a pure fraction containing water soluble starch products thereof as glucose and oligosaccharides and a bran fraction, which products mixed or separately isolated are of food industrial interest.

It is evident from above that the main steps of the process are carried out in an aqueous solution or suspension. For economical reasons it is desirable to evaporate the product/products obtained to a suitable water amount for obtaining the product in dry, semimoist, or liquid bust concentrated form.

The removal of excess water can be carried out in any suitable manner as e.g. by roller drying, freeze drying, and lyophilisation or the like.

According to the further object of the present invention an economically preferable way for handling whey and its nutritionally valuable content is obtained. The invention thus concerns in a preferred embodiment the use of whey or concentrated whey as aqueous medium in the process of the invention.

In industrial preparation of cheese from milk considerable amounts of whey are obtained as biproduct.

The whey is then obtained as a low concentrated solution containing about 6.5% dry matter, (5% of lactose, 1% of proteins, and 0.5% of salts).

Whey has hitherto been used to a very small extent and its main use has been as a feed additive for animal feedstuffs especially for pigs. Depending on the high water content of the whey the kidneys are subject to great strain in connection with the excretion of large water amounts and for this reason whey can only be restrictedly used as feed stuff or feed stuff additive.

It has of course been tried to reduce the water content of whey but as evident the costs are too high to evaporate so large volumes as about 93.5%. One has thus been forced to let the whey being fed to the waste water off-flow. This gives however great environmental problems, and it is, today, no longer possible to let the whey go this way depending on environmental laws and similar directions.

One may either use whey as such or a concentrate thereof, whereby only a minor part of the water of the whey has been evaporated. According to another preferred embodiment of the invention the lactose

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of the whey is transformed to glucose and galactose, which transformation may take place either separately prior to the addition of the whey to the grain or may be done enzymatically together with process steps (a) and/or (b).

The transformation of lactose to glucose and galactose is preferred as in some areas of the world a great part of the population is unable to utilize lactose due to lack of enzyme lactase. This is especially pronounced in many developing countries. Too high amounts of lactose in the food may even create gastro intestinal disturbances in such groups of people which can not utilize lactose.

The transformation of lactose to glucose and galactose is carried out enzymatically using a suitable lactase as e.g. "Novo Lactase" sold by Novo Industry A/S, Copenhagen, Denmark.

In the preferred process using whey products are thus obtained which are still more enriched with regard to saccharides, proteins, and nutritionally important salts.

As mentioned above all the important components of the cereal raw materialare recovered in the end product/products. The final syrup, which can be filtrated through a standard filtration procedure can be used either directly as a nutrient or in combination with other nutrients in drinks, breakfast flakes, food for children. A syrup prepared is very suitable for bread baking purposes, as it is similar to flour with regard to its constituents. The baked products obtained are positively affected with regard to colour, taste and freshness.

The syrup can also be used in beer production.

The invention will be described in the following examples showing embodiments thereof.

EXAMPLE 1

0.5 g of proteolytic enzyme "Neutrase" (Novo Ind.) were dissolved in 3 liters of water having a temperature of 50 DEG C. 1500 g of coarsely crushed wheat containing 15% of water and 12% of gluten protein (N.times.6.25) were suspended in the water. After one hour at 50 DEG C. all protein had been transformed into water soluble products thereof, preferably polypeptides, whereby 55% of the peptides contained more than 25 aminoacid residues, 41% of the peptides contained 5-20 amino acid residues, and 4% of the peptides contained 1-4 amino acid residues. Thereupon 0.1 g of .alpha.amylase "BANL 120" were added and the temperature was raised to 75 DEG C. The reaction mixture was kept at 75 DEG C. for 2 hrs, whereupon it was cooled to 60 DEG C. and 0.5 g of maltose forming enzyme "Fungamyl 1600" were added. The suspension was kept at 60 DEG C. for 12 hours. At this time 60% of maltose had been formed. Depending on the use of the final product the suspension may be sterilized by heating to about 100 DEG C. or further heated. The suspension is then sieved and undissolved husk residues are washed with water. Said water is used in following, new reaction.

The bran components thus washed are dried and the solution is evaporated to the consistency of syrup or is dried alternatively, to a powder. Yield: 85% of syrup dry matter, including dry matter of the wash water; 15% of bran dry matter.

EXAMPLE 2

0.5 g of protease "Neutrase"

0.2 g of -amylase "BANL 120", and

0.2 g of amyloglucosidase "AMG 150" were added to 3 liters of water of 65 DEG C. The temperature was kept at 65 DEG C. and 1500 g of coarsely crushed wheat were introduced. After 2 hrs all protein and all starch had been transformed to watersoluble form. pH was decreased to 5.0 by the addition of citric acid q.s. and the temperature was kept at 60 DEG C. After 24 hrs 96% of all starch present had been converted to pure glucose. pH of the suspension was increased to 6.0 by adding sodium carbonate. The solid bran fraction was sieved off and washed with water, and dried. The wash water was fed to a new treatment. The solution obtained was used without further treatment in the preparation of still drinks. Yield: 90% sugar/protein dry matter, calculated on the starting material, 15% of bran dry matter.

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The bran fraction, which contained about 20% of water, was used without further treatment for mixing with the syrup obtained after evaporation of the solution for baking purposes or form casted with syrup or mixed and dried to a powder. The product thus obtained contained all the valuable nutrients of the wheat grain and the bran fraction. The same product may be obtained by mixing the products obtained from each of the steps (a), (b) and (c).

The bran fraction was analyzed and compared with other types of bran preparations.

In the table 1 below product A is a bran fraction according to Example 2 above, product B is a common wheat bran fraction obtained at an ordinary mill, product C is a rye bran fraction, and product D is the official U.S. "AACC Certified Food Grade Wheat Bran RO7-3691". Values given as % of dry substance.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Carbohydrate chemical analysis of bran fractions.

>;tb; A B C D

>;tb;______________________________________

>;tb;Extrationable

>;tb;using 80%

>;tb;ethanol 7.7 15.0 13.0 14.5

>;tb;Ash 6.1 -- -- 5.9

>;tb;Starch@(1) 1.1 21.3 37.0 20.0

>;tb;Cellulose@(2)

>;tb; 13.9 14.9 13.5 10.4

>;tb;Hemicellulose@(2)

>;tb;(neutral part) 37.1 28.9 23.7 23.7

>;tb;Fibers

>;tb;Hemicellulose@(3)

>;tb;(acidic part) +

>;tb;pectin 2.3 -- -- 1.5

>;tb;Lignin acc. to

>;tb;Klason 10.2 14.4 15.0 5.2

>;tb;Fiberanalysis acc. to Van

>;tb;Soest:

>;tb;NDF@(4) approximative

>;tb;cellulose + hemicellu-

>;tb;lose + lignin 74.2 -- -- 44.9

>;tb;ADF@(4) approximative

>;tb;cellulose + lignin

>;tb; 22.1 -- -- 12.2

>;tb;______________________________________

>;tb; @(1) Determined enzymatically

>;tb; @(2) Determined by gas liquid chromatography using an ethanol

>;tb; extracted, starch freed sample after total hydrolysis, the glucose value

>;tb; being used approximatively for calculating the values of cellulose and

>;tb; other values of neutral sugars being used for calculating of neutral

>;tb; hemicellulose

>;tb; @(3) Determined by decarboxylation

>;tb; @(4) Not determined freed from ashes.

EXAMPLE 3

The preparation according to Example 2 was repeated with the exception that the transformation using amyloglucosidase was carried out at pH 6 instead of pH 5, whereby the starch was recovered as maltose instead of glucose.

EXAMPLE 4

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0.5 g of the proteolytic enzyme "HT Proteolytic" and 0.1 g of the .alpha.-amylase "Optiamyl-L" were added to 3 liters of water of 65 DEG C. The suspension was kept at 65 DEG C. and 1.5 kg of maize were added. The maize was coarse crushed. After 3 hours all proteins and all starch has been transformed into soluble form. The temperature was raised to 80 DEG C. and was kept there for 2 hrs.

Then the solution was cooled to 60 DEG C. and pH was adjusted to 4.5 by addition of citric acid. 0.2 g of glucose forming amyloglucosidase "Optidex-L" were added. After 24 hrs 97% of the starch present had been transformed into pure glucose. Then pH was adjusted to 6.0 by addition of sodium carbonate and from pH 6.0 to pH 7.0 by addition of magnesium hydroxide. 2 g of fructose forming isomerase enzyme "Optisweet P" were added and the temperature was kept at 60 DEG C. for another 24 hrs while pH was automatically adjusted to pH 7.0 by adding sodium carbonate.

At this moment 40% of the original amount of glucose (97%) had been transformed into fructose.

Hereby a crystallisation was inhibited, when the solution after clear filtration was evaporated to a syrup. The bran parts sieved off were washed with water and dried. The wash water was returned. pH of the solution was adjusted to about 6 by adding a small amount of citric acid and was evaporated, as mentioned above, to a syrup. Yield: 90% of a water soluble proteinaceous syrup (dry matter); 15% of bran fraction (dry matter).

EXAMPLE 5

0.2 g of proteolytic enzyme "Neutrase" were added to 3 liters of water of 65 DEG C. To the water a mixture of 0.5 kg of malted and dried wheat and 1 kg of common wheat were added, the malted wheat and the wheat having been crushed together. The mixture of wheat contained 13% of water and 11.5% of protein (N.times.6.25) of dry substance. After 1 hr at 65 DEG C. the temperature was raised to 80

DEG C. and kept at 80 DEG C. for another hour. Then the solution was cooled to 60 DEG C. and 0.5 g of amyloglucosidase "AMG 150" (Novo A/S) were added. The mixture was kept at 60 DEG C. for another 12 hrs after when the sugar amount had raised to 66 dextrose equivalents. (66 DE). Then the bran fraction was separated off by sieving washed and dried, the wash water being fed in return. The solution was evaporated to a syrup. Yield: 83% proteinacous syrup (calculated on dry matter); 17% bran dry matter.

EXAMPLE 6

0.5 g of proteolytic enzyme "Neutrase" were added to 2.5 liters of water having a temperature of 22

DEG C. 1200 g of malted, crushed barley so called malt having 6% of water and 12% of proteins

(N.times.6.25) therein calculated on dry matter, were added. The mixture was allowed to stand for 12 hrs, after when all proteins had been hydrolysed into water soluble state. The mixture was then added to 0.5 liter of water of 65 DEG C. during 15 minutes and was kept at 65 DEG C. for another 2 hrs whereby 46 dextrose equivalents (46 DE) had been obtained. The bran fraction was sieved off, washed, and dried, the wash water being returned to a new process. The solution obtained was evaporated to a syrup. Yield: 82% proteinacous syrup (dry matter). 18% bran (dry matter).

EXAMPLE 7

0.5 g of proteolytic enzyme "Neutrase" were added to 4 liters of water of 55 DEG C. 1500 g of coarsely crushed wheat were added at 55 DEG C. which temperature was kept for 1 hr at which time all gluten protein has been solubilized. The reaction temperature was raised to 75 DEG C. while adding 0.5 g of

.alpha.-amylase "BANL 120". The reaction mixture was kept at 75 DEG C. for 6 hrs, whereby all starch had been solubilized (DE-value 38). The suspension was freed from solid components by sieving. The bran fraction was washed with water. The solution obtained was evaporated to dryness

(powder). Yield: 82% of protein-sugar (dry matter), 18% of bran (dry matter).

EXAMPLE 8

0.2 g of .alpha.-amylase "BANL 120" were added to 4 liters of water of 75 DEG C. Into the solution at

75 DEG C. 1500 g of coarsely crushed wheat were introduced. The temperature was kept at 75 DEG C. for 6 hrs, whereby all starch had been converted into watersoluble products. The temperature was lowered to 55 DEG C. and 1 g of amyloglucosidase and 1.5 g of proteolytic enzyme "Neutrase" were added. After 6 hrs all the proteins had been transformed into watersoluble state and the sugar value had

1499/2197

increased to a DE-value of 60. The bran fraction was sieved off and washed with water. Yield: 84% of syrup (dry matter; including wash water dry substance). 18% of bran (dry matter).

EXAMPLE 9

2 kg of crushed wheat (dry matter 87%) were added to 4 liters of water containing 3 g of proteolytic enzyme "Neutrase", and were treated therein for 4 hrs at 50 DEG C. The solubilized phase containing hydrolyzed proteins was separated off by centrifuging and was recovered for, if so desired, a combination with pure starch. The solid phase left in the centrifuge together with the bran components was washed with water, about 2 liters, which was recovered for a new process cycle. The solid phase was suspended in 2 liters of water was allowed to pass through a fine meshed vibration sieve. The fine ground wheat starch and the water was allowed to pass, while one bran fraction was vibrated over the sieve and was recovered. The starch suspension was introduced into a further centrifuge provided with a suitable filtration cloth. The aqueous phase obtained (about 2 liters) was recovered and was used in a new process cycle.

The starch was either recovered as such or hydrolysed to a syrup or sugar as described in the foregoing examples. Yield:

1200 g of starch dry matter (68.5%)

200 g of protein dry matter (11.5%)

300 g of bran dry matter (20.0%)

EXAMPLE 10

4 kg of whey containing 6.5% dry matter were heated to 60 DEG C. and 0.5 g of proteolytic enzyme,

"Neutrase" (Nova A/S) were added 1.5 kg of coarsely crushed wheat were introduced. The temperature of the mixture was kept at 60 DEG C. for 1 hr when all water insoluble protein had become water soluble derivatives. Then 0.1 g of .alpha.-amylase "BANL 120" (Novo A/S) were added and the reaction temperature was raised to 75 DEG C., which was maintained for 6 hrs, when all starch had been converted into water soluble saccharides, DE-value 38.

The temperature was lowered to 60 DEG C. and 1.0 g of amyloglucosidase "AMG 150" was added.

The reaction temperature was kept at 60 DEG C. for another 12 hrs whereby a DE-value of 66 had been obtained.

The reaction mixture was heated to 100 DEG C. for sterilization and inactivation of the enzymes, whereupon the bran fraction was sieved off by centrifuging. The solution was evaporated to a syrup and the bran fraction was dried.

The product obtained had a dry matter content of 1460 g of which 260 g were dry matter derived from whey i.e. 18%.

EXAMPLE 11

4 kg of whey containing 6.5% dry matter were heated to 40 DEG C. 0.4 g of lactase enzyme (Novo

A/S) were added and the temperature was kept at 40 DEG C. for 6 hrs. At this time the lactose of the whey had been converted to equal amounts of glucose and galactose.

The temperature was raised to 60 DEG C. and 0.5 g of proteolytic enzyme, "Neutrase" (Novo A/S) were added. 1.5 kg of coarsely crushed wheat were introduced into the reaction mixture and the following treatment was continued in accordance with Example 10 above.

EXAMPLE 12

4 kg of whey, (6.5% dry matter), were heated to 45 DEG C. 0.5 g of lactase, 0.5 g of protease,

"Neutrase", 0.1 g of .alpha.-amylase, "BANL 120", and 0.5 g of amyloglucosidase "AMG 150" (all from Novo A/S) were introduced therein.

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1000 g of coarsely crushed wheat were introduced and the reaction temperature was kept at 45 DEG C. for 5 hrs, when the lactose had been converted to glucose and galactose, and water insoluble proteins of the wheat had been converted into water soluble products.

The temperature was raised to 70 DEG C. and kept there for another 5 hrs, when all water insoluble starch had been converted into water soluble saccharides having a DE-value of 50.

The bran fraction was separated off by centrifuging, and the solution was evaporated to a syrup. The end product contained 25% of dry matter derived from whey.

EXAMPLE 13

4 kg of concentrated whey (13% dry matter) were heated to 65 DEG C. 0.5 g of proteolytic enzyme,

"Neutrase" 0.1 g of .alpha.-amylase "BANL 120" and 0.5 g of amyloglucosidase "AMG 150" (all from

Novo A/S) were added.

The temperature was kept at 65 DEG C. for 12 hrs, when water insoluble protein and starch had been converted into water soluble products. The solution had a DE-value of 6.5. The bran fraction was separated off, and the solution was concentrated to a syrup, 30% of the dry matter of the syrup derived from whey.

EXAMPLE 14

4 liters of concentrated whey (20% dry matter) were kept at ambient temperature (20 DEG C.) 1 g of proteolytic enzyme "Neutrase" (Novo A/S) and 1.1 kg of crushed barley were added.

The mixture was stirred for 4 hrs when all protein had been dissolved.

Then 0.2 g of .alpha.-amylase "BANL 120" (Novo A/S) were added, and the temperature was raised to

75 DEG C. and kept at 75 DEG C. for another 4 hrs. After said 4 hrs all starch had been converted to water soluble sugar derivatives, and a DE-value of 40 was determined. The reaction mixture was sterilized at 100 DEG C. and the bran fraction was separated off.

The solution was dried to a powder. 50% of the dry matter obtained derived from whey.

EXAMPLE 15

Wheat bread having separate bran.

A wheat bread was prepared from

1000 g of water

25 g of salt

300 g of wheat syrup (DE value 65, 80% dry substance, pH 6.2) prepared acc. to Example 2.

50 g of yeast

200 g of bran obtained acc. to Example 2

1000 g of wheat flour.

The ingredients are mixed together, fermented, and baked in oven in conventional way.

The bread obtained contains 124 g of protein, whereby 100 g derives from the wheat flour. Increase about 25%.

If the wheat flour in a normal bread is replaced by whole wheat flour such a bread will contain 150 g of bran, compared with a bread above which contains 200 g of bran. A normal bread will thereby become more "heavy" and not so porous as a bread above.

EXAMPLE 16

A milkshake was prepared from

1501/2197

1200 g of wheat syrup (DE-value 70, 20% dry substance, protein 11%) acc. to Example 2.

400 g of milk from whole milk powder 20% dry substance.

0.1 ml of vanilla essence

The components are mixed and pH is adjusted to 6.2 using sodium bicarbonate and sterilized. The end product may be diluted with equal part of water prior to use.

EXAMPLE 17

A milkshake with cocoa flavor was prepared:

1200 g of wheat syrup acc. to Example 2 (17% dry substance) were boiled together with

15 g of cocoa powder and is then adjusted to 17% dry substance by adding water. 400 g of milk having

17% dry substance from whole milk powder are added. pH is adjusted to 6.8 using sodium bicarbonate and is sterilized. The final product is consumed in the end form.

EXAMPLE 18

A milkshake with coffee flavour was prepared:

In 1200 g of wheat syrup acc. to example 2 (13% dry substance) 7.5 g of freeze dried coffee (Nescafe,

Nestle) are dissolved. Then 400 g of whole milk (13% dry substance) are added and pH is adjusted to

6.8 using sodium bicarbonate. The solution is sterilized and consumed as such.

EXAMPLE 19

A drink with taste of beer is prepared from:

750 ml of wheat syrup (DE-value 67, 36% dry substance) acc. to example 3.

8.5 ml of hopextract (Flavoring 010977)

5.5 g of citric acid

3 g of sodium bicarbonate.

The ingredients are mixed. 70 ml thereof are diluted to

330 ml using water. Dry substance 7.5%. pH 4.1.

This drink can, if desired, be brewed in a conventional way by adding common yeastculture.

EXAMPLE 20

A soft drink was prepared from:

1750 ml of wheat syrup acc. to example 2 (DE-value 67, 52% dry substance)

0.5 ml of lemon flavour (Flavoring 061271)

10 ml of grape extract (Flavoring 140278)

7 ml of mango essence

20 g of citric acid

15 g of Na-benzoate.

The ingredients are mixed and diluted to 2.500 ml using water, which gives a dry matter content of

35%, pH 4.4. The solution is filtered to clearness. 80 ml of the solution are diluted to 330 ml using carbonated water or ordinary water. It should be understood that any other flavour than in this example as cola, coffee, pear, banana etc. may be used.

EXAMPLE 21

"Fruit juice" containing protein, maltose and dextrose was prepared from:

>;tb;______________________________________

>;tb;100 g

>;tb; of wheat syrup (DE 70, 42% dry substance) acc. to Ex. 2.

>;tb; 90 g

>;tb; of conc apple juice. (47% dry substance).

1502/2197

>;tb;190 g

>;tb; juice (44% dry substance).

>;tb;______________________________________

1.5 g of citric acid and 1 g of Na-benzoate are added. 95 g of the solution are diluted to 320 ml using water. Dry substance 13%.

In Example 21 above apple juice has been used. It should be understood that any other juice as orange, grapefruit, lemon, lime and the like juices may be used.

EXAMPLE 22

Breakfast Cereal product containing wheat syrup and bran prepared from

1000 g wheat bran made acc. to Ex. 2

250 g wheat syrup acc. to Ex. 2

10 g salt

The ingredients are mixed and the mix is dried and eventually roasted.

In the examples above, especially examples 15-18 it is evident that a syrup according to any of examples 10-14 prepared one way or the other can be used for preparation of the products.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A hydrolyzed protein and starch product prepared according to the process for preparing in situ, enzymatically hydrolyzed protein and starch products from whole grain, comprising crushing said grain and thereafter subjecting the crushed grain to a treatment which consists essentially of both the following steps: (a) subjecting said grain to an enzymatic treatment in an aqueous medium with an endopeptidase so as to transform substantially all water-insoluble proteins present in the grain to watersoluble protein products, which thereafter are filtered and recovered from the crushed grain as a clear filtrate containing protein products containing about 50 to 60% peptides having at least 25 amino acid residues, 35 to 45% peptides having between about 5 to 20 amino acid residues and 4-8% peptides having up to 4 amino acid residues and subjecting the remaining crushed grain to (b) an enzymatic treatment in an aqueous medium with .alpha.-amylase followed sequentially by an amyloglucosidase both enzymes substantially free from other carbohydrate hydrolyzing enzymes so as to transform substantially all the water-insoluble starch fraction in the grain to watersoluble, degraded products of starch, wherein the amyloglucosidase is at a pH of between 4 to 4.5, so as to transform substantially all the water-insoluble starch fractions in the grain to glucose.

2. The hydrolyzed protein and starch products prepared according to the process for preparing in situ, enzymatically hydrolyzed protein and starch products from whole grain, comprising crushing said grain and thereafter subjecting the crushed grain to a treatment which consists essentially of both the following steps: (a) subjecting said grain to an enzymatic treatment in an aqueous medium with an endopeptidase so as to transform substantially all water-insoluble proteins present in the grain to watersoluble protein products, which thereafter are filtered and recovered from the crushed grain as a clear filtrate containing protein products containing about 50 to 60% peptides having at least 25 amino acid residues, 35 to 45% peptides having between about 5 to 20 amino acid residues and 4-8% peptides having up to 4 amino acid residues and subjecting the remaining crushed grain to (b) an enzymatic treatment in an aqueous medium with at least one starch hydrolyzing enzyme so as to transform substantially all of the water-insoluble starch fraction in the grain to water-soluble, degraded products of starch, and wherein the starch hydrolyzing enzyme is amylase substantially free from other carbohydrate hydrolyzing enzymes, Wherein upon completion of process steps (a) and (b) any remaining water-insoluble husk components of said grain such as bran and water-insoluble starch components are separated, wherein said husk component, after washing, contain at least about 60% by weight of fibers and no more than about 2% by weight of residual starch.Data supplied from the esp@cenet database - Worldwide

1503/2197

343.

US4440794 - 4/3/1984

INSTANT RICE PUDDING MIX


Inventor(s): DAVIES DAVID L (GB)



IP Class: A23L1/168; A23L1/195; A23L1/187

E Class: A23L1/164F; A23L1/187



Family: US4440794

Abstract:


An instant rice pudding mix which comprises a mixture of a powder comprising 15 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat; 5 to 25% by weight of a dried skim-milk powder; up to 3% by weight of an emulsifier and 0 to 4% by weight of an edible gum; and granules formed by the extrusion of a dough formed from 87 to 100% by weight of rice flour, up to 4.0% by weight of a starch-complexing agent, up to 5% by weight of an aerating agent and up to 4.0% of dried skim milk powder and/or dried whey powder mixed with a proportion of water sufficient to produce an extrudable dough. The pudding mix of the invention may conveniently be made up by the addition of hot or boiling water to produce a product having the texture of a traditional rice pudding. The pudding mix of the invention may be packed in pouches, envelopes or other protective cartons which afford moisture-barrier features.Description:


TECHNICAL FIELD

The present invention relates to an instant rice pudding mix and, in particular, to a rice pudding mix which, when mixed with hot or boiling water rehydrates rapidly to provide a dessert product with the texture and appearance of a traditional rice pudding.

BACKGROUND ART

European Patent Specification No. 0016649 (Application No. 80300890.3) describes a process for producing a reformed rice product by the cold extrusion of a dough formed from a composition comprising a mixture of pregelatinized and ungelatinized flour, sodium chloride and fat in powder form, to obtain simulated rice grains and then drying the simulated rice grains at an elevated temperature. The reformed rice product produced in this manner rehydrates in water in about three minutes and the time required for the preparation of a simulated rice from such a product is thus significantly reduced.

We have not developed an instant rice pudding mix which is a mixture of granules preformed from rice flour by extrusion and a powder containing a starch which provides the overall body of the pudding on rehydration of the pudding mix with hot or boiling water. An instant rice pudding mix of this type

1504/2197

would not, however, be formed from the reformed rice product disclosed in European Patent

Specification No. 0016649.

DISCLOSURE OF THE INVENTION

Accordingly, the present invention provides an instant rice pudding mix which comprises a mixture of a powder comprising 15 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat; 5 to 25% by weight of a dried skim-milk powder; up to 3% by weight of an emulsifier and 0 to 4% by weight of an edible gum and granules formed by the extrusion of a dough formed from 87 to 100% by weight or rice flour, up to 4.0% by weight of a starchcomplexing agent, up to 5% by weight of an aerating agent and up to 4.0% of dried skim milk powder and/or dried whey powder mixed with a proportion of water sufficient to produce an extrudable dough.

The rice pudding mix of the present invention preferably comprises from 55 to 80% by weight of the powder and from 20 to 45% by weight of the granules.

The finely divided sugar which is used in the pudding mix of the invention may be glucose, corn syrup solids, fructose or most preferably, sucrose. Artifical sweetening aids may also be included in the composition, if desired.

The starch which is used in the pudding mix of the invention is preferably waxy rice starch. The starch is a powder, 99% by weight of which passes through a 105 micron sieve.

The finely divided fat used in the pudding mix of the invention can preferably by provided by the use of a spray-dried fat emulsion which includes the emulsifier component therein.

The edible gum used in the pudding mix of the invention is preferably guar gum or xantham gum.

The granules may be formed by the extrusion of the dough at an elevated temperature preferably in the range of from 70 DEG to 140 DEG C. The granules are dried in a manner known per se, for example by air drying or microwave heating at an elevated temperature. Alternatively and preferably, a thick rope may be extruded which is then dried as described above and subsequently reduced in size to granules. The granules preferably have the size and appearance of rice grains (i.e., about 2 mm.times.4 mm).

The rice flour used in the formation of the granules is preferably formed by the grinding of long grain rice, although rices with other grain lengths may be used.

The dough may contain up to 5% by weight of an aerating agent which will release a gas during extrusion to develop an aerated structure. Suitable gas forming agents include sodium bicarbonate, ammonium carbonate, solid carbon dioxide and baking powder, which is the preferred aerating agent.

In an alternative embodiment of the invention the aerating agent may be omitted from the composition or the amount thereof significantly reduced if a gas such as carbon dioxide or nitrogen is injected into the dough during the extrusion process to provide the dough with an aerated structure.

Flavoring and coloring materials may be included in the rice pudding mix, as desired, as an ingredient of either or both components.

The present invention is further illustrated by the following example.

EXAMPLE

A dough was formed by the addition of 28% by weight of water to the following dry mixture of ingredients.

>;tb;______________________________________

>;tb;Medium grain rice flour

>;tb; 97.15%

>;tb;Baking Powder 2.00%

1505/2197

>;tb;Glyceryl monostearate

>;tb; 0.75%

>;tb;Xanthan gum 0.10%

>;tb;______________________________________

This dough was extruded at a temperature of 66 DEG C. through a single screw extruder to form a rope which was dried at 121 DEG C. in an air-flow oven for 20 minutes. The dried extrudate was then comminuted to form granules of the size and appearance of rice grains.

A powder was formed by blending the following dry ingredients.

>;tb;______________________________________

>;tb;Pulverized sucrose 25.00%

>;tb;Waxy rice starch 33.00%

>;tb;Dried fat emulsion 32.00%

>;tb;Dried skim-milk powder

>;tb; 8.50%

>;tb;Color and flavoring

>;tb; 1.50%

>;tb;______________________________________

A pudding mix was prepared by compounding 20% by weight of the granules with 80% by weight of the powder.

The rice pudding mix of the invention is typically made up by the addition of 430 ml of hot (minimum temperature 80 DEG C.) or boiling water to 100 grams of the mix. The texture of the product is typical of that of a traditional rice pudding. This would not be achieved by the separate addition of hot or boiling water to each of the granules and powder components and subsequently combining them, since the grains would then lose their discrete nature.

The rice pudding mix of the present invention may be packed in pouches, envelopes and other protective cartons which afford moisture-barrier features.Data supplied from the esp@cenet database -

Worldwide Claims:


I claim:

1. An instant rice pudding mix which comprises a mixture of a powder comprising 15 to 35% by weight of a finely divided sugar, 25 to 40% by weight of a starch, 5 to 20% by weight of a finely divided fat; 5 to 25% by weight of a dried skim-milk powder; up to 3% by weight of an emulsifier and

0 to 4% by weight of an edible gum; and granules formed by the extrusion of a dough formed from 87 to 100% by weight of rice flour, up to 4.0% by weight of a starch-complexing agent, up to 5% by weight of an aerating agent and up to 4.0% of dried skim milk powder and/or dried whey powder mixed with a proportion of water sufficient to produce an extrudable dough.

2. An instant rice pudding mix as claimed in claim 1 which comprises from 55 to 80% by weight of the powder mixture and from 20 to 45% by weight of the granules.

3. An instant rice pudding mix as claimed in claim 1 wherein the finely divided sugar is glucose, corn syrup solids, fructose or sucrose, the starch is a waxy rice starch, the finely divided fat is a spray-dried fat emulsion which includes the emulsifier therein and the edible gum is guar gum or xantham gum.

4. An instant rice pudding mix as claimed in claims 1, 2 or 3 wherein the rice flour used in the formation of the granules is formed by the grinding of the long grain rice.

5. An instant rice pudding mix as claimed in claims 1, 2 or 3 wherein the starch-complexing agent is glyceryl monostearate.

1506/2197

6. An instant rice pudding mix as claimed in claims 1, 2 or 3 wherein the aerating agent used in the extrudable dough is sodium bicarbonate, ammonium carbonate, solid carbon dioxide or baking powder.

7. An instant rice pudding mix as claimed in claims 1, 2 or 3 which is packed in a pouch or an envelope or another protective carton which affords moisture-barrier features.Data supplied from the esp@cenet database - Worldwide

1507/2197

344.

US4442130 - 4/10/1984

CONTINUOUS PROCESSING OF RICE


Inventor(s): AUTREY HARRY S (US); HUNNELL JOHN W (US)

Applicant(s): RIVIANA FOODS INC (US)


IP Class: A23B9/00; A23L1/10

E Class: A23L1/182; A23L1/10H2; A23B9/02F; A23B9/08



Family: US4442130

Abstract:

1508/2197


A method for processing rice wherein paddy rice is heat treated, the heat treated rice is shelled to separate the hulls from the brown rice, the hulls are fed into a burner unit wherein they are burned in two stages to produce ash and relatively clean hot gases, and the hot gases are cycled for use in the heat treating phase.Description:


This invention relates to the efficient processing of parboiled rice and particularly to novel methods and apparatus wherein rice hulls separated from paddy rice after the paddy rice has been subjected to the processing operations required for parboiling involving heat treatment are burned to produce a desirable ash product and recovered heat from controlled combustion which is used in the heat treatment phases, in a substantially continuous self-sustaining operation.

Paddy rice harvested from the fields and dried to a stable moisture of 12 to 14 percent consists of a hull or husk surrounding the rice grain. The hull constitutes about 15 to 25 percent of the paddy rice by weight, and the invention here is concerned with the efficient use of hulls.

Since rice processing is one of the oldest arts, there has been considerable effort to find beneficial and profitable and use for the hulls which may be considered as the inevitable product of all rice processing. Currently, rice hulls are disposed by returning them to the field soil, or as a relatively low value material for chicken litter, animal feed roughage, fruit juice pressing aid, substrate for furfural production, medicated animal feed carrier or as an extender for plastics. Some are hauled away and dumped.

One of the major uses proposed and to a limited degree practiced has been to utilize the hulls as boiler fuel to produce steam, frequently where the rice mill uses steam engines for power.

Among the current uses of rice hulls is that based on the fact that rice hulls contain 20 percent ash and when almost completely burned the ash product will contain about 85-98 percent silicates. Ash of this composition has several beneficial uses, for example as a component of refractory material as indicated in U.S. Letters Patents to Jones No. 2,720,427, and Rowland No. 3,489,581.

In this invention rice hulls derived from paddy rice which has been subjected to a heat treatment process, have been separated into hull and brown rice components, and are burned in a two stage burner wherein silica-containing ash is produced and volatile components separate therefrom in a first stage, the volatile components are burned to provide clean dry hot gases in a second stage and these hot gases are directed to supply the necessary heat in various steps of parboiling whereby a continuous self sustaining operation is attained.

A further advantage of the invention is that it can provide a novel continuous system wherein paddy rice is parboiled, the hulls are separated from the parboiled rice, the separated hulls are burned and heat from the products of combustion is directed to effect the parboiling operation.

Another feature of the invention comprises a novel rice processing system including a two stage burning method and apparatus wherein in a first stage rice hulls are essentially continuously fed into an air agitated mass above a supporting grate and are burned at a temperature below the fusion point of silica but sufficient to drive off the organic volatile components and wherein the volatile components are completely burned at a much higher temperature in a second stage to provide clean hot gases consisting essentially of carbon dioxide and water, with these hot gases being continuously recirculated into the system to provide heat for the rice processing phases.

The U.S. patent to Gravel No. 3,125,043 discloses apparatus and a process wherein volatile components are removed from burning rice hulls, but there is no disclosure therein of two stage burning and/or of the use of the cleanly burned gas from the second stage to treat directly the rice processed.

BRIEF DESCRIPTION OF DRAWING

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The drawing diagrammatically illustrates the system of the invention according to a preferred embodiment.

PREFERRED EMBODIMENTS

The invention will be described specifically in a continuous method and apparatus wherein rice hulls are burned to separately produce on the one hand silica-containing ash with the silica in the desired form, and on the hand clean gas that is directly utilized in contact with rice in a treatment operation such as parboiling.

With reference to the drawing the major steps of a rice parboiling operation with the associated steps of a two stage burning of rice hulls are designated in rectangular figures and the products at each stage in circular figures with directional lines indicating flow.

In this operation rough or paddy rice is removed from storage (1) cleaned, (2) to remove contaminants such as dirt, straw, loose hulls and grains without hulls to produce clean paddy ricefeed, (3) which is fed into tanks, (4) wherein it is covered by hot water and allowed to steep for a period of time. In this steep the moisture content of the rice is increased from 12 to 14 percent to typically about 37 percent in water introduced at a range of 145 DEG F. to 170 DEG F. The temperature of this water and the optional use of air pressure permit control of the time required to reach the desired moisture content in the rice. This operation may be continuous by batch with a series of steeping tanks employed. The steeping time may be about 40-60 minutes to a few hours depending upon the feed rice quality and the desired characteristics of the finished parboiled rice.

The steeped rice (5) is conveyed to a second heat processing section, (6) wherein the starch is gelatinized in place in a steam atmosphere for a desired time. Typically this will be done at a steam pressure of 8-10 pounds per square inch gauge with a residence time of about 5-15 minutes.

The steamed or cooked rice (7) is conveyed into a drying section (8) where the moisture is reduced by the action heated air in a series of, usually three, stepped stages wherein the temperature is carefully controlled. In a typical process the temperature of the drying mixture of gas and air will be about 500

DEG-600 DEG F., and 200 DEG-300 DEG F. respectively, and the tempratures of the rice removed from those stages will be about 180 DEG F. and 100 DEG F. Between drying steps the moisture in the kernel will migrate from the center to the surface with the surface region having been dried more than the center in the previous drying step. Upon reaching ambient temperature the moisture content will have been reduced back to about 13 percent and stable parboiled rough or paddy rice (9) will have been produced. This product rice (9) is conveyed to a sheller machine (10) wherein the rice grains are removed from the hulls (15) and brown rice (11) is discharged and sent to milling machines (12) where the bran is removed and finished primary product of parboiled rice (13) and by-product rice bran (14) are recovered.

The rice hulls (15) are conveyed into the first stage or primary burner (16) where they ignite and are burned in a chamber on a grate structure which permits ash (17) to be removed. An air supply (18) is introduced on a controlled basis to regulate the temperature of combustion. The remaining products of combustion (19) are gaseous and rise to a second stage burner (20) where combustion is completed at a higher temperature and the clean hot gas is drawn off and continuously supplied to the dryers and to a boiler to supply heat for the various operations of parboiling. Combustion in the second stage burner

(20) takes place in an excess of oxygen introduced with a forced air stream (21).

The dry hulls entering the primary burner have a moisture content generally in the range of 12-14 percent. Since they are of light weight and substantially in uniform particulate condition, they may readily be controllably fed in a smooth essentially uniform stream by a ram. The grate is of a convenient area with a multiplicity of perforations enabling the air to pass through the grate while at the same time providing for the hulls accumulating in a pile or loose mass supported on the grate. Some combustion air of course enters the burner with the hulls and added combustion air is preferably provided as at (18). The design of the grate and the pressures involved in feeding in the hulls and

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combustion air are mutually correlated to ensure that once on the grate the hulls are supported thereon in a relatively loose, easily ignited and steadily burning mass.

The openings in the grate are advantageously sized whereby they contribute to breakup and further particularize the hull fragments, so that the mass collecting over the grate contains relatively uniformly sized small particles capable of partial air support on the grate and efficient combustion. At start up an igniter is energized to start combustion of the mass of hulls on the grate but after a short time the igniter may be de-energized since the mass becomes self-combustible. The rate of combustion is correlated to the speed of infeed hulls so that the burning process becomes continuous.

Burning of rice hulls within the first stage chamber (16) takes place in a temperature range below the fusion point of silica and advantageously takes place in a range of about 1650 DEG F. to 1800 DEG F.

At these temperatures the moisture is dissippated and the solid hulls are converted partially into a powdery ash which has a very high silica content and the balance into a swirling mixture of volatile gases. The ash falls off mainly to the edge of the mass to be pushed off the outer periphery of the grate by radial sweeps revolving at the upper surface of the grate concentrically therewith. The discharged ash is recovered (17), and the volatile gases rise into the second stage chamber (20) of the burner.

As the volatile gases from the fuel bed on the grate they may be subjected to a cyclonic scrubbing action by a series of high velocitity air inlets. This results in any solid particles such as carbon entrained in the rising gases being entrained and carried outwardly to the chamber wall where they abut and drop back toward the grate. Thus the volatile gases entering the second stage burner contain substantially no solid particles.

By maintaining the temperatures within the primary burner below 2000 DEG F. it is ensured that higher temperatures required to burn the volatile gases are not produced, and as a result there is no fusion of the ash to produce a solid clinker structure that would interfere with hull fragment feed and efficiency of combustion.

The volatile gases rising into and through the second stage chamber (20) of the burner combine with the introduced excess air from conduit (21) and complete combustion occurs at a much higher temperature, advantageously about 2000 DEG F.-2400 DEG F. At least about 15 percent excess air by volume is introduced at (21). The inner wall of the secondary burner chamber (20)is preferably cylindrical so that the volatile gases rise in a generally helical path. The excess air from the conduit

(21) enters tangentially at the chamber upper end and moves mainly downwardly in a generally helical path in counter flow relation to the gases, whereby there is a relatively cool outer vortex of gas adjacent the chamber wall while the volatiles are burned at high temperature in the swirling inner vortex.

Suitable burners having provision for both the primary and secondary burning steps are available as the

Lamb Wet All Burner from Lamb Cargate Industries, Ltd., P.0. Box 400, 1135 Queens Avenue, New

Westminster, B.C., V3L4Y6, Canada. Suitable burner apparatus having provision for both primary and secondary burning are sold by Econo-Therm Energy Systems Corp., 11535 K Tel Drive, Minnetonka,

Minn. 55343, USA, as their Controlled Air Incinerator Model CA2500.

As a result of the foregoing, clean hot gases free of particulate and other objectionable material exit the second stage burner (20) through a conduit which is connected to both a boiler (23) having fresh water input (24) with exhaust returned to the main stream (25), and directly to the drying section (8). The hot gases directly contact the rice for more efficient heat transfer. Since the volatile organics (phenols, creosotes, etc.) have been consumed in the high temperature second stage burner, the gases do not impart objectionable flavor or odor to the rice in process.

Gas control valving and cooling devices indicated at (26) are placed so as to perform the heating requirements of the dryers. In each of the dryers cooling may be accomplished for example by blending in ambient air in sufficient quantity to provide for the necessary drop in gas temperature.

Steam (27) generated in the boiler (23) is used for the cooking/steaming step (6) and to heat water in a heat exchanger (28). The hot water (29) so produced is used for the steeping operation (4).

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In some embodiments a portion of the heated gases may be extracted and recycled whereby to preheat the incoming stream of hulls, thereby promoting overall efficiency.

The invention in the disclosed embodiment provides a system for generating a hot clean gas in quantity, quality and temperature sufficient to satisfy heat needs for hot water, steam and drying in a parboil plant. The hulls are burned in two stages. The first stage is held below the fusion point of silica and makes a valuable ash product and drives off the organics and volatiles which are essentially completely burned to CO2 and water leaving a clean hot gas for introduction into the heat requiring phases.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed and desired to be secured by Letters Patent is:

1. In a method for producing parboiled rice which comprises the steps of heat treating paddy rice to produce cooked rice, shelling the cooked rice to produce hulls and brown rice, feeding said hulls to a burner wherein the hulls are burned in a first stage under controlled temperature conditions below the fusion point of silica to produce ash and volatile components and whereby said volatile components are delivered to a second stage where complete combustion of said volatile components takes place in a higher temperature range, and feeding at least a portion of the products of combustion resulting from said second stage combustion into direct contact with said cooked rice to effect predetermined drying of said cooked rice.

2. The method defined in claim 1, wherein said method is substantially continuous and cyclic.

3. A substantially continuous self-sustaining method for parboiling rice in a sequence wherein paddy rice is steeped, cooked and dried comprising the steps of hulling the dried rice, burning the hulls in a first stage at a predetermined controlled temperature to drive off the volatile components and then effecting complete combustion of said volatile components in a second stage at a temperature higher than said predetermined controlled temperature in the presence of excess oxygen to produce hot products of combustion to provide the heat requisite to the drying steps of the parboiling sequence, at least a substantial portion of said hot products of combustion being delivered to said rice in direct contact therewith during the drying operation.

4. A method for producing parboiled rice which comprises the steps of heat treating paddy rice to produce cooked rice, shelling the cooked rice to produce hulls and brown rice, feeding said hulls to a burner wherein the hulls are burned to produce ash and relatively clean hot gases, said hulls being burned in a first stage in an air agitated fluid bed at a temperature in the range of 1650 DEG F. to 1800

DEG F. which is below the fusion point of silica wherein the volatile components are driven off and delivered to a second stage where complete combustion of the volatile components takes place in a higher range of from 2000 DEG F. to 2400 DEG F. in the presence of excess oxygen, and feeding at least a portion of said hot gases into direct contact with said cooked rice to effect predetermined drying of said cooked rice.Data supplied from the esp@cenet database - Worldwide

1512/2197

345.

US4450181 - 5/22/1984

METHOD OF HUMIDIFYING POLISHED RICE


Inventor(s): SATAKE TOSHIHIKO (JP)

Applicant(s): SATAKE ENG CO LTD (JP)


IP Class: A23L1/10

E Class: A23L1/182



Family: AU522046

Equivalent: NL8004462; JP56026164; GB2056254; DE3030091; BE884693; IT1130499

Abstract:


A method of humidifying polished rice wherein moisture is added continuously to the same polished rice and caused to be absorbed thereby by adding moisture proportionally in the amount of moisture

1513/2197

with respect to time such that the amount does not exceed 0.3% by weight of the polished rice treated per one hour.Description:


This invention relates to a method of humidifying polished rice.

Generally, it is believed that the standard moisture contents of white rice or polished rice are one of the important factors concerned in obtaining improved taste in cooked rice. The standard moisture contents range, for example, from 14.0 to 15.0%. It has hitherto been customary for farmers to deliver superdried rice of about 13% in moisture content to be on the safe side lest the rice delivered by them should be disqualified upon examination in the process of drying the rice in the form of unhulled rice.

Thus hulled rice or brown rice subjected to polishing by a rice-polishing machine has hitherto shown a tendency to have a moisture content of about 13.0% in many cases, and it has generally been customary to subject such brown rice to humidifying treatment to adjust its moisture content to an essentially standard rate of about 14.5% (mean value for a whole grain) to improve its taste. However, brown rice is provided on its surface with a coating containing moisture-repellent wax and low in temperature

(generally below 25 DEG C.), so that the resistance offered thereby to humidifying treatment is considerably high. Processes employed in the past for humidifying brown rice have had some disadvantages. In one process known in the art, brown rice is given with moisture of about 0.2-0.3% by weight in a series of operations performed over a period of 10 seconds to 10 minutes, and then the humidified brown rice is subjected to tempering treatment over a period of time longer than the period of time for effecting humidifying. In this process, humidifying and tempering are alternately performed repeatedly. However, moisture remains in the bran layer of the brown rice, and since a large amount of moisture is introduced into the brown rice at a time, cracks are likely to be formed in the brown rice when the moisture content becomes excessive. Crack formation results in sudden invasion of the starch layer by moisture, so that the starch layer also develops cracks due to the shock of sudden expansion.

In order to obviate the aforesaid disadvantage, an attempt has been made to humidify brown rice on a moderate scale in a conservative fashion. However, this entails a prolonged period of time for carrying out humidifying and tempering, and difficulties are still experienced in introducing humidity into the inner layers of rice grains. Generally, processes of the prior art have been considered to have difficulties in humidifying brown rice by even 1%.

Thus when the brown rice humidified and tempered by a process of the prior art is processed by a ricepolishing machine, it is usually the case that the majority of its moisture content is eliminated together with bran and released from the machine and the polished rice obtained generally has a moisture content of about 13.5% which is lower than that of brown rice. Thus processes of the prior art for humidifying and tempering brown rice have been unable to produce polished rice of a mositure content of 14.5% which is considered optimum for obtaining cooked rice of improved taste.

In polished rice, starch is exposed and absorption of moisture readily takes place. Thus polished rice is essentially high in moisture absorbing power and humidifying of the inner layers can be readily effected. Moreover, the absorption of moisture takes place actively because the temperature of the polished rice released from a rice-polishing machine is kept at a level over at least 30 DEG C., so that humidifying of polished rice should be effected readily by taking advantage of this quality of polished rice. Even if brown rice is humidified by processes of the prior art, the moisture content is eliminated when the brown rice is polished, so that the processes of the prior art of humidifying brown rice are unable to attain the end of humidifying polished rice to impart an accurate standard moisture content thereto. Thus there is no alternative but to humidify polished rice to accomplish the object of producing polished rice of a moisture content of 14.5% which is optimum for improving the taste of cooked rice.

However, it has hitherto been considered risky to humidify polished rice because the polished rice has an elevated temperature due to the polishing treatment and would immediately absorb humidity when subjected to humidifying treatment, causing crack formation in the rice grains. If processes of the prior art relying on addition of a large amount of water in intermittent operations are followed in humidifying polished rice of high moisture absorbing power, the grains of polished rice would develop cracks as soon as treatment is started.

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The present invention obviates the aforesaid disadvantages of the prior art. Accordingly, the invention has as its object the provision of a method of humidifying polished rice wherein humidifying is carried out continuously by adding moisture to polished rice in an optimum proportion to amount with respect to time for carrying out humidification so that no sudden expansion of the grains of polished rice will occur due to the addition of moisture thereto in large amounts, whereby humidifying of polished rice can be effected uniformly with an increased degree of efficiency in a shorter period of time without regard to tempering.

The aforesaid object of the invention can be accomplished by a method of humidifying polished rice comprising the step of continuously adding moisture to the same polished rice and causing the added moisture to be absorbed thereby, wherein the addition of moisture is carried out proportionally in the amount of moisture with respect to time such that the amount does not exceed 0.3% by weight of the polished rice treated per one hour.

If a conventional humidifying process were used for humidifying polished rice, moisture would be added in excess to the surface layers or part of layers of rice grains in 2 to 4 seconds and no moisture would be added for about 15 minutes. This process would be carried out for 1 hour to add moisture of

0.25% by weight in that period while the humidifying step and the prolonged intervals of no addition of moisture are alternated. This would mean that moisture of 0.03-0.015% by weight is added to the surface of rice grains in 1 second. On the other hand, according to the method of the invention, addition of the same amount of moisture or 0.25% by weight to polished rice can be effected by continuously adding moisture of only 0.00007% by weight of moisture in 1 second. Stated differently, the intermittent addition of moisture according to the conventional process is carried out with a moisture density of 400-200 times that of the continuous addition of moisture according to the method of the invention. It is important that addition of moisture be carried out with a low moisture density.

The foregoing and still other advantages of the present invention will be made more apparent from the following detailed explanation of the preferred embodiment of the invention in conjunction with the accompanying drawings, in which:

FIG. 1 is a side view, with certain parts being broken away, of a polished rice humidifying apparatus suitable for carrying into practice the method according to the invention;

FIG. 2 is a front view, with certain parts being broken away, of the apparatus shown in FIG. 1;

FIG. 3 is a plan sectional view of the apparatus shown in FIG. 1;

FIG. 4 is a side view, with certain parts being broken away, of another polished rice humidifying apparatus suitable for carrying the method according to the invention into practice;

FIG. 5 is a front sectional view of the apparatus shown in FIG. 4; and

FIG. 6 is a side view, with certain parts being broken away, of still another polished rice humidifying apparatus suitable for carrying the method according to the invention into practice.

An example of the apparatus shown in FIGS. 1-3 suitable for use in carrying the method according to the invention into practice will be described. A grain tank 1 has in its interior a plurality of airpermeable porous walls 2 extending along the length of the tank 1 in suitably spaced-apart relation to define therebetween a plurality of air chambers 5 and a plurality of humidifying chambers 6A, 6B, 6C and 6D located in such a manner that the air chambers 5 and the humidifying chambers 6A, 6B, 6C and

6D are disposed alternately with the air chambers 5 forming the outermost chambers on opposite sides of the tank 1. The air chambers 5 each communicate with an air supply chamber 3 and an air discharging chamber 4 disposed at the front and rear of the tank 1 respectively. The tank 1 has in its upper portion an upper grain tank section 7 communicating with the humidifying chambers 6A, 6B, 6C and 6D and having a grain layer formed of the rice grains supplied thereto and functioning as a cover for preventing air leaks. The upper grain tank section 7 has a volume which is smaller than the total of volumes of the humidifying chambers 6A, 6B, 6C and 6D. The humidifying chambers 6A, 6B, 6C and

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6D each have at the lower end an outlet port 8 provided with a discharge valve 9 of the rotary bladed rotor type. The rice grains discharged through the discharge valves 9 are introduced into a screw conveyor 11 mounted in a fluid grain tank 10 disposed at the bottom of the tank 1 which conveys the rice grains to an elevator 12 for returning them to the upper grain tank section 7.

The elevator 12 has mounted in its lower portion a supply hopper for supplying from outside the apparatus polished rice to the upper grain tank section 7 and at its upper portion an outlet port provided with a change-over valve for discharging humidified polished rice to the next operation station upon completion of a humidifying operation. This construction of the elevator 12 is known and detailed description and showing will be omitted.

The air supply chambers 3 are connected to air passages A and B which are selectively opened and closed by an on-off valve 13 mounted in a air supply duct 14 which is connected to a blower 15 and a humidifier 16, such as an ultrasonic humidifier suitable for humidifying a small amount, of a humidifying device. The air discharging chambers 4 are connected to air passages C and D which are selectively opened and closed by an on-off valve 17 mounted in an air discharging duct 19 which also mounts therein an exhaust blower 18. The grain tank 1 is formed at its top with a supply port 20 having a disperser 21 connected thereto through a shaft for rotation to obtain uniform downflow streams of grains. 22 designates an electromagnetic switch for opening and closing each of the on-off valves 13 and 17.

In the apparatus of the aforesaid construction, polished rice to be humidified is supplied to the hopper of the elevator 12 and moved upwardly to the upper grain tank section 7 to form a layer of polished rice grains as shown which functions as a cover for the humidifying chambers 6A, 6B, 6C and 6D for preventing air leakage. Then the on-off valve 13 of the air supply duct 14 is actuated to close the air passage B and open the air passage A on the air supply side, and at the same time the on-off valve 17 of the air discharging duct 19 is actuated to close the air passage C and open the air passage D on the air discharging side, before starting the humidifying device. The humid air supplied by the humidifying device flows through air passage A into the humidifying chambers 6A, 6B, 6C and 6D as indicated by solid line arrows in the drawings, and discharged therefrom through air passage D on the air discharging side. While the humid air flows in currents through the humidifying chambers 6A, 6B, 6C and 6D as aforesaid, the polished rice grains of a grain layer formed in each chamber is humidified by a current of humid air flowing from one direction. By actuating the on-off valves 13 and 17 at a suitable time for opening the air supply side passage B and air discharging side passage C and closing passages

A and D, it is possible to cause the humid air supplied by the humidifying device to flow through the humidifying chambers 6A, 6B, 6C and 6D in directions indicated by dash line arrows or in a direction opposite to the direction indicated by solid line arrows, so that the layer of grains in each humidifying chamber can be humidified by a current of humid air flowing in a direction opposite to the one direction described hereinabove. Thus the grain layer in each humidifying chamber can be subjected to humidifying air currents from opposite directions, to thereby obtain substantially uniform humidification of the grains in each layer. Meanwhile the grains in each humidifying chamber humidified as described hereinabove are discharged through the discharge valve 9 into the lower fluid grain tank 10 from which they are returned, via the screw conveyor 11, elevator 12 and disperser 21, to the upper grain tank section 7. When necessary, the grains in the lower fluid grain tank 10 can be discharged to outside through the outlet port formed in the elevator 12.

In the humidifying chambers 6A, 6B, 6C and 6D, moisture which is 0.2-0.3% by weight of the polished rice is uniformly supplied to the polished rice in 60 minutes.

FIGS. 4 and 5 show another example of the apparatus suitable for use in carrying the method according to the invention into practice. A grain tank 101 has in its interior a plurality of air guides 103 and 104 of the inverted triangle shape in cross section arranged alternately in layers and disposed parallel to one another below an upper chamber 102 of the tank 101 in a manner to extend lengthwise of the tank 101 in a plurality of layers and disposed in a plurality of rows crosswise of the tank 101 between two end walls 105 and 106 of the tank 101. One end wall 105 is formed with a multiplicity of ventilating openings 107 communicating with one end of the layers of air guides 103 which are closed at the other end by the other end wall 106, so that the air guides 103 serve as humid air supply passages. The other end wall 106 is formed with a multiplicity of ventilating openings 110 communicating with one end of the layers of air guides 104 which are closed at the other end by the one end wall 105, so that the air

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guides 104 serve as humid air discharging passages. Formed on the outer surface of the end wall 105 in positions corresponding to the openings 107 are an upper air supply chamber 108a and a lower air supply chamber 108b. When the polished rice to be humidified is small in volume, the upper air supply chamber 108a is closed to stop the supply of humid air thereto from an air humidifying device 121 connected to the chamber 108a via a duct 122. Formed on the outer surface of the end wall 106 is a discharging chamber 123 disposed in a position corresponding to the ventilating openings 110. In the apparatus of the aforesaid construction, the grain tank 101 having the air guides of inverted trough shape 103 and 104 disposed therein includes a humidifying section 111 disposed below the upper chamber 102 and having a lower chamber 112 disposed therebelow. In the lower chamber 112, outlet ports 113 are formed in the lower portion thereof and have discharge valves 114 of the rotary bladed rotor type arranged parallel to the air guides 103 and 104 and in a row extending crosswise of the tank

101. The rice grains flowing down through the outlet ports 113 are conveyed by a screw conveyor 117 to an elevator 118 which returns the rice grains to a rice grain supply section 119 of the tank 101. A disperser 120 for obtaining uniform dispersion of the rice grains is mounted in the upper chamber 102 of the tank 101.

FIG. 6 shows still another example of the apparatus suitable for use in carrying the method according to the invention into practice. A humidifying vessel 201 is formed with a front end wall 202 and a rear end wall 203 each including discrete portions. Each discrete portion of the front end wall 202 has attached to its lower end an on-off valve 212 composed of an inclined wall portion 204 and a outwardly projecting member 213 and capable of moving in pivotal movement. Each discrete portion of the rear end wall 203 has an inclined wall portion 205 attached to its lower end. The inclined wall portions 204 and 205 are disposed in staggered relation in two rows, and an air supply passage 208 is formed below each inclined wall portion 204 while an air discharging passage 209 is formed below each inclined wall portion 205. The humidified air supplied from the air humidifying device 211 flow across a passage

210 of polished rice grains or a humidity adjusting chamber in currents flowing through the air supply passages 208 into the chamber 210, until the air currents reach the air discharging passages 209. The polished rice grains flow in a zigzag stream through the passage 210 while being uniformly humidified.

When the vessel 201 is not filled with the polished rice grains, the inclined wall portions 204 are not pushed by the grains so that the on-off valves 212 pivotally supported by the front end wall 202 are actuated to close the air supply passages 208 by weight of the outwardly extending members 213 heavier than the weight of the inclined wall portions 204, to thereby prevent air leakage. When the polished rice flows downwardly through the passage 210 as shown in FIG. 6, the inclined wall portions

204 are pushed by the grains to move downwardly so that the air supply passages 208 are opened.

The above-mentioned apparatus may have a grain lifting apparatus 214 connected thereto, so that the same polished rice grain can be recycled to flow downwardly through the passage 210 several times in the vessel 201, to thereby obtain satisfactory humidification of polished rice grains.

From the foregoing description, it will be appreciated that the method according to the invention for humidifying polished rice is characterized by supplying to the polished rice humidity which is 0.2-

0.3% by weight of the polished rice to be humidified in 60 minutes. The invention has enabled humidification of polished rice, which has hitherto been considered unfeasible, to be effected satisfactorily. This enables adjustments of humidity content of polished rice to be effected immediately before the rice is cooked for food, thereby permitting polished rice of accurate moisture content having improved taste to be provided. The humidified polished rice provided by the present invention is of high quality and devoid of crack formation.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. A method of humidifying polished rice, comprising the step of: adding moisture to the polished rice at a rate to cause the rice to adsorb the moisture progressively so that its moisture content increases gradually and continuously or almost continuously at approximately 0.2 to 0.3 percent by weight of the polished rice per one hour, until the desired moisture content is achieved.

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2. A method of humidifying polished rice as defined in claim 1, further comprising the step of continuously moving the polished rice from a first location to a second location, the moisture being continuously added to the polished rice while it is moved from the first location to the second location.

3. A method of humidifying polished rice as defined in claim 2, wherein the rice moving from the first to the second locations descends under gravity.

4. A method of humidifying polished rice as defined in claim 3, wherein the descent of the rice is substantially vertical.

5. A method of humidifying polished rice as defined in claim 3, wherein the descent of the rice follows a zig-zag path.

6. A method of humidifying polished rice as defined in any one of claims 2 to 5, wherein the rice is continuously recycled through said moistureadding step until the polished rice has its final moisture content of approximately 14 to 15 percent.

7. A method as defined in any one of claims 1 to 4, wherein the moisture is added by passing moist air through the moving rice.

8. A method as defined in claim 7, wherein the direction of flow of the moist air is periodically reversed.Data supplied from the esp@cenet database - Worldwide

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346.

US4478862 - 10/23/1984

HEAT-TREATMENT OF CEREAL


Inventor(s): GREETHEAD GEOFFREY F (AU)

Applicant(s): GREETHEAD GEOFFREY PTY LTD (AU)


IP Class: A23B9/00; A23L1/10

E Class: A23L1/182; A23L1/10H2; A23B9/02F; A23B9/08; B02B1/08


Priority Number: AU1981PE07764 (19810226)

Family: CA1195170

Equivalent: EP0059565; JP57159463; BR8200779

Abstract:


A method for rapidly heat treating a cereal such as rice in at least two cyclones wherein the cereal is contacted for 10 to 15 seconds with hot gas at a temperature of 400 DEG to 600 DEG C. Substantially all the heat treatment occurs in the cyclones which provide conditions of extreme turbulence enabling the vaporization of water in the cereal to produce a substantially uniform microporous product. Quick cooking rice cookable in about six minutes may be produced very economically.Description:



1519/2197

The present invention relates to an apparatus for the treatment of a cereal by contacting it with gas at a high temperature for a short period of time so as to rapidly remove water and produce a micro-porous product.

The treatment is particularly suitable for treating unmilled, milled or polished rice; and may be carried out on uncooked, partially cooked or gelatinised rice. The treated rice so produced is a quick cooking rice which requires substantially less cooking time than ordinary untreated rice, generally around six minutes.


There is increasingly a consumer demand for food products which may be prepared quickly and with guaranteed results. There are on the market a number of quick cooking rice products whose cooking time is substantially lower than that of ordinary rice. In general, this is achieved by precooking the rice.

The precooking step results in the absorption of water by the rice so that its moisture content rises from around 12% to 14% by weight for uncooked rice to around 60% by weight. It is then necessary to remove this absorbed water so as to bring the moisture content back to its original level. This drying step must be carried out carefully in order to avoid tainting the rice and is usually achieved by heating or freeze drying.

Often, the speed of subsequent cooking of the treated rice is enhanced by breaking up the granule structure, for example by puffing the cooked grain, flattening between rollers, freeze drying or freezing and thawing.

The main quick cooking rice products currently on the market are produced as follows. "Minute Rice"

(General Foods) is produced by sequentially cooking, draining, granulating, drying, rolling and further drying. "Quick Rice" (Uncle Bens) is produced by sequentially cooking, draining, freezing, thawing, and drying. Other commercial products are produced by sequentially cooking, draining, drying, granulating, rolling and drying. Freeze drying is an expensive technique but is used in certain applications, notably for army field rations, calling for reconstitution simply by the addition of water.

However, since all these processes involve a cooking step and a subsequent drying step, they require a high energy input and the product is consequently expensive. Moreover, specialised expensive apparatus is generally required.

Australian patent specification No. 244,945 proposes the production of a quick cooking rice by contacting the rice with air at a temperature of 205 DEG to 315 DEG C. for a short time of 10 to 40 seconds. The apparatus used in this proposal is described in Australian patent specification No.

242,588. In fact, it seems that this process has never been put into commercial use. Experiments show that rice treated as described in these patents is unsuitable for use since the rice is not treated homogeneously, some rice being undertreated and other rice being scorched.

U.S. patent specification No. 2,992,921 describes an apparatus for heat treating brown rice in a fluidised bed. The rice is fed onto a perforated belt which is indexed under a conical chimney and hot air passed through the perforations to lift the rice off the belt. After a short time, the hot air is interrupted, the rice falls back onto the belt and the belt is indexed under a further chimney. Here cold air is passed through the rice. Not only is this apparatus complex with a large number of moving parts but it is found that the rice so treated shows unacceptable variations in the degree of heat treatment.

The present invention seeks to mitigate these disadvantages.


The present invention provides an apparatus for rapidly heat treating a cereal in a stream of hot gas under homogenous heating conditions, which comprises a furnace having an outlet for delivering a stream of hot gas, at least one cyclone having at an upper end an inlet for hot gas and cereal connected by a hot gas duct to the furnace outlet, a gas outlet, and a treated cereal outlet at a lower end thereof, introduction means for introducing cereal into the hot gas stream in the duct;

1520/2197

the arrangement being such that cereal entrained in the hot gas is heat treated by contact with the gas prior to being separated therefrom, substantially the whole of the heat treatment being carried in the cyclone(s).

The cyclone provides conditions of extreme turbulence leading to production of a very uniform heattreated cereal.

Generally, in order to achieve the correct treatment times, two or more cyclones arranged in series will be provided and it is advantageous that cereal leaving a cyclone be entrained in a stream of fresh hot gas to transport it into the subsequent cyclone, so as to keep the cereal at a high temperature. Thus, the cereral outlet of a cyclone will usually be connected into further introduction means for feeding the cereal into a further duct leading directly from the furnace to the inlet of the subsequent cyclone.

Preferably, the gas outlet of one or more of the cyclones is connected for recycling the gas to the furnace so as to conserve heat. A vent will usually be provided for venting a portion of the total amount of used gas.

A variety of introducing means may be employed for introducing the cereal into the gas stream, including screw transport means such as an auger, or a rotary hopper. A venturi arranged to suck cereal into the hot gas duct by pressure reduction is preferred since it has no moving parts.

The invention in a further aspect provides a method of heat-treating a cereal.

Generally, the treatment comprises rapidly heating the cereal to a temperature of from 100 DEG to 600

DEG C., preferably 400 DEG to 600 DEG C. for a time of from 2 to 30 seconds, preferably 10 to 15 seconds, so as to vapourise water in the cereal and produce a substantially uniform microporous product.

The rapid short-duration heating causes water to be rapidly evolved as steam. This renders the product microporous and reduces the moisture content, for example rice is dried usually down to 6 to 8 weight

%. However, if desired water may be added to the treated cereal so as to restore its water content to the original level prior to sale.

A quick cooking milled rice so produced may generally be cooked in about 6 minutes in boiling water, is microporous and generally has a density of below 0.6 g/ml. Untreated milled rice requires from 18 to

20 minutes cooking time and has a density in the region 0.80 to 0.85 g/ml. The present invention may be applied to all kinds of rice including brown rice, long grain rice, short grain rice and glutinous rice.

After treatment according to the present invention, the density of long grain rice is generally in the region 0.3 to 0.6 g/ml, particularly 0.45 to 0.55 g/ml. After treatment short grain rice generally has a density of 0.30 to 0.50 g/ml, particularly 0.35 to 0.45 g/ml.

The quick cooking rice may also be employed in the production of gelatinised rice, e.g. for use in making puffed rice bubbles. Normally, prior to puffing, rice is cooked under pressure (e.g. 15 psi) for

60-90 minutes with steam and some water to give a gelatinised product of relatively low water content

(e.g. 30 wt %). This product is then puffed. However, the quick cooking rice of the present invention can be gelatinised under the same conditions in less than 20 minutes. It has also been found possible to conduct the gelatinisation at atmospheric pressure.

It will be appreciated that a considerable saving in energy results from the fact that according to the present invention it is unnecessary to precook rice in boiling water. However. for certain applications a certain degree of precooking may be desirable.

Depending upon the operating conditions, the rice is generally in a non-gelatinised form such that the rice still exhibits the starch granule structure of uncooked rice and still polarises light. It has been observed that rice treated according to the present invention produces substantially no free starch when cooked. Moreover, the rice is tolerant of poor cooking techniques and can stand considerable overcooking.

1521/2197

The rice treated may be unmilled rice, milled rice or polished rice. When applied to unmilled rice, the treatment tends to assist dehusking by loosening the husk.

The rapid heating step may be carried out by contacting the rice with hot gas, having a temperature of from 100 DEG to 600 DEG C. The furnace may be a combustion furnace, electrical furnace or any other means of producing a hot gas stream directly or indirectly. One form of indirect heating would comprise a so-called hulls furnace wherein rice hulls were combusted. The flue gas would be used to heat the gas stream indirectly in a heat exchanger. The furnace preferably comprises a gas-air burner for directly producing a taint-free stream of hot flue gas for entraining the cereal.

After heating, it is preferred that the rice be rapidly cooled so as to stabilise the moisture content and the flavour. This may be achieved by quickly cooling in from 0.5 to 10 seconds down to a temperature of 30 DEG to 70 DEG C. Subsequent cooling to room temperature may then be carried out more slowly.

The apparatus of the present invention produces cereal heat treated to a high uniformity. This is believed to be due to the extreme agitation which occurs in the cyclones.

Of course, cyclones have been used for separating heat treated cereal from gaseous flows (see for example, U.S. patent specification No. 3,661,071). However, in the present apparatus the cyclones are employed for substantially the whole of the heat treatment time and have unexpectedly been found to impart a sufficiently high degree of agitation to allow uniform heat treatment. Furthermore, the capacity of the cyclones of the present invention greatly exceeds the capacity required for simple separation purposes.

Thus, advantages of preferred embodiments of the present invention include:

1. The absence of complex mechanical arrangements for conveying, exposing and cooling the grain or cereal.

The hot air used for treatment of the grain is also used to convey it through the ducts and treatment chambers. The cyclones are not designed primarily to remove the grain from the hot air stream.

They are designed and sized so that typically about 85% of the total exposure of the grain to the hot air occurs in the cyclone chamber. The only moving parts generally required are an air blower supplying a gas burner, and a main blower at the end of the hot air furnace. These components are very simple to construct and require minimal maintenance.

2. The present apparatus is able to work with much higher air velocities than is possible for prior art fluidised bed systems (the grain would be blown out of the fluidised bed at the linear velocities used in the present system). This enables the use of a much greater ratio of air mass to grain mass thus providing more efficient and more rapid heat transfer from hot air to grain.

3. The excellent exposure and agitation of the grain provided in the present apparatus enables use of very high air temperatures and short exposure times.

4. The simplicity of the present apparatus makes it cheap and simple to construct.

5. Recirculation of the hot gas for reheating is easily accomplished thus leading to reduced fuel bills.

The air flow may be held in balance, it only being required to bleed to atmosphere sufficient spent air to accommodate the fresh air needed to supply the gas burner.

6. The entire installation may be fully insulated so that there are no heat losses caused by continuous extraction of heat, such as in the prior art from moving metal parts as they index through the cooling, discharge and loading steps.

DESCRIPTION OF PREFERRED EMBODIMENTS

1522/2197

Embodiments of the invention will now be described by way of example with reference to the drawings, wherein

FIG. 1 is a schematic diagram of a first embodiment,

FIG. 2 is a cross-sectional elevation of a cyclone,

FIG. 3 is a side elevation of a second embodiment, and

FIG. 4 is a view of the second embodiment from above.

The apparatus shown in FIG. 1 comprises a furnace 4 for feeding hot combustion gases to cyclones 1, 2 and 3 through respective ducts 5, 6 and 7. Untreated rice is introduced at R into duct 5 by inlet 8. The bottom of cyclone 1 is connected to duct 6 via pipe 9 and the bottom of cyclone 2 is connected to duct

7 via pipe 10. The bottom of cyclone 3 is connected to cooler 11 via pipe 12.

Each of the cyclones has a respective gas outlet pipe 13, 14 and 15 connected to a manifold 16 for returning gas to the furnace 1. A vent 17 is provided for venting a fraction of the recycled gas.

The apparatus may be operated as follows. Hot flue gases are generated in the furnace 4 and passed into the duct 5. Rice is trickled through the inlet 8 into a venturi in the duct 5 and is entrained in the high velocity stream of hot gas. The hot gas and entrained rice is then introduced into the cyclone 1 where the rice receives substantial agitated heat treatment and is finally spun out of the gas flow. The separated rice exits through pipe 9 and the hot gas is removed through outlet pipe 13. Typically the residence time of the rice in the cyclone is from 2 to 10 seconds.

The separated rice then passes through pipe 9 and is reintroduced into a further high velocity flow of gas from the furnace in duct 6 and thereafter passes to cyclone 2 where the treatment is repeated.

Finally, the treated rice leaves cyclone 3 through pipe 12 and passes to the cooler 11.

In the cooler 11 the separated rice is mixed with cold air and cooled to a temperature of around 50

DEG C. typically in 2 to 5 seconds. The warm rice then leaves the cooler 11 and is allowed to slowly cool to ambient temperature.

Hot gas leaves the cyclones through outlets 13, 14 and 15 and enters the manifold 16 and is recycled to the furnace 4. A fraction of the gas is vented at 17.

Depending on the residence time required, any number of cyclones may be employed. The use of cyclones enables the provision of an apparatus having few moving parts which is relatively cheap to construct.

If desired, the treated rice may be remoisturised by passage under a spray so as to restore the moisture content to the level of the untreated rice.

FIG. 2 shows in more detail the cyclone construction. The cyclone comprises a chamber 19 having an upper generally cylindrical portion 20 and a lower funnel-shaped portion 21. An inlet 18 for gas and entrained rice is directed tangentially into the top of upper chamber portion 20. A gas outlet pipe 22 extends down the centre of the chamber 19. A treated rice outlet 23 is provided at the apex of the lower chamber portion 21.

Rice entrained in the gas enters through inlet 18 and swirls around the chamber. Rice is thrown outwardly by centrifugal force towards the chamber walls and eventually drops to the bottom of the chamber, before being withdrawn via outlet 23. Gas is recirculated to the furnace through outlet pipe

22.

FIGS. 3 and 4 show a second embodiment which is very similar to the first embodiment except that no cooler is provided and that only gas from the first and second cyclones is recycled to the furnace, gas from the third cyclone being vented to atmosphere.

1523/2197

The furnace comprises a gas-fired burner 24. Fresh hot gas is mixed with recycled gas and fed by blower 25 operated by motor 26 into manifold 27. The manifold has three branches attached to ducts 5,

6 and 7 leading to cyclones 1, 2 and 3 respectively. Untreated rice is introduced into duct 5 at R before passing into duct 6 and passes into cyclone 2. Similarly rice from cyclone 2 is fed to cyclone 3. The residence time of the rice in the ducts is very small compared to the time spent in the cyclones.

Gas exits from cyclones 1, 2 and 3 via outlet pipes 13, 14 and 15. Outlets 13 and 14 are connected to pipe 28 for recycling the gas back to burner 24, whilst outlet pipe 15 from the third cyclone leads into the atmosphere.

Fully treated rice is collected from the bottom of the third cyclone from pipe 12.

It has been found desirable to use three cyclones arranged to sequentially treat the rice with a fresh charge of hot gas. A single cyclone generally provides an insufficiently short treatment time; attempts to remedy this by slowing the gas flow velocity result in problems in entraining the rice in the gas flow.

Moreover, the rice quickly cools the gas of entrainment so that it is desirable to contact the rice with a number of charges of fresh hot gas in order to maintain the rice at the desired high treatment temperature.

The invention will now be illustrated with reference to the following Examples.

EXAMPLE 1

Milled long grain rice was contacted with hot gas from the furnace at a temperature of approximately

420 DEG C. for 12 seconds in the apparatus shown in FIGS. 3 and 4. The initial moisture content prior to treatment was 13 weight %. The treated rice had a moisture content of 7%. The density of the untreated material was 0.82 g/ml and this was reduced to 0.50 following treatment.

The treated rice required only 6 minutes to cook but could be cooked for up to 15 minutes without any noticeable deterioration in quality. There was no detectable change in the flavour of the treated rice as compared to untreated rice cooked by conventional techniques.

EXAMPLE 2

The same procedure as described in Example 1 was applied to medium grain rice of initial density 0.87 and a moisture content of 13 wt %.

The treated product had a density of 0.56 g/ml and a moisture content of 9%. The treated rice cooked in

6 minutes and was of comparable quality to untreated rice cooked by conventional techniques.

EXAMPLE 3

The procedure of Example 1 was repeated using a fresh gas temperature of about 500 DEG C. and a total treatment time of about 15 seconds. It was estimated that the average temperature of gas in contact with the rice would be around 300 DEG C. Rice heat-treated to excellent uniformity was obtained.

However, the rice itself never reaches these temperatures and treated rice was found to leave the last cyclone at a temperature of around 135 DEG C.

EXAMPLE 4

The procedure of Example 1 was repeated using long, medium and short grain brown rice.

The treated product cooked in 8 minutes, compared to a time of 40-50 minutes typically required for untreated brown rice.Data supplied from the esp@cenet database - Worldwide

Claims:


1524/2197

I claim:

1. A method for rapidly heating a cereal containing water in a stream of hot gas under homogenous heating conditions in at least two cyclones to produce a substantially uniform microporous product, which comprises generating a stream of hot gas, entraining a cereal in the gas stream, introducing the gas and entrained cereal into a first cyclone wherein the cereal is heat treated by the hot gas, separating the cereal by centrifugal force from the gas, and removing the separated treated cereal and the gas separately from the cyclone, generating a further stream of hot gas, entraining the treated cereal from the first cyclone in the further gas stream, introducing said further gas stream and heat treated cereal into a second cyclone wherein the cereal is further heat treated by hot gas, separating the twice-treated cereal by centrifugal force from the gas, and removing the separated twice-treated cereal and the gas separately from the second cyclone; said heat treatments being sufficiently rapid to raise the temperature of the cereal to vaporize the water in said cereal to produce a substantially uniform microporous product.

2. A method according to claim 1 wherein the gas from the cyclone is reheated and recycled to the hot gas stream, a portion being vented.

3. A method according to claim 1 wherein the separated treated cereal from the second cyclone or the last cyclone is cooled in 0.5 to 10 seconds to a temperature of from 30 DEG to 70 DEG C.

4. A method according to claim 1 wherein the cereal is entrained in the gas stream by means of a venturi-induced pressure drop in the gas stream.

5. A method according to claim 1 wherein the temperature of the hot gas is from 400 DEG to 600 DEG

C.

6. A method according to claim 1 wherein the cereal is in contact with the hot gas for a total time of from 2 to 30 seconds.

7. A method according to claim 1 wherein the cereal is rice which becomes dried to a moisture content of from 5 to 10 wt %.Data supplied from the esp@cenet database - Worldwide

1525/2197

347.

US4505942 - 3/19/1985

MANUFACTURE OF SNACK FOODS


Inventor(s): ITO HIDEAKI (JP); ITO HARUO (JP)

Applicant(s): ITO HIDEAKI (--); ITO HARUO (--)


IP Class: A23L1/01

E Class: A23L1/20D4; A23L1/164E; A23L1/164



Family: US4505942

Abstract:


A method for making a base material for a snack food wherein 100 parts of a bean-cured refuse are mixed with 120 to 180 parts of wheat flour, 30 to 70 parts starch, and 12 to 28 parts water. The mixture is steamed and boiled into a rice-cake state after which the mixture is formed into a sheet, cooled, and matured. The mixture is then dried to produce a base material having a water content of 13 to 20% by weight. This base material can then be suitably processed to form a nutrition snack food.Description:




This invention is in the field of the manufacture of snack foods utilizing a bean-curd refuse which is a by-product resulting from the manufacture of soybean milk, and to which wheat flour and starch are added as viscosity enhancing materials.


Conventional snack foods are mostly made from wheat flour, corn, rice, or potatoes. Particularly in

Japan, such snack foods are manufactured by a process in which the main ingredients are mixed together with seasoning and leavening agents, steamed or boiled into a rice-cake state, rolled into sheets, and then cooled and ripened. The sheet is then cut into a desired shape and dried to make the base material. This base material is transformed into the snack food by preheating, frying in oil or toasting or roasting and seasoning to produce foods such as rice crackers, rice-cake cubes, and the like.


Recent studies have shown additional benefits from natural foods, particularly soybean milk. It has been recognized again that high quality plant protein is contained in soybean milk which is highly nutritious and that the linoleic acid present is effective for controlling cholesterol.

1526/2197

In accordance with the present invention, bean-curd refuse which is a by-product in the production of soybean milk is used as a principal ingredient in the manufacture of snack foods. Although sometimes used as a food itself, bean-curd refuse (also known as okara or soy pulp) is presently available in large amounts as the production of soybean milk has increased, but only a small portion of it has been used as food, with the remainder being used as a feed for animals or discarded. Utilization of bean-curd refuse is therefore socially important. In addition, bean-curd refuse contains almost the same amount of protein and fat as soybean milk, providing consumers with snack foods which are high in nutrition.

After soybeans have been ground, the smooth puree is immersed in boiling water, returned to the boil, and simmered. The boiled product is then filtered through a filter cloth or by means of a hydraulic press or centrifuge. The insoluble residue which remains constitutes the bean-curd refuse. It contains about

17% of the protein in the original soybeans.

The following table provides a comparison between the nutrients in soybean milk and the bean-curd refuse:

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Carbohydrate

>;tb; Protein Fat Water

>;tb;______________________________________

>;tb;Soybean Milk 3.2 3.7 93.1

>;tb;Bean-curd refuse

>;tb; 9.7 4.8 3.6 81.9

>;tb;______________________________________


It was found that as the amount of bean-curd refuse is increased, it is difficult to make it into a ricecake state in the conventional process of producing rice-cake cubes which are familiar snack foods to

Japanese people. In the usual process of making such snack foods, the raw materials are mixed, steamed, and boiled into a rice-cake state.

As shown in Table 1, the beam-curd refuse contains carbohydrate, protein and fat only and does not contain starch so it does not become viscous even when heated and mixed. Consequently, a suitable base material cannot be formed unless some starchy material such as wheat flour is added. As shown in the following Table 2, an experiment was made varying the ratio of bean-curd refuse to wheat flour with the following results:

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Relation between bean-curd refuse and wheat flour

>;tb; 1st test

>;tb; 2nd 3rd 4th 5th

>;tb; parts by volume

>;tb;______________________________________

>;tb;Bean-curd 100 100 100 100 100

>;tb;refuse

>;tb;Wheat flour

>;tb; 90 120 150 180 210

>;tb;Starch 50 50 50 50 50

>;tb;Water 0 8 20 35 50

>;tb;Water/total

>;tb; 39% 32% 32% 32% 32%

>;tb;volume

>;tb;Rice-cake Fair Good Excellent

>;tb; Excellent

>;tb; Excellent

>;tb;state

>;tb;Taste Good Excellent

1527/2197

>;tb; Good Fair

>;tb;______________________________________

>;tb; Note:

>;tb; Cake is hard and sheeting is impossible.

In the foregoing experiment, the rice-cake conditions of the material were observed with the volumes of bean-curd refuse and starch fixed, and the volume of wheat flour varied. When the wheat flour is present in large amounts, the rice cake conditions are good but the taste is poor. It was found also that when the wheat flour was added in too small an amount, the rice-cake was not glutinous and could not be rolled into a sheet. As a result of this experiment, it was found that where 100 parts by volume of bean-curd refuse were added to 90 to 210 parts by volume of wheat flour and 50 parts by volume of starch, a good result was obtained when 120 to 180 parts by volume of wheat flour were added.

Another problem which occurs results from the necessity of adding a viscous material such as starch to the base since the base becomes easily cracked when rolled and dried if the content of bean-curd refuse is increased. Since the bean-curd refuse does not contain any viscous material itself, the cake is easily cracked in the process where the raw materials are mixed, steamed, and boiled into a rice-cake state, rolled and dried if the volume of starch present is small. In accordance with the present invention, this problem was solved by adding not only wheat flour but also a kind of starch which was more viscous and elastic that wheat flour to the bean-curd refuse. In the group of starches, viscosity increases in the following order:

Corn starch, sweet potato, potato and tapioca.

The base becomes more resistant to cracking when starch with a higher viscosity is used.

In the following table, there is shown results of experiments made using sweet potato or potato starch.

100 parts of bean-curd refuse was used in conjunction with 150 parts of wheat flour, and the volume of starch was varied.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; 1st 2nd 3rd 4th 5th

>;tb; test test test test test

>;tb; parts

>;tb;______________________________________

>;tb;Bean-curd

>;tb; 100 100 100 100 100

>;tb;refuse

>;tb;Starch 10 30 50 70 90

>;tb;Wheat flour

>;tb; 150 150 150 150 150

>;tb;Water 2 11 20 30 40

>;tb;Rice-cake

>;tb; Good Excel- Excel-

>;tb; Excellent

>;tb; Good (Too

>;tb;conditions lent lent elastic)

>;tb;Base Easily Good Excel-

>;tb; Excellent

>;tb; Good

>;tb;conditions

>;tb; cracked lent

>;tb;______________________________________

In the above experiment, the strength of the base was observed by varying the ratio of bean-cured refuse to starch. It was found that the base was easily cracked when the volume of starch was small. On the other hand, when the volume of starch was too large, the rice-cake became very elastic making it difficult to process it. Good results were obtained from the second to fourth tests utilizing 150 parts of wheat flour and 30 to 70 parts starch for every 100 parts of bean-curd refuse. It was therefore

1528/2197

concluded that the best procedure was to add 120 to 180 parts of wheat flour and 30 to 70 parts of starch to 100 parts of the bean-curd refuse.

Another problem which arises is selecting the proper volume of water to be added to the bean-curd refuse, wheat flour and starch since the bean-curd refuse contains substantial amounts of moisture. In the manufacture of typical flour-cake cubes, a good cake is obtained using about 35 kg of water to 100 kg of wheat flour. However, when the bean-curd refuse is used, the amount of water to be added is an important problem since the bean-curd refuse itself contains about 82% water. The relation of water to bean-curd refuse, starch and wheat flour was tested utilizing the best volume relationships according to

Tables 2 and 3, with the water content of the bean-curd refuse assumed to be 82%. The following table lists the results.

>;tb; TABLE 4

>;tb;______________________________________

>;tb; 2nd

>;tb; 1st test

>;tb; test 3rd test

>;tb; 4th test

>;tb; 5th test

>;tb; 6th test

>;tb; parts

>;tb;______________________________________

>;tb;Bean-curd

>;tb; 0 100 100 100 100 100

>;tb;refuse

>;tb;Wheat flour

>;tb; 100 150 150 150 150 150

>;tb;Starch 20 50 50 50 50 50

>;tb;Water 35 4 12 20 28 36

>;tb;"Rice-cake"

>;tb; Excel- Too Excel-

>;tb; Excel-

>;tb; Excel-

>;tb; Too

>;tb;conditions

>;tb; lent hard lent lent lent soft

>;tb;Total solid

>;tb; 77.4% 71.7% 69.9% 68.1% 66.5% 64.9%

>;tb;part

>;tb;Total 22.6% 28.3% 30.1% 31.9% 33.5% 35.1%

>;tb;moisture

>;tb;content

>;tb;______________________________________

The first test illustrates the standard compound ratio in flour-cake cubes, wherein the total moisture content is 22.6%. When the bean-cured refuse is added, the water content becomes 28 to 33% as shown in the third to fifth tests since the bean-curd refuse has a high moisture content. If more water than this is added, the rice-cake becomes too soft for proper sheeting to be made.

As seen from Table 4, good results could be obtained where the moisture content was about 30 to 33%.

The bean-curd refuse contains about 50% fibrous material and the problem arose as to how to make it soft and pleasant to the tongue. This was accomplished by softening and swelling the fibrous material by immersing the bean-curd refuse in a slightly alkaline solution prior to mixing with the other ingredients, making the product base smooth, soft, and pleasant to the tongue.

Specifically, the bean-curd refuse was immersed in a slightly alkaline buffer solution containing sodium bicarbonate, potassium bitartrate and alum having a pH of 7.5 to 8.5 for about 5 to 12 hours.

This was followed by adding 120 to 180 parts of wheat flour, 30 to 70 parts of starch, and 12 to 28 parts of water, some seasoning and leavening agents such as baking powder or sodium bicarbonate to

1529/2197

100 parts of the bean-curd refuse. The mixture is then mixed, steamed and boiled to obtain a soft and elastic rice-cake-like substance. This material can be rolled by means of a roller into a sheet having a thickness of 1 to 3 mm followed by cooling and ripening the sheet to mature it. The sheet is then cut into particular sizes and shapes and dried to produce a base material having a 13 to 20% moisture content. This base material is then made into a snack food by preheating, frying in oil, or toasting, or by roasting, followed by seasoning the base material.

The cake made from the base material is soft and pleasant to the tongue and is not rough due to the presence of fiber even if a substantial amount of bean-curd refuse is used. It is neither too soft nor too elastic when steamed and boiled together with wheat flour and starch mixed in. The base material does not crack even when rolled into a sheet and dried. Delicious snack foods can be made which have the mellow sweetness characteristic of soybean milk.

It will be evident that various modifications can be made to the described embodiments without departing from the scope of the present invention.Data supplied from the esp@cenet database -

Worldwide Claims:


We claim as our invention:

1. A method for making a base material for a snack food which comprises mixing 100 parts of beancurd refuse with 120 to 180 parts of wheat flour, 30 to 70 parts starch, and 12 to 28 parts water, steaming and boiling the resulting mixture into a rice-cake state, forming the mixture into a sheet, cooling and maturing the mixture, and drying the matured mixture to produce a base material having a water content of 13 to 20%.

2. A method according to claim 1 which includes the step of adding a leavening agent to the original mixture.

3. A method according to claim 1 in which said sheet has a thickness of about 1 to 3 mm.

4. A method according to claim 1 wherein said bean-curd refuse prior to said mixing is immersed in a mildly alkaline solution having a pH of 7.5 to 8.5 for 5 or 12 hours.

5. A method according to claim 4 in which said mildly alkaline solution contains sodium bicarbonate, potassium bitartrate, and alum.

6. A method according to claim 1 in which said starch is sweet potato starch.

7. A method according to claim 1 in which said starch is potato starch.Data supplied from the esp@cenet database - Worldwide

1530/2197

348.

US4526800 - 7/2/1985

CEREAL SNACKFOODS AND COMPOSITIONS AND METHODS FOR

MAKING THE SAME


Inventor(s): HOWARD ALAN N (GB)

Applicant(s): HOWARD ALAN N (GB)


IP Class: A23L1/10

E Class: A23L1/164E; A23L1/217B; A23L1/10E; A23L1/164



Family: US4526800

Equivalent:

Abstract:

EP0039185; US4938982; JP57170157; GB2074436; IE810926L; IE51089


The invention provides cereal snackfoods of the expanded variety such as crisps and the like. The snackfoods of the invention comprise discrete cooked portions of a dough composition comprising gelatinized starch and added cereal bran other than rice bran, in which the amylolytic activity of the bran is controlled, and contain at least about 5% by weight and generally no more than about 35% by weight of oil or fat. The snackfoods may be produced from a half product comprising at least some gelatinized starch and added cereal bran by frying or by immersion in a bed of hot particulate material followed by spraying with fat or oil. Even when fried the snackfoods have a lower energy value than comparable known products; moreover they are highly palatable, and the bran content provides a useful source of fibre in any diet.Description:



(a) Field of the Invention

The present invention relates to expanded snackfoods such as crisps and like foods obtained by cooking discrete portions of a dough composition.

(b) Description of the Prior Art

An essential requirement to obtain such expanded snackfoods is that before cooking at least some of the starch in the dough should be gelatinized. Gelatinization of the starch is typically achieved by cooking it in the wet state, whence a physical change takes place in its structure such that it becomes more viscous. It is believed the presence of gelatinized starch is necessary to trap the steam produced on cooking so as to give the necessary expanded structure.

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Various processes for preparing expanded snackfood products have been described by Willard, Snack

Foods, 62, pages 52 to 54, 1973, (see also U.S. Pat. No. 3,997,684) and Matz, Snack Food Technology,

The AVI. Publishing Company, Inc., Westport, Conn., U.S.A., pages 144 to 149.

The processes using dough can generally be grouped into three categories and summarised as follows:

(1) The dry collett process:

In this process a thin portion of dried starch-based gel is expanded by a short immersion in hot fat or, as described in British Patent Specification No. 2,008,924 A, by cooking in a hot bed of, for example, salt or calcium carbonate.

Typical of such a process is that disclosed in British Patent Specification No. 888,689 which describes the manufacture of a potato-based foodstuff in which potato flour is mixed with powdered potato starch, water is added to form a dough, and the dough is cooked so as to gelatinize the starch, the swollen dough being dried to form a product having a rubber-like consistency. After drying, the dough can be sliced, the slices further dried, and then cooked in boiling fat to provide potato crisps.

In another such process described in U.S. Pat. No. 4,140,803 starch is gelatinized by feeding an aqueous slurry containing starch onto a hot double roller dryer, and the multilaminar film obtained is cut into small pieces and fat fried.

In other such processes as described in, for example, British Patent Specification Nos. 1,358,097 and

1,484,455, a dough containing some pre-gelatinized starch is extruded through a die under conditions of temperature and pressure which lead to further gelatinization; the small pieces of this dried material are then fried as before.

(2) Frying a wet completely gelatinized dough:

In this process a wet dough containing about 30 to about 85% solids is cut into desired shapes, and then fried, the starch in the dough being completely gelatinized before it is fried. Some of the products made in this category are described in U.S. Pat. Nos. 3,539,356; 3,297,450; 3,451,822; and 4,007,292; and

Canadian Patent Specification No. 871,648.

(3) Frying a wet dough containing some ungelatinized starch:

In this process the dough contains a mixture of gelatinized and ungelatinized starch, and consists of from about 30 to about 70%, usually from about 40 to about 50%, by weight of solids. The dough is formed into pieces and fried. With such a dough, for example, as described in U.S. Pat. No. 3,997,684, the expansion is only about 1.6 times the original volume compared with the over three times expansion obtained by the processes of the two previous categories.

In the production of baked or toasted cereal products of the kind used as breakfast foods, and in the production of biscuits and cookies, it is known to employ a dough mixture including bran in various proportions of up to about 100% of the product. Examples of such foods are disclosed in British Patent

Specification Nos. 344,055, 1,561,190 and 2,010,656 A.

In addition, British Patent Specification Nos. 1,465,843 and 1,544,843 disclose snackfoods including rice bran material, particularly in the latter case to afford a rice cracker flavour.

Furthermore, U.S. Pat. No. 2,701,200 to Huber, is concerned with a novel puffed product which may contain bran and with a process of producing that product. In the Huber process heated pressure rollers are employed to solve problems encountered in the prior art both with puffing guns and "radiant" puffing, the product produced mainly being a breakfast cereal-type product which is fat- or oil-free.

While the earlier disclosure mentions that in place of whole grain materials one may use selected fractions of grains and, as examples of such fractions, selected flours, meals, farina, bran and the like-and indeed while, in its Example 10, the earlier disclosure employs wheat bran and oat bran along with white corn cones and yellow corn cones to give a dry-mix bran content of about 18% by weight--there is no expressed or implied appreciation of the use of added cereal bran in a snackfood product. The

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presence of bran is incidental to the problem solved by the earlier invention in the provision of heated pressure rollers to achieve a puffed product.

Also, U.S. Pat. No. 3,656,966 to Ball et al, which relates to a process for making a ready-to-eat food chip from cereal grain, includes products prepared by the disclosed process having their own natural bran, that is non-added bran at a level of up to no more than about 9% by weight. It is furthermore disclosed that in the resulting dough the wheat particles of the wheat or rye bran are retained after cooking and it is said that the oil content of the final product may range from about 25% to about 40% and preferably is about 30%. Again, however, the earlier invention is concerned with the use of a cutting operation to reduce the size of individual grain kernels to increase their total surface area and to expose the endosperm, thereby improving the absorption of moisture capabilities of the kernals when combined with water, and not specifically with the provision of a bran-containing food. The presence of bran is again incidental to the problem solved.

Thus, in the prior art, bran-containing products can be seen to fall into one of the following categories, namely:

1. Specialised products with a distinctive flavour e.g. with added rice bran to impart that flavour,

2. Fat-free products e.g. breakfast cereal products, and

3. Products including their own natural bran with relatively high oil or fat contents.

Furthermore, it might be thought that to add bran to an expanded snackfood product as opposed say to a breakfast-food product would detract from the degree of expansion or lead to no expansion at all.

Also, it might be thought that to add bran would lead to unacceptably high levels of fat or oil, where fat or oil cooking is employed to expand the snackfood dough.

However, I have now found surprisingly that a snackfood can be produced successfully from a dough mix of predetermined volume comprising gelatinized starch and added bran, the snackfood being both expanded to at least about 1.25 said predetermined volume and of relatively low fat content, provided the amylolytic activity of the bran is controlled to prevent breakdown of gelatinized starch in the dough composition subsequent to the formation of the dough composition to be cooked and up to cooking of the dough.


Accordingly, the present invention provides an expanded snackfood prepared from a dough composition of predetermined volume and comprising cooked portions of dough composition comprising gelatinized starch and added cereal bran selected from the group consisting of wheat bran, barley bran, oat bran, rye bran, maize bran and mixtures thereof, the snackfood containing from about

5% to about 35% by weight of oil or fat and from about 10% to about 70% by weight of bran, and having a volume at least about 1.25 times said predetermined volume, the amylolytic activity of the bran being controlled to minimise breakdown of gelatinised starch in the dough composition subsequent to the formation of the dough composition to be cooked and up to cooking of the dough.


The expanded snackfood of the present invention is intended to be a crisps-like product. That is to say it should have a "fried" flavour imparted to it by the presence of at least about 5% by weight of saturated or unsaturated oil or fat, whether incorporated by frying or otherwise, e.g. by spraying onto the cooked product. In addition, the bran employed must not in itself nor in the amount in which it is employed impart to the snackfood organoleptic properties which significantly detract from a crisps-like feel and/or flavour. Thus, the bran used should not be rice bran which has a distinctive character and flavour sufficient to detract from the properties required, and it is to be understood that the term "cereal bran" as used herein and in the claims does not include rice bran.

Moreover, the snackfood must be expanded, that is the dough portions from which it is derived must be expanded by frying or other cooking processes generally to at least about 1.25 times their original volume, preferably to at least about 1.5 or about 1.6 times, more preferably to at least about 2 times, e.g. about 2.5 or about 3 times their original volume. Surprisingly, the incorporation of bran does not lead (as was expected) to a crisps-like snackfood in which the expansion is kept to an undesirably low

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level. Thus, with a product containing 50% by weight of bran the mean expansion may be, for example, about 1.5 times.

The present snackfood is highly palatable and can contain a high content of bran, generally a content higher than that present in whole wheat flour (about 9% by weight of bran), and always a content higher than the natural content of whatever starch source is employed. Generally, therefore, the snackfood of the invention comprises at least about 10% by weight of bran, for example, from about 15 to about 70% by weight of bran, and preferably from about 20 to about 50% by weight of bran. The inclusion of bran in a snackfood provides a highly palatable means of including fibre in a diet, the necessary level of fibre often lacking in the diets of Western populations.

It is a particularly surprising feature of the present snackfood that it has a high palatability, both from the point of view of taste and of texture. The snackfood while still being a crisps-like product differs from conventional potato crisps in being harder to bite, and thus affords a "crunchy" feel, which provides much more oral satisfaction. Moreover, while many bran products are disliked because of a heavy bran flavour, surprisingly the inclusion of bran in the present snackfood gives a more pleasant

"proteinaceous" flavour than in other bran-containing products.

The snackfood of the invention may be in any of the many usual discrete portion forms. Thus, for example, it may be in the form of thin wafers such as crisps, or in the form of rings, straws, chips, small "sausages", cones and the like.

The gelatinized starch may be used alone or in admixture with ungelatinized starch and may be incorporated in the dough in any convenient form. Thus, at least some of the starch may be pregelatinized or at least some of the starch may be gelatinized by cooking once the dough composition has been prepared. By way of example, the starch may be one obtained from wheat, oats, barley, rye, maize, rice, cassava, potatoes, tapioca, sago, legumes and arrowroot. Preferably, the starch is one provided by incorporating a cereal flour, in particular wheat flour, in the dough. In an especially preferred aspect the wheat flour is one in which the starch has been pre-gelatinized, e.g. one made by taking white wheat flour, making it into a slurry with water, and then spraying the mixture onto hot rollers. The dried material is scraped off and remilled to give a fine powder which can later be reconstituted with water into a dough. A similar technique can be applied to flours from sources other than wheat to afford the necessary pre-gelatinized material.

In another preferred aspect, the gelatinized starch is provided by dehydrated cooked potateos.

Preferably the cereal bran used in the present invention is wheat bran. However, other forms of cereal bran may be used where these are available and can produce the desired fibre content, for example, barley, oats, rye or maize bran.

Commercially available bran is the residue left over from the milling of grain to produce flour, and comprises the grain husk with varying but relatively small amounts of adhering endosperm. Thus, wheat bran is available as course bran, middlings (or weatings) and superfine weatings which respectively comprise up to about 10% by weight, up to about 5.8% by weight and up to about 4.5% by weight of crude fibre. Since the amount of crude fibre in commercially available bran can vary it is to be understood that the term cereal bran as used herein and in the claims means a bran material including not less than about 4.0% by weight of crude fibre, crude fibre being the residue left after extraction with petroleum ether and then (a) boiling with about 1.25% sulphuric acid and (b) boiling with about 1.25% caustic soda, minus ash. Preferably, the bran used in the present invention is one comprising at least about 4.5% by weight of crude fibre.

It will be understood by those familiar with dietary nomenclature that the terms "dietary fibre" and

"crude fibre", although related, are not equivalent. Generally speaking, for any one product, the latter is lower than the former by a factor of about 5. Thus, by way of example, typical analyses for coarse wheat bran and middlings may be as follows:

>;tb; TABLE I

>;tb;______________________________________

>;tb; Coarse Bran

>;tb; Middlings Bran

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>;tb;______________________________________

>;tb;% Fat 2.75 3.45

>;tb;% Protein 13.55 13.45

>;tb;% Starch 9.2 38.9

>;tb;% Sugars 8.6 7.55

>;tb;% Dietary Fibre

>;tb; 58.5 32.5

>;tb;% Crude Fibre 10.0 5.6

>;tb;Calorific Value

>;tb; 149 271

>;tb;Kcals/100 g

>;tb;______________________________________

It will be appreciated from the above discussion that wheat bran on average can provide a content of say about 45% by weight of dietary fibre, although the content of crude fibre provided is much less. In any event, however, a snackfood containing about 15% by weight or more of wheat bran in accordance with the invention will contain a significant and useful amount of dietary fibre.

In putting the present invention into practice it is essential that the dough composition which is finally cooked to produce the snackfood should include at least some gelatinized starch. The presence of such starch is essential to the formation of an expanded structure, and preferably the dough should contain at least about 25% by weight of gelatinized starch based on the total weight of starch, for example, from about 30% to about 70% by weight or higher. Most preferably, however, the dough may contain up to about 100% by weight of gelatinized starch based on the total weight of starch.

Furthermore, since high amylolytic activity introduced into the dough through the added bran can greatly reduce the content of gelatinized starch, that activity must be controlled. In particular, such control must be exercised at least subsequent to the formation of a dough including both the desired final amount of gelatinized starch and added bran, and before final cooking to expand the dough to the desired snackfood.

It is important to control the effect of amylolytic activity on the content of gelatinized starch during the process of making the "half-product" from which the present snackfood is prepared because excessive breakdown of gelatinized starch (once the dough to be cooked has been prepared) can lead to a product which expands poorly, or not at all, on cooking. Furthermore, such control is also important because once a mixture of a bran with high amylolytic activity together with gelatinized starch and water is formed, and if no control is exercised, the strength and elasticity of the dough become impaired. It then becomes difficult, or impossible, to extrude the dough in a continuous manufacturing process.

In processes which employ ungelatinized starch to give an initial mixture of bran, starch and water, prior to the making of the final dough composition, it is not necessary initially to treat the bran, since the amylolytic enzymes in raw bran attack ungelatinized starch only slowly. However, once gelatinized starch is present, it is important to control the amylolytic activity of the mixture to prevent breakdown of gelatinized starch either on further processing and/or on storage.

Such control of the amylolytic activity is as required in the preparation of the present snackfood, can be exercised in a number of ways. In one aspect of the invention the bran can be treated externally of the dough, i.e. pre-treated, to reduce its amylolytic activity to below a level at which it appreciably decreases the gelatinized starch content of the dough. Alternatively, in another aspect of the invention, the bran can be treated internally of the dough to reduce its amylolytic activity to below a level at which it is detrimental to any gelatinized starch present.

Thus, for example, the amylolytic activity of the bran within the dough can be controlled by mixing the dough under refrigerated conditions, generally wherein the temperature of the dough composition is held at no more than about 10 DEG C. prior to cooking. In that manner digestion of gelatinized starch by amylase present in the bran can be kept to a minimum, and the structure of the final snackfood can be maintained.

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Preferably, however, the bran is treated to reduce its amylolytic enzyme, e.g. amylase, content (and consequently its amylolytic activity) so as to avoid the necessity to employ refrigeration prior to cooking. In that case it is preferred that any treatment of the bran, whether before or after addition to the dough, should reduce its amylolytic enzyme content to a level where the bran has a maltose value of not more than about 350 mg/10 g. More preferably, however, the bran is one having a maltose value reduced to not more than about 250 mg/10 g, e.g. about 200 mg/10 g or below, and most preferably not more than about 100 mg/10 g.

The treatment of the bran to reduce its maltose value may be effected by any convenient technique.

Preferably, however, the amylolytic enzyme conent of the bran is reduced by a heat treatment. A heat treatment will destroy enzymes such as amylase and may under certain circumstances gelatinize residual starch in the bran.

Thus, in one process, the amylolytic activity of the bran may be controlled by heating the bran before it is added to the dough composition. For example, natural or raw bran may be treated by one of the following techniques, namely:

(i) By autoclaving at about 120 DEG C. for about 20 minutes.

(ii) By extruding the bran in a heated extruder which heats the bran to about 160 DEG C. for about 10 seconds.

(iii) By mixing the bran with water to form a slurry, which is then extruded onto a roller dryer operated at about 100 DEG C., followed by milling of the dried product to a fine powder.

Alternatively, in another process, whole wheat grain is heated by live steam at about 100 DEG C. for about 20 minutes. The thus-produced grain on subsequent milling gives a bran with reduced amylolytic activity.

Additionally or alternatively, the heat treatment of the bran may be effected after it is added to the dough composition, but before the dough includes its finally required content of gelatinized starch. In that case, there is preferably first formed a dough composition comprising raw bran and ungelatinized starch, and the dough composition is heated both to reduce the amylolytic enzyme content of the bran and to gelatinize at least some of the starch in the dough.

A particularly unexpected property imparted to the snackfood of the present invention by the incorporation of added cereal bran is the ability to have a relatively low fat content compared with known crisps or the like, even when frying is used for cooking. One drawback of potato crisps and other fried snackfoods is their high caloric value, and it is a significant advantage of the present snackfood that its caloric value can be much less per unit weight than other such foods not containing bran.

Thus, the present snackfood is advantageous in that it provides a good source of fibre in any diet, it is highly palatable, it has a fried flavour, and yet since it can contain fewer calories than comparable known products not containing bran, it can be produced in a form acceptable to those on weight loss diets.

Subject to what is said above, the expanded snackfood of the present invention may be prepared by any process which comprises mixing starch, e.g. wheat flour, and bran, and treating the mixture by any technique which affords the necessary instantaneous, severe, localised heating conditions to provide discrete cooked portions of said dough expanded to the necessary level. For example, the snackfood may be prepared by any of the processing techniques in categories (1) to (3) described above.

Thus, for example, such a process may comprise adding water to a mixture of bran and ungelatinized starch or a source thereof to form a dough, heating the dough to gelatinize at least some of the starch

(and to treat the bran), sub-dividing the resulting dough composition, e.g. by slicing, and drying the subdivided dough to form discrete portions of a "half product" which can be cooked either by frying in fat or oil or, for example, by immersion in heated salt or calcium carbonate. The "half product" can also be made by mixing pre-heated bran with pre-gelatinized starch and water to form a dough which is cut or otherwise subdivided and then dried, or by forming a slurry of bran and ungelatinized starch or a source thereof, which is then hot roller dried, and the thus-formed sheet of dried dough sub-divided e.g.

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cut, into discrete portions. Such cut portions may be cooked as such or ground, and reconstituted with water to make a dough, which itself is cut or otherwise sub-divided and dried.

As another example, the process of the invention may comprise forming a dough comprising either pretreated and/or raw bran and starch, some of which is gelatinized, extruding the dough through a die under conditions of temperature and pressure which lead to gelatinization of more of the starch (and treatment of the bran, if raw bran is used), sub-dividing the extruded dough into discrete portions, and cooking the portions.

Preferably the snackfood of the invention is prepared by a process using pre-gelatinized starch suitably in the form of a gelatinized wheat flour or potato flour.

An advantage of employing pre-gelatinized starch is that flavouring and other materials can be incorporated in the dough and there is much less likelihood of these materials being destroyed than might be the case when the dough is cooked to provide gelatinization.

In order to achieve the necessary expansion, it is desirable that the half product prepared in any process employed to produce the snackfood of the invention should have a moisture content no lower than about 7% by weight. Preferably, however, the moisture content should be from about 10% to about

30% by weight, typically about 11% by weight.

In the processes of the invention, frying may be accomplished in hot fat or oil, typically hot cooking oil, within the usual temperature range of from about 160 DEG C. to about 215 DEG C. In that respect, it is a particular advantage of the dough used in the present invention that it can be cooked at temperatures below the upper end of the range, e.g. at about 190 DEG to about 195 DEG C. (typically about 193 DEG C.). This is advantageous in that the oil will be further from its boiling point and will tend to smoke less.

Alternatively, "half products", preferably of from about 10 to about 15% moisture content by weight, can be cooked by heating the "half product" by immersion in a bed of hot particulate material such as salt or calcium carbonate, and separating excess particulate material from the expanded cooked product. The cooked product can then be sprayed or otherwise treated to incorporate the necessary amount of oil or fat, which affords the desired flavour.

A variety of additives may be included in the snackfood of the present invention to provide the required visual and/or organoleptic properties. Such additives may be included either in the dough, especially in the case where a pre-gelatinized starch is employed, or by spraying onto the cooked food. Thus, the palatability of the snackfood can be improved by adding flavouring agents, amongst the preferred being salt and vinegar, cheese and/or onion, bacon, meat, fist, tomato, chicken and ham. Such flavouring agents are commercially available and may comprise hydrolysed vegetable protein, monosodium glutamate, common salt, spices, synthetic flavours and/or natural flavours, as well as sugar and/or one or more artificial sweeteners, for example, aspartame, to give the required flavour and aroma. Typically up to about 30% by weight of flavouring agent may be incorporated in the dry mixture from which the dough may be prepared by adding water, and the preferred level is about 10% by weight or lower, for example, 4% by weight.

Currently, Health Authorities are tending towards a policy of wishing to limit salt in dietary products and the like. Accordingly, if desired a snackfood according to the invention for use in conjunction with a low-salt or salt-free dietary regime may have a "salty" taste provided by the inclusion of potassium and/or ammonium chloride in approximately the same amount by weight as (and as a whole or partial substitute for) sodium chloride.

In addition, the snackfood may be supplemented by including a proteinaceous supplement and typically up to about 75% by weight or proteinaceous material may be incorporated in the dry mixture from which the dough is prepared. Typically such proteinaceous materials may be milk proteins, especially caseinates, soya, wheat and corn gluten. The inclusion of proteinaceous material improves the nutritional value of the snackfood.

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To achieve the necessary level of bran in the final product, up to about 75% by weight of bran may be included in the dry mixture from which the dough is prepared. However, the especially preferred range for palatability is from about 30 to about 40% by weight of bran in the mixture.

As mentioned above, the expanded snackfood of the present invention can contain less fat or oil than similar known snackfoods. In particular, typical snackfoods in accordance with the present invention will contain no more than about 35%, preferably no more than about 30%, more preferably no more than about 25%, and still more preferably no more than about 20% by weight of fat or oil, e.g. about 8 to about 20% by weight fat or oil. Typically also, the moisture content of the final product may be between about 2.5 and about 3% by weight.

The following Table II gives typical bran, fat and moisture contents for snackfoods in accordance with the present invention compared with a snackfood containing no bran.

>;tb; TABLE II

>;tb;__________________________________________________________________________

>;tb;Composition of wheat/bran crisp with different contents of bran

>;tb;Bran Composition of Crisp @a (% by weight)

>;tb;Content of Wheat Dietary

>;tb; Energy Value

>;tb;Dry Mix

>;tb; Bran

>;tb; Fat

>;tb; Flavour

>;tb; Flour

>;tb; Moisture

>;tb; Protein

>;tb; Fibre

>;tb; Kcal/100 g

>;tb;__________________________________________________________________________

>;tb; 0 0 40 5.5 48.5

>;tb; 2.5 4.8 1.5 523

>;tb;10 7 30 6.5 51.5

>;tb; 2.5 6.0 4.5 467

>;tb;20 15 24 7.1 46.9

>;tb; 2.5 6.8 8.1 405

>;tb;30 24 20 7.5 43.5

>;tb; 2.5 7.6 12.0 375

>;tb;40 35 13 8.2 38.8

>;tb; 2.5 8.8 17.0 320

>;tb;50 45 9 8.6 32.4

>;tb; 2.5 9.5 21.0 285

>;tb;__________________________________________________________________________

>;tb; @a Assumes Wheat Flour contains 10% by weight protein and 3% by weigh

>;tb; fibre

>;tb; Bran contains 14% by weight protein and 44% by weight fibre


The following Examples (including a first comparative Example) illustrate the preparation of expanded snackfoods according to the present invention. All of the expanded snackfoods described have an oil or fat content of at least about 5% by weight and are expanded to at least about 1.25 times the volume of the original dough portions. Also, in each case the bran used is a middlings bran having an analysis is set out in Table I above.

EXAMPLE 1

In order to compare the results obtained with raw and treated bran, a dough composition was prepared from the following ingredients, using three different types of bran:

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Water: 700 mls

Potato starch: 580 g

Bran: 600 g

Potato flour: 40 g

Palm oil: 14 g

Salt: 40 g

Doughs having the above composition were prepared by first mixing the starch only with the water.

The mixing was effected at about 90 DEG C. in a mixing bowl immersed in a container of water at about 90 DEG C., thereby forming a hot water jacket to minimise heat loss during mixing, for a period of about 5 minutes, which permitted the starch visibly to gel. The other ingredients were then added and the whole mixed for a further 15 minutes in a Hobart mixer. Finally, the mix was extruded through a plate with three-eighths of an inch diameter holes.

The dough compositions produced and extruded were as follows:

Composition A in which the bran was raw bran having a maltose value of about 550 mg/10 g;

Composition B in which the bran was a partially-heated commercially-available product having a moltose value of about 186 mg/10 g and a moisture content of about 12.4% by weight; and

Composition C in which the bran was a specially heat-treated bran autoclaved at about 120 DEG C. and under about 15 psi of pressure for about 20 minutes, and having a maltose value of about 90 mg/10 g and a moisture content of about 10.3% by weight.

Composition A produced with the raw bran was very sticky. Moreover, it proved impossible to extrude properly and there were visible signs of starch liquefaction. On the other hand Composition B produced with partially-heated bran extruded satisfactorily and was not sticky, although the strand elasticity was only fair and the strands broke rather easily.

However, with Composition C produced using the fully heat-treated bran, a much better extruded material was obtained, of good gel strength and elasticity, with strands of about 1 meter in length and capable of holding their own weight without breaking.

In addition, two further dough mixes were produced as described above, one mix being produced using the bran used for composition B and the other mix being produced using the same bran but after it had been autoclaved at about 120 DEG C. and about 15 psi for about 20 minutes. Each mix was divided into two portions, one portion being placed in a polythene bag and the other portion being extruded as before. The samples from each of the two mixes that had been placed in polythene bags were incubated for about two hours at about 40 DEG C., after which those too were extruded as before.

A comparison of the extruded material after incubation with the material extruded without delay showed there was little difference in the fully-heated bran mix, but a significant difference in the partially-heated bran mix, as exhibited by a marked lowering of the strength and elasticity of the extruded strands with time.

In each case, the half-product produced on extrusion using unincubated Composition B or Composition

C whether incubated or not could be cooked to produce a suitable snackfood in accordance with the invention, for example, by frying in hot vegetable fat at about 193 DEG C. for about 10 seconds.

Furthermore, two other dough mixes were produced as described above, this time with brans of maltose value 350 mg/10 g and 450 mg/10 g respectively. On incubation for various time periods, the results given in Table III below were obtained:

>;tb; TABLE III

>;tb;______________________________________

>;tb; Dough including

>;tb; Dough including

>;tb;Incubation time

>;tb; bran of maltose

>;tb; bran of maltose

>;tb;at 40 DEG C.

>;tb; value 350 mg/10 g

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>;tb; value 450 mg/10 g

>;tb;______________________________________

>;tb;Nil Extruded evenly

>;tb; Extruded evenly

>;tb; and cleanly - and cleanly -

>;tb; dough strength dough strength

>;tb; and elasticity and elasticity

>;tb; only fair poor

>;tb;30 minutes Sticky giving Extruded poorly -

>;tb; uneven extrusion -

>;tb; dough of very

>;tb; dough of poor poor strength and

>;tb; strength and elasticity and

>;tb; elasticity - very sticky

>;tb; strands adhered

>;tb; to one another and

>;tb; were of sticky

>;tb; texture

>;tb;1 hour Extruded with Very difficult to

>;tb; difficulty - extrude - strands

>;tb; strands very very sticky with

>;tb; sticky and of no strength or

>;tb; insufficient elasticity - broke

>;tb; strength or up and adhered to

>;tb; elasticity not one another

>;tb; to break

>;tb;2 hours Very difficult to

>;tb; Would not extrude -

>;tb; extrude - strands

>;tb; consistency resem-

>;tb; inseparable and

>;tb; bling porridge

>;tb; very sticky with

>;tb; no strength

>;tb;______________________________________

It is to be noted here that all of the maltose values referred to herein and in the claims are measured by the method of Blish and Sandstedt (1933)--see, for example, "Modern Cereal Chemistry" (1967)--Kent,

Jones and Amos--and "Pearsons Chemical Analysis of Foods", 1981. Since there are other methods which employ different principles and units e.g. those of Rumsey (pre 1933) and Hildebrand and

McClellan (1938), it is important to note the method and units employed in the present invention.

In the next following Examples, various preparative processes are illustrated using either a mix containing pre-heated bran and gelatinized starch, or a mix initially containing raw bran and ungelatinized starch, together with a process step in which both the bran and starch are heated to reduce amylolytic activity of the former and at least partially to gelatinize the latter.

(A) EXAMPLES OF DRY COLLET PROCESSES

EXAMPLE 2

A mix was made of the following ingredients:

Gelatinized wheat flour: 60 g

Flavouring: 10 g

Wheat bran (pre-heated): 30 g

To 100 g of this mix were added 80 ml of water and the whole mixed well into a dough. The dough was formed into a cylindrical rod of 25 mm diameter and cut into thin slices 1 mm thick. The latter

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were dried in a warm room overnight. The dried slices were then cooked in hot vegetable fat at 193

DEG C. for about ten seconds.

EXAMPLE 3

A mix is made of the following ingredients:

Gelatinized wheat flour: 60 g

Flavouring: 10 g


Soya protein isolate: 10 g

A snackfood is prepared from this mix as described in Example 2.

EXAMPLE 4

Potato flour is produced by washing and peeling raw potatoes, then boiling and mashing them after straining and rejecting the water. The mashed potato is rolled dry over hot rollers as a powder of moisture content about 4 to about 5%. Wheat starch in fine powder form and wheat bran are mixed with the potato flour in the following proportions:

Potato flour: 20 g

Wheat starch: 40 g

Bran (unheated i.e. raw): 30 g

Sufficient water is added to make a dough (80 ml). The dough is extrudedinto a cylindrical rod, cut into lengths of about 30 cm, placed in boiling water and allowed to boil for 45 minutes at least partially to gelatinize starch and to reduce the amylolytic activity of the bran. The gelatinized product is cut with a sharpknife into thin wafers, which are then dried in a warm room overnight. The slices are fried in oil at 193 DEG C.

EXAMPLE 5

The following ingredients are intimately mixed according to the formula below:

Potato granules (gelatinized): 30 g

Potato starch (non-gelatinized): 30 g

Pre-gelatinized potato starch: 7 g


Salt: 3 g

The ingredients are mixed for 8 minutes in a vertical mixer and the moisture content adjusted to about

35% by weight by addition of water. After mixing, the material is extruded through a standard pasta press at a temperature of from 55 DEG to 65 DEG C. and at a pressure of from 90 to 110 Kg/cm@2.

The die produced spiral shaped pieces approximately 30 mm in length and 1 cm in diameter, with a wall thickness of 1 mm. After extrusion, the pellets are slowly dried in a drum drier at a temperature of from 35 DEG to 55 DEG C. for about 6 hours. The final moisture content of the "half product" is about

11% by weight. The "half product" is fried in oil at 205 DEG C. for about 15 seconds.

EXAMPLE 6

The following ingredients are mixed at 55 DEG C. for 20 minutes into a slurry:

Potato flour: 20 g

Wheat bran (unheated): 20 g

Flavouring: 5 g

Water: 55 g

The slurry is extruded onto a roller dryer operated at 100 DEG C. to gelatinize starch and to reduce the amylolytic activity of the bran. The drums are allowed to rotate for 1 minute until a film of approximately 0.5 mm thickness has built up. The multi-layer film is removed as a sheet with a blade and cut into 2.5 cm.times.4 cm rectangles and dried to about 11% by weight moisture. These are deep fried for 10 seconds in fat at 170 DEG C.

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In the above Example the potato flour can be replaced by pea or wheat flour.

EXAMPLE 7

The above Examples are repeated except that the dried "half product" is cooked by immersion in hot particulate salt instead of by frying to produce a cooked, but fat-free product. For each repeat Example, a snackfood having an oil content of a magnitude which give a palatable product is produced from the cooked product by spraying with a vegetable oil. In this way there are produced five batches of snackfood having respectively an oil content of 35%, 30%, 25% and 15% by weight.

(B) EXAMPLES OF FRYING WET COMPLETELY GELATINIZED DOUGH

EXAMPLE 8

A mix is made as described below of the following ingredients:


Isolated soya protein: 300 g


Salt: 60 g

Glycerol monostearate: 20 g

Water: 700 g

The water, salt and glycerol monostearate are mechanically blended and the remaining dry ingredients mixed in a Hobart mixer. The wet blended ingredients are then added to the dry mixed ingredients and mixed until the mass is free flowing. The mixture is then extruded in a press using a 1.25 mm by 2.5 mm ribbon die at a temperature of 74 DEG C. The extruded ribbon is stretched by from 30% to 40% and cut into 3 cm lengths and fried at 190 DEG C. for 45 seconds.

EXAMPLE 9

A potato dough is made from the following composition:



Guar gum: 1.5 g

Salt: 1.5 g

The above dry ingredients are mixed together and then uniformly mixed with about 226 ml water at 60

DEG C. to form a dough slurry of about 30% by weight solids content. The dough is fed through a piston extruder with a die of 1 cm.times.1 cm and cut into portions 7.5 cm long. The cut portions are discharged into a deep fat fryer at 170 DEG C. for about 90 seconds. The part-fried material is stored deep frozen until required. To prepare for consumption the frozen portions are toasted in a standard bread toaster for from 1 to 3 minutes.

EXAMPLE 10

The process of Example 9 is repeated, except that raw bran is used instead of heated bran, and the temperature of the dough slurry is kept below 10 DEG C. by refrigeration. The dough is fed through a piston extruder and fried as before.

EXAMPLE 11

The following ingredients are mixed in a Hobart mixer to form a dough:

Potato flakes (gelatinized): 200 g

Bran (pre-heated): 100 g

Hydrolysed soyabean oil*: 5 g

Ascorbic acid: 1 g

Water: 200 g

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*containing 40% monoglycerides, 40% diglycerides and 20% triglycerides.

The dough at a temperature of 45 DEG C. is passed through a two roll mill to give a sheet 0.4 mm thick which is cut into elliptical pieces of 7.5 cm.times.5 cm diameter. These are deep fried in cottonseed oil at 175 DEG C.

EXAMPLE 12

A mix is made of 97% by weight of tapioca and 3% by weight of salt. About 700 g of the mix are then cooked with 300 ml of water in a pressure cooker. The cooked dough is extruded through holes 3 mm diameter and cut into pellets 1.5 mm to 3 mm length. The pellets are then mixed with dehydrated mashed potatoes and bran as follows:

Pellets (32% by weight moisture): 25 g

Mashed potato (gelatinized): 25 g

Bran (pre-heated): 25 g

Water: 18 g

The overall moisture content is 32% by weight.

The mixture is finely chopped and blended and the granular material fed through rollers to form a sheet

0.75 mm thick from which elliptical shaped chips are cut. These are fried in coconut oil at 200 DEG C. for 15 to 20 seconds.

(C) Examples of frying a wet dough containing some ungelatinized starch

EXAMPLE 13

The following ingredients are combined in a 5 quart Hobart mixer using a paddle turning at low speed for 1 minute:

Dried potato flakes (gelatinized): 100 g

Potato starch (ungelatinized): 100 g


Salt: 7 g

During an additional one minute, 347 mls of water at room temperature are added and mixing continued for one minute thereafter. The mixture is then placed in a piston extruder. By application of force, the mixture is extruded through a die opening of 2.5 cm by 1 mm dimensions. The extruded dough is cut with a knife into pieces approximately 5 cm long, and as cut the pieces are allowed to fall into a standard fryer containing hydrogenated vegetable oil at 190 DEG C. where they are fried for 90 seconds.

In the above Example, potato starch can be replaced by tapioca starch with excellent results.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. An expanded snackfood prepared from a dough composition of predetermined volume and comprising cooked portions of dough composition comprising gelatinized starch and added, heattreated cereal bran having amylase therein destroyed, said bran being selected from the group consisting of wheat bran, barley bran, oat bran, rye bran, maize bran and mixtures thereof, the snackfood containing from about 5% to about 35% by weight of oil or fat and from about 15% to about

70% by weight of bran, and having a volume at least about 1.25 times said predetermined volume.

2. A snackfood according to claim 1, containing from about 20% to about 50% by weight of bran.

3. A snackfood according to claim 1 or claim 2, which contains less than about 30% by weight of fat or oil.

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4. A snackfood according to claim 9, which contains less than about 20% by weight of fat or oil.

5. A snackfood according to claim 1 or claim 2, wherein the dough portions are expanded to at least about 1.50 times their original volume by cooking.

6. A snackfood according to claim 1 or claim 2. wherein the dough which is cooked contains about

100% by weight of gelatinized starch.

7. An expanded snackfood prepared from a dough composition of predetermined volume and comprising cooked portions of dough composition comprising gelatinized starch, about 15% to about

70% by weight of added cereal bran selected from the group consisting of wheat bran, barley bran, oat bran, rye bran, maize bran and mixtures thereof, and about 5% to about 35% by weigth of oil or fat, and having a volume at least about 1.25 times said predetermined volume, wherein said bran is heated before it is added to said dough composition.

8. In a process for preparing an oil- or fat-containing expanded expanded snackfood in which a dough composition having a predetermined volume and containing gelatinized starch is expanded as it is cooked to a volume at least about 1.25 times said predetermined volume, the improvement comprising including in said dough composition added, heat-treated bran having amylase therein destroyed, said bran being selected from the group consisting of wheat bran, barley bran, oat bran, rye bran, maize bran and mixtues thereof.

9. In a dough composition having a predetermined volume and of the type for use in preparing an expanded snackfood and which contains gelatinized starch in an amount to effect during cooking of the dough composition an expansion thereof of at least about 1.25 times the volume of said predetermined volume, the improvement comprising said dough composition including added bran selected from the group consisting of wheat bran, barley bran, oat bran, rye bran, maize bran and mixtures thereof which has been heat-treated, prior to inclusion in said composition, to destroy amylase therein.

10. A snackfood according to claim 9 including about 15% to about 70% by weight of said bran.Data supplied from the esp@cenet database - Worldwide

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349.

US4544563 - 10/1/1985

PROCESS OF PREPARING A GELLED PASTA PRODUCT


Inventor(s): LECHTHALER JUERG (CH)

Applicant(s): NESTEC SA (CH)


IP Class: A21D8/00; A23L1/04

E Class: A23L1/16; A23L1/0532; A23L1/216B



Family: US4544563

Equivalent: EP0105100; OA7535; MX172862; JP59066855; GB2127271; ES8405253

Abstract:


The invention relates to a process for the production of pasta based on starchy materials by gelatinization, extrusion and drying. A flour or semolina of a starchy material is mixed with soft water and an ionic gelling agent to obtain a dough containing from 35 to 55% of water, the dough is gelatinized by heating and kneading under pressure, is then cooled to a temperature below 100 DEG C., extruded in the form of pasta, and the pasta is brought into contact with water containing a cation which forms a gel with the ionic gelling agent, and is dried. The pasta produced may be based on rice or maize alone.Description:


This invention relates to a process for the production of pasta based on starchy materials by gelatinisation, extrusion and drying operations.

The domestic and small-scale production of rice noodles has long been widespread in Eastern riceproducing countries. The processes which are used vary from one region or from one country to another, but they are all based on a small number of basic operations which are linked and/or repeated as dictated by the local traditions and also as a function of the particular qualities of the local types of rice. The fundamental problem is to confer to the rice dough the cohesion which it lacks. The low protein content of the rice on the one hand and the very nature of these proteins on the other hand means that it is impossible to produce a network with rice which is comparable to that formed by wheat gluten in such products as bread or pasta. In order to replace this network in which the starch grains are embedded, it is necessary to either use binders, or to subject the starch grains to treatments, so that they are capable on their own of forming a mass having the necessary cohesion. These problems of cohesion are re-encountered at the stage of working the fresh pasta dough as well as at the stage of the reconstitution and consumption of the final product.

The number of conventional and typical basic operations may include for example soaking the grains of rice, wet milling, pre- and post-gelatinisation, cooling and mechanical working of the dough. Thus, a typical, conventional process includes the successive stages of soaking a ground rice over a period of several hours, pre-gelatinisation, cooling, extrusion, post-gelatinisation and drying. Moreover, the

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following may be mentioned as conventional binders which have been proposed: egg proteins, soluble proteins of whey, or wheat gluten, for example. In particular, processes are known in which ground rice is used combined with wheat flour, which is not obvious, because if ground rice mixed with wheat flour is pregelatinised, the wheat gluten is denatured and it is no longer possible to shape the dough.

In order to simplify the small-scale production process of Eastern rice pasta known in South East Asia under the name of "Beehoon" and to guarantee a constant quality of production, an industrial production process has been proposed, in which the grains of rice are dry ground and 10 parts of the resulting flour are mixed with 4 parts by weight of hot water. The dough is kneaded and passed through a sieve to produce grains of about 4 mm@3. The grains are subjected to lengthy steaming, then cooled and extruded a first time. The strips or tubes thus formed are cut into short pieces which are delivered to a second extruder where they are re-worked. The second extruder produces long vermicelli or spaghetti which are suspended on horizontal bars, subjected to a lengthy steaming operation, and then dried. A process of this type still has too many extrusion and steam-treatment operations, and the latter necessitate in particular very large installations.

Moreover, in order to allow the production of rice pasta, incorporating therein wheat flour, it has been proposed initially to soak and boil the rice, then to mix it with wheat flour, form a sheet of the mixture, cut the sheet into noodles and then dry and pack them. However attractive a process of this type may be on a technical level, it is hardly rational when, for example, the local starting material is rice and not wheat.

Finally, a process has been described in which soya flour and cornflour are used to replace most of the wheat flour in the production of pasta. In this process, the part which is played by the various components on the one hand and the gelatinisation on the other hand is discussed, with the objective of compensating for the absence of wheat gluten. Moreover, the possibility of using certain additives, such as gelling agents is also mentioned. However, this process does not allow pasta to be produced from maize alone in a simple, industrial manner, not to mention pasta based, for example, only on rice, and does not disclose how this would be possible.

An object of the present invention is to provide a process for the production of pasta based on starchy materials which does not have the above-mentioned disadvantages of the known processes, as much regarding the number of operations as the equipment and starting materials, which process is, however, simple to carry out and allows the use of rice or maize on its own, as well as other starchy materials, such as potato or legumes.

The process according to the present invention is characterised in that a flour or semolina of a starchy material is mixed with soft water and an ionic gelling agent to obtain a dough containing from 35 to

55% of water, the dough is gelatinised by heating and kneading under pressure, it is then cooled to a temperature below 100 DEG C., extruded in the shape of pasta, the pasta is brought into contact with water containing a cation which forms a gel with said ionic gelling agent, and the pasta is then dried.

Thus, the present process is notable for its simplicity, a single gelatinisation stage and a single extrusion stage. None of the known processes has attained this simplicity, in spite of all the efforts made in this direction. However, the present process is also noteworthy for the quality of the products which may be obtained thereby, and these products may be considered equal to the best corresponding

Eastern small-scale products. Finally, the present process is very economic, not only because it requires less equipment and fewer operations compared to the known processes, but also because it guarantees minimum losses of starting material during production and even in the home, that is, during cooking.

To carry out the present process, it is possible to use any vegetable starting material which is rich in starch and is consequently classified as a starchy material by food product specialists, in particular grains of cereals and legumes, and tubers which are rich in starch, such as potatoes or yams. Rice or maize is preferably used.

It is also possible to incorporate a starch supplement rich in amylose in the said dough containing from

35 to 55% of water, in particular to compensate for a relatively high protein content, as in the case of legumes, or to compensate for a relatively high amylo-pectin content, as in the case of potatoes.

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The extent of milling of the flour or semolina of the said starchy material may be selected as a function of the dimensions of the openings of the extrusion die. The operation is preferably carried out to a grain fineness which allows the grains to pass singly through the openings. In effect, the coarser the grain, the easier and more complete the gelatinisation operation.

An acid polysaccharide, such as a pectate, an alginate or carboxymethylcellulose may be used as the ionic gelling agent. Particularly good results are obtained using sodium alginate. The ionic gelling agent may be added in a proportion of from 0.5 to 2% by weight of the dough.

An alkaline-earth metal ion is preferably selected as the cation forming agel with said ionic gelling agent. An ion which is particularly desirable in terms of food and which is very suitable for the present use is the divalent calcium ion.

It is important to prepare the initial mixture with soft water. It has been found that if the mixture of flour or semolina and ionic gelling agent is prepared with hard water, the extruded dough loses all cohesion and disintegrates. The term "soft water" is to be understood as designating water with a calcium ion concentration of less than 2.times.10@-4 M.

The gelatinisation of the dough by heating and kneading under pressure is preferably carried out under a pressure of from 70 to 100 bars at a temperature of from 60 DEG to 100 DEG C. over a period of from about 20 to 120 seconds. If this operation is carried out at a higher pressure or at a higher temperature, it is difficult to avoid an expansion of the dough at the outlet of the extruder. If attempts are made to reduce the viscosity of a dough, which is possibly too viscous, by further increasing the temperature during gelatinisation, the excessive viscosity returns during cooling before extrusion and stops the dough passing through the die. On the other hand, if the operation is carried out at a pressure below 70 bars and at a temperature lower than 60 DEG C., the extruded dough is too soft and it disintegrates due to insufficient gelatinisation. As far as the effects of the duration of the treatment are concerned, it is possible to say that too short a treatment also entails insufficient gelatinisation and a treatment duration which is prolonged so that it is longer than necessary represents a useless expenditure of energy. The range of from 20 to 120 seconds is to be considered as indicating a practical order of magnitude rather than categorical limits. In fact, although the moment when the dough emerges from the die may be determined with some degree of precision, the starting point in a continuous installation is uncertain because of some backwards and forwards motion of the starting material which is being engaged.

The sufficiency or insufficiency of the gelatinisation are practical ideas which are linked with the sufficient or insufficient cohesion of the dough at the outlet of the extruder on the one hand and of the reconstituted and cooked dough on the other hand. However, if numerical expressions are preferred, it may be indicated by way of guidance that, for rice and maize, a gelatinisation of from 70 to 100% may be considered as suitable, whereas a gelatinisation below 70% may entail difficulties, such as pasta which is too soft at the outlet of the extruder, or pasta which disintegrates during cooking.

The dough is then cooled to a temperature below 100 DEG C. to avoid an expansion at the outlet of the extruder under the effect of the vapour which expands inside the dough and seeks to escape. It is recommended to cool the dough to a temperature of from 55 DEG to 90 DEG C., since too low a temperature is unfavourable from the point of view of the viscosity of the dough to be extruded.

In order to bring the extruded pasta into contact with water containing the cation which forms a gel with the ionic gelling agent, it is possible to either sprinkle the pasta with a jet of this water when it passes out of the extrusion die or to plunge it for an instant into a bath of this water. The extruded pasta is preferably continuously passed through water at from 20 DEG to 70 DEG C. containing the cation in a concentration of from 0.05 to 0.2M over a period of from 2 to 30 seconds.

In order to prevent the water which clings to the surface of the pasta after this treatment from causing the individual pieces of pasta to stick together or to themselves, in particular during the optional subsequent shaping into balls or nests, it is possible to remove most of this water, for example by blowing air. It has been found that this operation is best carried out if air is blown downwards onto the pasta which is positioned on a foraminous support, such as an open mesh endless belt and if air is simultaneously drawn up by suction under the support.

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It has been found that the drying operation of the pasta properly speaking may be carried out fairly rapidly at a moderate temperature and at a moderate to high relative humidity. Drying at a temperature of from 50 DEG to 90 DEG C. may be recommended at a relative humidity of from 30 to 90% over a period of from 2 to 4 hours. It has also been found that the pasta thus obtained may check during storage, but that it is possible to avoid this phenomenon by abruptly cooling the pasta after drying. This abrupt cooling may be carried out by circulating the pasta in a flow of, for example cold and humid air.

The present process may be carried out using conventional apparatus, such as kneading troughs, presses and driers employed in the pasta industry. It lends itself particularly well to production in a compact apparatus of the single- or double-screw extruder type provided with a casing divided into successive sections which may be brought to different temperatures by the circulation of fluids at suitable temperatures.

The following Examples are provided by way of illustration. The percentages and parts used therein are by weight.

In these Examples, the organoleptic information concerns above all the texture of the cooked pasta.

Although the taste of a pasta is easily reproducible and rarely suffers from troublesome defects unless the starting material itself is not of a satisfactory quality, its texture or behaviour when chewed is particularly critical. The quality of this texture is not necessarily well reflected by examination using apparatus which measure the resistance to crushing. A crisp pasta (referred to as "al dente" in Italy) may offer less resistance to crushing than, for example a sticky pasta. An elastic pasta, to the liking of the Orientals can produce values which may be confused with those obtained for crisp pasta using the same instrument.

In these Examples, the degree of gelatinisation was determined by the enzymatic method according to

R. M. Shetty, D. R. Lineback and P. A. Seib, Cereal Chemistry 51, 364-375 (1974). The losses during cooking were determined by cooking 1 part of pasta in 9 parts of water, drying the pasta and comparing it with the initial pasta. Controls were carried out by concentrating the cooking water and drying and weighing the residue.

EXAMPLE 1

A round grain rice (Oryza sativa japonica)semolina is mixed continuously with soft water containing about 1.times.10@-4 M of Ca@++ and with sodium alginate in order to obtain a dough containing from 45 to 50% of water, and 0.66% of sodium alginate. This mixture is produced in the first part of a double screw extruder having different successive zones surrounded by independent jackets in which it is possible to circulate fluids at different temperatures. In the present case, the extruder has half a dozen successive zones in which the operations of mixing, kneading, gelatinisation, cooling and extrusion follow one another without interruption.

The starting materials, water, ground rice and alginate are then poured through a hopper into the first zone of the extruder. The simple mixing operation continues in a second zone. In these first zones or in the first part of the extruder, the flights are wide apart and are simply positioned in order to mix the material and to advance it into the extruder.

In the following zones, the dough is thoroughly kneaded and subjected to considerable shearing stresses between the screws, the flights of which are closer and overlap more intimately. The exact arrangement of the screws and of the pitches is set up and the rotational speed of the screws is adjusted so that a pressure of about 95 bars prevails in these zones or in this second part of the extruder. A heating fluid is circulated in the corresponding jackets so that the temperature of the dough is maintained just below 100 DEG C. under the effect of this heating and of the heat generated by the friction. The passage of the dough in this second part of the extruder takes on average 90 seconds.

In the last zone or in the third and last part of the extruder, the screws are arranged and adjusted in order to exert a thrust on the gelatinised dough in order to force it through the extrusion die. A cooling fluid is circulated in the jacket of this last part so that the temperature of the extruded pasta is from

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about 75 DEG to 80 DEG C. at the moment when it emerges from the die. The die itself comprises a thick steel plate pierced by a plurality of small holes having a diameter of 0.9 mm.

At the outlet of the die, the pasta has a degree of gelatinisation of 100%. It is immediately plunged or drawn out continuously in a bath containing 2% of CaCl2. The residence time of the pasta in this bath is about 8 seconds. It is then positioned on an open mesh endless belt and is simultaneously passed under a strong vertical flow of air and above a strong-suction orifice. It is then cut into long pieces and arranged into balls.

The pasta is then dried over a period of 3 hours at a temperature of 50 DEG C. at a relative humidity of

30%. It is then abruptly cooled under a strong flow of cold air at 30 DEG C. and under 90% relative humidity.

The rice pasta thus obtained resembles a tangled glass fibre. It does not stick during cooking. The losses during cooking are less than 5%. The pasta is ready for consumption after cooking for 4 to 5 minutes in gently boiling water, in a proportion of 75 g of pasta and 1.5 g of salt per half liter of water.

It has an elastic texture judged as excellent and typical by experienced tasters in the countries of origin of these Oriental noodles.

EXAMPLE 2

Rice pasta is produced in the manner described in Example 1, but using a round grain rice flour. Pasta of a quality comparable to that obtained in Example 1 is obtained. However, the pasta of Example 1 has a substantially firmer texture.

EXAMPLE 3

Rice pasta is produced in the manner described in Example 1, but using a long grain rice (Oryza sativa indica)semolina. Pasta of a quality comparable to that obtained in Example 1 is produced.

EXAMPLE 4

Maize pasta is prepared using an extruder similar to the one described in Example 1.

A dry mixture containing 99% of cornflour and 1% of sodium alginate is prepared. This dry mixture and soft water are continuously introduced into the extruder in order to form a dough having a water content of 45%.

The dough is gelatinised at from 90 DEG to 95 DEG C. under a pressure of about 85 bars with vigorous mechanical working over a period of about 30 seconds.

The gelatinised dough is extruded through a cooled die having small holes of 0.9 mm. The extruded pasta is at a temperature of from 70 DEG to 75 DEG C. at the outlet of the die and it has a degree of gelatinisation of 93%. It is drawn during about 5 seconds through a bath containing 1% of CaCl2. The pasta is then passed over an open mesh endless belt where the water which adheres to its surface is driven off and entrained by means of an air blast above and an air suction from below. If only the blowing from above is carried out, the water is driven off from the pasta laterally and the pasta cannot be maintained immobile on the belt. If only the suction from below is carried out, too much water remains on the surface of the pasta. However, if the effects of blowing from above and suction from below are combined, the pasta is well distributed laterally over the mesh, it lies flat thereon and is effectively freed from water which it has entrained on emerging from the CaCl2 bath.

The pasta is then cut into lengths of about 2 m and is arranged in small piles by allowing it to fall vertically. The small piles or balls of pasta are dried for 2 hours at 70 DEG to 80 DEG C. at a relative humidity of 90%. They are then abruptly cooled using air at 30 DEG C. and 90% relative humidity.

Maize pasta is obtained having a very pleasant appearance and presenting the colour of maize and a glazed aspect. It does not stick during cooking. After cooking for 4 minutes in gently boiling water, the behaviour of the pasta when chewed is between that of a cooked Italian pasta "al dente" and that of the

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rice pasta of the previous Example. The taste of the pasta is almost identical to that of a maize semolina which is cooked in the form of porridge or griddle cakes. The cooking water remains relatively clear.

Losses during cooking amount to only 3 to 5%.

EXAMPLES 5 to 8

Maize pasta, potato pasta, soya pasta and lentil pasta is prepared in a manner similar to the one described in Example 4.

The following Table gives details concerning the composition of the drymixtures, the respective quantities of dry mixture and of water introduced into the extruder, the gelatinisation temperature and pressure, the temperature at the outlet of the extrusion die, the water content and the degree of gelatinisation of the extruded pasta.

>;tb;______________________________________

>;tb;Dry mixture

>;tb;Example Quantity Water

>;tb;No. Composition (kg/h) (l/h)

>;tb;______________________________________

>;tb;5 Cornflour 99% 60 40

>;tb; Sodium alginate

>;tb; 1%

>;tb;6 Potato flour 74% 40 27

>;tb; Cornstarch 25%


>;tb; 1%

>;tb;7 Defatted soya flour

>;tb; 50% 60 39



>;tb; 1%

>;tb;8 Lentil flour 74% 60 39



>;tb; 1%

>;tb;______________________________________

>;tb; Extrusion die outlet

>;tb; Degree of

>;tb;Ex- Gelatinisation Temper- Water gelatin-

>;tb;ample Temperature

>;tb; Pressure ature content

>;tb; isation

>;tb;No. ( DEGC.)

>;tb; (bars) ( DEGC.)

>;tb; % (%)

>;tb;______________________________________

>;tb;5 75-88 90 62 41 74

>;tb;6 61-68 80 60 46 33

>;tb;7 73-90 85 57 42 55

>;tb;8 75-87 77 59 45 97

>;tb;______________________________________

After passing into the CaCl2 bath, and after draining, cutting, forming of balls and drying under conditions similar to those described in Example 4, pasta of a pleasant glazed appearance is obtained each time, having the colour typical of the starchy material which was used. Likewise, the behaviour of the pasta when chewed is without fault and bears comparison with that of the pasta of Example 4.

With respect to the cornstarch which was used in Examples 6 to 8, it may be noted first of all that it was selected for its high amylose content with the objective of compensating for the high protein content of the soya and of the lentils and the high amylopectin content of the potato. However, it must

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also be noted that the indicated quantities are very generous and in fact it is not necessary to use as much to obtain the desired chewing behaviour of the pasta in question.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A process for the production of pasta based on starchy materials, which comprises mixing a flour or semolina of a starchy material with soft water and an ionic gelling agent to obtain a dough containing from 35 to 55% of water, gelatinising the dough by heating and kneading under pressure, cooling the dough to a temperature below 100 DEG C., extruding it in the form of pasta, bringing the pasta into contact with water containing a cation which forms a gel with the ionic gelling agent, and drying the pasta.

2. A process as claimed in claim 1 wherein the ionic gelling agent is an acid polysaccharide, and the cation is an alkaline-earth metal ion.

3. A process as claimed in claim 1, wherein the ionic gelling agent is an alginate and the cation is divalent calcium.

4. A process as claimed in claim 1, wherein the ionic gelling agent is added in a proportion of from 0.5 to 2% by weight of the dough, and the soft water has a concentration of calcium ions of less than

2.times.10@-4 M.

5. A process as claimed in claim 1, wherein the dough is gelatinised by kneading under a pressure of from 70 to 100 bars at a temperature of from 60 DEG to 100 DEG C. over a period of 20 to 120 seconds.

6. A process as claimed in claim 1, wherein the dough is cooled to from 55 DEG to 90 DEG C. before extrusion.

7. A process as claimed in claim 1, wherein after extrusion the pasta is plunged for 2 to 30 seconds into water containing the cation in a concentration of from 0.05 to 0.2M.

8. A process as claimed in claim 1, wherein after the pasta has been brought into contact with water containing the cation, excess water adhering to the surface of the pasta is removed by blowing air downwards onto the pasta which is arranged on a foraminous support and by simultaneously sucking in air below said support.

9. A process as claimed in claim 1, wherein the pasta is dried at a temperature of from 50 DEG to 90

DEG C. and a relative humidity of from 30 to 90% over a period of from 2 to 4 hours.

10. A process as claimed in claim 1, wherein after drying, the pasta is abruptly cooled.

11. A process as claimed in claim 1, wherein the starchy material is selected from rice, maize, legumes and potatoes.

12. A pasta when produced by a process as claimed in any of claims 1 to 11.Data supplied from the esp@cenet database - Worldwide

1551/2197

350.

US4649052 - 3/10/1987

METHOD FOR PRODUCTION OF GARLIC PASTE


Inventor(s): SUMI NAOKI (JP); YAMASHITA HIROSHI (JP); SEKIZUKA YASUO (JP)

Applicant(s): MEIJI SEIKA KAISHA (JP)


IP Class: A23L1/214; A23L1/221

E Class: A23L1/24; A23L1/221B



Family: US4649052

Equivalent: EP0165544; JP60262565

Abstract:


A method for the production of non-odorous garlic paste is disclosed. This method comprises (i) subjecting garlic bulbs as wrapped in the skin to a heating treatment, adding water to the garlic bulbs, coarsely crushing the garlic bulbs, and separating the skin and the unwanted part of garlic bulbs from the resultant crushed mass of garlic and leaving behind a garlic clove-containing liquid, (ii) heating the clove-containing liquid together with vitamin B1, rice bran, or yeast added thereto, (iii) heating the resultant blend in the presence of a cellulase or in the absence of the cellulase thereby obtaining a mixture, and (iv) heating either the liquid part of the mixture resulting from the removal of solids therefrom or the mixture in its unmodified form together with soybean flour, soybean milk, or soybean milk flour. The cellulase used in this method is produced by a microorganism belonging to genus

Trichoderma or the genus Aspergillus.Description:



This invention relates to a method for the production of garlic paste.

Garlic (Allium sativum L.) emits an irritating odor when it is peeled and then minced or ground. In accordance with the present invention, non-odorous garlic paste can be obtained from raw garlic by conducting a specific sequence of method steps.


Heretofore, a method for obtaining non-odorous garlic in powdery form has been described in Japanese

Patent Publication 32578/83, which comprises finely crushing garlic bulbs with a cutter, extracting the crushed garlic bulbs with an alcoholic aqueous solution, removing allicin from the extract of garlic, combining the resultant extract with soluble or insoluble soybean protein of an amount of from 1 to 5 times the amount of the extract, stirring the resultant mixture thereby entrapping a sulfer-containing odorous component therein, and thereafter drying the blend formed.

1552/2197

Since the method requires raw garlic bulbs to be finely crushed with a cutter in the first step, the irritant odor issuing from the garlic is extremely sharp, and therefore, the alcohol extract of crushed garlic still retains an extremely intense irritant odor.

Further, since the soybean protein is added in a large amount to the extract for the purpose of entrapping the odorous component, the resultant moist solid blend is produced before it is dried.

However, it inevitably must be dried, because the moist solid is difficult to handle in the subsequent use thereof.

Moreover, the product obtained by this method has an excessively high soybean protein content. When this product is subsequently used as a condiment, it undergoes an undesirable phenomenon of coloration.


This invention aims to overcome the various drawbacks mentioned above and provide a method for the production of non-odorous garlic paste without entailing any emission of the irritant odor of garlic during the course of the production.

More specifically, this invention is directed to a method for the production of garlic paste, comprising the steps of (i) subjecting garlic bulbs as wrapped in the garlic skin to a heating treatment, adding water to the garlic bulbs, coarsely crushing the garlic bulbs, and separating the skin and other unwanted parts of garlic bulbs from the resultant crushed mass of garlic and leaving behind a garlic clove-containing liquid, (ii) heating the clove-containing liquid together with vitamin B1, rice bran, or yeast added thereto, (iii) heating the resultant blend in the presence of a cellulase or in the absence of cellulase to thereby obtain a mixture, and (iv) heating either the liquid part of the mixture resulting from the removal of solids therefrom or the mixture in its unmodified form together with soybean flour, soybean milk, or soybean milk flour.

The other functions and characteristic features of this invention will become apparent from the further disclosure of the invention hereinbelow with reference to the accompanying drawings.


FIG. 1 is a graph showing degrees of loss of viscosity of a garlic clove-containing liquid due to addition of cellulases of varying species to the liquid.

FIG. 2 is a graph showing variations of viscosity of a garlic clove-containing liquid along the course of time due to addition of a cellulase to the liquid as compared with addition of Meiselase (a commercially available enzyme composition, described in more detail hereinafter).

FIG. 3 is a graph showing the relation between pH and viscosity as observed in a garlic clovecontaining liquid due to addition of a cellulase to the liquid as compared with addition of Meiselase.

FIG. 4 is a graph showing the relation between temperature and viscosity as observed in a garlic clovecontaining liquid due to addition of a cellulase to the liquid as compared with addition of Meiselase.


The garlic to be used in the present invention is in the form of garlic bulbs wrapped in the skin thereof.

When the garlic in that form is treated with steam or hot water, or is exposed to microwaves, alliinase therein is inactivated in an extremely short span of time. The garlic bulbs while wrapped in the skin does not expose the garlic cloves to the ambient air, and therefore emission of the irritant odor of garlic is avoided. When the garlic bulbs are stripped of the skin and are minced, they immediately emit the irritant odor peculiar to garlic because alliin, one of the components of garlic, is decomposed by activated alliinase into allicin.

1553/2197

As the heating means for precluding the emission of the irritant odor peculiar to garlic, any of the treatment with steam, the treatment with hot water, or the exposure to microwaves is suitable. The present invention can be applied in the case of any of these heating means. The heating is preferably carried out at a temperature in the range of 99 DEG to 120 DEG C. If this temperature is lower than 99

DEG C., the garlic bulbs still tend to emit the irritant odor during the subsequent step of peeling and coarse crushing. If the temperature exceeds 120 DEG C., the garlic itself tends to assume a brown color and this brown color persists in the garlic paste as a finished product and impairs the appearance of the product.

The heating treatment can be effected by placing the garlic bulbs as wrapped in the skin in an autoclave or retort and steaming them at a temperature not exceeding 120 DEG C. under application of pressure, or by placing them into boiling water. Alternatively, the heating treatment may be accomplished by exposing the garlic bulbs wrapped in the skin to microwaves of a frequency of 2,450 MHz (this frequency value is permitted under the Radio Law in Japan). The exposure to microwaves is carried out in a manner, for example, that 300 g of garlic bulbs wrapped in the skin is exposed to microwaves at a frequency of 2,450 MHz and an output of 1 kw for about 3 minutes. When the garlic bulbs wrapped in the skin are exposed to microwaves, water contained in the garlic bulbs is activated and boiled and, thus, garlic bulbs can be heated. If the exposure to the microwaves is carried out in a dry atmosphere, the garlic itself is dried and is quickly scorched. The atmosphere, therefore, is desired to be saturated with steam in advance of the exposure. In other way, the garlic bulbs wrapped in the skin is sprayed with water and then exposed to microwaves.

To the garlic bulbs which have undergone the heating treatment described above, water is added, preferably in an amount by weight of from 0.3 to 2 times the amount by weight of the garlic bulbs prior to the heating treatment (i.e., garlic bulbs wrapped in the skin). If the amount of water added is less than 0.3 time the amount of the garlic bulbs wrapped in the skin, the clove tends to be produced in poor yield due to that a part of the produced clove is miscible with and passes into the skin and the roots and bottoms of the garlic bulbs discarded as waste after the coarse crushing, the treatment with a finisher for separation, or the treatment with a strainer in a subsequent step. If the amount of water exceeds 2 times the amount of the garlic bulbs, the energy required in heating, and possibly in concentrating and drying, the resultant blend in the subsequent step tends to be undesirably large. Any increase of the amount of water so added does not result in an increase in the yield of the garlic clove (also referred to herein simply as "clove"). The meshes in the aforementioned finisher or strainer to be used in the treatment preferably fall in the range of 1 to 3 mm. If the mesh size is less than 1 mm, the yield of the clove is generally not sufficient. If it exceeds 3 mm, the skin and the roots and bottoms which are desired to be discarded as waste will tend to penetrate and mingle with the separated clove.

The clove-containing liquid obtained in consequence of the treatment in the preceding step together with vitamin B1, rice bran or yeast added thereto are stirred and heated, preferably at 60 DEG to 70

DEG C., to further decrease the peculiar odor of garlic still persisting in the clove. In this heating step

(ii), one of vitamin B1, rice bran and yeast is added to the clove-containing liquid, but an addition of a mixture thereof is not suitable since the undesirable mixed odor thereof persists in the finished product.

In the addition of vitamin B1 to the clove-containing liquid, a hydrochloride salt of vitamin B1 is used for facilitating the solution. This salt is added preferably in an amount of about 0.001 to 0.005 wt% based on the amount of garlic bulbs wrapped in the skin. Although the deodorizing effect of the added vitamin B1 increases with the increasing amount of vitamin B1 added, the taste of vitamin B1 persists, and renders the finished product bitter if the amount exceeds 0.005 wt%. If the amount is less than

0.001 wt%, the deodorizing effect is not manifested.

In the treatment with vitamin B1 described above, the effect in decreasing the odor of garlic becomes conspicuous when the heating treatment is carried out at a temperature in the range of 60 DEG to 70

DEG C. at a pH value of about 8. After the heating treatment, the pH value of the liquid under treatment is returned to a range of from 7 to 6 to prepare the liquid for the subsequent step.

When rice bran is added to the clove-containing liquid, it is added preferably in an amount of from about 0.5 to 2.5% by weight based on the amount of garlic bulbs wrapped in the skin. If the amount of rice bran so added exceeds 2.5% by weight, the fractionation by centrifugal separation in the subsequent step is difficult to attain, the yield of the product is low, and the odor of rice bran persists in

1554/2197

the finished product. If this amount is less than 0.5% by weight, the deodorizing effect aimed at is not obtained.

When yeast is added to the clove-containing liquid, it is added preferably in an amount of from 1% to

3% by weight based on the amount of the garlic bulbs wrapped in the skin. If the amount of yeast so added exceeds 3% by weight, the taste of the yeast stands out in the finished product. If this amount is less than 1% by weight, the deodorizing effect the yeast is expected to bring about is not obtained.

Next, a cellulase is added to the clove-containing liquid obtained by the treatment described above and the resulting mixture is stirred and heated at a temperature in the range of 40 DEG to 60 DEG C., thereby the cellulase reacts upon the liquid and consequently lowers the viscosity of the liquid significantly (refer to Comparative Experiment 5 hereinafter). If the temperature deviates from the range mentioned above, there is the possibility that the viscosity will be increased so much as to render the treatment of concentration and/or pulverization difficult. If the temperature exceeds 60 DEG C., the cellulase tends to be inactivated.

The cellulase can be produced, e.g., by Aspergillus niger, Trichoderma koningi, or Trichoderma viride

(refer to Comparative Experiment 2). The enzymatic activity of the cellulase is expressed in the units of carboxymethyl cellulase (CMCase) activity per g of solids of the clove. The unit activity is such as to form reducing sugar equivalent to 0.01 mg of glucose from carboxymethyl cellulose per minute. The value of the expected viscosity is not more than about 1,500 cp. When the cellulase obtained from a microorganism belonging to the genus Trichoderma is used, the amount of the cellulase added to the clove-containing liquid is at least about 5 units per g of the solids of the clove-containing liquid. When the cellulase obtained from a microorganism belonging to the genus Aspergillus is used, the amount of the cellulase added to the clove-containing liquid is at least about 50 units per g of the solid of the clove-containing liquid. When cellulase is used in the amounts above, the viscosity can be decreased to the expected value (i.e., not more than 1,500 cp, see Comparative Experiment 2). The duration of the cellulase reaction is required to be not less than 1 hour (refer to Comparative Experiment 3 hereinafter).

The optimum working pH value of the enzyme falls in the range of 4 to 6. The desired decrease of the viscosity tends not to be fully obtained if the pH value deviates from the range just mentioned (refer to

Comparative Experiment 4 hereinafter).

The clove-containing liquid of lowered viscosity obtained as described above and soybean milk flour or soybean flour added thereto in an amount of preferably from about 1 to about 10% by weight, more preferably from about 1 to about 8% by weight, most preferably about 4% by weight, based on the solids of the clove-containing liquid are heated to a temperature of about 60 DEG C. By this treatment, the trace of the odor of garlic persisting in the clove-containing liquid is thoroughly removed (refer to

Comparative Experiment 6 hereinafter). The soybean flour used for this purpose may be in a form obtained by grinding raw soybeans. Optionally, the soybeam flour so produced may be further subjected to a heating treatment prior to use. If the heating treatment is carried out at a temperature exceeding 80 DEG C., the soybean liberates soluble matter and the flavor of the finished product is adversely affected.

Subsequently, the liquid obtained consequently is preferably homogenized with a plain homogenizer or a pressure homogenizer to provide non-odorous garlic paste.

On the other hand, in the case of the absence of the cellulase, the clove-containing liquid to which vitamin B1, rice bran, or yeast has been added as described above is divided by centrifugal separation into a liquid part and a sediment part. The liquid part so obtained and soybean flour, soybean milk, or soybean milk flour added thereto are heated to a temperature of up to about 80 DEG C., and preferably about 60 DEG C. The resultant mixture is again divided by centrifugal separation into a liquid part and a sediment part. In this case, the deodorizing effect is particularly conspicuous when the temperature is at a level of about 60 DEG C. If this temperature exceeds 80 DEG C., the unpleasant odor is perceived.

The soybean flour, soybean milk or soybean milk flour to be used in this step is desired to have undergone a thermal treatment with steam for denaturation. The amount of addition thereof is preferably from about 1 to about 20% by weight, more preferably from about 1 to about 15% by weight, most preferably about 4 to 8% by weight, based on the dry weight of the clove-containing liquid, thereby removing the trace of odor of garlic still persisting in the liquid. If the amount of soybean flour added is less than 1% by weight or that of soybean milk (based on the dry weight) or

1555/2197

soybean milk flour added is less than 2% by weight, thorough removal of the persisting odor cannot be obtained.

Subsequently, the mixture is devided with the centrifugal separator into solid and liquid.

In the non-odorous galic paste obtained as described above, the flavor and favorable taste inherently possessed by garlic remains intact, but the irritant odor of garlic emitted during normal treatments of garlic is not emitted at all.

When the non-odorous garlic paste obtained by the present invention is diluted with sugar solution or carbonated water and sugar solution, therefore, there is obtained a delicious non-odorous nutritious drink. The non-odorous garlic paste also is suitable for incorporation in sauce for roast meat, dressing, garlic butter, garlic salt, and kimchi sauce. This garlic paste can also be used for flavoring candies, snacks, rice cracker, etc. The non-odorous garlic paste can be converted by freeze drying, foam mat drying, or spray drying into a powder for convenience of handling.

The present invention is described more specifically below with reference to working examples.

EXAMPLE 1

A 1,000 g bunch of garlic bulbs wrapped in the skin was washed with cold water, placed in a gauze basket, set in place in a retort, and heated at 110 DEG C. for 10 minutes. After the heating treatment, the bunch of garlic bulbs, still held in the basket, was cooled by being kept in running water, and was then drained. Thereafter, the garlic was dropped into 1,500 g of cold water and by the use of a finisher designed for squeezing juice from fruits, divided into a clove-containing liquid and unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of the garlic bulbs. Consequently, the clovecontaining liquid was obtained in a total amount of 2,000 g.

The clove-containing liquid was mixed with 40 mg of hydrochloride of vitamin B1. The resultant mixture was adjusted to a pH of 8 with an aqueous solution of 10% by weight sodium hydroxide and stirred over a hot water bath at 60 DEG C. for 40 minutes. Thus, the mixture was neutralized to pH 7 with an aqueous solution of 36% by weight of hydrochloric acid. After the neutralization, the mixture was divided into a liquid and solids by the use of a centrifugal separator. The liquid thus obtained by the separation in an amount of 1,200 g was mixed with 36 g of soybean flour prepared in advance by boiling soybeans with steam and drying and comminuting the boiled soybeans. The resultant mixed solution was heated until the temperature reached 60 DEG C. Subsequently, the solution was again centrifugally separated to produce 1,000 g of garlic paste.

The garlic paste, by measurement with a portable refractometer, was found to possess a refractive index of 11. When this garlic paste was concentrated with a rotary evaporator under 25 Torrs at 60 DEG C., there was obtained delicious non-odorous garlic extract, which was found with the aforementioned refractometer to possess a refractive index of 70.

A mixture consisting of 1% by weight of the aforementioned non-odorous garlic extract, 43% by weight of starch syrup, and 56% by weight of sugar was boiled at 145 DEG C. and then molded to form candies in a conventional manner. These candies emitted no odor, but gave forth the flavor and favorable taste of garlic.

Separately, garlic paste as a comparative sample was obtained by following the procedure described above, except that the heating treatment was omitted, and the addition of vitamin B1 and that of soybean flour were both omitted. Candies were similarly produced by using the garlic paste. The two kinds of candies were subjected to sensory test. The ratings in the test were made on the following scale.

Scale of Rating (odor of garlic)

2: Intense odor of garlic perceived.

1: Strong odor of garlic perceived.

0: Odor of garlic easily perceived.

-1: Odor of garlic barely perceived.

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-2: No odor of garlic perceived.

A panel of 18 members rated the candies as shown in the following Table 1. The candies of the present invention were concluded to be free from odor at a level of significance of 5%.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Odor of Garlic

>;tb; Candies Containing

>;tb; Non-Odorous

>;tb;Panel Candies Containing

>;tb; Garlic Paste

>;tb;Member Odorous Garlic Paste

>;tb; of This Invention

>;tb;______________________________________

>;tb; 1 2 0

>;tb; 2 2 1

>;tb; 3 2 0

>;tb; 4 2 -1

>;tb; 5 2 0

>;tb; 6 2 0

>;tb; 7 2 -1

>;tb; 8 2 0

>;tb; 9 2 0

>;tb;10 2 1

>;tb;11 2 1

>;tb;12 2 0

>;tb;13 2 1

>;tb;14 2 0

>;tb;15 2 0

>;tb;16 2 0

>;tb;17 2 0

>;tb;18 2 0

>;tb;______________________________________

EXAMPLE 2

A 1,000 g bunch of garlic bulbs wrapped in the skin was placed in an electronic oven operated at a frequency of 2,450 MHz and an output of 3.5 kw together with a glass container holding water for saturating the oven interior with steam. The electronic oven was operated to irradiate its contents with microwaves for 3 minutes. Then, the garlic so treated was dropped into 1,600 g of cold water and treated with a finisher similarly to Example 1 to divide the treated garlic into the unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of garlic bulbs, and a clove-containing liquid.

Thus, the clove-containing liquid was obtained in an amount of 2,200 g. On a hot water bath, 2,200 g of the clove-containing liquid and 30 g of yeast obtained by culture on a medium of whey were heated at 60 DEG C. for 60 minutes at a pH of 8. After adjusting the pH to 6, the resultant mixture was divided with a centrifugal separator into solids and a liquid. Thus, the liquid was obtained in an amount of 1,300 g.

This liquid and 36 g of the same soybean flour as used in Example 1 were stirred and heated until the temperature of the resultant mixture reached 60 DEG C. The mixture was subsequently divided with the centrifugal separator into solids and a liquid. Consequently, 1,100 g of garlic paste was obtained which, by measurement with a portable refractometer, was found to possess a refractive index of 10.

When 1,100 g of the garlic paste was concentrated with a rotary evaporator under 25 Torrs at 60 DEG

C., there was obtained 150 g of non-odorous garlic paste which was found by measurement with the aforementioned refractometer to possess a refractive index of 70.

A sauce for roast meat was prepared by mixing 1.5% by weight of the aforementioned non-odorous garlic paste, 75% by weight of soy sauce, 18.5% of sugar, and 5% by weight of mirin (sweet sake)

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(Japanese seasoning alcohol obtained by saccharifying an intimate mixture of ethyl alcohol, koji, and glutinous rice for a brewing length of time in the presence of about 10% of alcohol). When meat soaked with this sauce was roasted, there was produced roast meat which emitted no odor of garlic but gave forth the flavor and favorable taste of garlic. Sauce for roast meat which is commercially available containing grated garlic emits intense odor of garlic. A sauce for roast meat which contained the nonodorous garlic paste obtained in the present example emitted no odor of garlic and, therefore, was found acceptable even by panel members who dislike the odor of garlic.

Separately, a garlic paste as a comparative sample was obtained by following the procedure described above, except that the treatment in the electronic oven was omitted and the addition of yeast and that of soybean flour were both omitted, and a sauce for roast meat was prepared by using this garlic paste.

The roast meats prepared by using the two sauces were subjected to sensory testing. The ratings in the test were made on the following scale.







A panel of 21 members rated the roast meats as shown in the following Table 2. The roast meat using the sauce of the present invention was concluded to be free from the odor of garlic.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Odor of Garlic*

>;tb; Roast Meat Using Sauce

>;tb; Roast Meat Using

>;tb; Containing Non-Odorous

>;tb;Panel Sauce Containing

>;tb; Garlic Paste of

>;tb;Member Odorous Garlic Paste

>;tb; This Invention

>;tb;______________________________________

>;tb; 1 0 0

>;tb; 2 1 0

>;tb; 3 0 0

>;tb; 4 2 -2

>;tb; 5 -1 0

>;tb; 6 1 0

>;tb; 7 0 -2

>;tb; 8 0 -1

>;tb; 9 1 -1

>;tb;10 1 0

>;tb;11 0 0

>;tb;12 1 -2

>;tb;13 0 -2

>;tb;14 0 -1

>;tb;15 -1 -2

>;tb;16 -2 -2

>;tb;17 1 0

>;tb;18 -2 -1

>;tb;19 -1 -1

>;tb;20 2 2

>;tb;21 0 -2

>;tb;______________________________________

>;tb; *Level of significance 5%

EXAMPLE 3

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In 2,500 g of boiling water, a 1,050 g bunch of garlic bulbs wrapped in the skin was boiled for 30 minutes. After the boiling, it was immediately treated with a finisher designed for squeezing juice from fruits to be divided into the unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of garlic bulbs, a clove-containing liquid. Thus, the clove-containing liquid was obtained in an amount of 2,000 g. The clove-containing liquid and 25 g of rice bran added thereto were stirred and heated at

60 DEG C. for 1 hour at a pH of 8. After adjusting the pH to 6, the resultant mixture was divided by centrifugal separation into solids and a liquid. The liquid was obtained in an amount of 1,000 g. This liquid and 50 g of soybean milk flour added thereto were heated and subsequently centrifuged.

Consequently, there was obtained non-odorous garlic paste which, by measurement with a portable refractometer, was found to possess a refractive index of 12.

A nutritious beverage was obtained by preparing a mixture consisting of 5% by weight of the nonodorous garlic paste obtained as described above, 12% by weight of sugar, 0.5% by weight of honey,

0.5% by weight of plum juice, 0.22% by weight of citric acid, 0.15% by weight of flavor, and 81.63% by weight of water, dispersing this mixture in a unit volume of 160 ml among bottles, sealing the filled bottles, and sterilizing their contents. As compared with a commercially available garlic-containing beverage, this beverage emitted no perceptible odor of garlic, but did provide the delicious taste of garlic.

Separately, a nutritious beverage was obtained by using garlic paste prepared by following the procedure described above, except that the boiling treatment was omitted and the addition of rice bran and that of soybean flour were both emitted. The two beverages were subjected to sensory test similarly to Example 1. The results were as shown below in Table 3. It is noted from the results that the beverage of the present invention was rated more favorably than the other beverage used for comparison.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Odor of Garlic*@1

>;tb; Beverage Using

>;tb; Beverage Using Non-Odorous

>;tb;Panel Member

>;tb; Odorous Garlic Paste

>;tb; Garlic Paste

>;tb;______________________________________

>;tb; 1 2 0

>;tb; 2 2 0

>;tb; 3 2 -1

>;tb; 4 2 0

>;tb; 5 2 -1

>;tb; 6 2 0

>;tb; 7 2 0

>;tb; 8 2 1

>;tb; 9 2 0

>;tb;10 2 1

>;tb;11 2 0

>;tb;12 2 1

>;tb;13 2 1

>;tb;14 2 1

>;tb;15 2 1

>;tb;16 2 1

>;tb;17 2 -1

>;tb;18 2 -1

>;tb;______________________________________

>;tb; *@1 Level of significance 5%

EXAMPLE 4

In 2,500 g of boiling water, a 1,000 g bunch of garlic bulbs wrapped in the skin was boiled for 30 minutes. After the boiling, the garlic was immediately treated with a finisher designed for squeezing

1559/2197

juice from fruits, and thus divided into the unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of garlic bulbs, and a clove-containing luquid. The clove-containing liquid was obtained in an amount of 2,000 g. The clove-containing liquid and 25 g of rice bran added thereto were stirred at

60 DEG C. for 1 hour at a pH of 8. After adjusting the pH to 6, the resultant mixture was divided by centrifugal separation into solids and a liquid. Liquid was thus obtained in an amount of 1,000 g. Then, this liquid and 500 g of soybean milk added thereto were heated to 60 DEG C. The resultant mixture was immediately centrifuged to obtain non-odorous garlic paste which, by measurement with a portable refractometer, was found to possess a refractive index of 8.

When this non-odorous garlic paste was freeze dried, there was obtained non-odorous powdered garlic extract in the form of a foam mat. The product thus-obtained emitted no odor, but gave forth the flavor and favorable taste of garlic.

Separately, powdered garlic was prepared as a control by repeating the procedure of the present example, except that the boiling treatment was omitted and the addition of rice bran and that of soybean milk were both omitted. The powdered garlic produced in the present example, the control powdered garlic prepared as described above, and a product of S & B Shokuhin Co., Ltd. marketed under the designation of "Garlic Powder" were severally suspended in a concentration of 5% by weight. The suspensions were placed in Erlenmeyer flasks of a volume of 150 ml, kept tightly stoppered at 37 DEG C. for 30 minutes, and subjected to sensory testing conducted by a panel of 20 members. The ratings in this test were made on the following scale.







The results of the sensory test were as shown in the following Table 4. It is noted from the test results that no significant difference was found on a level of 5% between the commercial product and the control of the present example and significant difference was found on a level of 5% between the product of the present example and the control of the present example and between the product of the present example and the commercial product.

>;tb; TABLE 4

>;tb;______________________________________

>;tb; Commercial Product of

>;tb;Panel Members

>;tb; Product Control This Example

>;tb;______________________________________

>;tb; 1 1 1 -1

>;tb; 2 0 1 -1

>;tb; 3 1 2 0

>;tb; 4 0 2 -1

>;tb; 5 0 2 -2

>;tb; 6 1 2 0

>;tb; 7 0 2 -1

>;tb; 8 2 2 0

>;tb; 9 1 2 0

>;tb;10 2 1 -1

>;tb;11 2 2 -1

>;tb;12 2 1 0

>;tb;13 2 2 -2

>;tb;14 0 0 0

>;tb;15 -1 -1 -2

>;tb;16 2 2 1

>;tb;17 1 0 -2

>;tb;18 1 2 0

>;tb;19 2 2 -1

1560/2197

>;tb;20 2 2 -1

>;tb;______________________________________

EXAMPLE 5

A 10 kg bunch of garlic bulbs wrapped in the skin was washed with cold water, placed in a gauze basket, set in place within a retort, and subjected to a heating treatment at 110 DEG C. for 10 minutes.

After the heating treatment, the garlic still held in the basket was cooled in running water and then drained. Subsequently, the garlic was dropped into 3 kg of cold water and treated with a finisher having meshes 1.5 mm in diameter to be thus divided into the unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of garlic bulbs, and a clove-containing liquid. Thus, the clove-containing liquid was obtained in an amount of 10 kg.

The clove-containing liquid was mixed with 400 mg of hydrochloride of vitamin B1. The resultant mixture was adjusted to a pH of 8 with an aqueous solution of 10% by weight of sodium hydroxide.

Over a hot water bath, the mixture was stirred and heated at 60 DEG C. for 40 minutes. The heated mixture was cooled and then adjusted to a pH of 6 with an aqueous solution of 36% by weight of hydrochloric acid. The mixture and 130,000 units of a cellulase from a microorganism of genus

Aspergillus (a product of Nagase Biochemical Co., Ltd. marketed under the trademark designation

"Cellulase 2000 CUN/g") added thereto were stirred over a hot water bath at 50 DEG C. for 2 hours, causing the cellulase to react on the mixture. The resultant broth was heated at 90 DEG C. to inactivate the enzyme consequently produced therein. At this point, the clove-containing liquid showed a viscosity of 600 cp. By measurement with a portable refractometer, the liquid was found to possess a refractive index of 25. The viscosity was determined under the conditions of 1 DEG34" of cone angle,

10 rpm of rotational speed, and 12 seconds of rotation time. This determination was made with a viscosimeter, type E, made by Tokyo Measuring Instrument Co., Ltd.

The aforementioned clove-containing liquid and 98 g of raw soybean flour added thereto were heated to 60 DEG C. and then treated with a homogenizer, T.K. MY Colloider, Type L. By the use of a centrifugal spray drier (maximum capacity 250 kg/hour), the liquid resulting from the treatment with the homogenizer was spray dried. The powder consequently produced emitted no odor but gave forth the flavor and favorable taste of garlic. This powder was applied to the surface of rice crackers at a rate of 2.5 g per 100 g of rice crackers in conjunction with soy sauce. The finished crackers emitted absolutely no odor, but gave forth the flavor and favorable taste of garlic.

The rice crackers and ordinary rice crackers coated with garlic powder were subjected to sensory testing similar to Example 1. The results of the test were as shown in Table 5.

>;tb; TABLE 5

>;tb;______________________________________

>;tb;Odor of Garlic*@1

>;tb; Rice Crackers Using

>;tb; Non-Odorous

>;tb;Panel Rice Crackers Using

>;tb; Garlic Powder of

>;tb;Member Odorous Garlic Powder

>;tb; This Invention

>;tb;______________________________________

>;tb; 1 2 0

>;tb; 2 2 1

>;tb; 3 2 0

>;tb; 4 2 1

>;tb; 5 2 0

>;tb; 6 2 0

>;tb; 7 2 1

>;tb; 8 2 0

>;tb; 9 2 0

>;tb;10 2 0

>;tb;11 2 -1

>;tb;12 2 0

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>;tb;13 2 0

>;tb;14 2 0

>;tb;15 2 0

>;tb;16 2 -1

>;tb;17 2 0

>;tb;18 2 1

>;tb;______________________________________

>;tb; *@1 Level of significance 5%

EXAMPLE 6

A 1 kg bunch of garlic bulbs wrapped in the skin was placed in an electronic oven rated for 2,450 MHz of frequency and 3.5 kw of output and a glass container holding water intended to keep the oven interior saturated with steam was placed in the electronic oven. The electronic oven was operated to irradiate its contents with microwaves for 3 minutes. Then, the individual garlic bulbs so treated were manually peeled and deprived of the skin and the roots and bottoms of garlic bulbs. The remaining garlic and 1,600 g of water added thereto were stirred in a large combination juicer and mixer and converted into like a slurry. Consequently, a clove-containing liquid was obtained in an amount of

2,300 g. This liquid was mixed with 30 g of a yeast produced by microorganic culture on whey as a medium. The resultant mixture was adjusted to a pH of 8 with an aqueous solution of 10 wt% NaOH and then stirred over a hot water bath at 60 DEG C. for 60 minutes. The heated mixture was cooled and then adjusted to a pH of 6 with an aqueous solution of 36% by weight of hydrochloric acid. This mixture and 1,230 units of a cellulase produced by Trichoderma koningi (product of Meiji Seika

Kaisha, Ltd. marketed under trademark designation of "Meiselase") added thereto were stirred and heated over a hot water bath at 50 DEG C. for 2 hours, causing the cellulase to react on the mixture.

The resultant broth was heated to 90 DEG C. to inactivate the enzyme consequently produced therein.

The liquid thus produced was mixed with 9.8 g of soybean flour thermally denatured by steaming in advance. The resultant mixture was heated to 60 DEG C. and then treated with a pressure homogenizer under pressure of 150 kg/cm@2 (gauge). The liquid resulting from the treatment with the homogenizer was concentrated under a vacuum of 700 mmHg/cm@2 (gauge) at 60 DEG C., to give rise to nonodorous garlic paste having a refractive index of 50 and a viscosity of 2,200 cp. This garlic paste retained the flavor and favorable taste of garlic, but emitted no odor of garlic. When this garlic paste was added to "gyoza" (a ground pork-leek mixture wrapped in dough skin and baked) at a rate of 3.2 g per plate of gyoza served on 4 persons, the gyoza produced provided the flavor and favorable taste of garlic but emitted no odor of garlic.

EXAMPLE 7

A 10 kg bunch of garlic bulbs wrapped in the skin was washed with cold water, placed in a gauze basket, set in place within a retort, and subjected to a heating treatment at 120 DEG C. for 5 minutes.

The garlic resulting from the heating treatment was mixed with 3 kg of cold water and treated with a strainer made by Aikosha Co., Ltd. to be divided into the unwanted portions of garlic bulbs, i.e., the skin and the roots and bottoms of garlic bulbs, and a clove-containing liquid. Thus, the clovecontaining liquid was obtained in an amount of 10 kg. This liquid was mixed with 250 g of deodorized rice bran. The resultant mixture was adjusted to a pH of 8 and then stirred and heated at 60 DEG C. for

1 hour. The heated mixture was cooled and then adjusted to a pH of 6. The clove-containing liquid and

12,250 units of the same cellulase (i.e., Meiselase) as was used in Example 6 were stirred over a hot water bath at 50 DEG C. for 2 hours, causing the cellulase to react on the liquid. The resultant broth was heated to 90 DEG C. to inactivate the enzyme consequently produced therein. The resultant liquid and 98 g of soybean flour added thereto were heated to 60 DEG C. and then homogenized under pressure of 150 kg/cm@2 (gauge). By freeze drying the liquid and comminuting the resultant dry mass,

2,500 g of garlic powder was obtained. When this garlic powder was added to meat buns at a rate of

0.7%, the meat buns produced gave forth the flavor and favorable taste of garlic, but emitted no odor of garlic.

COMPARATIVE EXPERIMENT 1

A powdered garlic was obtained by following the procedure of Example 5, except that the addition of vitamin B1 was omitted. The powdered garlic thus produced and the powdered garlic obtained as the

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final product in Example 5 were subjected to sensory testing. The results of the tests were as shown in

Table 6. It is noted from the test results that the odor of garlic was stronger in the sample containing no vitamin B1 than the sample containing vitamin B1 at a level of significance of 5%.

>;tb; TABLE 6

>;tb;______________________________________

>;tb; Powdered Garlic

>;tb;Panel Containing No

>;tb; Powdered Garlic

>;tb;Members Vitamin B1

>;tb; Containing Vitamin B1

>;tb;______________________________________

>;tb; 1 o x

>;tb; 2 o x

>;tb; 3 x o

>;tb; 4 o x

>;tb; 5 o x

>;tb; 6 o x

>;tb; 7 o x

>;tb; 8 o x

>;tb; 9 x o

>;tb;10 o x

>;tb;11 o x

>;tb;12 x o

>;tb;13 o x

>;tb;14 x o

>;tb;15 o x

>;tb;16 o x

>;tb;17 o x

>;tb;18 x o

>;tb;19 o x

>;tb;20 o x

>;tb;Total 15 5

>;tb;of o's

>;tb;______________________________________

>;tb; o: Stronger odor of garlic, x: Weaker odor of garlic


The same clove-containing liquid as obtained in Example 5 was mixed with vitamin B1. The mixture was adjusted in pH level, heated, then cooled, and portions thereof were mixed with various cellulases as indicated below. Again by following the procedure of Example 5, the resultant mixture was adjusted in pH level and stirred and heated for 2 hours, causing the cellulase to react on the liquid. The relation between the amount of cellulase added (in units based on solids of clove-containing liquid) and the viscosity of the liquid is shown in FIG. 1.

Meiselase: Product of Meiji Seika Kaisha, Ltd. (origin: Trichoderma koningi)

Cellulase Onozuka: Product of Kinki Yakult Mfg. Co., Ltd. (origin: Trichoderma viride)

Cellulase 2000 CUN/g: Product of Nagase Biochemical Co., Ltd. (origin: Aspergillus niger)

Cellulase AP: Product of Amano Pharmaceutical Co., Ltd. (origin: genus Aspergillus)

Any of the cellulase species originating in genus Trichoderma is required to be added in an amount exceeding 5 units/g and any of the cellulase species originating in genus Aspergillus in an amount exceeding 50 units/g, respectively, based on solids of the clove-containing liquid.


A clove-containing liquid was obtained by following the procedure of Example 5 as far as the steps of addition of vitamin B1, stirring and heating of the mixture, and cooling of the heated mixture.

Meiselase was added to one portion of the clove-containing liquid in an amount of 5 units/g and

Cellulase 2000 CUN/g to another portion of the clove-containing liquid in an amount of 50 units/g. The

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two samples were tested for loss of viscosity over the course of time. The results of the test are shown in FIG. 2.



Meiselase was added in a fixed amount of 5 units/g to aliquots of the clove-containing liquid of varying pH value and Cellulase 2000 CUN/g in a fixed amount of 50 units/g to other aliquots of varying pH value. The samples thus prepared were tested for loss of viscosity due to pH value. The results of the test are shown in FIG. 3. It is noted from the test results that the optimum pH value for the effect of the cellulase falls in the range of from 4 to 6.



Meiselase was added in a fixed amount of 5 units/g to aliquots of the clove-containing liquid held at various temperatures and Cellulase 2000 CUN/g was added in a fixed amount of 50 units/g to other aliquots held at various temperatures. The relation between loss of viscosity and temperature was as is shown in FIG. 4. It is noted from the test results that the optimum temperature for the effect of the cellulase falls in the range of from 40 DEG to 60 DEG C.


A clove-containing liquid was obtained by following the procedure of Example 5 as far as the step of inactivation of enzyme by the application of heat. Three aliquots of the clove-containing liquid, the first having no soybean flour added thereto, the second having soybean flour added in an amount of 4% by weight (based on solids of the clove-containing liquid), and the third having soybean flour added in an amount of 10% by weight (same as above), were processed further by following the procedure of

Example 5 to provide three species of powdered garlic.

Each of the species of powdered garlic was suspended in a concentration of 5% by weight. A 20 ml portion of the suspension was placed in an Erlenmeyer flask in a volume of 100 ml and heated to 37

DEG C. (for 30 minutes). The samples thus prepared were subjected to sensory testing conducted by a panel of 20 members. The rating in this sensory test was made on the following scale.



1: Odor of garlic barely perceived.

0: No odor of garlic perceived.

Scale of Rating (odor of soybean)

2: Odor of soybean easily perceived.

1: Odor of soybean barely perceived.

0: No odor of soybean perceived.

The results of this sensory testing were as shown in Table 7. The test results were examined for level of significance at the size of 5%, based on the value in the range determined by the Student Method, as described in the book "Handbook of Sensory Test in Manufacture" issued by J.U.S.E. Press Ltd. in

Japan. The results of this examination indicate that the odor of garlic was significantly less in the sample containing 4% by weight of soybean flour than in the sample containing no soybean and that no significant difference of garlic odor existed between the sample containing 10% by weight of soybean flour and the sample containing 4% by weight of soybean flour. In the case of the odor of soybean, the results of the examination indicate that no significant difference existed between the sample containing

4% by weight of soybean flour and the sample containing no soybean flour, and that a significant difference existed between the sample containing 4% by weight of soybean flour and the sample containing 10% by weight of soybean flour.

>;tb; TABLE 7

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>;tb;__________________________________________________________________________

>;tb;Odor of Garlic Odor of Soybean

>;tb; Sample Sample Sample Sample

>;tb; Sample Containing 4%

>;tb; Containing 10%

>;tb; Sample Containing 4%

>;tb; Containing 10%

>;tb;Panel

>;tb; Containing No

>;tb; by Weight of

>;tb; by Weight of

>;tb; Containing No

>;tb; by Weight of

>;tb; by Weight of

>;tb;Members

>;tb; Soybean Flour

>;tb; Soybean Flour

>;tb; Soybean Flour

>;tb; Soybean Flour

>;tb; Soybean Flour

>;tb; Soybean Flour

>;tb;__________________________________________________________________________

>;tb; 1 1 0 1 0 0 0

>;tb; 2 2 1 0 1 2 2

>;tb; 3 2 1 0 0 0 1

>;tb; 4 1 0 0 1 2 2

>;tb; 5 1 0 0 0 0 0

>;tb; 6 1 1 0 0 0 2

>;tb; 7 1 0 1 1 1 2

>;tb; 8 0 0 0 0 0 1

>;tb; 9 2 0 0 0 0 0

>;tb;10 2 0 1 0 0 2

>;tb;11 2 1 1 0 1 2

>;tb;12 1 1 0 0 0 0

>;tb;13 0 1 1 0 2 2

>;tb;14 2 0 0 1 1 2

>;tb;15 1 0 0 0 0 0

>;tb;16 2 1 0 1 2 2

>;tb;17 2 0 0 0 0 1

>;tb;18 1 0 0 0 0 0

>;tb;19 2 0 0 0 0 1

>;tb;20 1 1 1 0 0 1

>;tb;__________________________________________________________________________

From the working examples and the comparative experiments cited above, it is noted that the present invention brings about the following described effects:

(1) The non-odorous garlic paste produced in accordance with the present invention retains intact the flavor and favorable taste inherently possessed by garlic.

(2) The method of this invention successfully precludes the otherwise inevitable emission of the irritant odor of garlic, and, therefore, enables the production of non-odorous garlic paste to be carried out with better workability than the conventional methods which subject garlic bulbs directly to preponderantly physical treatments.

(3) The garlic paste obtained by the method of this invention adopting cellulase possesses a refractive index of 35 (as measured with a portable refractometer) and yet exhibits a viscosity of not more than about 1,500 cp. Thus, it can be converted into a powder or concentrated by vacuum evaporation, foam mat drying, or spray drying when desired.

While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein

1565/2197

without departing from the spirit and scope thereof.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A method for the production of garlic paste, comprising the steps of: (i) subjecting garlic bulbs as wrapped in the skin to a heating treatment in the range of from 99 DEG to 120 DEG C., adding water to said garlic bulbs in an amount by weight of from 0.3 to 2 times based on the amount of said garlic bulbs, coarsely crushing said garlic bulbs, and separating said skin and other unwanted parts of the garlic bulbs from the resultant crushed mass of garlic, leaving behind a garlic clove-containing liquid,

(ii) heating said garlic clove-containing liquid to a temperature in the range of from 60 DEG to 70 DEG

C. together with vitamin B1 in an amount of about 0.001 to 0.005 wt% (calculated based on hydrochloride salt of vitamin B1) based on the amount of garlic bulbs wrapped in the skin, rice bran in an amount of from about 0.5 to 2.5% based on the amount of garlic bulbs wrapped in the skin, or yeast in an amount of from 1 to 3% by weight based on the amount of garlic bulbs wrapped in the skin added thereto, (iii) optionally adding a cellulase to the product of step (ii) and heating the resultant blend at a temperature in the range of from 40 DEG to 60 DEG C. and at a pH of from 4 to 6, and (iv) heating either the liquid part of the product of step (iii) resulting from the removal of solids therefrom together with soybean flour, soybean milk, or soybean milk flour in an amount of from about 1 to about 10% by weight based on the dry weight of the clove-containing liquid or said product of step (ii) in the unmodified form thereof together with soybean flour, soybean milk, or soybean milk flour in an amount of from about 1 to about 20% by weight based on the dry weight of the clove-containing liquid.

2. A method according to claim 1, wherein said cellulase is obtained from a microorganism belonging to Trichoderma koningi, Trichoderma viride or Aspergillus niger.

3. A method according to claim 2, wherein said cellulase obtained from a microorganism belonging to

Trichoderma koningi or Trichoderma viride is added in an amount of at least about 5 units per g of solids of said clove.

4. A method according to claim 2, wherein said cellulase obtained from a microorganism belonging to

Aspergillus niger is added in an amount of at least about 50 units per g of solids of said clove.Data supplied from the esp@cenet database - Worldwide

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351.

US4649055 - 3/10/1987

PROCESS FOR PRODUCING IMPROVED DEHYDRATED RICE AND

PRODUCT


Inventor(s): KOHLWEY DAVID E (US)

Applicant(s): LOUISIANA STATE RICE MILLING C (US)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/18C6



Family: US4649055

Abstract:


The process of the invention may be employed with raw or parboiled non-waxy rice and produces a cooked and dehydrated rice. In a preferred embodiment the cooked and dehydrated rice is expanded, or puffed, to produce a rice product capable of rehydration to palatable textural state within 90 seconds after the addition of boiling water. The process consists of gelatininzing and glassifying the rice, and then drying the rice. The preferred process employs this process and then expands, or puffs, the rice.

Apparatus for expanding rice in accordance with the preferred process is provided.Description:



This invention relates to the processing of rice to produce dehydrated rice products, and more particularly, relates to the processing of rice to produce precooked and dehydrated rice products for use as precooked rice products. In a preferred embodiment of the invention produces a precooked and dehydrated rice product for use in dehydrated foods such as soups and other foods which require only the addition of boiling water to provide a cooked and palatable food.

Precooked and dehydrated foodstuffs for use in dehydrated food mixes preferrably require only the addition of a specified quantity of boiling water to both warm and reconstitute the foodstuff to a palatable, hydrated condition. Such foodstuffs do not require any additional cooking to render them ready to eat and are capable of being consumed within a few minutes after the addition of the boiling water.

Typically, dehydrated food mixes come in a package which serves to store the product and serves as a moisture barrier. For some ready-to-eat products the package may also serve as the eating container, after rehydration with boiling water. These food mixes have initially been confined to simple products having a relatively small number of constituents, such as soups, but now include many diverse and complex products, such as entire dinners.

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Further, these food mixes have tended to include wheat products because wheat products do not require a complete wheat "grain" to be recognized as a foodstuff and are thereby easily included in non-grain processed forms that are coked and dehydrated. For example, soups may include cooked and dehydrated noodles that are very thin to allow for quick rehydration of the noodle. The desire to include whole grain rice products in these foodstuffs has led to the need for a precooked and dehydrated whole grain rice product compatible with other such precooked and dehydrated foodstuffs.

However, such a whole grain rice product must have an appearance similar to conventionally cooked rice grains, as well as being comparable in taste, or palatability, texture, and stickiness.

Although the need for such a precooked and dehydrated rice product has been known for some time, the existing products and processes for producing these products have not been completely successful on a commercial basis. U.S. Pat. No. 4,333,960 to Barry et al discusses the shortcomings of some of the processes available in this area. In summary, Barry et al states that these prior processes are not commercially successful because they: (1) require additional cooking after the addition of boiling water, or (2) produce a ready to eat product not requiring rehydration, or (3) use an initial raw rice product that results in materials that are difficult, if not impossible, to handle on an economic and commercial scale.

U.S. Pat. No. 4,333,960 to Barry et al does not easily lend itself to an economical and continuous commercial process because of its initial "soaking" step. Further, as taught in this patent, the color of the product after the "puffing" step is very dependent upon the "puffing" temperature and the product is easily scorched or burned at the higher puffing temperatures taught in this patent.

Further the Barry et al process, and other prior art processes, are designed to prevent any bursting, or popping, of starch granules in the rice grain. This prevention of bursting is to minimize cooking losses, but such processes provide starch of reduced solubility in the starch granules, as compared with the solubility of starch outside the granules. However, increasing the solubility of starch substantially increases the rate of rehydration especially for expanded, or "puffed", rice grains, as compared to rice grains which have been expanded with intact starch granules.

These and other limitations and disadvantages of the prior art are overcome by the present invention, and improved methods and apparatus are provided for producing a cooked and dehydrated rice capable of rapid rehydration, using an economical and continuous commercial process.

SUMMARY OF INVENTION

In a preferred embodiment of the present invention, processes for producing improved cooked and dehydrated rice products are provided. The process consists of partially gelatinizing and hydrating nonwaxy parboiled rice in moderately acidic hot water, steaming the rice to completely gelatinize and glassify the rice, and then drying the rice. In a preferred process, the dried rice is then expanded. These processes may be employed by equipment used to prepare commercial instantized rice, with minor modifications, preferrably in combination with appropriate expanding apparatus, on a continuous basis, rather than a batch basis.

Alternatively, the process may consist of hydrating and partially gelatinizing non-waxy raw (white or brown) rice by soaking in moderately acidic warm water and then multiple steamings and washings; gelatinizing and glassifying the rice by steaming; and then drying the rice. In a preferred process the glassified rice is then expanded. These processes may also be employed by equipment used to prepare instantized rice, with minor modifications, preferrably in combination with appropriate expanding apparatus.

An additional alternate process may consist of hydrating, gelatinizing and glassifying rice by steaming at pressures greater than atmospheric pressure, drying the rice, and then preferrably, expanding the rice.

It is an object of the present invention to provide a cooked and dehydrated rice product.

It is also an object of the present invention to provide processes for producing a cooked and dehydrated rice product.

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It is a further object of the present invention to provide an expanded, cooked and dehydrated rice product capable of rehydration to a palatable state within one and one-half minutes after the addition of boiling water.

It is an additional object of the present invention to provide processes for economically producing an expanded, cooked and dehydrated rice product capable of rehydration to a palatable state within one and one-half minutes after the addition of boiling water.

It is yet an additional object of the present invention to provide apparatus for use in the process for producing an expanded, cooked and dehydrated rice product.

It is a specific object of the present invention to provide a process for producing a cooked and dehydrated rice, comprising: glassifying dried rice of a predetermined moisture content and variety at a temperature functionally related to said moisture content and variety, and thereafter drying said glassified rice.

It is a further specific object of the present invention to provide a process for producing a cooked and dehydrated rice, comprising: glassifying dried rice of a predetermined moisture content and variety at a temperature functionally related to said moisture content and variety, drying said glassified rice, and thereafter expanding said dried rice.

It is yet a further specific object of the present invention to provide apparatus for expanding rice, comprising: hot air means for supplying hot air at a preselected temperature, blower means adjacent said hot air means for increasing the speed of said hot air, expansion means interconnected with said blower means to receive said hot air and for receiving rice to be fluidized and expanded by said hot air therein, and product separation means interconnected with said expansion means for removing said expanded rice from said apparatus.

These and other objects and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.

IN THE DRAWINGS

FIG. 1 is a simplified pictorial diagram of curves representing glassification temperatures for different varieties of rice grains at different moisture contents.

FIG. 2 is a simplified pictorial illustration of an expander, and cooling and packaging apparatus, partially in cross-section, for use in the process of the invention.

FIG. 3 is a side view of the apparatus depicted in FIG. 2.

FIG. 4 is a top view of the apparatus depicted in FIG. 2.

FIG. 5 is an enlarged cross-sectional side view of a portion of the apparatus depicted in FIG. 4.

FIG. 6 is a cross-sectional side view of a portion of the apparatus depicted in FIG. 4.

FIG. 7 is an enlarged top view, partially in cross-section, of a different portion of the apparatus depicted in FIG. 3.

FIG. 8 is an enlarged cross-sectional view of a different portion of the apparatus depicted in FIG. 3.


The processes of the present invention provide improved cooked and dehydrated rice products. The processes of the present invention may be practiced over widely varying moisture contents and with most varieties of rice. Referring to FIG. 1, there may be seen curves depicting energy input for

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temperatures at which glassification occurs for different moisture contents of different varieties of rice.

The "x" axis corresponds to glassification temperatures in DEGC. and the "y" axis corresponds to moisture content in percent by weight.

As used herein, the term glassification, or glassifying, is used to mean the process wherein the amylose-lipid complexes in the rice grain are melted, or broken by heat. The temperatures at which glassification occurs, decreases for increases in moisture content in the rice grain, as depicted in FIG. 1.

Glassification also occurs in a narrow temperature band for a specific moisture content and rice variety.

However, the processes of the present invention are not applicable to waxy rices, as they contain very little or no amylose.

Thus, curves a and b of FIG. 1 depict the band of temperatures during glassification corresponding to an increasing rate of energy input into a given variety of rice. Curves c and d depict the band of glassification temperatures corresponding to a decreasing rate of energy input, and curves b and c of

FIG. 1 depict the band of glassification temperatures corresponding to a constant rate of energy input into this variety of rice.

The curves of FIG. 1 may be obtained from a differential scanning calorimeter and represent volume fractions of water converted to moisture contents. The distance between the curves, or width of the glassification temperature band, is primarily determined by the rate of heating employed in the differential scanning calorimeter. For a given rice variety and different heating rates, the center of the band remains at approximately the same temperature.

However, for different rice varieties the center of the band may change slightly. Therefore, to determine the specific glassification temperature band for a selected moisture content, a sample must be run in a differential scanning calorimeter. This step may be avoided by employing a temperature at least as high as the center of the band of curves of FIG. 1, i.e. the center of curves b and c, or preferrably a temperature greater than curve d of FIG. 1, for the selected moisture content.

As used herein, the term gelatinization, or gelatinizing, is used to mean the process wherein the starch granules in a rice grain have lost all birefringence and the crystalline structure in the starch granule is disrupted. The temperatures at which this process occurs increases with decreasing moisture content in the rice grain. Further, for a specific moisture content, the temperature over which the process begins and ends is a narrow band of temperatures, typically a few degrees, i.e. 3 DEG-5 DEG C. This definition is in accord with most, but not all, of the prior art dealing with starches.

When rice grains are both gelatinized and glassified the internal structure of grain is disrupted and the starch granules melt, or dissolve such that the resulting grain when cooled and dried has an oval or flattened cross-section. A rice grain that has only been gelatinized has the usual circular cross-section upon cooling and drying. The lack of internal structure in a cooled and dried glassified grain is presently believed to cause the observed translucence of glassified and dried rice grains.

The glassification process is used in the processes of the invention to increase the solubility of starch in the rice grain and improve its ability to rapidly rehydrate, especially after expansion. The glassification process places the interior of the rice grain in a uniform glass-like state and removes as much of the residual internal structure as is possible. This process combined with the gelatinization process surprisingly allows for a much more rapid rehydration of the interior of the rice grain (after expansion) than a rice grain only taken through the gelatinization process.

For a given moisture content, the temperature for glassification is normally greater than the temperature for gelatinization. However, the gelatinization temperature band is currently theorized and believed to increase at a faster rate for decreasing moisture content than the rate of increase for the glassification temperature band. A rice grain must normally pass through gelatinization in order to be glassified.

However, as the moisture content in the rice grain increases, both these temperature bands shift to lower temperatures. Thus, by processing rice grains at a high moisture content, the temperatures for both of these processes are reduced, which thereby reduces the likelihood of undesirable color in the grain.

1570/2197

Glassification also surprisingly reduces the tendency for stress cracks to develop and a more uniform expanded product results. The glassified product may be used as a precooked rice product, capable of rehydration in above five to twenty minutes at about 100 DEG C. The expanding step is required to expand the volume of the rice grain to allow the grain to rapidly (within one and one-half minutes) rehydrate throughout its entire volume. Expansion, or expanding typically requires a moisture content of 8%-15% for maximum volume expansion.

The processes of the present invention may be practiced in a continuous manner by commercially available equipment conventionally arranged to produce commercial instantized rice, similar to the process taught in U.S. Pat. No. 2,828,209, in combination with appropriate expanding apparatus such as that described later herein.

The processes of the present invention may be employed with non-waxy raw rice or non-waxy parboiled rice. Waxy rice is a special variety of rice having substantial amounts of amylopectin and substantially no amylose.

Parboiled rice is paddy rice that has been steeped in water, briefly steamed, dried, shelled to remove the hull, and then milled to remove the bran layers from the rice grains. Depending upon the temperature of the steeping water parboiled rice may be fully or partially gelatinized. Parboiled rice is readily available in a many varieties, or types, and sizes of rice grain. Parboiled rice is usually preferred for commercial applications because of its enhanced mineral and vitamin content, and because of its discrete grain texture after rehydration and lack of stiffness (i.e. the cooked grains are separate and do not stick together to form a sticky mass of rice grains).

Paddy rice that has been shelled to remove the hull and milled to remove the bran layers is conventionally called white rice. Paddy rice that has been shelled but not milled is typically known as brown rice. The term raw rice is used herein to mean both white rice and brown rice as herein defined.

Parboiled rice, raw rice, or paddy rice may be employed in the processes of the present invention.

Referring to FIG. 1 for parboiled rice, saturated steam at atmospheric pressure (corresponding to 100

DEG C.) may be employed to glassify the parboiled rice, if its moisture content is increased above about 60%. Commercially available parboiled rice normally has a moisture content of about 8%-15%.

Thus, if atmospheric pressure steam is to be used to glassify the parboiled rice the parboiled rice must be first hydrated.

For parboiled rice, the processes of the invention preferrably partially gelatinizes and hydrates the rice in excess water. The water is maintained at a temperature between 70 DEG-100 DEG C. and is moderately acidic, with a pH adjusted between 4.5 to 7.0. Preferrably the water temperature is 95 DEG

C. and the pH is between 5.5 and 6.5. The acid of the processes of the present invention may be any conventional food processing acid, such as, for example, but not limited to phosphoric or hydrochloric acids.

The parboiled rice is partially cooked, or partially gelatinized, and hydrated in this acidic excess water condition for 10 to 30 minutes, depending upon the variety, crop year, cooking temperature, etc. of rice employed in the processes of the present invention. This hydration and partial cooking, or partial gelatinization, step raises the moisture content of the rice from its initial 8%-15% to a final content of about 60% to 70%, by weight. The moisture content may be raised above 60% to enable the rice grains to be more resistant to any "browning" from high temperatures of subsequent operations and to preferrably reduce the temperature at which glassification occurs. This final moisture content also depends upon the variety, crop year, degree of milling, etc. of the rice employed in this process and the maximum internal temperature the rice reaches during this step.

The parboiled rice may be hydrated and partially cooked, according to the processes of the present invention, by employing a commercially available screw type water cooker. Such a water cooker may be easily adjusted to provide the hereinabove described water temperatures and cooking times. Such a water cooker may be employed with additional equipment described later herein to operate according to the processes of the present invention in a preferrably continuous mode, or alternatively, in a batch mode.

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After hydration and partial cooking, or partial gelatinization, in excess water, the parboiled rice is quickly drained of excess water and according to the processes of the present invention, steamed with saturated steam at substantially atmospheric pressure. Preferrably, the steam fully gelatinizes and also glassifies the rice during this step.

The rice is gelatinized and glassified by the steam at a temperature of substantially 100 DEG C. for about 10 to 15 minutes, preferrably 12-14 minutes, depending on the depth of bed, variety, crop year, etc. of rice. During this steaming step the moisture content of the rice may be raised slightly. Steam gelatinization and glassification may be accomplished by employing any commercially available steam cooker used for rice.

Such steam cookers conventionally employ steam directed at a moving conveyor belt in a shroud to cook the rice and are open at either end to atmospheric pressure. Thus, the hereinabove described water cooker may discharge the rice and excess water to the conveyor belt of the steam cooker. The point of discharge may be selected to recover and allow reuse of this excess water in the water cooker. The speed of the steam cooker conveyor belt may be easily adjusted to obtain the hereinabove described steaming times.

Also, according to the processes of the present invention, raw rice may be hydrated to increase its moisture content above about 60%, and be partially gelatinized by: first washing, or soaking the rice for at least one minute in water below the gelatinization temperature, and then steaming the rice at atmospheric pressure for 8-20 minutes at 100 DEG C., preferrably about 10 minutes. This initial steaming partially gelatinizes the rice grain starch and develops a water absorbing surface layer on the outside of the grain. Thereafter, all subsequent operations may be conducted in a water-limiting fashion to avoid increasing the surface moisture content above about 75%. This steamed rice is then washed, preferrably with agitation, or sprayed with water, for about one minute, drained of excess water, and steamed as before, at least three times to hydrate, fully gelatinize, and glassify the rice. Three such washings with agitation, or sprayings, and steamings are equivalent to the previously herein described step of hydration and partial gelatinization for parboiled rice. The final wash with agitation, or spray, should raise the moisture content of 60% to 70%, i.e. this sequence is equivalent to the parboiled rice step of hydrating and partial gelatinization. The final steam step is thus equivalent to the parboiled rice step of gelatinization and glassification. After the last wash and steam step the rice is essentially in the same hydrated, cooked and glassified state as the steamed parboiled rice and continues through the rest of the processes of the invention in the same manner as that described hereinafter for parboiled rice.

Although the processes of the present invention described herein are typically illustrated by use of steam (preferrably), as a means of increasing the temperature of rice grains, it should be understood that suitable equivalent methods for increasing the internal energy and temperature of the rice grains are within the scope of these processes. For example, hot gas, or microwave or convection ovens may be employed to increase the temperature of rice grains as described in the processes of this invention.

The steamed parboiled rice may be quenced, or cooled, to prevent any further cooking and to transform the rice from a molten plastic to a rubbery state by immersing the rice for a few seconds in a water bath at a temperature less than about 50 DEG C. This quenching step may be omitted and adjustments made in the final steaming time to compensate for no quenching if the rice is naturally cooled, or cooled with a stream of air at 50 DEG C. or less.

Quenching may be accomplished by the steam cooker conveyor belt dropping the rice into a water bath. The water bath may be arranged to also carry or transport the rice from the steam cooker to the conveyor belt input of a dryer, all within a few seconds.

Alternatively, the processes of the invention may be practiced by hydrating to any desired preselected moisture content below 60% and then gelatinizing and glassifying rice in one step. This "one-step" method may be performed with paddy, raw or parboiled non-waxy rice. This one-step process may be accomplished by heating the rice with steam to a temperature, as indicated in FIG. 1, corresponding to the moisture content and variety of the rice to be employed in the process of the invention for about 1-

15 minutes.

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However, for rice grains having a moisture content below about 60%, this one-step method will require a temperature greater than 100 DEG C., which requires steam at a pressure greater than atmospheric pressure. By way of example, for 50% moisture content, this temperature is about 110 DEG C. from

FIG. 1. For 30% moisture content, this temperature from FIG. 1, is about 130 DEG C. The steam pressure corresponding to these or other selected temperatures may be conveniently obtained from conventional steam tables. Thus, a pressurized steam cooker is generally needed to perform this embodiment of the invention.

According to the processes of the invention, the steamed rice is dried in a dryer. The moisture content is reduced to about 8%-15%, preferrably 9%-12%, and most preferrably 10%-11%.

The dryer may be a multi-zone conveyor fed, hot air, tunnel dryer. The initial zone may be operated at

100 DEG C., or higher with increased air velocity through the rice bed, with successive zones at lower temperatures in a continuous mode of operation. For a batch mode operation, the initial temperature may be at or above 100 DEG C. and successive temperatures are at such lower temperatures as to ensure the internal rice temperature remains below about 50 DEG C. This prevents browning of the rice in localized high/low moisture areas in the rice bed.

For "raw" glassified rice, the dried rice grain has a dense oval or flattened cross-section and has a clear translucent color. For "parboiled" glassified rice, the dried rice has a dense or flattened oval crosssection and has a slightly yellow translucent color. Both "raw" and "parboiled" glassified rice have moisture contents of 8% to 15%, preferrably 9% to 12%, and most preferrably 10-11% when dried. The moisture content of the dried rice is thus suitable for long-term storage, if desired.

The rice may optionally be held in such a storage location at 15 DEG to 30 DEG C. for at least 4 hours to temper the rice grains. This tempering step allows the moisture in the grains to fully equilibrate within the lot and within each grain, and thereby to produce a more uniform expanded product. The dehydrated glassified product is suitable for rehydration to produce a palatable cooked rice by treatment with excess water at about 90 DEG to 100 DEG C. for about 5-20 minutes. It is also suitable for storage at these moisture contents and preferrably it may then be expanded to produce a rice product for use in dehydrated food mixes, such as, for example, but not limited to, "instant" soup mixes.

Thereafter, the dried rice may be expanded in accordance with the preferred processes of the invention.

This expanding step may be accomplished by exposing the grains of rice to hot air at a temperature of

150 DEG-320 DEG C., preferrably at least 230 DEG C. The dried rice grains, preferrably 9%-12% moisture content (and most preferrably 10%-11%), are exposed to this hot air for 5-60 seconds, depending upon the temperature of operation of the expander apparatus and moisture content of the rice. Lower operating temperatures require longer exposure times and higher operating temperatures require shorter exposure times. For 250 DEG-260 DEG C., the exposure time is about 11 seconds.

However, the dried rice may be alternatively expanded by employing: a hot fluid or gas, such as oil; or hot sand; or a hot metal plate; or radiant energy, such as microwave or infrared. Moisture contents, operating temperatures, and exposure times for such alternative expansion methods are as described hereinbefore for hot air expansion.

For hot air expansion in upwardly flowing air, exposure time may be conveniently selected by adjusting the velocity of the upwardly flowing hot air. In this manner the rice grain is suspended on and in the air column until it expands to at least several times its initial volume. Upon expansion, the reduced density of the grain allows the air to carry the expanded grain up out of the expansion chamber to an air/grain separator, where the rice grains are ejected from the hot air stream mechanically or gravitationally and are thereafter cooled by air at ambient temperature, i.e. less than about 30 DEG C.

A particularly suitable apparatus for accomplishing this expanding, and subsequent cooling and packaging, steps is shown in FIG. 2. The same item number is used for the same part for various portions of apparatus depicted in the Figures. Continuing to refer to FIG. 2, there may be seen a simplified pictorial representation of an expander, and cooling and packaging apparatus. The expander apparatus 3 supplies hot expanded rice to cooling apparatus 4, which in turn supplies cooled, expanded rice to packaging apparatus 5.

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The packaging apparatus 5 may be a conventional screening and shaker device that discharges expanded product through packaging apparatus product discharge duct 31 into a shipping container 6.

The packaging apparatus 5 also serves to discard any defective rice to a waste container (not shown).

The expander apparatus 3 is supplied hot air by gas burner assembly 2. Gas burner assembly 2 may burn any available gas fuel, such as propane, butane, or natural gas, capable of cleanly heating air to temperatures above about 300 DEG C. The hot air from gas burner assembly 2 is fed into hot air inlet pipe 10. Inlet pipe 10 is connected to the suction of blower 11. Blower 11 is operated by motor 19.

The discharge of blower 11 is connected to expander chimney 12 which extends upwardly in a vertical direction. The rice to be expanded is injected into chimney 12 through chimney feeder 14. To prevent rice from dropping down into the blower 11, backflow screen holder 13 (holding screen 60--see FIG. 7) is located below feeder 14.

Chimney 12 is attached at its upper end to chimney outlet 15. Chimney outlet 15 in turn is connected to recirculation collector box 17, with product screen holder 16 (holding screen 55--see FIG. 6) located therebetween. Box 17 is in turn connected to recirculation line 18, which returns hot air to inlet pipe 10.

Expander apparatus 3 operates at temperatures between 150 DEG-320 DEG C. Gas burner assembly 2 supplies hot air at the desired temperature. Motor 19 is operated to supply hot air from blower 11 at the desired air velocity to chimney 12. The air velocity should be sufficient to prevent incoming nonexpanded rice grains from feeder 14 from falling onto screen holder 13 and its screen 60 (see FIG. 7).

The incoming grains are thus supported and tumbled on the hot air column passing up chimney 12. The expander apparatus 3 has an upward air flow adjusted to fluidize the non-expanded rice grains.

Fluidization allows each grain to be uniformly exposed to the hot air. As the grain is quickly heated, it will begin to melt and develop superheated water in the grain. This superheated water flashes to steam and causes the melted grain to form bubbles, or pockets, of steam throughout the grain. The steam bubbles cause the grain to expand and thereby reduce the density of the grain. This fluidization provides a uniform and even heating of the grains and a substantially uniform expanded product.

Thus, the grains are supported by air velocity until they expand, whereupon the air carries them up the chimney 12 because of their reduced density. The air velocity decreases in the chimney outlet 15 because it has a larger cross-sectional area than chimney 12. The decrease in air velocity allows the expanded grains to fall downward, because of gravity. In so doing, the expanded grains fall out of the chimney outlet 15 through an opening 56 (see FIG. 6) along its bottom edge. Other conventional methods of removing the product from the air flow may also be employed, and are considered within the scope of expander apparatus 3, as described herein.

Product screen holder 16 and its screen 55 (see FIG. 6) are positioned at the end of outlet 15 to prevent any grains from passing into recirculation box 17 and into recirculation line 18.

Dampers (not shown) may be placed in recirculation line 18 and inlet pipe 10 to adjust the amount of air recirculated and the amount of hot air that is provided to the inlet of blower 11. Such dampers, blower speed and gas burner 2 are adjusted to support and tumble the unexpanded grains in hot air at the desired temperatures until they are expanded.

The expanded grains from chimney outlet 15 are collected on a wire mesh conveyor belt 22 which passes over a large cooling duct 23 mounted on supports 33. Cooling blower 24 pulls air from supply duct 25 which in turn pulls air from duct 23, thereby causing air to pass over and through the grains on belt 22. The cooling duct 23 cools the hot expanded rice grains by passing cool (ambient temperature) air over the grains. Cooling blower 24 is operated by motor 26 and draws in air at ambient temperature.

Conveyor belt 22 transports the expanded grains from the discharge point of chimney outlet 15 to product collector 30 at the discharge point of belt 22. Collector 30 in turn supplies the expanded grains to the packaging apparatus 5. Conveyor 22 is driven by drive pulley, or spocket, 27 and passes over bottom idler pulley, or sprocket, 28 and end idler pulley, or sprocket, 29.

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Referring now to FIG. 3, there may be seen a different view of the apparatus depicted in FIG. 2.

Specifically the expander apparatus 3, cooling apparatus 4 and packaging apparatus 5 are again depicted. The operation of these apparatus are as described hereinbefore.

Continuing to refer to FIG. 3, and specifically to cooling apparatus 4, there may be seen conveyor belt drive motor 32. Drive motor 32 is suitably connected by belt, or chain, to belt drive pulley, or sprocket,

27. Drive motor 32 is preferrably of adjustable speed to allow adjustment of the speed of conveyor belt

22, if desired.

Expander apparatus 3 may also be seen to have a product deflector 41 attached to chimney outlet 15.

Deflector 41 serves to prevent product from bouncing off of belt 22 as it exits outlet 15 through slot 56, and also serves to more evenly distribute the product at a uniform depth on belt 22.

Referring now to FIG. 4, the apparatus of FIG. 2 are again depicted in a different view. The proximity of gas burner assembly 2 to inlet pipe 10 of expander apparatus 3 is clearly shown. For lower operating temperatures of expander apparatus 3, it may be desirable to increase the distance between burner 2 and inlet 10, when burner 2 is supplied feed gas at a fixed rate. For higher operating temperatures, this distance may be decreased. For variable gas feed rates, it is unnecessary to change this distance.

Further, the operation of product collector 30 at the discharge of belt 22 may be clearly seen. This operation is, as previously described herein, to collect cooled product falling from belt 22 and transfer the product to the inlet, or supply, of packaging apparatus 5.

Referring now to FIG. 5, the feeder portion of expander apparatus 3 is depicted. Motor 37 turns an auger screw 38 located in chimney feeder 14. Unexpanded rice grains are loaded into inlet collector box 35 from which they pass by gravity feed into inlet feed duct 36. Inlet feed duct 36 provides rice to auger screw 38. Motor 37 may also be of adjustable speed, to adjust the rate of feed into chimney 12.

In this manner, rice is deposited in inlet box 35 and conveyed by auger screw 38 into chimney 12 through chimney feeder 14. There the rice is heated, tumbled and expanded as described hereinbefore.

Continuing to refer to FIG. 5, backflow screen 60 and backflow screen holder 13 are again depicted. As described hereinbefore, screen 60 prevents grains from inadvertently falling into blower 11 during continuous operation, or during startup or shutdown of expander apparatus 3. Holder 13 is mounted between opposing flanges 61 and 62 on chimney 12 by bolts 63 and nuts 64. This provides an air-tight seal at flanges 61 and 62.

Flanges 61 and 62 may be modified to have a space between them with a sliding "drawer" arrangement to allow for easy removal of screen 60, if desired. Such modification is within the scope of expander apparatus 3, as described herein.

Referring now to FIG. 6, there may be seen a portion of expander apparatus 3. Product screen 55 and product screen holder 16 may be clearly seen in FIG. 6. The cross-sectional area of outlet 15 may be clearly seen to be much larger than the cross-sectional area of chimney 12. This larger cross-sectional area allows the speed of the hot air exiting chimney 12 to decrease to a speed insufficient to transport expanded rice grains. Thus, the expanded rice grains fall, by gravitational forces, out through slot 56 of outlet 15. The product outlet slot 56 through which product exits from chimney outlet 15 may also clearly be seen.

Screen 55 is provided to prevent grains from passing into recirculation line 18 and then into blower 11.

The mounting of screen 55 and holder 16 may be similar to the mounting of backflow holder 13 described herein.

Referring now to FIG. 7, there may be seen a portion of expander apparatus 3. Specifically, the mounting of screen 60 in holder 13 is clearly shown. Although screen 60 is depicted, for ease of illustration, as resting on a lip of holder 13 protruding into chimney 12, holder 13 is preferrably constructed so that this lip does not extend into chimney 12. Screen 60 and 55 (see FIG. 6) are wiremesh metal screens capable of withstanding the operating temperatures of expander apparatus 3.

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Referring now to FIG. 8, there may be seen a portion of chimney 12, in cross-section, of expander apparatus 3. Air flow baffles, or straighteners, 65 are shown in chimney 12. These straighteners 65 are located adjacent the outlet of blower 11 to minimize air flow turbulence in chimney 12. This provides uniform air velocity in chimney 12 to avoid "dead" spots in which rice grains might collect and be exposed to heat for excessive lengths of time.

After cooling, the expanded rice grains may be suitably packaged in package 6 to prevent damage to the expanded grain structure and to prevent any absorbtion of moisture by the expanded rice grains.

Embodiments of the preferred processes of the invention are hereinbelow described by way of example. The first example employs parboiled rice, the second example employs raw rice, and the third example also employs raw rice but in the one-step embodiment of the present invention.

EXAMPLE 1

Parboiled long grain (StarBonnet variety) rice was partially cooked in excess water of pH 6.0 for 18 minutes in a conventional water cooker at 95 DEG C. The rice was quickly drained of excess water and steamed at 100 DEG C. for 14 minutes. The rice was quenched for approximately 10 seconds in a water bath at 40 DEG C. The rice was dried at 120 DEG C. for about 11 minutes, then at 105 DEG C. for about 11 minutes and finally at 102 DEG C. for about 11 minutes; total drying time was 32 minutes.

The above process was a continuous mode of operation.

The rice at 10.4% moisture content was continuously expanded in an upwardly flowing hot air stream at 265 DEG C. for about 11 seconds, in apparatus as described hereinbefore.

Some of the expanded rice was broken open and inspected. It showed a multiply-porous interior having small pores and did not have a major longitudinal cavity along its axis. The volume of the puffed rice grain was about 3-4 times the volume of dried grains, on the average.

A 25 gm sample of the expanded rice was immersed in an excess of boiling water and mixed therewith.

The rice was allowed to stand 90 seconds and was then drained and reweighed. The weight of the rehydrated sample was about 3 times the weight of the dehydrated sample.

The rehydrated sample was white with a yellowish tint, fluffy, and the individual grains were clearly distinguishable and not sticking to each other. The grains when crushed were completely cooked and when eaten were texturally comparable to conventionally prepared rice.

Samples were also employed in "instant" soup mixes and achieved a palatable consistency in about 45-

60 seconds. The grains were as described hereinabove and remained palatable for as long as desired after the addition of boiling water. That is, the identity of the grains were texturally complete (i.e. they were detectably present when chewed) for as long as desired.

EXAMPLE 2

A 6.4 Kg sample of white (New Rex variety) rice was washed and soaked in excess water having a temperature of about 65 DEG C. and a pH of 5.1 for 15 minutes. The rice was drained of excess water and steamed at atmospheric pressure (i.e. 100 DEG C.) for 10 minutes. The rice was then immersed and agitated in a water bath having a pH of 5.1 and a temperature of 65 DEG C. for about 60 seconds and then drained of excess water. The rice was then steamed and subsequently washed and agitated as described hereinabove two additional times, i.e. for 2 cycles of steaming followed by washing and agitating.

The rice was then again steamed at 100 DEG C. for 15 minutes and thereafter quenched in tap water at about 25 DEG C. for about 10 seconds and then drained. The moisture content after this fourth steaming was 68%, by weight.

The rice was subsequently dried in air at 50 DEG C. for one hour followed by air at ambient temperature (about 35 DEG C.) for 90 minutes.

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The rice at 10.7% moisture content was batch expanded in an upwardly flowing hot air stream at 300

DEG C. for 10-13 seconds, in apparatus as described hereinbefore.

The volume of the expanded rice was about 3 times the volume of the white rice. The interior of a broken grain exhibited a multiply-porous spongey interior and had no major longitudinal cavity.

A sample was rehydrated as in Example 1 and was about 3 times the weight of the dehydrated sample.

The expanded sample and rehydrated sample were both white in color. The rehydrated sample was fluffy, cooked, non-sticking and had good texture as in the Example 1 rehydrated sample. Tests of the expanded rice in instant soup mixes gave results as described in Example 1.

EXAMPLE 3

A 500 gm sample of brown (LaBelle variety) rice was washed and soaked for 4 hours in excess water at about 65 DEG C. and then drained of excess water. The moisture content of the rice at the end of this

4 hour time was 29%, by weight. The rice was then steamed in an autoclave by pressurized steam at a pressure corresponding to 140 DEG C. for 5 minutes. The rice was thereafter cooled by removing it from the autoclave and exposing it to air at ambient temperature, i.e. about 25 DEG C. The rice was then dried for 72 hours in air at ambient temperature (approximately 25 DEG C.).

Thereafter, the rice was milled to remove the bran layer in a conventional manner.

The rice at about 10% moisture content was then batch expanded in an upwardly flowing hot air stream at 275 DEG C. for about 11 seconds, in apparatus as described hereinbefore.

The volume of the expanded rice was about 4 times the volume of the brown rice grain. The expanded grain interior similarly exhibited a multiply-porous interior as noted in previous Examples.

The expanded rice exhibited rehydration weights, texture and palatability as noted in previous

Examples. However, the color of the expanded rice was white with a light yellow tint. Tests of the expanded rice in instant soup mixes gave results as described in Example 1.

EXAMPLE 4

Two four ounce samples of parboiled rice of Example 1 were obtained after gelatinization and glassification but prior to the preferred expansion, or puffing, step. Each sample was introduced into six ounces of boiling water and held at approximately 90 DEG to 95 DEG C. for twenty minutes.

During the twenty minute rehydration time, test specimens were taken at seven, ten, fifteen and twenty minute intervals. The resulting rehydrated rice was edible and palatable after seven minutes, but the specimens taken at 7 and 10 minutes rehydration time were found to be somewhat rubbery or chewy.

The specimens taken after 15 and 20 minutes rehydration were firm and palatable with good eating texture. Each grain was discrete and the rehydrated rice was noted to have relatively large grains.

Many other variations and modifications may be made in the apparatus and techniques hereinbefore described, by those having experience in this technology, without departing from the concepts of this invention. Accordingly, it should be clearly understood that the apparatus and methods depicted in the accompanying drawings and referred to in the foregoing description are illustrative only and are not intended as limitations on the scope of the invention.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for producing cooked and dehydrated rice which rapidly rehydrates in about one minute to a palatable consistency by mixing with hot water, comprising: hydrating a non-waxy variety of dry rice with water at a temperture of up to 65 DEG C. for a period of time sufficient to raise the moisture content of said rice from an initial 8-15% to up to 70%; gelatinizing said hydrated rice at a temperature

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above 65 DEG C.; glassifying said gelatinized rice in a water limiting environment which maintains the moisture content of said rice below about 75%; and thereafter drying said glassified rice.

2. A cooked and dehydrated rice product produced by the process of claim 1.

3. The process of claim 1, wherein in the hydrating step said non-waxy rice is raised, to a moisture content above about sixty percent.

4. The process of claim 3, wherein the glassifying step is performed by steaming said hydrated rice at substantially atmospheric pressure.

5. The process of claim 4, wherein said step of hydrating comprises soaking said non-waxy rice in excess water.

6. The process of claim 5, wherein said water has a pH in the range between 4.5 to 7.0.

7. The process of claim 1, further comprising the step of first hydrating said non-waxy rice to a moisture content below about sixty percent prior to complete gelatinization thereof.

8. The process of claim 7, wherein the steps of gelatinizing and glassifying are performed by steaming said hydrated rice at a pressure greater than atmospheric pressure.

9. The process of claim 8, wherein said step of hydrating comprises soaking said non-waxy rice in excess water.

10. The process of claim 9, wherein said water has a pH in the range between 4.5 to 7.0.

11. A process for producing cooked and dehydrated rice, comprising: partially gelatinizing and hydrating a selected non-waxy parboiled rice in moderately acidic, hot, excess water, draining said hydrated rice, steaming said drained rice at atmospheric pressure to complete gelatinization and to glassify said rice; quenching said steamed rice in water and drying said quenched rice.

12. A process for producing cooked and dehydrated rice, comprising: soaking raw non-waxy rice in water at a temperature below the gelatinization temperature of said raw rice, draining said soaked rice, steaming said soaked rice at a pressure greater than atmospheric pressure to gelatinize and to glassify said rice, cooling said glassified rice, and drying said cooked rice.

13. A process for producing cooked and dehydrated rice, comprising: soaking non-waxy raw rice in moderately acidic water at a temperature below the gelatinization temperature of said raw rice, steaming said soaked rice at atmospheric pressure to partially gelatinize said raw rice, washing and agitating said steamed rice, draining said washed rice, steaming said drained rice at atmospheric pressure to further partially gelatinize said drained rice, washing with agitation, draining and steaming said steamed rice a plurality of times to complete gelatinization and to glassify said steamed rice, quenching said multiply steamed rice, draining said quenched rice, and thereafter drying said quenched rice.

14. The process of any one of claims 1, 11, 12, 13, 3, 4, 5, 6, 7, 8, 9 or 10, further comprising expanding said glassified and dried rice.

15. An expanded cooked and dehydrated rice produced according to the process of claim 14.Data supplied from the esp@cenet database - Worldwide

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352.

US4677907 - 7/7/1987

APPARATUS FOR PREPARING QUICK COOKING RICE AND VEGETABLES


Inventor(s): WEIBYE BJARNE (NO)

Applicant(s): APOTHEKERNES LAB (NO)


IP Class: A23L1/00; A23L3/00

E Class: A23L1/182; A23B9/02F; A23B9/08; A23B7/005F; A23B7/02D; A23L1/212C; A23L1/216D



Family: US4677907

Abstract:


A continuous process and apparatus for producing quick cooking rice or vegetables are provided. Such rice or vegetables produced according to the present invention require only approximately 3 to 5 minutes swelling time in hot, not boiling, water to prepare for consumption. The rice and vegetables produced by this process are also high in nutrients in that very little removal of starch or other nutrients occur, with consequent minimal water fouling. The process involves contacting rice or vegetable pieces with water or steam until the rice or vegetable pieces are completely gelatinized and then drying the rice or vegetables.Description:



This invention relates to a continuous process and apparatus for producing quick cooking (instant) rice and vegetables. Rice or vegetables produced in accordance with the present invention would require only about five minutes contact in hot, not necessarily boiling, water for swelling to make the rice or vegetables suitable for consumption, while retaining most of the nutritional value in the rice or vegetables.

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Standard milled white rice and vegetables, such as potatoes, carrots, peas, corn and the like generally require about 20 to 35 minutes of cooking in boiling water before consumption. In addition to the long cooking time required for rice and these vegetables, the starch in rice and some of these vegetables is sometimes not entirely gelatinized. In the case of rice and some conventionally prepared vegetables, an undue number of the starch cells in the rice or vegetable may burst to form a viscous, sticky, pasty cooked mass. For these reasons and others, the consumption of rice and certain vegetables has been restricted for many years. Accordingly, considerable effort has been directed towards the production of quick cooking rice and vegetables.

Generally, "quick cooking rice" has been defined as rice that has been hydrated and/or gelatinized to various degrees and dried in such a manner to produce individual kernels for subsequent cooking in boiling or hot water for a short period of time.

An excellent discussion of quick cooking rice is given in RICE CHEMISTRY AND TECHNOLOGY edited by D. F. Houston, published by the American Association of Cereal Chemists, Incorporated, St.

Paul, Minn., Chapter 15, Quick Cooking Rice, Robert L. Roberts, pages 381-399.

Generally most prior art methods of making quick cooking rice involves soaking the rice in water. For example, see U.S. Pat. Nos. 2,438,939; 2,733,147; 3,740,719; and 2,828,209. The soaking technique, however, is time consuming, involves a loss of valuable rice starch and produces a waste water pollution problem. Soaking involves the use of excess water which invariably leads to a dissolving of rice starch into the water which not only lowers the nutritional value of the rice (loss of carbohydrates and calories), but also results in the production of a starchy water effluent which must be disposed.

Another technique used in producing quick cooking rice invoves fissuring the rice and such method is disclosed in various patents including U.S. Pat. No. 3,157,514 and Norwegian Pat. No. 107,170. U.S.

Pat. No. 3,157,514 suffers from the fact that it specifically requires hydrated rice to be used as a raw starting material. Further, U.S. Pat. No. 3,157,514 involves the soaking technique and cooling the rice before drying (a very energy wasteful step). The rice product of U.S. Pat. No. 3,157,514 is not completely gelatinized and thus requires boiling to render the rice suitable for consumption. The rice produced by the method of Norwegian Pat. No. 107,170 is also not completely gelatinized and thus requires boiling in water before consumption.

Still another process to produce quick cooking rice is given in U.S. Pat. No. 2,937,946 which discloses the use of spraying with hot water to gelatinize the rice. This technique requires large amounts of hot water and is thus very energy consuming. Also, the process of U.S. Pat. No. 2,937,946 involves a great deal of time to achieve gelatinization.

Although less attention has been focused on the preparation of quick-cooking vegetables, there has been some progress in this field.

Several patents describe processes for pre-cooking potatoes. Exemplary of these patents are German

Pat. Nos. 743,714 and 833,441; and German Offenlegungsschrifts No. 1,946,129 published Oct. 1,

1970 and 2,856,764 published July 12, 1979; Swiss Pat. No. 590,617; Norwegian Pat. No. 134,683;

United Kingdom Pat. No. 2,008,383; and U.S. Pat. Nos. 3,038,813; 3,410,702 and 3,635,729. The soaking of peas and beans in water prior to cooking is described in U.S. Pat. Nos. 1,813,268;

1,859,279; 3,291,615 and 3,388,998.

The drying of gelatinized rice and vegetables usually places a great strain on the rice of vegetable resulting in the deterioration of its cell walls. The more times rice or the vegetable is dried, the more cell walls are destroyed. The result is that the rice or vegetables loses its capacity to reconstitute and reshape to its original form when soaked in water. Experience shows that for rice and vegetables that are dried several times, the ability to reconstitute is reduced by 40% to 60%. On the other hand, for rice and vegetables which have been dried only once, the ability to absorb water and reshape is reduced only by 5% to 10%. It is therefore important to find a method that provides suitable water absorptivity for sufficiently dried rice and vegetables.

DEFINITIONS

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"Completely gelatinized" as referred to herein means the condition of rice or a vegetable when all of the starch in the rice or vegetable is completely softened and all of the starch in the rice or vegetable is converted in such a manner that the rice or vegetable swells in hot water.

"Cycle" as referred to herein is one water spray followed by one steam spray.

"Discrete pieces" as referred to herein means vegetables in individual, distinct (separate) pieces having a certain size and shape as opposed to mashed vegetables. A discrete piece of potato, for example, would be a slice or cube of potato. No particular shape is necessary.

"Gelatinization" as referred to herein means the condition of rice or a vegetable after it has been treated at a certain temperature in a sufficient amount of moisture such that the starch in the rice or vegetable is softened, structurally broken down and converted in such a manner that the rice or vegetable swells in hot water.

"Moisture" as referred to herein is water, steam or a mixture of water and steam.

"Moisture content" as referred to herein and expressed as a weight percentage is the weight percent of moisture with respect to the total weight of the dry vegetable plus the weight of moisture contained in the vegetable.

"Steam" or "dry steam" as referred to herein is water vapor (in the gaseous phase) which does not contain any particles of water. Steam (dry steam) will experience a rise in temperature when exposed to an increase in heat. Steam which contains water particles is referred to herein as "wet steam".

"Vegetable" as referred to herein means corn and the edible part of any herbaceous plant. The term

"vegetable" includes, but is not limited to leaves such as spinach, cabbage and collards; seeds such as peas, beans and corn; roots such as carrots, beets and turnips; pods such as string beans and okra; tubers such as potatoes; stems such as celery; bulbs such as onions; shoots such as asparagus; sprouts and stalks such as broccoli; and flower clusters such as cauliflower.

"Water" as referred to herein is water in the liquid phase and does notinclude water in the gaseous phase, i.e., steam.


There has now been discovered a process to prepare a quick cooking rice or vegetable in which most of the carbohydrate and nutritional value is retained and in which the structural integrity of the rice or vegetable is maintained. Depending on the nature of the rice or vegetable utilized, the rice or vegetable product made by this new process will have a starch content which is 15% to 20% higher than a corresponding rice or vegetable product made by conventional batch processes. The rice and vegetables prepared by this novel process can be cooked in about three to five minutes by swelling in hot water.

The novel process of this invention is also economical, saves energy, saves time, and produces a minimum of starchy pollutant effluents. This process can also be conducted in a closed chamber, thus avoiding undue contamination of the area in which the rice or vegetable is processed.

The continuous process of the present invention when applied to rice involves the spraying of rice with water and steam, such that the rice is completely gelatinized and attains a moisture content of between about 24 weight percent and about 78 weight percent with a resultant temperature for the gelatinized rice of between about 79 DEG C. and about 100 DEG C. The gelatinized rice is then dried to attain a final moisture content of between about 10 weight percent and about 14 weight percent, with the rice not being agitated to the extent where the rice forms a sticky mass.

The continuous process of the present invention when applied to vegetables involves the spraying of moisture on discrete pieces of a vegetable that contains carbohydrates that can be broken down. If dried vegetables are used, both water and steam are sprayed on the vegetables. If fresh vegetables are utilized, only steam spraying need be employed. The vegetable is sprayed until it attains a moisture content of between about 50 weight percent and about 97 weight percent and a resultant temperature of between about 72 DEG C. and about 110 DEG C. such that the vegetable pieces are completely

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gelatinized. The gelatinized vegetable pieces are then dried to attain a final moisture content of between about 5 weight percent and about 15 weight percent.

For some vegetables, such as very starchy vegetables, it is preferred to avoid agitating the vegetables during spraying to avoid the formation of a sticky mass of vegetable pieces.

The present invention also concerns an apparatus for producing quick cooking rice or vegetables. The apparatus includes a selectively closable chamber. A porous conveyor belt is disposed within the chamber for supporting rice or vegetable pieces. At least one set of nozzles is provided. Each set of nozzles is composed of a water nozzle adjacent a steam nozzle. The nozzles spray water and steam onto the rice or vegetable pieces contained on the conveyor belt. Means are provided for drying the sprayed rice or vegetable pieces.


For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.

FIG. 1 is a sectional view of an embodiment of an apparatus for conducting the continuous quick cooking processes of the present invention.

FIG. 2 is a plot of treating time to obtain complete gelatinization of rice as a function of the weight percentage of moisture in the rice.

FIG. 3 is a sectional view taken along the line 3--3 of FIG. 1 showing the predrying section of the apparatus depicted in FIG. 1.

FIG. 4 is a sectional view taken along the line 4--4 of FIG. 1 showing the gelatinization section of the apparatus depicted in FIG. 1.


When rice is processed according to the present invention, dehulled rice is used. Non-limiting examples of rice that can be utilized in this invention include white rice, brown rice, long grain rice, medium grain rice, short grain rice and parboiled rice.

Although untreated rice can be utilized in the process of this invention, i.e., ordinary dehulled unpreheated rice, it is preferable to use fissured (finely cracked) rice grains. Without wishing to be bound by any particular theory of operability, it is believed that fissuring or causing fine cracks in the rice causes liquid to penetrate the grains quickly. The preferred method of obtaining this fissuring is by preheating the rice. This preheating is preferentially accomplished by contacting the rice with a hot gas, for example, air, oxygen, nitrogen, etc. The extent of preheating to achieve fissuring depends on the rice quality, for example, its starch content. The appropriate amount of preheating to achieve fissuring is empirical and must be determined experimentally. Generally, the temperature of preheating is between about 110 DEG C. and about 150 DEG C., and preferentially, between about 130 DEG C. and about 140 DEG C. The duration of preheating is between about 10 minutes and about 15 minutes, and preferentially between about 11 minutes and about 13 minutes.

Vegetables contain different groups and qualities of carbohydrates, from high molecular weight compounds to low molecular weight compounds. The process of this invention is particularly directed to softening the starchy component of the vegetables; breaking down the higher molecular weight carbohydrates in vegetables to compounds of lower molecular weight and converting vegetables in such a manner that the treated vegetables will swell in hot water.

Without wishing to be bound by any particular theory, it is believed that the breaking down of the higher molecular weight carbohydrates is achieved by activating the natural enzymes present in the raw

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vegetables by applying a certain amount of moisture and heat. The enzymes will then be broken down and disappear, but the process that is initiated may continue by further addition of heat. The starch that is formed in the process may gelatinize because of the influence of the moisture and heat.

Exemplary of the vegetables that can be utilized in the present invention include peeled potatoes, carrots, peas, corn, cauliflower, celery, beans, parsley, cabbage, leek and rutabaga (sweed). With potatoes, it is preferred to use fresh potatoes rather than pre-dried potatoes. Similarly, fresh carrots are preferred for use over dried carrots. Dried peas can be utilized in the same manner as fresh peas, but it is preferred that the dried peas be soaked in water for several hours prior to processing. It is preferred to use fresh corn rather than dried corn in this invention.

The vegetables treated according to the process of this invention are in discrete pieces. Mashed vegetables are not employed. Throughout the method of this invention, the structural integrity, i.e., shape and size, of the vegetable pieces generally remain intact.

For most vegetables, a size of 10 mm.times.10 mm.times.10 mm is generally acceptable for most purposes, whereas 10 mm.times.10 mm.times.30 mm, or 10 mm.times.10 mm.times.60 mm are the most preferred sizes for potatoes. It is mainly the cross-sectional area of the pieces that is the most important factor, as far as the processing time is concerned. Generally, a cross-sectional area of about

100 mm@2 is preferred. Vegetable pieces having cross-sectional areas greater than 100 mm@2 generally require long treatment times and consequently more energy is consumed during processing.

The length of the pieces may be varied within wide limits such as between about 3 mm and about 100 mm. The length of the piece will generally be dictated by the dimension most convenient for cooking and serving. In many instances, a length of about 60 mm is preferred.

The shape of the pieces would depend on the particular vegetable employed. Peas, for example, could be used in their natural state when removed from the pod and corn can be used directly as kernels removed from the corn cob. Potatoes and carrots, on the other hand, would require cutting or slicing into fragments. Vegetables such as potatoes and carrots can be cut into any convenient shape such as a square cut or a cylindrical cut.

Generally, it is not required to fissure (to cause cracks in) the raw vegetables prior to processing them in accordance with the present invention.

The raw vegetables utilized in the present invention preferably are all naturally grown and thus the carbohydrate, protein, and water contents of a particular vegetable may vary according to the place of growing, quality of the vegetable itself, weather conditions during growing, etc. Thus the amount of moisture content attained during complete gelatinization may vary to some extent both for different kinds of vegetables and even for different vegetables of the same kind.

The rice, either untreated or preheated, or vegetable piece are completely gelatinized and a certain predetermined moisture content is imparted thereto by intermittently spraying the rice or vegetable pieces with water and steam. If preheated rice is used, such rice is sprayed while it is still hot.

A controlled amount of water and steam is utilized during spraying in order to completely gelatinize the rice or vegetable pieces.

The moisture content of the rice at complete gelatinization is between about 24 weight percent and about 78 weight percent. It is preferred to achieve a moisture content of between about 52 weight percent and about 73 weight percent, and more preferably to achieve a moisture content of between about 68 weight percent and about 71 weight percent.

This moisture content of the vegetable at complete gelatinization is between about 50 weight percent and about 97 weight percent. It is preferred to achive a moisture content of between about 65 weight percent and about 95 weight percent and more preferred to achieve a moisture content of between about 78 weight percent and about 93 weight percent.

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The resultant temperature for the completely gelatinized rice is between about 79 DEG C. and about

100 DEG C. It is preferred to attain a resultant temperature of the gelatinized rice of between about 87

DEG C. and about 95 DEG C., and more preferred to achieve a resultant temperature of between about

90 DEG C. and about 93 DEG C.

The resultant temperature for the completely gelatinized vegetable is between about 72 DEG C. and about 110 DEG C. It is preferred to attain a resultant temperature of the gelatinized vegetable of between about 80 DEG C. and about 105 DEG C., and more preferred to achieve a resultant temperature between about 85 DEG C. and about 100 DEG C.

The spraying of water and steam onto the rice or vegetable pieces can beperformed at once using wet steam, or with one or more cycles of sprays of water and steam (a cycle consists of one spray of water and one spray of steam) either alternately or simultaneously, with alternate spraying preferred. For rice, each individual spray of water lasts between about 5 seconds and about 40 seconds, preferably between about 10 seconds and about 40 seconds. The temperature of the water utilized is not crucial (it may be hot or cold) anc can be ambient, for example, between about 10 DEG C. and about 20 DEG C. Water such as tap water, distilled water, etc. can be utilized. Also, both hard and soft water can be employed.

When vegetables are sprayed with water and steam, each individual spray of water lasts between about

15 seconds and about 90 seconds, preferably between about 30 seconds and about 60 seconds. The duration of total water spraying is between about 2 minutes and about 20 minutes and preferably between about 2.5 minutes and about 12 minutes. The temperature of the water utilized is not crucial (it may be hot or cold) and can be ambient, for example, between about 10 DEG C. and 20 DEG C. Water such as tap water, distilled water, etc. can be utilized. Also, both hard and soft water can be employed.

The number of cycles of sprays for processing rice according to the present invention, may be between about 3 and about 7. The actual number of cycles of sprays will depend upon the starch content of the rice. Italian rice, for example, has a starch content of between about 85 weight percent and about 87 weight percent and preferably is treated in 5 cycles. American rice, on the other hand, has a starch content of between about 87 weight percent and about 90 weight percent and preferably is treated in 5 or 6 cycles extended spraying and steaming.

The number of cycles of sprays for processing vegetables according to the present invention may be between about 1 and about 12. The actual number of cycles of sprays will depend upon the vegetable processed and more particularly on the starch content of the vegetable. For dried potatoes, it is preferred to use about 10 to 11 cycles of sprays. It is preferred to use 10 cycles of sprays for peas and corn and 5 cycles of sprays for dried carrots.

For fresh vegetables which have a water content by weight of about 75% to 95%, spraying with water is not generally required. Fresh vegetables need generally only be sprayed with steam. Such steam may be sprayed in one cycle for a duration of between about 20 and about 25 minutes.

Steam treating time during spraying is dependent upon the depth of the vegetable layer being contacted. The less the depth, the less treating time required. It must be noted that during steaming of dried vegetables, the depth may increase due to swelling.

The cross-sectional area of the vegetable pieces will also influence the steam treating time. Crosssectional areas greater than 100 mm@2 would require longer treating times.

The spraying of the rice can be accomplished by using alternate separate sprays of water and steam, or with wet steam.

The steam utilized when processing either rice or vegetable pieces should have a pressure of between about 3.8 kg/cm@2 and about 6 kg/cm@2, with a corresponding temperature of between about 135

DEG C. and about 160 DEG C. Each individual spray of steam lasts between about 0.5 minutes and about 4 minutes, and preferably between about 1 minute and about 3 minutes.

A typical scheme for spraying water and steam on rice is as follows: First, water is sprayed onto the rice for between about 10 seconds and about 30 seconds (such as about 15 seconds), followed by a

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steam spray for between about 0.25 minute and about 3 minutes (such as about 2 minutes). This cycle for spraying water and steam onto the rice is repeated up to about 7 cycles, depending on the type of rice utilized, the duration of the sprays, the temperature of the sprays, etc. until the rice is completely gelatinized.

The total contact time during the intermittent spraying of the rice with the steam and water is between about 2 minutes and about 26 minutes, preferably between about 2 minutes and about 20 minutes, and more preferably between about 3 minutes and about 17 minutes. It is preferred to conduct the spraying of the rice with water and steam with the rice on a moving perforated bed or belt such that the sprays can contact the rice from either above or below the rice, or both above and below the rice. It is preferred that the rice layer on the belt or bed be between about 3 millimeters and about 10 millimeters, and more preferably between about 5 millimeters and about 7 millimeters in depth. The spraying can be conducted in a closed chamber to avoid contamination.

The rice or vegetable pieces may also be sprayed by using alternate pulses of water, steam and heat. In this instance, the rice or vegetable pieces would be alternately sprayed with water and steam, then heated, then sprayed with water and steam, then heated, and so on for a number of cycles of watersteam spraying and heating.

A typical scheme for spraying water and steam is as follows: first, water is sprayed onto the vegetable for between about 30 seconds and about 60 seconds, followed by a steam spray for between about 0.25 minutes and about 4 minutes such as about 2 minutes. This cycle for spraying water and steam onto the vegetable is repeated a number of times, depending on the type of vegetable utilized, the duration of the sprays, the temperature of the sprays, etc. until the vegetable is substantially completely gelatinized.

The total contact time during the intermittent spraying of the vegetables with the steam and water is approximately between about 5 minutes and about 50 minutes, preferably between about 7 minutes and about 40 minutes, and more preferably between about 8 minutes and about 30 minutes.

It is preferred to carry out the spraying of the rice or vegetable pieces as the rice or vegetable pieces moves on a perforated bed or belt so that the sprays can contact the rice or vegetable pieces from either above or below the rice or vegetable pieces, or both above and below the rice or vegetable pieces.

It is preferred that a vegetable layer on the bed or belt initially be between about 30 mm and about 90 mm high, and more preferably between about 40 mm and about 80 mm in height. When considering the height of the vegetable layer on the bed, one has to weigh the production capacity of the processing equipment against the amount of energy required during processing. Such height would also depend on the kind of vegetable being processed.

The spraying of the rice or vegetable pieces can be conducted in a closed chamber to avoid contamination.

Gelatinization may be carried out to completion while the rice or vegetable pieces are being sprayed. In rare instances, gelatinization may extend to completion to a small extent in a subsequent drying operation. However, it is preferred and contemplated that all of the gelatinization occur during spraying.

The total amount of moisture imparted to the rice or vegetable pieces depends on several variables including the nature and type of the rice or vegetable pieces, the pressure and temperature of the steam, the temperature of the water, the time of treatment (contact time) and the weight and surface area of the rice or vegetable pieces being contacted. The time for obtaining complete gelatinization depends, among other variables, on the rice or vegetable quality, such as, for example, its carbohydrate content.

Steam treating time during spraying is dependent upon the height of the rice layer being contacted. The less the height, the less treating time required. During steaming the rice height may increase due to swelling.

After the spraying the rice with water and steam, with the rice now being completely gelatinized and having a moisture content of between about 24 weight percent and about 78 weight percent, such as

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approximately 70 weight percent, and at a temperature of between about 79 DEG C. and about 100

DEG C., such as approximately 90 DEG C., the rice while still hot, is dried.

After spraying the vegetable with water and steam, with the vegetable now being completely gelatinized and having a moisture content of between about 50 weight percent and 97 weight percent, such as approximately 75 weight percent, and at a temperature of between about 72 DEG C. and about

110 DEG C., such as approximately 90 DEG C.

Such drying can be accomplished by transferring the rice or vegetable pieces on a moving bed to a drying section. It is important that when the rice is handled between the spraying and drying steps that the rice not be stirred or agitated so as to prevent a sticky mass from forming. Avoidance of agitation during the spraying and drying steps may be important for certain vegetables, especially when starchy vegetables are treated.

Agitation would not be such a problem for vegetables such as, for example, carrots, beets and turnips which do not have a relatively high starch content.

During the drying step, the gelatinized rice is reduced to a final moisture content of between about 10 weight percent and about 14 weight percent.

During the drying step, the gelatinized vegetable is reduced to a final moisture content of between about 5 weight percent and about 15 weight percent.

It is preferred that the drying be carried out in two steps namely, a predrying step and a final drying step. For rice, a predrying step involves reducing the moisture content to between about 25 weight percent and about 35 weight percent and a final drying step involves reducing the moisture content to between about 10 weight percent and about 14 weight percent. Thus, a predrying section could be operated at a temperature between about 100 DEG C. and about 140 DEG C. with a duration of drying of between about 2 minutes and about 3 minutes. The final drying section could be operated at a temperature of between about 50 DEG C. and about 70 DEG C. and for a duration of drying of between about 20 minutes and about 30 minutes.

For vegetables, a predrying step involves reducing the vegetable moisture content to between about 20 weight percent and about 30 weight percent and a final drying step involves reducing the moisture content to between about 5 weight percent and about 15 weight percent. Thus, the predrying section is operated at a temperature between about 80 DEG C. and about 140 DEG C. with a duration of drying of between about 5 minutes and about 15 minutes. Predrying can for some vegetables, however, require as much as an hour. It is preferred that predrying be conducted for about 8 minutes. The final drying section is operated at a temperature of between about 50 DEG C. and about 110 DEG C. and for a duration of drying of between about 25 minutes and about 75 minutes, with the preferred duration being about 50 minutes.

Drying of either rice or vegetables can be carried out in any convenient manner such as in a drying tunnel. Methods to conduct this drying include the use of hot air, indirect heat exchangers (steam heat exchangers), microwaves, electric resistance heating, fired heaters, etc. During drying, efforts should be made to avoid case hardening of the rice or vegetable pieces.

If hot air is utilized, the optimum velocity of air during the predrying stage is about 125 meters per minute, with a range of between about 100 and about 140 meters per minute. In the final drying stage, the optimum velocity is about 90 meters per minute with a range of between about 75 and about 110 meters per minute. After drying, the rice or vegetable may pass into a tempering (cooling) section. In the tempering section, cool air at between about 25 DEG C. and about 30 DEG C. can be employed.

After tempering, the finished quick cooking rice or vegetable is then ready to be sent for packing or storage.

Some conventional processes blanch vegetables with steam or water. Blanching a vegetable involves destroying enzymes near the skin. Such enzymes if left intact might adversely effect the quality of the product during subsequent cooking. Blanching also serves to remove traces of foreign matter which

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might detract from the flavor. In the present invention, the attributes of blanching are imparted to the product without blanching being required.

The process of the present invention yields a more nutritional product when fresh, rather than dry, vegetables are used. The amount of starch in the final product using fresh vegetables would be about

20% higher as opposed to utilizing dried vegetables.

Now referring to FIG. 1 in detail in which like parts are designated by like reference numerals, unpreheated or preheated rice or vegetable pieces schematically represented by numeral 10, enter an apparatus 12 for producing quick cooking rice and vegetables via a hopper 14. Arrow 11 shows the entry point. The hopper 14 deposits the rice or vegetable pieces 10 onto a perforated stainless steel conveyor belt 16. The conveyor belt 16 moves on wheels 18, 20. An electric motor 22 connected to a belt 24 drives wheel 20 to turn conveyor belt 16.

While moving on conveyor belt 16, the rice or vegetable pieces 10 are alternately contacted with water from sprayers 26 and steam from sprayers 28 located both above and below the conveyor belt 16 in gelatinizing section 30. In the case of fresh vegetables, only steam sprayers 28 would be utilized. Vent

32 in the upper wall of gelatinizing section 30 allows for the exhaust of steam. Drain 34 in the bottom wall of gelatinizing section 30 allows for water drainage.

After being contacted with water and steam, the rice or vegetable pieces 10 then move into a predryer section 36. Hot air is distributed in the predryer section 30 by gas distributor 38. Vent 40 in the top wall of the drying section 36 allows for the exhaust of hot gases. Drain 42 in the bottom wall of the drying section 36 allows for the discharge of condensate.

After being predried, the rice or vegetable pieces 10 pass through through a hopper 44 and are deposited onto a conveyor belt 46 in a drying tunnel 48. Conveyor belt 46 moves on wheels 50, 52. An electric motor 54 connected to a belt 56 drives wheel 50 to turn the conveyor belt 46. Although not so illustrated, the drying tunnel 48 may include several drying sections with each section heated by a separate source of heat, such as by the illustrated indirect heat exchanger 58. In heat exchanger 58, steam or hot water flows in at 60 and out at 62.

The last section of the drying tunnel 48 is a cooling section 64. The rice or vegetable pieces 10 are discharged from the cooling section 64 at outlet 66. The finished processed quick cooking rice or vegetable 10 is then ready to be transported for packing and/or storage.

FIG. 3 illustrates the predrying section 36 in detail. Ambient air 68 enters an air fan 70 and is directed via conduit 72 to a heater 74, such as, for example, an electric resistance heater or heat exchanger. Hot air from heater 74 is then directed to a distributor 76 via conduit 78. The distributor 76 is disposed under the rice or vegetables 10 on conveyor belt 16.

FIG. 4 illustrates the gelatinization section 30 in detail. Spray nozzles 80, 82 which are disposed above the rice or vegetable pieces 10 on conveyor belt 16 receive water and/or steam via conduit 84. Steam flows into conduit 84 via conduit 86. The flow of steam in conduit 86 is controlled by valve 88. Water flows into conduit 84 via conduit 90. The flow of water in conduit 90 is controlled by valve 92 and is measured by flow device 94. Check valve 96 prevents the steam from conduit 86 entering into water conduit 90.

Spray nozzle 98 which is disposed below the rice or vegetable pieces 10 on conveyor belt 16 receives water and/or steam via conduit 100. Steam flows into conduit 100 via conduit 102. The flow of steam in conduit 102 is controlled by valve 104. Water flows into conduit 100 via conduit 106. The flow of water in conduit 106 is controlled by valve 108 and is measured by flow device 110. Check valve 112 prevents steam from conduit 102 entering into water conduit 106.

With respect to the capacity of the continuous instantizing equipment when vegetables are processed, it is believed that the capacity will be reduced compared to the processing of rice. The reason for this reduction in capacity is that vegetables have a different carbohydrate composition than rice and therefore require longer processing time for obtaining comparable results. Generally, in instantizing

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vegetables, the capacity is reduced by 20% to 30% with respect to rice. For example, the loading on the belt for potatoes or peas is generally 65% to 80% with respect to processing rice.

The present invention is very advantageous in that a superior quick cooking rice or vegetable product is obtainable. The rice or vegetable product produced does not require conventional cooking in boiling water for a long period of time to be suitable for consumption. The rice or vegetable product produced by the present process requires only a few minutes (3 to 5 minutes) swelling time in hot water before it can be served. Furthermore, the rice or vegetable product obtained by the present process is more nutritious than that obtained by prior art processes in that most of the proteins, minerals, fatty materials and starches in the rice or vegetables are retained therein and not lost during processing. In conventional processes where a relatively long cooking time is required, these valuable nutrients dissolve into the cooking water and are lost.

As compared to prior art instant rice or vegetable processes, the process of the present invention has the advantages of consuming less time, energy and labor. Also, the present process is less polluting than conventional processes and is more economical to operate.

The invention will now be described in greater detail by reference to the following specific, nonlimiting examples.

EXAMPLES 1-3

A layer of rice supported on a perforated steel bottom of an uninsulated chamber was contacted with wet steam. Such wet steam was sprayed through orifices located both above and beneath the rice bed.

After the rice was sprayed with wet steam, the rice was dried by predrying the hot material at 120 DEG

C. for 1-2 minutes. The rice was then gently turned and after-dried at 60 DEG-65 DEG C. for about 10-

30 minutes. To prevent formation of a sticky mass, excess water had to be quickly removed. To accomplish such drying, high velocity air at about 100 meters/minute was employed. Conditions for

Examples 1-3 are given in Table 1 hereinafter. The results for Examples 1-3 were good. In each example, the rice was completely gelatinized.

Determination of the water content of the finished dry rice product was accomplished by using a Sauter balance with an infrared lamp located about the balance pan in a manner well known to those skilled in the art. A 10 gram sample of the rice was measured on the balance and then the lamp was turned on for a period of about 10 minutes. After the 10 minute period, the sample was reweighed and the difference in weight represented the loss of water.

>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; Area of

>;tb; Steam

>;tb; Rice Utilized

>;tb; Rate of Water

>;tb; Total Temp. of

>;tb; Amount of Moisture

>;tb;Ex.

>;tb; Treatment,


>;tb; Mixed With The

>;tb; Duration of

>;tb; Channel,

>;tb; Imparted To

>;tb;No.

>;tb; m@2

>;tb; kg/cm@2

>;tb; Type kg Steam, liter/min.

>;tb; Steaming, min.

>;tb; DEGC.

>;tb; the Rice,

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>;tb;__________________________________________________________________________

>;tb; liters

>;tb;1 0.19 5 3 min.

>;tb; 0.8 0.25 4 92 1.0*

>;tb; rice*

>;tb;2 0.19 5 parboiled

>;tb; 1.1 0.25 10 90 2.5**

>;tb;3 0.30 3.8 3 min.

>;tb; 1.2 via top 6 93 30**

>;tb; rice* orifice: 5

>;tb; via bottom

>;tb; orifice: 10

>;tb;__________________________________________________________________________

>;tb; *"3 min" or "10 min" rice referred to in this Table and elsewhere herein

>;tb; means rice that is heated so it requires 3 minutes (or 10 minutes) boilin

>;tb; time for consumption.

>;tb; **Not including some condensed water from the steam

EXAMPLES 4-15

A pilot apparatus similar in principle to the process equipment depicted in FIG. 1 was utilized in

Examples 4-15. In Examples 4-15, separate sprays of water and steam were sprayed alternately and progressively from separate orifices onto the rice.

In Examples 5-9, the gelatinized rice before drying was found to have a moisture content of between about 65 and 70 weight percent. In Examples 10-12, the moisture content of the rice after gelatinization varied between 62% and 70%. In Examples 13-15, the moisture content of the rice after gelatinization varied between 63% and 70%. Gelatinization conditions for Examples 4-15 are given in Table 2 hereinafter. Table 3 hereinafter gives the predrying and afterdrying conditions and results for Examples

4-15.

In Examples 13-15, untreated rice was used as a starting material, i.e., ordinary, dehulled white rice which was not preheated. Examples 13-15 clearly show that the process of this invention also works well with this type of rice, but the process time is longer and the loss of starchy material is greater.

It was found that the time for obtaining complete gelatinization depends on the rice quality, among other variables. FIG. 2 is a plot of treating time to achieve complete gelatinization as a function of the weight percentage of moisture in the rice. Referring to FIG. 2, the time required from point A to point

B and from point B to point C for various types of rice, providing that a constant temperature is maintained of between about 90 DEG C. and about 93 DEG C., is as follows:

>;tb;______________________________________

>;tb; A to B B to C



>;tb;Rice quality in minutes) in minutes)

>;tb;______________________________________

>;tb;Untreated rice

>;tb; 11 2-3

>;tb;3 minute rice

>;tb; 3 1

>;tb;10 minute rice

>;tb; 6 1

>;tb;Parboiled rice

>;tb; 11 1

>;tb;______________________________________

If the treating time is extended beyond point C, the rice will be destroyed, thus losing its form and consistency.

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The steam treating time is also dependent on the depth of the rice layer on the perforated bed. In

Examples 4-15, the depth was 5 mm, which increased to 25 mm during the gelatinization process. This was due to swelling of the rice grains.

Although rice of any quality may be used in the novel process of this invention, the best results were achieved by using 3 minute rice, since the steam quickly penetrated the outer layer and started the gelatinization in the interior of the rice grain. Three minute rice also required the shortest steaming time. The most chewy and temperature stable product, however, was obtained by using ordinary dehulled white long grain rice which was not preheated.

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb; Area of Steam Pressure,

>;tb; Rice Utilized Rate of Water

>;tb;Example No.

>;tb; Treatment, m@2

>;tb; kg/cm@2

>;tb; Type Amount, kg

>;tb; Utilized, liters/min.

>;tb;__________________________________________________________________________

>;tb; 4* 0.3 3.8 3 min. rice

>;tb; 3.0 5

>;tb; 5 0.3 4.0 3 min. rice

>;tb; 3.0 4.8

>;tb; 6 0.3 4.0 3 min. rice

>;tb; 3.0 4.8

>;tb; 7 0.3 4.0 3 min. rice

>;tb; 3.0 4.8

>;tb; 8 0.3 4.0 3 min. rice

>;tb; 3.0 4.8

>;tb; 9 0.3 4.0 3 min. rice

>;tb; 3.0 4.8

>;tb;10 0.3 4.0 10 min. rice

>;tb; 3.0 4.8

>;tb;11 0.3 4.0 10 min. rice

>;tb; 3.0 4.8

>;tb;12 0.3 4.0 10 min. rice

>;tb; 3.0 4.8


>;tb; 3.0 4.8


>;tb; 3.0 4.8


>;tb; 3.0 4.8

>;tb;__________________________________________________________________________

>;tb;Water Sprays Steam Sprays

>;tb; Total Total

>;tb; Duration of

>;tb; Duration of

>;tb; Duration of

>;tb; Duration of

>;tb; Temp. of

>;tb;Example

>;tb; No. of

>;tb; Each Spray,

>;tb; Spraying,

>;tb; No. of

>;tb; Each Spray,

>;tb; Spraying,

>;tb; Channel

1590/2197

>;tb;No. Sprays

>;tb; min. min. Sprays

>;tb; min. min. DEGC.

>;tb; Gelantinization

>;tb;__________________________________________________________________________

>;tb; 4* 5 1/2 21/2 5 1 5 94 Not completely

>;tb; gelatinized,

>;tb; some crispy

>;tb; fragments

>;tb; 5 5 1/4 11/4 2 1 8 98-100

>;tb; Very Good

>;tb; 3 2

>;tb; 6 5 1/4 11/4 2 1 8 98-100

>;tb; Very Good

>;tb; 3 2

>;tb; 7 5 1/4 11/4 2 1 8 98-100

>;tb; Satisfactory

>;tb; 3 2

>;tb; 8 5 1/4 11/4 2 1 8 98-100

>;tb; Satisfactory

>;tb; 3 2**

>;tb; 9 6 1/4 11/2 2 1 10 98-100


>;tb; 4 2 seemed to go

>;tb; too far

>;tb;10 7 1/4 13/4 2 1 12 98-100

>;tb; Good (5

>;tb; 5 2 sequences

>;tb; were not

>;tb; sufficient)

>;tb;11 5 1/4 11/4 2 1.25 10 98-100

>;tb; Satisfactory

>;tb; 3 2.5

>;tb;12 5 1/4 11/4 2 1.25 10 70-85

>;tb; Not satisfac-

>;tb; 3 2.5 tory - trouble

>;tb; with the steam

>;tb;13 6 1/4 11/2 2 1.25 12.5 98-100

>;tb; Rice was hard

>;tb; 4 2.5 after 5

>;tb; sequences -

>;tb; gelatinization

>;tb; was satisfac- - tory

>;tb; after an

>;tb; additional

>;tb; sequence

>;tb;14 6 1/4 11/2 2 1.25 12.5 98-100

>;tb; Satisfactory

>;tb; 4 2.5

>;tb;15 6 1/4 11/2 2 1.5 15 98-100

>;tb; Satisfactory

>;tb; 4 3

>;tb;__________________________________________________________________________

>;tb; *Amount of water added to the rice was 12.5 liters, not including some

>;tb; condensed water from the steam.

>;tb; **Rice was sprayed with cold water immediately after the last steaming

>;tb; cold water had no effect on gelatinization.

>;tb; TABLE 3

>;tb;__________________________________________________________________________

1591/2197

>;tb;Pre-Drying Conditions

>;tb; After-Drying Conditions

>;tb; Air Air

>;tb;Ex. Velocity,

>;tb; Temp.,

>;tb; Duration,

>;tb; Velocity,

>;tb; Temp.

>;tb; Duration,

>;tb;No. m/min.

>;tb; DEGC.

>;tb; min. m/min.

>;tb; DEGC.

>;tb; min. Results

>;tb;__________________________________________________________________________

>;tb; 4 125 114 4 90 55 21 Good results were obtained

>;tb; 5 125 110 11/2 90 53 25 Case hardening had occurred and the

>;tb; grains had a hard

>;tb; shell with a soft kernel.

>;tb; 6 125 100 21/2 90 55 25 The product was not perfectly dry.

>;tb; 7 125 100 21/2 90 55 25 Very good. The rice agglomerates could

>;tb; be broken apart

>;tb; into separate grains very easily. A


>;tb; pared by swelling in hot water for 5

>;tb; minutes. The rice

>;tb; was well cooked and the consistency was

>;tb; nice and soft

>;tb; without any hard fragments in the

>;tb; grains.

>;tb; 8 125 100 3 90 70 25 Very good. Exactly the same result as

>;tb; in Example No. 7.

>;tb; 9 125 110 3 90 70 25 The product was satisfactorily dried

>;tb; and the agglomer-

>;tb; ates were easily broken apart into

>;tb; separate grains. A

>;tb; sample which was prepared for eating by

>;tb; swelling in hot

>;tb; water was too soft. The gelatinization

>;tb; process had gone

>;tb; too far.

>;tb;10 125*

>;tb; 115 3 90 70 25 The product was not satisfactorily

>;tb; dried and the dry-

>;tb; ing had to continue for another 3

>;tb; minutes. Still, the

>;tb; product was not as dry as desired and

>;tb; it was almost

>;tb; completely impossible to break up the

>;tb; agglomerates.

>;tb;11 125 108 3 90 70 25 Very good. The rice agglomerates could

>;tb; easily be

>;tb; broken apart to single grains. A sample

>;tb; was prepared

>;tb; for eating by swelling in hot water for

>;tb; 5 minutes.

>;tb; The grains had a firm and nice

>;tb; consistency without any

>;tb; hard zones and were more chewy than

1592/2197

>;tb; that from "3 minute

>;tb; rice". This is the way this kind of

>;tb; rice should be.

>;tb;12 125 110 2 90 70 26 The product was satisfactorily dry but

>;tb; the grains had

>;tb; crispy zones because of unsatisfactory

>;tb; gelatinization.

>;tb;13 125 110 2 90 70 26 Although the product was not perfectly

>;tb; dry, the result

>;tb; was promising.

>;tb;14 125 120 2 90 70 30 The product was sufficiently dry and

>;tb; the rice agglomer-

>;tb; ates could easily be broken apart. A


>;tb; pared for eating by swelling the rice

>;tb; in hot water for

>;tb; 5 minutes. The grains had some crispy

>;tb; zones which in-

>;tb; dicated that the gelatinization process

>;tb; was not completed.

>;tb;15 125 108 2 90 70 30 The product was satisfactorily dry and

>;tb; the aggolomer-

>;tb; ates could quite easily be broken up. A

>;tb; sample was

>;tb; prepared for eating by swelling in hot

>;tb; water for 5

>;tb; minutes. The rice was firm and nice and

>;tb; probably still

>;tb; more chewy than that from the "10

>;tb; minute rice". The

>;tb; result was very good.

>;tb;__________________________________________________________________________

>;tb; *Rice was sprayed with water before drying

EXAMPLES 16-29

Examples 16-20 were directed to carrots; Examples 21-26 were directed to potatoes; Examples 27-28 were directed to green peas; and Example 29 was directed to corn.

Some examples were specifically directed to treating dried vegetables, such as dried carrots (Examples

16-19), dried potatoes (Examples 21-22), dried green peas (Examples 27-28) and dried corn (Example

29). Other examples were specifically directed to the treatment of fresh vegetables such as fresh carrots

(Example 20) and fresh potatoes (Examples 23-26).

The dried treated vegetables were cut into 10 mm.times.10 mm.times.10 mm pieces. Prior to treating, the fresh potatoes and carrots were washed, cleaned, peeled and mechanically cut in pieces of 8 mm.times.8 mm.times.3 mm, or 10 mm.times.10 mm.times.10 mm.

In Examples 16-29, the raw vegetable material was loaded on a perforated steel belt and conveyed through a channel where it passed several alternating zones for water spraying and steaming. The cycles varied between 4 and 6 (the broadest range of cycles was 1 to 12) depending on the quality and type of material. Fresh vegetables were not sprayed with water, only with steam, as they naturally contain 75%-90% moisture. The dried green peas were soaked in water overnight before they were processed in the above-described apparatus. The reason for soaking the peas was to save time, capacity and energy in the process. If the soaking had been omitted, the process probably required about 10 to

15 water/steam cycles.

After the vegetables had been satisfactory gelatinized, they were directly and continuously conveyed to drying sections in a drying channel. There the vegetables passed through zones for predrying, final

1593/2197

drying and cooling. At the end of each experiment, the vegetables were reconstituted (cooked) by soaking them for 3 to 5 minutes in hot water which previously had been heated to boiling and removed from a hot plate.

Determination of the water content of the finished dry vegetable product was accomplished by using a

Sauter balance with an infrared lamp located above the balance pan in a manner well known to those skilled in the art. A 10 gram sample of the vegetable was measured on the balance and then the lamp was turned on for a period of about 10 minutes. After the 10 minute period, the sample was reweighed and the difference in weight represented the loss of water.

The main parameters in the processing apparatus were as follows:

>;tb;______________________________________

>;tb;Pressure in the gelatinizing/

>;tb; Atmospheric

>;tb;drying channel

>;tb;Temperature in the steam

>;tb; 100 DEG C.

>;tb;channel

>;tb;Pressure in the steam tube

>;tb; 6 kg/cm@2

>;tb;Rate of cold water spraying

>;tb; 5 liters/min.

>;tb;Diameter of the holes in

>;tb; 2.5 mm

>;tb;the steel belt

>;tb;Velocity of the air during predrying

>;tb; 125 m/min.

>;tb;maximum range 100-140 m/min.

>;tb;Velocity of the air during final drying

>;tb; 90 m/min.

>;tb;maximum range 75-100 m/min.

>;tb;______________________________________

The results for Examples 16-29 are given in the description of the individual Examples that follow and in Table 4 following the Examples.

It was found that the vegetable products obtained in this continuous process had a higher nutrition value compared to materials instantized in conventional batchwise methods. Thus, the carbohydrate content was about 15% to 20% higher and the contents of vitamins and minerals were 30% to 50% higher as compared to vegetables produced by conventional processes. Because the process was operated continuously at a relatively high constant temperature, the effluent problem normally associated with prior art processes was negligible. All vegetables prepared in these examples were ready for serving after being soaked in hot water for about 3 to 5 minutes. Besides the very short cooking time necessary to prepare the vegetables according to this invention, the "shelf-life"

(freshness) of the vegetables was superior when compared to conventionally prepared vegetables, no peeling was necessary, no waste occurred and the products weighed less because water was removed which made them easier to transport.

The process was operated at a relatively high temperature to prevent the formation of condensed water which would by the nature of the process contain starchy material. Such starch containing water would in turn cause an effluent disposal problem.

Apart from the peas, the best results were obtained by using fresh raw vegetables, although dried vegetables also gave acceptable results. The fresh raw vegetables had the best visual and organoleptic qualities. The examples support my reasonable belief that this method also can be applied to other kinds of vegetables, such as, for example, celery, cabbage, leak, sweed, parsely, etc. Since these vegetables have almost the same carbohydrate configuration as carrots, they should work well with this invention.

1594/2197

EXAMPLES 16-20 (Carrots)

Examples 16-19

Examples 16-19 concerned the treatment of dried carrots cut in 10 mm.times.10 mm.times.10 mm pieces. Examples 16-19 were directed to treating carrot pieces that were not soaked prior to being treated. After the drying process, the sides of the carrot pieces had a concave and wrinkled appearance.

This drawback was not removed by reconstitution in hot water after the carrots were processed according to the present invention, not even after swelling the carrots in hot water for 30 minutes. The carrot product was not dry after final drying for 30 minutes. The carrot product had a tendency to case harden that prevented the moisture from the interior of the carrot pieces to penetrate and disappear. The taste of the product was not very distinct, but the consistency was fairly good.

In Example 19, dry raw carrots were soaked in water overnight before processing. After soaking, these pieces had a good appearance. Because of the high moisture absorption (the weight had increased by

300%), it was not necessary to spray the carrots with water during the instantizing process. After being dried, the carrots were brittle and reconstitution in hot water for 5 minutes gave a fairly good product that had a better taste than previous products. The pieces still had, however, a wrinkled appearance.

They were not satisfactory. The taste was still weak, but the consistency and color were good.

Example 20

In this example, fresh carrots were used as the raw material. The size of the fresh carrot pieces was 8 mm.times.8 mm.times.3 mm. The processed carrot product had a delicate appearance. After being reconstituted in hot water for about 5 minutes, the carrot product had a very pleasing color and appearance, a good taste and a very good consistency. The result was in fact very good. The weight of the carrots was reduced during the steaming operation. This is always the case with fresh raw materials, because some of the cells rupture and water is pressed out of the material and is lost.

Because of the low content of free starch in carrots, there was no problem with pieces sticking together during drying.

EXAMPLES 21-26 (Potatoes)

Examples 21 and 22 dealt with dried potatoes of size 10 mm.times.10 mm.times.10 mm. The processed product had an excellent taste after being swelled in hot water for 5 minutes, but the appearance was not satisfactory. In spite of the fact that extra water was added during the gelatinization process, the pieces were still wrinkled.

Example 21

The processed potato product when reconstituted in hot water for 5 minutes had some hard pieces, some of which had brown spots due to too intense heat during drying.

Example 22

The reconstituted potato product was better than the product of Example 21, but the appearance was not good enough.

Examples 23-26

Examples 23-26 concerned the treatment of fresh potatoes. In preparing this material, the potatoes were washed, peeled and mechanically cut into pieces of two different sizes, namely, 8 mm.times.8 mm.times.3 mm and 10 mm.times.10 mm.times.10 mm. Ready prepared raw potatoes which would not be processed at once were stored by covering the potatoes with water to prevent the effect of the

Maillard reaction (browning reaction). Because of their high content of free starch, the potatoes had a greater tendency to cling together in the drying process than the carrots. This tendency was considerably reduced by spraying the material with cold water between gelatination and drying. The potato pieces still stuck together but they were very easy to separate. The potato product had a light and

1595/2197

delicate appearance and was ready for serving after being soaked in hot water for 5 minutes. Taste, color, appearance and consistency were excellent. The potatoes of both sizes gave the same good result.

In Example 23, fresh raw potatoes of a cut size of 8 mm.times.8 mm.times.3 mm were used. After soaking the processed potatoes in hot water for 5 minutes, the product was ready for serving. The potatoes had a light, delicate appearance and a fine consistency. No brown spots were observed.

In Example 24, fresh potatoes were cut into pieces of 10 mm.times.10 mm.times.10 mm. The gelatinized potatoes were predried for 6 minutes in hot air (at 80 DEG C.) of high velocity to prevent case hardening. Some of the processed potato pieces turned brown due to extending the final drying too long. However, a very good potato product was obtained after the potato pieces were swelled in hot water for 3 minutes. The appearance, taste and consistency of most pieces were generally excellent.

Example 25 involved ascertaining the effect of cold water spraying between steaming and drying. The dried potato pieces still stuck together after a cold water spray, but were easy to separate. The result was like that of Example 24.

Fresh raw potatoes of size 8 mm.times.8 mm.times.3 mm were used in Example 26. The gelatinized potato pieces were sprayed with cold water before drying and the ready made product was very easy to separate. Reconstitution in hot water for 3 minutes gave a very delicate product ready for consumption.

EXAMPLES 27-28 (Green Peas)

Examples 27 and 28 concerned treating common air dried green peas. A small test sample showed that it was necessary to soak the peas in cold water overnight before processing. After soaking, the peas were fairly soft, had swelled considerably and their weight had increased by 100%. In spite of the water-soaking, it was necessary to employ water spraying during the gelatinization process. Even though the amount of raw green peas in Example 27 was double the amount in Example 28, it was necessary to apply the same processing time in both examples. A certain puffing effect was obtained both during steaming and predrying. This seemed difficult to avoid if a satisfactory instantized pea product was to be obtained. The peas had no tendency to stick together in the drying process.

The instantized pea products had a delicate appearance. The peas from both Examples 27 and 28 were ready for serving after being swelled in hot water for 3 minutes. The pea products were delicate and had a very good taste, color and consistency. With respect to the required processing time, it seemed important to use peas of about the same size.

EXAMPLE 29 (Corn)

Example 29 was directed to the treatment of corn. In this example, dried corn of popcorn quality was used. An introductory test showed that it would be necessary to soak the raw corn material in water before processing. Therefore, the raw corn was soaked in water for 72 hours, boiled for 2 hours and then soaked in water for another 15 hours before processing. Neither the steaming nor the drying process had any adverse effect on the corn. After reconstituting in hot water, the corn was just as hard as before processing and was generally unchanged in size and shape.

It is believed that if the process would have been employed on fresh corn, satisfactory results would have been obtained. However, fresh corn was not obtainable at the time when this example was performed.

>;tb; TABLE 4

>;tb;__________________________________________________________________________

>;tb; Load On

>;tb; Water

>;tb; Steam-

>;tb; Water Spraying

>;tb; Increase

>;tb; Dried or

>;tb; Steel

1596/2197

>;tb; Spraying

>;tb; ing, Between In Wt.

>;tb;Ex. Fresh Raw

>;tb; Belt,

>;tb; no. .times.

>;tb; no. .times.

>;tb; Gelatin.

>;tb; During

>;tb;No.

>;tb; Vegetable

>;tb; Material

>;tb; kg/m@2

>;tb; min. min. and Drying

>;tb; Gelatin.

>;tb;__________________________________________________________________________

>;tb;16 carrots

>;tb; dried 5 5 .times. 1/2

>;tb; 2 .times. 1

>;tb; Yes

>;tb; 3 .times. 2

>;tb;17 carrots

>;tb; dried 10 5 .times. 1

>;tb; 2 .times. 1

>;tb; No 170%

>;tb; 3 .times. 2

>;tb;18 carrots


>;tb; 2 .times. 1

>;tb; No

>;tb; 3 .times. 2

>;tb;19 carrots

>;tb; dried 44 No 10 .times. 1

>;tb; No 9%

>;tb;20 carrots

>;tb; fresh 41 No 20 .times. 1

>;tb; No -8%

>;tb;21 potatoes


>;tb; 2 .times. 1

>;tb; No 137%

>;tb; 4 .times. 2

>;tb;22 potatoes


>;tb; 2 .times. 1

>;tb; No 212%

>;tb; 9 .times. 2

>;tb;23 potatoes


>;tb; No 6.5%

>;tb;24 potatoes


>;tb; No 0

>;tb;25 potatoes

>;tb; fresh 3.3 No 7 .times. 1

>;tb; Yes 0

>;tb;26 potatoes


>;tb; Yes 0

>;tb;27 green peas

1597/2197


>;tb; 10 .times. 3

>;tb; No 8%

>;tb;28 green peas


>;tb; 10 .times. 3

>;tb; No 8.3%

>;tb;29 corn dried 24.6 10 .times. 1

>;tb; 10 .times. 4

>;tb; No

>;tb;__________________________________________________________________________

>;tb; Height of Material

>;tb; On Steel Belt

>;tb;Predrying Final Drying

>;tb; Humidity After

>;tb;Ex.

>;tb; Temp.

>;tb; Time,

>;tb; P, mm

>;tb; Temp.

>;tb; Time,

>;tb; P, mm

>;tb; in Start,

>;tb; Gelatin.,

>;tb;No.

>;tb; C. DEG

>;tb; mins.

>;tb; H2 O

>;tb; C. DEG

>;tb; mins.

>;tb; H2 O

>;tb; Product

>;tb; mm mm

>;tb;__________________________________________________________________________

>;tb;16 110 4 60 30 26.3%

>;tb;17 110 2 80 25

>;tb;18 120 8 90 25 24.0

>;tb;19 130 8 90 95 50 40 8.9% 70 90

>;tb;20 120 8 140 90 50 40 5.83%

>;tb; 80 90

>;tb;21 120 8 60 85 25 40

>;tb;22 120 8 60 90 45 40 9.5% 35 80

>;tb;23 120 8 80 90 50 40

>;tb;24 80 6 110 75 80 9.3% 75 75

>;tb;25 85 55 100

>;tb;26 80 8 40 80 50 70 7.8% 75 75

>;tb;27 120 8 30 90 50 60 80 80

>;tb;28 120 8 40 90 30 60 2.6% 40 40

>;tb;29 120 5 80 100 45 20

>;tb;__________________________________________________________________________

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1598/2197

1. An apparatus for continuously preparing completely gelatinized rice or vegetable pieces comprising: a selectively closable chamber; a porous conveyor belt disposed for movement through said chamber for supporting the rice or vegetable pieces; at least two sets of nozzles, each said set of nozzles including a water spray adjacent to a steam spray, said sets of nozzles positioned in an opposing relationship on opposite sides of said belt such that said belt passes between a water spray prior to passing between a steam spray during movement thereof and means for controlling the moisture added by said sets of nozzles to the rice or vegetables pieces.

2. An apparatus for continuously producing quick cooking rice or vegetables without first hydrating the rice or vegetable pieces, the apparatus comprising: a selectively closable chamber; a porous conveyor belt disposed within said chamber for supporting the rice or vegetable pieces; an upper series of nozzles and a lower series of nozzles positioned above and below, respectively, and adjacent the belt along the run of the belt, each series of nozzles having at least five sets of alternating water nozzle and steam nozzles positioned such that the rice or vegetable pieces are alternately sprayed with a water spray followed by a steam spray along the conveyor run, the upper series of nozzles being substantially aligned with the lower series of nozzles such that the respective water nozzles and the respective steam nozzles of each series are positioned in an opposing relationship with each other; means to control the amount of moisture added by each set of water and steam nozzles; and means for drying the sprayed rice or vegetables after passing between the series of nozzles.

3. An apparatus for continuously producing quick cooking rice or vegetables without first hydrating the rice or vegetable pieces comprising: a selectively closable chamber, a porous conveyor belt disposed within said chamber for supporting the rice or vegetable pieces, at least one set of nozzles disposed above the belt, each set having a water nozzle adjacent to a steam nozzle for alternately spraying water and steam onto rice or vegetable pieces contained on the conveyor belt, a second set of nozzles disposed below the belt in an opposing relationship with said first mentioned set of nozzles such that rice or vegetable pieces pass between a water spray prior to a steam spray during movement with the belt, and means for drying the sprayed rice or vegetable pieces.Data supplied from the esp@cenet database - Worldwide

1599/2197

353.

US4693900 - 9/15/1987

SHAPED PASTA PRODUCTS


Inventor(s): MOLINARI CLAUDIO (IT)

Applicant(s): UNIMAC SRL (IT)


IP Class: A23L1/16; A23L3/10

E Class: A23L1/16D


Priority Number: IT19840046866 (19840928)

Family: US4693900


Abstract:


Long life pasta shapes suitable for constituting the first course, consisting of portions of pre-cooked, de-aerated, pressed, sterilized and processed alimentary paste. The alimentary paste may be dry, fresh or egg pasta or rice and may be cooked with sauce or flavored according to the typical recipes of the

Italian regions. The shapes are ready to eat as a quick meal after being heated in the oven, grilled or fried.Description:



1. Field of the invention

This invention refers to long life pasta shapes suitable to be preserved for along period of time and which are ready to serve after heating, as a quick meal. In particular, this invention refers to shapes made from fresh or dry alimentary pasta, alimentary egg paste or rice, the pasta or rice are cooked with or without sauce, pre-shaped into single or multiple portions and stored in sealed or non-sealed packs.

2. Description of the prior art

In almost all the countries marked by rapid expansion, both from the point of view of dynamic economic growth, and from the point of view of expansion of tourism and intercultural relations in general, the rhythm of daily life is becoming increasingly more hectic.

In particular, due to very tight traveling schedules required by work, trips organized by tourist agencies and frequent journeys made by the younger populations eager to travel and to see the world keeping expenses as low as possible, the need has arisen for quick, light meals at low prices in a restaurant. In these restaurants, which are now given the name of sandwich bars, "fast food", or even pubs, these meals which are usually eaten at the counter, consist mainly of rolls variously filled with dressed pork products, sandwiches and toasted sandwiches, hot dogs, hamburgers, small pizzas or slices of pizza, savoury pastries, and so on.

1600/2197

Even though these meals give a sufficient number of calories for satisfactory nutrition, they nevertheless have a substantial drawback: with respect to current dietetic studies, they represent diets in which the basic ingredients consist of meat, vegetables, eggs and, in any case, foodstuffs which normally form part of the components of second courses in the known Mediterranean diet.

The basic dish of the Mediterranean diet, which consists of a first course based on pasta is, in fact, missing from the aforesaid diets.


This invention makes it possible to overcome this drawback, in that it provides a first course based on pasta, according to the characteristics of the Mediterranean diet, which has the same nutritional value as the traditional first courses of pasta and can be prepared, served and eaten very quickly and cheaply in the same fast food restaurants mentioned above.

The advantages achieved by means of this invention consist in ensuring an ever-increasing number of customers of a better, more complete, healthier and more well-balanced diet in greater comfort, in the short period of of time that they dedicate to indispensable physiological necessities of eating, and at a limited cost.

According to this invention, the first course consists of shapes of pre-cooked alimentary pasta, with or without sauce, which is de-aerated, pressed, sterilized and subjected to long-life processing.

This invention is described in greater detail hereunder, with reference to a number of particular methods of preparation and some of its packs or forms of preparation or presentation.

To prepare the shapes, first the pasta is cooked and single-portion packs of a pre-established weight are prepared.

The packs are then pressed, sealed, or not sealed, pasteurized and/or thermally sterilized and subjected to long-life treatment by means of deep-freezing and/or refrigeration. Any type of alimentary pasta may be used, such as dry and/or fresh pasta, such as spaghetti, rigatoni, macaroni, noodles, squares and so on, or egg-pasta such as noodles and the like, or also rice.

The alimentary pasta is pre-cooked, preferably in a double-bottomed cooker or steamed, or in special moulds, and mixed in a low-speed blender.

The pre-cooking or boiling should preferably be carried out in a sufficient quantity of water as to be completely absorbed by the pasta, in order to obtain a pre-cooked end product which retains its balanced content of starches intact.

The sauces which are subsequently mixed with the pre-cooked pasta are also subjected to a similar precooking preparation.

The pre-cooked pasta is then mixed with the sauce and placed in molds, preferably of a cylindrical or parallelepipedal shape, subjected to a de-aerating treatment under vacuum for the necessary length of time to obtain its complete de-aeration, and then pressed by means of the action of adjustable-pressure lids fitted on to the said molds; after which the pasta is cooled.

The de-aerating treatment under vacuum serves the purpose of removing all the air trapped between the interspaces of the cooked pasta, in order to obtain layers of product as even as possible and to prevent any changes in the flavour of the products, after a some time, due to undesirable oxidation. Excellent results are already obtained with a treatment of approximately five minutes. When the pre-cooked, flavoured, de-aerated and pressed pasta has cooled down, it is cut into single portions of equal weight, in the form of circular, square or rectangular shapes, or of other shape.

1601/2197

The single portions are then packed, either singly or together with others, in containers for alimentary use, such as bags, trays, cartons and the like for distribution, or can be stored hermetically sealed in vacuum packs.

In addition to the treatment of deep-freezing or pasteurization and refrigeration for long storage life of the packs, the shapes may be submitted to thermal sterilization.

Upon completion of the pre-cooking phase, the subsequent phases described above can be carried out automatically by means of molding machines which carry out the operations of slicing, shaping and pressing in a continuous cycle, under vacuum.

Likewise, the treatment of thermal sterilization and of deep-freezing, or pasteurization with refrigeration, can be carried out in a substantially automatic continuous processing cycle.

The shapes of pasta, thus produced, are ready for use, after reheating in the oven or by grilling.

The pasta packed in shapes can be topped with any known type of sauce, such as for example tomato sauce, meat sauce, herb pesto, cheese and so on, according to all the recipes and variations included in the Italian traditional regional specialities. IN addition, it can be flavoured and/or coloured with spices or concentrated natural flavouring in powder or liquid form. The use of such products facilitates the preparation of shapes which do not require subsequent and more elaborate sauces, as they are flavoured and coloured by means of natural flavourings and spices obtained from concentrates or purees of spinach, carrots, beetroot, onions and the like.

Alternatively, the pasta shapes, obtained as described above, can also be prepared without any flavouring or sauce, leaving the choice to the consumer when the product is eaten.

Another method of preparation comprises the pasta shapes without sauce packed together with packets of sufficient portions of any type of sauce, to be spread on the pasta before it is eaten.

A futher method of preparing the pasta shapes is that of covering them with breadcrumbs or batter, after they have been boiled or pre-cooked and after the sauce, if any, has been added.

These pasta shapes are also subsequently pressed, divided into portions, packed and subjected to thermal sterilization and long-life treatments identical to those described previously.

Before eating, they should preferably be reheated by frying, or in the oven or under the grill.

The pasta shapes produced, packed and stored as hereinbefore described, constitute a nourishing, wholesome, complete and well-balanced first course, as prescribed by the Mediterranean diet.

They can be quickly and easily eaten on any public premises or, thanks to their preparation and packing, can also be retailed by grocery supermarkets, shops or factories, or even by means of automatic or non-automatic dispensers, refrigerators or freezers.Data supplied from the esp@cenet database - Worldwide Claims:


What I claim is:

1. A shaped pasta product produced by cooking said pasta with water to obtain cooked pasta, placing said cooked pasta in a mold, deaerating under vacuum said cooked pasta in said mold to obtain deaerated cooked pasta, compressing said deaerated cooked pasta under vacuum to obtain compressed cooked pasta, cooling said compressed pasta to obtain a product consisting essentially of cooled compressed cooked pasta, cutting said product into portions, packaging said portions to obtain packaged portions, sterilizing said packaged portions, storing said sterilized packaged portions under vacuum condition to prevent oxidation.

2. The pasta product according to claim 1, which is frozen or refrigerated.

1602/2197

3. The pasta product according to claim 1, wherein said pasta after cooking in water is mixed with a sauce or flavoring agents.

4. The pasta product according to claim 1 wherein said pasta is cooked with the quantity of water which is absorbed by said pasta during cooking.

5. The pasta product according to claim 1 wherein said pasta is egg-noodles or spaghetti.

6. The pasta product according to claim 1, wherein said product after cooking is covered with breadcrumbs or batter.Data supplied from the esp@cenet database - Worldwide

1603/2197

354.

US4722851 - 2/2/1988

FLAN-TYPE PUDDING USING CEREAL FLOUR


Inventor(s): KADAN RANJIT S (US); ZIEGLER JR GEORGE M (US)

Applicant(s): US AGRICULTURE (US)


IP Class: A23L1/187

E Class: A23C9/154D2; A23L1/187B



Family: US4722851

Abstract:


A new flan-type pudding using cereal flour to improve human nutrition is disclosed. The flan comprises the following combination of ingredients: Non Fat Dry Milk of from about 10 to 30 g;

Sucrose of from about 10 to 20 g; Carrageanan of from about 0.2 to 1.0 g; Locust Bean gum of from about 0.07 to 0.3 g; Pectin of from about 0.05 to 0.3 g; Tetra Potassium Pyrophosphate of from about

0.1 to 1.0 g; and, Rice Flour of from about 0.5 to 8.0 g.Description:



(1) Field of the Invention

This invention relates to a flan-type puddings.

(2) Description of the Prior Art

Dairy products, particularly milk, have played an important role in human nutrition for centuries. These products have also been the major source of calcium in people of Caucasian background. Of recent date the consumption of dairy products has decreased in persons of middle and elderly age groups which also represents the fastest growing segment of population in developed countries.

Several socioeconomic reasons are responsible for this reduction. Serious health problems exist with this group which is more susceptible to both osteoporosis and hypertension which can result from a deficiency of calcium. Consequently, there exists a critical need for a convenient appealing novel diary food which fits the life style of this rapid growing segment of population.

Flan or custard type dairy desserts (milk pudding) have traditionally been an attractive food for this target population. Old fashion type flan is a moldable fresh dairy product utilizing eggs as a gelling agent. However, modern food technology has developed several ingredients, e.g. carrageenan, gelatin, gums and other stabilizing agents which can replace eggs (hence cholesterol free) for its gelling property. Several examples of such usage are available, but all use milk, sugar, carrageenan (or other stabilizing agent) and sometimes small amounts of pregelatinized or modified starch because

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ungelatinized starch is known to retard the formation of the characteristic smooth egg flan-like gel obtained by these gelling agents. One such typical composition and process for making milk puddings would be found in U.S. Pat. No. 2,808,337.

U.S. Pat. No. 3,250,621 describes frozen glues using an extract of Euchema seaweed as gelling agent, and U.S. Pat. No. 3,443,968 discloses flan-type milk pudding with minimal syneresis, by adding to heated milk carrageenan and phosphates in amounts sufficient to decrease the influence of calcium content of the milk on the carrageenan.

U.S. Pat. No. 3,367,783 teaches that a variety of gel formulations can be improved by using a mixture of locust bean gum and calcium carrageenan for gel formulation.

None of the prior art teaches the use of native or untreated cereal flour for use in egg flan-like food processing or composition of flan-type puddings primarily because it was believed that certain properties in cereal flour would interfere with the gelling mechanism of carrageenan and other stabilizers.


A new flan-type pudding using cereal flour to improve human nutrition is disclosed and comprises the following combination of ingredients: Non Fat Dry Milk of from about 10 to 30 g; Sucrose of from about 10 to 20 g; Carrageenan of from about 0.2 to 1.0 g; Locust Bean gum of from about 0.07 to 0.3 g;

Pectin of from about 0.05 to 0.3 g; Tetra Potassium Pyrophosphate of from about 0.1 to 1.0 g; and,

Rice Flour of from about 0.5 to 8.0 g, is disclosed.

The minor components of rice flour such as proteins, lipids and fiber, etc. in combination with non fat dry milk, carrageenan and other additives of the preferred embodiments contribute an important role in imparting a very desirable flan-like texture to the instant invention. Furthermore, it is the rice flour which adds the nutritional enrichment addition to the flan. This invention represents an important advance in the food industry in view of the fact that previously it was thought that the presence of starch and other components of cereal flour, such as rice flour, would retard the gelling properties of carrageenan which is a necessary gelling ingredient for making flan-type puddings which do not utilize eggs and whole milk.


This invention relates to a new flan-type of pudding which utilizes untreated cereal flour, more specifically rice flour, as an important nutritional enrichment addition to flan. Dehulled rice, for example, brown rice consists typically of 77% carbohydrate, about 7.5% protein, 2% lipids, 1% fiber

(complex carbohydrate), 1.2% ash and 12% moisture. Brown rice is normally further milled or polished to obtain so called white or polished rice. During the milling the lipids, ash and fiber contents are reduced to about 0.5%, however, the protein content is affected (reduced) only slightly. Both brown rice and white rice flours are disclosed in this invention as possessing satisfactory properties for making flan.

Chemically, starch is a carbohydrate and the basic monomeric unit is D-anhydroglucose, and when starch is hydrolyzed with dilute acids it will yield D-glucose. The predominant linkage is the 1,4-alpha glucosidic bond. Two basic types of polymers are present in most starches, amylose and amylopectin.

Both are polymers made up of anhydroglucose units. Amylose is a linear polymer in which essentially all of the anhydroglucose units are linked through 1,4-alpha-glucosidic bonds. It may contain anywhere from about 200 to 2000 anhydroglucose units. Amylopectin, the other polymer in starch, has a highly branched structure. Each branch contains about 15-25 anhydrous units interconnected by linkages attaching carbon 1 of the anhydroglucose unit at the start of the branch to carbon 6. Amylose and amylopectin contents of a starch are known to have different functional properties and hence its food applications. Various food starches have varying amounts of amylose/amylopectin contents. For example, long grain rice flour have about 22-24% amylose with the balance being amylopectin.

Food starches are produced commercially by extraction from the seeds of plants such as corn, wheat, sorghum, and rice or roots such as potato and tapioca. The character of starch will vary with the plant

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source from which it was derived. It can also vary as a result of processing (purification) when extracted from the plant. Most commercial starches are relatively pure, that is, nonstarch components of seed such as lipids, proteins and fiber, etc. are removed during processing and are gelatinized

(cooked) or ungelatinized. Gelatinized starches require little or no cooking and are used in ready to use foods.

Modified starches are either chemically treated or in some cases produced by genetic manipulation of parent seed plants. In this way specified properties are designed into processed food. Obviously, the cost of such food products obtained from modified and gelatinized starches rises considerably as to naturally occurring cereal flour.

Carrageenan is a high molecular weight linear polysaccharide obtained from sea weeds and made up of repeating galactose units linked with alternating alpha 1-3, and beta 1-4 glycosidic linkages. In addition, the galactose units in this general structure often occur as 3,6-anhydro-D-glactose and sulphate esters may also be present on some glactose units. The many sea weed plants approved as sources for extracts which are used in food applications contain various amounts of three types of carrageenan known as kappa, iota and lambda. [The primary differences which influence the properties of carrageenan are numbers and position of the ester sulfate groups on the repeating galactose units.]

Locust bean gum is the refined endosperm of the seed of the carob tree (cerotonia siliqua). Structurally, locust bean is a neutral galactomannan polymer consisting of a main chain of D-mannose units with a side chain of D-glactose on every fourth or fifth unit.

Pectin is a carbohydrate type polymer commonly used in the food, cosmetic and pharmaceutical industry. It is comprised of chains of galacturonic acid units joined by (1-4) glycosidic linkages.

For purposes of this invention rice flour was obtained by grinding polished rice (broken rice from milling) to about 100 mesh size. Whole brown or white rice was also used by grinding to 100 mesh size. These flours were then evaluated by combining with other ingredients necessary to make flan.

EXAMPLE 1

Flan from Non Fat Dry Milk and White Rice Flour

To a beaker, was added the following:

12.6 g Non Fat Dry Milk

14.0 g Sucrose (sugar)

0.49 g Carrageenan (FL 674 P)

[A mixture of various carrageenans obtained from Marrine Colloids]

0.16 g Locust Bean Gum

0.112 g Pectin

0.364 g Tetra Potassium Pyrophosphate

3.44 g Rice Flour (Long Grain)

144 g Water

The mixture was stirred to a homogeneous slurry [Note: (1) all components will not suspend (dissolve) homogeneously at room temperature; (2) the final texture was found to be affected by the total hydration time before heating] and held for 10 minutes. The beaker containing the mixture was transferred into a boiling water bath. The contents were stirred, while heating till it reached 88 DEG C.

It was held in boiling water bath for additional two minutes, while stirring. Then the contents were transferred into a mold and stored at refrigeration temperatures overnight. Next day the finished food product was evaluated by a FMC gel tester and also organoleptically (tasting) for texture and other desirable attributes. The results are shown in Table I.

A very desirable texture, similar to flan made from sweetened milk and beaten eggs was obtained. It had good chewiness, good demolding properties and can be sliced and eaten with a spoon and resembled creamy pudding or desert. Commonly used food colors, and flavors such as citrus (orange), vanilla and butter scotch were added without any problems. This example shows that flans were

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produced using naturally occurring rice flour and non fat dry milk which are as good as older known recipies using eggs and whole milk.

EXAMPLE 2

Flan Utilizing Specially Prepared Starches

All the ingredients were the same as in Example 1, except 0.364 g of Tetra Sodium Pyrophosphate was substituted for Tetro Potassium Pyrophosphate.

The product was very soft, and had poor demolding properties. The textures of demolded samples literally collapsed within 15-30 minutes into a mushy food. This example shows that acceptable flans cannot be produced using a commonly recommended ingredient such as tetra sodium pyrophosphate in combination with rice flour.

EXAMPLE 3

All the ingredients were the same as in Example 1, except 3.44 g of modified starch (H-50) from

National Starch and Chemical Co., P. O. Box 6500, Bridgewater, N.J. 08807 was substituted for long grain rice flour.

The sample had satisfactory texture but collapsed within a few minutes of demolding. This example showed that the rice flour was necessary and could not be substituted by specialized starch.

EXAMPLE 4

All the ingredients were the same as in Example 1, except 3.44 g of modified starch (Thermtex) from

National Starch and Chemical Co., P. O. Box 6500, Bridgewater, N.J., 08807 was substituted for long grain rice flour.

The sample had soft, undesirable texture which collapsed within few minutes of demolding. This example shows the same as Example 3.

EXAMPLE 5

All the ingredients, were the same as in Example 1, except 3.44 g of brown rice flour made from long grain rice was substituted for rice flour.

The texture was comparable to that of Example 1 which was very desirable. The product had brownish color and typical flavor of brown rice. Commonly used food flavors and colors were found compatible.

EXAMPLE 6

All the ingredients were the same as in Example 1, except 14 g of fructose was substituted for sucrose.

The texture improved significantly over that of Example 1 as far as demolding, slicing and spoonability properties were concerned. The taste was considerably sweeter (as expected) than Example 1 but resulted in a very desirable flan.

EXAMPLE 7

All the ingredients were the same as in Example 1, except 14 g of dextrose was substituted for sucrose.

The texture was comparable to the results of Example 5 and (as expected) less sweet than both

Examples 1 and 5. However, a very desirable flan resulted.

EXAMPLE 8

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All the ingredients were the same as in Example 1, except 33.3 g of Iso Sweet 100, (Fructose syrup) containing 42% fructose (remaining about 16% dextrose, 3% complex carbohydrate, and 3% water) obtained from A. E. Staley Manufacturing Co., P. O. Box 151, Decator, Ill. 62525, was substituted for sucrose. The amount of water in Iso Sweet 100 was taken into account so that final product had equal solids to liquid ratio as was in Example 1.

The texture was similar to that of Example 1, however it was found to be smoother and (as expected) sweeter than that of Example 1.

EXAMPLE 9

All the ingredients were the same as in Example 8 except 25.5 g of Iso Sweet 5500, containing 55% fructose, 9% dextrose, 3% complex carbohydrate and 33% water (A. E. Staley Manufacturing Co.) was substituted for Iso Sweet 100.

The texture was similar to that of Example 1, however it was found to be smoother and (as expected) sweeter than that of Example 1.

EXAMPLE 10

All the ingredients were the same as in Example 1, except 140 ml of whole (regular) milk was substituted for non fat dry milk and water.

The demolding, slicing and spoonlike characteristics improved over that of Example 1. The product had creamy, soft and desirable mouth feel. Commonly used food flavors and colors were compatible.

The result was a desirable flan.

EXAMPLE 11

All the ingredients were the same as in Example 1, except 17.75 g of specially prepared mixture containing 71% NFDM, 27.6% milk fat and 1.5% Durlac 100 (Emulsifier, obtained from Durkee

Foods, 900 Union Commerce Bld. Cleveland, Ohio 44115) was substituted for NFDM. The mixture was prepared by suspending appropriate quantities of the mixture in water (13% solids). Durlac 100 and milk fat was heated to melt before addition to the water. The mixture was homogenized in a Gaulin

Laboratory (Type 15 M 8 TA, single piston, two stage) homogenizer at 800 lb (1st stage) and 3000 lb

(2nd stage) pressure and freeze dried to about 4% moisture.

The demolding, slicing and spoonlike characteristics improved over the results of Example 1. The product had creamy, soft and desirable mouth feel. Commonly used food flavors and colors were compatible.

EXAMPLE 12

All the ingredients were the same as in Example 11, except 27.6% Crisco (hydrogenated vegetable oil obtained from Proctor and Gamble, Cincinnati, Ohio, 45202) was substituted for milk fat.

The demolding, slicing and spoonlike characteristics improved that of Example 1. The product had creamy, soft and desirable mouth feel. Commonly used food flavors and colors were compatible.

EXAMPLE 13

All the ingredients were the same as in Example 11, except peanut oil was substituted for milk fat.

The demolding, slicing and spoonlike characteristics improved significantly over that of Example 1.

The product had creamy, soft and desirable mouth feel. Commonly used food flavors and colors were compatible.

>;tb; TABLE I

>;tb;__________________________________________________________________________

>;tb;Texture and Organoleptic Properties of Flan-Like Experimental Foods

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>;tb;FMG GEL TEXTURE

>;tb; Force (grams)

>;tb; Plunger Depth

>;tb; Needed to Break

>;tb; at (cms) the

>;tb; Organoleptic

>;tb;Ex. 1

>;tb; the Gel Break Point

>;tb; Characterization

>;tb;__________________________________________________________________________

>;tb;1 93 0.74 Desirable flan-like texture

>;tb;2 30 0.80 Very soft, mushy undesirable texture

>;tb; 3 57 0.70 Very soft, mushy undesirable texture

>;tb; no clear

>;tb;4 54 break pt

>;tb; 0.76 Very soft, mushy undesirable texture

>;tb;5 90 0.80 Good desirable flan-like texture

>;tb;6 95 0.94 Excellent desirable flan-like texture







>;tb;13 142 1.87 Excellent flan-like texture

>;tb;__________________________________________________________________________

FMC Gel Tester is a specially designed instrument to measure stress/strain curves (and hence the break force of a wide variety of gels). This is accomplished by lowering a plunger (simulated knife at the end) into the gel at a constant rate (accomplished by a synchronous motor). The assembly enables to record both the force required to rupture (break) the gel and indirectly (converted from time into the distance) the distance. A high force indicates firm gel.

A regular flan, made from whole milk, egg and sugar was found to have about 120 to 150 g (force needed to break the gel) and 1.1-1.3 cm depth.

It should be noted that several other oil seeds, such as partially defatted peanut and almonds and regular peanut/almonds also gave very desirable texture, if these products were blended and homogenized as in Example No. 11. The finished product naturally had typical flavor characteristics of starting oil seeds.

Also several frozen fruits, like peaches, strawberries and blue berries could also be added without sacrificing the texture.

>;tb; TABLE II

>;tb;______________________________________

>;tb;POSSIBLE INGREDIENTS FOR FLAN

>;tb; Allowable Preferred

>;tb;Ingredients Range-(g) Range-(g)

>;tb;______________________________________

>;tb;Non Fat Dry Milk (NFDM)

>;tb; 10-30 12.0-14.0

>;tb;Sucrose 10-20 12.0-16.0

>;tb;Fructose 10-20 12.0-16.0

>;tb;Dextrose 10-20 12.0-16.0

>;tb;Iso Sweet 100 (42% Fructose)

>;tb; 23-46 25.0-35.0

>;tb;Iso Sweet 5500 (55% Fructose)

>;tb; 18-35 22.0-30.0

>;tb;Carrageenan (FL 674P)

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>;tb; 0.20-1.0 0.40-0.60

>;tb;Locust Bean Gum 0.07-0.03

>;tb; 0.12-0.20

>;tb;Pectin 0.05-0.3 0.10-0.15

>;tb;Salt (NaCl) To Taste To Taste

>;tb;Tetro Potassium Phosphate

>;tb; 0.1-1.9 0.20-0.50

>;tb;Rice Flour (Whole Brown)

>;tb; 0.5-8.0 2.0-5.0

>;tb;Rice Flour (Brown, White or Brown)

>;tb; 0.5-8.0 2.0-5.0

>;tb;Rice Flour (Whole Polished White)

>;tb; 0.5-8.0 2.0-5.0

>;tb;Water 120-160 120-160

>;tb;Vegetable Oil 1.0-12.0 4-8

>;tb;Peanut Oil 1.0-12.0 4-8

>;tb;Homogenated Oil 1.0-12.0 4-8

>;tb;Milk Fat 1.0-12.0 4-8

>;tb;Whole Milk (instead of water &

>;tb; 120-160 120-160

>;tb;NFDM

>;tb;______________________________________Data supplied from the esp@cenet database -

Worldwide Claims:


We claim:

1. An egg-free flan-type pudding comprising the following composition of ingredients: Non Fat Dry

Milk of from about 10 to 30 g; Sucrose of from about 10 to 20 g; Carrageenan of from about 0.2 to 1.0 g; Locust Bean gum of from about 0.07 to 0.3 g; Pectin of from about 0.05 to 0.3 g; Tetra Potassium

Pyrophosphate of from about 0.1 to 1.0 g; and untreated Rice Flour of from about 0.5 to 8.0 g.

2. The flan of claim 1 wherein the composition comprises the following combination of ingredients:

Non-fat dry milk of from about 12.0 to 14.0 g; Sucrose of from about 12.0 to 16.0 g; Carrageenan of from about 0.40 to 0.6 g; Locust Bean Gum of from about 0.12 to 0.2 g; Pectin of from about 0.10 to

0.15 g; Tetra Potassium Pyrophosphate 0.20 to 0.50 g; and, untreated Rice Flour of from about 2.0 to

5.0 g.

3. The flan of claim 1 including of from about 120-160 g water.

4. The flan of claim 1 wherein the rice flour is selected from the group consisting of brown, polished white, broken and whole rice.

5. The flan of claim 1 including of from about 0.5 to 10 g of oil selected from the group consisting of peanut, vegetable, animal and homogenated oils.

6. The flan of claim 2 including of from about 120-160 g water.

7. In an egg-free flan-type pudding of the type comprising milk and carrageenan as a substitute gelling and stabilizing agent for eggs, the improvement wherein the pudding further contains from 2 to 13% untreated rice flour, wherein said flour essentially is the only starch-containing substance in said pudding, and further wherein said pudding includes tetra potassium pyrophosphate.

8. An instant flan-type pudding as described in claim 7 wherein said milk is nonfat dry milk in amounts of from 47 to 50% of the dry weight of the pudding.

9. An instant flan-type pudding as described in claim 8 which further comprises locust bean gum in amounts of from 0.3 to 0.5% of the dry weight of the pudding.

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10. An instant flan-type pudding as described in claim 9 which further comprises pectin in amounts of from 0.2 to 0.5% of the dry weight of the pudding.

11. An instant flan-type pudding as described in claim 8 which further comprises vegetable or animal oils in amounts of from 2 to 14% of the dry weight of the pudding.Data supplied from the esp@cenet database - Worldwide

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355.

US4734289 - 3/29/1988

FOOD MATERIAL FOR PUFFING


Inventor(s): YAMAGUCHI NORIAKI (JP); SHIBUYA KIYOSHI (JP); KUBO TAKAKO (JP)

Applicant(s): HOUSE FOOD INDUSTRIAL CO (JP)


IP Class: A23L1/18

E Class: A23L1/164; A23L1/18B



Family: KR8903246

Equivalent: JP61199746; GB2173387

Abstract:


This invention provides a food material for puffing, which enables easy and uniform puffing without a special appliance and which has good taste, smell and texture. The food material for puffing comprises pre-gelatinized cereal grain, 0.2 to 11% by weight of ethyl alcohol, 0.25 to 16% by weight of fat and/or oil and if desirable other additives, the water content of said food material being between 5 and 45 weight %. The food material is used as a breakfast food or snack as well as for making rice crackers.Description:




The present invention relates to a food material for puffing, which can be easily puffed by heating, in particular by heating in a microwave oven, so that there can be obtained a puffed food such as a rice cracker.

(2) Description of the Prior Art

Puffed foods such as puffed rice crackers or puffed cereal grains are widely marketed. As a rule, it is necessary to use a special pressure-type appliance for puffing food, and, therefore, it is difficult to puff food at home. However, since selling food in a pre-puffed condition lowers the cost of transportation and puffing the food just before eating gives it better taste, smell and texture, much research has been conducted toward realizing a food material which enables easy puffing at home. For example, Japanese

Patent Pre-examined Publication (KOKAI) No. 12264/1975 discloses a process for preparing a food material cooked by a microwave oven, which comprises kneading and rolling pre-gelatinized cereal grain; dehydrating the grain to a water content of between 13 and 28 weight %; and mixing the resulting solid material with 5 to 30% by weight of fat or oil. In this connection, the publication also discloses that the food material thus obtained easily produces a baked cracker by heating in a microwave oven. However, the food material thus obtained has faults in that the crackers formed of the

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food material adhere to each other when they are heated in a microwave oven, and the degree of puffing is not uniform.

Japanese Patent Pre-examined Publication (KOKAI) No. 136859/1976 further discloses a process for preparing food material for puffing, which comprises drying a rice cake (Japanese MOCHI) until the water content thereof is between 20 and 30 weight %; and adding water thereto before heating it in a microwave so as to increase the surface water content of the dried rice cake 5 to 15 weight % higher than the inner water content thereof. However, this method can neither prevent adherence of the rice cakes to each other nor accomplish uniform and high puffing of the cakes.


Under such circumstances, the present inventors made various studies and found that a food material which can be easily and uniformly puffed into a final puffed food which has good taste, smell and texture, which can be obtained by using pre-gelatinized cereal as a raw cereal grain, combining the pregelatinized cereal with a specific amount of ethyl alcohol and fat or oil, and adjusting the overall water content thereof to within a specific amount.

It is, therefore, a primary object of the present invention to provide a food material for puffing which enables easy and uniform puffing without a special appliance.

Another object of the present invention is to provide a food material for puffing which produces a puffed food having good taste, smell and texture, and which does not result in the pieces of the puffed food adhering to each other when they are heated for puffing.

Another object of the present invention is to provide a food material which enables easy puffing by use of a microwave oven.

These and other objects of this invention will be clear from the following description.

In accordance with the present invention, there is provided a food material for puffing, which comprises pre-gelatinized cereal grain, 0.2 to 11% by weight of ethyl alcohol and 0.25 to 16% by weight of fat and 1 or oil, the water content of said food material being between 5 and 45 weight %.


The pre-gelatinized cereal used in the present invention constitutes the matrix of the food material for puffing. Examples of the pre-gelatinized cereal include pre-gelatined material made from cereal kernels such as glutinous rice, nonglutinous rice and barley; cereal grain flour such as glutinous rice flour, nonglutinous rice flour, wheat flour, barley flour and corn flour; and starch such as corn starch and potato starch. Among these raw materials, for rice crackers, it is preferable to use a raw material such as a pre-gelatinized rice flour or pre-gelatinized starch, because use of such a material gives products good texture. The pre-gelatinizing treatment of the cereal can be conducted by known methods, for example by gelatinizing the starch contained in the cereal by boiling or steaming the cereal, but it is not necessary to gelatinize all the starch in the cereal. In this connection, non-pre-gelatinized starch, i.e., starch itself or cereal grain flour itself, may be used together with the pre-gelatinized cereal, preferably in an amount of not more than 40% by weight of the raw material. Salt, sugar, a seasoning agent and the like can be added to the cereal during pre-gelatinizing treatment.

The aforesaid pre-gelatinized cereal can be used in its natural form, for example, in kernel form, but can also be used in an appropriate shape obtained by molding according to a known method. For example, there can be used rice cakes (Japanese MOCHI) of an appropriate size (1 to 15 mm per side) which are produced according to the following process. Glutinous rice is immersed in water and pregelatinized by steaming, after which it is cut into appropriate size cakes. Alternatively, water is added to rice flour or starch, then kneaded, pre-gelatinized by steaming, molded into a large cake, left to stand until cooled, and thereafter is cut into appropriate size cakes. Furthermore, there can be used cakes molded to an appropriate size by a screw feeder. In this case, for example, a mixture of rice flour, starch and water is pre-gelatinized (pressed, steamed and mixed) in screw feeder and is then molded into the desired shape by the extruder. It is desirable to pre-gelatinize the cereal and mold it, as

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described above, using an extruder, because the drying treatment after molding can be omitted by adjusting the amount of water added, making it possible to reduce the number of steps for preparing the pre-gelatinized cereal. The pre-gelatinized cereal grain can be used in various shapes such as strips, cubes and spheres, but it is preferable to employ a cube- or sphere-like shape since the pieces of pregelatinized grain having such a shape adhere to each other less easily than when they have a flat shape.

As for the size of the pieces of molded cereal, it is preferable to employ comparatively small ones measuring, for example, not more than 15 mm per side, so that uniform puffing can be obtained and the puffing degree becomes high, and as a result, a pre-gelatinized cereal having good texture can be obtained.

The above-described pre-gelatinized cereal used in the present invention preferably has a water content of 8.5 to 45 weight %, more preferably 10 to 28 weight %, so that the overall water content of the food material for puffing will fall within a specific desired range and also so that uniform puffing of the pregelatinized cereal will be assured. This is because the puffing degree of the pre-gelatinized cereal decreases and the resulting products become hard when there is used a pre-gelatinized cereal having a water content of less than 8.5 weight %. On the other hand, when there is used a pre-gelatinized cereal having a water content of more than 45 weight %, the pieces of pre-gelatinized cereal easily adhere to each other upon heating in a microwave oven and also suffer a decrease in the degree of puffing. In addition, it is also desirable to use the pre-gelatinized cereal in an amount accounting for 33.02 to 94.55 weight % of the food material for puffing.

In the present invention, it is necessary to use ethyl alcohol in order to increase the degree of puffing of the pre-gelatinized cereal, to prevent adhesion of the pre-gelatinized cereal kernels to each other and to prevent scorching, as well as to increase storability (prevention of molding and degradation of taste). In this case, either ethyl alcohol itself or an ethyl alcohol containing liquor such as Japanese rice wine

(Japanese sake), brandy or wine can be used. The ethyl alcohol is preferable contained in the food material for puffing in an amount of 0.2 to 11 weight %, more preferably 0.35 to 10.3 weight %, as ethyl alcohol. The effect of preventing adhesion of the pre-gelatinized cereal kernels and of preventing scorching is small and degree of puffing of the pre-gelatinized cereal is insufficient when the ethyl alcohol content is less than 0.2 weight %, whereas it is not preferable to include more than 11% by weight of ethyl alcohol because smell of alcohol is produced during heating and puffing and, at the same time, the degree of puffing decreases. It is also preferable to use a pre-gelatinized cereal having a low water content when an alcohol containing liquor is used in the present invention because water contained in the liquor is absorbed by the pre-gelatinized cereal.

Examples of fat or oil usable in this invention include vegetable oils such as palm oil, rice oil, soybean oil, corn oil and salad oil; processed oil such as shortening, butter and powdered fat; and animal fats such as lard and tallow. Among these fats and oils, it is preferable to use a fat or oil having a melting point near room temperature (from 10 DEG to 25 DEG C.) because this gives a good appearance to the product and makes it easily to charge the product in the packaging container for heating and also makes it easy to take the product out of the container. Fat or oil are used in this invention in order to prevent adhesion of the pre-gelatinized cereal kernels to each other during puffing by heating as well as in storage. It is also used to increase the degree of puffing and to prevent scorching. Fat or oil is therefore added to the food material for puffing at 0.25 to 16 weight %, preferably 0.28 to 15.43 weight %. This is because the above effects cannot be obtained when the amount of fat and oil is less than 0.25 weight

%. On the other hand, when the amount of fat and/or oil is more than 16 weight %, the pre-gelatinized cereal may absorb so much fat and/or oil that the taste thereof becomes oily and the degree of puffing is decreased.

In the food material for puffing of this invention, there can be added, beside the above-described components, many kinds of other components such as emulsifying agents, many kinds of vitamins, animal and vegetable extracts, amino acids, minerals, perfumes, dyestuff etc., according to the desired taste and the product shape. Among these additives, it is preferable to add emulsifying agents, in particular sugar ester having an HLB of not less than 9, in an amount of 0.4 to 2 weight % relative to the total amount of food material for puffing since adhesion of the molded pre-gelatinized cereal kernels to each other can be prevented and the degree of puffing can also be increased by an interaction of the emulsifying agents and the fat and oil.

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The food material for puffing of this invention can be prepared according to any method, but it is preferably prepared according to a method which comprises molding pre-gelatinized cereal kernels or pre-gelatinized cereal to suitable size, pregnating ethyl alcohol into the resulting food material and then coating the surface thereof with fat and oil.

In addition, the water content of the food material for puffing of this invention is adjusted to 5 to 45 weight %, preferably 6.7 to 42 weight %. This process is employed to assure easy puffing and to prevent adhesion of the pre-gelatinized cereal kernels to each other. Accordingly, as described above, it is preferable to use a pre-gelatinized cereal having a water content 13 to 45 weight % and to adjust the water content to the above amount, considering the water content of other additives.

The food material for puffing of this invention can, for example, be sold as packed in a container also containing other related food maerials or as packed by itself with a seasoning agent used therewith being packed in a separate container. It is preferable sold as packed in a container made from a heat resistant material so that it can be puffed by heating in a microwave oven after the lid has been removed. It is also possible to puff the food material with known heat treatments not using a microwave oven.

The present invention will now be illustrated more concretely by referring to the following nonlimitative examples together with comparative examples.

EXAMPLE 1

50 parts by weight of rice cake (Japanese MOCHI; water content of 43 weight %) prepared by a conventional method (glutinous rice.fwdarw.washing.fwdarw.immersion in water.fwdarw.removing water therefrom.fwdarw.steaming and kneadling.fwdarw.molding) were cut into 2.times.8.times.8 mm squares by a cutter, and the squares were dried in a stream of 75 DEG C. air until their water content had fallen to 22.9 weight %. 1.5 part by weight of ethyl alcohol was then added to the resulting rice cake to pregnant it therein, after which 2.5 parts by weight of palm oil, 1 part by weight of salt, 1 part by weight of soy sauce and 1 part by weight of sugar were added thereto and mixed with each other.

The resulting product was packed in a polyethylene bag and sealed, and therefore a product (water content: 20.7 weight %) of the present invention was obtained.

In the next stage, the product was taken out from the bag and was placed in a heat resistant container, after which it was heated in a microwave oven (500 W: 90 seconds). As a result, there was obtained salty puffed crackers (sample C) which did not adhere to each other at all, crackers had good texture.

According to the same process as described above, puffed crackers were prepared by varying the water content of the rice cake and the amounts of ethyl alcohol, fat and oil. As a result, sample product Nos.

A, B and D-K were obtained. The processing conditions and characteristics of the products are summarized in Table 1. In this table, the degree of puffing is shown as the value obtained by dividing the volume of crackers puffed by heating in a microwave oven by the volume of the raw material for the puffed crackers.

>;tb; TABLE - 1

>;tb;__________________________________________________________________________

>;tb;Conditions

>;tb;Water content Amount of

>;tb;of food Amount of

>;tb; ethyl Characteristics

>;tb; material for

>;tb; Water content

>;tb; fat and oil

>;tb; alcohol

>;tb; Degree of

>;tb;Sample

>;tb; puffing of rice cake

>;tb; (parts by

>;tb; (parts by

1615/2197

>;tb; puffing

>;tb; Degree of

>;tb; Scorching and

>;tb;Nos. (%) (%) weight)

>;tb; weight)

>;tb; (times)

>;tb; adhesion

>;tb; color Texture

>;tb;__________________________________________________________________________

>;tb;A* 4.0 4.4 2.5 1.5 1.2 no adhesion

>;tb; much hard

>;tb; scorching

>;tb;B 11.2 12.6 " " 3 " slight slightly hard

>;tb; scorching

>;tb;C 20.7 22.9 " " 9 " uniform

>;tb; crispy

>;tb;D 29.3 31.9 " " 6 " " "

>;tb;E* 46.8 49.9 " " 1.5 much adhesion

>;tb; " bad texture

>;tb;F* 22.6 23.5 0 5 " much slightly hard

>;tb; scorching,

>;tb; not uniform

>;tb; color

>;tb;G 21.3 23.5 2.5 " 8 no adhesion

>;tb; uniform

>;tb; crispy

>;tb;H* 18.1 23.5 10.0 " 5.3 slight " slightly hard

>;tb; adhesion

>;tb;I* 10.3 21.6 2.5 0 6.9 much adhesion

>;tb; much "

>;tb; scorching

>;tb;J 19.6 21.6 " 1.5 10 no adhesion

>;tb; uniform

>;tb; crispy

>;tb;K* 17.5 21.6 " 6.5 5.7 slight " slightly hard

>;tb; adhesion

>;tb;__________________________________________________________________________

>;tb; *Comparative example

EXAMPLE 2

Rice cakes were dried by the same method as described in Example 1 except that rice cakes having the shape of 4 mm cubes were employed. 1.5 part by weight of ethyl alcohol was then added thereto and pregnated therein, after which 2.5 parts by weight of palm oil, 2.2 parts by weight of white sugar and

0.5 part by weight of salt were added thereto and mixed with each other. As a result, a food material

(water content 17.5%) for puffing of this invention was obtained.

A sweet type--rice cracker having good texture was obtained by puffing the above food material according to the same method as described in Example 1.

EXAMPLE 3

78% of wheat flour, 18.5% of potato starch and 3.5% of a seasoning agent were used as raw materials.

Water was added to these materials and then subjected to steaming, kneading, rolling and drying in air, after which the resulting material was cut into 30.times.11.times.1 mm pieces. The cut material was dried again at a temperature of 80 DEG C. in hot air, whereby it was pre-gelatinized (water content

12.5%). 2 parts by weight of ethyl alcohol were added to 50 parts by weight of the pre-gelatinized cereal and pregnated therein. 2 parts of palm oil were then added and mixed therewith. As a result, a food material (water content: 11.5%) for puffing of this invention was obtained.

1616/2197

The resulting food material was heated for 100 seconds in a microwave oven (500 W) and there was obtained good product the pieces of which did not adhere to each other, were not scorched and were puffed to about 9.3 times to their original volume. The food was found to have a good taste and texture when it was eaten.

EXAMPLE 4

82% of corn flour, 2% of a seasoning agent and 16% of potato starch were employed, as raw materials.

In the first stage water and a seasoning agent were added to the corn flour and the mixture then was subjected to steaming and kneading under pressure. Thereafter potato starch was added thereto and the resulting dough was molded into 18.times.12.times.2 mm pieces. In the second stage, pre-gelatinized cereal (water content: 9%) was obtained by drying the pieces with hot air. 2.5 parts by weight of ethyl alcohol were added to 50 parts by weight of the pre-gelatinized cereal and pregnated therein. 2.5 parts by weight of palm oil were then added thereto and mixed in. As a result, a food material (water content:

8.2%) for puffing was obtained.

The resulting food material was heated by the same method as described inExample 3 and there was obtained a good food the pieces of which did not adhere to each other, were not scorched and were puffed to about 5.6 times to their original volume. The food was found to have a good taste and texture when it was eaten.

As described above, according to the present invention there can be obtained a food material for puffing, which enables easy and uniform puffing without a special appliance and which has good taste, smell and texture. In addition, there can be provided a food comprised of pieces of molded pregelatinized cereal which do not adhere to each other, which do not easily scorch when puffed by heating and which exhibit long-term storability. Accordingly, puffed food having a good taste can be obtained by only heating for 1 to 2 minutes in a microwave oven. At the same time, there can be enjoyed the taste of a home-made food.

Since the food material for puffing of the present invention has the characteristics described above, the food material is ideal as a breakfast food or snack, and can be widely used for making rice crackers such as Japanese Okaki. Furthermore, the food material is useful as an instant food (a light quickly prepared food) packed in a packaging container on the assumption that it will be puffed by heating in a microwave oven.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A process for preparing a food material for puffing containing 33.02 to 94.55% by weight of pregelatinized material selected from the group consisting of cereal grains, flours and starches; 0.2 to 11% by weight of ethyl alcohol and 0.25 to 16% by weight of edible fat, oil or mixtures thereof, the water content of said food material ranging between 5 and 45% by weight, which comprises the steps of: impregnating said pre-gelatinized material having a predetermined water content with said ethyl alcohol; and coating the material obtained with said edible fat, oil or mixture thereof, whereby pieces of said product do not adhere to each other upon puffing.Data supplied from the esp@cenet database -

Worldwide

1617/2197

356.

US4735819 - 4/5/1988

REDUCED CALORIE SASUAGE CONTAINING COOKED RICE


Inventor(s): JOHNSON GERALD R (US); JONES MILO C (US); JONES JR EDWARD C (US)

Applicant(s): JONES DAIRY FARM INC (US)


IP Class: A23L1/317

E Class: A23L1/314B4



Family: CA1281587

Abstract:


A sausage is disclosed which is reduced in calories by replacement of a portion of the fat with rice.Description:


This invention relates to a food product in the form of an improved substitute for conventional high fat sausage, and a method of making said product.


Historically, sausage has tended to contain the maximum amount of allowable fat permitted by regulation. For example, as recently as 15 or 20 years ago, the bulk of the pork sausage, beef sausage, and breakfast sausage manufactured tended to contain the maximum amount of fat allowable under

United States Department of Agriculture (USDA) regulations, generally about 50% by weight of the total sausage weight. In recent years, however, consumer tastes and dietary interests have been changing and meat products with less fat content have become more popular and increasingly demanded in the marketplace. Contributing toward the interest in lower fat meat products has been a growing body of scientific research indicating that excessive human consumption of fat, particularly animal fat, is a significant health hazard.

However, in the case of sausage products, it has been found that a substantial reduction of fat content causes the sausage to become tough, dry, less sweet, less succulent, and distinctly less palatable. For example, pork, beef, or breakfast sausage made from red meat having a fat content below about 35% is considered less palatable due to dryness and chewiness. This unpalatability is confirmed by scientifically conducted taste panels and published trade literature.

In addition to simply increasing the percentage of lean, there have also been efforts to reduce the amount of fat in sausage by including non-meat additives while still attempting to maintain a similar sausage flavor and appearance. One such example is U.S. Pat. No. 3,748,148, issued to Jehle, which discloses the use of admixing granules of Brazil nuts with the meat as a substitute for the fat that has been removed from the meat. According to the patentee, the Brazil nuts are suitable as a substitute for the animal fat in sausage because of their neutral taste, their higher vegetable content, smaller content

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of carbohydrates and neutral color. The Brazil nuts in Jehle cannot, however, be expected to provide the textural qualities of the high fat sausage substitute produced according to the present invention.

Another representative attempt at reducing the amount of fat in sausage is disclosed in U.S. Pat. No.

4,504,515, issued to Hohenester. This patent discloses a process for preparing low-fat meat products which precomminute major quantities of lean meat selected from the group consisting of beef, veal, pork and hare, then thoroughly admixing the meat with minor quantities of skimmed milk or whole milk in the presence of less than 5% by weight of seasonings and/or preservatives. The milk in

Hohenester cannot, however, be expected to provide the textural qualities of the more coarsely ground high fat sausage substitute produced according to the present invention.

In recent years attempts have also been made to fill the market demand for low-fat sausage with various poultry breakfast sausages, such as turkey breakfast sausage. While poultry is generally lower in fat than pork and beef, the poultry sausage currently available on the market is very dry and lacking in juiciness and succulence.

Another attempt in the mid-1970's proposed a sausage made with a high percent of lean meat which resulted in approximately 30% fat content. This product was commercially unsuccessful.

There is also a particular variation of boudin, a blood sausage originating in France, that contains rice.

It is produced by first grinding and cooking the meat before it is combined with the rice. The resulting composition is a soft, mushy, pudding-like texture with no resemblance to the high fat sausage substitute of this invention. Further, in boudin the rice is texturally and visually a clearly identifiable component which is in sharp contrast to the food product of this invention in which the rice, at least to the eye and taste of the lay observer, is indistinguishable from the fat.

Another class of sausage products includes the use of non-meat extenders. Originally such extenders were ingredients like bread crumbs and cereal which were simply mixed with higher cost ground meat to lower the cost of the recipe or product. Subsequently, sausage makers developed various milk and cereal derivatives which performed such additional functions as aiding the absorption of fat and the absorption of added moisture to increase finishing cooking yield; adding certain protein values to the sausage to improve the emulsion stability and, in certain cases, imparting a different flavor. The underlying reasons for seeking these additional functions remain principally economic; that is, increasing product yields and lowering product costs.

In the past, rice and meat have been used in the preparation of non-sausage foods. Examples of such non-sausage foods that contain meat and rice (in addition to other ingredients) include jambalaya,

Spanish rice with meat, poultry dressing, and peppers and cabbage leaves stuffed with a mixture of ground beef, rice and other vegetables. These foods use rice simply as part of a multi-vegetable meat mixture and the food neither resembles nor is identified as a sausage. In addition, unlike the high fat sausage substitute produced according to the present invention, the rice in these products is a clearly identifiable component, both texturally and visually.


The invention relates to an improved substitute for conventional high fat sausage in which a substantial portion of the animal fat in the high fat sausage is replaced with lean meat and rice. It has been found that the present invention produces a high fat sausage substitute having the widely accepted characteristics of texture, taste and appearance associated with conventional high fat sausage. In addition, the high fat sausage substitute produced according to the preferred method of the present invention has, as contrasted to the USDA pork sausage standard, 60% less fat, 45% less calories, 35% more protein, and a cooking yield 35% higher than conventional high fat sausage.

According to the present invention, when the high fat sausage substitute is a pork, beef or breakfast sausage, the ingredient formulation by weight for the meat portion is lean meat in the amount of between about 40% to 90%, fat in the amount of between about 5% to 35%, rice in the amount of between about 2% to 35%, salt in an amount sufficient to extract the myosin, that is, up to 4% of the weight of the meat-rice mixture, and a bonding agent, which bonding agent may be myosin, or myosin and one or more substances. High fat pork sausage substitute and high fat beef sausage substitute as

1619/2197

used herein refers to single species products that in addition to pork or beef may also contain water, sugar, dextrose, salt, spices and curing agents. Additional ingredients may include flavorings, flavor enhancers, antioxidants or typical extenders including cereal, textured vegetable protein (TVP) and dried milk.

High fat breakfast sausage substitute as used herein refers to a product containing the meat from one or more animal species and which may also include the non-meat ingredients listed above for pork and beef sausage substitutes.

In the present invention, the rice, which is an integral part of the product, binds with the meat portion of the formulation to provide the texture, taste and appearance of the substituted fat. It has been found that the rice provides a moist, fat-like character and structure which does not affect the basic meat flavors associated with the traditional higher fat sausage. In this manner, the rice and lean combination replaces a major portion of the fat and imparts an equally pleasing and palatable texture and mouth feel in a low fat product which, without the addition of the rice, would be tougher, drier, chewier, and distinctly less palatable.

While the above ingredients are preferred, the present invention contemplates varying the types of animal species, the fat/lean ratio, the meat/rice ratio, and the addition of other ingredients typically or sometimes used in sausage including, but not limited to, salt, spices, herbs, water, sugar, dextrose, flavorings, flavor enhancers, textured vegetable protein, antioxidants and curing agents. In addition it has been found that the aforementioned and other similar non-meat ingredients can be added to the high fat sausage substitute produced according to the present invention in similar proportions as they are used in conventional sausage without affecting the utility of the present invention. It has been found that the food product of the present invention can be adapted to all the forms, shapes, and processes typically associated with high fat sausage.


The method of producing high fat sausage substitute according to the present invention comprises, in general, the following steps.

A mixture of meat, containing both lean and fat, and rice is formed in the presence of a bonding agent in an amount and manner to form a matrix around and among the lean, fat and rice components of the base mixture. Salt is added, if needed, to this base mixture in an amount sufficient to assist the extraction of myosin from the meat. The bonding agent may be myosin, or myosin plus one or more recognized bonding agents such as hydrocolloids, egg albumin, gelatin, flours, starch, or collagen. The quantity of salt added may be anywhere from 0 to 4%. It will be understood that no salt need be added in those instances when there is sufficient salt already present in the base mixture to perform the desired function of assisting the extraction of myosin. Experience has shown that about 3-4% salt is the maximum upper tolerable limit of salt for human palatability.

Both the aforementioned bonding agents and salt may be considered to be additives. Other additives which may be added as desired are flavorings. (such as onions, garlic, celery, parsley, oleo resin spice extracts, and paprika), spices (such as pepper, sage ginger, thyme, marjoram, fennel), seasoning, water, anti-oxidants (such as butylated hydroxy anisole (BHA), butylated hydroxy toluene (BHT), citric acid, propylgallate), extenders (such as cereals, cereal derivatives, textured vegetable protein, milk derivatives), flavor enhancers (such as MSG, hydrolyzed plant and/or vegetable protein, autolyzed yeast extract), sweeteners (such as natural or artificial sugar, dextrose, synthetic sweeteners such as cyclamates), coloring agents (such as paprika, dyes), smoke, curing agents (such as sodium nitrite alone or in combination with sodium erythorbate, or sodium ascorbate) and vitamins. It will be noted that some substances fall under two or more of the above classes of additives, such as paprika.

Rice may be prepared in a wide variety of ways including hydrating, parboiling or cooking. It is preferred that precooked dried rice be the starting form of rice, with water being added in a proportion of about three parts of water to one part of rice, by weight, to rehydrate the rice prior to addition to the meat.

1620/2197

One of the outstanding features of the product is that the final rice content, regardless of the cooking or hydration method, is indistinguishable from fat globules; that is, only the extremely practiced eye and palate can discern the difference between an individual rice particle and a fat globule in both an uncooked and cooked condition. For all practical purposes, the rice and fat are indistinguishable to the consumer in the specified ranges.

A number of samples of the food product of this invention were prepared generally as follows.

First, water which may vary between approximately 32 DEG F. and boiling is added to rice. The rice is preferably dried, precooked rice, such as Minute Rice sold by General Foods, Riviana Instant Rice sold by Riviana Foods, Inc. or Uncle Ben's Precooked Rice. The ratio of the weight of the water to the weight of the rice when using precooked rice is preferably approximately 3 parts of water to 1 part of rice. The water and rice mixture should preferably remain in a 28 DEG F. cooler for 24 to 48 hours.

Although precooked Minute Rice and Riviana Rice have been successfully used in the production of the subject products, it is believed that other forms of cooked and rehydrated rice may also be used.

In the next step, boneless meat, at a temperature of between about 23 DEG F. to 102 DEG F., and having a fat percentage of between 4% to 35% is added to the rehydrated rice. The percent by weight of the meat to the total weight of the high fat sausage substitute may vary between 65% to 98% and the percent by weight of the rehydrated rice to the total of the high fat sausage substitute may vary between

2% to 35%.

In the next step, the boneless meat and rice are coarse ground through a large-hole plate to begin myosin extraction from the meat. This step may also be accomplished by chopping rather than grinding. The rice can be added to the meat either prior to coarse grinding or chopping, or after the meat is coarse ground or chopped.

Next, the meat and rice are blended in a mixer or chopper and the spices, such as salt, sage, black pepper and ginger, are added, although other seasonings and additives could be added as well. The mixing time will vary depending on the equipment that is used, the RPM's, and types of mixing arms or chopper blades, but it is usual for the average time of mixing to be approximately three minutes.

During this step, myosin is further extracted from the meat and the myosin envelops the meat and rice components to achieve the unique result of a traditional sausage flavor, texture, and consistency.

In the next step, the mixture is ground through a small-holed plate which has the effect of further extracting and distributing the myosin. A 9/64-inch plate has been used, although other small-holed plates, such as 1/8-inch, 5/32-inch, 3/16-inch, etc., plates may also be used. The same effect may also be achieved by chopping or a combination of chopping and grinding. If chopping is used, chopping time is dependent on the chopper speed and number and pattern of the blades. Care should be taken during this step to make certain that the rice particles maintain their structural integrity and that they maintain a size generally similar to the meat particles. The average finished composition particle should be preferably from 1/8 to 1/4-inch in particle size. The resulting composition should preferably have a finished temperature of between 36 DEG F. to 42 DEG F., although the temperature range for the product is prerigor meat is used may range between 23 DEG F. to 102 DEG F.

The composition is thereafter compacted and processed as a conventional sausage, either precooked or uncooked. The cooked or uncooked sausage may take any conventional form, including tubes or rolls and links in casings. Alternatively, the produce may be cooked or formed raw (with the casings peeled after the product is formed or cooked), or it may be extruded into skinless links or patties, or it may be processed as patties sliced or cleaved from a product that had been stuffed in a casing, or it may be formed into bulk sausage.

While the above methods and procedures are preferred, the equipment can be varied by using a variety of grinding plate sizes and/or grinding and/or chopping cycles and sequences consistent with the manufacture of conventionally manufactured sausage.

The high fat sausage substitute may then be cooked by the consumer by any of the conventional cooking methods.

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Several examples of varying ingredients and methods of formulation of compositions within the scope of the invention are as follows. All percentages are based on the total weight of only the meat and rice components of the mixture, except Example 7 which included the addition of free water. Further, hydrated cooked rice, which had been reformulated on the basis of three parts of water to one part of rice, by weight, was used unless otherwise noted as in Example 7.

EXAMPLE 1

The following ingredient formulation by weight percentages was prepared. In this example the finished product will have a finished fat level of approximately 20%.

>;tb;______________________________________

>;tb; 70.0% lean pork

>;tb; 19.8% pork fat

>;tb; 10.2% hydrated cooked rice

>;tb; 100.0%

>;tb;______________________________________

Meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and the cooked rice having an internal temperature of 40 DEG F. was added to the conveyorized scale with the meat.

The hydrated cooked rice was prepared in the following manner: Minute Rice and water were weighed

(25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 24 hours. Both the meat and rice were then ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces to begin the myosin extraction. The product was then conveyed to a mixer/grinder where the seasonings consisting of salt, sage, black pepper and ginger were added. The product was then mixed for three minutes causing further extraction of the myosin from the meat and a blending of the meat with the rice. The resulting composition was then ground through a 9/64-inch plate and the resulting temperature of the composition was 40 DEG F.

Portions of the composition were stuffed and linked in both natural and collagen casings, using a stuffer and linker. Another portion of the composition was stuffed into cellulose casings, using a stuffer and an automatic linker, and then cooked using a smokehouse. The cellulose casings were then peeled from the fully cooked links, some of which were also prebrowned. Additional portions of the composition were stuffed into plastic film tubing and fibrous casing and then formed as consumer sized tube packages (rolls) and also as longer sticks. Some of these tube packages were fully cooked. Some of the longer sticks were sliced as uncooked patties, and some sticks were cooked and then sliced as precooked patties, some of which were prebrowned. The equipment used for this was a forming and packaging machine, cleaver, and cooker. Another portion of the composition was extruded into skinless links, some of which were packed immediately in boxes and some fully cooked in a counter flow oven thereby producing precooked links, some of which were also prebrowned. Additional portions of the composition were stuffed and linked into both natural and collagen casings, using a stuffer and linker, and fully cooked in a counterflow oven producing precooked links, some of which were also prebrowned. Another portion of the composition was extruded into patties, a portion of the patties being cooked in a counterflow oven to produce a fully cooked patty, some of which were also prebrowned.

EXAMPLE 2

>;tb;______________________________________

>;tb; 66.9% lean beef

>;tb; 19.7% beef fat


>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was added to a six-bladed chopper. The chopper at low speed reduced the particle size to approximately 11/2 to 2-inch pieces in three bowl turns. The hydrated cooked rice having an internal temperature of 36 DEG F. was added to the meat and the seasonings consisting of salt, sugar, sage, black pepper and ginger were added to the meat. The hydrated cooked rice was formulated in the same manner as in Example 1, except that it was held for a

1622/2197

period of 48 hours prior to being formulated into the product. The product was then mixed in the chopper for 30 low speed bowl turns causing a further extraction of myosin from the meat, and a blending of the meat with the cooked rice. Thereafter the product was conveyed to a grinder and the finished product was ground through a 9/64-inch plate. The finished temperature of the product was 39

DEG F.

Portions of the composition may be stuffed and linked in both natural and collagen casings, using a stuffer and linker. Another portion of the composition may be stuffed into cellulose casings, using a stuffer and an automatic linker, and then cooked using a smokehouse. The cellulose casings may then be peeled from the fully cooked links, some of which may also be prebrowned. Additional portions of the composition may be stuffed into plastic film tubing and fibrous casing and then formed as consumer sized tube packages (rolls) and also as longer sticks. Some of these tube packages may be fully cooked. Some of the longer sticks may be sliced as uncooked patties, and some sticks may be cooked and then sliced as precooked patties, some of which may be prebrowned. The equipment used for this may be a forming and packaging machine, cleaver, and cooker. Another portion of the composition may be extruded into skinless links, some of which may be packed immediately in boxes and some may be fully cooked in a counter flow oven thereby producing precooked links, some of which may be also prebrowned. Additional portions of the composition may be stuffed and linked into both natural and collagen casings, using a stuffer and linker, and fully cooked in a counterflow oven to produce precooked links, some of which may also be prebrowned. Another portion of the composition may be extruded into patties, a portion of the patties being cooked in a counterflow oven to produce a fully cooked patty, some of which may also be prebrowned.

EXAMPLE 3

The following ingredient formulation by weight percentage was prepared:

>;tb;______________________________________



>;tb; 7.4% pork fat

>;tb; 9.3% beef fat


>;tb; 100.0%

>;tb;______________________________________

The meats having an internal temperature of 37 DEG F. were added to a conveyorized scale with hydrated cooked rice prepared in the same manner as in Example 1 having a temperature of 35 DEG F.

(The rice was held in a 28 DEG F. cooler for 72 hours.) The composition was then conveyed through a coarse grinder and the materials were ground through a one-inch plate and the product was conveyed to a mixer/grinder. The product was then mixed for two minutes during which time the myosin was further extracted from the meat. Spices consisting of salt, sugar, dextrose, sage, black pepper and ginger were added. The product was then final ground through a 5/32-inch plate and the temperature of the resulting composition was 41 DEG F. Thereafter the product may be processed in a manner similar to the processing described in Example 2.

EXAMPLE 4


>;tb;______________________________________

>;tb; 45.0% boneless turkey


>;tb; 9.0% pork fat


>;tb; 100.0%

>;tb;______________________________________

The meats (both the turkey and pork had an internal temperature of 34 DEG F.) were placed on a conveyorized scale and the hydrated cooked rice having an internal temperature of 50 DEG F. was added. The hydrated cooked rice was prepared in the same manner as in Example 1, except that it was

1623/2197

held for a period of 25 hours in a 28 DEG F. cooler. Both the meat materials and rice were conveyed to a coarse grinder and thereafter ground through a four-holed teardrop plate to reduce the particle size of the meat to approximately 11/2 to 2 inch pieces. The product was then conveyed to a mixer/grinder and the seasonings or additives consisting of salt, MSG, sage, black pepper and ginger were added. The product was then mixed for 21/2 minutes causing further extraction of the myosin from the meat and a blending of the meat with the rice. The resulting composition was then final ground through a 3/16inch plate and the resulting temperature of the product was 50 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 5

The following ingredient formulation by weight percentage was prepared to make Italian Sausage:

>;tb;______________________________________




>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and the cooked rice having an internal temperature of 40 DEG F. was added. The hydrated cooked rice was prepared in the following manner: Riviana Rice and water were weighed (25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 25 hours. Both the meat and rice were then conveyed to a grinder and coarse ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces. The product was then conveyed to a mixer/grinder and the seasonings consisting of salt, dextrose, black pepper, fennel and red pepper were added. The product was then mixed for three minutes causing further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The resulting composition was then ground through a 3/16-inch plate and the resulting temperature of the composition was 40 DEG F.

Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 6

The following ingredient formulation by weight percentage was prepared to make Bratwurst:

>;tb;______________________________________



>;tb; 12.4% cooked hydrated rice

>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale with rice.

The hydrated cooked rice was prepared in the following manner: Riviana Rice and water were weighed

(25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 24 hours. Both the meat and rice were then conveyed to a grinder and coarse ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces. The product was then conveyed to a mixer/grinder and the seasonings or additives consisting of salt, dextrose, MSG, sage, black pepper and celery powder were added. The product was then mixed for three minutes causing a further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The resulting composition was then ground through a 5/32-inch plate and the resulting temperature of the composition was 40 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 7


>;tb;______________________________________


1624/2197


>;tb; 3.1% dehydrated cooked rice

>;tb; 9.3% water

>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and rough ground through a four-hole plate. The meat materials were then conveyed to a mixer/grinder and the dehydrated Riviana Rice, water at a temperature of 58 DEG F., and seasonings consisting of salt, sage, black pepper and ginger were added to the mixer. The product was then mixed for four minutes causing further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The product was then final ground through a 5/32-inch plate and the resulting finished product had a temperature of 42 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 8


>;tb;______________________________________

>;tb;70.1% lean pork

>;tb;17.5% pork fat

>;tb;12.4% milled rice cooked from a raw state

>;tb;100.0%

>;tb;______________________________________

The meat having an internal temperature of 37 DEG F. was added to a chopper. The rice was cooked in a steam jacketed kettle with water at a temperature of 190 DEG-200 DEG F., for 15 minutes. After cooking, the rice was rinsed and chilled to a temperature of 45 DEG F. for one hour and then drained.

The meat materials were then reduced in a chopper to approximately 11/2 to 2-inch particles in three bowl turns. The cooked rice and seasonings consisting of salt, dextrose, sage, black pepper and ginger were added to the product and the product was mixed in the chopper for 25 bowl turns causing further myosin extraction and a blending of the meat with the cooked rice. The resulting mixture was then added to a grinder/mixer and the product was final ground using a 9/64-inch plate. Thereafter the product may be processed as earlier described in a manner similar to the processing described in

Example 2.

End products from the foregoing batches were then judged on the basis of texture, flavor, and appearance and all were determined to be acceptable by current commercial standards.

A further series of samples was prepared and subjected to panel testing. Specifically, a modified hedonic rating scale was used. In this method, the standard nine point hedonic rating scale is modified by eliminating the middle category, "neither like nor dislike," leaving eight categories consisting of like extremely, like very much, like moderately, like slightly, dislike slightly, dislike moderately, dislike very much, and dislike extremely. Each category has an assigned numerical value ranging from 8 for like extremely to 1 for dislike extremely.

In the panel testing, each panelist was presented, with respect to the pork base food product, with a control product sample and five sample mixes and asked to rate each of the six samples on the above described modified hedonic scale. The control product had a content of 52% lean pork, 48% pork fat and no rice and is a commercial product which has enjoyed wide acceptance. All samples in all tests had the same seasonings added as existed in the control sample so as to minimize the effect of spices and seasonings. Since no commercially available control product was available for beef, and panelists were confined to ranking the five beef samples against each other.

The compositions of the test samples and the rating thereof are shown in the following table.

>;tb;______________________________________

>;tb;TEST

>;tb;NO. LEAN FAT RICE RATING

>;tb;______________________________________

1625/2197

>;tb;PORK

>;tb; 1. 72 8 20 5.2

>;tb; 2. 90 8 2 6.0

>;tb; 3. 63 35 2 4.6

>;tb; 4. 73 25 2 6.0

>;tb; 5. 71 4 25 4.4

>;tb; 6. 50 25 25 4.2

>;tb; 7. 60 10 30 2.4

>;tb; 8. 55 10 35 3.0

>;tb; 9. 50 10 40 2.4

>;tb;10. 40 10 50 1.8

>;tb;11. 70 25 5 5.0

>;tb;12. 85 10 5 5.8

>;tb;13. 80 15 5 6.0

>;tb;14. 70 10 20 5.6

>;tb;15. 65 15 20 5.4

>;tb;16. 55 25 20 4.0

>;tb;17. 70 20 10 6.2

>;tb;18. 70 20 10 6.2

>;tb;BEEF

>;tb;19. 88 10 2 3.2

>;tb;20. 50 25 25 4.2

>;tb;21. 70 10 20 4.0

>;tb;22. 70 25 5 3.4

>;tb;23. 70 20 10 3.4

>;tb;______________________________________

>;tb; NOTES: Tests Nos. 17, 18 and 23 are approximate, with an accuracy believe

>;tb; to be within plus or minus about 1%. Test No. 18 included a milk powder

>;tb; derivative.

From the above it will be noted that compositions which ranged up to 35% rice, and as little as 4% fat had a rating of 3.0 or above with the variance noted below.

A 3.0 rating is considered to be a commercially acceptable rating on the modified hedonic scale used, though of course a higher rating is preferred. Specifically, on the standard hedonic, a rating of 7.0 is very outstanding (and quite unusual), and a rating in the range of 4.0 up to 7.0 is considered to be commercially acceptable. On the modified hedonic scale used in the above described panel testing, these values translate to 6.0, and 3.0 up to 6.0 respectively.

Compositions which fall within the range of 3.0 and bove are epitomized by test nos. 1-8 and 11-23.

(Test number 7 is considered an aberration since the compositions of test numbers 5, 6 and 20 which had rice contents only 5% lower than the composition of test 7 had a rating of 4.2 or higher, and the composition of test No. 8, which had a rice content 5% higher than that of test number 7, fell into the acceptable range).

Of particular significance is the fact that compositions which had as little as 15% fat or less, such as the compositions of tests 2, 12 and 13 were judged to be acceptable; indeed, excellent since the lowest rating of these three tests was 5.8. It appears that a very minor amount of rice--only 2% in the case of test 2--is sufficient to yield a commercially viable product in combination with heretofore unacceptably small percentages of fat.

It is also apparent that the fat content may be as low as 4% (see, for example, test 5), and a commercially viable product will result. This result appears to be attributable to the substantial quantity of rice present; i.e.: 25% in the composition of test 5.

From the foregoing it appears that fat and rice are to a major degree, interchangeable, though it is not known with certainty if the relationship is precisely proportional. In any event, a broad range of acceptable ingredients is considered to be the following:

Lean--40%-90%

1626/2197

Fat--4%-35%

Rice--2%-35%.

The aforesaid broad range includes several compositions which are at the low end of acceptability, such as the compositions of tests 8, 19, 22 and 23, all of which are in the 3.0-4.0 range.

Using a preferred rating of about 5.0 and above and a substantial fat reduction of approximately 10%

(i.e.: about a 30% decrease from the current minimally acceptable fat content of 35% of the base mixture), it will be noted that the compositions of test numbers 4 and 11-18, at least as to pork, define a rather clearly categorized group. When the compositions of tests 2 and 5 are compared, it will be noted that a relatively small percent increase in the fat content (i.e.: from about 4% in test 5 to 8% in test 2) results in a significant increase in rating. From these facts it is considered that a preferred range has the following nominal compositions:

Preferred

Lean--55-85%

Fat--10-25%

Rice--5-20%

A number of samples were made up to a nominal composition of lean 70%, fat 20%, rice 10%. With respect to pork, the ratings were above 6 which, as mentioned earlier, is the equivalent to 7 on the conventional hedonic scale which is outstanding. The ratings were not as high, with respect to beef, though still acceptable.

Most preferred

Lean--70%

Fat--20%

Rice--10%, all percentages being about .+-.one percent.

A typical panel result for a pork base product is set out in the following table:

>;tb;______________________________________

>;tb;Test Panelist Rating

>;tb;No. % Fat % Rice 0 K S M B Ave.

>;tb;______________________________________

>;tb;Control 48 0 8 6 5 6 8 6.6

>;tb; 2 8 2 7 8 3 7 5 6.0

>;tb; 7 10 30 2 3 2 2 3 2.4

>;tb;15 15 20 6 4 7 6 4 5.4

>;tb;16 25 20 2 5 3 4 6 4.0

>;tb;______________________________________

The panelist rating is in points in the range of 1-8, with 8 being the highest rating.

In all of the foregoing tabulated samples the lean and fat components of the base were substantially uncooked when in initial mixture with the rice. It should also be noted that all tabulated samples except

No. 18 had the same additives as were present in the control sample so that any differences attributable to differences in additives were eliminated or minimized. Further, all samples in the tabulated samples were judged on the basis of texture, flavor, and appearance as were Examples 1-8.

It will be understood that, although specific examples of the invention have been described in detail, modifications can be made within the scope of the invention. Accordingly it is intended that the scope of the invention not be limited to the foregoing disclosure, but only by the scope of the claims when interpreted in light of the relevant prior art.Data supplied from the esp@cenet database - Worldwide

1627/2197

357.

US4741264 - 5/3/1988

RICE BRAN PROCESSING APPARATUS


Inventor(s): MCPEAK DANIEL L (US)

Applicant(s): BRADY INTERNATIONAL INC (US)


IP Class: A23L1/20; A23K1/14; A23K3/00

E Class: A23K1/00B2; A23K1/14C; A23L1/015B; A23L1/10E; B30B11/24E



Family: CN86107712

Abstract:


A rice bran extruder apparatus maintains a continuous flow of bran with appropriate heating to stabilize the bran to prevent information of free fat acid and rancid oil. A supply hopper includes a rotating paddle to stir the bulk bran for continuous gravity feed of the bran into a feed conveyor mounted immediately beneath the hopper. The feed conveyor is aligned with the bran extruder to supply bran to the inlet opening. The extruder includes a flighted rotor and terminates in a conical discharge nozzle.

Extrusion of the bran results in heating of the bran to stabilize the lipase, destroy bacteria and produce a stable bran providing oil and an edible end product. The flighted rotor has closely spaced flighting and at least 12 agitator elements secured between the flights for at least the last four flights to establish a continuous movement of the powdery rice bran through the extruder and positively prevents blow back of the bran. The extruder is directly connected to a universal voltage and frequency motor which operates at 885 RPM and produces 75 horsepower with widely differing A.C. voltages and/or frequencies. A slipping clutch is provided in the direct drive connection to prevent damage if the extruder is overloaded.Description:


BACKGROUND OF THE PRESENT INVENTION

1628/2197

This application relates to a rice processing apparatus engineered to stablize the formation of free fatty acids in rice bran, and thereby, permit the extraction of edible oil and the processing of the remaining defatted rice bran into edible food products.

Rice is the most widely comsumed cereal in the world. Although rice is abundantly grown throughout the world, the processing of the collected rice has created a vast resource which is going to waste. The most nutritious part of the rice is polished off the grain during the milling process. One of the most nutritious foods known to man however starts to become rancid in a matter of minutes after the milling process, rendering it inedible to humans, and after several days, indigestible to animals. As a result, a tremendous demand has been created for an apparatus and a technology to stablize the rice bran, thus allowing the necessry time to: (1) extract the oil, and (2) utilize the remaining defatted rice bran as a high protein, low fat cereal food for human consumption.

The processing method and apparatus should, of course, be such as to maintain the maximum nutrients in the final cereal product, while permitting effective and relatively rapid processing. Further, it is essential that the apparatus and method be adaptable for use in environments of lesser developed countries. Optimally, the unit should be a relatively compact, self-contained unit, engineered and constructed to allow for ease of movement to various remote processing locations. This will permit the processing of the rice bran without the necessity for having to immediately transport the rice bran to a central processing location for stablization and/or extraction. It is also imperative that the equipment be simple to operate and low in cost to permit the economic stbilization of the rice bran without the necessity of making large capital investments.

After the hull is removed from the rice, approximately 6 to 8% of the brown rice kernal is polished, yielding white rice and a by-product, rice bran. During the milling process, lipase, a highly active enzyme, is released. Within minutes, the lipase reacts with oil in the rice bran, resulting in a very rapid hydrolysis of the oil into free fatty acids (F.F.A.) making the bran unfit for human consumption. Within one day, it is no longer economically feasible to extract oil from the rice bran, and after three days, it is no longer possible to use the bran as a feed for animals due to the rancidity of the oil.

Various methods of inhibiting the growth and stabilizing the F.F.A. level in the rice bran is found in the literature, including the heating of the bran product and reference therefore may be made to an article by Williams in the Journal of Oil Chem., Soc. 42, 151 (1965).

Although various bran processing systems have been suggested, the prior art has to the knowledge of the inventor completely failed to include any teaching of an apparatus and/or method for proper processing of rice bran to establish a suitable rice bran product which retains essentially all of the nutrients in a practical, low-cost method and apparatus particularly for use in lesser developed countries.

For example, U.S. Pat. No. 4,465,477 which is entitled "Apparatus for Continuously Extruding and

Drying/Cooling Cereal Bran", issued Aug. 14, 1984, discloses a large and bulky rice bran extruder for treating of bran to stabilize the bran product, and which would be primarily usable in association only with very large white rice processing plants.

Soybean processing equipment has also been developed for heating and processing of raw and untreated soybeans in such a manner as to cook the soybean for removal of a heat libile growth inhibiting material. For example, U.S. Pat. Nos. 3,685,429 and 3,685,430 to McBride and 3,695,891 and 3,765,319 to Fox all similarly disclose soybean processing equipment and methods specifically directed to the treating of raw and unprocessed soybeans by an expression process in which the raw soybean is extruded to heat the soybean. In particular, raw untreated soybeans are passed through the extruder and the soybeans are heated as a result of the extrusion process. As the extruded soybean is released, it emits the libile inhibiting material in the released moisture. The discharge end structure is an adjustable extrusion cone to control termperature and pressure as the soybeans are extruded. Such apparatus cannot be applied to rice bran processing because of different characteristics of rice bran and the generally different considerations encountered in the processing of the products.

SUMMARY OF THE PRESENT INVENTION

1629/2197

The present invention is particularly directed to an improved method and apparatus for heating the milled rice bran to a high nutrient rice bran product for human consumption. Generally in accordance with the teaching of the present invention, the extruding apparatus is specially constructed for use in various remote locations having widely differing electrical power sources. Generally in accordance with the teaching of the present invention, the extruder is formed generally such as taught in the

McBride patents with a rotor having a spiral flight, with the flights formed of round cross-section and permanently affixed to a solid core. The extruder chamber terminates in a discharge cone which is conically shaped. A hopper for receiving the rice bran is mounted above the extruder and includes a rotating stirrer unit driven with a separate D. C. motor. The stirrer unit agitates the bulk bran and positively prevents bridging of the material within the hopper and thereby insures the continuous gravity feed of the bran feed into the conveyor.

A feed conveyor is mounted immediately beneath the hopper, with a feed opening at the inner end of the extruder for controlled feeding of the rice bran to the extruder.

The flighted core extruder is specially formed with a plurality of agitator elements secured between the flights for a substantial distance from the extruder cone. The agitator elements are specially selected and located to establish a continuous pressurized state within the extruder acting to move the powdery rice bran in a forward direction through the extruder and particularly the extruder discharge cone. The extended agitator elements in particular positively prevent steam blow-back as a result of steam pressure created with the heating and compressing the bran from the cone back into the extruder. The inventor has discovered that the characteristics of powdery bran requires significant additional agitator elements located throughout an extended length of the extruder to insure a pressurized feeding over and above that affected by the simple extrusion forces. The compacted rice bran is extruded through the conically shaped discharge cone, where the pressure and heat characteristic is such as to effectively destroy the lipase action and all bacteria, thereby stablizing the rice bran and preventing the build up of free fatty acid. The extruder action does not destroy the nutrients or anti-oxidants present in the rice bran. The final product is suitable for human consumption and is of a particle size to allow efficient extraction of the oil therefrom. The flighting and agitator elements must be specially constructed and arranged to process the powdery bran product because of the characteristic imparted to the bran. Thus, it has been found necessary to provide a relatively closely spaced flighting construction with the oppositely oriented agitator elements to properly process rice bran. Although such a structure cannot be employed with heavier moist material such as soybeans, it has been found essential to the proper processing of rice bran.

Further, the less developed countries require special drive considerations. Thus, service must be maintained at an essential minimum to permit effective long life operation in a system which may be far removed from service personnel and/or parts. The apparatus should also be compact and sufficiently low cost to economically process the available. The rice bran processor is therefor constructed with a direct drive system using a universal voltage and frequency motor coupled directly to the extruder rotor. In an optinum construction, the motor is constructed to operate at 885 RPM and produce 75 horsepower, with widely differing alternating current voltage and/or frequencies which are encountered throughout the world.


The accompanying drawings illustrate the best mode presently contemplated by the inventor(s) for carrying out the invention.

In the drawings:

FIG. 1 is a side elevational view of a rice bran processing apparatus;

FIG. 2 is a side elevational view of a feed auger, rotor and stirrer only;

FIG. 3 is an enlarged vertical section of the drive train, rotor and cylinder; and

FIG. 4 is a fragmentary enlarged view of the bran extruder rotor structure shown in FIGS. 1-3.

1630/2197

DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

Referring to the drawings and particularly to FIGS. 1-3, a rice bran extruder apparatus is illustrated which includes a supporting base structure 1 adapted to be movably mounted on a supporting floor or other structure. The extruder 2 is mounted to the support structure 1. A multi-voltage and multifrequency A. C. (alternating current) motor 3 is secured to the structure 1 in alignment with and coupled to drive the extruder FIG. 1. A bran supply hopper 4 is mounted in overlying relation to the extruder and receives the rice bran 5 for controlled delivery to the extruder. A mechanical feed unit 6, is mounted in the bottom of the hopper and is operable for controlled transfer of the rice bran to an opening 7 between the mechanical feed unit 6 and the outside shell 2a of the extruder 2. A separate D.

C. (direct current) motor 6a is coupled to drive a feed auger 10 of the feed unit 6 and a stirrer 2 in the hopper 4. The feed auger 10 has a large spiral blade to move the powdery bran 5 to the extruder 2. The feed auger may be operated at 175 RPM.

The rice bran is a relatively fine powdery material having the characteristic of flour and when fed into the hopper 4 and feeder 6 for gravity feed, a bridging effect may result within the bottom of the mechanical feed unit 6 such that the bran no longer gravity feeds into the feed auger 2a. The multiple bladed stirrer 2 is mounted in the hopper 4 and rotates continuously at a lower speed than the feed auger to provide continuous stirring of the rice bran 5 during the operation of the feed unit 6 and extruder 2 and thereby to insure continuous gravity feed of the powdery rice bran to the feed auger 2a and thereby to the extruder 2.

In the illustrated embodiment of the invention FIG. 1, a special direct drive coupling 8 connects the special motor 3 to directly drive the extruder 2. Coupling 8 is operable to carry and transmit all anticipated bran extruding loads and thereby maintain an essentially rigid, direct connection of motor to the extruder. The coupling 8 is further specially constructed with a releasable clutch unit 9 that provides automatic slippage at a set amount of torque and thereby disconnects the motor 3 from the extruder 2 in the event of a complete jamming thereby and preventing the motor 3 from being destroyed by overheating.

The combination of the direct drive 8 with the multiple voltage and frequency motor 3 particularly adapts the present construction for essentially universal application throughout the world. The structure is particularly adapted for use in less developed countries where electrical supply is not of the characteristic and quality found in many developed countries and the apparatus may be subject to operation by personnel with minimal skill and knowledge of the machine operation.

The illustrated extruder of FIG. 1 generally includes a basic construction such as heretofore used for processing of rice bran as well as other processing products such as soybeans for other purposes and results, with special modification for more effective processing of rice bran. The illustrated embodiment of the invention is typical of soybean apparatus which has been constructed based on the teachings of the previously identified McBride patents with the structure specially modified as in the construction of the extruder, the releasing drive connection, mechanical feed unit using a D. C. motor, stirrer, hopper and discharge box for processing rice bran. The present inventor has heretofore been involved in construction and analysis of equipment for processing soybeans and it was found tht such apparatus would not provide appropriate processing of rice bran for purposes of stablizing the rice bran.

More particularly as shown in FIG. 1, the extruder 2 includes a cylindrical outer casing or shell 2a horizontally mounted to the support structure 1. The shell 2a is aligned with and extends outwardly from the motor coupling 8 to a discharge chamber 11. The shell 2a is supported on spaced support members 12 to rigidly support the outer shell in coaxial alignment with the motor 3 and the coupling unit 8. The extruder rotor 13 is mounted, as a cantilevered member, within the outer tubular shell 2a and extends therethrough. The rotor 13 is rotatably supported adjacent the motor coupling 8 in an appropriate rotary bearing unit 14 which supports the rotor projecting outwardly concentrically through the shell. The rotor 13 includes a special spiral flight 15 extended throughout the length of the rotor.

The rotor 13 is mounted with the flighting equally spaced between the upper wall and the lower wall of the outer shell 10, as subsequently described.

1631/2197

A processor cone section 16 is attached to the end of rotor 13 in an inwardly facing inclined or conical section located within a correspondingly shaped cup housing 17. The conical sections 16 and 17 define an annular extrusion gap 18.

Generally, the powdery bran 5 is fed by the feed auger 10 into the extruder through opening 7. The spiral flight 15 carries the rice bran 5 forwardly toward the discharge extruder opening 18. The bran 5 cannot move through the restricted opening at the feed rate created by the rotation of the flighted rotor

15 and as a result there is a compression and extrusion of the powdery bran 5. As is well known, this results in heating of the bran. The effective heating of the bran, however, requires that the powdery rice bran be progressively and continuously moved forwardly with a high degree of compression and high force extrusion through the opening 18 in order to properly heat the bran. In the United States for example, the United States Department of Agriculture will require treating of the bran at a temperature of at least 130 degrees Centigrade for stabilization of the bran and the prevention of free fatty acid build up within the bran. In particular, the heat treatment must be such as to effectively nullify the effects of the lipase and destroy all harmful bacteria in the bran. As previously noted, this requires that the rice bran be treated very shortly after milling the rice and at the appropriate temperature.

The present invention is particularly directed to the special construction of the extruding apparatus including the drive system to establish appropriate feeding of the powdery rice bran to an effective and reliable extruding apparatus.

More particularly in the illustrated embodiment of the invention, the motor 3 is a special multiple voltage and multiple frequency motor which can be operated at all voltages and frequencies produced by public utilities and the like throughout the world. The particular motor 3 which has been selected for a practical world wide apparatus is a 75 horsepower motor operating at 885 revolutions per minute

(RPM) and over a wide range of voltages and/or frequencies. The motor 3 may be of any suitable construction which will produce the necessary horsepower and related torque at the relatively low

RPM. Typically, the motor 3 should produce a maximum throuhgout horsepower in the range of 40 to

45 horsepower at a preferred RPM range of 850 to 900 RPM. The motor 3 should produce such a drive for either 50 cycle or 60 cycle power supply and a 230/460 voltage, with the usual practical variants in the nominal specified standards. This is in contrast to the typical prior art approach which used a conventional 100 horsepower motor, with different motors provided for 60 cycle operation and for 50 cycle operation, and operation at 1,770 revolutions per minute. In the prior systems, a gear transmission is connected to reduce the speed of the extruder rotor rotation and increase the torque.

The present invention uses a lower horsepower motor operating at the reduced revolutions and producing the necessary torque to permit direct drive. The direct drive coupling 8 not only adapts the unit to universal application, but significantly increase the efficiency of operation which is, of course, of particular significance for use throughout the world.

The motor shaft 24 is direct coupled to the rotor shaft 41 by the coupling unit 8. The release clutch unit

9 directly connects the universal coupling 7 and the extruder rotor shaft, as more fully developed hereinafter. The coupling 8 includes a motor-connected universal coupling 26, a splined shaft 2, rotorconnect universal coupling 27, and the release clutch 9. The universal coupling 26 includes a flanged yoke 30 which is coupled by bolting to a hub 30a on the motor shaft. The yoke unit 30 includes a splined hub 31 that connects to splined shaft 32.

The universal coupling 27 includes a splined hub 33, slideably mating with splined shaft 32. A yoke 35 has a flange which is bolted or otherwise directly interconnected to a rotating member of the releasable clutch unit 9.

The releasable clutch unit includes a pair of clutch plates 37 and 38 which are located within the rotating housing. Clutch plate 37 is secured to and rotates with housing 36. Clutch plate 38 is rigidly secured to a rotating hub 39.

The clutch plates 37 and 38 are continuously urged into frictional engagement by a Belville spring assembly 40 mounted within the housing 36 and acting on the bearing plates 38 to establish a high load frictional engagement between the plates 37 and 38. The friction forces are such as to readily transmit

1632/2197

the large torque required in the rice bran extruder. In practical application, the static torque strength of the shaft was equal to 22,125 inch pounds and the assembly readily transmitted torque of 443 foot pounds with the motor rotating at 885 RPM.

The clutch unit 9 may be of any suitable construction to produce an operative disconnection in response to a selected abnormal load on the motor. A slipping clutch design is preferred to produce an essentially tamper proof unit. For example, a shear pin coupling could provide protection against jamming loads. Such a coupling would require special replacement of the pin and the user could substitute a stronger shear pin thereby effectively by passing the necessary safety feature. The highly efficient direct drive coupling 8 with the releasably clutch unit provides a very significant advance in a rice bran processor particularly for application in less developed countries.

The extruder rotor shaft 41 is fixed within the hub 39 by a plurality of set screws 42 and plate 38 rotates with the extruder rotor. The drive of the motor 3 is transmitted directly through the yoke units

26 and 27, with the splined connection 25, and the engaged clutch plates 37 and 38.

The rotor 13 is thus direct driven to continuously move the powdery bran material 5 through the extruder and the extrusion gap 18. The constant speed of the rotation of the rotor 13 and the variable size of the gap 18 affects the compression sheet pressure and thereby the heat created in the powdery rice bran 5 at the extrusion cone.

In the illustrated embodiment of the invention, the rotor 13 is mounted for axial movement for varying of gap 18. Referring to FIG. 3, the bearing structure 14 includes a hub 43 threaded into a correspondingly threaded end of the extrusion shell, at 44. A double tapered roller bearing 45 is fixed within the hub and clamped to shaft 41 as by nut 46. The axial threaded movement of the hub 43 correspondingly axially moves the rotor 13. The axial movement of the rotor 13 is accomodated by the splined connection 25 in the direct drive coupling unit 8 as heretofore described. After proper positioning, the hub 43 is locked in place by a mechanical worm gear box 47.

A rotaing sprocket 48 is coupled to the hub 43 at one end by a chain 49 and to a worm gear box 47 at the other end. A hand crank connected to the worm gear box (which may have a 10-1 ratio) is used to axially move the rotor 13 for limited adjustment of the threaded connection of 43 and 44, thereby adjusting the length of the gap 18. The system may therefore be adjusted for proper heating of the powdery bran by the extruder.

The stirrer unit 2 is provided for maintaining the continuous feed of the powdery bran 5 to the feed auger 2a and thereby to the rotor 13. The stirrer unit 2 is shown as a simple paddle-type unit. The stirrer unit 2 includes a support shaft 51 rotatably journalled in mechanical feed unit 6. The shaft 51 protrudes out of the mechanical feed unit 6 and is coupled to the d.c. motor 6a and feed auger 2a using a chain 52 to establish and maintain a continuous and constant speed of the stirrer unit 2 with the feed unit 6. The die motor 6a is connected in circuit to operates simultaneously with the extruder and provides continuous stirring of the powdery bran during the entire bran process cycle. A plurality of axially and circumferentially distributed paddles or blades 53 are secured to the shaft in alignment with the top of the feed auger 2a. The blades 53 are flat radial blades secured preferably on one inch spacings to the shaft 51. The blades 53 may be canted slightly as in the mounting of propeller blades of aircraft to effectively and continuously agitate and break up the bran and thereby insure the gravity movement downwardly into the auger. In actual practice, ten blades 53 were secured to the shaft 51 circumferentially offset and spaced on one inch centers, generally as illustrated in FIGS. 1 and 2.

The extruder rotor 13 has the spiral flight 15 formed with evenly-spaced spiral 180 degree flights having a constant flight angle. The flights 15 are formed from a rod-like member spirally wound about the rotor 13 and tack welded or otherwise firmly affixed to the core. The core may be grooved to receive the rod-like flight member.

Because of the powdery characteristics of rice bran, normal construction of the flighted rotor 13 does not provide the proper transfer and extrusion of the rice bran, particularly without moisture blowback.

The heating and crushing effect is created by the extrusion process on rice bran 5 reducing the bran essentially to a slurry. Pressure builds within the extrusion gap 18 and throughout the shell 10. Further, the moisture in the bran 5 tends to create a back pressure within the shell 10 and may create blow-back

1633/2197

of the powdery bran rearwardly within the shell 10 and back into the hopper 4, and thereby destroy the processing of rice bran 5. The conventional soybean machine which produces excellent soybean processing was found to be practically inoperative for processing rice bran. The inventor has discovered that the problem is simply solved by closely spacing of the flights and by the addition of a substantial number, and at least 12, reverse angled agitator bars 55 secured to the rotor 13 between the adjacent turns of flight 15 in the outer end of the extruder 2. The previously referenced Brady patent discloses the use of a few beater bars at the very discharge end and in one or two of the last flight grooves. The inventor has found that the bars must be substantially extended toward the inlet opening and that a minimum of 12 bars are necessary in the extruder when processing of powdery rice bran.

The agitator bars 55 are small square bar members which are welded to the rotor between the flights.

The agitator bars 55 are angularly oriented, and the bars in the space or grooves between adjacent flights turns are aligned with each to form reverse or oppositely directed flighting extending in an opposite direction and with the extruder forward flighting product capture chambers. The bars 55 are located at essentially 30 degrees to the horizontal and extend substantially from the extrusion opening

18 rearwardly to the feed opening and in particular extend into at least the last four flight grooves as shown in FIG. 4. In an optimum construction, the flights are spaced at substantially four inches. The agitator bars 35 are circumferentially spaced about the rotor in each turn of flight 15, with three to four bars located in circumferential spaced and parallel relation. The bars 55 are spaced only slightly less than the flighting 15 from the shell 2a and serve to force the powdery and the heated bran to move axially through the extruder cone.

The agitator bars 55 serve to appropriately increase the sealing of the heated bran slurry within the shell

10 at the gap 18 and in particular prevent the heated moisture pressure from blowing back through the slurry and the powdery bran 5 in the back portion of the extruder. The special addition of the agitator bars 55 in fact stabilize the relatively light, powdery rice bran prior to its movement into the high temperature area, and assure movement thereof into the area and through the area with sufficient force and compaction to isolate and prevent moisture blow-back.

In processing of soybeans and the like, the raw soybeans are relatively large beans providing a more or less free flow of air and steam through the beans in the feed end of the extruder. The powdery bran and the heated slurry effectively prevents such free flow of the pressurized constitutents and the inventor found that such apparatus would not maintain a flow of the powdery bran. Thus, the pressurized constitutents forced the powdery bran back into the feed system, with a resulting loss of pressure on the slurry in the extruder cone. The present invention provides a continuous flow of the powdery bran through the extruder 2.

The discharge box unit 11 is a simple box structure with an opening in the bottom which is secured directly over the discharge cone of the extruder. A mounting flange 56 abuts the cone and is bolted or otherwise fixedly secured in place. The extruded bran 5 is thus forced and injected into the discharge box 11 and immediately transferred to a low temperature cooler, not shown, for rapid cooling of the stablized bran.

As previously noted, the feed auger 2a is electrically driven with a D.C. motor 6a. The speed of the feed auger 2a is controlled such as by a rheostat, not shown, for adjusting the constant speed of the feed auger 2a. The auger 2a is driven to increase or decrease the input of bran 5 through the opening 7 into the rotor 13.

Various modes of carrying out the invention are contemplated as being within the scope of the following claims, particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A rice bran extruding apparatus for extruding powdery rice bran and thereby heating said rice bran, said heat functioning to inactivate the lipase, destroy the bacteria and stabilize the free acid in said rice bran, comprising an extruder having a tubular shell, a rotor rotatably mounted within said tubular shell, said rotor including a free end protruding outwardly of said shell, said shell and said rotor having

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complementing spaced surfaces defining an extrusion passageway from said shell to the exterior of said shell at said free end of said rotor, an extrusion cone secured to said shell about the free end of said rotor and defining an extrusion passageway, said rotor having a spiral flight including a plurality in excess of four turns and defining a spiral passageway extending backwardly from said extrusion passageway, a plurality of at least twelve agitator bar members secured within the final four spiral turns defined by said spiral flight, said agitator bars being angularly oriented to define a reverse flight construction, said agitator bars being substantially at a smaller angle to the horizontal axis than said flights to extrude the powdery rice bran, an electric motor mounted in alignment with said rotor, a direct drive connection unit connecting said motor to said rotor and establishing a direct one-to-one drive between said motor and said rotor, said rotor being operable to move said rice bran in a continous manner through said shell and said extrusion cone, and a releasable connection unit in said direct drive connection unit and operably disengaging said rotor from said motor in response to a predetermined differential pressure across said connection unit.

2. The bran extruding apparatus of claim 1 wherein said direct drive connection unit includes a splined shaft and a mating splined hub slideably mounted on said splined shaft, said releasable connection unit including a clutch unit having an outer rotatable housing, a clutch plate member mounted to said housing, a second clutch plate member in opposed relation to said first named clutch plate member and having a mounting hub, and resilient spring means biasing said clutch plate members in frictional engagement.

3. The rice bran apparatus of claim 1 wherein said extrusion passageway emits said rice bran in an annular stream, a discharge box unit mounted in overlying relationship to said extrusion cone and directing said extruded stabilized rice bran downwardly thereform, a rapid cooling means coupled to said discharge unit for receiving of said rice bran and providing essentially instantaneous cooling thereof.

4. A rice bran extruding apparatus comprising a high pressure extruder adapted to receive powdery rice bran in one end and to progressively transfer said bran under increasing compression and extruding the bran through a restricted extrusion cone defining an extrusion opening, said powdery rice bran being rapidly raised in temperature to a temperature of at least approximately 130 DEG C. to completely neutralize the lipase and reduce bacterial count to a count of the order of less than 10, a multi-voltage and multi-frequency motor operable over a wide range of frequencies and a wide range of voltages, a direct drive coupling between said motor and said extruder, said extruder having a flighted member rotatably mounted and having an outwardly projected rigid shaft projecting from said extruder, said motor having an integral rigid driven motor shaft, said direct drive coupling including a slip clutch mechanism having a torque transmitting characteristic in excess of all normal torque created by extrusion of bran from said extrusion cone, whereby said direct drive operates to continuously extrude bran, said slip clutch means being responsive to abnormal loads on said flighted rotor to operatively disengage the rotor from said motor and permit operation of the motor without rotation of said flighted member.

5. The apparatus of claim 4 wherein said motor produces 75 horsepower rotating at 885 revolutions per minute.

6. The apparatus of claim 4 wherein said flighted member includes a center core having a core shaft extending from one end, said direct drive coupling includes a splined shaft and a hub coupling mounted on said splined shaft, said splined shaft and said splined hub each being connected to said motor shaft and to said core shaft whereby said core shaft may be axially positioned relative to said motor shaft, and means coupled to said rotor shaft for axially moving of said rotor and setting the size of said extrusion opening and thereby the temperature of said rice bran, said heat functioning to inactivate the lipase in said rice bran.

7. A rice bran extruding processor for extruding powdery rice bran and thereby heating said rice bran, said heat functioning to inactivate the lipase, destroy the bacteria and stablize the free fatty acid in said rice bran, comprising an extruder having a flighted rotor rotatably mounted within a tubular shell and terminating in an extrusion nozzle, said rotor having a spiral flight including a plurality of flight turns in excess of four and defining a spiral passageway extending backwardly from said extrusion nozzle, a plurality of at least twelve agitator bar elements secured within the final four spiral turns defined by

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said spiral flight, said agitator bars being angularly oriented to define a reverse flight construction between said spiral turns, said agitator bars being substantially at a smaller angle to the horizontal axis than said spiral flight to extrude the powdery rice bran.

8. The apparatus of claim 7 wherein said agitator bar elements are spaced from said shell only slightly less than said spiral light.

9. The apparatus of claim 7 wherein said spiral flight is formed from a round rod-like element, said extruder having a rotatable core having a spiral groove, said rod-like element being located in said groove within the rotor core and being intimately secured to said core, said agitator bar elements being round rod-like elements secured to the surface of said rotor core and having an outermost edge surface located slightly within the outermost edge surface of the flighting round rod-like element.

10. The apparatus of claim 7 having a bran supply hopper for gravity feed of powdery bran, a feed auger unit mounted between the hopper and extruding for supplying of bran to the extruder, a bran stirrer located within said hopper, said stirrer includes a horizontal support shaft and a plurality of stirring blades secured to said shaft, said blades being canted from a perpendicular plane through said shaft and means to continuously rotate the bran stirrer during operation of the feed auger.

11. The rice bran apparatus of claim 7 wherein said extrusion nozzle emits said rice bran in an annular stream, a discharge box unit mounted in overlying relationship to said nozzle and directing said extruded stablized rice bran outwardly therefrom, a rapid cooling means coupled to said discharge unit for receiving of said rice bran and providing essentially instantaneous cooling thereof.

12. A rice bran extruding processor for extruding powdery rice bran andthereby heating said rice bran, said heating of said bran functioning to inactivate the lipase, destroy the bacteria and stablize the free fatty acid in said rice bran, comprising an extruder having a flighted rotor rotatably mounted within a tubular shell and terminating in an extrusion nozzle, said rotor having a spiral flight which with said shell defines a spiral passageway extending backwardly from said extrusion nozzle, an electric motor mounted in alignment with said rotor, a direct drive connection unit connecting said motor and said rotor and establishing a direct one-to-one drive between said motor and said rotor, said rotor being operable to move said rice bran in a continuous manner through said shell and said extrusion nozzle, and a releasable connection unit in said direct drive connection unit and operably disengaging said flighted rotor from said motor in response to a predetermined differential pressure across said connection unit.

13. The bran extruding apparatus of claim 12 wherein said direct drive unit includes a splined shaft and a mating splined hub slideably mounted on said splined shaft, said releasable connection unit including a clutch unit having an outer rotatable housing, a clutch plate member mounted to said housing, a second clutch plate member in opposed relation to said first named clutch plate member and having a mounting hub, and resilient spring means biasing said clutch plate members into frictional engagement.

14. The apparatus of claim 12 wherein said spiral flight includes a number of turns substantially in excess of four turns, and a plurality of at least 12 agitator bar elements are circumferentially distributed within at least the last four turns defined by said spiral flight and are spaced from said shell only slightly less than said spiral flight.

15. The apparatus of claim 14 wherein said rotor includes a core having a spiral groove, said spiral flight is formed from said round rod-like element, said rod-like element being located in said groove within the rotor core and being intimately secured to said core, said agitator bar elements being round rod-like elements secured to the surface of said rotor core and having an outermost edge surface located slightly within the outer most edge surface of the spiral flight rod-like element.

16. The apparatus of claim 14 having a bran supply hopper for gravity feed of powdery bran, a feed auger unit mounted between the hopper and supplying bran to the extruder, a bran stirrer located within said hopper, said stirrer includes a horizontal support shaft and a plurality of stirring blades secured to said shaft, said blades being canted from a perpendicular plane through said shaft and means to continuously rotate the bran stirrer during operation of the feed auger.

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17. A rice bran extruding apparatus comprising a high pressure extruder adapted to receive rice bran in one end and to progressively transfer said rice bran under increasing compression and extruding the rice bran through a restricted opening in an extrusion cone, said rice bran being rapidly raised in temperature to a temperature of at least approximately 130 DEG C. to completely neutralize the lipase and reduce bacteria count to a count of the order of less than 10, a multi-voltage and multi-frequency

A.C. motor connected to operate said extruder and operable over a wide range of frequencies and a wide range of voltages, said A.C. motor having a horsepower rating of less than 100 horsepower and a through-put of 40 to 45 horsepower and rotating in the range of 850 to 900 RPM.

18. The apparatus of claim 17 wherein said extruder having a flighted rotor rotatably mounted and having an outwardly projected rigid rotor shaft projecting from said flighted rotor, said motor having an integral rigid driven motor shaft, a direct drive coupling connecting said shafts and including a slip clutch means having a torque transmitting characteristic in excess of all normal torque created by extrusion of bran from said extrusion cone, whereby said direct drive coupling operates to continuously extrude bran, said slip clutch means being responsive to abnormal loads on said flighted rotor to operatively disengage the rotor from said motor and permit operation of the motor without rotation of said flighted rotor.

19. The apparatus of claim 17 wherein said motor produces 75 horsepower at 885 RPM.

20. The apparatus of claim 18 wherein said direct drive coupling includes a splined shaft and a hub coupling mounted in line with said motor shaft and said flighted rotor shaft, said splined shaft and said splined hub each being connected to said motor shaft and to said flighted rotor shaft whereby said flighted rotor shaft may be axially positioned relative to said motor shaft, and means coupled to said flighted rotor shaft for axially moving of said rotor and setting the size of the extrusion opening of said extrusion cone and thereby the temperature of said rice bran, said heat functioning to neutralize the lipase and reduce the bacterial count in said rice bran.

21. The bran extruding apparatus of claim 20 wherein said slip clutch mechanism includes an outer rotatably housing, a clutch plate member mounted to said housing, a second clutch plate member in opposed relation to said first named clutch plate member and having a mounting hub, and resilient spring means biasing said clutch plate members into frictional engagement.

22. The rice bran apparatus of claim 21 having a discharge box unit mounted in overlying relationship to said cone and directing said extruded stabilized rice bran downwardly therefrom, and a rapid cooling means coupled to said discharge unit for receiving of said rice bran and providing essentially instantaneous cooling thereof.Data supplied from the esp@cenet database - Worldwide

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358.

US4744992 - 5/17/1988

NUTRITIONAL RICE MILK PRODUCTION


Inventor(s):

ROBERT (US)

MITCHELL CHERYL R (US); MITCHELL PAT R (US); NISSENBAUM

Applicant(s): MITCHELL CHERYL R (US); MITCHELL PAT R (US); NISSENBAUM

ROBERT (US)


IP Class: A23L1/10; A23L2/38

E Class: A23L1/105B; A23C11/10



Family: US4744992

Abstract:


The method of the invention comprises selection of whole grain rice, either white or brown rice, which is liquefied, preferably with alpha-amylase enzymes, and then treated with relatively high levels of a glucosidase enzyme and/or a beta-amylase enzyme in a saccharifying step. The total enzymatic reaction time in both the liquefaction and saccharification steps is limited to prevent development of undesirable off-flavors to yield a non-allergenic rice milk product having surprising milk-like texture and functionality, the rice milk product being characterized by the absence of a rice-like flavor and having a preferred composition defined as follows: Soluble Complex Carbohydrates-10 to 70% of solids; Maltose-0 to 70% of solids; Glucose-5 to 70% of solids; Ash or Minerals-0.1 to 0.6% of solids;

Protein and Fat-1 to 3.5% of solids; Fiber-0.05 to 0.4% of solids. The rice milk product can also be converted to a dried product.Description:



The present invention relates to an enzymatic method for producing a milk-like rice liquid for use either as a beverage or in a variety of food products as well as a product of the method.


The traditional Japanese method for the preparation of a nutritional, non-alcoholic beverage from rice requires the blending of steamed or cooked rice with rice koji. The rice koji is prepared by inocculating steamed or cooked rice with the spores of the mold (Aspergillus oryzae) and cultivating the inocculated rice.

The rice koji contains a significant conglomeration of enzymes, predominantly alpha-amylase. It is characterized by both dextrinizing or liquefying and saccharifying action on starch.

After cultivation or fermentation for periods between 4 and 48 hours, the saccharified mass is passed through a sieve or filter. Dependent upon the starting materials used, (polished or unpolished rice or

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combination thereof) the filtrate is a white to beige colored slurry having a distinctly sweet, rice-like taste. The texture and sweetness of the slurry is determined by the total solids and the degree of starch conversion and may be mildly sweet or thick and sweet (similar to a milk-shake). This nutritional beverage prepared from rice is commonly termed amazake.

The amount of sweetness derived from the amazake is dependent upon the total solids of the liquid and the amount of time the rice is allowed to culture with the koji under optimum conditions. Sweet amazake products resulting from long culturing times have an inherent problem of developing a "flat" or "sour" flavor. This flat souring presumably is the result of microbial action in the nutrient rich media as well as the oxidation of fats naturally occurring in the rice.

In some cases, culturing is terminated prior to the development of this flat souring. However, this results in the limitation of the amount of conversion from rice starch to maltose, glucose and higher dextrins. Typically, amazake prepared using koji results in the relative formation of substantial quantities of maltose and very low levels of glucose typically no more than two to three percent of the total carbohydrates. This quantitative relationship between maltose and glucose is limited by the nature of the koji culture itself. lt is these limitations on the quality and quantity of sugars produced in making amazake via the traditional koji method that prompted us to seek an alternative.

The use of enzymes as an alternative method for the liquefaction and saccharification of starch from grains and tubers other than rice is very well known for the production of 100% carbohydrate products including dextrins, fillers and sweeteners intended to be competitive with sucrose. In these products, usually made from corn, the starch-containing portion of the grain or tuber is first separated from the non-starch containing portions before enzymatic conversion. Thus, a relatively pure starch is obtained which can be enzymatically converted and processed to produce a pure carbohydrate product free of impurities.

Because of the preliminary separation of the starch fragment from the grain, not only is a pure carbohydrate product obtained but the enzymatic conversion process is uncomplicated and uninhibited by the fat, fiber and protein contaminants. Unfortunately, this enzymatic conversion process yields a relatively pure carbohydrate product and therefore does not have the nutritional advantages yielded by the traditional koji method involving whole or ground rice.

Traditionally prepared amazake using koji produces a thick, pulpy type of beverage with a rice-like flavor, limited sweetness and stability, and in most cases a distinct sour flavor. Because of its textural and functional properties, this traditionally prepared amazake has a very limited usage, if any, as a substitute for milk.

Accordingly, there has been found to remain a need for improved rice liquids which can be employed either as a beverage or in the preparation of food products. Because of the generally non-allergenic response to rice, it may be anticipated that such products may have a similar characteristic oi being generally non-allergenic.

As an example of other beverage products developed for this market, soy beverages have been employed recently as a milk substitute in powdered, canned and aseptic packaged form. Disadvantages associated with these soy-based milk substitutes arise primarily because of the allergenic response which many people have toward soy products, the bean-like flavor of the products and their common need for the addition of a sweetener.

As noted above, there has been found to remain a need for an improved rice liquid product and method of its preparation.

Another invention set forth in a copending application, Ser. No. 06/856,504 filed Apr. 28, 1986, entitled RICE SYRUP SWEETENER AND METHOD OF PRODUCTION, and assigned to California

Natural Products is related to the present invention and is accordingly incorporated herein by reference as though set forth in its entirety. The above noted reference involves rice syrup sweeteners which are formed by generally the same steps employed for the nutritional rice milk product of the present invention. However, as a final step, the rice syrup sweeteners are partially clarified, preferably by sieving and centrifuging in order to remove substantially all rice fiber from the product resulting in the

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rice syrup sweetener. That reference is incorporated herein to the extent that it may be of assistance in disclosing and facilitating a further understanding of the present invention.


It is an object of the invention to provide such an improved rice liquid, hereinafter referred to as a "rice milk" because of its surprising milk-like texture and functionality.

It is also an object to provide a method for producing the rice milk.

It is a further object of the invention to provide such a rice milk product which is also nutritional in nature because the method for producing the rice milk product of the invention employs as a starting material "whole grain rice". Within the present invention, whole grain rice refers to either white rice

(polished) or brown rice (unpolished) unlike typical prior art corn products which are developed by enzymatic treatment of carbohydrate components removed or separated from the remainder of the grain.

In connection with the above objects, the present invention is based upon the discovery that enzymes could be used for treating whole grain rice as opposed to a purified starch slurry and that it would thereupon be possible to produce a rice liquid having nutritional values. At the same time, the invention is based upon the further discovery that it is possible to overcome the inherently limited sweetness of traditional koji prepared amazake by employing a relatively high level of a glucosidase enzyme either alone or in combination with a beta-amylase enzyme in a saccharification step to produce rice milk products or "modified amazake" products with a variety of glucose to maltose ratios while still having similar nutritional advantages as noted above.

It was further discovered in connection with the present invention that,through the controlled use of dextrinizing and saccharifying enzymes it is possible to eliminate souring and to produce a sweet, nutritional, hypoallergenic product surprisingly similar in texture and functionality to cow's milk and very much unlike traditional amazake as discussed above.

The composition of the rice milk of the invention was found to include minerals, fats, fiber, protein, complex carbohydrates, vitamins, maltose and glucose. All of the above products derived from the starting material of whole grain rice itself. It is also noted in particular that the "complex carbohydrates" referred to above include oligosaccharides such as maltotriose, dextrins, and higher saccharides. In any event, all of these forms of complex carbohydrates according to the present invention may appear in the rice milk product in a wide variety depending upon the whole grain rice selected as a starting material and also upon characteristics of the process as will be described in greater detail below.

Accordingly, it is yet a further object of the invention to provide a method for producing a nutritional rice milk from whole grain rice which can be ground or otherwise divided to form particles of selected size. A rice water slurry containing approximately 25-40% dry weight rice is heated and then liquefied, preferably by treatment with an alpha-amylase enzyme as noted above to form a liquid slurry which is treated with a glucosidase enzyme in a saccharification step to yield a rice milk product retaining nutritional values from the whole grain rice and exhibiting a milk-like texture and functionality.

The concentration of glucosidase enzyme and the concentration of optionally employed beta-amylase enzyme in the saccharification step are set forth respectively in Diazyme Units and DP DEG. These standards are employed with the following explanation to assure a proper understanding of the invention. In that regard, the term "DP DEG" reiers to Degrees of Diastic Power. A further deiinition as well as an extensive assay procedure in connection with that term is set forth for example in Food

Chemicals Codex, third edition, beginning at page 484.

The term "Diazyme Units" refers to a Diazyme assay commercially available from Miles Laboratories,

Inc., Elkhart, In. That term is employed herein at least partially since one glucosidase enzyme found suitable for use in the present invention comprises glucoamylase E.C. 3.2.1.3, 1,4-alpha-D-Glucan glucohydrolase, unit activity of about 200 Diazyme Units/ml. (available under the trade name Diazyme from Miles Laboratories, Inc., Elkhart, In.).

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It is a iurther related object oi the invention to provide such a method wherein at least about 440

Diazyme Units of glucosidase per kilogram of whole grain rice particles are employed in the saccharification step and the enzymatic reaction time ior the saccharification step is limited to about three hours in order to prevent development of off-flavors.

It is yet a further related object of the invention to employ the glucosidase enzyme either alone or in combination with varying amounts of beta-amylase enzymes in order to produce a nutritional rice milk product having the composition:

Soluble Complex Carbohydrates--About 10 to 70% of solids;

Maltose--About 0 to 70% of solids;

Glucose--About 5 to 70% of solids;

Non-Carbohydrate Nutritional Values--About 1 to 5% of solids.

Yet another further related object of the invention consists of selecting the whole grain rice starting material and characteristics of the liquefaction and saccharification steps so that the rice milk product further includes nutritional values comprising ash or minerals at about 0.1 to 0.6% of solids, protein and fat at about 1 to 3.5% of solids and rice fiber at about 0.05 to 0.4% of solids.

The method of production for rice milk according to the present invention has been found to result in a rice milk product or modified amazake which can be substituted for milk, milk solids and other milk forms in the preparation of various food products including but not limited to beverages, puddings and other food products corresponding to various dairy-based dessert products.

It is yet another object of the invention to provide the rice milk product in combination with other components to form a variety of iood products including but not limited to a novel ice cream analog and other products as listed above.

It has also been found that the rice milk or modified amazake product of the present invention can be dried, ior example by drum drying and preferably by spray drying to form a dried rice milk-like product or modified amazake which can be stored and subsequently used either in its dried form or reconstituted to a liquid consistency.

Accordingly, it is yet a further object of the invention to provide both a dried rice milk-like product and method of its preparation. lt is a still further object to provide a nutritional rice milk product using whole grain rice as a starting material and employing a beta-amylase enzyme of at least 1,000 DP DEG per kilogram of whole grain rice in a saccharification step limited to about three hours. This process has been found to yield a high maltose rice milk product which is nutritional and non-allergenic while also being characterized by ireedom irom a rice-like and a milk-like texture and functionality.

Substantially greater amounts of the beta-amylase enzyme may be used if desired. However, it has generally been found to be preferred to use about 1,000 to 3,000 DP DEG of the beta-amylase enzyme per kilogram of whole grain rice to economically achieve the advantages of the invention. This high maltose rice milk product may also be converted to a dried product.

Numerous additional objects and advantages of the invention will be apparent from the following description which includes a number of examples to further define and fully disclose the invention.


Generally, in the enzymatic conversion of the starch from grains such as corn, the starch containing fragment of the grain is first separated from the hull, germ and other grain portions before reaction with the added enzyme. In this way, contamination of the starch by proteins, fats and fibers is minimal and therefore processing is not complicated by these impurities. As a consequence of this preliminary starch separation, a purified carbohydrate product is produced having none of the nutritional advantages found in whole or ground grains as used in traditional koji preparation of amazake.

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We found in our invention that whole grain rice (white or brown) can be ground or divided and used in an enzymatic process. Consequently, contamination by protein, fat, and fiber may be expected to cause significant deviations in enzymatic activity and processing conditions. In the typical enzymatic conversion of purified starches, reaction parameters such as time, temperature, pH and water concentration of the starch slurry are usually adjusted to obtain hydration and swelling of the starch so that the liguefying alpha-amylase enzymes works under optimum conditions to hreak down and dextrinize the starch completely with a minimum of starch retrogradation. The same reaction parameters are then adjusted ior optimum enzyme activity during saccharification.

In our invention, it is preferred to carry out enzymatic sacchariiicationof whole grain rice with a glucosidase enzyme at the natural pH of rice slurry, that is, ahout 6.3 or within a range of 6.0 to 6.5. In addition the pH may be adjusted for example, to an optimum level required by the enzyme. In either event, saccharification according to the invention results in a milk-like product which is highly palatable and characterized by absence of a rice flavor. We have also found, that by increasing the saccharifying enzyme dosage from two to ten times that necessary to convert an equivalent amount of purified starch and by maintaining enzyme reaction time of less than about four hours, a modified amazake can be produced having no sour flavor while exhibiting unique functional properties and economic advantages unlike traditional koji amazake.

In other words, the rice milk or modified amazake of the invention prepared with glucosidase with or without beta-amylase enzymes during saccharification has a composition based on total solids as set forth in Table I.

Table I from about 5 to 70% glucose from about 0 to 70% maltose, and from about 10 to 70% complex carbohydrates.

By contrast, prepared amazake from the prior art has the following composition based on total carbohydrates: about 3 to 5% glucose, from about 20 to 45% maltose, and from about 30 to 70% higher saccharides.

As noted above, the rice milk product, because of the selection of whole grain rice as a starting material, includes substantial nutritional values as were also discussed and summarized above.

Accordingly, the preferred composition set forth above in Table I further comprises nutritional values which, according to the present invention, comprise ash or minerals at about 0.1 to 0.6% of solids, protein and fat at about 1 to 3.5% of solids and rice fiber at about 0 05 to 0.4% of solids. These materials are only representative of the nutritional values in the rice milk product which may also include other nutritional values such as vitamins, for example.

In the process of this invention, steamed or cooked rice material, selected from the group consisting of polished, unpolished, partially polished or any combination thereof, in a slurry of from 25-40% of rice weight basis, is liquefied with alpha-amylase enzyme having dextrinizing activity and which is produced from a micro-organism selected from Bacillus subtillus, Bacillus Stearothermophilus and

Bacillus licheniformis or a fungal source such as Aspergillus oryzae, substantially free from protease, at a temperature of from 30 DEG C. to 100 DEG C. and at a pH of from 3.5 to 7.5 to yield a liquefied slurry.

The liquefied slurry is then cooled to from 45 DEG to 65 DEG C. and the saccharifying enzyme or enzymes are added. The pH may be maintained at about the normal pH of rice, i.e., about 6.3, or may be adjusted to from 3.5 to 7.5. The sacchariiying enzymes include a glucosidase which is glucose liberating and which is produced by a micro-organism selected from many species of Rhizopus or

Bacillus, strains of the Aspergillus niger group, Aspergillus oryzae, Muco species, Endomyces species,

Endomyces fibuliger, Saccharomyces diastaticus, Chlostridium acetobutylicum and possibly a betaamylase (which is maltose liberating) extracted from either barley, wheat, rye, sweet potatoes or soybeans.

Glucosidase enzymes used in the saccharification step are available from a number of sources including Miles Laboratories, Elkhart, In.; Novo Industries, Denmark and the FinnSugar Group,

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Finland. Trade names for glucosidase products from Miles Laboratories are set forth in certain of the examples. Similar glucosidase enzymes are available irom Novo Industries under the trade name

Amyloglucosidase Novo.

It will of course be apparent irom the preceding comments that numerous other glucosidase enzymes can similarly be employed in the saccharification step of the present invention. The beta-amylase enzymes which are also optionally employed within the saccharification step are believed to be sufficiently well-known that no further discussion is required.

The dosage level of added saccharification enzyme is anywhere from two to ten times that necessary for the analogous conversion of an equivalent amount of purified starch, the dosage level being dependent upon the quantity and type of sugar to be liberated. After the slurry has been allowed to react with the saccharifying enzyme a relatively short period of time (less than four hours) the slurry can then be sieved and/or centrifuged to remove unwanted fiber, fat or amylose. The filtrate or modified amazake, of varying glucose and maltose content depending upon the quantity and type of saccharifying enzyme used, can then be dried via spray or drum dryer, or reduced in moisture to a concentrate of between 60 and 85% soluble solids, or pasteurized and immediately cooled to between 0

DEG and 18 DEG C. for use as a liquid.

Accordingly, the process of the present invention initially involves the selection of whole grain rice as a starting material.

The whole grain rice is liquefied, preferably employing alpha-amylase enzyme to produce a liquid slurry. In order to prevent development of undesirable off-flavors, the enzymatic liquefication step is preierably limited to no more than about one hour.

Thereafter, the liquid slurry is subjected to a saccharification step employing a high level of a glucosidase enzyme, either alone or in combination with a beta-amylase enzyme, to form an enzyme system substantially excluding other enzymes in order to achieve the desired milk-like texture and functionality realized for the rice milk product of the invention.

The manner of defining the amount and activity of the glucosidase and beta-amylase enzymes for purposes of the present invention are set forth in EXAMPLE 1. In any event, the glucosidase enzym is present from about 440 to about 2,200 Diazyme Units per kilogram of whole grain rice (see

EXAMPLE 1). The beta-amylase enzyme is optionally present in an amount from about 1,000 to 3,000 degrees of Diastic Power (DP DEG) per kilogram of whole grain rice.

In order to achieve desired conversion while further preventing development of undesirable off-flavors, the saccharification step is also limited, preferably to about three hours and more preferably within the range of about two to three hours.

It has further been found that the milk-like texture and functionality of the resulting rice milk product is enhanced if the pH of the saccharification step is maintained approximately equal to the pH of natural rice (about 6.3). Accordingly, the pH of the saccharification step is most preferably limited to the range of about 6 to 6.5.

However, it has iurther been found possible to generally maintain the desirable milk-like texture and functionality of the product even with the pH of the saccharification step being adjusted, generally toward acid levels. In this regard, it is often considered desirable to adjust the pH to a range of about

3.5 to 7 in order to enhance enzymatic activity. Accordingly, that range is a broader preferred range within the present invention.

The solids content of the rice milk or modified amazake may be adjusted to between 8 and 28% soluble solids by the addition of water to yield a milk-like beverage very similar in appearance and taste to milk. If desired, up to 5% vegetable oil may be added and the mixture homogenized to yield a rice beverage having a fatty texture or "mouthfeel" similar to whole milk.

The rice milk or modified amazake of this invention can also he used in the preparation of a novel frozen dessert. The rice milk or modified amazake is used as a replacement for both the milk and sugar

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in a standard ice cream mix. The rice milk or modified amazake is blended with from 0 to 12% by weight vegetable oil, from 0 to 1% by weight stabilizers, from 0 to 12% flavors, from 0 to 1% salt, the blend heated to between 65 DEG and 70 DEG C., homogenized at between 2,000 and 3,000 PSI, cooled to between 0 DEG and 18 DEG C., additional flavors added if desired and the mix frozen and packaged according to standard practice in ice cream manufacturing.

The rice milk or modified amazake provided in this invention can also be used in the preparation of other frozen desserts, puddings or whipped toppings by the replacement in standard formulations for milk solids, sugar solids, corn syrup solids and or moisture content by the rice milk or modified amazake.

The rice milk or modified amazake provided in this invention of varying glucose to maltose ratios may be dried to a powder form by using drum type dryers, spray dryers or the like. The resulting powder may then be ground or sifted, or agglomerated as needed to a size of between 4 and 300 mesh. This dried powder may then be used as a replacement for corn syrup solids, powdered milk, sweeteners, or any combination thereof. The rice milk or modified amazake may also be used as a source of complex carbohydrates.

Another application of the rice milk or modified amazake prepared by this new process is in the preparation of 100% rice solids concentrate by concentration of the rice milk or modified amazake. The rice milk or modified amazake is concentrated to between 60 and 85% soluble solids by using a vacuum type evaporator.

Having outlined the steps in our invention we will now provide detailed examples of the process for preparing rice milk of varying sugar content; preparation of non-dairy desserts using rice milk or modified amazake; preparation of milk substitutes using the rice milk or modified amazake of this invention; preparation of novel frozen desserts by using modified amazake of this invention; preparation of powdered rice milk or modified amazake by using the rice milk or modified amazake of this invention; preparation of instant dessert mixes and beverages using the powdered rice milk or modified amazake of this invention; preparation of 100% rice concentrates by using the rice milk or modified amazake of this invention.

EXAMPLE 1

Rice Milk Containing Approximately 10% Glucose

Forty-five kilograms of milled white rice of thirty (30) mesh were added to 100 Liters cold tap water having a calcium ion content of 250 ppm (the calcium could be present in the water naturally or added in the form of a calcium salt) in a steam jacketed 225 Liter kettle under constant agitation. One hundred grams of bacterial alpha-amylase of Bacillus subtilis origin with an activity of 1,200,000 modified

Wohlgemuth Units per gram were added to the water. The temperature of the suspension was gradually increased to 80 DEG C. and held for approximately 30 minutes. The temperature was then increased to

100 DEG C. and held there for an additional 15 minutes. The slurry was then cooled to approximately

60 DEG C., 50 ml of Barley beta-amylase with an activity of 1,500 degrees of Diastic Power per ml, as well as 100 ml of glucosidase E.C. 3.2.1.3, 1,4-alpha-D-Glucan glucohydrolase, unit activity of 200

Diazyme units/ml (Diazyme assay is available upon request from Miles Laboratories, Inc., Elkhart, In.) were added. The slurry was held at 60 DEG C. for two hours after which it was sieved through a 30 mesh screen to produce a liquid similar in appearance to milk. This rice milk or rice milk product had the composition of 10% glucose and 35% maltose based on total solids and a total soluble solids content of 31%.

The rice milk product produced in EXAMPLE 1 has the nutritional advantage of high maltose and complex carbohydrates which are metabolized more slowly than glucose and hence do not result in rapid blood sugar increase. The use of glucosidase enzyme in conjunction with beta-amylase enzyme yields a product with slightly increased sweetness as well as less rice-like flavor when compared with traditional koji amazake. The textural properties are similar to milk, particularly condensed milk and the high dextrin concentration allows for easier drying of the rice milk product with good dispersibility

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of the dried product upon reconstitution with water. The dried product can be used as a mildly sweet, bland filler in powdered food formulations.

EXAMPLE 2


Forty-Five kilograms of milled brown rice of twenty (20) mesh were added to 80 Liters cold tap water in a steam jacketed 225 Liter kettle under constant agitation. One hundred grams of bacterial alphaamylase of Bacillus subtilis origin with an activity of 1,200,000 modified Wohlgemuth Units per gram were added to the water initially. The temperature of the suspension was gradually increased to 80

DEG C. and held ior approximately 30 minutes. The temperature was then increased to 100 DEG C. and held there for an additional 15 minutes. The slurry was then cooled to approximately 60 DEG C.,

450 ml of glucoamylase E.C. 3.2.1.3, 1,4 -alpha-D-Glucan glucohydrolase, unit activity of 200

Diazyme units/ml (Diazyme assay is available upon request from Miles Laboratories, Inc., Elkhart, In.) being added. The slurry was held at a constant temperature for three hours after which it was then sieved and centrifuged to produce a liquid similar in appearance to milk. This rice milk or modified amazake had the composition of 70% glucose based on total solids with a total soluble solids content of

31%.

The rice milk product produced in EXAMPLE 2 has economic advantages from the standpoint that when the product is diluted with water or air in the case of ice cream, it yields a very acceptable sweetness level with obviously no additional sweetener needed. At 30% soluble solids, the rice milk product is generally too sweet to be used as a beverage directly. The high glucose also provides an increased freezing point depression which is an essential part of making a non-dairy ice cream analog which is creamy in texture as opposed to being hard and icy. Upon drying of this rice milk product, a very sweet powder results which is acceptable for use as a sweetener in powdered food formulations.

EXAMPLES 1 and 2 are representative of a broad range of rice milk products which can be prepared according to the present invention. The products resulting irom both EXAMPLES 1 and 2 are representative of the invention in that they have surprising milk-like texture and functionality while being almost entirely free of a rice-like flavor and retaining the non-allergenic properties from the rice itself. Furthermore, the products of both EXAMPLES 1 and 2 have retained nutritional values present because of the whole grain rice employed as a starting material. These desirable properties for the products of EXAMPLES 1 and 2 are also retained in the other following EXAMPLES which are based upon either EXAMPLE 1 or 2.

EXAMPLE 3

Non-Dairy Pudding From Rice Milk

Eight grams of alginate (Protanal PM673; Protan, Drammen, Norway) were blended in a bowl with 250 g of the rice milk product of EXAMPLE 2 and vigorously agitated for one minute using a mechanical stirrer. An additional 300 g of tbe rice milk product of EXAMPLE 2 were slowly added under constant stirring and allowed to sit for 30 to 45 minutes. A very acceptable pudding was produced.

Milk based puddings are produced by cooking milk, sugar and starch together. These milk puddings have soluble solids content approximately 30%. By using the rice milk product of EXAMPLE 2, with approximately 30% soluble solids, no sugar or sweetener need be added. Consequently, only the alginate, starch, gelling, or thickening agent need be considered to produce a very sweet non-dairy pudding of desired consistency. Therefore, the product has simple ingredient labeling being predominantly a rice milk product.

EXAMPLE 4

Rice Beverage (Milk Substitute) from Rice Milk

One liter of the Rice Milk Product of EXAMPLE 2 was dIIuted with cold water to obtain a total soluble solids of 13%. To 1 liter of the above 13% soluble solids beverage were added 2.5 g safflower

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oil, 0.005 g salt, and the mixture homogenized at 2,500 PSI. A pleasing milk-like beverage was produced.

A major economic advantage of the high glucose rice milk product of EXAMPLE 2 is that it can be diluted with water to about 13% soluble solids to produce a beverage of acceptable sweetness. The diluted product of EXAMPLE 4 is very similar to cows milk with regard to texture and mouthfeel.

EXAMPLE 5

Non-Dairy Frozen Dessert

Four liters of the rice milk product of EXAMPLE 2 (approximately 28% soluble solids) were blended with 400 g safflower oil, 120 g vanilla, 20 g salt, and 20 g carrageenan, the blend heated to 75 DEG C. and homogenized at 2,500 PSI. The mix was then cooled to 18 DEG C. and the mix packaged and frozen according to standard practice in ice cream manufacturing.

The frozen dessert outlined in EXAMPLE 5 has a high freezing point depression resulting in a creamy product without crystalline brittleness caused by ice crystals. The ingredient declaration for this product is simplified since no added sweetener is required as is common with all other ice creams or frozen dessert products. Again, the rice milk product of EXAMPLE 2 allows for the dilution by air of the non-dairy ice cream mix resulting in an increased economical advantage for the use of a high glucose rice milk.

EXAMPLE 6

Powdered Rice Milk Product

Rice milk product of EXAMPLE 2 (approximately 28% soluble solids) was pumped through a standard air atomized spray dryer having an inlet temperature of 120 DEG C. and was collected as a white dry powder of approximately 60 to 300 mesh.

The powdered form of the rice milk product of EXAMPLE 2 can be used to replace glucose or iructose derived irom corn and containing allergens associated with corn. Because no reiining is done as is with sucrose from sugar beet or cane sugar, this powdered rice milk product provides a more natural and nutritionally balanced sweetener. The presence of complex carbohydrates, proteins, fat and minerals also make this powdered sweetener more attractive as a nutritional sweetener.

The powdered rice milk product made irom the rice milk of EXAMPLE 1 has much less sweetening power than the product of EXAMPLE 2 but is more desirable as a source of complex carbohydrate or filler powder in formulations where a bland powder is required for bulking purposes and source of complex carbohydrates.

EXAMPLE 7

Instant Brownie Mix Containing Powdered Rice Milk Product

The following ingredients were blended to make a brownie mix:

200. g: Powdered Rice Milk Product of EXAMPLE 6

55. g: Flour

2.5 g: Baking Powder

3.5 g: Salt

25. g: Cocoa Powder

Preparation of brownies using the above brownie mix: To the above mix were added 112 g butter, one egg and 2 g vanilla extract. The mixture was stirred until uniform, then poured into a greased

23.times.23 cm pan and baked 25 minutes at 175 DEG C. A tasty brownie product was produced.

This EXAMPLE is representative of applications where the powdered rice milk product of EXAMPLE

6 can be used to replace the sugar and milk of a standard brownie mix recipe. The brownies produced

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are suitable for people with dairy allergies with the added advantage of including a nutritional rice sweetener.

EXAMPLE 8

Instant Chocolate Flavored Beverage Mix

The following ingredients were blended to make a non-dairy cocoa mix:

25. g: Cocoa Powder

1.5 g: Salt

120. g: Powdered Rice Milk Product of EXAMPLE 6

The hot chocolate beverage of this EXAMPLE was prepared by mixing the above components to form an instant chocolate flavored beverage mix. Eight hundred milliliters of boiling water were added with constant stirring. The mixture was beaten with a wire wisk prior to serving.

The product of EXAMPLE 8 illustrates how the powdered rice milk product of EXAMPLE 6 can be used as a replacement for the sugar and milk portion in a cocoa mix.

EXAMPLE 9

High Maltose Rice Milk

The steps of EXAMPLE 1 were repeated except that 100 ml of beta-amylase enzyme were used without any glucosidase enzyme.

This resulted in a product having about 3% glucose and about 55% maltose, the composition and characteristics of the product otherwise being as described above in EXAMPLE 1. In particular, the high maltose rice milk was found capable of being dried in the same manner set forth in EXAMPLE 6 to yield a dried high maltose rice milk.

EXAMPLES 3-9 are further representative of a wide variety of food products which can be formed from rice milk product prepared for example in accordance with EXAMPLES 1 and 2. In particular, as is demonstrated by EXAMPLE 6, the rice milk product of the present invention particularly lends itself either to drum drying or preferably to spray drying in order to iorm a dried product which can either be used as is or stored and later reconstituted to form a liquid product.

Numerous variations and modifications are obvious from the preceding description. Accordingly, the scope of the present invention is defined only by the following appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method for producing a nutritional rice and milk product, comprising the steps of selecting as a starting material a whole grain rice dividing it into particles of reduced size, liquifying the whole grain rice particles with an alpha-amylase enzyme in an aqueous medium substantially free from protease, in an amount and for a period of time which is sufficient to form a liquid slurry, and treating the liquid slurry with a glucosidase enzyme in a saccharification step, in an amount and for a period of time less than about three hours which is sufficient to yield a rice milk product retaining nutritional components from the whole grain rice and having a glucose content of about 5 to 70% solids.

2. The method of claim 1 wherein at least about 440 Diazyme Units of glucosidase enzyme per kilogram of whole grain rice particle are employed in the saccharification step.

3. The method of claim 2 wherein the total enzymatic reaction time for both liquefaction and saccharification steps is from about two to four hours to permit desired enzymatic conversion while preventing development of undesirable flat-sour flavors.

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4. The method of claim 2 wherein about 440 to 2,200 Diazyme units of glucosidase enzyme per kilogram of whole grain rice particles are employed in the saccharification step.

5. The method of claim 4 wherein up to about 3,000 DP DEG of beta-amylase enzyme per kilogram of whole grain rice particles is also employed in the saccharification step with the resulting nutritional rice milk product having total solids of about 30%, balance essentially water, with a composition of: soluble complex carbohydrates--about 10 to 70% solids; maltose--about 0 to 70% solids; glucose--about 5 to

70% solids; noncarbohydrate nutritional components--about 1 to 5% solids; and fiber--about 0.05 to

0.4% solids.

6. The method of claim 5 wherein the starting material is selected as whole grain rice particles and the liquefaction and saccharification steps are performed so that the nutritional components comprise ash or minerals at about 0.1 to 0.6% of solids and protein and fat about 1 to 3.5% of solids.

7. The method of claim 5 wherein beta-amylase of about 1,000 to 3,000 DP DEG is employed in the saccharification step.

8. The method of claim 5 wherein the saccharification step is carried out at a pH in the range of about 6 to 6.5 to approximate the natural pH of rice.

9. The method of claim 5 wherein the saccharification step is carried out at a pH in the range of about

3.5 to 7.

10. The method of claim 5 further comprising the step of drying the rice milk product to substantially remove water and form a dried rice milk product.

11. The method of claim 5 wherein the saccharification step is carried out substantially free from other enzymes.

12. The method of claim 2 wherein the saccharification step is carried out substantially free from other enzymes.

13. The method of claim 2 further comprising the step of drying the rice milk product to substantially remove water and form a dried rice milk product.

14. A method for producing a nutritional rice milk product, comprising the steps of selecting as a starting material a whole grain rice and dividing it into particles of reduced size, combining the whole grain particles in an aqueous medium substantially free from protease with an alpha-amylase enzyme in a liquefaction step in an amount sufficient and for a period of time limited in enzyme reaction duration to about one hour which is sufficient to form a liquid slurry while permitting desired enzymatic liquefaction and preventing development of undesirable flat-sour flavors, treating the liquid slurry with an enzymatic system including a glucosidase enzyme of at least about 440 Diazyme Units per kilogram of whole grain rice particles in a saccharification step limited in enzyme reaction duration to about three hours, said amount of glucodiase enzyme and said enzyme reaction duration being sufficient to permit desired enzymatic reaction while preventing development of undesirable flat-sour flavors to yield a rice milk product retaining nutritional components from the whole grain rice.

15. The method of claim 14 wherein the amounts of glucosidase and beta-amylase enzymes are selected to yield a nutritional milk product having total solids of about 30%, balance essentially water, with a composition of: soluble complex carbohydrates--about 10 to 70% solids; maltose--about 0 to

70% solids; glucose--about 5 to 70% solids; noncarbohydrate nutritional components--about 1 to 5% solids; and fiber--about 0.05 to 0.4% solids.

16. The method of claim 15 wherien the starting material is selected as divided whole grain rice particles and the liquefaction and saccharification steps are selected so that the nutritional components comprise ash or mineral at about 0.1 to 0.6% of solids and protein and fat at about 1 to 3.5% of solids.

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17. The method of claim 14 wherein the saccharification step comprises treatment of the liquid slurry by the glucosidase enzyme in combination with a beta-amylase enzyme of at least about 1,000 DP

DEG per kilogram of whole grain rice particles.

18. A method for producing a nutritional rice milk product, comprising the steps of selecting as a starting material a whole grain rice, liquefying the whole grain rice with an alpha-amylase enzyme in an aqueous medium substantially free from protease in an amount and for a period of time which is sufficient to form a liquid slurry, and treating the liquid slurry with a beta-amylase enzyme in a sacharification step with at least about 1,000 DP DEG of beta-amylase enzyme per kilogram of whole grain rice, the reaction time for the saccharification step being limited to about three hours, the amount of beta-amylase enzyme and the reaction time being sufficient to yield a rice milk product retaining nutritional components from the whole grain rice exhibiting a milk-like appearance without development of flat-sour flavors.

19. The method of claim 18 further comprising the step of drying the rice milk product to substantially remove water and form a dried rice milk product.Data supplied from the esp@cenet database -

Worldwide

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359.

US4761297 - 8/2/1988

METHOD OF MANUFACTURING DRIED RICE


Inventor(s): YAMAGUCHI NORIAKI (JP); NAKANO MAKI (JP); SUGISAWA KO (JP);

SHIBUKI MASARU (JP)



IP Class: A23L1/182; A23L1/00

E Class: A23L1/182



Family: CN86108194

Equivalent: JP62134048; GB2184932; DE3641667; IT1199844

Abstract:


The present invention provides a method of manufacturing dried rice, which is capable of allowing the cooking time to be reduced, and which allows the rice to have an appearance and a texture when cooked as excellent as rice cooked using an electric rice cooker. The method of manufacturing dried rice comprises as steps of: adjusting a water content of polished rice so that it reaches at least 23 wt % after the rice has been washed with water; soaking the rice in a sugar solution so as to allow the sugar to permeate the rice and to remove 6 to 38 wt % of the water contained in the rice; separating the sugar solution adhered to the rice; and drying the rice under conditions in which starch contained therein will not be pregelatinized.Description:




The present invention relates to a method of manufacturing dried rice. More specifically, the present invention is directed to a method of manufacturing dried rice which, in comparison with the conventional rice, need not be washed with water or soaked in water before being cooked, which is capable of allowing the cooking time to be reduced, and which allows the rice to have an appearance and a texture when cooked as excellent as rice cooked using an electric rice cooker.

(2) Prior Art

Development of the electric rice cooker has reduced the time required for cooking rice and has simplified the cooking procedure. However, there has been in increasing demand for methods of cooking rice in even simpler ways and in even shorter times, and various methods have accordingly been developed. Japanese Patent Laid-Open (KOKAI) No. 141257/1982, for example, proposes a method of making vacuum packed rice, in which polished rice washed with water is dehydrated and dried, and is then vacuum packed when the water content thereof has reached a predetermined value

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above that of the ordinary rice. However, dried rice made in this manner remains hard when cooked for about 15 minutes, and does not become at all fluffy. Apart from vacuum packing, a method of preparing dried rice with a pregelatinized starch content has also been developed, and examples of this method include Japanese Patent Laid-Open (KOKAI) No. 85258/1974 and Japanese Patent Publication

No. 1964/1965. The former involves the drying of rice with a pregelatinized starch content after it has absorbed at least one type of basic amino-acid and at least one type of sugar alcohol. The latter discloses a method of manufacturing quick-cooking rice in which rice is soaked in water to which a retrogradation accelerator such as starch decomposing enzyme, polymerized phosphate, sorbitol or surface-active agent has been added, is steamed or boiled and then fried to pregelatinize the starch contained in the rice. The dried rice prepared by either of these methods can be made edible in a relatively short period of time by pouring hot water over it, and the rice has no core when cooked.

However, since the starch in the rice has been pregelatinized beforehand, it is an inherent problem with such rice that when it is cooked, the texture thereof becomes too soft as compared with the cooked polished rice. In addition, when cooked, the rice prepared in either of the above methods lacks the special aroma inherent to well cooked rice. On the other hand, Japanese Patent Publication No.

31942/1977 describes a method of preparing modified rice by adding to polished rice a modifier consisting of 0.5 to 20% of rice bran oil, 3 to 30% of sorbitol, 0.05 to 5% of emulsifier and the balance water, in an amount between 0.5 and 2% by weight relative to the weight of the polished rice. In this method, since rice starch is not pregelatinized in preparation of modified polished rice, the rice has a good texture when cooked. However, this method does not allow the cooking time to be reduced sufficiently.


The present invention is based on the knowledge that the above-described problems can be effectively solved by allowing the polished rice to contain at least a predetermined water content and thereby causing the grains of rice to swell, by impregnating the grains of rice with sugar solution and removing a specific amount of the water contained in the grains of rice utilizing the dehydrating action of the sugar solution, and by drying the rice under specific conditions.

It is, therefore, a primary object of the present invention to provide, without employing rice with a pregelatinized starch content, a method of manufacturing dried rice which need not be washed with water or soaked in water before being cooked, and which is capable of allowing the cooking time to be reduced. Another object of the present invention is to provide a method of manufacturing dried rice which can be made edible easily and in a short period of time, and which allows it to have a texture when cooked as excellent as cooked polished rice. These and other object of the present invention will be clean from the following description.

In accordance with the present invention, there is provided a method of manufacturing dried rice which comprises the steps of: adjusting the water content of polished rice so that it reaches at least 23 wt% after the rice has been washed with water; soaking the rice in a sugar solution so as to allow the sugar to permeate the rice and to remove 6 to 38 wt% of the water contained in the rice; separating the sugar solution adhered to the rice; and drying the rice under conditions in which the starch contained therein will not be pregelatinized.


All types of polished rice including no matter where produced and hard and soft rices can be trated in the present invention. New rice, long-stored rice, nonglutinous rice and glutinous rice can also be employed. When the employed rice is of glutinous type, it is possible to obtain dried rice that could be made edible in about 10 minutes.

In the present invention, after any of the abovementioned types of polished rice (in general such types of rice contain 13 to 16 wt% of water) has been washed with water, the water content of the grains of rice is adjusted so that it becomes at least 23 wt% (hereinafter referred to as %). This adjusting operation is necessary to allow the water to permeate the interior of each grain of rice, so that this water may be replaced by the sugar solution when the rice is soaked therein in the subsequent process, whereby the sugar solution is caused to permeate the interior of the rice. This adjustment of the water content of the rice is performed by soaking the polished rice in water. In a practical application, the rice

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is soaked in water having a temperature of 25 DEG C. for more than 30 minutes, preferably for 50 to

70 minutes, whereby the water content of the grains of rice is adjusted to be at 23% or above, preferably 28% or above, and more preferably between 28 and 35%. The higher the temperature of the soaking water, the shorter the time required to set the water content of the rice at any given value. A suitable temperature for the water may therefore be between 15 DEG and 60 DEG C., at which temperature the starch content is not pregelatinized. In the present invention, it is necessary to adjust the water content of the grains of polished rice at a given value in the particular range after the washing of the rice with water, since when the rice is soaked in sugar solution having a low concentration without adjustment of the water thereof, it is difficult to impregnate the rice with a sufficient amount of sugar, although the sugar will to some extent permeate the rice. On the other hand, with sugar solution of high concentration, no permeation will occur at that time. In addition, it is possible to color or season the rice by employing various seasonings at the time of adjusting the water content.

Subsequently, the grains of rice with a water content adjusted in the above range is soaked in a sugar solution to impregnate the rice with sugar and simultaneously the water content of the rice is dehydrated by 6 to 38%. Sugar solutions that can be employed include a solution of sorbitol, mannit, sucrose, or glucose, and a liquid containing starch hydrolyzate, called liquid sugar, Among these, a solution of sorbitol is preferable, since the rice does not become sweet when soaked therein, and since it permeates faster. Soaking of the rice in the sugar solution is performed in the present invention to dehydrate the grains of rice efficiently without generating cracks therein and to thereby impregnate the interior of the grains of rice with sugar, whereby the need for an operation of soaking rice in water is eliminated at the time of cooking and the time required for cooking is reduced. Thus, 3 to 9% of sugar is impregnated in the grains of rice, and simultaneously 6 to 38. preferably 12 to 35%, of the water contained in the rice which has been soaked in water is removed. If the amount of water removed is less than 6%, a large amount of water must be dried in the subsequent drying process, generating cracks. If the amount of water removed exceeds 38%, the rice will become too sweet when cooked, degrading the taste of the cooked rice.

Concentration of the sugar solution employed in the present invention can be set at any value.

However, in the case of sorbitol, it is preferable to employ a solution having a concentration of 20 to

70%. A solution of a higher concentration (30 or above) is preferable, since the higher the concentration is, the shorter the time required to remove the large amount of water absorbed during soaking. A supersaturated solution may also be employed. Thus, the grains of rice are soaked in a sugar solution having a concentration in the above-mentioned range and a temperature of 15 DEG to 60 DEG

C. for 10 to 120 minutes, preferably for 60 to 120 minutes. If a solution of sucrose or glucose is employed, it is desirable to use a saturated aqueous solution with a view to reducing the time required for soaking.

After the grains of rice have been soaked in the sugar solution, the sugar solution adhered to the rice is separated therefrom. Any separation method may be used including centrifugal separation so long as it ensures an effective separation of the sugar solution adhered to the surface of the rice. Preferably, solution separation is conducted to such a degree that it takes the gloss off the surface of the rice grains.

Removal of sugar solution from the grains of rice is performed in the purposes of preventing the rice from becoming too sweet, for increasing the drying efficiency during the drying process and for taking the gloss off the surface of the rice, thereby improving the appearance thereof.

Subsequently, the grains of rice are dried under conditions wherein the starch content will not be pregelatinized. In a practical operation, they are dried at a relatively low temperature and at high humidity for a long period of time, since in this way generation of cracks on the grains of rice can be prevented as much as possible. Preferably, hot-air drying incorporating a fan, or constant-humidity constant-temperature drying is adopted. Drying is conducted under the following conditions:

Temperature: Between 10 DEG and 75 DEG C., preferably between 15 DEG and 50 DEG C.,

Humidity: Between 50 and 90% RH preferably between 60 and 85% RH,

Time: Between 2 and 24 hours, preferably between 4 and 15 hours,

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By drying the rice under these conditions, the water content thereof is finally adjusted to be between 10 and 15.5%. If it is less than 10%, it takes too much time to cook the thus-obtained dried rice. If the water content exceeds 15.5%, the rice is subject to molding during the storage thereof, making it impossible for the rice to be preserved for a long time.

The principle of the present invention is to treat polished rice in the above-described processes.

However, the rice may be seasoned by using a solution of salt, Japanese Sake or seasonings, or may be colored by using saffron or the like during the soaking of the rice in water. The rice may have separately dried ingredients or powdered seasonings added thereto during the packing thereof after it has been dried.

The present invention makes it possible to manufacture dried rice which need not be washed with water or soaked in water (generally soaking for 30 minutes or above is required), and which can be made edible in a very short period of time. By using the dried rice manufactured in accordance with the present invention, it is possible to reduce the time required for cooking the rice from 25 minutes or above to about 15 minutes, as well as to eliminate the hard core from the cooked rice and to give a good texture thereto. Further, the dried rice manufactured in accordance with the present invention can be stored for a long period of time. It has no cracks therein, and therefore looks attractive.

Although the dried rice of the present invention may be made edible using an ordinary electric rice cooker, it can be easily cooked by package cooking (in which the rice is packed in a bag having a large number of small openings, and is cooked in that state by placing the bag in boiling water).

The present invention will be described hereinunder by the following non-limitative example.

EXAMPLE

After 100 g of polished rice with a water content of 15% had been washed with water, it was soaked in water having a temperature of 20 DEG C. for 1 hour. Water adhered to the surface of the rice was then removed so as to obtain rice with a water content of 30%. The rice was then soaked in 200 g of 70% sorbitol solution at a temperature of 20 DEG C. for 90 minutes to replace the water contained in the rice with the sorbitol solution. The sorbitol solution adhered to the surface of the rice was removed using a centrifugal separator (of basket type), thereby providing dehydrated rice with a water content of

20% (dehydration was conducted at a rate of 33.3%.

Subsequently, the rice was dried for 8 hours at a temperature of 40 DEG C. and at a humidity of 80%

RH to obtain dried rice in accordance with the present invention (Sample A). The water content of the thus-obtained rice was 15%, while the sorbitol content was 8.2%.


Dried rice with a water content of 15% (Sample B) was obtained in the same manner as Example with the exception that soaking in sorbitol was not performed and that the rice was dried for 10 hours.


Polished rice similar to that employed in Example was soaked in 200 g of 70% sorbitol solution for 90 minutes without being soaked in water beforehand, and the water was then drained to obtain dried rice with a water content of 15% (Sample C). Drying was not performed in this Comparative Example.


Dried rice with a water content of 15% (Sample D) was obtained in the same manner as Example with the exception that the polished rice, after being washed with water, was soaked in a 10% sorbitol solution and that the water was centrifugally separated to prepare dehydrated rice with a water content of 29% (dehydration rate . . . 3.3%)


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Dried rice with a water content of 14.8% (Sample E) was obtained in the same manner as Example, with the exception that the polished rice was soaked in water for 10 minutes so that the water content thereof was adjusted to be at 22% and the rice was then soaked in sorbitol solution to obtain rice with a water content of 18%.


Rice cooked in the same manner as that in Control (to be described later), but which was not allowed to steam, was dried with hot air at 80 DEG C. for 30 minutes to obtain dried rice with a pregelatinized starch content and water content of 10% (Sample F).

Table 1 shows the results of comparison between the tastes of the above samples, each sample being prepared by packing 40 g of it in a 7.times.8 cm heat-resistant bag having small openings, and by cooking the bag in boiling water for 15 minutes.

Control was prepared by soaking 1.4 kg of polished rice in water for 1 hour after washing with water, cooking it for 30 minutes using an electric rice cooker and by steaming the boiled rice for 10 minutes.

Sample F was prepared by pouring hot water into the bag containing the rice, draining the water after 5 minutes, then steaming the cooked rice for 5 minutes.

>;tb;__________________________________________________________________________

>;tb; Taste

>;tb;Item Appearance (before cooking)

>;tb; Hardness of

>;tb;Sample

>;tb; Cracking Brittleness

>;tb; center

>;tb; Texture

>;tb;__________________________________________________________________________

>;tb;A Very few cracks

>;tb; Hard to break

>;tb; - Fluffy and good

>;tb;B Many cracks

>;tb; Very easily broken

>;tb; + Hard

>;tb;C No cracking

>;tb; Hard to break

>;tb; + Hard

>;tb;D Many cracks

>;tb; Easily broken

>;tb; .+-. Slightly hard

>;tb;E Very few cracks

>;tb; Hard to break

>;tb; + Hard

>;tb;F Yes Easily broken

>;tb; - Lacks stickness and too

>;tb; soft, lacks the special

>;tb; aroma of cooked rice

>;tb;Control

>;tb; No Hard to break

>;tb; -- Fluffy and good

>;tb;__________________________________________________________________________

>;tb; *Sample A is that of the invention, while the others are comparison

>;tb; examples.

The state of the center was evaluated by the following criteria:

- . . . The center is not hard.

.+-. . . . The center is slightly hard.

+ . . . The center is hard.

1654/2197

Thus, according to the present invention, it is possible to obtain very good dried rice.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method of manufacturing dried rice consisting essentially the steps of: adjusting the water content of polished rice so that it reaches at least 23 wt% after the rice has been washed with water; soaking the rice in a sugar solution consisting essentially of a sugar and water so as to allow the sugar to permeate the rice and to remove 6 to 38 wt% of the water contained in the rice; separating the sugar solution adhered to the rice; and drying the rice under conditions in which starch contained therein will not be pregelatinized.

2. A method as set forth in claim 1, wherein the water content of the polished rice is 13 to 16 wt% before it is washed with water.

3. A method as set forth in claim 1, wherein the water content of the polished rice is adjusted so that it reaches 28 to 35 wt% after the rice has been washed with water.

4. A method as set forth in claim 1, wherein the sugar solution is an aqueous solution containing at least one sugar selected from the group consisting of sorbitol, mannit, sucrose, glucose and liquid sugar.

5. A method as set forth in claim 1, wherein the sugar is permeated in the rice in an amount of 3 to 9 wt% by soaking the rice in a sugar solution.

6. A method as set forth in claim 1, wherein 12 to 35 wt% of the water contained in the rice is removed therefrom by soaking the rice in a sugar solution.

7. A method as set forth in claim 1, wherein the rice is soaked in a sugar solution at a temperature of 15

DEG to 60 DEG C. for 10 to 120 minutes.

8. A method as set forth in claim 1, wherein the rice is dried at a temperature of 10 DEG to 75 DEG C.,

50 to 90% RH for 2 to 24 hours.

9. A method as set forth in claim 1, wherein the rice is dried so that the water content of the rice reaches 10 to 15.5 wt%.Data supplied from the esp@cenet database - Worldwide

1655/2197

360.

US4764390 - 8/16/1988

PROCESS FOR MAKING MICROWAVABLE SHAPED RICE PRODUCTS


Inventor(s): ZUKERMAN HAROLD W (US); ZUKERMAN RACHEL B (US)

Applicant(s): ZUKERMAN HAROLD W (US); ZUKERMAN RACHEL B (US)


IP Class: A23L1/01; A23P1/00

E Class: A23L1/10H; A23L1/182C; A23L1/164C



Family: US4764390

Abstract:


A microwavable shaped rice product made with limited amounts of water, producing cooked rice grains with centers that are not fully hydrated. These shaped rice products are held in frozen storage and prior to serving they are reheated in a microwave oven. When the shaped rice products are microwave reheated from the frozen state, a portion of their water that was originally bound with the rice grain structure, is released. During this microwave reheating, this released water becomes very hot, both cooking and being absorbed by the not fully hydrated rice grain centers. When microwavable shaped rice products are later served, they have a crust and their overall inner texture is soft and firm, but not soggy.Description:



There are several products such as rice cakes and granola bars, that consist of dry, puffed rice, and/or dry, puffed cereals. Syrup binders hold together the dry, puffed rice and/or dry puffed cereals in granola bars. Other methods are used to hold together other dry, puffed cereal products. However, these dry, puffed cereal products all have a very low moisture content, and are neither frozen, stored frozen, or reheated before the consumer eats the product.

The procedures for making frozen shaped rice products are set forth in U.S. Pat. No. 3,711,295. The techniques for preparing a frozen cooked rice product that has a portion of its amylose and amylopectin modified are discussed in U.S. Pat. No. 3,961,087.

Cooked rice grains are soft and fragile, and can easily become pasty and gummy during the cooking and shaping process. Some high shear shaping machinery is designed to create a high shear action and will always produce shaped rice products with mashed and sheared rice grains that have an excessively pasty and gummy texture. Some low shear shaping machinery is designed with features that are not as destructive to the soft, cooked rice grains. When most low shear shaping machines are operated at very slow speeds, they make shaped rice products that have a satisfactory texture. However, when some low shear shaping machines are run at a faster rate, shearing, mashing, and rice grain destruction occurs, and the shaped rice products' texture become excessively pasty and gummy.

1656/2197

Currently, frozen shaped rice products, which are usually reheated by oven baking or fat frying, become very soggy and are judged unacceptable when reheated with a microwave oven. My invention incorporates procedures and equipment to make microwavable frozen shaped rice and/or other grain products that have a surface crust and interiors that are not excessively pasty and gummy even though they are produced at relatively high production rates.

BRIEF SUMMARY OF THE INVENTION

It is the object of the present invention to provide a shaped rice product that utilizes broken or whole grain rice that has a surface crust and an interior of soft rice grains that are not excessively pasty and gummy.

It is another object of the present invention to provide a microwavable shaped rice product that utilizes broken or whole grain rice that does not become soggy when it is reheated from the frozen state by a microwave oven.

It is another object of the present invention to provide a mixed grain shaped product that comprises broken or whole grain rice with other cereal grains, starch or cereal components, such as wheat, buckwheat, sorghum, potato, millet, corn, barley, triticale, cassava, oats, or rye having a surface crust and a soft interior [wherein that contains] the other grains dispersed together with rice grains.

It is another object of the present invention to provide a microwavable shaped rice product having identifiable, natural food pieces such as mushrooms, shrimp, vegetables, fruits, nuts, sesame seeds, onions, apples, raisins, diced poultry or ham, dispersed together with the soft, cooked rice grains or mixed grains.

It is another object of the present invention to provide an oriental-flavored microwavable shaped rice product having short or medium grain rice that does not become soggy when reheated from the frozen state by microwave ovens.


FIG. 1 is a perspective view of a covered transfer-conveyor suitable for receiving partially cooked rice from the cooking kettles.

FIG. 2 is a graphic view of a low shear roll extrusion device.

FIG. 3 is a perspective view of a shape forming device having molds to form the shaped rice units.

FIGS. 4A and 4B illustrate a device for forming a sheet of joined cooked rice grains and then cutting the sheet into shaped rice units.

FIG. 5 illustrates the separated units of the rice shapes before they are submerged in the hot fat.

FIG. 6 illustrates cooked rice grains in a rectangular shape before the surface crust is formed. The rectangular shape is illustrated in two parts to show both the interior and surface textures.

FIG. 7 illustrates mixed grains with natural food pieces in a rectangular shape before the surface crust is formed. The rectangular shape is illustrated in two parts to show both the interior and surface textures.

FIG. 8 illustrates a microwavable circular shaped rice product made from mixed grains and natural food pieces. It is depicted after its crust has been developed. This product is made so that the consumer can reheat the frozen product within a minute or two by microwave energy. The circular shape is illustrated in two parts to show both the interior texture and the surface crust.


1657/2197

The present invention relates to a shaped rice and/or grain food product and more particularly, it is directed to a shaped rice and/or grain food product suitable for cooking in a microwave oven or the like. To more simply describe my invention, I refer to it as a shaped rice product. However, it is understood that it may consist of rice or rice and other grains as more fully described hereinafter.

Microwavable shaped rice and/or grain food products are generally prepared in a three step procedure:

(1) Cooking, (2) Shape Formation; and (3) Crust Formation.

The first step is the rice-cooking process wherein my preferred embodiment, one hundred pounds of dry, whole or broken grain rice, is cooked in approximately two hundred pounds of 170 DEG F.-212

DEG F. water. The cooking takes place in a kettle having non-shear scrapers suitable for handling the aforesaid quantities of rice and water. Cooking kettles for this purpose are well-known in the art and are readily available in the market place and, therefore, not illustrated in the drawings. A pre-blend of one pound glycerol monostearate and one-quarter pound of vegetable oil may be mixed with the cooked rice. The oil and starch complexing materials prevent the rice grains from sticking together in the early phase of rice cooking. They also complex the amylose and amylopectin starch during cooking, and finally, by providing some additional lubrication to the rice, there is less mechanical damage during the shaping of the units. This results in significantly less damaged rice grains in the shaped rice products interiors.

Other starch complexing agents that can be used include: glyceryl monostearate, glyceryl monopalmitate, glycerol monolaurate, glyceryl monomyristate, glyceryl monoarachidate, glyceryl monooleate, glyceryl monolinoleate, calcium stearoyl-2-lactylate, sodium stearoyl-2-lactylate, polyoxyethylene monostearate, sodium stearoyl-fumate, sucrose fatty acids, and succinylated monoglycerides.

The glycerol monostearate-vegetable oil-water mixture is agitated in the hot liquid before the dry rice is added, and is continuously agitated during and after the dry rice is added. Non-shear scraper mixers

(not illustrated) in the kettle agitate the rice at a slower rate as the rice absorbs the hot water and becomes softer in texture. Finally, the water and oil dispersion becomes absorbed into the rice grain structure.

The second step of the rice cooking process is the addition of the flavor. The flavor is added to the cooking kettle by means well known in the art and blended together with the now hot, soft, partially cooked rice grains. There are three categories of flavors:

1. Herb and Spice Flavor Blend. This category consists of soluble and dispersible ingredients such as salt, butter, dextrose, monosodium glutamate, soy sauce, honey, sodium acid pyrophosphate, herbs, and spices.

2. Mixed Cereal Flavor Blend. Mixed cereals provide both an improved taste and also an improved texture. This is especially true when they are also blended together with natural food pieces such as raisins and apples. Grains or parts of grains such as wheat, soy, millet, corn, oats, barley, triticale, cassava, buckwheat, and rye should be cooked together with the rice grains in the cooking kettle.

Precooked or toasted grains or parts of grains can be added as a flavor and blended together with the soft, partially cooked rice grains.

3. Natural Food Pieces Flavor Blend. Natural food pieces such as mushrooms, shrimp, vegetables, fruits, nuts, sesame seeds, onions, apples, raisins, and diced poultry or ham can be dispersed together with the soft, cooked rice grains.

Two ingredients in the flavor blend, dextrose and sodium acid pyrophosphate, are used to help control the golden brown surface color of shaped rice products. Lighter surface colors are obtained when less dextrose is used. Dark surface colors are obtained when more dextrose is used. Sodium acid pyrophosphate is in the product for two reasons:

1. It improves the texture of the shaped rice products, and

1658/2197

2. It also chelates the heavy metals in the rice. If the heavy metals are not chelated, they will cause the surface of the shaped rice products to become dark in color.

The added flavor also contains about 1% butter, margarine, or vegetable oil for both lubrication and improved flavor. The added butter, margarine, and/or oil provides lubrication which reduces the mechanical damage during the shaping operation which in turn yields rice shapes with more undamaged soft rice grains.

The added flavor could also contain water. The amount of water added to the cooking kettle for each

100 lbs. of dry, raw rice is influenced by how the consumer is later expected to reheat the shaped rice product from frozen storage:

(A) Rice grains for microwavable shaped rice products are cooked with a total of about 100 lbs. to 350 lbs. of water per 100 lbs. of dry rice.

(B) Rice grains for shaped rice products are cooked with a total of about 100 to 400 lbs. of water per

100 lbs. of dry rice when one of the following three reheating techniques is used: (1) fat frying, (2) oven baking, or (3) microwave--but with the use of special microwave absorbing materials that become hot from the microwaves and then bakes the shaped rice products in the microwave oven.

Gums, well known in the art are good water binders and may be used to soak up the released water that becomes available when the shaped rice products are reheated from frozen storage by a microwave oven. However, it is redundant to add the gums because rice grains prepared for microwavable shaped rice products soak up and bind the water that becomes released when the shaped rice products are reheated.

The third step of the rice cooking process takes place in a covered transfer-conveyor 10 (illustrated in

FIG. 1). When the rice is moved from a cooking kettle 12 to the transfer-conveyor 10, it is still fluid.

The rice at this time is only partially cooked. The rice grain centers are not fully hydrated and they can even have small sections that are hard and dry while their surface is soft. The conveyor cover is then closed, and the rice continues to cook in an enclosed environment at temperatures above 160 DEG F.

While the rice is cooking, the transfer-conveyor moves the rice very slowly from the cooking kettle 12 to a shaping device. FIG. 2 illustrates one type of shaping device. FIG. 3 illustrates a second type of shaping device 16, and FIGS. 4A and 4B illustrate a third type of shaping device, 20. The rice is cooked in the transfer-conveyor without agitation that could shear or mash the soft rice grain texture.

Covered transfer-conveyors are well known in the art and readily available in the market place.

By the time the cooked rice for the microwavable shaped rice products reaches the shaping equipment

15 to 30 minutes later, the surface of the rice grains still remain soft and the rice grain centers have absorbed some of the surface moisture. However, the rice grain centers are still only partially hydrated, i.e., they are either soft and partially hydrated, or a very small part of the rice grain center is still hard and virtually uncooked.

In my preferred embodiment, the rice cooking process cooks rice formicrowavable shaped rice products so that the rice grains do not get fully cooked and fully hydrated. This way they have extra capacity to soak up additional water when they are later reheated with microwave energy. This additional water becomes available from the thawed rice starch granules that are broken during freezing, frozen storage, and freeze/thaw abuse and from some retrograded rice starch granules.

Microwave oven reheating does not evaporate much water. Microwave reheating works on the principle that during the microwave reheating process, the released water becomes very hot, both cooking and being absorbed by the not fully hydrated rice grain centers. Therefore, when microwavable shaped rice products are served, all the extra moisture has been reabsorbed by the rice grains and the inner texture is soft and firm, but not soggy.

Rice shapes can be made from the cooked rice by one of the following low shear, multiple-deposit, shaping devices well known in the art and readily available in the market.

(a) A roll extrusion device 14 having 3 to 200 parallel rows of rice shapes, is graphically illustrated in

FIG. 2.

1659/2197

(b) A form shaping device 16 having molds 18 to form the shapes is illustrated in FIG. 3.

(c) A form shaping device 20 in FIGS. 4A and 4B illustrates the forming of a sheet of joined cooked rice grains and then cutting the sheet into shaped rice units.

FIG. 2 shows the roll extrusion device 14 that feeds the cooked rice between two rolls and extrudes between 3 and 200 parallel ribbons of joined, cooked rice grains. This technique is used to produce rectangular, cylindrical, square, oval, and other special shapes, not illustrated. With this shaping device, more desirable rice grain textures are achieved when the maximum number of die holes, not illustrated, are used. Also, it is preferable to use at least 4 inch diameter rolls (larger diameter rolls are even better because they reduce churning during the rice feeding). Finally, it is also preferred to use rice that is hot and freshly prepared.

A cutter such as a rotary or a guillotine cutter can be used to cut the 3 to 200 parallel rows of cooked rice into units that are 2, 21/2, or 3 inches long or any other desirable length. Once the units are cut, they then have to be separated as illustrated in FIG. 5 so that there is a space between them. If the units are not properly spaced, they might stick to one another when they are fat fried.

FIG. 3 shows the shape forming device 16 having molds 18. This device consists of two parallel horizontal cylinders that rotate in opposite directions. One roll is smooth: the other has several side by side designs of the product shape engraved in the cylinder. FIG. 3 illustrates how the soft cooked rice is compressed into the molds and the shaped rice units containing the cooked rice grains are then released onto a conveyor belt. The pattern illustrated in FIG. 3 shows the shaped rice products already properly spaced for the crust forming operation.

FIGS. 4A and 4B show a shape forming device 20 using the technique of cutting a sheet of rice grains into shapes.

The cooked rice from the transfer conveyor 10 illustrated in FIG. 1 can be reduced to a sheet which in turn can be cut into shapes. There are several ways to form a sheet of cooked rice grains. One way is illustrated in FIG. 4A which shows two conveyors converging: 15 is the top conveyor; 17 is the bottom conveyor: and 19 is the cooked rice grains. The rice 19 is compressed between the two conveyors 15 and 17 so that it becomes a sheet of joined rice grains by the time it leaves the two conveyors.

FIG. 4B shows a second technique: a shape forming device that forms rice sheets by compressing soft cooked rice grains. This second technique is accomplished by systematically reducing the height of a bed of cooked rice grains with one, two, or more compression rolls or plates 22. This sheet is then cut into shaped rice units.

The form-shaping device 20 illustrated in FIG. 4B can also be used to make a shpaed rice product that has a more concentrated flavor on its top side. This is accomplished by layering on the top side of the sheet of joined cooked rice grains 32 (between the two compressions rolls 22) either one or all of the following flavor blends:

(a) a herb and spice flavor blend,

(b) a mixed cereal flavor blend,

(c) a natural food pieces flavor blend,

(d) a cooked rice with a different flavor.

The last compression roll 22 compresses the flavor layer into the sheet of joined cooked rice grains so that it becomes a multilayered sheet.

Rotary cutters 24 (3 to 150 per machine) cut the sheet of compressed rice grains into strips. A guillotine or rotary cutter 26 cuts the strips into 2-inch to 3-inch long units. The rice shapes have to be separated as illustrated in FIG. 5. This is accomplished by using a belt spreader 28 to create a 1/4 inch space between the rows of compressed rice grains. A space between the lengths of the units is created when the rice units are transferred from one conveyor to a second conveyor 30 moving at a slightly faster speed. If the units are not properly separated, they might stick to one another when they are fat fried.

1660/2197

Shaped rice products can be made in many different shapes and flavors. Some can be made to be reheated from frozen storage by microwave energy while others can be made to be reheated from frozen storage by (a) oven baking, (b) fat frying or (c) baking in a microwave oven with a browning element or hot microwave absorbing material. The following three embodiments illustrate how different flavors, cereal mixtures, and rice varieties can be appropriately formulated to produce different products.

EXAMPLE 1

MICROWAVABLE ONION-BUTTER SHAPED RICE PRODUCTS

This example lists the formula for an onion-butter flavored cooked rice. The cooked rice grains are first formed into a given shape. FIG. 6 illustrates cooked rice grains in a rectangular shape before the surface crust is formed. The rectangular shape is illustrated in two parts to show the interior and surface textures. Then, the surface crust is developed and the units are frozen and stored frozen.

>;tb;______________________________________

>;tb;WEIGHT RANGE

>;tb;INGREDIENTS (PERCENT) (PERCENT)

>;tb;______________________________________

>;tb;Water 57.00 45-60

>;tb;Medium grain rice 38.00 20-50

>;tb;Salt 1.20 0.2-2

>;tb;Butter 1.20 0.5-5

>;tb;Dextrose 0.95 0.5-1

>;tb;Dry minced onion 0.70 0.2-5

>;tb;Monosodium glutamate

>;tb; 0.40 0.2-1

>;tb;Distilled glyceryl monostearate

>;tb; 0.33 0.1-1

>;tb;Sodium acid pyrophosphate

>;tb; 0.07 0.01-.5

>;tb;Vegetable oil 0.15 0.1-5

>;tb; 100.00

>;tb;______________________________________

EXAMPLE 2

SESAME/SOY-ORIENTAL FLAVORED SHAPED RICE PRODUCTS

This example lists the formula for a sesame/soy flavored cooked rice. The cooked rice grains are first formed into a given shape. FIG. 6 illustrates cooked rice grains in a rectangular shape before the crust is formed. The rectangular shape is illustrated in two parts to show both the interior and surface textures. Then, the surface crust is developed, and the units are frozen and stored. Short and/or medium grain rice was selected for the oriental style shape rice product because of its distinctive taste and texture and its excellent freeze/thaw resistant properties.

>;tb;______________________________________

>;tb;WEIGHT RANGE


>;tb;______________________________________

>;tb;Water 68.00 50-75

>;tb;Medium or short grain rice

>;tb; 25.00 20-45

>;tb;Soy sauce 3.00 0.5-5

>;tb;Sesame oil 1.00 0.5-5

>;tb;Sugar 0.85 0.2-2

>;tb;Salt 0.80 0.5-1.5

>;tb;Dextrose 0.62 0.2-1

>;tb;Glycerol Monostearate

>;tb; 0.25 0.1-1

1661/2197

>;tb;Minced onion 0.40 0.1-4

>;tb;Disodium Pyrophosphate

>;tb; 0.05 0.01-0.5

>;tb;Minced garlic 0.02 0.01-0.3

>;tb; 100.00

>;tb;______________________________________

EXAMPLE 3

SHAPED RICE PRODUCT WITH MIXED GRAINS AND ALSO WITH NATURAL FOOD PIECES

This example lists the formula for a cooked rice flavored with other mixed grains and also with natural food pieces. The cooked rice blend is first formed into a given shape. FIG. 7 illustrates a rectangular shape with the cooked rice grains dispersed together with the other cereal grains and also with the natural food pieces before the surface crust is formed. The rectangular shape is illustrated in two parts to show the interior and surface textures. Then, the surface crust is developed and the units are frozen and stored frozen.

FIG. 8 illustrates a microwavable circular shaped rice product made from mixed grains and natural food pieces. It is depicted after its crust has been developed. The circular shape is illustrated in two parts to show both the interior 34 texture and the surface crust 36. This product is made so that the consumer can reheat the frozen product within a minute or two by microwave energy.

>;tb;______________________________________

>;tb;WEIGHT RANGE


>;tb;______________________________________

>;tb;Water 68.00 50-75

>;tb;Broken grain or whole grain

>;tb; 10.00 5-25

>;tb;long grain white rice

>;tb;Medium grain brown rice

>;tb; 10.00 5-25

>;tb;Steel cut oats 2.00 1-10

>;tb;Pearl barley 2.00 1-5

>;tb;Corn oil 1.50 0.1-5

>;tb;Diced apples 1.50 0.5-5

>;tb;Black raisins 1.50 0.5-5

>;tb;Honey 1.00 0.5-2

>;tb;Salt 1.00 0.2-3

>;tb; 100.00

>;tb;______________________________________

When the cooked rice product has been formed and shaped, it is conveyed to a deep fat fryer (not illustrated) by a suitable conveyor belt (illustrated in FIG. 5.) There are three steps to the frying operation:

(a) precooking the surface so that the units don't stick together.

(b) crust formation, and

(c) draining the excess fat before the units are cooled and frozen.

FIG. 5 is an illustration of the rice shapes on a mesh belt conveyor. There is a space between the units. the first row of rice units is just about to move into the hot fat. It is not yet submerged, however. The hot bubbling fat is creeping up the mesh belt conveyor and is already frying their bottoms and sides.

This pre-frying is helpful because it starts the crust formation process while the rice units are laying straight. This pre-frying operation also seals the shaped rice products' surfaces which makes them less likely to become stuck to one another when they become submerged or are allowed to float in the hot fat. A crust is formed by fat frying the units for about 40 to 60 seconds at 375 DEG F. -410 DEG F.

Longer frying times may be required for microwavable shaped rice products because they sometimes need a thicker crust.

1662/2197

During the fat frying operation, approximately 10%-25% of the shaped rice products' moisture boils off while the submerged units pick up approximately 5%-20% of the hot cooking fat. Since the cooking fat has now become one of the major ingredients of the product, it is important to assure that its quality is properly controlled. Finally, the excess fat is drained from the units, by means well-known in the art.

A second means to form a crust on the surface of shaped rice products is with a hot air oven at oven temperatures of about 550 DEG F. for about five to ten minutes. Crusts developed by oven baking are useful for shaped rice products that are merchandised as low calorie or controlled calorie foods.

The development of a crust is important because without the surface crust, the thawed shaped rice products fall apart or become stuck together.

The shaped rice product is conveyed from the fryer to a packaging device, not shown but well-known in the art and readily available in the market. The packages of shaped rice product are preserved in two ways:

(1) Freezing and storing the product frozen. The shaped rice product should be frozen rapidly because a better texture is achieved when small ice crystals are formed rather than when large crystals are formed. Large ice crystals are more prone to break rice starch granules and create more free, unbound fluid when the shaped rice products are reheated from frozen storage.

(2) Shaped rice products treated with an antimycotic agent such as 0.10% to 0.4% sorbic acid, sodium benzoate or sodium sorbate can be manufactured frozen and held in frozen storage until sold. The product can then be refrigerated for up to 10 days.

It is to be understood that the above described process and the above examples are simply illustrative of the application of principles of the invention and many other modifications may be made without departing from the spirit and scope of the invention.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A process for making a microwavable shaped rice product, said process comprising the steps of: (a) partially cooking 100 lbs. of raw, hard, whole or broken grain dry rice with 100 lbs. to 350 lbs. of water at 170 DEG F. to 212 DEG F.; (b) combining one or more of a plurality of flavors with the partially cooked rice; (c) removing the partially cooked rice from the hot water prior to the center of the rice becoming fully cooked; (d) conveying the partially cooked rice on a horizontal belt through an enclosed environment at a temperature above 160 DEG F. whereby the rice and flavor continue to cook, leaving the center of the rice grains not fully cooked and not fully hydrated; (e) shaping the cooked rice with low-shear, multiple-deposit, multiple-extrusion and multiple-cutting devices to form a shaped rice product; (f) forming a crust on the shaped rice product surface by floating the shaped rice product in a fat fryer; the floating of the product being related to its density; and (g) freezing the rice product.

2. The process set forth in claim 1 wherein the rice is cooked in the presence of a starch complexing agent comprising glycerol monostearate, in a ratio of starch complexing agent to dry rice is about 1 lb. of complexing agent to about 100 lbs. of dry rice.

3. The process set forth in claim 2 wherein the shaping step comprises compressing the cooked rice grains by means of a two-roll extrusion device that forms from 3 to 200 or more continuous rope-like shapes containing the soft rice grains that are joined to each other, said rope-like shapes being conveyed to a guillotine cutter for the purpose of simultaneously cutting the said 3 to 200 ropes of cooked rice into 2-inch to 4-inch long units.

1663/2197

4. The process set forth in claim 3 wherein the shaping step further comprises compressing the cooked rice grains simultaneously into 3 to 200 molds of one of a plurality of rice shapes; said rice shapes being simultaneously deposited across the width of the conveyor having a minimum of a 1/16 inch shape between the units.

5. The process set forth in claim 4 wherein the rice is cooked with a chelating agent comprising sodium acid pyrophosphate.

6. The process set forth in claim 5 wherein cereal grains, starch and cereal components are combined with the whole or broken grain rice.

7. The process set forth in claim 6 wherein the shaped rice product is treated with 0.10 to 0.4% sodium bensoate, sorbic acid or sodium sorbate.

8. The process set forth in claim 7 wherein natural food pieces are dispersed together with the cooked rice grains.

9. The process set forth in claim 8 wherein said starch complexing agent is selected from the group consisting of glyceryl monopalmitate, glyceryl monolaurate, glyceryl monomyristate, glyceryl monostearate, glyceryl monoarachidate, glyceryl monoleate, glyceryl monolinoleate, calcium stearoyl-

2-lactylate, sodium stearoyl-2-lactylate, polyoxyethylene monostearate, sodium stearoyl fumarate, and succinylated monoglycerides.

10. The process set forth in claim 1 wherein a herb and spice flavor blend is layered on the top side of the rice grains having centers not fully cooked and not fully hydrated prior to the crust being formed.

11. The process set forth in claim 1 wherein a mixed cereal flavor blend is layered on the top side of the rice grains having centers not fully cooked and not fully hydrated prior to the crust being formed.

12. The process set forth in claim 1 wherein natural food pieces flavor blend is layered on the top side of the rice grains having centers not fully cooked and not fully hydrated prior to the crust being formed.

13. The process set forth in claim 1 wherein a cooked rice with a different flavor is layered on top of the rice grains having centers not fully cooked and not fully hydrated prior to the crust being formed.

14. The process set forth in claim 2 wherein natural food pieces are combined with the rice grains having centers not fully cooked and not fully hydrated.Data supplied from the esp@cenet database -

Worldwide

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361.

US4765996 - 8/23/1988

ENRICHED RYE AND BARLEY AND ITS PRODUCTION


Inventor(s): MISAKI MASARU (JP); MURATA HISASHI (JP); YAMAMOTO HIDEO (JP);

WATANABE YASUHIKO (JP)

Applicant(s): TAKEDA CHEMICAL INDUSTRIES LTD (JP)


IP Class: A23L1/30

E Class: A23L1/182B; A23L1/10B



Family: JP60118153


Abstract:


Polished rice or barley enriched with nutrients, wherein the nutrients are fixed in and on the grain by coating an oil/fat and/or a wax on the grains, coating the same with a hydrophilic emulsifier and further coating them with a starch-based coating agent. The enriched polished rice or barley has essential nutrients in good balance and quality-wise advantageous characteristics.Description:

US4765996 : No description available

Data supplied from the esp@cenet database - Worldwide Claims:


What we claim is:

1. In a process for producing enriched polished rice or barley which consists essentially of incorporating or depositing an assortment of nutrients selected from the group consisting of watersoluble vitamins, fat-soluble vitamins, amino acids and minerals, in or on polished rice or barley grains, coating each of the grains with an oil/fat and/or a wax having a melting point of about 40 DEG C. to 80

DEG C., and coating the resultant grains with a starch coating agent containing starch and a binding agent wherein the starch is selected from the group consisting of corn starch, wheat starch and rice starch in raw form, the improvement wherein a hydrophilic emulsifier selected from the group consisting of sucrose fatty acid esters, sorbitan fatty acid esters and glycerol fatty acid esters which have an HLB value of 8 or more, proteins and vegetable gums, is coated on the grains in an amount of

0.05 to 1 weight percent based on the finished product, between the oil/fat and/or wax coating and the starch coating.

2. A process according to claim 1, wherein the oil/fat is hydrogenated cottonseed oil, the wax is rice wax, the hydrophilic emulsifier is sucrose fatty acid ester of HLB15 and the starch is wheat starch.

3. Enriched polished rice or barley which consists essentially of polished rice or barley grains, nutrients selected from the group consisting of water-soluble vitamins, fat-soluble vitamins, amino acids and

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minerals, fixed in or on said grains, a first coating layer of an oil/fat and/or a wax having a melting point of about 40 DEG C. to 80 DEG C., a second coating layer of hydrophilic emulsifier selected from the group consisting of sucrose fatty acid esters, sorbitan fatty acid esters and glycerol fatty acid esters which have an HLB value of 8 or more, proteins and vegetable gums, in an amount of 0.05 to 1 weight percent based on the finished product, and a third coating layer of a starch coating agent containing starch and a binding agent wherein the starch is selected from the group consisting of corn starch, wheat starch and rice starch in raw form, in that order.

4. The rice or barley enriched with nutrients according to claim 3, wherein the oil/fat is hydrogenated cottonseed oil, the wax is rice wax, the hydrophilic emulsifier is sucrose fatty acid ester of HLB15 and the starch is wheat starch.Data supplied from the esp@cenet database - Worldwide

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362.

US4767636 - 8/30/1988

METHOD FOR ADHERING SPICES ON THE SURFACE OF RICE


Inventor(s): RAMOS HECTOR V (US); ROTHENBERG JOAN R (US); SMITH DAVID L

(US); FAGAN JR KENNETH W (US)



IP Class: A23L1/36

E Class: A23L1/182B



Family: CA1316754

Abstract:


The present invention is concerned with a continuous process for preparing a non-segregating, freeflowing dried instant rice and sauce dish comprising coating rice in a rotating coating reel with a layer of oil followed by contacting the coating rice with dry ingredients then applying a second layer of oil and finally adding vegetable inlays prior to packaging.Description:



The present invention is concerned with a process for producing an instant rice and sauce dish. More particularly, the present invention is concerned with a process for adhering a powder spice/flavor blend to the surface of rice so that a sauce will form upon cooking with water and the packaged product will have portion controlled features.


Food processors desire to package their food products in a manner compatable with the broadest range of consumer needs. Consumers, on the other hand, require the freedom to choose their own serving size. Consequently, foodstuffs are packaged to optimize the consumer's choice of serving sizes whenever practical. However, free-flowing mixtures of different size and density particles segregate after packaging, thereby restricting the feasible serving sizes to one: the entire package. Generally, the art has corrected this problem by agglomerating the segregating mixture to produce a non-segregating mixture.

In the past, foods have been agglomerated by a variety of methods, including: steaming and contacting the moistened food particles; moistening and pressing the food partciles together, U.S. Pat. No.

518,891 issud to Manwaring; and blending a solid food or foods with an aqueous or an aqueous miscible fluid, U.S. Pat. No. 3,100,909 issued to Schapiro. However, the structure of some foodstuffs, e.g., bread crumbs, collapses at intermediate and high moistures when agitated, thus precluding the use of agglomeration methods wherein the foodstuff is moistened to these levels. Consequently, Hege, U.S.

Pat. No. 3,987,138, developed a low moisture method of agglomeration. Hege teaches the use of a

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small amount of water dispersed in a large volume of a nonmiscible, inert, liquid carrier to lightly moisten the food. However, this procedure, may leave an unacceptable residue of the nonmiscible, inert, liquid carrier in the food.

Block et al., U.S. Pat. No. 3,409,442, teaches a procedure that produces a single particle by aggregating dry ingredients with a foamed, edible binder. According to the Block et al. disclosure, the foam and not the dry ingredients, provides the agglomerated particle with its structure. Furthermore, the Block et al. teaching directs the production of a perceptually moist product. Consequently, Block et al. disclose that the foaming agent should constitute only about 2% of the foam and that the foam overrun is limited to between 150 to 250%. In the Block et al. process, the foam moistens, agglomerates, and provides the framework for the dry ingredients.

U.S. Pat. No. 4,476,145 by Hardie-Muncy et al. discloses a means for agglomerating food material whose structure is moisture sensative and colapses upon exposure to the moisture levels used in traditional agglomeration methods. This is accomplished in Hardie-Muncy by dissolving a hydrophylic binding agent in water and whipping to form a high overrun form. The foam is then coated on to the moisture sensative material followed by the addition of the other ingredients. Further, U.S. Pat. No.

4,530,848 by Bannon et al. accomplishes the same end by coating oil onto the surface of a moisture sensative material such as specifically sized bread crumbs then distributing a powdered seasoning over the oil coated crumbs. The oil causes the powdered seasoning to aggregate on the surface of the bread crumbs. The resulting product can be prepared in a single hydration step, and any desired serving size can be easily prepared from a bulk packaged product.

It is, therefore, an object of the present invention to prepare a portion-controlled rice product.

A further object of the present invention is a process for agglomerating rice and other food materials.

Another object of the present invention is a process for preparing a non-segregating, free-flowing dehydrated rice product.


The present invention is concerned with a continous process for preparing a non-segregating, freeflowing, dry instant rice and sauce dish comprising: conveying rice to a rotating coating reel, coating the rice with oil in amounts ranging from 3.0 to 6.5% by weight, contacting the oil coated rice with dry ingredients, applying a second layer of oil to the rice coated with dry ingredients in amounts ranging from 3.0 to 6.5% by weight, and applying a third layer of oil to the oil coated rice in amounts ranging from 3.0 to 6.5% all by weight of the uncoated rice.


The present invention is concerned with the production of a non-segregating, free-flowing and dehydrated instant rice product which can be quickly prepared by the consumer in a one-step process.

This invention will be further described in terms of manufacture of a rice product which includes rice, dry spices and/or flavoring and dried vegetables.

In the present invention, parboiled rice at a predetermined flow rate of about 1,000 to 4,000 lbs./hour is fed to a coating reel which is rotating at about 5 to 9 revolutions per minute. Rotation enhances even distribution of added oil and dry ingredients about the surface of the rice and further prevents the rice particles from sticking together. To promote continuous movement of the rice through the rotating coating reel, said coating reel is positioned at an angle ranging from 10 DEG to 30 DEG from the horizontal.

A partially hydrogenated vegetable oil is then sprayed onto the rice at a rate ranging from 30 to 40 lbs/hr to a level of from to 3.0% to 6.5% by weight of the rice. Typically, oil is applied to the tumbling rice through a plurality of spray nozzles so that an essentially uniform oil coating is produced on all of the rice kernels.

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The nozzles through which the oil is applied in the present invention is located on the inside of the coating reel, with each nozzle spaced about one foot apart. The oil is pumped from a holding tank at about 10 to 30 psig to the nozzles. A pressure drop of about 40 to 100 psig is developed across each nozzle. Further, about 10 to 20 psig of air pressure is required to create an atomized hollow cone spray pattern of about 5 to 8 inches in diameter. These nozzles must be pointed to ensure that the atomized oil is deposited on the product.

The dry ingredients containing a mixture of salt, sugar, spices, flavoring materials, coloring materials and the like and combinations thereof are then contacted with the oil coated rice in a manner which will effect uniform distribution of the dry ingredients onto the surface of the oil coated rice kernel. The dry ingredients will be dispersed by feeding said ingredients froma loss-in-weight feeder to a 10 feet auger feeder located inside the coating reel next to the spraying system. The dry ingredients are applied through the 10 feet auger at a distance up to and not exceeding one-half the length of the coating reel, so that the dry ingredients will be typically distributed across the entire width of the moving oil coated rice kernels. During addition, continuous agitation is necessary to ensure that the oil coated rice is covered in its entirety with the dry ingredients. The amount of dry ingredients which is utilized may vary over wide ranges, but will typically be between 5% and 20% by weight of the rice (uncoated).

Once the rice becomes coated with dry ingredients in its entirety, a second layer of oil is coated onto the rice. This is accomplished by a second set of spray nozzles located 6 feet from the inlet within the mixer. Agitation is also essential to ensure a uniform oil coat. The purpose of the second oil layer is to ensure good adhesion of the dry ingredients. This results in a layer of oil totally surrounding the uniform dry ingredients coated rice, preventing said dry ingredients from falling off during subsequent processing. The oil is coated onto the rice coated with dry ingredients at a rate ranging from 30 to 40 lbs/hr to a level of from 3.0 to 6.5% by weight of the rice.

Prior to the addition of vegetable inlays, a third layer of fat is coated onto the rice kernel at the same rate and in the same amounts as the first and second layers, to ensure good adhesion of the vegetable inlays.

After the third layer of oil is evenly applied throughout the surface of the rice kernels, the vegetable inlays are added to the tumbling mixer. This is accomplished in a continuous manner by way of a long vibratory pan which is inserted after the third spray nozzles. The vegetable inlays will preferably have a particle size and density comparable to that of the rice kernels. Suitable cutting and sizing techniques will be employed so that essentially all of the vegetable pieces have a maximum dimension of between

3/8" and 3/8".times.3/4". In this manner the vegetable pieces and rice will be less likely to segregate either during handling, packaging or distribution of the packaged product. The vegetable pieces will typically be added at a level from 0.25% to 14.50% by weight of the rice. Dieced and dried celery, carrots, onions and the like may be included depending on the desired final product.

Since the product of the present invention is designed to be prepared by the consumer in a single step

(i.e., single hydration step), the dried vegetables must be hydrated at essentially the same rate as the rice kernels/dry ingredient aggregate. As will be appreciated by those skilled in the art, both the oil coating and the adhered dry blend will tend to retard hydration of the rice; however, it will still be necessary to employ dried vegetable pieces which hydrate faster than conventional air dried vegetables.

Freeze-dried vegetables and/or puffed dried vegetables will be suitable for use in this invention.

The finished product is fed from the reel onto a belt conveyor for packaging.

The following examples will further illustrate the features of the present invention.

EXAMPLE 1

A flow rate of 717.7 lbs/hour of Parboiled rice was fed to a coating reel. At the time of addition the coating reel was rotating at 6 RPM and positioned at an angle of 25 DEG from the horizontal. The rice was fed gravimetrically from a hopper onto a belt feeder then onto a vibratory pan which delivers the rice into the reel. A bed of about 3 inches was allowed to be formed in the reel before the oil was

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added. Oil (at room temperature) was then applied to the rice at a rate of 36.1 lbs./hr. or 12 lbs./hr./nozzle.

The oil was pumped from a holding tank at about 50 psig to a set of three two-fluid nozzles which were spaced about 1 foot apart in the center of the dryer. About 15 psig of air pressure was required with the oil spray to create an atomized hollow cone spray pattern of 8 inches in diameter. The nozzles were positioned so that the atomized oil was sprayed directly onto the tumbling product.

The dry ingredients (spice mix) were fed from a loss-in-weight auger feeder to a 10 feet auger feeder at a rate 115.3 lbs/hr. The spice mix was fed to the oil coated tumbling rice up to the center (length) of the coating reel.

Two additional layers of oil were coated onto the rice, coated with dry ingredients sequentially at the rate disclosed above. After the third layer of oil was applied, vegetables were added. The vegetables were fed to the mixer through an inlet located 1.5 feet from the outlet of the mixer. The vegetables were fed at a rates which varied with the particular vegetable. Orzo was fed at 95.3 lbs./hr.; onions at

22.9 lbs./hr.; dried mushrooms at 10.2 lbs./hr. and parsley at 2.5 lbs./hr. respectively.

The finished product was fed from the reel onto a belt conveyer at a rate of 1000 lbs./hr to be packed.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A continuous process for preparing a non-segregating, free-flowing, dried instant rice and sauce dish comprising the steps of: (a) conveying dried instant rice to a coating reel rotating at from 5 to 9 revolutions per minute at a rate of 1,000 to 4,000 lbs./hr. and wherein said coating reel is positioned at an angle ranging from 10 DEG to 30 DEG from the horizontal; (b) coating the rice with oil to levels ranging from 6.5% to 30% by weight of the rice; (c) coating the oil coated rice with dry sauce producing ingredients in amounts ranging from 5% to 20% by weight of the rice; (d) applying a second coat of oil to the rice coated with dry ingredient to levels ranging from 3.0% to 6.5% by weight of the rice; and (e) applying a third coat of oil to the oil coated rice of step (d) to levels ranging from 3.0% to

6.5% by weight of the rice.

2. A process according to claim 1 wherein the oil is sprayed onto the rice at a rate ranging from 30 to

40lbs/hr.

3. A process according to claim 1 further comprising the addition of vegetable inlays to the oil coated rice after the third oil coating step.

4. A process according to claim 1 wherein the dry ingredient is a member selected from a group consisting of salt, sugar, spices, flavoring material, coloring materials and combinations thereof.

5. A process according to claim 3 wherein the vegetable inlays are a member selected from a group consisting of orzo, onions, mushrooms, parsley and combinations thereof.

6. A process according to claim 2 wherein the vegetable inlays are added after the third oil coating step in amounts ranging from 0.25% to 14.50% by weight.Data supplied from the esp@cenet database -

Worldwide

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363.

US4775477 - 10/4/1988

CRANBERRY COLOR EXTRACTION


Inventor(s): STAHL HOWARD D (US); BORDONARO MICHAEL E (US); NINI DAVID (US)


IP Class 4 Digits: B01D

IP Class: B01D13/00

E Class: C09B61/00; A23L1/275B



Family: US4775477

Abstract:


A process for the extraction of cranberry presscake is disclosed which involves the steps of grinding the presscake, preferably with a filter aid like rice hulls, subjecting this mixture to water extraction, microfiltering the extract to remove colloidal high molecular weight components and passing the microfiltered extract through reverse osmosis to recover a red-colored solution.Claims:


What is claimed is:

1. A process for the extraction of cranberry presscake comprising the steps of grinding the presscake to obtain a ground presscake having a size between 1/16 to 1/2 inch, subjecting the ground presscake to a water extraction, microfiltering the extract to remove colloidal high molecular weight components and thereafter subjecting the filtrate to reverse osmosis to recover a feed of a red-colored solution passing the reverse osmosis membrane.

2. The process of claim 1 wherein the presscake is blended with a minor weight percent of filter aid.

3. The process of claim 2 wherein the filter aid is rice hulls.

4. The process of claim 2 wherein the cranberry presscake and filter aid incorporated at a level of from

15% to 45% by weight (dry weight) of filter aid is subjected to a water extraction wherein the water/presscake-filter aid ratio is 4:1 to 15:1, said extraction occurring at a temperature of from 70

DEG F. to 160 DEG F. for a period of time of from 5 to 60 minutes.

5. The process of claim 4 wherein microfiltration of the extract is performed by filtration through a membrane having a porosity of 0.5 to 3.0 micron.

6. The process of claim 5 wherein the inlet temperature of the extract undergoing microfiltration will range from 70 DEG to 140 DEG F., inlet pressure of the extract passing the microfiltration membrane ranges from 3 to 8 bars and the outlet pressure ranges from 1 to 4 bars.

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7. The process of claim 6 wherein the reverse osmosis is conducted by the use of a membrane having a salt rejection capacity greater than 90% and wherein reverse osmosis is conducted at temperatures of

80 DEG-140 DEG F.

8. The process of claim 7 wherein the extract undergoing reverse osmosis is at a temperature of 80

DEG-140 DEG F. and the feed pressure ranges from 300 to 900 psig.

9. The product of the process of claim 1.

10. The product of the process of claim 4.

11. The product of the process of claim 8.Data supplied from the esp@cenet database - Worldwide

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364.

US4777045 - 10/11/1988

HIGH BRAN SNACK


Inventor(s):

(US)

VANDERVEER FRED (US); STRAKA ROBERT (US); CALANDRO THOMAS P

Applicant(s): NABISCO BRANDS INC (US)

IP Class 4 Digits: A01N

IP Class: A01N65/00

E Class: A23L1/164B; A23L1/10E; A23L1/18B2; A61B5/00



Family: US4777045


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Abstract:


A high bran snack, for the prevention of colon cancer, of which a typical formulation is: graham (whole wheat) flour, 40 percent; rice flour, 10 percent; whole wheat bran flour, 50 percent; calcium carbonate,

1.25 percent; reduced iron, 0.013 percent; and riboflavin (as a tracer), 0.02 percent. About 5 ounces of water is added per 80 ounces of dry materials. The dry materials are mixed in a ribbon blender and then fed dry into a cooker extruder. Then the water is added to the mixture in the extruder. The mixture is extrusion cooked and formed in, for example, a twin-screw cooker extruder. Each of the ingredients in the formulation has a processing, nutritional or therapeutic purpose. The extruded pieces are coated with coconut oil and powdered flavorant.Description:




The invention relates to the consumption of dietary fibers to prevent the occurrence or recurrence of colon polyps and to prevent colon cancer.

2. Background Art

Observational epidemiological studies and clinical experiments have generated a number of hypothesis about the role of dietary factors in the etiology of colorectal cancer: fat and meat, especially beef, may enhance the risk, while fiber, cruciferous vegetables, lactose and vitamins C and E may protect.

According to Lineback et al., "Food Carbohydrates", (1982), page 296, there is not any completely satisfactory definition of the material which is generally referred to as fiber. The indigestible matter in animal feeds has always been designated as "crude fiber", and the term "dietary fiber" has been suggested for the plant cell wall constituents that are not digested by the secretion of the human digestive tract. The current definition of dietary fiber is not entirely satisfactory. There is a distinction between crude fiber and dietary fiber, since the former is a designation of a fraction determined analytically in a manner that gives an approximation of only cellulose and lignin and not of other cellwall constituents not digested by man.

The substance that the lay public most readily equates with the term dietary fiber is wheat bran. Wheat bran is a heterogeneous substance which contains, in addition to fat and protein, at least 15 different minerals ranging from phosphorus and potassium at 1.04 and 1.38 percent, respectively, to iron (122 ppm), manganese (80 ppm), silicon (.+-.ppm) and selenium (0.1 ppm). Burkitt, D. P., "Epidemiology of cancer of the colon and rectum", Cancer 28, 3, (1971); Burkitt, D. P., "Colonic-rectal cancer: fiber and other dietary factors", Am. J. Clin. Nutr. 31, S58, (1978), and Trowell, H., "Ischemic heart disease and dietary fiber", Am. J. Clin. Nutr. 25, 926, (1972), concluded from epidemiological observations that populations subsisting on high residue diets exhibted fewer of the diseases of Western civilization

(cancer, heart disease and, gallstones). Cleave, T. L., "The neglect of natural principles in current medical practice", J. R. Nav. Med. Serv. 42, 55, (1956), suggested that modern day diseases were due to increasing intake of refined flour and sugar. It must be remembered that Burkitt and others were referring to a type of diet rather than a single component.

Epidemiologic studies have identified a low intake of dietary fiber as one of the factors associated with an increased rate of cancer of the colon [for example, see "Dietary fibre, transit time, faecal bacteria, steroid and colon cancer in two Scandanavian population", International Agency for Research on

Cancer, Intestinal Microbiology Group, Lancet, July 30: 207-211, (1977), and Wynder, E. L., "The environment and cancer prevention", J. Environ. Path. Toxicol. 3: 171-192, (1980)]; other such studies include high intake of fat and animal protein [for example, see Armstrong, B., et al., "Environmental factors and cancer incidence and mortality in different countries with special reference to dietary practices", Int. J. Can., 15: 617-631, (1975)].

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Different methods of estimating fiber consumption have lead to different conclusions about its association with national mortality: Lui, K., et al., "Dietary cholesterol, fat and fibre and colon-cancer mortality", Lancet, 782-785, (Oct. 13, 1979), found a negative association, while Draser, B. S., et al.,

"Environmental factors and cancer of the colon and breast" British Journal of Cancer, 27, 167, (1973), did not find such a negative association.

Retrospective studies designed to compare the dietary habits of colon cancer patients with controls have also failed to provide consistent evidence on the fiber hypothesis. Several of the studies have supported it [Bjelke, E., "Case control study of cancer of the stomach, colon and rectum", In Oncology

(1970) Eds. R. L. Clarke, R. W. Cumley, J. E. McCay and M. M. Copeland. Proceedings of the 10th

International Cancer Congress, Volume V, Chicago, Ill.: Year Book Medical Publishers Inc., (1971), p.

320; Modan, B., et al., "Low-fibre intake as an etiological factor in cancer of the colon", Journal of the

National Cancer Institute, 55, 15, (1975); Graham, S., et al., "Diet in the epidemiology of cancer of the colon and rectum", Journal of the National Cancer Institute, 61, 709, (1978); and Dales, L. G., et al., "A case-control study of relationships of diet and other traits to colorectal cancer in American blacks",

American Journal of Epidemiology 109 (2), 132-144, (1978)], while others have not [Higginson, J.,

"Etiological factors in gastrointestinal cancer in man", Journal of the National Cancer Institute, 37 (4),

527-545, (1966); Wynder, E. L., et al., "Environmental factors of cancer of the colon and rectum",

Cancer 20, 1520-1561, (1967); and Jain, M., et al., "A case-control study of diet and colorectal cancer",

International Journal of Cancer, 26, 757-768, (1980)].

Concerning the incidence of colon cancer seen in industrialized populations which has been associated with lack of dietary fiber, the presence of fiber in the intestinal tract decreases transit time, which reduces contact time between potential carcinogens and the mucosa, and it dilutes the intestinal contents and thus reduces the possibility of interaction of procarcinogens with bacteria. Although some epidemiological data would appear to bear out the above stated hypothesis, some investigators, working from the same data base, have found little correlation between dietary fiber but a strong correlation with ingestion of animal fat. However, a high fiber diet is usually a low-fat diet and vice versa.

Experimental studies have shown that some kinds of fiber can protect against chemically induced cancer. Rats fed stock diets had fewer 2-acetylaminofluorene-induced tumors than those fed semipurified diets. Colon cancer can be induced in rats by several compounds, including 1,2dimethylhydrazine, methylnitrosourea and azoxymethane. Wheat bran has been found to protect rats against colon tumors induced by either injection [Fleiszer, D., et al., "Protective effect of dietary fibre against chemically induced bowel tumors in rats", Lancet 2, 552 (1978)] or oral administration of 1,2dimethylhydrazine [Barbolt, T. A., et al., "The effect of bran on dimethylhydrazine-inducedcolon carcinogenesis in the rat", Proc. Soc. Exp. Biol. Med. 157, 656, (1978)]. In Watanabe, K., et al., "Effect of dietary alfalfa, pectin and wheat bran on azoxymethane or methylnitrosourea-induced colon carcinogenesis in F344 rats", J. Natl. Cancer Inst. 63, 141, (1970), rats were fed 15 percent alfalfa, pectin or wheat bran and the effects of an injected carcinogen (azoxymethane) in one group were compared with one administered by intrarectal instillation (methylnitrosourea) in another. Pectin and bran protected against azoxymethane-induced tumors but not against methylnitrosourea. Alfalfa did not affect the course of azoxymethane-induced tumors but significantly increased the incidence of methylnitrosourea-induced tumors. The data indicates that the action of dietary fiber was mediated by the mode of administration of the carcinogen.

The decreased intake of dietary fiber has been implicated as a factor in diseases such as cancer, diabetes and coronary disease. In the case of diabetes, increased dietary fiber definitely lowers plasma glucose and insulin levels. Data relating to heart disease and colon cancer are not as clear cut and must be assessed in the light of differences in total diet and lifestyle between populations at high and low risk. (Lineback et al., ibid., page 306.)

"FDA Studies Advertising For Kellogg's All-Bran--Linked to Cancer Prevention", The Washington

Post, (Nov. 6, 1984), pages E1 and E4, states:

"The Food and Drug Administration has launched a preliminary review of a new advertising campaign by the Kellogg Co. that links its All-Bran cereal to cancer prevention."

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"The Kellogg ad campaign is the first by a major food manufacturer to specifically link its product to cancer prevention, a claim the FDA fears may violate federal rules. Under FDA regulations, it is illegal to make health claims about specific foods without prior FDA approval."

"`Is this promotion, in its language, offering a drug because of the product's linkage to the disease called cancer?` said FDA spokesman Bruce Brown. If so, then Kellogg has failed to win FDA approval of All-Bran as a way to prevent cancer, Brown added." [p. E-1]

"However, Kellogg's All-Bran Advertisement represents the first time a major manufacturer has gone a step further and cited the quality of a specific food--in this case high fiber--as a way to prevent a specific disease."

"As a result, federal regulators say they are faced with a serious problem. On the one hand, Brown noted, they applaud Kellogg for bringing vital health information to the public. For the ad clearly points out that the `National Cancer Institute believes a high fiber, low fat diet may reduce your risk of some kinds of cancer.`"

Nonetheless, Brown said, the claims may ultimately be considered misleading by federal regulators because it not include enough information. Although the promotion encourages consumers to eat All-

Bran, it may give the impression that all consumers need to do to prevent cancer is to eat All-Bran."

"That it has apparently angered California's Cancer Advisory Council, which, under the auspices of the state's Department of Health Services, is currently drafting a letter to the FDA."

"State officials declined to talk about the letter, saying it was premature to discuss it since it had not been approved and mailed yet. Advertising Age, however, noted that the cancer advisorycouncil was disturbed because there is no scientific proof that All-Bran prevents cancer."

"Kellogg officials, however, said that all they were trying to do was work with the National Cancer

Institute to publicize the cancer awareness prevention project. `We want to communicate the NCI report that says that a high fiber, low fat diet may reduce your risk of some kinds of cancer,` said

Celeste Clark, director of corporate publicity. `This is the first time Kellogg has mentioned cancer in its advertisements . . . We worked very closely with NCI in developing the advertising message.`"

[Emphasis supplied][p. E-1 and p. E-5]

"Among the possible objections FDA could have, Brown said, was that there are many different types of cancer. Kellogg implies high-fiber is a good way to prevent all types of cancer."

"Additionally, Brown said, the claims don't say how to use All-Bran if it really is to prevent cancer."

[p. E-5]

Physiological effects of dietary fiber ought to be neither simple nor uniform, because the human gastrointestinal tract can accommodate to altered conditions and shows large variability in its actions. It has been postulated that beneficial effects of fiber in the large intestine include a binding and dilution of injurious substances. Although food remnants in the human large intestine are thought to provide little if any direct nutrition, they serve as substrates for microflora.

Lineback et al., ibid., states:

"Following the reawakening interest in dietary fiber, the physiological as well as technological aspects of materials considered suitable supplements for fiber-enrichment in various food formulations have become the subject of many investigations. Attempts have been made to draw conclusions as to the relationships between the type of dietary fiber and its functional behavior under varying processing conditions. Because of the high individuality of the test material, drawing of generally valid conclusions proved to be a very difficult task. It is now recognized that a thorough physical and chemical characterization of the fiber-rich material must preclude any valid prediction regarding its functional or physiological effects (Parrott and Thrail 1978)."

"We are thus approaching the more advanced phase of research in this field, in which attempts are being made to relate the functionally relevant physical and physicochemical properties of dietary fiber to its detailed chemical profile, rather than to its total content or distribution of more or less arbitrarily defined fractions. There is still a great deal of ambiguity surrounding these relationships. Great complexitiy of the studied material, lack of uniform methodology, high risk of creating artifacts under in vitro conditions and disreprancies between in vitro and in vivo situations are mostly responsible for a hitherto unsatisfactory status of our knowledge on this subject." [Emphasis supplied] [pages 333 and

334]

There are some potential disadvantages to the use of dietary fiber. Fiber-rich diets appear to induce malabsorption of minerals. Another potential hazard of fiber is in respect to reduce energy intake and protein utilization. Other possible deleterious effects of fiber such as persorption or volvulus of the

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sigmoid colon do not seem to be an immediate problem in populations ingesting normal, well-balanced diets.

In the case of colorectal cancer, colorectal polyps might be a suitable precursor of malignant disease.

There is evidence for the causal association of adenomatous polyps and adenocarcinoma of the colon.

Briefly, the prevalence of adenomatous polyps in several countries follows the incidence of colon cancer.

Allen, L. M., "Calciium bioavailability and absorption: a review", Am. J. Clin. Nutr. 35: 783-808,

(1982), discussed the question of the adverse effect of bran intake on calcium bioavailability. Particular reference was was made in Allen to Cummings, J. H., et al., Am. J. Clin. Nutr. 32: 2086, (1979), which described the creation of a negative calcium balance in a few controlled subjects on a high bran diet.

U.S. Pat. No. 1,173,932 (Cockrell) discloses a cereal breakfast food consisting of about 60 percent of wheat bran and the remainder corn meal and oats flour, the latter two items being added to make the bran more palatable. The bran is used for its laxative properties.

U.S. Pat. No. 1,210,589 (Black) discloses a bran biscuit or cake which contains shredded cereal and syrup for nutrition and to make the bran palatable. The shredded cereal can be corn, wheat or rice.

About 371/2 percent of bran is used in the formula. Black mentions that bran has laxative properties.

U.S. Pat. No. 1,244,586 (Cockrell) discloses a cereal breakfast food consisting of about 60 percent of wheat bran and the remainder corn meal, wheat and oats. The bran is used for its laxative properties.

U.S. Pat. No. 1,263,609 (Schuyler) discloses a self-rising pancake flour which contains ground rice bran, baking powder, wheat flour, soy flour, rice polish and salt. The mixture can include rice flour.

The given example uses 22.5 percent of ground rice bran. The bran is used as a flavorant.

U.S. Pat. No. 1,271,139 (Dickerson) discloses a composition which includes bran (e.g., 15 percent), whole wheat flour, wheat flour, rye flour, etc. The composition is used to make biscuits.

U.S. Pat. No. 3,062,659 (Vollink) discloses an extrusion-cooked, ready-to-eat breakfast cereal flakes which can contain rice flour or bran. A moist comminuted starch-containing cereal mixture is passed through a cooker extruder, the expanded extrudate is tempered and then the cereal material is flaked and toasted. Example 2 uses a starting formula that includes 60 percent of ground whole wheat and 24 percent of bran.

U.S. Pat. No. 4,327,116 (Weith) discloses a bran bakery product from dough composed of 100 parts by weight of bran, 200 to 300 parts by weight of water and 2.5 to 15 parts by weight of carob bean flour

(or other vegetable thickening agent). Other conventional dough ingredients such as flavoring agents can be used. Weith specifically mentions wheat bran and rye bran. The prior art section of Weith states that cereal fibers are used as casual therapy of obstipation and intestinal diseases.

U.S. Pat. No. 4,350,714 (Duvall) teaches a corn bran, extrusion-cooked, expanded cereal which further contains corn flour, oat flour, ground limestone, [i.e., CaCO3 ], sugar, salt, soda, vitamin premix and colorant. Duvall states that wheat flour and rice flour can be present. Example 1 shows the use of 25 percent of corn bran flour, and the claims recite that sufficient ground corn bran is used to provide 3.5 to 10 weight percent of fiber. The extruded pieces are enrobed in a syrup which includes sugar, coconut oil and water.

British Pat. No. 1,561,190 (Weetabix) discloses a food mixture containing bran and a binding agent

(starchy material or gum) is mixed with water. The mixture is extrusion cooked. The mixture (on a dry basis) contains 10 to 95 percent of bran. The mixture can also contain wheat and rice flours.

German O. S. No. 2,837,294 (Bories et al.) discloses an extrusion cooked foodstuff composed of bran,

20 to 80 percent gluten, 5 to 20 percent, and the balance flour or starch, with the addition of 5 to 20 percent water after charging the mixture to an extruder.

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Known foods containing bran include bran muffins and cereals, such as, All Bran, 100% Bran,

Shreddies, Bran Flakes and Bran Crunchies. Wheat bran is found naturally in whole-wheat breads and cereals, can be bought separately for adding to other foods and is rich in dietary fiber.

BROAD DESCRIPTION OF THE INVENTION

An object of the invention is to provide a composition and process for the prevention of the occurrence and recurrence of colorectal polyps. Another object of the invention is to provide a composition and process for the prevention of colorectal cancer. Other objects and advantages of the invention are set out herein or are obvious herefrom the one skilled in the art.

The objects and advantages of the invention are achieved by the composition and processes of the invention.

The invention involves a food composition or snack in the form of extrusion-cooked extrudate pieces, for consumption by humans. The invention extruded, high bran snack includes:

(a) about 40 to about 70 weight percent of bran flour;

(b) about 20 to about 50 weight percent of whole wheat flour;

(c) about 5 to about 15 weight percent of rice flour;

(d) about 0.5 to about 3 weight percent of calcium carbonate;

(e) about 0.03 to about 0.005 weight percent of reduced iron; and

(f) about 0.1 to about 0.005 weight percent of riboflavin.

The weight percent of ingredients (a) to (f) are based on the total dry weight of the food composition.

The invention of dietary wheat bran serves as a mens of prevention of the recurrence of colorectal polyps. This serves as a means for reducing the incidence of colorectal cancer.

The invention further includes the extruded, high bran composition or snack coated with a layer of an edible organic oil and flavorant in particulate form. Preferably the edible organic oil is coconut oil and the flavorant is in powder form. The layer of organic oil serves to adhere the flavorant particles to the extruded pieces. This form of the invention food snack is much more palatable and edible.

The invention high bran snack has been developed for the prevention of colon cancer and is being studied in a five-year test for effectiveness. The control (placebo) was to have only whole wheat flour, and the test composition was to have 50 percent of whole wheat bran and 50 percent of whole wheat flour. This was the first development. Riboflavin was added. The riboflavin was used as a tracer which can be detected in stool. Then commercially available flavorants were added to the extruded pieces.

Then an edible organic oil, preferably, coconut oil, was sprayed onto the composition pieces to enhance the flavor and to provide adhesion between the flavorant and the snack. However, it was found that the test high bran formulation was too deficient in calcium and iron to be consumed on a regular basis in substantial amounts to effect prevention of colon cancer. So calcium carbonate was added along with reduced iron. The calcium carbonate and the reduced iron made the product very hard; this problem was solved by adding rice flour to the formulation. Corn meal might provide a softer texture also, but it may also alter taste. A leavening agent to provide a lighter texture would erratically expand the product. The product is produced in a Creusot Loire extruder, which is a twin screw extruder having heating means for cooking the formulation. A preferred final formulation has 40 weight percent of graham flour, 10 weight percent of rice flour, 50 weight percent of bran flour, 1.25 weight percent of calcium carbonate, 0.013 weight percent of reduced iron and 0.02 weight percent of riboflavin. All of the dry ingredients are mixed in a ribbon blender and are fed to the extruder dry. Additionally, about 5 ounces of water are added per 80 ounces of dry materials, which is approximately 4 to 5 weight percent. The water is added to the extruder after the blended dry ingredients. Preferably then the extrudate pieces then coated with the edible organic oil and the particulate flavorant is affixed to the extrudate pieces.

The biologidal plausibility of the association between adenomatous polypsand malignant disease is supported by the observation that the morphology of lesions varies from adenomas exhibiting microfoci of malignant tissue to obvious cancer with residual benign tumor at the edge. Also, the amount of benigh tumor is inversely related to the amount of spread of the malignant disease. In addition, the size, histology and grade of the polyps are associated with the probability of occurrence of

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malignant tissue. Finally, cases have been documented in which an untreated adenomatous polyp has progressed to malignant disease. [Day D., et al., "The adenoma-carcinoma sequence, 58-71, in

Pathogenesis of colrectal cancer", Morson, B., W. B. Saunders Co. Philadelpha, (1978)].

The primary advantage with colorectal polyps as the outcome measure of a randomized trial is that the study can be of a practical size. The prevalence of polyps in Western man is high, approaching 50 percent at 70 years of age. A small trial studying the recurrence of polyps can be as sensitive as a large trial in which the outcome is death from colon cancer. The study of the recurrence of polyps offers an additional practical advantage; when patients with colorectal polyps are routinely examined every two or three years with fibreoptic colonoscopy, studies can be carried out between two colonoscopic examinations with essentially no additional medical cost or morbidity. The investigation given in detail below is therefore designed as a randomized trial to examine the role of a dietary fiber supplement in the recurrence of colorectal polyps, among patients who have had at least one adenomatous polyp removed by polypectomy.

An important advantage of the composition of the invention is that its continued consumption by humans prevents the recurrence of colon polyps, which are a problem themselves and which confer a high risk of colon cancer. A low fiber diet has been identified as one of the factors associated with an increased risk of cancer of the colon. The consumption of bran fiber prevents the recurrence of polyps in people with this problem. Polyps are not cancers, but sometimes they do become malignant.

The use of dietary fiber in the invention composition is important because it is one of the dietary components which can be manipulated to confer protection against colorectal cancer without making the diet unacceptable.


In the drawing:

FIG. 1 is a front schematic view of an extrusion die used in the preparation process of the invention;

FIG. 2 is a side schematic view of the extrudate of the invention as it leaves the extruder fie and

FIG. 3 is a side view of the extruded food composition of the invention.


As used herein, all parts, percentages, ratios and proportions are on a weight basis unless otherwise stated herein or otherwise obvious herefrom to one skilled in the art.

Dietary fiber is widely distributed in unrefined cereals, fruits and vegetables. However, previous studies [Armstrong et al., ibid., and Maruchi, N., et al., "Relation of food consumption to cancer mortality in Japan with special reference to international figures", Gann 68: 1-13, (1977)], as well as our own recent review of international data, show that cereals rathe than fruits and vegetables correlate best with color cancer death rates. Our review of international data also found that, according to such data, total cereal seems important rather than any single type of cereal.

There are two general classes of products provided by a wheat mill, namely, flour and millfeed. These two general classes are subdivided into products depending upon the degree of purity desired. The subclasses for straight flour are patent flour (less than 70 percent of wheat) and clear flour (residue left when a patent flour is removed from a straight flour). The subclasses for millfeed are bran (seed coat material left after milling flour), germ (wheat seed embryo) and shorts (everything left after the bran and germ have been removed from millfeed).

The absolute amount of fiber in the invention used is well within the range found in diets in many parts of the world. The amounts have been used previously with no reported ill effects. [Cummings, J. H., et

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al., "Changes in fecal composition and colonic function due to cereal fibre", Am. J. Clin. Nutr. 29:

1468-1473, (1976)].

The following is the protocol used in a short preliminary study of invention products designed for use in a subsequent long term study:

Test Products

Two test products were developed. The lower fiber one was made from wheat flour and contained about 6.5 grams of dietary fiber per 100 grams. The other test product contained equal amounts of wheat flour and wheat bran for a total of 26.5 grams of dietary fiber per 100 grams of the product. The bran used corresponded to the composition of the AACC Standard Bran currently used as a reference.

The test products were intentionally low in calories (about 150 Kcal and 200 Kcal per day for the lower fiber and higher fiber products, respectively) in order to make little contribution to the total intake. The products were also developed as snacks to avoid systematic replacement of any one food or group of foods. The snacks were covered with a light coat of oil and one of four flavors selected by a preliminary taste panel. They were also coated with riboflavin or riboflavin phosphate (equivalent of 30 mg riboflavin per package, e.g., 100 grams of the higher fiber product and 50 grams of the lower fiber product). The excretion of riboflavin by the human test subjects served as a marker of intake.

Human Test Subjects

The human test subjects were adults recruited from the volunteers at certain hospitals. They were between 45 and 70 years of age, which is a range that corresponds to that expected in the study of polyp patients. These subjects did not have any gastrointestinal problems which might affect their tolerance to fiber, were not taking any antibiotics or laxatives and were not on any therapeutic or self prescribed diets. The subjects were approached through volunteer coordinators, the study was explained to them and those wishing to participate were asked to sign a consent form.

Test Procedures

At the beginning of the study, a short diet and health history was obtained which served to:

1. identify those who should be excluded from the study because specific diseases, gastrointestinal surgery, use of laxatives or therapeutic diets;

2. characterize the study group;

3. sensitive them to their seating habits and methods of recording food intake as required in the study.

Forty volunteers were assigned to one of Group A or Group B (20 each). The volunteers consumed the two products according to the following schedule:

>;tb; TABLE I

>;tb;______________________________________

>;tb;Weeks Group A Group B

>;tb;______________________________________

>;tb;1 25 g of low fiber

>;tb; 50 g of high fiber

>;tb;2 to 6 50 g of low fiber

>;tb; 100 g of high fiber

>;tb;7 50 g of high fiber

>;tb; 25 g of low fiber

>;tb;8 to 12 100 g of high fiber

>;tb; 50 g of low fiber

>;tb;______________________________________

The human test subjects were instructed in keeping four day food records (two week days and a weekend) and they kept these records before they started the products and at 3, 6 and 12 weeks. The records were checked to determine whether there has been any apparent change in eating pattern due to the consumption of the snacks.

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The subjects were also asked to keep a daily health/food record throughout the study. This record included an estimate of the amount of product eaten each day. The subjects were asked to return any uneaten bags of snacks or portions of bags as a further estimate of actual consumption.

At the end of the study of short questionnaire was complete. The questionnaire contained questions on the use of the products, which if any foods were replaced by them, and a subjective evaluation of ability to continue to consume the products.

The subjects also supplied samples as follows:

>;tb; TABLE II

>;tb;______________________________________

>;tb;Time,

>;tb;Weeks Sample Analysis Purpose

>;tb;______________________________________

>;tb;0 and 12

>;tb; venous blood

>;tb; hemoglobin check for any

>;tb; ferritin possible effect

>;tb; on iron status

>;tb;0, 3, 6

>;tb; 14 hour urine

>;tb; riboflavin marker for

>;tb;and 12 phenols intake indicator

>;tb; of transit time

>;tb;0, 3, 6

>;tb; breath hydrogen and indication of GI

>;tb;and 12 methane bacterial

>;tb; activity

>;tb; pentane and indication of

>;tb; other breath lipid peroxi-

>;tb; gases dation in body

>;tb;0, 6 feces mutagen by potential

>;tb;and 12 the Ames Assay

>;tb; carcinogen

>;tb; bile acid, potential cancer

>;tb; cholesteral promoters

>;tb; and degreda-

>;tb; tion products

>;tb;______________________________________

Sample Collection And Analysis

On the designated days, the volunteers were asked to void at 6 p.m. and discard the sample. All subsequent voiding, until 8 a.m. were pooled and collected in coded brown glass bottles. These bottles were brought to the hospital and placed in a freezer provided. They were collected and analyzed by

HPLC for urinary phenols and riboflavin.

On designated days, each volunteer was asked to breathe purified air for two minutes through a mouth piece prior to supplying a breath sample by flowing into a tube provided for such. Samples were collected in large syringes and analyzed directly for hydrogen, pentane, methane and other gases by means of gas liquid chromatography.

Samples of feces were collected in coded plastic containers stored in dry ice boxes and stored in the freezers. The samples were transferred to a deep freezer (-70 DEG C.). At an appropriate time thereafter, the samples were extracted and tested for mutagenicity (Salmonella typhinurium TA-100) and for the presence of the mutagen by HPLC and U.V. spectra. Aliquotes were sometimes analyzed for bile acids, cholesterol and cholesterol derivatives (cholestanol and cholestanone).

Analyses

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The first objective of the test was to ascertain the acceptability of the products, judged by as follows: the number of subject consuming 50 percent or more of the product each day of the study; the changes in the diet introduced by use of the product as measured by the food intake records; and the subjective evaluation of the subjects of their ability to continue using the products.

The second objective of the test was to collect preliminary biochemical data to be used as a basis for determining what, if any, analyses should be made in the intervention trial (long-term test described below).

Miscellaneous Matters

In some prior art short term studies, bran had decreased the absorption of calcium, iron, copper, zinc and magnesium, although the results were not always consistent. Because anemia is sometimes a problem among the test age group, the iron status of the subjects was monitored, with hemoglobin checks and with analysis of ferritan status at the beginning and end of the study. The methods available for assessment of other trace minerals was not considered accurate at the moment. They were also not necessary for such a short term study because the negative mineral balances are small in comparison with body stores and, therefore, of no clinical significance for the short time period.

The following is the protocol used in a long term study of the invention products. The investigation involved a clinical trial of dietary bran in the prevention of the recurrence of colorectal polyps. The investigation was designed as a randomized trial to examine the role of a dietary fiber supplement (i.e., invention product) in the recurrence of colorectal polyps, among patients who had previously had at least one adenomatous polyp removed by polypectomy.

Objectives Of The Test

The first objective of the test was to determine the feasibility for clinical use of increasing daily fiber intake by means of a dietary supplement.

The second objective of the test was to determine the effect of a dietary supplement of fiber (a) on the recurrence of gastrointestinal polyps and (b) on a number of biochemical parameters.

Summary Of Design

The investigation was and is being conducted as a randomized controlled trial. The human subjects are about two hundred consecutive patients who have had one or more adenomatous polyps identified and removed by colonoscopy at certain hospitals.

After the polypectomy, each eligible patient was informed of the study of his/her surgeon, was given a pamphlet summarizing the proposed investigation and invited to participate. Patients who wished to participate were interviewed at home--a detailed nutritional interview was conducted and samples of urine and blood were collected. The patient was provided with a supply of either (i) a supplement of wheat fiber (equivalent to over 26.5 grams per day) or (ii) a low fiber placebo supplement (equivalent to less then 4.0 grams per day). See below for the development of the full ingredient lists of the two compositions used in the test. Random allocation to the high or low fiber groups was made. The interviewer was initially blind to the allocation of the patients.

Each patient was contacted at regular intervals by the interviewer who collected information on diet and health and obtained urine and blood samples according to a pre-arranged schedule.

Two years after the initial colonoscopic examination, the patient was re-examined by the surgeon who performed the initial examination. Finds from both examinations were compared to ascertain any change in the number of polyps. The extent of this change was compared for the treatment and placebo groups. This long term study is still being conducted.

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Details Of Investigation--Eligible Subjects

A patient was considered eligible for the study if the patient had at least one adenomatous (based on the final pathological report) polyp identified in the colon or rectum at the time of the intial colonoscopic examination, and

(a) was under 75 years of age and resident in a certain area;

(b) had no history of previous bowel disease (except polyps), previous bowel resection, or familial polyposis, was not currently anemic and was not a regular user of laxatives;

(c) had no evidence of malignancy requiring bowel resection; and

(d) was not currently on a medically supervised diet for renal, liver or gallbladder disease. Any patient who satisfied the above criteria was not included if, in the documented opionion of the colonoscopist, inclusion in the study would be detrimental to the patient's health.

The study involved about 216 patients equally allocated at random into each of the high and low fiber supplement groups. This is based on an estimated rate of recurrence of gastrointestinal polyps of 24 percent in the low fiber group and a recurrence rate of 8 percent in the high fiber group. It was anticipated that approximately one hundred eligible patients are seen each year at the involved hospitabls. If 80 percent of eligible patients were willing to participate in the study, the required number of patients would be enrolled over a two to three year period.

Initial Medical Examination

Prior to each colonoscopy clinic, patients was be identified with appointments.

During each colonoscopic exmaination, the physician completed the colonoscopy form. For patients with a polyp, a polypectomy was performed and a quick pathological section examined immediately. A complete pathological examination of all polyps was subsequently conducted by a single pathologist.

For each patient with a polyp considered to be adenomatous by the quick pathological section, the physician established whether the patient was otherwise eligible for the trial. After a suitable period of recovery from the colonscopy, the physician informed each eligible patient of the possibility of participating in a study. The patient was given a pamphlet describing the study and proposing that the patient be called to discuss the patient's participation. To confirm that a patient was eligible for the study, the complete pathology report for each patient was obtained and read; when there was mention of malignancy, the colonoscopist was consulted as to whether a bowel resection was indicated.

After ensuring that a patient was eligible for the study, and if the patient agreed to be interviewed, the patient's identifying information (including age, sex and colonoscopist) was passed to a designated study coordinator. If the patient refused to participate, the reason for refusal was recorded and the coordinator informed.

Study Coordination

For all patients, the study coordinator verified the eligibility orineligibility of all patients by reviewing all colonoscopy forms and kept records of the proportion of eligible subjects who do not agree to a first meeting with the interviewer.

For eligible patients who agree to participate, a designated interviewer was given the patient's name, address and telephone number. The randomization process, described below, was conducted and the interviewer was provided with the fiber supplement appropriate for each patient. After each interview, the completeness and accuracy of all documents was checked and it was ensured that specimens were sent to the appropriate laboratory. When the laboratory results were obtained, all follow-up visits were coordinated.

Randomization

Patients were stratified by surgeon, sex and age. Within each stratum, patients were randomly allocated to receive the high or low fiber supplement using appropriate statistical methods of random allocation.

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Fiber Supplements

Two test products were developed: namely, a low fiber snack composed primarily of whole-wheat flour and a high fiber snack made of equal parts of whole-wheat flour and wheat bran. The low fiber snack is a control. The snacks were to be sprayed with five percent oil alone or with the oil plus one of four flavors selected by an informal taste panel. Initially the snacks were also to be coated with riboflavin phosphate (30 mg per 50 grams of low fiber snack and per 100 grams of high fiber snack). The excretion of riboflavin in the urine serves as one test of compliance to the regimen. The contents of the extrudates and the coatings on the extrudates changed before the long term test started and during the long term test--the history thereof and the ingredient changes are chronologed below. The low fiber product was to be used in amounts of 50 grams per day (3.3 grams of fiber) and the high fiber one as

100 grams per day (26.5 grams of fiber).

Interviews

Interview were conducted in the patient's homes according to the following schedule:

>;tb; TABLE III

>;tb;______________________________________

>;tb; CONTACTS (MONTHS)

>;tb;INFORMATION 0-.25 2 12 18 24

>;tb;______________________________________

>;tb;Consent Form x -- -- -- --

>;tb;Food Frequency

>;tb; x x x -- x

>;tb;Questionnaire

>;tb;Health Status Record

>;tb; x x x x x

>;tb;Pin-Prick Hb. Test

>;tb; x -- x -- x

>;tb;Blood For Iron-Status

>;tb; x -- -- -- x

>;tb;Workup

>;tb;Urine Riboflavin

>;tb; x x x x x

>;tb;______________________________________

At the first visit, the study was described to the prospective participants and provided samples with of the snacks to taste. The patient was then asked whether the patient wished to continue in the study and, if so, the consent form was signed. The participants provided samples of urine and blood for initial biochemical analysis. The participants were provided with a week's supply of the appropriate fiber supplement and an appointment was made to return the next week to deliver the first batch of snacks, to administer a food frequency questionnaire and to complete a health status record.

Further interviews will be conducted by the same data collector and information and samples were collected for biochemical measurement. At each meeting, the unused snacks were collected--their quantity was a measure of the level of compliance to the dietary regime. Depending on the results of an initial evaluation of the fiber supplement, a sample of participants was also asked to provide samples of breath gases and feces for biochemical analysis.

Final Medical Examination

Two years after the initial medical examination the patient was re-examined by colonoscopy by the same surgeon. The logistics of such examination were similar to the initial examination. The surgeon completed a colonoscopy form, which was sent to the study coordinator, together with the pathology report. When symptoms lead to early recognition that polyps may have recurred, the patient received the second colonoscopy at whatever time was chosen by the surgeon to be appropriate for the patient's medical care.

Withdrawal of Subjects

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Withdrawal of the patents from the study could occur in a number of circumstances:

(1) the patient wished to discontinue his participation and did not continue to receive the dietary supplement. Patients were informed that they could withdraw from the study at any time;

(2) the patient developed a condition which made continuation on the fiber supplement inappropriate or developed signs or symptoms of a side effect of the fiber supplement. (Serious side effects of the fiber supplements were not anticipated. The amounts of fiber in the high fiber have been used in several studies without serious ill effects. This level of consumption will likely increase the number and volume of stools produced and may also result in mild gas pains and increased flatulence until the individual adapts to the high fiber intake. Some studies have suggested that intake at the levels of the high fiber supplement has decreased adsorption of calcium, iron, copper, zinc and magnesium but other studies have not confirmed this effect. Because methods of assessment of most trace minerals are not reliable, only iron status was monitored in the present investigation.) If the patient develops any condition which might necessitate the withdrawal of the patient from the investigation, the testers were notified. The health of the participants was also monitored through assessment of hemoglobin and iron status.

(3) the patient developed symptoms which lead to the identification of recurrent polyps before the examination scheduled two years after the start of the study. These patients received normal medical care for the diagnosis and treatment of the recurrent polyps. After such a diagnosis, patients did not continue in the trial and did not receive the dietary supplement; or

(4) the patient did, moved or for some reason failed to attend the final colonoscopic examination. Such patients received the fiber supplements for the entire period during which they were in contact with the testors.

Monitoring the Results of the Trial

The health of individual subject were monitored at intervals during the study and subjects were withdrawn if they develop side effects of the fiber supplements. The rate of occurrence of any serious side effects in the high and low fiber groups was compared (consideration was to be given to terminating the trial if the rate appeared appreciably higher in eithr group).

In addition, consideration was given to the possibility of monitoring the results of the trial as it is running to determine whether, contrary to expectation, polyps recur more frequently among subjects receiving the high fiber diet. The findings from such an intermediate data analysis would, however, be difficult to interpret because it is conceivable that the high fiber diet may lead to the early detection of polyps which have recurred by causing them to bleed (indeed, high fiber diets are used prior to the hemocult blood tests to precipitate bleeding). If a detection bias of this nature were to occur, it might be falsely concluded from an early analysis of the data that the high fiber diet was causing a higher rate of recurrence of polyps than the low fibers supplement. For this reason, it was proposed that the data will be analyzed only after completion of the study for all 216 patients who will be enrolled.

ANALYSIS

First Objective

The feasibility of increasing dietary fiber intake by means of a daily supplement was assessed in terms of:

(a) the proportion of eligible patients who refused to enter the trial;

(b) the proportion of patients on each regime who requested to be withdrawn from the study prior to completion but who have no medical reasons for so doing;

(c) the levels of compliance estimated from the average levels of riboflavin in the urine and from the quantity of unused snacks returned by the patients.

The use of the fiber supplements will be considered to be feasible for potential clinical use if at least 75 percent of the patients are willing to enter the trial and if at least 75 percent of those assigned to the high fiber regime consume an average of at least 50 percent of the supplement each day for the two year period.

Second Objective

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The effect of the dietary supplement was assessed as follows: patients will be classified as having polyps which recurred or did not recur; recurrence rates will be compared by Cox regression analysis for the treated and placebo groups, taking account of confounding variables and premature withdrawal of study subjects.

If the fiber supplement is found to reduce the rate of recurrence of polyps, it will be concluded that fiber consumption plays a role in the etiology of gastrointestinal polyps and in consequence may play a role in the etiology of colorectal cancer.

If the fiber supplement is not found to reduce the rate of recurrence of polyps, it is possible that either

(i) fiber consumption of the amount given here is not related to the etiology of polyps or (ii) the initiation of the polyps occurred before the intervention with the fiber supplement so that the lag time necessary for expression of the polyps was greater than two years; this would imply that the fiber intervention after the polyps had been identified was too late to affect the process.

Confounding Variables

Data from the food frequency questionnaire was combined to provide measures of ten dietary components: fat, fiber, lactose, cruciferous vegetables, pulses, vitamin C, caffeine, alcohol, red meat and other meat. These ten variables were recorded at the start and end of the study, and at two intermediate points; each variable was averaged over the study period, with weights reflecting the duration of the eating habits. For each variable, the starting value and the average value during the study were used as confounding variables in the analysis. Age, sex and surgeon were also confounding variables. Compliance was assessed from urine samples and from counts of supplement packages consumed at 2, 12, 18 and 24 months. An index of compliance was obtained at each point in time and these were averaged over the study period. This average compliance index was an additional confounding variable.

Withdrawal

Patients who withdraw from the study were treated in the analysis according to the reason for withdrawal:

(a) Those who withdraw from the dietary regime before completion of the study but who undergo the final endoscopic examination two years after the initial examination were analyzed as if they had completed the study: their compliance index reflected the length of time on the dietary regime.

(b) those who developed symptoms which lead to the identification of recurrent polyps, and hence to withdraw from the study before two years, were counted as `failures` in the Cox analysis at the time of recurrence.

(c) For those who failed to undergo the final colonoscopic examination but either continued on the dietary regime from a two year period or withdrew early, it was not known whether they developed recurrent polyps during the study period. They were, therefore, analyzed first under the assumption that polyps did recur and then under the assumption that polyps did not recur. In both analysis, the compliance index indicated the duration of use of the dietary regime. It is hoped that there will be so few of these patients that analysis under both assumptions will not substantially alter the conclusions.

Third Objective

A subsidiary objective of the investigation was to examine the effect of the different dietary supplements on biochemical measurements, in order to ellucidate the mechanism of action of fiber. The precise biochemical measures could not, however, be determined without the results of the abovedescribed prelinary evaluation. Based on the results of such preliminary study, samples of blood, feces, urine and breath gases were collected and analyzed to determine change in levels of the defined biochemical parameters from start to completion of the investigation. The changes were compared for the subjects on the high and low fiber supplements, taking into account the confounding variables.

The long term test has been going on for several years and is not yet completed.

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Initially an extruded snack food of about one to two mm. thick and one to two cm. square was to be produced using a Creusot Loire BC 45 extruder. These products were to be made on a Creusot Loire extruder, model. A barrel temperature of 180 DEG C. and die face pressure of 500 to 1500 psi was to be used, and sufficient water was to be added to yield an air dried product of 7 to 10 percent moisture.

The screw profile was to be typical for starch extrusion. The extrudate (mainly flour) was to be forced through slot dies and then to be cut at the die surface. The hot product was to be tumbled with powdered flavorant and air dried. The samples could be packed in 50 to 100 g poly sleeves, 24 to a cardboard box. The formulations were to be:

(1) Bran Product:

Bran: 50 weight percent

Whole Wheat: 50 weight percent

(2) Control Product:

Whole Wheat: 100 weight percent

With both formulae, there was to be 30 mg of added riboflavin per 100 g of raw material. It was found that the riboflavin colored the product bright yellow. Riboflavin was to be analyzed in the subjects to insure that the high fiber snack was consumed. It was found that the placebo containing only wheat flour and was brown in color. The flavorant coatings were to be added and tumbled onto the hot extrudate at levels of 3 to 6 weight percent for the bran product and control, respectively. Both snacks were found to have a high bulk density.

The flavorants, produced by Givaudan Limited, Toronto, Canada, were to be: SPL4047 B.B.Q.

(barbeque) powder, salt content 36-40 percent; SPL4048 beef & onion powder, salt content 38-42 percent; SPL4032 natcho powder, salt content 23-37 percent; and SLP4049 taco powder, salt content

42-46 percent. Both products were to be coated with seasonings obtained from space/flavor companies to make a four or five variety line. The snacks were to be small (about 1 cm squares) to discourage using them with dips. A metallized foil pouch was to be used since the product shelf life had not been tested. One year was desired and a good package material would be a safe way to insure such stability.

Analysis of the whole wheat and bran was:

>;tb; TABLE IV

>;tb;______________________________________

>;tb; Whole Wheat,

>;tb;Items Percent Bran, Percent

>;tb;______________________________________

>;tb;Dry Matter 90.03 93.69

>;tb;In the dry matter:

>;tb;Total Ash 3.34 5.52

>;tb;Crude Protein 17.78 17.50

>;tb;ADF-CP 0.63 0.48

>;tb;Cell Wall 6.53 26.28

>;tb;Hemicellulose 4.38 16.81

>;tb;Cellulose(s) 1.47 6.47

>;tb;Cellulose (ks) 1.49 6.26

>;tb;Lignin (k) 0.60 2.92

>;tb;Lignin (s) 0.65 2.53

>;tb;Lignin (sk) 0.38 1.43

>;tb;Cutin (ks) 0.13 0.25

>;tb;Cutin (sk) 0.27 1.10

>;tb;______________________________________

>;tb; Notes:

>;tb; (a) Dry Matter sample dried at 100 DEG C.

>;tb; (b) Total Ash sample ashed at 550 DEG C.

>;tb; (c) Crude Protein total skeldahl nitrogen .times. 6.25

>;tb; (d) ADFCP nitrogen in the acid detergent fiber .times. 6.25 (bound,

>;tb; Maillard, unavailable)

>;tb; (e) Cell Wall and Constiuents done sequentially [Robertson and Van Soest

>;tb; (1980)

>;tb; (f) Sequence 1:

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>;tb; (g) Sample ND .fwdarw. AD .fwdarw. 72% H2 SO4 .fwdarw.

>;tb; KMnO4 .fwdarw. Ash

>;tb; (h) Sequence 2:

>;tb; (i) Sample ND .fwdarw. AD .fwdarw. KMnO4 .fwdarw. 72% H2

>;tb; SO4 .fwdarw. Ash

>;tb; (j) Does not seem to be any damage from processing.

As noted above, the feeding study was to involve 200 people who have previously undergone surgery to remove colon polyps. The test population was to be divided into 100 people receiving snacks fortified with wheat bran and 100 people receiving a placebo without bran. Each person would be on the diet for two years. Three years worth of polyp patients from the involved hospitals would be required to get a sample size of 200 people and, allowing two years per patient, the total study would take five years.

The whole-wheat-and-bran snack, which was to be extruded from 50 weight percent of wheat bran, with approximately 50 percent of whole wheat flour, including 0.2 weight percent of riboflavin (20 mg per 100 gm of finished product), had the desired size, density and shape for the subsequent operation of adding oil, flavor and eventually packaging. Samples of finished products, with 4 different flavors, applied at a level of 3 weight percent to the extruded base product, with the addition of 3 weight percent of vegetable oil, as well as samples without oil, were examined by several people. The consensus decision was that the oil addition significantly improved adhesion of the flavor particles, enhanced flavor acceptibility and improved mouth feel organoleptically.

The whole wheat snack, which was extruded from whole wheat, including 0.4 weight percent of riboflavin (20 mg per 50 gms of finished product) was puffed slightly so that a 50 gm volume of the product had approximately the same volume as 100 gm of the 50 percent bran product. Snacks with and without 5 to 6 weight percent of vegetable oil and 4 flavors were examined by several people. The consensus decision was preferance of the oil addition. The flavor used at 6 weight percent in the product, so both the oil and flavor in 50 gms of the snack represented the same intake as 100 gm of the whole-wheat-and-bran snack.

The riboflavin in both series of such snacks was added via a water addition into the feed of the extruder. This apparently resulted in uneven riboflavin distribution, visible as yellow "spots" on the products. The distribution was greatly improved by blending the riboflavin with the other powder components prior to feeding to the extruder, thereby eliminating the problem.

The oil is a definite advantage to the products and preferably the most stable vegetable oil possible is used. Coconut oil (with a low iodine number) is preferred. The sprayed snacks have shelf life of at least

6 months against rancidity. The level of 3 percent on the 50 percent bran product, and 6 percent on the whole wheat product, represent an intake of 3 gms of oil per day for the people taking either snack product, equivalent to 27 kilo calories per day or about 1 percent of total daily caloric intake. The 5th

"flavor" was an unflavored snack which also had oil, but with no flavor added. Packaging with plastic bag, laminated foil-plastic film bags and metalized mylar film bags were satisfactory. Uniformity of the package weights was important for the long term test program.

The inclusion of the food grade vegetable oil significantly improves adhesion of the flavor particles, enhances flavor acceptability and improves mouth feel organoleptically. The procedure involves heating the mass of extruded snack product coating such material with heated oil uniformly (e.g., by spraying) and adding the finely powdered flavors. About 1 to about 10 weight percent, preferably about

3 weight percent, of vegetable oil is used and about 1 to about 10 weight percent, preferably about 3 weight percent, of flavorant is used--in each case the weight percent is based on the weight of the extrudate.

The prior procedure for applying the seasoning (flavorant) to hot moist product directly out of the extruder, bulk packed and shipped to a copacker was found to be unsatisfactory. It was found that most of the seasoning vibrated off the product during shipping and packaging operation. Accordingly, the unseasoned product is heated, a light spray oil applied and then seasoned.

Analysis of the snack products was:

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>;tb; TABLE V

>;tb;______________________________________

>;tb; Low Fiber High Fiber Bran

>;tb;Items Snack, percent

>;tb; Snack, percent

>;tb;______________________________________

>;tb;Moisture 6.06 6.36

>;tb;Ash 1.66 4.21

>;tb;Protein (N .times. 5.7)

>;tb; 16.02 19.40

>;tb;Fat 1.48 2.61

>;tb;Fiber 1.19 6.02

>;tb;______________________________________

Analysis of the Givaudan seasoning for Lipase Activity produced the following results:

>;tb; TABLE VI

>;tb;______________________________________

>;tb;Barbeque Powder (SPL 4047)

>;tb; 0.010 percent

>;tb;Beef & Onion Powder (SPL 4048)

>;tb; 0.006 percent

>;tb;Nacho Powder (SPL 4032)

>;tb; 0.025 percent

>;tb;Taco Powder (SPL 4049)

>;tb; 0.011 percent

>;tb;______________________________________

The results were typical for seasonings.

The subjects on the preliminary trial seemed to be at the lower normal range of calcium to start, so as not to "stress" their calcium intake it was decided to add calcium to the snack from whole wheat and wheat bran. Some similar thoughts related to iron intake also. So the whole-wheat-and-bran snack product was further developed by adding calcium and iron. 10 mg of iron, in the form of reduced iron was added per 100 gm of finished product package. The level was intended to supply an entire RDA of iron, to compensate for any adverse effect of bran on bioavailability. (Types of food grade iron are the electrolytic iron, Electrolytic Iron A-131, and the reduced iron, Reduced Iron 716, of Glidden-Durkee.

Both of such irons are amorphous, elemental iron powders.) Two levels of calcium were to be tried by adding different amounts of calcium carbonate (40 percent calcium content). The first level is 200 mg calcium per 100 gm product, from 550 mg. calcium carbonate, or 0.5 percent calcium carbonate in the product. The second level is 500 mg calcium per 100 gm product, from 1250 mg calcium carbonate, or

1.25 percent calcium carbonate in the product. It is also decided to add 100 mg of calcium, from 250 mg of calcium carbonate to each package (50 gm) of daily intake of the low fiber control product. This is about 0.5 percent of calcium carbonate in the control product. Calcium monophosphate could also be used.

A suitable wheat bran typically contains 40 weight percent of dietary fiber, 15 weight percent of protein, 4 weight percent of fat and 3 weight percent of ash, and a moisture content of 12 weight percent. Examples of suitable brans are wheat bran (which is preferred), rye bran, oat bran, corn bran and durum bran.

It is decided not to use soy sauce as an ingredient in the high bran composition. Samples of the 50 percent bran snack made with soy sauce used at 7 ounces of soy sauce per 8 pounds of dry product, equivalent to 5.5 percent soy sauce are organoleptically excellent. Tests marked improvement in manufacturing characteristics with the soy sauce. Most of the ingredients soy sauce pose no problem, but the salt content however does. The sodium content of soy sauce is 7.325 percent, equivalent to 18.8 percent of sodium chloride. Considering that soy sauce has only 63 percent water content, this represents essentially a saturated solution (30 percent salt) in the available water. Used at 7 ounces of soy sauce per 8 pounds of finished dry product (5.5 percent), this 18.8 percent salt content calculates to

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slightly over 1 percent salt content (1.03 gm of salt per 100 gm of finished dry product) the finished bran snack. This poses problems for an "unflavored" snack, which is surprisingly then the flavorant.

Next is the solving of the texture and taste problems of adding calcium carbonate at 1.25 percent to the product, equivalent to about 0.5 percent of calcium content, to contain 500 mg of calcium per 100 gm of daily intake of the high bran product. The addition of reduced iron at 10 mg per 100 gm of the finished high bran product (0.01 percent) seems to present no problems. For the low fiber control, the addition of 0.5 percent of calcium carbonate, equivalent to about 100 mg calcium per 50 gm of low fiber product in the finished package, would seem to offer no problem, as the problems have apparently been solved with the high bran product and the level of calcium carbonate in the low fiber product is far less. The problems of handling the calcium carbonate are solved by altering the composition of the

"inactive" flour components, to use cracked wheat and/or rice flour in place of all or part of the wheat flour in the original formulation. At this point, the low fiber product does not contain added iron. The low fiber product and the high fiber product are available in unflavored form, flavored with barbeque flavorant and flavored with beef-and-onion flavorant. The compositions were:

>;tb; TABLE VII

>;tb;______________________________________

>;tb; Low Fiber

>;tb; High Fiber Product (non-bran)

>;tb; Product (with bran) Amount per

>;tb; Amount per 50 gm

>;tb;Ingredients

>;tb; % 100 gm package

>;tb; % package

>;tb;______________________________________

>;tb;Bran (Wheat)

>;tb; 50 50 gms 0 0

>;tb;Riboflavin

>;tb; 0.02 20 mg 0.04 20 mg

>;tb;Calcium Car-

>;tb; 1.25 1.25 gm 0.50 250 mg

>;tb;bonate

>;tb;(40% calcium

>;tb; (0.5) (500 mg) (0.20)

>;tb; (100 mg)

>;tb;content)

>;tb;Reduced Iron

>;tb; 0.01 10 mg 0 0

>;tb;Cracked Wheat

>;tb; about about about about

>;tb;or Rice Flour

>;tb; 42 42 gm 88 44 gm

>;tb;Coconut oil

>;tb; 3 3 gm 6 3 gm

>;tb;Seasoning or

>;tb; 3 3 gm 6 3 gm

>;tb;Flavorant

>;tb;(where

>;tb;applicable)

>;tb;______________________________________

It is decided that it is better to use a combination of rice flour and whole wheat flour (Graham flour), so the following compositions are prepared:

>;tb; TABLE VIII

>;tb;______________________________________

>;tb; High Fiber Low Fiber

>;tb; Composition, Composition,

>;tb;Ingredients Percent (Approx.)

>;tb; Percent (Approx.)

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>;tb;______________________________________

>;tb;Graham Flour 40.0 80.0

>;tb;Rice Flour 10.0 20.0

>;tb;Bran 50.0 0

>;tb;Calcium Carbonate

>;tb; 1.25 0.5

>;tb;Reduced Iron 0.013 0

>;tb;Riboflavin 0.02 0.04

>;tb;______________________________________

To provide a better control as the long term investigation progressed, i.e., after about one year, it is decided to also fortify the control with an equivalent daily intake amount of reduced iron. So the following compositions are prepared for further use in the long term investigation:

>;tb; TABLE IX

>;tb;______________________________________

>;tb; Low Fiber

>;tb; High Fiber Product (non-bran)

>;tb; Product (with bran) Amount per

>;tb; Amount per 50 gm

>;tb;Ingredients

>;tb; % 100 gm package

>;tb; % package

>;tb;______________________________________

>;tb;Bran (Wheat)

>;tb; 50 50 gms 0 0

>;tb;Riboflavin

>;tb; 0.02 20 mg 0.04 20 mg

>;tb;Calcium 1.25 1.25 gm 0.50 250 mg

>;tb;Carbonate

>;tb;(40% calcium

>;tb; (0.5) (500 mg) (0.20)

>;tb; (100 mg)

>;tb;content)

>;tb;Reduced Iron

>;tb; 0.01 10 mg 0.02 10 mg

>;tb;Cracked Wheat

>;tb; about about about about

>;tb;or Rice Flour

>;tb; 42 42 gm 88 44 gm

>;tb;Coconut oil

>;tb; 3 3 gm 6 3 gm

>;tb;Seasoning or

>;tb; 3 3 gm 6 3 gm

>;tb;Flavorant

>;tb;(where

>;tb;applicable)

>;tb;______________________________________

Both of the compositions were prepared without any flavorant, with beef-and-onion flavorant and with barbeque flavorant.

The following is the latest extruded portion of the formulations used in the long term investigation:

>;tb; TABLE X

>;tb;______________________________________

>;tb; Low Fiber High Fiber

>;tb;Ingredients Composition

>;tb; Composition

>;tb;______________________________________

>;tb;Wheat Bran 0 200 lbs.

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>;tb;Graham Flour 400 lbs. 160 lbs.

>;tb;Rice Flour 100 lbs. 40 lbs.

>;tb;Calcium Carbonate

>;tb; 2 lbs. 5 lbs.

>;tb;Reduced Iron 50 gm 25 gm

>;tb;Riboflavin 90 gm 36 gm

>;tb;______________________________________

Both compositions are extruded using a twin-screw speed of 150 rpm and are baked in an oven at 700

DEG C. at 15 rpm. The high fiber composition has a standard plate count of 200 and an aerobic plate count/gram of 10; and the low fiber composition has a standard plate count of 50 and an aerobic plate count/gram of 30.

Both compositions are extruded in a cooker extruder having a rectangular shaped die opening to provide direct expanded products. As each of the compositions exits from the die, it curls and expands in all directions and is immediately cut into short pieces. Both extruded compositions are more puffed

(i.e., more expanded) than are the earlier compositions. A conventional enrober is used to apply the oil to heated extrudate pieces and then the flavorant powder was applied.

The long term test is progressing using the latest snack formulations. The test is based on the point that, in the case of colorectal cancer, colorectal polyps can serve as a suitable precursor for the malignant disease. Briefly, the malignant potential on the adenoma is well recognized, and while that of the adenomatous and tubulovillous type is still debated, these three histologic types have each been observed with a cytologic atypia associated with malignancy. Further, while polyps can progress to malignancy, remain benign, or regress, patients with polyps are at an increased risk of additional polyps and of colorectal cancer, and the risk increased with the size and number of polyps.

In FIG. 1, numeral 1 represents a die (for a cooker extruder) having rectangular opening 2. In FIG. 2, the snack exits die 2 in end 3 of extruder barrel 4 as continuous material 5. Note the upwards curling of continuous material 5. Reciprocating blade 7 of cutter 6 is used to cut continuous material 5 into individual pieces 8 (see FIG. 3).Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. Food composition in the form of extrusion-cooked extrudate pieces, comprised of: (a) about 40 to about 70 weight percent of bran flour; (b) about 20 to about 50 weight percent of whole wheat flour; (c) about 5 to about 15 weight percent of rice flour; (d) about 0.5 to about 3 weight percent of calcium carbonate; (e) about 0.03 to about 0.005 weight percent of reduced iron; and (f) about 0.1 to about

0.005 weight percent of riboflavin, the weight percents of ingredients (a) to (f) being based on the total dry weight of said food composition.

2. The food composition as claimed in claim 1 wherein the bran flour is whole wheat bran or corn bran.

3. The food composition as claimed in claim 1 wherein about 50 weight percent of bran flour is present.

4. The food composition as claimed in claim 1 wherein about 40 weight percent of whole wheat flour is present.

5. The food composition as claimed in claim 1 wherein about 10 weight percent of rice flour is present.

6. The food composition as claimed in claim 1 wherein about 1.25 weight percent of calcium carbonate is present.

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7. The food composition as claimed in claim 1 wherein about 0.013 weight percent of reduced iron is present.

8. The food composition as claimed in claim 1 wherein about 0.02 weight percent of riboflavin is present.

9. Food composition comprised of: (A) extrusion-cooked extrudate pieces, comprised of: (a) about 40 to about 70 weight percent of bran flour; (b) about 20 to about 50 weight percent of whole wheat flour;

(c) about 5 to about 15 weight percent of rice flour; (d) about 0.5 to about 3 weight percent of calcium carbonate; (e) about 0.03 to about 0.005 weight percent of reduced iron; and (f) about 0.1 to about

0.005 weight percent of riboflavin, the weight percents of ingredients (a) to (f) being based on the total dry weight of said food composition; (B) a layer of about 1 to about 10 weight percent of an edible organic oil on each of the extrudate pieces, the weight percent of said organic oil being based on the total dry weight of said food composition; and (C) about 1 to about 10 weight percent of particulate flavorant on the outer surface of said extrudate pieces, said particulate flavorant being adhered to said extrudate pieces by said organic oil, the weight percent of said particulate flavorant being based on the total dry weight of said food composition.

10. The food composition as claimed in claim 9 wherein the organic oil is coconut oil.

11. The food composition as claimed in claim 9 wherein about 3 weight percent of the organic oil is present.

12. The food composition as claimed in claim 9 wherein the particulate flavorant is in powder form.

13. The food composition as claimed in claim 9 wherein about 3 weight percent of the particulate flavorant is present.

14. The food composition as claimed in claim 9 wherein the bran flour is whole wheat bran or corn bran.

15. The food composition as claimed in claim 9 wherein about 50 weight percent of bran flour is present.

16. The food composition as claimed in claim 9 wherein about 40 weight percent of whole wheat flour is present.

17. The food composition as claimed in claim 9 wherein about 10 weight percent of rice flour is present.

18. The food composition as claimed in claim 9 wherein about 1.25 weight percent of calcium carbonate is present.

19. The food composition as claimed in claim 9 wherein about 0.013 weight percent of reduced iron is present.

20. The food composition as claimed in claim 9 wherein about 0.02 weight percent of riboflavin is present.

21. Process of preventing the occurrence of colorectal polyps in a human, except for one who is genetically incapable of developing colorectal polyps, comprised of consuming the food composition of claim 1 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent the occurrence of colorectal polyps in said human.

22. Process as claimed in claim 21 wherein the occurrence colon polyps is prevented.

23. Process as claimed in claim 21 wherein the occurrence of rectal polyps is prevented.

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24. Process of preventing the occurrence of colorectal polyps in a human, except for one who is genetically incapable of developing colorectal polyps, comprised of consuming the food composition of claim 9 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent the occurrence of colorectal polyps in said human.

25. Process as claimed in claim 24 wherein the occurrence colon polyps is prevented.

26. Process as claimed in claim 24 wherein the occurrence of rectal polyps is prevented.

27. Process of preventing the recurrence of colorectal polyps in a human, except one who is genetically incapable of developing colorectal polyps, comprised of consuming the food composition of claim 1 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent the recurrence of colorectal polyps in said human.

28. Process as claimed in claim 27 wherein the recurrence of colon polyps is prevented.

29. Process as claimed in claim 27 wherein the recurrence of rectal polyps is prevented.

30. Process of preventing the recurrence of colorectal polyps in a human, except one who is genetically incapable of developing colorectal polyps, comprised of consuming the food composition of claim 9 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent the recurrence of colorectal polyps in said human.

31. Process as claimed in claim 30 wherein the recurrence of colon polyps is prevented.

32. Process as claimed in claim 30 wherein the recurrence of rectal polyps is prevented.

33. Process of preventing colorectal cancer in a human, except one who is genetically incapable of developing colorectal cancer, comprised of consuming the food composition of claim 1 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent colorectal cancer in said human.

34. Process as claimed in claim 33 wherein colon cancer is prevented.

35. Process as claimed in claim 33 wherein rectal cancer is prevented.

36. Process of preventing colorectal cancer in a human, except one who is genetically incapable of developing colorectal cancer, comprised of consuming the food composition of claim 9 by said human on a daily basis over an extended period of time, the amount of said food composition consumed by said human being an amount effective to prevent colorectal cancer in said human.

37. Process as claimed in claim 36 wherein colon cancer is prevented.

38. Process as claimed in claim 36 wherein rectal cancer is prevented.

39. Process for preparing a food composition in the form of extrusion-cooked extrudate pieces, comprised of: (a) admixing: (i) about 40 to about 70 weight percent of bran flour; (ii) about 20 to about

50 weight percent of whole wheat flour; (iii) about 5 to about 15 weight percent of rice flour; (iv) about

0.5 to about 3 weight percent of calcium carbonate; (v) about 0.03 to about 0.005 weight percent of reduced iron; (vi) about 0.1 to about 0.005 weight percent of riboflavin; and (vii) about 1 to about 10 weight percent of water, the weight percents of ingredients (i) to (ii) being based on the total dry weight of said food composition; and (b) extruding said wetted admixture in said cooker extruder to form said extrusion-cooked extrudate pieces.

40. The process as claimed in claim 39 wherein said admixing is done in a ribbon blender.

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41. The process as claimed in claim 39 wherein ingredients (i) to (vi) are first admixed and feed to said cooker extruder, and then water (vii) is admixed with the mixture of ingredients (i) to (vi) in said cooler extruder.

42. Process for preparing a food composition in the form of coated, extrusion-cooked extrudate pieces, comprised of: (a) admixing: (i) about 40 to about 70 weight percent of bran flour; (ii) about 20 to about

50 weight percent of whole wheat flour; (iii) about 5 to about 15 weight percent of rice flour; (iv) about

0.5 to about 3 weight percent of calcium carbonate; (v) about 0.03 to about 0.005 weight percent of reduced iron; (vi) about 0.1 to about 0.005 weight percent of riboflavin; and (vii) about 1 to about 10 weight percent of water, the weight percents of ingredients (i) to (ii) being based on the total dry weight of said food composition; (b) extruding said wetted admixture in said cooker extruder to form said extrusion-cooked extrudate pieces; (c) placing a layer of about 1 to about 10 weight percent of an edible oil on each of the extrudate pieces, the weight percent of said organic oil being based on the total dry weight of said food composition; and (d) placing about 1 to about 10 weight percent of particulate flavorant on the extrudate pieces, said particulate flavorant being adhered to the extrudate pieces by the organic oil, the weight percent of the particulate flavorant being based on the total dry weight of said food composition.

43. The process as claimed in claim 42 wherein said admixing is done in a ribbon blender.

44. The process as claimed in claim 43 wherein ingredients (i) to (vi) are first admixed and feed to said cooker extruder, and then water (vii) is admixed with the mixture of ingredients (i) to (vi) in said cooler extruder.

45. The process as claimed in claim 42 wherein the oil layer is sprayed on the extrudate pieces.

46. The process as claimed in claim 45 wherein the particulate flavorant is placed on the oil coated extrudate pieces.Data supplied from the esp@cenet database - Worldwide

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365.

US4778690 - 10/18/1988

PROCESS CONTAINING A COOKING EXTRUSION STEP FOR FORMING A

FOOD PRODUCT FROM A CEREAL


Inventor(s): SADEL JR STANLEY S (US); SANGIOVANNI VALERIO (US)

Applicant(s): MAPAM INC (US)


IP Class: A23P1/14

E Class: A23L1/164E; A23L1/164; A23L1/164F2



Family: US4778690

Abstract:


A snack food is prepared from whole kernel cereal, without milling, such as corn, rice or wheat and the like. By rehydrating the cereal to at least 25% moisture prior to low shear cooking extrusion to achieve about 75% gelatinization, then cooling and drying the material prior to extrusion into a selected form for further mechanical treatment or finish cooking and flavoring. When cooked in oil a lower fat product results.Claims:


What is claimed is:

1. A process for preparing a food product from a cereal starting material, the steps comprising: providing a quantity of dry cereal starting material in the unmilled, whole kernel state, hydrating the starting material to a moisture content at least greater than 15% moisture, draining the unabsorbed water from the cereal material, subjecting the material to low shear extrusion cooking for a time and with sufficient heat to gelatinize to about 75% the starch constituent of the material, reducing the

1696/2197

moisture content of the extruded material through aeration in a conditioning step, extrusion forming the material to a pre-selected shape, and further cooking the material.

2. The process of claim 1 wherein the starting material is hydrated to achieve a moisture content of between 20 to 30%.

3. The process of claim 1 wherein, preceeding the low shear extrusion cooking, the whole kernel cereal material is mixed to achieve mechanical breakage of the outer kernel wall.

4. The process of claim 3 wherein further ingredients are supplied to the cereal materials during the mixing step, such materials being from the group consisting of white corn flour, yellow corn flour, corn starch, flavorings, lime or water.

5. The process of claim 3 wherein the whole kernel cereal material is from the group consisting of corn, wheat and rice.

6. The process of claim 1 wherein the material is subjected in the low shear cooking extrusion step to temperature gradients of between 40 DEG C. to 140 DEG C., and thereafter the material is substantially cooled by as much as 40 DEG C.

7. A process for preparing a corn-based, snack food product, the steps comprising: providing a quantity of whole kernel corn as a starting material, soaking the corn kernels in water to achieve a corn moisture content in the range from about 20% to about 40% moisture, separating the corn kernels from the soak water, mixing the corn kernels for a period of time sufficient to distribute surface water substantially evenly and to abraid the kernels, applying low shear cooking extrusion forces to the kernels for a time and temperature sufficient to gelatinize about 80% of the starch constituents of the corn kernels, conditioning the extruded material under conditions sufficient to reduce the moisture content within the material on the order of about 4% and pressing the material through a die into a pre-selected shape, and then further cooking the material.

8. The process of claim 7 wherein during the cooking extrusion step a temperature profile is maintained over a plurality of cooking stages beginning at about 80 DEG C. and progressively increasing to a final cooking temperature of about 130 DEG C.

9. The process of claim 8 wherein following the forming extrusion step the material is laminated then cut, and thereafter cooked in a vat of cooking oil.

10. The process of claim 8 wherein the processed material has a residence time in the low shear cooking extrusion step of between 1 and 4 minutes.

11. A process of preparing a corn-based product, the steps comprising: providing a quantity of whole kernel corn as a starting material, soaking the corn kernels in water to achieve a moisture content of substantially 30%, draining the soak water from the corn kernels and discharging the water directly into the sewer system without substantial water treatment, mixing the corn kernels for a period of time sufficient to distribute surface water substantially evenly and then treating the material to low shear cooking extrusion for a time between 1 and 4 minutes at temperatures of between 80 DEG C. and 140

DEG C. to gelatinize substantially 80% of the starch constituents of the corn kernels, and thereafter cooling the material, converting the material into pieces with a nominal piece size on the order of between 5 to 10 mm, forming the material into a sheet and cutting the sheet material.Data supplied from the esp@cenet database - Worldwide

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366.

US4794012 - 12/27/1988

METHOD OF MANUFACTURING DRIED RICE WITH PREGELATINIZED

STARCH CONTENT


Inventor(s): TANIGUCHI MORIO (JP); NAKANAGA RYUSUKE (JP); YANO NORIKO (JP)



IP Class: A23L1/10

E Class: A23L1/182



Family: CN87101738

Equivalent:

Abstract:

JP62181746; GB2186178; IT1203332


A method of manufacturing dried rice with a pregelatinized starch content which comprises the steps of: (a) soaking polished rice in water having a temperature below 30 DEG C.; (b) soaking the polished rice resulting from said step (a) in warm water having a temperature between 50 DEG and 70 DEG C.;

(c) steam cooking the polished rice resulting from said step (b); and (d) drying the polished rice resulting from said step (c). The method allows the dried rice to be made edible within a short period, and allows the rice to be processed without making the surface of the rice grains too sticky, and thus provides constantly high yields with low energy costs.Description:



The present invention relates to a new method for manufacturing dried rice with a pregelatinized starch content, and more particularly to a method of this kind which allows the rice to be made edible readily when it is cooked by heating in a microwave over or the like.


With the development of food processing techniques, various types of foods that may be kept for extended periods have been developed and sold on the market. These foods can be cooked by a simple means and within a short time, while providing the original taste. There have also been developments with respect to cooked rice, and various types of products and manufacturing methods are already known.

For instance, Japanese Patent Publication No. 34730/1971 discloses a method of manufacturing

"instant rice", and Japanese Patent Publication No. 43222/1982 discloses a method of manufacturing rice for storage. However, these methods suffer from the following problems. Although the former method is capable of providing dried rice with a high content of pregelatinized starch, it necessitates

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steaming and boiling the rice over a long time period, and is thus disadvantageous with respect to the demand for reducing energy costs. The latter method necessitates steps which may lead to loss of the pregelatinized content typical of such steps being a boiling step, thus resulting in a reduction of the yield.


Accordingly, an object of the present invention is to provide a method of manufacturing dried rice with a high pregelatinized starch content which allows the rice to be made edible within a short period, and which allows the rice to be processed without making the surface of the rice grains too sticky, and thus provides constantly high yields with low energy costs.

The present invention has been accomplished on the basis of the finding that if polished rice is soaked in warm water having a predetermined temperature after the rice has been soaked in cold water and before it is steamed and boiled, the content of pregelatinized starch can be increased while the grains' surface is prevented from becoming too sticky, accordingly also preventing any reduction in the yield, even if the period during which the rice is to be steamed and boiled is short.


The present invention provides a method for manufacturing dried rice with a pregelatinized starch content which comprises the the steps of: (a) soaking polished rice in water having a temperature below

30 DEG C.; (b) soaking the polished rice resulting from the step (a) in warm water having a temperature between 50 DEG and 70 DEG C.; (c) steam cooking the polished rice resulting from the step (b); and (d) drying the polished rice resulting from the step (c).

The method of the invention will now be described in detail.

(a) Water Soaking Process

According to the method of the present invention, polished rice is first soaked in water having a temperature below 30 DEG C.

Rice which has previously been washed is normally used as the polished rice. The water in which the rice is to be soaked should have a temperature below 30 DEG C. This will allow the polished rice to absorb water uniformly. Preferably, the temperature of the water should be within the range between 10 and 20 DEG C. This will allow the speed at which water is absorbed to be kept at an appropriate value and prevent propagation of bacteria during soaking. The period of soaking is normally about 1 to 16 hours. From the viewpoint of obtaining a uniform moisture distribution in the resulting rice as well as a high degree of production efficiency, and of preventing putrefaction, the water soaking period should preferably be about 2 to 4 hours.

The moisture content in the polished rice thus obtained normally ranges between about 30 and 40%.

(b) Warm Water Soaking Process

In this process, the polished rice containing about 30 to 40% moisture following soaking in cold water is soaked in warm water having a temperature between 50 DEG and 70 DEG C.

By virtue of soaking the polished rice in warm water having a temperature between 50 DEG and 70

DEG C., the moisture content of the rice can be increased within a relatively short period. This makes it possible to prevent eluation of critical ingredients in the polished rice such as nutritious contents, and also to prevent rapid pregelatinization from taking place on the surface of the rice, thus preventing water absorption from being impeded by a film of glue which would otherwise be formed on the surface of the rice, preventing the handling of the rice from becoming difficult due to increased stickiness of the rice grains.

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The soaking period should normally be less than about 3 hours. This will make it possible to prevent eluation of critical ingredients and propagation of bacteria. The soaking period should preferably be about 30 minutes to 90 minutes.

The moisture content of the polished rice which has thus been obtained normally ranges between about

40 and 65%. By virtue of having a moisture content within this range, pregelatinization in the ensuing steam cooking step will be completed to an adequate degree within a short period, and accordingly it will be possible to prevent eluation of critical ingredients, and formation of a coarse surface or breakage of the rice.

(c) Steam Cooking Process

In this process, the polished rice having a moisture content of 40 to 50% following the warm water soaking is steamed and boiled. This steam cooking can be performed by any known method such as a one-stage steaming/boiling method or a two-stage steaming/boiling method. A one-stage steaming/boiling method is undertaken at a temperature between about 95 DEG and 100 DEG C., and for a period of about 5 to 20 minutes. A two-stage steaming/boiling method includes the step of water spraying or soaking for a short period between two steaming/boiling stages. If required, a seasoning stock may be used in place of water. Each steaming/boiling stage is undertaken at a temperature between 95 DEG and 100 DEG C., and for a period of 2 to 15 minutes.

The polished rice with a pregelatinized starch content resulting from the steam cooking process contains about 45 to 75% moisture.

(d) Drying process

In this process, the polished rice having a pregelatinized starch content and containing about 45 to 75% moisture following the steam cooking process is dried.

The conditions under which this drying process is performed are not specifically limited. A typical drying method is a hot-air drying method which is undertaken at a temperature between about 60 DEG and 100 DEG C., and for a period of 20 to 140 minutes. The moisture content after drying will be about

5 to 15%. Sometimes it is preferable to bring the rice grains into a loosened state at least once by shaking because this enables uniform drying, and prevents the rice grains from adhering to each other, and increases the yield.

In addition, a swelling treatment may be effected after the hot-air drying. Such swelling treatment is normally undertaken at a temperature between about 200 DEG and 400 DEG C., preferably between

250 DEG and 330 DEG C., and for a period of 7 to 30 seconds. By effecting this swelling treatment, the moisture content is reduced to about 2 to 8%.

The dried rice with a pregelatinized starch content is very suitable for use as a food for storing, and shows excellent properties which allow it to be made edible readily when cooked, for instance, by a microwave oven.

Examples of the present invention will be described below.

EXAMPLE 1

500 g of polished rice (nonglutinous rice containing 13.8% moisture) which had been washed was first soaked in water having a temperature of 15 DEG C. for a period of 2 hours. The moisture content of the rice grains was 32.8% after this soaking. Subsequently, the resulting rice was soaked in warm water having a temperature of 65 DEG C. for a period of one hour. The moisture content of the rice grains was 61.3% after this warm water soaking. After excessive water had been removed from the rice, it was subjected to a first steaming and boiling at a temperature of 98 DEG C. for a period of 10 minutes, then to cold water soaking for a period of 3 minutes, followed by a second steam cooking at a temperature of 100 DEG C. for a further period of 10 minutes. The moisture content of the grains of the resulting rice was 72.5%. The rice was then hot-air dried at a temperature of 95 DEG C. for a period of

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25 minutes. The thus dried rice was loosened, and then hot-air dried at a temperature of 80 DEG C. for a period of 30 minutes, dried rice with a pregelatinized starch content (Example 1) produced by the method of the present invention thereby being obtained.

To 75 g of the thus obtained dried rice was added to 130 ml of water, and the rice and water were heated in a microwave oven (500 W) for a period of 4 minutes, which operation was followed by allowing the thus heated rice to settle by its own heat for 5 minutes.

Table 2 shows the properties of the thus cooked rice (i.e. whether there was any uncooked hard portion at the center, and the outer appearance), and the loss ratios experienced during the production. The loss ratios were calculated in the following manner.

Loss Ratio (1): the loss ratio during the production process

This ratio was calculated from the weight (g) of the rice used with its moisture content expressed as 8% of the total weight, and from the weight (g) of the rice when it had been dried by hot-air, using the following equation: ##EQU1##

Loss Ratio (2): the loss ratio during sieving of the dried rice

This ratio was calculated from the weight (g) of the hot-air dried rice and from the weight of a portion of the dried rice which passed through size 9 mesh, using the following equation: ##EQU2##

COMPARISON EXAMPLES 1 TO 4

Comparison rice samples (Comparison Examples 1 to 4) were produced by following the procedure used in Example 1 except that the soaking steps (i.e. the first soaking and the second soaking) were conducted under the conditions shown in Table 1. The results, such as the loss ratios, are shown in

Table 2.

EXAMPLE 2

500 g of polished rice (glutinous rice containing 14.0% moisture) which had been washed was first soaked in water having a temperature of 15 DEG C. for a period of 2 hours. The moisture content of the rice grains was 32.5% after this soaking. Subsequently, the resulting rice was soaked in warm water having a temperature of 65 DEG C. for a period of 40 minutes. The moisture content of the rice grains was 58.5% after this warm water soaking. After excessive water was removed from the rice, it was subjected to a first steam cooking at a temperature of 98 DEG C. for a period of 3 minutes, then to cold water soaking for a period of 30 seconds, followed by a second steam cooking at a temperature of 100

DEG C. for a further period of 10 minutes.

The moisture content of the grains of the resulting rice was 72.6%. The rice was then hot-air dried at a temperature of 95 DEG C. for a period of 25 minutes. The thus dried rice was loosened, and then hotair dried at a temperature of 80 DEG C. for a period of 30 minutes. Whereby dried rice with a pregelatinized starch content (Example 2) produced by the method of the present invention, was obtained.

To 75 g of the thus obtained dried rice was added 100 ml of water, and the rice and water were heated in a microwave oven (500 W) for a period of 2 minutes, which operation was followed by allowing the thus heated rice to settle by its own heat for 5 minutes.

The results such as the loss ratios are shown in Table 2.

COMPARISON EXAMPLES 5 TO 8

Comparison rice samples (Comparison Examples 5 to 8) were produced by following the procedure used in Example 2 except that the soaking steps (i.e. the first soaking and the second soaking) were conducted under the conditions shown in Table 1. The results such as the loss ratios are shown in Table

2.

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>;tb; TABLE 1

>;tb;__________________________________________________________________________

>;tb; FIRST SECOND

>;tb; FIRST SECOND STEAMING/

>;tb; WATER STEAMING/

>;tb; HOT-AIR

>;tb;STEP SOAKING

>;tb; SOAKING BOILING SOAKING

>;tb; BOILING DRYING

>;tb;__________________________________________________________________________

>;tb;EXAMPLE 1

>;tb; 15 DEG C.; 2 hr.

>;tb; 65 DEG C.; 1 hr.

>;tb; 10 min. 3 min.

>;tb; 10 min.

>;tb; (32.8%)*

>;tb; (61.3%) (64.3%) (71.0%)

>;tb; (72.5%) (7.8%)

>;tb;COMPARISON

>;tb; 15 DEG C.; 2 hr.

>;tb; 85 DEG C.; 30 min.


>;tb; 10 min.

>;tb;EXAMPLE 1

>;tb; (32.8%)

>;tb; (76.0%) (75.8%) (79.6%)

>;tb; (79.5%) (8.5%)

>;tb;COMPARISON

>;tb; 65 DEG C.; 2 hr.


>;tb; 10 min.

>;tb;EXAMPLE 2

>;tb; (71.8%) (72.8%) (76.0%)

>;tb; (76.1%) (8.0%)

>;tb;COMPARISON

>;tb; 15 DEG C.; 15 hr.


>;tb; 10 min.

>;tb;EXAMPLE 3

>;tb; (33.3%) (37.6%) (49.1%)

>;tb; (50.1%) (6.6%)

>;tb;COMPARISON

>;tb; 65 DEG C.; 1 hr.

>;tb; 15 DEGC.; 2 hr.


>;tb; 10 min.

>;tb;EXAMPLE 4

>;tb; (59.9%)

>;tb; (65.3%) (65.3%) (71.3%)

>;tb; (72.6%) (7.9%)

>;tb;EXAMPLE 2

>;tb; 15 DEG C.; 2 hr.

>;tb; 65 DEG C.; 40 min.

>;tb; 3 min. 30 sec.

>;tb; 10 min.

>;tb; (38.5%)

>;tb; (58.5%) (61.4%) (66.4%)

>;tb; (66.3%) (7.5%)

>;tb;COMPARISON

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>;tb; 15 DEG C.; 2 hr.

>;tb; 85 DEG C.; 22 min.


>;tb; 10 min.

>;tb;EXAMPLE 5

>;tb; (38.5%)

>;tb; (69.7%) (72.5%) (72.4%)

>;tb; (72.6%) (7.8%)

>;tb;__________________________________________________________________________

>;tb; FIRST SECOND

>;tb; FIRST SECOND STEAMING/

>;tb; WATER STEAMING/

>;tb; HOT-AIR

>;tb;PROCESS SOAKING

>;tb; SOAKING BOILING SOAKING

>;tb; BOILING DRYING

>;tb;__________________________________________________________________________

>;tb;COMPARISON

>;tb; 65 DEG C.; 2 hr.


>;tb; 10 min.

>;tb;EXAMPLE 6

>;tb; (73.4%) (70.8%) (71.6%)

>;tb; (72.8%) (7.9%)

>;tb;COMPARISON

>;tb; 15 DEG C.; 15 hr.


>;tb; 10 min.

>;tb;EXAMPLE 7

>;tb; (39.4%) (45.0%) (53.1%)

>;tb; (55.1%) (6.8%)

>;tb;COMPARISON

>;tb; 65 DEG C.; 40 min.

>;tb; 15 DEG C.; 2 hr.


>;tb; 10 min.

>;tb;EXAMPLE 8

>;tb; (59.2%)

>;tb; (66.6%) (65.2%) (67.0%)

>;tb; (69.3%) (7.6%)

>;tb;__________________________________________________________________________

>;tb; *Values within parentheses indicate the moisture content after processing

>;tb; TABLE 2

>;tb;__________________________________________________________________________

>;tb; PROPERTIES AFTER BEING

>;tb; LOSS LOSS MADE EDIBLE

>;tb; RATIO (1)

>;tb; RATIO (2)

>;tb; HARD OUTER

>;tb; (%) (%) CENTER

>;tb; APPEARANCE SUMMARY

>;tb;__________________________________________________________________________

>;tb;EXAMPLE 1

>;tb; 9.6 7.1 NONE RICE GRAINS HAD BOTH GOOD TASTE

>;tb; AND GOOD TEXTURE

>;tb;COMPARISON

>;tb; 11.7 7.1 " RICE GRAINS LACKED GLUTINOUSNESS

>;tb;EXAMPLE 1 WITH DRY TEXTURE

>;tb;COMPARISON

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>;tb; 20.6 10.2 " FORMED INTO A MASS

>;tb; CRACKED DURING SOAKING

>;tb;EXAMPLE 2 SIMILAR TO RICE CAKE

>;tb; AND WAS BRITTLE

>;tb;COMPARISON

>;tb; 3.9 1.8 YES RICE GRAINS

>;tb;EXAMPLE 3

>;tb;COMPARISON

>;tb; 10.2 10.2 NONE FORMED INTO A MASS

>;tb; BRITTLE AFTER SOAKING


>;tb;EXAMPLE 2

>;tb; 8.8 10.2 " RICE GRAINS HAD BOTH GOOD TASTE

>;tb; AND GOOD TEXTURE

>;tb;COMPARISON


>;tb; EXCESSIVELY GLUEY


>;tb; TENDING TO AFFECT

>;tb; PROCESSING

>;tb;COMPARISON


>;tb; CRACKED DURING SOAKING


>;tb; AND WAS BRITTLE

>;tb;COMPARISON

>;tb; 7.9 7.1 YES RICE GRAINS

>;tb;EXAMPLE 7

>;tb;COMPARISON

>;tb; 15.6 15.6 NONE FORMED INTO A MASS

>;tb; BRITTLE AFTER SOAKING


>;tb;__________________________________________________________________________

EFFECTS OF THE INVENTION

The method in accordance with the present invention provides dried rice which, after having been soaked, has an increased moisture content, which is provided with an adequate content of pregelatinized starch while being steamed and boiled, and which is allowed to swell to a large degree while being dried. The thus produced dried rice can therefore be made edible readily by employing a microwave oven or by pouring hot water over it, and yet has a good taste.

In addition, according to the method of the invention, the moisture distribution after soaking can be made uniform. This enables the rice to be made edible uniformly, while eliminating any portions remaining uncooked at the center of the rice grains after making the rice edible.

Further, the moisture content can be increased without causing eluation of critical ingredients in the polished rice such as the nutritious contents and the contents which provide good taste.

In addition, the method in accordance with the present invention is advantageous in reducing the ratio of rice lost during the production process, including the sieving performed to loosen the rice grains.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A method for manufacturing dried rice having a pregelatinized starch content, comprising: (a) soaking polished rice for a period of time of 1 to 16 hours in water having a temperature below 30

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DEG C.; (b) soaking the polished rice resulting from said step (a) for a period of time of 30 to 90 minutes in water having a temperature between 50 DEG and 70 DEG C.; (c) steam cooking the polished rice resulting from said step (b) at a temperature of from 95 DEG to 100 DEG C. for a period of time of 5 to 30 minutes; and (d) drying the polished rice resulting from said step (c).

2. The method of claim 1, wherein said steam cooking step (c) comprises steam cooking the polished rice obtained in said step (b), adding water thereto, and steam cooking the resulting rice.

3. The method of claim 1, wherein said drying step (d) comprises hot-air drying the polished rice obtained in said step (c) at a temperature of between 60 DEG and 140 DEG C. for a period of time of

20 to 100 minutes.

4. The method of claim 1, wherein said drying step (d) includes loosening the aggregate of the rice during the course of drying.

5. The method of claim 3, wherein said drying step (d) includes a swelling treatment performed after hot-air drying, at a temperature of between 200 DEG and 400 DEG C., for a period of time of 7 to 30 seconds.

6. The method of claim 1, comprising soaking a polished rice in said step (a) in water having a temperature of from 10 DEG C. to 20 DEG C.

7. The method of claim 1, comprising soaking the polished rice in said step (a) for a period of time of 2 to 4 hours.

8. The method of claim 1, comprising steam cooking the polished rice in said step (c) for a period of time of 5 to 20 minutes.

9. The method of claim 1, wherein said steam cooking of the polished rice in said step (c) is a twostage steam-boiling operation, wherein each steam-boiling stage is performed at a temperature of between 95 DEG and 100 DEG C. for a period of time of 2 to 15 minutes.

10. A dried rice having a pregelatinized starch content composition, obtained by a process comprising the steps of: (a) soaking polished rice for a period of time of 1 to 16 hours in water having a temperature below 30 DEG C.; (b) soaking the polished rice resulting from said step (a) for a period of time of 30 to 90 minutes in water having a temperature between 50 DEG and 70 DEG C.; (c) steam cooking the polished rice resulting from said step (b) at a temperature of from 95 DEG to 100 DEG C. for a period of time of 5 to 30 minutes; and (d) drying the polished rice resulting from said step (c).

11. The composition of claim 10, wherein said steam cooking step (c) comprises steam cooking the polished rice obtained in said step (b), adding water thereto, and steam cooking the resulting rice.

12. The composition of claim 10, wherein said drying step (d) comprises hot-air drying the polished rice obtained in said step (c) at a temperature of between 60 DEG and 140 DEG C. for a period of time of 20 to 100 minutes.

13. The composition of claim 10, wherein said drying step (d) includes loosening the aggregate of the rice during the course of drying.

14. The composition of claim 12, wherein said drying step (d) includes a swelling treatment performed after hot-air drying, at a temperature of between 200 DEG and 400 DEG C., for a period of time of 7 to

30 seconds.

15. The composition of claim 10, wherein said polished rice is soaked in said step (a) in water having a temperature of from 10 DEG C. to 20 DEG C.

16. The composition of claim 10, wherein said polished rice is soaked in said step (a) for a period of time of 2 to 4 hours.

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17. The composition of claim 10, wherein the polished rice resulting from step (b) is steam cooked in a one-step steaming-boiling operation for a period of time of about 5 to 20 minutes.

18. The composition of claim 10, wherein said polished rice resulting from step (b) is steam cooked in said step (c) in a two-stage steaming-boiling operation, where each stage of the operation is performed at a temperature of between 95 DEG and 100 DEG C. for a period of time of from 2 to 15 minutes.Data supplied from the esp@cenet database - Worldwide

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367.

US4794016 - 12/27/1988

REDUCTION OF INSTANT RICE POUR-OFF


Inventor(s): SHAH MANOJ K O (US); COHEE JR ARTHUR H (US); BURKE JOSEPH D

(US); GREENWALD GARY F (US)



IP Class: A23L1/182

E Class: A23L1/182B



Family: US4794016

Abstract:


The present invention teaches a method for reducing pour-off in instant rice product by coating cooked rice prior to drying with instant rice fines, said instant rice fines having a granulation of -20 m+80 m and is applied in amounts up to 2% by weight of the instant rice.Claims:


What is claimed is:

1. a method for reducing pour-off in instant rice products comprising: coating instant rice prior to drying with instant rice fines, said rice fines having granulation ranging from -20 m to +80 m and in amounts up to 5% by weight, said amounts being sufficient to lower the pour-off of the finished instant rice product by up to 100%, subsequently drying the coated instant rice to a moisture content ranging from 5.0% to 15%.

2. A method according to claim 1 wherein the amount of instant rice fines ranges from 2% to 3.5% by weight.

3. An instant rice product comprising an instant rice coated with instant rice fines, said fines having granulation ranging from -20 m to +80 m and being present in amounts up to 5% by weight, said amounts being sufficient to lower the pour-off of the finished instant product by up to 100%.

4. An instant rice product according to claim 3 wherein the amount of instant rice fines range from 2% to 3.5% by weight.Data supplied from the esp@cenet database - Worldwide

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368.

US4810511 - 3/7/1989

PROCESS FOR PARBOILING RICE


Inventor(s):

MARCEL (US)

VELUPILLAI LAKSHMAN (US); VERMA LALIT R (US); TSANGMUICHUNG

Applicant(s): UNIV LOUISIANA STATE (US)


IP Class: A23L1/182

E Class: A23L1/182



Family: US4810511

Abstract:


This invention relates to a process for parboiling rough rice, which process includes: (1) soaking the rough rice; (2) subjecting the soaked rough rice to a first value of microwave energy to partially gelatinize the starch in the rice and raise its water content; (3) draining free water, if any, from the treated soaked rough rice; and (4) subjecting the drained rough rice from (3) to a second level of microwave energy to effect substantially complete gelatinization and to lower the rough rice water content.Claims:


We claim:

1. A process for producing parboiled rice, which process comprises: (a) soaking rough rice in water at a temperature of from about 40 DEG C. to about 70 DEG C. until said rough rice has a water content within the range of from about 26 wt. % to about 32 wt. %; (b) treating a slurry of free water and the soaked rough rice from (a) with a first value of microwave energy to partially gelatinize the starch in the endosperm portion of said rough rice and to raise the water content of said rough rice to be within the range of from about 32 wt. % to about 40 wt. %; (c) draining substantially all of the free water, if any, from the treated slurry of free water and rough rice from (b); (d) treating the drained rough rice from (c) with a second value of microwave energy to substantially complete said gelatinization of said starch and to reduce the water content of the thus treated rough rice to about 22 wt. %; and (e) drying the rough rice from (d) to reduce its water content to at least 14 wt. %.

2. The process of claim 1 wherein said soaking in (a) is for a period of time within the range of from about 3.5 hours to about 5 hours.

3. The process of claim 1 wherein the temperature of the slurry of free water and rough rice in (b) is raised to be within the range of from about 95 DEG C. to about 100 DEG C. during said treatment in

(b).

4. The process of claim 1 wherein the higheht temperature of the drained rough rice in (d) is within the range of from about 90 DEG C. to about 110 DEG C. during said treatment in (d).

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5. The process of claim 1 wherein said drying in (e) is effected by passing hot air over the treated rough rice from (d).

6. The process of claim 2 wherein the temperature of the slurry of free water and rough rice in (b) is raised to be within the range of from about 95 DEG C. to about 100 DEG C. during said treatment in

(b).

7. The process of claim 6 wherein the highest temperature of the drained rough rice in (d) is within the range of from about 90 DEG C. to about 110 DEG C. during said treatment in (d).

8. The process of claim 7 wherein said drying in (e) is effected by passing hot air over the treated rough rice from (d).Data supplied from the esp@cenet database - Worldwide

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369.

US4857348 - 8/15/1989

PROCESS FOR PRODUCING INSTANTIZED PARBOILED RICE


Inventor(s):

(CA)

ABRAHAM THOMAS E (CA); MALFAIT JACQUE L (CA); WHITE ARNOLD J

Applicant(s): GEN FOODS INC (CA)


IP Class: A23L1/182

E Class: A23L1/182



Family: US4857348

Abstract:


A process is described to provide an improved instantized parboiled rice that maintains the texture, appearance and flavor characteristics of eating quality parboiled finished rice product.Description:


TECHNICAL FIELD

This invention relates to a process for producing an improved instantized parboiled rice by incorporating specific amounts of water into long grain milled parboiled rice, reducing the water content over a period of time to obtain a texture having a specific range of a shear press value to provide an instantized product capable on rehydration to produce a rice product having the texture, appearance and flavor characteristics of eating quality parboiled rice.


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Parboiled rice is preferred over white rice by many consumers for its texture, appearance, flavor, aroma, and recipe tolerance. However, due to the pretreatment of the rice in the paddy form which produces parboiled rice, the grain is rendered longer-cooking than milled white rice. Most parboiled rice of commerce calls for immersion-cooking of at least 20 minutes in boiling water to prepare the parboiled rice to the desired edibility. During the process of converting rough rice to parboiled rice, the paddy is soaked, steamed, dried, and then milled. It appears that the heat treatment involved in this processing reduces product rehydratability and renders it harder and longer to cook.

Many attempts have been made to produce an instantized parboiled rice having the texture, appearance and flavor characteristics of eating quality parboiled rice but success has not been completely achieved.

In U.S. Pat. No. 2,720,460 entitled "Production of Quick-Cooking Rice" techniques are described for producing instantized rice by hydrating rice grains in stages but did not consider parboiled rice as the starting material. U.S. Pat. No. 2,438,939 entitled "Quick Cooking Rice And Process For Making

Same" describes a milled rice (not parboiled) cooked in boiling water until its starch is substantially gelatinized and its moisture content is raised to about 65-70%, cooled and quick dried by removing moisture from its surface at a rate sufficiently faster than it can diffuse thereto from their interiors at

140 DEG C. for 10 to 15 minutes. Another U.S. Pat. No. 3,408,202 entitled "Process For Preparing A

Quick-Cooking Rice" prepares a quick cook rice by soaking parboiled rice in water below its gelatinized temperature 160 DEG F. to increase its moisture content to 15-50%, steaming the rice to temperatures of 180 DEG-212 DEG F., reimmersing the rice in water below 160 DEG F., steamed again and reimmersed again and then dehydrating the cooked rice. This multiple step process is time consuming and complicated. U.S. Pat. No. 2,903,360 entitled "Method Of Making Quick-Cooking

Cereals From Parboiled Grains" soaks parboiled rice in water for 2 to 5 hours at temperatures between about 50 DEG F. and 82 DEG F. to a moisture content between 45 and 55% compared to temperatures between about 130 DEG F. to 160 DEG F. to a moisture content between 65% and 77%. The rice is then boiled in water for about 2 to 5 minutes, separating the boiled grains from the boiling water, spraying the grains with cold water to about 130 DEG F., squeezing the cooled grains to 1/3 to 1/5 their thickness, washing and drying the grains. This multiple step process is also time consuming and complicated. Finally, U.S. Pat. No. 4,361,593 entitled "Process For Preparing Dry Quick-Cooking

Parboiled Rice And Product Thereof" prepares dry parboiled rice by soaking rough rice in water to increase the moisture content to 30 to 45% by weight without effecting substantial gelatinization, steaming the hydrated rice under conditions effective to partially gelatinize the starch granules, tempering the partially-gelatinized rice at temperatures below the gelatinization temperature of the starch while maintaining the level of moisture above 20%, drying the rice to a moisture content less than 15% and milling the rice. This process occurs within the hull of the rice. Other references are known to produce quick-cooking rice but no references are known which describe the process of this invention relating to the production of an instantized parboiled rice which is unique in its operation to provide an outstanding quality product having the texture, appearance and flavor characteristics of eating quality parboiled rice finished product.


The present invention provides a process for making an improved instantized parboiled rice which comprises incorporating about 68 to about 78% of water into long grain milled parboiled rice which has been substantially gelatinized. The resulting product is carefully dried to reduce the water content of the rice to about 6 to about 14% over a period of time to obtain a rice having a texture with a shear press value in the range from about 85 to about 110 lbs/force, preferably about 100 to about 105 lbs/force, and having a 41/2 to 71/2 minute stand when an equal volume of rice is combined with an equal volume of boiling water to produce an instantized eating quality finished rice product.


The starting rice material for this invention is a parboiled rice typically prepared by soaking rough rice paddy (unmilled rice, substantially as it comes from the field) in cold, warm or hot water for a substantial period of time, until the rice kernels have increased their moisture content, generally to at least above 20%; steaming the rice, generally at super-atmospheric pressure to substantially gelatinize at least 85% and up to 95 to 100% of the starch and the rice is dried and milled. This procedure ensures

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separateness of grain but it is well known that parboiled rice requires increased cooking time to fully rehydrate the dry parboiled rice to achieve a cooked product.

By this invention, long grain milled parboiled rice substantially gelatinized, is exposed to water at temperatures from about 160 DEG F. to 212 DEG F. and higher by soaking, immersion, steaming and the like for a period of time to increase the water content of the rice to about 68 to about 78% by weight, preferably about 72 to about 74%, of the total parboiled rice. When the water content of the parboiled rice is achieved, the product is dehydrated using drying temperatures in the range from about

260 DEG F. to about 325 DEG F., preferably from about 290 DEG F. to about 310 DEG F. over a period of time such as 30 to 45 minutes, preferably 35 to 42 minutes to reduce the water content of the rice to about 6 to about 14% by weight, preferably about 7% to about 11%, to produce a rice having a texture with a shear press value in the range from about 85 to about 110 lbs/force, preferably about

100 to about 105 lbs/force. This rice will have a 41/2 to 71/2 minute stand preferably 5 minute stand which means that when an equal volume of rice is combined with an equal volume of boiling water, the product produced is an instantized eating quality finished parboiled rice product.

The "long grain rice" as used herein and known in the art, is defined as a rice which is long and slender in shape, as much as 4 to 5 times as long as it is wide. When cooked, the grains tend to separate and are light and fluffy.

The drying procedure used to dehydrate the high water containing rice is a long drying procedure when compared to the quick drying dehydrating procedure of regular milled rice (not parboiled) normally taking 10 to 15 minutes.

The so called "long drying" technique of this invention is conducted to achieve specific texture with a specific shear press value as described above.

U.S. Pat. No. 2,972,884 issued Feb. 28, 1961 describe a tenderness testing apparatus for food products.

The apparatus and test has become known as "shear press". This test involves the use of a standardized container and cell within which a suitable quantity of product such as rice is placed and the product is penetrated by a multiple bladed ram. The ram as it is passing through the material, operates to shear the individual particles or fibers. The force necessary to produce penetration is considered a measure of the tenderness of the product. Under carefully controlled conditions, the numerical value of force or thrust for a given product has been found to have a good correlation with tenderness. In the operation of the shear press test, especially for rice kernels, the rate at which the blade assembly of the ram is driven through the cell box is an important parameter which must be controlled if the end result is to be accurate and reproducible. The force applying mechanism used in this test is a hydraulic system operated under precise conditions.

The shear press value of the dehydrated long grain parboiled rice product is determined on an Allo-

Kramer Shear Press Model SP12 equipped with FTA-300 force transducer and a TG-4 (Food

Technology Corp.) digital texture gauge, as described in the accompanying drawing as follows: A hydraulic cylinder 10 with a power ram 11, containing a force transducer 12 and a blade assembly containing 10 equally placed blades attached as vertical blades 14 is used which contact and completely penetrate the rice sample in the cell box 15. The force transducer 12 is connected to a digital texture gauge 13 to measure the force produced. A directional control valve 17 is set to activate the power ram

11 in the hydraulic cyclinder 10. A ram speed control value 16, controls the speed of the power ram 11.

A hydraulic pump and reservoir 18 is activated by the pump switch 19 to supply the pressure to the hydraulic cyclinder 10. The pressure is read on the pressure gauge 20 and can be controlled by a pressure relief value 21.

The texture of the rice product is measured by the shear press model in the following manner: The rice product, 131.1 grams, is covered by an equal volume of boiling water (212 DEG F.) with stirring. After

5 minutes of standing the water is drained for 30 seconds while the blade assembly is mounted on the shear press and locked into position. The cell box, cover and blades are immersed in 75 DEG-85 DEG

F. water until required for use. At the end of the drain period, the rice product is placed into the cell box and leveled without compressing the product. The cover is placed on the cell box and inserted into position under the blade assembly. The hydraulic pump is turned on and the direction control valve is placed in the down position and the stroke time of the power ram is 2 minutes, 30 seconds .+-.10

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seconds. The digital texture gauge, periodically standardized to obtain the accurate reading, is read in terms of pounds/force.

The cell box is of sufficient size to hold 131 grams of rice which has been covered with an equal volume of boiling water and after 5 minutes of standing, the water is drained for 30 seconds. After draining, the rice product is placed into the cell box and leveled without compressing the product. The cell box or shear cell is formed in three parts, a top plate, a bottom plate and a hollow body portion.

The top and bottom plates are passing through the rice being tested. The cell box has dimensions of 6.6 cm.times.6.5 cm.times.6.3 cm (volume =270.3 cm@3) and made out a suitable material such as stainless steel, mild steel or the like. The cell box has guide slots on the upper and bottom sides of the cell box to receive the fingers or blades of the ram and exact alignment of the blade slots is essential so the blades will pass through and penetrate the rice product.

The following Examples demonstrate the invention in greater detail. It is understood that these

Examples are furnished only by way of illustration and not limitation.

EXAMPLE 1

Material: Long grain milled parboiled rice substantially gelatinized.

Parboiled rice is metered into a flume tank at a rate of 750 lbs./hr. The water temperature is 205 DEG

F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer, the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195

DEG to 205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long,

6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed reel (fluffer--like a lawn mower reel). Rice entering the drier is approximately 3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 DEG to 310 DEG F., zone two 290 DEG to

310 DEG F. and zone three at 130 DEG to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

Finished Product

This instanized rice product will have a shear press value of 100 to 105 lbs/force at a 5 minute stand with equal volumes of rice and boiling water. The density of the finished product in the dry form will be in the range of 400 to 475 grams per liter.

This superior rice product after rehydration for 5 minutes, will be smooth with separate kernels (not sticky) and, will have a desirable chewy and rubbery texture. This product is firm and fluffy not mushy or sticky. The final eating moisture at a 5 minute stand is 67%.

EXAMPLE 2

Raw Material: Long grain milled parboiled rice substantially gelatinized.

- Parboiled rice is metered into a flume tank at a rate of 750 lbs./hr. The water temperature is 205 DEG

F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195 DEG to 205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed reel (fluffer--like a lawn mower reel). Rice entering the drier is approximately

3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 DEG to 310 DEG F., zone two 290 DEG to 310 DEG F. and zone three at 130 DEG to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

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The process can be altered to give a softer (less firm) finished product that is still an excellent product after a 5 minute stand.

By means of a longer retention time in the steamer (45 minutes) the rice contains 76 to 78% moisture.

The drying retention time is maintained from 30 to 35 minutes at temperatures in zone 1 at 260 DEG to

285 DEG F.; zone 2 at 260 DEG to 285 DEG F. and zone 3 at 130 DEG to 140 DEG F. The rice exits the dryer at 7 to 11% moisture.

FINISHED PRODUCT

This instantized rice product will have a shear press value of 85 to 90 lbs/force at a 5 minute stand with equal volumes of rice and boiling water. The density of the finished product is slightly less than in

Example 1; in the range of 375 to 430 grams per liter.

This product is still far superior to other instant rice products. It is a softer (less firm) rice compared to

Example 1 product, but still has a firm, chewy, rubbery texture. Separate kernels and fluffy rice are still maintained and there is a slightly higher moisture content after a 5 minute stand (69%).

EXAMPLE 3



F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195 DEG to 205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed reel (fluffer - like a lawn mower reel). Rice entering the drier is approximately

3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 DEG to 310 DEG F., zone two 290 DEG to 310 DEG F. and zone three at 130 DEG to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

The process can be altered to give a very soft rice. This is achieved by over cooking the parboiled rice in the steamer. A retention time of 50 minutes is used which increases the kernel moisture to 82% will give a shear press value of 75 lbs/force. Therefore the rice is very soft and many kernels are split open.

The rice is more sticky and there are less separate kernels. Most of the desired texture characteristics are lost. It is less chewy, less rubbery and somewhat mushy. The eating moisture content at a 5 minute stand is 72%.

EXAMPLE 4


- Parboiled rice is metered into a flume tank at a rate of 750 lbs./hr. The water temperature is 205 DEG

F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195 DEG to 205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated town water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed reel (fluffer--like a lawn mower reel). Rice entering the drier is approximately 3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 DEG to 310 DEG F., zone two 290 DEG to

310 DEG F. and zone three at 130 DEG to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

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The process can be altered to make a very smooth and firm desirable product which is ready in 71/2 minutes, but not a 5 minute stand. The shear press value is 100 lbs/force. The rice is cooked in the steamer to a moisture of 72% at a 750 lbs/hr. infeed rate. The drying is conducted for a much longer time (56 minutes retention time in the dryer) at temperatures in the same range as Example 2. A slower dryer belt speed is used and the bed depth used is about 1/2 inch thicker 11/4 to 11/2to inches thick).

The density is 450 to 500 grams per liter. This product is very smooth when rehydrated. It is firm and rubbery and has separate kernels. This is an excellent product when rehydrated for a 71/2 minute stand.

It is too firm and dry in 5 minutes (65% eating moisture).Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for producing instantized parboiled rice which consists essentially of incorporating about

68 to about 78 weight percent water into long grain milled parboiled rice in which the starch has been substantially gelatinized, drying said water-containing rice at temperatures from about 260 DEG F. to about 325 DEG F. to reduce the water content of said rice to about 6 to about 14% over a period of time to obtain rice having a texture with a shear press value in the range from about 85 to about 110 lbs/force and having about a 41/2 to about 71/2 minute stand recipe when an equal volume of rice is combined with an equal volume of boiling water to produce an instantized eating quality parboiled finished rice product.

2. The process of claim 1 wherein the water incorporated into the long grain milled parboiled cell ranges from about 72 to about 74 weight percent.

3. The process of claim 1 wherein the water content of the long grain milled parboiled rice is reduced to about 7 to about 11 weight percent.

4. The process of claim 1 wherein said drying temperatures of said water-containing long grain milled parboiled rice are from about 290 DEG F. to about 310 DEG F.

5. The process of claim 1 wherein the drying time ranges from about 30 to about 45 minutes.

6. The process of claim 1 wherein the shear press value ranges from about 100 to about 105 pounds per force.

7. The process of claim 1 wherein the instantized parboiled rice product has a 5 minute stand.Data supplied from the esp@cenet database - Worldwide

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370.

US4861609 - 8/29/1989

PREVENTION OF PUFFING DURING FRYING OF EXPANDED SNACK

PRODUCTS


Inventor(s): WILLARD MILES J (US); DAYLEY KYLE E (US)

Applicant(s): WILLARD MILES J (US); DAYLEY KYLE E (US)


IP Class: A23L1/10; A23L1/217; A21D2/36

E Class: A23L1/164E; A23L1/214D; A23L1/217B



Family: US4861609

Abstract:


A process for making fried expanded snack products includes preparing a moist dough principally from solids, such as corn or potato solids. Larger particle size dry food particles, such as wheat or rice particles, are included in the dough. The dough is then formed, such as by roller-forming, into a thin sheet, and dough pieces cut from the sheeted dough are fried in hot cooking oil to form a fried expanded snack. The larger food particles project through or are contained in the surface of each dough piece to cause steam to escape during frying, which greatly reduces "puffing", i.e., formation of undesired bubbles in the snack, during frying. By providing a sufficient number of larger particles with an average particle size at least about to the thickness of the dough piece (so that an appreciable number of particles can project through or be contained in the surface of the dough piece), formation of undesired large bubbles is significantly reduced. The size of the largest bubbles formed during drying is proportionately reduced as the amount of larger particles added to the dough is increased. Formation of bubbles larger than a maximum tolerable size can be controlled to within acceptable limits by adding particulates greater in particle size than the dough thickness and in an amount that results in at least one particle per unit surface area of the sheeted dough piece, where said unit surface area is the largest acceptable size (area) of any bubbles formed during frying.Description:


BACKGROUND


This invention relates to a process for making expanded fried snack products from any of a number of combinations of dry starch-containing ingredients, including cereal flours, dried potatoes, etc.; and more particularly, to a process for reducing undesired "puffing" of an expanded snack during deep fat frying.


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A variety of deep fat fried snacks are on the market today. These snack products are commonly made from a dough containing corn or potato solids. Typically, the dough is shaped or formed, such as by roller-forming or extrusion under high pressure, and the shaped or formed dough pieces are then deep fried to produce the finished expanded fried snack product. It has been widely recognized that the problem of "puffing" can occur in snack products made from a formed moist dough piece that is deep fat fried. Puffing commonly occurs because of the accumulation of steam between the outer surfaces of the dough piece during frying. This causes the sides of the dough piece to separate, forming bubbles

(i.e., internal voids) or, when the bubbles rupture, exposed holes in the snack. Puffing detracts from the appearance of the snack, and when filled with excess fat, it greatly increases the fat content of the product. Separation of a dough piece in the fryer also has been referred to in the art as "pillowing" or

"blistering", but the term "puffing" is used herein to describe each of these phenomena, generally.

There have been a number of prior art techniques devoted to reducing puffing in expanded fried snacks.

U.S. Pat. No. 2,905,559 to Anderson et al describes an attempt to avoid puffing by perforating the dough sheet with spikes after discrete pieces are formed. In a related patent, U.S. Pat. No. 3,278,311 to

Brown et al, partly cooked corn kernels are treated by cutting the kernels to a size range of 0.5 to 1.27 mm and plasticizing the cut particles to make a cohesive dough. The dough is then rolled into sheet form and the dough sheet is perforated prior to frying.

U.S. Pat. No. 3,886,291 to Willard discloses experiments illustrating the importance of proper ingredient selection to eliminate puffing in extruded products made from mixtures of dehydrated potatoes and various starches. Only products made from potato starch and tapioca starch were of acceptable quality. No attempts were made to control puffing in these experiments.

U.S. Pat. No. 2,916,378 to Kunce et al mentions that ordinary corn chips do not puff because they are coarsely ground so that the dough is "discontinued" and steam from moisture within the dough can readily escape from the surface during the frying process. The manufacture of corn chips is described in several patents, such as U.S. Pat. Nos. 2,002,053 to Doolin and 3,278,311 to Brown et al.

Controlling the particle size of the ground corn is extremely difficult because of many critical process variables, including the size, age and moisture content of the dry corn kernels, variations in moisture content and thus the softness of the soaked, partially-cooked kernels, rate of feed to the grinder, adjustment of clearance between the rotating grinding wheels and the gradual wearing of the grinding wheels. As a result, controlling puffing in sheeted snacks made from corn processed in this manner by relying on the critical control of particle size in the dough is impractical. In the Kunce et al process the corn is finely ground and the corn-based dough has a smooth continuous surface which would ordinarily puff if fried with a 50% moisture content; but Kunce et al rapidly predry the formed corn snacks in a high-temperature oven to about 15% moisture prior to frying, which creates an acceptable texture of small surface blisters following frying.

U.S. Pat. No. 3,883,671 to Shatila describes a process in which formation of surface blisters or puffing is reduced by moistening the surfaces of the flat dough pieces with water after forming and before frying. The surfaces can be moistened by spraying, dipping, or steaming. The Shatila patent also refers to other methods known to reduce puffing or blistering in similar processes. These include reference to

U.S. Pat. No. 3,608,474 to Liepa, in which potato-based dough pieces are confined within a mold to physically prevent large blisters from forming. Another prior art technique is to form dough pieces with a corrugated surface, which also tends to prevent blistering. A further technique involves forming the dough to very thin layers of about 0.4 mm thickness, since blistering is reduced with thinner dough pieces. Shatila U.S. Pat. No. 3,883,671 emphasizes the difficulty of consistently producing a snack product with a smooth, blister-free surface when the thickness is in the range 0.030 to 0.045 inch (0.76 to 1.1 mm).

Thus, the prior art has disclosed a number of attempts at solving the problem of puffing or blistering; but the prior art has not provided a method that successfully controls puffing to within acceptable limits independently of such factors as (1) the thickness of the dough pieces (i.e., for thicker dough pieces of about 1.0 mm thickness or more), (2) the moisture content of the dough (i.e., for a moisture content greater than about 40% to 50%), and (3) the particular ingredients contained in the dough, without requiring special equipment such as water-moistening apparatus, hightemperature ovens, dough perforating apparatus, corrugating apparatus, molds for confining the dough, etc.

1717/2197


Briefly, this invention provides a process for producing a fried expanded snack product in which undesired puffing can be prevented, or at least controlled to within acceptable limits. The process includes the step of preparing a dough from a variety of relatively fine particle size dry solid ingredients, and dry food particles of relatively larger particle size. A dough piece is formed from the dough and fried in hot cooking oil to produce an expanded fried snack product. The larger food particles are of a particle size at least about the same thickness as the formed dough piece prior to frying, so that the particles can project through or be contained in the surface of the dough piece to allow steam to escape during frying. This greatly reduces undesired puffing of the snack during frying.

In one form of the invention, the larger food particles are provided by extraneously added dry food particles of the proper particle size. In another form, the larger food particles are naturally contained in one or more of the dry solid ingredients that are part of the original dough mixture. For example, cracked wheat and cracked bulgur can be made to contain a sufficient amount of properly-sized larger particles that can be used in this process to reduce puffing.

The size of bubbles produced from puffing can be controlled by the amount of sufficiently large dry food particles included in the dough. The size of the largest bubbles formed during frying is proportionately decreased as the number of sufficiently large particles added to the dough is increased.

Formation of bubbles larger than a certain tolerable size can be controlled to within acceptable limits by providing particles in an amount that results in one or more particles per unit surface area of the dough piece, where said unit surface area is the largest acceptable size (area) of any bubbles formed during frying. For example, in one practice of the invention, formation of bubbles larger than 6 mm in size can be essentially prevented by mixing a sufficient number of particles of proper size into the dough that will provide, on the average, one or more such particles for approximately each 36 sq mm of surface area of the dough piece.

The process of this invention greatly reduces puffing without requiring additional special equipment, such as high-temperature ovens, water moistening apparatus, equipment for for externally puncturing the surface of the dough piece or for corrugating the dough piece, or molds for confining the dough piece, for example. As a result of this process, novel snack products can be produced, inasmuch as food particles which would ordinarily not be used in the manufacture of such snacks can be used as novel flavoring ingredients, in addition to serving as a means for reducing puffing.

This method has been found to be particularly useful in preventing undesired puffing in snack products made from dough pieces about 1.0 mm in thickness or greater, with a moisture content in excess of about 40%. Dough pieces of this thickness and moisture content are ordinarily thought of as being particularly susceptible to undesired puffing, when compared with thinner, drier dough pieces.

These and other aspects of the invention will be more fully understood by referring to the following detailed description.


A fried expanded snack product is produced from a dough prepared principally from dry food solids selected from the group consisting of corn, potato, tapioca, amioca, wheat, and rice solids, and mixtures thereof. More specifically, the principal dry solid ingredients from which the dough is prepared can include various combinations of cereal flours such as corn flour; dried starch-containing root crops such as potato flakes; and starches separated from either. The corn solids contained in the dough can include pre-cooked whole corn flour, lime-treated corn flour (known as tortilla flour) and pre-cooked or raw corn meal, for example. Other pre-gelatinized or raw cereal flours, such as oak flour, bulgur flour, wheat flour, or rice flour can be used. The dried root crop solids can be from various combinations of dehydrated mashed potatoes, potato flour, or ground dehydrated potatoes, or cassava flour. Various combinations of corn, tapioca, potato, amioca and other starches, gelatinized or ungelatinized, also can be used in preparing the dough.

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The principal dry food solids contained in the dough are of relatively fine particle size. In one practice of the invention, the average particle size of such principal dry food solids is less than about 0.5 mm.

Snack products made from a dough containing such fine particles size ingredients as its principal component commonly experience problems of puffing when fried.

A sufficient quantity of properly-sized dry food particles are combined with the principal dough ingredients to reduce puffing of the dough during subsequent deep fat frying. These particles are of larger size, on the average, than the size of the dry food solids that comprise the principal component of the dough. These larger particles can be a variety of extraneously added dry food particles, such as intact cereal grains or seeds; or they can be ground to the desired particle size, as in the case of peanuts, for example. Other examples are the larger particles naturally contained in one or more of the whole cereal grains that also provide the principal component of the dough formulation. Cracked wheat, cracked bulgur, cracked rice, dry milled corn, rolled oats, barley and rye are examples.

Water is combined with the dry solid ingredients to form a moist dough preferably containing about

40% to about 60% moisture, by weight. A dough containing such a moisture content typically puffs when deep fat fried, especially if the dough piece has a thickness of about 1.0 mm or more; but this problem is overcome by including the larger dry food particles, as described in more detail below. The larger dry food particles are normally included with the principal dry ingredients of the dough formulation before the water is added to more easily form a dough in which the larger particles are uniformly dispersed throughout the dough. The number of dry particles within the desired particle size range (described below) is adjusted to control the amount of puffing during subsequent frying. During preparation of the dough the larger particles are not appreciably altered in size or character, and they also are not reactive with the other ingredients of the dough when subsequently fried, i.e., they essentially retain their particular nature during subsequent frying.

After the dough containing the particulates is prepared, the dough is formed into desired shapes.

Preferably the dough is roller-formed into a thin sheet, about 1.0 mm to 1.2 mm in thickness. The sheeted dough is then cut into small pieces which are immediately deep fat fried in hot cooking oil.

Alternatively, the dough can be extruded under pressure through a small die opening, and pieces cut from the extruded dough are then immediately fried. The dough also can be extruded into thin tubular rods about 2 mm in diameter. In any case the dough piece being fried has a moisture content at least about 40%, by weight, and typically from about 40% to about 60%, by weight, at the time of frying.

The presence of the proper number of properly-sized larger food particles results in much less puffing in the fried product when compared with a similar product that does not contain such larger particles.

The particles are of a size at least similar to the thickness of the dough piece being fried, which causes a considerable number of the particles to project through or be contained in the surface of the dough piece. For thin-sheeted dough pieces, it is most preferable to select the particle size such that particles will project randomly from both sides of the dough piece. For different shapes, such as an extruded cylindrical rod (say 2 mm in diameter), the number of larger particulates contained in the dry ingredients used in preparing the dough is increased. Thus, a sufficient number of particles will be present in the surface of the extruded dough piece to limit puffing to desirable levels. In either case, the particles allow steam from evaporating moisture throughout the dough piece to escape from the surface of the dough, avoiding undesired puffing that would otherwise occur.

The dough pieces can be pre-moistened before frying, in a manner similar to that described in U.S. Pat.

No. 3,883,671 to Shatila, which also can reduce the amount of puffing. However, it has been discovered that the presence of the food particles in the dough reduces puffing independently of whether or not the dough pieces are moistened before frying and in fact is more effective than moistening.

The method of this invention will be more fully described in the context of the following examples.

EXAMPLE 1

Corn snacks were prepared in a pilot-plant to determine the effects of spraying (pre-moistening) on puffing, with and without use of particulates in the dough mixture.

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A corn snack was made with the following dry ingredients:

>;tb;______________________________________

>;tb;Ingredients 1A % Grams

>;tb;______________________________________

>;tb;Partially-cooked whole corn

>;tb;flour, through US 40 mesh

>;tb; 52.7 158.1

>;tb;Gelatinized corn flour,

>;tb;through US 80 mesh 19.0 57.0

>;tb;Amioca starch 19.0 50.7

>;tb;Corn starch 9.3 27.9

>;tb;Salt 2.0 6

>;tb;Water -- 195

>;tb;______________________________________

Using a Hobart 5-qt mixer, the water at room temperature was added to the dry mix using the flat paddle attachment, with the mixer on low speed, about 60 rpm. After mixing for a total of 60 seconds, the paddle was removed and replaced with a dough hook and mixing was continued for an additional 4 minutes at 109 rpm.

The dough was allowed to rest 15 minutes and was then sheeted between the rollers of a conventional tortilla chip sheeter, such as that made by Electra Food Machinery Company, Model HTO-17. The sheeter was adjusted to produce a dough thickness of about 1.1 mm. A rotary die situated under the discharge roller cut the sheet into triangles, approximately 5 cm per side. The cut pieces were treated with various spraying treatments; one portion was not sprayed; but fried directly; a second portion was sprayed on one side only; a third portion was sprayed on both sides; and the fourth portion was sprayed on both sides and allowed to rest for two minutes before being fried.

The treated dough pieces were immediately fried at 175 DEG C. in a Belshaw continuous donut frier fitted with a circulating pump and adjustable speed take-out mechanism. After frying, the product was drained and examined for puffing. The product was segregated into four portions: those containing bubbles less than 3 mm diameter, those with bubbles between 3 and 6 mm, between 6 and 12 mm, and finally those with bubbles larger than 12 mm diameter. The percentage of each portion by weight was then recorded.

A portion of cracked wheat was added to the same formula at a level of 10% of the total dry ingredients:

>;tb;______________________________________

>;tb;Ingredients 1B % Grams

>;tb;______________________________________



>;tb; 47.94 143.8



>;tb;Amioca Starch 15.34 46.0

>;tb;Corn Starch 8.46 25.4

>;tb;Cracked wheat particulate

>;tb; 10.00 30.0

>;tb;Salt 2.00 6.0

>;tb;Water -- 195.0

>;tb;______________________________________

>;tb;The screen analysis of the cracked wheat was as follows:

>;tb;______________________________________

>;tb;On 20 mesh (0.833 mm opening)

>;tb; 35.8%


>;tb; 51.2%


1720/2197

>;tb; 6.7%

>;tb;Under 60 mesh 6.3%

>;tb;______________________________________

Dough samples were prepared as described before, sprayed by the same treatments, fried and the puffing observed. The results are shown below in Table A.

>;tb; TABLE A

>;tb;__________________________________________________________________________

>;tb;EFFECT OF SPRAYING AND PARTICULATES (Example 1)

>;tb; Without Particulates

>;tb; With Particulates

>;tb;Sample A B C D E F G H

>;tb;__________________________________________________________________________

>;tb;Spray None

>;tb; 1 side

>;tb; 2 sides

>;tb; 2 sides +

>;tb; None

>;tb; 1 side

>;tb; 2 sides

>;tb; 2 sides +

>;tb; 2 min 2 min

>;tb; hold hold

>;tb;Average dough

>;tb;thickness, mm

>;tb; .96 1.19

>;tb; 1.22

>;tb; 1.05 0.82

>;tb; 1.10

>;tb; 0.97

>;tb; 1.18

>;tb;Puffing Count

>;tb;>;3 mm, % 2 8 17 3 16 19 54 53

>;tb;3/6 mm, % 0 3 10 12 14 16 21 19

>;tb;6/12 mm, % 5 4 15 18 42 34 21 20

>;tb;+12 mm, % 93 85 58 67 28 31 4 8

>;tb;Total over 6 mm, %

>;tb; 98 89 73 85 70 65 25 28

>;tb;Total under 6 mm, %

>;tb; 2 11 27 15 30 35 75 72

>;tb;__________________________________________________________________________

The results of Example 1 illustrate that the larger particles contained in the cracked wheat greatly reduce the amount of puffing, independently of whether the dough pieces are moistened prior to frying.

The amount of fried products having puffing within an acceptable range, i.e., with bubbles below 6 mm in size, is increased by the addition of the dry particles. In this and later series of experiments, bubbles greater than 6 mm diameter are judged "unacceptable"; those snacks with bubbles under 6 mm diameter are judged "acceptable". In Example 1, the amount of acceptable product increased, on the average, 6.45 times when the particulates were added, independent of the premoistening treatments.

We have discovered that the number of larger particulates and the size of the particulates in relation to dough thickness control both the number and size of bubbles in the fried product. As the number of properly-sized dry food particulates contained in the dough formulation is increased, a generally proportionate decrease in the size and number of bubbles in the fried product is produced.

The amount of larger particulates contained in the dough formulation is preferably on a number basis

(i.e., number of individual particles), rather than on a weight basis. The number of individual particles contained in a gram of particulate material is initially determined. A sufficient number of these particles are then included in the dough mixture (by providing a reasonably uniform number of the

1721/2197

particles per unit area of sheeted dough) to produce a fried product that essentially avoids undesired puffing.

The particles are included on a number basis, rather than a weight basis, because it has been found necessary to provide at least a certain number of particles per unit area of sheeted dough in order to control puffing to within acceptable limits. Particles are not added on a weight basis because of the differences in bulk densities between different types of particulate materials. For example, the following shows the difference in bulk density of particles from raw cut wheat and precooked bulgur.

The latter is more dense, since the wheat has been precooked and dried before grinding, i.e., it has shrunk and has become almost glass-like. The cracked wheat, on the other hand, contains particles of separated bran which are very light in weight.

Density of Snack Particulates

>;tb;______________________________________

>;tb;Ingredient Sieve Size

>;tb; Number/gram

>;tb;______________________________________

>;tb;Cracked Wheat 10/16* 1200

>;tb; 16/20 2625

>;tb; 20/40 4560

>;tb;Precooked Wheat

>;tb; 10/16 244

>;tb; 16/20 1343

>;tb; 20/40 3397

>;tb;______________________________________

>;tb; *passes 10 U.S. mesh, retained on 16 U.S. mesh

It can be assumed that the presence of a particle in the dough prevents the formation of a bubble at the point in the dough where the particle penetrates or is present in the surface, allowing steam to escape.

Thus, a bubble that is formed in the dough piece must necessarily be formed between adjacent particulates. Assuming that bubbles 6 mm in size (largest dimension) are the maximum size allowable for an acceptable snack, then the sheeted dough should have at least one particle for about every 36 mm@2 (equivalent to a square 6 mm per side) of surface area. The larger particulates, being in the form of dry food particles, are capable of being measured as to the specific number of snack particles included in the dough formulation.

EXAMPLE 2

An experiment was conducted to determine the amount (on a weight basis) of dry food particles in a given material that should be included in 100 grams of dry solids in a dough having one particle for each 36 mm@2 of a surface area when the dough is sheeted to an average thickness of 1 mm.

A corn snack dough is prepared from 100 grams of dry solids combined with 63.6 grams of water. The specific gravity of this dough is determined to be 1.107 gm/cc, the total volume of the dough being

147.8 cc. Assuming that cracked wheat is to be included in the dry solids with a particle size of 10/16

(passes 10 mesh, retained on 16 mesh), it is determined that there are 1200 such particles per gram.

Knowing the desired sheet thickness of the dough, i.e., 1.0 mm, and the weight and density of the dough, the area of the sheeted dough can be determined to be 1478 cm@2. Assuming that one particle of cracked wheat is required for each 36 mm@2 of sheet area, it is determined that 4106 particles are required. Knowing the number of particles per gram, it can be determined that 3.42 grams of such particles per 100 grams of solids in the dough are required to provide at least one particle for each 36 mm@2 of the sheeted dough.

These relationships can be expressed by the following formula: ##EQU1##

Using this formula for the example given above, where 1000 equals the factor for converting milligrams to grams, the weight of cracked wheat particles to be added to the dough is: ##EQU2##

EXAMPLE 3

1722/2197

Experiments were conducted to determine the effect on puffing of snacks of increasing dough thickness.

In this test, the formula of Example 1B was used with a particulate consisting of a commerciallyavailable precooked wheat known as bulgur. This product was ground to pass a 16 mesh screen.

>;tb;______________________________________

>;tb;Ingredients % Grams

>;tb;______________________________________



>;tb; 47.94 143.8



>;tb;Amioca Starch 15.34 46.0

>;tb;Corn Starch 8.46 25.4

>;tb;Particulates (Total Bulgur)

>;tb; 10.00 30.0

>;tb;Salt 1.0 3.0

>;tb;Water -- 200

>;tb;______________________________________

The screen analysis of the bulgur used in this experiment was as follows:

>;tb;______________________________________

>;tb; Max. Dia,

>;tb; Min. Dia, Ave. Dia,

>;tb; mm mm mm

>;tb;______________________________________

>;tb;On 20 mesh

>;tb; 57.7% 1.168 0.833 1.00

>;tb;On 40 mesh

>;tb; 26.4% 0.833 0.417 0.62

>;tb;On 60 mesh

>;tb; 6.2% 0.417 0.250 0.33

>;tb;through 60

>;tb; 2.9% 0.250 -- --

>;tb;______________________________________

The dough, prepared as in Example 1, was held for a period of 25 minutes before forming. It was then sheeted, using a Rondo sheeter in five passes of 12, 8, 5, 3, mm and then to the final thickness shown in the table below. Rectangular pieces approximately 1".times.2" were cut manually from the final sheet and fried directly in a deep-fat fryer in which vegetable oil was maintained at 175 DEG C. Before frying, the cut pieces were sprayed lightly on each side with finely-atomized spray of water.

The final Rondo settings were 0.5, 0.75, 1.0, and 1.25 mm. Measurements were made of the final dough sheet thickness after the dough was cut into individual pieces, but before it was sprayed.

The 16/20 fraction (passes 16 mesh, retained on 20 mesh), average diameter 1.0 mm of the ground bulgur or 57.7% of the total bulgur, was defined as the particulate in this example and was examined and found to have 1343 particles/gm. The mixed dough had a specific gravity of 1.107 gm/cc.

The amount of particulate measuring over 20 mesh for 1.0 mm average diameter in the sheeted dough was determined according to the formula in Example 2. In addition, the average number of particulates for each 36 mm@2 of sheeted dough surface was calculated, based on the level of particulates in the dry mix (10%) and the quantity of 16/20 particulates in the cracked bulgur (57.7%). The units of dough in the experiment were determined by dividing total the surface area of the dough (in mm@2) by 36 mm@2. The number of particles per unit of dough were then determined by the following formula:

##EQU3## For the dough ingredients described above, ##EQU4## These results, as well as the percentage of product with puffing over 6 mm diameter, are shown below.

1723/2197

>;tb;______________________________________

>;tb;Sample A B C D

>;tb;______________________________________

>;tb;Rondo opening, mm 0.5 .75 1.0 1.25

>;tb;Average dough thickness, mm

>;tb; 0.82 1.11 1.49 1.9

>;tb;Particulates

>;tb;Type: Bulgur 16/20 mesh

>;tb;Level in formula, %

>;tb; 5.77 5.77 5.77 5.77

>;tb;No. per 36 mm sq. 1.5 2.1 2.8 3.5

>;tb;Ratio to dough thickness

>;tb; 1.22 .90 .67 .53

>;tb;Puff

>;tb;>;3 mm, % 59 19 8 5

>;tb;3/6 mm, % 32 23 21 2

>;tb;6/12 mm, % 9 41 21 6

>;tb;;12 mm, % 0 16 50 87

>;tb;Total over 6 mm, %

>;tb; 9 57 71 93

>;tb;Acceptable, under 6 mm, %

>;tb; 91 43 29 7

>;tb;______________________________________

The results of Example 3 showed that puffing can be controlled to within acceptable limits with thin dough pieces (less than about 1 mm in thickness). However, the results also showed that the added particulates did not reduce puffing to within acceptable limits for thicker dough pieces above 1.0 mm in thickness, since the particulates were too small in relation to the dough thickness.

EXAMPLE 4

The procedure of Example 3 was followed, except that the size of the particulates was chosen so that each dough sheet would have an added larger particulate of approximately the same thickness as the dough sheet, as well as a second sample with a smaller particulate. The results, shown below in Table

B, indicated that particulates with a particle size similar to the dough thickness produced products essentially free of puffing, whereas undesired puffing progressively increased as the dough thickness became increasingly greater than the particle size.

EXAMPLE 5

A base mixture was made of the snack ingredients shown as Formula 1A. A series of snack mixtures were made from the same base mixture in which the level of particulates was varied from 0% to 15% of the total dried mix. 3000 gm each of the blended mix was blended with 2000 ml of water in a 20-qt.

Hobart using a procedure identical to that of Example 1. The samples were sheeted in the pilot plant tortilla chip sheeter as used in Example 1. All samples were sprayed lightly on both sides before frying at 175 DEG C. The results, shown below in Table C, indicated that undesired puffing is progressively reduced as the amount of particles increases. The amount of puffing over 6 mm decreases to within acceptable limits as the number of particles for each 36 mm@2 of dough surface area approaches one.

EXAMPLE 6

The same base mixture of snack ingredients as in Example 1A was mixed with various size bulgur particles at a level of 10% of the total dry solids. The samples were processed as in Example 5 and analyzed for puffing, and the results shown below in Table D indicate that puffing is controlled to within desirable limits when the particle size is about the same or greater than the dough thickness.

>;tb; TABLE B

>;tb;__________________________________________________________________________

>;tb;EFFECT OF PARTICLE SIZE ON PUFFING (Example 4)

>;tb;Sample A B C D E F G H

1724/2197

>;tb;__________________________________________________________________________

>;tb;Rondo opening, mm

>;tb; 0.5 0.5 0.75 .75 1.0 1.0 1.5 1.5


>;tb; .79 .81 1.13 .96 1.38 1.49 2.05 2.05

>;tb;Particulates

>;tb;Screen Size 20/25

>;tb; 35/40

>;tb; 16/20

>;tb; 25/30

>;tb; 14/16

>;tb; 20/25

>;tb; 10/14

>;tb; 16/20

>;tb;Size, average diameter, mm

>;tb; .77 .46 1.0 .65 1.29 .77 1.69 1.0

>;tb;Number/gm 2942 8070 1370 4610 588 2942 286 1340

>;tb;Type, Bulgur


>;tb; 10 10 10 10 10 10 10 10

>;tb;No. per 36 mm@2

>;tb; 0.56 1.56 0.36 1.05 0.19 1.04 0.14 0.65


>;tb; .97 .57 .88 .68 .89 .52 .80 .49

>;tb;Puff

>;tb;Over 6 mm, % 0 22 44 65 31 72 69 81

>;tb;__________________________________________________________________________

>;tb; TABLE C

>;tb;__________________________________________________________________________

>;tb;EFFECT OF QUANTITY OF PARTICULATES ON PUFFING (Example 5)

>;tb;Sample A B C D E F G

>;tb;__________________________________________________________________________


>;tb; 1.04 1.07

>;tb; 1.14

>;tb; 1.08

>;tb; 1.13

>;tb; 1.2

>;tb; 1.2

>;tb;Particulates


>;tb;Size, average diameter, mm

>;tb; 1.58 same

>;tb;Number/gm 244

>;tb;Type, Bulgur


>;tb; 15 12.5

>;tb; 10 7.5

>;tb; 5 2.5

>;tb; 0


>;tb; 0.91 0.78

>;tb; 0.66

>;tb; 0.47

>;tb; 0.33

>;tb; 0.17

>;tb; 0


>;tb; 1.51 1.47

1725/2197

>;tb; 1.38

>;tb; 1.46

>;tb; 1.40

>;tb; 1.32

>;tb; 0

>;tb;Puff

>;tb;Over 6 mm, % 6 5 9 10 34 68 74

>;tb;__________________________________________________________________________

>;tb; TABLE D

>;tb;__________________________________________________________________________

>;tb;EFFECT OF PARTICLE SIZE ON PUFFING (Example 6)

>;tb; A B C D E F

>;tb;__________________________________________________________________________


>;tb; 1.12

>;tb; 1.12 1.16 1.21 1.21 1.09

>;tb;Particulate screen size

>;tb; 10/16

>;tb; 16/20

>;tb; 20/40

>;tb; 40/60

>;tb; 60/80

>;tb; -80

>;tb;Maximum diameter, mm

>;tb; 1.981

>;tb; 1.168

>;tb; 0.833

>;tb; 0.417

>;tb; 0.25 0.18

>;tb;Minimum diameter, mm

>;tb; 1.168

>;tb; 0.833

>;tb; 0.417

>;tb; 0.25 0.18 --

>;tb;Average diameter, mm

>;tb; 1.58

>;tb; 1.00 0.62 0.34 0.22 --

>;tb;Number/gm 244 1340 3400 10,000+

>;tb; 10,000+

>;tb;Type Bulgur, screened as indicated


>;tb; 10 10 10 10 10 10


>;tb; 0.65

>;tb; 3.6 9.4 23 -- --


>;tb; 1.41

>;tb; .89 .53 .28 -- --

>;tb;Fat 29 30 29 31 32 34

>;tb;Puff

>;tb;Over 6 mm, % 13 15 31 89 98 84

>;tb;__________________________________________________________________________

EXAMPLE 7

Typical precooked rice (MJB Instant retail product) was milled and screened to prepare particulates with mesh size 10/16, average diameter 1.58 mm, and mesh size 16/20 with average diameter 1.0 mm.

The formula of Example 1A was used as the base snack mix to which the particulates were added at various levels of the dried mix. The laboratory Rondo sheeter was used as described in Example 2, with

1726/2197

final settings of 0.75 and 0.5 mm. From experience, it was known that these settings would give a dough thickness of approximately 1.1 and 0.85 mm.

The formula described in Example 2 was used to determine the quantity of particulates to add to the examples to achieve levels of approximately 1, 2, 3, and 4 units per 36 mm@2. The results are tabulated in Table E below.

In Examples C, E, G, and J, the level of 1.0 mm diameter particles in the dough (particles per 36 mm@2) and the resulting percentage of snacks having puffing over 6 mm diameter were 1.08 and 44%,

2,25 and 24%, 3.07 and 1.5%, 3.84 and 1.0%. In these examples, the added particulates had a larger particle size than the average thickness of the dough, thereby assuring that a large percentage of the particles punctured the surface of the dough piece. When the particulates were added similarly to the thicker dough, as in Examples B, D, F and H the results in terms of reduced puffing were not as significant, although puffing was reduced as the amount of added particulates was increased. The number of particulates added (particles per 36 mm@2) and the percentage of products showing puffing over 6 mm were 1.24 and 79%, 2.69 and 68%, 5.08 and 29%, 5.69 and 23%, in Samples B, D, F, and

H, respectively.

An additional product, Sample A, was made with the thicker sheet, at a level of 1.09 particles/36 mm@2, using the larger 1.58 mm particles. This example illustrates that even particulates with a larger particle size than the dough thickness cannot, of itself, produce desired products. In this example, the amount of added particles was clearly not enough, since undesired puffing was found in 68% of the finished products.

Portions of this experiment were repeated with particulates made from raw uncooked rice and precooked corn, using the same fraction sizes. The results were substantially identical. A particularly flavorful snack was made by adding chopped peanuts to the same corn matrix, at levels of 30% of the total dry mix.

EXAMPLE 8

A base mixture was made from the following ingredients:

>;tb;______________________________________

>;tb;Ingredients %

>;tb;______________________________________

>;tb;Potato flakes (-20)

>;tb; 45.4

>;tb;Potato Starch 45.4

>;tb;Raw Corn Flour 7.3

>;tb;Salt 1.5

>;tb;MSG 0.4

>;tb;Water 100% relative

>;tb;______________________________________

A series of experiments were made in which the sheeted snacks were first made from the base mixture without particulates and later with added particles of precooked rice, 16/20 mesh. 300 ml of cold tap water was added to 300 grams of dry ingredients in the 5-quart bowl of the Hobart #50 mixer. Mixing was continued for one minute on Speed 1, at which point the dough became cohesive enough to be formed into a ball. The dough was held 5 minutes to equilibrate and then sheeted, using a Rondo sheeter in five passes of 12, 6, 3, 2 mm, and then to the final thickness shown in Table F below. The cut pieces were sprayed lightly on each side with a finely atomized spray of water and then fried in a deepfat fryer in which vegetable oil was maintained at 175 DEG C. Ten measurements were made, and averaged, of the final dough sheet thickness were made, and averaged, after the dough was cut into individual pieces, but before it was sprayed. The products were examined for puffing, and those showing puffed sections over 6 mm diameter were segregated, weighed, and expressed as a percentage of the total finished product. The results, shown below in Table F, indicate that the added particles can produce products essentially free of undesired puffing, even for relatively thicker dough pieces

(approximately 1.0 mm thickness) in a dough with a relatively high moisture content (approximately

50% moisture by weight).

1727/2197

>;tb; TABLE E

>;tb;__________________________________________________________________________

>;tb;ADDITION OF RICE PARTICULATES TO CORN SNACKS AT 1, 2, 3, and 4 PARTICLES

>;tb;PER MM@2 (Example 7)

>;tb;Sample A B C D E F G H J

>;tb;__________________________________________________________________________

>;tb;Rondo opening, mm

>;tb; .75 .75 .5 .75 .5 .75 .5 .75 .5


>;tb; 1.22

>;tb; 1.02 .89 1.11 .93 1.39 .84 1.17 .79

>;tb;Particulate Precooked rice, ground and sifted


>;tb; 16/20

>;tb; 16/20 16/20

>;tb; 16/20 16/20

>;tb; 16/20

>;tb; 16/20 16/20

>;tb;Average diameter, mm

>;tb; 1.58

>;tb; 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

>;tb;Number/gm 374 1780 1780 1780 1780 1780 1780 1780 1780

>;tb;(wt. basis)

>;tb;Level in % 10.06

>;tb; 2.86 2.86 5.73 5.73 8.60 8.60 11.46 11.46

>;tb;Ratio particle to

>;tb; 1.29

>;tb; .98 1.12 .90 1.07 .71 1.19 .85 1.26

>;tb;dough thickness

>;tb;Puff, over 6 mm, %

>;tb; 68 79 44 68 24 29 1.5 23 1

>;tb;__________________________________________________________________________

>;tb; TABLE F

>;tb;______________________________________

>;tb;EFFECT OF PARTICULATES IN SHEETED

>;tb;POTATO SNACKS (Example 8)

>;tb;Sample A B C D

>;tb;______________________________________

>;tb;Rondo Setting, mm

>;tb; .75 .5 .75 .5

>;tb;Sheet Thickness, mm

>;tb; 1.00 .71 .95 .83

>;tb;Particulates

>;tb;Type Precooked rice

>;tb;Size 16/20 16/20 16/20 16/20

>;tb;Diameter, mm 1.00 1.00 1.00 1.00


>;tb; 0 0 4.66 4.07

>;tb;Ratio to Dough Thickness

>;tb; 0 0 1.05 1.20

>;tb;Product:

>;tb;Puffing, % over 6 mm

>;tb; 64 17 2 0

>;tb;Fat Content 35.1 39.1 38.0 34.2

>;tb;______________________________________

The following is a summary of acceptable products made in accordance with the various examples described above. The table summarized for each sample the ratio of particle size to dough thickness,

1728/2197

the number of particles contained per 36 mm@2 of the sheeted dough, and the resulting percentage of products that experienced undesired puffing, i.e., bubbles greater than 6 mm in size.

>;tb;______________________________________

>;tb;Ratio Level Partic.

>;tb; Puffed Product,

>;tb;Particulate/Dough

>;tb; per 36 mm@2

>;tb; % (6 mm dia.)

>;tb;______________________________________

>;tb;.57 1.56 22

>;tb;.85 5.7 23

>;tb;.89 3.6 15

>;tb;.97 .56 0

>;tb;1.05 4.66 2

>;tb;1.19 3.1 2

>;tb;1.20 4.1 0

>;tb;1.22 1.5 9

>;tb;1.26 3.8 1

>;tb;1.38 .66 9

>;tb;1.41 .65 13

>;tb;1.46 .47 10

>;tb;1.47 .78 5

>;tb;1.51 .91 6

>;tb;______________________________________

The results of the tests have indicated that the ratio of particle size to dough thickness is most critical of the factors influencing puffing, and that products essentially free of undesired puffing can be produced when the average particle size of the particulates is at least about the same thickness as the formed dough piece. For example, the tests have shown that products essentially free of puffing are produced when the ratio of particle size to dough thickness is about 0.80 or more. Products in which puffing greater than 6 mm occurs in about 15% of the products, or less are considered essentially free of puffing. Commercially acceptable products can be produced when such products puffing occurs in about 25% of the products, or less.

The test results also have indicated that the amount of larger particulates in the dough (on a number basis) provides a correspondingly increasing reduction in puffing as the number of particulates in increased. Particularly for products with a greater dough thickness (about 1.0 mm, or more) undesired puffing can be minimized by providing particulates in an amount of at least one particulate for each 36 mm@2 of sheeted dough. Good results also can be obtained with fewer particles when the particulates are much greater in particle size than the dough thickness (a particle/dough ratio greater than about 1.5, for example). Dough thickness also affects puffing, since the test results have indicated that reducing dough thickness from, say 1.0 mm to 0.7 mm can of itself produce a large reduction in puffing.

Although the thinner dough sheet can reduce puffing, it should be recognized that in instances where a snack product of greater thickness is more desirable, the added particulates can reduce puffing to within acceptable limits.

Thus, the present invention provides a method in which fried expanded snack products can be made essentially free of puffing from a relatively thick dough piece (about 1.0 mm in thickness) made from a moist dough (about 40% to 60% moisture content) without the need for additional special equipment to reduce puffing.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method for reducing puffing of a fried expanded snack product made from a dough comprising finely divided dry starch-containing solids from which the dough is formed as a thin dough sheet and fried, the method comprising the steps of: a. preparing a dough principally comprised of finely divided dry starch-containing solids selected from the group consisting of corn, potatoes, wheat, rice, oats,

1729/2197

tapioca, and mixtures thereof, in which a portion of the starch in the finely divided dry starchcontaining solids is gelatinized and additional starch in the finely divided dry starch-containing solids comprises extraneously added ungelatinized starch, and in which the finely divided dry starchcontaining solids are mixed with water to form a dough having a moisture content from about 40% to about 60% by weight of the dough; b. cracking dry cereal grains and combining said dry cracked cereal grains with said dough, the dry cracked cereal grains having a larger average particle size than the average particle size of the finely divided dry starch-containing solids; c. roller forming the dough for compressing the dough into sheet form of essentially uniform thickness and forming a piece from the dough sheet, the dry cracked cereal grains having an average particle size at least about the same as the thickness of the formed dough piece so that said dry cracked cereal grains project through or are contained in the surface of the formed dough piece; and d. frying the dough piece in hot cooking oil at said 40% to 60% moisture content and with said combination of gelatinized and ungelatinized starches contained in the dough piece at the time of frying, for forming an expanded fried snack product in which the dry cracked cereal grains provide a means of escape for the moisture contained in the dough piece and in which the larger food particles are present in the dough piece in an amount sufficient to reduce puffing of the snack product during frying when compared with the amount of puffing of a fried snack product made from the same dough piece that does not contain said larger food particles.

2. The method according to claim 1 in which the dry cracked cereal grains are contained in the dough piece in an amount such that formation of bubbles greater in size than about 6 mm is substantially prevented in at least about 85% of the fried products made from the dough.

3. The method according to claim 1 in which the cracked cereal grains are extraneously added to the dough ingredients.

4. The method according to claim 1 in which the cracked cereal grains are uniformly dispersed throughout the dough and remain in a solid art particulate form throughout frying.

5. The method according to claim 1 in which the thickness of the formed dough piece is from about 0.7 mm to about 2.0 mm.

6. The method according to claim 1 in which the dry cracked cereal grains comprise a component of the finely divided starch-containing solids which has been coarsely ground to a larger particle size than the principal finely divided dry starch-containing solids.

7. The method according to claim 1 in which the dough pieces has a sheet thickness up to about 1.0 mm to about 1.2 mm, and the dry cracked cereal grains have an average particle size of at least about

0.8 mm.

8. The method according to claim 1 in which the dry cracked cereal grains are contained in the dough piece in an amount such that there is at least about one such particle for about each 36 mm@2 of surface area of the formed dough piece.

9. The method according to claim 1 in which the finely divided dry starch-containing solids have an average particle size of about 0.5 mm or less.

10. A method for reducing puffing of a fried expanded snack product made from a dough comprising finely divided dry starch-containing solids from which the dough is formed as a thin dough sheet and fried, the method comprising the steps of: a. preparing a dough principally comprised of finely divided dry starch-containing solids selected from the group consisting of corn, potatoes, wheat, rice, oats, tapioca, and mixtures thereof, in which a portion of the starch in the finely divided dry starchcontaining solids is gelatinized and additional starch in the finely divided dry starch-containing solids comprises extraneously added ungelatinized starch, and in which the finely divided dry starchcontaining solids are mixed with water to form a dough having a moisture content from about 40% to about 60% by weight of the dough; b. cracking dry cereal grains and combining said dry cracked cereal grains with said dough, the dry cracked cereal grains having a larger average particle size than the average particle size of the finely divided dry starch-containing solids; c. roller forming the dough for compressing the dough into thin sheet form of essentially uniform thickness, and forming a dough piece from the dough sheet, the dry cracked cereal grains being present in the dough piece in an amount

1730/2197

that provides, on the average, at least one dry cracked cereal grains particle for each 36 mm@2 of surface area of the dough piece, the dry cracked cereal grains having an average particle size about the same as the thickness of the dough piece so that the larger food particles project through or are contained in the surface of the formed dough piece; and d. frying the dough piece at said 40% to 60% moisture content and with said combination of gelatinized and ungelatinized starches contained in the dough at the time of frying to form an expanded fried snack product, the dry cracked cereal grains providing a means of escape for the moisture contained in the dough piece during frying and being present in an amount sufficient to reduce puffing of the fried product when compared with the amount of puffing of a fried snack product made from the same dough sheet that does not contain said larger food particles.

11. The method according to claim 10 in which the larger dry cracked cereal grains are extraneously added to the dough ingredients.

12. The method according to claim 10 in which the larger cracked cereal grains re contained in the dough piece in an amount such that the formation of bubbles greater in size than about 65 mm is substantially prevented in at least about 85% of the fried products made from the dough.

13. The method according to claim 10 in which the dry cracked cereal grains are uniformly dispersed through the dough and remain in a solid particulate form throughout frying.

14. The method according to claim 52 in which the thickness of the dough piece is from about 0.7 mm to about 2.0 mm.

15. The method according to claim 10 in which the dry cracked cereal grains comprise a component of the finely divided starch-containing solids which has been coarsely ground to a larger particle size than the principal finely divided starchcontaining solids.

16. The method according to claim 10 in which the dough piece has a sheetthickness from about 1.0 mm to about 1.2 mm, and the dry cracked cereal grains have an average particle size of at least about

0.8 mm.

17. The method according to claim 10 in which the finely divided dry food solids have an average particle size of about 0.5 mm or less.Data supplied from the esp@cenet database - Worldwide

1731/2197

371.

US4871557 - 10/3/1989

GRANOLA BAR WITH SUPPLEMENTAL DIETARY FIBER AND METHOD


Inventor(s): LINSCOTT SUSAN E (US)

Applicant(s): AMWAY CORP (US)


IP Class: A23L1/10

E Class: A23L1/164C; A23L1/164; A23G3/00



Family: JP2039870


Abstract:


The present invention is a granola bar with supplemental dietary fiber which is added to the granola bar in the form of compressed flakes, as well as the method of making such a granola bar. The method includes the steps of providing a mixture of granola ingredients selected from the group consisting of grains, fruits, and nuts. Supplemental dietary fiber is provided in the form of compressed flakes and mixed with the granola ingredients. Preferably, the compressed flakes of supplemental dietary fiber are made by combining with water and a binder material, such as rice flour, and then extruding. The extrudate is preferably dried and then ground to the desired particle size.Description:



The present invention relates to the field of food products with high dietary fiber content. More particularly, the invention relates to the field of granola bars with high dietary fiber content.

The term "dietary fiber" has been defined as the indigenous components of plant materials in the diet which are resistant to digestion by enzymes produced by humans. Stated another way, dietary fiber is the sum of all polysaccharides and lignin that are not digested by the secretions of the human digestive tract. It is noted that, although the term "fiber" generally refers to filamentous, stringy materials,

"dietary fiber" is often gelatinous or mucilaginous in character.

In recent years, the physiological benefits of adequate levels of dietary fiber in the diet have become more and more evident. Such benefits include the normalization of the bowel function and reduction of the occurrence of certain colonic diseases. Increased dietary fiber intake has been used in the treatment for diabetes, hypoglycemia, hypercholesterolemia, hypertriglyceridmedia. Dietary fiber has also been used as a control for metabolic rates to help prevent obesity.

In view of these benefits, health authorities have recommended a daily consumption of 20-35 grams of dietary fiber. Survey results have shown, however, that the average American consumes only 11.1 to

13.3 g of dietary fiber a day. It has been further recommended that the dietary fiber which is ingested

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should comprise about 70 percent insoluble fiber and about 30 percent soluble fiber. Common types of soluble dietary fiber include gum arabic, gum ghatti, guar gum, psyllium, carrageenans, xanthan, tragacanth, karaya, locust bean gum, agar, and alginates.

Various food products, such as breads and breakfast cereals, have been modified in order to include a greater dietary fiber content. In addition, consumers have looked to snack and convenience foods to provide increased fiber in their diet.

Granola bars have enjoyed a reputation as a healthy snack with a high fiber content. Unfortunately however, analysis of granola bars currently available in the market has shown that the fiber content is typically less than 5 percent by weight of the granola bar. Thus the typical 28 g. granola bar provides less than about 1 g. of fiber.

One factor working against the inclusion of a high level of dietary fiber in a granola bar is that adding too much supplemental dietary fiber to the granola bar formulation can have a negative impact on the texture and mouthfeel of the granola bar. For example, many of the common sources of dietary fiber are available only in a powdered form. It has been found that adding too much dry, powdered material to a granola bar formulation can result in a granola bar that has a dry and powdery mouthfeel. In other words, the addition of powdered supplemental dietary fiber interferes with the natural texture and mouthfeel otherwise associated with the granola ingredients such as rolled oats, chopped nuts, crisped rice, coconut, and the like. Such a texture and mouthfeel problem is particularly disadvantageous in view of the trend toward soft and chewy granola bars.


Briefly stated, the present invention is a granola bar with supplemental dietary fiber which is added to the granola bar in the form of compressed flakes, as well as the method of making such a granola bar.

The method includes the steps of providing a mixture of granola ingredients selected from the group consisting of grains, fruits, and nuts. Supplemental dietary fiber is provided in the form of compressed flakes and mixed with the granola ingredients.

In accordance with a preferred embodiment of the invention, the compressed flakes of supplemental dietary fiber are made by mixing supplemental dietary fiber with a binder and water. In particular, 2 parts apple fiber, 1 part corn bran, and 1 part rice flour are mixed and moistened with water and then heated, extruded, dried, and particle sized. Preferably, the mean particle size of these flakes is about 20

U.S. mesh. These fiber/corn bran flakes are added at a level of about 9 percent to a granola bar mixture which includes a mixture of granola ingredients constituting about 34 percent of the granola bar.

Preferably, the granola ingredients comprise rolled oats, crisped rice, chopped almonds, and coconut flakes. In this embodiment, other supplemental dietary fiber is added to about 17 percent of the granola bar and comprises soy fiber, apple pectin, gum arabic, gum ghatti, and guar gum. The preferred embodiment includes a humectant system comprising hydrogenated glucose syrup at a level of about

20 percent of the granola bar and glycerine at a level of about 5 percent of the granola bar. This preferred embodiment also includes about 7 percent fructose. This preferred embodiment further includes about 2 percent oil, about 5 percent brown sugar, and about 1 percent of natural flavors and lecithin.

It is noted that the term "supplemental dietary fiber," as used in this specification and the appended claims, is intended to refer to dietary fiber which is added to the granola bar apart from the fiber which is naturally included as part of the typical granola ingredients.

It is also noted that, unless otherwise state, all percentages given in this specification and the appended claims refer to percentages by weight. In the same regard, it is noted that although the preferred granola bar of the present invention includes a coating of chocolate or the like, unless otherwise noted, the weights of the granola bar ingredients are determined before the coating is added.

The present invention is advantageous in that it provides a granola bar which has a high dietary fiber content and a satisfactory texture and mouthfeel. In particular, the invention provides a method of incorporating higher levels of supplemental dietary fiber into a granola bar formulation with minimal interference with the natural texture and mouthfeel of the granola bar.

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These and other objects, advantages, and features of the present invention will be better understood upon review of the following detailed description of the preferred embodiments.


The preferred embodiment of the present invention is identical to that described as the most preferred embodiment in the co-pending U.S. patent application Ser. No. 207,368 filed on the same day by the same inventor and assigned to the same assignee. The co-pending application is directed to a chewy high-fiber granola bar with a particular humectant system. The entire disclosure of this co-pending application is incorporated herein by reference.

In accordance with the invention which is the subject of the present invention, supplemental dietary fiber is used in the form of compressed flakes. Preferably, the compressed flakes of supplemental dietary fiber are made by an extrusion process. Alternatively, other techniques such as wet mixing combined with a drying and a rolling, pressing, chopping and/or a grinding step can be used.

The supplemental dietary fiber used in the compressed flakes can be of various types and is preferably a mixture of various types of dietary fiber. More preferably, the supplemental dietary fiber is a mixture of soluble and insoluble dietary fiber. Most preferably, the dietary fiber of the granola bar will comprise about 70 percent insoluble dietary fiber and about 30 percent soluble fiber.

Although sources of supplemental dietary fiber can contribute both soluble and insoluble fiber, sources generally known to contribute insoluble fiber include but are not limited to soy fiber, apple fiber, corn bran, wheat bran, oat bran, barley bran, rye bran, triticale bran, cellulose, pea fiber, sugar beet fiber, and peanut fiber. Sources generally known to contribute soluble fiber include but are not limited to gum arabic, gum ghatti, guar gum, pectins, psyllium, carrageenans, xanthan, tragacanth, karaya, locust bean gum, agar, and alginates.

Of these sources of supplemental dietary fiber, soy fiber, apple fiber, corn bran, cellulose and its derivative, oat bran, sugar beet fiber, peak fiber, guar gum, gum arabic, gum ghatti, locust bean gum, karaya, xanthan, and apple pectin are preferred. A mixture of apple fiber and corn bran is most preferred. A suitable apple fiber can be obtained from Tastee Apple Inc. under the designation "Apple

Fiber". A suitable corn bran can be obtained from A.E. Staley Co. under the designation "Bestbran 90,

Refined Corn Bran, G-Ultrafine".

Alternatively, other types of supplemental fiber can be incorporated into the compressed flakes of the present invention. In addition, other ingredients can also be added to the compressed flakes. For example, a sweetener, flavorant, or colorant can be added to the compressed flakes to add to their function within the granola bar.

Preferably, the supplemental dietary fiber is mixed with a binder before being extruded. Preferable binders include rice flour, wheat flour, oat flour, corn flour, rye flour, potato flour, and mixtures thereof. Rice flour, such as that sold by Riviana under the designation "Rice Flour RL-100, long grain," is most preferred.

Preferably, the compressed flakes include between about 40 and about 60 percent apple fiber, between about 20 and about 30 percent corn bran, and between about 20 and about 30 percent rice flour. Most preferably, the flakes include about 50 percent apple fiber, about 25 percent corn bran, and about 25 percent rice flour.

The apple fiber, corn bran, and rice flour are preferably mixed together with an amount of water sufficient to bind the mixture together and sufficient to facilitate extrusion of the mixture. Typically, the water is added to between about 10 and about 30 percent of the mixture. Most preferably, the damp mixture includes about 26 percent water just prior to extrusion.

The extrusion step can be performed by conventional techniques in conventional extrusion apparatus.

Preferably, the damp mixture is heated to a temperature between about 300 DEG and about 330 DEG

F., most preferably about 315 DEG F. during the extrusion process. Preferably, the damp mixture is

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extruded at a pressure of between about 100 p.s.i. and about 900 p.s.i. Preferably, the die through which the mix is extruded includes one round hole with a diameter of about 0.5 inches.

Preferably, the extrudate is particle sized by being ground before being dried. This can be accomplished by using a conventional Wenger Shredder. After grinding, the flake are dried in an oven at 270 DEG F. for about 20 minutes. Preferably, the dried particles will have a moisture content of about 7 percent.

Alternatively, the extrudate is first dried and then particle sized, e.g. by grinding, rolling, or other conventional techniques.

The particle size of the compressed flakes is an important feature in the method of the present invention. Preferably, the compressed flakes will have a mean particle size of between about 100 and about 5 U.S. mesh. More preferably, the compressed flakes will have a mean particle size of between about 60 and about 10 U.S. mesh, and most preferably about 20 U.S. mesh. In particular, the particle size of the flakes made according to the most preferred embodiment ranges from 200 to 5 U.S. mesh with less than about 5 percent retained on a 10 U.S. mesh screen and less than about 7 percent passing through a 60 U.S. mesh screen.

While not wishing to be bound by any particular theory, it is currently believed that the particle size of the compressed flakes is related to the success of the present invention in incorporating supplemental dietary fiber into a granola bar with minimal interference with the texture and mouthfeel of the granola bar. In particular, it is believed that by aggregating the otherwise fine particles of supplemental dietary fiber into the larger compressed flakes, the supplemental dietary fiber is made more compatible, in a physical sense, with the other ingredients of the granola bar. In other words, the supplemental dietary fiber is put into a physical form which is more like that of the granola ingredients such as the rolled oats, chopped nuts, and the like. That is, the supplemental dietary fiber is put into a physical form which mimics, to some extent, the physical form of the granola ingredients. As a result, the supplemental dietary fiber added in this way is physically less distinguishable from the granola ingredients.

In light of the above, the preferred particle size of the compressed flakes can also be stated in relative terms. The ratio of the mean particle size of the compressed flakes to the mean particle size of the granola ingredients is preferably between about 1.0:1 and about 2:1. More preferably, the ratio is between about 0.5:1 and about 1:1.

Another reason the use of compressed flakes of supplemental fiber is believed to improve the texture and mouthfeel of the granola bar over that resulting from simply incorporating dry powdered supplemental fiber, is that the rate of hydration of the compressed flakes is lower than that of a powdered ingredient. Because of a lowered surface area, the compressed flakes do not absorb water as fast as the separate powders would. As a result, the compressed flakes do not contribute to the dry mouthfeel normally experienced with powders.

Another possible reason for the success of the preferred embodiment is the fact that the supplemental dietary fiber is combined with the binder material. In particular, it is believed that the supplemental dietary fiber may be more compatible within the granola bar because it it combined with a more compatible material, i.e, the binder material.

After the compressed flakes are appropriately particle sized and dried they are ready to be incorporated into the granola bar of the present invention. As stated above, the preferred embodiment of the present application is identical to that described in the co-pending application. According to this preferred embodiment, the ingredients of the granola bar formulation are generally divided between the liquid ingredients and the dry ingredients. Preferably, the liquid ingredients of the granola bar are combined in a syrup pre-blend. Most preferably, this syrup pre-blend includes the hydrogenated glucose syrup and glycerine of the humectant system, together with fructose, brown sugar, oil, lecithin, and flavors.

The preferred humectant system comprises hydrogenated glucose syrup and glycerine. Hydrogenated glucose syrups have also been referred to as hydrogenated starch hydrolysates or hydrogenated corn syrup (if made from corn syrup). Generally hydrogenated glucose syrups comprise a blend of sorbitol,

1735/2197

maltitol, and longer chain polyhydric alcohols. The longer chain polyhydric alcohols are usually referred to by the degree of polymerization (DP). For example, "DP 3" refers to maltotriatol, i.e a polyhydric alcohol comprised of 3 glucose units.

The most preferred hydrogenated glucose syrup is that sold by LONZA, INC. under the designation

"Hystar TPF 70 %." This particular hydrogenated glucose syrup comprises about 30 percent water, about 50 percent sorbitol, about 8 percent maltitol, about 3 percent DP 3 (maltotriatol), and about 8 percent DP 4 and higher.

The level of hydrogenated glucose syrup in the granola bar of the present invention is at least 2 percent of the granola bar. Preferably, the hydrogenated glucose syrup is present at between about 2 and about

45 percent. Levels above about 45 percent typically result in a granola bar that is too soggy. More preferably, the hydrogenated glucose syrup should be between about 4 and about 25 percent. In accordance with the most preferred embodiment, the above-described hydrogenated glucose syrup is present at about 20 percent.

The second component of the humectant system is glycerine. Most preferably the glycerine is 99.5% pure and is sold by the GLYCO CO. under the designation "glycon G-100." The level of glycerine in the granola bar is between about 2 and about 6 percent of the granola bar. Preferably, the glycerine is present at between about 3 and about 6 percent, more preferably between about 4 and about 6 percent.

In accordance with the most preferred embodiment, the above-described glycerine is present at about 5 present.

The granola bar of the present invention preferably includes fructose as a sweetener/humectant.

Although other sugars such as sucrose can be used, fructose is preferred because it is better than sucrose as a humectant in binding water within the bar. Fructose is also preferred because it does not require insulin for transport and is thus preferred in a diabetic diet. Also, fructose has a higher sweetness potential than sucrose.

According to the most preferred embodiment, the fructose is added in the form of granola fructose along with roughly the same amount of water to the syrup pre-blend. The syrup pre-blend is eventually boiled down to remove substantially all of this added water. Alternatively, the fructose can also be added in the form of a carbohydrate syrup, such has high fructose corn syrup.

When fructose is used in the granola bar of the invention, it is preferably added to between about 1 and about 12 percent of the granola bar. In this most preferred embodiment, the fructose is added to a level of about 17 percent of the syrup pre-blend and about 7 percent of the granola bar.

Preferably, brown sugar is also added to the syrup pre-blend in an amount between about 1 and about

10 percent of the granola bar. Most preferably, the grown sugar is added to about 12.5 percent of the syrup pre-blend and about 5.0 percent of the granola bar. A suitable brown sugar is that sold by C & H

Sugar Co. under the designation "Golden C Medium Brown Sugar." Preferably, the syrup pre-blend is heated and stirred sufficiently to assure dissolution of the brown sugar before the syrup pre-blend is added to the dry ingredients.

The granola bar of the present invention also preferably includes between about 1 and about 10 percent of an edible oil. In the most preferred embodiment, a hydrogenated soybean/cottonseed oil is added to comprise about 5 percent of the syrup pre-blend and about 2 percent of the granola bar.

Preferably, flavors are also added to the syrup pre-blend. In this most preferred embodiment, natural vanilla flavor, coconut flavor, and natural butter flavor are added in a combined amount of about 2.5 percent of the syrup pre-blend and about 1.0 percent of the granola bar.

Lecithin is also preferably added to the syrup pre-blend in an amount between about 0.1 and about 1 percent of the syrup pre-blend to act as an emulsifier for the oil in the granola bar. Most preferably, the lecithin is added in an amount of about 0.25 percent of the syrup pre-blend and about 0.1 weight percent of the granola bar.

1736/2197

The most preferred method of combining the ingredients of the syrup pre-blend is as follows: The blending takes place in a bowl of a hobart mixer equipped with a steam jacket for heating the contents of the mixing bowl. With the mixer on the low speed, the hydrogenated glucose syrup, glycerine, granulated fructose, brown sugar, and water are added to the mixing brown which is heated to boiling until the mixture is boiled down to between about 80 and about 86 percent solids, most preferably about 83 percent solids. The mixture is then allowed to cool to 120 DEG F. after which the oil is added and mixing is continued for about 5 minutes. The lecithin and vanilla and coconut flavors are added and mixing is continued for another 5 minutes. Finally, the butter flavor is added and the mixing is continued for another 5 minutes. At this point, the syrup pre-blend is ready to be mixed with the remainder of the ingredients of the granola bar.

The granola ingredients are selected from the group consisting of grains, nuts, and fruits, as well as mixtures thereof. Preferably, the granola ingredients will comprise a mixture of ingredients selected from the group consisting of toasted rolled oats, crisped rice, chopped nuts, coconut flakes, dried fruit, wheat flakes. Chocolate chips have also become popular in granola bars. Preferably, the granola ingredients comprises between about 30 and about 40 percent of the granola bar, most preferably about

35 percent.

In the most preferred embodiment, the mixture of granola ingredients comprises a mixture of toasted rolled oats, crisped rice, chopped almonds, unsweetened coconut flakes in the following amounts: toasted rolled oats at about 54.5 percent of the granola ingredients, about 30.5 percent of the dry ingredients, and about 18.3 percent of the granola bar; crisped rice at about 19.6 percent of the granola ingredients, about 11.0 percent of the dry ingredients, and about 6.6 percent of the granola bar; chopped almonds at about 14.3 percent of the granola ingredients, about 8.0 percent of the dry ingredients, and about 4.8 percent of the granola bar; and unsweetened coconut flakes at about 11.6 percent of the granola ingredients, about 6.5 percent of the dry ingredients, and about 3.9 percent of the granola bar.

Preferably, part of the total supplemental dietary fiber, namely the apple fiber/corn bran flakes described above and apple pectin extract, is mixed with the granola ingredients before the syrup preblend is added. Other supplemental dietary fiber is added after the syrup pre-blend and granola ingredients have been blended.

Preferably, supplemental dietary fiber, both untreated and in the form of compressed flakes, is added to the granola bar in an amount such that the total dietary fiber content of the granola bar is at least about

5 percent. Because the granola ingredients are likely to contribute some dietary fiber, the amount of fiber contributed by the supplementary dietary fiber will vary depending on the ingredients selected. In the most preferred embodiment, the granola ingredients contribute about 15 percent of the total dietary fiber and the supplemental dietary fiber contributes about 85 percent.

Preferably, the supplemental dietary fiber is added to the granola bar in an amount such that the total dietary fiber content of the granola bar is at least about 10 percent, more preferably, at least about 15 percent.

Preferably, the compressed flakes of supplemental dietary fiber comprise between about 0.5 and about

20 percent by weight of the granola bar, more preferably between about 6 and about 12 percent.

Various techniques are available for measuring the total dietary fiber content of food products. A suitable technique is an enzymatic gravimetric method designated by the Association of Official

Analytical Chemists as #43.A14-43.A20. The entire granola bar can be analyzed by a method such as this. Alternatively, the total dietary fiber content of the granola bar can be calculated by determining the dietary fiber contents of the individual ingredient.

In the most preferred embodiment, the supplemental dietary fiber consists of soy fiber added at about

36.4 percent of the supplemental dietary fiber, about 16 percent of the dry ingredients, and about 9.6 percent of the granola bar; apple fiber/corn bran flakes (described in detail above) at about 33.0 percent of the supplemental dietary fiber, about 14.5 percent of the dry ingredients, and about 8.7 percent of the granola bar; gum arabic at about 9.1 percent of the supplemental dietary fiber, about 0.4 percent of the dry ingredients, and about 2.4 percent of the granola bar; gum ghatti at about 5.7 percent of the

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supplemental dietary fiber, about 2.5 percent of the dry ingredients, and about 1.5 percent of the granola bar; apple pectin extract at about 11.4 percent of the supplemental dietary fiber, about 5.0 percent of the dry ingredients, and about 3.0 percent of the granola bar; guar gum at about 4.5 percent of the supplemental dietary fiber, about 2.0 percent of the dry ingredients, and about 1.2 percent of the granola bar.

In the most preferred embodiment, the toasted rolled oats, apple pectin extract, apple fiber/corn bran flakes, crisped rice, unsweetened coconut flakes, and the chopped almonds are first mixed together and then added in the proper amount to the syrup pre-blend. Preferably, these ingredients are added to the syrup pre-blend one fourth at a time until completely mixed in.

The last ingredients added are the supplemental dietary fibers which are in the form of fine powders, i.e. the guar gum, gum ghatti, gum arabic, and soy fiber. These powders are first dry blended and then added to the mixing bowl containing the syrup pre-blend and the rest of the dry ingredients.

Preferably, the granola bar will constitute between about 35 and about 45 percent of the syrup preblend and between about 55 and about 65 percent of the dry ingredients. Most preferably, the granola bar will constitute about 40 percent of the syrup pre-blend and about 60 percent of the dry ingredients.

After mixing is complete, the mixture is transferred to a conventional granola bar forming line. The mixture is first formed into a slab with thickness of about 7/16". After cooling to about 60 DEG F., the slab is slit into ribbons about 1.14 inches wide. The ribbons are then cut to a bar weight of about 28.0 g which is typically about 3.38 inches long.

In the most preferred embodiment, analysis of the granola bar reveals that the granola bar includes about 5 g. of dietary fiber which is about 17 percent of the total bar. The analysis used is an enzymatic gravimetric method designated by the Association of Official Analytical Chemists as #43.A14-43.A20.

The granola bar made according to this most preferred embodiment possesses a remarkably soft and chewy texture.

Preferably, the granola bar has a coating, such as chocolate, applied to it. Alternatively, the bar is left uncoated or has yogurt, peanut butter, and other flavored coatings applied to it. Most preferably, conventional coating techniques are used to surround the granola bar with about 10 g. of chocolate. A suitable chocolate for coating is a milk chocolate sold by the AMBROSIA CHOCOLATE CO. under the designation "#S-5943.

EXAMPLES

The following examples are provided by ways of explanation and description and should not be seen as limiting the scope of the invention.

Two batches of compressed flakes of supplemental dietary fiber were made according to the most preferred embodiment described above, with the exception that the batches varied in particles size. To determine the particle size range of the flakes produced in each batch, a set of screens of increasing mesh were arranged vertically. 100 g. of the flakes were poured onto the top screen and the screen were vibrated with a sonic sifter. The screens were then removed and weighed to determine the weight percentage of compressed flakes retained on each screen. The following data was obtained:

>;tb;______________________________________

>;tb;Mesh Size Opening (in.) Batch 1 Batch 2

>;tb;______________________________________

>;tb; .250 0.0 0.6

>;tb; 5 .157 0.0 26.57

>;tb; 6 .132 0.0 12.5

>;tb; 8 .0937 1.0 42.6

>;tb;10 .0661 4.08 10.4

>;tb;14 .0469 23.61 3.8

>;tb;20 .0337 24.61 1.1

>;tb;pan 46.7 2.5

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>;tb;______________________________________

Because such a high percentage of flakes from the first batch passed through to the pan, the contents of the pan from the first batch were then poured onto a second set of screens of increasing mesh numbers.

The following data was obtained:

>;tb;______________________________________

>;tb;Mesh Size Opening (in.)

>;tb; Batch 1

>;tb;______________________________________

>;tb;40 .0165 28.55

>;tb;60 .0098 14.24

>;tb;80 .0070 3.91

>;tb;100 .0059 1.60

>;tb;200 .0029 1.13

>;tb;pan 0.57

>;tb;______________________________________

In the three examples, compressed flakes from the first bath were used in making 50 g. batches for granola bars. Each of the examples included 40 percent syrup pre-blend and 60 percent of the dry ingredients. The mixing was carried out as described above for the most preferred embodiment. In each example, the resultant mix was formed into granola bars of the size and weight described above.

Examples 1 through 3 were carried out to determine the effects of varying the amount of apple fiber/corn bran flakes within the granola bar. The formulation of the syrup pre-blend for the three examples was kept constant as follows:

>;tb;______________________________________

>;tb; % of % of

>;tb; formula

>;tb; pre-blend

>;tb;______________________________________

>;tb;Fructose 6.9 17.3

>;tb;Hydrogenated Glucose

>;tb;Syrup (Hystar TPF-70)

>;tb; 20.0 50.0

>;tb;Glycerine 5.0 12.5

>;tb;Brown Sugar 5.0 12.5

>;tb;Hydrogenated Oil 2.0 5.0

>;tb;Flavors 1.0 2.5

>;tb;Lecithin .1 .25

>;tb; 40.0% 100.0%

>;tb;______________________________________

Example 1 was carried out in accordance with the most preferred embodiment. Example 2 included more crisped rice and less supplemental dietary fiber compressed flakes. The granola bars made in

Example 2 thus had only about 4 g. of dietary fiber by analysis compared to 5 g. for the granola bars made in Example 1. Example 3 included less crisped rice and more supplemental dietary fiber compressed flakes, and thus had about 6 g. of dietary fiber by analysis. The formulations of the dry ingredients were as follows:

>;tb;______________________________________

>;tb; % of % of % of % of

>;tb; formula

>;tb; blend formula blend

>;tb;______________________________________

>;tb; Example 1 Example 2

>;tb;Rolled Oats 18.3 30.5 23.5 39.2

>;tb;Soy Fiber 9.6 16.0 9.6 16.0

>;tb;Apple Fiber/Corn Bran

>;tb; 8.7 14.5 0.6 1.0

>;tb;Flakes

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>;tb;Crisped Rice 6.6 11.0 9.5 15.8

>;tb;Almonds 4.8 8.0 4.8 8.0

>;tb;Coconut 3.9 6.5 3.9 6.5

>;tb;Apple Pectin Extract

>;tb; 3.0 5.0 3.0 5.0

>;tb;Gum Arabic 2.4 4.0 2.4 4.0

>;tb;Gum Ghatti 1.5 2.5 1.5 2.5

>;tb;Guar Gum 1.2 2.0 1.2 2.0

>;tb; 60.% 100.0% 60.0% 40.0%

>;tb; Example 3

>;tb;Rolled Oats 12.4 20.7

>;tb;Soy Fiber 9.6 16.0

>;tb;Apple Fiber/Corn Bran

>;tb; 17.3 28.8

>;tb;Flakes

>;tb;Crisped Rice 3.9 6.5

>;tb;Almonds 4.8 8.0

>;tb;Coconut 3.9 6.5

>;tb;Apple Pectin Extract

>;tb; 3.0 5.0

>;tb;Gum Arabic 2.4 4.0

>;tb;Gum Ghatti 1.5 2.5

>;tb;Guar Gum 1.2 2.0

>;tb; 60.% 100.0%

>;tb;______________________________________

It was observed that the granola bar made in Example 2 was slightly softer and chewier than that of

Examples 1 and 3. The granola bar made in Example 3 had the driest texture of the three. It is noted that the formulation for the dry ingredients in Example 1 yield about 17 percent dietary fiber per bar and that the ratio of insoluble fiber to soluble fiber is about 70 to 30.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A granola bar with supplemental dietary fiber comprising: a mixture of granola ingredients selected from the group consisting of grains, fruits, and nuts; supplemental dietary fiber in the form of compressed flakes, wherein the compressed flakes of supplemental dietary fiber have a mean particle size between about 100 and about 5 U.S. mesh and comprise between about 5 and about 20 percent of the granola bar.

2. The granola bar of claim 1 wherein the compressed flakes of supplemental dietary fiber comprise at least one source of supplemental dietary fiber and at least one binder material.

3. The granola bar of claim 2 wherein the supplemental dietary fiber is selected from the group consisting of apple fiber, corn bran, soy fiber, pectin, guar gum, gum ghatti, and gum arabic, as well as mixtures thereof.

4. The granola bar of claim 2 wherein the binder material is selected from the group consisting of rice flour, wheat flour, oat flour, corn flour, rye flour and potato flour, as well as mixtures thereof.

5. The granola bar of claim 1 wherein the compressed flakes of supplemental dietary fiber have a mean particle size between about 60 and about 10 U.S. mesh.

6. The granola bar of claim 1 wherein the compressed flakes of supplemental dietary fiber have a mean particles size of about 20 U.S. mesh.

1740/2197

7. The granola bar of claim 1 wherein the ratio of the mean particle size of the compressed flakes of supplemental dietary fiber to the mean particle size of the granola ingredients is between about 0.1:1 and about 2:1.

8. The granola bar of claim 7 wherein the compressed flakes of supplemental dietary fiber comprise at least one supplemental dietary fiber and at least one binder material.

9. The granola bar of claim 7 wherein the supplemental dietary fiber is selected from the group consisting of apple fiber, corn bran, soy fiber, pectin, guar gum, gum ghatti, and gum arabic, as well as mixtures thereof.

10. The granola bar of claim 7 wherein the binder material is selected from the group consisting of rice flour, wheat flour, oat flour, corn flour, rye flour, and potato flour, as well as mixtures thereof.

11. The granola bar of claim 1 wherein the ratio of the mean particle size of the compressed flakes of supplemental dietary fiber to the mean particle size of the granola ingredients is between about 0.5:1 and about 1:1.

12. The granola bar of claim 1 wherein the compressed flakes of supplemental dietary fiber comprise between about 6 and about 12 percent of the granola bar.

13. A method of making a granola bar with supplemental dietary fiber comprising the steps of: forming compressed flakes of supplemental dietary fiber; providing a mixture of granola ingredients selected from the group consisting of grains, nuts, and fruits; and combining the compressed flakes of supplemental dietary fiber with the mixture of granola ingredients to form a granola bar, wherein the compressed flakes of supplemental dietary fiber have a mean particle size between about 100 and about

5 U.S. mesh in the granola bar and comprise between about 0.5 and about 20 percent of the granola bar.

14. The method of claim 13 wherein the method of forming said compressed flakes of supplemental dietary fiber comprises the steps of: combining supplemental dietary fiber with a binder material and water; extruding the mixture of supplemental dietary fiber, binder material, and water; drying said extruded moisture; and particle sizing said dried extruded mixture to produce compressed flakes of supplemental dietary fiber of a desired particle size.

15. The method of claim 14 wherein the mixture of supplemental dietary fiber, binder material, and water is heated.

16. The method of claim 14 wherein the supplemental dietary fiber is selected from the group consisting of apple fiber, corn bran, soy fiber, pectin, guar gum, gum ghatti, and gum arabic, as well as mixtures thereof.

17. The method of claim 14 wherein the binder material is selected from the group consisting of rice flour, wheat flour, oat flour, corn flour, rye flour, and potato flour, as well as mixtures thereof.

18. The method of claim 13 wherein the compressed flakes of supplemental dietary fiber have a mean particle size between about 60 and about 10 U.S. mesh.

19. The method of claim 13 wherein the compressed flakes of supplemental dietary fiber have a mean particle size of about 20 U.S. mesh.

20. The method of claim 13 wherein the ratio of the mean particle size of the compressed flakes of supplemental dietary fiber to the mean particle size of the granola ingredients is between about 0.1:1 to about 2:1.

21. The method of claim 13 wherein the ratio of the mean particle size of the compressed flakes of supplemental dietary fiber to the mean particle size of the granola ingredients is between about 0.5: to about 1:1.

1741/2197

22. A method of making a granola bar with supplemental dietary fiber comprising the steps of: combining supplementary dietary fiber with a binder material and water; heating and extruding the mixture of supplemental dietary fiber, binder material, and water; drying said extruded mixture; and particle sizing said dried extruded mixture to produce compressed flakes of supplemental dietary fiber of a desired particle size; providing a mixture of granola ingredients selected from the group consisting of grains, nuts, and fruits; and combining the compressed flakes of supplemental dietary fiber with the mixture of granola ingredients to form a granola bar, wherein the compressed flakes of supplemental dietary fiber have a mean particle size between about 100 and about 5 U.S. mesh in the granola bar and comprise between about 0.5 and about 20 percent of the granola bar.Data supplied from the esp@cenet database - Worldwide

1742/2197

372.

US4871575 - 10/3/1989

FLAVOR AND TEXTURE IMPROVED CANNED ANIMAL FLESH AND

PROCESS


Inventor(s): CALLAHAN TIMOTHY (US); HERZ JACK (US)

Applicant(s): DELTOWN CHEMURGIC CORP (US)


IP Class: A23L1/325

E Class: A23L1/227; A23B4/20; A23B4/22; A23L1/318B


Priority Number: JP19890182341 (19890714); OA19890059617 (19890720); PH19890039763

(19891221); US19880164611 (19880307)

Family: JP3053842

Equivalent:

IT1228558

PH26824; OA10039; JP3053842; GB2216386; FR2649590; ES2012684; PT89932;

Abstract:


The invention relates to a process and composition for enhancing the flavor and improving the texture of animal flesh, such as tuna fish in a can, by adding flour, such as rice flour, which has been hydrolyzed with a proteolytic enzyme, to the animal flesh.Description:



This invention pertains to a process and composition for enhancing the flavor and texture of canned fish or meat and more particularly to the use and preparation of a proteolized flour as a moderator of canned animal flesh.


Canned fish and meat products are most often packed with oil or broth in order to eliminate variability, enhance flavors, or reduce unpleasant odors and flavors, and also to improve the texture and press weight of the animal flesh. The packing additives usually contain moderators such as hydrolyzed caseins and caseinates or vegetable broths of various kinds. While these additives have been most successful in achieving an improved product, research has continued, in order to develop protein hydrolysates of greater efficacy and efficiency.

The present invention has discovered that a flour base, such as rice, pea or potato flour, or bean or soy flour, can be hydrolyzed under neutral conditions by a proteolytic enzyme to provide a new and improved hydrolyzed protein additive.

1743/2197

In particular, rice flour which is neutralized to a pH of 7.0.+-.0.5, and treated with an enzyme, including but not limited to enzymes such as papain, pancreatin or a microbial enzyme i.e., a fungal proteolytic enzyme, or another fungal protease can provide an additive that on a one-to-one basis has approximately twice the effectiveness and benefits afforded by hydrolyzed casein based products, such as casein which has been hydrolyzed by a proteolytic enzyme.

This additive, while intended to be used primarily with fish flesh such as tuna, salmon, sardines, pilchard and mackerel, etc., is also useful for canned meat, such as ham, chicken, turkey, pork and beef, as well as shellfish.


The invention features an improved additive for canned animal flesh, and the process for fabricating same. The additive in the form of a moderator improves the flavor and texture of the canned product, and increases its press weight.

The moderator comprises neutralized, powdered rice flour which has been hydrolyzed by a proteolytic enzyme such as, papain, pancreatin or enzymes of microbial origin. After neutral hydrolysis, the rice flour is dried and then resolubilized to form a 1 to 6% aqueous solution. The moderator is applied, for example, to the flesh of tuna in the can by treating the aqueous solution to about 150 DEG to 180 DEG

F., and then pouring approximately two ounces of the heated solution over 4.5 ounces of tuna fish flesh in the can.

The hydrolyzed rice flour solution can be mixed in various ratios with other moderators, such as: acidhydrolyzed casein, acid-hydrolyzed rice protein isolate, or concentrate hydrolyzed vegetable protein, and enriched rice protein isolate. These added moderators are solubilized in a range from 1 to 50% by weight, and add to the efficacy of the hydrolyzed flour.

Rennet- or other enzyme-hydrolyzed casein in a 1 to 95% by weight can be added to the hydrolyzed rice flour directly or can be admixed with any one of the other moderators and the rice flour hydrolysate.

The rice flour protein hydrolysate is prepared by first neutralizing a rice flour solution to a pH of approximately 7.0.+-.0.5, by the addition of a sufficient amount of an alkaline hydroxide, such as sodium or potassium hydroxide.

The neutralized rice flour is then admixed with a proteolytic enzyme at sufficient temperature for a sufficient time until the protein is digested. The enzyme is then inactivated.

The hydrolyzed rice flour is then spray dried, to form a powder, which can then be resolubilized for use. Other vegetable flours, such as pea, bean, soy, potato and the like may be similarly treated, provided that they have a sufficient concentration of enzyme-hydrolyzeable protein.


Generally speaking, the invention relates to a protein hydrolysate formed from the action of a proteolytic enzyme upon a flour base. The protein hydrolysate is used as a moderator for canned animal flesh, such as tuna fish.

The flour base of the invention can be a rice, pea or potato flour, etc., but the rice flour is preferred.

The rice flour is neutralized in solution to a pH of approximately 7.0.+-.0.5. If acidic, sodium or potassium hydroxide can be added. If too basic, hydrochloric or sulfuric acid can be used.

The neutralized rice flour is then adjusted to the temperature of the particular proteolytic enzyme used to hydrolyze the rice flour.

In the case of papain, the preferred enzyme, the temperature is adjusted to between 120 DEG to 140

DEG F. The papain is added into the neutralized rice flour and the admixture is allowed to react for approximately 1 to 2 hours.

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The degree of hydrolysis is monitored in the laboratory by measuring either the amino nitrogen content, which should be in the range from 0.1 to 3.0%, or a 50% decrease in viscosity, which can be measured by a Brookfield viscometer.

Other techniques for measuring hydrolysis may include SDS Page electrophoresis and H.P.C.C. molecular weight analysis.

In commercial practice, the time necessary to effect the digestion of the protein will be calculated in advance, thus requiring little or no monitoring.

If using pancreatin as the proteolytic enzyme, the admixture is maintained at a temperature between

120 DEG to 125 DEG F. for about 1 to 2 hours.

If utilizing a microbial protease, the admixture is maintained at a temperature between 120 DEG to 25

DEG F. for approximately 1 to 2 hours.

After digestion has been completed, the enzyme is deactivated by elevating the temperature to approximately between 150 DEG to 180 DEG F. for about 1 hour.

The pH of the hydrolyzed rice flour can then be readjusted to 7.0.+-.0.5 using NaOH, KOH or HCl, H2

SO4, if necessary.

The neutralized and hydrolyzed rice flour solution is then fed into a spray dryer, for example, one manufactured by Sterner Industries, Winsed, Wisc. The solution is fed into the spray dryer under a pressure in the range from 2,000 to 4,000 lbs. per sq. inch. Preferrably, the pressure is maintained at somewhere around 2,800 lbs. per sq. inch.

A maximum exhaust temperature of 190 DEG F. is maintained so that the resulting powder will not be burned.

A typical analysis of a hydrolyzed rice flour processed in accordance with the invention, is set forth below in Table I.

>;tb; TABLE I

>;tb;______________________________________

>;tb;CHEMICAL CHARACTERISTICS

>;tb;AN/TN .times. 100 12.5%

>;tb;Ash 1.1%

>;tb;NaCl 0.5%

>;tb;Moisture >;5.0%

>;tb;pH (2% solution 5.9%

>;tb;MICROBIAL CONTENT

>;tb;Standard Plate >;5000/gm

>;tb;Coliform >;10/gm

>;tb;Thermophiles >;1000/gm

>;tb;Yeast and Mold >;100/gm

>;tb;Salmonella Neg/25 gm

>;tb;______________________________________

>;tb;AMINO ACID COMPOSITION

>;tb; mg/gm mg/gm

>;tb;______________________________________

>;tb;Lysine 3.0 Alanine 4.5

>;tb;Histidine 2.0 Cystine 1.4

>;tb;Arginine 8.1 Valine 5.2

>;tb;Aspartic Acid

>;tb; 7.4 Methionine 2.4

>;tb;Threonine 2.8 Isoleucine 3.7

>;tb;Serine 3.9 Leucine 7.1

>;tb;Glutamic Acid

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>;tb; 13.7 Tyrosine 3.2

>;tb;Proline 3.8 Phenylalanine

>;tb; 3.9

>;tb;Glycine 3.8 Tryptophan 0.9

>;tb;______________________________________

An example of rice flour which can be used in the invention has the commercial designation Riviana

Rice Flour RL-100.

A typical batch process is described in the following example:

EXAMPLE

In a sanitized blending Yat, 300 gallons of water at 110 DEG was mixed with 250 pounds of rice flour.

The pH was adjusted from 7.34 to 7.06 by the addition of 55 mls of concentrated HCl.

The neutralized rice flour solution was heated to 120 DEG F., and 1.25 pounds of pancreatin was mixed in.

The temperature of the admixture was held for 1.5 hours, and then raised to 155 DEG F..+-.5 DEG F. for about 0.75 hours.

The admixture was kept at 150 DEG F. until introduction into the dryer.

Prior to drying the pH of the reaction mixture was re-adjusted from 6.89 to 7.13 using 300 gr. of potash.

A yield of 80% was obtained.

Using the spray dried batch of the foregoing example, the following tests were conducted upon canned tuna, with various flours:

Test No. 1

A 6% by weight solution of the hydrolyzed rice flour was mixed under slow heat with a 6% by weight solution of DELLAC 86-101 in a ratio of 1:1. DELLAC 86-101 is a commercially processed casein based protein hydrolysate system manufactured by Deltown Chemurgic., Fraser, N.Y. There was about a 3.5% increase in drain weight with better flavor vs. water, when 2 ounces were applied to 4.5 ounces of tuna fish flesh in the can.

Test No. 2

Two ounces of a 3% by weight solution of the hydrolyzed rice flour was applied neat to 4.5 ounces of tuna fish flesh in the can.

There was a 9% increase in drain weight vs. water.

Test No. 3

Two ounces of a 6% by weight solution of the hydrolyzed rice flour was applied neat to 4.5 ounces of tuna fish flesh in a can. Using this same 6% weight solution, this was also done with respect to potato flour, soy flour and pea flour. In the case of rice flour, there was a 13% increase in drain weight vs. H2

O. Also, in another test with rice flour, there was an 18% increase in drain weight vs. water. In all cases with rice, potato, soy and pea flour, there was a 13% to 18% increase in drain weight vs. water.

Two ounces of a 3% by weight solution of hydrolyzed rice flour and pea flour were each applied neat to tuna flesh in a can. This produced either a 6% or a 9%, up to 13%, increase in drain weight vs. water

1746/2197

and therefore it is clearly indicated that potato flour and soy flour would produce the same result, in terms of range of increase in drain weight.

Test No. 4

Comparison was made between 6% by weight solutions of DELLAC 86-101 and the hydrolyzed rice flour of the invention. When two ounces of each solution were separately applied to 4.5 ounces of tuna fish flesh in the can, a 7.2% increase in drain weight was noted with the hydrolyzed rice flour.

It is contemplated within the inventive scope, that the rice flour hydrolysate can be mixed with 1 to

95% by weight solutions of DELLAC 86-101, or E-PRO-HY, a product of U.S. Pat. No. 3,846,397 , and rennet-hydrolyzed casein.

Other admixtures are also contemplated including 1 to 20% by weight solutions of acid-hydrolyzed casein; acid-hydrolyzed rice protein isolate; and hydrolyzed vegetable protein.

Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed:

1. A composition of canned tuna fish flesh of enhanced flavor and improved texture, comprising said tuna fish flesh in combination with a water soluble or dispersable rice flour which has been neutralized and hydrolyzed by a proteolytic enzyme.

2. The composition of claim 1 in admixture with at least one other protein hydrolysate selected from the group consisting of: acid-hydrolyzed casein, acid-hydrolyzed rice protein isolate, enzymehydrolyzed casein, enzyme-hydrolyzed rice protein isolate, hydrolyzed vegetable protein, rennethydrolyzed casein.

3. The composition of claim 1, wherein said neutralized hydrolyzed and rice flour is solubilized to form an aqueous solution of approximately 1 to 6% by weight and combined with said flesh.

4. The composition of claim 3, wherein said solution is in admixture with an aqueous solution of approximately 1 to 20% by weight of at least one other protein hydrolysate selected from the group consisting of acid- or enzyme-hydrolyzed casein, acid- or enzyme-hydrolyzed rice protein isolate and hydrolyzed vegetable protein.

5. The admixture of claim 4, in further admixture with an aqueous solution of approximately 1 to 95% by weight of rennet- or other hydrolyzed casein.

6. The composition of claim 3, in admixture with an aqueous solution of approximately 1 to 95% by weight of rennet-hydrolyzed casein.Data supplied from the esp@cenet database - Worldwide

1747/2197

373.

US4873917 - 10/17/1989

APPARATUS FOR CONTINUOUSLY COOKING RICE BY STEAMING


Inventor(s): SUGIMURA TUYOSHI (JP); HORI KENJI (JP); OBA KIYOYUKI (JP)

Applicant(s): ISEKI FOOD ENGINEERING KABUSHI (JP); HORIKEN KK (JP)


IP Class: A47J37/12

E Class: A23L1/10H2; A47J27/18



Family: US4873917


Abstract:


The apparatus comprises a primary steaming unit for exposing rice being conveyed on a first conveyor to steam, a water tank for immersing rice discharged from the first conveyor in hot water, a second conveyor for conveying rice discharged from the water tank, and a secondary steaming unit for exposing rice being conveyed on the second conveyor to steam. Above an inlet end of the second conveyor, a space is formed, which is free from intrusion of steam from the secondary steaming unit. A seasoning liquid feeder is disposed in the space for supplying a season liquid such as salt, shoyu, sake, vinegar to rice. An ingredient feeder for supplying vegetables, meat, fish and so on to rice is disposed in or near the space.Description:



This invention relates to an apparatus for continuously cooking a large amount of grain, particularly rice, by steaming.

U.S. Pat. No. 4,561,347 discloses an apparatus for continuously cooking rice by steaming, which comprises a primary steaming unit for exposing rice on a belt conveyor to steaming, a immersing unit

1748/2197

for immersing the rice discharged from the primary steaming unit in hot water and a secondary steaming unit for exposing the rice discharged from the immersing unit to steam again.


The present invention has an object of improving the disclosed apparatus noted above and provide an apparatus for continuously cooking rice by steaming, in which a seasoning liquid containing salt, shoyu, sake, vinegar, edible oil, etc. and such ingredients as vegetables, meat, fish, etc. are added to rice being steamed to obtain seasoned steamed rice with ingredients.


FIG. 1 is a side view showing an embodiment of the invention;

FIG. 2 is plan view showing the same;

FIG. 3 is a back view of the same; and

FIG. 4 is a plan view showing a seasoning liquid feeder.


An embodiment of the invention will now be described with reference to the accompanying drawing.

Referring to the Figures, there is showing a cooking apparatus comprises a tank 1 which can contain a predetermind quantity of material grain (which is assumed to be rice in this embodiment), a primary steaming unit 2, for supplying steam to rice which was immersed in water and alphatizing starch, an immersing unit 3 for immersing the rice discharged from the tank 1 in hot water and making the rice softer by replenishing with necessar water content, and a secondary steaming unit 4 for supplying finishing steam to the rice discharged from the immersing unit 3.

An immersion tank (not shown) is provided near the tank 1, and rice is immersed in water in the immersion tank for a predetermind period of the time. The immersion tank and tank 1 are connected to each other by a transfer unit (not shown).

The primary steaming unit 2, noted above, is provided beneath the tank 1. The unit 2 includes a net type endless belt conveyor 5 having innumerable steam passage holes smaller in diameter than the rice grain, and rice in the tank 1 is allowed to fall onto the belt conveyor 5. Between the upper and lower runs of the belt of the belt conveyor 5, a plurality of steam chambers 6 are provided in a row extending in the conveying direction. In each steam chamber 6, a team discharge tube 7 with innumerable steam passage holes is provided. The individual steam discharge tubes 7 are connected to a separately provided steam source (not shown). Steam discharged from the tubes 7 is suitably at a temperature of about 100 DEG C. Steam supplied from the steam discharge tubes 7 rises through the steam passage holes of the belt conveyor 5 to steam the rice on the belt conveyor 5 and alphatize the rice starch.

The immersing unit 3, noted above, is connected to the outlet of the primary steaming unit 2. The immersing unit 3 includes a water tank 8 for immersing the rice discharged from the belt conveyor 5 in hot water at a temperature of about 85 DEG C. In the water tank 8 is disposed a transfer unit 9, which includes a movable endless belt 10 and a plurality of rectangular material push-on plates 11 of stainless steel provided on the endless belt 10 at a predetermined interval. Hot water is supplied to the water tank

8 from a hot water feeder (not shown).

The rice from the immersing unit 3 is supplied to the secondary steaming unit 4. The secondary steaming unit 4, like the primary steaming unit 2, includes a net type endless belt conveyor 12 with steam passage holes incapable of being penetrated by rice grains and a plurality of steam chambers 13 provided between the upper and lower runs of the belt. The steam chambers 13 are provided along the rear half of the belt conveyor 12 in the conveying direction for a reason to be described later. A steam discharge tube 14 with innmerable steam passage holes 14 is provided in each steam chamber 13, and

1749/2197

the individual steam discharge tubes 14 are connected to a separately provided steam source (not shown). The steam discharged from the tubes 14 is suitably at a temperature slightly higher than that in the primary steaming unit 2, typically 110 DEG C. 130 DEG C. Steam supplied from the steam discharge tubes 14 rises through the steam passage holes of the net type conveyor 12 to steam the rice on the belt conveyor 12, thus giving the rice grain surface a gloss and viscosity.

Along the top of the belt conveyor 12, there are provided a plurality of stirrers 15 to 19 which also serve as feeders. These stirrers are rotated in the counterclockwise direction in FIG. 1 to feed the rice on the belt conveyor 12. They each include a shaft extending perpendicular to the conveying direction and a plurality of radially spaced-apart bars each embedded in the shaft and having an L-shaped free end. They are rotated such that the ends of the bars are moved faster than the belt conveyor 12. The Lshaped bar ends thus stir the rice on the belt conveyor surface such as to push out the rice.

The primary steaming unit 2, immersing unit 3 and secondary steaming unit 4 are surrounded by front and rear end walls 20 and 21, left and right side walls 23 and 22 and a stop wall 24. The front and rear end walls 20 and 21 are provided with respective doors 25 and 26. The right side wall 22 is provided with doors 29 for the immersing unit 3, and the left side wall 23 is provided with doors 30 for the immersing unit 3 and doors 35 to 38 for the secondary steaming unit 4.

Above the belt conveyor 12 of the secondary steaming unit 4, there are provided a pair of substantially vertical guide plates 39 spaced apart a distance slightly smaller than the width of the belt. The guide plates 39 are secured by suitable means to the left and right side walls or the top wall. Between the lower edge of each guide plate 39 and belt conveyor 12 a gap is formed, through which rice can not leak. The guide plates 39 cover the entire length of the belt conveyor 12.

A pair of enclosure plates 40 extend upwardly from the respective guide plates 39. These enclosure plates 40 extend from a position corresponding to the front inlet of the stirrer to a position behind the stirrer 16. The upper edge of each enclosure plate 40 is removably secured to the top wall 24. Lateral regulator plates 41 and 42 are in contact with the respective front and rear edges of the enclosure plates

40. The regulator plates 41 and 42 have their upper edge removably coupled to the top wall 24. They extend downwards to the position corresponding to the upper edge of the guide plates 39. The upper half of each of the stirrers 15 and 16, therefore, is found in a space 43 defined by the enclosure plates

40, regulator plates 41 and 42 and top wall 24.

In the space 43, there are provided seasoning liquid supply tubes 44 and 45 of a seasoning liquid feeder for spraying a seasoning liquid, which is prepared by suitably mixing together salt, shoyu, sake, vinegar, edible oil, etc. against rice being stirred by the stirrers 15 and 16. The supply tubes 44 and 45 extend obliquely above the front inlets of the respective stirrers 15 and 16. The seasoning liquid sprayed from supply ports 46 of the supply tubes 44 are immediately mixed with rice by the stirrer 15, and the seasoning liquid supplied from supply ports 46 of the supply tube 45 is immediately mixed with rice by the stirrer 16.

As noted before, the steam chambers 13 are provided along the rear half of the net type belt conveyor

12. This is done so for avoiding intrusion of steam into the space 43 from the steam chambers 13. If steam enters the space 43, the seasoning liquid sprayed from the seasoning liquid supply tube 44 is heated by the steam, and its moisture content is evaporated, resulting in attachment of salt, shoyu, sake, vinegar, edible oil, etc. to the seasoning liquid supply tube 44 in a short period of time and giving rise to the clogging of the supply ports 46. Behind the space 43, an ingredient feeder 47 is provided for supplying finely sliced vegetables, meats, fish and other ingredients to rice on the belt conveyor 12.

The ingredient feeder 47 includes an ingredient tank 48, an ingredient guide 49 provided at the lower end of the ingredient tank 48 and a shutter 50. The ingredient guide 49 has an outlet facing a laterally central portion of the belt conveyor 12. The ingredient feeder 47, like the seasoning liquid supply tubes, is desirably provided at a position free from the access of steam from the steam chambers 13 for the ingredients will be dried and deteriorated if heated by steam. Therefore, the ingredient feeder 47 may be provided in the space 43, or the space 43 may be rearwardly shifted in position so that the ingredient feeder 47 is found ahead of the space 43.

The top wall 24 is provided with exhausting members 51 to 54 respectively of the primary steaming unit 2, immersing unit 3, space 43 and secondary steaming unit 4. Each exhausting member is

1750/2197

connected to an exhausting fan (not shown). Reference numeral 55 designates a motor for the belt conveyor 5; 56, a motor for the belt 10; 57, a motor for the stirrers 15 and 16; 58, a motor for the stirrers 17 and 18; 59, a motor for the belt conveyor 12; 60, a motor for the stirrer 19; and 61, an operating unit.

OPERATION

In the use of this apparatus, rice which was immersed in water for a predetermined period of time is stored in the tank 1, and then the shutter is opened. As a result, the rice is allowed to fall onto the belt conveyor 5 to be conveyed as a layer having a predetermined thickness on the conveyor 5 to the immersing unit 3. During this time, the rice is heated by steam at about 100 DEG C. supplied from the steam discharge tubes 7 into the steam chambers 6 and rising through the steam passage holes in the conveyor.

The rice supplied to the water tank 8 is fed by the material push-on plates 11 toward the secondary steaming unit 4 while absorbing hot water at about 85 DEG C.

The rice discharge from the water tank 8 is given a predetermined seasoning with the seasoning liquid sprayed from the supply ports 46 of the supply tubes 44 and 45 as it is stirred by the stirrers 15 and 16 while it is conveyed on the conveyor 12. Since the supply tubes 44 and 45 are provided in the space 43, which is free from intrusion of steam from the steam chamber 13, the seasoning liquid at this time is never heated, that is, it will not attach the supply tubes 44 and 45 near the ports 46. Thus, it is possible to supply the seasoning liquid stably and uniformly.

The rice having been seasoned is supplied with vegetables, meat, fish and other ingredient, followed by stirring by the stirrers 17 and 18. Thus, the ingredient are uniformly mixed with the rice. Since the ingredient feeder 47, like the seasoning liquid supply tubes, is free from heating by steam from the steam chambers 13, it is possible to avoid drying of the ingredients.

The rice conveyed forwards by the conveyor 12 is exposed to steam at about 110 DEG C. to 130 DEG

C. supplied from the steam chambers 13 to be steamed to obtain seasoned steamed rice, which is then discharged to vessels directly or to a separate belt conveyor.Data supplied from the esp@cenet database

- Worldwide Claims:


What is claimed is:

1. An apparatus for continuously cooking rice by steaming comprising: a tank for storing rice after being immersed in water; a first conveyor for conveying rice supplied from said tank; a primary steaming unit for exposing rice being conveyed on said first conveyor to steam; a water tank for immersing rice discharged from said first conveyor to water at a high temperature; conveying means for forwardly conveying rice in said water tank; a second conveyor for conveying rice discharged from said water tank; a seasoning liquid feeder provided above an inlet end of said second conveyor for suppling a seasoning liquid such as salt, shoyu, sake, vinegar, edible oil to rice being conveyed; an ingredient feeder provided above an inlet end of said second conveyor for supplying vegetables, meat, fish and other ingredients to rice being conveyed; and a secondary steaming unit disposed behind said seasoning liquid feeder and ingredient feeder for exposing rice being conveyed on said second conveyor to steam.

2. The apparatus according to claim 1, wherein a space free from intrusion of steam from said secondary steaming unit is formed above an inlet end of said second conveyor, said seasoning liquid feeder being disposed in said space.

3. The apparatus according to claim 2, wherein said ingredient feeder is provided ahead of said space.

4. The apparatus according to claim 1, wherein a stirrer for stirring rice on said second conveyor is provided at a position behind said seasoning liquid feeder.

1751/2197

5. The apparatus according to claim 1, wherein stirrers for stirring rice on said second conveyor are provided behind said seasoning liquid feeder and ingredient feeder, respectively.Data supplied from the esp@cenet database - Worldwide

1752/2197

374.

US4886675 - 12/12/1989

FAST-COOKED GRANULAR RICE PRODUCT AND METHOD OF

PRODUCTION THEREOF


Inventor(s): JODLBAUER HEINZ D (DE)

Applicant(s): JODLBAUER INTECH GMBH (DE)


IP Class: A23L1/168; A23P1/12

E Class: A23L1/168



Family: JP63287452

Equivalent:

Abstract:

EP0291566; JP63287452; DE3716467


Fast-cooked granular rice product, consisting of the rice components obtained as byproducts in producing table rice from raw rice and comprised of husking flour, scouring flour, polishing flour and broken rice, including 20 to 40% by weight of water, related to the weight of the anhydrous components, partly agglutinated and granulated.Description:


The invention relates to a fast-cooked rice product and a method of production thereof.

To obtain polished rice, also called table rice or white rice, raw rice is first freed from undesirous foreign matters and thereafter the dehusked grains are sorted according to their thickness. This improves the husking effect and reduces the occurrence of fracture upon husking. The husked product passes over sorting sifters which withdraw husking flour and broken rice. Thereafter the husks are drawn off. The separation of unhusked and husked grains (brown rice) takes place by the so-called paddy selection tables. The paddy rice must be rehusked once again, whereas the brown rice is subjected to the scouring step.

Scouring takes place at an emery-covered cone which rotates in a stationary wire shell. The rice has to pass up to four such scouring cones, until the pericarp which is the fruit or seed vessel, but also germs and the aleurone layer are abraded and each drawn off through the wire shell.

To remove last remnants from the grains and lend them a smooth appearance, a polishing cone is arranged therebehind which is covered with leather strips rather than emery. Polishing yields the socalled polishing flour. Finally the white rice obtained is freed from fragments and sorted according to size via sorting sifters.

In the above-described process in the rice mill the chief amount of the vitamins and minerals of the whole-meal rice are removed with the pericarp and the aleurone layer.

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The approximate gain rates in processing raw rice to table rice are as follows: 45 to 55% white rice

(table rice), 9 to 17% broken rice, 7 to 12% husking and scouring flour, 20 to 24% husks and other offals.

The amount of vitamins is substantially higher in the milling products than in the kernel.

The same applies also to the minerals. Of the total ash content of the brown rice the white rice contains only 28%, the germ 10%, the scouring flour 51%, though.

About half the total amount of phosphor contained in the brown rice is in the "husk", about 8% in the kernel, and about 42% in the endosperm.

The marinal layers of the brown rice, as the germ, are rich in protein and fat, so that the content of said two matters are about twice as high (raw protein) or higher by a multiple (raw fat) in the scouring flour than in the white rice. As to the amino acid composition, the amount of cystine, glycine, histidine and in particular lysine is higher in the scouring flour than in the white rice, the amount of glutaminic acid, leucine and phenylalanine is, however, lower.

Whole-meal granules are equal to whole-meal rice.

The above explanations reveal that the most nutritious components of the unhusked rice grain are no longer present when the rice is used as human food, since especially high-lysine proteins, the vitamins and the minerals are separated by the processing of the rice.

The components resulting from husking, scouring and polishing of the raw rice are hitherto used as fodder (see the manual "Die Reismullerei" by Kurth Fischer, published by Moritz Schafer, Detmold, page 83). Broken Broken rice is converted to grits and starch.

JP-A2 59-192047 (JP-Z. Patent Abstracts of Japan, Vol. 9, 1985, No. 52, C-269) teaches that the bran of a particular particle size distribution obtained upon grinding cereals and mixed with water is extruded as binderfree pellets. Such procedure is inapplicable to the rice components obtained as byproducts upon processing raw rice to table rice, because the water binding capacity is much too low.

JP-A2 60-66957 (dito No. 196, C-297) proposes to roast specific fractions obtained upon polishing rice, to granulate the brown powder and dry it in the moving bed and spray it with a binder. This method is complicated; only a certain part of the byproducts obtained upon treating raw rice is used, so that the final product fails by far to contain all nutritious components. And, finally, the product additionally contains a binder.

German Disclosed Specification No. 28 37 294 describes the production of a low-calory article of food on the basis of bran. Bran, in particular wheat bran, is mixed with gluten and wheat flour, water is then added and the resultant mixture is passed through a dual-worm extruder in which the temperature rises from 80 DEG to 220 DEG C. At this temperature the components of the mixture are drastically reduced, so that the nutritive quality of the final product is necessarily low. In addition, the starting materials are incomparable with broken rice, husking flour, scouring flour and polishing flour from rice.

The object of the present invention is to provide a rice product which combines three desirous properties. It contains the nutritious substances of raw rice that hitherto were lost for human food as byproducts in the production of table rice; it has the appearance of table rice, and has only a very short cooking time to be ready. Moreover, a method is provided to produce such rice product.

It has been found that all byproduct components ie husking flour, scouring flour, polishing flour and broken rice, obtained in converting raw rice into table rice (white rice), can be combined into a product which contains unchanged the nutritious components which are contained in the raw rice, especially in the marginal layers of brown rice. The product has the form similar to that of table rice, and it is cooked in a very short time of about 3 to 4 minutes.

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In accordance with the invention, the product is obtained in that the rice byproduct components are mixed with a certain amount of water, and that the mixture is passed through a single-worm extruder in which the mixture is compressed to a certain extent and is heated from room temperature at the filling aperture of the extruder to about 110 DEG C. at the exit nozzle. This causes soaking, partial hydrolysis and finally agglutination of the starch contained in the byproduct components, whereby the required cohesion is ensured. The temperature is high enough so that partial hydrolysis and agglutination can occur, but, on the other hand, low enough so that the danger of reduction of carbohydrates and proteins or killing of B1 vitamin exists not at all or only minimally. Moreover, the water evaporates so that a dry product is obtained.

The feature of obtaining the product in the form of granules substantially of the size of table rice is achieved in a simply manner in that a multihole nozzle is used as extruder nozzle whose holes have the diameter of the desirous granule thickness, e.g. of 1 to 5 mm. The thin ropes emerging from the extruder nozzle cool quickly and are then cut to the desirous granule length of 5 to 10 mm. A granule size of 1.5 mm in thickness and 8 mm in length is preferred.

According to a preferred embodiment of the invention, the product is also post-dried so that the moisture content is maximally 6% by weight. Thereafter the product is durable for a long time. If, however, the product is to be used soon, post-drying can be omitted. Also refrigeration of the semifinished product, e.g. as semi-preserve is possible.

According to another preferred embodiment, salt and/or curry or another spice is added to the mixture of the byproduct components and water. Obtained thereby is a particularly delicious rice product to which no seasonings need be added later.

The byproduct components are mixed with so much water as required to soak for partial or full agglutination. The byproduct components received from the rice mill have normally a moisture content of 8 to 14% by weight. Under this premise, 12 to 24 kg water are required for 100 kg byproduct components. In the case of a moisture conent of e.g. 11% by weight 18 kg of water are required for 100 kg of byproduct components.

Mixing can be executed in any known mixer, such as a paddle mixer, a mixer provided with magnetic agitators, or a drum mixer.

The worm extruder used is a single-worm extruder. It is heatable. Worm length and compression depend of course on the size of the charge amount. In the case of a total charge of about 120 kg

(byproduct components plus water) a worm extruder having a worm of 90 mm in diameter, a worm length of 1500 mm and a compression of 2:1 has proved expedient. Preferably the compression in the first third is from 100% by volume to 75% by volume and in the second and third thirds from 75 to

50%. It is sufficient to set the extruder wall to a relatively low temperature, e.g. to 40 DEG to 60 DEG

C. Since the mass is heated owing to the compression (in respnse to the worm speed), the resultant mass temperature at the exit nozzle is 100 DEG to 110 DEG C. The rise in temperature is conducive to the hydrolysis and agglutination and the evaporation of the water, so that a generally dry product is obtained.

The ropes emerging from the multihole nozzle are then cut into granules of desired length. To this end, a rotary circular knife or timed drop knives or any other suitable cutting device can be used.

When the granular rice product is post-dried to still further improve its durability, this can be done by any known method, e.g. in a hot-air stream, via IR radiation or the like. Also a microwave treatment for surface drying purposes or layer drying of the extruded granule is favourable. The rice granules can also be specifically re-moistured (penetration depth e.g 2 mm) to be thereafter exposed to a high microwave dose so as to achieve drying to a predetermined depth and e.g. a desired browning effect. A further possibility consists in spraying the rice granule with a concentrated sugar solution, thereby obtaining a frosted rice granule upon microwave treatment. Such product is particularly suitable for making rice pudding for instance.

The rice product obtained, as table rice, can be cooked in water at about 100 DEG C., the product being, however, already ready after 3 to 4 minutes.

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The invention will now be described by way of an exemplary embodiment to which the invention is not restricted, however.

A paddle mixer was filled with

100 kg of a mixture received from the rice mill and containing approximately 50 kg of husking, scouring or polishing flour, up to about a third of each, and 50 kg of broken rice having a moisture content of about 11%,

18 l water at a temperature of 18 DEG C.,

1.5 kg salt,

2.0 kg curry.

The above components were well mixed and subsequently fed into a single-worm extruder having a worm of 90 mm in diameter and a worm length of 1.500 mm. The spiral volume decreases in the first third of the worm from 100% to about 75%, in the second and third thirds to about 50% of the initial volume, so that an increasing pressure with respect to the exit nozzle was build up in the extruder. The mass temperature before the exit nozzle was at 110 DEG C.

The nozzle included a plurality of round nozzle bores of a diameter of 1.2 mm. Before the nozzle is arranged a rotary cutting knife which cuts each of the ropes emerging from the nozzle bores into lengths of about 7 to 10 mm.

The elongated rice-like granules obtained were dried via hot air to a moisture conent of about 6% to reduce the water activity of the granular product and thus ensure a higher durability.

The drying process can be varied depending upon the desired moisture content, is dispensable, though.

A very delicious product was obtained which has the typical curry rice flavour, is of high quality in terms of physiology of nutrition and is made of a very cheap raw material.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A granular rice product comprising rice components obtained as byproducts in producing table rice from raw rice, the rice components comprising husking flour, scouring flour, polishing flour and broken rice, including 20 to 40% by weight of water, related to the weight of the anhydrous components, partly agglutinated and granulated.

2. The rice product as in claim 1, characterized by a granule length of 5 to 10 mm and a granule diameter of 1 to 5 mm and a moisture content of maximally 6% by weight.

3. The rice product as in claim 1, characterized by an additional amount of 0.1 to 0.3% by weight of salt or curry or both salt and curry.

4. A method of producing rice product characterized in that 100% by weight of a mixture of rice components obtained as byproduct in processing raw rice and comprised of husking flour, scouring flour, polishing flour and broken rice with an average moisture content in the range of 8 to 14% by weight is well mixed with 12 to 24% by weight of water; said mixture is passed though a heated singleworm extruder for partial hydrolysis and agglutination, the extruder having a certain compression and provided with a multihole nozzle with a hole diameter of 1 to 5 mm; and the emerging ropes are cut to the desirous granule length.

5. Method as in claim 4, characterized in that a mixture of 100% by weight of the byproduct components with a moisture content of 11% by weight and 18% by weight of water at 18 DEG C. is used.

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6. Method as in claim 4, characterized in that 0.1 to 0.3% by weight of salt or curry or both salt and curry is added to the mixture comprised of the byproduct components and water.

7. Method of claim 4, characterized in that an extruder with a compression of about 2:1 is used, and that the surface temperature is set to about 40 DEG to 60 DEG C. so that the temperature of the mass at the exit nozzle is between 100 DEG and 110 DEG C.

8. Method of claim 4, characterized in that a single-worm extruder including a worm with 90 mm in diameter and 1500 mm in length is used, the spiral volume being reduced in the first third from 100 to

70% of the initial volume and in the second and third thirds to 50% thereof.

9. Method of claim 4, characterized in that the granular product obtained is post-dried via hot air to a moisture content of maximally 6% by weight.

10. Method of claim 4, characterized in that drying takes place via microwaves.

11. Method as in claim 10, characterized in that a specific humidification takes place prior to the drying step.

12. Method as in claim 10, characterized in that humidification with a sugar solution is performed prior to the drying step.Data supplied from the esp@cenet database - Worldwide

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375.

US4888180 - 12/19/1989

A METHOD OF PREPARING GRAIN CAKES


Inventor(s): WU REI-YOUNG (US)

Applicant(s): QUAKER OATS CO (US)


IP Class: A23L1/18; A23L1/14

E Class: A23L1/10H2; A23L1/18C2



Family: US4888180

Abstract:


An improved grain cake, method and apparatus. In the prior art, rice cakes have been made by heating a predetermined quantity of rice grains in a hermetically sealed chamber at superatmospheric pressure and then expanding the heated rice grains while they are confined to the chamber by abruptly releasing the superatmospheric pressure such that the confined, expanded grains bond together to form a selfsupporting mass. The improvement of this invention comprises pretreatment of cereal grains, including rice, wheat, rye, corn and the like, by steaming the cereal grains to bring them to an effective temperature to partially gelatinize the starch therein and to maintain the cereal grains at the effective temperature for an effective period of time to produce a desired degree of expansion when puffed in a conventional rice cake machine. The resulting grain cakes have increased expansion and reduced fragility over those made by prior art pretreatment methods.Description:


BACKGROUND

The present invention relates to puffed food products made from cereal grains in the shape of a small cake or cracker, and the method and apparatus for their manufacture.

Cereal puffing methods are well established in the prior art. For example, gun puffing has long been used to produce discrete, highly expanded cereal products such as puffed wheat or puffed rice. In a typical gun puffing operation, a raw whole grain is placed into a relatively large chamber and a hinged lid is secured. The chamber is then pressurized with steam. After a time, when the chamber has reached a desired pressure and temperature, a lid release mechanism is activated which allows the lid to open suddenly. In the resulting explosion of steam and grain from the chamber, individual grain particles become plastic and undergo rapid expansion until they are many times larger than they were when first placed into the chamber. During the time when the cereal grains are expanding, they are inherently cohesive and adhesive but they do not bond together because the grain particles have little opportunity to contact each other. They are propelled separately from the puffing chamber while they are in the cohesive/adhesive condition and therefore have no opportunity to become bonded together.

Similarly, puffing methods which do not add moisture to the grains during the puffing process but which instead rely only on the moisture in the cereal grains are also well known in the art. An example

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of such a method is the expansion of cereal grains (especially rice) in an enclosed chamber to produce a puffed food product in the shape of a small cake or cracker.

The apparatus capable of forming such rice cakes is well known. For example, in the 1973 patent to

Omer Gevaert (Belgian Patent No. 799,316) an apparatus is disclosed in which a measure of cereal grains is mechanically fed onto a heated piston. The piston and cereal grains are then advanced by a hydraulic cylinder into a heated female mold to create a small, hermetically sealed chamber enclosing the cereal grains. Heat and superatmospheric pressure are thereby applied to the cereal grains until, at a predetermined time, the pressure in the chamber is suddenly released by retracting the hydraulic cylinder. The suddenly depressurized chamber is not, however, sufficiently opened to release the cereal grains by the retracting of the cylinder, but is instead retained in a substantially closed but vented position by a locking device. Therefore, as the pressure is released, the cereal grains expand to substantially fill the chamber and while still in the plastic state bond together to form a small cake or cracker. The locking device is then released, the piston is fully retracted to open the chamber, and the cake is mechanically ejected. Similar devices are disclosed in U.S. Pat. Nos. 4,281,593 issued to

Gevaert, 4,328,741 issued to Yoshikazu and 4,667,588 issued to Hayashi.

These cake-forming devices are most frequently used with rice as the cereal grain since rice is capable of relatively easy expansion into a self-supporting cake. The rice used in the process is typically pretreated by washing and tempering steps. For example, in U.S. Pat. No. 4,328,741, the rice at a moisture content of about 15% to 16% is first cleaned by a rice washing machine and received in a basket to be left for 15 to 20 minutes to remove water. The moisture content of the rice immediately after washing is about 30%. Following the addition of salt to the rice, it is dried for a day and then is further dried in a drying machine for two or three hours to a moisture content in the range of 15% to

20%. The rice thus prepared is then ready to be loaded into the rice cake apparatus.

Even though rice pretreated by moisture adjustment and tempering as employed in the prior art expands to form cohesive rice cakes when expanded in a rice cake machine, other cereal grains, when essentially the same pretreatment is applied, expand less readily and form cakes which are both more dense and more fragile than rice cakes. Another problem with the pretreatment of rice by moisture adjustment and tempering as practiced in the prior art is the time required to temper the rice. Yet another problem with prior art rice cakes is their relative fragility and susceptibility to breakage during packaging and shipment.

It is therefore an object of the present invention to provide a grain cake from such cereal grains as wheat, rye, corn, oats, millet, sorghum, barley and buckwheat in which the cereal grains are more highly expanded than those in the prior art.

It is also an object of the present invention to provide a grain cake from such cereal grains as wheat, rye, corn, oats, millet, sorghum, barley and buckwheat which is less fragile than those in the prior art.

It is also an object of the present invention to provide a method for making grain cakes from such cereal grains as wheat, rye, corn, oats, millet, sorghum, barley and buckwheat which employs the same puffing apparatus now used to make rice cakes.

It is also an object of the present invention to provide a grain cake from rice which is less fragile than those in the prior art and less susceptible to breakage during packaging and shipment.

It is also an object of the present invention to provide a method for making grain cakes from rice, wheat, rye, corn, oats, millet, sorghum, barley and buckwheat in which the time required for their pretreatment is reduced.

It is also an object of the present invention to provide an apparatus for pretreatment of such cereal grains as rice wheat, rye, corn, oats, millet, sorghum, barley and buckwheat for the manufacture of grain cakes.


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These and other objects are accomplished by the present invention. I have discovered in a method for making a puffed, cake-shaped food product by heating a predetermined quantity of cereal grains in a hermetically sealed chamber at superatmospheric pressure and then expanding the heated grains while they are confined to the chamber by abruptly releasing the superatmospheric pressure such that the confined, expanded grains bond together to form a self-supporting mass, an improvement which comprises pretreatment of the cereal grains by steaming the cereal grains to bring them to an effective temperature to partially gelatinize the starch therein and to maintain the cereal grains at the effective temperature for an effective period of time to produce a desired degree of expansion in the final product.

In a preferred embodiment of the present invention, the moisture content of the cereal grains is first adjusted by adding any water needed to bring the desired cereal grains or cereal grain mixture to a moisture content in the range of about 12% to about 18%. In some cases, the cereal grains may be stored at a moisture in the desired range and will not require the addition of water. While the cereal grains are in an unpressurized container, steam is applied to the grains. Steam at a pressure of about 35 psi could be used to initially raise the temperature of the grains into the desired range followed by steam at a pressure of about 15 psi to continue the steaming of the cereal grain for the desired period of time. The steaming takes place for a period of time and at a temperature required to partially gelatinize the starch in the grain. That time and temperature depends on the particular cereal grain which is being steamed, the moisture content of the cereal grain and the desired degree of expansion in the final product. For example, wheat at a moisture content of 14% could be steamed at about 205 degrees F. for about four minutes to produce a highly expanded product. Also, for example, corn at a moisture content of 15% could be steamed at about 205 degrees F. for about 20 minutes to produce a highly expanded product. Following steaming, the cereal grain is preferably dried to a moisture content of less than about 18% to facilitate loading of the steamed cereal grains into the cake-forming apparatus.

The following detailed description further describes preferred embodiments of the invention to those skilled in the art and further distinguishes the invention from the prior art.


FIG. 1 is a flow sheet drawing showing the various steps employed in an embodiment of the present invention.

FIG. 2 is a schematic drawing showing an industrial embodiment of the present invention.

FIG. 3 is partly cut-away perspective view of the steamer apparatus of FIG. 2.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, the cereal grains rye 1 and wheat 2 are first combined with water 3 to adjust the moisture of the cereal grains into the desired range. These ingredients are typically combined by mixing 5 the rye 1 wheat 2 and water 3 for a short period. The combined ingredients are then subjected to steaming 10. Steam 12 is admitted to a steamer until the temperature of the combined ingredients has been raised to the desired level and until the grain has been steamed for the desired period of time.

Further mixing 5 may be undertaken during steaming 10 in order to provide a uniform temperature to the combined ingredients. Following steaming 10, drying 15 of the mixed ingredients may be undertaken to bring the moisture content of the mixed ingredients into a desired range. The dried ingredients are then ready for puffing 20 in a conventional rice cake machine.

Referring now to FIG. 2, the present invention may be practiced industrially such that one or more rice cake machines 100 can be continuously supplied with ingredients treated in accordance with the present invention. The process of the present invention is started by sending untreated ingredients by a conveyor 110 from storage bins 115, 117 into a steamer 120. The untreated ingredients can include the cereal grains and any other materials desired in the final product. The steamer 120 includes a chamber

125 and a shaft 130 with attached agitator blades 132 (the agitator blades may be those of a conventional ribbon blender). The shaft 130 extends axially along the chamber 125 and may be rotated

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by a motor 134. The steamer 120 also contains a hinged cover 140 to admit untreated ingredients and an closeable outlet 145. The steamer 120 is also connected to a source of steam 150, and a source of water 155 by steam lines 151 and water lines 156 respectively.

Still referring to FIG. 2, in operation, while the closeable outlet 145 remains closed, the steamer 120 is provided with untreated ingredients from the storage bins 115, 117 through the conveyor 110 and sufficient water 155 is provided through the water lines 156 to raise the moisture content of the untreated ingredients into the desired range. The motor 134 is then activated for a short period of time to turn the shaft 130 and agitator blades 132, thereby mixing the contents of the steamer 120. Following this short mixing period, steam 150 is admitted through the steam lines 15 to the steamer 120 while the motor 134 is activated intermittently or very slowly to promote even heating of the ingredients.

When the untreated ingredients have been steamed at the desired temperature and for the desired time, the closeable outlet 145 is opened and the steamed ingredients which include cereal grains in which starch has been partially gelatinized, are transferred by conveyor 160 to a first surge tank 170, and then by conveyor 180 to a rotary dryer 190 of conventional design having an inlet 192, a rotatable drum

194, and outlet 196, a motor 198 for rotating the drum 194 and, Optionally, a source of heat (not shown). During the drying operation, the addition of heat to the dryer 190 may not be required since the steamed ingredients normally retain sufficient heat from the steaming step to dry them to a desired moisture content.

When the dried and cooled, the treated ingredients which include cereal grains in which starch has been partially gelatinized, are discharged from the dryer 190 and sent by conveyor 200 into a second surge tank 210 and then from the second surge tank 210 by conveyor 220 to individual rice cake machines

100. It should be noted that although FIG. 2 may give the impression that the equipment depicted is operated in a continuous rather than a batch mode, it should be apparent from the above description that individual pieces of equipment can be operated in a batchwise process while the surge tanks can, if desired, provide for a continuous supply of treated ingredients to the rice cake machines 100.

Referring now to FIG. 3, the steamer 120 includes a chamber 125 and a shaft 130 with attached agitator blades 132 (the agitator blades may be those of a conventional ribbon blender). The shaft 130 extends axially along the chamber 125 and may be rotated by a motor (not shown). The steamer 120 also has a hinged cover 140 which may be opened to admit untreated ingredients to the steamer 120 and a closeable outlet 145. The steamer 120 is also connected to a source of steam (not shown) connected by a steam line 151 to spargers 152 and a source of water (not shown) connected by a water line 156.


The grain cakes of the present invention are made in a conventional rice cake machine by heating a predetermined quantity of cereal grains in a hermetically sealed chamber at superatmospheric pressure and then expanding the heated grains while they are confined to the chamber by abruptly releasing the superatmospheric pressure such that the confined, expanded grains bond together to form a selfsupporting mass. The improvement of the present invention comprises pretreatment of the cereal grains by steaming the cereal grains to bring them to an effective temperature to partially gelatinize the starch therein and to maintain the cereal grains at that temperature for an effective period of time to produce a desired degree of expansion in the final product. The improvement may also comprise a step in which water is added to the cereal grains to bring them into a desired moisture range for steaming and a step in which the cereal grain is dried to a desired moisture content after steaming. The resulting grain cakes have improved properties over those made by methods taught in the prior art, including improved expansion and reduced fragility.

The apparatus for forming rice cakes referred to herein is a conventional apparatus for forming rice cakes which employs the steps of heating a predetermined quantity of cereal grains in a hermetically sealed chamber at superatmospheric pressure and then expanding the heated grains while they are confined to the chamber by abruptly releasing the superatmospheric pressure such that the confined, expanded grains bond together to form a self-supporting mass. Machines which form rice cakes by this method are as disclosed in U.S. Pat. Nos. 4,281,593 issued to Gevaert or as disclosed in 4,328,741 issued to Yoshikazu or as disclosed in 4,667,588 issued to Hayashi. These patents are hereby incorporated by reference.

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The term cereal grains as used herein refers to the seeds or fruits of the various cereal grasses and shall specifically include rice, wheat, corn, rye, oats, millet, sorghum, barley and buckwheat. Such cereal grains need not be used whole in the present invention, but may instead be processed to remove the hull, husk or germ portion of the seed or to be ground to a desired size. The most preferred cereal grains include pearled durham wheat, long-grained brown rice, and degerminated coarse ground yellow corn. To provide satisfactory grain cakes with cereal grains such as oats which are known to expand poorly in conventional gun puffing, they should be used in the present invention only in grain cake formulations which combine them with major amounts of other cereal grains.

Referring again to FIG. 1 but now in greater detail, cereal grains such asrye 1 and wheat 2 may first be combined with water 3 to adjust the moisture of the cereal grains into a desired range. The desired moisture content is a moisture content which will provide both the desired degree of expansion in the final product and which will be capable of being easily handled once the cereal grains have been steamed (in some cereal grains, high moisture contents can cause the cereal grains to stick together after steaming). Moisture contents in the range of about 12% to about 18% have been found to be acceptable and a moisture content in the range of about 14% to about 16% is preferred for the most common cereal grains such as corn, wheat or rice, although the moisture requirement for the best result in the final product may vary according to the cereal grain used. If the moisture content of the cereal grain is already in a desired range, no water is to be added. If the moisture content of the cereal grain is below a desired range, the ingredients can be combined and moistened by mixing 5 the cereal grains such as rye 1 and wheat 2 together with an appropriate quantity of water 3 to produce the desired moisture content. A short mixing time with gentle mixing is desired to prevent breakage of the cereal grains which would produce fine cereal pieces in the final product. A mixing time of about one minute in a ribbon blender has been found to be acceptable. Other mixing times and methods can also be used as those skilled in the art will readily appreciate.

The combined ingredients are then subjected to steaming 10. The steaming 10 is preferably conducted in a steamer with the same capability for gentle mixing as that described above. The steaming 10 and mixing 5 are also preferably and conveniently conducted in the same combined steaming and mixing apparatus. Steam 12 is admitted to the steamer to raise the temperature of the combined ingredients to the desired level. The desired temperature for the present invention is an effective temperature to partially gelatinize starch in the cereal grains.

The term "effective temperature to partially gelatinize" or the term "effective temperature" as used herein means a temperature required, if applied for a period of time, to heat and swell starch granules such that the starch granules become softer, more flexible, and readily digestible by enzymes, even though the starch granules may retain much of their crystallinity and may not have lost birefringence when viewed under a polarizing microscope. The term alphalyzation is sometimes used interchangeably with the term partial gelatinization in the cereal processing art in connection with these effects. Complete gelatinization of the starch (loss of birefringence) could also result in the present invention at the effective temperature if the moisture content in the cereal grains were sufficient to permit gelatinization. At the preferred moisture contents of the present invention, however, (about 12% to about 18% in the cereal grain prior to steaming) gelatinization is inhibited and, as a result, the cereal grains are only partially gelatinized. The "effective temperature to partially gelatinize" or the "effective temperature" is therefore essentially the same as the temperature required to gelatinize the starch in the cereal grains as set forth in standard reference works. Accordingly, the temperature required in the present invention is at or above the well known gelatinization temperature for the particular cereal grains being steamed. According to Osman (Osman, E. M. in Starch: Chemistry and Technology, Vol.

II, P. 163, R. L. Whistler and E. F. Paschall, eds., Academic Press, New York, 1967) the gelatinization temperature for wheat is in the range of about 59.5-64 degrees C., the gelatinization temperature for corn is in the range of about 62-70 degrees C. and the gelatinization temperature for rice is in the range of about 68-78 degrees C. Therefore, temperatures at or above these gelatinization temperatures must be employed as an "effective temperature to partially gelatinize" or "effective temperature" in the present invention.

Temperatures above the gelatinization temperatures identified above are generally preferred in order to shorten the time required to provide the desired treatment to the cereal grains. Preferred steaming temperatures are in the range of about 190 degrees F. to about 210 degrees F. since these temperatures

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are adequate to provide a short processing time and since they are the highest temperatures that can be readily achieved by steaming in inexpensive unpressurized equipment. Higher or lower temperatures can, however, be used in the present invention, as desired. The steam provided to the steamer can be at a wide range of pressures. For example, 50 psi steam or 15 psi steam could be used. A preferred procedure for steaming is to use higher pressure steam initially, for example, 30-50 psi steam, to rapidly bring the cereal grain to a temperature in the preferred range (e.g. 190-210 degrees F.) and then to use steam at pressures up to about 15 psi to maintain that temperature for the desired processing time. This dual pressure steaming provides a rapid processing cycle for the cereal grain in the steamer.

Mixing 5 is preferably undertaken during steaming 10 in order to provide a uniform temperature to the cereal grains. When following the preferred dual pressure steaming procedure heretofore described, the preferred procedure is to mix intermittently or very slowly while the higher pressure steam is applied and then to leave the mixer off when the lower pressure steam is applied. For example, the mixer could be run on a one minute on three minute off pattern to provide adequate temperature uniformity in the cereal grains during the initial steaming phase.

Once the cereal grain has reached an effective temperature during steaming 10 to partially gelatinize the starch therein, it is to be maintained at the effective temperature for an effective period of time to partially gelatinize the starch in the cereal grains to the extent required to produce a desired degree of expansion in the final product. The effective period of time can vary substantially according to the desired degree of expansion in the final product, the particular cereal grain being steamed and the moisture content of the grain. If a relatively great degree of expansion of cereal grains is desired in the final product, a longer period of time for steaming may be required. Also, if the moisture content of the cereal grains is relatively low, a relatively longer period of time for steaming would be required to achieve the same degree of expansion in the cereal grains. When steamed according to the preferred steaming procedure recited above, an effective period of time required for a high degree of expansion in wheat and rye can be about two minutes to eight minutes while the effective period of time required for a high degree of expansion in corn can be about ten minutes to thirty minutes. The moisture content of the cereal grains following the preferred steaming procedure is typically in the range of about 18% to 25%.

It will be readily recognized by those skilled in the art that although the preferred embodiment disclosed above employs cereal grains which have been premixed prior to steaming 10, the present invention can also be practiced by treating individual cereal grains in accordance with this invention and then mixing them in the proportions desired in the final grain cake product. It will also be recognized that either preceding or following steaming 10, the cereal grains may be mixed with seasonings to produce a desired flavor, texture or appearance in the final product. For example, salt, flavors or colors may be added either before or after steaming 10. Also, for example, cereal grains which are not desired to be greatly expanded in the final product may be combined with cereal grains which have been treated in accordance with the present invention.

Drying 15 of the steamed ingredients may then be undertaken to bring the moisture content of the steamed ingredients into a desired range. Although drying 15 is not required in the present invention to produce a highly expanded grain cake, a drying step is usually desirable in order to improve the behavior of the steamed cereal grain in mechanical handling systems. Cereal grain at moisture contents above about 18% tends to clump and stick during mechanical conveying. In particular, it can produce uneven feeding in conventional rice cake machines. By drying the cereal grains to a moisture content below about 18%, their mechanical handling can be considerably improved. This can be accomplished in conventional rotary drying equipment suitable for use with cereal grains. Since the steamed cereal grains are at a high temperature as they exit the steamer, drying 15 can usually be accomplished with the addition of very little or no heat from the dryer.

The dried ingredients are then ready for puffing 20 in a conventional rice cake machine as heretofore described. No modifications to the rice cake machine are required to make grain cakes from the dried ingredients. As those skilled in the art will readily appreciate, minor changes in operating conditions such as temperature and closing pressure for the puffing chamber may be desired for optimum operation.

1763/2197

Referring again to FIG. 2 and FIG. 3 but now in greater detail, the present invention may be practiced industrially such that one or more rice cake machines 100 can be continuously supplied with treated ingredients which include cereal grains in which starch has been partially gelatinized. The process of the present invention is started by sending untreated ingredients by conveyor 110 from storage bins

115, 117 into a steamer 120. The untreated ingredients can include the cereal grains and any other materials desired in the final product. For example, wheat and rye can be taken from bulk storage bins

115, 117 and individually metered into the conveyor 110 by conventional means. Alternatively, wheat, rye and other materials could be premixed prior to being metered into the conveyor 110 and then into the steamer 120.

The steamer 120 includes a chamber 125. Although not required in the present invention, the chamber

125 may, if desired, be a chamber capable of containing steam at superatmospheric pressure and may be insulated to reduce heat loss during operation. The steamer 120 also includes a shaft 130 with attached agitator blades 132 (the agitator blades may be those of a conventional ribbon blender). The shaft 130 extends axially along the chamber 125 and may be rotated by a motor 134. The steamer 120 also has a hinged cover 140 which may be opened to admit untreated ingredients and an closeable outlet 145. The steamer 120 is also connected to a source of steam 150 connected by at least one steam line 151 and a source of water 155 connected to the steamer by at least one water line 156. Spargers

152 allow steam to enter the chamber 125 while preventing ingredients from entering the steam lines

151. The steam lines 151 should be free of condensate and the steamer 12 itself should be substantially dry when the untreated ingredients are conveyed into the steamer 120.

Still referring to FIG. 2, in operation, while the closeable outlet 145 remains closed, the steamer 120 is provided with untreated ingredients from the conveyor 110 and sufficient water 155 to raise the moisture content of the untreated ingredients into the desired range. The amount of water to be added is the difference between the amount of water in the untreated ingredients and the amount of water desired in the untreated ingredients during steaming. The moisture content of untreated ingredients can be determined while they are in storage by conventional methods and equipment for determining the moisture content of cereal grains. A moisture content for ingredients to be steamed in the range of about 12% to about 18% has been found to be acceptable and a moisture content in the range of about

14% to about 16% is preferred. Of course, if the moisture content of the untreated ingredients is in the desired range, no additional water must be added. If water is added, the motor 134 is then activated for a short period of time to turn the shaft 130 and agitator blades 132, thereby gently mixing the water and untreated ingredients in the steamer 120. As those skilled in the art will readily recognize, the use of the steamer 120 for the mixing of water and untreated ingredients is merely a matter of convenience.

Other methods for adjusting the moisture of grain products would be equally applicable to the present invention. No tempering period prior to steaming is required.

Following this short mixing period, steam is admitted to the steamer 120 while the motor 134 is activated intermittently to promote even heating of the ingredients. The desired temperature for the ingredients in the present invention is an effective temperature to partially gelatinize the starch in the cereal grains as heretofore described. Preferred steaming temperatures are in the range of about 190 degrees F. to about 210 degrees F. and most preferably in the range of about 200 degrees F. to about

210 degrees F. since these temperatures are adequate to provide a short processing time and since they are the highest temperatures that can be readily achieved by steaming in an inexpensive unpressurized steamer 120. A thermocouple inserted into the mass of ingredients as they are being steamed can be used to determine whether an effective temperature has been achieved. Higher or lower temperatures than the preferred temperatures above can, however, be used in the present invention, as desired and as permitted by the steamer 120 design. The steam provided to the steamer 120 is initially preferably higher pressure steam, for example, 30-50 psi steam and most preferably about 35 psi, to rapidly bring the cereal grain to a temperature in the preferred range (e.g. 190-210 degrees F.) and preferably steam up to about 15 psi thereafter.

Once the cereal grain has reached an effective temperature in the steamer 120 to partially gelatinize the starch therein, that temperature or a higher temperature is to be maintained in the steamer 120 for an effective period of time to produce a desired degree of expansion in the final product as heretofore described. For example, an effective period of time required for a high degree of expansion in wheat and rye can be about two minutes to eight minutes and preferably about four minutes while the

1764/2197

effective period of time required for a high degree of expansion in corn can be about ten minutes to thirty minutes and preferably about twenty minutes.

When the untreated ingredients have been steamed at the desired temperature and for the desired time, the steam supply is turned off and the closeable outlet 145 is opened. As the steamed ingredients which include cereal grains in which starch has been partially gelatinized are discharged from the steamer

120, they are transferred to conventional grain handling equipment; for example, a convenient arrangement would be to transfer the steamed ingredients to a surge tank 170, and then to a dryer suitable for drying cereal grains, for example, a rotary dryer 190 having an inlet 192, a rotatable drum

194, an outlet 196, a motor 198 for rotating the drum 194. Conveyors -10, 160, 180, 200, 220 utilized in the industrial embodiment of the present invention can be conventional conveyors of various types suitable for use with cereal grains. It should be apparent to those skilled in the art that some of the conveyors described above could be eliminated depending upon the equipment used at the production facility and its arrangement within the production facility.

Although drying is not required in the present invention to produce a highly expanded grain cake, drying the steamed ingredients in a dryer 190 suitable for drying cereal grains is usually desirable in order to prevent uneven feeding in the rice cake machines 100. By drying the cereal grains to a moisture content below about 18% and preferably to a moisture in the range of about 14% to about

17%, its mechanical handling can be considerably improved. The addition of heat to the dryer 190 may not be required since the steamed ingredients normally retain sufficient heat from the steamer 120 to dry them. The steamed ingredients can usually be dried to a moisture content in the preferred range merely by tumbling them in the dryer 160 for about 10-15 minutes. As the treated ingredients 160 are discharged from an unheated dryer 190 they are typically at a temperature of about 70 degrees F. to about 90 degrees F. and a moisture content of about 14% to about 17%.

When dried and cooled as set forth above, the treated ingredients can be discharged from the dryer 190 to conventional grain handling equipment: for example, a convenient arrangement could be to transport the treated ingredients by conveyor 200 to a second surge tank 210 located near the dryer and then by conveyor 220 from the second surge tank 210 to the rice cake machines 100. As those skilled in the art will recognize, combinations of equipment other than that given above could also be used depending on the most desirable arrangement of equipment at the production facility.

The following examples illustrate and explain the present invention but are not to be taken as limiting the present invention in any way.

EXAMPLES 1-3

In an apparatus substantially as shown in FIG. 2 and FIG. 3 and as described above, grain cakes were made in accordance with the present invention by first sending untreated ingredients shown in Table 1 into an uninsulated, unpressurized steamer 120 having a 36 cubic foot capacity and ribbon blender agitator blades 132 (a modified ribbon blender model DRB-36 made by American Process Systems

Co., Gurnee, IL) while the closeable outlet 145 remained closed. Sufficient water 155 was added to raise the moisture content of the untreated ingredients as shown in Table 2. The motor 134 was then activated for one minute to turn the shaft 130 and agitator blades 132, thereby mixing the contents of the steamer 120. Following this short mixing period, 35 psi steam 150 was admitted to the steamer 120 while the motor 134 was activated intermittently on a one minute on, three minute off cycle to promote even heating of the ingredients until the desired temperature shown in Table 3 had been achieved.

When the desired temperature of the ingredients had been achieved, 15 psi steam was applied to maintain the desired temperature.

When the untreated ingredients had been steamed at the temperature and for the time set forth in Table

3, the closeable outlet 145 was opened and the steamed ingredients, at a moisture content shown in table 4, were transferred to a 40 cubic foot surge tank and from there to rotary dryers 190 of conventional design (two Aeroglide model R1-30-10NEX dryers made by Aeroglide Corporation,

Raleigh, NC connected in series) where the steamed ingredients were tumbled and dried to a moisture content and temperature shown in Table 4.

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When the dried and cooled, the treated ingredients were discharged from the dryer 190 and transferred to a 60 cubic foot surge hopper and from there to individual rice cake machines 100. When puffed and dried to a moisture content of about 3.5%, the resulting grain cakes had the density and sheer strength given in Table 5.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Ingredient (LBS)

>;tb;EXAMPLE RICE WHEAT CORN RYE TOTAL

>;tb;______________________________________

>;tb;1 1200 1200

>;tb;2 1080 84 1164

>;tb;3 588 612 1200

>;tb;______________________________________

>;tb; TABLE 2

>;tb;______________________________________

>;tb;EX- INITIAL ADDED FINAL

>;tb;AMPLE MOISTURE (%) WATER (LBS) MOISTURE (%)

>;tb;______________________________________

>;tb;1 9 70 14

>;tb;2 9 68 14

>;tb;3 12 42 15

>;tb;______________________________________

>;tb; TABLE 3

>;tb;______________________________________

>;tb; GRAIN STEAMING TIME (MIN)

>;tb;EXAMPLE TEMP (F.) 35 PSI 15 PSI

>;tb;______________________________________

>;tb;1 205 16 4

>;tb;2 205 14 4

>;tb;3 205 16 20

>;tb;______________________________________

>;tb; TABLE 4

>;tb;______________________________________

>;tb;EX- STEAMED DRYING DRIED

>;tb;AMPLE MOISTURE (%) TIME (MIN) MOISTURE (%)

>;tb;______________________________________

>;tb;1 20 13 15

>;tb;2 20 13 15

>;tb;3 22 13 16

>;tb;______________________________________

>;tb; TABLE 5

>;tb;______________________________________

>;tb;EX-

>;tb;AMPLE DENSITY (OZ/CU.FT.)*

>;tb; STRENGTH (LBS)**

>;tb;______________________________________

>;tb;1 65 0.7

>;tb;2 65 0.6

>;tb;3 68 0.5

>;tb;______________________________________

>;tb; *Calculated by stacking 7 grain cakes.

>;tb; **Measured by a shear tester made by John Chatillon & Sons, N.Y., NY

>;tb; Model LTCM operated with a 3 inch blade at 3 inches per minute.

EXAMPLES 4-16

Grain cakes can also be made by the present invention from other cereal grains and at other processing conditions. In an apparatus substantially as shown in FIG. 2 and FIG. 3 and as described above, make grain cakes in accordance with the present invention by first sending untreated ingredients shown in

1766/2197

Table 6 into a steamer 120 while the closeable outlet 145 remains closed. Add sufficient water 155 to raise the moisture content of the untreated ingredients as shown in Table 7. Activate the motor 134 for one minute to turn the shaft 130 and agitator blades 132, thereby mixing the contents of the steamer

120. Following this short mixing period, admit 35 psi steam 150 to the steamer 120 while the motor

134 is activated intermittently on a one minute on, three minute off cycle to promote even heating of the ingredients until the desired temperature in Table 7 has been achieved. When the desired temperature of the ingredients has been achieved, apply 15 psi steam to maintain the desired temperature.

When the untreated ingredients have been steamed at the temperature and for the time set forth in Table

7, open the closeable outlet 145 and transfer the steamed ingredients to a rotary dryer 190 of conventional design where the steamed ingredients are tumbled and dried.

When the dried to a moisture content below about 18% and cooled to a temperature below about 80 degrees F., discharge the treated ingredients from the dryer 190, transfer the treated ingredients to individual rice cake machines 100 and puff the ingredients into grain cakes.

>;tb; TABLE 6

>;tb;__________________________________________________________________________

>;tb;GRAIN INGREDIENTS (LBS)

>;tb;EXAMPLE

>;tb; RICE RYE

>;tb; BARLEY

>;tb; OATS*

>;tb; WHEAT

>;tb; CORN

>;tb; MILLET

>;tb; SORGHUM

>;tb;__________________________________________________________________________

>;tb;4 1200

>;tb;5 1200

>;tb;6 300 300 600

>;tb;7 250 350 100 200 200 100

>;tb;8 1000 50 50 50 50

>;tb;9 50 50 50 1000 50

>;tb;10 600 600

>;tb;11 600 600

>;tb;12 200 150

>;tb; 150 100 200 100 50 250

>;tb;13 200 200 250 200 200 150

>;tb;14 200 250

>;tb; 200 200 150 100 100

>;tb;15 450 250 500

>;tb;16 200 150

>;tb; 150 100 200 100 250 50

>;tb;__________________________________________________________________________

>;tb; *Oat groats

>;tb; TABLE 7

>;tb;______________________________________

>;tb; STEAMING

>;tb;EX- PRESTEAMING GRAIN TIME (MIN)

>;tb;AMPLE MOISTURE (%)* TEMP (F.) 35 PSI**

>;tb; 15 PSI

>;tb;______________________________________

>;tb;4 14-15 205 11-17 3-5

>;tb;5 14-15 205 11-17 5-20

>;tb;6 15-16 205 11-17 10-20

>;tb;7 15-16 205 11-17 15-30

>;tb;8 14-15 205 11-17 5-10

>;tb;9 15-16 205 11-17 5-10

1767/2197

>;tb;10 14-15 205 11-17 5-20

>;tb;11 14-15 205 11-17 5-20

>;tb;12 15-16 205 11-17 15-30

>;tb;13 15-16 205 11-17 15-30

>;tb;14 15-16 205 11-17 10-30

>;tb;15 14-15 205 11-17 5-10

>;tb;16 15-16 205 11-17 10-30

>;tb;______________________________________

>;tb; *The moisture content of the grain immediately prior to steaming and afte

>;tb; any moisture adjustment step.

>;tb; **The time required to bring the temperature of the grain to the

>;tb; temperature specified in the preceding column.

Although the above description and examples of the invention are disclosed herein for the purpose of describing the invention to those with ordinary skill in the art, each and every modification and variation of the invention is not described in detail. It is intended, however, that all modifications and variations within the scope of the claims are to be included within the scope of the invention.Data supplied from the esp@cenet database - Worldwide

1768/2197

376.

US4892747 - 1/9/1990

LOW-CALORIE CEREAL AND PROCESS FOR PREPARING THE SAME


Inventor(s): OHTA ATSUTANE (JP)

Applicant(s): TERUMO CORP (JP)


IP Class: A23L1/10

E Class: A23L1/182; A23L1/10H



Family: EP0251925


Abstract:


Low-calorie boiled cereal, preferably rice gruel, with reduced carbohydrate, particularly a saccharide component. The cereal is useful as low-calorie food for the therapy and prevention of obesity and therapy of diabetes. The cereal is prepared by adding to one part by weight of boiled cereal, 2-10 parts by weight of water or diluted aqueous acid heated at 60 DEG C. or higher, warming the mixture of 60

DEG C. or higher for 1 to 30 min. while maintaining the viscosity of the water of diluted aqueous acid at 200 cP or below, removing the liquid part and adding 0.05-5 parts by weight of water containing 0.1-

10 parts by weight of water-soluble dietary fiber.Description:




The invention relates to a low-calorie cereal and a process for preparing the same.

More particularly, it is concerned with a boiled granular low-calorie cereal with a reduced carbohydrate component and a process for preparing the same.

The cereal of the invention has reduced carbohydrate, particularly saccharide content so that it is useful as low-calorie food for therapy and prevention of obesity as well as therapy of diabetes.

2. Description of Prior Art

In order to limit caloric intake in the therapy and prevention of obesity and the therapy of diabetes, in some cases, there has been applied intake of plain rice gruel or rice gruel with vegetables. The method is based upon reduction of caloric level per unit weight due to swelling of rice grains as a result of absorption of a large amount of water when rice is boiled into gruel. However, as starch which accounts for almost all of the saccharides in rice is converted to .alpha.-starch when rice is boiled into

1769/2197

gruel, it becomes more digestible and utilizable in the body thereby reducing the effect of the limited caloric intake.

Furthermore, prior gruels have the disadvantage that turning yellow and disintegration of the grains of rice readily occur.

On the other hand, there has been adopted a reduction of calorie level per unit weight by intake of a filler and thickener such as dietary fibers, alone or in addition to other foods.

In recent years attention has been called to dietary fibers because of their action in improving the metabolism of saccharides and lipids.

The dietary fibers, however, are disadvantageous in that it is difficult to take them alone and an addition of them to other food will deteriorate taste and flavor in many cases due to their unpleasant taste and flavor.


FIG. 1 and FIG. 2 are graphs indicating cumulative removal percentage of saccharide by extraction and the remaining percent of saccharides in the desaccharified rice obtained in Example 1 and Example 2, respectively.


It is an object of the present invention to provide a boiled granular low-calorie cereal in which the problems of the prior art have been overcome, that is, caloric level per unit weight is very low.

Nevertheless, dietary fibers can easily be taken in, and moreover, appearance, taste and flavor are similar to those of plain rice gruel.

It is another object of the present invention to provide a process for preparing the same.

According to the invention, there is provided a low-calorie cereal comprising a boiled granular lowcalorie cereal with reduced carbohydrates, particularly a reduced saccharide content and, as needed, thickeners, fillers and seasonings.

Further according to the invention, there is provided a process for preparing a boiled granular lowcalorie cereal which comprises boiling a cereal, adding to the boiled cereal water or a diluted aqueous acid at a temperature of 60 DEG C. or higher, warming the mixture to 60 DEG C. or higher for a period from 1 to 30 min. while maintaining viscosity of said water or diluted aqueous acid at 200 cP or below and then removing the solution.

A cereal as used herein includes rice, wheat, barley, rye, foxtail millet, barnyard grass and the like.

When rice is employed as the starting material in the invention, any of whole rice, half-polished rice,

70%-polished rice, polished rice, rice with germs and alpha rice, in grain or crushed form may be used.

Dietary fibers are used as the thickener or filler of the present invention. Those which are highly soluble such as carrageenin, pectin, xanthan gum, guayule gum and arabic gum are preferable.

As the seasonings, any one or more of the conventional ones such as salt, soybean sauce, sodium glutamate, vinegar, sweet sake (mirin), rice wine (sake) and miso may be used. In addition, spices may be added as needed.

The preparative process of the invention will be described below with reference to the use of rice as the starting material. The process may be carried out in the same way with a cereal other than rice. Raw rice, after it is washed, is boiled by a conventional method such as using a pressure cooker, an electronic cooker or a kettle. To the boiled rice is added a sufficient amount of water or a diluted

1770/2197

aqueous solution of an acid such as acetic acid or phosphoric acid warmed to a temperature of 60 DEG

C. or higher. Preferably, 2-10 parts by weight of water or a diluted aqueous acid is added. The mixture is gently heated with stirring. Concentration of the acid in the solution is suitably in the range between

0.025 and 0.5%. The heating with stirring is continued for a period between 1 min. and 30 min., and the solution is removed by filtration or decantation. If the temperature of the water or the diluted aqueous solution of an acid such as acetic acid or phosphoric acid is lower than 60 C desaccharification of the boiled rice will disadvantageously be slow. The higher-temperature and shorter-time treatment results in swelling 1.5 to 2.5 times larger than the original while keeping the rice grains in shape. By carrying out the above-described procedures one to several times, the saccharide content is extracted into the solution so that the calorie level per unit weight becomes much lower than boiled rice.

Removal of the saccharides by extraction may also be effected by circulating water or a dilute aqueous acid such as acetic acid or phosphoric acid warmed to 60.C or higher in an extraction tank.

In the desaccharification of boiled rice it is necessary to maintain the viscosity of a saccharideextraction solution not higher than 200 cP. If viscosity of the extraction solution exceeds the above level, the shearing force applied to the rice grains will be so large that they will be apt to be deformed and separation of the rice grains from the solution will be difficult.

Separation of rice grains from the liquid portion by means of a 20-mesh screen is difficult even with the usual 50:50 plain rice gruel. Then, permeability through the screen and degree of the transformation of rice into gruel were compared under various viscosity conditions of the extract. To 650 g of polished rice was added 1 lit. of water, and the mixture was boiled in an electric cooker in a conventional way.

There was produced 1450 g of boiled rice. The boiled rice was divided into 350 g portions which were each placed in size 3 lit. kettles. To the kettles were added 0.5, 0.75, 1.0, 1.25, 1.5 and 2 lit. of water, respectively. The kettles were then put over a slow fire for 30 min. Permeability through the screen and degree of the transformation of rice into gruel of the saccharide extract were compared using the six samples thus obtained. The result are shown in Table 1. As seen from Table 1, the rice grains are hardly deformed when the viscosity of the extract is 200 cP or lower, desirably 100 cP or lower.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Degree of the

>;tb;Water Permeability through transforma-

>;tb;added the screen Viscosity

>;tb; tion into

>;tb;(lit.)

>;tb; 20 mesh 35 mesh 100 mesh

>;tb; cP gruel

>;tb;______________________________________

>;tb;0.5 X X X Not mea-

>;tb; Transformed

>;tb; surable

>;tb;0.75 .circle. X X 210 Transformed

>;tb;1.0 .circle. X X 152

>;tb;1.25 .circleincircle.

>;tb; .circle. .circle.

>;tb; 62



>;tb; .circle.

>;tb; 25



>;tb; .circle.

>;tb; 18

>;tb;______________________________________

>;tb; Permeability through the screen:

>;tb; X . . . Poor

>;tb; .circle. . . . Good

1771/2197

>;tb; .circleincircle.. . . Excellent

According to the above method, it is usually possible to reduce the remaining percent of carbohydrates to 80% by weight or lower.

To the boiled rice desaccharified in such a way as described above is added an aqueous solution containing 0.1-10% of one or more of the above-mentioned dietary fibers in a volume 0.5 to 5 times as much, and the mixture is heated with stirring. In general, the temperature at which the heating is made is desirably 60 DEG C. or higher though it may be varied depending upon the solubility of the dietary fibers employed. The heating time is desirably from 1 min. to 5 min.

The rice gruel of the present invention can be preserved for a long period without substantially turning yellow or allowing substantial disintegration of the grains of rice. The gruel is preferably preserved after airtight sealing in an aluminum pack and sterilization by retort.

Finally, one or more of the above-mentioned seasonings are added to give aflavor to be fixed depending upon the need for the therapy or the patient's liking.

The invention will be described in more detail below by way of examples and test examples.

EXAMPLE 1

To 320 g of polished rice, after it was washed, was added 480 ml of water, and the mixture was boiled in an electric cooker. To the boiled rice was added 2 lit. of water, heated to 90 DEG C., and the mixture was gently stirred for 5 min. while being heated. Then, the solution was removed by decantation. The above procedures were repeated three times in total. The solution and the rice grains produced at each operational stage were measured for saccharide concentration (in terms of glucose) by the phenolsulfuric acid method to determine cumulative removal percent of saccharides by extraction and the remaining percent of saccharides. The results are shown in FIG. 1. As seen in FIG. 1, the above procedures resulted not only in removal of approximately 50% of the saccharides but also in swelling of the rice gains to approximately twice as much in volume. Next, 20 solutions of dietary fibers were prepared in 20 beakers each containing 50 ml of water heated at 80.C in which were dissolved 0.05 g,

0.1 g, 0.5 g, 1 g and 5 g of carrageenin, xanthan gum, pectin and arabic gum (manufactured by San-ei

Kagaku), respectively. To each of the solutions was added 50 g of the desaccharified boiled rice, and the mixture was heated at 90 DEG C. for 5 min. and allowed to cool at room temperature for 10 min.

An organoleptic test was performed for flavor with the 20 samples thus obtained. The results are shown in Table 2.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Nature of dietary fibers

>;tb; Xanthan Arabic

>;tb;Amount added

>;tb; Carrageenin

>;tb; gum Pectin gum

>;tb;______________________________________

>;tb;0.05 g .circle. .circle. .circleincircle.

>;tb; .circle.

>;tb;0.1 g .circleincircle.

>;tb; .circle. .circle.

>;tb; .circle.

>;tb;0.5 g .circleincircle.

>;tb; .DELTA. .DELTA.

>;tb; .DELTA.

>;tb;1.0 g .DELTA. X X X

>;tb;5.0 g X X X X

>;tb;______________________________________

>;tb; .circleincircle. Excellent

>;tb; .circle. Good

1772/2197

>;tb; .DELTA. Fairly poor

>;tb; X Poor

As the amount of dietary fibers added was increased, gelation became greater and the flavor was worse, though there was also variation depending upon the nature of the dietary fibers. Addition of 0.1 g 1 g or

0.5 g of carrageenin or 0.05 g of pectin produced excellent flavor.

EXAMPLE 2

160 g of polished rice was washed and then 240 ml of water was added thereto, and the mixture was boiled in an electric cooker. To a half of the boiled rice was added 1 lit. of 0.01% aqueous acetic acid heated to 90 DEG C., and the mixture was gently stirred for 5 min. while being heated. The solution was then removed by decantation. The above procedures were repeated three times in total. The solution produced at each operational stage was measured for saccharide by the phenol-sulfuric acid method to determine cumulative removal percent by extraction of saccharides from the boiled rice and the remaining percent of saccharides in the rice. The results are shown in FIG. 2. As seen from FIG. 2, the above procedures resulted not only in removal of approximately 45% of the saccharides but also in swelling of the rice grains to approximately twice as much in volume. To 100 g of the desaccharified boiled rice was added 100 ml of a solution in which 0.5 g of carrageenin had been dissolved, and the mixture was heated with stirring at 90 DEG C. for 5 min. To the resulting mixture Was added 1 g of salt, 0.25 g of sugar and 0.05 g of sodium glutamate for seasoning to produce a low-calorie gruel-like food.

Separately, to 100 g of the above-prepared boiled rice was added 150 ml of water, and the mixture was heated over a slow fire for approximately 45 min. To the resulting mixture was added 1 g of salt, 0.25 g of sugar and 0.05 g of sodium qlutamate for seasoning to produce a plain rice gruel.

An organoleptic test was preformed by eleven persons on the low-calorie gruel-like food for appearance, taste and flavor taking the plain rice gruel obtained above as standard. The results are shown in Table 3. As seen in Table 3, the low-calorie gruel-like food was judged as equivalent to gruel for appearance, taste and flavor.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Better than

>;tb; Equivalent Worse than

>;tb; gruel to gruel gruel

>;tb;______________________________________

>;tb;Appearance

>;tb; 0 10 1

>;tb;Taste 2 6 3

>;tb;Flavor 1 7 3

>;tb;______________________________________

EXAMPLE 3

2.5 kg of polished rice was washed and then 4 lit. of water was added thereto. The rice was boiled in an electric cooker to obtain 5 kg of boiled rice. To the boiled rice was added 5 lit. of boiling water and the resulting mixture was heated under gentle stirring for 20 min. The upper layer was then removed by filtration to afford 9 kg of boiled rice with reduced saccharide.

Thirty 300-ml aluminum pack for retort were prepared and 140 ml of the carrageenin solution and 140 of the desaccharide boiled rice were placed in each pack. The packs were desired and made airtight by heat sealer to obtain the food of the present invention.

Separately, 2.5 kg of polished rice was washed and 4 lit. of water was added thereto. The rice was boiled in an electric cooker to obtain 5 kg of boiled rice. To the boiled rice was added 5.5 lit. of water.

The mixture was heated under gentle stirring for about 60 min. to obtain 10 kg of gruel. Thirty 300-ml aluminum pack for retort were prepared and 280 g of the gruel was placed in each pack. The packs were desired and made airtight by heat sealer to obtain control food.

1773/2197

The food of the present invention and the control food were sterilized at 115 DEG C. for 20 minutes in a retort. Each group was divided into 3 groups of 10 packs each and stored in three different conditions: a low temperature (4 DEG C.), room temperature (about 25 DEG C.) and a high temperature (137 DEG

C.) for six months. The packs were opened six months later and tested. As to the control food, there was recognized disintegration of grain of rice in the groups stored at a room temperature and at a high temperature.

Further there was recognized discoloration to pale yellow in the group stored at a high temperature.

However, as to the present food, there was recognized no change in the groups stored at any conditions.

The food of the present invention, as mentioned above, was confirmed to be superior to the control food in stability when process to retort food.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. A stabilized retort food obtained by sealing in a pack for retort a rice gruel containing granular rice with saccharide reduced more than 20% which is obtained by adding 2-10 parts by weight of water or a dilute aqueous acid heated at 60 DEG C. or higher to 1 part by weight of boiled granular rice, warming the resulting mixture at 60 DEG C. or higher for a period from 1 to 30 minutes while maintaining the viscosity of said water or dilute aqueous acid at 200 cP or below, removing the liquid part of the mixture from the granular rice and adding 0.5-5 parts by weight of water containing 0.1-10 parts by weight of water-soluble dietary fiber to the remaining granular rice, and sterilizing by retort.

2. The stabilized retort food according to claim 1 wherein the dietary fiber is carregeenin.Data supplied from the esp@cenet database - Worldwide

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377.

US4892749 - 1/9/1990

METHOD OF MANUFACTURING A REDUCED CALORIE SAUSAGE

CONTAINING COOKED RICE


Inventor(s): JOHNSON GERALD R (US); JONES MILO C (US); JONES JR EDWARD C (US)

Applicant(s): JONES DAIRY FARM (US)


IP Class: A23L1/317

E Class: A23L1/314B4



Family: US4892749

Abstract:


A method of manufacturing sausage is disclosed. This sausage is reduced in calories and is prepared by replacing a portion of the fat in the sausage with cooked rice.Description:


This invention relates to a food product in the form of an improved substitute for conventional high fat sausage, and a method of making said product.


Historically, sausage has tended to contain the maximum amount of allowable fat permitted by regulation. For example, as recently as 15 or 20 years ago, the bulk of the pork sausage, beef sausage, and breakfast sausage manufactured tended to contain the maximum amount of fat allowable under

U.S. Department of Agriculture (USDA) regulations, generally about 50% by weight of the total sausage weight In recent years, however, consumer tastes and dietary interests have been changing and meat products with less fat content have become more popular and increasingly demanded in the marketplace Contributing toward the interest in lower fat meat products has been a growing body of scientific research indicating that excessive human consumption of fat, particularly animal fat, is a significant health hazard.

However, in the case of sausage products, it has been found that a substantial reduction of fat content causes the sausage to become tough, dry, less sweet, less succulent, and distinctly less palatable. For example, pork, beef, or breakfast sausage made from red meat having a fat content below about 35% is considered less palatable due to dryness and chewiness This unpalatability is confirmed by scientifically conducted taste panels and published trade literature

In addition to simply increasing the percentage of lean, there have also been efforts to reduce the amount of fat in sausage by including non-meat additives while still attempting to maintain a similar sausage flavor and appearance. One such example is U.S. Pat. No. 3,748,148, issued to Jehle, which discloses the use of admixing granules of Brazil nuts with the meat as a substitute for the fat that has

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been removed from the meat. According to the patentee, the Brazil nuts are suitable as a substitute for the animal fat in sausage because of their neutral taste, their higher vegetable content, smaller content of carbohydrates and neutral color The Brazil nuts in Jehle cannot, however, be expected to provide the textural qualities of the high fat sausage substitute produced according to the present invention.

Another representative attempt at reducing the amount of fat in sausage is disclosed in U.S. Pat. No.

4,504,515, issued to Hohenester This patent discloses a process for preparing low-fat meat products which precomminute major quantities of lean meat selected from the group consisting of beef, veal, pork and hare, then thoroughly admixing the meat with minor quantities of skimmed milk or whole milk in the presence of less than 5% by weight of seasonings and/or preservatives The milk in

Hohenester cannot, however, be expected to provide the textural qualities of the more coarsely ground high fat sausage substitute produced according to the present invention.

In recent years attempts have also been made to fill the market demand for low-fat sausage with various poultry breakfast sausages, such as turkey breakfast sausage. While poultry is generally lower in fat than pork and beef, the poultry sausage currently available on the market is very dry and lacking in juiciness and succulence.

Another attempt in the mid-1970's proposed a sausage made with a high percent of lean meat which resulted in approximately 30% fat content. This product was commercially unsuccessful.

There is also a particular variation of boudin, a blood sausage originating in France, that contains rice.

It is produced by first grinding and cooking the meat before it is combined with the rice. The resulting composition is a soft, mushy, pudding-like texture with no resemblance to the high ft sausage substitute of this invention. Further, in boudin the rice is texturally and visually a clearly identifiable component which is in sharp contrast to the food product of this invention in which the rice, at least to the eye and taste of the lay observer, is indistinguishable from the fat.

Another class of sausage products includes the use of non-meat extenders. Originally such extenders were ingredients like bread crumbs and cereal which were simply mixed with higher cost ground meat to lower the cost of the recipe or product. Subsequently, sausage makers developed various milk and cereal derivatives which performed such additional functions as aiding the absorption of fat and the absorption of added moisture to increase finished cooking yield; adding certain protein values to the sausage to improve the emulsion stability and, in certain cases, imparting a different flavor. The underlying reasons for seeking these additional functions remain principally economic; that is, increasing product yields and lowering product costs.

In the past, rice and meat have been used in the preparation of non-sausage foods. Examples of such non-sausage foods that contain meat and rice (in addition to other ingredients) include jambalaya,

Spanish rice with meat, poultry dressing, and peppers and cabbage leaves stuffed with a mixture of ground beef, rice and other vegetables. These foods use rice simply as part of a multi-vegetable meat mixture and the food neither resembles nor is identified as a sausage. In addition, unlike the high fat sausage substitute produced according to the present invention, the rice in these products is a clearly identifiable component, both texturally and visually.


The invention relates to an improved substitute for conventional high fat sausage in which a substantial portion of the animal fat in the high fat sausage is replaced with lean meat and rice. It has been found that the present invention produces a high fat sausage substitute having the widely accepted characteristics of texture, taste and appearance associated with conventional high fat sausage. In addition, the high fat sausage substitute produced according to the preferred method of the present invention has, as contrasted to the USDA pork sausage standard, 60% less fat, 45% less calories, 35% more protein, and a cooking yield 35% higher than conventional high fat sausage.

According to the present invention, when the high fat sausage substitute is a pork, beef or breakfast sausage, the ingredient formulation by weight for the meat portion is lean meat in the amount of between about 40% to 90%, fat in the amount of between about 5% to 35%, rice in the amount of between about 2% to 35%, salt in an amount sufficient to extract the myosin, that is, up to 4% of the

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weight of the meat-rice mixture, and a bonding agent, which bonding agent may be myosin, or myosin and one or more substances. High fat pork sausage substitute and high fat beef sausage substitute as used herein refers to single species products that in addition to pork or beef may also contain water, sugar, dextrose, salt, spices and curing agents. Additional ingredients may include flavorings, flavor enhancers, antioxidants or typical extenders including cereal, textured vegetable protein (TVP) and dried milk.

High fat breakfast sausage substitute as used herein refers to a product containing the meat from one or more animal species and which may also include the non-meat ingredients listed above for pork and beef sausage substitutes.

In the present invention, the rice, which is an integral part of the product, binds with the meat portion of the formulation to provide the texture, taste and appearance of the substituted fat. It has been found that the rice provides a moist, fat-like character and structure which does not affect the basic meat flavors associated with the traditional higher fat sausage. In this manner, the rice and lean combination replaces a major portion of the fat and imparts an equally pleasing and palatable texture and mouth feel in a low fat product which, without the addition of the rice, would be tougher, drier, chewier, and distinctly less palatable.

While the above ingredients are preferred, the present invention contemplates varying the types of animal species, the fat/lean ratio, the meat/rice ratio, and the addition of other ingredients typically or sometimes used in sausage including, but not limited to, salt, spices, herbs, water, sugar, dextrose, flavorings, flavor enhancers, textured vegetable protein, antioxidants and curing agents. In addition it has been found that the aforementioned and other similar non-meat ingredients can be added to the high fat sausage substitute produced according to the present invention in similar proportions as they are used in conventional sausage without affecting the utility of the present invention. It has been found that the food product of the present invention can be adapted to all the forms, shapes, and processes typically associated with high fat sausage.


The method of producing high fat sausage substitute according to the present invention comprises, in general, the following steps.

A mixture of meat, containing both lean and fat, and rice is formed in the presence of a bonding agent in an amount and manner to form a matrix around and among the lean, fat and rice components of the base mixture. Salt is added, if needed, to this base mixture in an amount sufficient to assist the extraction of myosin from the meat. The bonding agent may be myosin, or myosin plus one or more recognized bonding agents such as hydrocolloids, egg albumin, gelatin, flours, starch, or collagen. The quantity of salt added may be anywhere from 0 to 4%. It will be understood that no salt need be added in those instances when there is sufficient salt already present in the base mixture to perform the desired function of assisting the extraction of myosin. Experience has shown that about 3-4% salt is the maximum upper tolerable limit of salt for human palatability.

Both the aforementioned bonding agents and salt may be considered to be additives. Other additives which may be added as desired are flavorings, (such as onions, garlic, celery, parsley, oleo resin spice extracts, and paprika), spices (such as pepper, sage, ginger, thyme, marjoram, fennel), seasoning, water, anti-oxidants (such as butylated hydroxy anisole (BHA), butylated hydroxy toluene (BHT), citric acid, propylgallate), extenders (such as cereals, cereal derivatives, textured vegetable protein, milk derivatives), flavor enhancers (such as MSG, hydrolyzed plant and/or vegetable protein, autolyzed yeast extract), sweeteners (such as natural or artificial sugar, dextrose, synthetic sweeteners such as cyclamates), coloring agents (such as paprika, dyes), smoke, curing agents (such as sodium nitrite alone or in combination with sodium erythorbate, or sodium ascorbate) and vitamins. It will be noted that some substances fall under two or more of the above classes of additives, such as paprika.

Rice may be prepared in a wide variety of ways including hydrating, parboiling or cooking. It is preferred that precooked dried rice be the starting form of rice, with water being added in a proportion of about three parts of water to one part of rice, by weight, to rehydrate the rice prior to addition to the meat.

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One of the outstanding features of the product is that the final rice content, regardless of the cooking or hydration method, is indistinguishable from fat globules; that is, only the extremely practiced eye and palate can discern the difference between an individual rice particle and a fat globule in both an uncooked and cooked condition. For all practical purposes, the rice and fat are indistinguishable to the consumer in the specified ranges.

A number of samples of the food product of this invention were prepared generally as follows.

First, water which may vary between approximately 32 DEG F. and boiling is added to rice. The rice is preferably dried, precooked rice, such as Minute Rice sold by General Foods, Riviana Instant Rice sold by Riviana Foods, Inc. or Uncle Ben's Precooked Rice. The ratio of the weight of the water to the weight of the rice when using precooked rice is preferably approximately 3 parts of water to 1 part of rice. The water and rice mixture should preferably remain in a 28 DEG F. cooler for 24 to 48 hours.

Although precooked Minute Rice and Riviana Rice have been successfully used in the production of the subject products, it is believed that other forms of cooked and rehydrated rice may also be used.

In the next step, boneless meat, at a temperature of between about 23 DEG F. to 102 DEG F., and having a fat percentage of between 4% to 35% is added to the rehydrated rice. The percent by weight of the meat to the total weight of the high fat sausage substitute may vary between 65% to 98% and the percent by weight of the rehydrated rice to the total of the high fat sausage substitute may vary between

2% to 35%.

In the next step, the boneless meat and rice are coarse ground through a large-hole plate to begin myosin extraction from the meat. This step may also be accomplished by chopping rather than grinding. The rice can be added to the meat either prior to coarse grinding or chopping, or after the meat is coarse ground or chopped.

Next, the meat and rice are blended in a mixer or chopper and the spices, such as salt, sage, black pepper and ginger, are added, although other seasonings and additives could be added as well. The mixing time will vary depending on the equipment that is used, the RPM's, and types of mixing arms or chopper blades, but it is usual for the average time of mixing to be approximately three minutes.

During this step, myosin is further extracted from the meat and the myosin envelops the meat and rice components to achieve the unique result of a traditional sausage flavor, texture, and consistency.

In the next step, the mixture is ground through a small-holed plate which has the effect of further extracting and distributing the myosin. A 9/64-inch plate has been used, although other small-holed plates, such as 1/8-inch, 5/32-inch, 3/16-inch, etc., plates may also be used. The effect may also be achieved by chopping or a combination of chopping and grinding. If chopping is used, chopping time is dependent on the chopper speed and number and pattern of the blades. Care should be taken during this step to make certain that the rice particles maintain their structural integrity and that they maintain a size generally similar to the meat particles. The average finished composition particle should be preferably from 1/8 to 1/4-inch in particle size. The resulting composition should preferably have a finished temperature of between 36 DEG F. to 42 DEG F., although the temperature range for the product if prerigor meat is used may range between 23 DEG F. to 102 DEG F.

The composition is thereafter compacted and processed as conventional sausage, either precooked or uncooked. The cooked or uncooked sausage may take any conventional form, including tubes or rolls and links in casings. Alternatively, the product may be cooked or formed raw (with the casings peeled after the product is formed or cooked), or it may be extruded into skinless links or patties, or it may be processed as patties sliced or cleaved from a product that had been stuffed in a casing, or it may be formed into bulk sausage.

While the above methods and procedures are preferred, the equipment can be varied by using a variety of grinding plate sizes and/or grinding and/or chopping cycles and sequences consistent with the manufacture of conventionally manufactured sausage.

The high fat sausage substitute may then be cooked by the consumer by any of the conventional cooking methods.

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Several examples of varying ingredients and methods of formulation of compositions within the scope of the invention are as follows. All percentages are based on the total weight of only the meat and rice components of the mixture, except Example 7 which included the addition of free water. Further, hydrated cooked rice, which had been reformulated on the basis of three parts of water to one part of rice, by weight, was used unless otherwise noted as in Example 7.

EXAMPLE 1

The following ingredient formulation by weight percentages was prepared. In this example the finished product will have a finished fat level of approximately 20%.

>;tb;______________________________________


>;tb;19.8% pork fat

>;tb;10.25% hydrated cooked rice

>;tb;100.0%

>;tb;______________________________________

Meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and the cooked rice having an internal temperature of 40 DEG F. was added to the conveyorized scale with the meat.

The hydrated cooked rice was prepared in the following manner: Minute Rice and water were weighed

(25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 24 hours. Both the meat and rice were then ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces to begin the myosin extraction. The product was then conveyed to a mixer/grinder where the seasonings consisting of salt, sage, black pepper and ginger were added. The product was then mixed for three minutes causing further extraction of the myosin from the meat and a blending of the meat with the rice. The resulting composition was then ground through a 9/64-inch plate and the resulting temperature of the composition was 40 DEG F.

Portions of the composition were stuffed and linked in both natural and collagen casings, using a stuffer and linker. Another portion of the composition was stuffed into cellulose casings, using a stuffer and an automatic linker, and then cooked using a smokehouse. The cellulose casings were then peeled from the fully cooked links, some of which were also prebrowned. Additional portions of the composition were stuffed into plastic film tubing and fibrous casing and then formed as consumer sized tube packages (rolls) and also as longer sticks. Some of these tube packages were fully cooked. Some of the longer sticks were sliced as uncooked patties, and some sticks were cooked and then sliced as precooked patties, some of which were prebrowned. The equipment used for this was a forming and packaging machine, cleaver, and cooker. Another portion of the composition was extruded into skinless links, some of which were packed immediately in boxes and some fully cooked in a counter flow oven thereby producing precooked links, some of which were also prebrowned. Additional portions of the composition were stuffed and linked into both natural and collagen casings, using a stuffer and linker, and fully cooked in a counter flow oven producing precooked links, some of which were also prebrowned. Another portion of the composition was extruded into patties, a portion of the patties being cooked in a counterflow oven to produce a fully cooked patty, some of which were also prebrowned.

EXAMPLE 2

>;tb;______________________________________

>;tb;66.9% lean beef

>;tb;19.7% beef fat

>;tb;13.4% hydrated cooked rice

>;tb;100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was added to a six-bladed chopper. The chopper at low speed reduced the particle size to approximately 11/2 to 2-inch pieces in three bowl turns. The hydrated cooked rice having an internal temperature of 36 DEG F. was added to the meat and the

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seasonings consisting of salt, sugar, sage, black pepper and ginger were added to the meat. The hydrated cooked rice was formulated in the same manner as in Example 1, except that it was held for a period of 48 hours prior to being formulated into the product. The product was then mixed in the chopper for 30 low speed bowl turns causing a further extraction of myosin from the meat, and a blending of the meat with the cooked rice. Thereafter the product was conveyed to a grinder and the finished product was ground through a 9/64-inch plate. The finished temperature of the product was 39

DEG F.

Portions of the composition may be stuffed and linked in both natural and collagen casings, using a stuffer and linker. Another portion of the composition may be stuffed into cellulose casings, using a stuffer and an automatic linker, and then cooked using a smokehouse. The cellulose casings may then be peeled from the fully cooked links, some of which may also be prebrowned. Additional portions of the composition may be stuffed into plastic film tubing and fibrous casing and then formed as consumer sized tube packages (rolls) and also as longer sticks. Some of these tube packages may be fully cooked. Some of the longer sticks may be sliced as uncooked patties, and some sticks may be cooked and then sliced as precooked patties, some of which may be prebrowned. The equipment used for this may be a forming and packaging machine, cleaver, and cooker. Another portion of the composition may be extruded into skinless links, some of which may be packed immediately in boxes and some may be fully cooked in a counter flow oven thereby producing precooked links, some of which may be also prebrowned. Additional portions of the composition may be stuffed and linked into both natural and collagen casings, using a stuffer and linker, and fully cooked in a counterflow oven to produce precooked links, some of which may also be prebrowned. Another portion of the composition may be extruded into patties, a portion of the patties being cooked in a counterflow oven to produce a fully cooked patty, some of which may also be prebrowned.

EXAMPLE 3


>;tb;______________________________________



>;tb; 7.4% pork fat

>;tb; 9.3% beef fat


>;tb; 100.0%

>;tb;______________________________________

The meats having an internal temperature of 37 DEG F. were added to a conveyorized scale with hydrated cooked rice prepared in the same manner as in Example 1 having a temperature of 35 DEG F.

(The rice was held in a 28 DEG F. cooler for 72 hours.) The composition was then conveyed through a coarse grinder and the materials were ground through a one-inch plate and the product was conveyed to a mixer/grinder. The product was then mixed for two minutes during which time the myosin was further extracted from the meat. Spices consisting of salt, sugar, dextrose, sage, black pepper and ginger were added. The product was then final ground through a 5/32-inch plate and the temperature of the resulting composition was 41 DEG F. Thereafter the product may be processed in a manner similar to the processing described in Example 2.

EXAMPLE 4


>;tb;______________________________________

>;tb; 45.0% boneless turkey


>;tb; 9.0% pork fat


>;tb; 100.0%

>;tb;______________________________________

1780/2197

The meats (both the turkey and pork had an internal temperature of 34 DEG F.) were placed on a conveyorized scale and the hydrated cooked rice having an internal temperature of 50 DEG F. was added. The hydrated cooked rice was prepared in the same manner as in Example 1, except that it was held for a period of 25 hours in a 28 DEG F. cooler. Both the meat materials and rice were conveyed to a coarse grinder and thereafter ground through a four-holed teardrop plate to reduce the particle size of the meat to approximately 11/2 to 2 inch pieces. The product was then conveyed to a mixer/grinder and the seasonings or additives consisting of salt, MSG, sage, black pepper and ginger were added. The product was then mixed for 21/2 minutes causing further extraction of the myosin from the meat and a blending of the meat with the rice. The resulting composition was then final ground through a 3/16inch plate and the resulting temperature of the product was 50 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 5

The following ingredient formulation by weight percentage was prepared to make Italian Sausage:

>;tb;______________________________________




>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and the cooked rice having an internal temperature of 40 DEG F. was added. The hydrated cooked rice was prepared in the following manner: Riviana rice and water were weighed (25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 25 hours. Both the meat and rice were then conveyed to a grinder and coarse ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces. The product was then conveyed to a mixer/grinder and the seasonings consisting of salt, dextrose, black pepper, fennel and red pepper were added. The product was then mixed for three minutes causing further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The resulting composition was then ground through a 3/16-inch plate and the resulting temperature of the composition was 40 DEG F.

Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 6

The following ingredient formulation by weight percentage was prepared to make Bratwurst:

>;tb;______________________________________



>;tb; 12.4% cooked hydrated rice

>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale with rice.

The hydrated cooked rice was prepared in the following manner: Riviana rice and water were weighed

(25% rice, 75% water) and the water and rice were mixed and the mixture was stored in a 28 DEG F. cooler for 24 hours. Both the meat and rice were then conveyed to a grinder and coarse ground using a four-hole teardrop plate to reduce the particle size of the meat to approximately two-inch pieces. The product was then conveyed to a mixer/grinder and the seasonings or additives consisting of salt, dextrose, MSG, sage, black pepper and celery powder were added. The product was then mixed for three minutes causing a further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The resulting composition was then ground through a 5/32-inch plate and the resulting temperature of the composition was 40 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 7

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>;tb;______________________________________



>;tb; 3.1% dehydrated cooked rice

>;tb; 9.3% water

>;tb; 100.0%

>;tb;______________________________________

The meat having an internal temperature of 34 DEG F. was placed on a conveyorized scale and rough ground through a four-hole plate. The meat materials were then conveyed to a mixer/grinder and the dehydrated Riviana rice, water at a temperature of 58 DEG F., and seasonings consisting of salt, sage, black pepper and ginger were added to the mixer. The product was then mixed for four minutes causing further extraction of the myosin from the meat and a blending of the meat with the cooked rice. The product was then final ground through a 5/32-inch plate and the resulting finished product had a temperature of 42 DEG F. Thereafter the product may be processed as earlier described in a manner similar to the processing described in Example 2.

EXAMPLE 8


>;tb;______________________________________


>;tb;17.5% pork fat

>;tb;12.4% milled rice cooked from a raw state

>;tb;100.0%

>;tb;______________________________________

The meat having an internal temperature of 37 DEG F. was added to a chopper. The rice was cooked in a steam jacketed kettle with water at a temperature of 190 DEG-200 DEG F., for 15 minutes. After cooking, the rice was rinsed and chilled to a temperature of 5 DEG F. for one hour and then drained.

The meat materials were 10 then reduced in a chopper to approximately 11/2 to 2-inch particles in three bowl turns. The cooked rice and seasonings consisting of salt, dextrose, sage, black pepper and ginger were added to the product and the product was mixed in the chopper for 25 bowl turns causing further myosin extraction and a blending of the meat with the cooked rice. The resulting mixture was then added to a grinder/mixer and the product was final ground using a 9/64-inch plate. Thereafter the product may be processed as earlier described in a manner similar to the processing described in

Example 2.

End products from the foregoing batches were then judged on the basis of texture, flavor, and appearance and all were determined to be acceptable by current commercial standards.

A further series of samples was prepared and subjected to panel testing. Specifically, a modified hedonic rating scale was used. In this method, the standard nine point hedonic rating scale is modified by eliminating the middle category, "neither like nor dislike," leaving eight categories consisting of like extremely, like very much, like moderately, like slightly, dislike slightly, dislike moderately, dislike very much, and dislike extremely. Each category has an assigned numerical value ranging from 8 for like extremely to 1 for dislike extremely.

In the panel testing, each panelist was presented, with respect to the pork base food product, with a control product sample and five sample mixes and asked to rate each of the six samples on the above described modified hedonic scale. The control product had a content of 52% lean pork, 48% pork fat and no rice and is a commercial product which has enjoyed wide acceptance. All samples in all tests had the same seasonings added as existed in the control sample so as to minimize the effect of spices and seasonings. Since no commercially available control product was available for beef, the panelists were confined to ranking the five beef samples against each other.

The compositions of the test samples and the rating thereof are shown in the following table.

>;tb;______________________________________

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>;tb;TEST

>;tb;NO. LEAN FAT RICE RATING

>;tb;______________________________________

>;tb;PORK

>;tb;1. 72 8 20 5.2

>;tb;2. 90 8 2 6.0

>;tb;3. 63 35 2 4.6

>;tb;4. 73 25 2 6.0

>;tb;5. 71 4 25 4.4

>;tb;6. 50 25 25 4.2

>;tb;7. 60 10 30 2.4

>;tb;8. 55 10 35 3.0

>;tb;9. 50 10 40 2.4

>;tb;10. 40 10 50 1.8

>;tb;11. 70 25 5 5.0

>;tb;12. 85 10 5 5.8

>;tb;13. 80 15 5 6.0

>;tb;14. 70 10 20 5.6

>;tb;15. 65 15 20 5.4

>;tb;16. 55 25 20 4.0

>;tb;17. 70 20 10 6.2

>;tb;18. 70 20 10 6.2

>;tb;BEEF

>;tb;19. 88 10 2 3.2

>;tb;20. 50 25 25 4.2

>;tb;21. 70 10 20 4.0

>;tb;22. 70 25 5 3.4

>;tb;23. 70 20 10 3.4

>;tb;______________________________________

>;tb; NOTES:

>;tb; Tests Nos. 17, 18 and 23 are approximate, with an accuracy believed to be

>;tb; within plus or minus about 1%. Test No. 18 included a milk powder

>;tb; derivative.

From the above it will be noted that compositions which ranged up to 35% rice, and as little as 4% fat had a rating of 3.0 or above with the variance noted below.

A 3.0 rating is considered to be a commercially acceptable rating on the modified hedonic scale used, though of course a higher rating is preferred. Specifically, on the standard hedonic, a rating of 7.0 is very outstanding (and quite unusual), and a rating in the range of 4.0 up to 7.0 is considered to be commercially acceptable. On the modified hedonic scale used in the above described panel testing, these values translate to 6.0, and 3.0 up to 6.0 respectively.

Compositions which fall within the range of 3.0 and above are epitomized by test nos. 1-8 and 11-23.

(Test number 7 is considered an aberration since the compositions of test numbers 5, 6 and 20 which had rice contents only 5% lower than the composition of test 7 had a rating of 4.2 or higher, and the composition of test No. 8, which had a rice content 5% higher than that of test number 7, fell into the acceptable range).

Of particular significance is the fact that compositions which had as little as 15% fat or less, such as the compositions of tests 2, 12 and 13 were judged to be acceptable; indeed, excellent since the lowest rating of these three tests was 5.8. It appears that a very minor amount of rice--only 2% in the case of test 2--is sufficient to yield a commercially viable product in combination with heretofore unacceptably small percentages of fat.

It is also apparent that the fat content may be as low as 4% (see, for example, test 5), and a commercially viable product will result This result appears to be attributable to the substantial quantity of rice present; i e.: 25% in the composition of test 5.

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From the foregoing it appears that fat and rice are to a major degree, interchangeable, though it is not known with certainty if the relationship is precisely proportional In any event, a broad range of acceptable ingredients is considered to be the following:

>;tb;______________________________________

>;tb; Lean

>;tb; 40%-90%

>;tb; Fat

>;tb; 4%-35%

>;tb; Rice

>;tb; 2%-35%.

>;tb;______________________________________

The aforesaid broad range includes several compositions which are at the low end of acceptability, such as the compositions of tests 8, 19, 22 and 23, all of which are in the 3.0-4.0 range.

Using a preferred rating of about 5.0 and above and a substantial fat reduction of approximately 10%

(i.e.: about a 30% decrease from the current minimally acceptable fat content of 35% of the base mixture), it will be noted that the compositions of test numbers 4 and 11-18, at least as to pork, define a rather clearly categorized group. When the compositions of tests 2 and 5 are compared, it will be noted that a relatively small percent increase in the fat content (i.e.: from about 4% in test 5 to 18% in test 2) results in a significant increase in rating. From these facts it is considered that a preferred range has the following nominal compositions:

>;tb;______________________________________

>;tb;Preferred

>;tb;______________________________________

>;tb; Lean 55-85%

>;tb; Fat 10-25%

>;tb; Rice 5-20%

>;tb;______________________________________

A number of samples were made up to a nominal composition of lean 70%, fat 20%, rice 10%. With respect to pork, the ratings were above 6 which, as mentioned earlier, is the equivalent to 7 on the conventional hedonic scale which is outstanding. The ratings were not as high, with respect to beef, though still acceptable.

>;tb;______________________________________

>;tb;Most preferred

>;tb;______________________________________

>;tb;Lean 70%

>;tb;Fat 20%

>;tb;Rice 10%, all percentages being

>;tb; about .+-. one percent.

>;tb;______________________________________

A typical panel result for a pork base product is set out in the following table:

>;tb;______________________________________

>;tb;Test Panelist Rating

>;tb;No. % Fat % Rice 0 K S M B Ave.

>;tb;______________________________________

>;tb;Control

>;tb; 48 0 8 6 5 6 8 6.6

>;tb;2 8 2 7 8 3 7 5 6.0

>;tb;7 10 30 2 3 2 2 3 2.4

>;tb;15 15 20 6 4 7 6 4 5.4

>;tb;16 25 20 2 5 3 4 6 4.0

>;tb;______________________________________

The panelist rating is in points in the range of 1-8, with 8 being the highest rating.

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In all of the foregoing tabulated samples the lean and fat components of the base were substantially uncooked when in initial mixture with the rice. It should also be noted that all tabulated samples except

No. 18 had the same additives as were present in the control sample so that any differences attributable to differences in additives were eliminated or minimized. Further, all samples in the tabulated samples were judged on the basis of texture, flavor, and appearance as were Examples 1-8.

It will be understood that, although specific examples of the invention have been described in detail, modifications can be made within the scope of the invention. Accordingly it is intended that the scope of the invention not be limited to the foregoing disclosure, but only by the scope of the claims when interpreted in light of the relevant prior art.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. A method of forming a food product said method including the steps of forming a particulate mixture of lean meat, fat and rice by mixing said components to form a base mixture, grinding said meat, fat, and said rice together to form a mixture, maintaining meat particles and rice particles of said mixture at a size generally similar to one another, making sure said rice particles maintain their structural integrity, blending said mixture with spices, and without adding additional fat to said mixture, forming said mixture into a final product selected from the group including tub.RTM.s, links, both caseless and cased, patties and bulk sausage, the particles size of the components being sufficiently small to enable the available supply of myosin to tend to form a matrix, the fat content being no more than about 35% nor less than 4%, the rice content being no more than about 35% nor less than 2%, balance lean meat in an amount no more than about 90% nor less than 40%, all in weight percent of the base mixture, whereby a generally coarse mixture of breakfast sausage is formed in which said rice particles are generally indistinguishable from fat globules, which is suitable for forming into patties and links, and which has the texture, consistency, appearance, and taste of a high-fat breakfast sausage.

2. The method of claim 1 further characterized in that salt is added until the weight of salt is between about 1/2% to 4% of the weight of the base mixture.

3. The method of claim 1 further characterized by and including the step of adding at least one additive to the base mixture in its substantially uncooked condition.

4. A method of forming a substitute for high-fat breakfast sausage, said method comprising: preparing a mixture containing both lean meat and fat, preparing a quantity of pre-cooked re-hydrated rice, combining and coarse grinding said meat and said rice together to form a mixture, maintaining particles of said rice at a size generally similar to the size of meat particles in said mixture making sure said particles retain their structural integrity, blending said mixture with spices, without adding additional fat to said mixture, forming said mixture into a final product selected from the group including tubes, links, both caseless and cased, patties and bulk sausage, whereby said product is a generally coarse mixture of breakfast sausage in which said rice particles are substantially indistinguishable from fat globules, giving said product an appearance, texture and taste of high-fat content breakfast sausage.Data supplied from the esp@cenet database - Worldwide

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378.

US4894242 - 1/16/1990

NUTRITIONAL RICE MILK PRODUCT


Inventor(s):

ROBERT (US)

MITCHELL CHERYL R (US); MITCHELL PAT R (US); NISSENBAUM

Applicant(s): MITCHELL CHERYL R (US); MITCHELL PAT R (US); NISSENBAUM

ROBERT (US)


IP Class: A23L1/10; A23L2/38

E Class: A23L1/105B; A23C11/10



Family: US4894242

Abstract:


The method of the invention comprises selection of whole grain rice, either white or brown rice, which is liquefied, preferably with alpha-amylase enzymes, and then treated with relatively high levels of a glucosidase enzyme and/or a beta-amylase enzyme in a saccharifying step. The total enzymatic reaction time in both the liquefaction and saccharification steps is limited to prevent development of undesirable off-flavors to yield a non-allergenic rice milk produce having surprising milk-like texture and functionality, the rice milk product being characterized by the absence of a rice-like flavor and having a preferred composition defined as follows: -Soluble Complex Carbohydrates 10 to 70% of solids; -Maltose 0 to 70% of solids; -Glucose 5 to 70% of solids; -Ash or Minerals 0.1 to 0.6% of solids; -Protein and Fat 1 to 3.5% of solids; -Fiber 0.05 to 0.4% of solids. - The rice milk product can also be converted to a dried product.Description:



The present invention relates to an enzymatic method for producing a milk-like rice liquid for use either as a beverage or in a variety of food products as well as a product of the method.


The traditional Japanese method for the preparation of a nutritional, non-alcoholic beverage from rice requires the blending of steamed or cooked rice with rice koji. The rice koji is prepared by inocculating steamed or cooked rice with the spores of the mold (Aspergillus oryzae) and cultivating the inocculated rice.

The rice koji contains a significant conglomeration of enzymes, predominantly alpha-amylase. It is characterized by both dextrinizing or liquefying and saccharifying action on starch.

After cultivation or fermentation for periods between 4 and 48 hours, the saccharified mass is passed through a sieve or filter. Dependent upon the starting materials used, (polished or unpolished rice or

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combination thereof) the filtrate is a white or beige colored slurry having a distinctly sweet, rice-like taste. The texture and sweetness of the slurry is determined by the total solids and the degree of starch conversion and may be mildly sweet or thick and sweet (similar to a milk-shake). This nutritional beverage prepared from rice is commonly termed amazake.

The amount of sweetness derived from the amazake is dependent upon the total solids of the liquid and the amount of time the rice is allowed to culture with the koji under optimum conditions. Sweet amazake products resulting from long culturing times have an inherent problem of developing a "flat" or "sour" flavor. This flat souring presumably is the result of microbial action in the nutrient rich media as well as the oxidation of fats naturally occurring in the rice.

In some cases, culturing is terminated prior to the development of this flat souring. However, this results in the limitation of the amount of conversion from rice starch to maltose, glucose and higher dextrins. Typically, amazake prepared using koji results in the relative formation of substantial quantities of maltose and very low levels of glucose typically no more than two to three percent of the total carbohydrates. This quantitative relationship between maltose and glucose is limited by the nature of the koji culture itself. It is these limitations on the quality and quantity of sugars produced in making amazake via the traditional koji method that prompted us to seek an alternative.

The use of enzymes as an alternative method for the liquefaction and saccharification of starch from grains and tubers other than rice is very well known for the production of 100% carbohydrate products including dextrins, fillers and sweeteners intended to be competitive with sucrose. In these products, usually made from corn, the starchcontaining portion of the grain or tuber is first separated from the non-starch containing portions before enzymatic conversion. Thus, a relatively pure starch is obtained which can be enzymatically converted and processed to produce a pure carbohydrate product free of impurities.

Because of the preliminary separation of the starch fragment from the grain, not only is a pure carbohydrate product obtained but the enzymatic conversion process is uncomplicated and uninhibited by the fat, fiber and protein contaminants. Unfortunately, this enzymatic conversion process yields a relatively pure carbohydrate product and therefore does not have the nutritional advantages yielded by the traditional koji method involving whole or ground rice.

Traditionally prepared amazake using koji produces a thick, pulpy type of beverage with a rice-like flavor, limited sweetness and stability, and in most cases a distinct sour flavor. Because of its textural and functional properties, this traditionally prepared amazake has a very limited usage, if any, as a substitute for milk.

Accordingly, there has been found to remain a need for improved rice liquids which can be employed either as a beverage or in the preparation of food products. Because of the generally non-allergenic response to rice, it may be anticipated that such products may have a similar characteristic of being generally non-allergenic.

As an example of other beverage products developed for this market, soy beverages have been employed recently as a milk substitute in powdered, canned and aseptic packaged form. Disadvantages associated with these soy-based milk substitutes arise primarily because of the allergenic response which many people have toward soy products, the bean-like flavor of the products and their common need for the addition of a sweetener.

As noted above, there has been found to remain a need for an improved rice liquid produce and method of its preparation.

Another invention set forth in an application co-pending with the above noted parent Ser. No. 856,504, filed Apr. 28, 1986, and now U.S. Pat. No. 4,756,912, and entitled RICE SYRUP SWEETENER

PRODUCTION, and assigned to California Natural Products is related to the present invention and is accordingly incorporated herein by reference as though set forth in its entirety. The above noted reference involves rice syrup sweeteners which are formed by generally the same steps employed for the nutritional rice milk product of the present invention. However, as a final step, the rice syrup sweeteners are partially clarified, preferably by sieving and centrifuging in order to remove

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substantially all rice fiber from the product resulting in the rice syrup sweetener. That reference is incorporated herein to the extent that it may be of assistance in disclosing and facilitating a further understanding of the present invention.


It is an object of the invention to provide such an improved rice liquid, hereinafter referred to as a "rice milk" because of its surprising milk-like texture and functionality.

It is also an object to provide a method for producing the rice milk.

It is a further object of the invention to provide such a rice milk product which is also nutritional in nature because the method for producing the rice milk product of the invention employs as a starting material "whole grain rice". Within the present invention, whole grain rice refers to either white rice

(polished) or brown rice (unpolished) unlike typical prior art corn products which are developed by enzymatic treatment of carbohydrate components removed or separated from the remainder of the grain.

In connection with the above objects, the present invention is based upon the discovery that enzymes could be used for treating whole grain rice as opposed to a purified starch slurry and that it would thereupon be possible to produce a rice liquid having nutritional values. At the same time, the invention is based upon the further discovery that it is possible to overcome the inherently limited sweetness of traditional koji prepared amazake by employing a relatively high level of a glucosidase enzyme either alone or in combination with a beta-amylase enzyme in a saccharification step to produce rice milk products or "modified amazake" products with a variety of glucose to maltose ratios while still having similar nutritional advantages as noted above.

It was further discovered in connection with the present invention that,through the controlled use of dextrinizing and saccharifying enzymes, it is possible to eliminate souring and to produce a sweet, nutritional, hypoallergenic product surprisingly similar in texture and functionality to cow's milk and very much unlike traditional amazake as discussed above.

The composition of the rice milk of the invention was found to include minerals, fats, fiber, protein, complex carbohydrates, vitamins, maltose and glucose. All of the above products derived from the starting material of whole grain rice itself. It is also noted in particular that the "complex carbohydrates" referred to above include oligosaccharides such as maltotriose, dextrins, and higher saccharides. In any event, all of these forms of complex carbohydrates according to the present invention may appear in the rice milk product in a wide variety depending upon the whole grain rice selected as a starting material and also upon characteristics of the process as will be described in greater detail below.

Accordingly, it is yet a further object of the invention to provide a method for producing a nutritional rice milk from whole grain rice which can be ground or otherwise divided to form particles of selected size. A rice water slurry containing approximately 25-40% dry weight rice is heated and then liquefied, preferably by treatment with an alpha- amylase enzyme as noted above to form a liquid slurry which is treated with a glucosidase enzyme in a saccharification step to yield a rice milk product retaining nutritional values from the whole grain rice and exhibiting a milk-like texture and functionality.

The concentration of glucosidase enzyme and the concentration of optionally employed beta-amylase enzyme in the saccharification step are set forth respectively in Diazyme Units and DP DEG. These standards are employed with the following explanation to assure a proper understanding of the invention. In that regard, the term "DP DEG" refers to Degrees of Diastic Power. A further definition as well as an extensive assay procedure in connection with that term is set forth for example in Food

Chemicals Codex, third edition, beginning at page 484.

The term "Diazyme Units" refers to a Diazyme assay commercially available from Miles Laboratories,

Inc., Elkhart, Ind. That term is employed herein at least partially since one glucosidase enzyme found suitable for use in the present invention comprises glucoamylase E.C. 3.2.1.3, 1, 4 - alpha - D-Glucan

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glucohydrolase, unit activity of about 200 Diazyme Units/ml. (available under the trade name Diazyme from Miles Laboratories, Inc., Elkhart, Ind.).

It is a further related object of the invention to provide such a method wherein at least about 440

Diazyme Units of glucosidase per kilogram of whole grain rice particles are employed in the saccharification step and the enzymatic reaction time for the saccharification step is limited to about three hours in order to prevent development of off-flavors.

It is yet a further related object of the invention to employ the glucosidase enzyme either alone or in combination with varying amounts of beta-amylase enzymes in order to produce a nutritional rice milk product having the composition:

>;tb;______________________________________

>;tb;Soluble Complex Carbohydrates

>;tb; About 10 to 70% of solids;

>;tb;Maltose About 0 to 70% of solids;

>;tb;Glucose About 5 to 70% of solids;

>;tb;Non-Carbohydrate Nutritional Values

>;tb; About 1 to 5% of solids.

>;tb;______________________________________

Yet another further related object of the invention consists of selecting the whole grain rice starting material and characteristics of the liquefaction and saccharification steps so that the rice milk product further includes nutritional values comprising ash or minerals at about 0.1 to 0.6% of solids, protein and fat at about 1 to 3.5% of solids and rice fiber at about 0.05 to 0.4% of solids.

The method of production for rice milk according to the present invention has been found to result in a rice milk product or modified amazake which can be substituted for milk, milk solids and other milk forms in the preparation of various food products including but not limited to beverages, puddings and other food products corresponding to various dairy-based dessert products.

It is yet another object of the invention to provide the rice milk product in combination with other components to form a variety of food products including but not limited to a novel ice cream analog and other products as listed above.

It has also been found that the rice milk or modified amazake product of the present invention can be dried, for example by drum drying and preferably by spray drying to form a dried rice milk-like product or modified amazake which can be stored and subsequently used either in its dried form or reconstituted to a liquid consistency.

Accordingly, it is yet a further object of the invention to provide both a dried rice milk-like product and method of its preparation.

It is a still further object to provide a nutritional rice milk product using whole grain rice as a starting material and employing a beta-amylase enzyme of at least 1,000 DP DEG per kilogram of whole grain rice in a saccharification step limited to about three hours. This process has been found to yield a high maltose rice milk product which is nutritional and non-allergenic while also being characterized by freedom from a rice-like and a milk-like texture and functionality.

Substantially greater amounts of the beta-amylase enzyme may be used if desired. However, it has generally been found to be preferred to use about 1,000 to 3,000 DP DEG of the beta-amylase enzyme per kilogram of whole grain rice to economically achieve the advantages of the invention. This high maltose rice milk product may also be converted to a dried product.

Numerous additional objects and advantages of the invention will be apparent from the following description which includes a number of examples to further define and fully disclose the invention.


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Generally, in the enzymatic conversion of the starch from grains such as corn, the starch containing fragment of the grain is first separated from the hull, germ and other grain portions before reaction with the added enzyme. In this way, contamination of the starch by proteins, fats and fibers is minimal and therefore processing is not complicated by these impurities. As a consequence of this preliminary starch separation, a purified carbohydrate product is produced having none of the nutritional advantages found in whole or ground grains as used in traditional koji preparation of amazake.

We found in our invention that whole grain rice (white or brown) can be ground or divided and used in an enzymatic process. Consequently, contamination by protein, fat, and fiber may be expected to cause significant deviations in enzymatic activity and processing conditions. In the typical enzymatic conversion of purified starches, reaction parameters such as time, temperature, pH and water concentration of the starch slurry are usually adjusted to obtain hydration and swelling of the starch so that the liquefying alpha-amylase enzymes works under optimum conditions to break down and dextrinize the starch completely with a minimum of starch retrogradation. The same reaction parameters are then adjusted for optimum enzyme activity during saccharification.

In our invention, it is preferred to carry out enzymatic saccharificationof whole grain rice with a glucosidase enzyme at the natural pH of rice slurry, that is, about 6.3 or within a range of 6.0 to 6.5. In addition the pH may be adjusted for example, to an optimum level required by the enzyme. In either event, saccharification according to the invention results in a milk-like product which is highly palatable and characterized by absence of a rice flavor. We have also found, that by increasing the saccharifying enzyme dosage from two to ten times that necessary to convert an equivalent amount of purified starch and by maintaining enzyme reaction time of less than about four hours, a modified amazake can be produced having no sour flavor while exhibiting unique functional properties and economic advantages unlike traditional koji amazake.

In other words, the rice milk or modified amazake of the invention prepared with glucosidase with or without beta-amylase enzymes during saccharification has a composition based on total solids as set forth in Table I.

Table I from about 5 to 70% glucose from about 0 to 70% maltose, and from about 10 to 70% complex carbohydrates.

By contrast, prepared amazake from the prior art has the following composition based on total carbohydrates: about 3 to 5% glucose, from about 20 to 45% maltose, and from about 30 to 70% higher saccharides.

As noted above, the rice milk product, because of the selecteion of whole grain rice as a starting material, includes substantial nutritional values as were also discussed and summarized above.

Accordingly, the preferred composition set forth above in Table I further comprises nutritional values which, according to the present invention, comprise ash or minerals at about 0.1 to 0.6% of solids, protein and fat at about 1 to 3.5% of solids and rice fiber at about 0.05 to 0.4% of solids. These materials are only representative of the nutritional values in the rice milk product which may also include other nutritional values such as vitamins, for example.

In the process of this invention, steamed or cooked rice material, selected from the group consisting of polished, unpolished, partially polished or any combination thereof, in a slurry of from 25-40% of rice weight basis, is liquefied with alpha-amylase enzyme having dextrinizing activity and which is produced from a micro-organism selected from Bacillus subtillus, Bacillus Stearothermophilus and

Bacillus licheniformis or a fungal source such as Aspergillus oryzae, substantially free from protease, at a temperature of from 30 DEG C. to 100 DEG C. and at a pH of from 3.5 to 7.5 to yield a liquefied slurry.

The liquefied slurry is then cooled to from 45 DEG to 65 DEG C. and the saccharifying enzyme or enzymes are added. The pH may be maintained at about the normal pH of rice, i.e., about 6.3, or may be adjusted to from 3.5 to 7.5. The saccharifying enzymes include a glucosidase which is glucose liberating and which is produced by a micro-organism selected from many species of Rhizopus or

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Bacillus, strains of the Aspergillus niger group, Aspergillus oryzae, Muco species, Endomyces species,

Endomyces fibuliger, Saccharomyces diastaticus, Chlostridium acetobutylicum and possibly a betaamylase (which is maltose liberating) extracted from either barley, wheat, rye, sweet potatoes or soybeans.

Glucosidase enzymes used in the saccharification step are available from a number of sources including Miles Laboratories, Elkhart, Ind.; Novo Industries, Denmark and the FinnSugar Group,

Finland. Trade names for glucosidase products from Miles Laboratories are set forth in certain of the examples. Similar glucosidase enzymes are available from Novo Industries under the trade name

Amyloglucosidase Novo.

It will of course be apparent from the preceding comments that numerous other glucosidase enzymes can similarly be employed in the saccharification step of the present invention. The beta-amylase enzymes which are also optionally emplyed within the saccharification step are believed to be sufficiently well-known that no further discussion is required.

The dosage level of added saccharification enzyme is anywhere from two to ten times that necessary for the analogous conversion of an equivalent amount of purified starch, the dosage level being dependent upon the quantity and type of sugar to be liberated. After the slurry has been allowed to react with the saccharifying enzyme a relatively short period of time (less than four hours) the slurry can then be sieved and/or centrifuged to remove unwanted fiber, fat or amylose. The filtrate or modified amazake, of varying glucose and maltose content depending upon the quantity and type of saccharifying enzyme used, can then be dried via spray or drum dryer, or reduced in moisture to a concentrate of between 60 and 85% soluble solids, or pasteurized and immediately cooled to between 0

DEG and 18 DEG C. for use as a liquid.

Accordingly, the process of the present invention initially involves the selection of whole grain rice as a starting material.

The whole grain rice is liquefied, preferably employing alpha-amylase enzyme to produce a liquid slurry. In order to prevent development of undesirable off-flavors, the enzymatic liquefication step is preferably limited to no more than about one hour.

Thereafter, the liquid slurry is subjected to a saccharification step employing a high level of a glucosidase enzyme, either alone or in combination with a beta-amylase enzyme, to form an enzyme system substantially excluding other enzymes in order to achieve the desired milk-like texture and functionality realized for the rice milk product of the invention.

The manner of defining the amount and activity of the glucosidase and beta-amylase enzymes for purposes of the present invention are set forth in EXAMPLE 1. In any event, the glucosidase enzyme is present from about 440 to about 2,200 Diazyme Units per kilogram of whole grain rice (see

EXAMPLE 1). The beta-amylase enzyme is optionally present in an amount from about 1,000 to 3,000 degrees of Diastic Power (DP DEG) per kilogram of whole grain rice.

In order to achieve desired conversion while further preventing development of undesirable off-flavors, the saccharification step is also limited, preferably to about three hours and more preferably within the range of about two to three hours.

It has further been found that the milk-like texture and functionality of the resulting rice milk product is enhanced if the pH of the saccharification step is maintained approximately equal to the pH of natural rice (about 6.3). Accordingly, the pH of the saccharification step is most preferably limited to the range of about 6 to 6.5.

However, it has further been found possible to generally maintain the desirable milk-like texture and functionality of the product even with the pH of the saccharification step being adjusted, generally toward acid levels. In this regard, it is often considered desirable to adjust the pH to a range of about

3.5 to 7 in order to enhance enzymatic activity. Accordingly, that range is a broader preferred range within the present invention.

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The solids content of the rice milk or modified amazake may be adjusted to between 8 and 28% soluble solids by the addition of water to yield a milk-like beverage very similar in appearance and taste to milk. If desired, up to 5% vegetable oil may be added and the mixture homogenized to yield a rice beverage having a fatty texture or "mouthfeel" similar to whole milk.

The rice milk or modified amazake of this invention can also be used in the preparation of a novel frozen dessert. The rice milk or modified amazake is used as a replacement for both the milk and sugar in a standard ice cream mix. The rice milk or modified amazake is blended with from 0 to 12% by weight vegetable oil, from 0 to 1% by weight stabilizers, from 0 to 12% flavors, from 0 to 1% salt, the blend heated to between 65 DEG and 70 DEG C., homogenized at between 2,000 and 3,000 PSI, cooled to between 0 DEG and 18 DEG C., additional flavors added if desired and the mix frozen and packaged according to standard practice in ice cream manufacturing.

The rice milk or modified amazake provided in this invention can also be used in the preparation of other frozen desserts, puddings or whipped toppings by the replacement in standard formulations for milk solids, sugar solids, corn syrup solids and or moisture content by the rice milk or modified amazake.

The rice milk or modified amazake provided in this invention of varying glucose to maltose ratios may be dried to a powder form by using drum type dryers, spray dryers or the like. The resulting powder may then be ground or sifted, or agglomerated as needed to a size of between 4 and 300 mesh. This dried powder may then be used as a replacement for corn syrup solids, powdered milk, sweeteners, or any combination thereof. The rice milk or modified amazake may also be used as a source of complex carbohydrates.

Another application of the rice milk or modified amazake prepared by this new process is in the preparation of 100% rice solids concentrate by concentration of the rice milk or modified amazake. The rice milk or modified amazake is concentrated to between 60 and 85% soluble solids by using a vacuum type evaporator.

Having outlined the steps in our invention we will now provide detailed examples of the process for preparing rice milk of varying sugar content; preparation of non-dairy desserts using rice milk or modified amazake; preparation of milk substitutes using the rice milk or modified amazake of this invention; preparation of novel frozen desserts by using modified amazake of this invention; preparation of powdered rice milk or modified amazake by using the rice milk or modified amazake of this invention; preparation of instant dessert mixes and beverages using the powdered rice milk or modified amazake of this invention; preparation of 100% rice concentrates by using the rice milk or modified amazake of this invention.

EXAMPLE 1


Forty-five kilograms of milled white rice of thirty (30) mesh were added to 100 Liters cold tap water having a calcium ion content of 250 ppm (the calcium could be present in the water naturally or added in the form of a calcium salt) in a steam jacketed 225 Liter kettle under constant agitation. One hundred grams of bacterial alpha-amylase of Bacillus subtilis origin with an activity of 1,200,000 modified

Wohlgemuth Units per gram were added to the water. The temperature of the suspension was gradually increased to 80 DEG C. and held for approximately 30 minutes. The temperature was then increased to

100 DEG C. and held there for an additional 15 minutes. The slurry was then cooled to approximately

60 DEG C., 50 ml of Barley beta-amylase with an activity of 1,500 degrees of Diastic Power per ml, as well as 100 ml of glucosidase E.C. 3.2.1.3, 1,4-alpha-D-Glucan glucohydrolase, unit activity of 200

Diazyme units/ml (Diazyme assay is available upon request from Miles Laboratories, Inc., Elkhart,

Ind.) were added. The slurry was held at 60 DEG C. for two hours after which it was sieved through a

30 mesh screen to produce a liquid similar in appearance to milk. This rick milk or rice milk product had the composition of 10% glucose and 35% maltose based on total solids and a total soluble solids content of 31%.

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The rice milk product produced in EXAMPLE 1 has the nutritional advantage of high maltose and complex carbohydrates which are metabolized more slowly than glucose and hence do not result in rapid blood sugar increase. The use of glucosidase enzyme in conjunction with beta-amylase enzyme yields a product with slightly increased sweetness as well as less rice-like flavor when compared with traditional koji amazake. The textural properties are similar to milk, particularly condensed milk and the high dextrin concentration allows for easier drying of the rice milk product with good dispersibility of the dried product upon reconstitution with water. The dried product can be used as a mildly sweet, bland filler in powdered food formulations.

EXAMPLE 2


Forty-Five kilograms of milled brown rice of twenty (20) mesh were added to 80 Liters cold tap water in a steam jacketed 225 Liter kettle under constant agitation. One hundred grams of bacterial alphaamylase of Bacillus subtilis origin with an activity of 1,200,000 modified Wohlgemuth Units per gram were added to the water initially. The temperature of the suspension was gradually increased to 80

DEG C. and held for approximately 30 minutes. The temperature was then increased to 100 DEG C. and held there for an additional 15 minutes. The slurry was then cooled to approximately 60 DEG C.,

450 ml of glucoamylase E.C. 3.2.1.3, 1,4 -alpha-D-Glucan glucohydrolase, unit activity of 200

Diazyme units/ml (Diazyme assay is available upon request from Miles Laboratories, Inc., Elkhart,

Ind.) being added. The slurry was held at a constant temperature for three hours after which it was then sieved and centrifuged to produce a liquid similar in appearance to milk. This rice milk or modified amazake had the composition of 70% glucose based on total solids with a total soluble solids content of

31%.

The rice milk product produced in EXAMPLE 2 has economic advantages from the standpoint that when the product is diluted with water or air in the case of ice cream, it yields a very acceptable sweetness level with obviously no additional sweetener needed. At 30% soluble solids, the rice milk product is generally too sweet to be used as a beverage directly. The high glucose also provides an increased freezing point depression which is an essential part of making a non-dairy ice cream analog which is creamy in texture as opposed to being hard and icy. Upon drying of this rice milk product, a very sweet powder results which is acceptable for use as a sweetener in powdered food formulations.

EXAMPLES 1 and 2 are representative of a broad range of rice milk products which can be prepared according to the present invention. The products resulting from both EXAMPLES 1 and 2 are representative of the invention in that they have surprising milk-like texture and functionality while being almost entirely free of a rice-like flavor and retaining the non-allergenic properties from the rice itself. Furthermore, the products of both EXAMPLES 1 and 2 have retained nutritional values present because of the whole grain rice employed as a starting material. These desirable properties for the products of EXAMPLES 1 and 2 are also retained in the other following EXAMPLES which are based upon either EXAMPLE 1 or 2.

EXAMPLE 3

Non-Dairy Pudding From Rice Milk

Eight grams of alginate (Protanal PM673; Protan, Drammen, Norway) were blended in a bowl with 250 g of the rice milk product of EXAMPLE 2 and vigorously agitated for one minute using a mechanical stirrer. An additional 300 g of the rice milk product of EXAMPLE 2 were slowly added under constant stirring and allowed to sit for 30 to 45 minutes. A very acceptable pudding was produced.

Milk based puddings are produced by cooking milk, sugar and starch together. These milk puddings have soluble solids content approximately 30%. By using the rice milk product of EXAMPLE 2, with approximately 30% soluble solids, no sugar or sweetener need be added. Consequently, only the alginate, starch, gelling, or thickening agent need be considered to produce a very sweet non-dairy pudding of desired consistency. Therefore, the product has simple ingredient labeling being predominantly a rice milk product.

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EXAMPLE 4

Rice Beverage (Milk Substitute) from Rice Milk

One liter of the Rice Milk Product of EXAMPLE 2 was diluted with cold water to obtain a total soluble solids of 13%. To 1 liter of the above 13% soluble solids beverage were added 2.5 g safflower oil,

0.005 g salt, and the mixture homogenized at 2,500 PSI. A pleasing milk-like beverage was produced.

A major economic advantage of the high glucose rice milk product of EXAMPLE 2 is that it can be diluted with water to about 13% soluble solids to produce a beverage of acceptable sweetness. The diluted product of EXAMPLE 4 is very similar to cows milk with regard to texture and mouthfeel.

EXAMPLE 5

Non-Dairy Frozen Dessert

Four liters of the rice milk product of EXAMPLE 2 (approximately 28% soluble solids) were blended with 400 g safflower oil, 120 g vanilla, 20 g salt, and 20 g carrageenan, the blend heated to 75 DEG C. and homogenized at 2,500 PSI. The mix was then cooled to 18 DEG C. and the mix packaged and frozen according to standard practice in ice cream manufacturing.

The frozen dessert outlined in EXAMPLE 5 has a high freezing point depression resulting in a creamy product without crystalline brittleness caused by ice crystals. The ingredient declaration for this product is simplified since no added sweetener is required as is common with all other ice creams or frozen dessert products. Again, the rice milk product of EXAMPLE 2 allows for the dilution by air of the non-dairy ice cream mix resulting in an increased economical advantage for the use of a high glucose rice milk.

EXAMPLE 6

Powdered Rice Milk Product

Rice milk product of EXAMPLE 2 (approximately 28% soluble solids) was pumped through a standard air atomized spray dryer having an inlet temperature of 120 DEG C. and was collected as a white dry powder of approximately 60 to 300 mesh.

The powdered form of the rice milk product of EXAMPLE 2 can be used to replace glucose or fructose derived from corn and containing allergens associated with corn. Because no refining is done as is with sucrose from sugar beet or cane sugar, this powdered rice milk product provides a more natural and nutritionally balanced sweetener. The presence of complex carbohydrates, proteins, fat and minerals also make this powdered sweetener more attractive as a nutritional sweetener.

The powdered rice milk product made from the rice milk of EXAMPLE 1 has much less sweetening power than the product of EXAMPLE 2 but is more desirable as a source of complex carbohydrate or filler powder in formulations where a bland powder is required for bulking purposes and source of complex carbohydrates.

EXAMPLE 7

Instant Brownie Mix Containing Powdered Rice Milk Product

The following ingredients were blended to make a brownie mix:

200. g Powdered Rice Milk Product of EXAMPLE 6

55. g Flour

2.5 g Baking Powder

3.5 g Salt

25. g Cocoa Powder

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Preparation of brownies using the above brownie mix: To the above mix were added 112 g butter, one egg and 2 g vanilla extract. The mixture was stirred until uniform, then poured into a greased

23.times.23 cm pan and baked 25 minutes at 175 DEG C. A tasty brownie product was produced.

This EXAMPLE is representative of applications where the powdered rice milk product of EXAMPLE

6 can be used to replace the sugar and milk of a standard brownie mix recipe. The brownies produced are suitable for people with dairy allergies with the added advantage of including a nutritional rice sweetener.

EXAMPLE 8

Instant Chocolate Flavored Beverage Mix

The following ingredients were blended to make a nondairy cocoa mix:

25. g Cocoa Powder

1.5 g Salt

120. g Powdered Rice Milk Product of EXAMPLE 6

The hot chocolate beverage of this EXAMPLE was prepared by mixing the above components to form an instant chocolate flavored beverage mix. Eight hundred milliliters of boiling water were added with constant stirring. The mixture was beaten with a wire wisk prior to serving.

The product of EXAMPLE 8 illustrates how the powdered rice milk product of EXAMPLE 6 can be used as a replacement for the sugar and milk portion in a cocoa mix.

EXAMPLE 9

High Maltose Rice Milk

The steps of EXAMPLE 1 were repeated except that 100 ml of beta-amylase enzyme were used without any glucosidase enzyme.

This resulted in a product having about 3% glucose and about 55% maltose, the composition and characteristics of the product otherwise being as described above in EXAMPLE 1. In particular, the high maltose rice milk was found capable of being dried in the same manner set forth in EXAMPLE 6 to yield a dried high maltose rice milk.

EXAMPLES 3-9 are further representative of a wide variety of food products which can be formed from rice milk product prepared for example in accordance with EXAMPLES 1 and 2. In particular, as is demonstrated by EXAMPLE 6, the rice milk product of the present invention particularly lends itself either to drum drying or preferably to spray drying in order to form a dried product which can either be used as is or stored and later reconstituted to form a liquid product.

Numerous variations and modifications are obvious from the preceding description. Accordingly, the scope of the present invention is defined only by the following appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A nutritional rice milk product produced by a method comprising the steps of selecting a starting material as a whole grain rice and dividing it into particles of reduced size, liquifying the whole grain rice particles with a alphaamylase enzyme in an aqueous medium to form a liquid slurry, and treating the liquid slurry with glucosidase enzyme in a saccharification step for a period of less than about three hours in order to yield a rice milk product retaining nutritional components from the whole grain rice, having a glucose content of about 5 to 70% of solids, a protein content on a dry-weight basis of less than about 3.5%, the rice milk product being distinctly cloudy and colloidal or non-filtratable.

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2. The product of claim 1 wherein at least about 440 Diazyme Units of glucosidase enzyme per kilogram of whole grain rice particles are employed in the saccharification step.

3. The product of claim 2 wherein the rice milk product is formed into a food product selected from the group consisting of frozen desserts, instant dessert mixes, puddings, whipped toppings, flavored beverages, and milk substitute or modified amazake beverages.

4. The product of claim 2 wherein the total enzymatic reaction time for both the liquifaction and saccharification steps is from about two to four hours in order to yield a rice milk product having desired enzymatic conversion without the development of undesirable flat-sour flavors.

5. The product of claim 2 wherein about 440 to 2,200 Diazyme Units of glucosidase enzyme per kilogram of whole grain rice particles are employed in the saccharification step.

6. The product of claim 5 wherein up to about 3,000 BP DEG of beta-amylase enzyme per kilogram of whole grain rice particles are also employed in the saccharification step in order to yield the resulting nutritional rice milk product having total solids of about 30%, balance essentially water, with a composition of:

>;tb;______________________________________

>;tb;Soluble complex carbohydrates

>;tb; about 10 to 70% of solids;

>;tb;Maltose about 0 to 70% of solids;

>;tb;Glucose about 5 to 70% of solids;

>;tb;Non-carbohydrate about 1 to 5% of solids;

>;tb;nutritional components

>;tb; and

>;tb;Fiber about 0.05 to 0.4% of solids.

>;tb;______________________________________


8. The product of claim 6 wherein the starting material is selected as whole grain rice particles and the liquifaction and saccharification steps are performed so that the resulting nutritional rice milk product having nutritional components comprising ash or minerals at about 0.1 to 0.6% of solids and protein and fat at about 1 to 3.5% of solids.

9. The product of claim 6 wherein the saccharification step is carried out at a pH in the range of about 6 to 6.5 approximating the natural pH of rice.

10. The product of claim 6 wherein the saccharification step is carried out at a pH in the range of about

3.5 to 7.

11. The product of claim 6 produced from the method further comprising the step of drying the rice milk product to substantially remove water and thereby forming a dried rice milk product.

12. The product of claim 11 wherein the dried rice milk product is formed into a food product selected from the group consisting of frozen desserts, instant dessert mixes, puddings, whipped toppings, flavored beverages, and milk substitute or modified amazake beverages.

13. The product of claim 2 produced from the method further comprising the step of drying the rice milk product to substantially remove all water resulting in a dried rice milk product.

14. The product of claim 13 wherein the dried rice milk product is formed into a food product selected from the group consisting of frozen desserts, instant dessert mixes, puddings, whipped toppings, flavored beverages, and milk substitute or modified amazake beverages.

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15. A nutritional rice milk product formed by a method comprising the steps of selecting as a starting material a whole grain rice and dividing it into particles of reduced size, combining the whole grain particles in an aqueous medium substantially free from protease with an alpha-amylase enzyme in a liquifaction step in an amount sufficient and for a period of time limited in enzyme reaction duration to about one hour which is sufficient to form a liquid slurry while permitting desired enzymatic liquifaction and preventing development of undesirable flat-sour flavors, and treating the liquid slurry with an enzymatic system including a glucosidase enzyme of at least about 440 Diazyme Units per kilogram of whole grain rice particles in a saccharification step limited in enzyme reaction duration to about three hours, the amount of glucosidase enzyme and the enzyme reaction duration being sufficient to permit desired enzymatic reaction while preventing development of undesirable flat-sour flavors in order to yield the rice milk product retaining nutritional components from the whole grain rice, having a protein content on a dry-weight basis of less than about 3.5%, the rice milk product being distinctly cloudy and colloidal or non-filtratable.

16. The product of claim 15 wherein the amounts of glucosidase and beta-amylase enzymes are selected to yield the nutritional rice milk product having total solids of about 30%, balance essentially water, with a composition of:

>;tb;______________________________________







>;tb; and


>;tb;______________________________________

17. The product of claim 16 wherein the starting material is selected as divided whole grain rice particles and the liquifaction and saccharification steps are selected to yield the rice milk product having nutritional components comprising ash or minerals at about 0.1 to 0.6% of solids and protein and fat at about 1 to 3.5% of solids.


19. A rice milk product having a milk-like or distinctly cloudy appearance and enzymatically produced by liquifaction followed by saccharification to have about 30% total solids, balance essentially water, and a composition of:

>;tb;______________________________________







>;tb; and


>;tb;______________________________________

20. The product of claim 19 wherein the rice milk product has nutritional components comprising ash or minerals at about 0.1 to 0.6% of solids and protein and fat at about 1 to 3.5% of solids.

21. The product of claim 20 being dried to substantially remove water for yielding a dried rice milk product.

22. The product of claim 19 being dried to substantially remove water and form a dried rice milk product.

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23. The product of claim 21 being wherein the dried rice milk product is formed into a food product selected from the group consisting of frozen desserts, instant dessert mixes, puddings, whipped toppings, flavored beverages, and milk substitute or modified amazake beverages.

24. The product of claim 19 being wherein the rice milk product is formed into a food product selected from the group consisting of frozen desserts, instant dessert mixes, puddings, whipped toppings, flavored beverages, and milk substitute or modified amazake beverages.

25. A nutritional rice milk product formed by a method comprising the steps of selecting as a starting material whole grain rice particles, liquifying the whole grain rice particles with an alpha-amylase enzyme in an aqueous medium substantially free from protease in an amount and for a period of time sufficient to form a liquid slurry, and treating the liquid slurry with a beta-amylase enzyme in a saccharification step with at least about 1,000 BP DEG of betaamylase enzyme per kilogram of whole grain rice particles, the reaction time for the saccharification step being limited to about three hours, the amount of beta-amylase enzyme and the reaction time being sufficient to yield the rice milk product retaining nutritional components from the whole grain rice and exhibiting a milk-like or distinctly cloudy appearance without development of flat-sour flavors.

26. The product of claim 25 formed from the method further comprising step of drying the rice milk product to substantially remove water in order to form a dried rice milk product.Data supplied from the esp@cenet database - Worldwide

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379.

US4901632 - 2/20/1990

THREE-PHASE PROCESS AND MACHINE FOR COOKING FOODS AS DRY

PASTA, RICE, LEGUMES AND THE LIKE


Inventor(s): LORI GIULIO (IT)

Applicant(s): LORI GIULIO (IT)


IP Class: A47J44/00

E Class: A23L1/01D; A47J27/18; G07F9/10B



Family: US4901632

Abstract:


The invention relates to a new process for the quick cooking of foods such as pasta, rice, legumes and the like, and the automatic machine to carry it out. The process comprises three phases, namely precooking, cooking and final cooking starting with overheated water. The process and the machine allow reduction of cooking time, improving efficiency of cooking level, avoiding excess of water hardness, reducing power consumption, avoiding or reducing scales, simplifying the machine and extending its

1799/2197

life, having different types of heating, according to the local availability, and keeping comfortable the surrounding room where the machine has been installed.Description:



It is known that for obtaining a rapid cooking of dry foods it is necessary, for a short time, pre-cook in overheated water and then cook by condensation vapour. The present invention relates to a new contemporary cooking method of dry foods to eat immediately, according to a three-phases cycle:

(1) pre-cooking phase in overheated water at high temperature and pressure (160 DEG-200 DEG C. at

8-18 bar);

(2) cooking phase by water and vapour at lower temperature and pressure (80 DEG-160 DEG C. at 1.5-

5 bar); and

(3) final cooking at atmospheric pressure with mixing the cooked food, draining and adding of seasoning if requested. The machine according to the invention can have two cooking lines, feeded by one boiler, for the three-phases cycle.

On a continuous request of cooked food the time is reduced of 1/3 at least; in fact food can be at the same time in precooking, cooking and final cooking cycles. The machine comprises: (see FIG. 1) two or more dispensers (A) for the dry food ; pre-cooking chambers (C) fitted in the generator of overheated water; cooking chambers (G) with expeller pipe; final chambers (J) with spherical valve

(L); gas heating devices; exhausted vapour chimney; salt regulation inside the boiler and anti-scales device for the water. The known machines cannot produce an accpetable cooking because:

(1) It is difficult to find power supplies to fulfill the high need of power requested by the machine, when working at cycles of 60 sec;

(2) It is necessary to remove scales in the heating element of boiler;

(3) There is not the control of mineral salt increase in the sevice water:

(4) There is a blast of power during each cycle because of the water thermal expansion causing the safety values opening and water overflowing;

(5) Difficulties for obtaining a constant temperature in the pre-cooking chamber after inactivity are encountered; and

(6) Room moisture comes out after few cycles because of the vapour.


The purpose of the invention is to carry out a machine that, with a proper process, by starting a pushbutton, or by introducing coins, gives automatically a portion of cooked pasta, rice and legumes under hygienic conditions while keeping the quality of the same food.

The machine can work automatically like the distributor of drinks and foodstuffs and can be installed in self service areas at low cost.

All the materials that are in contact with food are approved by all European and American rules; besides an automatic device gives hygienic process by washing with water and vapour to remove residual food.

The machine properly works also after a period of inactivity; the devices are easy to run and test without any special maintenance.

The process is carried out in three phases: At first, the dry food is pre-cooled in over-heated water until it becomes soft, then, the food and water are poured off in a chamber for the cooking, while pressure is reduced to the water condensation temperature; finally, food and water come in the chamber where they are mixed, released of water, seasoned on request, and put over a plate. The machine can have two or more cooking lines for allowing feeding of different foods. The following is a detailed description of a machine having two cooking lines, both feeded by one dispenser. The machine comprises:

1800/2197

(a) two dispensers for dry foods, connected in cascade by spherical valves (B) with pre-cooking chambers.

The dispenser can vary according to the kind food: one type has been designed to put in dry and long pasta in fixed and adjustable quantity.

From a storage hopper the food goes down through a bottleneck, comprising two inclined planes put in front each other, in a cylinder splitted in four cells.

The cells are formed by splitting the cylinder in four parts by orthogonal planes passing through the axis of the cyclinder. The cylinder, motor driven, gives a dose when rotated 90 degrees from its axis;

(b) an over-heated water generator, or boiler, which is vertically crossed by two pre-cooking chambers where the food is in bain-marie at the pressure and temperature of generator. The insertion in the boiler of the pre-cooking chambers prevents them from becoming cold when the machine is not working and the greater thermal capacity of the generator improves temperature uniformity in the above mentioned chambers.

The boiler comprises a vertical cylinder wherein a pipe beam is provided, that is crossed by hot fumes of a gas flame combustion.

When power supply outlets are present, the pipe beam can be replaced by an electric resistance.

The cylindrical body comprises two or more horizontal parts (both having a pre-cooking chamber) interconnected with each other and with the container;

(c) two cooking chambers both connected with the bottom of the pre-cooking chambers by a second spherical valve (F). The cooking chambers have double capacity if compared with the pre-cooking chambers, because of the presence of a pipe for pressurized vapour (expeller pipe).

In the bottom of the chamber the cooking of food continues that, stopped by a third spherical valve (H), stores in the bottom condensation water.

On the outer part of this side of chamber there is a jacket for recovering heat, which is given to the service cold water of boiler.

(d) two final chambers bigger than previous, connected by the third interdiction device with the lower end of the cooking chambers.

Such chambers, of cylindrical shape, vertically placed for better pick-up and condensing a portion of vapour from the cooking water, are connected with the by-pass of the combustion products of boiler.

The vapours in excess not condensed come through the by-pass to the outside to avoid entering in the surrounding room. The bottom of the final chamber is closed by a semi-spherical valve, avoiding direct connection with the room. The valve is fitted with a strainer and a double bottom in which the drained water is contained.

When the valve overturns, the food inside the drain falls into a plate, while the cooking water remains in the double bottom.

Through a by-pass, provided in the valve axis, the cooking water exits and discharges into the sewer.

(e) two sauce mixers connected with the inner of the final chamber and a space portion to the food after draining.

(f) an anti-calcareous treatment device for the boiler service water to avoid hard scales of the heating elements.

The scales have a low heat transmission and consequently the surface temperature increases; the breaking of a layer of scale produces a contact between water and over-heated surface and an overpressure that can cause the explosion of boiler. To avoid scales a physical treatment is used instead of chemical.

1801/2197

By physical treatment the water flows through magnetic fields that affect ions dipolar moment; water chemical composition and drinking are not changed, but only modified salts are generated that remain suspended and are no more able to make scales.

The sediments are easily eliminated with water.

(g) a device allowing a continuous control of salts concentration in the boiler.

The water leaves an amount of mineral salt in the boiler, that prevents heat exchange.

Two electrodes immersed in the water of the boiler check the salts concentration.

A control device operates a drainage electrovalve to open it when the fixed limits are overcome, discharging the excess of salts using a minimum quantity of water.

(h) a programmable logic controller PLC, for operating the machine.

The controller comprises a feeder, a central program unit (cpu), input/output modules, timers and programming keyboard. The programming is carried out by using contacts plan and is pre-recorded.

Different programs are available according to the type of feeding.


The enclosed drawings 1 and 2 show an embodiment of the machine.


FIG. 1 shows the internal devices while FIG. 2 shows the outside shape. The present invention is directed to a three-phase process for the cooking of foods such as dry pasta, legumes and the like, in which the food is placed in a first chamber with over-heated water and high temperature and pressure, then in a second chamber with water and vapor at medium temperature and pressure, and finally in a third final chamber at 80 DEG C. temperature and atmospheric pressure, where the food is completely cooked, seasoned, and placed over a plate, while residual water is removed. The cooking cycle takes place in three phases.

The present invention is also directed to an automatic machine for carrying out the cooking process in three phases, which comprises the following features:

Dispensors (A) having outputs connected to pre-cooking chambers;

Pre-cooking chambers (C) having inlet valves (B) and outlet valves (F);

Cooking chambers (G) having inlet valves (F) and outlet valves (H) and provided with a cooling jacket and an expeller pipe for vapor;

Final chambers (J) provided with semispherical valves (C) with a strainer with an under-bottom for picking and elimination of cooking water;

Seasoning dispensers (O) with nozzles for discharging directly into the final chambers (J) upon the cooked food;

A boiler (Q) for producing overheated water;

Anti-scale treating devices of the water from the boiler;

An electrometer device for the continuous control of salt concentration in the boiler;

Water feeding pump in the boiler;

Main burner for heating the boiler and a safety pilot burner; gas valve for the control of temperature in the boiler; electric board for programming of PLC logic for the operating control of cycles; and

Group of devices, pump, safety valves, electrovalves, limit switches, pressure switches, thermostats, control and measurement instruments, including connection fittings. Preferably, up to six lines are provided with simultaneous operation.

Below the operating of one cooking line is described, being the same as the second line. Start-up of machine depends on rating of boiler temperature.

1802/2197

After start-up--monitored by a lamp--one line is selected; the cycle can start by pushing the start-button or introducing a coin.

The dispenser (A) delivers a portion of food that goes through the valve (B) and into the below precooking chamber (C). After closure of the valve (B), overheated water is introduced through the electrovalve (D) into the chamber. The boiler pressure goes down; the pump (P) starts working for increasing again the pressure in the boiler (Q) then in the chamber (C) to a value set by the pressure switch (E). Inside the chamber (C) the temperature and pressure conditions are 160 DEG-200 DEG C. and 8-18 bar. The pre-cooking is preferable carried out at a 160 DEG-200 DEG C. temperature and 8-

18 bar pressure.

Elapsed the time t1 and ended the pre-cooking phase, the spherical valve (F) opens.

Because of the pressure existing in the pre-cooking chamber (C) the food and over-heated water go into the cooking chamber (G). The cooking is carried out at a 80 DEG-160 DEG C. temperature and 1.5-5 bar pressure.

In this moment the two chambers are interconnected: the volumes add and the pressure goes to 5 bar.

The valve (F) closes and the food stays in the chamber (G) cooking in water which starting temperature of 160 DEG-200 DEG C. goes down to 80 DEG C., as measured by the thermostat (I).

The temperature decrease in the chamber (G) is accelerated by a cooling jacket that recovers heat

(given the cooling water of the boiler).

Consequently the pressure decreases; in the expeller pipe of chamber (G) there remains a quantity of vapour at 1,5-2 bar pressure.

Under this pressure, when the spherical valve (H) opens, the food and the remaining cooking water of chamber (G) go in a final chamber (J) at atmospheric pressure: food is then picked up in the semispherical valve (L).

As the food goes out at a temperature of 80 DEG C. the remaining vapour is reduced, being condensed in the chamber (G). The remaining vapour goes out through the chimney (Z). Valve (H) closes and the mass of food in the strainer (L) completes the cooking; meanwhile the mixer (K) starts and the remaining water stays under-bottom.

On request, cold water can be sprayed for stopping the cooking. After a time t2 the dispenser (O) adds a portion of sauce to the food.

The semispherical valve (L) upsets the seasoned food over a plate (N) enclosed in an openable chamber and simultaneously emptying of cooking water from the double bottom happens. By washing the strainer with boilinng water and emptying of washing water the cycle ends.

For starting a new cycle, push again the operating button. The machine can deliver continuously portions of food: in this case the time-cycle is reduced by 1/3 because the three chambers can work at the same time.

All the compartments are provided with opening plexiglass screen for taking plates with cooked food and feeding plates and food if necessary.

By way of example, the following data are furnished, relating to a machine according to the invention:

Net weight: 100 kg.

Cooking time: less than 60 sec.

Capacity: 120 plates/hour.

Portion per plate: 120 gr.

Electric power: 110-220 V.--service water--gas signalling lamp for exhaust food.

1803/2197

Numbers indicated in FIG. 2 refer to:

1-PLASTIC PLATES

2-DRY SPAGHETTI (FOOD)

3-SLOT COINS

4-CONTROL BOARD FOR STARTING COOKING

5-WARNING LIGHT

6-7--PLATES WITH COOKED SPAGHETTI (FOOD)

8-CUTLERY

The machine as described is easy to manage and to operate. The cooking is carried out at a 80 DEG-

160 DEG C. temperature and 1.5-5 bar pressure.

The cycle is preferably carried out at a 65 DEG-200 DEG C. temperature and 0-18 bar pressure. The final cooking is preferably carried outat a 65 DEG-100 DEG C. temperature and at atmospheric pressure. The start flow process is over-heated water.

The boiler preferably comprises a cylindrical body crossed by a pipe beam heated by combustion products of a flame with gas (methane, propane, LPG). The boiler may also comprise a central cylindrical body heated by an electric resistance. The boiler itself is preferably composed by horizontal connected modules, each containing a pre-cooking chamber. The pre-cooking chambers preferably operate in bain-marie. The pre-cooking chambers may be dipped in the boiler itself. In particular, the pre-cooking chambers give stable and uniform temperature, and produce uniform treatment also after inactivity of the machine itself.

Service water, before entering into the boiler, is preferably subjected to physical treatment consisting of applying magnetic fields to avoid forming hard scales on the heating elements. In particular, the growing salt heap in a boiler is continuously checked by a device (electrode and electrovalve) that discharges the mineral salt excess contained in the water. Each chamber (G) has an expeller pipe in which vapor, because of opening of the valves (H), carried out the function of emptying the chamber

(G). The cooking chamber (G) is fitted with a jacket for heat recovery, transferred to the cold service water for the boiler.

The final chamber (J) is fitted with a semi-spherical valve (L) that closes the bottom of the final chamber (J). This valve (L), in turn, contains a semi-spherical and perforated strainer and a chamber for picking or retention of cooking water which, when upset, allows the food to fall upon a plate, and the flow of the cooking water along a perforated axis of the same valve.

A seasoning dispenser (O) is placed at the same side of the final chamber (J) and is connected to the same chamber for admitting the seasoning in the draining food.

The dispenser (A) for dry foods, connected with the pre-cooking chambers (C), comprises a hopper where the dry food is stored, with discharge therefrom being carried out along two inclined planes placed in front of one another forming a bottle-neck through which the food drops down into one of four dispenser spaces in a cylinder that is cross-split along an axis thereof. This cross-splitting is motor driven which turns inside a cylindrical chamber thus causing the discharging of a portion of the dry food from the four portion total at a time.

The treatment of the cooking phases on both lines as illustrated in FIG. 1, is preferably controlled by

PLC (Programmable logic controller).Data supplied from the esp@cenet database - Worldwide

Claims:


I claim:

1. Automatic machine for carrying out a cooking operation in three phases, having a line comprising a pre-cooking chamber for performing a first of said three phases, comprising an inlet and an outlet, a first valve disposed in said pre-cooking chamber inlet, and a second valve disposed in said pre-cooking chamber outlet, a dispenser coupled to said pre-cooking chamber inlet in a manner such that feed in

1804/2197

said dispenser cascades into said pre-cooking chamber when said first valve is open, a cooking chamber for performing a second of said three phases, having an inlet coupled to said outlet of said precooking chamber and an outlet in a bottom thereof, with a third valve disposed in said cooking chamber outlet, a cooling jacket surrounding at least a part of said cooking chamber, an expeller pipe communicating with an interior of said cooking chamber for releasing pressurized vapor therefrom, a final cooking chamber for performing a third of said three phases, having a inlet coupled to said outlet of said cooking chamber through said third valve, being substantially cylindrical in shape and vertically positioned with a fourth valve closing a bottom thereof, avoiding direct connection with a surrounding area, and a boiler for generating over heating water for said cooking operation.

2. The combination of claim 1, additionally comprising a fifth valve through which said boiler communicates with said interior of said cooking chamber.

3. The combination of claim 1, wherein said pre-cooking, cooking, and final cooking chambers are arranged such that the feed falls from one chamber to the next when the respective valve is opened.

4. The combination of claim 1, comprising two separate lines, each line comprising its own respective pre-cooking, cooking, and final cooking chambers each communicating with one another, and with said boiler arranged to feed water to both said cooking chambers of said two lines.

5. The combination of claim 1, wherein all said valves are spherical.

6. The combination of claim 1, wherein said cooking chamber has a greater capacity than said precooking chamber.

7. The combination of claim 1, wherein said final cooking chamber has a greater capacity than said cooking chamber.

8. The combination of claim 2, wherein said final cooking chamber is coupled to a flue duct of said boiler for combustion products of said boiler, whereby said excess vapor is conveyed from said final cooking chamber to avoid contamination in the surrounding area.

9. The combination of claim 4, comprising up to six of said separate lines.

10. The combination of claim 1, wherein said boiler comprises a central cylindrical body crossed by a pipe beam, heated by combustion products of a flame of gas.

11. The combination of claim 10, wherein said gas includes methane, propane, LPG.

12. The combination of claim 1, wherein said boiler comprises a central cylindrical body heated by an electrical resistance.

13. The combination of claim 10, wherein said boiler additionally comprises two horizontal parts interconnected with said central cylindrical body and each part containing a pre-cooking chamber.

14. The combination of claim 13, wherein each said pre-cooking chamber is dipped in said boiler.

15. The combination of claim 14, wherein said two pre-cooking chambers are arranged to exhibit stable and uniform temperature.

16. The combination of claim 15, wherein said pre-cooking chambers additionally produce uniform treatment even after activation in activation of said machine.

17. The combination of claim 1, additionally comprising means for subjecting service water to a physical treatment of applying magnetic field before the service water is introduced into the boiler, to avoid forming hard scales on heating elements within the boiler.

1805/2197

18. The combination of claim 1, additionally comprising means for continuously checking growing salt heap in said boiler comprising an electrode device connected by a control unit with an electrode valve, which remove mineral salt excess by discharging a minimum quantity of water.

19. The combination of claim 1, wherein said expeller pipe of said cooking chamber is arranged to empty said chamber of vapor when said third valve is opened.

20. The combination of claim 1, wherein said cooling jacket is arranged to transfer heat recovered from said cookingn chamber to service water entering said boiler.

21. The combination of claim 1, wherein said fourth valve contains a semispherical and perforated strainer and a double bottom for retention of water which, when upset, allows food contained in said strainer to fall thereoff while the water remains in said double bottom, and additionally comprising a duct communicating with said double bottom along an axis of said fourth valve for discharging the water to a sewer.

22. The combination of claim 1, additionally comprising a seasoning dispenser conntected to said final cooking chamber for introducing the seasoning for foods.

23. The combination of claim 1, wherein said dispenser comprises a hopper and a cylinder divided into four portions by cross-dividing the same along an axis thereof, said hopper arranged to discharge food into one of said four portions which are rotated by said cross-splitting being motor driven to turn inside said cylinder, whereby a portion at a time is discharged of the four portions of dry food.

24. The combination of claim 4, wherein said cooking phases of both said lines are controlled by a PLC

(programmable logic controller).

25. The combination of claim 1, wherein said pre-cooking chamber is arranged to provide a pressure of about 8-18 bar and a temperature of about 160 DEG-200 DEG C. therein.

26. The combination of claim 1, wherein said cooking chamber is arranged to provide a pressure of about 1.5-5 bar and a temperature of about 80 DEG-160 DEG C. therein.

27. The combination of claim 1, wherein said final cooking chamber is arranged to provide a temperature of about 65 DEG-100 DEG C. therewithin.

28. The combination of claim 1, wherein said chambers and boilers are all arranged to provide an overall operating temperature of about 65 DEG-200 DEG C. and pressure of about 0-18 bar.

29. The combination of claim 13, wherein each said pre-cooling chamber is situated to operate in a water bath.Data supplied from the esp@cenet database - Worldwide

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380.

US4902528 - 2/20/1990

PREPARATION OF DRIED PRECOOKED RICE PRODUCT


Inventor(s): HSU JAU Y (US); GROESBECK CHERYL (US); LARSON GARY J (US)

Applicant(s): NESTEC SA (CH)


IP Class: A23L1/18

E Class: A23L1/182



Family: US4902528

Abstract:


A dried precooked rice product is prepared by cooking rice grains for obtaining a moisture content of from 55% to 75% by weight and then by drying the cooked rice grains at a temperature of from 140

DEG C. to 185 DEG C. in two stages, firstly under stationary conditions to a moisture content of from

20% to 35% and secondly under agitated conditions to a moisture content of from 3% to 15%, for providing a precooked dried rice produce having a bulk density of from 37 g/100 cm to 42 g/100 cm.

100 g of the rice product so produced is capable of absorbing from 195 g to 225 g of boiled hot water in 10 minutes rehydration in 500 g of boiled hot water.Description:



The present invention relates to a process for the production of a convenient rice product, more particularly to a pre-cooked rice product that requires no cooking for consumption.

There are basically three kinds of commercial parboiled rice products:

(1) Regular parboiled rice this is prepared for consumption by cooking (simmering) for about 20 minutes and the product has a good texture. However, the time taken to prepare this product for consumption is rather long and depending on the amount of water used and the heating conditions, the texture is not always consistent and, therefore, the product is not particularly convenient to use.

(2) Quick cooking parboiled is 85-95% gelatinised and is produced by partial cooking and drying of regular parboiled rice. This product also requires cooking (simmering) for consumption but, as the time required is only about 5-10 minutes, it is more convenient to use than regular parboiled rice. However, depending on cooking conditions, the water absorption of rice is usually varied and consequently, the rice texture is not consistent. It also requires attention during cooking and, therefore, it is not really convenient.

(3) Instant is 95-100% gelatinised and is usually produced by complete cooking of the rice followed by low temperature drying (50 DEG-65 DEG C.) to a moisture content of about 10% and then high temperature drying (180 DEG-350 DEG C.) for a high degree of puffing. This type of rice is more

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convenient than quick cooking rice because it is reconstituted for consumption by rehydrating in boiled hot water for a period of from only about 1 to 5 minutes. The high degree of puffing is carried out because of the requirement of instant rehydration but, because of this high degree of puffing, the rice structure is usually damaged and, consequently, the texture of the product is not good.

It would be very desirable to produce a convenient rice product which can be reconstituted simply and quickly like instant rice while still possessing the good texture of regular cooked rice. Up to the present time, this has not been achieved because fast rehydration requires a change of the rice structure and texture. In order to maintain the good rice structure, it is important that the rehydration time is at least 8 minutes, preferably at least 9 or 10 minutes.


We have found, surprisingly, that a mildly-puffed convenient rice product, having a good and constant texture when reconstituted to a palatable state by rehydration, can be produced by a process which does not involve a high degree of puffing of low moisture cooked rice and which can be reconstituted for consumption simply by rehydrating in boiled, hot water and allowing to stand for a minimum of about

8 minutes and preferably a minimum of 9 or 10 minutes. Since there is no high puffing step, the rice has a better texture than conventional instant rice. Compared with quick cooking rice, since cooking and attention are not required in the preparation for consumption, not only is it more convenient to use but the texture and quality of the rice product are also more constant.

Puffing can be defined as the expansion of rice grain size and this can be expressed by the bulk density which is measured by weighing the loose weight of dried rice in a 100 ml graduated cylinder. It is essential that the mildly-puffed convenient rice product of the present invention has a bulk density of from 37 to 42 and preferably from 38 to 41 g/100 cc. In addition, to achieve a palatable state on reconstitution, 100 g of the product of the present invention should absorb from 195 to 225 g of water after 10 minutes rehydration in 500 g hot water which has just been boiled without any further heating, which we shall refer to in this invention as "boiled, hot water". In contrast, non-puffed quick cooking rice usually has a bulk density of from 43 to 50 g/100 cc and absorbs less water during rehydration while highly-puffed instant rice usually has a bulk density of from 30 to 36 g/100 cc and absorbs more water after 1 to 5 minutes rehydration.

According to the present invention there is provided a process for the production of a convenient precooked rice product characterized in that rice grains are cooked with water at a temperature and for a time sufficient that their moisture content is from 55% to 75% by weight and dried at a temperature from 140 DEG C. to 185 DEG C. in two stages, firstly under stationary conditions to a moisture content of from 20 to 35% and secondly under agitated conditions to a moisture content of from 3 to

15%, such that the dried rice has a bulk density of from 37 to 42 g/100 cm. For obtaining a palatable product upon rehydration, the dried product is rehydrated in boiled, hot water for a minimum of 8 minutes.

Any type of rice grain can be used, for example, milled white rice (long or short grain), arborio rice, or basmati rice, but the process of this invention is particularly advantageous for parboiled rice.

In addition to the hereinabove described methods of preparing these rice products for consumption, i.e., regular parboiled rice, quick cooking parboiled rice, instant rice and the convenient rice prepared by the process of the present invention, all these rice products can, if desired, be prepared for consumption by microwave cooking. The time required for microwave cooking ranges from about 2 to 20 minutes depending upon the degree of rice gelatinisation, rice puffing, variety of rice and the amount of rice and water used during microwave cooking. For example, to prepare the convenient rice produced by the process of the present invention for consumption in a microwave oven as utilized commonly in the home, it is possible to cook 120 g rice with 230 cc water at high power in 5 minutes and 240 g rice with

460 cc water at high power in 8 minutes. These times are shorter than those required for regular or quick-cooking parboiled rice, and the convenient rice produced by the process of the present invention has a better texture than instant rice after preparation for consumption by microwave cooking because of the optimum puffing of the rice.

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The cooking may be carried out by boiling the rice grains in water, steaming, or by a combination of boiling and steaming. Superatmospheric pressure may be used, if desired. The temperature of the cooking may be from 90 DEG C. to 110 DEG C. and preferably from 95 DEG C. to 105 DEG C. and the duration of the cooking may be from 5 to 20 minutes. The pH during cooking may conveniently be from 3.0 to 7.5. Preferably, for a product which is to be prepared for consumption by heating in boiled, hot water, the pH during cooking is from 6.5 to 7.5, while for a product which is to be prepared for consumption by microwave cooking the pH during cooking is preferably from 3.0 to 5.5, especially 3.5 to 5.0. Optionally, the rice grains may be soaked in water prior to cooking.

Drying in two stages, first under stationary and then under agitated conditions at from 140 DEG C. to

185 DEG C. in each stage, is critical for obtaining the required bulk density which results in the water absorption properties which provide the excellent rehydrated texture of the convenient precooked rice product of the present invention when rehydrated for the stated time. In both drying steps the cooked rice is preferably dried at a temperature from 145 DEG C. to 180 DEG C. and especially from 150

DEG C. to 175 DEG C.

In the first drying step, the cooked rice is preferably dried to a moisture content of from 23 to 35%. The drying under stationary conditions may be carried out on a regular belt dryer or on a high velocity belt dryer with nozzle tubes that produce hot air.

When the rice is dried in a regular, hot air belt dryer, it is conveniently fed onto the dryer in a thin layer. The thickness of the layer of rice grains on the belt may be from 2 to 10 mm and preferably from

3 to 6 mm. The velocity of the hot air is conventional and is usually from 10 to 20 meters per minute.

The duration of the first drying step in a regular belt dryer to obtain the required moisture content is usually from 10 to 20 minutes and preferably from 12 to 18 minutes depending on the drying temperature used and velocity of the hot air.

When the rice is dried in a high velocity hot air dryer, the cooked rice may be dried by passing the hot air through a layer of cooked rice, which has preferably been dewatered, for instance by suction, to remove some surface moisture. The thickness of the layer of cooked rice is conveniently from 5 to 12 mm thick, and the drying time may be from 2 to 8 minutes, preferably from 3 to 7 minutes. The velocity of the hot air preferably ranges from 100 to 200 meters/min.

After the first drying step, the partially dried rice cake is broken and the rice separated. The dewatering step which advantageously precedes the first drying step when using a high velocity hot air dryer can reduce the stickiness of the cooked rice and enables a thicker layer of rice to be dried. In particular, the dewatering step can reduce the sticking of rice cooked at a pH of 6.5 to 7.5.

In the second drying step, the partially dried rice grains are preferably dried to a moisture content of from 6% to 12% by weight. The drying under agitated conditions may be carried out in a vibrating dryer such as a vibrating fluid bed dryer or a high velocity belt dryer with nozzle tubes that produce hot air similar to the one used in the first drying step. The velocity of the hot air generally ranges from 20 to 200 meters/min and the drying time is usually from 30 to 120 seconds. Preferably, the velocity of the hot air in the second drying step is not greater than that in the first drying step.

In both drying steps, the temperature, hot air flow and times are adjusted to create a rice product with the required bulk density, optimum water absorption and texture after about 10 minutes rehydration with boiled, hot water. The duration of the cooking time also affects the bulk density, water absorption and texture and for longer cooking times, the drying temperature and/or hot air velocity are advantageously lower, while for shorter cooking times, the drying temperature and/or hot air velocity are advantageously higher. Compared with conventionally puffed rice which is usually dried at a lower temperature for a longer time (e.g., 50 DEG C. for 2 hours) to a moisture content of about 10% and then puffed at a high temperature for a short period of time (e.g., 180 DEG-350 DEG C. for a few seconds) the rice prepared by the process of the present invention is only mildly puffed and has good texture. In addition, the rehydration and the water absorption is improved by the longer rehydration time of at least 8, 9 or preferably 10 minutes for conventionally puffed rice.

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Another advantage of the present invention is that by drying at a temperature of from 140 DEG C. to

185 DEG C. instead of at a lower temperature, e.g., about 50 DEG C. to 60 DEG C., as for conventionally puffed rice, the rice need not be cooked completely in the boiling step, thus reducing cooking losses which can amount to about 10% or more. The cooking is further completed in the drying step at temperatures from 140 DEG C. to 185 DEG C. in the present invention.

The present invention also provides a convenient rice product whenever produced by a process hereinbefore described.

It should be understood that although the product of this invention may be reconstituted by rehydrating with boiled, hot water in 8 minutes, the texture of the reconstituted product is superior when the rehydration time is 10 minutes or more. However, reconstitution times appreciably longer than 10 minutes reduce the convenience of the product.

EXAMPLES


EXAMPLE 1

1000 g parboiled rice were boiled in water at pH of 7.0 for 15 minutes, rinsed with cold water and drained to give a total weight of 2840 g (68.5% moisture). The rice was then placed in a layer of 5 mm on a Proctor & Schwartz's hot air belt dryer with a hot air velocity of 12 meters/min and dried at 175

DEG C. for 12 minutes whereupon the moisture content was reduced to 32%, after which the rice grains did not stick together. The partially dried rice was then placed on a Witte's vibrating, fluid bed dryer in a layer of 8 mm and dried at 175 DEG C. for 1 minute to a moisture content of 8-10%. The dehydrated rice had a bulk density of 40 g/100 cc. 180 g of this rice product was prepared for consumption by adding to 500 cc boiled, water and allowed to stand for 10 minutes 376 g water was absorbed and the product had a good, tender, firm, even texture.

COMPARATIVE EXAMPLE A

180 g of regular parboiled rice were prepared for consumption by boiling for 20 minutes in 500 cc water. 500 g water were absorbed. Because the cooked rice was not rinsed, it was softer and more starchy than the reconstituted product of Example 1.

COMPARATIVE EXAMPLE B

A quick cooking parboiled rice was prepared by boiling 1000 g parboiled rice for 15 minutes to 68.5% moisture, and then drying at 50 DEG C. for 2 hours. The dehydrated rice had a bulk density of 43 g/100 cc 180 g of this product were prepared for consumption by adding to 1000 cc of boiling water and simmering for 10 minutes. 344 g water were absorbed but the product had a more grainy and slightly undercooked texture when compared with the reconstituted product of Example 1.

COMPARATIVE EXAMPLE C

An instant parboiled rice was prepared by boiling 1000 g parboiled rice for 20 minutes to 70% moisture, then drying in a hot air dryer at 50 DEG C. for 3 hours and finally puffing at 240 DEG C. for

10 seconds. The dehydrated rice had a bulk density of 32 g/100 cc 180 g of this instant parboiled rice were prepared for consumption by adding to 500 cc boiled, hot water and allowing to stand for 5 minutes. 415 g water were absorbed but the product had a broken rice texture and had no structural characteristic of rice.

EXAMPLE 2

1000 g parboiled rice were boiled in water with pH of 7.0 for 15 minutes, rinsed with cold water and drained to give a total weight of 2840 g (68.5% moisture). The cooked rice was then dewatered for one minute by placing the rice under force of suction. The rice was then placed in a hot air dryer (12 mm thick) with a jet-tube nozzle (Wolverine's Jetzone dryer), the hot air velocity was 150 meters/min and

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the temperature was 150 DEG C. After drying for 5 minutes to a moisture content of 25%, the partially dried rice cake was then broken, the rice was separated and dried again at the same temperature and velocity for 45 seconds. The dehydrated rice had a bulk density of 39 g/100 cc 180 g of this rice was added to 500 cc boiled, hot water and allowed to stand for 10 minutes. 374 g water was absorbed and the product had a good, tender firm, even texture.

COMPARATIVE EXAMPLE D

By following a similar procedure to that described in Example 2, but where the velocity of hot air used was 75 meters/min and pre-drying time was 10 minutes, the dehydrated rice had a bulk density of 44 g/100 cc and 180 g of rice absorbed 340 g boiled, hot water after 10 minutes. The rehydrated rice texture was hard and grainy.

COMPARATIVE EXAMPLE E

By following a similar procedure to that described in Example 2, but where the hot air velocity was 450 meters/min and the pre-drying time was 3 min, the dehydrated rice had a bulk density of 36 g/100 cc and 180 g of this rice absorbed 410 g boiled, hot water after 10 minutes. The texture of the rehydrated rice was soft and had no structural characteristics of rice. The same rice was rehydrated for only 7 min, the water absorbed was 317 g but the texture was still soft.

COMPARATIVE EXAMPLE F

By following a similar procedure to that described in Example 2, but where the drying temperature was

190 DEG C. and the pre-drying time was 4 min, the dehydrated rice had a bulk density of 35 g/100 cc of this rice absorbed 412 g boiled, hot water after 10 minutes. The texture of the rehydrated rice was soft and had no structural characteristics of rice.

EXAMPLE 3

By following a similar procedure to that described in Example 2, but using regular long grain, milled rice instead of the parboiled rice (the white rice was boiled for 12 minutes instead of 15 minutes for parboiled rice), the dehydrated rice had a bulk density of 37 g/100 cc and 180 g of this rice absorbed

364 g of boiled, hot water after 10 minutes. The rehydrated rice had a good, tender, firm texture better than some commercial instant white rices which required 5 or 7 minutes rehydration.

EXAMPLE 4

By following a similar procedure to that described in Example 2, but using arborio rice instead of the parboiled rice (the arborio rice was boiled for 12 min instead of 15 min for parboiled rice), the dehydrated arborio rice had a bulk density of 38 g/100 cc and 180 g of this rice absorbed 365 g of boiled, hot water after 10 minutes. The rehydrated rice had the good, tender texture typical of cooked arborio rice.

EXAMPLE 5

By following a similar procedure to that described in Example 1 but wherein the pH of the boiling water was 4.0 instead of 7.0 there used, the dehydrated rice produced had a bulk density of 40 g/100 cc

120 g of this rice product was prepared for consumption by cooking with 230 g of water in a microwave oven (high power) for 5 minutes and the product had a good, tender, firm even texture and an attractive white color.

EXAMPLE 6

By following a similar procedure to that described in Example 2 but wherein the pH of the boiling water was 4.5 instead of 7.0 there used, the dehydrated rice produced had a bulk density of 39 g/100 cc

240 g of this rice product was prepared for consumption by cooking with 460 g of water in a microwave oven (high power) for 8 minutes and the product had a good tender, firm, even texture and

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an attractive white color.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. A process for producing a dried precooked rice product comprising cooking rice grains with moisture at a temperature and for a time sufficient for providing cooked rice grains having a moisture content of from 55% to 75% by weight and then drying the cooked rice grains at a temperature of from

140 DEG C. to 185 DEG C. in two stages, firstly under stationary conditions to a moisture content of from 20% to 35% and secondly under agitated conditions to a moisture content of from 3% to 15%, for providing a dried precooked rice product having a bulk density of from 37 g/100 cm to 42 g/100 cm.

2. A process according to claim 1 wherein the cooked rice is dried in the first stage of drying with a belt dryer providing hot air for drying the cooked rice.

3. A process according to claim 2 wherein the hot air has a velocity of from 10 meters per minute to 20 meters per minute.

4. A process according to claim 3 wherein the cooked rice lies in a layer of from 2 mm to 10 mm thick on a belt of the dryer and is dried for from 10 minutes to 20 minutes.

5. A process according to claim 2 wherein the hot air has a velocity of from 100 meters per minute to

200 meters per minute.

6. A process according to claim 5 wherein the cooked rice has been dewatered to remove surface moisture prior to drying.

7. A process according to claim 5 wherein the cooked rice lies in a layer of from 5 mm to 12 mm thick on a belt of the dryer and is dried for from 3 minutes to 7 minutes.

8. A process according to claim 1 wherein the cooked rice is dried to a moisture content of from 23% to

35% in the first stage of drying.

9. A process according to claim 1, wherein the cooked rice forms a cake upon first stage drying, further comprising breaking the cake and separating the rice gains for second stage drying.

10. A process according to claim 2 further comprising rinsing the cooked rice, draining the rinsed rice and, wherein the cooked rice forms a cake upon first stage drying, further comprising breaking the cake and separating the rice grains for second stage drying.

11. A process according to claim 1 wherein the first stage dried rice is dried in the second stage of drying with a dryer selected from a group of dryers consisting of a vibrating dryer and a belt dryer providing hot air at a velocity of from 20 meters per minutes to 200 meters per minute.

12. A process according to claim 11 wherein the first stage dried rice is dried for from 30 seconds to

120 seconds in the second stage drying.

13. A process according to claim 1 wherein the first stage dried rice is dried to a moisture content of from 6% to 12% in the second stage drying.

14. A process according to claim 1 wherein the rice grains are cooked at a pH of from 3 to 7.5.

15. A process according to claim 1 wherein the rice grains are cooked at a pH of from 3 to 5.

16. A process according to claim 1 wherein the rice grains are cooked by a method selected from a group consisting of boiling and steaming and combinations thereof.

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17. A process according to claim 16 wherein the rice grains are cooked at temperatures of from 90

DEG C. to 110 DEG C. for from 5 minutes to 20 minutes.Data supplied from the esp@cenet database -

Worldwide

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381.

US4919958 - 4/24/1990

FLAN-TYPE PUDDING


Inventor(s): KADAN RANJIT S (US); ZIEGLER JR GEORGE M (US)


IP Class 4 Digits: A23L; A23C

IP Class: A23L1/187; A23L1/04; A23C9/154

E Class: A23L1/187B; A23C9/154D



Family: US4919958

Abstract:


The present invention is drawn to improvements in egg-free compositions for flan-type puddings (of the type generally described in U.S. Pat. No. 4,722,851), which provide pudding properties more closely resembling the properties of egg flan. The improved egg-free compositions of the present invention comprise: milk, sweetener, rice flour, carrageenan, tetra potassium pyrophosphate, pectin, locust bean gum and at least one material selected from the group consisting of cheese whey protein isolate and xanthane gum.Description:




The present invention is drawn to improvements in egg-free flan-type pudding of the type generally described in U.S. Pat. No. 4,722,851 (2/2/88) to Kadan and Ziegler.

2. Background Art

Custards are a popular food in many parts of the world. Recently, similar foods called flans, made from milk and certain colloids have been introduced in the U.S. market. These foods are considered to have a great potential for use as a snack, and/or meal replacement. Continuous changes in the lifestyle of affluent and working populations, particularly in developed countries, lead to novel food demands to meet their increased awareness of health, fitness and well-being. Most of the developed countries have also reached a static population growth but will continue to have increases in the proportion of middle age and elderly segments of the population. The fastest growing segment of the U.S. population is 65 and older. This group is prone to certain nutritional diseases such as obesity, osteoporosis and hypertension. Nutritionists are advocating the increased consumption of calcium rich foods to combat many of these diseases (Heaney, R. P., 1986, Osteoporosis: The Need and Opportunity for Calcium

Fortification, Cer. Foods World 31:349). Dairy products are the major source of calcium in the

American diet. Nonfat dry milk (NFDM) can be used as a convenient and natural source not only of calcium but also of high quality protein to engineer new foods for this group.

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A custard-like dairy food has been recognized as having good potential in the U.S. food market (Flan:

The Next Yogart, Prep. Foods, 1984, p. 157). Similar foods, called flans, are already popular in Europe.

An old fashioned egg custard or egg flan is a moldable fresh diary product, made from a measure of milk and sugar and utilizes eggs as a gelling agent. The product is consumed as a dessert or snack food.

Advances in food technology have shown that a moldable/demoldable flan can also be made by using special mixtures of carrageerans which form the gel thereby permitting production of egg-free and hence cholesterol free flan (Application Bulletin Number D-10, 1984, FMC Corp. Marine Colloids Dir.

Philadelphia, Pa.). The carrageenan gel shrinks in a controlled marker as it sets up, allowing easy demolding. Only, small amounts of specially prefered and purified starches are used in the flans to avoid pastiness or `mealy` mouth feel to the finished product. Several examples of such products are described in Appl. Bulletin No. D-10, Ibid.


While the egg-free flan-type puddings of our U.S. Pat. No. 4,722,851 (incorporated herein by reference) are highly desirable and advantageous in duplicating most of the textural response characteristics of egg-flan, said puddings do not duplicate the resiliency or resistance to chewing

(which may be characterized by the time required for a textural response curve to reach a maximum height) or mouth feel (i.e. organoleptic properties) of egg-flan. It has surprisingly been found, that the egg-free flan-type puddings of the type disclosed in our U.S. Pat. No. 4,722,851 may be improved to more closely resemble the properties of egg flan (e.g. in regard to resiliency or resistance to chewing, texture (which may be characterized by texturometer or organoleptic evaluation), and increased force and time required to break the gel) by addition of cheese whey protein isolate and/or manthane gum.

These improved results have been achieved with egg-free compositions comprising a mixture of: milk, sweetener, rice flour, carriageenan, tetra potassium pyrophospate, pectin, locust bean gum and at least one material selected from the group consisting of: cheese whey protein isolate and xanthane gum (i.e. either cheese whey protein isolate, or xanthane gum, or both cheese whey protein isolate and xanthane gum). The compositions of the present invention may either be in the form of: (1) a pudding, e.g. distributed to a consumer as a completely prepared pudding, or; (2) an essentially dry mixture or powder (i.e. an instant pudding mix) which a consumer may combine with liquid (e.g. water) and cook to produce a pudding.

Optionally, the flan-type puddings of the present invention may include additional additives such as: vegetable oil, animal oil, peanut oil, almond oil, hydrogenated vegetable oil or shortening, milk fat, supplemental nutrients such as minerals and vitamins, emulsifier, coloring, flavoring, fruit, etc..

In traditional egg-flan the texture is imparted by the denaturation of proteins in egg (albumin) and hence the typical and predictable texture. However, the properties of a multicomponent food, such as the flans of the present invention, are due to the complex, unpredictable, and unknown interactions of its ingredients, including: inter-molecular hydrogen bonding, electrostatic forces, Van der Waals forces, and hydrrphobic interactions. Consequently, the improved properties of the flans of the present invention are surprising, unexpected and could not have been anticipated or predicted.


FIG. 1 is a graph of texturometer measurements of force versus time for: an egg flan (sample 1), an egg-free flan produced according to our U.S. Pat. No. 4,722,851 (sample 2) and an egg-free flan of the present invention (sample 3).

FIG. 2 is a graph of texturometer measurements of force versus time for: an egg flan (sample 1), and two egg-free flans of the present invention (samples 4 and 5).


The egg-free coxpositions of the present invention may comprise a mixture of:

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(a) milk, which may be whole milk or milk of lowered butter fat content such as, low-fat milk, skim milk or non-fat milk (e.g. produced from non-fat dry milk i.e. NFDM (such as low heat extragrade from Mid-America Farms, Springfield, Mo.) and water (e.g. deionized water). For those compositions of the present invention which are essentially dry, or dry or powdered, the milk may be in the form of dry or powdered milk e.g. full fat dry milk (FFDM) or non-fat dry milk (NTDM). In regard to selection of butter fat content, it should be noted that the proportion of butter fat affects the organoleptic characteristic or "mouth feel" of the pudding;

(b) sweetener, such as: sucrose, glucose, dextrose, corn syrup, fructose e.g. as in a high fructose corn syrup (such as Isosweet 5500 (containing 55% fructose, 9% dextrose, 3% complex carbohydrate and

33% water) or Isosweet 100, tooth available from the A.E. Staley Manufacturing Co., Decator, Ill.), or the caloric content of the pudding may be decreased by utilizing an artificial or nonnutritive sweetner such as aspartame, saccharin, etc.;

(c) rice flour, which may be any of the types of rice flour disclosed in our aforementioned U.S. Pat. No.

4,722,851 (e.g. untreated rice flour), and may for example include long grain rice flour available from

Riviana Foods Inc., Houston, Tex.;

(d) carrageenan, which may act as a gelling agent. have been used as a gelling agent in milk for hundreds of years, initially by boiling `Irish Moss` with milk and sugar to form gels. The extracted carrageenans have many forms, each having distinct gel characteristics. Usually various forms such as kappa, iota and lambda forms are blended to provide the desired gel characteristics. Examples of carrageenan which may be used in the present invention include; FL 674 or FL 431 available from

FMC Corporation, Marine Colloids Division, Philadelphia, Pa.;

(e) tetra potassium pyrophreate, which may be to enhance bonding of pudding constituents such as milk and carrageenan, and may act as an emulsifier. Food grade tetrapotassium pyrophosphate useable in the present invention is sold by FMC Corp., Philadelphia, Pa.;

(f) pectin, which it is theorized, aids in bonding of calcium to other pudding constituents. An example of pectin which may be utilized in the present invention is Genulacta type PL93 available from

Hercules, Inc., PFW Division, Wilmington, Del.; (g) locust tean gum, as described in our aforementioned U.S. Pat. No. 4,722,851. An example of a locust tean gum which may be used in the present invention is, FL 50-50 available from Hercules, Inc., PFW Division, Wilmington, Del., and;

(h) at least one material selected from the group consisting of, cheese whey protein isolate i.e. a composition typically including 35 to 75 wt. % protein, lactose and ash (an example of cheese whey protein isolate useable in the present invention is Meloskim WP-25 from Dairyland Products, Inc.

Savage, Minn.), and xanthane gum e.g. that available from Miles Laboratories, Inc., Biotech Product

Division, Elkhart, Ind. may be utilized in compositions of the present invention.

Carrageenan, pectin and xanthane gum, apart from imparting characteristics of gel strength to the pudding, can also contribute desirable nutritional attributes. For example, the glycosidic linkages of food gums are resistant to small intestinal digestion. Therefore, these additives can also be considered as sources of water-soluble fibers (Ink, S. L. and Hurt, D. H., 1987 Nutritional Implications of Gums,

Food Tech. 41:77). The compositions of the present invention are especially advantageous for the elderly population, small infants and children, because said compositions are convenient, quick cooking, are a valuable source of much needed calcium and high quality protein, and are of controlled caloric content.

Optionally the coxpositions of the present invention may further comprise:

(a) vegetable oil, animal oil, peanut oil, almond oil, defatted peanut or almond oil, hydrogenated vegetable oil (such as CRISCO.TM. shortening available from Proctor and Gamble, Co., Cincinnati,

Ohio), or milk fat, any or all of which may be added in order to increase the caloric content and/or to modify the textural characteristics of the pudding;

1816/2197

(b) supplemental nutrients, such as and vitamins, may conveniently be added to the dry mix, especially if the pudding is intended for consumption by persons with special nutritional needs, such as infants or children;

(c) in those mixtures having added oil, shortening or milk fat, it may be advantageous to utilize a emulsifier (such as Durlac 100 from SCM, Durkee Industrial Foods, Louisville, N.Y.) to aid in homogenously combining ingredients;

(d) food coloring may readily be added to provide any desired color;

(e) flavorings, such as vanilla, butter rich, chocolate, orange, salt (NaCl), etc., may be added to provide a variety of pudding flavors; and

(f) fruit, such as peaches, strawberries and pies may be added if desired.

Advantages of the flans of the present invention include, that the ingredients may all be dry blended, therefore permitting convenient preparation of an essentially dry or dry or powdered mix. In these embodiments of the present invention which include oil(s) and milk fat, homogeneous blending of ingredients may be facilitated by the process set forth in example 11 of our U.S. Pat. No. 4,722,851 i.e. combining the milk, emulsifier and oil(s) or milk fat, heating if necessary, homogenizing, and freeze drying or spray drying. Another advantage of the present invention, is that the flan may be stored in a refrigerator for extended periods withcut developing objectionable syneresis or significant changes in texture.

The foregoing detailed description is given merely for purposes of illustration. Modifications and variations may be made therein without departing from the spirit and scope of the invention.

EXAMPLES

The following table illustrates exemplary proportions of ingredients.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; exemplary range of

>;tb; preferred most

>;tb; proportions of in-

>;tb; proportions

>;tb; preferred

>;tb; gredients (in weight

>;tb; (in weight

>;tb; proportions

>;tb;Ingredient

>;tb; %), about: %), about:

>;tb; (in weight %)

>;tb;______________________________________

>;tb;Water 69 to 87 77.5 to 84

>;tb; 81.67

>;tb;Sucrose 5 to 12 7 to 9.3 8.16

>;tb;NFDM 5 to 12 7 to 9.3 7.349

>;tb;Rice Flour

>;tb; .2 to 6 1 to 3 2

>;tb;Carrageenan

>;tb; .1 to .6 .23 to .35

>;tb; 0.282

>;tb;Tetra .06 to .6 .14 to .35

>;tb; .212

>;tb;Potassium

>;tb;Pyrophosphate

>;tb;Locust Bean

>;tb; 0.5 to .20 .1 to .14 .116

1817/2197

>;tb;Gum

>;tb;Cheese Whey

>;tb; .01 to .6 .04 to .1 .073

>;tb;Protein

>;tb;Isolate

>;tb;Xanthane Gum

>;tb; 0.1 to .6 .04 to .1 .073

>;tb;Pectin .02 to .6 .04 to .1 .065

>;tb;______________________________________

Comparative Example

The following is a comparative example showing that the improved compositions of the present invention provide texture which more closely resembles the texture of egg flan than the texture of the compositions of our U.S. Pat. No. 4,722,851. The following samples were prepared:

Sample 1, Egg Flan was prepared according to the recipe in, New Cookbook, 1968, page 157, Better

Homes and Gardens, Meredith Press, New York, N.Y., i.e. the ingredients were mixed in the proportion of: 3 slightly beaten eggs, 1/4 cup sugar (sucrose) and 2 cups scalded milk; and the mixture was baked at 325 DEG F. for 1 hour.

Sample 2; Flan of our U.S. Pat. No. 4,722,851, with the following ingredients

>;tb;______________________________________

>;tb;Nonfat Dry Milk 13.3 grams

>;tb;Sucrose 14.0 grams

>;tb;Rice Flour 3.0 grams

>;tb;Carrageenan (FL 431) 0.50 grams

>;tb;Locus Bean Gum 0.20 grams

>;tb;Pectin 0.112 grams

>;tb;Tetra Potassium Pyrophosphate

>;tb; 0.40 grams

>;tb;Water 140 grams

>;tb;______________________________________

Sample 3: All of the ingredients of sample 2 and 0.125 grams of WP-25 whey protein isolate obtained from Dairyland Products, Inc., Savage, Minn.;

Sample 4: All of the ingredients of sample 2 and 0.125 grams of xanthane gum obtained from IIC

Gum, Inc., New York, N.Y.;

Sample 5: All of the ingredients of sample 2, 0.125 grams of WP-25 whey protein isolate, and 0.125 grams of xanthane gum.

Sample 6: The ingredients of sample 5, except that full fat dry milk was substituted for the nonfat dry milk.

The puddings of samples 2-6 were prepared by mixing all of the ingredients homogeneously and then cooking, according to the process set forth in our aforementioned U.S. Pat. No. 4,722,851.

A FMC Marine Colloids Gel Tester, Model GT-2 was modified to compare the gel strength of the samples. This was a custom designed instrument to measure the `break force` and to develop texturometer curves of food gels. The modification involved using a Mettler PE 2000 top loading balance interfaced with a computer to record force (in grams). The forces exerted by the plunger on the experimental gel was then recorded as a function of time. A circular `knife` (having a cylindrical die about 2 cm in diameter, fitted within a circular ring 4.5 cm in diameter, with said die and ring being attached by 4 spokes which are 0.05 cm thick and 0.5 cm high) was used as a plunger. The plunger gave reproducible curves (force vs time) during initial evaluation. The instrument was fitted with a synchroncus motor which lowered the plunger into the gel at a constant rate of 10.9 sec/cm. The rate can be adjusted depending upon the sample characteristics. After the knife contacted the gel, the top

1818/2197

loading balance started transmitting weight signals every 0.125 seconds, thus recording force (grams) vs time (seconds) data. From the rate of descent, knife penetration (distance) into the gel can also be determined. The measurements taken with said tester, as well as results of organoleptic evaluation, are set forth in Table 2 and and FIGS. 1 and 2.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Texture and Organoleptic Characteristics of Improved Flan

>;tb; Force re-

>;tb; quired to Time in seconds

>;tb;Sample break needed to break

>;tb;Number the gel the gel Organoleptic Evaluation

>;tb;______________________________________

>;tb;1 195 grams 4.542 Typical egg-flan texture

>;tb;2 191 grams 4.088 Egg-flan like texture,

>;tb; but lacking some aspects

>;tb; of typical chewiness of

>;tb; egg flan.

>;tb;3 178 grams 3.785 Improved chewiness as

>;tb; compared with above.

>;tb;4 191 grams 5.148 Very chewy but rubbery

>;tb; brittle texture.

>;tb;5 208 grams 4.845 Typical egg-flan texture.

>;tb;6 179 grams 4.454 Typical egg-flan testure,

>;tb; with smooth chewiness.

>;tb;______________________________________

As illustrated in table 1 in regard to samples 3-6, the compositions of the present invention provide the advantages of: (1) improved chewiness, (the use of both whey protein isolate and xanthane gum providing texture typical of egg-flan); (2) use of xanthane gum, and xanthane gum with whey protein isolate (samples 4 and 5) providing, higher force required to break the gel and longer time needed to break the gel. FIGS. 1 and 2 show that the compositions of the present invention (i.e. samples 3-5) provide force vs. time curves which closely resemble the curve for egg flan (sample 1). It is especially noteworthy that FIG. 2 shows, that for samples 4 and 5 the initial peak is higher and occurs after the initial peak for egg flan (sample I), thus indicating a highly desirable resilence and chewiness (i.e. a relatively high force, and a relatively long period, required to break the gel).

The foregoing examples are intended only to illustrate the invention, and are not intended to limit the scope of the invention which is defined by the claims.Data supplied from the esp@cenet database -

Worldwide Claims:


We claim:

1. An egg-free composition comprising a mixture of: milk, sweetener, rice flour, carrageenan, tetra potassium pyrophosphate, pectin, locust bean gum, and at least one material selected from the group consisting of cheese whey protein isolate and xanthane gum

2. The composition of claim 1 including cheese whey protein isolate.

3. The composition of claim 1 including xanthane gum.

4. The composition of claim 1 including both cheese whey protein isolate and xanthan gum.

5. The composition of claim 4 consisting of: about 69 to 87 weight % water, about 5 to 12 weight % sucrose, about 5 to 12 weight % non-fat dry milk, about 0.2 to 6 weight % rice flour, about 0.1 to 0.6 weight % carrageenan, about 0.06 to 0.6 weight % tetra potassium pyrophosphate about 0.05 to 0.20 weight % locust bean gum, about 0.01 to 0.6 weight % cheese whey protein isolate, about 0.10 to 0.6 weight % xanthane gum, and about 0.02 to 0.6 weight % pectin.

1819/2197

6. The composition of claim 5 consisting of: about 77.5 to 84 weight % water, about 7 to 9.3 weight % sucrose, about 7 to 9.3 weight non-fat dry milk, about 1 to 3 weight % rice flour, about 0.23 to 0.35 weight % carrageenan, about 0.14 to 0.35 weight % tetra potassium pyrophosphate, about 0.1 to 0.14 weight % locust bean gum, about 0.04 to 0.1 weight % cheese whey protein isolate, about 0.04 to 0.1 weight % xanthane gum, and about 0.04 to 0.1 weight % pectin.

7. The composition of claim 1 further including one or more oils selected from the group consisting of: vegetable oil, animal oil, peanut oil, almond oil and hydrogenated vegetable oil.

8. The composition of claim 7 further including an emulsifier.

9. The composition of claim 1 further including added milk fat.

10. The composition of claim 9 further including an emulsifier.

11. The composition of claim 1 wherein said milk is selected from the group consisting of: whole milk, low-fat milk and non-fat milk.

12. The composition of claim 11 wherein said milk is dry or powdered milk.

13. The composition of claim 1 wherein said sucrose is one or more sweetener selected from the group consisting of: sucrose, glucose, dextrose, corn syrup, fructose, high fructose corn syrup, aspartame and saccharin.

14. The composition of claim 1 in the form of a pudding.

15. The composition of claim 1 wherein said milk is dry or powdered milk.

16. The composition of claim 15 in the form of an essentially dry mixture.Data supplied from the esp@cenet database - Worldwide

1820/2197

382.

US4921718 - 5/1/1990

METHOD FOR PRODUCING QUICK COOKING PROCESSED RICE


Inventor(s): OHTSU SUSUMU (JP)

Applicant(s): ISHIMOTO FOOD IND CO LTD (JP)


IP Class: A23L1/182

E Class: A23L1/182



Family: JP1148157


Abstract:


A method for producing quick cooking processed rice in which brown rice is pounded and refined into cleaned rice. The cleaned rice is washed in water, removed from the water and the remaining water is removed. The cleaned rice is soaked in an ethanol aqueous solution for absorbing the solution. The solution absorbed rice is removed from the remaining solution and is packaged in a sealed container.Description:


The present invention relates to a method for producing quick cooking processed rice which provides much shorter cooking time than the common cleaned rice (so called white rice), and a method for producing quick cooking processed rice which contains ethanol aqueous solution in it and which absorbs boiled water due to osmotic pressure while being cooked giving a resultant cooked rice with good taste and excellent chewing texture.

Considerable research has been conducted to make good quality cooked rice (flavor, stickiness, elasticity, hue) from cleaned rice. It is well known to improve rice species, cooking devices and various cooking techniques such as by a preliminary soaking of rice in water, to add proper volume of water, to control cooking time, and to adjust steaming time. No prior art however, has been presented for production of harvested processed rice itself which will provide quick cooking, quality rice where a conventional rice cooker is used with new or old rice.

It is necessary to distinguish the relationship between the characteristics of rice and the function of cooking in order to find a way to cook rice quickly while achieving high quality rice.

Rice cooking provides for turning starch particles consisting of amylose and amylopectin contained in rice to alpha starch. Rice starch, which composes 75% of the refined rice contents, has linkages of glucose consisting of polysaccharide amylose of more than hundred thousands of molecules and polysaccharide amylopectin with similar linkages and branched glucose of more than tens of millions of molecules. Non-glutinous rice contains on an average 83 parts of amylopectin to 17 parts of amylose.

1821/2197

The albumen (called white rice, the main grain body remaining after refining of the rice) has the above mentioned molecules forming a single starch particle, 5 to 15 of which flock together. As rice plants ripen, the starch particles become filled with amyloplasts which are starch cells. A grain of rice is made up from 10 thousands to 15 thousands of the amyloplasts.

Amylose and amylopectin in raw rice starch have their glucose linkages bundled (micellizied) so tight that even water molecules do not permeate in them. If starch and water are heated together, their molecules are activated to increase their movement. If energy movement is increased and exceeds the energy of the micell structure, the micell structure collapses to become random in its arrangement, through which water penetration occurs resulting in swelled starch. Swelled and wet starch is easier for digestion and is called alpha starch, which reacts easily to digestive enzymes because of the collapsed micell structure. On the other hand, free movement of the linked molecules of amylose and amylopectin is restricted in the swelled, wet starch which results in stickiness of the cooked rice.

Especially, intricately linkage branches of long amylopectin molecules are the essential factor which gives stickiness to cooked rice, so that the important chewing texture of the cooked rice is created.

Understanding of the features and denaturization of rice as mentioned above provides important information to determine the heat required which is necessary to turn rice starch smoothly to alpha starch when cooking.

The starch of the cleaned rice is changed easily to the alpha starch when it is heated with water at 65

DEG to 70 DEG C., but long cooking time and high temperature heating is necessary to affect the center of the rice grain because the structure of its amyloplast is so dense and hard that water can hardly penetrate it. Quality cooked rice is characterized by its reasonable stickiness and elasticity. A long cooking time causes, dissolution of starch from the rice grain causing lowered elasticity of the resultant cooked rice. It is, therefore, important that the time lag between heating the center of the rice grain and the time heating the surroundings to become alpha starch should be minimized so that starch dissolution from the center of the rice grain is prevented.

The List of Experimental Results below shows the relationship between the time required to turn the cleaned rice starch to the alpha starch and the temperature of water used.

In the experiment, 20 gs of rice were respectively put in 500 cc of hot water which was maintained at each set temperature. Then the respective time required to change the rice starch to the alpha starch at different temperatures and visual, touch sense and chewing texture observations were recorded.

>;tb;______________________________________

>;tb;LIST OF EXPERIMENTAL RESULTS

>;tb;Set Water

>;tb; Alpha Starch

>;tb;Temperature

>;tb; Production Time

>;tb; Shape of Cooked Rice

>;tb;______________________________________

>;tb;70 DEG C.

>;tb; 200-250 Minutes

>;tb; The original shape of

>;tb; the rice grain is com-

>;tb; pletely given away, and

>;tb; becomes almost like

>;tb; paste.

>;tb;80 DEG C.

>;tb; 80-100 Minutes

>;tb; The rice grain is col-

>;tb; lapsed and starch is

>;tb; dissolved in water.

>;tb;90 DEG C.

>;tb; 60-80 Minutes The surface of the rice

>;tb; grain is collapsed and

1822/2197

>;tb; a small amount of

>;tb; starch is dissolved in

>;tb; water.

>;tb;95 DEG C.

>;tb; 30-40 Minutes The rice grain remains

>;tb; in its original shape,

>;tb; but is too wet and

>;tb; lacks elasticity.

>;tb;98 DEG C.

>;tb; 20-25 Minutes The rice remains in its

>;tb; original shape and its

>;tb; elasticity and sticki-

>;tb; ness are favorable.

>;tb;______________________________________

The experiment has revealed that rice is cooked favorably to produce alpha starch when a high temperature is applied for a short period of time rather than cooked at a low temperature for a long time. The undesirable pasty result of cooked rice is caused by dissolution of starch in water and occurs more with a long cooking time than with a high cooking water temperature.

Because of the above mentioned reasons, the cooked rice with reasonable stickiness and elasticity is attributed to the shortest possible time to turn the rice starch to the complete alpha starch. The rice cooking time is made short to obtain complete alpha starch without the help of an improved rice cooking device if the rice itself is improved and possesses water absorbing capability.

It is accordingly an object of the present invention to accomplish improvement of rice by providing a process to have it absorb ethanol aqueous solution which facilitates its absorption of water assisted by osmotic pressure developed while it is cooked. Thus, the rice starch completely becomes the alpha starch very quickly with the resultant quality cooked rice.

A process of producing the quick cooking processed rice of this invention and its function are mentioned in the following:

Brown rice is pounded and refined to make cleaned rice, and then its is washed. The pounding of refined whitness is required to around 39% to 41%, preferably 40%. Washing of the rice in this preliminary stage aims at saving the pre-cooking washing, but it should be finished in as quick as 2 to 3 minutes using a known stir type washing apparatus so that only a little water is absorbed. The washed, cleaned rice is removed from the wash water and the surface of the cleaned rice grain is removed and then soaked in 4 mol to 13 mol ethanol aqueous solution (184-598 gs ethanol dissolved in 1 liter of water), preferably 10 mol ehtanol aqueous solution (460 gs ethanol in 1 liter of water), in which the rice aborsbs ethanol. The washed rice dipped in the aqueous solution first dissipates water, thinning the density of the solution. It is, therefore, necessary to add ethanol to the solution measuring with a hydrometer in order to maintain a required solution density. Ethanol absorbed in the rice ranges from

25% to 10% weight ratio of the cleaned rice in 4 mol to 13 mol ethanol aqueous solution and about

10% in 10 mol ethanol aqueous solution.

The thicker the ethanol aqueous solution, the longer it takes for said cleaned rice to absorb the solution.

For example, it takes more than 10 hours to have the rice absorb the solution by 15% of the rice weight in 10% ethanol aqueous solution at room temperature and atmospheric pressure. If the cleaned rice is soaked in the ethanol aqueous solution in an air-tight vessel and if the pressure in the vessel is reduced and increased alternatively by an air compressor, the absorption is attained in 1/10 of the time, although absorption time varies depending on pressure differential. The rice with absorbed ethanol aqueous solution is taken out of the solution and the remaining solution is removed from the surface of the rice grains. A centrifugal separator drains it quickly, but a container with a net at the bottom is also satisfactory although removing it takes time. The ethanol aqueous solution contains dissolved residuals of unseparated fat or other rice bran. These are carried in with the cleaned rice and the residuals remain on the surface of the processed rice causing it to ruin both quality and taste of the cooked rice if the remaining solution is not removed from the surface of the rice grain.

1823/2197

A desired volume of the solution absorbed rice is then packaged in a sealed synthetic resin bag. The packed, processed rice is well preserved because of the absorbed ethanol. Sealing nitrogen gas into the bag is desirable as it prevents multiplication of some bacteria which may not be destroyed by the ethanol and the nitrogen gas also inhibits oxidation.

The function and advantages provided by the processed rice of the present invention after it has been cooked are described in the following:

The processed rice is cooked in a conventional cooker as an iron pot, electric or gas cooker. To cook the processed rice, equal amounts of rice and water are added to the cooker and heated.

When heat is applied in cooking, water active AW of the ethanol aqueous solution contained in the processed rice is expressed in the following formula: ##EQU1## where the mol density of water is

55.51. In case of 10 mol ethanol solution, AW is calculated as follows: ##EQU2##

This water activation causes development of osmotic pressure between the processed rice and cooking water. The osmotic pressure at AW=0.85 and a temperature of 20 DEG C. is about 250 atmospheric pressure. Such a high osmotic pressure enables boiled water to penetrate into the rice so that starch in the quick cooking processed rice is turned shortly to alpha starch resulting in perfectly cooked rice.

The water active value AW ranges from 0.91 to 0.81 when the quick cooking processed rice contains 4 mol to 13 mol ethanol solution. The minimum water active value which allows vegetation of the microorganisms in free water is 0.91 for bacterium, 0.88 for yeast, and 0.8 for mold fungus. The processed rice is, therefor, well preserved so that the processed rice produced through the method of this invention can be stored for a long period of time without deterioration of the quality. In addition, a long storage time does not effect the original taste of the processed rice no matter when it may be cooked.

The boiling point of ethanol is 78.3 DEG C. No ethanol is left in the cooked rice because of vaporization during the cooking. The cooked rice does not carry the nasty odor of ethanol and the original flavor of the rice remains.

The following examples further describe preferred advantages within the scope of the present invention.

EXAMPLE I

Old rice of "KITAHIKARI" harvested in Japan was pounded and refined up to 40% whiteness and was mixer-washed for 3 minutes. It was then soaked in 10 mol ethanol aqueous solution for 30 minutes, and the solution density was compensated and the inside pressure was reduced and increased alternatively during the process. Thus, processed rice containing 15% ethanol aqueous solution of the weight ratio was obtained. The ethanol absorbed rice was then moved immediately to a net container where it was left for 2 hours. Later, 200 gs (300 cc) of the ethanol absorbed rice was scooped out to be moved into a

RINNAI automatic gas cooker (1 kg capacity), in which 300 cc of water was added to complete preparation for cooking.

Boiling inside the cooker started 3 minutes after the cooker had been turned on. The switch was automatically turned off in 6 minutes 20 seconds after boiling started and then steaming (caring) was allowed to take place with the warming switch kept on. After 5 minutes of steaming, the warming switch was manually turned off to complete cooking. The processed rice weighed 420 gs when it was cooked. Five monitor panelists observed the cooked rice and found that all the grains of rice were what is called "standing", that is, all of the grains arranged lengthwise. The hue of the rice was pure white as had not before been observed in ordinarily cooked rice. The panelists tried it and agreed that the sample was among the best of those they had ever tried in its stickiness, elasticity, flavor and taste.

EXAMPLE II

1824/2197

In this test, 100 gs (180 cc) of the processed rice obtained in Example I were put into a china bowl, into which 180 cc of water was poured. The china bowl without a top cover was then placed in a 500 W electric oven to complete preparation for cooking.

The oven was turned off 7 minutes after it had been turned on although it was not known when boiling started. The top cover was placed on the china bowl and left in the oven for 7 minutes for steaming

(caring) before it was taken out of the oven. The cooked rice weighed 215 gs. The five monitor panelists tried it and agreed that the result was the same as that of EXAMPLE I except for the fact that the center of the rice grain where the microwave was supposedly concentrated was a little too dried.

In addition to the above described advantage that the processed rice of the present invention provides better cooked quality and shorter cooking time than the existing refined rice, it also provides the following advantages:

For cooking, the quick cooking processed rice of the present invention does not require preliminary preparations such as washing and soaking which are ordinarily necessary before cooking of the existing cleaned rice. This feature helps same time and labor.

Another advantage of the quick cooking processed rice is that it enables the use of the conventional heavy duty rice cooker in spite of the small cooking quantity. It is most suitable to the modern society where nuclear families and individualized taste in food is on the increase.

Another advantage of the quick cooking rice is that its cooking time is 1/2 as long as that of the conventional cleaned rice and that meets with the rushing customers requirement in business, while labor and fuel are saved.

A further advantage of the quick cooking processed rice is that the cooked rice comes out better than the existing refined rice in flavor, elasticity, stickiness and hue in spite of the quality of cleaned rice whether new or old.

Another advantage of the quick cooking processed rice is that the starch of the rice is turned into complete alpha starch even when cooked at a high altitude where atmospheric pressure is lower.

A further advantage of said quick cooking processed rice is that not only an automatic rice cooker but also an electric range can be utilized to cook it, and that a specialized cooker enables it to cook in a shorter time so that it is cooked conveniently with good quality while customers wait for the "KAMA

MESHI" dish (rice with ingredients in a small pot, KAMA being cooked at the customer's table for immediate serving) such as KINOKO MESHI (rice with mushroom) in restaurants.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method for producing quick-cooking, processed rice, comprising the steps of: pounding brown rice until a cleaned rice is obtained having a whiteness of at least 39 to 41 per cent; washing said cleaned rice in water for a period of about 2 to 3 minutes, said period being too short to swell said cleaned rice; removing all water from the surface of said cleaned rice; soaking said cleaned rice in an about 4 mol to 13 mol aqueous solution of ethanol for a time adequate to permit absorption of a portion of said solution throughout said cleaned rice and thereby yield ethanol-absorbed rice; removing all ethanol solution from the surface of said ethanol-absorbed rice while retaining in said ethanol-absorbed rice said portion of said ethanol solution absorbed; and packaging said ethanol-absorbed rice in a container sealed adequately to retain said portion of said ethanol solution absorbed in said ethanolabsorbed rice.

2. The method according to claim 1, wherein said packaging step is carried out employing an airtight container comprising a bag made from a sheet material laminated with a synthetic resin film.

1825/2197

3. The method according to claim 1, wherein said packaging step includes placing an inactive gas in said container with said ethanol-absorbed rice.

4. The method according to claim 1, wherein said soaking step is carried out from about 10 minutes to

1 hour.

5. The method according to claim 1, wherein said soaking step is carried out by placing said cleaned rice and said solution in a solution vessel and adjusting the pressure in said solution vessel so as to maintain a weight ratio of said ethanol aqueous solution to said cleaned rice of about 25 to 10 per cent.

6. The method according to claim 5, wherein said pressure adjusting step is carried out by alternately increasing and reducing the pressure inside said solution vessel.

7. The method according to claim 6, wherein said pressure adjusting step is carried out using an air compressor connected to said solution vessel.

8. The method according to claim 1, wherein said washing step is carried out using a stirring washing apparatus.

9. The method according to claim 3, wherein said inactive gas is nitrogen.

10. The method according to claim 1, wherein said soaking step comprises controlling the density of said ethanol aqueous solution to maintain a predetermined desired solution density and to compensate for any change in solution density arising from water carried over into said solution by said cleaned rice from said washing step.

11. The method according to claim 1, wherein said washing step is carried out by immersion of said cleaned rice in said water, and said water-removing step is carried out by removing said cleaned rice from said water.

12. The method according to claim 1, wherein said soaking step is carried out by immersion of said cleaned rice in said ethanol solution, and said solution-removing step is carried out by removing said ethanol-absorbed rice from said solution.

13. The method according to claim 12, wherein said ethanol-absorbed rice is removed from said solution by netting.

14. The method according to claim 1, wherein said solution-removing step is carried out by centrifugal separation of said ethanol-absorbed rice and said solution.

15. The packaged rice and sealed container product produced by the method of claim 1.Data supplied from the esp@cenet database - Worldwide

1826/2197

383.

US4927660 - 5/22/1990

MANUFACTURING PROCESS OF PACKED FAST-COOKING RICE


Inventor(s): SANO JOJI (JP)

Applicant(s): SANO JOJI (JP)


IP Class: A23L1/182

E Class: A23L1/182



Family: US4927660

Abstract:


A manufacturing process for preparing packaged fast-cooking rice prepared by a process wherein raw material rice after being washed and soaked in water is heated to become gelatinized rice having a water absorptive property, and the resultant hot gelatinized rice is impregnated with an additive liquid so that swelled rice grains having non-sticking properties are produced. A predetermined amount of the produced rice is packed in an air evacuated package. The product rice can be cooked in an ordinary manner in a short time. By changing the additive liquid, rice containing a preservative or a seasoning can be obtained.Description:



The present invention relates to a process for making a packaged fast-cooking rice.

A conventional manufacturing process for making a packaged rice includes freeze-drying rice which is then cooked by the consumer by adding hot water. In the free-dried process rice is washed with water to remove bran, and a predetermined amount of water is added to the washed rice. The mixture is heated to produce gelatinized cooked rice, and in order to remove pasty materials such as dextrin, and to separate cooked grains from each other the cooked rice is subjected to large water flows and the

1827/2197

pasty materials are washed away. Then a mass of wet grains of rice is subjected to a freeze-drying treatment, and the resultant freeze-dried (FD) rice is packed under vacuum in a package. In a second process, instant or quick-cooking rice is manufactured to produce a retort-pouch rice which is obtained by heating raw material washed rice at high temperatures under pressure.

The conventional FD rice manufacturing method is defective in that dextrin and other nutritious ingredients of rice are washed away in the treating procedure for separating the cooked grains of the rice from each other. When cooked by the consumer, such rice has a reduced viscoflexibility, umami

(palatable taste), texture and lucidness or gloss as compared with ordinary cooked rice. The drying step in this method is inevitable, as are long drying periods requiring the use of an uneconomical drying apparatus. On the other hand, the method of manufacturing the retort-pouch rice requires especially high temperature heating under pressure which requires using an expensive retort apparatus. In addition, cracking and thermal decomposition of the rice grains occurs and the nutrient value, taste, flavor and lucidness of the cooked rice is reduced.

OBJECTS AND SUMMARY OF THE INVENTION

It is the object of the present invention to provide a manufacturing process for preparing packaged fastcooking rice which overcomes the defects of the above-mentioned conventional manufacturing methods.

It is another object of the present invention to provide a manufacturing process for preparing packaged fast-cooking rice in which the paste material, or water soluble ingredients, are not washed away and a drying procedure for drying wet rice at a high temperature is abolished, so that on cooking the packaged fast-cooking rice the rice retains the original ingredients of the original raw material rice and retains substantially the same viscoflexibility, good taste, flavor and lucidness as ordinary cooked rice, and the product can be easily and economically preserved for a long time.

To achieve the above objects, the present invention provides a manufacturing process for preparing packaged fast- of quick-cooking rice, which is characterized in that the raw material or original rice is washed to remove bran therefrom and is soaked in water for a predetermined time. Then the water is removed and a predetermined amount of the washed rice is subjected to a heating treatment so that

.beta.-starch of the raw material rice is changed into .alpha.-starch and at the same time the gelatinized rice grains may have a water absorptivity, and the resultant grains of rice are impregnated with an additive liquid so that swelled grains of rice in a loose non-sticking condition are obtained. Thereafter a mass of the resultant grain is packaged by sealing the rice in an air-evacuated package.

In the process, a small amount of barley may be mixed with the raw material rice. In greater detail, the barley is composed of milled grains of unpressed or pressed barley, and the rice/barley mixture is washed in water and soaked in water for a desired time, and is then heated in a manner as described above.

Also, any desired amount of subsidiary raw material, such as beans, vegetables, etc. may be mixed with the raw material rice or a mixture of the raw material rice and barley.

The heating treatment for gelatinizing the raw material rice and making the same water absorptive is carried out by steam heating, microwave heating, infrared heating and far infrared heating.

The additive liquid may be water, alcohol, an alcohol aqueous solution or a seasoning liquid or a mixture thereof. The additive liquid is added to the rice either without or with the barley and/or the subsidiary raw material. When the alcohol or alcohol aqueous solution is impregnated in the raw material rice, the final product, fast-cooking rice, can be preserved for a long time, and when cooked in water by the consumer the alcohol contained therein is evaporated and there is obtained ordinary cooked rice in which the alcohol and its odor are removed. In addition, when seasoning liquid is impregnated in the rice, the resultant final product can be seasoned with desired seasonings.

During the impregnation of the additive liquid in the heated cooked rice, the additive liquid can serve to swell the grains of the cooked rice and at the same time to cool the heated cooked rice. In this

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occasion, cooling air or warm air below 40 DEG C. is blown against the cooked rice grains for accelerating cooling of the heated rice.


The present invention is more fully understood from the detailed description given hereinbelow and by the accompanying drawing which is presented for illustration purposes only. The drawing is a schematic plan view of an apparatus for carrying out the present invention.


In a first step, polished rice in an amount of 10 Kg, for instance, as a raw material rice, is washed with water to remove bran, and is then soaked in water for a desired period of time, for instance, for one to two hours. Thereafter, water is removed from the rice and the rice is transferred to a perforated vessel such as a bamboo basket, so that excessive water drains from the rice. The rice, containing absorbed water, in the basket is heated by steam so that the raw material rice may be gelatinized. In other words, the .beta.-starch of the rice is changed into .alpha.-starch, and at the same time the steamed rice acquires water absorptivity properties. The resultant steamed rice is impregnated with an additive liquid such as 2000 g of water or 2000 g of an alcohol aqueous solution in which 500 g of pure alcohol is dissolved in 1500 g of water. By spraying the rice the additive liquid is fully and uniformly absorbed in the grains of the steamed rice. The additive liquids and the porous steamed rice grains produce an unsaturated condition, and consequently all of the additive liquid, such as water or alcohol, can be absorbed quickly by the rice. It is to be understood, of course, that water and alcohol may be absorbed therein one after another by separate applications.

By the forgoing impregnation treatment with an additive liquid such as water or an alcohol aqueous solution, the steamed rice grains swell to become swelled rice grains and the surface binding property of the rice grains is lost. Thus, large-sized rice grains having a good appearance are obtained in a loose non-sticky condition. Simultaneously, with the impregnation treatment, the steamed rice is cooled by the additive liquid. Consequently, this treatment prevents the inconvenience of washing away, with water, soluble proteins, carbohydrates, vitamins, inorganic ingredients or other nutrients which is required when the cooked rice is subject to a large water flow for removing the binding property of the grains as is carried out by conventional methods discussed above. The instant method is such that the viscoflexibility, umami (palatable taste), and nutrient ingredients possessed by the raw material rice are maintained, resulting in gelatinized rice grains having substantially their original viscoflexibility, delicious taste, nutritive value and gloss.

In order to accelerate the cooling of the steam swelled rice grains, it is preferable to blow cool air, or air at room temperature, or warm air at a temperature not causing thermal decomposition of the rice, preferable below 40 DEG C., against the rice grains for about 2-30 hours.

When the additive liquid used in the impregnation step contains alcohol, the alcohol evaporates from the surface of the rice grain and thereby latent heat is taken away accelerating the cooling effect, and at the same time the alcohol serves to solidify pasty materials such as dextrin adhering to the surfaces of the rice grains preventing the same from being blown or washed away and also preventing the grain from binding to each other.

The term "alcohol" means ethyl alcohol including chemical processed, refined or pure alcohol and other alcohol aqueous solutions containing any desired concentration range. The term "alcohol" also includes any kind of fermented alcohol such as whisky, wine, sake (Japanese wine), etc. The alcohol aqueous solution contains at least 0.5% of alcohol prepared by adding water to any kind of alcohol product discussed above. In general, it is sufficient to use an alcohol aqueous solution containing a small percentage of alcohol. Of course, an alcohol aqueous solution containing a higher alcohol content can be used, but it is preferable, from an economic view point, to limit the upper content of alcohol to about 30%.

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The resultant steamed rice impregnated with an additive liquid such as water or alcohol is treated as follows: a predetermined amount of the rice is put in a package such as a polyethylene or other synthetically made bag, and is hermetically sealed under a vacuum. Thus, there is obtained a packaged fast-cooking rice. When required, a deoxidant, such as butylated hydroxy anisol (BHA), butylated hydroxy toluene, etc., is put in the package prior to hermetically sealing the package.

The moisture content of the swelled rice grains sealed in the package is about 40%, for instance, and these grains are large sized and glossy having a good appearance. In addition, when the swelled grains contain alcohol, the grains are preserved for a long time as the growth of the anaerobic bacteria, especially the growth of heat resistant spores is restrained by the sterilization effect of the alcohol, and a good quality rice can be maintained during storage of the packaged products as there is no generation of gas caused by the growth of bacteria. Thus, in this embodiment, there is obtained 14.5 Kg of steamed swelled rice as a result of impregnating 10 Kg of raw material rice with 2000 g of additive liquid.

A seasoned fast-cooking rice can be obtained by using a seasoning liquid instead of water or an alcohol solution as the additive liquid. Seasoning liquids include fermented liquid seasonings such as soy, vinegar, etc., a synthetic seasoning prepared by dissolving in water a desired combination of salt, sugar, soy, vinegar, chemical seasonings, such as monosodium glutamate, sodium 5'-inosinate, etc., spices, and flavor or essential oils, and a soup stock prepared by adding any kind of foodstuff to boiling water such as katsuo bushi (dried bonito), meats, tangle, etc., and extracting palatable ingredients therefrom.

By adding at least one kind of seasoning mentioned above to the steamed rice, there is obtained a seasoned rice comprising a mass of swelled grains. This composition is packaged in air tight containers as described above. In this case, the seasoning liquid and a desired amount of alcohol may be used for impregnating seasoning into the steamed rice in order to make a seasoned product which can be preserved for a long time.

The impregnation treatment, i.e., the addition of additive liquid into steamed rice, can also be carried out even after the temperature of the steamed hot rice is lowered.

In the above description of the invention gelatinized rice having water absorptivity has been obtained by steaming the washed rice after soaking the rice in water. However, instead of heating with steam, the washed rice may also be heated by microwaves using an electronic apparatus, or by infrared radiation or far infrared radiation to produce gelatinized rice. Such heating treatments cause the gelatinized rice to have a lower moisture content than the gelatinized rice obtained by heating with steam, and thus the amount of additive liquid impregnated into the gelatinized rice can be increased to obtain larger swelled rice grains.

In the case where the alcohol is used as an additive liquid, the addition rate of the additive liquid added to the raw material is about 0.5 to 30% wt. % which, in general, is preferable from an economical point of view.

As is clear from the above description the present inventive method lies in the fact that raw material rice containing water is heated to a gelatinized rice having a water absorptivity property, and then the resulting gelatinized rice is subjected to the impregnation treatment with the additive liquid, so that swelled gelatinized rice grains are obtained.

The attached drawing shows a plan view of a manufacturing apparatus which can be used for carrying out the present invention.

Numeral 1 denotes a conveyor for feeding raw material rice, for instance, a batch containing 10 Kg of either white rice or brown rice, or a mixture thereof, one after another, and numeral 2 denotes a row of rice washers of the water jet type which are disposed on a side of the conveyor 1, and each batch of rice is charged in each of the rice washers, and the raw material rice is washed to remove bran. The washed rice in each rice washer is transferred to each of a row of soaking tanks 3 disposed to be opposite to each of the row of the rice washers 2 through delivery pipes (not shown) and by the aid of a water jet flow. The rice is soaked therein for about 30 minutes in the summer season, and for about 2 hours in the winter season. Thereafter, water in each tank 3 is removed and after the water is drained from the tank, each batch of the rice in each tank is dropped to a conveyor 4 and a row of each rice batch is

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moved to the interior of a tunnel-shaped steamer 5, and heated with steam as it is being moved forward through the steamer 5. Thus, steamed rice is continuously obtained and is then transferred onto a conveyor provided in a tunnel-shaped additive liquid spray chamber 6 provided in front of and perpendicularly to the steamer 5. The rice is moved forward by the conveyor, and while the steamed rice is being moved forward, an additive liquid such as an aqueous solution containing a desired content of alcohol is sprayed uniformly on the whole of the steamed rice from a row of spray nozzles

6a disposed at regular intervals on a front part of the whole length of a ceiling of spray chamber 6, so that a predetermined ratio of the alcohol aqueous solution, in relation to the amount of the steamed rice, is impregnated into the steamed rice. The resultant swelled steamed rice grains containing the predetermined amount of alcohol aqueous solution is dropped on a conveyor in a tunnel-shaped cooling chamber 7 provided in front of and perpendicular to the conveyor in the liquid spray chamber 6. The swelled rice is further moved forward by the conveyor. During movement thereof, the swelled rice grains are blown with cooling air from plural cooling fans 7a disposed longitudinally on a ceiling of the tunnel-shaped cooling chamber 7 for uniformly blowing cool air or warm air against the swelled rice.

In this case, it is preferable to use a perforated conveyor such as a net conveyor having good ventilation properties. The outer end portion of the cooling chamber 7 is connected to a working clean room 8 as shown by surrounding dotted lines in the drawing. In clean room 8 there is a working conveyor 9 connected to the conveyor in the cooling chamber 7, and the alcohol containing and swelled rice grains are cooled to room temperature, or approximately thereto, are transferred onto conveyor 9. While being moved on conveyor 9, by utilizing working tables 10 located on either side of conveyor 9 a predetermined amount of the swelled rice is weighed and, for instance, 1 Kg thereof is put into a package for holding 1 Kg of the rice, by manual operation, and vacuum packing is carried out by a vacuum packaging apparatus 11 installed near the outer end of conveyor 9. The manual operation may be substituted by a mechanical operation. It is preferable that rice packages are conveyed through metal detector 12. In addition, prior to the vacuum packaging thereof, it is preferable to put an oxygen scavenger or absorber in the rice package. An oxygen scavenger, for instance, containing a combination of iron powder and common salt catalyzer sold in small gas permeable packages by

Mitsubishi Gas Chemistry Kabushiki Kaisha of Japan under the trade name "AGELESS" can be used, but any other desirable oxygen scavenger may be used.

Referring to the drawing, numeral 13, is a boiler connected to the steamer 5, numeral 14 designates a container for a water softener, numeral 15 designates an oil tank, and numeral 16 designates a rice stock room.

Raw material rice, includes non-glutinous rice, but any part of a whole thereof may be replaced by glutinous rice. In the foregoing description the rice has been treated alone, but as desired, the rice can be used as a principal raw material, and about 1-30% of barley can be mixed with the rice, and a mixture thereof is washed in water and soaked in water and water is removed from the mixture and the mixture is subjected to a heating treatment as discussed above. Barley, such as milled unpressed barley or pressed barley may be used.

Furthermore, any kind of a subsidiary raw material can be mixed with the rice or a mixture of the rice and barley for making a packaged fast-cooking rice according to the present invention.

Subsidiary raw materials include, for instance, beans, such as soybeans, red beans, green peas, broad beans, etc., vegetables include such as carrots, radishes, mushrooms, etc.

When using beans, the beans are washed in water and soaked in water for a predetermined time, and thereafter mixed with the rice which has been soaked in water. When using vegetables, the vegetables are washed in water and cut in pieces as desired and then mixed with the rice to be heated. The beans are mixed with the rice or a mixture of the rice and barley in a ratio of about 10-30 wt. % relative to the rice or rice and barley mixture.

Thus, when any subsidiary raw material is mixed with the principal raw material composed of raw material rice or a mixture of raw material rice and barley, the resultant mixture of raw materials is subjected to the heating treatment, and then impregnated with the additive liquid, and then packaged in an air tight package. The method produces various kinds of packaged fast-cooking rice which vary in taste and appearance.

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In summary, according to the present invention, the raw material rice is washed with water, and is then soaked in water, and the water is removed from the rice and the rice is heated so as to become gelatinized rice having a water absorptivity and the resultant gelatinized rice is impregnated with an additive liquid. Thereby, a mass of swelled rice grains in a loose non-sticky condition is prepared.

Thereafter, a predetermined amount of the swelled rice grain is packaged and sealed in an air tight package to produce a packaged fast-cooking rice. By this method, the foregoing defects of conventional methods for producing FD rice and the retort rice are overcome, and there is easily and economically manufactured a fast-cooking rice of good quality. In addition, the present invention has the advantage that when fast-cooking rice is to be cooked, cooking requires merely adding a predetermined amount of water to a rice cooker, without washing and soaking the rice in water. The rice is cooked in a short time in an ordinary cooking manner and thereby a cooked rice is obtained having almost the same gloss, viscoflexibility, texture and palatable taste as an ordinary cooked rice obtained by cooking raw material rice. Furthermore, when alcohol is impregnated in the hot gelatinized rice grains, solidification of the water-soluble matter present on the surfaces of the rice grains is accelerated, and at the same time, cooling of the hot gelatinized rice can be accelerated. The process of using alcohol as the impregnating additive liquid also sterilizes rice and prevents the germination of spores and the growth of germs which during storage can generate gasses caused by decomposition of the product rice. Therefore, the products can be stored in a stable and good quality condition.

EXAMPLE 1

A sealed package containing alcohol impregnated rice is opened, and 1 KG thereof, for instance, is placed in a rice boiler without being washed. 880 cc of water is added and then the mixture is heated.

The rice is cooked in about 25 minutes. During cooking the alcohol contained in the steamed swelled rice grains is evaporated completely, and there is obtained a cooked rice, free from alcohol and free from the odor of alcohol, which has the same viscoflexibility, delicious taste, texture and gloss as ordinary cooked rice obtained by cooking raw material rice.Data supplied from the esp@cenet database

- Worldwide Claims:


I claim:

1. A process for preparing packaged fast-cooking rice, comprising washing raw material rice in water, soaking said washed rice in water, draining water from the rice, heating the rice to gelatinized grains of cooked rice having a water absorptive property, impregnating said gelatinized and water-absorptive grains of rice with an additive liquid to swell the grains of rice causing the grains of rice to separate from each other, and packaging the swelled and separated rice grains in an air evacuated package.

2. A process according to claim 1, wherein the raw material rice is selected from the group consisting of non-glutinous rice, glutinous rice and a mixture thereof.

3. A process according to claim 2, further comprising mixing about 1-30% of barley with the raw material rice prior to the water washing step.

4. A process according to claim 2 further comprising mixing the raw material rice with a subsidiary raw material prior to the heating step.

5. A process according to claim 4, wherein the subsidiary raw material is bean.

6. A process according to claim 5, wherein about 10-40 wt. % of the bean is mixed with said raw material rice.

7. A process according to claim 4, wherein the subsidiary raw material is at least one vegetable.

8. A process according to claim 7 wherein about 10-30% of said at least one vegetable is mixed with said raw material rice.

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9. A process according to any one of claims 2-8 and 1, wherein said heating treatment is conducted by steam-heating, microwave heating, infrared or far infrared heating.

10. A process according to claim 1, wherein the additive liquid is at least one liquid selected from the group consisting of water, ethyl alcohol, an ethyl alcohol aqueous solution, and a seasoning liquid.

11. A process according to claim 10, wherein the alcohol aqueous solution contains about 0.5% to 30% alcohol.

12. A process according to claim 10 wherein the seasoning liquid is an aqueous solution selected from the group consisting of fermented seasoning, soup stock containing palatable ingredients extracted from tangle, meats or dried fermented bonito and solutions of water and at least one ingredient selected from the group consisting of salt, sugar, vinegar, soy monosodium glutamate, sodium 5'-inosinate, flavor and essential oils.

13. A process according to claim 3 further comprising mixing the mixture of raw material rice and barley with a subsidiary raw material prior to the heating step.

14. A process according to claim 13 wherein the subsidiary material is bean.

15. A process according to claim 14 wherein about 10-40 wt. % of the bean is mixed with said mixture of raw material rice and barley.

16. A process according to claim 13 wherein the subsidiary raw material is at least one vegetable.

17. A process according to claim 16 wherein about 10-30 wt. % of said at least one vegetable is mixed with the mixture of raw material rice and barley.Data supplied from the esp@cenet database -

Worldwide

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384.

US4931292 - 6/5/1990

METHOD OF PREPARING IRON(III) PHOSPHATE COMPOUNDS FOR IRON

FORTIFICATION OF FOOD PRODUCTS


Inventor(s): TORSTENSSON LARS-GUNNAR (SE); DAHLQVIST PER-ARNE (SE);

BENJELLOUN MALIKA (SE)

Applicant(s): EKA NOBEL AB (SE)


IP Class: A23L1/304

E Class: A21D2/02; A23L1/304C


Priority Number: SE19860001880 (19860423)

Family: FI875632

Equivalent: WO8706433; EP0265505; FI875632; SE452397; FI89760C; FI89760B

1834/2197

Abstract:


PCT No. PCT/SE87/00208 Sec. 371 Date Dec. 22, 1987 Sec. 102(e) Date Dec. 22, 1987 PCT Filed

Apr. 22, 1987 PCT Pub. No. WO87/06433 PCT Pub. Date Nov. 5, 1987.Use of a certain type of complex iron(III)phosphate compounds for iron fortification of food products, in particular grain products. Especially flour and flour products, breakfast cereals, milk-based beverages, broths, rice and fermented food products, such as bread, are here concerned. The iron (III)phosphate compounds used have general formula Z. [FeM3y-3(PO4)y]. XH2O, wherein M is one of the ions H+, Na+, K+, NH4+ or a combination thereof, 1.5>;/=y>;/=3.0, X ;/=O and Z is an integer from 1 and upwards, Z . y being an integer. A preferred embodiment is the use oy being an integer. A preferred embodiment is the use of a compound having the formula Fe3H8(NH4)(PO4)6.6H2O. The invention also relates to a method preparing iron-fortified food products and further to the iron-fortified food products.Claims:


We claim:

1. A method for iron fortification of a food product, comprising combining with the food product a complex iron (III) phosphate compound in an amount effective for providing iron fortification, said compound having the formula

Z.multidot.[FeM3y-3 (PO4)y ].multidot.XH2 O wherein M is H@+, Na@+, K@+, NH4@+ or a combination thereof, 1.5.ltoreq.y .ltoreq.3.0,

X.gtoreq.0 and Z is a positive integer, the product Z.multidot.Y being an integer, and wherein the food product comprises vegetable material, broth, or a milk-based product.

2. A method as claimed in claim 1, wherein the vegetable material comprises a grain product.

3. A method as claimed in claim 2, wherein the grain product comprises flour or flour products.

4. A method as claimed in claim 1, wherein said food product is fermented.

5. A method as claimed in claim 4, wherein said food product comprises bread.

6. A method as claimed in claim 1, wherein said food product comprises breakfast cereals.

7. A method as claimed in claim 1, wherein M comprises H@+ and NH4@+.

8. A method as claimed in claim 1, wherein the complex iron (III) phosphate compound comprises

Fe3 H8 (NH4)(PO4)6 .multidot.6H2 O.

9. An iron-fortified food product, comprising vegetable material, broth, or a milk-based product and a complex iron (III) phosphate compound having the formula

Z.multidot.[FeM3y-3 (PO4)y ].multidot.XH2 O wherein M is H@+, Na@+, K@+, NH4@+ or a combination thereof, 1.5.ltoreq.y .ltoreq.3.0,

X.gtoreq.0 and Z is a positive integer, the product Z.multidot.y being an integer, said compound being present in an amount effective for providing iron fortification.

10. An iron fortified food product as claimed in claim 9, wherein the complex iron (III) phosphate compound comprises

Fe3 H8 (NH4)(PO4)6 .multidot.6H2 O.

11. A method for treating iron deficiency in an organism need of such treatment, comprising administering to the organism an iron fortified food product containing an effective amount of a complex iron (III) phosphate compound having the formula

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Z.multidot.[FeM3y-3 (PO4)y ].multidot.XH2 O wherein M is H@+, Na@+, K@+, NH4@+ or a combination thereof, 1.5.ltoreq.y.ltoreq.1.8,

X.gtoreq.0 and Z is a positive integer, the product Z.multidot.y being an integer, and wherein the food product comprises vegetable material, broth, or a milk-based product.

12. A method for treating iron deficiency as claimed in claim 11, wherein the complex iron (III phosphate compound comprises

Fe3 H8 (NH4)6 .multidot.6H2 O.Data supplied from the esp@cenet database - Worldwide

1836/2197

385.

US4952416 - 8/28/1990

PROCESS FOR PRODUCING INSTANTIZED PARBOILED RICE


Inventor(s):

(CA)

ABRAHAM THOMAS E (CA); MALFAIT JACQUE L (CA); WHITE ARNOLD J

Applicant(s): GEN FOODS INC (CA)


IP Class: A23B9/00

E Class: A23L1/182



Family: US4952416

Abstract:


A process is described to provide an improved instantized parboiled rice that maintains the texture, appearance and flavor characteristics of eating quality parboiled finished rice product.Description:


TECHNICAL FIELD

This invention relates to a process for producing an improved instantized parboiled rice by incorporating specific amounts of water into long grain milled parboiled rice, reducing the water content over a period of time to obtain a texture having a specific range of a shear press value to provide an instantized product capable on rehydration to produce a rice product having the texture, appearance and flavor characteristics of eating quality parboiled rice.


Parboiled rice is preferred over white rice by many consumers for its texture, appearance, flavor, aroma, and recipe tolerance. However, due to the pretreatment of the rice in the paddy form which produces parboiled rice, the grain is rendered longer-cooking than milled white rice. Most parboiled rice of commerce calls for immersion-cooking of at least 20 minutes in boiling water to prepare the parboiled rice to the desired edibility. During the process of converting rough rice to parboiled rice, the paddy is soaked, steamed, dried, and then milled. It appears that the heat treatment involved in this processing reduces product rehydratability and renders it harder and longer to cook.

Many attempts have been made to produce an instantized parboiled rice having the texture, appearance and flavor characteristics of eating quality parboiled rice but success has not been completely achieved.

In U.S. Pat. No. 2,720,460 entitled "Production of Quick-Cooking Rice" techniques are described for producing instantized rice by hydrating rice grains in stages but did not consider parboiled rice as the starting material. U.S. Pat. No. 2,438,939 entitled "Quick Cooking Rice And Process For Making

Same" describes a milled rice (not parboiled) cooked in boiling water until its starch is substantially gelatinized and its moisture content is raised to about 65-70%, cooled and quick dried by removing moisture from its surface at a rate sufficiently faster than it can diffuse thereto from their interiors at

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140 DEG C. for 10 to 15 minutes. Another U.S. Pat. No. 3,408,202 entitled "Process For Preparing A

Quick-Cooking Rice" prepares a quick cook rice by soaking parboiled rice in water below its gelatinized temperature 160 DEG F. to increase its moisture content to 15-50%, steaming the rice to temperatures of 180-212 DEG F., reimmersing the rice in water below 160 DEG F., steamed again and reimmersed again and then dehydrating the cooked rice. This multiple step process is time consuming and complicated. U.S. Pat. No. 2,903,360 entitled "Method Of Making Quick-Cooking Cereals From

Parboiled Grains" soaks parboiled rice in water for 2 to 5 hours at temperatures between about 50 DEG

F. and 82 DEG F. to a moisture content between 45 and 55% compared to temperatures between about

130 DEG F. to 160 DEG F. to a moisture content between 65% and 77%. The rice is then boiled in water for about 2 to 5 minutes, separating the boiled grains from the boiling water, spraying the grains with cold water to about 130 DEG F., squeezing the cooled grains to 1/3 to 1/5 their thickness, washing and drying the grains. This multiple step process is also time consuming and complicated. Finally, U.S.

Pat. No. 4,361,593 entitled "Process For Preparing Dry Quick-Cooking Parboiled Rice And Product

Thereof" prepares dry parboiled rice by soaking rough rice in water to increase the moisture content to

30 to 45% by weight without effecting substantial gelatinization, steaming the hydrated rice under conditions effective to partially gelatinize the starch granules, tempering the partially-gelatinized rice at temperaturs below the gelatinization temperature of the starch while maintaining the level of moisture above 20%, drying the rice to a moisture content less than 15% and milling the rice. This process occurs within the hull of the rice. Other references are known to produce quick-cooking rice but no references are known which describe the process of this invention relating to the production of an instantized parboiled rice which is unique in its operation to provide an outstanding quality product having the texture, appearance and flavor characteristics of eating quality parboiled rice finished product.


The present invention provides a process for making an improved instantized parboiled rice which comprises incorporating about 68 to about 78% of water into long grain milled parboiled rice which has been substantially gelatinized. The resulting product is carefully dried to reduce the water content of the rice to about 6 to about 14% over a period of time to obtain a rice having a texture with a shear press value in the range from about 60 to below 85 lbs/force, preferably about 64 to about 74 lbs/force, and having a 41/2 to 71/2 minute stand when an equal volume of rice is combined with an equal volume of boiling water to produce an instantized eating quality finished rice product.


The starting rice material for this invention is a parboiled rice typically prepared by soaking rough rice paddy (unmilled rice, substantially as it comes from the field) in cold, warm or hot water for a substantial period of time, until the rice kernels have increased their moisture content, generally to at least above 20%; steaming the rice, generally at super-atmospheric pressure to substantially gelatinize at least 85% and up to 95 to 100% of the starch and the rice is dried and milled. This procedure ensures separateness of grain but it is well known that parboiled rice requires increased cooking time to fully rehydrate the dry parboiled rice to achieve a cooked product.

By this invention, long grain milled parboiled rice substantially gelatinized, is exposed to water at temperatures from about 160 DEG F. to 212 DEG F. and higher by soaking, immersion, steaming and the like for a period of time to increase the water content of the rice to about 68 to about 78% by weight, preferably about 72 to about 76%, of the total parboiled rice. When the water content of the parboiled rice is achieved, the product is dehydrated using drying temperatures in the range from about

260 DEG F. to about 325 DEG F., preferably from about 260 DEG F. to about 305 DEG F. over a period of time such as 10 to 30 minutes, preferably 11 to 15 minutes to reduce the water content of the rice to about 6 to about 14% by weight, preferably about 7% to about 11%, to produce a rice having a texture with a shear press value in the range from about 60 to below 85 lbs/force, preferably about 84 to about 74 lbs/force. This rice will have a 41/2 to 71/2 minute stand preferably 5 minute stand which means that when an equal volume of rice is combined with an equal volume of boiling water, the product produced is an instantized eating quality finished parboiled rice product.

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The "long grain rice" as used herein and known in the art, is defined as a rice which is long and slender in shape, as much as 4 to 5 times as long as it is wide. When cooked, the grains tend to separate and are light and fluffy.

The drying procedure used to dehydrate the high water containing rice is a long drying procedure when compared to the quick drying dehydrating procedure of regular milled rice (not parboiled) normally taking 10 to 15 minutes.

The so called "long drying" technique of this invention is conducted to achieve specific texture with a specific shear press value as described above.

U.S. Pat. No. 2,972,884 issued Feb. 28, 1961 describe a tenderness testing apparatus for food products.

The apparatus and test has become known as "shear press". This test involves the use of a standardized container and cell within which a suitable quantity of product such as rice is placed and the product is penetrated by a multiple bladed ram. The ram as it is passing through the material, operates to shear the individual particles or fibers. The force necessary to produce penetration is considered a measure of the tenderness of the product. Under carefully controlled conditions, the numerical value of force or thrust for a given product has been found to have a good correlation with tenderness. In the operation of the shear press test, especially for rice kernels, the rate at which the blade assembly of the ram is driven through the cell box is an important parameter which must be controlled if the end result is to be accurate and reproducible. The force applying mechanism used in this test is a hydraulic system operated under precise conditions.

The shear press value of the dehydrated long grain parboiled rice product is determined on an Allo-

Kramer Shear Press Model SP12 equipped with FTA-300 force transducer and a TG-4 (Food

Technology Corp.) digital texture gauge, as described in the accompanying drawing as follows: A hydraulic cyclinder 10 with a power ram 11, containing a force transducer 12 and a blade assembly containing 10 equally placed blades attached as vertical blades 14 is used which contact and completely penetrate the rice sample in the cell box 15. The force transducer 12 is connected to a digital texture gauge 13 to measure the force produced. A directional control value 17 is set to activate the power ram

11 in the hydraulic cyclinder 10. A ram speed control value 16, controls the speed of the power ram 11.

A hydraulic pump and reservoir 18 is activated by the pump switch 19 to supply the pressure to the hydraulic cyclinder 10. The pressure is read on the pressure guage 20 and can be controlled by a pressure relief value 21.

The texture of the rice product is measured by the shear press model in the following manner: The rice product, 131.1 grams, is covered by an equal volume of boiling water (212 DEG F.) with stirring. After

5 minutes of standing the water is drained for 30 seconds while the blade assembly is mounted on the shear press and locked into position. The cell box, cover and blades are immersed in 75 DEG-85 DEG

F. water until required for use. AT the end of the drain period, the rice product is placed into the cell box and leveled without compressing the product. The cover is placed on the cell box and inserted into position under the blade assembly. The hydraulic pump is turned on and the direction control value is placed in the down position and the stroke time of the power ram is 2 minutes, 30 seconds .+-.10 seconds. The digital texture guage, periodically standardized to obtain the accurate reading, is read in terms of pounds/ force.

The cell box is of sufficient size to hold 131 grams of rice which has been covered with an equal volume of boiling water and after 5 minutes of standing, the water is drained for 30 seconds. After draining, the rice product is placed into the cell box and leveled without compressing the product. The cell box or shear cell is formed in three parts, a top plate, a bottom plate and a hollow body portion.

The top and bottom plates are slotted for receiving the 10 equally spaced blades passing through the rice being tested. The cell box has dimensions of 6.6 cm.times.6.5 cm.times.6.3 cm (volume=270.3 cm@3) and made out a suitable material such as stainless steel, mild steel or the like. The cell box has guide slots on the upper and bottom sides of the cell box to receive the fingers or blades of the ram and exact alignment of the blade slots is essential so the blades will pass through and penetrate the rice product.

The following Examples demonstrate the invention in greater detail. It is understood that these

Examples are furnished only by way of illustration and not limitation.

1839/2197

EXAMPLE 1



F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer, the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195 to 205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed real (fluffer--like a lawn mower real). Rice entering the drier is approximately

3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 to 310 DEG F., zone two 290 to 310 DEG F. and zone three at 130 to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

Finished Product

This instanized rice product will have a shear press value of 100 to 105 lbs/force at a 5 minute stand with equal volumes of rice and boiling water. The density of the finished product in the dry form will be in the range of 400 to 475 grams per liter.

This superior rice product after rehydration for 5 minutes, will be smooth with separate kernels (not sticky) and, will have a desirable chewy and rubbery texture. This product is firm and fluffy not mushy or sticky. The final eating moisture at a 5 minute stand is 67%.

EXAMPLE 2



F., and flume retention time is 15 seconds before the rice enters the front of the steamer (cooker). In the steamer the rice is cooked on a moving belt by means of topical water addition and steam addition from the top and bottom of the steamer belt (atmospheric pressure). The spray water temperature is 195 to

205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed real (fluffer--like a lawn mower real). Rice entering the drier is approximately 3/4 to

1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 to 310 DEG F., zone two 290 to 310 DEG F. and zone three at 130 to

145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

The process can be altered to give a softer (less firm) finished product that is still an excellent product after a 5 minute stand.

By means of a longer retention time in the steamer (45 minutes) the rice contains 76 to 78% moisture.

The drying retention time is maintained from 30 to 35 minutes at temperatures in zone 1 at 260 to 285

DEG F.; zone 2 at 260 to 285 DEG F. and zone 3 at 130 to 140 DEG F. The rice exits the dryer at 7 to

11% moisture.

Finished Product

1840/2197

This instantized rice product will have a shear press value of 85 to 90 lbs/force at a 5 minute stand with equal volumes of rice and boiling water. The density of the finished product is slightly less than in

Example 1; in the range of 375 to 430 grams pre liter.

This product is still far superior to other instant rice products. It is a softer (less firm) rice compared to

Example 1 product, but still has a firm, chewy, rubbery texture. Separate kernels and fluffy rice are still maintained and there is a slightly higher moisture content after a 5 minute stand (69%).

EXAMPLE 3




205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed real (fluffer--like a lawn mower real). Rice entering the drier is approximately 3/4 to

1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 to 310 DEG F., zone two 290 to 310 DEG F. and zone three at 130 to

145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

The process can be altered to give a very soft rice. This is achieved by over cooking the parboiled rice in the steamer. A retention time of 50 minutes is used which increases the kernel moisture to 82% will give a shear press value of 75 lbs/force. Therefore the rice is very soft and many kernels are split open.

The rice is more sticky and there are less separate kernels. Most of the desired texture characteristics are lost. It is less chewy, less rubbery and somewhat mushy. The eating moisture content at a 5 minute stand is 72%.

EXAMPLE 4




205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (72-74%) with a retention time of 40 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated town water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed real (fluffer--like a lawn mower real). Rice entering the drier is approximately

3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 290 to 310 DEG F., zone two 290 to 310 DEG F. and zone three at 130 to 145 DEG F. The rice exits the dryer with a moisture content of 7 to 11%.

The process can be altered to make a very smooth and firm desirable product which is ready in 71/2 minutes, but not a 5 minute stand. The shear press value is 100 lbs/force. The rice is cooked in the steamer to a moisture of 72% at a 750 lbs/hr. infeed rate. The drying is conducted for a much longer time (56 minutes retention time in the dryer) at temperatures in the same range as Example 2. A slower dryer belt speed is used and the bed depth used is about 1/2 inch thicker (11/4 to 11/2 inches thick).

1841/2197

The density is 450 to 500 grams per liter. This product is very smooth when rehydrated. It is firm and rubbery and has separate kernels. This is an excellant product when rehydrated for a 71/2 minute stand.

It is too firm and dry in 5 minutes (65% eating moisture).

EXAMPLE 5




205 DEG F. at a rate of approximately 175 pounds per hour and covers the entire rice bed. The rice is cooked to the desired moisture (74.5%) with a retention time of 45 minutes in the 39 foot long, 6 foot wide steamer. At the end of the steamer, the rice is flumed with unheated town water (Maximum flume water temp. 100 DEG F.) to a drain belt. At the drain belt, the rice is spread evenly onto the drain belt and excess surface water is dripped off before rice enters the dryer. The rice is evenly spread onto the dryer belt with a bladed real (fluffer--like a lawn mower real). Rice entering the drier is approximately

3/4 to 1 inch deep on the belt. Retention time in the dryer is 40 minutes with varying temperatures in each of three drying zones: Zone one 304 DEG F., zone two 262 DEG F. and zone three at 144 DEG F.

The rice exits the dryer with a moisture content of 7 to 11%.

Finished Product

This instantized rice product will have a shear press value of 60 to 69 lbs/force at a 5 minute stand with equal volumes of rice and boiling water.

This product is still superior to other instant rice products. It is a softer (less firm) rice compared to

Example 1 product, but still has a firm, chewy, rubbery texture. Separate kernels and fluffy rice are still maintained and there is a slightly higher moisture content after a 5 minute stand (69%).Data supplied from the esp@cenet database - Worldwide

1842/2197

386.

US4986995 - 1/22/1991

PROCESS FOR PRODUCING RETORT BOILED RICE


Inventor(s): KOBAYASHI YUKIO (JP); SASAKI HITOSHI (JP); MATSUO NORISHIGE (JP);

OHBA MITSURU (JP)

Applicant(s): AJINOMOTO KK (JP)


IP Class: A23B9/02; A23B9/20

E Class: A23L1/182; A23B9/02



Family: US4986995


Abstract:


A process for producing retort boiled rice by charging raw rice and water into a container, adjusting the quantity of oxygen in the head space of the container to from 4-12 ml/100 g of raw rice, sealing the container and then boiling and sterilizing the rice.Description:




The present invention relates to a process for producing retort boiled rice directly from raw rice, with no coloring of rice.

2. Discussion of the Background

Heretofore, retort rice has been produced by a method in which raw rice is boiled at about ambient pressure, and a predetermined quantity of rice so boiled or steamed is weighed and charged into a container, followed by sealing and retorting. Alternatively, retort rice has been produced by charging a predetermined quantity of raw rice into a container together with water, sealing the container, and then performing the boiling and sterilization of the rice under retort conditions. In either method, however, the resulting boiled rice is inevitably colored brown.

If raw rice is charged into a container or bag together with water and, after the sealing of the container or bag, boiled under retort conditions without replacing, neither in part nor whole, the air in the head space of the container or bag with an inert gas, there is results boiled rice having a brown color. In the case where all of the air in the head space above the rice and water is replaced with an inert gas, such as nitrogen gas or the like, for the purpose of avoiding the undesirable coloring, there results boiled rice having a bluish light gray color. This undesirable coloring can be avoided if the boiling of the rice is carried out at a relatively low temperature for a prolonged period of time. In this method, however, a

1843/2197

retort rice product having inferior preservability results due to insufficient sterilization. In addition, it is time-consuming and hence requires energy in quantities larger than in the present invention.

In view of the above problems, a need continues to exist for a process for producing retort boiled rice which is free from the undesirable coloring.

It is presumed that the coloring (browning) is caused by reaction products between oxygen and certain components of rice or products formed through decomposition of certain rice components. It is also presumed that the browning phenomenon is related to not only oxygen, but also heating temperature and time. The phenomenon does not take place at temperatures of ordinary home use pressure cookers.

However, the surface of boiled rice becomes colored under high temperature retort conditions (120

DEG C. or above) commonly employed in the food industry, if oxygen is present in the system in quantities above a certain level.


Accordingly, one object of the present invention is to provide a process for producing retort boiled rice which produces rice having no undesirable coloring and yet retaining good taste characteristics.

This and other objects which will become apparent from the following specification have been achieved by the present process in which raw rice and water are charged into a container; the quantity of oxygen in the head space of the container is adjusted to from 4-12 ml per 100 grams of raw rice using an inert gas and then the rice is boiled.


Under high temperature retort conditions, boiled rice is not colored if oxygen is present in an amount of

12 ml or less, per 100 g of raw rice, and boiled rice having only inferior flavor results if oxygen is present in an amount exceeding 12 ml. On the other hand, if the quantity of oxygen is decreased to 4 to

0 ml per 100 g of raw rice, there results boiled rice which is colored to a bluish brown to a degree clearly recognizable by the naked eye. Accordingly, if part of the oxygen in the head space of a container is replaced by an inert gas, such as nitrogen or the like, to adjust its quantity to 4 to 12 ml, per

100 g of raw rice (which corresponds to oxygen concentrations in the range of 2 to 6% in the case where 100 g of rice is charged into a container of 400 ml) and the rice is boiled, after the sealing of the containing, under high temperature retort conditions, non-colored boiled rice with no deterioration of its flavor is obtained.

Retort packs of rice have hitherto been produced by either of the following methods:

(1) Rice is boiled or steamed at around ordinary temperature and ambient pressure and cooled to an appropriate temperature; a predetermined quantity of rice so boiled or steamed is weighed and charged into a retort container; the air in the head space (vacant space) of the container is sealed; and then the rice is subjected to retorting or retort sterilization under relatively low temperature conditions; or

(2) A predetermined amount of raw rice is weighed and charged into container together with a predetermined quantity or water; the air in the head space of the container is replaced by an inert gas, such a nitrogen or the like; the container is sealed; and then boiling and sterilization of the rice are simultaneously effected under high temperature retort conditions (in this case, the boiled rice is colored in bluish light gray).

As mentioned above, the above method (2) results in undesirable coloring of rice a bluish light gray. In addition, rice products produced by the method have a slight hydrogen sulfide odor. When the step of replacing air by an inert gas is omitted in method (2), the resulting rice will have an unpleasant flavor.

Although the coloring may not become noticeable in the case of boiled rices with assorted mixtures, such as boiled rice with red beans and boiled rice with wild plants, it becomes apparent in the case of a plain boiled rice. However, the method is energy efficient and can be advantageous in simplicity of weighing.

1844/2197

On the other hand, the process of the present invention makes it possible to obtain boiled rice which is excellent in flavor and is free from the undesirable coloring. Further, the process of the invention is as energy efficient as method (2). The present process, like the method (2), can be carried out by using less water since no water escapes in the form of vapor during the boiling step. Accordingly, the total energy required in the present process is only 1/2 to 1/3 of that in the method (1). The weighing step in the process of the present invention can be readily automated since material to be weighed is highly flowable raw rice just immersed in water. In addition, the process of the invention requires only a short production time.

If rice is boiled before it is charged into a container, the viscosity of boiled rice makes its handling highly difficult, and the grains of boiled rice are often crushed. In contrast, the process of the present invention is free from such problems since material which is to be weighed and charged is hard and wet grains of raw rice. Because of these reasons, retort boiled rice obtainable by the process of the present invention has a higher commercial value than that of prior products.

Various materials can be used for the container to boil the rice. It is advantageous to use a material having excellent gas barrier properties, in particular oxygen barrier properties, since such a material is capable of providing retort boiled rice with excellent long-term preservability. The container is composed of a laminated material containing at least one layer of a material having an oxygen transmission rate of 2 ml/m@2 -day-atm or less at 20 DEG C. and an oxygen transmission rate of 50 ml/m@2 -day-atm or less at 120 DEG C. As examples of such materials, mention may be made of laminated products containing one or more layers of aluminum foil, vinylidene chloride resins, e.g. biaxially stretched vinylidene chloride resins, ethylene-vinyl alcohol copolymers, polyacrylonitrile resins, silicon oxide vacuum evaporation films, and the like.

The retort boiled rice according to the invention can be heated by a microwave oven if the container has a laminate structure in which one or more interlayers consisting of vinylidene chloride resins, ethylenevinylalcohol copolymers, polyacrylonitrile resins, silicon oxide vacuum evaporated films, or the like, are sandwiched with layers of, e.g., polypropylene, polyethylene or a material obtained by adding fillers to such polymers. There is no particular restriction on the kind of films to be used as a base for the silicon oxide vacuum evaporated films. As examples of films usable for this purpose, mention may be made of polyesters, nylons and polypropylene.

In cases where a lid-containing vessel is used as a container, the material to be used for the lid of the container is not necessarily the same as that used for the main body of the container. In cases where the vessel is to be heat sealed with a film or the like, there must be used a combination having good heatsealing properties. In the examples described below, there were employed polypropylene vessels in combination with a lid of polypropylene. However, the material to be used as a lid for a polypropylene vessel is not limited to polypropylene.

As described above, when a container consisting of a material having a high oxygen transmission rate is used, colored boiled rice results. On the other hand, when a material having a high vapor transmission rate is used as a packing material, the resultant boiled rice becomes excessively sticky due to moisture penetration through the packing material during the high temperature retorting.

Accordingly, if a packing material having not only an allowable oxygen transmission rate, but also a low vapor transmission rate is used, there can be obtained non-colored boiled rice which is excellent in both flavor and texture, even if boiling and sterilization are performed simultaneously under high temperature retort conditions.

The retort boiled rice product according to the invention can be treated with a microwave oven when the container is made of a packing material containing no metals, for example, a material in which one or more intermediate gas and vapor barrier layers of vinylidene chloride resins, ethylene-vinyl alcohol copolymers, polyacrylonitrile resins, silicon oxide vacuum evaporated films, or the like, are sandwiched by outer layers of polypropylene resins, polyethylene resins, a polypropylene or polyethylene resin incorporated with conventional fillers, polyester resins, or the like. In this case, the product can be heated quite conveniently without opening the container and hence can be served within a short period of time. Moreover, the product is of high commercial value since the packing material is transparent, and hence the contents contained in the container can be seen from the outside.

>;tb; TABLE 1

1845/2197

>;tb;______________________________________

>;tb;Relationship of Raw Rice and Water

>;tb;Raw Rice and Water Absorption (20 DEG C.)

>;tb;Immersed Time (hrs)

>;tb; Weight Increase (%)

>;tb;______________________________________

>;tb;0.5 18.5

>;tb;1 19.8

>;tb;2 19.8

>;tb;6 19.7

>;tb;15 20.0

>;tb;______________________________________

The water absorption rate of raw rice at 20 DEG C. is shown in Table 1. The rate becomes almost constant after an immersion of 1 hour. In the examples, therefore, raw rice was used after being immersed for 1 hour. The object of the immersion is to swell starch contained in rice grains and to facilitate the gelatinization of the grains. In order to make the production process simpler, it is preferable to render raw rice saturated with water at a constant water absorption rate.

In ordinary non-retort boiling processes, rice is boiled with addition of water in an amount 1.5 times that of rice, and excessive water is allowed to escape in the form of vapor, thereby forming so-called

"crab holes" which function as passages for the vapor. This is a technique to produce boiled rice having a soft texture.

In the process of the present invention, the ratio of water to rice was set at about 1:1, i.e., no excessive water is used, since boiling is performed in a sealed container. In order to obtain boiled rice having a soft texture, the boiling of rice was conducted with a relatively large head space within the container, thereby utilizing the retort sterilization technique.

The present invention will further be illustrated by examples. It should however be noted that the invention is by no means limited to these examples.

EXAMPLES

Reference Examples

In Table 2 is shown the conventional process which has been employed for the production of retort boiled rice. In this process, rice is boiled at ambient pressure, and a predetermined quantity of the rice so boiled is weighed and charged into a container. The air in the head space of the container is replaced by nitrogen, and the container is sealed, followed by retorting.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Conventional Process for Producing Retort Boiled Rice

>;tb;______________________________________

>;tb; ##STR1##

>;tb;______________________________________

EXAMPLE 1

>;tb; TABLE 3

>;tb;______________________________________

>;tb;Outline of the Process of the Present INVENTION

>;tb;______________________________________

>;tb; ##STR2##

>;tb;______________________________________

(1) Sealing

1846/2197

The containers used were sealed after part of the air in the head space in the container had been replaced by nitrogen to adjust the quantity of oxygen contained therein to 8 ml at ambient temperature, per 100 g of raw rice.

>;tb; TABLE 4

>;tb;______________________________________

>;tb;Relationship between Quantity of Oxygen

>;tb;and Coloring & Flavor of Boiled Rice

>;tb;Quantity of

>;tb;Oxygen* Appearance Flavor

>;tb;______________________________________

>;tb;40 Brown Unpleasant odor

>;tb; 0 Bluish gray

>;tb; Odor of hydrogen sulfide

>;tb; 4-12 White Good

>;tb;14-20 Brown No flavor

>;tb;______________________________________

>;tb; *Quantity of oxygen (ml) per 100 g of raw rice

(2) Retort Sterilization

In order to produce boiled rice having good texture, retorting was conducted with a head space of about

50% of the total volume of the containers. Because of this, it was performed under the following strict retort conditions: 120 DEG C., 20 minutes, Fo=5 to 6. The difference between the pressure of the inside of the containers and that of the inside of the retort autoclave was .+-.1 kg. The resultant boiled rice was comparable in not only softness and texture but appearance to boiled rice obtained by using conventional rice cookers. At the same time, microorganisms contained in the containers were completely sterilized.

It was confirmed that retort boiled rice produced as above could be stored for about one year under ordinary distribution conditions without any discoloration and decomposition, and that the texture of freshly boiled rice could be enjoyed even after the storing. In this example, trays having a depth of about 5 cm and a capacity of about 400 ml were used as containers. Accordingly, the concentration of oxygen of their head space was 2 to 6%.

Results attained by the present process are shown in Table 5, in comparison with those attained by the conventional process.

>;tb; TABLE 5

>;tb;__________________________________________________________________________

>;tb;Comparison between Present Process and Prior Process

>;tb;Items Present Invention

>;tb; Reference Example

>;tb;__________________________________________________________________________

>;tb;Time Required for

>;tb; 100 min. 200 min.

>;tb;Production

>;tb;Weighing & Charging

>;tb; Simple and easy

>;tb; Difficult

>;tb; (Predetermined quantity, for

>;tb; (Predetermined quantity, for

>;tb; one meal, of raw rice is

>;tb; one meal, of boiled rice is

>;tb; weighed and charged)

>;tb; weighed and charged)

>;tb;Sealing Partially substituted by

>;tb; Completely substituted by

>;tb; nitrogen nitrogen

>;tb;Conditions for Retort

>;tb; 125 DEG C., 25 min.

>;tb; 121 DEG C., 20 to 25 min.

1847/2197

>;tb;Sterilization

>;tb; (Gelatinization & boiling)

>;tb; (Sterilization only)

>;tb;Preservable Period

>;tb; 1 year (when distribution at

>;tb; 4 months (when distributed at

>;tb; ordinary temperature)

>;tb; ordinary temperature)

>;tb;Organoleptic Evaluation

>;tb; Comparable to boiled

>;tb; Comparable to boiled

>;tb; rice prepared by

>;tb; rice prepared by

>;tb; conventional rice cooker

>;tb; conventional rice cooker

>;tb;__________________________________________________________________________

EXAMPLE 2 - PLAIN BOILED RICE

>;tb;______________________________________

>;tb;Rice immersed in water (Japonica)

>;tb; 85 g

>;tb;Water 50 g

>;tb;______________________________________

Since 67 g of raw rice, when immersed in water, adsorbed about 18 g of water (total weight=85 g), the quantity of water to be supplemented was set at 50 g. The rice and water was placed in a flat tray (the same one as in Example 1). The tray was sealed after part of the air of its head space had been replaced by nitrogen gas to adjust the quantity of oxygen to 88 ml at ambient temperature, per 100 g of raw rice.

The thus sealed tray was subjected to boiling sterilization treatment in the same manner and under the same conditions as in Example 1. The thus obtained retort packed plain boiled rice, as well as boiled rice produced by a conventional rice cooker (Control 1) and marketed retort packed boiled rice

(Control 2) were organoleptically evaluated by a panel of 20 members. Boiled rices of Example 2 and

Control 2 were evaluated in comparison with Control 1 (which was rated as 10).

>;tb; TABLE 6

>;tb;______________________________________

>;tb;Results of Evaluation of Plain Boiled Rice

>;tb; Example 2 Control 1

>;tb; Control 2

>;tb;______________________________________

>;tb;Appearance 9 10 8

>;tb;Mouth Feel 9 10 9

>;tb;Taste 10 10 10

>;tb;Flavor 10 10 8

>;tb;Overall 9 10 8

>;tb;Rating

>;tb;______________________________________

The retort boiled rice according to the present invention was superior in all the above items evaluated to the marketed retort packed boiled rice, although it was slightly inferior to the boiled rice cooked by the conventional method using a conventional rice cooker.

The quantity of water adsorbed changed little, irrespective of the kind and quality of raw rice used, and the quality of resulting boiled rice showed no substantial change even when quantity of water used fluctuated by up to about 10%.

EXAMPLE 3 - SEKIHAN (BOILED RICE MIXED WITH RED BEANS)

>;tb;______________________________________

>;tb;Glutinous rice washed with water

>;tb; 120 g

1848/2197

>;tb;Boiled adzuki beans 20 g

>;tb;Bean stock (used for boiling of

>;tb; 75 g

>;tb;adzuki beans)

>;tb;______________________________________

In order to produce Sekihan (boiled rice mixed with red beans) of high commercial value, it is necessary to color it uniformly to a reddish-brown. Accordingly, 10 g of adzuki beans was boiled in

100 g of water for about 20 minutes, and the resulting beans (20 g) and the bean stock (75 g) were placed in a flat tray together with 120 g of washed glutinous rice, and subjected to simultaneous boiling and sterilization under the same conditions as in Example 1. In cases where sufficient amount of bean stock could not be obtained, the shortage was supplemented by water. Results of organoleptic tests are shown in Table 7.

>;tb; TABLE 7

>;tb;______________________________________

>;tb;Results of evaluation of Sekihan


>;tb; Control 4

>;tb;______________________________________



>;tb;Taste 10 10 9

>;tb;Flavor 10 10 9

>;tb;Overall 10 10 9

>;tb;Rating

>;tb;______________________________________

The Sekihan according to the present invention was superior in all the items tested to Control 4

(marketed Sekihan) although it was inferior in appearance to Control 3 (Sekihan produced by a conventional rice cooker).

EXAMPLE 4 - SANSAIGOHAN (BOILED RICE MIXED WITH WILD PLANTS)

>;tb;______________________________________

>;tb;Nonglutinous rice immersed in water

>;tb; 85 g

>;tb;Wild plants 20 g

>;tb;Seasoning liquid 45 g

>;tb;______________________________________

The above ingredients were weighed and placed in a flat tray as in Example 2. Part of the air of its head space was replaced by nitrogen gas to adjust the quantity of oxygen to 8 ml, per 100 g of raw rice.

After the tray had been sealed the boiling and sterilization were carried out simultaneously in the same manner as in Example 2.

>;tb; TABLE 8

>;tb;______________________________________

>;tb;Results of Evaluation of Sansaigohan


>;tb; Control 6

>;tb;______________________________________



>;tb;Taste 10 10 10

>;tb;Flavor 10 10 10

>;tb;Overall 9.8 10 9.5

>;tb;Rating

>;tb;______________________________________

1849/2197

After boiling, the product according to the invention exhibited quality comparable to Control 6

(marketed Sansaigohan), and it was slightly inferior in appearance to Control 5 (Sansaigohan prepared by a conventional cooker).

EXAMPLE 5 - RICE GRUEL

>;tb;______________________________________

>;tb;Rice immersed in water

>;tb; 60 g

>;tb;Water 240 g

>;tb;______________________________________

The above ingredients were mixed and boiled in a similar manner as in Example 2, except that the retorting time was extended by 10 minutes to give a thin rice gruel. Upon organoleptic tests, the product gave the same results as in Example 2.

EXAMPLE 6

A retort boiled rice was produced in the same manner as in Example 2. As a control, a retort boiled rice was prepared in the same manner as in Example 2, except that a nylon/polyethylene laminated film was used as a sealing material for the tray. The boiled rice of the control was excessively sticky, lacked reproducibility and could not be controlled by adjusting the quantity of water added.

EXAMPLE 7

Retort boiled rice was produced in the same manner as in Example 2, except that the kind of rice used was changed for Japonica to Indicia. The same results as in Example 2 were obtained wherein Japonica rice was used.

When the air in the head space is not replaced by an inert gas, there is results boiled rice which is brown in color and suffers from an unpleasant odor. On the other hand, the process of the present invention makes it possible to obtain boiled rice which possesses good flavor and is free from the undesirable coloring. In addition, the process of the present invention requires less water and hence less energy since the quantity of water which escapes in the form of vapor during boiling is reduced. The energy required for boiling in the present process is only from 1/2 to 1/3 of that required in conventional processes. With regard to weighing, what is to be weighed in the present process is highly fluid raw rice which has been immersed in water, and hence the process can be readily automated and carried out within a shorter period of time.

In prior processes where rice is boiled prior to charging into a container, boiled rice is likely to be crushed and can be handled only with difficulty because of its stickiness. In contrast, in the present process in which wet grains of hard raw rice are weighed, there is no danger of crushing of the grains and the weighing and charging operations are easily performed thanks to its high fluidity. Because of above reasons, retort boiled rice products obtainable by the present process are of higher commercial value, compared with those obtainable by prior processes.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.Data supplied from the esp@cenet database - Worldwide

1850/2197

387.

US5009905 - 4/23/1991

SUSHI FORMING METHOD


Inventor(s): IKEDA TAKEO (US)

Applicant(s): IKEDA TAKEO (US)


IP Class: A23L1/00

E Class: A23L1/00P8E; A23L1/325H; A23L1/337; A23P1/08E



Family: US5009905

Abstract:


A gauge member is provided for mounting overlying a bamboo mat, wherein initially a seaweed sheet is mounted overlying the bamboo mat, the gauge is mounted overlying the seaweed sheet.

Subsequently, a layer of rice is deposited within the gauge defined by a framework and filled within the gauge up to a predetermined marking. A layer of seafood is then deposited overlying the rice, whereupon the gauge is removed. Finally, the bamboo sheet is rolled and arced to enable rolling of the seaweed sheet containing the rice and seafood therewithin.Claims:


What is claimed as being new and desired to be protected by Letters Patent of the United States is as follows:

1. A method of gauging and forming sushi comprising the steps of: a. providing a bamboo mat defined by a predetermined upper surface and positioning the mat on a support surface, and b. placing a flexible seaweed sheet on said bamboo mat, said flexible seaweed sheet defined by a further surface less than that of the predetermined surface of the bamboo mat, and c. providing a frame member and positioning the frame member onto an upper surface of the seaweed sheet, and d. forming a layer of rice within the

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frame member, and e. forming a layer of seafood overlying the layer of rice to completely fill the frame member, and f. removing the frame member, and g. rolling the bamboo mat, the seaweed sheet, rice and seafood in unison to form a sushi roll.

2. A method as set forth in claim 1 wherein the step of providing a frame member includes forming the frame member as a rectangular framework, with tapering interior side walls and forming spaced "V" shaped notches through an upper surface of the frame member downwardly thereof, and wherein the step of filling the framework with a layer of rice includes filling the framework to a bottom portion of each "V" shaped notch.Data supplied from the esp@cenet database - Worldwide

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388.

US5017395 - 5/21/1991

METHOD OF MAKING A STEAMTABLE QUALITY PARBOILED RICE

PRODUCT


Inventor(s):

STEVEN D (US)

MCCASKILL DON R (US); ORTHOEFER FRANK T (US); DANFORTH

Applicant(s): RICELAND FOODS INC (US)


IP Class: A23L1/182; A23B4/03

E Class: A23L1/182; A23B9/08



Family: US5017395

Abstract:


A process of producing a high-stability parboiled rice product which is not quickly rehydrated, but which is highly resistant to breakdown during long periods of steamtable exposure. The parboiling process comprises a hot water soak followed by steaming to effectuate substantially complete gelatinization. The rice is then pre-dried at an elevated temperature and tempered for an extended period of four to six hours. Plural stages following tempering reduces stress and thus enhances kernel integrity.Description:



This invention relates broadly to parboiled rice products and to methods for producing parboiled rice.

More particularly, the present invention relates to a parboiled rice product exhibiting greatly improved steamtable quality, characterized by an enhanced resistance to breakdown. Methods of the invention relate to rice parboiling processes sequentially involving soaking, steaming, drying and tempering stages.

As will be appreciated by those familiar with rice processing methods, the broad concept of parboiling rice to preserve its nutritional integrity and resistance to insect invasion during long storage periods has been known and applied for hundreds of years. The main advantage of the parboiling process is the resulting retention of nutrients and minerals in the starchy center of the rice. Over the years, it has been demonstrated that parboiling also results in a grain which is more easily dehulled, is more resistant to breakage during milling, has a higher percentage of superior quality bran oil, and withstands longer cooking times without becoming undesirably sticky.

Broadly, parboiling comprises the steps of soaking the harvested grains in water to increase the moisture content, steaming the moistened grains under pressure, and subsequently drying the rice prior to storage and milling. The soaking and steaming steps result in swelling and restructuring of the starch granules or starch-lipid complex in the rice grain. Research indicates that the overall minimum

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moisture content achieved during soaking and steaming is roughly 30% dry solids basis (d.s.b.) Drying typically comprises a plurality of drying phases during which the rice temperature and moisture content are gradually reduced so that heat stresses on the rice are minimized. During drying, the rice endosperm hardens, making the grain more resistant to breakage during milling. Milling removes the outer hull and bran layers from the starchy center of the rice grain.

Prior parboiling practices can be divided into three broad categories: the "conventional" method, the dry-heat method, and the pressure-steaming method. The conventional method comprises soaking, draining, steaming at atmospheric pressure, followed by drying and milling stages. The dry-heat method replaces the steaming step of the conventional method with a heating stage, in which the rice is cooked in dry, hot air or sand prior to drying. Finally, the pressure-steaming method comprises a low moisture initial soak (roughly 25-67% d.s.b. moisture content) followed by pressurized steaming prior to drying and milling. Various combinations of these individual steps have been applied in the art.

Parboiled rice finds a ready market in both large food service organizations, and in the home. Simple parboiled rice usually requires relatively long cooking times, which is a disadvantage for home use where "quick cooking rice" is favored. To produce quick cooking rice, an "instantization" process is required after parboiling, raising the cost of the product. Larger institutions, however, do not require quick cooking rice, since they have more than adequate time to slow-cook traditionally parboiled rice.

As will be appreciated by those skilled in the food service arts, in larger food service organizations such as institutions, cafeterias and the like, foods such as rice are commonly pre-cooked in volume and then transferred to steamtable pans. Typically, the pans are held in hot steam carrier cabinets or

"carters" at temperatures of between 70-105 degrees Celsius prior to serving. When serving commences, the heated pan will be transferred to a steamtable and maintained at serving temperatures typically between 50-70 degrees Celsius.

Many relatively large scale food service operations have found it convenient and profitable to reduce labor-intensive individual service by abandoning a-la-carte offerings in favor of self-serve "buffets" or cafeterias. In such establishments a variety of conventional steamtables are quite commonly used for temporarily storing food, while maintaining the desired temperature. Even in "full service" restaurants or diners steamtables are often employed adjacent a salad bar, and their use provides customers with a convenient "self service" option. While such arrangements no doubt offer many advantages, product losses as a result of food deterioration over time can often result.

A clear advantage of steamtables is that while the food remains hot for serving, the food tends not to drY out in the heat. But conventionally processed parboiled rice may degrade measurably in response to steamtable overexposure. As will be appreciated, however, steam introduces water to the food product, and foods continue to slowly cook during steamtable storage. Since hot foods served in a typical luncheon buffet may remain over burners or in steamtable trays for a full two to three hour serving period, steamtable foods eventually tend to become soft and mushy, overcooked, and tasteless.

Conventional rice processed by typical prior art parboiling methods is particularly vulnerable to steamtable degradation.

The focus of many prior art rice processing developments discussed below has been to produce a quick-cooking rice product for home consumption. Processes for "instantizing" rice require that the rice be essentially fully cooked after milling and redried (whether made from raw white or parboiled rice), resulting in substantial grain breakage and increased energy costs. As a result instantized rice is more expensive than mere parboiled rice. "Instant" or "quick-cooking" rice products are capable of rapid rehydration, so that cooking times are meaningfully shortened. While not a major consideration for large food service operations, a short cooking time is extremely important, for example, to one preparing a typical family meal for a small or limited number of diners. Food products which are capable of "instant" cooking are in great favor for home-prepared family meals. The shorter the cooking time of the various menu items, the easier it can be for the head of the household to coordinate the meal and serve all items concurrently. Rice provides a tasty and convenient side dish and thus quick-cooking rice products are in great demand.

But instantized rice which may be ideal for home preparation is not optimum for larger food services employing steam tables. Such rice is more expensive than simple parboiled rice, and its primary

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consumer advantage, that of "quick cooking," is not a benefit to food service establishments which typically have several hours to prepare their food. Further, we believe that many instantized rice products are at least somewhat susceptible to steam table degradation. Moreover, the known prior art has not attempted to customize a parboiled rice product which is immunized from the above discussed phenomena of steam table degradation. After relatively short periods of steamtable exposure, even quick-cooking rice may partially degenerate, as multiple kernels fall apart and clump together in an unappealing, soft, "pasty" mass. Over time the steamtable storage of rice typically results in the loss of consumer-appealing color, texture, and flavor.

As a result of steamtable degradation, rice is wasted. For large volume cafeterias, for example, cumulative food service losses engendered by wasted, steamtable-degraded products can be prohibitive. Hence, it is desired to produce a rice product which maintains an appealing light color and a chewy, non-sticky texture after extended periods of steamtable storage.

Recent research efforts to improve parboiled rice products have been directed at the modification of the rice starch structure. Modifying the grain starch in various ways may result in desirable product qualities, such as quick-cooking, freeze-thaw stability, and resistance to breakdown or "mushiness" during cooking. Native starch exists in two related forms in the rice granule, as amylose, or the

"straight-chain" form and as amylopectin, or the molecular "branch" form. The greater percent of native rice starch is amylopectin. In the past, chemical treatments have been used to modify the native starch structure to achieve different qualities.

It has also been found advantageous to force gelatinization of rice starch granules. For purposes of this discussion, "gelatinization" refers to the disruption of the crystalline structure of the rice starch, usually as a result of the addition of water by soaking and steaming. In effect, gelatinized starch granules are

"melted" together into an amorphous mass. Ungelatinized, crystalline starch is generally white in color.

Most prior art parboiling methods attempt to avoid any significant gelatinization in the soaking phase and to vary steaming time, pressure, and temperature in order to thereafter effectuate the desired degree of gelatinization. As demonstrated in the specific examples discussed hereinafter, different processing methods achieve varying degrees of gelatinization of the native rice starch. As revealed in the prior art discussed hereinafter, at least some degree of gelatinization of the rice starch is desired in order to provide rice with improved kernel integrity when cooked.

Modified or gelatinized starch may also "reassociate" or recrystallize in different forms. In essence, the starch is crystallized from its gelatinized state to a strongly angular starch crystal structure. The extent of starch reassociation depends on both the moisture content and the temperature of the stored rice. As will be demonstrated in the specific examples hereinafter, reassociation forms new starch linkages which substantially affect product stability.

In this context, the term "stability" refers generally to the resistance of rice to the release or "leachout" of free starch during and after cooking. "Kernel integrity" broadly refers to maintenance of firm and compact individual grains throughout cooking. Typically, kernels of rice cooked or steamed for long periods of time will split open and fall apart. As the starch is freed or released from the kernel, the rice becomes sticky or pasty and may mass into unmanageable clumps.

Rice stability and kernel integrity can be measured through the use of various subjective standardized taste and visual tests after cooking. "Cooked quality" of the rice is measured immediately after cooking, and includes analysis of the rice texture, color, amount of free starch or stickiness of the cooked rice, and kernel integrity. The scores are commonly averaged together to obtain an overall average cooked quality score. Similar standard tests are conducted to determine "steamtable quality".

Steamtable quality as used herein is measured after the rice has been exposed to water and heat on the steamtable for a predefined period. The scores for texture, color, free starch, kernel integrity, and overall steamtable quality can be readily compared to cooked quality scores. Various qualities of a rice product can also be predicted prior to cooking through the use of other laboratory procedures.

The degree of starch gelatinization and the amount of starch reassociation in a rice granule may be revealed with the use of a differential scanning calorimeter (DSC). DSC scans are used widely in the plastics industry to measure endothermic and exothermic characteristics of materials at given temperatures. Amylopectin starch is a naturally occurring high polymer, and thus naturally lends itself

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to DSC testing. A rice sample subjected to a DSC scan displays a heat flow curve, which can be compared to standard curves for interpretation of the internal structure and characteristics of the rice starch.

All of the above standard tests commonly applied in the food industry facilitate comparison of rice samples produced under different processes. The food service industry, however, is now most interested in consistent performance of the rice product on the steamtable. Additionally, the food canning and freezing industries may benefit.

A number of prior art methods are directed to the production of "quick cooking" or rehydratable rice which overcome problems resulting from undesirably long cooking times, particularly associated with

"brown" rice products. One such "instantizing" method is disclosed by McCabe in U.S. Pat. 3,959,515, issued May 25, 1976 and comprises alternating soaking and baking stages. Soaking the rice results in starch gelatinization and increased grain size. Baking at temperatures of approximately 300 degrees F. dries the grains for storage and provides desirable color quality.

Other methods for producing "precooked" or quick-cooking rice products are described by Lou in U.S.

Pat. No. 4,521,436, issued June 4, 1985; Barry, U.S. Pat. No. 4,333,960, issued June 8, 1982; and

Kohlwey, U.S. Pat. No. 4,649,055, issued Mar. 10, 1987. The last two references disclose an additional puffing stage in which the rice is expanded under high heat.

The parboiling process set forth in U.S. Pat. No. 4,810,511 issued to Velupillai on Mar. 7, 1989 is directed mainly to reduction of energy expenditures and resultant product costs. The initial soaking stage results in a 26-32 percent (wet basis) water content. Thereafter the rice slurry is exposed to microwave energy (heated) for partial gelatinization to roughly forty percent water content. The rice is then drained and microwaved a second time to a water content of roughly fourteen percent The process results in a rice product which is substantially completely gelatinized, and purportedly resulted in higher than average milling yields.

Taniguchi, in U.S. Pat. No. 4,794,012 issued Dec. 27, 1988, proposes a method for producing a pregelatinized rice which can be stored for long periods and quickly cooked, for example, in a microwave oven. The method comprises successive soaking steps during which temperatures are gradually raised to prevent undesired putrefaction and to increase uniform moisture distribution throughout the rice grain. The rice is then steamed and boiled, resulting in gelatinization, with a moisture content of 45-75 percent w.b. Finally, the grains are dried and puffed to reduce the moisture content to roughly eight percent.

The aforementioned prior art references are generally directed to producing quick-cooking or instantized rice products. Increased starch gelatinization is achieved during initial steaming stages.

Based on our experimentation, none of the above-referenced methods is capable of economically producing a rice product which is suitably resistant to steamtable breakdown. Moreover, none of the above-addressed prior art suggests effective means for both increasing rice kernel integrity and controlling energy expenditure and resultant production costs.

One reference of relevance to the present process and product is U.S. Pat. No. 4,361,593, issued Nov.

30, 1982 to Brooks. It is noted that the process defined therein is directed to the production of a parboiled rice suitable for subsequent instantization. Briefly, the '593 process comprises an initial soaking step, i which the moisture content is raised to 30-45 percent w.b.; a high-pressure steaming step, in which the degree of gelatinization is closely restricted; and an extended, controlled "tempering" step, which purportedly reduces the amount of free starch in the rehydrated rice. In this context,

"tempering" generally refers to a "resting" period in which starch molecules are permitted to associate into water-resistant bonds at lower temperatures, averaging roughly 100 degrees Celsius. The tempering step purportedly hardens the starch in the rice and assures a non--sticky, quick--cooking rice product. After the tempering step, the rice is slowly dried to a moisture content of under fifteen percent w.b.

In U.S. Pat. No. 4,361,593 drying does not precede tempering. In column 5, lines 56-60, the latter reference states that "...Where the moisture content is reduced too rapidly to too great an extent...the tempering will not proceed to the proper degree and the product will tend to be relatively more

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starchy." The prior art thus teaches away from our concept, since we have found that a predrying step prior to tempering can be critical to the production of a parboiled rice product of enhanced steamtable quality.

Based on experimentation, however, it has been demonstrated that thus restricting gelatinization substantially reduces kernel integrity. In addition, tempering moist rice at high temperatures actually retards starch reassociation. While the process purportedly favors the production of a quick-cooking rice, it is demonstrated incapable of producing a high-stability, steamtable rice product, such as is currently in commercial demand.

Importantly, it is our experience that tempering the rice directly after steaming is commercially impractical. For example, the rice of the '593 method is immediately tempered after steaming.

However, when very moist rice is stored for tempering as taught, the rice tends to release starch and

"ball up" into sticky masses which cannot be conveyed or handled conveniently as individual or separate grains. Additionally, while such a high moisture tempering process may be easily carried out in the research laboratory, its translation to the production environment is highly impractical. Special equipment and processing required to accomplish such tempering would greatly raise production costs and render the rice end product too expensive for commercial purposes. In addition, the '593 process tends to reduce milling yields, which in turn further increases production costs.

Thus it is desired to provide a rice parboiling process which provides substantially complete gelatinization and favors starch reassociation whereby to yield a high-integrity kernel. No teaching is found in the prior art known to us for an economically feasible process for simultaneously achieving substantially complete gelatinization and controlled tempering for attaining high starch reassociation.

None of the known prior art discloses adequate means for efficiently producing a rice product which retains kernel integrity as well as desirable color, texture, and taste qualities during extended periods of steamtable storage.

SUMMARY

The present invention is directed to a rice product which exhibits enhanced steamtable breakdown resistance, as well as a parboiling process for producing such rice. The high-stability rice product is resistant to breakdown under heat and moisture stresses typically experienced during long periods on a buffet steamtable.

The resulting rice product is not quickly rehydrated and thus takes longer to cook. Importantly, the latter characteristic is not crucial to most food service operations employing steam tables. Our new rice product displays high kernel integrity, low water uptake, and maintains appealing flavor, texture, and color during long periods of steamtable exposure. The process affords a rice product having the desired qualities without the use of chemical treatments and at minimum equipment cost.

The parboiling process of the present invention begins with hot water soaking to raise the rice moisture content. A subsequent pressure steaming step raises the moisture content to approximately 49-54 percent d.s.b. In the steaming step substantially complete gelatinization of the rice starch is achieved. It is generally accepted that as the moisture content of starch decreases, the gelatinization time and temperature increase.

Thereafter, in a critical predrying stage the rice moisture content is reduced to 25-33 percent d.s.b.

Predrying is followed by an extended tempering step averaging four to six hours in duration.

Preferably, tempering temperatures ranging from 38 to 66 degrees Celsius and a moisture content of

25-33 percent d.s.b. are maintained. Substantial starch recrystallization is achieved. Additionally, it is shown that reassociation at high temperatures is favored by low moisture content. Successive drying steps maintain kernel integrity, and establish a favorable storage moisture content of approximately sixteen percent d.s.b. Thereafter, the rice may be stored or milled. When milled the outer bran layers are substantially completely removed.

Importantly, subsequent milling processes are virtually unaffected by our new process. No reduction of milling yields has been noted in rice produced in accordance with the process. Further, experimentation reveals that the present process results in higher quality of texture, free starch content, and kernel

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integrity. As a result, food losses based upon the number of unserved portions (i.e. unconsumed food portions abandoned on the steamtable) are substantially reduced.

The tempering bin system used for effectuating the process of the present invention comprises a small batch continuous system. A plurality of thermally insulated bins containing multiple, operatively associated hoppers are sequentially employed to achieve first in, first out (i.e. FIFO) bulk processing.

Each of the bins comprises a channeled inlet for receiving rice passing from the initial drying stage, and each is fed by a cyclone distributor unit. Each of the bins is preferably thermally insulated.

Individual bin hoppers are serially filled, and when the bin is to be emptied, the individual hoppers are emptied in the same order to effectuate FIFO processing. Each individual hopper comprises baffle structure for holding the rice for tempering. The baffles facilitate the downward travel of rice through an air-controlled outlet gate which dispenses the tempered rice onto a conveyor system for further processing. A first-in-first-out tempering stage is thus achieved.

Hence it is a fundamental object of the present invention to provide a steamtable-resistant, parboiled rice product.

A related object is to provide a process for producing a high-stability parboiled rice product which, although not rapidly rehydrated, is substantially immunized from steamtable degradation.

Another basic object of the present invention is to provide a practical and cost-effective method for producing a highly stable rice product suitable for economic consumption in large volume food service institutions.

A further broad object of our invention is to provide a rice product which demonstrates high steamtable stability while retaining appealing color, flavor, and texture.

Another object of the present invention is to provide a process for producing a rice product which is resistant to moisture stress and starch leachout for long periods after cooking.

Still another object of our invention is to provide a rice product which requires longer initial cooking times, but is capable of maintaining appealing quality during extended storage on a steamtable.

Another object is to provide a non-chemical process for producing a highly stable, steamtable rice product.

A further object of the present invention is to provide a process for producing a steamtable rice product which incorporates a low-moisture tempering step between drying stages.

A still further object of the present invention is to provide a rice product which, by virtue of its greater steamtable stability, will result in substantial decrease of food waste.

Another object of the present invention is to provide a process for producing a high-stability rice product having lower free starch levels after cooking.

Yet another object is to provide a parboiled rice product suitable for the prepared foods processing industry.

Still another object of the present invention is to provide a process for producing a completely gelatinized (85% or more) steamtable rice product having a lower maximum water uptake at room temperatures than has been previously achieved through pressurized steam processes.

Yet another specific object of the present invention is to provide a process of producing a highstability, low viscosity rice product without deleteriously affecting milling yields.

A further specific object of the present invention is to provide a rice product which is substantially completely gelatinized.

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Still another specific object of the present invention is to provide a rice product which displays substantial starch reassociation.

An additional object of the present invention is to provide a rice product which retains appealing color, texture, flavor, and kernel integrity throughout extended serving time periods typical of conventional steamtable operations.

These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.


In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:

FIG. 1 is a block diagram illustrating the various stages of our improved parboiling method;

FIG. 2 is a fragmentary, isometric view of the preferred tempering bin system thereof, with alternative path configurations illustrated in dashed lines;

FIG. 2A is an enlarged, fragmentary sectional view of the preferred baffle structure;

FIG. 3A illustrates the cluster model of native amylopectin starch in the rice kernel as viewed at the molecular level prior to processing;

FIG. 3B figuratively illustrates amorphous, substantially completely gelatinized rice starch as viewed at the molecular level after steaming;

FIG. 3C figuratively illustrates recrystallized rice starch as viewed at the molecular level after tempering;

FIG. 4 is a graph depicting comparative DSC scans of various rice samples, illustrating crystallization and gelatinization peaks characteristic of our new rice product;

FIG. 5 is a bar graph relating rice tempering temperatures to average panel scores;

FIG. 6 is a graph relating tempering temperature and time to maximum distilled water uptake

(MDWU);

FIGS. 7-11 are graphs relating average panel scores for tested rice to steamtable exposure, respectively plotting factors of color, texture, free starch, kernel integrity, and overall quality;

FIG. 12 is a bar graph illustrating relative improvements in sensory panel scores for texture and free starch of parboiled rice tempered with and without pre-drying; and,

FIG. 13 graphically illustrates the relation between MDWU (as final percent moisture, d.s.b.) to certain rice qualities.


The best mode of carrying out the rice parboiling process of the present invention is broadly illustrated in block diagram form in FIG. 1 of the accompanying drawings. The parboiling process, generally designated by the reference numeral 30, broadly comprises a plurality of rice processing steps which result in the production of a high-stability rice product capable of retaining appealing color, flavor, texture, and kernel integrity during long periods of steamtable exposure. The preferred bin apparatus is also disclosed for facilitating an extended tempering stage.

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With initial reference now directed to FIG. 1 of the appended drawings, our parboiling process 30 begins with an initial pre-cleaning stage 40, in which rough, harvested rice is cleaned and subsequently sorted according to grain size and quality. Stage 40 is conventional, and it involves processing details which are well known to those skilled in the rice processing arts. For example, pre-cleaning stage 40 involves several different apparatuses, such as conventional grading, sorting and cleaning equipment.

Such devices are operatively linked for efficient processing by conventional mechanical conveyors and conduits. Precleaned and sorted long grain rice entering the process at 41 generally has a moisture content of 16 percent dry solids basis (d.s.b.).

After the initial cleaning phase 40 is complete, precleaned rice is transported via conveyor 44 to a system of holding tanks for soaking. As explained in detail hereinafter, the soaking stage 50 effectuates a hot water soak. The soak water is maintained at relatively high temperatures, roughly between 55 and

75 degrees Celsius. The soaking phase 50 preferably results in elevation of the rice moisture content to roughly 43-54 percent d.s.b. Gelatinization of the rice starch during soaking stage 50 is incomplete, since soaking here is merely for hydration. Soaking preferably occurs beneath the final gelatinization temperature of approximately 77 degrees Celsius.

Moisturized rice is conveyed via a valved line 56 which drains the soak solution and dispenses the rice into a pressurized bin for steaming stage 60. Steaming continues at controlled temperatures until substantially complete gelatinization of the rice starch is accomplished. Gelatinization can be monitored by well known techniques including D.S.C. phenomena or loss of birefringence. This latter phenomena generates the optically perceived "maltese cross effect."

Saturated steam is typically injected at ten to twenty p.s i.g. into the tanks and circulated throughout the rice. The steaming stage 60 typically lasts one to ten minutes, until gelatinization is substantially completed. On the average, at least 85 percent gelatinization is achieved. Hence it is important that the desired high moisture content of the rice be established prior to the steaming stage to assure complete gelatinization.

The reference numeral 66 generally designates pneumatic conveying. Predrying stage 70 reduces the rice moisture content and encourages the reassociation of starch in the rice granules into a highly resistant crystalline amylose structure. The initial drying stage 70 (i.e. the "predrying" stage) also facilitates subsequent conveying and storage of the rice granules for further processing. The reassociated starch is substantially prevented from "leaching out" during conveying, so that the individual rice kernels do not lump together into a sticky, unmanageable mass. Predrying stage 70 is followed by tempering. It is important that the temperature of the rice be maintained relatively constant at approximately 55-66 degrees Celsius during conveying, so that rapid cooling does not inhibit desired amylose starch reassociation.

The predried rice is fed into a tempering system broadly designated by the reference numeral 75.

Tempering in this context generally means resting or holding at controlled temperature (38-66 degrees

Celsius) prior to further processing. As explained in detail hereinafter, tempering encourages starch reassociation in the rice kernel. The tempering system broadly comprises a plurality of bulk storage hoppers 78 internally divided into numerous individual compartments 184 for holding the rice.

When it is desired to produce a highly resistant rice in accordance with the present process, the rice must be routed into the tempering system 75 (FIGS. 1, 2) . Rice is distributed into a plurality of tempering hoppers 78, where it remains for an extended, predefined period known as the "dwell time."

Preferably, dwell time averages four to six hours. The temperature in the tempering hoppers is maintained at preferably 38-66 degrees Celsius. As best viewed in FIG. 2, each hopper 78 comprises a plurality of separate individual chambers 184.

As illustrated in the examples described hereinafter, tempering favors reassociation of the starch molecules in the rice kernel, and thus enhances kernel integrity. Based on our experimentation, it is critical that the rice be subjected to the initial drying stage prior to tempering, since starch reassociation is favored at elevated temperatures and low moisture content.

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The small batch continuous tempering system preserves first in, first out processing. Pipe 77 must be routed as illustrated in FIG. 2 to transmit rice through pipe 76 into one or more hoppers 78. A conventional cyclone separator 130 associated with each hopper feeds the rice into grain distributor

133. Distributor 133 comprises an inlet mouth 137 and a plurality of outlet ports 186 which sequentially feed the individual hopper compartments 184, entering through roofs 184A. The individual hopper compartments are fed serially so that first one is filled, and then filling of an adjacent hopper commences. For example, hopper 189A may be filled prior to hopper 189B. When the rice is released, the hopper compartment which was filled first will be emptied first.

Internal baffles 193 (FIG. 2A) extend angularly outwardly from the interior walls of each chamber 184, and facilitate bulk transfer. Each lower outlet orifice 196 is controlled by an air gate assembly 199. In the best mode each of the tempering hoppers is thermally insulated. Thus a layer of insulation 191 is disposed between outermost walls 185 and inner wall 183.

After tempering, the rice is conveyed to one or more dryer stages 83. When the tempering stage is complete, the rice is released from the tempering hoppers via air gate assemblies 199 onto a conventional conveyor 202, thereafter being fed into conduit 208 via a rotary valve 210 (FIG. 1). A blower 213 associated with conduit 208 drives rice via conduit 208 into dryer input conduit 122. The rice moisture content is reduced to approximately Sixteen percent d.s.b. The gradual reduction of drying temperatures between drying phases reduces the stress on the rice product, thereby increasing rice integrity.

Thereafter, the rice is distributed via conduit 218 into storage stage 95 prior to milling stage 100. In the best mode, the rice is milled until a substantial portion of the outer bran is removed. Depending on market demands, the processed rice may remain in storage for an extended period or be promptly milled.

Alternatively, where it is desired to conventionally parboil, rice may be conveyed directly to the dryer stages 83. The selective channeling of the rice is facilitated by removably connected pipe 77 associated with the end of conduit 76. Conduit 76 terminates in a flange 106 adapted to be coupled to flange 109 associated with pivotal pipe 77. When bolted together, flanges 106, 109 maintain conduit 76 and pipe

77 in alignment. Pipe 77 may terminate at its opposite end in a similar flange 112 which mates with a corresponding flange 114 associated with the dryer input conduit 122. When the system is thus configured, rice exiting the initial drying stage 70 passes from conduit 76, via pipe 77 through dryer input conduit 122 and into the intermediate drying unit 83 without tempering. When the tempering stage is bypassed as described, the connection between conduit 208 and dryer input conduit 122 must also be temporarily blocked by rotary valve 210.

With joint reference now directed to FIGS. 3A-3C, amylopectin, which makes up the greater portion of native starch in the rice kernel, is depicted symbolically in FIG. 3A. It will be appreciated that the starch structure is not visible to the naked eye as it occurs on the molecular level. While various models have been proposed, the "cluster" model such as that depicted herein is believed most expressive of amylopectin properties. Amylopectin is the branch-form crystal structure of starch which typically appears in raw, unprocessed rice. As water is absorbed into the rice kernel during soaking and steaming, the starch crystal structure breaks down, and the starch gelatinizes, or "melts" together to a non-structured "gel." Gelatinized starch is depicted symbolically in FIG. 3B. When substantially complete gelatinization occurs such as in the present process, the crystal structure of the starch is fully broken down. Gelatinizing starch in the rice kernel facilitates the inflow of nutrients and vitamins from the outer bran layers into the rice kernel. As the rice endosperm hardens during drying, the vitamins and nutrients are "captured" within the kernel.

During tempering, the rice kernel "cools" slowly so that the gelatinized starch molecules are allowed to reassociate or "retrograde." The starch forms into crystals which have a more angular, rigid crystal structure than the branch-form native amylopectin designated in FIG. 3A. With reference to FIG. 3C, reassociated starch is symbolically depicted as it appears after tempering. The nutrients and vitamins are locked within the kernel. The rigid crystal structure of the reassociated starch makes the rice highly resistant to breakdown and starch leachout during subsequent exposure to water and heat, such as on a steamtable. However, based on our experimentation, if tempering occurs at higher moisture content levels (e.g. prior to pre-drying) reassociation at practical tempering temperatures is substantially

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inhibited. Benefits of reduced starchiness and stickiness are largely lost if the rice is not pre-dried prior to tempering. Moreover, closely controlling tempering temperatures in relation to moisture content significantly enhances the rate of starch reassociation, as evidenced by a reduction in maximum distilled water uptake (MDWU).

Experimental comparison of rice samples of various processes reveals that the present process renders new and unexpected results not achieved by application of prior art processes. Experimental data illustrated in the graphs of FIGS. 4-6, and in the tables set forth below is explained in detail in the following examples. Generally speaking, the results illustrate that the high-integrity rice product of the present process displays substantial resistance to breakdown during extended periods of steamtable exposure and retains appealing color, texture, flavor, and overall eating quality. The following examples are presented for clarification and are not intended to be construed as limiting.

EXAMPLE I

Laboratory processing of parboiled rice samples revealed that tempering in accordance with our invention between drying stages resulted in improved rice. Specifically, kernel integrity was increased, and the rice was less sticky and starchy than conventionally processed samples. The tested rice retained a pleasing appearance and flavor. Results are listed in Tables I and II hereinafter.

The control samples 1 and 1' were processed by standard methods. Samples 2 and 2' were tempered for four hours at 49-55 degrees Celsius after partial drying to approximately 28% moisture d.s.b. before final drying. Afterward, the samples were lab-milled and subjected to various tests for various quality factors, including MDWU and "cooked" and "steamtable" sensory evaluations for color, texture

(stickiness), the presence/absence of free starch, and kernel integrity. An overall average score was then calculated from the panel scores. Such "cooked" evaluations were made immediately after cooking was complete. The "steamtable" evaluations were performed after 90 minutes on a steamtable. Results of these tests are shown in Tables I and II:

>;tb; TABLE I

>;tb;__________________________________________________________________________

>;tb;COOKED QUALITY OF PARBOILED RICE

>;tb;Sensory Panel Scores

>;tb; Free

>;tb; Kernel

>;tb; Overall

>;tb;SAMPLE

>;tb; TEMPERED

>;tb; MDWU*

>;tb; Color

>;tb; Texture

>;tb; Starch

>;tb; Integrity

>;tb; Average

>;tb;__________________________________________________________________________

>;tb;1 NO 157 7.0 6.8 6.8 7.0 6.9

>;tb; 1' NO 144 7.5 7.0 6.8 6.8 7.0

>;tb;2 YES 97 7.3 7.3 7.3 7.3 7.3

>;tb; 2' YES 95 7.5 7.3 7.3 7.0 7.3

>;tb;__________________________________________________________________________

>;tb; *Expressed as final percent moisture, d.s.b.

>;tb; TABLE II

>;tb;______________________________________

>;tb;STEAMTABLE QUALITY OF PARBOILED RICE

>;tb;Sensory Panel Scores

>;tb;SAM- TEM- Tex- Free Kernel Overall

>;tb;PLE PERED Color ture Starch

>;tb; Integrity

>;tb; Average

>;tb;______________________________________

1862/2197

>;tb;1 NO 6.9 5.8 5.8 5.8 6.1

>;tb; 1' NO 7.3 6.0 6.0 6.3 6.4

>;tb;2 YES 7.3 6.7 6.7 6.7 6.9

>;tb; 2' YES 7.3 6.5 6.5 6.5 6.7

>;tb;______________________________________

As indicated, tempering between drying phases in accordance with the present process dramatically reduced MDWU. Importantly, tempering resulted in less free starch with no perceived loss in kernel integrity.

EXAMPLE II

With reference to the bar shown in FIG. 5, the importance of tempering temperature in achieving the desired effect is demonstrated. Samples of parboiled rice, after partial pre-drying, were subjected to a four-hour treatment of tempering at either 22 degrees Celsius or 55 degrees Celsius. Samples were then finish-dried to approximately 16 percent moisture, d.s.b. and lab-milled. Cooked samples of each were then held on a steamtable for 90 minutes and evaluated by standard sensory panel procedures. As shown in FIG. 5, rice tempered at 55 degrees Celsius resulted in a far superior product for steamtable use.

EXAMPLE III

FIG. 6 illustrates the effects of tempering time and tempering temperature upon MDWU at room temperature for milled rice. For this study, samples of parboiled and partially pre-dried rice were tempered for zero, two, four and six hours at either 22 degrees Celsius (trace 351) or 49 degrees

Celsius (trace 35) prior to finish-drying. MDWU is generally inversely related to tempering time.

Tempering at 49 degrees Celsius produced a much greater reduction in MDWU for a given tempering time than did tempering at 22 degrees Celsius. It is therefore concluded that MDWU is also inversely related to the degree of starch reassociation in completely gelatinized (85% or more) rice starch. Thus,

MDWU may be monitored as a quality control parameter in the production of rice of improved stability by our new process.

EXAMPLE IV

Rice soaked to roughly 43% d.s.b. moisture content was thereafter steamed to substantially completely gelatinize the starch content and to increase the water content to 59 percent d.s.b. Control sample (A) was dried after steaming. Samples B-D, after predrying, were subjected to various tempering times as indicated. The samples were dried and allowed to rest prior to testing for cooking quality. All samples were then subjected to extended steamtable exposure of ninety minutes. Average scores for the sample groups are listed in Table III below.

>;tb; TABLE III

>;tb;______________________________________

>;tb;COOKED AND STEAMTABLE QUALITIES OF

>;tb;PARBOILED RICE

>;tb;Scores first listed for each sample (A) are initial cooking quality

>;tb;prior to steamtable exposure. The second-listed scores for each

>;tb;sample (A') were achieved after steamtable exposure.

>;tb;Sam- Hours Tex- Free Overall

>;tb;ple Dwell Time Color ture Starch

>;tb; Integrity

>;tb; Quality

>;tb;______________________________________

>;tb;A 0 7.3 7.0 6.8 7.0 7.0

>;tb; A' 0 7.1 6.2 6.2 6.1 6.4

>;tb;B 4 7.5 7.3 7.2 7.2 7.3

>;tb; B' 4 7.4 7.0 6.9 6.9 7.1

>;tb;C 6 7.9 7.9 7.8 8.0 7.9

>;tb; C' 6 7.7 7.6 7.6 7.6 7.6

1863/2197

>;tb;D 6.5 7.9 8.0 8.0 8.0 8.0

>;tb; D' 6.5 7.6 7.6 7.6 7.6 7.6

>;tb;______________________________________

A comparison of scores of the untempered control samples (A, A') with those of the tempered samples reveals that prolonged periods of tempering substantially improved color, texture, and kernel integrity.

The cooked free starch levels are also notably improved in the tempered rice. Even after prolonged steamtable exposure, free starch scores are acceptable. Overall quality of the rice samples improves with prolonged periods of tempering in accordance with the present process.

EXAMPLE V

Reference is now directed to FIG. 4, which depicts the results of DSC scans of samples of rice of various processes. The graphical traces reveal the degree of starch gelatinization and starch reassociation in the particular samples. The degree of gelatinization may be determined by the presence or absence of an endothermic peak observed in the temperature range of 75 to 85 degrees Celsius.

Raw, ungelatinized starch, for example, exhibits a major peak, while fully gelatinized starch produces virtually no peak in this temperature range. Peak size is inversely proportional to the degree of gelatinization. Starch reassociation produces an endothermic peak in the DSC in the temperature range of 55-65 degrees Celsius. Peak size is directly proportional to the extent of starch reassociation.

In the DSC, a rice sample of roughly 4 grams is exposed to temperatures ranging from 40.0 to 100.0 degrees Celsius at a rate of 10.0 degrees Celsius per minute. The heat flow into the rice sample is measured in terms of milliwatts per second. Temperature is plotted along the X-axis 240 in degrees

Celsius. Heat flow in MW/SEC is plotted along the Y-axis 245 of FIG. 4.

A sample of rice processed by conventional parboiling methods without tempering is indicated by the solid line designated by the reference numeral 250. The graph of 250 is practically linear, with a minor peak visible at roughly 82 degrees Celsius and roughly 0.2 MW/SEC. The absence of other peaks also indicates that practically no starch reassociation has occurred in this sample.

A sample of rice processed in accordance with the present invention is indicated by trace 260. That sample was tempered for 6.5 hours. Graph 260 reveals two notable peaks. The gelatinization peak 265 occurs at roughly 86 degrees Celsius and 0.15 MW/SEC. This indicates a gelatinization of roughly 94 percent, and gelatinization is thus substantially complete in this sample. A more prominent peak 270 is reported at approximately 63 degrees Celsius and roughly 0.275 MW/SEC. Based on experimentation, peak 270 reveals substantial starch reassociation in the sample. Such a crystallization peak is not demonstrated in the conventionally parboiled rice sample of line 250.

A third sample of rice processed in accordance with the present invention, and indicated by trace 280, was tempered for four hours. The gelatinization peak 285 occurs at roughly 82 degrees Celsius and

0.160 MW/SEC. Thus substantially complete gelatinization is also indicated in this sample.

Importantly, the reduced tempering period resulted in substantially decreased starch reassociation. The starch reassociation peak 290 is notably smaller than that of the longer-tempered sample 260, occurring at roughly 62 degrees and 0.195 MW/SEC.

These graphs demonstrate, in accordance with the data illustrated in Tables II and III above, that prolonged tempering at low moisture content favors substantial starch reassociation. As indicated, such starch reassociation enables the rice product to withstand extended steamtable exposure without breakdown or deterioration of kernel integrity, color, texture, or flavor.

Thus, the present process yields a highly resistant rice which is ideally adapted for extended periods of steam table storage.

EXAMPLE VI

In FIGS. 7-11 the duration of steamtable exposure is plotted on the X-axis from 0 to 90 minutes. The average overall quality scores achieved are plotted on the Y-axis, and range between 6.0 and 8.5. In

1864/2197

FIGS. 7-11 untempered, parboiled rice has been indicated by the traces 301-305 respectively. Rice samples tempered four hours are represented by traces 311-315; traces 321-325 represent rice tempered six hours. Traces 301-305 show significant steamtable degradation.

From these graphs one can see that in the quality factors of concern, especially texture, free starch and kernel integrity, the rates of quality decline were greatly reduced in the tempered samples produced by our new process. This is evidenced by the reduction in slope in these curves.

EXAMPLE VII

The effects of tempering after partial pre-drying to approximately 25-35% moisture d.s.b. versus tempering immediately following steaming and without pre-drying (at approximately 49-54% moisture d.s.b) are compared in FIG. 12. Parboiled rice samples were collected either immediately following steaming or after partial drying and tempered on a laboratory scale basis. Samples were subsequently finish-dried, milled, cooked, and tested for sensory quality after 90 minutes on a steamtable. As graphically illustrated, tempering after pre-drying resulted in vastly improved free starch and texture

(stickiness) scores. In contrast, only very minor improvement in these parameters was observed in the sample tempered without pre-drying.

EXAMPLE VIII

A rice sample was soaked, steamed to essentially complete gelatinization (i.e. approximately 85% gelatinization), pre-dried to approximately 25-33% moisture d.s.b., and then tempered for zero, two, four or six hours. Afterwards it was finish dried to approximately 16% moisture d.s.b., and then milled and tested for MDWU and sensory quality after 90 minutes on a steamtable. Sensory scores for texture, free starch, and kernel integrity were then plotted against MDWU as shown in FIG. 13. The data clearly demonstrates that as MDWU is reduced, higher sensory scores result. We believe this data further substantiates the negative correlation between MDWU and extent of starch reassociation.

Thus, the present process is demonstrated capable of producing a unique rice product which is well suited for use in the modern food service setting. While the rice product requires longer cooking times for rehydration, it is nonetheless highly resistant to breakdown and starch leachout in response to exposure to steamtables.

From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. A process for immunizing parboiled rice from steam table degradation by making it highly resistant to breakdown and stickiness over extended periods of exposure to water and heat in a steam table, said process comprising the steps of: (a) providing a source of raw, precleaned rice; (b) soaking said precleaned rice to provide a uniformly distributed grain moisture content of approximately 43-49% d.s.b.; (c) steaming the soaked rice outputted from step at between 10-20 p.s.i.g. for one to ten minutes to effectuate substantially complete and uniform gelatinization of the rice starch; (d) predrying the rice from step (c) to quickly reduce the moisture content thereof to an overall moisture content of approximately 25-33% d.s.b.; (e) tempering the rice of step (d) for at least two hours between 38 and

66 degrees Celsius so as to accelerate bonding between the starch molecules to encourage substantial

1865/2197

starch reassociation and crystallization for increasing the resistance of the rice to breakdown, starch leachout, and stickiness to particularly adapt said rice for steam table use; (f) drying the tempered rice of step (e); and, (g) milling the dried rice of step (f) to provide said high integrity rice.

2. The parboiling process as defined in claim 1 wherein rice is transferred through said tempering step

1 (e) in small batches on a first in, first out basis.

3. A process for producing a high integrity, slow cooking rice product for steam tables, said process comprising the steps of: (a) providing a source of raw, precleaned rice; (b) soaking said precleaned rice to provide a uniformly distributed grain moisture content of approximately 43-49% d.s.b.; (c) steaming the soaked rice outputted from step (b) at between 10-20 p.s.i.g. for one to ten minutes to effectuate substantially complete and uniform gelatinization of the race starch; (d) predrying the rice from step (c) to quickly reduce the moisture content thereof to an overall moisture content of approximately 25-33% d.s.b.; (e) tempering the rice of step (d) for at least two hours at temperatures below the cooking or gelatinization point of rice starch so as to accelerate bonding between the starch molecules to encourage substantial starch reassociation and crystallization and to particularly adapt said rice for steam table use by making it resistant to steam table degradation; (f) drying the tempered rice of step

(e); and, (g) milling the dried rice of step (f)) to provide said high integrity rice.

4. The parboiling process as defined in claim 3 wherein rice is transferred through said tempering step

3 (e) in small batches on a first in, first out basis.Data supplied from the esp@cenet database -

Worldwide

1866/2197

389.

US5026568 - 6/25/1991

SOYBEAN SNACK AND A PROCESS FOR PRODUCING IT


Inventor(s): TAKEMORI TOSHIO (JP); ISHIGA MASARU (JP); OOTSUBO TOSHIMI (JP)

Applicant(s): LOTTE CO LTD (JP)


IP Class: A23L1/10; A21D2/00

E Class: A23L1/20D4; A23L1/164E



Family: JP2084135


Abstract:


A soybean snack comprising 25-70 parts by weight of soybean powder of whole grain or soybean powder of hull-removed grain and 75-30 parts by weight of starch and/or cereal flour as main components is disclosed. This snack may be produced by grinding soybean of whole grain or soybean of hull-removed grain, adding to 25-70 parts by weight of the resultant soybean powder of whole grain or soybean powder of hull-removed grain with 75-30 parts by weight of starch and/or cereal flour and water, optionally adding a seasoning, a leavening agent and the like, adding an alkaline agent to make a pH of dry material after steam treatment 7.5-9.5, treating with steam to form a dough which has an elasticity and a plasticity which are substantially equivalent to those of the touch of rice cakes, rolling, molding, and forming a dry material to fry or to bake.Description:



The present invention relates to a snack food and a process for producing it, and in particular relates to a soybean snack and a process for producing it using substantially whole soybean material, not having a disagreeable unripe odor characteristic of soybean, having a flavorful soybean taste characteristic of soybean as an expressed taste, having a good leavening property and a good mouth-feel, components from soybean being homogeneously distributed throughout the food.


Soybean is a good food material which has rich nutrients and is good for the health, so that various snack foods utilizing soybean have been developed. For example, a snack food in which dry soybean juice is used as a material is disclosed in Japanese laid-open patent application No. 48-85755, snack foods in which a residue of soybean juice extract or "Okara" which is a byproduct of the production of soybean juice, soybean oil, soybean protein or the like are disclosed in Japanese patent publication No.

56-34257, Japanese laid-open patent application No. 56-55154 or Japanese laid-open patent application

No. 59-162837, and a snack food in which soybean protein is used as a material is disclosed in

Japanese laid-open patent application No. 62-111640. Any of these utilizes only a part of the soybean

1867/2197

material as a powder of soybean juice extracted from soybean, a residue of soybean juice extraction a soybean protein in which only a protein portion of soybean is used or the like, so that it is not intended to wholly utilize nutrients characteristic of soybean and distinct flavorful soybean taste. Therefore, these cannot reproduce the whole flavor and taste completely and are not necessarily sufficient to further emphasize the flavor and taste of soybean.

It is necessary for utilizing soybean "as a whole" to overcome several difficulties to obtain a snack food. An ideal soybean snack has not been realized in which substantially the whole part of soybean material is used, there is no disagreeable unripe odor characteristic of soybean, having a flavorful soybean taste characteristic of soybean as an expressed taste, having a good leavening property and a good mouth-feel, components from soybean being homogeneously distributed in the whole of the food.

For example, in Japanese patent publication No. 55-2255, it is intended to utilize whole soybean to produce a baked confection, in which problems arising from physical property of soybean such as

"bean-removal" are mainly intended to be avoided, soybean being ground before addition of cereal flours to treat with steam before molding in a shape of cylinder or soybean-like shape to dry to add to a material for rice confection, so that the components from soybean are not homogeneously distributed in the whole food in the resultant baked confection. Generally, when a snack is desired in which whole soybean is used, the content of the components from soybean is increased to express taste and flavor of soybean material, and the components from soybean are homogeneously distributed in the whole part of food, the leavening property of the snack worsens due to fat components which exist in the soybean material. In the above Japanese patent publication No. 55-2255, this problem is avoided by distributing the components from soybean in the whole food not homogeneously. In order to obtain a soybean material food of good mouth-feel without worsening the leavening property of snack, for example, as disclosed in Japanese patent publication No. 63-5067, a soybean material which suffered degreasing treatment is used. However, the degreasing treatment worsens the distinct flavor and taste of soybean.

Even if a good leavening is obtained, it is difficult to obtain a soybean snack in which the flavor and taste of soybean can be emphasized to express.

As the components of taste and flavor of soybean material, a flavorful soybean taste characteristic of soybean are included as well as a disagreeable unripe odor characteristic of soybean which is not preferable as a flavor of food. When a snack which has an expressed soybean taste is made, the disagreeable unripe odor characteristic of soybean is simultaneously emphasized without special treatment, and such snack has no value as a product. Namely, in order to realize an ideal soybean snack, it is necessary that among the components of taste and flavor of soybean material only the disagreeable unripe odor characteristic of soybean is removed, to retain the flavorful soybean taste characteristic of soybean, and that scattering of other components than the disagreeable unripe odor during removing the disagreeable unripe odor is prevented, simultaneously with which problems arising from components are prevented which may affect the production of snack such as fat components which have not been removed to maintain the flavor and taste of soybean.

Conventionally, although it has been believed that soybean is good for the health, the disagreeable unripe odor characteristic of soybean has been hated, so that a snack of expressed soybean taste has been prevented. And soybean has a relatively large amount of fat which inhibits leavening and precludes a soft mouth-feel, so that a soybean snack of good taste has not been obtained. It is desired to provide a snack which does not have the disagreeable unripe odor characteristic of soybean, has the flavor of soybean, and has a soft mouth-feel.


The object of the present invention is to provide a soybean snack and a process for producing it using substantially whole soybean material, not having a disagreeable unripe odor characteristic of soybean, having a flavorful soybean taste characteristic of soybean as an expressed taste, having a good leavening property and a good mouth-feel, components from soybean being homogeneously distributed throughout the food.

According to the present invention, there is provided a soybean snack comprising 25-70 parts by weight of soybean powder of whole grain or soybean powder of hull-removed grain and 75-30 parts by weight of starch and/or cereal flour as main components characterized in that a steam-treated dough after steam treatment has an elasticity and a plasticity which are substantially equivalent to those of the

1868/2197

touch of rice cake, and that it contains such an amount of alkaline agent that a pH of a dry material after steam treatment is 7.5-9.5.

Also according to the present invention, there is provided a process for producing a soybean snack characterized by grinding soybean of whole grain or soybean of hull-removed grain, adding to 25-70 parts by weight of the resultant soybean powder of whole grain or soybean powder of hull-removed grain with 75-30 parts by weight of starch and/or cereal flour and water, optionally adding a seasoning, a leavening agent and the like, adding an alkaline agent to make a pH of dry material after steam treatment 7.5-9.5, treating with steam to form a dough which has an elasticity and a plasticity which are substantially equivalent to those of the touch of rice cake, rolling, molding, and forming a dry material to fry or to bake.


As the soybean powder of whole grain or as the soybean powder ofhull-removed grain which are used in the present invention, those which may be obtained as powder or paste by grinding soybean or hullremoved soybean may be used.

It is preferable that the soybean powder of whole grain or the soybean powder of hull-removed grain is a deodorized soybean powder of whole grain or soybean powder of hull-removed grain.

The deodorized soybean powder may be prepared, for example, by heat-treating whole grain or hullremoved grain, cooling and grinding, wherein it is preferable that the heat treatment is carried out in a steam treatment apparatus at 0.2 kg/m@2 for 5 minutes to grind with a melanger.

Preferably, the ratio of the deodorized soybean powder which may be the deodorized whole grain or soybean powder of hull-removed grain to the starch and/or cereal flour may be that the deodorized soybean powder is 30-60 parts by weight and the starch and/or cereal flour is 70-40 parts by weight, in order to obtain a better soybean snack. When the deodorized soybean powder is not more than 25 parts by weight, the flavor and taste of soybean becomes poor to reduce the value of soybean snack for emphasizing the flavor and taste of soybean, and when the deodorized soybean powder is not less than

70 parts by weight, leavening becomes bad to give hard mouth-feel, so that both of the above case are not preferable. It should be noted that all defined component ratios herein are on the basis of weight.

It is preferable that the soybean snack contains such an amount of alkaline agent that pH of the dry material after heat treatment is 8.0-9.0. When pH is not more than 7.5, the mouth-feel becomes hard to make dissolution in mouth bad, and when pH is not less than 9.5, the flavor and taste of soybean is worsened by the alkaline, so that both of the above case are not preferable. All alkaline agents which may added to food may be used as the alkaline agent of the present invention, for example, sodium bicarbonate may preferably be used.

A material mixture which is adjusted to a certain pH is steam-treated to form a dough for a preliminary raw material. The steam treatment may be carried out at a pressure not more than 5.0 kg/m for 30 minutes at most, preferably for 5-10 minutes. Although the suitable steam treatment time may be optionally defined in the range described in the above on the basis of kind of material, mixing ratio, pH or the like, such a standard may be used that a dough has an elasticity and a plasticity substantially equivalent to those of the touch of rice cake. Thus, alpha-conversion of starch may be carried out suitably to give a good taste. And then rolling, molding, drying, frying, baking and calcining may be carried out to process the material, so that a soybean snack with a desired flavor and taste may be obtained.

The disagreeable unripe odor characteristic of soybean may be removed by using the deodorized soybean powder of whole grain or soybean powder of hull-removed grain, and more complete maintaining of the flavor and taste of soybean may be achieved by preventing scattering of the components other than the disagreeable unripe odor during the deodorizing treatment. For example, after a pressurized steam treatment at 0.2 kg/m@2 for 5 minutes, little destruction of useful components of soybean takes place to remove only the component of the disagreeable unripe odor relatively specifically, for which it is postulated that the disagreeable unripe odor is unstable to steam, or it is extracted more rapidly than other components by steam.

1869/2197

A soybean snack corresponding to a desired flavor and taste of soybean and mouth-feel may be obtained by formulating materials in the specific range optionally. A certain amount of leavening may be obtained by frying without pH adjustment, while pH may be adjusted to reduce the inhibiting effect of fat on leavening to obtain a snack of more soft mouth-feel and good dissolution in mouth.

The steam treatment may be carried out in the above conditions with such a standard that a dough has an elasticity and a plasticity substantially equivalent to those of the touch of rice cake, and the alphaconversion of starch may be carried out for obtaining a good taste, after which the specified following processes are carried out for production, so that a flavorful and tasty soybean taste may be obtained.

According to the present invention, there is provided a soybean snack using substantially whole soybean material, not having a disagreeable unripe odor characteristic of soybean, having a flavorful soybean taste characteristic of soybean as an expressed taste, having a good leavening property and a good mouth-feel, components from soybean being homogeneously distributed in the whole of the food.

The present invention will be explained in detail by examples, only by which the present invention is not limited.

EXAMPLES 1-4

Tests were carried out for a relation between the amount of deodorized soybean powder, flavor and mouth-feel. Materials were blended according to the formulation shown in Table 1, water was added for steam treatment to roll with a rolling roll to 1 mm thickness to form a sheet, drying was carried out after molding to obtain a raw material with a water content of 12-15%, which was further heated and dried to fry for adding taste to produce a soybean snack. As a result of examination by experts, good soybean snacks were obtained in Examples 1-4, while that of Comparative test 1 had little flavor and taste of soybean, and that of Comparative test 2 had a good flavor and taste of soybean but had a hard mouth-feel.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Comp. 1

>;tb; Ex. 1 Ex. 2 Ex. 3

>;tb; Ex. 4

>;tb; Comp. 2

>;tb;______________________________________

>;tb;Soybean powder 30 50

>;tb;Deodorized 20 40 60 75

>;tb;soybean powder

>;tb;Starch 80 70 60 50 40 25

>;tb;Water suitable amount

>;tb;Flavor & taste

>;tb; x .DELTA.

>;tb; o .DELTA.

>;tb; o o

>;tb;Mouth-feel o o o o .DELTA.

>;tb; x

>;tb;(Total) x o o o o x

>;tb;______________________________________ where o indicates good, .increment. indicates fair, and x indicates poor.

Furthermore, results of eating test of these soybean snacks by 50 panelists were summarized in Table 2 as a search result of preference for soybean snack.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Samples

>;tb; Comp. 1

>;tb; Ex. 1 Ex. 2 Ex. 3

1870/2197

>;tb; Ex. 4

>;tb; Comp. 2

>;tb;______________________________________

>;tb;Main materials

>;tb;Soybean powder 30 50


>;tb;soybean powder

>;tb;Starch 80 70 60 50 40 25

>;tb;Evaluation

>;tb;(by 50 panelists)

>;tb;Good soybean

>;tb; 4 32 48 31 45 39

>;tb;flavor & taste

>;tb;Good mouth-feel

>;tb; 31 47 50 49 32 2

>;tb;Good in total

>;tb; 4 38 48 40 32 2

>;tb;______________________________________

EXAMPLES 5-7

Tests were carried out for deference of mount-feel by addition of alkaline agent (pH adjustment).

Materials were blended according to the formulation shown in Table 3, sodium bicarbonate was added to carry out steam treatment, so that a raw material was obtained as described in Examples 1-3. pHs of the raw materials are shown in the Table. These were further fried for adding taste to produce a soybean snack as Examples 1-3, with which comparison for mouth-feel, dissolution in mouth and flavor and taste was carried out. As a result of examination by experts, as shown in Table 3, increasing pH to achieve a specific pH made mouth-feel and dissolution in mouth, while excess increasing was found to worsen the flavor and taste of soybean.

>;tb; TABLE 3

>;tb;______________________________________

>;tb; Comp. 3

>;tb; Ex. 5 Ex. 6 Ex. 7 Comp. 4

>;tb;______________________________________

>;tb;Soybean powder 40


>;tb;soybean powder

>;tb;Starch 60 60 60 60 60

>;tb;Sodium -- 0.5 0.7 1.1 1.5

>;tb;bicarbonate

>;tb;Water suitable amount

>;tb;(pH of dry 6.7 7.9 8.7 9.3 9.7

>;tb;material)

>;tb;Mouth-feel .DELTA. o o o o

>;tb;Dissolution

>;tb; x o o o o

>;tb;in mouth

>;tb;Flavor & taste

>;tb; o .DELTA. o .DELTA.

>;tb; x

>;tb;(Total) x o o o x

>;tb;______________________________________

Furthermore, results of eating test of these soybean snacks by 50 panelists were summarized in Table 4 as a search result of preference for soybean snack.

>;tb; TABLE 4

>;tb;______________________________________

>;tb; Samples

>;tb; Comp. 3

1871/2197

>;tb; Ex. 5 Ex. 6 Ex. 7 Comp. 4

>;tb;______________________________________

>;tb;Main materials

>;tb;Soybean powder 40

>;tb;Deodoried 40 40 40 40

>;tb;soybean powder

>;tb;Starch 60 60 60 60 60

>;tb;Sodium 0 0.5 0.7 1.1 1.5

>;tb;bicarbonate

>;tb;pH 6.7 7.9 8.7 9.3 9.7

>;tb;Evaluation

>;tb;(by 50 panelists)

>;tb;Good mouth-feel

>;tb; 18 37 49 47 45

>;tb;Good dissolution

>;tb; 9 32 46 45 43

>;tb;in mouth

>;tb;Good soybean

>;tb; 36 31 48 29 3

>;tb;flavor & taste

>;tb;Good in total

>;tb; 9 35 47 30 3


Worldwide Claims:


What is claimed is:

1. A soybean snack comprising 25-70 parts by weight of whole grain soybean powder or soybean powder of hull-removed grain and 75-30 parts by weight of at least one of starch and cereal flour as main components in the form of a steam-treated dough having elasticity and plasticity, and containing an amount of alkaline agent such that the pH of dry material of said snack after steam treatment is 7.5-

9.5.

2. The soybean snack according to claim 1, wherein the whole grain soybean powder or the soybean powder of hull-removed grain is a deodorized whole grain soybean powder or soybean powder of hullremoved grain.

3. A process for producing a soybean snack comprising grinding whole grain soybean or soybean of hull-removed grain, adding to 25-70 parts by weight of the resultant soybean powder 75-30 parts by weight of at least one of starch and cereal flour and water, adding an alkaline agent in an amount sufficient to make the pH of dry material after steam treatment 7.5-9.5, treating with steam to form a dough having elasticity and plasticity, rolling, molding, and forming a dry material to fry or to bake.

4. The process according to claim 3, wherein the whole grain soybean powder or the soybean powder of hull-removed grain is a deodorized soybean powder.

5. The soybean snack according to claim 1, comprising as main components about 40 parts by weight of whole grain soybean powder or soybean powder of hull-removed grain and about 60 parts by weight of starch.

6. The soybean snack according to claim 5, further comprising from about 0.5 to about 1.1 parts by weight sodium bicarbonate as said alkaline agent.Data supplied from the esp@cenet database -

Worldwide

1872/2197

390.

US5026570 - 6/25/1991

METHOD FOR PREPARING FREEZE-DRIED RICE


Inventor(s): SHIBATA TOSHIO (JP)

Applicant(s): FUTABA SHOKUHIN KOGYO KABUSHIK (JP)


IP Class: A23L1/20

E Class: A23L1/182; A23L3/44; A23B9/08



Family: US5026570

Abstract:


Disclosed is a method of making freeze-dried rice comprising boiling rice in water which contains acetic acid and sodium chloride and freeze-drying the boiled rice.

1873/2197

391.

US5035914 - 7/30/1991

CREAMY ORANGE SNACK CEREAL


Inventor(s): DOERR RICHARD A (US)

Applicant(s): DOERR RICHARD A (US)


IP Class: A23L1/18; A23P1/14

E Class: A23L1/18F; A23L1/164F



Family: US5035914

Abstract:


The present invention is directed to a food for snack or as use as a breakfast cereal which has a creamy orange flavor. The food product includes a popped cereal which is selected from oat, wheat, rye, soy, corn, rice and combinations of these and essentially includes a powdered dairy or dairy substitute product which simulates cream flavor in combination with powdered orange or artificial orange flavor.

Preferred embodiments include sweeteners such as fructose, sugar, corn syrup, dextrose, artificial sweeteners and combinations of these. Further, the food may include preservatives as well as vitamin and mineral supplements. In one embodiment, flavor enhancers are included. In yet another embodiment, the puffed cereal is formed in a shape of a sphere.

1874/2197

392.

US5057330 - 10/15/1991



Inventor(s): LEE YANIEN (US); MERRITT CARLETON G (US); GILLMORE STEPHEN R

(US); DERMODY NANCY E (US)



IP Class: A23L1/10; A23L1/16; A23L3/00

E Class: A23L1/182; A23L1/16D; A23B7/10; A23B9/26; A23L3/10; A23L3/3463; B65B25/00A



Family: US5057330

Abstract:


Fully cooked, starchy foodstuffs, such as rice and pasta, are preserved against microbiological spoilage by treatment with a predetermined quantity of an edible acid. Packages of fully cooked starchy foodstuffs are provided which are self-stable for periods in excess of 6 months and are neutralized to a proper pH to avoid sourness. Ready-to-eat meals of neutralized acid preserved starchy foodstuffs are also provided. Edible alkaline neutralizing agents are used to balance the pH. Also provided are methods for producing shelf-stable packages of fully cooked, starchy foodstuffs wherein measured quantities of acid are introduced to fully cooked, starchy foodstuffs to inhibit microbiological growth.Description:




This invention is directed to packaged fully cooked meals which are preserved against microbiological spoilage, methods for producing such packaged meals, and the ready-to-eat meals that may be so packaged. More particularly, this invention is directed to packaged fully cooked, starchy foodstuffs which are stabilized against spoilage at room temperature by reducing the pH to acidic levels.

2. Background of the Invention

Reducing the pH of food products by the addition of an edible acid to preserve against microbiological spoilage is well known. Such a method for preserving food is often referred to as "pickling" or "acid preservation". This method of preservation is common for uncooked foods such as olives, cucumbers, peppers and other raw vegetables. This method is well suited for foods where a tart flavor is desired, such as pickles, salad dressings, relishes and the like.

The preservation of starchy foodstuffs by the addition of an edible acid has been accomplished.

Although enhanced shelf-stability is obtained, there are drawbacks. Foodstuffs so preserved exhibit a tart, sour taste due to the presence of the acid. This is acceptable for some food preparations such as

1875/2197

cold pasta and potato salads with dressings having an acidic pH. It is recognized that to expand the versatility of acid-preserved starchy foodstuffs, the sour taste contributed by the acid used must be avoided.

For example, Tiberio et al., U.S. Pat. No. 4,477,478, teaches the use of fumaric acid in combination with acetic acid to preserve dressings for salad having a lower perceived tartness. In addition, Saitoh et al., U.S. Pat. No. 4,552,772, disclose the use of salt with citric or lactic acid to improve the palatability of cooked, acid-preserved, wheat flour based, alimentary pastes. Although an improvement in taste is alleged, Saitoh et al. admit the product exhibits a detectable sourness, although weakened, at column 4, line 15 of the patent.

It remains desirable to provide an acid-preservation system for cooked starchy foodstuffs, particularly alimentary pastes, rice and potatoes, while avoiding, minimizing or overcoming the sour taste of the acid utilized.


There is provided by this invention (1) a packaged shelf-stable, fully cooked meal, (2) a ready-to-eat meal obtained from such package, and (3) a method for producing a packaged, shelf-stable, fully cooked, starchy foodstuff.

In one embodiment, the package of a shelf-stable, fully cooked meal of this invention comprises 2 containers. A primary container isolates a preserved food composition sealed therein from atmospheric oxygen. This preserved food composition comprises a shelf-stable, fully cooked, starchy foodstuff and an edible acid that is uniformly dispersed in this primary container with said foodstuff, in a quantity which provides shelf-stability, said quantity preferably provides a pH for the starchy foodstuff of about

3.5 to about 4.6. A secondary container isolates the contents therein from the preserved food composition. The contents of the secondary container comprise an edible alkaline neutralizing agent in a quantity sufficient upon mixing with the starchy foodstuff to increase its pH to a value in the range of about 5 to about 7.

The ready-to-eat meal provided by this invention comprises an admixture of (1) a shelf-stable, fully cooked, starchy foodstuff which is shelf-stabilized with an edible acid, which preferably has a pH with a value in the range of about 3.5 to 4.6 provided by the edible acid and (2) an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of the starchy foodstuff to a value in the range of about 5 to about 7.

The process of this invention for producing a packaged, shelf-stable, fully cooked, starchy foodstuff comprises first preparing a starchy foodstuff for packaging by:

(a) heating the starchy foodstuff in boiling water, steam or combinations thereof until fully cooked, the quantity of water/steam being sufficient to provide the desired moisture level in the starchy foodstuff,

(b) adding a quantity of an edible acid to the fully cooked, starchy foodstuff sufficient to provide shelfstability, wherein said edible acid preferably provides a pH for the starchy foodstuff in the range of about 3.5 to about 4.6,

(c) mixing the edible acid and fully cooked, starchy foodstuff to distribute the edible acid on the foodstuff, and

(d) mixing an edible lubricant with the mixture of edible acid and starchy foodstuff, wherein the edible lubricant has a melting point below about 95 DEG F. (35 DEG C.) and is used in a quantity up to about

15% by weight, based on the weight of the total package contents.

A container is then filled with the thus prepared starchy foodstuff, sealed to exclude atmospheric oxygen and the contents of said container are then aseptically packaged, i.e., they are sterilized or pasteurized once packaged or are maintained under sterile or pasteurized conditions during packaging.

The container isolates its contents from atmospheric oxygen and is resistant to wet heat at a temperature above about 180 DEG F. (82 DEG C.). "Wet heat" refers to the condition of high temperatures (above about 180 DEG F.) and high humidity (above about 85% RH). Such conditions are present within a steam tunnel or within a vessel of boiling water.

1876/2197


The starchy foodstuffs suitable for use in this invention include grains, potatoes, starchy legumes and alimentary pastes. Preferably, the starchy foodstuff has a porous surface and is selected from grains, alimentary pastes and potatoes. Examples of preferred grains include rice, barley and wheat. The starchy foodstuffs used in the present invention must be in an edible state, prepared for consumption by the removal of any hard, inedible shell by peeling, pearling or other means. Of the grains, rice is most preferred.

Of the alimentary pastes, virtually any paste obtained from a glutinous flour is suitable for use in the embodiments of this invention. Examples of suitable glutinous flours include semolina flour, durum wheat flour, corn flour, buckwheat flour, farina flour and whole wheat flour. Their pastes all exhibit porous surfaces. Pastes obtained from rice flour, a nonglutinous flour, are also suitable, especially if the starch is gelatinized or partially gelatinized.

Potatoes that have been cut and/or peeled so as to expose porous surfaces are suitable for use. Any variety of potato may be used in the present invention.

The starchy foodstuff used is fully cooked so that it may be eaten as is from its container directly off the shelf or heated to the desired temperature. Heating the starchy foodstuff to cause it to absorb additional moisture, gelatinize additional starch, or denature additional protein is not required. Each of these phenomena may occur upon heating, but is of no consequence to this invention.

When fully cooked, alimentary pastes generally have a moisture content of about 65% to 85% by weight. Fully cooked rice generally has a moisture content of from about 60% to about 70% by weight and fully cooked potatoes generally have a moisture content of about 70% to 80% by weight. These values for moisture levels are provided as guides only. The fully cooked, starchy foodstuffs used in the present invention are not limited to species having these moisture levels.

The packaged starchy foodstuffs of the present invention are shelf-stable. The term "shelf-stable", as used herein, indicates that the foodstuff is stabilized against spoilage by microbiological growth at room temperature for a period of not less than 1 week. Preferably, the starchy foodstuffs are preserved against microbiological spoilage for a period of 6 months or more. To achieve shelf-stability, an edible acid is admixed with the starchy foodstuff. The pH of the starchy foodstuff is reduced to acidic levels of preferably from about 3.5 to about 4.6 with the edible acid.

Starch foodstuffs are not inherently acidic, so it is necessary to add an edible acid, i.e., one which can be ingested without harmful effect. Suitable acids include acetic acid, citric acid, tartaric acid, hydrochloric acid, malic acid, propionic acid, adipic acid, fumaric acid, phosphoric acid, lactic acid, sorbic acid, benzoic acid and mixtures thereof. Certain acids may be preferred because of their effectiveness. The quantity of edible acid added to the starchy foodstuff is preferably sufficient to provide a pH within the range described above. Most preferred pH values fall in the range of about 4.0 to 4.3. to be effective, the edible acid is distributed in a substantially uniform manner so as to retard the growth of molds, bacteria and yeasts which cause spoilage. The acid may be diluted to aid distribution.

It is preferable that the acid penetrate into the surface of the starchy foodstuffs, which is why porous starchy foodstuffs are preferred. For example, rice which has been acid preserved has been found to have a shelf life of more than 9 months at room temperature.

The package of a shelf-stable, fully cooked meal provided by one preferred embodiment of this invention comprises 2 containers. One of these containers is a primary container and serves to isolate a pasteurized food composition sealed therein from atmospheric oxygen. This preserved composition comprises a fully cooked, starchy foodstuff preserved with an edible acid. The edible acid is uniformly distributed within the preserved food composition and is preferably used in a quantity which provides a pH for the starchy foodstuff in the range of about 3.5 to about 4.6. This can be accomplished by adding and mixing a quantity of edible acid to the fully cooked, starchy foodstuff or by immersing the fully cooked, starchy foodstuff in a volume of diluted acid and weighing the volume of diluted acid both before and after immersion to determine the quantity of acid absorbed.

1877/2197

The preserved food composition may contain a mixture of fully cooked, starchy foodstuffs, shelf-stable foods other than starch foodstuffs, and other components such as vegetable oil for lubrication, water to aid acid dispersion, preservatives for added shelf life, seasonings or sauces for flavor, vitamin and mineral supplements, etc. The addition of these ingredients is optional.

The primary container must be comprised of a material having good oxygen barrier properties. Such materials include metals, glass, some synthetic resins, some resin coated papers or foils, and combinations thereof. Suitable containers include metal cans, glass jars, paper/metal foil pouches, some selected synthetic resin pouches, and suitably coated paper cartons. Metal cans or paper/foil pouches have high resistance to oxygen permeation, as do glass jars. However, such packages are undesirable for use in microwave ovens in that they reflect microwave energy. Synthetic resins generally do not reflect a significant amount of microwave energy and provide the advantage of convenience where the foodstuff is to be heated. However, synthetic resins generally have less desirable barrier properties to oxygen when compared to glass or metal.

Barrier properties of synthetic resins differ, and some resins must be modified to provide suitable barrier properties. Vapor barrier properties of synthetic resins can be enhanced by incorporating barrier resistant particles such as glass, minerals or metals in fiber, flake or particle form. Some synthetic resins are suitable without modification such as, for example, polyethylene terephthalate (medium and high density), polypropylene terephthalate (low density), polyvinylidene chloride (Saran), and polyamides.

Where a synthetic resin is selected for use in providing a container for the shelf-stable, fully cooked meal, the vapor barrier properties of the container may usually be enhanced by increasing the thickness of the container wall. The thickness of the wall for a container comprised of a synthetic resin preferably is in the range from about 2 mils to 5 mils. Such a container provides a reasonable resistance to puncture during handling and permits effective heat sealing of the pouch. Where the synthetic resin desired will not provide the desired barrier properties within this thickness range, thin layers of material with higher barrier properties can be added to help maintain the container thickness in this range. In a preferred embodiment, polyester pouches such as polyethylene terephthalate are used having a wall thickness of about 2 to 4 mils. Since polyethylene terephthalate has good oxygen barrier properties, it may also be used in a laminate with a base film layer that may be cheaper but is not a good oxygen barrier.

To isolate the preserved food composition from atmospheric oxygen, air must first be excluded prior to sealing the container. This can be accomplished by applying vacuum and/or compressing the container to evacuate air or by incorporating an inert atmosphere within the container such as nitrogen, carbon dioxide, or water vapor. Alternatively, water vapor may be generated from the container prior to and during sealing of said container so as to exclude a significant portion of atmospheric oxygen. A vacuum forms in the sealed container once the water vapor condenses upon cooling. Such a method is preferred in that it need not require a separate processing step where the contents of the container are sufficiently hot to generate adequate water vapor.

To complete the package of the shelf-stable, fully cooked meal provided by this invention, a second container is required which substantially isolates its contents from the preserved food composition. The contents of the second container comprise an edible alkaline neutralizing agent. The quantity of this alkaline neutralizing agent is matched with the quantity of edible acid within the primary container so that upon mixing, the pH of the fully cooked, starchy foodstuff is raised to a value in the range of about

5 to about 7 when mixed. Suitable alkaline neutralizing agents comprise edible alkali metal carbonates, such as sodium bicarbonate, sodium carbonate, potassium bicarbonate and potassium carbonate. These alkaline neutralizing agents are preferably encapsulated in inert fillers, fats or oils. Suitable fats and oils include dehydrated butterfat or palm oil and suitable inert fillers include edible salts. The alkaline neutralizing agent and encapsulant are preferably in solid, dry powder form so as to prevent the growth of microorganisms and to prevent loss of the encapsulated alkaline neutralizing agent by reaction with water. The contents of the second container are preferably in solid, dry form, so that the container need not exhibit the oxygen barrier properties required of the primary container. Preferably, however, the second container isolates its contents from moisture and humidity.

1878/2197

Other ingredients may be included in the second container along with the alkaline neutralizing agent and encapsulant, provided these ingredients are shelf-stable. Such additional ingredients will more commonly be seasonings, such as, for example, salt, dehydrated cheese, dried bread crumbs, dried onions, dried chives and the like. Conventional preservatives such as propylene glycol, sodium benzoate, etc. may also be introduced.

The contents of the primary container must be pasteurized or sterile. This can be accomplished by maintaining the fully cooked, starchy foodstuff and other components under pasteurized conditions or sterile conditions until sealed within the primary container. Maintaining the fully cooked, starchy foodstuff at a temperature above about 180 DEG F. (82 DEG C.) until packaged will generally provide a pasteurized food composition. Higher temperatures are necessary to provide a sterile food composition. Alternatively, or in addition to maintaining the fully cooked, starchy foodstuff under pasteurized or sterile conditions, the contents of the primary container may be sterilized or pasteurized by any conventional means after sealing. For example, pasteurization can be achieved by heating the contents of the primary container to a temperature above about 180 DEG F. (82 DEG C.) by treatment of the sealed primary container with steam or boiling water. For sterilization, the contents are heated to a temperature of about 212 DEG F. (100 DEG ) and above. Pasteurizing is preferred in that its effect on taste and texture of the food composition is minimized. Alternative methods of pasteurizing or sterilizing the contents of the primary container without radiant heat include treatment with microwave radiation and/or UV radiation.

A package of a shelf-stable, fully cooked meal will preferably have a shelf life greater than 1 month and more preferably will be shelf-stable for a period of at least about 6-9 months. It should be noted that a longer shelf life may be obtained by sterilizing the contents of the primary container, or by adding conventional food preservatives, such as, for example, propylene glycol, sodium benzoate and the like.

A further embodiment of the present invention is directed to a ready-to-eat meal comprising an admixture which comprises a fully cooked, starchy foodstuff selected from the group consisting of alimentary pastes, grains and potatoes. This fully cooked, starchy foodstuff is shelf-stabilized by preservation with an edible acid. Suitable edible acids include those described above for the package of a shelf-stable, fully cooked meal. Prior to incorporation into the admixture, this shelf-stable starchy foodstuff preferably exhibits a pH value in the range of about 3.5 to about 4.6, most preferably about

4.3, due to the presence of the edible acid.

Also included in the admixture is a quantity of edible alkaline neutralizing agent, generally sufficient to neutralize at least 40% by weight of the edible acid, but in any case sufficient to provide a pH having a value in the range of about 5 to about 7 for the fully cooked, starchy foodstuff within the admixture.

The ready-to-eat meals are distinguished from the packaged meals of this invention in that the edible neutralizing agent is combined with the preserved food composition in the ready-to-eat meals but the edible neutralizing agent remains isolated from the preserved food composition in the packaged meals.

Therefore, the condition of the ready-to-eat meals will be a neutralized starchy foodstuff having a pH in the range of 5-7. When in such a condition, the meal is considered "ready-to-eat."

Suitable edible neutralizing agents include sodium bicarbonate, potassium bicarbonate, sodium carbonate and potassium carbonate. The starchy foodstuffs used in the ready-to-eat meals are preferably rice and alimentary pastes. The preferred edible acids are propionic acid and lactic acid.

It is important to note that the admixture may contain other components such as sauces (cheese, egg/cream), vegetables, seasonings (salt, garlic, onion, chives), oils, foodstuffs other than the stachy foodstuffs selected above (mushrooms, meats, vegetables) which are common to ready-to-eat meals. In addition, this ready-to-eat meal may be heated, maintained at ambient temperature or chilled, where desired. The additional ingredients may be premixed with either the edible alkaline neutralizing agent or the fully cooked, starchy foodstuff. Alternatively, the additional ingredients may be mixed simultaneously with or subsequently to the admixture of these primary components.

The ready-to-eat meals provided by this invention may be obtained from a package of a shelf-stable, fully cooked meal provided by this invention and described above. However, it is important to note that

1879/2197

these ready-to-eat meals may be obtained by utilizing components which are not packaged or are packaged by alternative means and methods.

A further embodiment of the present invention is directed to processes for producing packaged, shelfstable, fully cooked, starchy foodstuffs. The starchy foodstuffs utilized in this process are those previously defined as preferred, i.e., those selected from the group consisting of alimentary pastes, grains and potatoes. Of these starchy foodstuffs, rice and alimentary pastes are most preferred.

The package produced by the process of the present invention contains an edible acid and an edible lubricant in addition to the starchy foodstuffs therein. Suitable edible acids are those as defined previously. Preferred edible acids include propionic acid and lactic acid.

The edible lubricant within the package produced by this process must have a melting point below about 95 DEG F. (35 DEG C.) to provide the desired function of preventing the fully cooked, starchy foodstuff from sticking and forming a solid mass. Preferably, below about 15% by weight edible lubricant is used, based on the total weight of the package contents. This weight limit prevents the finished product from becoming too greasy and unpalatable. Preferred quantities of edible oil generally range from about 1% to 8% by weight of the total package contents. Suitable edible lubricants include corn oil, unsaturated safflower oil, palm oil, olive oil, peanut oil, coconut oil, sunflower oil and solid fats such as butterfat.

The process of this invention comprises preparing a starchy foodstuff for packaging by heating it in boiling water, steam or combinations of both until it is fully cooked. Cooking the starchy foodstuff increases its moisture content and thereby increases its tenderness. The degree of tenderness for a fully cooked, starchy foodstuff varies, depending upon personal tastes. The term "fully cooked", as used herein, is intended to include all degrees of tenderness commonly desired for ready-to-eat starchy foodstuffs. For example, with respect to alimentary pastes, those pastes cooked to provide a soft surface texture and a hard, firm center commonly referred to as "aldente" are included within the term

"fully cooked", as well as those pastes which are cooked to a soft texture throughout, providing maximum moisture levels and maximum tenderness.

The quantity of water and steam utilized to cook the starchy foodstuff must be sufficient to provide the desired tenderness. Excess quantities of water can be utilized. However, when excess water is used, the starchy foodstuff must be drained, often resulting in product loss. It is preferable to avoid draining the fully cooked, starchy food product.

To this fully cooked, starchy foodstuff is added an edible acid in a predetermined quantity sufficient to provide shelf-stability, said quantity preferably provides a pH having a value in the range of about 3.8 to about 4.6. Suitable quantities of acid generally range from about 0.01% to 1.5% by weight acid based on the weight of fully cooked, starchy foodstuff. The most preferred pH is one having a value of about 4.0 to 4.3.

The edible acid and fully cooked, starchy foodstuff are agitated so as to disperse the acid on the surface of the cooked foodstuff. The pH values for the starchy foodstuffs herein are determined by first mincing the starchy foodstuff, or a sample thereof, in distilled water to form a slurry or puree and then measuring the pH of the resultant slurry or puree. Adequate slurries can be obtained for 50 gm samples of starch foodstuff with 50 gm of distilled water from a Waring blender in operation for about 1 minute and longer. In obtaining the desired pH, porous foodstuffs such as rice, potatoes and alimentary pastes absorb the edible acid beneath their surfaces. This is a beneficial phenomenon in that it typically enhances shelf-stability.

Agitation of the edible acid and foodstuff is preferably sufficiently mild to preserve the integrity of the foodstuff's shape and form. It is undesirable to cut, grind or mince the foodstuff during agitation.

Therefore, agitation equipment which provides the desired dispersion without damaging the shape of the foodstuff is preferred. Examples include ribbon type mixers, and the like. Where a ribbon mixer is used, agitation of from 1 to 3 minutes is suitable.

1880/2197

To the agitated acidified, fully cooked, starch foodstuff is added an edible lubricant in a quantity as described above. Agitation of the acidified, fully cooked, starch foodstuff and the edible lubricant is not essential; however, to obtain the most beneficial effect, agitation is preferred.

It should be recognized that further steps in preparing the starchy foodstuff for consumption are suitable, such as marination, frying, blending and seasoning, etc., provided these added treatments do not interfere with shelf-stability. Other components may be added if they are shelf-stable, such as food preservatives.

The starchy foodstuff thus prepared for packaging is sealed within a container so as to exclude atmospheric oxygen. The container must be resistant to wet heat in excess of 180 DEG F. (82 DEG C.) to permit subsequent processing and to accept the prepared starchy foodstuff when said foodstuff is hot from cooking. Those containers described above as suitable for packages of fully cooked meals provided by this invention are also suitable for use in the process described herein. Containers of glass, metal and synthetic resins are acceptable with preferred containers being comprised of synthetic resins, particularly polyesters (polyethylene terephthalate). As with the packages provided by this invention, the preferred thickness for these pouches ranges from about 2 mils to 4 mils.

Air must be excluded from the container prior to sealing. This can be accomplished by any conventional means such as applying vacuum or incorporating an inert atmosphere such as nitrogen, carbon dioxide or water vapor within the container. Generating a water vapor within the container is preferred in that a separate processing step is not needed where the prepared stachy foodstuff remains hot from the cooking steps.

The contents of the packages produced by the process herein are pasteurized or sterile. This condition may be achieved by exposing the contents to sterilization processes and/or pasteurization processes subsequent to sealing the container. For example, pasteurization can be accomplished by heat treatment of the sealed packages with steam vapor or by immersion in hot water at a temperature above about

180 DEG F. (82 DEG C.). By utilizing higher temperatures, sterilization is achieved. Alternative methods for providing a sterile or pasteurized condition include treatment with UV radiation and microwave radiation.

A convenient method for achieving a pasteurized sterile condition is to maintain the prepared starchy foodstuff under pasteurized/sterile conditions after cooking until sealed in the container. Cooking the starchy foodstuff in boiling water, steam or combinations of both will pasteurize or sterilize it, depending on the temperature used. This condition can be retained by maintaining the foodstuff at a sufficiently high temperature after cooking until it has been sealed in an aseptic container. The preferred temperature range is about 180 DEG F. (82 DEG C.) to about 210 DEG F. (98 DEG C.), which provides a pasteurized condition. To insure against growth of microorganisms the contents of the aseptic container may be subjected to a pasteurization step or sterilization step after sealing.

The packaged, shelf-stable, fully cooked, starchy foodstuffs produced by the process of this invention will have a shelf life greater than 1 month and typically greater than 6 months. Shelf life may be extended by selecting particular acids, incorporating food preservatives within the fully cooked, starchy foodstuff, and/or by sterilizing the contents of the sealed package.

The following examples are provided to further illustrate the invention. In these examples and throughout the specification, all temperatures are expressed in degrees Fahrenheit and each value is accompanied by an approximation of such value in degrees Celsius. All pH values for the starchy foodstuff, described in the examples and the claims which follow are measured from slurries of 50 gm samples of these starchy foodstuffs with distilled water obtained after mincing the 50 gm starchy foodstuff samples in a Waring blender for about one minute. In addition, all parts and percentages are by weight, unless expressly indicated to be otherwise.

EXAMPLES 1-4

Long Term Stability of Several Packaged, Cooked, Starchy Foodstuffs

1881/2197

These examples demonstrate the long term stability of packaged, fully cooked, starchy foodstuffs prepared in accordance with one preferred embodiment of the process of this invention. The packages produced were suitable for use in the ready-to-eat meals provided by this invention and also the packaged meals provided by this invention.

The starchy foodstuffs in Examples 1-4 were prepared by boiling in excess water until fully cooked.

Rice was boiled for approximately 12 to 14 minutes to achieve a final moisture content of about 72% to

75% by weight. Elbow macaroni having a size of about 1" in length and 3/8" in diameter was boiled 6 to 7 minutes to achieve a final moisture content of about 68% to 72%. Egg noodles of 11/2" length and

1/16" thickness were boiled for 7 to 9 minutes to achieve a final moisture content of about 66% to about 70% by weight. The excess water was drained after these cooking times.

Edible acids diluted in water to an acid:water ratio of about 1:10 were then added to the fully cooked, starchy foodstuffs. For rice, about 0.9% by weight lactic acid and about 0.027% by weight propionic acid were added, based on the weight of starchy foodstuff. For elbow macaroni, about 1.0% by weight lactic acid and about 0.030% by weight propionic acid were added, based on the weight of starchy foodstuff. For the egg noodles, about 1.1% by weight lactic acid and about 0.033% by weight propionic acid were added, based on the weight of starchy foodstuff.

After the addition of acid, agitation of the components was accomplished within a ribbon-type mixer for 1 to 3 minutes. During mixing, corn oil was added in all examples to minimize sticking. To rice, about 8% by weight corn oil, based on the dry weight of rice, was added. For elbows, about 6% by weight corn oil was added, based on the dry weight of elbows, and for egg noodles, about 7% by weight corn oil was added, based on the dry weight of egg noodles. After the addition of corn oil, mixing continued in the ribbon mixer for about 1 to 3 minutes. The temperature of each starchy foodstuff was maintained above 180 DEG F. (82 DEG C.) in preparation for sealing within polyester pouches.

About 200 g to about 250 g of each of the starchy foodstuffs were filled in 61/2" by 8", 2 mil polyethylene terephthalate polyester pouches. These pouches were heat sealed and passed through a steam saturation tunnel to raise or maintain the internal temperature to about 180 DEG F. (82 DEG C.) or above within each pouch.

TABLE I

Stability Tests

Samples of the packaged foodstuffs produced in Examples 1-4 were evaluated for storage stability

(bacterial growth) and the results are reported below.

>;tb;______________________________________

>;tb; Storage Time in Months

>;tb; Starch 86 DEG F.

>;tb; 86 DEG F.

>;tb;Example Food- RT@a /

>;tb; (30 DEG C.)

>;tb; (30 DEG C.)

>;tb;No. Stuff 30% RH@b

>;tb; 30% RH 85% RH@b

>;tb;______________________________________

>;tb;1 Elbow Macaroni

>;tb; 9 -- --


>;tb; 9 9 9

>;tb;3 Rice 9 9 9

>;tb;4 Egg Noodles 9 9 9

>;tb;______________________________________

>;tb; @a RT is room temperature.

>;tb; @a RH is relative humidity.

1882/2197

Bacterial growth was monitored over the course of 9 months. The total plate count for samples taken from Examples 2 and 3 above was found to decrease from 102 colonies to 80 colonies per gram after 8 weeks storage at 86 DEG F. (30 DEG C.), indicating microbiological growth was still inhibited at this time. The total plate count was acceptable after 9 months. The starchy foodstuffs were found to have the same acceptable flavor and texture after storage for 9 months as when first packaged. Beyond 9 months, microbiological spoilage was inhibited but taste, flavor and texture were found to deteriorate.

EXAMPLE 5

Package of Acid/Rice Admixture Low End of the pH Range

This example demonstrates the stability of packages produced by this invention where the starchy foodstuff has a pH near the low end of the range of suitable values. Packages of fully cooked rice were produced by heating water (about 26.5 pounds) with about 200 g oil to a boil in a jacketed kettle, adding rice (about 11 pounds par-boiled rice) and returning the water to a boil. After 12 minutes, the heat was turned off, the kettle covered, and the rice was allowed to stand in the hot water for about 3 minutes. The kettle was filled with more hot water and stirred with a spoon.

The excess water was drained and the cooked rice (about 29.5 pounds) was transferred to a ribbon mixer. A solution of diluted lactic acid (55 g acid+550 g water) was added and mixed in the ribbon mixer followed by the addition of 600 g corn oil. The oil and rice were mixed until the oil was uniformly dispersed.

About 59 pouches were each filled with about 220 g to 230 g of the rice/acid/oil mixture and sealed.

The pouches were then heated in a steam chamber for about 9 minutes or until an internal temperature of at least 180 DEG F. (82 DEG C.) was reached. The pH of the rice in a sample pouch was found to be

3.62 utilizing the following procedure: a 50 gm sample of rice was obtained from the pouch, blended with an equal amount of distilled water in a Waring blender for 1 minute and the pH of the resultant slurry was measured with a pH meter. Conventional pH meters such as a Corning pH meter and

Beckman pH meter were used. To test for shelf stability, 4 bags were placed in 86 DEG F. (30 DEG

C.)/85% RH for 1 week and no sign of microbiological growth was observed at the end of that time.

EXAMPLE 6

Package of Acid/Rice Admixture High End of the pH Range

This example demonstrates the stability of packages produced by this invention where the starchy foodstuff has a pH near the high end of the range of suitable values. Packages of fully cooked rice were produced by heating 19.25 pounds of water with 200 g corn oil in a Groen kettle to a boil and adding

11.0 pounds rice). After 9.5 minutes of boiling, the heat was turned off and the kettle covered. After an additional 6 minutes with no stirring, the rice was transferred to a Ribbon-Type Mixer. The rice was mixed with dilute acid (55 g of 85% lactic acid+300 g water) and about 600 g corn oil. Individual pouches were filled with 230.+-.10 g of the rice/oil/acid mixture. All pouches were heat treated for 9 minutes in a steam chamber. The heat treated pouches were exposed to 86 DEG F. 30 DEG C./85% RH for about 1 week. The pH of the treated rice within a sample pouch was about 4.65, as measured by the procedure of Example 5. No spoilage was observed at the end of 1 week.

EXAMPLE 7

Package of Acid/Rice Admixture Without a Sterilization or Pasteurization Step

This example demonstrates that a separate sterilization or pasteurization step is not necessary in the process of this invention if the starchy foodstuff is maintained pasteurized/sterile after cooking.

Individual packages produced in accordance with Example 6 were exposed to 86 DEG F. (30 DEG

C.)/85% RH for 1 week without heat treatment in a steam chamber. The pH of the treated rice within a sample pouch was about 4.20 after 1 week as measured by the procedure of Example 5. No spoilage resulted in these pouches.

CONTROL A

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Packages of Acid/Rice Admixtures Neutralized to a pH Below 5

This control demonstrates the importance of neutralizing the starchy foodstuff to a pH above 5 to obtain acceptable flavor. Packages of fully cooked rice were prepared by bringing 21.0 pounds of water to a rapid boil in a Groen kettle, adding about 11.0 pounds of rice (parboiled rice) and 176.0 g of mixing oil (Centrafry) and returning the water to a boil. After 9.5 minutes, the heat was turned off and the rice was allowed to stand for 10 minutes with stirring at 3 minute intervals. The cooked rice was transferred to a Secomak tumbler and agitated. Dilute lactic acid (100 g 85% lactic acid+450 g water) was quickly added followed by lubricant (600 g Centrafry oil+24 g lecithin). Fifteen pouches were each filled with the rice/acid/oil mixture (about 220 g), sealed, and heat pasteurized in a steam chamber. The contents of sampled pouches had a pH value of about 3.86, as measured by the procedure of Example 5, and a moisture level of about 60 % by weight. Three bags were placed in 86 DEG F. (30

DEG C.)/85% RH for about 1 week. The total plate count (bacteria) after the 1 week was less than 10.

Two 50 g samples of rice were taken from a sample package and neutralized by adding water (100 g) and mixing 15 g and 30 g, respectively, of a blend of seasoning and the neutralizing agent described below. The neutralizing agent was mixed with seasoning in a 30:1 weight ratio of seasoning to neutralizing agent. Mixing proceeded for about 1 minute. The final pH was about 4.90 and 4.48 for the meals having 30 g seasoning/neutralizing agent and 15 g seasoning/neutralizing agent, respectively.

The final pH was determined by forming a slurry of rice sample with distilled water with a waring blender and measuring the pH of the slurry. The taste of each 50 g sample was distinctively sour.

Neutralizing Agent

The neutralizing agent was a food grade encapsulated sodium bicarbonate provided by SCM.RTM.

Durkee Industrial Foods under the trademark Durkote.RTM. sodium bicarbonate 135-70. The sodium bicarbonate is coated with vegetable oil so as to not react or release prematurely.

This encapsulated sodium bicarbonate is designed to be used in combination with food acids in dry mix baking and other chemically leavened products where it is desired to delay and control the reaction of an acid and the encapsulated sodium bicarbonate. The encapsulation process provides the formulator with the ability to engineer a consistent quality product. According to product specifications of Durkee

Industrial Foods, this particular encapsulated sodium bicarbonate comprises about 70% by weight anhydrous sodium bicarbonate (substrate) and about 30% by weight partially hydrogenated palm oil

(coating). This Durkote.RTM. encapsulated sodium bicarbonate 135-70 is packed in 100 pound (45.3 kilogram) polyethylene lined fiber drums and is stable at temperatures below 80 DEG F. in odor free environments.

EXAMPLE 8

Packages of Acid/Rice Admixture Neutralized to a pH Above 5

This example illustrates that acceptable flavor is obtained where the starchy foodstuff is neutralized to a pH above 5. Packages of fully cooked rice were prepared by bringing about 21.0 pounds of water to a rapid boil in a Groen kettle, adding 11.0 pounds of rice (parboiled) with about 176 g of oil (Centrafry) and returning the water to a boil. The heat was shut off after 9.5 minutes and the rice was allowed to stand for about an additional 10 minutes with stirring at 3 minute intervals. After standing, the cooked rice was transferred to a ribbon-type mixer. Dilute acid (67 g 85% lactic acid and 300 g water) was sprayed on to the rice to enhance dispersion. Lubricating oil (about 600 g Centrafry oil and 24 g lecithin) was immediately poured over the rice.

Individual pouches were each filled with about 220.+-.10 g of the rice/oil/acid mixture, sealed while the mixture was still hot (about 180 DEG F.), and heat pasteurized in a steam chamber at a temperature above 180 DEG F. for 10 minutes or more. The pH of the cooked rice was sampled in 4 bags and found to be 4.38, 4.47, 4.36 and 4.38, respectively, following the procedures described in Example 5 for pH measurement. The moisture level for the rice in the pouches was approximately 59.7% by weight.

Samples of rice (about 220 g) were obtained from each pouch and neutralized with a blend of seasoning and the neutralizing agent described above in the following amounts.

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(1) 10 g of a blend having a 30:1 seasoning to neutralizing agent weight ratio;

(2) 20 g of a blend having a 30:1 seasoning to neutralizing agent weight ratio;

(3) 20 g of a blend having a 20:1 seasoning to neutralizing agent weight ratio; and

(4) 10 g of a blend having a 10:1 seasoning to neutralizing agent weight ratio.

Upon neutralization, the above samples (1-4) were found to have the following pH values: 5.66, 5.19,

6.23 and 6.49, respectively, utilizing the pH measurement procedures described in Example 5. All samples exhibited good taste with no objectionable sourness. These data suggest that 13 g of seasoning to 1 g of sodium bicarbonate is the preferred level for the packaged, fully cooked, starch foodstuffs of

Example 8.

CONCLUSION

While the invention has been disclosed by reference to the details of preferred embodiments, this disclosure is intended to be in an illustrative rather than in a limiting sense, as it is contemplated that modifications will readily occur to those skilled in the art, within the spirit of the invention and the scope of the appended claims. This invention includes many embodiments which have not been described in the detail provided by the above examples. The absence of such detail for all embodiments does not exclude them from the embodiments claimed herein. The examples described above could be repeated with other starchy foodstuffs, edible acids, lubricants and neutralizing agents with similar results.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A shelf-stable, fully cooked packaged meal comprising (a) a primary sealed container which substantially isolates its contents from atmospheric oxygen, said contents being a preserved food composition comprised of (i) a fully cooked starchy foodstuff selected from the group consisting of alimentary pastes and grains; and (ii) an edible acid uniformly dispersed in said primary container with said foodstuff in a quantity sufficient to provide shelf-stability; and (b) a secondary container which substantially isolates its contents from said preserved food composition, the contents within said secondary container comprising an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 following storage; wherein said edible alkaline neutralizing agent is sufficiently reactive at ambient temperature to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 for consumption, within a short time after mixing; wherein the pH of the starchy foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.

2. A packaged meal as in claim 1 wherein the quantity of edible acid provides a pH for said starchy foodstuff in the range of about 3.5 to about 4.6.

3. A packaged meal as in claim 1 wherein said foodstuff is an alimentary paste prepared from a flour selected from the group consisting of semolina flour, durum wheat flour, corn flour, buckwheat flour, farina flour, rice flour, whole wheat flour, and mixtures thereof.

4. A packaged meal as in claim 1 wherein said foodstuff is selected from rice and an alimentary paste obtained from semolina flour.

5. A packaged meal as in claim 1 wherein the edible acid is selected from the group consisting of acetic acid, citric acid, tartaric acid, propionic acid, hydrochloric acid, fumaric acid, adipic acid, benzoic acid, malic acid, phosphoric acid, lactic acid, sorbic acid and mixtures thereof.

6. A packaged meal as in claim 1 wherein the edible acid is selected from propionic acid and lactic acid.

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7. A packaged meal as in claim 1 wherein the preserved food composition additionally comprises an edible lubricant selected from the group of vegetable oils consisting of unsaturated safflower oil, peanut oil, coconut oil, palm oil, sunflower oil, corn oil, olive oil and combinations thereof.

8. A packaged meal as in claim 1 wherein the alkaline neutralizing agent is selected from the group consisting of sodium bicarbonate, sodium carbonate, potassium bicarbonate and potassium carbonate.

9. A packaged meal as in claim 8 wherein the edible alkaline neutralizing agent is encapsulated in dehydrated fat or dehydrated oil.

10. A packaged meal as in claim 1 wherein the preserved food composition additionally comprises components selected from the group consisting of seasonings, preservatives, water, vitamin supplements, mineral supplements, and shelf-stable foodstuffs other than starchy foodstuffs.

11. A packaged meal as in claim 1 wherein the primary sealed container is a pouch comprised of a synthetic resin.

12. A packaged shelf-stable, fully cooked meal comprising (a) a synthetic resin pouch which substantially isolates the contents from atmospheric oxygen, said contents being a preserved food composition comprised of (i) a fully cooked starchy foodstuff selected from the group consisting of rice, alimentary pastes and combinations thereof, (ii) an edible acid uniformly dispersed in said synthetic pouch in a quantity sufficient to provide a pH for said foodstuff having a value in the range of about 3.5 to 4.6, and (iii) an edible lubricant uniformly dispersed in said synthetic pouch in a quantity less than 15% by weight of the total preserved food composition, (b) a secondary container which substantially isolates the contents from said preserved food composition, the contents within said secondary container comprising an edible alkaline neutralizing agent in a quantity sufficient upon mixing with said foodstuff to increase its pH to a value in the range of about 5 to 7 following storage; wherein said edible alkaline neutralizing agent is sufficiently reactive at ambient temperature to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 for consumption, within a short time after mixing; wherein the pH of the starchy foodstuff is determined by mincing about a 50 gram sample of said starchy foodstuff in a blender for about 1 minute with about

50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.

13. A packaged meal as in claim 12 wherein the edible alkaline neutralizing agent is sodium bicarbonate encapsulated with an encapsulant selected from the group consisting of dehydrated fat, dehydrated oil and combinations thereof.

14. A packaged meal as in claim 12 wherein the secondary container additionally comprises seasonings selected from the group consisting of salt, dehydrated cheese, dried onions, dried chives and dried bread crumbs.

15. A packaged meal as in claim 12 wherein the secondary container additionally comprises preservatives selected from propylene glycol and sodium benzoate.

16. A packaged shelf-stable, fully cooked meal comprising (a) a polyester pouch which substantially isolates the contents from atmospheric oxygen, said contents being a preserved food composition comprised of (i) a fully cooked starchy foodstuff selected from the group consisting of rice, alimentary pastes obtained from semolina flour and combinations thereof, (ii) an edible acid uniformly dispersed in said polyester pouch selected from the group consisting of propionic acid, lactic acid and combinations thereof, in a quantity sufficient to provide a pH for said foodstuff having a value in the range of about 4.0 to 4.3, and (iii) about 1% to 8% by weight of the preserved food composition, uniformly dispersed in said polyester pouch, (b) a secondary container which substantially isolates the contents from said preserved food composition, the contents of said secondary container comprising sodium bicarbonate encapsulated with an encapsulant selected from the group consisting of dehydrated fat, dehydrated oil and combinations of both in a quantity sufficient upon mixing therewith to increase the pH of said foodstuff to a value in the range of about 5 to 7 following storage; wherein said edible alkaline neutralizing agent is sufficiently reactive at ambient temperature to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 for consumption, within a short time after mixing; wherein the pH of the starchy foodstuff is determined by mincing about a 50

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gram sample of said starchy foodstuff in a blender for about 1 minute with about 50 grams of distilled water to form a puree and measuring the pH of the puree with a pH meter.

17. A package as in claim 16 wherein the contents of said secondarycontainer additionally comprise seasonings selected from the group consisting of salt, dried chives, dried onions, dried bread crumbs, dehydrated cheese and combinations thereof.

18. A shelf-stable, fully cooked packaged meal comprising (a) a primary sealed container which substantially isolates its contents from atmospheric oxygen, said contents being a preserved food composition comprised of (i) a fully cooked foodstuff selected from the group consisting of alimentary pastes and grains that does not require further heating once cooked; and (ii) an edible acid uniformly dispersed in said primary container with said foodstuff in a quantity sufficient to provide shelf-stability; and (b) a secondary container which substantially isolates its contents from said preserved food composition during storage, the contents within said secondary container comprising an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 following storage; wherein said edible alkaline neutralizing agent is sufficiently reactive at ambient temperature to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 for consumption, within a short time after mixing.

19. A shelf-stable, fully cooked packaged meal comprising (a) a primary sealed container which substantially isolates its contents from atmospheric oxygen, said contents being a preserved food composition comprised of (i) a fully cooked foodstuff selected from the group consisting of alimentary pastes and grains that does not require further heating once cooked; and (ii) an edible acid uniformly dispersed in said primary container with said foodstuff in a quantity sufficient to provide shelf-stability; and (b) a secondary container which substantially isolates its contents from said preserved food composition during storage, the contents within said secondary container comprising an edible alkaline neutralizing agent in a quantity sufficient to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 following storage; wherein said edible alkaline neutralizing agent is sufficiently reactive at ambient temperature to increase the pH of said foodstuff upon mixing therewith to a value in the range of about 5 to about 7 for consumption, within a short time after mixing.Data supplied from the esp@cenet database - Worldwide

1887/2197

393.

US5201265 - 4/13/1993

APPARATUS FOR PREPARATION OF SUSHI RICE


Inventor(s): MATSUI SHOKICHI (JP)

Applicant(s): KYOKUO KK (JP)

IP Class 4 Digits: A23B; B01F

IP Class: A23B4/03; B01F13/02; B01F15/06

E Class: A23L1/182; A23L1/182B; A23G3/26; A23P1/08B2D; A23P1/08B14; A47J37/04G;

A47J39/00A


Priority Number: US19920844048 (19920302); US19900541856 (19900621); JP19890158204

(19890622)

Family: US5201265

Abstract:


Apparatus for preparing Sushi rice, and discharging opening provided at one end thereof, which is openably closed by a lid having a ventilation opening formed in a central portion thereof, the rotatable container being rotatable about a lateral axis of rotation and having a laterally extending partition plate mounted therein, and an air-blowing fan disposed with a space from the ventilation opening so that the ventilation opening can function as an inlet opening and also as an outlet opening for air.Description:

1888/2197



The present invention relates to an apparatus for processing granular foodstuffs such as boiled rice in particular for seasoning, flavoring or the like. More specifically, the invention relates to an apparatus for preparing vinegared boiled-rice, a main foodstuff of the Japanese cuisine widely known as Sushi, at a high preparation efficiency utilizing power. In the apparatus, a seasoning additive comprising such as a vinegar, sugar and a natural or chemical seasoning is added to boiled rice hot from boiling, and then the apparatus can mix the boiled rice and the additive together homogeneously and rapidly to prepare a desirable boiled and vinegared rice.

In preparing boiled and vinegared rice which is often called Shari in Sushi shops and among Sushigoers, it is necessary to homogeneously apply or coat a seasoning mix or additive mainly comprising a vinegar and containing such as sugar, salt and a chemical seasoning substance on grain surfaces of boiled rice, hot from boiling. For avoiding complexity in description, the boiled rice treated as above will hereinafter be referred to as Sushi rice. In the preparation of the Sushi rice, it becomes important to know how to carry out the vinegaring of boiled rice within a short period of time while the rice is still in a softened condition soon after boiling and in a manner of not allowing grains of the boiled rice to become crushed or to be made a dumpling or doughboy. Whether or not a satisfactory vinegaring of boiled rice can be done greatly depends on a skill which one can gain only after years of experience and it constitutes an important factor greatly influential upon the taste of resulting Sushi food. The seasoning mix or additive with which boiled rice is treated contains other substances than a vinegar, such as sugar, salt and a seasoning material as above, but "vinegaring" of boiled rice as termed in the above and will be termed also elsewhere in this specification because generally in the cases of Sushi rice, a greater emphasis is placed on "vinegaring" than on "seasoning". Also, while "boiled" rice as termed throughout this specification, it should be understood that Sushi rice can be made also of

"steamed" rice: For example, while in household preparations of Sushi rice, mostly boiled rice is used, in the cases of an industrial-scale preparation as made at such as large-scale Sushi shops and other suppliers of processed rice foods, steamed rice is mostly used.

As noted above, the preparation of Sushi rice involves the requirement for a particular skill for a delicate manual handling and/or a particular keen sense which one can gain only after experiences for a long period of time. However, a limitation is applied to the number of available skilled Sushi cooks, and today in newly opening Sushi shop or expanding an existing Sushi shop, it is first of all difficult to secure the necessary hands. In the circumstances, it has been strongly demanded in the business fields of Sushi shops and other suppliers of processed rice foods as well that there may be an apparatus provided, by which the vinegaring of boiled rice or the preparation of Sushi rice can be carried out easily and rapidly, without the need for a skilled cook having a long-term experience in such processing of boiled rice.

As already pointed out, to automatically prepare Sushi rice, it is necessary to provide an appropriate mixing apparatus by which operations for the preparation of Sushi rice (mixing and/or stirring operations) can be worked within a short period of time without causing boiled rice to become a dumpling or doughboy or allowing grains of boiled rice to become crushed. However, a desirable apparatus for such an automatic preparation of Sushi rice has not yet been provided.

Mixing devices in general comprise a fixed main body provided therein with rotatable mixing means such as a mixing blade or blades. In a test, soft rice hot from boiling or steaming was put into such an existing mixing device together with an additive or a vinegaring mix and an attempt was then made to operate a mixer to prepare Sushi rice, when it was found that within a short period of the operation time, the boiled rice became crushed to completely lose its original state of grains and was turned into the form of a Mochi, a Japanese food prepared by pounding boiled rice into a cake. From this result of the test, it is told that an ordinary mixing device cannot be effectively utilized for the preparation of

Sushi rice and that for the Sushi rice preparation, it is required to provide a particular apparatus by or in which the necessary mixing can take place without permitting boiled rice to be subjected to a large force application.

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Prior to the making of the present invention, the inventor of the present invention developed devices by which two or more kinds of material such as livestock feeds can be mixed together within a short period of time without greatly changing original shapes of the materials, and proposed those devices in

Japanese Patent Publications Nos. 62-57371 and 62-57372.

The above device pertaining to the present inventor's earlier inventions comprise a cylindrical rotatable container elongate in the direction of axis of rotation, which is provided at one of its longitudinal ends with an inlet and outlet opening for the materials. In one of two embodiments of the devices, two or more partition plates are mounted in the rotating container at an inclination to the axis of rotation of the container, while in the other embodiment, the partition plates are supported in an end staggered arrangement such that the end of one plate lies outward or inward of the corresponding end of another plate near each end of the cylindrical container in the direction of axis of rotation.

Taking into account the technical contents of such earlier inventions and a number of technical discoveries made during the making of the inventions, the present inventor has conducted a variety of experiments so as to effectively apply the acquired techniques to the vinegaring of boiled rice or the preparation of Sushi rice, namely an operation for the addition and mixing of a vinegar-based additive to and in rice hot from boiling, and as a result of the confirmation then obtained that the above described mixing devices according to the inventor's earlier inventions can be effectively applied to the vinegaring of boiled rice, arrived at the present invention.


Therefore, a primary object of the present invention is to provide an apparatus by which vinegaring of boiled rice, namely preparation of Sushi rice, can be easily made even by a person without a particular skill, without the risk of destroying original grain shapes of the boiled rice and by which an additive or a vinegaring mix mainly comprising a vinegar and containing such as sugar, salt and a natural or chemical seasoning can be homogeneously mixed in the boiled rice and coated on surfaces of grains of the rice.

It is also an object of the present invention to provide an apparatus for processing granular foodstuffs by which a liquid-type or granule- or other particle-type additive can be automatically homogeneously coated on surfaces of grains of boiled rice or other granular foodstuffs which resemble the rice gains in shape and/or nature, while their original shapes are maintained substantially unchanged.

It is a further object of the invention to provide an apparatus which is of a size or volume which is suitable for preparing Sushi rice in an amount which is suitable for placement in a Sushi rice pail which is normally used in Sushi restaurants.

It is a further object of the invention to provide an apparatus which, after preparation of Sushi rice therein, can be suitably placed at a site for hand-shaping of the Sushi rice, without further transfer into separate or additional containers.

The apparatus for processing a granular foodstuff for attaining the above objects according to the present invention comprises a rotatable container provided at its one end or in its body portion with an opening closable with a lid, the container being rotatable about a lateral axis of rotation, an air-blowing fan having a discharge opening disposed at an end of the rotatable container for supplying cooling air into the container, and a partition plate mounted to laterally extend inside the rotatable container.

The apparatus having the above structure, it may be operated to charge a material to be processed comprising appropriate proportions of boiled rice hot from boiling or soon after boiling and an additive mainly comprising a vinegar, namely a vinegaring mix, into the rotatable container through the opening, namely a charging and discharging opening for the materials, then close the opening with the lid, drive the container to rotate about its lateral or horizontal axis of rotation, and while the material undergoes mixing as it is received on the partition plate and then drops off the plate, send cooling air into and out of the container through a ventilation opening of the container to thereby effect a cooling of the material or the boiled rice, whereby preparation of Sushi rice can be completed at a high operation efficiency.

1890/2197

Preferably, the rotatable container comprises a cylinder, and it is provided at its longitudinal one end with an opening, which is utilized as opening for charging a material to be processed and discharging the processed material and which can be closed with a lid formed in its central portion with a hole, which is utilized as ventilation opening, facing which an air discharging opening of an air-blowing fan is disposed so that cooling air can be supplied into the rotatable container to cool the material charged in the container while it undergoes mixing, and then the air can be discharged out of the container.

It is also possible to provide the charging and discharging opening from the material not at a lateral or longitudinal end of the container but in a body portion of the container, and provide a lid to openably close the opening.

Although the rotatable container may be of any of a variety of cross-sectional shapes, generally containers of a cylindrical cross-section are suitably useful in that they are relatively easy to manufacture, easy to close with a lid and easy to clean the inside.

According to the invention, it is required that the rotatable container is rotated not about a vertical axis but a lateral or horizontal axis of rotation and that the partition plate mounted inside the container can mix the soft material to be processed such as boiled rice without the danger of destroying the grain or particle condition of the rice or the material. Apparatus having two or more partition plates mounted therein at an inclination to the axis of rotation of the container is particularly suitable in that mixing of the material and motion thereof towards left or right can easily take place in the container. Although it is most expedient to slantly arrange the partition plates as above, it alternatively is possible to mount the plates parallel to the axis of rotation of the container. Also, it is possible to arrange two or more partition plates parallel to one another or to arrange the ends of the plates to be staggered or offset relative to one another in the direction of the axis of rotation of the container.

Further, although the two or more partition plates are normally parallel arranged relative to one another as above, it is alternatively possible to mount those plates in positions in which they extend in lateral directions but not in a mutually parallel relationship.

As described above, the apparatus of the invention is mainly directed in its function to the preparation of Sushi rice which comes under a mixture together of boiled rice hot from boiling and an additive mainly comprising a vinegar. However, now that it can effect stirring and mixing of soft granular or particulate material resembling the boiled rice without destroying or impairing their shapes in a cooling atmosphere, the apparatus of the invention is effectively useful also as apparatus for processing such material and foodstuffs other than boiled rice which comprise soft grains, granules or particles including those which have a longer and a shorter axes and/or which may comprise a solid body or a hollow body.


FIG. 1 is a partly broken-away perspective view, showing an apparatus for the preparation of Sushi rice or a like foodstuff, embodying the present invention;

FIG. 2 shows a side elevation of the apparatus of FIG. 1, taken for illustration of the condition of mixing taking place in a rotatable container of the apparatus;

FIG. 3 shows a front view of FIG. 2;

FIG. 4 is a perspective view, showing the rotatable container and a driving mechanism for the container;

FIG. 5 shows a side elevation of an air-blowing fan;

FIG. 6 shows a sectional side view, illustrating the condition in which the rotatable container is brought into an erect position and charging of a material to be processed is being carried out;

FIG. 6B is a cross-sectional view of FIG. 6A;

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FIGS. 7A and 8A are sectional side views, showing the operation condition in which the rotatable container into which the material was charged in the condition shown in FIG. 6A is now brought into a horizontal position as shown in FIGS. 1 and 2 and is put into rotation;



FIG. 9A through FIG. 9E are perspective views, showing in combination the operation steps for the preparation of Sushi rice carried out by the apparatus shown in FIGS. 1 and 2;

FIG. 10 is a perspective view, showing apparatus according to a second embodiment of the invention;

FIG. 11A is a schematic side elevation, showing essential portions of apparatus according to a third embodiment of the invention.

FIG. 11B shows a front view of FIG. 11A;

FIGS. 12 and 13 are side elevational views, showing an apparatus according to a fourth and a fifth embodiment of the invention, respectively;

FIG. 14A is a sectional view, showing the rotatable container and the disc-shaped lid in a dismounted condition, according to a sixth embodiment of the invention;

FIG. 14B shows a sectional view, taken along line XIV--XIV in FIG. 14A; and

FIG. 15 shows the lid of the rotatable container having a separate air inlet and outlet.


The apparatus according to the invention can be effectively utilized not only for the preparation of

Sushi rice but also for a similar processing of various other foodstuffs comprising grains, granules or particles, as before stated. However, for a simplicity of the description and illustration, in the following the invention will be described only in connection with the case of preparation of Sushi rice or vinegaring of boiled rice.

The apparatus of the invention is for adding and mixing a liquid additive to and in boiled rice which is still hot soon after boiling. In a first embodiment of the apparatus according to the invention, illustrated in FIG. 1 through FIG. 4, a rotatable container of a cylindrical configuration is formed with an opening

2 for charging a material to be processed and discharging the processed material, at either of the lateral or longitudinal ends thereof, for example at the right-hand end thereof in FIGS. 1 to 4, and this opening

2 is openably closed with a lid 2A comprising a disk, through a central portion of which a ventilation hole or opening 3 is formed, through which cooling air is blown into the container 1 by an adjacently disposed air-blowing fan 12. After it has cooled the charged material inside of the container, the air is permitted to come out of the container through the above ventilation hole 3.

Within the rotatable container 1, there are mounted two partition plates 4, which are disposed parallel to each other and arranged at an inclination to an axis of rotation X of the container 1. The partition plate 4 comes under a kind of stirring means, and while it may be provided in a number of only one or two or more, in each of the illustrated embodiments of the invention, two partition plates 4 and 4 are provided. In the present first embodiment, two plates 4 and 4 of a same length are secured in a mutually parallel arrangement to their respective support members 4A having an end portion protruding beyond the corresponding side end of the plate 4, as show in FIG. 1. Also as show in FIG. 1, between each longitudinal end of the plate 4 and the inner wall surface at the corresponding end of the container 1, a gap g is maintained, and between each side edge of the plate 4 and the inner wall surface along the corresponding side of the container, a gap G is maintained.

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In the present embodiment, the longitudinal ends of one partition plate 4 are aligned or registered with the corresponding ends of the other partition plate 4. Alternative to this, it is possible to arrange the ends of one partition plate staggered or offset from the corresponding ends of the other plate in the direction of the axis of rotation X so that while one of the two ends of one plate 4 is located relatively close to one end face of the container, the corresponding end of the other plate 4 is located relatively close to the other end face of the container.

A main body or a body portion of the apparatus which is composed of the rotatable container 1 of the lid 2A formed with the opening 2 for charging or discharging of the material may be made of any of a synthetic resin, a metal, a reinforced glass and wood, the inner wall surface of the body portion that undergoes contact with the material to be processed comprising boiled rice 14 and a vinegar-based additive may be coated or laminated with a tetrafluoro ethylene resin (commercially obtainable under the registered trade name of Teflon, at E. I. du Pont de Nemours & Co., Inc., U.S.A.)

Externally, the body portion comprises the rotatable container 1 and the disk-type lid 2A may be covered with a thermal insulator as needs be and may be further applied with a surface covering of a metallic material or a synthetic resin material so that this body portion of the apparatus can be utilized as a warm keeping container after the completion of the vinegaring of boiled rice.

The rotatable container 1 is supported on a base stand 6 through two or four bearing rollers 8 to be rotated by a motor 7, and it is rotated about the horizontal axis of rotation X. To prevent the container from moving in the direction of the rotation axis X while it is rotated, the container is provided with a guide portion 9, which comprises a ring of a ridge or groove extending over a whole of the outer circumference of the container 1, and a compensatory guide portion 10 is provided on the bearing rollers 8, comprising a ring of a groove or ridge engageable with the guide portion 9.

By way of an example of practical dimensional specifications of the apparatus of the above described first embodiment of the invention, the rotation container 1 has a diameter and a length of 400 mm, the ventilation opening 3 formed in the disk-shaped lid 2A has a diameter of 110 mm, and the discharge opening of the air-blowing fan 12 has a diameter d (FIG. 5) of 50 mm.

The above described apparatus employs such an air-flow reversing system in which air is caused to flow as shown by arrows A in FIG. 2 so that flowing of air into the container and flowing of air out of the container take place through a same opening, namely the ventilation opening 3. This opening has a tapered configuration such that its bore size is smallest at the external end of the opening and is enlarged at the internal end of the opening. As a result of this, the material charged in the container 1 can be prevented from being sent out of the container. Further, the air-blowing fan 12 shown in FIG. 5 is provided with a damper 13 so that the rate of blowing of air can be adjusted.

Using the above described apparatus, vinegaring of boiled rice or the preparation of Sushi rice may be carried out according to the following described steps (a) and (b).

(a) Material Feeding Step

In the condition shown in FIG. 9A in which the axis of rotation X of the rotatable container 1 is fixed in a vertical position, the disk-type lid 2A openably closing the charging and discharging opening 2 may be opened, and through the opening 2, boiled rice 14 which is immediately after boiling and is still very hot may be rapidly charged into the rotatable container 1 in a manner as shown in FIGS. 6A and

6B. The feed amount of the rice 14 should be such that when the container 1 is rotated after charging of the boiled rice 4, the rice 14 does not come out of the container.

Thereafter, an additive or a vinegaring mix 15 mainly comprising a vinegar and containing such as sugar, salt and a natural or a chemical seasoning is applied over the rice 14 as shown in FIG. 9B, in an amount in an appropriate proportion to the amount of the charged rice 14.

Then, as shown in FIG. 9C, the lid 2A is applied to cover the opening 2 and fixed in position by means of fixing metals 16, whereby the step for feeding the material into the container 1 is completed.

(b) Cooling/Mixing Step

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The rotatable container is charged with the material will then be placed in the prescribed horizontal position on the two or four bearing rollers 6 secured on the base stand 6 as shown in FIG. 9D, and will be rotated in the direction shown by an arrow R at a number of rotation of 5 to 10 rpm for 2 to 3 minutes.

During the rotation of the container 1, a shown in FIGS. 7A, 7B, 8A and 8B, the material within the container 1 is repeatedly moved up and down, the movement of the material including sliding motions, and subjected to an effect of mixing by the partition plates 4 mounted at an inclination relative to the axis of rotation X and with gaps G and g maintained between the side edges and the end edges thereof on the on hand and the inner wall surfaces of the container 1 on the other, whereby the boiled rice 14 and the additive 15 becomes mixed together to attain vinegaring of the boiled rice.

An important characteristic of the present invention resides in the arrangement in which during the step of mixing the boiled rice 14 and the additive 15 together, a step is taken to supply air to effect cooling.

As shown in FIG. 9E, while the vinegaring mix or additive 15 is added to and mixed in the boiled rice

14 hot from boiling, air is blown into the container 1 by the air-blowing fan 12 to cool the rice 14 to an appropriate temperature so that after it is processed, the boiled rice can have a savor and glossiness each of which is attractive.

The air blown out from the fan 12 enters the container 1 through the ventilation hole 3 as shown by arrows A in FIG. 2, flows in a diffused condition in contact with grains of the rice 14 to cool the latter, then reverses direction of its flow and eventually comes out of the same ventilation hole 3 as above.

That is to say, according to the present invention, an air-flow reversing is employed in which the flow of air into the container and its flow out of the container are carried out at the same time through the single ventilation hole 3 formed in a central portion of the disk-type lid 2A.

The vinegared boiled rice or Sushi rice prepared by the above steps can be easily taken out of the container 1 by opening the disk-like lid 2A to open the material charging and discharging opening 2.

As described above, in the apparatus according to the invention, when the container 1 is rotated, the material is imparted with the effect of riding on the partition plates 4, sliding on the plates 4 and upsetting its position, repeatedly. Therefore, in contrast to the cases of ordinary mixing devices, in the case of the apparatus according to the invention mixing of the material takes place without any large force applied to the material, and the material repeats upsetting and rolling. Further, during such mixing of the material, air is supplied into the container 1 by the air-blowing fan 12, so that a sufficient amount of air can be supplied to grains of the rice while they are kept moving, including upsetting motions, rolling motions and sliding motions within the container. Therefore, the material can be cooled to an optimal temperature and, at the same time as this, become imparted with an appropriate degree of moisture.

Now, the series of steps for the preparation of Sushi rice using the apparatus of the present invention may be compared with the ordinarily operated steps. In ordinary methods of preparation of Sushi rice, fresh boiled rice which is very hot soon after boiling is placed in a mixing pail of a relatively small depth, and in adding the additive mainly comprising a vinegar to the boiled rice in the mixing pail, rice scoop held by either hand is handled to quickly upset the rice in portions to effect mixing of the additive with the rice, and at the same time as this, a hand fan held by the other hand is also quickly operated to send a great amount of air to the hot rice. The above manual operations require not only a considerable amount of labor but also a particular experienced skill to carry out an even upsetting of rice grains and an even effect of mixing of the rice and the additive together.

Using the apparatus according to the invention, the above mixing operation and the cooling operation to be made during the mixing operation can be carried out at the same time and automatically.

Now, entering a description into the second embodiment of the invention illustrated in FIG. 10, the basic structure and arrangement of and in the apparatus of the present embodiment have almost same structural features and operational feature as the above considered first embodiment, and same parts and elements in respective embodiments are indicated by same reference numerals and characters.

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The rotatable container 1 of which FIG. 10 shows a perspective view is driven to rotate as it is supported also in a horizontal position, but in the present embodiment, the material charging and discharging opening 2 having the disk-type lid 2A to openably close the opening is provided not at an end but in a body portion of the container 1. Same as the above described first embodiment, the ventilation hole or opening 3 is provided in a central portion at one end of the container 1.

In operation, the material to be processed, which comprises the boiled rice 14 and the additive 15, is charged into the container 1 in the condition in which the material charging and discharging opening 2 is brought at a top position. After charging of the material, the container 1 may be rotated in the direction as indicated by an arrow R, when the material slides along two partition plates 4 disposed at an inclination to the axis of rotation X of the container and moves first towards the left side in FIG. 10.

Then, as the container 1 is further rotated, the material moves in the circumferential direction of the container 1, and as the direction of inclination of the partition plates 4 are then reversed, it slides along the plates to collect at the right side in FIG. 10 while it moves in the circumferential direction.

As described above, as the container 1 is rotated, the material charged in the container repeats motions towards left or right along the axis of rotation X, motions in the circumferential direction of the container and motions towards up and down, whereby a sufficient effect of mixing of the material is attained, when the material charging and discharging opening 3 may be brought to and set at a bottom position, and the lid 2A may be opened to discharge the processed rice towards below out of the container 1.

The above-described structure and arrangement according to the second embodiment of the invention is expediently applicable particularly to an apparatus having a container 1 having a relatively large length in the direction of the axis of rotation X for the preparation of a relatively large amount of Sushi rice through a single operation cycle.

Then, in the third embodiment of the invention shown in FIGS. 11A and 11B, two partition plates 4 mounted in the rotatable container 1 are arranged parallel to the axis of rotation X and with space from the inner peripheral surface of the container 1. In comparison with the cases of the before described first and second embodiments in which the partition plates 4 are arranged at an inclination to the axis of rotation X, both the mounting of the plates 4 and the cleaning of the interior of the container 1 can be more easily made according to the present third embodiment.

Further, same as in the above first embodiment, in the present embodiment, too, gaps are maintained between the periphery of the partition plates 4 and the inner wall surfaces of the container 1 so that the material can be prevented from collecting in any one location within the container 1.

FIG. 12 shows a fourth embodiment of the invention, and in the apparatus according to the present invention, the ends of one of two partition plate 4 and the corresponding ends of the other partition plate 4 in the direction of the axis of rotation X are disposed in a staggered arrangement or are offset from one another. According to this arrangement of the partition plates 4, even in the case in which two partition plates 4 are disposed parallel to the axis of rotation X, a sufficient effect of mixing of the material can be attained in that the material can repeat movements in the direction of the axis of rotation X and movements in the circumferential direction of the container 1 and also in that a portion of the material tending to attach on the inner wall surface of the container 1 can be permitted to fall down as it is moved to an upper position within the container, this movement of the material also taking place in repetition.

In a fifth embodiment of the invention, which is illustrated in FIG. 13, two parallel arranged partition plates 4 are mounted at an inclination to the axis of rotation X, same as in the first embodiment illustrated in FIGS. 1 to 3. However, in the present embodiment, the two plates 4 are in an endstaggered arrangement. That is to say, ends of one of the two plates 4 are offset from the corresponding ends of the other plate 4 in the direction of the axis of rotation X, same as in the above fourth embodiment shown in FIG. 12. According to this arrangement, too, a same sufficient effect of mixing as obtained in the first embodiment can be obtained.

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FIGS. 14A and 14B in combination illustrate the apparatus according to the sixth embodiment of the invention, which is structured same as the apparatus according to the foregoing described embodiments, except that the partition plates 4 are fixed to the disk-shaped lid 2A, which do not touch the inner wall of the rotatable container 1, at all. Thus, the apparatus of the present sixth embodiment is characterized particularly in that when the disk-shaped lid 2A is disengaged from the rotatable container 1, the partition plates 4 can be removed out of the container 1 together with the lid 2A, whereby an advantage can be brought about such that the need for once transferring the prepared Sushi rice in the container 1 into a separate Sushi rice pail is effectively cancelled, and the container 1 containing the prepared Sushi rice can be intact carried onto a Sushi cook's table or to a site or the vicinity of a site at which the hand-shaping or hand-rolling of Sushi rice is operated.

Although in the illustrated embodiment the lid 2A is formed with a single ventilation hole 3, through which supply and evacuation of air take place, it is otherwise possible as illustrated in FIG. 15 to provide a hole 3 for supply of air at a radially central portion of the lid 3A and another hole for evacuation at a portion of the lid spaced from the axis of rotation of the container 1.

Further, in the above description of first to sixth embodiments of the invention, two or more partition plates 4 are described in each instance to be so arranged as to form mutually parallel planes.

However, it is not always necessary that the plurality of partition plates 4 are arranged to form mutually parallel planes, and alternative to this, they may be mounted to form planes in an A or V arrangement or form planes cross each other at a right angle. Also, the shape of the partition plates 4 is not necessarily limited to the flat surface-forming shape as in each of the above described embodiments, but the plates 4 may otherwise have a waved shape or have a grid structure.

Furthermore, while in each of the described specific embodiments the rotatable container 1 comprises a cylindrical one, this is only by way of an example, and insofar as it comprises a rotatable container, the container 1 may of course be of any other cross-sectional shape, for example it may have a polygonal shape such as a square or rectangular shape, pentagonal shape and so forth in cross-section.

The above described apparatus for the preparation of Sushi rice or for processing granular foodstuffs according to the present invention can bring about the advantage that without the need for a skilled hand, an additive can be added to and mixed in hot boiled rice without the danger of destroying grains of the rice while an effect of cooling is imparted to the hot rice, whereby it is possible to easily and rapidly prepare Sushi rice having attractive glossiness and savor.

Particularly, when the apparatus of the invention is used as an apparatus for Sushi rice, boiled rice can be prevented from becoming a dumpling and grains of the rice can be prevented from becoming crushed during the operation steps, and yet an additive mainly comprising a vinegar can be homogeneously mixed in the rice, so that a satisfactory Sushi rice can be easily prepared in a large amount through each operation cycle. Thus, the apparatus of the present invention is highly effective in enhancing the operation efficiency in the preparation of Sushi rice or in the processing of granular foodstuffs.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. An apparatus for preparation of sushi rice, comprising: a rotatable container having a horizontal axis of rotation and being in the form of a pail having a cylindrical wall and a closed bottom wall, the container having at an end opposite said closed bottom wall an opening for adding boiled rice and liquid seasoning mix mainly comprising vinegar and for discharging prepared sushi rice out of the rotatable container; a lid removably secured to the rotatable container to close and open the opening of the container and formed with a ventilation hole comprising a through-hole at a central portion of the lid for supplying cooling air into the container; at least one partition plate secured to the removable lid, and having a width smaller than an inner diameter of the rotatable container such that when said lid covers said rotatable container said at least one partition plate projects into said container toward said container bottom wall with space maintained between edges of the at least one partition plate and an inner surface of said cylindrical wall of said rotatable container; a base for rotatably supporting the

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rotatable container in its horizontal position, the base comprising a means for rotating the rotatable container about its horizontal axis; and a blower for blowing cooling air into the rotatable container through said through-hole of said lid so as to cool the rice therein.

2. An apparatus as claimed in claim 1, wherein there are at least two of said partition plates, said plates being spaced apart.

3. An apparatus as claimed in claim 2, wherein said at least two partition plates are mounted at an inclination to the axis of rotation of the rotatable container.

4. An apparatus as claimed in claim 2, wherein said at least two partition plates are mounted parallel to the axis of rotation of the rotatable container.

5. An apparatus as claimed in claim 2, wherein said at least two partition plates are disposed adjacent said ventilation hole.

6. An apparatus as claimed in claim 1, wherein said means for rotating comprises a plurality of rows of bearing rollers arranged along the axial direction of the rotatable container and bearing the outer surface of the cylindrical wall of the rotatable container, at least one of the rows of rollers being operably connected to a driving device for rotation.

7. An apparatus as claimed in claim 1, wherein said lid further comprises an air evacuation hole in said lid disposed radially outwardly from the air introduction through-hole.

8. An apparatus as claimed in claim 7, wherein the at least one partition plate comprises at least two spaced apart partition plates.

9. An apparatus as claimed in claim 8, wherein said at least two partition plates are mounted at an inclination to the axis of rotation of the rotatable container.

10. An apparatus as claimed in claim 8, wherein said at least two partition plates are mounted parallel to the axis of rotation of the rotatable container.

11. An apparatus as claimed in claim 7, wherein said means for rotating comprises a plurality of rows of bearing rollers arranged along the axial direction of the rotatable container and bearing the outer surface of the cylindrical wall of the rotatable container, at least one of the rows of rollers being operably connected to a driving device for rotation.

12. An apparatus as set forth in claim 7, wherein said rotatable container and lid are removably disposed on said base such that said rotatable container is adaptable for use as a sushi rice holding pail when said rotatable container and lid are removed from said base, and said lid is removed from said rotatable container.

13. An apparatus as claimed in claim 7, further comprising latching means for latching said lid to said rotatable container.

14. An apparatus as claimed in claim 7, wherein said blower comprises a valve for adjusting the flow rate of air into the rotatable container.

15. An apparatus as claimed in claim 7, wherein said cylindrical wall of said rotatable container comprises a smooth cylindrical surface.

16. An apparatus as set forth in claim 1, wherein said rotatable container and lid are removably disposed on said base such that said rotatable container is adaptable for use as a sushi rice holding pail when said rotatable container and lid are removed from said base, and said lid is removed from said rotatable container.

17. An apparatus as claimed in claim 16, further comprising latching means for latching said lid to said rotatable container.

1897/2197

18. An apparatus as claimed in claim 1, wherein said blower comprises a valve for adjusting the flow rate of air into the rotatable container.

19. An apparatus as claimed in claim 1, wherein said cylindrical wall of said rotatable container comprises a smooth cylindrical surface.

20. An apparatus as claimed in claim 1, wherein said blower is disposed so as to supply cooling air into the rotatable container through part of said ventilation hole so as to allow the discharging of air out of a remaining part of said ventilation hole.Data supplied from the esp@cenet database - Worldwide

1898/2197

394.

US5209940 - 5/11/1993

STABILIZING UNMILLED BROWN RICE BY ETHANOL VAPORS


Inventor(s):

GEORGE (US)

CHAMPAGNE ELAINE T (US); HRON SR ROBERT J (US); ABRAHAM



IP Class: A23B9/18; A23B9/26

E Class: A23L1/182; A23L1/10H; A23B9/26; C11B1/10; A23L1/015C



Family: US5209940

Equivalent: WO9201391

Abstract:


The present invention relates to stabilizing unmilled or partially milled brown rice by contact thereof with ethanol vapors. The present invention also encompasses products of said stabilizing including, stabilized unmilled or partially milled brown rice, and partially stabilized flour produced by grinding of said stabilized unmilled or partially milled brown rice.Description:



1899/2197

The present invention relates to: a process for stabilizing unmilled brown rice using ethanol vapors, and; stabilized unmilled brown rice (and brown rice flours produced therefrom) produced by the aforementioned process.

BACKGROUND AND SUMMARY OF THE INVENTION

Brown rice has a short shelf life (approximately 3-6 months) because of hydrolytic and oxidative deterioration of bran lipids. Brown rice lipids are readily hydrolyzed by lipases, both natural to the bran and of microbial origin, that release free fatty acids. Free fatty acids are the precursors of off-flavors and off-odors associated with lipid degradation products generated in subsequent oxidation reactions.

The susceptibility of brown rice to readily becoming rancid has limited the marketing of the kernels, flours, bran, and oil. Bran high in free fatty acids loses its animal feed and food value. At the elevated temperatures experienced during the transport of brown rice from the U.S. to other countries, the oil in the bran is subject to lipolytic hydrolysis. The higher the free fatty acids in the oil the more uneconomical it is to refine. The losses for potentially edible oil during refining are two to three times the free fatty acid content of the oil (Enochian et al, 1981, "Stabilization of rice bran with extruder cookers . . . ", A preliminary analysis of operational and financial feasibility, U.S. Department of

Agriculture Marketing Res. Report 1120).

Three approaches have been taken to stabilize brown rice to hydrolysis by lipases: 1) inactivating lipase by subjecting raw or brown rice to moist or dry heat (U.S. Pat. No. 2,585,978 to Van Atta et al, 1952;

U.S. Pat. No. 2,992,921 to Bardet et al, 1961; U.S. Pat. No. 4,582,713 to Hirokawa et al, 1986) or to parboiling or precooking processes (U.S. Pat. No. 3,086,867 to Miller, 1963; U.S. Pat. No. 3,959,515 to

McCabe, 1976; Sowbhagya and Bhattacharya, 1976, "Lipid autoxidation in rice" J. Food Sci. 41:1018-

1023), 2) removing kernel oil which serves as a substrate for lipase by organic solvent extraction [U.S.

Pat. No. 2,538,007 to Kester, 1951; U.S. Pat. No. 3,261,690 to Wayne, 1966 (as discussed more fully in

"Solvent Extractive Rice Milling" in Rice Chemistry and Technology, D. F. Houston, Editor, Am.

Assoc. of Cereal Chemists, St. Paul, Minn.)], and 3) denaturation of lipases, both natural to the bran and of microbial origin, by ethanol extraction, (U.S. patent application Ser. No. 07/557,822 to

Champagne et al, 1990). The aforementioned Champagne et al patent application teaches stabilizing brown rice by contacting unmilled brown rice with liquid ethanol.

The present invention is drawn to a highly advantageous and unobvious process for stabilizing unmilled brown rice to lipolytic hydrolysis comprising: contacting unmilled or partially unmilled brown rice with ethanol vapor (i.e. the phrase "ethanol vapor" encompasses either vapor of pure 100% absolute ethanol, or vapor of aqueous mixtures including ethanol) under conditions providing no substantial loss of oil from the unmilled or partially milled brown rice by the ethanol vapor, thereby producing stabilized unmilled or partially milled brown rice and ethanol having rice extracts therein; and separating the stabilized unmilled or partially milled brown rice from the ethanol having rice extracts therein.

Other aspects of the present invention include production by the aforementioned process, of stabilized unmilled brown rice and partially stabilized unmilled brown rice flour having highly advantageous and unobvious properties; e.g. not susceptible to hydrolytic deterioration by lipase, improved storage stability, absence of solvent(s) not generally regarded as safe, having ungelatinized starch as a raw product, having very low bacterial and fungal populations, desirable kernel surface appearance, highly desirable cooking properties, no or minimal loss of oil, minerals, thiamine, protein, dietary fiber and carbohydrates, etc.

Other objects and advantages of the present invention will become readily apparent from the ensuing description.


FIG. 1 is a side view of an apparatus which was employed for treating brown rice kernels with ethanol vapors. (A) 500 ml round bottom two neck glass flask; (B) heating mantle; (C) glass vent tube; (D) 3

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cm.times.12 cm glass butt tube holding 40 g brown rice; (E) wire mesh sample retaining screen; (F) plexiglass jacket; (G) inlet; and (H) outlet for jacket water.

FIG. 2 is a graph of % free fatty acids by weight of lipid in brown rice kernels treated with vapors from boiling aqueous ethanol for 3, 5, and 10 minutes, control kernels, and heat-treated kernels versus months stored at 36 DEG C.

FIG. 3 is a graph of % free fatty acids by weight of lipid in flours prepared from brown rice kernels treated with vapors from boiling aqueous ethanol for 3, 5, and 10 minutes, control kernels, and heattreated kernels versus months stored at 36 DEG C.

FIG. 4 is a graph of change in conjugated diene hydroperoxides content .DELTA. CDHP (micromoles per gram of rice, dry basis) in brown rice kernels treated with vapors from boiling aqueous ethanol for

3, 5, and 10 minutes, control kernels, and heat-treated kernels versus months stored at 36 DEG C.

FIG. 5 is a graph of change in conjugated diene hydroperoxides content .DELTA. CDHP (micromoles per gram of rice, dry basis) in flours prepared from brown rice kernels treated with vapors from boiling aqueous ethanol for 3, 5, and 10 minutes, control kernels, and heat-treated kernels versus months stored at 36 DEG C.


The term ethanol is utilized in the accompanying specification and claims, in its well established art accepted meaning (see e.g. The Condensed Chemical Dictionary, 10th Ed., G. Hawley, ed., 1981, page

423) to include either: (1) pure 100% absolute ethanol (dehydrated); or (2) aqueous mixtures including ethanol, such as food (U.S.P.) grade which consists essentially of about 95% by volume ethanol and about 5% by volume water.

The contacting employed in the present invention may include either continuous or batch contacting of ethanol vapor with the unmilled or partially milled brown rice. In continuous contacting, the unmilled or partially milled brown rice may be moved through conventional equipment either counter-current, co-current, or cross-current to the flow of ethanol vapor. In batch contacting, either fresh-pure ethanol vapor or ethanol vapor from previous treatments (i.e. ethanol vapor is contacted with a first batch of unmilled or partially milled brown rice, separated therefrom, and subsequently contacted with at least one additional batch of unmilled or partially milled brown rice), may be used.

It is preferred that the contacting of the present invention be carried out at temperatures at or above the condensation point of ethanol vapor (78 DEG for 95% v/v ethanol at atmospheric pressure). A preferred temperature range for carrying out the contacting at atmospheric pressure or above is from about 78 DEG C. to about 100 DEG C. depending upon the concentration of ethanol used (100% to

1%, v/v). Pressure and temperature ranges used vary directly with ethanol concentration used and the accompanying condensation temperature of its vapors. Super-heated ethanol vapor may be used but may result in starch gelatinization. A variety of pressures may be utilized in practicing the instant application: i.e. below atmospheric pressure, at atmospheric pressure, or above atmospheric pressure.

When subatmospheric pressure (i.e. pressure below atmospheric) is utilized, the preferred temperature range is from about 15 DEG C. to about 100 DEG C. It is preferred to carry out the contacting of rice and ethanol vapor in an atmosphere which is saturated with ethanol vapor, in order to promote thorough contacting of the rice with the vapor.

Typically unmilled brown rice has about 12-13% moisture (moisture that rough rice is typically dried to after harvest). Rice having such typical moisture content or drier rice may be vapor-treated in accordance with the present invention. Prior to ethanol vapor treatment, it is preferred to: 1) reduce the moisture (i.e. water content) of the rice to a level where it is essentially in equilibrium with the water content of the ethanol vapor (i.e. this step may be utilized so that the ethanol vapor will not absorb water from the rice and the rice will not absorb water from the ethanol vapor); and 2) raise and maintain the temperature of the kernels at or above the condensation temperature of the ethanol vapor.

This will prevent condensation of ethanol on the kernels, and no moisture, oil or bran components will be lost. Condensation of ethanol on the kernels is not desirable since a small amount of kernel oil

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(>;3%) and possibly some other bran components will be extracted. Also a water content equilibrium between the ethanol vapor and the rice may be achieved by: prior to the step of contacting, measuring the water content of the rice; and selecting and utilizing in said step of contacting, ethanol vapor having a water content which is essentially in equilibrium with the measured water content of the rice.

Anhydrous ethanol vapors are not preferred since they will readily absorb water from the rice kernels and condense.

When the contacting is carried out using operating conditions under which the ethanol does not condense (or appreciably condense), the separating of rice and ethanol will involve separating rice from ethanol which consists of vapor, or consists essentially of vapor. When the contacting is carried out using operating conditions under which the ethanol partially condenses, the separating of rice and ethanol will involve, separating the stabilized rice from condensed ethanol which may contain rice extracts (some oil and other bran components) and from ethanol vapor and evaporating condensed residual liquid ethanol from the stabilized rice.

Subsequent to the separation, rice stabilized in accordance with the present invention may be ground to flour using conventional grinding equipment and methods. The present invention also encompasses such a step of grinding unmilled or partially milled brown rice which has been stabilized in accordance with the instant invention, as well as flour produced thereby.

The instant invention also encompasses a step of separating the rice extracts from the ethanol having rice extracts therein, so that the ethanol may be reused for further extraction. The rice extracts may be separated from the ethanol using conventional separations such as distillation, filtration, centrifugation, adsorption, ion exchange or membrane separation. In a continuous process employing such separation and ethanol recycle, ethanol will need to be added to the process because a small amount of ethanol will leave the process as residue on the rice. In accordance with the present invention the stabilized unmilled brown rice may have a residual ethanol content of up to about 200 parts per million by weight.

The present invention produces stabilized unmilled or partially milled brown rice, not susceptible to enzymatic deterioration by lipase, not having gelatinized starch and having essentially full oil content, produced by the processes as described hereinabove. It is preferred that the contacting provides extraction of about 5% or less of brown rice oil from the unmilled or partially milled brown rice so as to retain its full nutritional value.

The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention as defined by the claims:

EXAMPLES

Rough rice samples of Tebonnet (1989 crop) were obtained from the Louisiana State University Rice

Experiment Station, Crowley, La. The samples were dehulled in a McGill Sheller (H. T. McGill,

Houston, Tex.).

FIG. 1 depicts the apparatus employed for treating brown rice samples with vapors from boiling ethanol. A 40 gram (g) sample of freshly dehulled brown rice was placed in a jacketed (F), glass butt tube (3 cm dia..times.12 cm high) (D) which was fitted with a wire mesh sample retaining screen (E).

Water from a water bath set at 83 DEG C. was circulated through the jacket (F). After the temperature of the sample reached 78 DEG C., which required 20 minutes, the glass butt (D) was inserted into the neck of a 500 ml round bottom flask (A) containing boiling aqueous ethanol (95% v/v; b.p. 78 DEG

C.). Samples were treated with ethanol (EtOH) vapors for 3, 5, and 10 minutes. Following treatment the samples were transferred to shallow stainless steel pans and allowed to cool in room temperature

(24 DEG C.) air.

Brown rice samples at 12.8% moisture (moisture level of control) and 8.0%moisture were treated with

EtOH vapors. Samples at 8.0% moisture were obtained by drying the 12.8% moisture brown rice for

2.5 hours at 65 DEG C. Untreated brown rice kernels and flours prepared from them served as controls.

Brown rice kernels were placed in a 83 DEG C. jacketed, glass butt tube for 30 minutes to allow the effect of heat on kernel stability to be evaluated. To compare the action of aqueous EtOH with that of

1902/2197

the common, commercial vegetable oil extractive solvent hexane, brown rice kernels were treated with vapors from boiling hexane (b.p. 68 DEG C.).

Brown rice flours were prepared by grinding vapor-treated kernels to a powder in a Udy Cyclone Mill

(Udy, Corp., Fort Collins, Colo.) using a 20 mesh sieve screen. Brown rice kernel and flour samples were stored in half pint-size capped glass jars with air headspace at 36 DEG C. Two batches of vaportreated and control kernel and flour samples were subjected to analytical tests to determine thiamine content, bacterial and mold populations, and storage stabilities.

As a measure of the extent of lipolytic hydrolysis of brown rice kernel and flour lipids during storage, the free fatty acids contents of vapor-treated and control rice samples were determined the day following vapor treatment and then periodically by a micro method, Hoffpauir et al, 1947,

"Germination and free fatty acids . . . ", Science 106:344-345. Meta-cresol purple was substituted for the phenolphthalein indicator. Free fatty acids content was calculated as oleic acid and expressed as percent of oil.

As a measure of oxidative deterioration of unsaturated lipids in brown rice kernels and flours during storage, conjugated diene hydroperoxides CDHP content was determined by the method of St. Angelo et al, 1972, "A comparison of minor constituents in peanut butter as possible sources . . . ", J. Am.

Peanut Res. and Educ. Assoc. 4:186-197. Samples were ground in a Udy cyclone mill (Udy Corp.,

Boulder, Colo.) to pass through a 20-mesh screen. One-half gram samples were shaken with 25 ml high performance liquid chromatography grade hexane for 30 minutes and then filtered through 0.45 .mu.m

Millex-HV Millipore filters. Absorbancies of the filtrates at 234.0 nm were determined, using hexane as a reference. An absorptivity coefficient (As) of 24,500 mol liter@-1 cm@-1 was used to calculate the concentration of CDHP in micromoles per gram brown rice (dry basis).

For microbiological assays, 10 g samples of rice were weighed, transferred aseptically into sterile blender jars and blended with 90 ml of sterile pH 7.2 phosphate-buffered distilled water. Serial dilutions of 10@-1, 10@-2, and 10@-3 were prepared using sterile pH 7.2 phosphate-buffered distilled water. Duplicate nutrient agar pour plates for total plate counts and triplicate potato dextrose agar plates for total molds were inoculated with the appropriate dilutions and incubated as described by

DeLucca et al, 1978, "Isolation and identification of lipolytic microorganisms found on rough rice from two growing areas", J. Food Protection 41:28-30.

Thiamine contents of vapor-treated and control rice samples were determined in duplicate by the

Association of Official Analytical Chemists, 1985, Official Methods of Analysis, 14th ed., The

Association, Arlington, Va.

Free fatty acids (FFA) were determined periodically during storage as a measure of the extent of lipolytic hydrolysis of lipids in brown rice kernel and flour samples. FIG. 2 shows the effect of storage time at 36 DEG C. on the accumulation of FFA in brown rice kernels (12.8% moisture) which were treated with vapors from boiling aqueous EtOH, heat-treated, or untreated (control). Samples were stored at 36 DEG C. to accelerate the rate of lipolytic hydrolysis. FFA levels in brown rice kernels treated with EtOH vapors for 3 or 5 minutes increased from 3.0% to 3.9% and 3.6%, respectively, after

6 months of storage at 36 DEG C. There was no change in FFA content in kernels treated with vapors for 10 minutes, while that of control kernels increased from 3% to 24%. During storage the increase in

FFA in heat-treated kernels was approximately 15% lower than that of the control kernels, indicating some deactivation of lipase by heat-denaturation.

The vapors from boiling aqueous EtOH extracted surface water from the kernels and condensed on the kernels during treatment. The vapor treatment lowered the moisture content of the brown rice kernels approximately 1.5%; loss of kernel oil was less than 3%. To determine whether the action of the EtOH vapors in stabilizing brown rice kernels to FFA formation depended on the vapors condensing on the kernels, brown rice kernels at 8.0% moisture were treated with EtOH vapors. The EtOH vapors did not condense on the 8% moisture kernels; the water content of the kernels did not change and no oil or other bran components were extracted. FFA levels did not increase in the 10 minute vapor-treated 8% moisture kernels following storage at 36 DEG C. Thus, vapors from boiling aqueous EtOH were effective in stabilizing the kernels to FFA formation. Stabilization was not dependent on the vapors condensing into a liquid.

1903/2197

FIG. 3 shows the effect of storage time at 36 DEG C. on FFA levels in flours prepared from 12.8% moisture brown rice kernels treated with EtOH vapors. Following 5 months of storage, FFA levels in flours prepared from kernels treated with vapors for 3, 5, and 10 minutes increased from 3% to 9%,

7%, and 6%, respectively. In contrast, the FFA levels in flours prepared from control and heat-treated kernels increased from 3% to 80% and 46%, respectively. The low increases in FFA in the flours prepared from 3, 5, and 10 minutes vapor-treated kernels indicated a low level of residual lipase activity in the flours.

Vapors from boiling hexane were ineffective in preventing FFA formation in brown rice kernels.

Following one month storage at 36 DEG C., the FFA level in kernels treated with hexane vapors for 3,

5, and 10 minutes increased from 3% to 18%, 17%, and 12%, respectively; the FFA levels in control kernel and heat-treated kernels increased to 17% and 14%, respectively.

Conjugated diene hydroperoxide (CDHP) contents were determined periodically during storage as a measure of the extent of oxidative deterioration of unsaturated lipids in brown rice kernel and flour samples. FIGS. 4 and 5 depict the effects of storage at 36 DEG C. on the development of CDHP in brown rice kernels treated with EtOH vapors and flours prepared from these kernels, respectively.

CDHP levels increased rapidly in the kernels treated with EtOH vapors and in their flours. Only a slight increase in CDHP level was observed for control and heat-treated kernels during storage. The higher rate of increase in CDHP in the EtOH vapor-treated kernels and their flours compared to the control kernels and flour, indicates an increased susceptibility of the lipids in the former to oxidative rancidity.

Table I shows the effect of EtOH vapor treatment on the bacterial and mold populations of brown rice kernels. Total plate counts and mold counts were very low in the EtOH vapor-treated kernels. The vapors from boiling aqueous EtOH denatured the organisms and thus killed them.

>;tb; TABLE I

>;tb;______________________________________

>;tb;Effect of EtOH vapor treatment on microbial population of

>;tb;brown rice. Counts were determined one week after

>;tb;dehulling kernels. Initial moisture content 12.8%.

>;tb; TOTAL PLATE MOLD COUNT

>;tb;TREATMENT COUNT (No./g)

>;tb; (No./g)

>;tb;______________________________________

>;tb;Control 14,000 10

>;tb;Heat-Treated 250 >;10

>;tb; 3 minutes EtOH Vapors

>;tb; 10 >;10


>;tb; 10 >;10

>;tb;10 minutes EtOH Vapors

>;tb; >;10 >;10

>;tb;______________________________________

Brown rice is rich in the B vitamins. Thiamine was chosen as an indicator of the degree of retention of the B vitamins in kernels treated with EtOH vapors. As shown in Table II, there was no loss of thiamine in the EtOH vapor-treated kernels.

>;tb; TABLE II

>;tb;______________________________________

>;tb;Effect of EtOH vapor treatment on thiamine content of brown

>;tb;rice.

>;tb; THIAMINE

>;tb;TREATMENT (mg/100 g)

>;tb;______________________________________

>;tb;12.8% MOISTURE BROWN RICE

>;tb;Control 0.72

>;tb;Heat-Treated 0.74

1904/2197


>;tb; 0.72


>;tb; 0.72


>;tb; 0.73

>;tb; 8.0% MOISTURE BROWN RICE

>;tb;Control 0.72

>;tb;Heat-Treated 0.71


>;tb; 0.71

>;tb;______________________________________

An economically feasible, stable, full fat, product with ungelatinized starch can be produced by treating brown rice with the vapors from boiling aqueous EtOH. Brown rice kernels stabilized by EtOH vapor treatment are stable to lipolytic hydrolysis, as indicated by no or minimal increases in FFA during storage. EtOH vapors act by denaturing lipases endogenous to the brown rice kernel with concomitant deactivation. The longer the treatment time, the more effective the EtOH vapors were in denaturing the endogenous lipases. Flours produced from kernels treated with EtOH vapors for 3-10 minutes had low residual lipase activities. Since endogenous lipases are so close to the kernel surface, denaturation by ethanol vapors is plausible. The action of EtOH vapors can also be attributed to ethanolic denaturation of bacteria and mold found on the kernel surfaces, which kills the organisms. DeLucca et al., 1978,

Supra, determined that approximately 10% of the total bacterial population on rough rice and all of the isolated molds showed lipolytic action. Microbial and mold lipases are possibly more contributory to free fatty acid formation in brown rice than endogenous lipases (DeLucca and Ory, 1987, "Effects of microflora on the quality of stored rice", Trop. Sci. 27:205-214). Loeb and Mayne, 1952, "Effect of moisture on the microflora and formation of free fatty acids in rice bran", Cereal Chem. 29:163-175, found a relationship between moisture content of rice, microflora, and free fatty acids formation in rice bran.

Brown rice kernels stabilized to lipolytic hydrolysis by EtOH vapors were more susceptible to oxidative deterioration than untreated kernels. However, with proper packaging oxidative deterioration of brown rice can be slowed (Ory et al, 1980, "Storage quality of brown rice as affected by packaging .

. . " J. Food Protection 43:929-932; Sharp and Timme, 1986, "Effects of storage time . . . " Cereal

Chem. 63:247-25) and thus it should not be a deterrent to utilizing this process.

The foregoing detailed descriptions and examples are given merely for purposes of illustration.

Modifications and variations may be made therein without departing from the spirit and scope of the invention.Data supplied from the esp@cenet database - Worldwide Claims:


We claim:

1. A process comprising: contacting unmilled or partially milled brown rice with ethanol vapor under conditions providing no substantial loss of oil from said unmilled or partially milled brown rice by said ethanol vapor in order to produce stabilized unmilled or partially milled brown rice and ethanol having rice extracts therein; and separating said stabilized unmilled or partially milled brown rice from said ethanol having rice extracts therein.

2. The process of claim 1 further including the step of grinding said stabilized unmilled or partially milled brown rice into flour.

3. The process of claim 1 wherein said contacting is carried out at the boiling point of said ethanol.


1905/2197

5. The process of claim 3 wherein said contacting is carried out at a pressure equal to, or greater than, atmospheric pressure, and at a temperature of from about 78 DEG C. to about 100 DEG C.


7. The process of claim 3 wherein said contacting is carried out at a temperature of from about 15 DEG

C. to about 100 DEG C. and at a pressure less than atmospheric pressure.


9. The process of claim 1 wherein said contacting is carried out with vapors of food grade ethanol consisting essentially of about 95% by volume ethanol and about 5% by volume water.

10. The process of claim 1 wherein, said unmilled or partially milled brown rice has a water content and said ethanol vapor has a water content, and further including the step of: prior to said step of contacting, changing said water content of said unmilled or partially milled brown rice to a water content which is essentially in equilibrium with said water content of said ethanol vapor.

11. The process of claim 1 wherein said unmilled or partially milled brown rice has a water content, and further including the steps of: prior to said step of contacting, measuring said water content of said unmilled or partially milled brown rice; and selecting and utilizing, in said step of contacting, ethanol vapor having a water content which is essentially in equilibrium with said measured water content of said unmilled or partially milled brown rice.

12. The process of claim 1 further including the step of: prior to said step of contacting, heating said unmilled or partially milled brown rice to a temperature which is equal to or greater than the condensation temperature of said ethanol vapor.

13. The process of claim 1 wherein during said step of contacting, said unmilled or partially milled brown rice is maintained at a temperature which is equal to or greater than the condensation temperature of said ethanol.

14. The process of claim 1 wherein said step of separating includes separating said stabilized unmilled or partially milled brown rice from ethanol vapor.

15. The process of claim 14 wherein said step of separating further includes: separating said stabilized unmilled or partially milled brown rice from condensed ethanol containing said rice extracts therein.

16. The process of claim 14 wherein said step of separating includes: separating said stabilized unmilled or partially milled brown rice from said ethanol vapor; and evaporating condensed residual liquid ethanol from said stabilized unmilled or partially milled brown rice.

17. The process of claim 1 further including a step of separating said rice extracts from said ethanol selected from the group consisting of distillation, filtration, centrifugation, adsorption, ion exchange and membrane separation.

18. The process of claim 1 wherein subsequent to said step of separating, said ethanol vapor is contacted with at least one additional batch of unmilled or partially milled brown rice.

19. The process of claim 1 wherein said step of contacting provides extraction of about 5% or less of brown rice oil from said unmilled or partially milled brown rice.

20. The process of claim 1 wherein said step of contacting is carried out in an atmosphere which is saturated with said ethanol vapor.Data supplied from the esp@cenet database - Worldwide

1906/2197

395.

US5213026 - 5/25/1993

COMMODITY DEHYDRATING STABILIZER


Inventor(s): HOUSE J EDWARD (US)

Applicant(s): NEVENTURES FOUNDATION (US)


IP Class: A23L1/20; A23K1/14; A23K3/00

E Class: A23K1/00B2; A23L1/10E; B30B11/24; A23P1/12; A23N17/00; B30B11/24F



Family: US5213026


Abstract:


An apparatus and system is disclosed for extruding commodities such as rice bran and which includes symmetrically disposed beater bar segments on the extruder rotor that will simultaneously impact symmetrically positioned knives mounted within the extruder housing. The apparatus preferably includes a sufficient number of knives and beater bars that impacts occur more than once each ninety degrees of rotation and at substantially equal degrees of rotation from each other. The device includes a widened and lengthened extrusion gap with variable width, a generally solid extrusion rotor, and a control system for adjusting the cooking temperature by varying the width of the extrusion gap. The extruder is fed using a drag conveyor with angled blades which push the rice bran into the extruder housing.Description:




The present invention relates generally to extrusion processing and, more particularly, to an extrusion apparatus for processing rice bran.

1907/2197

2. Description of the Background

In recent years published medical studies have shown strong links between heart trouble and high cholesterol levels. As a result, consumers have become much more interested in products, especially natural products, which have beneficial effects on cholesterol levels. Rice bran is a low fat product that has been shown to have a favorable effect on cholesterol levels. Consequently there has been an increased demand for rice bran and particularly for rice bran breakfast cereals. Furthermore, there are indications that rice bran oil, which may be used for cooking oil, has the unique ability, under certain conditions, to lower harmful cholesterol levels up to 30 percent without reducing the amount of socalled good cholesterol that protects against heart attacks. Tests with animals show rice bran oil can even raise the good cholesterol levels in some cases.

Although rice is abundantly grown throughout the world, only a small percentage of the rice bran contained within the raw rice has, in the past, been used for human consumption. The fact is that one of the most nutritious foods known to man, rice bran, becomes rancid within a few hours after the milling process, making it substantially inedible by humans after that time and, after several days, digestible only by animals. If the rice bran is to be saved, it must be stabilized almost immediately after milling.

One method of stabilizing the rice bran involves processing it within an extrusion cooker. A rice bran extrusion cooker, which has been used to process the rice bran, is described and illustrated in U.S. Pat.

No. 4,741,264 to D. L. McPeak, incorporated herein by reference. By processing the rice bran in the

McPeak apparatus, for typically less than one second, the rice bran will often experience a ten fold increase in value due to the fact that it can now be used for human as well as animal consumption. The

McPeak apparatus has been used in stabilizing the rice bran so that time is available to extract the rice bran oil and also to utilize the remaining defatted rice bran as high protein, low fat food for human consumption.

However, the McPeak apparatus has a number of serious drawbacks. For instance, the McPeak machines often experience an inordinate amount of vibration during operation. In some cases, the vibration is so severe that even providing a suitable mounting for the machine becomes troublesome.

The vibration produces wear in the machine due to increased mechanical strain. Also the vibration indicates inefficiency in that the energy spent on vibration is not being used for processing the rice.

Linked to the vibration problem is a rice bran extruder flow problem in that the rice bran is often extruded from the McPeak apparatus in a turbulent or pulsating flow rather than a smooth flow. A turbulent or pulsating output may result in less consistent cooking of the rice bran and therefore lower quality and a generally short shelf life of the processed rice bran.

Another significant problem which can occur in the McPeak machine concerns difficulty in maintaining a steady temperature on the output. The United States Department of Agriculture generally sets a temperature range within which the cooking temperature must remain. A typical range might be

130 degrees Centigrade plus or minus 4 degrees. The McPeak machine has a hand crank to adjust the extrusion gap and thereby vary the cooking temperature. In some instances, however, it has been observed that a very small change in the extrusion gap quickly results in up to a 10 degree Centigrade temperature change, thus making adjustment of the cooking temperature difficult. The instability of the output temperature is such that it is perplexing, if not impossible, to design an automatic control system adapted to the machine that will control the temperature adequately. This problem also results in a processed bran output that is not always of the best quality due to inconsistent cooking.

Power outages can create difficult problems for a rice bran extrusion machine. If the power to the machine should become cut off, within a short time the liquified bran remaining in the extrusion housing begins to solidify. Even after a short period the extrusion shaft may be effectively glued into the extrusion housing. If the bran solution is allowed to cool inside the housing, a large force, in some cases over twenty tons, may be required for disassembly. An operator may not always be immediately available in time to prevent this problem due to the fact that sometimes these machines run for days at a time making constant observation difficult.

Another problem, which the McPeak patent specification addresses, in column 4, is the problem of providing the extrusion device with a continuous feed of rice bran. Rice bran, due to its oil content, has

1908/2197

a tendency to bridge or stick rather than flow freely into the extruder housing. The McPeak machine utilizes a hopper to gravity feed the rice bran into a feed conveyor. However, a gravity feeding hopper is, itself, subject to bridging or sticking of the bran.

A further wear related complication with the McPeak machine is that even though most wear occurs near the output end of the extrusion rotor, the entire rotor, including sections of the rotor without appreciable wear, must be replaced when the output end of the rotor requires replacement.

In summary, the McPeak machine is generally subject to problems of excessive vibration, unstable cooking temperature, reduced efficiency and uncertain reliability.

Consequently, there has been a long felt but unfulfilled need in the rice bran processing industry for an improved apparatus utilizing improvements in extrusion processing techniques for rice bran. The industry has long sought improved rice bran processing apparatus and methods which will result in greater reliability and dependability of operation at reduced levels of capital investment and energy consumption.


The present invention provides a unique design for beater bars on the extrusion rotor to greatly reduce vibration and wear problems. Additional features which improve the consistency of the output bran include a substantially solid metal extrusion rotor, a lengthened, variable width extrusion gap, a computerized control system and a unique drag conveyor belt for feeding rice bran into the extrusion housing.

The applicant has determined that the vibration problem in previous rice bran extruders arises, for the most part, due to asymmetrical and substantially non-continuous impacting between the beater bars and the knives located in the extruder housing. The present invention provides parameters for this relationship which not only reduce vibration but also produce a generally steady flow of rice bran through the extrusion cooker rather than a turbulent or pulsing flow. Thus the rice bran is cooked more evenly and more consistently to yield an improved quality product. The beater bar segments, in a preferred embodiment of the present invention, substantially simultaneously impact the knives in the extruder housing. Also, in this preferred embodiment, these impacts occur during rotor rotation at substantially equal degrees of rotation from each other. Experimentation has established that these impacts should occur more often than once each ninety degrees of rotation.

Another feature of the present invention is a rotor with a replaceable beater bar section. The portion of the rotor in which the most wear occurs, i.e., that part which contains the beater bars, is made separately replaceable in a preferred embodiment of the present invention. Therefore the longer wearing part of the rotor may continue to be used with a new beater bar portion to thereby reduce costs.

Also, in a preferred embodiment, the beater bar portion of the rotor is made of hardened steel or carbon steel to increase its service time before replacement. In other words, this section is made especially resistent to wear by treating the metal in some way well known in the field of metallurgy. Due to the extra cost of this treatment, it need not be provided to other parts of the extruder to save manufacturing costs. Applicant also anticipates that other wear resistent materials besides metal may be discovered in the future and could be used in making the beater bar section.

Another feature of the present invention is a lengthened extrusion gap with variable width. By lengthening the extrusion gap, adequate pressure is maintained to extrusion cook the bran while permitting a wider path through the gap for greater rice bran flow. This feature also generally permits more accurate temperature control since a given change in the extrusion gap does not result in the drastic cooking temperature changes which occurred in earlier machines. The wider extrusion gap and redesigned beater bars of the present invention appear, at least in some test cases, to increase output from an earlier machine as much as about 40 percent. For example, a typical output of an earlier machine averaging 1400 lbs. of processed bran per hour may be increased to approximately 2000 lbs. per hour while using substantially the same energy. This increase in output is generally coupled with an increase in the output quality of the rice bran due to more consistent cooking of the rice bran. More consistent product cooking appears to extend the shelf life of the processed bran to more than one year and perhaps considerably longer.

1909/2197

Another feature of the present invention is a generally solid metal rotor to provide a heat sink to smooth out the rapid temperature fluctuations which occurred in earlier machines. This feature increases the time required for the machine to reach the proper cooking temperature by several minutes but, by acting to stabilize the cooking temperature, the output quality of the processed bran is improved. Due to the fact that rice bran extruders often run for several days in a row, the few minutes lost at the start up period is insignificant compared to the improved quality product.

Incorporation of the above mentioned features permits development of a computer control system to more accurately maintain the cooking temperature. A computer controlled system incorporating these features produces an improved, more consistent, rice bran output while requiring less attention by a human operator.

Still another feature of the present invention is a drag conveyor for feeding the bran into the extruder housing. This conveyor includes blades which are angled so that they not only push the bran along the belt but also positively force the bran off of the conveyor to force the bran into the extruder housing rather than relying on mere gravity feeding.

The present invention provides a smoother operating rice bran extruder having a continuous rather than pulsating or turbulent bran output flow by providing a unique design for the beater bar segments. The present invention increases the throughput of the rice bran extruder by redesigning the beater bars to more efficiently use energy and by providing a longer extrusion gap of variable width. The present invention provides a beater bar portion of the extrusion rotor which is replaceable, thereby lowering repair costs in the most wear prone part of the extruder apparatus. The present invention provides a solid metal rotor to decrease fluctuations in cooking temperatures, creating a more consistent, higher quality, product. In summary, the vibration problems of the McPeak rice bran extruder have been significantly reduced. The throughput of the rice bran extruder has been increased, in some cases, by up to approximately 40 percent while keeping the power requirements the same. Repair costs have been lowered on certain components of the apparatus. Output quality and consistency have generally been significantly improved. Accordingly, the present invention provides the improved apparatus and methods for processing rice bran which have been long sought by the industry. These and other meritorious features and advantages of the present invention will be more fully appreciated from the following description and claims.


Other features and intended advantages of the present invention will be more readily apparent by the references to the following detailed description in connection with the accompanying drawings:

FIG. 1 is an upper elevational view, partially in section, showing a rice bran extruder in accordance with the present invention.

FIG. 2 is a side elevational view, partially in section, showing the rice bran extruder of FIG. 1.

FIG. 3A is a front elevational view, partially in section, with the beater bars being in phantom and showing irregularities in the relationship of the beater bars and the knives which may occur in a prior art extruder.

FIG. 3B is a front elevation view, partially in section, along the line of 3B--3B of FIG. 2, showing a preferred embodiment in accordance with the present invention with the beater bars being in phantom and revealing the relationship of the beater bars and the knives.

FIG. 4 is a block diagram schematic of a control system for a rice bran extrusion apparatus in accordance with the present invention.

FIG. 5 is a side elevational view of a drag conveyor in accord with the present invention.

1910/2197

FIG. 6 is an upper elevational view of a system for processing rice bran in accord with the present invention.

While the invention will be described in connection with the presently preferred embodiment, it will be understood that it is not intended to limit the invention to this embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included in the spirit of the invention as defined in the appended claims.

BRIEF DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to the drawings, and more particularly, to FIG. 1, a rice bran extruder, generally designated 10, according to a preferred embodiment of the present invention is shown. Rice bran extruder 10 includes a rice bran extruder housing 21 and extrusion rotor 31. Housing 21 is affixed to movable housing plates 19 and 25. Housing plates 19 and 25 are movable axially with respect to rotor

31 along rods 17 and 37 by means of bushings 20, 27, 32, and 34. By axial movement, the width of extrusion gap 40 is altered, thus changing the cooking temperature of the extruded rice bran 119 (FIG.

2). Housing plate 25 is moved axially when shafts 28 and 30 are rotated. Traveling nut couplings 24 and 39 are rotatably fixed in housing plate 25 and have internal threads (not shown) so that housing 21 moves axially in response to rotation of shafts 28 and 30. In the preferred embodiment, traveling nut couplings 24 and 39 are in the form of lost motion couplings as described in U.S. Pat. No. 4,229,907 to

Hall, incorporated herein by reference. As explained and illustrated in detail in Hall, gap 26, within nut coupling 24, permits control motor 111 (FIG. 2) to generate significant momentum before applying driving force to housing plate 25. This feature can become very important if a power outage occurs.

The rice bran tends to set up very quickly after rotation of rotor 31 stops. By applying a backup power supply voltage to motor 111, a significant jarring force can be applied to housing plate 25 to jar open the extruder housing 21 in the event housing 21 is sticking to rotor 31.

Extrusion rotor 31 is generally surrounded by spiral flutes 35 which are used to push the rice bran through housing 21. In the preferred embodiment shaft 14 extends through the center of rotor 31 (FIG.

3) and is rotatably fixed to rotor 31 by means of key 58. Shaft 31 is secured to outer plates 13 and 41 by bearings 12 and 29 so that rotor 31 is concentrically aligned with housing 21. This method of mounting rotor 31 also provides an improvement over prior rice bran extruders since bearing 12 is external to housing 21 and therefore no bearing for rotor 31 is necessary internal to housing 21 where little room is available. Also having bearing 12 some distance from extrusion gap 40, in which the extrusion pressure occurs, provides leverage in holding extrusion rotor 31 concentric despite possible variations in extrusion pressure which would tend to cause vibrations and further alter the width of gap

40 and cause temperature control problems.

In the preferred embodiment, rotor 31 has three main sections. The first section includes frustoconical shaped inner cone 16 which has surface 42 that forms the inner surface of extrusion gap 40. The second section includes beater bar section 36 which, in the preferred embodiment is separable from both inner cone 16 and the main portion of rotor 31. Beater bars 98 (FIG. 2) comprised of a plurality of beater bar segments 115 (FIG. 2) which are each interposed between fluting 35 are included in beater bar section

36. Beater bar section 36 receives most of the wear during the extrusion process. For this reason, beater bar section 36 is made detachable from the remainder of rotor 31 so that it can be replaceable. In the preferred embodiment beater bar section 36 is made of steel or other suitable material which is hardened against wear. The third section of extrusion rotor 31 includes the remainder of the rotor 31 running to bearing 29. In the preferred embodiment, inner cone 16 and beater bar section 36 are generally solid metal when seen as including shaft 14. In this way, rotor 31 has enough mass to act as a heat regulator to smooth out cooking temperature variations that may occur when the width of extrusion gap 40 is varied. Inner cone 16 and beater bar section 36 may be constructed of other materials which are both wear resistant and capable of functioning as a heat sink.

Outer cone 22, fixed to housing plate 19, has surfaces 38 which, together with surfaces 42 of cone 16, delineate extrusion gap 40. In the preferred embodiment, the axial length 18 of the extrusion gap has been increased from that found in prior art rice bran extruders. In prior extruders, axial length 18 was approximately 1 inch; in the presently preferred embodiment, axial length 18 is approximately 1.93 inches. Generally a length over approximately 1.5 inches provides a significant improvement over prior

1911/2197

devices for several reasons. Due to the extra length of extrusion gap 40, it is now possible to enlarge its width, thus allowing a greater flow of processed rice bran 119 while retaining enough pressure to satisfactorily extrusion cook the rice bran 119. The wider extrusion gap 40, coupled with other improvements to be discussed hereinafter, promotes a smoother flow of rice bran 119 which means that the rice bran 119 will be more uniformly cooked and therefore be of higher quality. Furthermore, since extrusion gap 40 is generally wider, variations in gap size result in smaller temperature fluctuations than occurred in prior rice bran extruders which allows more precise control over the cooking temperature.

FIG. 2 shows a side view of rice bran extruder 10. In a preferred embodiment, motor 110 rotates drive pulley 108 which is coupled by V-belts 106 to pulley 104. Control motor 111 drives sprockets 102 and

103 to rotate threaded shafts 28 and 30 and thereby control the width of extrusion gap 40. Rice bran enters extrusion housing 21 at opening 23 and leaves through extrusion gap 40. Generally a shroud (not shown) forces the rice bran 119 into valve housing 120.

Automated control is illustrated schematically in FIG. 4. In a preferred embodiment, computer 152, using temperature sensor 150, determines whether rice bran 119 has been cooked within the proper range of temperature as set by the FDA. Computer 152 then controls the opening of valve flap 116. If cooked properly, the rice bran 119 proceeds to packaging along belt conveyor 114. If the rice bran 119 has not been cooked properly, it proceeds down screw conveyor 118 to the scrap heap where it is mixed with animal feed.

FIGS. 3A and 3B show beater bar segments 115 (side view in FIG. 2) in a phantom view from section lines 3B of FIG. 2 wherein flutes 35 are invisible. FIG. 3A shows the beater bar segments 115 in an exemplary distribution used with prior extruders. Stationary knives 78, 60, and 66 are mounted upon extrusion housing inner surface 76. Stationary knife 113 is seen from the side in FIG. 2 near the end of housing 21 adjacent extrusion gap 40. In FIG. 3A, four beater bars 98 (side view FIG. 2) are shown and each takes up a circumferential surface area as indicated by arcs 52, 74, 64, and 62. This arrangement leaves gaps such as gap 68. Due to this lack of continuity, drive motor 110 will attempt to speed up during gap 68 resulting in unwanted vibration.

FIG. 3B shows a preferred embodiment of the present invention wherein thebeater bar segments 115 are spread to produce very few and much smaller gaps which results in a general reduction in vibration.

Of course, it is possible to widen the beater bars 98 so that all gaps are removed. Generally, the spacing between impacts should be equal so that impacts occur at substantially equal degrees of rotation of rotor 31 from each other.

FIG. 3A shows that four beater bar segments 50, 69, 63, and 54 will strike three knives 78, 66, and 60 at different times during the rotation of extrusion rotor 31. Comparatively, in FIG. 3B, the three beater bars 93 are used to correspond to three stationary knives 78, 66, and 60. Beater bar segments 80, 90, and 86 form a set of segments, generally equidistantly spaced so that stationary knives 78, 66, and 60, which are also generally equidistantly spaced, will be substantially simultaneously impacted. The other beater bar segments 115 are similarly spaced and are most clearly seen as being arranged in sets. In this way the impacting forces are spread around the housing equally to help further reduce vibration as each set of beater bar segments 115 strikes a corresponding knife. When reducing the number of beater bar segments 115 to a minimum, tests indicate that more than four generally simultaneous sets of impacts should occur per revolution. Generally, increasing the number of beater bar segments 115 increases the necessary horsepower required to operate the rice bran extruder 10. A suitable balance is achieved in the present invention with three beater bars 98 (FIG. 2) having four beater bar segments 115 each and using three knives 113 (FIG. 2) in extruder housing 21.

FIG. 4 shows a preferred embodiment control system. This system can operate one or more rice bran extruders 10 with proper additional connections. The input from at least one temperature sensor 150 is transmitted to computer 152 which determines whether the rice bran was cooked at the correct temperature. Output valve 116 is controlled responsive to that determination through relays 162. If the temperature stays out of range for too long a time, a malfunction is indicated and the computer causes control motor 111 to fully open the housing. An indicator, e.g., a malfunction indicator lamp 154 or alarm (not illustrated), may also be activated and the power to rotor 31 shut off. Computer 152 acts through relays 162 to control the various functions. The cooking temperature is adjusted via control

1912/2197

motor 111 by adjusting extrusion gap 40 according to input to computer 152 from temperature sensor

150. Of course, additional functions, including control of power to drive motor 110, may be included to allow a shut down, if necessary, based on a vibration sensor or other heat sensor readings. Backup power supply 158 operates to open up extrusion housing 21 in case of a power failure to avoid letting the rice bran set up within the housing 21 which could cause rotor 31 to become virtually cemented into housing 21.

FIG. 5 illustrates input drag conveyor 171 for introducing rice bran into extrusion housings 174, 178, and 182 which include rotors 176, 180, and 184. Blades 172 push rice bran through the conveyor on chain 168 after introduction into opening 170. Blades 172 are slanted away from the direction of movement of chain 168. This feature causes the blades to impart a downward force, as viewed in FIG.

5, to the rice bran to aid in forcing it into the rice bran extruder housings. Due to the stickiness of rice bran 119, gravity is not always adequate to move the rice bran 119. The same general concept of slanted blades can be used to force the rice bran into opening 170. Unused rice bran 186 will go to the scrap heap via opening 188 to be used with animal feed.

FIG. 6 illustrates a preferred embodiment system for processing rice bran using three rice bran extruder units 200, 202, and 204. Rice bran 212 is fed to the system typically from a milling area. Rice is transported by conveyor 198 to hopper 170, or to the scrap heap to be mixed usually with animal feed, depending on the position of valve flap 214. The rice bran 212 is conveyed to the extruder units 200,

202, and 204 through hoppers, such as hopper 206 in extruder 204 in the manner shown generally in

FIG. 5. The excess rice bran which goes through hopper 207 is returned to the scrap heap via conveyors 208, 118, and 199. The output rice bran from extruder units such as unit 204 goes through valve 120. Valve 120, controlled by computer 152, either sends the rice bran to packaging for human consumption over conveyor 210 or to the scrap heap via conveyor 118. Sensor 216 monitors rice bran going to the scrap heap. If the levels drop too low, this causes valve 214 to force more rice bran onto input conveyor 198. The converse is also true, too high a level, will cause valve 214 to send rice bran to the scrap heap thus regulating the flow of rice bran for processing.

It is thought that the rice bran extruder apparatus and system and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred or exemplary embodiment thereof. It is to be understood that while the specification is written in terms of rice bran, any bulk commodity including but not limited to corn, soybeans, wheat, animal fat waste products, fruit and vegetables, could be used with this invention.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. An extruding apparatus for processing commodites such as rice bran, comprising: a cylindrical extrusion housing having first and second ends with a feed opening proximate said first end for introducing said rice bran; an annular housing mounted to said second end with a passageway therethrough axially aligned with said extrusion housing and flared outwardly along a first inclined surface; at least one knife mounted about the interior of said extrusion housing proximate said second end; an extrusion rotor disposed within said extrusion housing and said annular housing; means for rotating operatively connected to said extrusion rotor; spiral threading about the portion of said rotor disposed within said extrusion housing; at least one beater bar disposed about the portion of said rotor adjacent said knives, each said beater bar angularly oriented with respect to said threading, each said beater bar comprised of at least one segment, each said segment interposed between adjacent threads and wherein said segments and said knives are arrayed to produce during rotation of said rotor a plurality of impacts between at least one segment and at least one knife, each of said plurality of impacts separated by approximately equal degrees of rotation of said rotor; a frustoconical section rotating with the portion of said rotor disposed within said housing and having a second inclined surface corresponding to said first inclined surface of said annular housing; and an extrusion gap formed between said inclined surfaces.

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2. The extruding apparatus of claim 1 wherein said segments and said knives are arrayed to provide substantially continuous impacting of at least one said segment with at least one said knife during rotation of said rotor.

3. The extruding apparatus of claim 1 comprising a plurality of said segments symmetrically disposed about said rotor and a plurality of said knives symmetrically disposed about said interior of said extrusion housing, said segments and said knives arrayed to substantially balance said impacting during rotation of said rotor.

4. An extruding apparatus for processing commodities such as rice bran, comprising: a cylindrical extrusion housing have first and second ends with a feed opening proximate said first end for introducing said rice bran; an annular housing mounted to said second end with a passageway therethrough axially aligned with said extrusion housing and flared outwardly along a first inclined surface; a plurality of knives symmetrically mounted about the interior of said extrusion housing proximate said second end; an extrusion rotor disposed within said extrusion housing and said annular housing; means for rotating said extrusion rotor with respect to said housing; spiral threading about the portion of said rotor disposed within said extrusion housing; a plurality of beater bars disposed symmetrically about the portion of said rotor adjacent said knives, said beater bars angularly oriented with respect to said threading, each said beater bar comprised of one or more segments, said segments being arranged in sets, said segments in each set including segments from a plurality of beater bars and being spaced symmetrically around said extrusion rotor in a manner corresponding to the spacing of said symmetrically mounted knives, said segments forming each said set being positioned to substantially simultaneously impact said knives having said corresponding spacing to said segments in said set during said rotation of said extrusion rotor; a frustoconical section rotating with the portion of said rotor disposed within said housing and having a second inclined surface corresponding to said first inclined surface of said annular housing; and an extrusion gap formed between said inclined surfaces.

5. The extruding apparatus of claim 4 wherein the number of said knives and the number of said sets of segments have been selected so that at least one of said substantially simultaneous sets of impacts occurs during each 90 degrees of rotation of said rotor.

6. An extruding apparatus for processing commodities such as rice bran, comprising: a cylindrical extrusion housing having first and second ends with a feed opening proximate said first end of introducing said rice bran; an annular housing mounted to said second end with a passageway therethrough axially aligned with said extrusion housing and flared outwardly along a first inclined surface; a plurality of knives symmetrically mounted about the interior of said extrusion housing proximate said second end; an extrusion rotor disposed within said extrusion housing and said annular housing; means for rotating said extrusion rotor with respect to said housing; spiral threading about the portion of said rotor disposed within said extrusion housing; a plurality of beater bars disposed symmetrically about a beater bar section of said rotor adjacent said knives, said beater bars angularly oriented with respect to said threading, each said beater bar comprised of at least one segment, each said segment interposed between adjacent threads; a frustoconical section rotating with the portion of said rotor disposed within said housing and having a second inclined surface corresponding to said first inclined surface of said annular housing; an extrusion gap formed between said inclined surfaces; and wherein at least one of said beater bar sections, said frustoconical section and said annular housing is comprised of a material which provides a heat sink for heat produced during extrusion of said rice bran.

7. The extruding apparatus of claim 6 wherein at least one of said beater bar section and said frustoconical section is substantially solid.

8. An extruding apparatus for processing commodities such as rice bran, comprising: a cylindrical extrusion housing having first and second ends with a feed opening proximate said first end for introducing said rice bran; an annular housing mounted to said second end with a passageway therethrough axially aligned with said extrusion housing and flared outwardly along a first inclined surface; a plurality of knives mounted about the interior of said extrusion housing proximate said second end; an extrusion rotor extending axially through said extrusion housing and said annular housing and rotatably fixed in said frame; means for rotating operatively connected to said extrusion rotor; spiral threading about the portion of said rotor disposed within said extrusion housing; a plurality of beater bars disposed about the portion of said rotor adjacent said knives, said beater bars angularly

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oriented with respect to said threading, each said beater bar comprised of at least one segment, each said segment interposed between adjacent threads; a frustoconical section rotating with the portion of said rotor disposed within said housing and having a second inclined surface corresponding to said first inclined surface of said annular housing; and an extrusion gap formed between said inclined surfaces, and having a length along said inclined surface at least about 1.85 inches.

9. An extruding apparatus for processing commodities such as rice bran, comprising: a cylindrical extrusion housing having first and second ends with a feed opening proximate said first end for introducing said rice bran; an annular housing mounted to said second end with a passageway therethrough axially aligned with said extrusion housing and flared outwardly along a first inclined surface; a plurality of knives symmetrically mounted about the interior of said extrusion housing proximate said second end; an extrusion rotor disposed within said extrusion housing and said annular housing; means for rotating operatively connected to said extrusion rotor; spiral threading about the portion of said rotor disposed within said extrusion housing; a plurality of beater bars disposed symmetrically about the portion of said rotor adjacent said knives, said beater bars angularly oriented with respect to said threading, each said beater bar comprised of at least one segment, each said segment interposed between adjacent threads and wherein the number of said knives and the number of said bars have been selected so that one number is evenly divisible by the other without remainder; a frustoconical section rotating with the portion of said rotor disposed within said housing and having a second inclined surface corresponding to said first inclined surface of said annular housing; and an extrusion gap formed between said inclined surfaces.

10. The extruding apparatus of claim 9 wherein the number of said bars is equal to the number of said knives.

11. The extruding apparatus of claim 9 wherein at least one of said beater bars is comprised of a plurality of said segments linearly disposed between alternate pairs of adjacent threads.

12. The extruding apparatus of claim 9 further including a frame in which said extrusion housing is mounted, and wherein said rotor extends axially through said ends of said extrusion housing and said frustoconical section and is rotatably fixed in said frame.

13. The extruding apparatus of claim 9 wherein said rotor comprises at least two separable portions with one said portion including said beater bars.

14. The extruding apparatus of claim 9 wherein said beater bars and knives are constructed of wear resistant materials.

15. The extruding apparatus of claim 9 wherein said beater bars are more resistant to wear than are said knives.

16. The extruding apparatus of claim 15 wherein said knives are replaceable.

17. The extruding apparatus of claim 16 wherein said knives are disposed substantially parallel to the axis of said cylindrical housing.

18. The extruding apparatus of claim 9 wherein each said bar is disposed along a line within an arc around said rotor and wherein the number of degrees around said rotor in each said arc is about 360 divided by the number of said bars or said knives.

19. The extruding apparatus of claim 18 wherein each said bar formed of said segments extends around said rotor substantially through said number of degrees in each said arc.

20. The extruding apparatus of claim 19 including three said knives and three said bars, each said bar comprising at least four said segments.

21. The extruding apparatus of claim 9 wherein said inclined surfaces are substantially parallel.

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22. The extruding apparatus of claim 9 wherein the length of said extrusion gap along said inclined surfaces is at least about 1.85 inches.

23. The extruding apparatus of claim 22 wherein said extrusion gap has an axial length component parallel to the axis of said rotor at least about 1.5 inches.

24. The extruding apparatus of claim 9 wherein at least one of said frustoconical section and said annular housing are comprised of a material which provides a heat sink for heat produced during extrusion of said rice bran.

25. The extruding apparatus of claim 9 wherein the width of said extrusion gap is adjustable, and further comprising: a temperature sensor for measuring the processing temperature of said rice bran; and a feedback loop for adjusting said width of said extrusion gap in response to said measured temperature to maintain a desired processing temperature.

26. The extruding apparatus of claim 25, further including: an output valve for discharged rice bran which emerges from said extrusion gap, said output valve operable responsive to said temperature sensor between first and second positions, said first position of said output valve for routing rice bran extruded within said desired processing temperature and said second position for routing rice bran extruded outside said desired processing temperature.

27. The extruding apparatus of claim 26, further including: an input conveyor system for bringing rice bran to said feed opening in said extrusion housing; a first conveyor system for transporting to a scrap heap unprocessed rice bran which did not enter said feed opening from said input conveyor system and improperly processed rice bran from said output valve; a sensor to determine the amount of rice bran on said output conveyor system; and a feedback loop from said sensor to said input conveyor system and said output valve to control the amount of rice bran on said input conveyor system.Data supplied from the esp@cenet database - Worldwide

1916/2197

396.

US5219597 - 6/15/1993

METHOD FOR PRODUCING HIGHLY CONCENTRATED, LACTIC-ACID

FERMENTED PRODUCT UTILIZING UNGROUND GRAINY RICE AND

IMPROVING QUALITIES THEREOF BY THE SECONDARY, ENZYMATIC

TREATMENT AT FERMENTATION


Inventor(s): MOK CHUL-KYOON (KR); NAM YOUNG-JUNG (KR); KIM YOUNG-JIN (KR)

Applicant(s): KOREA FOOD RES INST (KR)


IP Class: A23L1/22

E Class: A23L1/105; A23L1/238; A23L1/23


Priority Number: KR19910002747 (19910220)

Family: US5219597

Abstract:


Disclosed is a method for producing a highly concentrated, rice-derived lactic acid fermented product which tastes highly sweet and sour, and of which the flavor and texture are excellent. In this method, unground, grainy rice is gelatinized and then it is liquefied and saccharified by the primary treatment with alpha -amylase and glucoamylase. After sterilization, it is inoculated with lactic acid bacteria and undergoes a secondary treatment with alpha -amylase and glucoamylase. The glucose produced thereby continuously ferments to lactic acid. Finally, high concentrated lactic fermented product, tasting sweet and sour, and having excellent flavor and texture, is produced.Claims:


We claim:

1. A method for producing a highly concentrated, rice derived lactic acid fermented product having a sweet and sour taste, which comprises: gelatinizing unground, grainy rice by immersing said rice in water and heating to form a gelatinized rice product; liquefying and saccharifying said gelatinized rice product by treating said gelatinized rice product with a sufficient amount of an amylolytic enzyme containing .alpha.-amylase and glycoamylase to form a saccharified solution; inactivating said amylolytic enzyme and sterilizing said saccharified solution by heating to form a sterilized solution; inoculating said sterilized solution with a starter containing a microorganism selected from each of the genuses Streptococcus and Lactobacillus, to form an inoculated solution; fermenting said inoculated solution to form a fermented solution; and homogenizing said fermented solution, to obtain said highly concentrated rice-derived lactic acid fermented product.

2. The method according to claim 1, wherein said microorganism selected from the genus

Streptococcus is Streptococcus thermophilus and said microorganism selected from the genus

Lactobacillus is selected from the group consisting of Lactobacillus acidophilus, Lactobacillus bulgaricus, and Lactobacillus plantarum.

1917/2197

3. The method according to claim 1, wherein said starter contains said microorganism selected from the genus Streptococcus and said microorganism selected from the genus Lactobacillus in a mixing ratio of

1:1.

4. A method for improving the flavor and texture qualities of a rice-derived lactic acid fermented product having sweet and sour taste, which comprises: gelatinizing unground, grainy rice by immersing said rice in water and heating to form a gelatinized rice product; liquefying and saccharifying said gelatinized rice product by treating said gelatinized rice product with a sufficient amount of an amylolytic enzyme containing .alpha.-amylase and glycoamylase to form a saccharified solution; inactivating said amylolytic enzyme and sterilizing said saccharified solution by heating to form a sterilized solution; inoculating said sterilized solution with a starter containing a microorganism selected from each of the genuses Streptococcus and Lactobacillus, to form an inoculated solution; fermenting said inoculated solution while simultaneously adding an amylolytic enzyme containing

.alpha.-amylase and glycoamylase in a bacteria-free state in sufficient amounts to produce glucose, whereby said glucose produced is continuously fermented into lactic acid, to form a fermented solution; and homogenizing said fermented solution, to obtain said highly concentrated, rice-derived lactic acid fermented product.

5. The method according to claim 4, wherein said microorganism selected from the genus

Streptococcus is Streptococcus thermophilus and said microorganism selected from the genus

Lactobacillus is selected from the group consisting of Lactobacillus acidophilus, Lactobacillus bulgaricus, and Lactobacillus plantarum.

6. The method according to claim 4, wherein said starter contains said microorganism selected from the genus Streptococcus and said microorganism selected from the genus Lactobacillus in a mixing ration of 1:1.Data supplied from the esp@cenet database - Worldwide

1918/2197

397.

US5234706 - 8/10/1993

PROCESSES FOR PRODUCTS FROM POTATOES AND OTHER ROOTS,

SEEDS, AND FRUIT


Inventor(s): SLIMAK K M (US)

Applicant(s): SLIMAK K M (US)


IP Class: A23L1/214

E Class: A23L1/16; A23L1/164E; A23L1/214D; A61K35/78; A61Q19/00; A23K1/14; A23L1/164;

A23L1/00P8B4; A21D2/36; A23L1/38; A23G9/02; A23L1/187B; A21D13/04; A21D13/08;

A23L1/214; A23L1/214B; A61K8/73; A61K47/36


Priority Number: US19880294690 (19880801); US19900522820 (19900514); US19910696086

(19910506); US19860825656 (19860131)

Family: US5234706

Abstract:


A variety of different food products, prepared from edible roots, seeds, and starchy fruits including potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, bread fruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit are substitutes for wheat and other grains, milk, eggs, and a partial substitute for nuts. A variety of starches, soluble fibers, and insoluble fibers may be combined to provide products that are substitutes for wheat and other grains, milk, eggs, and a partial substitute for nuts.Description:



(1) Field of Invention

In my previous applications listed above, I disclosed whole flours prepared from sweet potatoes, cassava, malanga and other edible aroids, amaranth, quinoa, yams, lotus, and arrowhead, as well as products prepared from them as well as manufacturing processes, as well as edible products. The present application discloses alternate processes for manufacturing these and other flours as well as the obtaining of products from flours where the sources of raw materials for the flours are obtained from any of a variety of sources of starch, soluble fibers, and insoluble fibers. These flours and products can be manufactured and used in a manner similar to those described previously for sweet potatoes, cassava, malanga and other edible aroids, amaranth, quinoa, yams, lotus, arrowhead, and others, with modification as needed to allow for differences in consistency, moisture retention, and baking properties and the like. Unless otherwise indicated, all proportions, methods of preparation and so forth are as those described in the parent applications.

The present invention is concerned with the utilization of starch insoluble fiber, and soluble fiber to form flours suitable for obtaining baked products of risen structure, and also products with colloidal

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properties, and other properties as described for sweet potatoes in the above referenced patent application No. 522.820 filed on May 14, 1990, and as described for sweet potatoes, cassava, malanga, yam, lotus, amaranth, quinoa, and arrowheat and others in the above referenced patent application No.

294,690 filed on Aug. 1, 1988.

The present invention is also concerned with the utilization of other root vegetables, seeds, or starchy fruits such as potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, bread fruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit, with the purpose of producing various flours from the tubers, seeds, or starchy fruits, baked products of risen structure, and other valuable edible products and industrial products.

(2) Description of The Background

I have found that flours having properties similar to those of sweet potato and other flours described in the above referenced patent applications, may be obtained by combining the major components of the flours which may have been either obtained separately from the whole tuber vegetable, or starchy fruit, or from different sources. In other words whole flours may be used to obtain baked products of risen structure, and in addition combined flours obtained by combining starch, insoluble fiber, and soluble fiber may be used to obtain baked products of risen structure. These flours may be combined prior to baking or may be added to doughs together or at separate times during dough preparation.

SUMMARY OF THE PREFERRED EMBODIMENTS

It is one object of the present invention is to provide new flours or new combinations of ingredients, with properties similar to those of sweet potato and other whole flours described in the above referenced patent applications. These new flours or ingredient combinations may be provided by obtaining and combining separately the major components of the whole flours. In other words whole flours may be used to obtain baked products of risen structure, and in addition combined flours obtained by combining starch insoluble fiber, and soluble fiber may be used to obtain baked products of risen structure. These flours may be combined prior to baking or may be added to doughs together or at separate times during dough preparation.

The present invention is also concerned with the utilization of other root vegetables, seeds, or starchy fruits such as potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, bread fruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit, with the purpose of producing various flours from the tubers, and other valuable edible products and industrial products.

Briefly, these objects and other objects of the present invention as hereinafter will become more readily apparent can be attained by a plurality of method embodiments which employ a flour obtained from a the above sources to prepare a variety of different foodstuffs.


The present invention is also concerned with the utilization of root vegetables, seeds, and starchy fruits such as potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, bread fruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit with the purpose of producing various flours from the tubers, seeds and fruit, baked products of risen structure, and other valuable edible products and industrial products.

Flours and other products may be obtained from the above roots, seeds, and starchy vegetables according to methods, procedures, and examples described in the above referenced patent applications.

Unless otherwise indicated, all proportions, methods or preparation and so forth are as those described in the aforementioned patent applications.

Thus in another embodiment of the invention, dry uncooked potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice cotton seed meal, bread fruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit may each be processed to flour

1920/2197

material by the method as described in my previous applications for sweet potatoes, cassava, edible aroids, amaranth, quinoa, yams, lotus, and arrowhead as disclosed herein above, that is, U.S. patent application Ser. No. 522,820, U.S. patent application Ser. No. 825,656 and U.S. patent application Ser.

No. 294,690. The flours so produced may be used as described in the same applications as disclosed herein above.

Similarly, dried, completely or partially cooked potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, bread fruit, pumpkin, winter, squash, white squash, plantain, banana, and jack fruit may each be processed to flour material by the method as described in my previous applications for sweet potatoes cassava, edible aroids, amaranth, quinoa, yams, lotus, and arrowhead as disclosed herein above, that is, U.S. application Ser.

No. 522,820, U.S. application Ser. No. 825,656 and U.S. application Ser. No. 294,690. The flours so produced may be used as described in the same applications as described herein above.

The above flours may be used in many processes to produce desirable products.

It is within the scope of this invention to remove some of the naturally occurring fiber and substitute it with fiber from another source, e.g., cellulose or another tuber as well as adding additional fiber to that naturally occurring in a flour source, to this invention.

In another embodiment, the components of whole flours may be obtained separately and combined together to provide the properties of the whole flour. These components, such as starch, insoluble fiber, e.g., cellulose, and soluble substance such as but not limited to mucilages and gums, and dried vegetable juices may be assembled separately from materials obtained from different sources which may then be mixed together. Mixing such as milling together of such separately obtained sources of ingredients, provide the properties of the instant invention.

To prepare doughs not containing gluten from wheat or rye and yet having sufficient strength to maintain a risen structure, a starch, an insoluble fiber source, and a soluble fiber source may be utilized in the manner described in the above referenced patent applications for a whole vegetable flour ingredient. Applicant has found that these ingredients are essential to the preparation of doughs with the desired properties, when essentially gluten-free baking products are prepared.

Contrary to the teachings of the Art, when a non-wheat or non-rye starch is used in baking doughs, the addition of fiber especially fiber from plant roots or stem, enhances the ability of the doughs to trap and hold air and thus maintain a risen structure. When starch and water are combined together the starch granules tend settle out of the water and do not form a uniform mixture. When water and soluble fiber are combined, the result is a solution of dissolved solute. When water and insoluble fiber are mixed the result is a wet fibrous mat similar to wet paper pulp or wet wood pulp. Any combination of two of the three ingredients does not provide the desired properties in a baked dough. For example, when starch, insoluble fiber and water are combined and baked the result is a hard, rubbery dough mass in which whisps of fibers may be visually evident. When starch alone, or starch and soluble fibers are added to water and baked, the result is a hard, frothy mass of dried bubbles which looks and tastes like dried glue. Only when soluble fibers, insoluble fibers and starch are combined with water does the desired properties and texture of dough result.

In another embodiment of the invention, baked products having sufficient cohesive strength to maintain a risen structure may be prepared from starch, insoluble fiber, and soluble fiber by combining starch, insoluble fiber, and soluble fiber in proportions ranging from 1:0.09-1.5:0.02-0.36, and further combining these ingredients with water and baking powder or other leavening agent. Preferred ranges of starch, insoluble fiber, and soluble fiber are 1:0.25-0.6:0.03-0.3 part per unit weight.

The starch, insoluble fiber, and soluble fiber components have the properties, uses and proportions for baking and other uses which have been described in patent application Nos. 522,820 and 294,690 for whole flours of sweet potato, cassava, edible aroids, malanga, yam, amaranth, quinoa, lotus, and arrowhead. The specific ranges which apply depend upon the properties of the starch, and soluble and insoluble fibers selected for inclusion.

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It is within the skill of the art to adjust the necessary proportions according to the purity of the ingredients. Thus a less pure starch may also contain some amounts of soluble and/or insoluble fibers and so require the addition of correspondingly less of these added ingredients. Similarly, it is within the skill of the Art to adjust ingredients when a soluble or insoluble fiber ingredient also contains starch and/or fibrous material.

It is also within the skill of the art to combine several starches instead of using only one starch, and/or to combine several sources of insoluble fiber instead of using only one source of insoluble fiber, and/or to combine several sources of soluble fiber instead of using only one source of soluble fiber.

Suitable starches include but are not limited to: sweet potato starch, cassava starch, malanga starch, starch from any edible aroid, yam starch, lotus starch, arrowhead starch, amaranth starch, quinoa starch, buckwheat starch, arrowroot starch, potato starch, banana starch, green bean starch, water chestnut starch, oak starch, pumpkin starch, breadfruit starch, corn starch, oat starch, millet starch, milo starch, rice starch, barley starch, jackfruit starch, jicama starch, legume starch, oat starch, teff starch, winter squash starch, white pumpkin starch, white squash starch, and plantain starch.

Suitable sources of insoluble fiber include but are not limited to: pulverized vegetable fiber obtained by filtration after water extraction, which is then purified, dried, and pulverized to a fine powder, alpha cellulose flour, bran, rice hulls, oat hulls, amaranth hulls, milo hulls, corn cobs, bean hulls, and soybean hulls. Pulverized vegetable fiber refers to the insoluble fiber obtainable particularly from root vegetables. Although pulverized vegetable fiber may be obtained from about any edible plant source including stems and leaves as well as roots, insoluble fiber obtained from root vegetables is most preferred since this fibrous material can be used in very large quantities (30% and more by weight) without imparting a gritty taste or off flavor to the final product. Pulverized roots, stems, and leaves, when obtained as described above for pulverized vegetable fiber, are preferred over pulverized seed coats.

Suitable sources of soluble fiber include but are not limited to: dried, pulverized vegetable juices obtained from pulverized root or other vegetables, seeds, roots, or starchy fruits by pressing, filtration, and starch removal by centrifugation or by water extraction and subsequent starch removal or by other suitable methods; sodium carboxymethylcellulose, hydroxymethylcellulose, guar gum, tragacanth gum, karaya gum, algin, agar, carrageenan, and other mucilages and gums.

Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.

EXAMPLE NUMBER 1

BREAD PRODUCT FROM STARCH, INSOLUBLE FIBER AND SOLUBLE FIBER

Combine 0.24 lb white sweet potato starch, 0.09 lb of the dried, pulverized insoluble fiber from white sweet potato, and 0.02 lb dried. pulverized soluble fiber from white sweet potato, and mix well. Then add 0.53 lb water and 0.03 lb baking powder and mix thoroughly. Place in baking pan and bake for 25 minutes at 425 DEG F. Soluble fiber and insoluble fiber were obtained as described in Rule 132

Declaration of Karen M. Slimak, on May 4, 1988, published as part of the file of U.S. Pat. No.

4,925,697, and herein incorporated by reference.

EXAMPLE 2

BREAD PRODUCT FROM STARCH, INSOLUBLE FIBER AND SOLUBLE FIBER

Combine 0.24 lb arrowroot starch, 0.09 lb of the dried, pulverized insoluble fiber from white sweet potato, and 0.02 lb dried, pulverized soluble fiber from cassava, and mix well. Then add 0.53 lb water and 0.03 lb baking powder and mix thoroughly. Place in baking pan and bake for 25 minutes at 425

DEG F. Soluble fiber and insoluble fiber were obtained as described in Rule 132 Declaration of Karen

M. Slimak, on May 4, 1988, published as part of the file of U.S. Pat. No. 4,925,697, and herein incorporated by reference.

1922/2197

EXAMPLE 3

POTATO FLOUR

Thinly peel potatoes under running water, removing any spots, and other undesirable areas; rinse briefly in distilled water; remove excess water; do not soak. Shred to desired size, place on glass or metal trays; air dry at 145 DEG F. for 8-12 hours, preferably 10 hrs. Comminute shreds into a moderately fine flour product.

EXAMPLE 4

COOKED POTATO FLOUR

The method of example 4 is used to produce a cooked flour product, with the added process of heating the potato with steam until gelatinized, and then proceeding with shredding and drying steps.

EXAMPLE 5

BREADFRUIT FLOUR

Peel firm, green breadfruit under running water, removing any spots, and other undesirable areas; rinse briefly in distilled water; remove excess water; do not soak. Shred to desired size, place on glass or metal trays; air dry at 145 DEG F. for 8-12 hours, preferably 10 hrs. Comminute shreds into a moderately fine flour product.

EXAMPLE 6

COOKED BREADFRUIT FLOUR

The method of example 6 is used to produce a cooked flour product, with the added process of heating the breadfruit with steam until gelatinized, and then proceeding with shredding and drying steps.

EXAMPLE 7

ARROWROOT FLOUR

Thinly peel arrowroot under running water, removing any spots, and other undesirable areas; rinse briefly in distilled water; remove excess water; do not soak. Shred to desired size, place on glass or metal trays; air dry at 145 DEG F. for 8-12 hours, preferably 10 hrs. Comminute shreds into a moderately fine flour product.

EXAMPLE 8

COOKED ARROWROOT FLOUR

The method of example 8 is used to produce a cooked flour product, with the added process of heating the arrowroot with steam until gelatinized, and then proceeding with shredding and drying steps.

EXAMPLE 9

WATER CHESTNUT FLOUR

Thinly peel water chestnuts under running water, removing any spots, and other undesirable areas; rinse briefly in distilled water; remove excess water; do not soak. Shred to desired size, place on glass or metal trays; air dry at 145 DEG F. for 8-12 hours, preferably 10 hrs. Comminute shreds into a moderately fine flour product.

EXAMPLE 10

1923/2197

COOKED WATER CHESTNUT FLOUR

The method of example 10 is used to produce a cooked flour product, with the added process of heating the water chestnut with steam until gelatinized, and then proceeding with shredding and drying steps.

Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit of the invention as set forth herein.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed as new and so intended to be secured by Letters Patent is:

1. An edible flour, consisting essentially of comminuted particles obtained from separate sources, said sources consisting essentially of a source of starch, soluble fiber, and of insoluble fiber, said source of starch selected from the group consisting of sweet potato, cassava, edible aroids, malanga, yam, amaranth, quinoa, lotus, arrowhead, potatoes, arrowroot, water chestnut, jicama, buckwheat, green bean, legumes, oak, millet, milo, barley, oats, corn, teff, rice, cotton seed meal, breadfruit, pumpkin, winter squash, white pumpkin, white squash, plantain, banana, and jack fruit, said source of soluble fiber selected from the group consisting of dried, pulverized vegetable juices, mucilages, gums, sodium carboxymethylcellulose, hydroxymethylcellulose, guar gum, tragacanth gum, karaya gum, algin, agar, and carrageenan, and said source of insoluble fiber selected from the group consisting of vegetable fiber, alpha cellulose flour, bran, rice hulls, amaranth hulls, milo hulls, corn cobs, bean hulls, and soybean hulls, said flour comminuted to a size so that substantially all of said flour passes through a screen of 0.015 inch opening, said flour having a moisture content of less than 20%, and wherein said flour possesses the ability to maintain a risen structure in the absence of gluten.

2. The flour of claim 1 wherein the starch, soluble fiber and insoluble fiber are selected from the group consisting of sweet potato, cassava, edible aroids, malanga, yam, amaranth, quinoa, lotus, arrowhead, potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, cotton seed meal, breadfruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit, wherein the source of starch, soluble fiber and insoluble fiber is not selected from a single member of said group.

3. An edible, whole flour product consisting essentially of tubers, seeds or starchy fruits, selected from the group consisting of potatoes, arrowroot, water chestnut, jicama, buckwheat, legumes, millet, milo, barley, oats, corn, teff, cotton seed mean, breadfruit, pumpkin, winter squash, white squash, plantain, banana, and jack fruit, wherein the flour consists essentially of the starch, soluble fiber and insoluble fiber portions of the tuber, seed or starchy fruit, comminuted to a size so that substantially all of said comminuted tuber, seed or starchy fruit passes through a screen of 0.015 inch mesh opening, said flour having a moisture content of less than 20% by weight, wherein said edible whole flour product possesses the ability to maintain a risen structure in the absence of gluten or chemical modifiers.

4. The flour of claim 3 wherein the flour is from potatoes of the family Solonaceae.

5. The flour of claim 3 wherein the flour is from water chestnut.

6. The flour of claim 3 wherein the flour is from arrowroot.

7. The flour of claim 3 wherein the flour is from breadfruit.

8. The flour of claim 3 wherein at least one of said portions of the flour is obtained from a separate source of said tubers, seeds or starchy fruits.

9. The flour of claim 3 wherein substantially all of the flour passes through a screen opening of 0.001 inch.

1924/2197

10. A milk substitute comprising water and the flour of claim 3 in amounts effective to produce said milk substrate.

11. An infant formula comprising the flour of claim 10, and water in amounts effective to produce said infant formula.

12. An ice cream substitute formed by freezing the milk substitute of claim 10.

13. An imitation nut butter product comprising oil and the flour of claim 3 in amounts effective to produce said nut butter substitute.

14. A baked product comprising the flour of claim 3 water, and leavening agent, in amounts effective to produce said baked product.

15. An extruded product comprising water and the flour of claim 3 in amounts effective to produce said extruded product.

16. A colloidal product comprising the flour of claim 3 an oil; and water, in amounts effective to produce said colloidal product.

17. A fried product comprising the flour of claim 3 an oil; and water, in amounts effective to produce said fried product.

18. A batter-type product comprising the flour of claim 3 an oil; and water, in amounts effective to produce said batter-type product.Data supplied from the esp@cenet database - Worldwide

1925/2197

398.

US5258187 - 11/2/1993

FOOD COATINGSTUFF


Inventor(s): SHIMADA SEINOSUKE (JP)

Applicant(s): SHIMADA SEINOSUKE (JP)


IP Class: A23G1/00; A23G3/30

E Class: A23L1/00P8B4; A23G3/00M; A23G3/30; A23G3/30P4



Family: US5258187

Abstract:


Food coatingstuff comprising rice starch and food products obtained by coating or dusting with rice starch. Inorganic food additives like titanium dioxide, calcium carbonate, etc. are not necessary by use of the coatingstuff containing rice starch.

1926/2197

399.

US5387423 - 2/7/1995

LOW CALORIE FOOD MATERIAL AND METHOD OF MANUFACTURING

THE SAME


Inventor(s): EMOTO MITSUO (JP); MIZUNO MASATOSHI (JP); TAKAGI SADAICHI (JP);

AKAZAWA TETSUYA (JP); FUJII SADAO (JP); MURAI MADOKA (JP); NAKAI YOSHIHITO

(JP)

Applicant(s): OTSUKA FOOD CO LTD (JP)


IP Class: A23L1/0522; A23L1/0534

E Class: A23L1/182; A23L1/168



(19921009); JP19920348591 (19921228); JP19920348597 (19921228); JP19930015358 (19930202)

Family: US5387423

Abstract:


The invention presents a low calorie food material in dry granular state containing a starch such as processed starch, and a dextrine, a konjak mannan or other gelling agent, and a cellulose powder or other white turbid matter. The food material becomes, when water is added, a rice-like food possessing the same appearance and properties as cooked rice.Description:



The present invention relates to a low calorie food material and a method of manufacturing the same, and more particularly to an artificial rice material which becomes like a rice-like food of low calorie and high food fiber content, having properties and appearance like cooked rice, and method of manufacturing the same.

Recently, in Japan, due to the increasing trend of obesity, related adult diseases, and diet, the eating life is changing, and the rice consumption tends to decrease, but still the rice is the main food today.

However, the rice is high in calorific value, and too much is taken unknowingly, or those on diet fall in a dilemma by taking too much calorie when desired to have a more feel of satisfaction. Moreover, for patients with allergic diseases or renal disorder, taking of rice may not be preferred.

On the other hand, as artificial rice, first the enriched rice was proposed by adding extra portion of vitamin B1 which is insufficient in rice, but it was no popular because of its color, etc. Further, the surface of the rice was treated by gelation in order to improve the taste of the rice deteriorated by longterm storage, or instant rice and retort rice were prepared by seeking the handiness. In these products, the surface was too smooth, and there were such various problems in the eating sensation that biting reaction was poor.

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The Japanese Patent Publication No. 70461/1991 discloses a granular dry gel obtained by heating and gelling water dispersion sol containing a refined powder of konjak and a starch, and drying the produced water-containing gel. It is disclosed that when water is added to this dry gel and boiled, water-containing gel possessing both konjak jelly (devil's tongue)-like property and rice-like eating feel is obtained, but it is far from artificial rice in both appearance and eating sensation.

The Japanese Patent Publication No. 66180/1988 discloses a method of manufacturing dry gel by kneading a konjak mannan, a starch and the like to gel, and freezing, thawing and drying the produced gel, but it is nothing but dried konjak jelly, and not artificial rice.

Thus, artificial rice equally comparable with natural rice in both eating sensation and appearance is not available at the present.


It is hence a primary object of the invention to present a novel rice-like food material of lower calorie and higher food fiber content as compared with natural rice, presenting the eating sensation and appearance not different from those of natural rice, and a method of manufacturing the same.

As a result of intensive research, the present inventors succeeded in obtaining a food material as a new artificial rice conforming to the object, by using a starch, a dextrine, a gelling agent, and a white turbid matter at a proper rate.

Specifically, the invention presents a low calorie food material as dry granular matter containing starch, and 0 to 20 times of dextrine, 0.003 to 7 times of gelling agent, and 0.03 to 20 times of white turbid matter, to the starch weight.

The invention also presents a method of manufacturing a low calorie food material comprising the steps of extruding, and cutting a semi-solid matter possessing a composition of 1 to 30% by weight of starch, 20% by weight or less of dextrine, 0.1 to 7% by weight of gelling agent, 1 to 20% by weight of white turbid matter and 40 to 97% by weight of water to form a granular-shape, eluting the dextrine as required, gelling, and drying.

The food material of the invention presents, only by adding water, a texture similar to cooked rice (feel on teeth, biting feel, etc.).

The invention may be also a non-dried food material, and presents, in such a case, a rice-like low calorie food material comprising 1 to 30% by weight of starch, 0 to 20% by weight of dextrine, 0.1 to

7% by weight of gelling agent, 1 to 20% by weight of white turbid matter, and 40 to 97% by weight of water. More preferably, the invention presents a rice-like low calorie food material comprising 1 to

30% by weight of processed starch, 0 to 20% by weight of dextrine, 1 to 7% by weight of konjak mannan, 0.01 to 0.5% by weight of alkali agent, 1 to 20% by weight of powder cellulose, and 40 to

97% by weight of water, in which the weight of the powder cellulose exceeds 1.0 of the weight of konjak mannan.

The food material of the invention may contain food fibers not found in natural rice, and the original feature of low calorie is provided.

Still more, the invention presents a retort cooked rice prepared by the steps of adding and blending granular gel formed by using gelling agent to rice, adding water as required, putting the blend into a container that can be heated and sterilized, and heating and sterilizing, or processing in retort. The granular gel is preferably a food material similar to cooked rice obtained by extruding and cutting a semi-solid matter possessing a composition of starch of 1 to 30% by weight, dextrine of 20% by weight or less, gelling agent of 0.1 to 7% by weight, white turbid matter of 1 to 20% by weight and water of 40 to 97% by weight to form a granular-shape. The granular gel is preferred to possess a particle size nearly equal to the rice grain.

The retort cooked rice obtained in the invention possesses the following benefits. (1) Due to sufficiently heated and sterilized, it can be preserved for a long period. (2) There is no risk of

1928/2197

presenting stickiness due to mutual adhesion of natural rice experienced in retort treatment of natural rice alone. (3) The produce taken out by unpacking the container possesses the appearance and texture similar to natural rice cooked in traditional cooker. (4) Cellulose not contained in natural rice may be contained, and the calorie is low.

As the granular gel formed into particle size nearly equal to rice grain by using gelling agent, the food material of the invention mentioned above may be presented as a practical example, but it is not limitative, and various granular matters possessing nearly same particle size as the rice grains obtained similarly by using the gelling agent used in manufacture of the above food material may be used, such as alginic acid gel balls, jellied ball of curdlan balls, commercially available granular konjak jelly, cut pieces of commercially available konjak jelly noodle.


FIG. 1 is a front view of a die of an extruder suited to manufacture of the food material of the invention.

FIG. 2 is a sectional view of a die of an extruder suited to manufacture of the food material of the invention.

FIG. 3 is a partly magnified view of the die shown in FIG. 1.

FIG. 4 is a partly magnified view of the die shown in FIG. 2.


The starch used in the invention is not particularly limited, and there may be used various materials such as natural starch and processed starch hitherto used in food. Examples of the starch include rice starch, corn starch, wheat starch, barley starch, waxy cornstarch, sugar starch, potato starch, and other natural starches; grain powder containing these starches; high amylose starch, crosslinked starch, substitutional starch, thin boiling starch, acetate modified starch, hydroxyalkyl starch, alpha-starch, and other processed starches combining the processes either alone or in combination. In particular, processed starches obtained by chemical treatment of carboxyl group contained in crosslinked starch, substitutional starch, thin boiling starch, acetate modified starch, hydroxyalkyl starch and other starch by esterification or etherification are preferred. In the processed starches, those having the peak viscosity of Brabender viscosity (by viscometer of Brabender) of 600 to 800 Bu are most preferable.

Especially, the processed starch of which Brabender viscosity is maintained more than 500, even if stored for 4 hours or more at 90 DEG C., is preferred.

The content of starch used in the invention may be properly selected depending on the desired appearance, shape, and properties of the rice-like food obtained by adding water, and usually the content of starch in the granular matter containing water, that is, the content of starch of the whole amount of manufacturing materials of rice-like food containing water is about 1 to 30% by weight, or preferably about 10 to 20% by weight.

As dextrine, any substance soluble in water may be used, and usually the dextrine equivalent (DE) of about 10 to 40, or preferably about 20 to 30 may be suited. The dextrine is used in a range of 20 times or less, preferably about 0.16 to 10 times of the weight of the starch used. The dextrine is used for forming a porous structure by eluting from the granule in the process of manufacture, thereby to look more like natural cooked rice when water is added. Therefore, the dextrine is not absolutely required, but without using, it does not affect the quality of the artificial rice material of the invention itself.

The gelling agent is not particularly limited, too, and any material used in food processing field may be used. Both gelling agents to gel by bivalent cation and to gel by heating are included, and they may be used either alone or in combination.

1929/2197

The gelling agent to gel by bivalent cation includes, for example, pectic acid, pectic alkaline salt, carrageenan, alginic acid, alginic alkaline metal salt, low methoxy pectic acid, and its alkaline salt. The gelling agent to gel by heating includes, for example, gelatin, albumen, konjak refined powder, konjak mannan, caseine, gellan gum, gum arabic, gum guaiac, locust bean gum, and agar. In the invention, as the gelling agent, it is particularly preferred to use konjak refined powder or konjak mannan and other gelling agent in combination, and at this time the content of konjak refined powder or konjak mannan is preferred to be 50% by weight or more of the total gelling agent.

In the case of the combination of konjak mannan and other gelling agent such as locust bean gum, locust bean gum is contained at 0.5 to 6% by weight at solid (dry state), and in the cooked rice state

(swelling state with water), 0.1 to 1.2% by weight.

Furthermore, the gelling agent comprising the combination of one gelling by heating such as konjak mannan with an alkaline matter is preferably used. The alkaline matter used herein includes, for example, calcium hydroxide, sodium carbonate, potassium carbonate, sodium hydrogencarbonate, monosodium phosphate, disodium phosphate, and eggshell calcium, and the content of such alkaline matter may be selected in a range of 0.01 to 0.5% by weight. In combination of preferred konjak mannan and alkaline matter, the content may be selected in a range of about 1 to 7% by weight of total food material weight, or preferably about 0.3 to 3% by weight.

The gelling agent may be used in a range of 0.003 to 7 times, preferably about 0.01 to 3 times of the starch weight. When the particularly preferred konjak mannan is used, it may be 0.003 to 7 times, preferably about 0.1 to 3 times of the starch weight.

When using the gelling agent to gel by bivalent cation, the rice-like food obtained in the invention further contains bivalent metal ions. As the bivalent metal ions, those capable of forming a gel together with the gelling agent and free from causing problem in food sanitation may be used, and ions such as calcium, magnesium or the like are preferred from the viewpoint of taste. As a compound containing bivalent metal ions include, for example, at least one of water soluble bivalent metal salt, such as calcium chloride, calcium lactate, baked eggshell calcium, baked oyster shell calcium, and other calcium salts; and magnesium chloride, magnesium lactate, can be used. The content of the bivalent metal ions may be usually in a range of 1 times or less, preferably 0.006 times to 0.5 times, as bivalent metal salt, of the starch weight.

The white turbid matter is added for the purpose of obtaining the white turbid appearance of rice and as food fiber, and in particular the fine powder ground by physical or chemical process is preferred, and preferable examples include, among others, cellulose powder passing about 60 mesh screen with average polymerization degree of 100 to 300, and cellulose powder with polymerization degree of 100 or less (Japanese Unexamined Patent Publication Nos. 212231/1982, 219333/1984, 211342/1986,

138538/1987, 240302/1987, 1152130/1991, 163135/1991, Japanese Patent Publication Nos.

19921/1985, 30220/1987, 44763/1988, 2012494/1992, etc.). The preferred cellulose powder has a particle diameter of 6 .mu.m or less, more preferably 6 to 0.3 .mu.m. As a result, the cellulose powder brings about not only the effect of giving the white turbid appearance and the effect of adding food fiber, but also the effects of improving the water-retaining property of the food material of the invention to avoid separation of water from the grains when water is added, thereby realizing the properties of cooked rice such as biting reaction and tooth feeling of cooked rice. The white turbid matter contains, aside from or together with the cellulose, bone powder, silk, talc, kaolin, eggshell powder, oyster shell powder, calcium carbonate and the like.

The other white turbid matter except for cellulose is contained in a range from 0.5 to 20% by weight at a solid rate, and in the cooked rice state(swelling state with water) in a range from 0.1 to 4% by weight.

In combination with the cellulose, the other white turbid matter may be contained at 30% by weight or less at a solid rate in the total amount of mixture with the cellulose. If the total amount exceeds 30% by weight, eating sensation is lowered.

The other white turbid matter had preferably a particle diameter of 10 .mu.m or less.

The content of the white turbid matter is 0.03 to 20 times, preferably about 0.06 to 5 times of the starch weight. However, when processed starch is used as the starch, konjak refined powder or konjak

1930/2197

mannan as gelling agent, and when cellulose powder is used as white turbid matter, the cellulose powder must be added by more than 1.0 times, preferably more than about 1.5 times of the weight of konjak refined powder or konjak mannan, and if the ratio by weight is less than specified, these specific properties, that is, the appearance of cooked rice, eating sensation, and texture can be hardly given.

The food material of the invention may contain, aside from the ingredients described above, other various edible substances hitherto used in food properly if necessary as far as not adversely affecting the appearance, eating sensation and taste. Such substances may include vitamins, minerals, perfume, thickener, coloring matter, flavor, food fiber, and the like, and moreover various proteins, peptides, oils and fats, and seasonings (sugar, salt, soy sauce, and the like.) widely used as edible materials, which may be blended properly as required.

The manufacturing method of food material of the invention is described below.

First, specified amounts of the ingredients (except for bivalent metal salt) and a specified amount of water are mixed, agitated and kneaded to prepare a semisolid stock in the composition of 1 to 30% by weight of starch, 20% by weight or less of dextrine, 0.1 to 7% by weight of gelling agent, 1 to 20% by weight of white turbid matter, and 40 to 97% by weight of water. The operation of mixing, agitation and kneading may be executed according to the conventional methods by using proper rotary kiln, mixer and other kneading means. To raise the viscosity of the stock thus obtained, if necessary, a part of bivalent metal salt may be added, or the material may be properly heated. The viscosity of the obtained stock may be properly determined in consideration of the work in the subsequent extrusion process, and may be preferably in a range of about 10,000 to 100,000 cps. That is, it is adequate to possess the fluidity so as to be formed by the extruder, and the stiffness to retain the form after forming.

Thus obtained stock is charged into a proper extruder, and extruded at a proper speed, and is cut near the die discharge port to obtain pellets. In this case, any ordinary extruder may be used. The ordinary extruder is very convenient because the stock can be prepared in one process in the extruder.

In the invention, by particularly selecting the shape of the die and nozzle of the extruder, when water is added to the obtained food material being dry granules, the size and shape may be similar to the grains of cooked rice. For example, the die in the shape as shown in the accompanying drawings may be used preferably.

FIG. 1 is a front view of a die 1 suited to manufacture of the food material conforming to the method of the invention, FIG. 2 is a side sectional view of the die 1, FIG. 3 is a partly magnified view of FIG. 1, and FIG. 4 is a partly magnified view of FIG. 2. The die 1 is furnished with multiple discharge nozzles

2.

The nozzles 2 of the die 1 are preferably in a shape tapered in the middle part 3 as shown in FIG. 4. By such tapering, fracture is formed in the pellet surface when pulse flow is applied in extrusion, and the pellet surface is corrugated in the lateral direction. Besides, by forming the shape of the nozzles 2 in a wavy circle instead of smooth circle (see FIG. 3), the pellet surface may be also corrugated in the longitudinal direction, and thus the appearance resembling the rice grains may be achieved by the pellets. Moreover, by slightly inclining the nozzles 2 in the extrusion direction (see FIG. 2 and FIG. 4), the pellets may be cut in a rhombic cylindrical form, so that the appearance resembling the rice grains may be achieved.

In the method of the invention, the pellets are immersed in water bath, and are gelled after eluting the dextrine in the pellets as required. The elution of dextrine is not limited to the pellet surface, but may extended to the inside of pellets. As a result, a porous portion may be formed in a pellet in the dry state, and when presenting to be eaten by adding water, the surface is more similar to that of rice. The dextrine elution in water bath is desired to be conducted as promptly as possible after cutting the stock.

The elution operation in water bath is preferably performed for about 1 to 60 minutes at water bath temperature of about 0 DEG to 100 DEG C. Instead of water bath, moreover, running water may be used in elution operation.

1931/2197

The gelation operation following the elution should be preferably performed for about 5 to 30 minutes in a bivalent metal ion concentration of about 10 to 1000 mEq/liter, preferably about 300 to 800 mEq/liter. Besides, depending on selection of gelling agent, gelation by heating may be employed, instead of gelation by bivalent metal ions. This is executed by heating higher than the gelling temperature of the gelling agent, and heating may be executed by using proper heating means including warm water, hot water, steam, and hot air. Gelation is intended to achieve the same texture as natural rice when ingesting.

When it is intended to obtain the dry granular material, the obtained gel is presented for drying. The drying method is not particularly limited, and any known method may be employed, such as hot air drying, hot air fluidized drying, and vacuum drying. Drying is effected usually until the water content of the gelled granules may be 30% by weight or less, preferably 25% by weight or less, or more preferably 15% % by weight or less.

The dry granular material thus obtained may be presented to be eaten by adding water, and generally it is presented for ingestion by adding preferably about 8 parts by weight of water to 1 part by weight of the material and boiling for about 20 to 40 minutes, in the same manner as in ordinary rice cooking.

Besides, for example, by adding 10 parts by weight of polished rice and 20 parts by weight of water to

1 part by weight of the dry granular material of the invention, and boiling for 20 to 40 minutes, cooked rice in preferred ingestion state mixing the rice-like food derived from the material of the invention and polished rice at a rate of about 1:2 by weight is presented.

Thus obtained rice-like food possesses an excellent quality not substantially distinguished from natural rice in its appearance and eating sensation. Therefore, it may be used as low calorie artificial rice, instead of natural rice, in the food processing industry, for example as cooked rice effectively in various applications such as ochazuke, onigiri and sushi which are typical Japanese foods. Of course, as mentioned above, in combination with natural rice, it may be used in many applications.

The retort cooked rice in the invention may be prepared by adding and blending a proper amount of adequate granular gel such as rice-like food material obtained above to the rice, adding a proper volume of water, putting the blend into a proper container, and processing in retort.

As the rice, generally, steamed rice, which is obtained by boiling thenatural uncooked rice by stream, is preferable, but it is not limitative, and an ordinary alpha-rice such as cooked rice may be used, or their state before heating and cooking, which is mixture of natural uncooked rice and water, may be used. In the case of mixture of uncooked rice and water, the ratio may be similar to that of ordinary rice cooking, and usually the ratio of about 1:1 (by weight) is preferable. The rice may also include processed rice and rice-like materials.

The adding and blending rate of the granular gel such as rice-like food material of the invention in the rice may be arbitrary determined and is not particularly defined, but generally it may be about at least

10% by weight, and by this addition and blending, stickiness of the rice material may be effectively prevented. This stickiness preventive effect is greater when the content of the granular gel is higher, but if too much is added, the texture becomes likely loose as compared with the natural cooked rice, and there is a strange feel from the cooked rice. Usually, the adding amount of the granular gel is in a range of 10 to 80% by weight, or preferably 20 to 60% by weight.

In succession, by putting the blend of the granular gel and the rice into ordinary appropriate container that can be sterilized by heating, such as can, heat-resistant plastic container, and retort pouch, and processing by retort sterilization or heating sterilization according to the known method, a desired product may be obtained.

As the container, as far as it can be heated and sterilized, there is no limitation in the material and shape, and ordinary metal (including foil), glass, plastics, and their laminates may be used. The shape may be ordinary circular, square, bag or the like.

The retort processing and heating processing may be done in the same condition as employed in the food processing industry. For example, in a temperature range of 105 DEG to 130 DEG C., processing

1932/2197

may be done for about 10 to 60 minutes in the condition of ordinary pressure or pressurized state. At this time, saturated steam, high pressure hot water, steam or other vapor may be used as heat medium.

Thus obtained product possesses the long-term preserve property intrinsic to the retort food, and the granular gel added and blended to the rice is not substantially distinguished from the natural rice in appearance and eating sensation, and the granular gel magnificently prevents stickiness of the rice, and possesses an excellent quality as cooked rice, and by the addition and blending of the granular gel, moreover, cellulose may be supplemented, and the calorific value is low. Therefore, the retort rice of the invention, same as mentioned above, is effectively utilized in the food processing industry, for example, as cooked rice in various applications.

EXAMPLES

The invention is further described below by referring to some of examples, but the invention is not limited to them alone.

Example 1

The specified amounts of the following ingredients were homogeneously mixed in a mixer (model

20DMW manufactured by Sanei Seisakusho).

>;tb;______________________________________

>;tb;(Ingredients) (Parts by weight)

>;tb;______________________________________

>;tb;Starch 22

>;tb;Cellulose (mean diameter of 1.7 .mu.m)

>;tb; 2

>;tb;Pectin 2

>;tb;Dextrine 20

>;tb;Water 54

>;tb;______________________________________

The homogeneously blended paste was extruded into a cylindrical form by using a screw extruder

(model PX30 manufactured by FMI) having a hole of 3 to 4 mm in diameter at the outlet, and the extruded paste was cut into length of about 6 to 20 mm to obtain pellets.

The obtained pellets (mean diameter 3 mm.times.length 5 mm) were kept in the water for about 30 minutes, and then calcium chloride was charged in the water to obtain a 2% mixed solution, and the solution was left stand for about 20 to 40 minutes to allow to gel. Pellets were taken out of water, and white granular gel was obtained. The obtained get was dried for 60 minutes at 105 DEG C. in a belt type hot air dryer, and the granular food material (mean diameter 1 mm.times.length 4 mm) of the invention with water content of about 10% by weight was obtained.

To 1 part by weight of the obtained food material sample, water was added by 8 parts by weight, and it was mixed with natural cooked rice at specific rates to prepare specimens, and its strangeness felt by ten panelists was compared with the control of 100% cooked rice. The specimens were presented to the panelists in the ascending order of the content of the material of the invention.

The obtained results are shown in Table 1.

>;tb; TABLE 1

>;tb;______________________________________

>;tb; Different from

>;tb;Food Material

>;tb; Cooked rice control (Number

>;tb;(content) (content) of panelists)

>;tb;by weight % by weight Not feel Feel

>;tb;______________________________________

>;tb;20 80 10 0

>;tb;40 60 8 2

>;tb;60 40 6 4

1933/2197

>;tb;80 20 3 7

>;tb;100 0 2 8

>;tb;______________________________________

As known from the above result, when the material obtained in this example to which water was added, was added simply to cooked rice, the majority of the panelists did not feel strange, even if the majority of the content was not natural rice. Accordingly, it was known that the food material of this example presents a rice-like food having the eating sensation very similar to that of cooked rice.

In this test, cooked rice was used as the control, but without using the control, the food material to which water was added, was blended with ordinary rice at various rates, and was presented to panelists in actual meals to evaluate the strangeness in eating. The meal was presented in the same manner above, and ten panelists tasted.

The results are shown in Table 2.

>;tb; TABLE 2

>;tb;______________________________________

>;tb; Different from

>;tb;Food Material

>;tb; Cooked rice control (Number

>;tb;(content) (content) of panelists)

>;tb;by weight % by weight Not feel Feel

>;tb;______________________________________

>;tb;20 80 10 0

>;tb;40 60 10 0

>;tb;60 40 8 2

>;tb;80 20 6 4

>;tb;100 0 4 6

>;tb;______________________________________

As shown in Table 2, when the mixture of sample and rice was presented as cooked rice in the course of an ordinary meal, the number of panelists feeling strange further decreased from the results in Table

1. It proves the food material of the invention presents a rice-like food possessing an eating sensation similar to cooked rice practically. Therefore, when cooked together with other material in soy sauce, or taken together with vegetables, fried food or the like, it is expected that an excellent quality not distinguished from the natural rice may be presented.

Example 2

The following ingredients were homogeneously mixed in a mixer.

>;tb;______________________________________


>;tb;______________________________________

>;tb;Starch 5


>;tb; 5

>;tb;Konjak refined powder 2

>;tb;Dextrine 5

>;tb;Water 82.5

>;tb;Calcium hydroxide 0.5

>;tb;______________________________________

The homogeneously blended paste was extruded cylindrically by a screw extruder (model PX30 manufactured by FMI) having a hole of 3 mm in diameter at the outlet, and the extruded paste was cut in length of about 5 mm to obtain pellets.

The obtained pellets (mean diameter 3 mm.times.length 5 mm) were put in water for about 30 minutes, and water temperature was then raised to 90 DEG to 100 DEG C., and the pellets were gelled. Taking out of water, white granular gel was obtained.

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The obtained gel was dried for 60 minutes at 105 DEG C. in a belt type hot air dryer, and granular food material (mean diameter 1 mm.times.length 4 mm) having water content of 10% by weight, was obtained.

It was presented for the panel test conforming to Example 1, and the same results as in the food material of the invention in Example 1 were obtained.

Example 3

As the processed starch, a commercially available product of processed starch derived from waxy cornstarch having Brabender peak viscosity of 600 was used together with the following ingredients, and the food material of the invention was prepared in the procedure below.

>;tb;______________________________________


>;tb;______________________________________

>;tb;Processed starch 180

>;tb;Cellulose powder (mean diameter of 5.5 .mu.m)

>;tb; 40

>;tb;Konjak mannan 20

>;tb;Locust bean gum 15

>;tb;Dextrine 20

>;tb;Water 1210

>;tb;0.6% Calcium hydroxide solution

>;tb; 100

>;tb;______________________________________

To 450 pats by weight of water, 20 parts by weight of dextrine, 60 parts by weight of processed starch, and 15 parts by weight of locust bean gum were added, and mixed for 10 minutes by homogenizing mixer at 10,000 rpm to disperse the ingredients in water, and a dispersion liquid obtained by dispersing

125 parts by weight of processed starch and 20 parts by weight of konjak mannan in 400 parts by weight of chilled water was added to the dispersion liquid obtained above, and mixed and dispersed.

After mixing and dispersing, a mixture of 40 parts by weight of cellulose powder and 260 parts by weight of water was added and mixed to the obtained dispersion liquid. The mixture thus obtained was allowed to swell for 60 minutes at room temperature, and 100 parts by weight of 0.6% calcium hydroxide was added and mixed to gel.

Thus obtained homogeneous paste mixture was extruded from a perforated plate, and cut in length of about 5 mm, and the cut pellets were granulated to obtain granules of about 3 mm in diameter and about 5 mm in length. By heating for 30 minutes at 85 DEG C., washing in water, draining, and drying in a same manner as in Example 1, the food material having water content of 10% by weight was obtained.

By the panel test conforming to Example 1, it was evaluated to present rice-like food possessing an excellent eating sensation without feeling any strangeness from the natural cooked rice, similar to the food material obtained in Example 1.

The color was compared between the food material thus obtained and the natural cooked rice. As the natural cooked rice for the control, 150 g of Koshihikari brand rice was cooked in 210 g of water, and mixed well right after cooking and ground to paste by mill. The food material was similarly ground to paste by mill, and presented for color measurement.

The samples were measured by color difference meter (model SAZ-Omega 90 manufactured by

Nippon Denshoku Kogyo K. K.).

Obtained results are shown in Table 3.

>;tb; TABLE 3

>;tb;______________________________________

1935/2197

>;tb;Color Food material

>;tb; Natural cooked rice

>;tb;______________________________________

>;tb;Y 49.03 54.24

>;tb;X 47.61 52.29

>;tb;Z 56.85 55.87

>;tb;L 70.02 73.64

>;tb;a -1.19 -2.17

>;tb;b 0.94 6.63

>;tb;dL -27.46 -23.83

>;tb;da -1.00 -1.92

>;tb;db 1.11 6.80

>;tb;dE (H) 27.50 24.86

>;tb;L* 75.46 78.60

>;tb;a* -1.28 -2.30

>;tb;b* 1.02 7.32

>;tb;dL* -22.57 -19.44

>;tb;da* -1.09 -2.12

>;tb;db* 1.18 7.48

>;tb;dE (ab) 22.63 20.94

>;tb;______________________________________

Furthermore, in the obtained food material and the natural cooked rice (rice after cooking), properties

(viscoelasticity, cutting force) were measured by rheometer in the following conditions.

Instrument: Rheometer manufactured by Fudo Kogyo K. K

>;tb;______________________________________

>;tb;Conditions:

>;tb;______________________________________

>;tb;Meter sensitivity 200 mK

>;tb;Sample table speed 20 mm/min

>;tb;Recorder speed 30 mm/min

>;tb;Adapter Piano wire

>;tb; (for cutting stress)

>;tb;______________________________________

As a result, the cutting force of the food material and the natural cooked rice was both 25 mK, and the charts were hardly distinguishable.

Example 4

The following ingredients were homogeneously mixed by a mixer (model 20DMW of Sanei

Seisakusho).

>;tb;______________________________________


>;tb;______________________________________

>;tb;Glutinuou rice powder 22


>;tb; 10

>;tb;Curdlan 8

>;tb;Dextrine 2

>;tb;Water 58

>;tb;______________________________________

The homogeneously blended paste was extruded cylindrically by a screw extruder (model PX30 manufactured by FMI) having a hole of 3 to 4 mm in diameter at the outlet, and the extruded paste was cut in length of about 6 to 10 mm, and pellets were obtained.

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Obtained pellets (mean diameter 3 mm.times.length 5 mm) were put in water for about 30 minutes at

80 DEG to 95 DEG C. to gel. Pellets were taken out of water, and white granular gel was obtained. The obtained gel was dried for 60 minutes at 105 DEG C. by using belt type hot air dryer, and a granular food material (mean diameter 1 mm.times.length 4 mm) with water content of about 10% by weight was obtained.

Examples 5 and 6

Food materials were manufactured in the same manner as in Example 3, except that commercially available processed starch derived from tapioca starch with Brabender peak viscosity of 700, and commercially available processed starch derived from corn starch with Brabender peak viscosity of 800 were used as processed starch.

By the panel test conforming to Example 1, it was evaluated that the obtained materials to presents a rice-like food possessing an excellent eating sensation without feeling any strangeness from the natural cooked rice, similar to the food material obtained in Example 1.

Examples 7 and 8

Food materials were manufactured in the same manner as in Example 3, except that the content of the cellulose powder was changed from 40 parts by weight to 30 parts by weight and 60 parts by weight, respectively.

By the panel test conforming to Example 1, the obtained materials were evaluated to present rice-like food possessing an excellent eating sensation without feeling any strangeness from the natural cooked rice, same as the food material obtained in Example 1. By their comparison, the white turbidity was slightly insufficient in the powder cellulose content of 30 parts by weight as compared with the material of 60 parts by weight, and it was apparently distinguished from the natural rice.

Example 9 (Preparation of retort rice)

An aluminum pouch was filled with 40 parts by weight of non-dry white granular gel obtained in

Example 1 and 60 parts by weight of steamed rice, sealed, and heated under pressure for 20 minutes at

120 DEG C. to sterilize (retort processing), and a retort rice product was prepared.

It was heated and cooked in a microwave oven, and the content taken out by opening the aluminum pouch was free from stickiness due to adhesion of rice grains, and presented the same appearance as cooked rice, even after cooked, and the result of eating test was not distinguished from the cooked rice.

On the contrary, the comparative retort rice similarly prepared by filling the cooked rice in an aluminum pouch, was after heating and cooking similarly, very sticky like jelly due to mutual adhesion of rice grains.

Examples 10 and 11 (Preparation of rices)

A bag made of a laminate of aluminum foil and heat resistant thermoplastic film was packed with 20 parts by weight of the non-dry white granular gels obtained in Examples 2 and 3 and 80 parts by weight of steamed rice, and, after heat-sealing its opening, was heated under pressure for 20 minutes at 120

DEG C. to be sterilized (retort processing), and a retort rice product was obtained.

It was heated and cooked in a microwave oven, and the content taken out by opening the bag was free from stickiness due to adhesion of rice grains, and presented the same appearance as cooked rice, even after cooked, and the result of eating test was not distinguished from the cooked rice.

On the contrary, the retort rice similarly prepared by filling the steamed rice in a same bag was, after heating and cooking similarly, sticky due to mutual adhesion of rice grains.

Example 12 (Preparation of retort rices)

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In the same as in Example 10, a tin-plate can of No. 5 type was filled with 20 parts by weight of the non-dry white granular gel and 80 parts by weight of steamed rice, and was enclosed by evacuating, and sterilized in retort (10 minutes at 125 DEG C.), and a retort rice product was manufactured.

It was heated and cooked in a microwave oven, and the content taken out by opening the can was free from stickiness due to adhesion of rice grains, and presented the same appearance as cooked rice, even after cooked, and the result of eating test was not distinguished from the cooked rice.

Examples 13 to 17 (Preparation of retort rices)

A bag made of a laminate of aluminum foil and heat resistant thermoplastic film was packed with 50 parts by weight of the non-dry white granular gel obtained in Examples 3, 5 to 8 and 50 parts by weight of steamed rice, and, after heat-sealing its opening, was heated under pressure for 20 minutes at 120

DEG C. to be sterilized (retort processing), and a retort rice product was obtained.

It was heated and cooked in a microwave oven, and the content taken out by opening the bag was free from stickiness due to adhesion of rice grains, and presented the same appearance as cooked rice, even after cooked, and the result of eating test was not distinguished from the cooked rice.

On the contrary, the retort rice similarly prepared by filling a same bag with the steamed rice was, after heating and cooking similarly, sticky due to mutual adhesion of rice grains.

Examples 18 to 21 (Preparation of retort rices)

Using the following granular gels instead of the food material obtained in Example 4, they were heated and cooked in a microwave oven in the same manner as in Example 13, and retort rice products were prepared.

Granular gels used in examples

Example 18: Alginic acid gel ball (3 mm in diameter)

Example 19: Jellied ball of curdlan (4 mm in diameter)

Example 20: Konjak jelly granule ("Puti-kon", 4 mm in diameter)

Example 21: Konjak jelly noodle cut piece (2 mm.times.5 mm)

Alginic acid gel ball was obtained by extruding and forming 22 parts by weight of starch, 2 parts by weight of cellulose, 2 parts by weight of sodium alginate, 2 parts by weight of dextrine and 78 parts by weight of water, and charging into 2% calcium chloride solution to gel, Curdlan gel ball was obtained by extruding and forming a mixture of 4 parts by weight of curdlan and 96 parts by weight of water, and charging in the condition of 95 DEG C. to gel. The konjak jelly granule ("Puti-kon" 4 mm in diameter) was a commercially available product used as it was, and konjak jelly noodle cut piece was prepared by cutting the commercially available konjak jelly noodle into specified shape.

The retort rice products obtained by using these granular gels were free from stickiness when the content was taken out by opening the bag and was observed for mutual adhesion of rice grains, and excellent in loosening effect, but a slight contraction of grains was noted due to separation of water from the granular gels.

These disclosures of Japanese Patent Applications Serial No. 198712/1992, filed on Jul. 24, 1992; No.

198720/1992, filed on Jul. 24, 1992; No. 271907/1992, filed on Oct. 9, 1992; No. 348591/1992, filed on Dec. 28, 1992; No. 348597/1992, filed on Dec. 28, 1992; No. 15358/1993, filed on Feb. 2, 1993 is incorporated herein by reference.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. A low calorie food material comprising a granular matter obtained by gelling granular material with an alkali agent, followed by heating, wherein said granular material comprises processed starch having

1938/2197

a peak viscosity of Brabender viscosity of 600 to 800 Bu, 0.003 to 7 times of a gelling agent selected from the group consisting of a refined powder of konjak and konjak mannan, and 0.03 to 20 times of a white turbid matter comprising a cellulose powder, to the processed starch weight.

2. The low calorie food material of claim 1, wherein said white turbid matter comprises a combination of at least one ingredient selected from the group consisting of bone powder, silk, talc, kaolin, and cellulose.

3. A low calorie food material comprising a granular matter obtained by gelling granular material with an alkali agent, followed by heating, wherein said granular material comprises processed starch having a peak viscosity of Brabender viscosity of 600 to 800 Bu, 0.003 to 7 times of a gelling agent comprising a locust bean gum and a refined powder of konjak or konjak mannan, and 0.03 to 20 times of a white turbid matter comprising a cellulose powder, to the processed starch weight.

4. A low calorie food material comprising a granular matter obtained by gelling granular material, followed by heating, wherein said granular material comprises a processed starch, 0.003 to 7 times of a gelling agent comprising curdlan, and 0.03 to 20 times of a white turbid matter comprising cellulose powder, to the processed starch weight.

5. A low calorie food material, similar to rice, comprising 1 to 30% by weight of processed starch having a peak viscosity of Brabender viscosity of 600 to 800 Bu, 1 to 7% by weight of konjak mannan,

0.001 to 0.5% by weight of an alkali matter, 1 to 20% by weight of cellulose powder, and 40 to 97% by weight of water.

6. A method of producing a lower calorie food material, comprising the steps of: extruding and cutting a semi-solid matter comprising processed starch having a peak viscosity of Brabender viscosity of 600 to 800 Bu, 1 to 7% by weight of konjak mannan, 0.01 to 0.5% by weight of an alkali agent, 1 to 20% by weight of cellulose powder, and 40 to 97% by weight of water to obtain a granular matter; and gelling said granular matter to obtain a granular gel.

7. A low calorie retort cooked rice comprising a blend of a granular gel obtained according to the method of claim 6, and rice, wherein said blend is placed into a heatable-sterilizable container and subjected to heat sterilization or retort treatment.

8. The retort cooked rice according to claim 7, wherein said granular gel possesses a grain size similar to the size of a rice grain.

9. A low caloric retort cooked rice comprising a granular gel formed by using a gelling agent, and rice, wherein the blend of the granular gel and the rice is filled into a heatable-sterilizable container, followed by heating, sterilization, or retort treatment, wherein said granular gel is the low caloric food material of claim 1.

10. The low calorie retort cooked rice of claim 9, wherein the granular gel is the low calorie food material of claim 6.

11. The retort cooked rice of claim 9, wherein the granular gel possesses a grain size nearly equal to a rice grain.Data supplied from the esp@cenet database - Worldwide

1939/2197

400.

US5391388 - 2/21/1995

CEREAL FOOD PRODUCT FOR HOT AND COLD USAGES


Inventor(s): LEWIS VICTOR M (AU); LEWIS DAVID A (AU)

Applicant(s): BYRON AGRICULTURAL CO (AU)


IP Class: A23L1/10; A23L1/168

E Class: A23L1/168


Priority Number: AU1989PJ03510 (19890405)

Family: CA2013707


Abstract:


The invention concerns a cereal food product comprising a "waxy" cereal chosen from barley, corn, rice or sorghum or from other starchy seed or tissue material wherein less than about 10% of the starch present is amylose, and preferably the starch contains substantially no amylose. Preferably the cereal is waxy barley. The major part of the starch present is also in its ungelatinized form. A process for preparing the food cereal is also described. The cereal food product is preferably a quick cooking hot porridge-like breakfast food.Description:



The present invention concerns a convenient and nutritious food product, prepared from cereals and other starchy seeds or tissues, having predominant use as a hot breakfast cereal as well as other uses.

1940/2197

The base for the food is chosen from any one or more of barley, corn, rice, or sorghum, or other starchy seeds, or food raw materials of a suitable starchy composition.

Starch can be of two types; amylose, and amylopectin. Amylose is a straight chain glucose polymer having .alpha. 1,4 linkages. Amylopectin is a branched chain glucose polymer with 1,6 linkages at the branching points. In general, grains will contain both types of starch. Amylose is generally in the minor proportion in grains. However, with certain grains, such as barley, corn, rice, or sorghum there exist certain varieties which contain substantially no amylose or only a very small amount. It is conceivable that plant breeding technique can produce other starch-containing crops having this character.

It has now been found that food products as described herein made from raw materials which contain little or no amylose have unexpected and surprisingly useful advantages over other previously prepared food products of this general type. These low-amylose or amylose-free cereals are known as "waxy" cereals.

Alderman (U.S. Pat. No. 2,526,792) describes the use of waxy grains in flour, grits or wholegrain form or the use of starch derived from these to manufacture crispy ready-to-eat breakfast cereals by a factory process which involved total gelatinisation and a final oven puffing, producing a crispy browned cereal which was reasonably impervious to milk or cream when eaten, thus remaining crispy. Clausi et al

(U.S. Pat. No. 2,954,296) used a proportion (5-30%) of pre-gelatinised, optionally waxy-type starchy material to form into pellets with other ingredients, the pellets being gun-puffed to produce lowdensity, crispy breakfast cereal or snack foods which more faithfully resemble the defined shape of the dough piece. Goering et al (U.S. Pat. No. 4,311,714 & other patents) describe methods for producing from waxy barley grain high maltose syrups, protein, gums etc, using an integrated plant.

Barley is not known to have been reported or used for the manufacture of hot breakfast products of the porridge type. The previous use of barley as a food grain has been limited, and has mostly been used in soups as pearled barley, in beverages as barley water, as a rice extender, (namely rice mixed with pearled barley) in bakery products such as flour, kibbled or whole grain, and in the manufacture of malt for beer and spirits. Barley has also been widely used in the form of malt extract as a flavourant.

In the present specification, the invention is discussed in relation to barley, but the invention is not limited in any way to barley, and also has relevance to corn, rice or sorghum and other starchy seeds or food raw materials which have or may have this characteristic.


In its broadest form the present invention concerns a food product comprising of cereal chosen from barley, corn, rice or sorghum or from other starchy seed or tissue material wherein less than about 10% of the total starch present is amylose, and preferably the starch contains substantially no amylose. The major part of the starch present is in its ungelatinised form. A process for preparing the food cereal also forms part of the invention. The cereal food product is preferably a quick cooking hot porridge-like breakfast food.


The accompanying drawing illustrates the advantages of the present invention.

FIG. 1 is a graph (an "amylograph") of three different varieties of flaked cereals comparing relative viscosity of each variety with time.


The food product in its preferred form is a porridge for human consumption. In a most preferred form the food product is a porridge breakfast cereal made from barley containing substantially no amylose.

Barley varieties which have an unusual starch makeup such that all or almost all of the starch present is of the amylopectin type have been developed in some plant breeding programs, but the use of this type of grain is not known to be on a commercial scale. In general, commercial barley varieties may

1941/2197

contain 20% to 30% by weight of amylose. The uses of the new types of "waxy" grains which have been envisaged by the plant breeders include the production of amylopectin starch, production of syrups by the hydrolysis of the starch in a manner analogous to their production from corn, and in animal feeds, where it is claimed to enable more complete digestion and energy utilisation. An example of a barley variety of the type which contains essentially all amylopectin and little or no amylose is:

Waxy Barley e.g. Waxiro (C.S.I.R.O., Australia)

Similarly, special varieties of rice, corn, and sorghum exist which also contain substantially no amylose. To our knowledge, there has been no use, or understanding that the non-amylose cereal varieties have any advantages or special uses in cereal food products of the type described in the present invention. Some examples are: Waxy Corn, e.g. "84A" (Australia, Dekalb Shand Seed Co.),

Waxy Rice, (Many types available in Asian countries), Waxy Sorghum, e.g. "TX-615" (U.S.A.).

The use of these "waxy" grains to prepare the above food products has not been previously described.

The food product may be manufactured in the usual manner for manufacturing this type of cereal food product. The cereal may be plasticised as by heat (e.g. steam), flaked or otherwise shaped appropriately and if necessary dried by means commonly known in the art, or by any other suitable sequence of processing steps.

The grains may be heated to soften and plasticise the grains which can then be rolled to produce flakes without breaking. The heating also has the added effect of inactivating enzymes in the grain, and killing insect eggs, for example, which improved storage life. The heating is preferable carried out by means of live steam. The steam only needs to be applied for a relatively short time, for example, from about 5-20 minutes and preferably from about 7-12 minutes at atmospheric pressure. Of course, shorter times can be employed if the steam is superheated and/or at above atmospheric pressure. Other conventional methods of heating such as microwave and oven heating can be employed. The conditions employed in microwave or oven heating should be effective to provide the same degree of plasticizing as achieved by the preferred steam treatment. The cereal grains can be pre-moistened to increase their moisture content. However, steaming does not gelatinise the grains to a large extent. After rolling, the flakes produced are normally dried, sufficiently to produce cereal flakes for packing. Alternatively, instead of whole flakes, granules or flakes in subdivided form may be produced from the treated grain.

The starch present is not gelatinised to a significant extent, so that the major part of the starch is essentially ungelatinised. Preferably less than 30% is gelatinised, and more preferably less than 10% is gelatinised. Ideally, the starch present is substantially not gelatinised.

The novel food product of the present invention provides a very attractive, convenient and good tasting hot breakfast cereal as well as certain novel non-crispy cold breakfast cereal foods. Also, other related food products such as muesli (granola) bars, confectionery, and so on can also be prepared which take advantage of the present invention are superior in many respect to the prior art products; they are significantly more economical to produce and have superior properties as well.

The food product of the present invention when cooked or prepared for consumption is significantly

"lighter" in mouth feel and texture on the plate. The product of the present invention is also less sticky of porridgey as compared to comparable products of the prior art made from oats or from non-waxy cereals. This lightness is a physical characteristic such that on an equal-solids preparation basis, the waxy barley is less porridgey or sticky. In addition, the described lightness is consistent with the modern expectation of light foods as being lower in calorie intensity. In particular, the barley product of the invention has a lower calorie intensity because barley is lower in calories than oats as it has a much lower fat content than oats.

A further surprising and unexpected feature of the present invention is that the waxy barley flakes in hot breakfast foods when fully cooked in a comparable way to oat flakes, tend to remain more integral, even though they are extremely tender and easy to consume. The integral character of waxy barley flakes is believed to be derived from the face that since there is little or no amylose present, there is a continuity of amylopectin starch, which gelatinises very readily and in a continuous and unbroken manner in each flake. By contrast, oat flakes, or flakes prepared from regular barely (feed or malting barley) consist of a network of amylose and amylopectin. In comparing these flakes a difference shows vividly in that where amylose is present, the flakes before cooking have a more chalky texture and are

1942/2197

more friable and fragile. When dry flakes are tasted, those containing amylose melt on the tongue readily to a raw tasting starchy paste, while flakes prepared from waxy barley or other waxy grains, even though of a very fine caliper, do not melt away on the palate nor do they give a raw starchy flavour. As a consequence of the greater dispersibility of starch from oat flakes or regular (non-waxy) barley flakes, the porridge becomes very sticky and has a marked tendency to stick to the bottom of the cooking vessel and to scorch or burn on to the vessel unless the food is well stirred during cooking. In other words, more of the starch stays within the flakes derived from waxy barley, or other waxy grains, whereas with oats or regular grains, more of the starch disperses into the cooking liquid, creating the problems discussed above.

In addition, it has been surprisingly found that the fully cooked cereal prepared from waxy barley develops a more fully cooked flavour more quickly than oats or regular barley hot cooked cereal. This is believed to be due to the presence in the cooked non-waxy product of harder-to-cook amylose, since starch of this type is usually considered much more difficult to gelatinise and is also slower to gelatinise, than amylopectin. The presence of the relatively less-cooked amylose is evidenced by the more opaque appearance of the cooked hot cereal. The presence of persisting starch granules is shown by microscopic examination.

This is especially important with respect to the production of quick cooking hot cereals. It is clear from our observations that a hot cereal prepared from a waxy grain assumes a cooked flavour and texture after having been heated to a temperature of 70 DEG -80 DEG C. with milk or water. By contrast nonwaxy hot cereals require a greater degree of heating--bringing to the boil, then simmering for 5 minutes or more--in order to result in a food with a cooked taste and well thickened texture. In order to achieve quick cooking character in non-waxy-grain-based products it is necessary to increase the degree of precooking and pre-gelatinisation of the flaked cereal at the factory which adds considerably to the cost.

Accordingly, a quick-cooking hot cereal can be manufactured more economically from waxy grains than from non-waxy grains.

It is apparent that under the influence of live potable steam, which may be used to condition and heat grains prior to flaking, the waxy grain becomes markedly more plasticised than non-waxy grain. As a consequence of this, the waxy grain can be flaked between smooth flaking rolls to a very fine caliper without the tendency for the grain to shatter. This is even though the grain has not undergone any substantial degree of gelatinisation (see Example 2). By contrast the non-waxy grains have a lesser degree of plasticity under parallel conditions and as a consequence cannot be rolled to flakes of such fine caliper without shattering or becoming powdery and sintered.

It is a further feature and advantage of the present invention that waxy-grain-based hot cereal products are more easily and completely digested, because all the starch becomes well gelatinised during cooking by the consumer. In hot cereal products made from grains containing amylose, the amylose being harder to cook or less gelatinised, is to some degree less digestible than fully gelatinised starch.

Clearly, since the amylose content is in the order of 25% of the total starch content in most normal types of grains, then this factor is a relevant one.

The present invention has an unexpected economic advantage, in that cereals prepared from waxy barley of the hulled type, give a yield of 80 to 85% of flakes from raw grain. This is in marked contrast to oats, which gives a yield of flakes of 57% ("Technology Of Cereals", N. L. Kent, Pergamon Press

1966, Page 220 also "Oats: Chemistry And Technology", F. H. Webster Ed., American Association Of

Cereal Chemists Inc. 1986, Page 407). Since the farm price in many areas (such as Australia) of oats and barley tends to be similar, it is clearly a considerable economic advantage to utilise barley in the manner described. In addition, the processing of barley according to the preferred methods of the invention, is much more economical and requires less unit operations, machinery and energy inputs.

Even greater cost advantages can be achieved by using waxy barley varieties of the naked or hull-less type, from which the yield of food grain suitable for processing is even higher. In this case, the harvested grain is substantially free of any hull material.

A further advantage of waxy barley cereal as compared to oat flakes is that because of the high fat content of oats (7-10%) compared to barley (1-2%) there is a much greater tendency for oat flakes to develop rancidity in storage. Rancidity has always been a problem associated with storage life of packaged oat flakes. This same advantage also applies to other waxy grain varieties.

1943/2197

In addition, because the waxy barley cereal has a less raw or less uncooked flavour than oats, barley cereal in an appropriate processed form may be used as a ready-to-eat non-crispy cold breakfast cereal of a porridge-like consistency without the need to cook the product or to use hot water or milk in its preparation.

The substantial advantages described above in reference to waxy barley as the cereal, will generally also apply to the use of waxy corn, rice, sorghum and other seeds or food raw materials having low or zero content of amylose.

The invention is now described in reference to examples.

EXAMPLE I

Fully cleaned waxy barley grains (1000 g) were peeled free of hull using an abrasive grain peeling device. The degree of peeling was adjusted so that all the hull was removed but there was minimal removal of any bran. The yield of peeled barley on an equal solids basis was 86% as compared to the unpeeled grain. The moisture content of the peeled grain was 10.0% and was adjusted to 15-16% by addition of about 40 ml of water to the grain as it was tumbled in a mixer. The moisture was completely absorbed and was allowed to temper into the grain for at least 1 hour.

The tempered grain was heated in an insulated steamer in live potable steam for 7 minutes. The moisture content increased by 3.5% to 19.5%. The grains were still quite separate and non-cohesive.

The steaming-hot barley grains were passed between the smooth rolls of a flaking mill, the gap between the rolls being set at gap of 0.1 mm, the two rolls rotating at the same speed. The grain was thereby converted into fine flakes having marked integral character with little or no breakage of the flakes during rolling and with minimal cracking or disintegration of any of the flakes.

The flakes were dried to 12% moisture and still maintained their integral character.

To cook the flakes, one cup of flakes was added to 11/2 cups liquid comprising approximately equal parts milk and hot water, brought to the boil, and then simmered for 1-3 minutes. Even after 1 minute, the flakes of barley were fully cooked and had a pleasing flavour. By stirring the cooked flakes, they could be made to break up easily to form a porridge-like texture.

Alternatively the flakes could be served in a form comprising very soft and tender, substantially integral flakes along with the thickened cooking liquid.

As a further alternative the flakes may be served by placing in a bowl, along with cold milk, then briefly mixing with a spoon before consuming. The flakes have a pleasing mild flavour, with no raw starchy character, and a soft and tender mouth feel.

As a variation to the method described above, unhulled barley may be toasted lightly to induce a slight degree of darkening of the grain, which is then dehulled. This facilitates complete removal of the hull and all its vestiges without undue removal of the bran layer of the grain. It also induces a flavour change which in the finally cooked flakes is perceived as a mild malty sweetness, and a creamy or light brown colour.

As a further variation, flavourings, such as sugar, malt, honey, fruit juices and/or other additives may be added to and absorbed by the product at any suitable stage of the process.

EXAMPLE II

Fully cleaned dehulled oats (groats), malting barley (variety "Clipper") and waxy barley were used in this experiment. The samples of barley were dehulled as described in Example 1. All three grain samples were then processed by pre-dampening, steaming, flaking and drying as described in Example

1. The feed barley and oats produced flakes which were more chalky in appearance, were far more fragile, had a raw starch flavour on the palate and "melted" on the palate readily, when tasted. Waxy

1944/2197

barley flakes were more integral, much less fragile, did not have a raw starchy taste and did not "melt" on the palate when tasted.

Measurements were made as to the degree of gelatinisation of the starch in unprocessed grains, in the flakes produced as described, as well as after the flakes had been cooked in milk by simmering 3 and a half minutes. The method used to measure degree of gelatinisation was from "Gelatinisation and In

Vitro Digestibility of Starch in Baked Products" by Wootton and Choudhry, Journal of Food Research

Vol. 45, p 1783-4 (1980).

>;tb;______________________________________

>;tb;% Gelatinisation of Each Product

>;tb; in in in

>;tb; raw grain

>;tb; uncooked flakes

>;tb; cooked flakes

>;tb;______________________________________

>;tb;Oats 1.40 2.6 9.9

>;tb;Barley 0.2 0.8 9.8

>;tb;Waxy Barley

>;tb; 2.9 4.2 50.6

>;tb;______________________________________

It is apparent that a porridge prepared from waxy barley is significantly more gelatinised or cooked in a give time than with similarly prepared porridge using oats or barley. Because of the greater degree of gelatinisation of the starch in a waxy barley porridge, it can be expected that the food will be more digestible.

EXAMPLE III

Using flakes of the three types of grains prepared as described in Example II, tests were run using a

Brabender Amylograph, in which the materials were subjected to a programmed rate of temperature increase at 1.5 DEG C. per minute with standardised mixing in water, then a holding period, followed by controlled cooling also at 1.5 DEG C. per minute. This type of equipment is widely used in cereal industries and is well known to persons skilled in the art. The viscosity which develops is predominantly a measure of gelatinisation of the starches and is also indicative of the character of the starches being gelatinised. In these tests 4.5% of flaked cereal product was tested in water.

FIG. 1 shows the dramatic contrast in behavior between the whole flakes of the grains tested. The

Time (min.) axis on the graph refers to the time which has elapsed from the moment the cereal flakes are added to warm water in the mixer of the Amylograph. The initial temperature at the time of mixing is noted for each curve at the left of the diagram. The data in FIG. 1 clearly show that waxy grain took

36 minutes to reach the inflection point on the curve. This time, at a 1.5 DEG C. increase in temperature per minute plus the starting temperature of 38 DEG C. is the actual observed temperature.

The flat part of the curve is a holding phase, i.e., a period where the temperature is held steady. This is followed by a cooling period during which, in these examples, the viscosity increased. Table I below illustrates the program followed for each of the tested grains.

>;tb; TABLE I

>;tb;______________________________________

>;tb; Heating Cooled to

>;tb;Comm. Time To Holding

>;tb; 50 DEG C. over

>;tb;______________________________________

>;tb;Waxy 38 DEG C.

>;tb; 36 min.

>;tb; 92 DEG C.

>;tb; 15 min.

>;tb; 28 min.

>;tb;Clipper

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>;tb; 36 DEG C.

>;tb; 40.7 min.

>;tb; 97 DEG C.

>;tb; 15 min.

>;tb; 31.3 min.

>;tb;Oats 33 DEG C.

>;tb; 42.7 min.

>;tb; 97 DEG C.

>;tb; 15 min.

>;tb; 31.7 min.

>;tb;______________________________________

It is clearly apparent from FIG. 1 that waxy barley flakes produce a more viscous paste than barley or oat flakes. It is also apparent that a paste viscosity is developed to a degree equivalent to barley or oats at a lower temperature and in a shorter time by the waxy barley flakes.

When these products were examined microscopically after the amylographs were run, (the preparations were stained with iodine), no intact starch granules were seen in the case of waxy barley.

With oats and barley intact starch granules were visible. It is theorised that under the conditions of these tests, the less gelatinised amylose in the starch granules of barley and oats acts to hold the granule integral and hence to limit the viscosity which can be achieved.

A variety of modifications to the food products and method disclosed in this specification are believed to be apparent to persons skilled in the art. Accordingly, no limitation upon the invention is intended, except as set further in the claims.Data supplied from the esp@cenet database - Worldwide

Claims:


We claim:

1. A processed cereal food product, said product being obtained by treating cereal grains chosen from at least one of barley, corn, rice, sorghum or other starchy grains having an amylose content which is less than about 10% by weight of the total starch content in the grains so as to plasticize the grains, not more than 30% of the total starch content in the grains being gelatinized, and shaping the resultant product.

2. The cereal grain food product of claim 1 wherein said cereal is waxy barley.

3. The cereal food product of claim 1 or 2, wherein said food product is a quick cooking hot porridgelike breakfast food.

4. A process for preparing a waxy grain cereal food product which consists essentially of plasticizing whole waxy grain, without gelatinizing more than 30% of the starch content of said grain, wherein said grain is chosen from waxy barley, waxy corn, waxy rice and waxy sorghum and wherein less than about 10% by weight of the total starch content of said grain is amylose; and then shaping the plasticized material to form integral flakes, granules or flakes in subdivided form, in high yield.

5. A process for preparing a waxy grain cereal food product wherein less than about 10% by weight of the total starch of said waxy grain is amylose which consists essentially of the steps of:

a. optionally lightly toasting and thereafter optionally dehulling whole waxy grain chosen from waxy barley, waxy corn, waxy rice and waxy sorghum;

b. pre-moistening and tempering said waxy grain;

c. plasticizing said tempered waxy grain by steaming such that not more than 30% of the total starch content of said grain is gelatinized;

d. shaping the plasticized grain to produce integral flakes, granules or flakes in subdivided form; and

e. drying said integral flakes, granules or flakes in subdivided form, wherein said process is effective to produce said integral flakes, granules or flakes in subdivided form in high yield.

1946/2197

6. The process of claim 4 wherein said plasticizing is conducted by steaming.

7. The process of claim 4 or 5 wherein said plasticized grains are passed between smooth rolls to produce the integral flakes.

8. The process of claim 4 including the additional step of drying the integral flakes.

9. The process of claim 4 which further includes the steps of pre-moistening and tempering the grains before said steaming.

10. The process of claim 9 wherein the waxy grain is lightly toasted and dehulled before the premoistening and tempering step.

11. The waxy grain cereal food product of the process of either claim 4 or claim 5.

12. The waxy grain cereal food product of the process of claim 4 or 5 wherein said product is a quick cooking hot porridge-like breakfast cereal.

13. The process of claim 4 or 5 wherein said plasticizing is conducted by microwave or oven heating.

14. The cereal food product of claim 1 wherein said waxy cereal grain contains substantially no amylose.

15. The process of claims 4 or 5 wherein said waxy cereal grain contains substantially no amylose.Data supplied from the esp@cenet database - Worldwide

1947/2197

401.

US5403606 - 4/4/1995

PROCESS OF MAKING ENRICHED ARTIFICIAL RICE


Inventor(s): KURACHI HIDEO (JP)

Applicant(s): JAPAN CORN STARCH CO LTD (JP)


IP Class: A21D2/36

E Class: A23L1/168



Family: US5403606

Abstract:


A process of making an enriched artificial rice product comprising by dry weight 50% to 98% of at least one starch or starch derivative, 2% to 45% of at least one enriching material, and 0.1% to 10% of at least one gelling hydrocolloid whereby the enriched artificial rice product can be prepared with the cooking water being at least twice the volume of the rice.Description:


TECHNICAL FIELD

This invention relates to the formation of enriched artificial rice granules.


Artificial rice can be produced using a variety of methods from a variety of starch sources. An artificial rice allows the introduction of additional nutrients and flavorings into the granule that are not present naturally.

U.S. Pat. Nos. 3,620,762 and 3,628,966 provide a method for producing an enriched rice product. The method includes forming an enriched rice starch, heating the mixture so that it is partially gelatinized

(semigelatinized) and taking this viscous product and forming it into granules resembling rice granules and coating each granule with a waterproof coating. This method is cumbersome, and the requirements of the semigelatinizing step and coating step increase the cost of production.

Japanese patent HEI 4-13986, assigned to the assignee of the present invention, discloses a method of forming shaped granules of starch from non-rice sources. The starch is isolated, mixed with water and kneaded and then formed into artificial rice granules using a rolling granulator. The artificial rice granules do not require a coating nor is a semigelatinizing step required. The artificial rice that is formed retains a rice-like texture and consistency upon cooking.

Japanese patent HEI 3-69267, also assigned to the assignee of the present invention, discloses a method of forming a decorated artificial rice in which color is introduced by combining the starch with extracts

1948/2197

from vegetables, fruits, herbs, mushrooms, seafood and seaweed. The patent further discloses that these additives may make an enriched artificial rice by adding nutrients.

Both the HEI 4-13986 and HEI 3-69267 patents prepare the artificial rice so that it can be cooked using the Japanese cooking method of boiling in only 1.5 times the volume of water as rice. However, in the

United States, the Indica strain of rice is preferred. The cooking method for the Indica strain of rice requires that the cooking water be at least twice the volume of the rice, which can be referred to as the

American method. Therefore, any artificial rice introduced into the United States should conform to the cooking method that is most common in order to have consumer acceptance.

An artificial rice which contains 2% or more of vegetable matter and made by the above methods cannot be properly prepared using water at twice the volume of rice. The rice granules turn to a sticky gel and loose their rice-like texture or shape when cooked with the American method.

U.S. Pat. No. 4,129,900 discloses a method of preparing shaped granules of starch which includes water-soluble gelling hydrocolloids. The use disclosed for such granules is in puddings which are retorted or aseptically packaged. The method allows the formation of translucent pearls of gelatinized starch granules, i.e. tapioca-like, upon cooking. However, because of their formation and composition, the granules do not lend themselves to use in non-pudding applications. When cooked using the

American method for rice preparation, the granules have a pasta-like texture. The high shear of the extrusion method used to form the granules destroys the starch micro-particles giving rise to a product with a gummy texture unlike that of native rice.

U.S. Pat. No. 5,211,977 discloses a method of preparing a starch-based mixture that includes a starch source, flavorings including vegetable powders, from 3% to 10% dried weight, an emulsifier and hydrocolloid which is used to form a pasta product. The pasta is formed using a pressure extrusion process. However, this starch-based 10 mixture cannot be used in a rolling granulator. If the granulator is maintained at an elevated temperature, i.e. above 60 DEG C., the starch-based mixture will adhere to the granulator. If the granulator is maintained at a cooler temperature, i.e. below 60 DEG C., the mixture is too hard to form granules.

SUMMARY OF THE INVENTION AND ADVANTAGES

According to the present invention, an enriched artificial rice product is made comprising, by dry weight, 50% to 98% of at least one starch or starch derivative; 2% to 45% of at least one enriching material; and 0.1% to 10% of at least one gelling hydrocolloid. The enriched artificial rice product can be prepared using cooking water that is at least twice the volume of the rice.

The present invention further includes the method of preparing such an enriched artificial rice product including the steps of mixing together 50% to 98% by dry weight of at least one starch or starch derivatives with 2% to 45% by dry weight of at least one enriching material and 0.1% to 10% by dry weight of at least one gelling hydrocolloid to form a mixture. Water is added to the mixture, while the mixture is being kneaded, such that the final water content is 25% to 55%. The mixture is then granulated into rice-like granules using a roll-type granulator. The granules are then steamed for 3 to 30 minutes at a temperature of 70 DEG C. to 105 DEG C. The final step is to dry the granules to a water content of less than 20%. The enriched artificial rice granules formed by this method can be prepared in cooking water that is at least twice the volume of the rice.

The present invention allows the preparation of an artificial rice granule containing vegetable or fruit material. The method allows the introduction of additional nutrients and flavorings into the granule that are not present naturally.


The present invention is an enriched artificial rice product that includes a starch component, enriching matter and a gelling hydrocolloid.

The starch can be isolated from corn, waxy maize, potatoes, tapioca, sago, arrowroot, rice, wheat, and other cereal grains. The starch may be in the form of flours or seminolas of hard wheat, durum wheat,

1949/2197

soft wheat, corn or rice. Further, modified starch products such as esterified, etherified or crosslinked starch can be used. The starch component is 50% to 98%, by dry weight, of the mixture. The starch component can be a mixture of starch or starch derivatives. Preferably the starch content will be 25% or more in order to provide a more rice-like texture.

Vegetable material can be used for enriching the artificial rice product and can be isolated from carrots, spinach, tomatoes, onions and beets. Bell peppers, both red and green, can also be used, as can radishes and celery. Members of the cabbage family and the squash family, such as pumpkin, are also suitable sources of vegetable matter to be used. Additionally, edible seaweeds and fruits such as oranges, pineapples, apples, cherries, berries and the like may be used to enrich the rice.

The enriching material can be freshly minced material or pastes, juices and dried flakes or chips.

Additionally, powdered or freeze-dried enriching material can be used. The mixture will contain from

2% to 45% of at least one of the enriching materials.

The gelling hydrocolloid can be either egg white, curdlan, gellan gum,sodium alginate, sodium pectate, methylcellulose, ethylcellulose, hydroxypropylcellulose, methylhydroxypropylcellulose, methylethylcellulose, carrageenan, furcellaran, agar, gelatin, xanthan gum, locust bean gum, or guar gum. In a preferred embodiment, either egg white (3-7%), curdlan (0.5-3%) or gellan gum (0.1-2%) or a mixture thereof is used.

The amount of hydrocolloids the mixture will contain is from 0.1% to 10% of at least one of the gelling hydrocolloids. If less than 0.1% is used, there is no effect on the texture. If more than 10% is used, the artificial rice granules are too hard.

The present invention also allows the addition of flavorings, fiber, vitamins, carotenoids and proteins to the starch-based mixture. The starch-based mixture can include up to 10% protein. The source of protein can be gluten or protein extracted from soy beans. The preferred source of gluten is either active wheat gluten or corn gluten.

The starch-based mixture can include from 0.1% to 5% of at least one fiber supplement. In a preferred embodiment, microfibrilated cellulose and corn fiber are used. Also, apple fiber, wheat bran or rice bran can be used.

The starch-based mixture can include from 0.01% to 5% of at least one mineral supplement. In a preferred embodiment, calcium carbonate and ferric orthophosphate are used.

The starch-based mixture can include from 0.0001% to 2% of at least one vitamin supplement such as vitamin B1, B2, B6, B12, A, D, E and niacin or at least one carotene, such as .beta.-carotene.

The present invention also allows for the addition of up to 5% of at least one flavoring agent. There are many flavoring agents available in the form of herbs, spices and extracts that could be incorporated depending on the end use of the artificial rice product. Some of the suitable flavoring agents are salt, soya sauce, ginger, sugar, pepper and curry powder.

In the method of preparing the enriched artificial rice product, first a mixture is prepared by mixing together 50% to 98% by dry weight of at least one starch or starch derivative with 2% to 45% by dry weight of at least one vegetable derived material and 0.1% to 10% by dry weight of at least one gelling hydrocolloid. Additional ingredients such as flavorings, fiber, vitamins, carotenoids and proteins, at appropriate concentrations, can also be added at this step as detailed hereinabove.

The next step requires the forming of a dough-like material by adding water to the mixture, up to a water content of 25% to 55%. As the water is being added, the mixture is being kneaded, forming a semigelatinized mixture. The kneading can be done either at 30 DEG-80 DEG C. for 10-60 minutes with a batch type kneader and twin roll compression or at 60 DEG-95 DEG C. for 2-30 minutes with a continuous screw kneader. At this step, the starch is semigelatinized (partially gelatinized, gelatinization ratio is 40-80%).

1950/2197

The kneaded starch-based mixture is then formed into rice-like granules using a roll-type granulator. In the preferred embodiment, a twin-roll granulator is used as described in Japanese patent HEI 4-13986, incorporated herein by reference.

The method then requires steaming the granules for 3 to 30 minutes at a temperature of 70 DEG C. to

105 DEG C., and then drying the granules to a water content of less than 20%.

The above method forms an artificial rice granule in which the starch microgranules are not destroyed, but only partially gelatinized (semigelatinized) thereby retaining the particle structure in the processed product to give, if cooked, the same texture as cooked rice. The texture of cooked native rice differs from pasta in that it is not gummy, softer, but with a brittle feel to the teeth, as best shown in Examples

4 and 5 hereinbelow.

The following examples illustrate the application of the present invention:

EXAMPLE 1

A starch-based mixture containing the following ingredients was prepared according to the present invention:

>;tb;______________________________________

>;tb;65 kg corn starch

>;tb;25 kg hard wheat flour

>;tb; 9 kg dried carrot powder

>;tb; 1 kg guar gum.

>;tb;______________________________________

The starch-based mixture was then kneaded in a kneader with 38 kg of water.

The kneaded starch-based mixture was then formed into a sheet and passed through a twin-roll type granulator. The rollers have hollows shaped as rice granules formed on the surface so that the sheet is granulated as it passes through. During the granulation, the surface temperature is kept at or below 30

DEG C. by passing of cooling water through the inside of the rollers.

The rice-like granules were steamed for 10 minutes at 100 DEG C. and dried in a hot air dryer for 30 minutes at 105 DEG C. The resulting enriched artificial rice product had a water content of 10%.

Cooking Results:

100 g of the artificial rice were cooked in 300 g of boiling water for 15 minutes and dewatered with a sieve. The cooked enriched artificial rice maintained its rice granule-like shape and had a non-sticky texture.

EXAMPLE 2


>;tb;______________________________________


>;tb;5 kg hydroxypropylated tapioca starch

>;tb;5 kg dried spinach powder

>;tb;2 kg guar gum

>;tb;2 kg microfibrilated cellulose powder

>;tb;1 kg calcium carbonate

>;tb;0.001 kg thiamin mononitrate

>;tb;______________________________________


1951/2197

The kneaded starch-based mixture was then granulated as in Example 1.


Cooking Results:

A mixture of 100 g of the artificial rice and 100 g of Indica rice were cooked in 1000 g of boiling water for 15 minutes and dewatered with a sieve. The mixture of cooked enriched artificial rice and native rice maintained its rice granule-like shape and had a non-sticky texture.

EXAMPLE 3


>;tb;______________________________________



>;tb;7 kg dried pumpkin powder

>;tb;1 kg guar gum

>;tb;1 kg methylcellulose

>;tb;5 kg microfibrilated cellulose powder

>;tb;1 kg calcium carbonate

>;tb;0.01 kg riboflavin

>;tb;______________________________________


The kneaded starch-based mixture was then granulated as in Example 1.


Cooking Results:

A mixture of 100 g of the artificial rice and 100 g of Indica rice were cooked in 1000 g of boiling water for 15 minutes and dewatered with a sieve. The mixture of cooked enriched artificial rice and native rice maintained its rice granule-like shape and had a non-sticky texture. The boiled rice mixture was then lightly fried in butter and other flavorings. The mixture of fried enriched artificial rice and native rice maintained its rice granule-like shape and had a non-sticky texture.

EXAMPLE 4


>;tb;______________________________________




>;tb; 5 kg corn fiber

>;tb; 2 kg curdlan

>;tb;______________________________________

The starch-based mixture was then mixed with 45 kg of water and kneaded with a twin screw-type continuous kneader (ISHIKAWA-TOKI Co., Ltd.) to form a sheet (6 mm thickness) for 7 minutes retention time at 75 DEG C. The sheet had a gelatinization ratio of 55%.

1952/2197

The sheet was then granulated with a roll-type granulator. The rice-like granules were steamed for 5 minutes at 100 DEG C. and dried in a hot air dryer for 100 minutes at 85 DEG C. The resulting enriched artificial rice product had a water content of 11%.

Cooking results:

100 g of the artificial rice and 200 g of water were brought to a boil and heated about 15 minutes with lower heat until all the water was absorbed. The cooked enriched artificial rice maintained its rice granule-like shape and had a non-sticky texture and had a rice-like brittleness to the teeth.

EXAMPLE 5

A starch-based mixture containing the following ingredients was prepared:

>;tb;______________________________________




>;tb; 5 kg corn fiber

>;tb; 2 kg curdlan

>;tb;______________________________________

The starch-based mixture was then mixed with 45 kg of water and extruded through a 1 mm.times.3 mm diamond die and cut to granulate into rice-like granule. The rice-like granules were dried in a hot air dryer for 10 minutes at 105 DEG C. The resulting enriched artificial rice product had a water content of 10%.

Cooking results:

100 g of the artificial rice and 200 g of water were brought to boil, and heated about 15 minutes with lower heat until all the water was absorbed. The cooked enriched artificial rice maintained its rice granule-like shape, but its texture was gummy and not as brittle to the teeth as cooked native rice. Its texture was similar to cooked pasta.

The invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method of preparing an enriched artificial rice product comprising the steps of mixing together

50% to 98% by dry weight of at least one starch or starch derivatives with 2% to 45% by dry weight of at least one enriching material and 0.1% to 10% by dry weight of at least one gelling hydrocolloid to form a mixture; adding water to the mixture, while kneading the mixture, to have a water content of

25% to 55%; granulating the mixture into rice-like granules with a roll-type granulator; steaming the granules for 3 to 30 minutes at a temperature of 70 DEG C. to 105 DEG C., and drying to a water content of less than 20% whereby the enriched artificial rice product so formed can be prepared using at least twice the volume of cooking water as rice.

2. The method of claim 1 further characterized by adding to the mixture 0.1% to 5% of at least one fiber supplement selected from the group consisting of microfibrilated cellulose, corn fiber, apple fiber, wheat bran and rice bran.

1953/2197

3. The method of claim 1 further characterized by adding to the mixture 0.01% to 5% of at least one mineral supplement selected from the group consisting of calcium carbonate, ferric orthophosphate.

4. The method of claim 1 further characterized by adding to the mixture 0.0001% to 2% of at least one vitamin supplement or carotene.

5. The method of claim 1 further characterized by adding to the mixture up to 5% of at least one flavoring agent.

6. The method of claim 5 further characterized by selecting the flavoring agent from the group consisting of salt, soya sauce, ginger, sugar, pepper and curry powder.

7. The method of claim 1 further characterized by adding to the mixture up to 10% protein selected from the group consisting of gluten and soya protein.

8. The method of claim 1 further characterized by selecting the starch or starch derivatives from the group consisting of corn, waxy maize, potatoes, tapioca, sago, arrowroot, rice, wheat, other cereals and modified derivatives.

9. The method of claim 1 further characterized by selecting the enriching material from the group consisting of fresh minced material, pastes, juices, dried chips, freeze-dried and powdered prepared materials.

10. The method of claim 9 further defined by selecting the prepared enriching material from the group consisting of carrot, spinach, tomato, bell pepper, onion, beets, radish, celery, cabbage family, pumpkin, edible seaweeds, apples, oranges, pineapples and berries.

11. The method of claim 1 further characterized by selecting the gelling hydrocolloid from the group consisting of egg white, curdlan, gellan gum, sodium alginate, sodium pectate, methylcellulose, ethylcellulose, hydroxypropylcellulose, methylhydroxypropylcellulose, methylethylcellulose, carrageenan, furcellaran, agar, gelatin, xanthan gum, locust bean gum, and guar gum.Data supplied from the esp@cenet database - Worldwide

1954/2197

402.

US5405625 - 4/11/1995

CHEESE-FILLED SNACK


Inventor(s): BIGGS RICHARD H (US)

Applicant(s): NABISCO INC (US)

IP Class 4 Digits: A23L; A23P; A23C

IP Class: A23L1/217; A23P1/08; A23P1/12; A23C19/09

E Class: A23L1/164B; A23L1/216B2; A23C19/093; A23C19/09



Family: US5405625

Abstract:


Snacks with smooth, creamy cheese fillings contain pregelatinized rice flour in the filler and casing portions can be baked or microwaved. The cheese filling contains cheese and pregelatinized rice flour, and does not dry out or leak out on storage or heating. In preferred embodiments, pregelatinized rice flour comprises from about 5 to about 20% by weight of the filler portion. Some embodiments also contain fat and powdered cheese in the filler portion. The casing contains potato flakes and pregelatinized rice flour and retains its structural integrity and does not slip on heating. In preferred embodiments, potato flakes and pregelatinized rice flour comprise from about 10% to about 30% by weight of the starch component in the casing portion.Description:


TECHNICAL FIELD

This invention relates to cheese-filled snack products that can be baked or microwaved.

Center-filled food products are available in many varieties and are popular food items. Preferred filled snack products have a crisp baked outer dough shell, and a soft, lubricious filling. The dual texture of the product provides a pleasant eating experience. For some products such as cheese-filled snacks, the texture differential, flavor and aroma can be enhanced by heating the product.

The eating quality of cheese-filled snack products is superior when the interior is moist, but many products currently marketed contain low moisture levels so as to be shelf stable for extended periods without becoming soggy and having the cheese migrate into the shell or casing. Good shelf storage is thus achieved at the sacrifice of product taste and flavor quality. The products have a tendency to dry out further or leak out when heated. In addition, heating cheese-filled products having a casing made from conventional flour causes overexpansion and sometimes rupture or bursting of the snack.

It would be desirable to have a cheese-filled snack product that did not dry out, leak, overexpand or break when heated.

BACKGROUND ART

1955/2197

A number of publications describe the production of filled food products. Many describe machinery employed for the production of the dual textures, which is generally accomplished by coextrusion or by formation of the shell or casing followed by filling. Many others describe special formulations to keep the filling from migrating and the product from getting soggy.

U.S. Pat. No. 3,492,127 to Ketch and Barton, for example, suggested that the filling of a filled pastry be dehydrated to an overall moisture content of less than 6%, more commonly less than 4%, and preferably less than about 2%, and then rehydrated prior to baking. Cheese such as cottage cheese and other types in a dessicated form were disclosed as possible fillers, but the patent was chiefly directed to the preparation of shelf-stable pies filled with freeze-dried, vacuum-dried or air-dried fruit pieces.

Rehydration was accomplished by adding an aqueous fluid through the upper crust. The method was, therefore, chiefly useful for large products contained in a dish or pie plate, rather than for snacks.

In U.S. Pat. No. 4,612,198, Wallin, et al., disclosed a filled pastry that contained a fairly high moisture filling yet retained structural integrity on toasting. The pastry was formulated by carefully controlling filling and casing viscosity and pH, and preparing a laminated dough pad that was stable at the filling interface. The pH and viscosity ranges were critical, which complicated the process. Also the patent was directed to the production of toaster breakfast pastries such as those filled with fruit or jellies which have product instability primarily caused by acid and water migration from the filling into the dough, limiting the applicability of the invention to other product types.

Both Ward, et al., U.S. Pat. No. 4,613,509, and Wainwright, U.S. Pat. No. 4,618,499, disclosed slitted center-filled food products. The former patent disclosed a process for producing center-filled food products by forming a hollow cylindrical edible shell having a single continuous longitudinal slit, through which was inserted a filling that had to be substantially stationary at product storage temperatures. The latter disclosed the cooking and extrusion of a casing, which was then slit open for filling insertion. The processes were suggested to avoid various problems encountered in filling brittle shells or in coextruding product components that exhibit very different heating and cooling characteristics, but the slits left in the finished products would provide vents that could leak if the final products were heated.

In U.S. Pat. No. 4,661,360, Smith disclosed peanut butter-filled snack products formed by coating the filling with a hydrophilic material and then surrounding the coated filling with a layer of dough. The snack was baked after the layers were applied to the filling, but the patent did not report about product performance on reheating.

Barry, et al., in U.S. Pat. No. 4,919,947, disclosed fillings that were formulated to control the crystal structure of the shortening and the particle size of the flavoring so they could be pumped into outer shells of cooked dough without clogging the nozzle. The patent addressed the structuring of fillings so that they were pumpable prior to final formulation of the product, and not the reheating of filled products.

It would be desirable to have a formulation specifically directed to a savory cheese-filled snack that can be baked or microwaved.


It is an object of the invention to provide a flavorful cheese-filled snack product.

It is a further and more specific object of the invention to provide a cheese-filled snack product which has an organoleptically pleasing, moist filling both at room temperature and after heating and which can be baked or microwaved without overexpanding or leaking.

These and other objects are accomplished by the present invention which describes a cheese-filled snack product containing pregelatinized rice flour in the filling and in the casing. The snack product filling comprises cheese and pregelatinized rice flour. Typically, it also contains fat, and, in many embodiments, at least a portion of the cheese is powdered. The snack product casing comprises potato flakes and pregelatinized rice flour. The casing typically also contains a fat ingredient and conventional flour.

1956/2197

In preferred embodiments, the potato flakes and pregelatinized rice flour comprise from about 10% to about 30%, more narrowly from about 15% to about 25%, by weight of the starch component in the casing portion. In some embodiments, the casing portion comprises about equal amounts by weight of potato flakes and pregelatinized rice flour. In one embodiment, the potato flakes and pregelatinized rice flour comprise about 22% by weight of the starch component in the casing portion.

In preferred embodiments, the pregelatinized rice flour comprises from about 5% to about 20%, more narrowly from about 8% to about 16%, by weight of the filler portion. The filler may contain one or more cheeses such as American cheese, Parmesan cheese, cheddar cheese, Swiss cheese, and the like, and can also contains spices and/or seasonings.

Methods for maintaining the structural integrity of a cheese-filled snack product and providing a creamy filling when the product is heated are also disclosed.

BEST MODES FOR CARRYING OUT THE INVENTION

This invention is based upon the finding that including pregelatinized rice flour in both the filler portion and the casing portion of a cheese-filled snack formulation results in a product that can be heated in a convection or microwave oven without having the cheese filling dry or leak out, or the casing overexpand and break.

A "cheese-filled snack" includes any baked or unbaked food product having a cheese filling portion and a casing or shell portion. As used herein, the term "casing" is not limited, so that the casing or shell portion can enclose all or part the filler portion. Thus, cheese-filled snacks include, but are not limited to, cheese-filled balls and barrels, open-ended and closed-ended cheese-filled logs, cheese toastettes, cheese-filled shells, cheese-filled pretzels, cheese-filled breadsticks, cheese-filled biscuits and the like.

Low, intermediate, and high moisture cheese snack products are encompassed by this invention.

The casing portion is formulated to contain potato flakes and pregelatinized rice flour. These two starch ingredients preferably comprise from about 10% to about 30% by weight, more narrowly from about 15% to about 25% by weight, of the starch component in the casing portion, which typically also contains flour. In some embodiments, the casing portion comprises about equal amounts by weight of potato flakes and pregelatinized rice flour. In one embodiment, potato flakes and pregelatinized rice flour comprise about 22% by weight of the starch component in the casing portion.

By "pregelatinized rice flour" is meant any rice flour that has been gelatinized and then reprocessed by standard means, i.e., slurried in water, heated to gelatinization temperature to swell the starch granules, and then cooled and extruded and/or remilled as flour. As defined herein, the flour contains from about

11 to 13% by weight water; the weight percentages used must be adjusted for flours containing more or less moisture. An example pregelatinized rice product useful in the invention is marketed under the name Comet 2080 rice flour.

As used herein, the potato flakes contain from about 3 to 4% by weight moisture; weight percentages must be adjusted for flakes that contain more or less moisture. An example potato flake product useful in the invention is obtained from the Supreme Idaho Potato Company.

Any type of flour is typically used with the potato flakes and pregelatinized rice flour in the starch component of the casing portion. As used herein, flours contain from about 7 to about 9% by weight moisture; weight percentages must be adjusted for flours that contain more or less moisture. The flour can be all-purpose or unbleached wheat flour, potato, or other cereal flours such as corn, oats, rye, and mixtures thereof. The casing formulation also typically contains salt, a fat ingredient such as a shortening, butter, lard, vegetable oil, or fat mimetic, and an aqueous component of water, milk, fruit juice or other liquid, which, if baked, evaporates to some extent.

The casings may, optionally, contain other ingredients familiar to the skilled artisan such as leavening agents, cheese solids, browning agents, emulsifiers, plasticizers, spices, flavorings, antioxidants, and, in some embodiments, mold, bacteria, and yeast inhibitors. Example leavening agents include yeast, sodium or potassium bicarbonate, and the like. Browning agents include, for example, milk solids, corn

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sugar solids, or dihydroxyacetone that promote a golden brown color; these can be added up to about

12% by weight of the unbaked casing composition in some embodiments. Emulsifiers include, but are not limited to, mono- and diglycerides of fatty acids, sucrose partially fatty acid esters, sorbitan esters of fatty acids, polyoxyethylene sobitan esters of fatty acids, and the like. Plasticizers include, for example, propylene glycol, glycerine, sorbitol, dextrose, levulose, maltose, and corn syrup solids; these are usually present in small amounts (e.g., 0-3% by weight of the uncooked dough composition). Mold and yeast inhibitors, include, for example, sodium benzoate, benzoic acid, calcium propionate, sodium propionate, sorbic acid, potassium sorbate, calcium sorbate, diethylpyrocarbonate, and salts and esters of monohydroxybenzoic acid, added in small quantities (e.g., 0 to 0.3% by weight of the uncooked dough). Antioxidants such as, for example, butylated hydroxyanisole, tertiarybutylquinone, and citric acid typically are not required, but these may be included in some instances. Example formulations are given hereinafter.

The casing dough can be prepared by standard techniques for preparing snack and cracker doughs.

Typically, the dry ingredients are mixed together. The shortening and emulsifiers are co-melted and then mixed with the dry ingredients, and then the liquid ingredients are added.

The filler portion of the snack products of this invention contains cheese and pregelatinized rice flour.

The pregelatinized rice flour comprises from about 5% to about 20% by weight, more narrowly from about 8% to about 16% by weight, of the filler portion.

Any type of cheese may be employed, including high- or low-fat, unripened or ripened soft, semisoft, hard, very hard, processed, or whey cheeses. Legion cheese varieties are available and useful in the invention, including, but not limited to, American cheese, Parmesan cheese, Cheddar cheese, Swiss cheese and the like. Cheese blends may also be employed, and are preferred in some embodiments. In many embodiments, at least a portion of the cheese is powdered. As used herein, powdered cheese includes specialty powdered cheeses such as, for example, nacho-, pizza- and barbecue-flavored cheeses. Example formulations are given herein-after.

Many filler embodiments contain flavorings in addition to the flavor provided by the cheese or cheeses. Flavoring materials which can be incorporated into the filling compositions of this invention include, but are not limited to, spices, including onion, garlic and barbecue; meat flavorings, especially those that are commonly consumed with cheese such as pepperoni, salami, and pastrami; peanut butter and other nut flavorings; savory flavorings; dairy flavorings such as buttermilk and yogurt; and the like.

Many filler portion embodiments also contain a fat ingredient such as shortening, butter, lard, vegetable oil, or a fat mimetic. Hard filler fats are preferred in some embodiments. Processed fat solids comprise at least a portion of the fat ingredient in some embodiments. The filler portion can also contain aqueous ingredients such as water or milk, and other starch ingredients in addition to the pregelatinized rice flour component, such as all-purpose flour or potato flakes. The filler portion can also contain emulsifiers, antioxidants, and the like typical filler ingredients such as those mentioned for the casing component above. Example formulations are given hereinafter.

The cheese and other ingredients are thoroughly blended together to form the filler portion. In some embodiments, one or more cheeses, and, if used, solid fats, are melted prior to mixing to aid the blending process.

The snack products are manufactured using any means that partially or fully encloses the filler portion with the casing portion. This is accomplished either by forming a raw snack that can be cooked, e.g., baked, roasted or fried, before or after sale, or by preparing casing shells that can be filled after being cooked. In preferred embodiments, a raw snack comprising cheese filler and uncooked casing dough is prepared and then baked or roasted. In one embodiment, for example, the filler is placed on the casing dough and then the dough is sealed together to form a raw snack. In another embodiment, the filler is placed on a casing dough layer and a second layer of dough compressed around the filling and sealed against the first layer. In yet another embodiment, the two portions are coextruded.

Once the coated filling is enclosed or partially enclosed within the dough, the raw snack formed is then baked or roasted to form the finished baked filled snack product. Typically, the filled snack product is

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baked at a temperature of from about 350 DEG to about 500 DEG F. (117 DEG to 260 DEG C.) for from about 2 to 12 minutes. The particular baking conditions employed depend upon the size of the filled-snack product, the nature of the cheese in the filling, the amount of doneness required, and the like. Baking can be followed by a drying step at reduced temperature to achieve a desired water activity for the baked snack product. The water activity level of the finished product typically varies between

0.67 and 0.70.

The cheese-filled snack products of this invention exhibit a number of desirable characteristics. The dual texture is crisp on the outside and creamy on the inside, providing high flavor impact and pleasant eating quality. The filler has a smooth, uniform consistency that is moist both at room temperature and after heating, providing a good mouthfeel over a range of temperatures.

The cheese-filled products of the invention can be heated in conventional or microwave ovens without expanding, bursting, leaking, becoming soggy, drying out, or breaking apart. The casing does not slip off the filler during heating. The structural integrity is maintained over a wide temperature range so that the product can be easily handled. Flavor is retained on heating, and the oils do not migrate.

EXAMPLES

The following examples are presented to further illustrate and explain the present invention and should not be taken as limiting in any regard. Unless otherwise indicated, all parts and percentages are by weight, and are based on the weight at the particular stage of the processing being described. The flours used herein contain from about 11 to about 13% by weight moisture. Water activity is equal to the vapor pressure of a product divided by the vapor pressure of pure water under the same conditions.

Moisture is measured using Brabender.TM., and is expressed in units of % Salt is measured using

Dicormate.TM., and is expressed in units of %.

Example 1

To make a cheese filler of this invention, thoroughly combine the following ingredients for batches that can be small (grams) or large (lb., oz.):

>;tb;______________________________________

>;tb;Ingredient grams or lb., oz.

>;tb;______________________________________

>;tb;Powdered White Cheddar Cheese

>;tb; 500.0 25 0

>;tb;Cheddar Cheese (EMC)

>;tb; 30.0 1 8

>;tb;Parmesan Cheese (EMC)

>;tb; 30.0 1 8

>;tb;Malt 10.0 0 8

>;tb;Salt 6.0 0 4

>;tb;Soybean Oil #2 50.0 2 8

>;tb;Water 100.0 5 0

>;tb;Potato Flakes 100.0 5 0

>;tb;Staley Co. Pregelatinized Rice Flour

>;tb; 100.0 5 0

>;tb;______________________________________

Example 2

To make a non-slip casing for cheese-filled log snacks according to the invention, first combine the following dry ingredients for small (grams) or large (lb., oz.) batches:

>;tb;______________________________________


>;tb;______________________________________

>;tb;All-Purpose Flour

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>;tb; 484.4 70 0

>;tb;Staley Co. Rice Starch

>;tb; 70.0 10 0

>;tb;Potato Flakes 70.0 10 0

>;tb;Soda 5.2 0 12

>;tb;Sodium Acid Pyrophosphate

>;tb; 5.2 0 12

>;tb;Ammonia 14.0 2 0

>;tb;______________________________________

Then combine the following ingredients

>;tb;______________________________________


>;tb;______________________________________

>;tb;Soybean Oil #2 40.0 5 11

>;tb;Lecithin 1.3 0 3

>;tb;Sugar 40.0 0 11

>;tb;Salt 5.2 0 12

>;tb;Sodium 2-Stearoyl Lactylate

>;tb; 3.5 0 8

>;tb;Water 225.0 32 0

>;tb;______________________________________

Add to the dry ingredients and process in the usual manner.

Example 3

To make a pizza cheese filler of the invention, thoroughly combine:

>;tb;______________________________________

>;tb;Ingredient grams

>;tb;______________________________________

>;tb;Kraft Sequoia Yellow (722) Powdered Cheese

>;tb; 500.0

>;tb;Pregelatinized Rice Flour 100.0

>;tb;Quest AA91101 Pizza Flavor

>;tb; 60.0

>;tb;Parmesan Cheese (EMC) 30.0

>;tb;Cheddar Cheese (EMC) 30.0

>;tb;Soybean Oil #2 50.0

>;tb;Malt 10.0

>;tb;Onion Powder 10.0


>;tb; 3.5

>;tb;Annato Color #4 1.0

>;tb;Dried Oregano Flakes 1.0

>;tb;Dried Parsley Flakes 1.0

>;tb;Water 125.0

>;tb;______________________________________

Snack cheese logs are prepared using this filling and the casing of Example 2, except that no ammonia is employed. After baking, the products exhibit the following parameters:

water activity level 0.61

moisture 4.6

salt 1.8

pH 5.9

Example 4

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Other pizza cheese logs are prepared in small (grams) or large (lb., oz.) batches.

For the cheese filling, thoroughly combine

>;tb;______________________________________


>;tb;______________________________________

>;tb;Kraft American #21 Cheese

>;tb; 250.0 25 0

>;tb;Pregelatinized Rice Flour

>;tb; 100.0 10 0

>;tb;Quest AA91101 Pizza Flavor

>;tb; 30.0 3 0

>;tb;Parmesan Cheese (EMC)

>;tb; 15.0 1 8


>;tb; 15.0 1 8

>;tb;Onion Powder 5.0 1 0

>;tb;Garlic Powder 5.0 0 8

>;tb;Dried Oregano Flakes

>;tb; 1.0 0 1.6

>;tb;and Parsley Flakes 1.0 0 1.6

>;tb;with

>;tb;Hard Filler Fat (Centory Soya .TM.)

>;tb; 200.0 20 0

>;tb;Annato Color #4 1.5 0 3.5

>;tb;______________________________________

The casing of Example 2, without ammonia, is employed to make snack cheese logs that do not break during preparation. The snack logs are put in plastic and microwaved at a medium setting for 30 seconds. The hot snacks retain their structural integrity, and the cheese filling does not leak out, exhibiting a moist texture that is not dry. After 10 days, the snacks are placed in plastic and then microwaved at a medium setting for 20 seconds; once again, the snacks maintain their structural integrity, and the cheese does not leak out or harden.

Similar results are obtained on heating the logs in a toaster: the snack products retain their shape, and the cheese filling stays moist and does not leak out.

Example 5

Another cheese filling of this invention is prepared by thoroughly combining

>;tb;______________________________________


>;tb;______________________________________

>;tb;Kraft American #21 Cheese Powder

>;tb; 500.0 25 0


>;tb; 7.5 0 6


>;tb; 100.0 5 0

>;tb;Malt 10.0 0 8


>;tb;Soybean Oil 50.0 2 8


>;tb; 5.0 0 4

>;tb;Water 100.0 5 0

>;tb;______________________________________

1961/2197

Another cheese filling is prepared by combining

>;tb;______________________________________


>;tb;______________________________________

>;tb;Kraft American #21 Cheese Powder

>;tb; 250.0 25 0

>;tb;Hard Filler Fat (Centory Soya .TM.)

>;tb; 150.0 15 0


>;tb; 100.0 10 0

>;tb;Malt 10.0 0 8


>;tb;Soybean Oil 50.0 2 8


>;tb; 5.0 0 4

>;tb;Water 100.0 5 0

>;tb;______________________________________ Snack cheese logs are prepared using the second filling and the casing of Example 2, except that no ammonia is employed.

After baking, the products exhibit the following parameters:

water activity level 0.67

moisture 2.88

salt 1.3

pH 6.2

The above description is for the purpose of teaching the person of ordinary skill in the art how to practice the present invention, and it is not intended to detail all those obvious modifications and variations of it which will become apparent to the skilled worker upon reading the description. It is intended, however, that all such obvious modifications and variations be included within the scope of the present invention, which is defined by the claims that follow. The claims are meant to cover the claimed components and steps in any sequence which is effective to meet the objectives there intended, unless the context specifically indicates the contrary.Data supplied from the esp@cenet database -

Worldwide Claims:


I claim:

1. A filled snack product comprising:

(a) a filler portion comprising cheese and pregelatinized rice flour; and

(b) a casing portion comprising potato flakes and pregelatinized rice flour.

2. A product according to claim 1 wherein at least a portion of the cheese in the filler portion is powdered cheese.

3. A product according to claim 1 wherein the casing portion further comprises flour.

4. A product according to claim 1 wherein the filler portion further comprises fat.

5. A product according to claim 4 wherein the fat comprises processed fat solids.

6. A product according to claim 1 wherein the cheese is selected from the group consisting of

American cheese, Parmesan cheese, cheddar cheese, Swiss cheese, and mixtures thereof.

7. A cheese-filled snack product comprising a filler portion comprising cheese, fat and pregelatinized rice flour, and a casing portion comprising flour, potato flakes and pregelatinized rice flour.

1962/2197

8. A product according to claim 7 wherein the potato flakes and pregelatinized rice flour comprise from about 10% to about 30% by weight of the starch component in the casing portion.

9. A product according to claim 8 wherein the potato flakes and pregelatinized rice flour comprise from about 15% to about 25% by weight of the starch component in the casing portion.

10. A product according to claim 9 wherein the potato flakes and pregelatinized rice flour comprise about 22% by weight of the starch component in the casing portion.

11. A product according to claim 7 wherein the casing portion comprises about equal amounts by weight of potato flakes and pregelatinized rice flour.

12. A product according to claim 7 wherein the pregelatinized rice flour comprises from about 5% to about 20% by weight of the filler portion.

13. A product according to claim 11 wherein the pregelatinized rice flour comprises from about 8% to about 16% by weight of the filler portion.

14. A pizza-flavored cheese-filled product according to claim 7.

15. A product according to claim 7 comprising American cheese.

16. A product according to claim 7 which exhibits a water activity level of about 0.67 to 0.70.

17. A method for maintaining the structural integrity of a cheese-filled snack product and providing a creamy filling when the product is heated comprising incorporating pregelatinized rice flour in the filler portion of the product and pregelatinized rice flour and potato flakes in the casing portion of the product.

18. A method according to claim 17 wherein the rice flour and the potato flakes comprise from about

10% to about 30% by weight of the starch component of the casing portion, and about equal parts rice flour and potato flakes are incorporated in the casing portion.

19. A method according to claim 17 wherein the pregelatinized rice flour comprises from about 5 to about 20% by weight of the cheese filling portion.

20. A cheese log product prepared according to the method of claim 17.Data supplied from the esp@cenet database - Worldwide

1963/2197

403.

US5413805 - 5/9/1995

LOW OR NO FAT GRANOLA CEREAL MIX AND PROCESS


Inventor(s): DELPIERRE III PHILLIP (US); STANYON PAMELA J (US); ELDRED

CHARLES R (US)

Applicant(s): KRAFT FOODS INC (US)


IP Class: A23L1/18

E Class: A23L1/164C



Family: US5413805


Abstract:


Ready-to-eat, low or no fat granola cereal is prepared from a 60% to 85% cereal base by coating the cereal base with 10% to 30% sugars and drying. The granola cereal product contains little or no added fat and from 30% to 50% cereal flakes, 10% to 40% other cereal ingredients including 5% to 20% crisp rice, 5% to 20% rolled grains and up to 20% cereal flour. Optionally from 1% to 5% maltodextrin is added to tackify the product.Description:


TECHNICAL FIELD

This invention relates to ready-to-eat low or no fat added granola cereal and the process for preparing same.

BACKGROUND ART

Granola cereals are typically high in fat due to the addition of 10% or more oil, which is an important attribute of such cereals causing the cereal to cluster and have a pleasing appearance and texture.

Granola cereals and food bars have been known and available for some time. Granola's generally contain a grain or grains, nuts, possibly dried fruit, sweeteners and other ingredients. The ingredients can be mixed with a binder such as a sugar syrup and/or fat or shortening and agglomerated or compressed into bars or slabs which may be later cut to a desired size. Depending on the granola's composition, it may be mixed, formed and/or baked prior to packaging and sale.

Martin, U.S. Pat. No. 4,038,427, teaches a natural granola product known as C. W. Post brand granola cereal. An assortment of amylaceous and proteinaceous particles are aggregated around puffed, cupped, toasted cereal (such as crisp rice as it is referred to in the trade) which serve as focal points for the particles. The aggregates are preserved and agglomerated in a fat and sugar syrup coating.

1964/2197

A large number of people are desirous of having a granola product which is natural and yet contains low fat or no added fat while retaining the distinctive clustered appearance and the taste and crispy texture of such cereals or food bars.


Ready-to eat, low or no fat added granola cereals are prepared from a major amount of cereal base agglomerated and formed into clusters using a coating syrup. The cereal base contains a major amount of cereal flakes with the remainder rolled cereal, cereal flour and crisp rice.

Maltodextrin may be used to improve tackiness of the cereal mixture providing for better clusters typical of high fat products.

The product is prepared by mixing the cereal base and other granola type materials such as dried fruit and edible nuts and coating the mixture with a coating syrup followed by liquid sucrose. Fat, where added, is sprayed on the mix prior to the coating syrup. The mixture is baked or heated in a oven or drier to cook, brown and dry the product into a dry sheet of granola cereal which may be gently broken into bars or clusters and packaged.


According to this invention, a cereal mixture is disclosed that meets the shortcomings of the prior art in providing a no or low fat added granola cereal with clusters similar to granola cereals prepared with high levels of added fat.

The granola cereal comprises 60% to 85% cereal base and 10% to 30% added sugar (not contained within the cereal-based ingredients). The cereal base portion contains a major amount of cereal flakes with the remainder being other cereal solids such as rolled grains, grain flours and crisp rice. The base also, preferably, contains a small amount of maltodextrin.

The base is agglomerated using a low amount of fat, if desired, but preferably no fat followed by a coating syrup and finally a liquid sucrose. The mix is heated in an appropriate oven or drier to cook, brown and dry the product which is then gently broken into clusters. Granola bars or other forms may be prepared in a similar fashion.

In a preferred embodiment, maltodextrin is used to increase the tackiness of the mixture which helps give appropriately sized granola clusters.

In a further preferred embodiment, a major amount of the cereal base is cereal flakes where a major amount of the flakes after passing through a 1/4 inch screen are retained on a 12 mesh screen while the remainder of the flakes pass the 12 mesh screen.

The cereal flakes can be prepared from grain flakes such as wheat, corn, barley and oats with or without added bran or the like. We prefer to employ wheat, corn, barley or oat flakes which are ground to a particle size such that from 0 to 10% are retained on a 1/4 inch screen, of the remainder from 50% to 90% pass through a 1/4 inch screen and rest on #12, preferably from 60% to 80%, and 10% to 50% pass through a #12 and rest on the pan, preferably 20% to 40%. This particle size is preferred since it appears to agglomerate best with the other granola ingredients and form good size clusters after coating with sugar, drying and gentle breakage on a sizing screen. The preferred particle size is about 5% retained on a 1/4 inch screen, about 70% through a 1/4 inch screen and rest on #12 screen and about

25% through the #12 screen and rest on the pan.

The amount of cereal flakes based on the entire product varies from about 30% to about 50% with 35% to 45% preferred. The amount of other cereal ingredients other than cereal flakes comprise from about

10-40%, preferably 15 to 35% based upon the finished food product.

The non-flaked cereal portion of the food is prepared from rolled grains such as 5% to 20% rolled oats, wheat, barley and the like, preferably 5% to 15%, from 0% to 20% cereal flour such as wheat, rice, oat,

1965/2197

corn or the like, preferably 5% to 15% and from 5% to 20% crisp rice, preferably 5% to 15% crisp rice, all percentages based upon the final granola cereal product.

The admixture of cereal grain components can include rolled oat groats, bumped rolled wheat or bumped rolled barley. The level of oats, wheat and barley used will be dictated by nutritional requirements as well as palatability and other organoleptic considerations. Other cereal grains, such as cereal flour, may be employed in lieu of or in addition to oats, wheat and barley for ration balancing while still practicing the distinct aggregating advantages accruing from use of flaked cereal grains.

The agglomerate may also contain a number of alternative ration-balancing cereal protein or protein sources in the above preferred ration; e.g., soy bean curd, wheat germ, rye, corn, milo, sorghum, buckwheat meals and/or flours and mixtures of these ingredients, the range of such ratio balancing cereal proteins being between 0 and 10 percent of the total ration. Usually these cereal grains or protein sources as in the case of wheat germ or high protein classified wheat flours fractions recovered by sieving or air classification will be selected in accordance with intended nutritional benefits and organoleptic values that are compatible therewith.

Bumped oat, wheat, barley or equivalents are obtained by soaking in cold or warm water to soften the grain; steaming or partial cooking by other means; and subsequent tempering of the cereal grains; whereupon they are flattened and thus opened in structure so that they are more digestible and more readily rehydratable. The act of bumping produces a flattened shape which permits the aggregate to nest or bridge by virtue of the exposed dextrinous character of the surfaces thereof as they undergo tumbling in intimate association with the cereal flakes and crisp rice. Bumping coupled with soaking as in the case of grains such as oats renders the cereal grain more tender or pliable when consumed either dry or wetted and more organoleptically acceptable.

The use of crisp rice provides excellent texture and agglomerationproperties. The process used to produce the crisp rice is not a critical aspect of the invention. Typically, parboiled, milled white rice will be pressure cooked with a flavoring syrup whereupon the rice will be dried to a moisture content, say, in the order of 15% to 20% and then tempered for a prolonged period (e.g., 16 hours), whence it will be charged to a pre-heated oven to plasticize and warm the rice to a relatively high temperature to condition the rice for bumping. The rice will be bumped, but not flaked, to the point of producing a flattened, non-resilient rice mass; the rice will be flattened to less than that condition wherein it loses its integrity as a grain per se; the bumped rice will thus assume a thickness dimension generally 50% to

75% of the cooked tempered rice dimension just prior to bumping. After bumping, the rice will be charged to a puffing oven where it will be blasted with heated air (450 DEG F. to 500 DEG F.) at atmospheric conditions for a period of, say, 12 to 15 seconds to produce the characteristic puffed crisp rice.

The cereal flakes and other cereal ingredients are supplemented with conventionally employed dry fruits and edible nuts and milk derivatives. For example, dried fruit such as coconut, raisins and apricots may be employed. Edible nuts such as almonds, walnuts and other consumer preferred nuts may be used. Milk derivatives such as non fat milk, whole dried milk, sweet whey and the like can be employed.

The clusters of cereal are prepared by mixing the cereal flakes and other cereal components and optionally the maltodextrin with a coating syrup and optionally a small amount of oil which together render the cereal tacky and effect agglomeration on mixing. Sucrose syrup is then added. The coating syrup, sucrose syrup and cereal mixture may be mixed in a bowl or tumbled in rotating drums or in screw conveyors. Once the cereal is coated with syrup, the mixture is placed on trays or belts or other solid, perforated or screen surfaces and baked in an oven or hot air dried to evaporate water, cook and brown the cereal and adhere the cereal particles to each other.

We employ from 10% to 30% coating and sugar syrup, preferably from 10% to 25% based on the total final product weight.

The majority of the sugar employed, at least 70%, preferably 80% or more is sucrose with the balance made up of honey, molasses, corn syrup, both high fructose and conventional and other sweet

1966/2197

ingredients. The sugars may be applied as a single syrup or the corn syrup, molasses and other nonsucrose sweeteners may first be applied as by spray in a coating drum followed by sucrose syrup.

In this connection, the employment of 1% to 15%, preferably 1% to 5%, by weight of final cereal of amorphous monosaccharides, predominantly corn syrup made up of a majority of glucose or honey made up of a majority of fructose, is instrumental in achieving a semi-glossy, non-crystallizing coating which provides a substantially continuous barrier to oxidation.

In effecting agglomeration, syrup must be sprayed or poured into a mixing vessel containing the dry cereal ingredients. Suitable equipment for achieving agglomeration includes a batch system such as a coating reel, ribbon blender or a continuous system such as a single or multiple mixing auger. When utilizing a coating reel the pre-mixing of the dry blend ingredients to be agglomerated, the rate of rotation of the reel, the diameter thereof and the number of flights or baffles employed to promote a tumbling action are matters within the skill of art workers and form no part of the present invention.

However, it is preferred in effecting a tumbling action to avoid excessive heating of the coating reel.

Such low temperature processing promotes a good syrup distribution without premature moisture loss; a preferred embodiment is that the coating operation proceed at an ambient agglomerating temperature in the zone of aggregation below 120 DEG F.; the syrup will be at a more elevated temperature--say, about 120 DEG F. to 150 DEG F.--whereat it will be fluid and evenly distributable and possess requisite stickiness.

The tacky nature of the syrup, when warm, should promote sufficient initial aggregation to assure that clustering of particles occurs around the cereal flake and the crisp rice. Generally speaking, it will be a preferred embodiment of the invention that maltodextrin be added to the dry cereal ingredients which improves agglomeration of cereal flakes, flour, crisp rice, fruit and nut solids.

A major amount of sucrose solution is added after the initial coating of monosaccharide which on evaporation of the water forms a hard coating which adds strength and oxidative protection to the agglomerated cereal matrix and resists stickiness at high humidity and temperature during storage.

Should a low fat variety of product be desired, up to 10% fat, preferably about 5% to 9% fat can be added by spray prior to any sugar coating. Substantially less fat is used in this embodiment than prior art granolas. If desired, fat and sugar may be applied in a single step although we prefer to employ multiple coating steps. When no fat is added to the cereal, the fat content of the total cereal is usually less than 2%.

The sugar syrup will be applied at around 70 DEG Brix and will be fluid enough to be delivered by suitable spray or other coating application equipment known in the arts; generally the degrees Brix is below 75 in order to assure good distribution of syrup providing a complete continuous coating over the particles in the final agglomerate. Commonly, the syrup will be elevated to a temperature where all of the solids are in solution and the syrup may thereafter be applied after the particles are oil coated.

Fat and sugar may be applied by alternative coating means or simultaneously as an emulsion wherein the sugar is dissolved in water and the fat is emulsified therewith. Methods whereby the cereal components are aggregated and thereafter agglomerated will be varied depending upon ultimate intended texture. Thus, in one, the cereal particles may be co-mixed with a dry powderous saccharide mixture and the dextrinized cereal and wetted by a water spray, water addition to the mix or admission to a humid atmosphere. The saccharides, exposed to moisture, will be partially or totally dissolved and cause the cereal mixture particles to agglomerate on mixing or tumbling.

Another alternative may be the "creaming" of the aforesaid powderous saccharides with or without oil in a plastic state to produce a sugar-cream type of homogeneous mixture. This material will desirably have only minimal amount of water added to it and will be whipped or otherwise mixed to produce a moderate degree of overrun; having produced this low density matrix-forming saccharide mixture, the cereal mixture ingredients will be folded in uniformly to produce an agglomerate. The agglomerates mix can be ultimately subjected to a dehydration or baking operation with an optional forming operation, typically a 1 inch bed being compacted to, say, a 3/4 inch bed and subdivided or broken after drying for sizing to the desired agglomerate or cut into granola bars.

1967/2197

In the preferred embodiment, part of the basis for agglomeration of thecereal components is the use of from 1% to 5%, preferably 1% to 3% of a maltodextrin which is added dry with the cereal ingredients prior to sugar addition. On wetting, the maltodextrin causes the cereal surfaces to be tackler than would be the case without the dry maltodextrin. The maltodextrin can be a derived from a cereal grain or a tuber (i.e., tapioca, potato, etc.) wherein the starch is converted to maltodextrin with a DE of from 3 to

20 such as Rice*Trin brand rice maltodextrin available from Zumbro, Inc., Hayfield, Minn., 55940.

The invention is further described but not limited by the following examples.

EXAMPLE 1

A no fat-added granola is prepared as follows. The following dry fraction ingredients are weighed and added to a coating reel (multiflighted). For the purpose of this Example, a coating reel is utilized.

>;tb;______________________________________

>;tb; %

>;tb;______________________________________

>;tb;Ground Cereal Flakes 59.5

>;tb;Quick Cooking Rolled Oats

>;tb; 15.1

>;tb;Crisp Rice 20.8

>;tb;Maltodextrin 3.2

>;tb;Sweet Whey 1.4

>;tb;______________________________________

The dry fraction ingredients are mixed in a coating reel operating at 30-60 RPM for 5 minutes.

Optionally almonds or coconut could be added to the dried ingredients above. Where oil addition is desired, oil is poured or sprayed onto the preblended dry ingredients in the mixing vessel and mixed for an additional 5 minutes at the same speed to insure distribution of the oil on the surfaces of the ingredients and impregnation thereof. This particular example did not incorporate oil addition.

Separately, a coating syrup is prepared having the following ingredients.

>;tb;______________________________________

>;tb; %

>;tb;______________________________________

>;tb;Molasses 7.0

>;tb;Corn Syrup - 42 DE

>;tb; 9.0

>;tb;Honey 26.0

>;tb;Water 58.0

>;tb;______________________________________

The foregoing coating ingredients are dissolved at 170 DEG F. to produce a syrup solution which is poured or sprayed at 170 DEG F. onto the dry ingredients (optionally oil coated) fraction, in the rotating reel, and mixed for an additional 5 minutes of tumbling so as to promote uniform coating of the material and particle aggregation.

Liquid sucrose at 67% solids is then poured or sprayed on the cereal mix, and agitated to thoroughly coat the cereal mass.

Blend percentages of the following fractions is as follows:

>;tb;______________________________________

>;tb; %

>;tb;______________________________________

>;tb;Dry Ingredient Fraction

>;tb; 66.0

>;tb;Coating Syrup 8.0

>;tb;Liquid Sucrose 26.0

>;tb;______________________________________

1968/2197

The coated aggregates are then removed from the coating reel and loaded into tray-type dryer screens at a moisture content of approximately 15% and a bed depth of at least 1/2 inch and usually 3/4 inch to

1 inch or more. The material is leveled prior to drying with a spatula to induce slight compression and consequent compaction. The loaded screens are then subjected to an air circulation dryer wherein the material is dried using an air temperature of at least 180 DEG F., preferably 240 DEG-250 DEG F. for

15 minutes, with a maximum updraft air flow to produce a dried sheet of cereal having a moisture content under 5%. The dry cereal sheet is broken apart while still in a warm plastic state, cooled and sized by passing through a wire screen having 3/4 inch openings. The sized, cooled agglomerate is then collected for packaging. The dried agglomerates have a final moisture of 1-3.0%.

EXAMPLES 2 & 3

Two granola cereals were prepared designed to provide 3 grams of fat and 3 grams of fiber (3,3 formula) and 0 grams of fat and 3 grams of fiber (0,3 formula) for each 28.35 gram serving of cereal.

>;tb;______________________________________

>;tb; 3.3 formula

>;tb; 0.3 formula

>;tb;Ingredient % as is % as is

>;tb;______________________________________

>;tb;Wheat Bran Flake 37.5 38.9

>;tb;Rolled oats 4.8 --

>;tb;Crisp Rice 5.7 13.6

>;tb;A dry blend of other

>;tb; 17.0 12.8

>;tb;cereal ingredients

>;tb;Rolled oats Rolled oats

>;tb;Oat Flour Rice*Trin 10

>;tb;Rice*Trin 10 Sweet Whey

>;tb;Sweet Whey

>;tb;Sunflower oil 7.6 no oil added

>;tb;Coating Syrup I 8.4 8.5

>;tb;Water

>;tb;Honey

>;tb;2 DE Corn Syrup

>;tb;Molasses

>;tb;Sugar Syrup II 19.0 19.0

>;tb;Liquid Sucrose

>;tb;TOTAL 100.0 100.0

>;tb;______________________________________

The bran flakes are sized in a rotary mill at a rate of 1220 lbs./hr. Average screen fraction was:

>;tb;______________________________________

>;tb; %

>;tb;______________________________________

>;tb; On 1/4" 5.4

>;tb; On #12 screen

>;tb; 70.0

>;tb; On pan 24.6

>;tb;______________________________________

The flakes were conveyed to a feed bin which caused further breakage and gave a final screen fraction of:

>;tb;______________________________________

>;tb; %

>;tb;______________________________________

>;tb; On 1/4" 1.7

>;tb; On #12 screen

>;tb; 59.3

1969/2197

>;tb; On pan 39.0

>;tb;______________________________________

Rolled oats and crisp rice were prepared as is known in the art and described herein. The dry ingredients were combined as well as mixed. Sunflower oil was applied in formula 3,3 in a mixing conveyor. The coating syrup was mixed and heated to 170 DEG F. The mixture at 38% solids and about 150 DEG F. to 170 DEG F. was sprayed onto the cereal as it is mixed. The sucrose syrup (70% solids) was heated to 170 DEG F. and sprayed on the cereal mix as it was being mixed.

The brix of the liquid ingredients was as follows:

>;tb;______________________________________

>;tb; Bx

>;tb;______________________________________

>;tb;Sucrose 67.5

>;tb;Honey 81.8

>;tb;42 DE Corn syrup 83.5

>;tb;Molasses 79.2

>;tb;______________________________________

The mixture was conveyed to a Proctor and Swartz Drier operating under the following conditions.

>;tb;______________________________________

>;tb; 3,3 formula

>;tb; 0,3 formula

>;tb;______________________________________

>;tb;Belt speed (volts)

>;tb; 32-35 40

>;tb;Bed depth (inches)

>;tb; 1.5-1.75 1.75-2.0

>;tb;Air temperature ( DEGF.)

>;tb;Zone #1 205 215

>;tb;Zone #2 210 220

>;tb;Zone #3 210 220

>;tb;______________________________________

The dried product, in sheets, exiting the drier was forced through a 3/4 inch top table screen, cooled and then packaged.

A screen fraction of the product after cooling is:

>;tb;______________________________________

>;tb; Weight %

>;tb; After Cooling

>;tb;Screen 3,3 0,3

>;tb;______________________________________

>;tb;On 1/2" 6.9 6.3

>;tb;On 1/4" 42.2 37.5

>;tb;On #6 36.7 37.4

>;tb;On pan 14.2 18.2

>;tb;Moisture - % 3.1 2.8

>;tb;______________________________________

The final product characteristics (%) are as follows:

>;tb;______________________________________

>;tb; 3 Fat, 3 Fiber

>;tb; 0 Fat,3 Fiber

>;tb; Product Product

>;tb;______________________________________

>;tb;Wheat Bran Flakes

>;tb; 41.2 43.8

>;tb;Rolled Oats 10.4 11.1

1970/2197

>;tb;Oat Flour 10.0 --

>;tb;Maltodextrin (Rice*Trin 10)

>;tb; 2.3 2.3


>;tb;Sweet Whey 1.0 1.0

>;tb;Sugar 14.0 19.8

>;tb;Honey 2.0 2.0

>;tb;Corn Syrup .7 .7

>;tb;Molasses .5 .5

>;tb;Sunflower oil 8.3 none

>;tb;Water 3.5 3.5

>;tb; 100.00 100.00

>;tb;______________________________________

EXAMPLE 4

In a similar fashion as described in Examples 2 and 3, a granola cereal was prepared which provided 2 grams of fat and 3 grams of fiber for each 28.35 gram serving of cereal. The identical process was utilized to produce this granola cereal. The compositional makeup of the blend of ingredients and the finished final food product is given in the table below.

>;tb;______________________________________

>;tb; Blend Finished Food

>;tb; % %

>;tb;______________________________________

>;tb;Wheat Bran Flakes 38.2 41.9


>;tb;Oat Flour 9.5 10.4

>;tb;Rolled Grains 9.8 10.6

>;tb;(Combination of oats

>;tb;and barley)

>;tb;Sweet Whey 1.0 1.1

>;tb;Maltodextrin (Rice*Trin 10)

>;tb; 1.9 2.1

>;tb;Sunflower oil 5.8 6.4

>;tb;Honey 2.3 2.1

>;tb;Corn Syrup 42 DE .8 .7

>;tb;Molasses .6 .5

>;tb;Water 4.9 3.5

>;tb;Liquid Sugar 19.4 14.3

>;tb; 100.0 100.0


Worldwide Claims:


We claim:

1. A granola cereal containing up to 10% fat prepared from a major amount of cereal base which is agglomerated and formed into clusters with a coating syrup which comprises 60% to 85% cereal base and 10% to 30% added sugar, said cereal base comprising from 30% to 50% cereal flakes based upon the weight of the granola cereal product, 5% to 20% rolled grains selected from the group consisting of rolled oats, wheat, barley and combinations thereof, from 0 to 20% cereal flour and from 5% to 20% crisp rice, and from about 1% to about 5% maltodextrin to improve the tackiness of the cereal mixture, said cereal flakes having a particle size wherein a major amount of the flakes after passing through a

1/4 inch screen are retained on a #12 mesh screen while the remainder of the flakes pass the #12 mesh screen, said particle size further improving agglomeration of the clusters, and said 10% to 30% added sugar being present as a coating for the agglomerated clusters of cereal.

1971/2197

2. The product of claim 1 wherein the maltodextrin has a DE of from 3 to 20 and wherein the maltodextrin is derived from a cereal grain or tuber.

3. The product of claim 1 wherein the cereal flakes are ground to a particle size such that from 0 to about 10% are retained on a 1/4 inch screen, of the remainder of the cereal flakes from about 50% to about 90% pass through a 1/4 inch screen and rest on a #12 sieve screen and about 10% to about 50% pass through a #12 sieve screen and rest on the pan.

4. The product of claim 1 wherein the cereal flakes are ground to a particle size such that from about

60% to about 80% pass through a 1/4 inch screen and rest on a #12 sieve screen and about 20% to about 40% pass through a #12 sieve screen and rest on the pan.

5. The product of claim 1 wherein the cereal base comprises from 35% to 45% cereal flakes, from 5% to 15% rolled grains and from 5% to 15% crisp rice.

6. The product of claim 1 wherein the cereal base contains from 5% to 15% cereal flour.

7. The product of claim 1 wherein the sugar coating comprises from 1% to 15% of amorphous monosaccharides based upon the weight of the granola cereal said amorphous monosaccharides being effective to achieve a semi-glossy, noncrystallizing coating.

8. The product of claim 1 wherein the granola cereal contains no added fat.

9. The product of claim 2 wherein the cereal flakes are ground to a particle size such that from about

50% to about 90% pass through a 1/4 inch screen and rest on a #12 sieve screen and about 10% to about 50% pass through a #12 sieve screen and rest on the pan, the cereal base comprises from 35% to

45% cereal flakes, from 5% to 15% rolled grains, 5% to 15% cereal flour and from 5% to 15% crisp rice, and the sugar coating comprises from 1% to 15% of amorphous monosaccharides based upon the weight of the granola cereal, said amorphous monosaccharides being effective to achieve a semi-glossy noncrystalline coating.Data supplied from the esp@cenet database - Worldwide

1972/2197

404.

US5427810 - 6/27/1995

METHOD FOR HYDROTHERMAL TREATMENT OF STARCH PRODUCTS,

PARTICULARLY RICE


Inventor(s): VORWERCK KARLDIETRICH (DE); BRANDT UWE (DE)

Applicant(s): BUEHLER GMBH (DE)


IP Class: A23L1/182

E Class: A23L1/182; A23L1/10H2; A23B9/00


Priority Number: DE19904009157 (19900322); US19930135363 (19931012); US19920896491

(19920602); US19910660712 (19910222)

Family: US5427810

Abstract:


Parboiled rice, or a similar starch-containing product, is produced by moistening the rice in a preheating installation 1 and, thereafter, applying steam to heat the rice to boiling temperature. The rice

1973/2197

is kept at the boiling temperature in a heat-retaining vessel 9 for cooking rice. Thereupon, the rice is dried in a drying installation 12 and cooled, if necessary.Claims:


What is claimed is:

1. A method for hydro-thermally treating a starch containing product, wherein the product has a water content attained by absorption of water, the method comprising the steps of inserting the product into a heating element; supplying heat energy to the product via the heating element at atmospheric pressure until boiling temperature of the water content is attained, the product being moistened prior to said heat-supplying step in order to reach a predetermined content of said absorbed water in the starch product; inserting the product into a heat-retaining vessel; moving the product through the heatretaining vessel via movement in a first direction; maintaining the boiling product within the heatretaining vessel having a heat retaining zone so as to keep the product at an automatically controlled boiling temperature during a predetermined period, the maintaining being accomplished by flowing a heated medium in a second direction transverse to said first direction across a path of the movement of the product; inserting the product into a drying zone; and drying the product in the drying zone after completion of said maintaining step.

2. Method as claimed in claim 1, wherein heat energy is supplied by adding hot steam.

3. Method as claimed in claim 1, wherein heat energy is supplied to said heat retaining zone in an amount only for compensating natural heat losses.

4. Method as claimed in claim 1, further comprising a step of preheating the moist product up to a temperature between 50 DEG C. and 75 DEG C. before supplying heat energy to boiling temperature.

5. Method as claimed in claim 4, wherein said preheating step is effected up to a temperature of about

65 DEG C..+-.5%.

6. Method as claimed in claim 1, wherein said drying step is effected in at least two steps.

7. Method as claimed in claim 1, further comprising the step of cooling the product after said heat retaining zone and said drying step.

8. Method as claimed in claim 1, wherein said starch containing product is rice.

9. A method according to claim 1, further comprising a step, prior to said heat-supplying step of moistening the starch containing product, the product being in the form of numerous particles.

10. A method according to claim 9 further comprising concurrently with said maintaining step, passing the particles through the heat-retaining vessel to prevent deposition of the particles within the vessel, said passing step including a step of establishing predetermined flow profile to the particles.

11. A method according to claim 9, wherein said steam is at atmospheric pressure.

12. A method according to claim 11 further comprising concurrently with said maintaining step, passing the particles through the heat-retaining vessel to prevent deposition of the particles within the vessel, said passing step including a step of establishing a predetermined flow profile to the particles.

13. A method for hydro-thermally treating a starch containing product, comprising the steps of inserting the product into a soaking vessel; moistening a starch containing product in the soaking vessel, the product being in the form of numerous particles or rice, the moistening being accomplished by soaking the product in water up to a predetermined moisture content in the starch; preheating the product in the soaking vessel; transferring the product from the vessel to a steamer; supplying heat to the product in the steamer via steam, distant from said water, to raise the temperature of the product to boiling temperature; inserting the product in a heat-retaining vessel having a heat-retaining and heatloss compensating zone; moving the product through the heat-retaining vessel via movement in a first

1974/2197

direction; maintaining the boiling product within the heat-retaining vessel so as to keep the product automatically at a controlled boiling temperature during a predetermined period, the maintaining being accomplished by flowing a heated medium in a second direction transverse to said first direction across a path of the movement of the product; inserting the product into a drying zone; and drying the product in the drying zone after completion of said maintaining step.

14. A method for hydrothermally treating a non-parboiled starch containing product, wherein the product has a water content attained by absorption of water, the method comprising the at least quasicontinuous process steps of: inserting the product into a heating unit at atmospheric pressure; supplying heat energy to the product in the heating unit at atmospheric pressure until boiling temperature of the product is attained, the product being moistened prior to said heat energy supplying step in order to reach a predetermined content of absorbed water in the starch product; inserting the product into a heatretaining vessel; moving the product through the heat-retaining vessel via movement in a first direction; maintaining the boiling product within the heat-retaining vessel at atmospheric pressure so as to keep the product at an automatically controlled boiling temperature during a predetermined period, the maintaining being accomplished by flowing a heated medium in a second direction transverse to said first direction across a path of the movement of the product; inserting the product into a drying zone; and at least partially drying the product in the drying zone after completion of said maintaining step.

15. A method according to claim 14, further comprising the step of heating the boiling product within the heat-retaining vessel merely by compensating for natural heat losses causing the starch to slowly gelatinize.

16. A method according to claim 15, further comprising the steps of: supplying a limited amount of water to the product to heat the product during the heat energy supplying step; and performing said further heating step without further addition of water.

17. A method according to claim 14, wherein said predetermined period is approximately 10 to 40 minutes.

18. A method according to claim 14, wherein said predetermined content of absorbed water is approximately 30% to 35%.

19. A method according to claim 14, wherein the supplying of heat energy is performed by applying hot steam.Data supplied from the esp@cenet database - Worldwide

1975/2197

405.

US5489440 - 2/6/1996

RICE FLOUR-BASED ORAL REHYDRATION SOLUTION


Inventor(s): NDIFE LOUIS I (US); ANLOAGUE PAUL S (US); BEACH ROSA C B (US);

RUSHLOW MICHELLE M B (US); NEYLAN MICHAEL J (US)

Applicant(s): ABBOTT LAB (US)

IP Class 4 Digits: A61K

IP Class: A61K9/14

E Class: A23J3/34C; A23L1/105B; A23L1/305C



Family: US5489440

Abstract:

1976/2197


A method for producing an improved rice flour-based oral rehydration solution using the enzymes cellulase and protease is disclosed. The oral rehydration solution of the invention has low viscosity, low osmolality, and can be ingested through the nipple of a bottle. The oral rehydration product can also be dried into powder form before packaging and reconstituted at the time of use. The product is designed to treat individuals with severe diarrhea brought about by cholera or other causes.Description:


TECHNICAL FIELD

The present invention relates to an improved oral rehydration solution (ORS) that contains enzymatically treated rice flour. More particularly the invention relates to a stable rice flour oral rehydration solution with low viscosity and low osmolality that can be ingested through the nipple of a bottle. The improved ORS may be in ready-to-feed form or dehydrated to a powder that can be reconstituted at the time of consumption.


Diarrhea can be a debilitating disease in both children and adults. In developing countries diseases that result in diarrhea are the largest single cause of death among infants and children. Fluid and weight loss from diarrhea can result in severe dehydration, electrolyte imbalance, and acid-base disturbance.

The development of oral rehydration therapy has reduced morbidity and mortality from acute diarrheal diseases, particularly in less developed countries. Oral rehydration solutions (ORS) typically consist of a mixture of electrolytes and a carbohydrate component such as glucose or sucrose. The World Health

Organization (WHO) recommends that oral rehydration solutions contain 20 g of glucose, 3.5 g sodium chloride, 2.5 g sodium hydrogen carbonate, 2.9 g trisodium citrate dehydrate and 1.5 g potassium chloride. These are to be mixed with one liter of water. This and similar glucose-based oral rehydration solutions have provided a simple means for treating or preventing dehydration due to acute diarrhea in infants and children. However, while glucose-based solutions stimulate the intestinal absorption of fluid and electrolytes from isotonic luminal contents, they do not aid in the reabsorption of fluid secreted by the intestine and thus do not lessen the severity of diarrhea. This lack of efficacy in controlling diarrhea constitutes a barrier to global acceptance of oral rehydration therapy and indicates that there is a need for a superior product.

Many studies have indicated that oral rehydration solutions prepared from rice may not only ameliorate dehydration, but may also decrease diarrheal fluid loss and reduce stool output. Rice is cheap, safe, and easily obtained and eaten by a large fraction of the world population. However, rice, as used in several studies discussed below, has some disadvantages including the need for cooking, the possibility of incorrect preparation, its relative insolubility in liquid resulting in rapid precipitation after mixing, and the need for it to be spoon fed to infants. The rice-based oral rehydration solution of the instant invention, produced through a process that utilizes enzymatic digestion of the cellulose and protein fractions of rice flour, retains the advantages of a rice-based solution and overcomes these disadvantages.

Patra et al., (Archives of Disease in Childhood, 57:910-912, 1982) demonstrated in a controlled trial of oral rehydration therapy for infants and young children with acute diarrhea the superiority of a ricebased oral solution to the WHO recommended glucose electrolyte solution as shown by a lower rate of stool output, a shorter duration of diarrhea, and a smaller intake of rehydration fluid. In the solution of

Patra et al. glucose was replaced by "pop rice" powder. Pop rice, which is commonly consumed in the

Indian subcontinent, is prepared by popping unhusked rice on heated sand. In this study the pop rice was made into powder form and dissolved in the rehydration fluid before use. The rehydration solution was fed by cup and spoon or directly from a cup. Thus, although the efficacy of a rice-based solution was demonstrated, the methods of preparation and delivery had the disadvantage of requiring on-site activity by the person feeding the patient.

In a randomized trial of children and adults suffering from cholera or cholera-like diarrhea, Molla et al.,

(Bulletin of the World Health Organization, 63(4):751-756, 1985) found that rice-based oral

1977/2197

rehydration solutions decreased the stool volume more effectively than glucose or sucrose oral rehydration solutions. In this study, rice powder was boiled in water to produce a colloidal suspension.

After cooling, electrolytes were added to the gruel mixture. The mixture had to be prepared shortly before administration and was fed to patients by their attendants.

Bhan et al., (Journal of Pediatric Gastroenterology and Nutrition, 6:392-399, 1987) found a trend toward improvement in efficacy, as measured by recovery from diarrhea with 72 hours, with pop rice

ORS as compared with the standard glucose electrolyte solution or with a mung bean solution in children suffering from acute diarrhea caused predominantly by rotavirus or Escherichia coli. In this study rice was obtained from the local market and made into powder form before use. It was then mixed in boiled water, and given to the mother to be fed by cup and spoon.

In a controlled clinical trial with infants with acute diarrhea El-Mougi et al., (Journal of Pediatric

Gastroenterology and Nutrition 7:572-576, 1988) demonstrated the efficacy of rice powder-based oral rehydration solutions. Rice powder and salts were placed in packets and dissolved in hot water and stirred at the time of utilization. It was then cooked until a gel was formed, cooled, and consumed warm in a semi-liquid form. It was determined that the rice powder-based ORS did not ferment before

24 hours even without refrigeration. Outcome measurements, including watery stool output, showed that rice ORS is at least as good, and possibly better than glucose ORS therapeutically and nutritionally. The authors concluded by advocating additional food technology research to make a rice enriched ORS ready for use by mothers who do not read directions well. The present inventors have produced such a product.

Results of a clinical trial reported by Pizarro et al., (New England Journal of Medicine 324:517-521,

1991) indicated that stable, ready-to-use commercially prepared rice-based oral electrolyte solutions containing rice-syrup solids were more efficient than glucose-based solutions in promoting fluid and electrolyte absorption during rehydration in infants with acute diarrhea. This study demonstrates the utility of a rice-based, ready-to use commercially prepared ORS. However, the rice-based ORS of this study contained only rice glucose polymers, not whole rice, unlike the present invention, and the solution was not produced by the method of the present inventors.

Gore et al., (British Medical Journal 304:287-291, 1992) undertook a meta-analysis of clinical trials that compared the benefit of rice oral rehydration salts solutions with the glucose-based WHO oral rehydration salts solution for treating and preventing dehydration in patients with severe dehydrating diarrhea. Using stool output during the first 24 hours as the main outcome measure they found that rice solution significantly reduces stool output in adults and children with cholera and to a lesser extent reduces the rate of stool loss in infants and children with acute non-cholera diarrhea. This metaanalysis serves to confirm the results of previous individual trials of rice-based solutions, thereby underscoring the desirability of producing a product that delivers a rice-based ORS in a commercially available, safe, and easily ingested form as was done by the present inventors.

Islam et al., (Archives of Disease in Childhood 71:19-23, 1994) conducted a prospective, randomized controlled trial to evaluate the efficacy and digestibility of rice-based oral rehydration therapy in infants less than 6 months old compared with WHO ORS. The results of this trial support the hypothesis that rice oral rehydration therapy can be safely and effectively used in the management of acute diarrhea in infants younger than 6 months. These findings are consistent with the results of previous studies, discussed above, conducted with older children and adults.

Tao et al.(U.S. Pat. No. 5,096,894) disclose a ready-to-use ORS comprising a mixture of rice dextrin and electrolytes and a process for clarifying rice dextrins. Rice dextrins are rice syrup sugars containing glucose polymers of varying lengths. By contrast the present inventors use rice flour obtained from ground rice in the preparation of a ready-to-use ORS or an ORS in powdered form. Tao et al. teach that rice flour is not suitable as a carbohydrate component for a clear, shelf-stable, ready-to-use ORS because of its insolubility, product appearance, and problems associated with sterilization. These problems have all been successfully solved in the instant invention, which has the additional attribute of being nipple feedable.

Lebenthal (U.S. Pat. No. 5,120,539, WO 92/12721) discloses a method for treating diarrhea in infants by administering a solution containing a complex carbohydrate that has been hydrolyzed by .alpha.-

1978/2197

amylase. Rice powder is one of the carbohydrates that can be used in preparing the diarrhea treatment product disclosed by Lebenthal. Lebenthal does not address problems of osmolality and the propensity of the powder to precipitate out of solution. By contrast, the instant invention results in a stable product of low osmolality capable of being ingested through the nipple of a bottle.

Shacknai et al. (Wo 91/15199) disclose a composition for treating diarrhea that is suitable for children and adults and comprises a nutritional substance, a synthetic fiber, and electrolytes. Rice flour is one of the nutritional substances that can be used in this composition. Method and conditions of production are not taught, nor is product stability or viscosity addressed.

An object of the present invention is to provide a ready-to-use ORS containing rice flour in a stable form with low osmolality and low viscosity suitable for delivery to infants through the nipple of a bottle, or a powdered form of the product that can be reconstituted before use and that has the same desirable properties. A further object of the present invention is to provide an improved rice flour based

ORS that results in lower net fluid intake and reduced stool output during the rehydration period of treatment of children with dehydration caused by acute diarrhea.


FIG. 1 is a flow diagram of the process for producing the rice flour-based solution of the invention.


The present invention provides a product, a rice flour-based solution for oral rehydration therapy, and a process for preparing a product comprising enzymatic digestion of rice flour and addition of a stabilizer and electrolytes. The product may additionally be sweetened with Aspartame.RTM. or any other suitable artificial sweetener. The process of the invention results in a rice-flour based ORS that is stable, has low osmolality and low viscosity, and can be administered to an infant through a nipple. The product was terminally sterilized, making it microbiologically safe and ready-to-use. The product can, in another embodiment be dried, sterilized, and packaged in powder form to be reconstituted at the time of use.

There is disclosed a process for producing an oral rehydration solution containing electrolytes and rice flour comprising the steps of adding rice flour to water while agitating to produce a rice slurry; gelatinizing the rice slurry by heating; cooling the slurry sufficiently to permit enzymatic hydrolysis; adding the enzymes cellulase and protease to the slurry and allowing enzymatic digestion to occur for a period of time sufficient to permit hydrolysis of the rice flour; inactivating the enzymes with heat and then cooling the slurry; adding a stabilizer, minerals, and citric acid; homogenizing the slurry; standardizing the solution by adding water; and terminally sterilizing the product. There is further disclosed a process for drying the oral rehydration solution into a powder. There is further disclosed an oral rehydration product produced by the process for producing an oral rehydration solution and an oral rehydration product produced by the process for producing an oral rehydration solution where the product is dried into a powder. There is further disclosed a method of treating an individual requiring oral rehydration comprising feeding the individual a therapeutically effective amount of the oral rehydration product produced by the disclosed process.

Representative of the stabilizers useful in the present invention are carboxymethylcellulose (CMC), carrageenan, and gum arabic. CMC is the preferred stabilizer. Potassium chloride, sodium citrate, citric acid, and sodium chloride are representative of the electrolytes useful in the present invention. One skilled in this art will appreciate that various substitutes can be made. Neutrase.RTM. (a protease) and cellulase are representative of the enzymes useful in the present invention. Enzymes for digestion of rice flour protein and cellulase are available from various suppliers. Aspartame.RTM. is representative of the sweeteners useful in the present invention that may optionally be added. Strawberry, fruit punch, banana bubble gum, blue raspberry, and lemon cream are representative of artificial flavors that can be optionally added.


1979/2197

EXAMPLE I

Rice flour is made from rice kernels that have been boiled, dehusked, and ground. The rice flour-based oral rehydration solution of the present invention was prepared by first adding rice flour to cold or room temperature water while agitating until the mixture contains 6% total solids. To gelatinize the mixture the rice slurry was heated to 205 DEG-210 DEG F. (96 DEG-99 DEG C.) for 5 to 10 minutes and allowed to cool to 120 DEG-130 DEG F. (49 DEG-55 DEG C.) for enzymatic digestion. To hydrolyze the rice flour, a cellulase and protease were added and hydrolysis was allowed to proceed for a period of time that varies depending on the amount of enzyme added. When cellulase was added at

1% by weight of the fiber content of the rice flour and protease was added at 3% by weight of the protein content of the rice flour, one hour was required for hydrolysis. One skilled in the art will be able to determine the enzyme concentrations and hence the time required for hydrolysis under different conditions. The enzymes were inactivated by heating the slurry to 200 DEG-205 DEG F. (94 DEG-96

DEG C.) for 5 to 10 minutes. The slurry was then cooled to 155 DEG-165 DEG F. (68 DEG-74 DEG

C.). Carboxymethylcellulose (CMC), minerals and citric acid were added and the solution was homogenized at 4000/500 PSIG (27579.028/3447.3785 kPa). Concentrations of the components was brought to the desired dilution by the addition of water. Flavor and coloring solutions were optionally added. The solution can also be dried to a powder. FIG. 1 is a flow diagram of the process for producing a rice flour-based solution for oral rehydration therapy. The contents of the rice flour-based oral rehydration solution of this Example are shown in Table 1.

>;tb; TABLE 1

>;tb;______________________________________

>;tb;Rice Flour-Based Oral Rehydration Solution

>;tb; Total Yield

>;tb; kg/

>;tb;Ingredients lbs/1000 lbs

>;tb; 453 kg

>;tb;______________________________________

>;tb;Water 941.00 426.27

>;tb;Rice Flour (Riviana Rice, Houston, TX)

>;tb; 49.00 22.20

>;tb;CMC 4.81 2.18

>;tb;Potassium Chloride 1.55 0.70

>;tb;Sodium Citrate 1.36 0.62

>;tb;Citric Acid 1.12 0.51

>;tb;Sodium Chloride 0.83 0.38

>;tb;Neutrase .RTM. (Novo-Nordisk, Bagsvaerd,

>;tb; 0.25 0.11

>;tb;DK)

>;tb;Cellulase (Solvay Enzymes, Elkhart, IN)

>;tb; 0.10 0.05

>;tb;Flavors/Colors Optional

>;tb;______________________________________

It is known that adding rice in some form to an oral rehydration solution that contains electrolytes results in lower stool volume in patients suffering from acute diarrhea. The problem confronting the present inventors was to develop an ORS containing rice that could be commercially prepared so that it would not have to be mixed at the time of use, would be stable so that rice would not precipitate out of solution, had low osmolality, and could be ingested through the nipple of a bottle so that it did not have to be spoon fed to an infant. The product produced by the method of the present invention meets these criteria.

The following experiments illustrate the critical features determined during the development of the invention.

Experiment 1: Hydration of Rice Granules

1980/2197

Medium grain rice flour ground to 200 U.S. mesh size (RM-200) for use in the ORS of the invention was obtained from Riviana Rice (Houston, Tex.) and added to cold or room temperature water until the resulting rice flour slurry contains total solids in the range of 2 to 7%. Total solids should be within this range in order to optimize two requirements for a useful product. Water is normally absorbed from the digestive tract into cells of the large intestine and colon. Failure of the cells of the large intestine or colon to absorb water from the digestive tract can result in diarrhea, which can lead to dehydration and ion loss. Glucose is normally cotransported with sodium during the active transport of sodium ions.

This is accompanied by the diffusion of water into the cells from the lumen of the gut, a necessary process in the prevention or recovery from diarrhea. If total solids constitute less than 2% of the slurry, not enough glucose will be available to be cotransported with sodium ions from the digestive tract into the cells. This results in insufficient reabsorption of sodium and suboptimal reabsorption of water from the lumen into the cells of the gut. If total solids constitute more than 7% of the slurry, there will be insufficient water to fully hydrate the rice granules. A preferred range of total solids is between 5 and

6%, with the most preferred being 6%.

Experiment 2: Gelatinization of Rice Slurry at Critical Temperature

The rice slurry, which was at room temperature, was heated to between 205 DEG and 210 DEG F. (96

DEG-99 DEG C.) and held at a temperature within this range for between 5 and 10 minutes. It is critical for the practice of the invention that the temperature be maintained at 202 DEG F. (94.4 DEG

C.) or higher and preferably within the range 205 DEG-210 DEG F. (96 DEG-99 DEG C.) during the gelatinization period. Before arriving at the critical temperature, the inventors experimented with temperatures of 180 DEG and 195 DEG F. (82 DEG and 94.9 DEG C.). At these temperatures the rice granules were not adequately gelatinized, and consequently the product did not have the desired characteristic of low viscosity that would permit nipple feeding.

Experiment 3: Hydrolysis

The gelatinized rice slurry was cooled to between 120 DEG and 130 DEG F. (49 DEG-54.4 DEG C.) for enzymatic hydrolysis. As shown in Table 2 various combinations of hydrolyzing enzymes were tried before determining that a cellulase and a protease were the preferred enzymes for use in the invention. The cellulase and protease may be added simultaneously or sequentially, and either can be added first.

>;tb; TABLE 2

>;tb;______________________________________

>;tb;Treatment Viscosity (mPa s*)

>;tb;______________________________________

>;tb;No enzyme 46

>;tb;Protease 15

>;tb;Cellulase 20

>;tb;Protease + cellulase 9.1

>;tb;.alpha.-amylase 8.5

>;tb;amylasese + .alpha. 8.4

>;tb;amylasee + .alpha. 7.6

>;tb;amylasee + cellulase + .alpha.

>;tb; 6.5

>;tb;______________________________________

>;tb; *Viscosity values are in units of millipascal seconds (mPa s), which is

>;tb; equivalent to centipoises (cp)

The combination of amylase plus cellulase plus protease resulted in the least viscosity. That combination, however, had high osmolality, which is an undesirable characteristic for the treatment of diarrhea as osmotic pressure will result in the flow of water into the intestine. When amylase was eliminated, the resulting combination of cellulase plus protease had the desirable characteristics of low osmolality and low viscosity.

In the preferred embodiment Cellulase AC (Solvay Enzymes, Elkhart, Ind.) and Neutrase.RTM. (Novo-

Nordisk, Bagsvaerd, DK) were added to the slurry to hydrolyze the rice and the hydrolysis was allowed to proceed for one hour. The slurry was then heated to between 200 DEG and 205 DEG F. (94 DEG-96

1981/2197

DEG C.) for 5 to 10 minutes in order to inactivate the enzymes. It was determined that a one hour hydrolysis resulted in polymers of a size best suited for a product of low viscosity and low osmolality.

After the enzymes were inactivated the slurry was cooled to between 155 DEG and 165 DEG F. (68.5

DEG-74 DEG C.).

Experiment 4: Stabilizer, Minerals, and Citric Acid

Carboxymethylcellulose (CMC) was added as a stabilizer. A study was done to determine the optimal level of CMC for the rice flour-based ORS. CMC was added to the product at the following levels:

0.2%, 0.3%, 0.4%, 0.5%, 0.8% of the total weight of the final product. Results indicated that the level of CMC must be not less that 0.3% in order for the product to remain stable and homogenous for at least 4 hours. The maximum amount of CMC permitted by the FDA in food products is 0.8%, therefore, stability and homogeneity were tested up to that point only. Stability and homogeneity of the product at the 0.5% level were found to be as good as at the 0.8% level and were slightly better than at the 0.3% level. Therefore, in the most preferred embodiment 0.5% CMC was added as a stabilizer.

Experiments were performed to determine the preferred stabilizer. Carrageenan, in both the iota and kappa form, and gum arabic were tested at the 0.5% level and compared with CMC. The product had less physical stability as measured by phase separation when carrageenan or gum arabic were used. The most preferred stabilizer that best prevented phase separation within four hours was determined to be

CMC.

Potassium and sodium salts and citric acid were added as shown in Table 1 and comply with WHO recommendations for oral rehydration solutions. Citrate is required in order to maintain the acid:base balance. Mineral salts and citric acid were added within clinically accepted ranges.

Experiment 5: Homogenization and Standardization

The product was homogenized at 4000/500 PSIG (pressure per square inch gauge)

(27579.028/3447.3785 kPa) at a temperature between 160 DEG and 170 DEG F. (71 DEG-77 DEG C.) and then cooled. The product was made ready for packaging with the addition of enough water to bring total solid content of the product to between 5.0 and 5.5%.

Experiment 6: Production of Powdered Rice Flour-Based Product and Reconstitution

A known volume of the ready-to-feed product from Example I was freeze-dried completely to a powder. To reconstitute the product into a ready-to-feed solution, fresh, clean water was added at a volume equivalent in volume to the volume before freeze-drying.

The product produced by the process described above, both in its original ready-to-feed form or in its reconstituted form has low osmolality, which is desirable for water retention, and low viscosity so it can be fed to infants through the nipple of a bottle.

The following example illustrates the use of the invention in the treatment of acute diarrhea in children.

EXAMPLE II:

Clinical Comparison of Rice Flour-Based ORS with Glucose ORS

Oral electrolyte solutions currently used in the United States and the solution distributed by the WHO contain glucose as the carbohydrate source. Glucose-based solutions are effective in replacing fluid and electrolytes lost during acute diarrhea, but are ineffective in controlling stool volume or the duration of diarrhea. Oral rehydration solutions containing alternative carbohydrate sources, such as the rice flour of the present invention or other cereals, are intended to be an improvement in that they not only replace fluid and electrolytes but also decrease stool volume, reduce duration of diarrhea, and may have some nutritive value. The greatest efficacy has been shown to be solutions to which rice flour was added. However, because rice flour is relatively insoluble previously used solutions, as discussed above, had to be mixed and consumed by spoon feeding at the time of administration.

1982/2197

The present inventors have developed a rice flour-based solution in which the rice flour remains in suspension and has the added beneficial characteristics of low osmolality and low viscosity. A clinical study was carried out to evaluate the efficacy of the rice flour-based rehydration solution of the present invention when compared with a glucose-based ORS.

Children aged 3 to 24 months who presented with acute diarrhea, defined as three or more watery stools within 24 hours, were eligible for enrollment. Enrolled children were randomized to receive either a glucose-based ORS (Rehydralyte.RTM., Ross Products Division, Abbott Laboratories,

Columbus, Ohio) or the rice-flour based solution of the invention. It is envisioned that 100 children will eventually be enrolled. Data from the first 56 patients to complete the study were analyzed and are presented here. The inventors will amend this specification when the study has been completed.

Patients were rehydrated with either the glucose-based (Rehydralyte.RTM.) or the rice-based ORS of the invention, which has an electrolyte composition like that of Rehydralyte.RTM.. After rehydration, when the fluid deficit had been replaced, the control group that had received the glucose-based solution was given a standard maintenance solution (Pedialyte.RTM., Ross Products Division, Abbott

Laboratories, Columbus, Ohio) and the experimental group that had received the rice-based solution was continued on a rice-based solution that had an electrolyte composition similar to Pedialyte.RTM..

Both groups were also fed with Isomil.RTM. (Ross Products Division, Abbott Laboratories, Columbus,

Ohio), a soy-based infant formula.

A 48 hour fluid balance study was conducted to determine the volume of intake and stool losses. Fluid intake and losses due to either vomiting or stool output were determined by weighing the feeding containers before and after feeding, diapers before and after stool, and diapers placed under the patient's head to collect vomitus. Duration of diarrhea was also recorded.

Patient characteristics are shown in Table 3. The mean age of the subjects in the rice flour group and, consequently, their weights were significantly greater than in the Rehydralyte.RTM. group.

>;tb; TABLE 3

>;tb;______________________________________

>;tb;Characteristics of Patients on Admission (Mean .+-. SEM)

>;tb; Rice flour-based ORS

>;tb; Rehydralyte .RTM.

>;tb; (Invention)

>;tb;______________________________________

>;tb;No. of Patients

>;tb; 29 27

>;tb;Age at Admission

>;tb; 12 .+-. 1@a

>;tb; 15 .+-. 1@b

>;tb;(months)

>;tb;Weight (kg) 8.6 .+-. 0.2@a

>;tb; 9.4 .+-. 0.3@b

>;tb;Duration of Diarrhea

>;tb; 2.0 .+-. 0.2

>;tb; 1.9 .+-. 0.2

>;tb;Prior to Admission

>;tb;(days)

>;tb;Number of Stools in

>;tb; 12 .+-. 1 10 .+-. 1

>;tb;Previous 24 hrs

>;tb;(Mean .+-. SEM)

>;tb;Degree of Dehydration

>;tb;Mild 15/29 (52%) 19/27 (70%)

>;tb;Moderate 14/29 (48%) 8/27 (30%)

>;tb;Vomiting on Admission

>;tb; 20/25 (80%) 19/26 (73%)

>;tb;______________________________________

>;tb; a >; b, P >; 0.05

1983/2197

Fluid intake and stool output are shown in Table 4. During the first six hour of the study, fluid intake and stool output were significantly less, using parametric analysis, in the rice flour group when compared with the Rehydralyte.RTM. group. Although the trend was similar during other study periods, the differences were not statistically significant. These preliminary results suggest that a ricebased ORS solution of the kind produced by the process of the invention is clearly advantageous during the first six hours when treating children suffering from dehydration secondary to acute diarrhea and may continue to be similarly advantageous during for the following 42 hours of treatment.

>;tb; TABLE 4

>;tb;______________________________________

>;tb;Fluid Intake and Stool Output (Mean .+-. SEM)

>;tb; Rice Flour ORS

>;tb; Rehydralyte .RTM.

>;tb; (Invention)

>;tb;______________________________________

>;tb;Net Fluid Intake*

>;tb;(mg/kg/day)

>;tb; 0-6 hours 139 .+-. 11@a

>;tb; 110 .+-. 8@b

>;tb; 6-12 hours 89 .+-. 11 75 .+-. 9

>;tb;12-24 hours 138 .+-. 19 108 .+-. 10

>;tb;24-48 hours 212 .+-. 36 187 .+-. 22

>;tb;Stool Output (g/kg/day)

>;tb; 0-6 hours 64 .+-. 10@a

>;tb; 41 .+-. 7@b

>;tb; 6-12 hours 44 .+-. 6 45 .+-. 10

>;tb;12-24 hours 86 .+-. 15 62 .+-. 8

>;tb;24-48 hours 116 .+-. 30 90 .+-. 18

>;tb;______________________________________

>;tb; *Total Fluid Intake minus vomiting

>;tb; a ; b, P >; 0.05

Industrial Applicability

Previous studies have shown that oral rehydration solutions prepared from rice may be superior to glucose-based oral rehydration solutions in ameliorating dehydration and reducing stool output in individuals suffering from severe diarrhea. To be optimally useful the product must have the property of low osmolality. Previous formulations, however, suffered from the need to be prepared on-site and from the requirement that they be consumed either from a cup or fed by spoon. These presented problems of hygiene and administration. In one embodiment the present invention eliminates the need for on-site preparation and cup or spoon feeding by delivering a microbiologically safe product in liquid form that, because of its property of low viscosity, can be consumed by an infant through the nipple of a bottle. The low osmolality of the present invention alleviates the problem of fluid loss that accompanies severe diarrhea. In an alternative embodiment the product prepared according to the method of the invention is dried and must be reconstituted at the time of use. When reconstituted it still possesses low viscosity and, hence, the desirable property of being able to pass through the nipple of a bottle.

The method described herein constitutes preferred embodiments of this invention. However, the invention is not limited to this precise form of the method and changes may be made without departing from the scope of the invention, which is defined in the appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A process for producing an oral rehydration solution containing electrolytes and rice flour comprising the steps of: (a) adding the rice flour to water while agitating to produce a rice slurry; (b)

1984/2197

gelatinizing the rice slurry by heating; (c) cooling the slurry sufficiently to permit enzymatic hydrolysis; (d) adding the enzymes cellulase and protease to the slurry and allowing enzymatic digestion to occur for a period of time sufficient to permit hydrolysis of the rice flour; (e) inactivating the enzymes with heat and then cooling the slurry; (f) adding a stabilizer, minerals, and citric acid; (g) homogenizing the slurry; (i) standardizing the solution by adding water; and (j) terminally sterilizing the product.

2. The process according to claim 1 wherein the rice flour is added to cold or room temperature water to produce a rice slurry containing 2-7% total solids.

3. The process according to claim 1 wherein the rice slurry is gelatinized by heating to a temperature of at least 202 DEG F. (94.4 DEG C.) for between 5 and 10 minutes.

4. The process according to claim 3 wherein the rice slurry is gelatinized by heating to between 205

DEG and 210 DEG F. (96 DEG-99 DEG C.).

5. The process according to claim 1 wherein the gelatinized rice slurry is cooled to between 120 DEG and 130 DEG F. (49 DEG-54.4 DEG C.) and the enzymes are added thereafter.

6. The process according to claim 1 wherein the enzymes are inactivated after hydrolysis at a temperature between 200 DEG and 205 DEG F. (94 DEG-96 DEG C.) for 5 to 10 minutes.

7. The process according to claim 1 wherein the slurry is cooled to between 155 DEG and 165 DEG F.

(68.5 DEG-74 DEG C.) before adding the stabilizer, minerals, and citric acid.

8. The process according to claim 7 wherein the stabilizer is selected from the group consisting of carboxymethylcellulose (CMC), carrageenan, and gum arabic.

9. The process according to claim 8 wherein carboxymethylcellulose is added at 0.3%-0.8% of the total weight of the final product.

10. The process according to claim 8 wherein carboxymethylcellulose is added at 0.5% of the total weight of the final product.

11. The process according to claim 7 wherein the minerals are selected from the group consisting of potassium chloride, sodium citrate, and sodium chloride.

12. The process according to claim 1 wherein the slurry is homogenized at 4000/500 PSIG

(27579.028/3447.3785 kPa).

13. The process according to claim 1 further comprising drying the solution into a powder.

14. An oral rehydration product produced by the method of claim 1.

15. The oral rehydration product according to claim 14 wherein the product is dried into a powder.

16. A method of treating an individual requiring oral rehydration comprising feeding the individual a therapeutically effective amount of the oral rehydration product of claim 1.

17. A method of treatment according to claim 16 further comprising feeding through the nipple of a bottle.Data supplied from the esp@cenet database - Worldwide

1985/2197

406.

US5514398 - 5/7/1996

FOOD ADDITIVE AND USE THEREOF


Inventor(s): IMAI YUTAKA (JP); OGAWA TOMONARI (JP); TSURUMI CHIHO (JP);

KITAGAWA MASATOSHI (JP); TANAKA HIDERO (JP)

Applicant(s): AMANO PHARMA CO LTD (JP)


IP Class: A23D7/00

E Class: A23L1/10E; A23L1/308A; A23L1/24; A23L1/015E; A23L1/015E2; A61K31/575


Priority Number: WO1992JP01299 (19921006); JP19900300507 (19901105)

Family: US5514398

Abstract:


PCT No. PCT/JP92/01299 Sec. 371 Date Jun. 6, 1994 Sec. 102(e) Date Jun. 6, 1994 PCT Filed Oct. 6,

1992 PCT Pub. No. WO94/07378 PCT Pub. Date Apr. 14, 1994.An additive for cholesterol-containing food, containing a rice bran component and/or a derivative thereof as an active ingredient, a method of using same, and food treated thereby; and a process for producing mayonnaise controlled in the rise of a blood cholesterol level, or the absorption of cholesterol. A method of decreasing the effect of cholesterol contained in food on a living organism, for example, controlling the rise of a blood cholesterol level by adding to cholesterol-containing food a food additive capable of forming a complex with cholesterol, such as an extract of a rice bran component, gamma -orizanol ( gamma -OZ) which is a mixture of esters of ferulic acid with various alcohols prepared by refining said extract and/or a derivative of a rice bran component, thereby forming a cholesterol complex of the food additive, whereby the cholesterol contained in food becomes nonabsorbable by a living organism or can be removed therefrom.

1986/2197

407.

US5562021 - 10/8/1996

DEVICE FOR PREPARING GRAIN CAKES


Inventor(s): SLANIK JOSEF (CA)

IP Class 4 Digits: A23L; A47J; A23P

IP Class: A23L1/00; A23P1/00; A47J27/08; A47J37/00

E Class: A23L1/18C2; A23P1/14B4



Family: US5562021

Abstract:


A device for preparing puffed food products from cereals such as rice wherein the cereal is subjected to pressure and heat, the device comprising a mold having a cavity defined by a wall thereabouts, an interior surface extending about the cavity, a piston moveable into and out of the cavity, there being provided a recess formed in the interior surface of the cavity wall with an insert being located within the recess. The insert permits greater tolerances in the manufacture of the device and also acts as a thermal insulator to minimize thermal changes.Claims:

1987/2197


I claim:

1. A device for preparing food products from cereals which are subjected to pressure and heat, the device comprising a cavity defined by a cavity wall having an interior surface about said cavity, at least one piston movable into and out of said cavity, a recess being formed in the interior surface of said cavity wall, said recess having a certain depth, an insert being located within said recess, said insert having an interior dimension at least equal to or slightly greater than the external dimension of said piston, said insert having an external dimension less than the internal dimension of said recess such that said insert can move within said recess.

2. The device of claim 1 wherein said cavity and said piston are of a generally cylindrical configuration.

3. The device of claim 1 wherein said device comprises a mold having a plurality of cavities.

4. The device of claim 1 wherein said piston includes a heater mounted interiorly thereof.

5. The device of claim 1 wherein a bottom of said cavity is defined by a lower piston, said lower piston being moveable within said cavity to eject a product therefrom.

6. An apparatus for producing a cooked cereal product, said apparatus comprising a mold having at least one cavity therein, a piston moveable into and out of said cavity, means for feeding a cereal grain to said cavity, said piston having heating means associated therewith, a recess being formed within a side wall about said cavity, an insert located within said recess, said insert being dimensioned to be slightly spaced from said side wall, said insert being dimensioned to have a size equal to or slightly larger than the dimension of said piston.

7. The apparatus of claim 6 wherein both said piston and said mold adjacent said cavity have heating means associated therewith.

8. The apparatus of claim 7 wherein said mold has a plurality of cavities formed therein.

9. The apparatus of claim 7 wherein said mold has at least five cavities formed therein.

10. The apparatus of claim 8 further including pressure equalizing means associated with each piston moveable into and out of said cavity, said pressure equalizing means being adapted to equalize the pressure within each cavity.Data supplied from the esp@cenet database - Worldwide

1988/2197

408.

US5562938 - 10/8/1996



Inventor(s): LEE YANIEN (US); MERRITT CARLETON G (US); GILLMORE STEPHEN R

(US); DERMODY NANCY E (US)


IP Class 4 Digits: A23L; B65B; B65D

IP Class: A23L3/10; B65B25/02; B65D85/00

E Class: A23L1/182; A23L1/16; A23L1/16D; A23L1/182B; A23B7/10; A23B9/26; A23L3/10;

A23L3/3463; B65B25/00A; A23L3/3508; A23L1/16B; A23G3/26; A23P1/08B14; A21C15/00B;

A23L1/00P8B14; A23L3/16D


Priority Number: US19870140208 (19871231); US19900511965 (19900417); US19950446320

(19950522); US19940177950 (19940106); US19920912116 (19920709); US19920991454

(19921215); US19910745055 (19910806)

Family: US5562938

Abstract:


Fully cooked, starchy foodstuffs, such as rice and pasta, are preserved against microbiological spoilage by treatment with a predetermined quantity of an edible acid. Packages of fully cooked starchy foodstuffs are provided which are shelf-stable for periods in excess of 6 months and are neutralized to a proper pH to avoid sourness. Ready-to-eat meals of neutralized acid preserved starchy foodstuffs are also provided. Edible alkaline neutralizing agents may be used to balance the pH. Also provided are methods for producing shelf-stable fully cooked, starchy foodstuffs wherein measured quantities of acid are introduced to fully cooked, starchy foodstuffs to inhibit microbiological growth.Description:



This invention is directed to packaged fully cooked meals which are preserved against microbiological spoilage, methods for producing such packaged meals, and the ready-to-eat meals that may be so packaged. More particularly, this invention is directed to fully cooked, starchy foodstuffs which are stabilized against spoilage at room temperature by reducing their pH values to acidic levels, and to such packaged foodstuffs.


Reducing the pH of food products by the addition of an edible acid to preserve against microbiological spoilage is well known. Such a method for preserving food is often referred to as "pickling" or "acid preservation". This method of preservation is common for uncooked foods such as olives, cucumbers, peppers and other raw vegetables. This method is well suited for foods where a tart flavor is desired, such as pickles, salad dressings, relishes and the like.

1989/2197

The preservation of starchy foodstuffs by the addition of an edible acid has been accomplished.

Although enhanced shelf-stability is obtained, there are drawbacks. Foodstuffs so preserved exhibit a tart, sour taste due to the presence of the acid. This is acceptable for some food preparations such as cold pasta and potato salads with dressings having an acidic pH. It is recognized that to expand the versatility of acid-preserved starchy foodstuffs, the sour taste contributed by the acid used must be avoided.

For example, Tiberio et al., U.S. Pat. No. 4,477,478, teaches the use of fumaric acid in combination with acetic acid to preserve dressings for salad having a lower perceived tartness. In addition, Saitoh et al., U.S. Pat. No. 4,552,772, disclose the use of salt with citric or lactic acid to improve the palatability of cooked, acid-preserved, wheat flour based alimentary pastes. Although an improvement in taste is alleged, Saitoh et al. admit that the product exhibits a detectable sourness, although weakened, at column 4, line 15 of the patent.

It remains desirable to provide an acid-preservation system for cooked starchy foodstuffs, particularly alimentary pastes, rice and potatoes, while avoiding, minimizing or overcoming the sour taste of the acid utilized.


There is provided by this invention (1) a shelf-stable, fully cooked meal, (2) a ready-to-eat meal that can be packaged, and (3) a method for producing a shelf-stable, fully cooked, starchy foodstuff, that may be packaged.

In one embodiment, the package of a shelf-stable, fully cooked meal of this invention comprises two containers. A primary container isolates a preserved food composition sealed therein from atmospheric oxygen. This preserved food composition comprises a shelf-stable, fully cooked, starchy foodstuff and an edible acid that is uniformly dispersed in this primary container with said foodstuff, in a quantity which provides shelf-stability. The quantity of acid preferably provides a pH for the starchy foodstuff of about 3.5 to about 4.6, preferably 4.0 to 4.5, more preferably 4.2 to 4.5. A secondary container isolates the contents therein from the preserved food composition. The contents of the secondary container comprise an edible alkaline neutralizing agent in a quantity sufficient upon mixing with the starchy foodstuff to increase its pH to a value in the range of about 5 to about 7.

The process of this invention for producing a packaged, shelf-stable, fully cooked, starchy foodstuff comprises first preparing a starchy foodstuff for packaging by:

(a) heating the starchy foodstuff in boiling water, steam or combinations thereof until fully cooked, the quantity of water/steam being sufficient to provide the desired moisture level in the starchy foodstuff,

(b) adding a quantity of an aqueous solution of an edible acid to the fully cooked, starchy foodstuff sufficient to provide shelf-stability, wherein said edible acid preferably provides a pH for the starchy foodstuff in the range of about 3.5 to about 4.6, more preferably 4.0 to 4.5, and more preferably 4.2 to

4.5,

(c) mixing the edible acid solution and the fully cooked, starchy foodstuff to distribute the edible acid on the foodstuff, and

(d) mixing an edible lubricant, preferably a vegetable oil, with the mixture of edible acid and starchy foodstuff, wherein the edible lubricant has a melting point below about 95 DEG F. (35 DEG C.), is used in a quantity up to about 15% by weight, based on the weight of the total package contents, and forms a coating on the foodstuff.

A container is then filled with the thus prepared starchy foodstuff, sealed to exclude atmospheric oxygen and the contents of said container are then aseptically packaged, i.e., they are sterilized or pasteurized once packaged or are maintained under sterile or pasteurized conditions during packaging.

The container isolates its contents from atmospheric oxygen and is resistant to wet heat at a temperature above about 180 DEG F. (82 DEG C.). "Wet heat" refers to the condition of high temperatures (above about 180 DEG F.) and high humidity (above about 85 DEG RH). Such conditions are present within a steam tunnel or within a vessel of boiling water.


1990/2197

The starchy foodstuffs suitable for use in this invention include grains, potatoes, starchy legumes and alimentary pastes. Preferably, the starchy foodstuff has a porous surface and is selected from grains, alimentary pastes and potatoes. Examples of preferred grains include rice, barley and wheat. The starchy foodstuffs selected for use in the present invention must be ready to be cooked, i.e., prepared for cooking and consumption by the removal of any hard, inedible shell by peeling, pearling or other means. Of the grains, rice is most preferred.

Of the alimentary pastes, virtually any paste obtained from a glutinous flour is suitable for use in the embodiments of this invention. Examples of suitable glutinous flours include semolina flour, durum wheat flour, corn flour, buckwheat flour, farina flour and whole wheat flour. Their pastes all exhibit porous surfaces. Pastes obtained from rice flour, a nonglutinous flour, are also suitable, especially if the starch is gelatinized or partially gelatinized.

Potatoes that have been cut and/or peeled so as to expose porous surfaces are suitable for use. Any variety of potato may be used in the present invention.

The starchy foodstuff used is fully cooked so that it may be eaten as is from its container directly off the shelf or heated to a desired temperature. Heating the starchy foodstuff to cause it to absorb additional moisture, gelatinize additional starch, or denature additional protein is not required. Each of these phenomena may occur upon heating, but is of no consequence to this invention.

When fully cooked, alimentary pastes generally have moisture contents of about 65% to 85% by weight. Fully cooked rice generally has a moisture content of from about 60% to about 70% or more by weight, and fully cooked potatoes generally have a moisture content of about 70% to 80% by weight.

These values for moisture levels are provided as guides only. The fully cooked, starchy foodstuffs used in the present invention are not limited to species having these moisture levels.

The packaged starchy foodstuffs of the present invention are shelf-stable. The term "shelf-stable," as used herein, indicates that the foodstuff is stabilized against spoilage by microbiological growth at room temperature for a period of not less than 1 week. Preferably, the starchy foodstuffs are preserved against microbiological spoilage for a period of 6 months or more. To achieve shelf-stability, an edible acid is admixed with the starchy foodstuff. The pH of the starchy foodstuff is reduced to acidic levels of from about 3.5 to about 4.6 with the solution of edible acid, preferably 4.0 to 4.5, more preferably to

4.2 to 4.5, and most preferably, to 4.3.

Starchy foodstuffs are not inherently acidic, so it is necessary to add an edible acid, i,e., one which can be ingested without harmful effect. Suitable acids include acetic acid, citric acid, tartaric acid, hydrochloric acid, malic acid, propionic acid, adipic acid, fumaric acid, phosphoric acid, lactic acid, sorbic acid, benzoic acid and mixtures thereof. Certain acids may be preferred because of their effectiveness. The quantity of edible acid added to the starchy foodstuff is preferably sufficient to provide a pH within the ranges described above. Preferred pH values fall in the range of about 4.0 to

4.6, or more preferably 4.2 to about 4.5.

To be effective, the edible acid is distributed in a substantially uniform manner so as to retard the growth of molds, bacterial and yeasts which cause spoilage. The acid may be diluted to aid distribution.

For pasta, an acid concentration of 5% to 10% in an aqueous solution is preferred, and for rice, 10% to

20%. It is preferable that the acid penetrate into the surface of the starchy foodstuffs, which is why porous starchy foodstuffs are preferred. For example, rice which has been acid preserved has been found to have a shelf life of more than 9 months at room temperature.

The package of a shelf-stable, fully cooked meal provided by one preferred embodiment of this invention comprises 2 containers. One of these containers is a primary container and serves to isolate a pasteurized food composition sealed therein from atmospheric oxygen. This preserved composition comprises a fully cooked, starchy foodstuff preserved with an edible acid. The edible acid is uniformly distributed within the preserved food composition and is preferably used in a quantity which provides a pH for the starchy foodstuff in the range of about 4.0 to about 4.6, more preferably 4.2 to about 4.5

This can be accomplished by adding and mixing a quantity of an aqueous solution of an edible acid to the fully cooked, starchy foodstuff or by immersing the fully cooked, starchy foodstuff in a volume of

1991/2197

diluted acid and weighing the volume of diluted acid both before and after immersion to determine the quantity of acid absorbed.

The preserved food composition may contain a mixture of fully cooked, starchy foodstuff, shelf-stable foods other than starchy foodstuffs, and other components such as vegetable oil for lubrication, water to aid acid dispersion, preservatives for added shelf life, seasonings or sauces for flavor, vitamin and mineral supplements, etc. The addition of these ingredients is optional.

The primary container must be comprised of a material having good oxygen barrier properties. Such materials include metals, glass, some synthetic resins such as Saran.TM. film or other oxygen barrier films, some resin coated papers or foils, and combinations thereof. Suitable containers include metal cans, glass jars, paper/metal foil pouches, some selected synthetic resin film pouches, and suitably coated paper cartons. Metal cans or paper/foil pouches have high resistance to oxygen permeation, as do glass jars. However, such packages are undesirable for use in microwave ovens in that they reflect microwave energy. Synthetic resins generally do not reflect a significant amount of microwave energy and provide the advantage of convenience where the foodstuff is to be heated. However, synthetic resins generally have less desirable barrier properties to oxygen when compared to glass or metal.

Barrier properties of synthetic resins differ, and some resins must be modified to provide suitable barrier properties. Vapor barrier properties of synthetic resins can be enhanced by incorporating barrier resistant particles such as glass, minerals or metals in fiber, flake or particle form. Some synthetic resins are suitable without modification such as, for example, polyethylene terephthalate (medium and high density), polypropylene terephthalate (low density), polyvinylidene chloride SARAN.TM. trademark for a vinyl chloride-vinylidene chloride copolymer), and polyamides.

When a synthetic resin is selected for use in providing a pouch or rigid container for the shelf-stable, fully cooked meal, the vapor barrier properties of the container may usually be enhanced by increasing the thickness of the container wall. The thickness of the wall for a container pouch comprised of a synthetic resin preferably is in the range from about 2 mils to 5 mils. Such a container pouch provides a reasonable resistance to puncture during handling and permits effective heat sealing of the pouch.

Where the synthetic resin desired will not provide the desired barrier properties within this thickness range, thin layers of material with higher barrier properties can be added to help maintain the container thickness in this range. In a preferred embodiment, polyester pouches such as polyethylene terephthalate are used having a wall thickness of about 2 to 4 mils. Since polyethylene terephthalate has good oxygen barrier properties, it may also be used in a laminate with a base film layer that may be cheaper but is not a good oxygen barrier.

To isolate the preserved food composition from atmospheric oxygen, air must first be excluded prior to sealing the container. This can be accomplished by applying vacuum and/or compressing the container to evacuate air or by incorporating an inert atmosphere within the container such as nitrogen, carbon dioxide, or water vapor. Alternatively, water vapor may be generated from the container prior to and during sealing of said container so as to exclude a significant portion of atmospheric oxygen. A vacuum forms in the sealed container once the water vapor condenses upon cooling. Such a method is preferred in that it need not require a separate processing step where the contents of the container are sufficiently hot to generate adequate water vapor.

To complete one embodiment of the package of the shelf-stable, fully cooked meal provided by this invention, a second container is required which substantially isolates its contents from the preserved food composition. The contents of the second container comprise an edible alkaline neutralizing agent.

The quantity of this alkaline neutralizing agent is matched with the quantity of edible acid within the primary container so that upon mixing, the pH of the fully cooked, starchy foodstuff is raised to a value in the range of about 5 to about 7 when mixed. Suitable alkaline neutralizing agents comprise edible alkali metal carbonates, such as sodium bicarbonate, sodium carbonate, potassium bicarbonate and potassium carbonate. These alkaline neutralizing agents are preferably encapsulated in inert fillers, fats or oils. Suitable fats and oils include dehydrated butterfat or palm oil and suitable inert fillers include edible salts. The alkaline neutralizing agent and encapsulant are preferably in solid, dry powder form so as to prevent the growth of microorganisms and to prevent loss of the encapsulated alkaline neutralizing agent by reaction with water. The contents of the second container are preferably in solid,

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dry form, so that the container need not exhibit the oxygen barrier properties required of the primary container. Preferably, however, the second container isolates its contents from moisture and humidity.

Other ingredients may be included in the second container along with the alkaline neutralizing agent and encapsulant, provided these ingredients are shelf-stable. Such additional ingredients will more commonly be seasonings, such as, for example, salt, dehydrated cheese, dried bread crumbs, dried onions, dried chives and the like. Conventional preservatives such as propylene glycol, sodium benzoate, etc. may also be introduced.

The contents of the primary container must be pasteurized or sterile. This can be accomplished by maintaining the fully cooked, starchy foodstuff and other components under pasteurized conditions or sterile conditions until sealed within the primary container. Maintaining the fully cooked, starchy foodstuff at a temperature above about 180 DEG F. (82 DEG C.) until packaged will generally provide a pasteurized food composition. Higher temperatures are necessary to provide a sterile food composition. Alternatively, or in addition to maintaining the fully cooked, starchy foodstuff under pasteurized or sterile conditions, the contents of the primary container may be sterilized or pasteurized by any conventional means after sealing.

For example, pasteurization can be achieved by heating the contents of the primary container to a temperature above about 180 DEG F. (82 DEG C.) by treatment of the sealed primary container with steam or boiling water. For sterilization, the contents are heated to a temperature of about 212 DEG F.

(100 DEG) and above. Pasteurizing is preferred in that its effect on taste and texture of the food composition is minimized. Alternative methods of pasteurizing or sterilizing the contents of the primary container without radiant heat include treatment with microwave radiation and/or UV radiation.

A package of a shelf-stable, fully cooked meal will preferably have a shelf life greater than 1 month and more preferably will be shelf-stable for a period of at least about 6-9 months. It should be noted that a longer shelf life may be obtained by sterilizing the contents of the primary container, or by adding conventional food preservatives, such as, for example, propylene glycol, sodium benzoate and the like.

A further embodiment of the present invention is directed to a ready-to-eat meal comprising an admixture which comprises a fully cooked, starchy foodstuff selected from the group consisting of alimentary pastes, grains and potatoes. This fully cooked, starchy foodstuff is shelf-stabilized by preservation with an edible acid. Suitable edible acids include those described above for the package of a shelf-stable, fully cooked meal. Prior to incorporation into the admixture, this shelf-stable starchy foodstuff exhibits a pH value in the range of about 3.5 to 4.6, preferably 4.0 to about 4.6, more preferably 4.2 to 4.5, and most preferably about 4,3, due to the presence of the edible acid.

Also included in the admixture may be a quantity of edible alkaline neutralizing agent, generally sufficient to neutralize at least 40% by weight of the edible acid, but in any case sufficient to provide a pH having a value in the range of about 5 to about 7 for the fully cooked, starchy foodstuff within the admixture.

The ready-to-eat meals are distinguished from the packaged meals of this invention in that the edible neutralizing agent is combined with the preserved food composition in the ready-to-eat meals but the edible neutralizing agent remains isolated from the preserved food composition in the packaged meals.

Therefore, the condition of the ready-to-eat meals will be a neutralized starchy foodstuff having a pH in the range of 5-7. When in such a condition, the meal is considered "ready-to-eat."

Suitable edible neutralizing agents include sodium bicarbonate, potassium bicarbonate, sodium carbonate and potassium carbonate. The starchy foodstuffs used in the ready-to-eat and packaged meals are preferably rice and alimentary pastes. The preferred edible acids are propionic acid and lactic acid.

It is important to note that the admixture may contain other components such as sauces (cheese, egg/cream), vegetables, seasonings (salt, garlic, onion, chives), oils, foodstuffs other than the starchy foodstuffs selected above (mushrooms, meats, vegetables) which are common to pasta and rice meals, for example. In addition, this ready-to-eat or packaged meal may be heated, maintained at ambient

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temperature or chilled, where desired. The additional ingredients may be premixed with either the edible alkaline neutralizing agent or the fully cooked, starchy foodstuff. Alternatively, the additional ingredients may be mixed simultaneously with or subsequently to the admixture of these primary components.

The ready-to-eat meals provided by this invention may be obtained from a package of a shelf-stable, fully cooked meal provided by this invention and described above. However, it is important to note that these ready-to-eat meals may be obtained by utilizing components which are not packaged or are packaged by alternative means and methods.

A further embodiment of the present invention is directed to processes for producing packaged, shelfstable, fully cooked, starchy foodstuffs. The starchy foodstuffs utilized in this process are those previously defined as preferred, i.e., those selected from the group consisting of alimentary pastes, grains and potatoes. Of these starchy foodstuffs, rice and alimentary pastes are most preferred.

One preferable embodiment of the invention is a process of preparing an edible starchy foodstuff of pasta or rice that is characterized by inhibited microbiological spoilage, comprising the sequential steps of: heating said foodstuff at a temperature of at least about 180 DEG F. (82 DEG C.) to fully cook said foodstuff and render it edible, then applying to said fully cooked foodstuff an aqueous solution of an edible acid while maintaining said foodstuff at a temperature of at least about 180 DEG F. (82 DEG C.) whereby the pH of said hot acidified foodstuff is adjusted to be in the range from about 3.5 to about

4.6, as determined by placing a 50 g sample of said acidified cooked foodstuff together with 50 g of distilled water in a Waring or other intimate blender and operating said blender to form a puree, then measuring the pH of said puree, then optionally coating said foodstuff with edible oil, whereby a shelfstable cooked foodstuff is obtained.

The package produced by the process of the present invention contains an edible acid and optionally an edible lubricant in addition to the starchy foodstuffs therein. Suitable edible acids are those as defined previously, used as dilute aqueous solutions. Preferred edible acids include propionic acid and lactic acid.

The edible lubricant within the package produced by this process must have a melting point below about 95 DEG F. (35 DEG C.) to provide the desired function of preventing the fully cooked, starchy foodstuff from sticking and forming a solid mass. Preferably, below about 15% by weight edible lubricant is used, based on the total weight of the package contents. This weight limit prevents the finished product from becoming too greasy or oily and unpalatable. Preferred quantities of edible oil generally range from about 1% to 8% by weight of the total package contents. Suitable edible lubricants include corn oil, unsaturated safflower oil, palm oil, olive oil, peanut oil, coconut oil, sunflower oil and solid fats such as butterfat.

The process of this invention comprises preparing a starchy foodstuff by heating it in boiling water, steam or combinations of both until it is fully cooked. Cooking the starchy foodstuff increases its moisture content and thereby increases its tenderness. The degree of tenderness for a fully cooked, starchy foodstuff varies, depending upon personal tastes. The term "fully cooked," as used herein, is intended to include all degrees of tenderness commonly desired for ready-to-eat starchy foodstuffs. For example, with respect to alimentary pastes, those pastes cooked to provide a soft surface texture and a hard, firm center commonly referred to as "al dente" are included within the term "fully cooked," as well as those pastes which are cooked to a soft texture throughout, providing maximum moisture levels and maximum tenderness.

The quantity of water and steam utilized to cook the starchy foodstuff must be sufficient to provide the desired tenderness. Excess quantities of water can be utilized. However, when excess water is used, the starchy foodstuff must be drained, often resulting in product loss. It is preferable to avoid the need for draining the fully cooked, starchy food product.

To this fully cooked, starchy foodstuff is added an aqueous solution of an edible acid in a predetermined quantity and concentration sufficient to provide shelf-stability, i.e. to a pH having a value in the range of about 3.8 to about 4.6. Suitable quantities of acide generally fall in the range from

1994/2197

about 0.01% to 1.5% by weight of acid solution, based on the weight of fully cooked, starchy foodstuff.

The preferred pH is one having a value of about 4.0 to 4.6, or more preferably, 4.2 to 4.5.

The edible acid and fully cooked, starchy foodstuff are agitated so as to disperse the acid on the surface of the cooked foodstuff. The pH values for the starchy foodstuffs herein are determined by first mincing the starchy foodstuff, or a sample thereof, in distilled water to form a slurry or puree, and then measuring the pH of the resultant slurry or puree. Adequate slurries can be obtained for 50 gm samples of starchy foodstuff with 50 gm of distilled water by mixing in a Waring blender for about 1 minute and longer. In obtaining the desired pH, porous foodstuffs such as rice, potatoes and alimentary pastes absorb the edible acid beneath their surfaces. This is a beneficial phenomenon in that it typically enhances shelf-stability.

Agitation of the edible acid and foodstuff is preferably sufficiently mild to preserve the integrity of the foodstuff's shape and form. It is undesirable to cut, grid or mince the foodstuff while mixing it with the acid, oil, or other additive. Therefore, agitation equipment which provides the desired dispersion without damaging the shape of the foodstuff is preferred. Examples include ribbon type mixers, and the like. Where a ribbon mixer is used, agitation of from 1 to 3 minutes is suitable.

To the acidified, fully cooked, starchy foodstuff there is preferably added an edible lubricant in a quantity as described above. Mixing of the acidified, fully cooked, starchy foodstuff and the edible lubricant is not essential; however, to obtain the most beneficial effect, mixing is preferred, to distribute the lubricant over the starchy foodstuff.

It should be recognized that further steps in preparing the starchy foodstuff for consumption are suitable, such as marination, frying, blending and seasoning, etc., provided these added treatments do not interfere with shelf-stability. Other components may be added if they are shelf-stable, such as food preservatives.

The starchy foodstuff thus prepared may be sealed within a container so as to exclude atmospheric oxygen. The container must be resistant to wet heat in excess of 180 DEG F. (82 DEG C.) to permit subsequent processing and to accept the prepared starchy foodstuff when said foodstuff is hot from cooking. Those containers described above as suitable for packages of fully cooked meals provided by this invention are also suitable for use in the process described herein. Containers of glass, metal and synthetic resins are acceptable with preferred containers being comprised of synthetic resins, particularly polyesters (polyethylene terephthalate). The preferred thickness for resin film pouches ranges from about 2 mils to 4 mils.

Air must be excluded from the container prior to sealing. This can beaccomplished by an conventional means such as applying vacuum or incorporating an inert atmosphere such as nitrogen, carbon dioxide or water vapor within the container. Generating a water vapor within the container is preferred in that a separate processing step is not needed where the prepared starchy foodstuff remains hot from the cooking steps.

The contents of the packages produced by the process herein are pasteurized or sterile. This condition may be achieved by exposing the contents to sterilization processes and/or pasteurization processes subsequent to sealing the container. For example, pasteurization can be accomplished by heat treatment of the sealed packages with steam vapor or by immersion in hot water at a temperature above about

180 DEG F. (82 DEGC.). By utilizing higher temperatures, sterilization is achieved. Alternative methods for providing a sterile or pasteurized condition include treatment with UV radiation and microwave radiation.

A convenient method for achieving a pasteurized sterile condition is to maintain the prepared starchy foodstuff under pasteurized/sterile conditions after cooking until sealed in the container. Cooking the starchy foodstuff in boiling water, steam or combinations of both will pasteurize or sterilize it, depending on the temperature used. This condition can be retained by maintaining the foodstuff at a sufficiently high temperature after cooking until it has been sealed in an aseptic container. The preferred temperature range is about 180 DEG F. (82 DEG C.) to about 210 DEG F. (98 DEG ), which provides a pasteurized condition. To insure against growth of microorganisms the contents of the aseptic container may be subjected to a pasteurization step or sterilization step after sealing.

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The packaged, shelf-stable, fully cooked, starchy foodstuffs produced by the process of this invention will have a shelf life greater than 1 month and typically greater than 6 months. Shelf life may be extended by selecting particular acids, incorporating food preservatives within the fully cooked, starchy foodstuff, and/or by sterilizing the contents of the sealed package.

The following examples are provided to further illustrate the invention. In these examples and throughout the specification, all temperatures are expressed in degrees Fahrenheit and each value is accompanied by an approximation of such value in degrees Celsius. All pH values for the starchy foodstuff, described in the examples and the claims which follow, are measured from slurries of 50 gm samples of these starchy foodstuffs with 50 gm of distilled water measured after mincing the 50 gm starchy foodstuff samples in the distilled water in a Waring blender or other intimate blender for about one minute or longer. In addition, all parts and percentages are by weight, unless expressly indicated to be otherwise.

EXAMPLES 1-4

Long Term Stability of Several Packaged, Cooked, Starchy Foodstuffs

These examples demonstrate the long term stability of packaged, fully cooked, starchy foodstuffs prepared in accordance with one preferred embodiment of the process of this invention. The package produced were suitable for use as the ready-to-eat meals provided by this invention and also as the packaged meals provided by this invention.

The starchy foodstuffs in Examples 1-4 were prepared by boiling in excess water until fully cooked.

Rice was boiled for approximately 12 to 14 minutes to achieve a final moisture content of about 72% to

75% by weight. Elbow macaroni having a size of about 1" in length and 3/8" in diameter was boiled 6 to 7 minutes to achieve a final moisture content of about 68% to 72%. Egg noodles of 11/2" length and

1/16" thickness were boiled for 7 to 9 minutes to achieve a final moisture content of about 66% to about 70% by weight. The excess water was drained after these cooking times.

Edible acids diluted in water to an acid: water ratio of about 1:10, i.e. to a concentration of about 9%, were then added to the fully cooked, starchy foodstuffs. For rice, about 0.9% by weight the lactic acid solution and about 0.27% by weight the propionic acid solution were added, based on the weight of starchy foodstuff. For elbow macaroni, about 1.0% by weight the lactic acid solution and about 0.030% by weight of the propionic acid solution were added, based on the weight of starchy foodstuff. For the egg noodles, about 1.1% by weight of the lactic acid solution and about 0.033% by weight of the propionic acid solution were added, based on the weight of starchy foodstuff.

After the addition of acid, agitation of the components was accomplished within a ribbon-type mixer for 1 to 3 minutes. During mixing, corn oil was added in all examples to minimize sticking. To rice, about 8% by weight corn oil, based on the dry weight of rice, was added. For elbows, about 6% by weight corn oil was added, based on the dry weight of elbows, and for egg noodles, about 7% by weight corn oil was added, based on the dry weight of egg noodles. After the addition of corn oil, mixing continued in the ribbon mixer for about 1 to 3 minutes. The temperature of each starchy foodstuff was maintained about 180 DEG F. (82 DEG C.) in preparation for sealing within polyester pouches.

About 200 g to about 250 g of each of the starchy foodstuffs were filled in 61/2" by 8", 2 mil polyethylene terephthalate polyester film pouches. These pouches were heat sealed and passed through a steam saturation tunnel to raise or maintain the internal temperature to about 180 DEG F. (82 DEG

C.) or above within each pouch.

>;tb; TABLE I

>;tb;______________________________________

>;tb;Stability Tests

>;tb;Samples of the packaged foodstuffs produced in

>;tb;Examples 1-4 were evaluated for storage stability

>;tb;(bacterial growth) and the results were reported below.

>;tb; Storage Time in Months

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>;tb; 86 DEG F.

>;tb; 86 DEG F.

>;tb;Example

>;tb; Starchy RT@a /

>;tb; (30 DEG C.)

>;tb; (30 DEG C.)

>;tb;No. Food-Stuff 30% RH@b

>;tb; 30% RH 85% RH@b

>;tb;______________________________________


>;tb; 9 -- --


>;tb; 9 9 9

>;tb;3 Rice 9 9 9

>;tb;4 Egg Noodles 9 9 9

>;tb;______________________________________

>;tb; @a RT is room temperature.

>;tb; @b RH is relative humidity.

Bacterial growth was monitored over the course of 9 months. The total plate count for samples taken from Examples 2 and 3 above was found to decrease from 102 colonies to 80 colonies per gram after 8 weeks storage at 180 DEG F. (82 DEGC.) indicating microbiological growth was still inhibited at this time. The total plate count was acceptable after 9 months. The starchy foodstuffs were found to have the same acceptable flavor and texture after storage for 9 months as when first packaged. Beyond 9 months, microbiological spoilage was inhibited but taste, flavor and texture were found to deteriorate.

EXAMPLE 5

Package of Acid/Rice Admixture Low End of the pH Range

This example demonstrates the stability of packages produced by thisinvention where the starchy foodstuff has a pH hear the low end of the range of suitable values. Packages of fully cooked rice were produced by heating water (about 26.5 pounds) with about 200 g edible oil to a boil in a jacketed kettle, adding rice (about 11 pounds par-boiled rice) and returning the water to a boil. After 12 minutes, the heat was turned off, the kettle covered, and the rice was allowed to stand in the hot water for about 3 minutes. The kettle was then filled with more hot water and stirred with a spoon.

The excess water was drained and the cooked rice (about 29.5 pounds) was transferred to a ribbon mixer. A dilute lactic acid solution (55 g acid + 550 g water) was added and mixed in the ribbon mixer, followed by the addition of 600 g corn oil. The oil and acidified rice were mixed until the oil was uniformly dispersed.

About 59 pouches were each filled with about 220 g to 230 g of the rice/acid/oil mixture and sealed.

The pouches were then heated in a steam chamber for about 9 minutes or until an internal temperature of at least 180 DEG F. (82 DEG C.) was reached. The pH of the rice in a sample pouch was found to be

3.62 utilizing the following procedure; a 50 gm sample of rice was obtained from the pouch, blended with an equal amount (50 gm) of distilled water in a Waring blender for 1 minute and the pH of the resultant slurry was measured with a pH meter. Conventional pH meters such as a Corning pH meter and Beckman pH meter were used. To test for shelf stability, 4 bags were placed in 86 DEG F. (30

DEG C.)/85%RH for 1 week and no sign of microbiological growth was observed at the end of that time.

EXAMPLE 6

Package of Acid/Rice Admixture High End of the pH Range

This example demonstrates the stability of packages produced by this invention where the starchy foodstuff has a pH near the high end of the range of suitable values. Packages of fully cooked rice were produced by heating 19.25 pounds of water with 200 g corn oil in a Groen kettle to a boil and adding

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11.0 pounds rice. After 9.5 minutes of boiling, the heat was turned off and the kettle covered. After an additional 6 minutes with no stirring, the rice was transferred to a Ribbon-Type Mixer. The rice was mixed with dilute acid at a concentration of about 13% (55 g of 85% lactic acid + 300 g water) and about 600 g corn oil. Individual pouches were filled with 230.+-.10 g of the rice/oil/acid mixture. All pouches were then sealed, then heat treated for 9 minutes in a steam chamber. The heat treated pouches were exposed to 86 DEG 30 DEG RH for about 1 week. The pH of the treated rice within a sample pouch was about 4.65, as measured by the procedure of Example 5. No spoilage was observed at the end of 1 week.

EXAMPLE 7

Package of Acid/Rice Admixture Without a Sterilization or Pasteurization Step

This example demonstrates that a separate sterilization or pasteurization step is not necessary in the process of this invention if the starchy foodstuff is maintained pasteurized/sterile after cooking.

Individual sealed packages produced in accordance with Example 6 were exposed to 86 DEG F.(30

DEG C.)/85%RH for 1 week without heat treatment in a steam chamber. The pH of the treated rice within a sample pouch was about 4.20 after 1 week as measured by the procedure of Example 5. No spoilage resulted in these pouches.

CONTROL A

Packages of Acid/Rice Admixtures Neutralized to a pH Below 5

This control demonstrates the importance of neutralizing the starchy foodstuff to a pH above 5 to obtain acceptable flavor. Packages of fully cooked rice were prepared by bringing 21.0 pounds of water to a rapid boil in a Groen kettle, adding about 11.0 pounds of rice (Parboiled rice) and 176.0 g of mixing oil (Centrafry) and returning the water to a boil. After 9.5 minutes, the heat was turned off and the rice was allowed to stand for 10 minutes with stirring at 3 minutes intervals. The cooked rice was transferred to a Seconmak tumbler and agitated. Dilute lactic acid at about 15.5% concentration (100 g

85% lactic acid + 450 g water) was quickly added, followed by lubricant (600 g Centrafry oil + 24 g lecithin).

Fifteen pouches were each filled with the rice/acid/oil mixture (about 220 g), sealed, and heat pasteurized in a steam chamber. The contents of sampled pouches had a pH value of about 3.86, as measured by the procedure of Example 5, and a moisture level of about 60% by weight. Three pouches were placed in 86 DEG F.(30 DEG)/85%RH for about 1 week. The total plate count (bacteria) after the

1 week was less than 10.

Two 50 g samples of rice were taken from a sample package and neutralized by adding water (100 g) and mixing 15 g and 30 g, respectively, of a blend of seasoning and the neutralizing agent described below. The neutralizing agent was mixed with seasoning in a 30:1 weight ratio of seasoning to neutralizing agent. Mixing proceeded for about 1 minute. The mixture was then heated in a sauce pan until the sodium bicarbonate was released. The final pH was about 4.90 and 4.48 for the meals having

30 g seasoning/neutralizing agent and 15 g seasoning/neutralizing agent, respectively. The final pH was determined by forming a slurry of rice sample with distilled water as in Ex. 5, with a Waring blender, and measuring the pH of the slurry. The taste of each 50 g sample was distinctly sour.

Neutralizing Agent

The neutralizing agent was a food grade encapsulated sodium bicarbonate provided by SCM.RTM.

Durkee Industrial Foods under the trademark DURKOTE.RTM. sodium bicarbonate 135-70 wherein the sodium bicarbonate is encapsulated with vegetable oil so as to not react or release prematurely. The sodium bicarbonate is coated with vegetable oil so as to not react or release prematurely.

This encapsulated sodium bicarbonate is designed to be used in combination with food acids in dry mix baking and other chemically leavened products were it is desired to delay and control the reaction of an acid and the encapsulated sodium bicarbonate. The encapsulation process provides the formulator with the ability to engineer a consistent quality product. According to product specifications of Durkee

1998/2197

Industrial Foods, this particular encapsulated sodium bicarbonate comprises about 70% by weight anhydrous sodium bicarbonate (substrate) and about 30% by weight partially hydrogenated palm oil

(coating). This Durkote.RTM. encapsulated sodium bicarbonate 135-70 is packed in 100 pound (45.3 kilogram) polyethylene lined fiber drums and is stable at temperatures below 80 DEG F. in odor free environments.

EXAMPLE 8

Packages of Acid/Rice Admixture Neutralized to a pH Above 5

This example illustrates that acceptable flavor is obtained where the starchy foodstuff is neutralized to a pH above 5. Packages of fully cooked rice were prepared by bringing about 21.0 pounds of water to a rapid boil in a Groen kettle, adding 11.0 pounds of rice (parboiled) with about 176 g of oil (Centrafry) and returning the water to a boil. The heat was shut off after 9.5 minutes and the rice was allowed to stand for about an additional 10 minutes with stirring at 3 minute intervals. After standing, the cooked rice was transferred to a ribbon-type mixer. Dilute acid at about 15.5% concentration (67 g 85% lactic acid and 300 g water) was sprayed on to the rice to enhance dispersion. Lubricating oil (about 600 g

Centrafry oil and 24 g lecithin) was immediately poured over the rice.

Individual pouches were each filled with about 220.+-.10 g of therice/oil/acid mixture, sealed while the mixture was still hot (about 180 DEG), and heat pasteurized in a steam chamber at a temperature above

180 DEG F. for 10 minutes or more. The pH of the cooked rice was sampled in 4 bags and found to be

4.38, 4.47, 4.36 and 4.38, respectively, following the procedures described in Example 5 for pH measurement. The moisture level for the rice in the pouches was approximately 59.7% by weight.

Samples of rice (about 220 g) were obtained from each pouch and each was mixed with a blend of seasoning and the neutralizing agent described above in the following amounts.

(1) 10 g of a blend having a 30:1 to seasoning to neutralizing agent weight ratio;

(2) 20 g of a blend having a 30:1 to seasoning to neutralizing agent weight ratio;

(3) 20 g of a blend having a 20:1 to seasoning to neutralizing agent weight ratio; and

(4) 10 g of a blend having a 10:1 seasoning to neutralizing agent weight ratio.

Upon neutralization, brought about by heating in a sauce pan the mixture of rice with the seasoningneutralizing agent blend, the above samples (1-4) were found to have the following pH values: 5.66,

5.19, 6.23 and 6.49, respectively, utilizing the pH measurement procedures described in Example 5. All samples exhibited good taste with no objectionable sourness. These data suggest that 13 g of seasoning to 1 g of sodium bicarbonate is the preferred level for the package, fully cooked, starchy foodstuffs of

Example 8.

CONCLUSION

While the invention has been disclosed by reference to the details of preferred embodiments, this disclosure is intended to be in an illustrative rather than in a limiting sense, as it is contemplated that modifications will readily occur to those skilled in the art, within the spirit of the invention and the scope of the appended claims. This invention includes many embodiments which have not been described in the detail provided by the above examples. The absence of such detail for all embodiments does not exclude them from the embodiments claimed herein. These examples described above could be repeated with other starchy foodstuffs, edible acids, lubricants and neutralizing agents with similar results.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A process for preparing a preserved, packaged pasta or rice foodstuff characterized by inhibited microbiological spoilage comprising the sequential steps of: (a) heating said foodstuff in its raw uncooked state at a temperature of at least 180 DEG F. (82 DEG C.) to cook said foodstuff fully and render it edible, then (b) applying to said fully cooked foodstuff of step (a) a quantity of an aqueous solution of an edible acid while maintaining said foodstuff at a temperature of at least about 180 DEG

F. (82 DEG C.), said quantity of said aqueous acid solution being sufficient to produce a pH of said

1999/2197

cooked acidified foodstuff in the range from 3.5 to 4.6, inclusive, as determined by placing a 50 g sample of said acidified cooked foodstuff and 50 g of distilled water in a Waring or other intimate blender and operating said blender to form a puree, then observing the pH of said puree, then (c) as an optional step mixing said foodstuff with edible oil, and then (d) sealing said acidified foodstuff of step

(b) or optionally the acidified foodstuff of step (c) in an oxygen-barrier package, whereby a shelf-stable cooked foodstuff is obtained as a packaged product that, when the package is opened, is cooked and edible.

2. The process of claim 1 wherein the amount of acid added to said cooked foodstuff is such as to adjust the pH of said hot acidified foodstuff to a value in the range of 4.0 to 4.6, inclusive.

3. The process of claim 1 including, as an additional step, that of heating the packaged cooked foodstuff for a time and at a temperature to sterilize the contents of said package.

4. The process of claim 1 comprising the added step of incorporating in said package an inert atmosphere comprising nitrogen, prior to sealing it.

5. The process of claim 2 wherein the pH is adjusted to a value in the range of about 4.2 to about 4.5, inclusive.

6. The process of claim 5 wherein the pH is about 4.3.

7. The process of claim 5 wherein said foodstuff comprises pasta prepared from a flour selected from the group consisting of semolina, durum wheat, corn, buckwheat, farina, rice, whole wheat, and mixtures thereof.

8. A process of preparing an edible starchy foodstuff of pasta or rice that is characterized by inhibited microbiological spoilage, comprising the sequential steps of: heating said foodstuff at a temperature of at least about 180 DEG F. (82 DEG C.) to fully cook said foodstuff and render it edible, then applying to said fully cooked foodstuff an aqueous solution of an edible acid while maintaining said foodstuff at a temperature of at least about 180 DEG F. (82 DEGC.), whereby the pH of said hot acidified foodstuff is adjusted to be in the range from about 3.5 to about 4.6, as determined by placing a 50 g sample of said acidified cooked foodstuff together with 50 g of distilled water in a Waring or other intimate blender and operating said blender to form a puree, then measuring the pH of said puree, then optionally coating said foodstuff with edible oil, whereby a shelf-stable cooked foodstuff is obtained.

9. The process of claim 8 wherein the amount of said acid employed is sufficient to adjust the pH of said acidified foodstuff to be in the range from about 4.2 to about 4.5.

10. The process of claim 8 wherein said process includes the additional step of pasteurizing or sterilizing said acidified foodstuff by heating it at a temperature and for a sufficient time to sterilize it.

11. A fully cooked foodstuff that is adapted to be packaged in an oxygen-barrier container for storage, wherein said foodstuff is characterized by inhibited microbiological spoilage, consisting essentially of a fully cooked, edible, starchy foodstuff selected from the group consisting of rice and alimentary pastes from wheat or rice, said fully cooked foodstuff having applied thereto, after being fully cooked, and while being maintained at a temperature of at least 180 DEG F. (82.2 DEG C.), a sufficient amount of an aqueous solution of an edible acid to lower the pH of said foodstuff to fall within the range from about 3.5 to about 4.6 as determined by placing a 50 g sample of said acidified foodstuff, together with

50 g of distilled water, in a Waring or other intimate blender and operating said blender to form a puree, then measuring the pH of the puree, wherein said fully cooked, acidified foodstuff optionally is mixed with an edible oil.

12. The foodstuff of claim 11 wherein said acid is applied in sufficient amount that the pH of said blended foodstuff is in the range of about 4.2 to to about 4.5.

13. The foodstuff of claim 12 that is sealed within a pasturized or sterilized oxygen barrier package.

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14. The packaged foodstuff of claim 13 wherein an inert atmosphere of nitrogen is sealed in said package.

15. The starchy foodstuff of claim 14 consisting essentially of pasta.

16. A packaged, shelf-stable, fully cooked pasta product consisting essentially of a pouch made of a synthetic resin film that substantially isolates the contents of the pouch from atmospheric oxygen, the contents of said pouch being a preserved food composition consisting essentially of a fully cooked pasta, an edible acid mixed with said pasta and disposed in said pouch in a quantity sufficient to provide a pH for said pasta having a value in a range from about 4.0 to 4.6, as determined by placing a

50 g sample of acidified pasta together with 50 g of distilled water in a Waring or other intimate blender and operating said blender to form a puree, then measuring the pH of said puree, and optionally an edible lubricant mixed with said fully cooked pasta and disposed in said pouch in a quantity less than about 15% by weight of the total weight of said preserved food composition.

17. The packaged pasta of claim 16 wherein said edible acid is selected from the group consisting of propionic acid, lactic acid, and combinations thereof, and wherein said pH value is in the range from about 4.2 to about 4.5.

18. The packaged pasta of claim 16 wherein said synthetic resin film comprises a polyester film that is also a barrier to oxygen.

19. The packaged pasta of claim 16 wherein said edible acid is in the form of an aqueous solution at a concentration of the acid of not above about 12% by weight, and wherein the atmosphere in said pouch is predominantly nitrogen gas.Data supplied from the esp@cenet database - Worldwide

2001/2197

409.

US6210734 - 4/3/2001

SOFT UNPOLISHED RICE AND METHOD OF PREPARING THE SAME


Inventor(s): JUN HAK-JU (KR)


IP Class: A23L1/00

E Class: A23L1/182; A23L1/186


Priority Number: KR19970046668 (19970911); WO1998KR00275 (19980909)

Family: US6210734

Equivalent: WO9912433; KR240498

Abstract:


Softened unpolished rice on which knurling patterns are formed is provided. The rice has pores and cracks formed on a rice bran. Furthermore, the method of preparing the same is provided.Claims:


What is claimed is:

1. A method of preparing unpolished rice comprising:

dipping a rice grain into water of 25 to 35 DEG C. for 12 to 24 hours to germinate the rice and coldstoring the germinated rice at -1 to -5 DEG C. for 1 to 5 days;

cooking the cold-stored rice at 90 to 110 DEG C. for 30 to 35 minutes;

drying the cooked rice with hot air to obtain 20 to 23% of moisture content;

feeding the dried rice to two knurling rollers having different rotative speeds and rolling the rice to remove a hull of the rice and expand a rice bran of the rice;

2002/2197

spray-coating a dispersion to the rolled rice and fermenting the coated rice at 25 to 35 DEG C. for 6 to

12 hours to soften the rice bran and an endosperm of the unpolished rice; and

heating the fermented rice with hot air of 200 to 300 DEG C. for 1 to 5 minutes to carbonize the rice bran.

2. The method of claim 1 wherein the cooking step is performed using a cylindrical cooking tank which is capable of rotating, and is injected with steam.

3. The method of claim 1 or 2 wherein the cylindrical cooking tank has shaking wings.

4. The method of claim 1 wherein the fermenting step is performed by spraying a dispersion onto the rolled rice and shaking the rice, the dispersion being prepared by adding sugar, milk and soybean flour to yeast or cellulose.

5. A softened unpolished rice prepared by claim 1, wherein a knurling pattern and cracks are formed on the rice, and the rice has moisture content of 11 to 13%.

6. A method of preparing unpolished rice comprising the steps of:

dipping a rice grain into water of 25 to 35 DEG C. for 12 to 24 hours to germinate the rice and coldstoring the germinated rice at -1 to -5 DEG C. for 1 to 5 days;

cooking the cold-stored rice at 90 to 110 DEG C. for 30 to 35 minutes using a cylindrical cooking tank which is capable of rotating, is injected with steam and has stirring wings; drying the cooked rice with hot air to obtain 20 to 23% of moisture content;

feeding the dried rice to two knurling rollers having different rotative speeds and rolling the rice to remove a hull of the rice and expand a rice bran of the rice;

spray-coating a dispersion to the rolled rice and fermenting the coated rice at 25 to 35 DEG C. for 6 to 12 hours to soften the rice bran and an endosperm of the unpolished rice; and

heating the fermented rice with hot air of 200 to 300 DEG C. for 1 to 5 minutes to carbonize the rice bran.Data supplied from the esp@cenet database - Worldwide

2003/2197

410.

US6217311 - 4/17/2001

APPARATUS FOR AND METHOD OF PORTIONING RICE


Inventor(s): WADE COLIN MAXWELL (GB)

Applicant(s): SUSHI EXPRESS CO LTD (US)

IP Class 4 Digits: A23P; B29C

IP Class: A23P1/00; B29C43/00

E Class: A23L1/182; A23P1/10B



Family: US6217311


Abstract:


Apparatus for portioning rice, particularly for sushi, comprises a mould (14) horizontally shiftable between a charging position, in which a row of mould cavities (15) are filled with compressed rice, and a discharge position in which the mould cavities (15) are positioned over a tray (32) to receive the rice portions (11). When the mould (14) is in the discharge position, ejector members (26) move downwardly towards the mould, the ejector members (26) and the mould (14) then moving downwardly together until an over-centre mechanism is released to move the mould (14) upwardly with a snap action which causes the rice portions (11) to be released from the mould cavities (15) and placed in the receiving tray (32).Description:


This invention relates to apparatus for and a method of portioning rice, particularly but not exclusively, for making sushi. This is a transliteration of a Japanese word meaning seasoned rice, but it has in the western world become associated with raw fish because this is a common topping for or accompaniment to the rice.

A known machine for portioning cooked rice (called a Nigiri machine) has a number of rotatably driven wheels which, with gravity assistance, feed the rice downwardly to a pair of cooperating wheels defining a nip into which the rice is delivered. On their outer peripheries, the pair of cooperating wheels are recessed to define a mould cavity into which the rice is first delivered, then compressed as the recessed parts of the wheels move together and finally released under gravity as the recessed parts of the wheels move apart. The rice portions are thus formed and deposited individually. They are then lifted by hand and put into trays where the rice portions are normally topped, for example with fish or meat. This is a slow process the speed of which is limited by the rate of production of the rice portions by the Nigiri machine. The invention aims to provide an apparatus for and method of portioning rice which lends itself to quicker production of the rice portions.

According to a first aspect of the invention there is provided apparatus for portioning rice, comprising a mould having a mould cavity to receive a portion of the rice, filling means for filling the cavity with

2004/2197

rice, an ejector member, and means for effecting relative snap-action movement of the mould and the ejector member to cause release of the rice portion from the cavity.

Preferably, the means for effecting relative snap-action movement are operative to cause the mould to move with a snap-action with respect to the ejector member when the latter is in contact with or in close proximity to the rice portion in the cavity, to cause release of the rice portion from the cavity.

The cavity is preferably open at its top and bottom, the ejector member being of a cross-sectional shape complementary to that of the cavity, the mould moving suddenly upwardly relative to the ejector member when said snap action movement takes place.

The apparatus may comprise a chamber for holding a supply of the rice and the filling means may include compressing means for compressing the rice in the chamber, either before the rice is pressed into the mould cavity or at the same time as the rice is pressed into the mould cavity.

The mould is preferably reciprocatable between a charging position in which the mould cavity is aligned with an opening in the chamber to enable the compressing means to push the rice into the mould cavity, and a discharge position in which the mould cavity is aligned with the ejector member, ready for said snap action to take place. In a preferred embodiment, the mould is horizontally reciprocatable, in its discharge position the mould being aligned with a vertical path of movement of the ejector member.

The means for effecting relative movement between the ejector member and the mould preferably comprise an over-centre mechanism which, on release, causes a sudden release of stored energy which applies a step-function force to the mould to move the latter with respect to the ejector member with said snap action. The over-centre mechanism is preferably movable with the mould and engaged by a release member, such as a latch pin, movable with the ejector member.

When in the discharge position, the mould may be movable between a raised position and a lowered position, the ejector member being movable downwardly towards the mould when the latter is in the raised position, the ejector member and the mould then moving downwardly together until the overcentre mechanism is released to cause the mould to return to its raised position with said snap action, preferably under the force of a spring compressed during downward travel of the mould to its lowered position. When in its lowered position, the mould conveniently places the rice portion in a position very close to a receiving tray or the like, so that the snap action causes the rice portion to be released from the mould and immediately placed in the tray.

The cavity may be one of a plurality of cavities disposed side by side in the mould, the ejector member being one of a corresponding plurality of ejector members.

According to a second aspect of the invention there is provide a method of portioning rice, comprising filling a mould cavity in a mould with a portion of rice, effecting relative snap-action movement between the mould and an ejector member, thereby to release the rice portion from the mould cavity.

Rice portion apparatus, and a method of portioning rice, will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a diagrammatic side view of the apparatus,

FIG. 2 is an end view of the apparatus looking in the direction of the arrow A in FIG. 1, and

FIGS. 3 to 6 are fragmentary side views of part of the apparatus, showing four positions in a cycle of operation.

Referring principally to FIGS. 1 and 2, the apparatus comprises a hopper 1, open at the top, to receive a body of cooked rice 2. In the base of the hopper 1 is a belt conveyor 3 capable of being driven by an electric motor in the direction indicated by the arrows 4. The conveyor 3, together with rotatable paddles 5, acts to feed rice through an outlet aperture 6 in the base of the hopper and into a chamber 7 at one end of the hopper 1. A compression block 8 is vertically slidable (in the manner of a piston)

2005/2197

within the chamber 7 under the control of an operating handle 9. The base of the chamber 7 is defined by a downwardly facing opening 10 spaced vertically above a fixed support block 12. A mould assembly 13 is horizontally reciprocable in a longitudinal direction between a discharge position

(shown in full lines in FIG. 1), and a charging position (shown in broken lines in FIG. 1). The mould assembly 13 comprises a mould 14 formed with four laterally spaced mould cavities 15 each of which is of cuboid shape and open at the top and bottom of the mould. The mould 14 is attached to or integrally formed with a longitudinally projecting blanking plate 16 and with lateral extensions 17

(FIG. 2) terminating in horizontal support flanges 18. The support flanges 18 are apertured and receive, with a sliding fit, four vertical rods 19, two on each side of the apparatus.

To the base of each rod 19 is attached a linear bearing 20, the two pairs of bearing 20 on each side of the apparatus being guided along a corresponding one of two guide rails 22. Each rod 19 is surrounded by a corresponding helical compression spring 23 the lower end of which abuts the corresponding bearing 20 and the upper end of which abuts the underside of the corresponding flange 18 in oder to bias the mould 14 upwardly.

When the mould assembly 13 is in the discharge position (full lines in FIG. 1) the blanking plate 16 closes the lower opening 10 of the chamber 7 and the four mould cavities 15 are positioned below an ejector assembly 24. When the mould assembly occupies the charging position (broken lines in FIG. 1) the mould cavities 15 are aligned with the opening 10 of the chamber 7, and in this position the lower openings of the mould cavities 15 are closed by the mould support block 12 which underlines the chamber 7.

The ejector assembly 24, best shown FIG. 2, comprises a horizontal plate 25 from which project four vertically depending and laterally spaced ejector members 26 each in the form of a rod of rectangular cross-sectional shape complementary to the shape in plan of the mould cavities 15. The four ejector members 26 are in registration with the four mould cavities 15. The plate 25 also supports two depending latch pins 27. The whole ejector assembly 24 is movable in a vertical direction under the control of a handle 28.

Each lateral extension 17 carries a pivotally mounted and spring-loaded latch member 29 and beneath each latch member is disposed a fixed upwardly projecting stop 30.

The machine operates in the following manner. Cooked rice fed into the hopper 1 is delivered by the conveyor 3 and the paddles 5 into the base of the chamber. With the mould assembly 13 in the charging position, the handle 9 is operated to depress the block 8 and thereby push rice from the chamber 7 into the four mould cavities 15, the undersides of which are closed by the mould support block 12. The rice is thus compressed so as to form portions 11 occupying the whole of each mould cavity 15. When the rice has been thus compressed, it remains in the mould cavities 15 when the mould assembly 13 is shifted on the guide rails 22 to the discharge position shown in full lines in FIG. 1, the cohesiveness of the compressed rice of the portions 11 preventing the latter falling out of the now open undersides of the mould cavities 15.

The apparatus is now in the position illustrated in FIG. 3.

The handle 28 is now used to move the ejector assembly 24 downwardly against a spring bias (not shown). At the moment (FIG. 4) when the undersides of the ejector rods 26 come into close proximity to or light contact with the upper surfaces of the rice portions 11 in the cavities 15, the lower ends of the latch pins 27 engage ledges formed on the respective latch members 29, and continued movement of the handle 28 causes the whole ejector assembly 24 to move downwardly, taking the mould assembly 13 with it. During this movement from its raised position to its lowered position, the mould assembly 13 is guided for vertical movement on the rods 19 and progressively compresses the springs

23.

This downward movement of the ejector assembly and the filled mould assembly continues until the undersides of the latch members 29 engage the tops of the stops 30 (FIG. 5), whereupon the latch members move over-centre 29 and pivot (against their spring loading) until they clear the latch pins 27 to release the mould assembly 13 from the downward force applied by the ejector assembly 24. Energy for this snap action is derived from the compressed springs 23. The mould assembly 13 thus moves

2006/2197

upwardly (FIG. 6), guided on the rods 19, whilst the ejector members 26 remain in the lowered position. This separates the rice portions 11 from the mould cavities 15 and causes the rice portions 11 to be deposited neatly in the base of a collecting tray 32 which has been placed beneath the mould cavities 15 for this purpose. The downward movement of the ejector assembly 24 together with the mould assembly takes the mould 14 into the recess of the tray 32 so that the lower surfaces of the rice portions 11 are a very small distance above the tray 32. Hence the rice portions 11 have a very short vertical distance to fall into the tray when the snap action release occurs, minimising the chances of the rice portions 11 being damage After this, the handle 28 is raised to cause the ejector assembly 24 to return to its upper position under its spring loading, the latch members 29 then returning to their normal positions ready for the next cycle. The mould assembly 13, now in its raised position, is returned to its charging position beneath the chamber, for the next cycle.

It is important that the rice is pressed into the mould cavities 15 to fill the latter and to cause the rice to coalesce sufficiently to prevent it falling out of the mould cavities 15 when the latter are open. In the machine described this is achieved by the block 8 compressing the body of the rice in the chamber 7 and thereby causing the rice to be pressed into the cavities 15. If required, the rice in the chamber 7 could be pre-compressed in a separate stage whilst the cavities 15 filled in a preceding cycle are being emptied. Also, it will be appreciated that the described machine could be readily automated. For example, cooked rice could be delivered to the hopper 1 at a predetermined rate and trays 32 filled with rice portions could be successively filled at the outlet end of the apparatus.

The snap-action movement of the mould 14 is important because it is this step-function force or impulse which overcomes the frictional engagement of the rice with the mould cavity surfaces, and causes the rice portions 11 to be separated from the mould 14 without breakage of the rice portions 11.

The apparatus thus produces four rice portions for each cycle, a large improvement in speed over known machines. It will be appreciated that more than four portions could be produced in each cycle by appropriately increasing the number of mould cavities and the number of ejector rods.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. Apparatus for portioning cooked rice, the apparatus comprising a chamber for holding a supply of the cooked rice, a mould having a mould cavity with an open top and an open bottom, filling means for filling the cavity with cooked rice from the chamber, an ejector member of a cross-sectional shape complementary to that of the cavity, the mould being shiftable horizontally between a charging position in which the mould cavity is aligned with an opening in the chamber to enable the filling means to fill the cavity with a portion of the rice and a discharge position in which the mould cavity is aligned with the ejector member, the mould when in the discharge position also being shiftable vertically between a raised position, and a lowered position, an over-centre mechanism releasable when the mould is in the lowered position in order to apply a step-function force to the mould to move the mould to its raised position with a sudden impulsive movement, to cause the ejector member to penetrate the cavity and effect release of the rice portion from the cavity.

2. Apparatus according to claim 1, wherein the over-centre mechanism comprises a latch member movable with the mould, the latch member engaging a stop at the lowered position of the mould to cause release of the over-centre mechanism.

3. Apparatus according to claim 1, wherein the ejector member is movable downwardly towards the mould when the latter is in the raised position, the ejector member and the mould then moving downwardly together until the over-centre mechanism is released.

4. Apparatus according to claim 1, wherein a spring is compressed during downward travel of the mould to its lowered position, energy stored in the compressed spring providing the step-function force.

2007/2197

5. Apparatus according to claim 1, wherein the mould, when in its lowered position, places the rice portion in a position very close to a receiving tray, so that the impulsive movement causes the rice portion to be released from the mould and immediately placed in the tray.

6. Apparatus according to claim 1, wherein the filling means includes compressing means for compressing the rice in the chamber, either before the rice is pressed into the mould cavity or at the same time as the rice is pressed into the mould cavity.

7. Apparatus according to claim 1, wherein the cavity is one of a plurality of cavities disposed side by side in the mould, the ejector member being one of a corresponding plurality of ejector members, so that the apparatus produces a plurality of portions of cooked rice at each cycle of operation of the apparatus.Data supplied from the esp@cenet database - Worldwide

2008/2197

411.

US6231909 - 5/15/2001

FAT-HOMOGENIZER, BEVERAGE-FROTHER, KITCHEN APPLIANCE TO

PREPARE COFFEE, TEA, MILK, EGG, SOY, AND RICE FOODSTUFF


Inventor(s): LEVINSON MELVIN L (US)

IP Class 4 Digits: A23L; A23F

IP Class: A23L1/025; A23L1/32; A23L2/00; A23F3/00; A23F5/00

E Class: A23G9/02; A23F3/18; A23F5/26K; A23L1/32; A23L2/52; A47J31/20; A47J31/54M;

A47J43/10C2


Priority Number: US19990330443 (19990611); US19980141886 (19980828); US19980073694P

(19980204)

Family: US6231909

Abstract:


A microwave-oven, hand-operated kitchen appliance to prepare coffee, tea, soy, rice, and egg beverages, froths and desserts, methods for its use and products therefrom. The kitchen appliance homogenizes saturated and unsaturated fat into skim milk, milk, cream, soy, rice and egg to produce enriched beverages, froths and desserts. Microwave-roasting of green coffee beans, soy beans, rice grains and similar beans and grains provides microwave-roasted snacks and beverages. Beverages, froths and desserts are prepared frozen, chilled or heated with and without a foam topping both alcoholic and non-alcoholic. Semi-permanent, nylon-mesh filters replace disposable paper beverage filters.Description:




A hand-operated, small kitchen appliance to prepare coffee, tea, soy, rice, milk and/or egg beverages, froths and desserts. The kitchen appliance homogenizes saturated and unsaturated fat into skim milk, milk, cream, soy, rice, egg and similar foodstuff. The kitchen appliance is used to microwave-roast green coffee beans, soy beans, rice grains and similar beans and grains to provide microwave-roasted snacks, beverages, froths and desserts. Both alcoholic and nonalcoholic beverages and desserts, with and without foam toppings, are described frozen, chilled or heated. Semi-permanent, nylon-mesh filters replace disposable paper filters.

2. Discussion of the Prior Art

Hand operated French Press coffee makers are well known. Hand operated milk frothing apparatus are well known, for example the apparatus taught in U.S. Pat. Nos. 5,580,169 and 5,780,087.

2009/2197

My U.S. Pat. No. 5,635,233, "Methods for Preparing a Coffee, Tea or Milk Beverage," teaches separating the plunger-strainer of the French Press coffee maker into a plunger member and a contiguous filter member.

My U.S. Pat. No. 5,800,852, "A Coffee/Tea, Table Blender and Microwave Oven Apparatus and

Methods for Its Use," teaches to combine the utility of a conventional blender and a microwave oven.

U.S. Pat. No. 5,800,852, teaches to blend and brew, in the jar of a table blender, coffee, tea or herbal tea immersed in a liquid. Then the brewing coffee, tea or herbal tea, in the blender jar, is removed from its motor base. The blender jar containing the still brewing beverage is placed into a microwave oven, exposed to microwave energy and heated. The blender jar, containing the microwave heated, stillbrewing beverage, is returned to its motor base and the blender motor is energized to finish brewing the beverage. The finished brew is filtered out of the blender jar through a reusable filter that covers the blender jar. The instant invention is useful to prepare a cappuccino-type froth for use on top of a beverage prepared in my table-blender/microwave-oven coffee, tea and herbal tea apparatus.

My copending U.S. Pat. No. 5,925,394 for "Methods for Denaturing and Whipping into a Foam

Certain Denaturable Proteins Found in Milk Products and Egg Products" teaches how to produce longlasting milk and egg froths and how to increase the fat content of the resulting product. This copending application concerns electric mixers. This copending application teaches that, if desired, alcohol can be used.

My copending U.S. patent application Ser. No. 08/715,396, filed Sep. 13, 1996, for "Methods of

Freezing and Defrosting Certain Foodstuffs in a Microwave Oven," teaches how to freeze and dispense frozen froths and desserts.

Prior-art, hand-operated, milk-frothing apparatus, when operated rapidly, repeatedly up and down, permit liquid fat and coffee ground to by-pass and/or block the frother member. Prior art electric table blender, the hand operated beaters and electric mixers can permit a by-pass of liquid fat when blending and mixing the liquid-fat, milk and egg mixtures, taught herein.

It is well known that commercial equipment exists to homogenize fat in milk. Soy milk and rice milk are well known commodities.


A kitchen appliance is taught that combines a French Press coffee maker, a milk frothing device and a device that can homogenize fat into milk, egg, soy, rice and other liquid products. The kitchen appliance's plunger is designed to filter coffee and tea, to froth milk, cream and egg products and to homogenize saturated and unsaturated fat into skim milk, milk, cream, egg, soy, rice and other liquid products. The kitchen appliance can consist of multiple containers. The kitchen appliance can employ multiple plungers, for example, a dedicated plunger agitator, per se, a dedicated plunger strainer, per se, a dedicated homogenizer plunger, per se, and a dedicated frothing plunger, per se, or one or more plunger-strainer-homogenizer-frothers. In one embodiment, the plunger-strainer is separated into a plunger member and a contiguous filter member as taught in U.S. Pat. No. 5,635,233. Here, the plunger member and contiguous filter can homogenize fat into beverages while they retain their prior utility.

More than one nylonmesh Lycra.RTM. filter cover and filter covers of different gauge, dimension and elasticity can be part of the kitchen appliance. Both alcoholic and non-alcoholic beverages and desserts can be prepared frozen, chilled or heated, and with and without a foam topping. The beverages, froths and desserts taught are best prepared in a microwave oven but may be prepared on a conventional gas or electric burner. In addition to plain and enriched-with-oil beverages (e.g. coffee, soy milk and rice milk), froths and desserts and the like, filled milk, microwave-roasted rice, microwave-roasted soy and the like beverages, froths and desserts are taught. "Microwaveroasting" of green coffee beans, soy beans and rice is taught. The "microwave roasted coffee beans" are ground and brewed into an

"enriched microwave roasted coffee."

It is an object of this invention to provide a kitchen appliance to homogenize saturated (e.g. butter and the like) and unsaturated fat (e.g. vegetable oil and the like) into skim milk, milk, cream, egg, soy, rice and other liquid beverages to increase their fat content.

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It is an object of this invention to homogenize butter fat into skim milk, milk, and cream to produce conventional beverages, froths and desserts.

It is an object of this invention to homogenize unsaturated fat into skim milk, milk, cream, egg, soy, rice and other liquid protein beverages to produce filled beverages, froths and desserts.

It is an object of this invention to brew coffee, generate a milk froth, and prepare a cappuccino-type beverage in the same serving container.

It is an object of this invention to employ a semi-permanent nylon-mesh Lycra.RTM. filter cover as a replacement for conventional disposable coffee and tea paper filters.

It is an object of this invention to employ a semi-permanent nylon-mesh Lycra.RTM. filter cover as a replacement for the stainless steel screen component of a French Press strainer plunger.

It is an object of this invention to provide apparatus to microwave-roast dried soybeans, dried rice and the like to create microwave-roasted snack foods, beverages, froths and desserts.

It is a further object of this invention to provide a kitchen appliance that utilizes and complements the teachings of my U.S. Pat. No. 5,635,233, my U.S. Pat. No. 5,800,852 and my copending U.S. patent application Ser. No. 08/746,809, filed Nov. 18, 1996. For example, the instant invention can be used, as taught in my copending U.S. patent application Ser. No. 08/746,809, filed Nov. 18, 1996, to prepare a milk or egg froth to add on top of a hot beverage. For example, the instant invention can be used to microwave-roast green coffee beans, dried soybeans, dried rice and the like prior to grinding them into grounds and brewing them in my "Table Blender and Microwave Oven Apparatus."

DESCRIPTION OF THE DRAWINGS

The advantages and benefits resulting from this brewing, frothing and homogenizing, hand operated kitchen appliance will become apparent from the following detailed description and by reference to the accompanying drawings in which:

FIG. 1 illustrates a side-view, cross-section, composite view of the kitchen appliance and accessories.

On top is illustrated a plunger, frother and/or homogenizing member. Below is a beverage container with a nylon-mesh Lycra.RTM. filter cover. Between is an accessory filter member and an accessory cover. In the container is an accessory milk container.

FIG. 2 is a partial, side-view, cross-section view of the plunger, frother and/or homogenizing member and accessory filter member.

FIG. 3 is a partial, side-view, cross-section view of plunger, frother and/or homogenizing member forcing accessory filter member to the bottom of the coffee-tea-beverage container.

FIG. 4 is a partial, side-view, cross-section view of the plunger, frother and/or homogenizing member disengaged from the accessory filter member after securing it at the bottom of the container. The plunger-frother is rapidly moved up and down to froth a milk or egg, coffee or tea mixture.

FIG. 5 is a partial, side-view, cross-section view of the plunger, frother and/or homogenizing member removed from the resulting homogenized, froth-covered beverage.

FIG. 6 is a cut away view that illustrates the nylon-mesh Lycra.RTM. filter cover attached to one of the containers of the kitchen appliance or to a common coffee cup. FIG. 6 illustrates the nylon-mesh

Lycra.RTM. filter filtering out spent coffee grounds from a brewing coffee as the brewed coffee passes through it.

FIG. 7 is a cut away view that illustrates how the a nylon-mesh Lycra.RTM. filter cover attaches to a container that has a lip to secure the Lycra.RTM. band thereunder and how coffee grounds are filtered out of the brewing coffee through nylon mesh filter. FIG. 7 illustrates a tight fitting nylon-mesh

Lycra.RTM. filter cover.

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FIG. 8 is a cut away view that illustrates how the a nylon-mesh Lycra.RTM. filter cover attaches to a container that lacks a lip to secure the Lycra.RTM. band thereunder and how coffee grounds are filtered out of the brewing coffee through nylon mesh filter. FIG. 8 illustrates a loosely fitting nylonmesh Lycra.RTM. filter cover.

FIG. 9 is a side view, cross-section view of the plunger, frother and/or homogenizing member homogenizing fat into a coffee, tea, soy or rice-beverage in a container.

DEFINITIONS

1. "Filled milk was defined in the Filled Milk Act (PL-513) of 1923 as follows: any milk, cream, or skimmed milk whether or not condensed, evaporated, concentrated, powdered, dried, or desiccated, to which has been added or which has been blended or compounded with any fat or oil other than milkfat, so that the resulting product is an imitation or semblance of milk, cream, or skimmed milk whether or not condensed, evaporated, concentrated, powdered, dried, or desiccated." (Food Fundamentals, 4th

Edition, Margaret McWilliams, Macmillan Publishing Company, New York, page 216)

2. In what follows the terms "soy" and "rice" may be used in the same manner as one calls a cup of coffee, "coffee," and a cup of tea, "tea." When soy oil is added to a soy beverage it remains a conventional soy beverage. When other oils are added it may be termed a "filled soy beverage." The kitchen appliance can be used to prepare a true "soy/milk" (i.e. a soy flavored milk beverage) and a true

"rice/milk" (i.e. a rice flavored milk beverage) or it can be used to prepare a conventional "soy milk"

(i.e. a soy and water beverage) and a conventional "rice milk" (i.e. a rice and water beverage).

3. The term, "other beverages" connotes that many other beans and seeds, in addition to coffee, tea, herbal tea, soy and rice, provide useful results. For example, dried corn, wheat, and chick peas.

4. The finished beverage, froth or foodstuff may be made from dried ground beans, per se, or a commercially milled flour made from the bean. The commercially milled flour may be microwaveroasted. For example, the green coffee bean is microwave-roasted, ground and brewed into a cup of coffee. For example, dried soy beans are microwave-roasted, ground and brewed into a cup of microwave-roasted soy.

5. From On Food and Cooking, Harold McGee, Collier Books, Macmillan Publishing Company, New

York, 1988, page 14 teaches "Homogenization". . . "involves forcing the milk at high pressure through a very small nozzle onto a hard surface; it breaks the fat globules up into more uniform particles about a quarter of their original size . . . . When broken down to about a micron in diameter, the individual globules are too small to rise alone, and because their surface area has multiplied beyond the covering capacity of their membranes, some of the other dissolved milk proteins fill in, and apparently interfere with globule aggregation.". . . . "Fresh milk is never homogenized as is, because it will go rancid in a matter of minutes. When stripped of some of its protective membrane, the fat is exposed to the activity of fat-splitting enzymes in the milk, and these quickly produce unappetizing quantities of odiferous free fatty acids. The enzymes are inactivated by high temperatures, and accordingly all milk is pasteurized before or simultaneously with homogenization." Note, as taught herein, the oil is preferably added to pasteurized milk, pasteurized egg mixtures and microwave-roasted and boiled soy and rice.

6. The term "microwave-roasted" refers to a microwave-lossy bean or seed immersed in oil (for example, soy oil, Canola oil, olive oil, melted butter, and corn oil) and exposed to microwave energy.

In operation, first water is driven out of the bean or seed and then the dried bean or seed is free to rise to a baking-browning temperature. Exposure to microwave energy is terminated at a predetermined bean or seed color. Exposure is terminated well before the mixture can ignite or emit undesirable smoke and odors. "Microwave-roasting" differs from the core heating taught in my U.S. Pat. No.

5,223,291 in that it concerns homogeneous roasting. Not all beans and seeds microwave-roast. Pop corn pops. Microwave-roasted rice contains a few small, popped, rice kernels. The microwave-roasted rice seeds, per se, can be partaken as an edible, flavorful, roasted snack food. The oil-covered, microwave-roasted/popped rice seeds may be processed as taught herein to produce a flavorful, microwave-roasted, enriched, rice "milk"

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The kitchen appliance, taught herein, combines (a) a French Press plunger type coffee apparatus; (b) the apparatus taught in U.S. Pat. No. 5,635,233, "Methods for Preparing a Coffee, Tea or Milk

Beverage" (i.e. where a prior art one piece plunger-filter is separated into a plunger per se, operating a filter per se); (c) a milk-frothing type apparatus similar to that taught in U.S. Pat. No. 5,580,169, "Milk

Jug with Froth-Forming Device for Making `Cappuccino` and the Like;" (d) an apparatus to homogenize saturated and unsaturated fat into skim milk, milk, cream, coffee, soy, rice and egg, and

(e) a beverage filter. These five members of the kitchen appliance have independent utility and are useful in various combinations. The preferred filter is a nylonmesh Lycra.RTM. filter.

(a) The Kitchen Appliance Employed as a French Press Plunger Type Coffee Apparatus.

Presently, there are "microwave oven" plunger type coffee makers, illustrated in FIG. 9, in the marketplace, that teach, before you insert the one piece filter-plunger assembly 23, coffee grounds and water are heated, in glass cylinder container 1, in a microwave oven. Those that sell these prior art, plunger coffee makers teach:

First water is boiled in glass cylinder container 1. Thereafter, a predetermined amount of coffee grounds 2 are added to the boiled water and allowed to brew for a predetermined time, for example, four minutes. Whereupon, filter-plunger apparatus 23 with a permanent stainless steel mesh filter 17 on one end and a lid 4 and a plunger handle 24 on the other end, is inserted into cylinder container 1 and pressed down. Stainless steel mesh filter 17 filters brewed coffee 29 from spent grounds 2 and, thereafter, brewed coffee is poured out of container 1.

The plunger, homogenizer frother 6 (FIG. 1) of the instant invention can be employed as is a conventional plunger-strainer of a French Press coffee apparatus or reciprocated as a homogenizerfrother.

(b) The Kitchen Appliance Employed as the Apparatus Taught in U.S. Pat. No. 5,635,233, "Methods for Preparing a Coffee, Tea or Milk Beverage."

In FIG. 1, plunger, homogenizer frother 6 and beverage filter 7 are illustrated above container 1. Filter

7 is the contiguous, open-pore, polyurethane filter taught in U.S. Pat. No. 5,635,233, "Methods for

Preparing a Coffee, Tea or Milk Beverage." In U.S. Pat. No. 5,635,233, the improvement is that the unitary plunger-strainer of the plunger assembly of a French Press coffee maker is separated into a plunger member, per se, operating a separate filter member, per se. In the instant invention, both members may serve as filtering and frothing members.

In FIGS. 2 and 3, the kitchen appliance is supplied with open-pore, polyurethane filter 7 that coact with novel plunger, homogenizer frother 6 in the same manner as described in U.S. Pat. No. 5,635,233.

(c) The Kitchen Appliance Employed as is the Reciprocating Plunger, Milk-Frothing Type Apparatus

Taught in U.S. Pat. No. 5,580,169, "Milk Jug with Froth-Forming Device for Making `Cappuccino` and the Like."

Plunger, homogenizer frother 6 is fabricated for use in place of the plunger frother assembly and operated in the same manner as is the plunger frother assembly, taught in U.S. Pat. No. 5,580,169,

"Milk Jug with Froth-Forming Device for Making `Cappuccino` and the Like." In FIG. 4, plunger, homogenizer frother 6 is pumped up and down 12 and, in so doing, creates a multitude of small bubbles 13 in frothed liquid 25. In FIG. 5, after the desired amount of froth 14 is generated, plunger, homogenizer frother 6 is removed from container 1.

Optionally, in FIG. 4, when the frothing plunger 6 is employed to froth, frothing plunger 6 may be employed alone or the frothing can be enhanced by using open pore plastic filter 7. Open pore plastic filter 7 may be used after it is employed to trap expended coffee grounds at the bottom of container 1 or open pore plastic filter 7 can be used for the sole purpose of enhancing frothing. In operation, plunger, homogenizer frother 6 is pumped up and down 12 compressing and releasing filter 7 in frothing liquid

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25. The compressing and releasing of the open pores of both frother 6 and filter 7 generate a profusion of tiny bubbles 13.

Cylindrical containers of various heights and circumferences are useful. The wider the container the thicker the open pore polyurethane filter 7 must be to enable it to secure itself between the walls of container 1. If the open pores of open pore plastic frother 6 or filter 7 are too small, the hand pressure require to operate plunger 6 can shatter the glass walls of container 1.

By compressing and releasing the open pores of both frother 6 and/or filter 7 in clear water the generation of bubbles can be observed and the thickness and pore size of the individual filter members optimized to suite individual preferences.

(d) The Kitchen Appliance Employed to Homogenize Saturated and Unsaturated Fat in Skim Milk,

Milk, Cream, Soy, Rice and Egg Liquids.

Webster's Unabridged Dictionary of the English Language, Portland House, NY, 1989, defines homogenize: "2) to break up the fat globules in (milk or cream) in order to distribute them equally throughout." Here, the word "homogenize" includes the breaking up of saturated and non-saturated fat added to milk, cream or egg products in order to distribute the fat equally throughout the product. Here, the word "homogenize" means to process milk, soy, rice or other beverages so that the fat particles are so finely divided and emulsified that a layer of fat does not reform on standing.

McGraw-Hill Dictionary of Scientific and Technical Terms, 2@nd Edition, McGraw-Hill Book

Company, NY, 1978, defines a homogenizer as "[MECH ENG.] A machine that blends or emulsifies a substance by forcing it through fine openings against a hard surface." Plunger, homogenizer frother 6 blends or emulsifies liquid fat and milk and egg mixtures by forcing them to pass through the fine openings of plunger, homogenizer frother 6.

To force liquid fat and milk and egg mixtures through the fine openings of an open-pore polyurethane foam, stainless steel mesh or nylon mesh plunger, homogenizer, frother 6, plunger, homogenizer frother 6, must have a larger circumference than the top opening of container 1. In operation, the illustrated, polyurethane-foam, stainless steel mesh or nylon mesh homogenizer, frother, plunger 6, bends and compresses 28 against the walls of container 1. Because the plunger, homogenizer, frother member is elastic and compressible, it rides easily up and down the walls of container 1.

A knowledge of the relative hardness of materials is assumed. The walls of container 1 are harder than the material chosen for plunger, homogenizer, frother 6 so that when it is operated rapidly, repeatedly up and down, it will not abrade the walls of container 1. It is preferred to fabricate container 1 from a conventional transparent, heat-resistant material so that the progress of the frothing and heating operation may be visually monitored and the heating operation terminated before the heat processed liquid can boil out of container 1.

Plunger, homogenizer frother 6 will not emulsify liquid fat in plain water. It is believed that during homogenization a chemical reaction between the liquid fat and a component in the coffee, tea, herbal tea, soy, rice, milk, and egg takes place. Using too much liquid fat and not enough of said component

(for example, attempting to homogenize a volume of liquid fat equal to the same volume of coffee, tea, herbal tea, soy, rice, milk, egg or other beverage) results in incomplete homogenization.

The initial fat present has a bearing on how much more fat the particular beverage will accept. For example, egg white and skim milk mixtures have no fat, milk has 1 to 4% saturated fat, etc. Some experimentation is required to determine the maximum amount of liquid fat one can add to a selected product before free fat appears on the surface of that particular product. A good place to start is to add one fourth measure, by volume, liquid fat to a three fourth measure of milk. Then, after tasting the resultant homogenized mixture, add more or less liquid fat to achieve a desired result. If the milk will not accept any more liquid fat, to add more fat add more of said component, for example, add nonfat dry milk to the milk.

My copending U.S. Pat. No. 5,925,394, teaches methods for producing novel expanded foams, beverages and desserts and increasing the fat content of the expanded foam. It concerns conventional,

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household, electric mixers. In contrast, the novel kitchen appliance taught herein is hand operated. The hand operated kitchen appliance taught herein can homogenize saturated and unsaturated fat into egg and milk products as follows:

(1) Hand operated at slow speed, the kitchen appliance can be employed to increase the fat content of a milk to produce both conventional and/or filled half and half, light cream and heavy cream.

(2) Hand operated at frothing speed, the kitchen appliance can be employed to increase the fat content of a milk froth to produce both a conventional and/or a filled half and half, light cream and heavy cream froth.

Formulations of "non-saturated-fat heavy cream" can be whipped into a novel "non-saturated-fat whipped cream." This novel "non-saturated-fat whipped cream" differs from conventional whipped cream in that, when frozen, advantageously, it does not freeze with the rigidity of conventional whipped cream and can be hand scooped out of a frozen container and partaken as a novel "nonsaturated-fat ice cream." One may chose to homogenize a liquid vegetable fat (e.g. soy oil) into evaporated milk (i.e. saturated fat) so that, when flavored (e.g. strawberry, vanilla, or chocolate, and sweetener) and frozen, it is similar to ice cream. This novel "mixed fat ice cream" can be as smooth as is conventional ice cream.

(3) Saturated and non-saturated fat can be homogenized into various combinations of products. For example, one may choose to homogenize a saturated and/or a non-saturated fat into a liquid milk and/or a liquid-plus-egg product. One may choose to homogenize a saturated and/or a non-saturated fat into a powdered milk and/or a powdered egg and a liquid mixture. Or, powdered milk and/or powdered egg can be the employed to enriched a liquid milk and/or an egg mixture.

(4) Non-saturated fat can be homogenized into cold milk. Saturated fat requires that the milk be hot enough to melt the saturated fat.

(5) A liquid is mixed with egg products so that they will not be too viscous to pass through the homogenization screen. For safety, raw egg mixed with a liquid (for example, water, milk and/or an alcoholic beverage) is initially heated to pasteurize the egg.

If heavy cream is whipped too long, the whipped cream turns into butter and a liquid. The present hand operated kitchen appliance can be employed to homogenize liquid butter fat, back into said liquid and so reconstitute the heavy cream. In operation, a mixture of said liquid and butter is heated until the butter melts, it is homogenized as taught herein, and the renewed cream is chilled.

The present hand operated kitchen appliance can be employed to homogenized saturated and nonsaturated fat into egg and water, egg and alcohol (for example, wine) and egg and milk mixtures. These resulting saturated and non-saturated fat egg-plus-liquid mixtures can be whipped into an expanded foam similar to a meringue or whipped cream. One representative operation may include:

(a) To one whole shelled egg (two liquid ounces), add four ounces of water or milk, add two ounces of liquid fat (for example corn oil), then mix, beat or blend. Next, heat mixture in a microwave oven (use a thermometer) until the mixture reaches circa 165 DEG F. (to pasteurize the egg in the mixture).

Immediately, before the egg can cook (fully denature), remove from microwave oven insert and operate plunger, homogenizer frother therein. Plunger, homogenizer frother reciprocated at a slow speed simply homogenizes. Plunger, homogenizer frother reciprocated, at a faster speed, both homogenizes and froths the resulting beverage. Some may prefer to heat the egg mixture to a higher temperature and/or wait before homogenizing so that some solid cooked egg is present.

(e) The Kitchen Appliance Employed as an Improved Coffee Brewer.

The "reciprocating plunger" of the prior-art, hand-operated, milk-frothing apparatus, for example, the apparatus taught in U.S. Pat. Nos. 5,580,169 and 5,780,087, cannot be used as the plunger for the

French Press apparatus as its small frothing "sieve" like holes quickly fill with coffee grounds or tea leaves and coffee grounds and tea leaves pass around the circumference of the frothing plunger and in either case render the apparatus inoperable. Here, the plunger taught in U.S. Pat. No. 5,635,233,

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"Methods for Preparing a Coffee, Tea or Milk Beverage," is redesigned (1) to froth milk, (2) to homogenize liquid fat into milk and eggs and (3) to replace the plunger-strainer of a conventional

French Press coffee apparatus.

FIG. 1 illustrates a side-view cross-section composite view of this multiple utility kitchen appliance.

For members of a family, who desire black coffee, plunger, homogenizer frother 6 can function as does a prior art, French Press spring plunger.

I have discovered that the well known nylon-mesh Lycra.RTM. foot sock type fabrication makes an efficient, semi-disposable, easily employed and cleaned filter cover for both the instant hand operated coffee maker and for my motor operated coffee maker, U.S. Pat. No. 5,800,852, "A Coffee/Tea, Table

Blender and Microwave Oven Apparatus and Methods for Its Use." The instant kitchen appliance is provided with at least one nylon-mesh Lycrao.RTM. filter cover 9 for container 1.

The well known nylon or nylon and cotton mesh, Lycra.RTM. foot sock fabrication makes an efficient, easily employed and cleaned, filter cover 9 and 22. The Lycra band 20 secures the nylon mesh 22 under upper lip 11 of brewing container 1. Nylon fabrications are reusable. Common nylon foot socks are inexpensive and may be disposed of after each use as one disposes of paper coffee filters.

In FIG. 8, for brewing containers that do not have an upper lip to secure the Lycra.RTM. band 20 thereunder, for example, a coffee cup or a drinking glass, I have discovered that, if a plastic "rubber band" 21 is placed around the upper rim of brewing container 19, rubber band 21 acts as does upper lip

11 to secure the Lycra.RTM. band 20 there below.

Rubber band 21 simplifies the securing to and the removal of the Lycra.RTM. band from the many household beverage container that do not have an upper lip 11. Rubber band 21 prevents the

Lycra.RTM. band 20 from slipping off container 19 when it is subject to the weight of filtered coffee ground 2 and coffee 29. In FIG. 8, the nylon-mesh Lycra.RTM. filter cover 9 illustrated is larger than is necessary so that when the coffee and coffee grounds are filtered there through, the large size permits filtering to take place in a pouch outside of container 1. Some may prefer this large size mesh as it creates a large surface area to speed filtering. Some may prefer this oversized mesh because the spent coffee grounds remain in the pouch for easy disposal. In contrast, as illustrated in FIG. 7, some may prefer a tightly fitting nylon mesh that confines the spent coffee grounds to the interior of container 1.

The nylon-mesh pouch outside of container 1, illustrated in FIG. 8, is useful when the liquid to be filtered is viscous. To speed up filtering, table tongs (not shown) or the like can be employed to mechanically squeeze the pouch to force the viscous liquid through the nylon mesh.

Alternately, as illustrated in FIG. 6, some may prefer to place filter cover 9 on a receiving container 30 and the brewing coffee poured and filtered into the receiving container 30.

In one embodiment, FIG. 7, liquid and coffee grounds 2 are placed in container 1 and covered by nylon-mesh Lycra.RTM. filter cover 9. Water and milk are added and the brewing initiated by swirling coffee grounds 2 and liquid in container 1. Then, the brewing coffee grounds immersed in water and/or milk in container I are heated in a microwave oven. The brewing coffee is removed from the microwave oven and again agitated by swirling. The brewing coffee may be allowed to further brew for a predetermined time. Thereafter, the brew 29 is poured and filtered out of the container I through nylon mesh filter cover 9.

Nylon-mesh, Lycra.RTM. filter cover 9 is removed from container 1 emptied and rinsed. In a well known manner, one inserts one's hand into nylon mesh filter cover 9 and spreads open one's fingers thereby spreading open the nylon mesh. Whereupon, under running water one easily rinses out any remaining coffee grounds.

In contrast, to the ease in cleaning nylon mesh filter cover 9, open pore polyurethane filter 7 and openpore polyurethane filter are harder to clean for they can catch and hold small coffee grounds. To clean the open pore polyurethane filter, the plunger, homogenizer frother 6 assembly is taken apart and the open pore polyurethane filter is removed. Polyurethane filter can be cleaned in a number of ways. One

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way to clean filters 6 and 7 is to place the polyurethane filter in the sink under a running faucet and while water is poured over it, brush it clean with a kitchen sink brush. Brushing spreads the pores and releases trapped coffee ground. In contrast, some may dispose of nylon mesh filter cover 9 or the polyurethane filter after each use in the same manner as one disposes of used paper coffee filters.

Nylon-mesh Lycra.RTM. filter cover 9 is useful in my copending U.S. Pat. No. 5,800,852, "A

Coffee/Tea, Table Blender and Microwave Oven Apparatus and Methods for Its Use," that claims a filter cover secured to the top the blender jar.

It is believed that nylon mesh filter cover 9 provides a speedier filtering and an ease of use and cleanup than does either open pore polyurethane filter, prior art coffee paper filters or the prior art stainlesssteel French-Press plunger strainer. It should be appreciated that while a nylon and Lycra.RTM. filter is preferred, other combinations of nylon and cotton mesh and the like, and other elastic plastic mesh are useful. It should be appreciated that the prior art stainless-steel mesh filter member can be replaced with a nylon mesh fabric. After the stainless steel mesh filter is removed, the nylon mesh is wrapped around the remaining, stainless-steel plunger-spring combination and removably secured to the plunger rod. (not shown)

Some may prefer to brew and filter an individual portion of coffee, in one container of a multiple container kitchen appliance, while concurrently preparing a saturated or non-saturated-fat milk foam in a second container of the kitchen appliance. Thereafter, the foam is poured onto the coffee covering the coffee. The resulting "cappuccino" type coffee differs from conventional cappuccino coffee produced by a conventional expresso, milk-frother machine. Conventional expresso, milk-frother machines are limited to 1% milk froths because milk with more than 1% fat clogs the frothing nozzle. In contrast, the

"cappuccino" froths prepared, as taught herein, may have 30% saturated and/or non-saturated fat content.

The containers of this invention may be fabricated of metal and heated on a conventional gas and electric burner or fabricated of a microwave transparent material and heated in a microwave oven.

Container 1, fabricated from heat resistant glass, is useful in both conventional and microwave heating.

In the same manner as illustrated in the prior art French Press Coffee apparatus, in FIG. 1, a guide hole

26 can be fabricated into accessory cover 4 and used to guide rod 8 parallel to the vertical walls of container 1.

In operation, to prepare a Cappuccino type coffee beverage, in FIG. 2, after the coffee ground 2 and water 3 are heated and the coffee brewed, filter 7 is placed onto or inserted into the top of container 1.

Thereafter, in FIG. 3, plunger, homogenizer frother 6 forces filter 7 to the bottom of container 1 thereby securing between the bottom of filter 7 and the bottom 10 of container 1 filtered out coffee grounds 2. Next, in FIG. 4, plunger, homogenizer frother 6 is disengaged from filter 7. A milk or egg product is added to the filtered coffee 25 and, in FIG. 4, plunger, homogenizer frother 6 is reinserted into container 1 and rapidly agitated in an up and down direction 12 creating a froth 14 on top of filtered coffee 25. In FIG. 5, when froth 14 reaches a predetermined amount, plunger, homogenizer frother 6 is removed from container 1. Thereafter the beverage can be consumed directly from container 1 or poured into a cup, not shown, served and consumed. The methods taught in my copending U.S. Pat. No. 5,925,394 for "Methods for Denaturing and Whipping into a Foam Certain

Denaturable Proteins Found in Milk Products and Egg Products and the Resulting Product," are useful herein. Care must be taken to insure that the milk or egg product is not fully denatured before trying to create a lasting froth. If the added milk or egg is fully denatured, it will not create a useful froth.

A cook can use plunger, homogenizer frother 6 to produce the longer lasting expanded froths taught in my copending U.S. Pat. No. 5,925,394. Or, the same cook can use plunger, homogenizer frother 6 to produce the cool temporary milk froths taught in U.S. Pat. Nos. 5,580,169 and 5,780,087.

If milk is heated in container 1 directly on a conventional gas or electric burner, it coagulates (e.g. fully denatures) and bums where it contacts the directly heated inner, bottom wall of container 1. To obviate this undesirably coagulation and burning, when heating the brewing coffee directly on a conventional gas or electric burner, in FIG. 1, milk (or an egg and water mixture) 14 is placed in footed container 15 and is heated by the brewing coffee, in the manner of a double boiler. The brewing coffee

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is simmered (210 DEG F.) until the milk reaches the circa 180 DEG F. denaturing temperature of milk

(or the circa 165 DEG F. pasteurizing and denaturing temperature of egg), container 1 is removed from the conventional gas or electric burner. Handle 27 is used to lift the heated milk 14 from container 1.

The brewed coffee is filtered and poured into a second container. The hot milk 14 is poured out of container 15, (not shown) to mix with the hot filtered brewed coffee. The greater mass of the circa 210

DEG F. coffee brew raises the milk 14's circa 180 DEG F. temperature to the milk's circa 200 DEG F. denaturing temperature and the mixture is immediately frothed with plunger, homogenizer frother 6 to create a cup of coffee with long lasting froth.

Because microwave energy does not heat container 1, per se, when container 1 is heated in a microwave oven, milk 14 may be initially added to the heated, brewing mixture. Microwave energy does not coagulate and burn milk 14 touching container 1's cool inner walls. For those that employ a built in microwave oven thermometer, it is preferred to heat milk 14 in container 30, concurrent with the brewing of the coffee in container 1. It is preferred to heat the brewing coffee until it simmers.

Filter 7 is inserted into container 1. Plunger, homogenizer frother 6 is employed to drive filter 7 to the bottom of container 1 filtering coffee 25 and then, before the milk can fully denature, plunger, homogenizer frother 6 is employed to froth the mixture. Accessory cover 4 is useful during frothing to keep, when the plunger is raised, the generating froth within container. More than one container is in contemplation. More than one plunger, for example, a dedicated strainer plunger, per se, a dedicated homogenizer plunger, and a dedicated frothing plunger, per se, or two or more homogenizer frother strainers, can be part of the kitchen appliance. More than one nylon-mesh Lycra.RTM. filter cover and nylon-mesh Lycra.RTM. filter covers of different gauge, dimension and elasticity can be part of the kitchen appliance.

Hole 9 or a second hole, not shown, may hold a thermometer, not shown, to monitor the temperature of a brewing coffee, tea, or milk beverage. Cover 4 is useful when container 1 is used to prepare, serve hot and store coffee, tea, and herbal tea. Preferably, cover 4 is transparent to monitor the operation especially when container I is metal.

Clean up of homogenizer frother 6 and filter 7 is simple. Container 1 is partially filled with soapy water. The sudsy water, with filter 7 therein, is frothed by homogenizer frother strainer 6. Container 1 is emptied and the cleaning cycle is repeated followed by similar rinse cycles. Stainless steel mesh filters are easily cleaned. The polyurethane filter and the polyurethane frother disks are reusable. They are inexpensive to replace.

(f) The Kitchen Appliance Employed to Brew Fat Enriched Wheat, Rice and Soy Beverages.

In operation, to produce an enriched bean or seed beverage from its milled state one adds one coffee measure of, for example, a commercial soy, rice and/or wheat flour, to a cup of water in container 1.

Mix the mixture by hand or with an electric mixer. Add, for example, one ounce of a liquid fat and heat the mixture in a microwave oven until it almost boils out of container 1. Beans or rice take circa twenty minutes to cook conventionally. In contrast, milled particles of beans or rice cook in a few minutes.

The cooked mixture is removed from the microwave oven and plunger, homogenizer frother 6 is inserted into container 1 and operated and removed. A thin brew is an enriched "soy milk," "rice milk" and/or "wheat flour milk" beverage. A thick brew has the appearance and utility of cream.

Comments:

1. There is no need to filter the resulting homogenized enriched "soy milk," "rice milk" and/or "wheat flour milk."

2. Without adding any liquid fat and without filtering, the cooked milled soy or rice beverage is simply a home made soy milk or rice milk.

3. Adding too much soy, rice or wheat flour results in a paste or cereal.

4. The kitchen appliance is useful for those that do not have a table blender so cannot practice the teachings of my U.S. Pat. No. 5,800,852, "A Coffee/Tea, Table Blender and Microwave Oven

Apparatus and Methods for Its Use."

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(g) The Kitchen Appliance Employed to "Microwave-Roast" Beans and Seeds for Consumption as

Snacks and as Enriched Beverages.

In operation, to produce microwave-roasted beans (for example, green coffee beans and soy beans) and seeds (for example rice) add one serving of the beans and/or seeds to container 1. Add enough saturated or unsaturated fat to container 1 so that when heated the beans or seeds will be immersed in liquid fat. Place container 1 into a microwave oven and expose the mixture to microwave energy. First the mixture rises to the boiling point of water and holds at that temperature until the "dry" beans and/or seed fully dry. Thereafter, the temperature of the mixture rapidly rises until it reaches and is held at a circa 400 DEG F. browning temperature. The browning mixture is visually monitor until the microwave-roasting beans or seeds reach a desired color. The microwave-roasted beans and/or seeds are removed from the microwave oven. Since the beans and/or seeds self heat when exposed to microwave energy, they start to cool the moment the microwave energy is turned off. The microwaveroasted soy beans and microwave-roasted rice, still covered with oil or with the heating oil removed, may be partaken cool as a (cooked) snack food or may be ground and further processed as in "(f) THE

KITCHEN APPLIANCE EMPLOYED TO BREW ENRICHED WHEAT, RICE AND SOY

BEVERAGES," supra.

Comments on microwave-roasting:

1. The microwave-roasted soy beans and the microwave-roasted rice are small and fragile and can be partaken as a snack food. They can be added as one might add poppy and caraway seeds to a foodstuff.

2. A few of the microwave-roasted rice grains pop as does popcorn. These popped rice grains do not detract from the resulting snack or beverage.

3. If coffee beans are microwave-roasted until they are soft enough they may be partaken as a snack food.

4. Large microwave-roasted seeds as microwave-roasted chick peas are ground before, as taught supra, they are turned into a beverage. Large microwave roasted chick peas are too rigid to use as a snack food.

5. When used as a snack food the microwave-roasted beans and grains may be blotted to remove excess oil.

6. When used as a beverage, the microwave-roasting oil is left in place and a predetermined additional amount of oil added to the microwave-roasted beans or grains prior pulverizing them and turning them into the homogenized beverage described supra.

7. Because the grains and beans "microwave-roast" in oil at circa 400 DEG F., in microwave-roasting, the overpowering, objectionable odor, released by a conventional roaster, is not present.

8. Advantageously, to suit the varied tastes of individual members of a family, individual portions of green coffee beans can be microwave-roasted, at home, to suit individual preferences as to roasted color and/or flavor.

9. The ability to homogenize, as taught supra, an individually selected amount of liquid fat into ones coffee, tea, soy, or rice obviates the need to keep on hand half and half, light, medium and/or heavy cream.

10. Microwave-roasting beans and grains can be used to prepare "roasted soy milk," or "roasted rice milk" in a table blender by following the teachings of my U.S. Pat. No. 5,800,852, "A Coffee/Tea,

Table Blender and Microwave Oven Apparatus and Methods for Its Use."

Although this invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that numerous changes in methods, details of construction and arrangement of parts may be resorted to without departing from the spirit

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and scope of the invention.Data supplied from the esp@cenet database - Worldwide

Claims:


I claim:

1. A method for using a French Press coffee maker that includes the steps of:

placing, into the container of said French Press coffee maker, a preselected amount of foodstuff wherein said foodstuff is selected from a group consisting of a mammal foodstuff, a liquid-plus-bird foodstuff and combinations of said foodstuffs wherein said mammal foodstuff is selected from a group consisting of skim milk, whole milk, light cream, evaporated milk, and reconstituted powdered milk and wherein said liquid-plus-bird foodstuff is selected from the group consisting of whole egg, egg yolk, powdered whole eggs and powdered egg yolk,

adding in a preselected amount of a liquid fat,

reciprocating said French Press coffee maker's strainer member in said liquid fat and said foodstuff, thereby homogenizing said liquid fat and said foodstuff by forcing said liquid fat through small openings in said French Press coffee maker's strainer member.

2. A method for preparing a beverage that includes the steps of:

selecting a container,

placing into said container a foodstuff wherein said foodstuff is selected from the group consisting of bean foodstuff and seed foodstuff and combinations of said foodstuffs, wherein said bean foodstuff is selected from the group consisting of soy beans, coffee beans, and chick peas and wherein said seed foodstuff is selected from the group consisting of rice, corn and wheat,

adding a liquid,

cooking, while immersed in said liquid, said foodstuff,

adding a liquid fat, and

thereafter, within said container, reciprocating a homogenizer member that homogenizes said liquid fat into said foodstuff when said liquid fat passes through said homogenizer member.

3. A method for preparing a beverage, according to claim 2, that includes:

where said foodstuff is milled prior to being cooked.

4. A method for preparing a beverage, according to claim 2, that includes the steps of:

after adding said fat and before said adding a liquid and before said cooking,

microwave-roasting said foodstuff by exposing said foodstuff, immersed in said liquid fat, to microwave energy, and then grinding said microwave-roasted foodstuff.

5. A method of homogenizing a liquid fat into a foodstuff wherein said foodstuff is selected from the group that consists of a liquid milk product and a liquid-plus-egg product and a combination of said products that includes the steps of:

placing said liquid fat and said foodstuff in a container where said container is cylindrical with a closed bottom and an open top,

placing a plunger member and a homogenizer member fabricated to homogenize liquid fat into said foodstuff when said plunger member reciprocates said homogenizer member in said container,

where said homogenizer member has a larger circumference than said top opening of said container and is porous, elastic and bends and compresses against the walls of said container when inserted in said container, and moves easily on the walls of said container,

and reciprocating said plunger member and homogenizer member in said container.

6. A method of homogenizing a liquid fat into a foodstuff, according to claim 5, that includes the step of:

where said fat is solid at room temperature,

heating said solid fat until it melts.

7. In a method for using a French Press coffee maker where the improvement comprises:

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homogenizing a non-saturated-fat into a foodstuff wherein said foodstuff is selected from the group that consists of a non-fat milk, liquid-plus-egg white, and combination of said until said foodstuff has the fat content of cream, by

placing a mixture of a predetermined amount of non-saturated fat and a predetermined amount of said foodstuff into the French Press container, and

reciprocating the French Press plunger member until said non-saturated fat homogenizes into said foodstuff.

8. In a method for using a French Press coffee maker, according to claim 7, that includes the step of:

freezing said non-saturated-fat, homogenized foodstuff and subsequently partaking of said frozen, homogenized foodstuff.

9. In a method for using a French Press coffee maker where the improvement comprises the steps of:

heating coffee grounds and a liquid in said French Press coffee maker's container,

waiting a predetermined time until the coffee is brewed,

inserting a coffee filter into the top of said French Press coffee maker's container,

inserting the plunger, strainer member of said French Press coffee maker into said container on top of said filter and pushing said filter to the bottom of said container thereby securing between the bottom of said filter and the bottom of said container filtered out coffee grounds,

adding a predetermined amount of oil

adding a predetermined amount of milk,

rapidly agitating, in an up and down direction, said plunger, strainer member both to create a froth on said filtered brewed coffee and to homogenize said oil, milk and filtered coffee, and

removing said plunger, strainer member from said container.

10. In a method for using a French Press coffee maker, according to claim 9,

where said milk is egg.

11. A method of brewing a beverage from a foodstuff wherein said foodstuff is selected from the group consisting of coffee grounds, tea leaves, ground soybeans, ground rice seeds, and combinations of said coffee grounds, tea leaves, ground soybeans, ground rice seeds that includes the steps of:

placing a liquid and, at least one, of said foodstuff in a container that has an open top,

adding a plastic mesh filter cover and an elastic means to secure said mesh filter to said open top of said container,

heating said foodstuff in said liquid in said container, and then pouring said hot beverage out of said container through said filter cover.

12. A method of brewing a beverage, according to claim 11, that includes:

where said mesh filter is nylon.

13. A method of brewing a beverage, according to claim 11, that includes the step of:

where said open top of said container does not have an upper lip to secure said elastic means there under,

placing an elastic band around the upper rim of said container to act as an upper lip to secure said elastic means.

14. A method of brewing a beverage, according to claim 11, that includes the step of:

where said mesh filter cover is fabricated so that when said hot, beverage is poured out of said container through said filter cover said mesh filter cover forms a pouch that contains said filtered out foodstuff external said container.

15. A method for microwave-roasting a foodstuff wherein said foodstuff is selected from a group consisting of green coffee beans, dried soy beans, rice grains and combinations of said green coffee beans, dried soybeans, rice grains that includes the steps of:

placing, at least one, of said foodstuff in a container,

adding a liquid fat to immerse said foodstuff in said liquid fat in said container,

microwave-roasting said foodstuff by exposing said foodstuff, immersed in said liquid fat, to microwave energy, until said foodstuff heats to, at least, 400 DEG F. and browns to a preselected color.

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16. In the method of claim 15, the added steps of:

grinding the microwave roasted foodstuff,

brewing the ground microwave roasted foodstuff in a liquid, and filtering the resulting brew.

17. In the method of claim 16, the added step of:

homogenizing said liquid fat in said brew.Data supplied from the esp@cenet database - Worldwide

2022/2197

412.

US6244169 - 6/12/2001

AUTOMATIC APPARATUS FOR MAKING ROLLED SUSHI


Inventor(s): SHIMAZU YOSHINORI (JP)

IP Class 4 Digits: A23P; A22C

IP Class: A23P1/00; A22C7/00

E Class: A23L1/00P8E; A23P1/08E


Priority Number: US20000627369 (20000728); JP19970070584 (19970306)

Family: US6244169


Abstract:


The present invention provides an automatic rolled sushi producing apparatus consisting of a vinegared rice supply unit; a vinegared rice supply conveyer arranged below the vinegared rice supply unit; a carrying conveyer arranged at right angle to the vinegared rice supply conveyer; a vinegared rice extrusion mechanism arranged along an advancing direction of the carrying conveyer; a vinegared rice cutting mechanism; a tight rolling mechanism; a forming mechanism; a product extrusion mechanism; and a product take-out conveyer arranged at right angle to the carrying conveyer at a terminal end of the carrying conveyer, and wherein the vinegared rice supply conveyer, the carrying conveyer and the product take-out conveyer are arranged in the form of U as a whole.Description:



1. Technical Field of the Invention

The present invention relates to an automatic rolled sushi producing apparatus and the object of the present invention is to provide an automatic rolled sushi producing apparatus which can dispense with a large installation space, can be handled by small number of people, reduce people on production lines, reduce production cost and can obtain beautifully finished rolled sushi with the end faces of the sushi kept from getting out of shape.

2. Prior Art

Conventionally, rolled sushi has been produced by putting cooked, vinegared rice and ingredients on a sheet of laver, rolling the vinegared rice and ingredients with the sheet of laver, pressing them from side to give form and finally cutting up the rolled sushi with a knife. However, if rolled sushi is made by hand, people involved are disadvantageously fatigued with long-time work. Quite naturally, therefore, there is a limit to the mass production of rolled sushi for a long time. In view of these facts, there exist a rolled sushi producing apparatus for producing rolled sushi by spreading a film on a linearly stretched belt conveyer, supplying vinegared rice onto this film, next putting ingredients on the vinegared rice, gradually and continuously pressing and rolling the film on which the vinegared rice and ingredients are being put with a guide plate and a roller, cutting up the rolled film into pieces of a

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predetermined size with a cutting device and finally removing the film and rolling the vinegared rice and ingredients in a sheet of laver with hand, and an apparatus for producing rolled sushi by supplying a sheet of laver on a conveyer in advance and putting vinegared rice on the sheet of laver. Further, convenience stores often deal in sushi in recent years. For the purpose of shortening time from production to sale as much as possible, foods such as sushi are delivered to the convenience stores three times a day. In these circumstances, the demand of the industry of automatic rolled sushi producing apparatuses is being shifted from providing mass-production large-sized machines capable of producing large amounts of products once to small-sized machines which can be handled with a small number of people.

Nevertheless, according to the conventional rolled sushi producing apparatuses stated above, it takes labor to remove a film and then roll vinegared rice and ingredients in a sheet of laver and it is, therefore, necessary to use many people to carry out this operation. Furthermore, since the conveyer is linearly stretched, a large installation space is required. Either case cannot satisfy the recent demand of the industry. Besides, with the conventional rolled sushi producing apparatuses as stated above, vinegared rice flowing on the conveyer is tight rolled, formed and then cut up. Due to this, the end faces of the rolled sushi easily get out of shape, which is not suitable for providing beautifully finished sushi. Moreover, even if vinegared rice is cut up by fixed amount on the conveyer in advance, the vinegared rice is bonded to a film or a sheet of laver because the apparatus is constituted to supply vinegared rice onto a film or the sheet of layer. As a result, the vinegared rice cannot be cut up on the conveyer by fixed amount. The present invention has been made in view of the above-stated conventional problems and the object of the present invention is to provide an automatic rolled sushi producing apparatus which can dispense with a large installation space, can be handled with a small number of people, reduce production cost and obtain beautifully finished rolled sushi with the end faces of the sushi kept from getting out of shape.


The present invention has been made to solve the above-stated problems. An invention recited in claim

1 is an automatic rolled sushi producing apparatus characterized by comprising a vinegared rice supply unit; a vinegared rice supply conveyer arranged below the vinegared rice supply unit; a carrying conveyer arranged at right angle to the vinegared rice supply conveyer; a vinegared rice extrusion mechanism arranged along an advancing direction of the carrying conveyer; a vinegared rice cutting mechanism; a tight rolling mechanism; a forming mechanism; a product extrusion mechanism; and a product take-out conveyer arranged at right angle to the carrying conveyer at a terminal end of the carrying conveyer, and wherein the vinegared rice supply conveyer, the carrying conveyer and the product take-out conveyer are arranged in the form of U as a whole. An invention recited in claim 2 is an automatic rolled sushi producing apparatus according to claim 1, characterized in that the vinegared rice cutting mechanism comprises a vertical drive mechanism driven vertically toward the carrying conveyer; a cutting blade attached to the vertical drive mechanism; and a longitudinal drive mechanism for driving the cutting blade to reciprocate in a longitudinal direction of the carrying conveyer, and in that a speed for driving the cutting blade forward is set higher than a carrying conveyer advancing speed. An invention recited in claim 3 is an automatic rolled sushi producing apparatus according to claim 1, characterized in that the product extrusion mechanism is formed as a rotating vane mechanism provided with four vanes arranged at right angle to one another; a rotary shaft direction of the rotating vane mechanism is the same as the carrying conveyer advancing direction; the carrying conveyer is formed as a roller feed mechanism having a plurality of rollers aligned at required intervals in the vicinity of the terminal end of the carrying conveyer; each of the vanes consists of a plurality of rod members provided at corresponding intervals to the intervals of rollers.


FIG. 1 is a perspective view schematically showing the overall structure of an automatic rolled sushi producing apparatus according to the present invention.

FIG. 2 is a top view schematically showing the overall structure of the automatic rolled sushi producing apparatus according to the present another invention.

FIG. 3 is a schematic side view showing a vinegared rice supply mechanism.

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FIG. 4 is a perspective view of a vinegared rice extrusion mechanism.

FIG. 5 is a perspective view of the first flattening roller.

FIG. 6 is a perspective view of the second flattening roller.

FIG. 7 is a perspective view of the third flattening roller.

FIG. 8 is an explanatory view for the function of the vinegared rice extrusion mechanism.

FIG. 9 is a perspective view of a vinegared rice cutting mechanism.

FIG. 10 is a perspective view showing the function of the vinegared rice cutting mechanism.

FIG. 11 is an explanatory view for the function of an ingredient supply mechanism.

FIG. 12 is a side view of the ingredient supply mechanism.

FIG. 13 is a front view of the ingredient supply mechanism.

FIG. 14 is a perspective view of the extrusion screw member of the ingredient supply mechanism.

FIG. 15 is a perspective view of a tight rolling mechanism and a forming mechanism.

FIG. 16 is a front view of a product extrusion mechanism.

FIG. 17 is a top view of the product extrusion mechanism.

FIG. 18 is a side view of the product extrusion mechanism.

FIG. 19 is a perspective view showing that a vinegared rice cutting mechanism is provided at a difference position in the automatic rolled sushi producing apparatus according to the present invention.

FIG. 20 is a perspective view showing another embodiment of a vinegared rice cutting mechanism.

FIG. 21 shows the rotary blade of the vinegared rice cutting mechanism.


A preferred embodiment of an automatic rolled sushi producing apparatus according to the present invention will be described hereinafter based on the drawings. FIG. 1 is a perspective view schematically showing the overall structure of an automatic rolled sushi producing apparatus according to the present invention and FIG. 2 is a top view of another embodiment. In the automatic rolled sushi producing apparatus (1) shown therein, a vinegared rice supply conveyer (3) is arranged below a vinegared rice supply device (shown in FIG. 3) and a carrying conveyer (4) is arranged at right angle to the vinegared rice supply conveyer (3). Also, a vinegared rice extrusion mechanism (5), a vinegared rice cutting mechanism (6), an ingredient supply mechanism (7), a tight rolling mechanism (8), a forming mechanism (9) and a product extrusion mechanism (10) are sequentially arranged from a starting end side in the advancing direction of the carrying conveyer (4) in this order. A product takeout conveyer (11) is arranged at right angle to the conveyer (4) on the terminal end of the carrying conveyer (4).

As shown in FIG. 3, the vinegared rice supply device (2) consists of a bat (21) in which vinegared rice is contained, a bat reverser (22) and a vinegared rice supply hopper (23) having therein a rotating and loosening mechanism with a plurality of rod-like loosening vanes (23a). Below the vinegared rice supply hopper (23), the vinegared rice supply conveyer (3) is arranged.

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The vinegared rice extrusion mechanism (5) includes the first belt conveyer (51) and the second belt conveyer (52) provided below the first belt conveyer (51) and inclined downward toward the carrying conveyer (4). FIG. 4 is a perspective view showing the vinegared rice extrusion mechanism (5). A guide frame plate (53) having an opened lower side is arranged on the sides of the first and second belt conveyers (51) and (52). The first flattening roller (54), the second flattening roller (55) and the third flattening roller (56) are rotatably, pivotally supported by the guide frame plate (53).

Further, a sensor (11) for detecting blocks of vinegared rice is provided between the first flattening roller (54) and the second flattening roller (55). If the vinegared rice is not sufficiently loosened and flows in the form of large blocks, the sensor (11) detects the blocks and stops the apparatus.

As shown in FIG. 5, the first flattening roller (54) includes a plurality of concave portions (54a) formed axially on the outer peripheral surface of the roller (54) at fixed intervals, and a plurality of concave grooves (54c) formed circumferentially in a plurality of convex portions (54b). Some concave grooves are formed as deep concave grooves (54d) at required positions. The deep concave grooves

(54d) are constituted so as not to continuously appear at positions different from those formed in adjacent convex portions, i.e., at certain positions on the conveyer when rollers rotate. Further, the convex portions of the first flattening roller (54) are formed to bulge from the axial ends toward the center thereof.

As shown in FIG. 6, the second flattening roller (55) includes a plurality of concave portions (55a) formed axially on the outer peripheral surface of the roller (55) at fixed intervals, and a plurality of concave grooves (55c) formed circumferentially in a plurality of convex portions (55b). The concave portions (55a) and the concave grooves (55c) are formed narrower than the concave portions (54a) and the concave grooves (54c) of the first flattening roller (55), respectively.

As shown in FIG. 7, the third flattening roller (56) includes a plurality of concave portions (56a) formed axially on the outer peripheral surface of the roller (56) at fixed intervals, and a plurality of concave grooves (56c) formed circumferentially in a plurality of convex portions (56b). The concave portions (56a) and the concave grooves (56c) are formed narrower than the concave portions (55a) and the concave grooves (55c) of the second flattening roller (55), respectively.

According to the above-stated vinegared rice extrusion mechanism (5), vinegared rice (S) supplied from the vinegared rice supply conveyer onto the first belt conveyer (51) is first extruded by the first flattening roller (54) onto the second belt conveyer (52) downstream of the first belt conveyer (51), then extruded by the second flattening roller (55) onto the third flattening roller (56) downstream of the second flattening roller (55) and put on and supplied onto the carrying belt conveyer (4). At this moment, on the first flattening roller (54), the vinegared rice (S) is brought into the plural concave grooves (54c) on the outer peripheral surface of the roller (54) and flattened and, at the same time, brought into the plural concave portions (54a). In this state, the rice (S) is extruded downstream. Due to this, the rice (S) is extruded in a state in which the bulge of the rice (S) is maintained. Further, since the deep concave grooves (54d) are constituted so as not to continuously appear at positions different from those formed in the adjacent convex portions (54b), i.e., at certain positions on the conveyer when the roller rotates, vinegared rice, even if flowing on the conveyer in the form of large blocks, can be extruded onto the downstream second belt conveyer (52) in a state in which the blocks of vinegared rice are fully broken and flattened to certain degree. Besides, since the convex portions of the first flattening roller (54) are formed to bulge from the axial ends to the center thereof, it is possible to break and flatten the blocks of the vinegared rice bulging on the central portion more surely.

The vinegared rice (S) extruded onto the second belt conveyer (52) is brought into the plural concave grooves (55c) on the outer peripheral surface of the second flattening roller (55) and flattened and, at the same time, brought in to the plural concave portions (55a) and extruded downstream in a state in which the bulge of the vinegared rice (S) is maintained. Further, the vinegared rice (S) is brought into the plural concave grooves (56c) on the outer peripheral surface of the third flattening roller (56) and flattened and, at the same time, brought into the plural concave portions (56) and then extruded downstream in a state in which the bulge of the vinegared rice (S) is maintained. At this moment, since the concave portions and concave grooves formed in the respective rollers become gradually narrower from the first flattening roller (54) to the second flattening roller (55) and to the third flattening roller

(56) in this order, the vinegared rice is gradually flattened every time the rice passes through the

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respective rollers. By gradually flattening the vinegared rice, the vinegared rice is extruded onto the downstream carrying conveyer (4) in a state in which the bulge of the vinegared rice is maintained without squashing rice.

As shown in FIG. 9, the vinegared rice cutting mechanism (6) consists of a vertical drive mechanism

(62) driven vertically, a cutting blade (61) attached to the vertical drive mechanism (62) and a longitudinal drive mechanism (63) for driving the cutting blade (61) to reciprocate in the longitudinal direction of the carrying conveyer (4). As shown in FIG. 10, the mechanism (62) cuts up the vinegared rice (S) extruded after being flattened by the third flattening roller (56) into pieces of a fixed width. A speed for longitudinally driving the cutting blade (61) is set faster than the advancing speed of the carrying conveyer (5), whereby the vinegared rice on the carrying conveyer (4) is cut up into pieces with a fixed width at certain intervals and the cut pieces of the vinegared rice have longitudinal tight ends (see FIG. 11), thus preventing the end portions from getting out of shape when forming the vinegared rice into rolled sushi.

As shown in FIGS. 12 and 13, the ingredient supply mechanism (7) includes a hopper support mechanism (71), a tapered hopper portion (72) supported by the hopper support mechanism (71), a volumetric supply cylindrical portion (73) almost as long as the hopper portion (72), arranged on the lower end portion of the hopper portion (72) and extended downward therefrom by a predetermined length, an ingredient output nozzle (73a) provided on the lower end of the volumetric supply cylindrical portion (73), an extrusion screw member (74) ranging from the inside of the tapered hopper portion (72) into the volumetric supply cylindrical portion (73), a drive motor (75) for driving the extrusion screw member (74), coupling member (76) for detachably coupling the rotary shaft (75a) of the drive motor (74) with the upper end of the extrusion screw member (74), a position adjustment mechanism (77) provided at the hopper support mechanism (71) and adjusting the vertical and longitudinal positions of the hopper portion (72), and a control board (78) for controlling the rotation speed of the extrusion screw member (74) driven to rotate by the drive motor (75) and the like.

In the hopper support mechanism (71), a support base (71a) is fixedly attached to a producing apparatus main body (1) by a plurality of attachment bolts (71b), a horizontal support rod (71d) is attached, through the position adjustment mechanism (77), to a vertical support rod (71c) provided on the support base (71a), and a horizontal attachment plate portion (72a) formed on the outer peripheral surface of the hopper portion (72) is fixedly but detachably attached to a horizontal plate (71e) on the tip end of the horizontal support rod (71d) by a hinge bolt (72b), to thereby support the hopper portion

(72).

The position adjustment mechanism (77) is provided with a longitudinal elongate hole (77a) formed longitudinally with respect to the vertical support rod (71c), a lateral elongate hole (77b) formed horizontally with respect to the horizontal support rod (71d), and a fixed screw (77c) inserted into the longitudinal elongate hole (77a) and lateral elongate hole (77b). A position adjustment knob (77d) is provided on the head of the fixed screw (77c). With this constitution, if the position adjustment knob

(88d) is loosened and the horizontal support rod (71d) is vertically moved relatively to the vertical support rod (71c) through the longitudinal elongate hole (77a), the vertical position of the hopper portion (72) is adjusted. If the horizontal support rod (71d) is moved longitudinally relatively to the vertical support rod (71c) through the lateral elongate hole (77b), the longitudinal position of the hopper portion (72) is adjusted.

As shown in FIG. 14, the extrusion screw member (74) consists of an upper rod portion (74a), a lower rod portion (74b) provided integrally with the lower end of the upper rod portion (74a) and formed to have a smaller diameter than that of the upper rod portion (74a), the first screw vane (74c) provided on the lower portion-side outer peripheral surface of the upper rod portion (74a), formed to gradually reduce diameter from upper to lower portions and arranged within the hopper portion (72), and the second screw vane (74d) provided on the outer peripheral surface of the small-diameter lower rod portion (74b) and having the same diameter as that of the portion arranged within the volumetric supply cylindrical portion (73). By the rotation of the extrusion screw member (74), the ingredients, such as fermented soybeans, crab meat, tuna fish and mayonnaise, are outputted and supplied onto the surface of the vinegared rice through the volumetric supply cylindrical portion (73) with determined volume at fixed pressure.

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The ingredient supply mechanism (7) with the above-stated constitution supplies ingredients onto the vinegared rice on the carrying conveyer. However, the present invention does not necessarily employ the ingredient supply mechanism and ingredients may be put on the vinegared rice with hands depending on the types of the ingredients such as cucumber and kanpyo (dried gourd shavings).

FIG. 15 shows the tight rolling mechanism (8) and the forming mechanism (9). The tight rolling mechanism (8) is to tight roll the carrying conveyer (4), on which vinegared rice and ingredients are being put, to have a circular cross section. The tight rolling mechanism (8) consists of a pair of right and left vertical press rollers (81) arranged vertically and rotatably and on both upstream sides of the carrying conveyer (4), a horizontal press roller (83) supported horizontally and rotatably by a support member (82) provided downstream of the rollers (81), and a pair of right and left form keeping vertical rollers (84) arranged vertically and rotatably on both sides of the carrying conveyer (4) further downstream.

In addition, the forming mechanism (9) consists of a guide plate (91) arranged on one side of the tight rolling mechanism (8) downstream thereof, a vertical roller (92) arranged at opposite side to the guide plate (91) and holding the carrying conveyer (4) to be tight rolled between the roller (92) and the guide plate (91), and a horizontal forming roller (93) arranged downstream of the guide plate (91) and the vertical roller (92), horizontally, rotatably and pivotally supported onto the rear end portion of the guide plate (91) and forming the vinegared rice put on the carrying conveyer (4) which is gradually returned flat.

The tight rolling mechanism (8) and the forming mechanism (9) form the vinegared rice on which ingredients are put, into a long rolled sushi shape through the carrying conveyer (4). First, the paired right and left vertical press rollers (81) of the tight rolling mechanism (8) raise the both sides of the carrying conveyer (4) on which the vinegared rice is put. The vinegared rice is rolled in the horizontal press roller (82), the vinegared rice integral with the carrying conveyer (4) is rolled tight to have a circular cross section and the tight rolled state is held by the guide plate (91) and the vertical roller

(92). When the belt conveyer (4) is returned flat, the vinegared rice is formed into a long rolled sushi shape by the horizontal forming roller (93).

The vinegared rice including the ingredients and formed by the forming mechanism (9) is supplied to the product take-out conveyer (11) by the product extrusion mechanism (10). FIGS. 16 to 18 show the product extrusion mechanism (10). FIG. 16 is a front view, FIG. 17 is a top view and FIG. 18 is a side view thereof. As shown in FIG. 16, the product extrusion mechanism (10) is formed as a rotating vane mechanism having four vanes (10a) arranged at right angle to one another. The rotary shaft (10b) thereof is set in the same direction as the advancing direction of the carrying conveyer (4). Reference symbol (M) denotes a drive motor. By coupling the shaft of this drive motor and the rotary shaft (10b) by a belt or the like, the vanes (10a) rotate.

As shown in FIGS. 17 and 18, the carrying conveyer (4) is formed as a roller feed mechanism having a plurality of rollers (41) aligned in the vicinity of the terminal end thereof at required intervals. By using the vanes of the product extrusion mechanism (10) as a plurality of rod members (1Oc) provided at intervals corresponding to those of the rollers, the formed vinegared rice flowing on the carrying conveyer (4) (on the rollers) is raised by the rod members (10c) in response to the rotation of the vanes, supplied onto the product take-out conveyer (11) and finally rolled with a sheet of laver, thereby taking out the vinegared rice as a product.

In the automatic rolled sushi producing apparatus according to the present invention, the vinegared rice cutting mechanism (6) may be provided not at a position just downstream of the vinegared rice extrusion mechanism (7) but between the forming mechanism (9) and the product extrusion mechanism

(10) as shown in FIG. 19. In this case, the vinegared rice cutting mechanism (6) is preferably a rotary blade mechanism as shown in FIG. 20. FIG. 21 shows the rotary blade (81) of the vinegared rice cutting mechanism (6). The mechanism (6) is formed into generally S shape as a whole and a blade

(8a) is formed on a vertically curved bulge portion. The rotary blade is driven to rotate by a rotation drive motor (not shown). According to the above-stated vinegared rice cutting mechanism (6), another carrying conveyer is arranged in a gap formed at the terminal end of the carrying conveyer (4) to allow the rotary blade to pass through the gap, thereby cutting up the long rolled sushi (S) formed by the forming mechanism (9) into pieces of a fixed length in response to the rotation of the rotary blade. If

2028/2197

this cutting mechanism is used, a sheet of laver may be first supplied on the carrying conveyer, vinegared rice and ingredients may be supplied onto and put on the sheet of laver, rolled with the sheet of laver and formed, and the rolled sushi may be finally cut up by this cutting mechanism.

As stated so far, the invention recited in claim 1 is an automatic rolled sushi producing apparatus, characterized by comprising a vinegared rice supply unit; a vinegared rice supply conveyer arranged below the vinegared rice supply unit; a carrying conveyer arranged at right angle to the vinegared rice supply conveyer; a vinegared rice extrusion mechanism arranged along an advancing direction of the carrying conveyer; a vinegared rice cutting mechanism; a tight rolling mechanism; a forming mechanism; a product extrusion mechanism; and a product take-out conveyer arranged at right angle to the carrying conveyer at a terminal end of the carrying conveyer, and wherein the vinegared rice supply conveyer, the carrying conveyer and the product take-out conveyer are arranged in the form of U as a whole. Thus, the following advantage is obtained.

Since the vinegared rice supply conveyer, the carrying conveyer and the product take-out conveyer are arranged in the form of U as a whole, a large installation space is not required. Also, since there is no need to remove a film and roll a sheet of laver, it is possible to reduce the number of people and production cost.

The invention recited in claim 2 is an automatic rolled sushi producing apparatus according to claim 1, characterized in that the vinegared rice cutting mechanism comprises a vertical drive mechanism driven vertically toward the carrying conveyer; a cutting blade attached to the vertical drive mechanism; and a longitudinal drive mechanism for driving the cutting blade to reciprocate in a longitudinal direction of the carrying conveyer, and in that a speed for driving the cutting blade forward is set higher than a carrying conveyer advancing speed. Thus, the following advantage is obtained.

Since the vinegared rice is not supplied onto a sheet of laver or a film unlike the conventional apparatus, it is possible to cut up the vinegared rice on the conveyer in advance by fixed amount and then supply cut pieces, and to obtain beautifully finished rolled sushi with the end faces thereof kept from getting out of shape. Furthermore, since the vinegared rice can be supplied onto the conveyer as a sheet with a fixed width and a fixed length, it is also possible to supply the rice sheet to the outside of the apparatus and to produce rolled sushi at a difference place. Alternatively, by supplying the rice sheet onto a square sheet of laver and rolling them tight, rolled sushi can be produced. Thus, it is possible to enhance production efficiency.

The invention recited in claim 3 is an automatic rolled sushi producing apparatus according to claim

1, characterized in that the product extrusion mechanism is formed as a rotating vane mechanism provided with four vanes arranged at right angle to one another; a rotary shaft direction of the rotating vane mechanism is the same as the carrying conveyer advancing direction; the carrying conveyer is formed as a roller feed mechanism having a plurality of rollers aligned at required intervals in the vicinity of the terminal end of the carrying conveyer; each of the vanes consists of a plurality of rod members provided at corresponding intervals to the intervals of rollers. Thus, it is possible to easily, surely the formed vinegared rice flowing on the carrying conveyer to the product take-out conveyer arranged at right angle to the carrying conveyer.Data supplied from the esp@cenet database -

Worldwide Claims:


What is claimed is:

1. Automatic rolled sushi producing apparatus comprising:

a vinegared rice supply unit:

a vinegared rice supply conveyer arranged below the vinegared rice supply unit;

a carrying conveyer arranged at a right angle to the vinegared rice supply conveyer;

a vinegared rice extrusion mechanism arranged along an advancing direction of the carrying conveyer;

a vinegared rice cutting mechanism;

a tight rolling mechanism;

a forming mechanism;

a product extrusion mechanism; and

2029/2197

a product takeout conveyer arranged at right angle to the carrying conveyer at a terminal end of said carrying conveyer.

2. An automatic rolled sushi producing apparatus according to claim 1, wherein:

said vinegared rice cutting mechanism comprises a vertical drive mechanism driven vertically toward the carrying conveyer; a cutting blade attached to the vertical drive mechanism; and a longitudinal drive mechanism for driving the cutting blade to reciprocate in a longitudinal direction of the carrying conveyer; and

a speed for driving the cutting blade forward is set higher than a carrying conveyer advancing speed.

3. An automatic rolled sushi producing apparatus according to claim 1, wherein said product extrusion mechanism is formed as a rotating vane mechanism provided with four vanes arranged at right angle to one another; a rotary shaft direction of the rotating vane mechanism is the same as the carrying conveyer advancing direction; said carrying conveyer is formed as a roller feed mechanism having a plurality of rollers aligned at required intervals in the vicinity of the terminal end of the carrying conveyer; each of said vanes consists of a plurality of rod members provided at corresponding intervals to the intervals of rollers.Data supplied from the esp@cenet database - Worldwide

2030/2197

413.

US6248379 - 6/19/2001

PUFFED CEREAL CAKES


Inventor(s): CAPODIECI ROBERTO A (US); YONEMOTO LUCIO H (BR); BAILLIE

CATHERINE V (BR); JACH THEODORE (BE); GARGARO FABIANA F (BR)

Applicant(s): MASTERFOODS S A NV (US)


IP Class: A23L1/18

E Class: A23L1/18C2



Family: US6248379

Equivalent: EP1008307; GB2344504; CA2291478; DE69917873T; DE69917873D; AU762760

Abstract:


The invention provides a process for the preparation of puffed cereal cakes, preferably rice cakes, comprising the steps of: providing a cereal grain, preferably a milled parboiled rice, wherein the cereal grain is impregnated with a non-mineral food ingredient such as a sugar; introducing the grain into a mold; and puffing the cereal in the mold under pressure to form a shaped impregnated cereal cake. The cereal grains impregnated with organic food ingredients can be used to make puffed cereal cakes having improved taste, texture and nutritional properties.Claims:


What is claimed is:

1. A process for the preparation of a puffed cereal cake comprising the steps of:

providing a cereal grain impregnated with at least one organic food ingredient;

introducing said grain into a mold; and

puffing said cereal grain in said mold under pressure to form a shaped flavored cereal cake.

2. The process according to claim 1, wherein said cereal grain has a moisture content of 10 to 20 wt. % when it is introduced into said mold.

3. The process according to claim 1, wherein said at least one food ingredient is impregnated in an amount of from 0.01 to 60 wt. % based on the dry weight of the cereal grain.

4. The process according to claim 1, wherein said at least one food ingredient is impregnated in an amount of from 0.5 to 35 wt. % based on the dry weight of the cereal grain.

5. The process according to claim 1, wherein said at least one food ingredient is impregnated in an amount of from 1 to 25 wt. % based on the dry weight of the cereal grain.

6. The process according to claim 1 or 2, wherein the cereal grain comprises rice.

2031/2197

7. The process according to claim 6, wherein the rice is at least partially parboiled.

8. The process according to claim 6, wherein the rice has been milled to substantially remove the bran

(pericarp) therefrom.

9. The process according to claim 8, wherein the rice is at least partially parboiled.

10. The process according to claim 1 or 2, wherein the cereal has been milled to substantially remove the bran (pericarp) therefrom.

11. The process according to claim 10, wherein the cereal grain is at least partially parboiled.

12. The process according to claim 1, wherein said at least one organic food ingredient has a molecular weight less than 1,000.

13. The process according to claim 1, wherein said at least one organic food ingredient has a molecular weight less than 350.

14. The process according to claim 1, wherein said at least one organic food ingredient is selected from the group consisting of lipids, proteins, carbohydrates, vitamins, emulsifiers, edible dyes, organic flavorants, and mixtures thereof.

15. The process according to claim 1, wherein said at least one organic food ingredient includes at least one sugar.

16. The process according to claim 15, wherein said sugar is selected from the group consisting of sucrose, fructose, glucose, maltose, lactose, mannose, galactose, trehalose and mixtures thereof.

17. The process according to claim 15, wherein said organic food ingredient is selected from the group consisting of a carbohydrate syrup, maple syrup, partially inverted refiner's syrup, honey, fruit juice, fruit syrup or a combination thereof.

18. The process of claim 15, wherein said at least one sugar is impregnated in an amount of from 1 to

60 wt. % based on the weight of the cereal cake.

19. The process according to claim 1, wherein said step of providing said cereal grain comprises the steps of providing a plain cereal grain, followed by impregnating the plain cereal grain with a solution or dispersion of the said organic food ingredients in liquid water.

20. The process according to claim 19, wherein said step of providing an impregnated cereal grain comprises parboiling the cereal grain in an aqueous solution comprising at least one organic food ingredient.

21. The process according to claim 19, wherein said plain cereal grain has a moisture content of from 7 to 40 wt. % before said step of impregnating.

22. The process according to any one of claims 1, 19 or 21, wherein said cereal grain is at least partially parboiled.

23. The process according to claim 22, wherein said step of providing an impregnated cereal grain comprises parboiling the cereal grain in an aqueous solution comprising at least one organic food ingredient.

24. A puffed cereal cake obtained by the process of claim 23.

25. The puffed cereal cake of claim 24 wherein the cereal is rice.

26. The puffed cereal cake obtained by the process of claim 22.

2032/2197

27. The puffed cereal cake of claim 26 wherein the cereal is rice.

28. The process according to claim 19, wherein said impregnating is carried out at a temperature of from 0 DEG C. to 195 DEG C.

29. The process according to claim 19, wherein said impregnating is carried out at a temperature of from 20 DEG C. to the glass transition temperature of the cereal.

30. A puffed cereal cake obtained by the process of any of claims 1 or 19 to 29.

31. The process according to any one of claims 19 to 29, wherein said step of impregnating is carried out for a period of less than 2 hours.

32. The process according to any one of claims 19 to 29, wherein said step of impregnating is carried out for a period of from 5 minutes to 30 minutes.

33. The process according to any one of claims 19 to 29, wherein said aqueous medium contains from

1 to 35 wt. % of one or more sugars.

34. The process according to any one of claims 19 to 29, wherein said cereal imbibes from 5% to

125% by weight of said aqueous medium, based on the weight of the plain cereal grain, in said step of impregnating.

35. The process according to any one of claims 19 to 29, wherein the total moisture content of said cereal immediately following said impregnating is from 10 to 65 wt. %.

36. The process according to any one of claims 19 to 29, wherein the total moisture content of said cereal immediately following said impregnating is from 25 to 40 wt. %, based on the total weight of the impregnated cereal grain.

37. The process according to any one of claims 1 or 19, further comprising the step of adjusting the moisture content of the cereal grain to from 10 to 20 wt. % after said step of impregnating.

38. The process according to claim 37, wherein said step of adjusting the moisture content comprises drying the cereal grains, followed by rehydrating the cereal grains to 10-20 wt. % moisture content for puffing.

39. The process of claim 1, wherein the food ingredient comprises a lipid.

40. The process of claim 1, wherein the step of impregnating comprises increasing the moisture content of the cereal grain by at least 15%, based on the dry weight of the plain cereal grain.

41. A process for the preparation of a puffed cereal cake comprising the steps of:

providing a cereal grain impregnated with at least one organic food ingredient selected from the group consisting of lipids, emulsifiers, edible dyes, proteins, carbohydrates, vitamins, organic flavorings, sugars or a combination thereof, wherein said organic food ingredient is impregnated in an amount of from 0.01 to 35 wt. % based on the dry weight of the cereal grain;

adjusting the total moisture content of said cereal grain after impregnation to about 10 to 20 wt. % based on the total weight of the impregnated cereal grain;

introducing said grain into a mold; and

puffing said cereal grain in said mold under pressure to form a shaped flavored cereal cake.

42. The process according to claim 41, wherein the step of providing said cereal grain comprises the steps of providing a plain cereal grain, followed by impregnating the plain cereal grain with an aqueous solution or dispersion of the said organic food ingredients.

43. The process according to claim 41, wherein the cereal grain has been milled to substantially remove the brain (pericarp) therefrom.

2033/2197

44. The process according to claim 41, wherein said at least one organic food ingredient has a molecular weight less than 1,000.

45. The process according to claim 41, wherein said at least one organic food ingredient has a molecular weight less than 350.

46. The process according to claim 41, wherein said cereal grain is at least partially parboiled.

47. The process according to claim 41, wherein said sugar is selected from the group consisting of sucrose, fructose, glucose, maltose, lactose, galactose, mannose and mixtures thereof.

48. The process according to claim 41, wherein said organic food ingredient is selected form the group consisting of a carbohydrate syrup, maple syrup, partially inverted refiner's syrup, honey, fruit juice, fruit syrup or a combination thereof.

49. The process according to claim 41, wherein said step of providing said cereal grain comprises the steps of providing a plain parboiled cereal grain, followed by impregnating the plain parboiled cereal grain with an aqueous solution or dispersion of the said organic food ingredients.

50. The process according to claim 49, wherein said impregnating is carried out at a temperature of from 0 DEG C. to 195 DEG C.

51. The process according to claim 49, wherein said step of impregnating is carried out for a period of up to 2 hours.

52. The process according to claim 49, wherein said aqueous medium contains from 1 to 35 wt. % of one or more sugars.

53. The process according to claim 49, wherein said cereal imbibes from 5% to 125% by weight of said aqueous medium, based on the weight of the plain cereal grain, in said step of impregnating.

54. The process according to claim 49, further comprising the step of adjusting the moisture content of the cereal grain to from 10 to 20 wt. % after said step of impregnating.

55. The process according to claim 54 wherein said step of adjusting the moisture content comprises drying the cereal grains, followed by rehydrating the cereal grains to 10-20 wt. % moisture content for puffing.

56. The process according to claim 1, 19, 41 or 55 wherein said step of puffing is carried out at a temperature of 170-320 DEG C., for a time of 1-20 seconds.

57. The process according to any of claims 41 to 55, wherein the cereal grain comprises rice.

58. The process of any of claims 1, 19 or 41, wherein the cereal grain is selected from the group consisting of rice, wheat, millet, buckwheat, barley, corn and mixtures thereof.

59. The process of claim 58, wherein the cereal grain has been milled to substantially remove the bran

(pericarp) therefrom.

60. The process of claim 59, wherein the cereal grain has been at least partially parboiled.

61. The process of claim 60, wherein the cereal grain has been substantially completely parboiled.Data supplied from the esp@cenet database - Worldwide

2034/2197

414.

US6248390 - 6/19/2001

FIBER-WATER-WATER CONTAINING SOLUBLE FIBER


Inventor(s): STILLMAN SUZANNE JAFFE (US)


IP Class: A23L2/00; A23L2/54

E Class: A23L1/308; A23L2/38; A23L2/52; A23L2/58



Family: US6248390

Equivalent: WO0162108; CA2399918

Abstract:


A shelf stable, ready to use, essentially tasteless and odorless water-like fluid for humans/animals comprised of safe water and a significant quantity of one or more water-soluble dietary fibers. Fiberwater is intended to be consumed by drinking or by enteral feeding alone, and/or in combination. The inventive liquid may be consumed directly hot or cold or after use, at any required temperature, in the preparation/reconstitution of beverages or liquid food product (e.g. coffee, tea, concentrates such as

"HAWAIIAN PUNCH(R)", frozen concentrates such as lemonade/orange juice, soups and pet food). It can be used to enrich foods with soluble fiber through cooking, moistening, reconstituting or imbibing dried foods (e.g. oatmeal, rice, dried fruits, powdered soups, powdered beverages, powdered milks, nutritional shakes, "GATORADE(R)/TANG(R)/KOOL-AID(R)" products, gelatins, custards, puddings, and pet food). Fiber-water can be consumed in the frozen state either indirectly by adding it to a beverage as a cube or crushed "ice", or directly by licking a frozen "POPSICLE(R)" product).

Fiber-water is safe water fiber enriched intending to be a replacement and/or adjunct to other water to ensure proper hydration while at the same time provide significant soluble fiber. Depending on the soluble fiber(s) used, and the user's individual metabolism, the invention is non-caloric or extremely low in calories. The soluble fiber(s) used are proven to moderate the postprandial rise in blood glucose

(diabetes), address weight loss (obesity), lower serum cholesterol level (cardiovascular/heart), and address constipation and bowel regularity (colon cancer).Claims:


I claim:

1. A water composition for consumption by humans and animals comprising:

between 0.1% and 10% by weight water-soluble indigestible fiber; and

safe water, wherein fewer than 10 calories per 100 ml is metabolized by a human when consuming the water composition and wherein the water composition contains less than 500 mg./l of soluble salts and essentially no organic acids.

2. The water composition of claim 1 further comprising a soluble food grade color.

3. The water composition of claim 2, wherein the soluble food grade color acts as an indicator of an amount of the water soluble indigestible fiber contained in the water composition.

2035/2197

4. The water composition claim 1, wherein the water soluble indigestible fiber is selected from the group consisting of plant mucilage, plant gums, dextrins, maltodextrins, galactomannans, arabanogalactans, beta glucans, cellulose ethers, pectins, pectic material, water-soluble hemicellulose, inulin, alginates, agar, carrageenan, psyllium, guar gum, gum traganth, gum karya, gum ghatti, gum acacia, gum arabic, partially hydrolyzed products thereof and mixtures thereof.

5. The water composition claim 1, wherein the water-soluble indigestible fiber and water form an optically clear solution.


between 0.1% and 10% by weight water-soluble indigestible fiber selected from the group consisting of dextrins, maltodextrins, galactomannans, cellulose ethers, inulin, alginates, agar, carrageenan, psyllium, guar gum, gum traganth, gum karya, gum ghatti, gum acacia, gum arabic, partially hydrolyzed products thereof and mixtures thereof; and

safe water, wherein the water and the water-soluble indigestible fiber form an optically clear solution, wherein fewer than 10 calories per 100 ml are metabolized by a human when consuming the water composition and wherein the water composition contains a nutritionally insignificant amount of soluble minerals and essentially no organic acids.

7. The water composition of claim 6 further comprising a soluble food grade color.

8. The water composition claim 7, wherein the soluble food grade color acts as an indicator of an amount of the water soluble indigestible fiber contained in the water composition.


between 0.1% and 10% by weight water soluble indigestible fiber selected from the group consisting of dextrins, maltodextrins, inulin, guar gum, partially hydrolyzed products thereof and mixtures thereof; and

safe water, wherein the water and the water soluble indigestible fiber form an optically clear solution, wherein fewer than 10 calories per 100 ml are metabolized by a human when consuming the water composition and wherein the water composition contains a nutritionally insignificant amount of soluble minerals and essentially no organic acids.

10. The water composition claim 9 further comprising a soluble food grade color.

11. The water composition of claim 10, wherein the soluble food grade color acts as an indicator of an amount of the water soluble indigestible fiber contained in the water composition.

12. The water composition of claim 1, wherein said water-soluble fiber is selected to satisfy simultaneously both hydration requirements and fiber requirements when consumed.

13. The water composition of claim 1, wherein addition of said water-soluble fiber does not alter clarity of the water composition.

14. The water composition claim 1 formulated for managing constipation.

15. A method of managing bowel regularity comprising the step of ingesting a quantity of the water composition of claim 1.

16. A method of managing hemorrhoids comprising the step of ingesting a quantity of the water composition of claim 1.

17. A method of avoiding assimilation of toxic bowel compounds comprising the step of ingesting a quantity of the water composition of claim 1.

18. The water composition of claim 1 formulated for management of diabetes.

19. The water composition of claim 1 formulated for management of obesity.

2036/2197

20. The water composition of claim 1 formulated for appetite suppression.

21. The water composition of claim 1 formulated for lowering serum cholesterol levels.

22. The water composition of claim 2, wherein the soluble food grade color acts as an indicator of a type of the water-soluble indigestible fiber contained in the water composition.

23. The water composition of claim 6, wherein the water-like fluid contains fewer than 500 mg./l of soluble salts.

24. The water composition of claim 6, wherein said water-soluble fiber is selected to satisfy both hydration requirements and fiber requirements when consumed.


26. The water composition of claim 6 formulated for managing constipation.







33. The water composition of claim 6 formulated for lowering serum cholesterol levels.

34. The water composition of claim 10, wherein the soluble food grade color acts as an indicator of a type of the water-soluble indigestible fiber contained in the water composition.


between 0.1% and 10% by weight water-soluble indigestible fiber; and

safe water, wherein fewer than 10 calories per 100 ml is metabolized by a human when consuming the water composition and wherein the water composition contains a nutritionally insignificant amount of soluble minerals and essentially no organic acids.

36. The water composition of claim 35, wherein said water-soluble fiber is selected to satisfy simultaneously both hydration requirements and fiber requirements when consumed.


38. The water composition of claim 35 formulated for management of constipation.



2037/2197





45. The water composition of claim 35 formulated for lowering serum cholesterol levels.Data supplied from the esp@cenet database - Worldwide

2038/2197

415.

US6265001 - 7/24/2001

RICE BASED BEVERAGE PRODUCT AND PROCESS FOR MAKING THE

SAME


Inventor(s):

(KR)

NAM SUNG-HEE (KR); SEO JANG-HO (KR); KIM MI-LA (KR); KIM MI-JUNG


IP Class: A23L2/38

E Class: A23L1/105B; A23L2/38



Family: US6265001

Abstract:


Disclosed is the beverage product made of rice and the method for making the same. The method comprises A method of producing a beverage, comprising the steps of roasting the polished and unpolished rice; dividing the rice into particles of reduced size; mixing the rice with refined water; treating the rice with bacteria alpha-amylase whereby gaining a first reaction product; treating the first reaction product with glucoamylase, protease, and pectinase whereby gaining a second reaction product; deactivating the second reaction product; refining the second reaction product; and treating the second reaction product with sucrose fatty acid ester and refined water under uniform pressure of between 130 and 150 bar whereby being emulsified and homogenized.Description:



The present invention relates to a beverage product containing unpolished rice and polished rice and a method of producing the same.

The need for improved nutritious food supplements is greatly increasing as the public becomes more health and weight conscious. And many beverages containing rice have been suggested, one of which is a fermented rice punch. The rice punch uses polished rice whose embryo bud is removed through polishing process. Compared to the unpolished rice, the polished rice lacks vitamin B group, mineral, essential amino acid, and the like, which may cause a modern disease. Therefore it is preferable to use unpolished rice for the nutritious beverages.

To meet the needs, the beverages containing unpolished rice as well as polished rice have been developed, but they are made through a fermentation process by steaming the rice, or a sterilization process at high pressure in a retort, which requires high production cost. The high temperature and high pressure process performed in the retort reduces the freshness and nutritive value of the product.


Therefore, it is an object of the invention to provide a fresh and nutritious beverage.

2039/2197

It is also an object of the invention to provide a method for producing the beverage, which can reduce the production cost.

To achieve the objects, the present invention provides a method of producing a beverage which includes the steps of roasting the polished and unpolished rice; dividing the rice into particles of reduced size; mixing the rice with refined water; treating the rice with bacteria alpha-amylase whereby gaining a first reaction product; treating the first reaction product with glucoamylase, protease, and pectinase whereby gaining a second reaction product; deactivating the second reaction product; refining the second reaction product; and treating the second reaction product with sucrose fatty acid ester and refined water under uniform pressure of between 130 and 150 bar whereby being emulsified and homogenized.

The rice is preferably roasted for 10 to 20 minutes. The amount of the polished rice in the product is more than that of the unpolished rice, since taste of the polished rice becomes the consumers more than the unpolished.

It is another characteristic of the invention that the homogenized product is sterilized for several seconds.

It is still characteristic of the invention that the pH of the beverage is between 3.2 and 6.7.


1@st Process-roasting

First, the white or polished and brown or unpolished rice is carefully selected and roasted at temperature of 150 to 200 for 10 to 20 minutes, and flavor and the color is given to the rice. At this time, if the roasting temperature is lower than 150, it will require longer time and the color and the flavor of the rice is not so good. And if the temperature is over 230, the rice is ready to be burnt. Thus the roasting temperature is carefully selected.

2@nd Process-agitation

The white and the brown rice of the 1st process is reduced to powder to a size of between 10 and 50 mesh and mixed in the predetermined ratio. Then among the mixed rice from 8 to 20 wt % of weight of the predetermined product is chosen and is defined as a starting material, which is mingled by refined water of between 4 and 8 times of the weight of the starting material and agitated at about 100. The mingled solution is a starting solution in this production method

The weight ratios of brown rice to the white rice are from 1:9 to 35:5, preferably to 1:9 to 2:8. If too much brown rice is present, the production cost will increase.

3@rd Process-first Treatment with Enzyme

The agitated material is cooled to between 90 and 100, and is treated for 10 to 30 minutes with bacteria alpha amylase of 0.02-0.06 wt. %. The reaction product of this process has saccharinity of between 6 and 11 Brix.

4@th Process-second Treatment with Enzyme

The reaction product of the 3@rd process is again cooled to 50-60, and treated with 0.05 to 0.25 wt. % glucoamylase, 0.1 to 0.3 wt. % protease, and 0.05 to 0.25 wt. % pectinase for 3 to 8 hours. The reaction process of this process has saccharinity of between 8 to 13 Brix.

5@th Process-deactivation of Enzyme

The reaction product of the 4@th process is then heated to about 100 for 5 to 10 minutes to deactivate the enzymes.

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6@th Process-refinement

The result solution of 5@th process is strained through a strainer of size of 40-120 mesh and the remainders of the solution are removed after a centrifugal separator process. Then clean and clear solution is obtained. The refined solution is more than 80 wt. % of the starting solution and has saccharinity of between 11 and 13 Brix.

7@th Process-homogenized Emulsification Process

The solution which includes 40 to 65 wt % the refined solution, 57.018-27.35 wt % refined water, 2-6 wt % sugar or inverted sugar, 0.002-0.2 wt % vitamin C or citric acid, 0.1-0.8 wt % bean oil, 0.08-0.25 wt % palm oil, and 0.2-0.4 wt % sucrose fatty acid ester is then homogenized and emulsified under a uniform pressure of 130 to 150 bar. The emulsification process is performed 1-3 times to homogenize the solution uniformly.

The homogenized emulsification and mixing with sucrose fatty acid ester which has a bacterostatic ability enhances the sterilizing power and makes the product yellow or light yellow. The pH of emulsified solution is between 3.2 and 6.7 and is sterilized at a temperature from about 115 to about

128 for 20 to 40 seconds without being sterilized in a retort. The sterilized product is then filled in a bottle or polyethylen terephthalate container at a temperature from 85 to 95.

Since the sterilization time is short, the product can maintain its freshness and its nutritive value.

8@th Process-packing

Sterilization is conducted to the container having the product in at a temperature more than 85 for 10 to 20 minutes. After that it is cooled to 30 to 34 and packed.

As described above the processes according to the invention does not use retort-sterilization, which requires high temperature and high pressure, thus the processing time also can be reduced.

Also this method does not need large amount of cooling water and energy.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A method of producing a beverage, the method comprising the steps of:

roasting polished and unpolished rice;

reducing the rice into powder;

mixing the rice with water;

treating the rice with bacterial alpha-amylase whereby gaining a first reaction product;

treating the first reaction product with glucoamylase, protease and pectinase whereby gaining a second reaction product;

deactivating the second reaction product by heating;

refining the second reaction product by straining; and

treating the second reaction product with sucrose fatty acid ester and water and emulsifying and homogenizing under uniform pressure of between 130 and 150 bar.

2. The method of claim 1, wherein the roasting is done for 10 to 20 minutes.

3. The method of claim 1, wherein the amount of the polished rice is more than that of the unpolished rice.

4. The method of claim 1, further comprising, sterilization of the homogenized product for several seconds.

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5. The beverage product made by the process of claim 1.

6. The beverage product made by the process of claim 2.

7. A method of producing a beverage using a roasted and powdered rice, the method comprising the steps of:

mixing roasted and powdered rice with water;

treating the rice with bacterial alpha-amylase to produce a first reaction product;

treating the first reaction product with glucoamylase, protease and pectinase to produce a second reaction product;

heating the second reaction product;

filtering the second reaction product; and

treating the second reaction product with sucrose fatty acid ester and water, and emulsifying and homogenizing under uniform pressure of between about 130 and 150 bar.

8. The method of claim 7, wherein the roasting is done for 10 to 20 minutes.

9. The beverage product made by the process of claim 7.Data supplied from the esp@cenet database -

Worldwide

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416.

US6303586 - 10/16/2001

SUPPORTIVE THERAPY FOR DIABETES, HYPERGLYCEMIA AND

HYPOGLYCEMIA


Inventor(s): MCPEAK PATRICIA (US); CHERUVANKY RUKMINI (US); CHERUKURI

REDDY SASTRY V (US)

Applicant(s): RICEX COMPANY (US)


IP Class: A23L1/172; A61K31/715; A23L1/168; A23L1/18; A23L1/36

E Class: A61K35/78; A23L1/10E; A21D2/36; A23L1/308A


Priority Number: US19980143429 (19980828); US19970057409P (19970829)

Family: US6303586

Abstract:


Methods for controlling serum glucose level in a mammal comprising ingesting a stabilized rice bran derivative selected from the group consisting of a solubilized fraction, an insolubilized fraction, an enzyme treated stabilized rice bran and mixtures thereof, thereby reducing serum glucose level in said mammal.Description:


FIELD OF INVENTION

The present invention relates to methods for controlling serum glucose levels in mammals.


Diabetes is a chronic disease that has no cure. It affects 16 million people in the U.S. and more than

125 million people worldwide. Diabetes is the fourth-leading cause of death by disease in the United

States. In 1997, more than 178,000 people died from the disease and its relates complications.

Diabetes mellitus is characterized by an impaired ability to metabolize carbohydrates, increased glucose in the blood, and excretion of glucose in the urine. This defect involves interference with insulin in its role of facilitating uptake of glucose by cells, to give energy as ATP.

In people with diabetes, the pancreas produces insufficient or no insulin, the hormone which is responsible for the absorption of glucose into cells for energy needs. As a result, the level of glucose in the blood becomes abnormally high, causing excessive urination and constant thirst and hunger. The body's inability to store or use glucose causes weight loss and fatigue. Diabetes mellitus also results in disordered lipid metabolism and accelerated degeneration of small blood vessels.

There are two main types of diabetes mellitus. Type I which is the more severe form, usually first appears in people under the age of 35 and most commonly in people between the ages of 10 and 16. It

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develops rapidly. The insulin-secreting cells in the pancreas are destroyed, probably as a result of an immune response after a virus infection, and insulin production ceases almost completely. Without regular injections of insulin the sufferer lapses into a coma and dies. Type I diabetes results from the pathological error due to the inability of beta cells of the islets of Langerhans to secrete insulin. It may be due to a genetic disposition or a viral infection, wherein the beta cells are suppressed and are unable to secrete insulin. Individuals suffering from Type I diabetes are totally insulin dependent and is normally manifested by age 25.

The most prevalent type of diabetes, Type II diabetes, is usually of gradual onset and occurs mainly in people over 40. In many cases it is discovered only during a routine medical examination. Patients with

Type II diabetes have this condition due to pathological error of malabsorption of glucose or impaired utilization of peripheral insulin or due to the result of abnormal erythrocyte receptors (partly genetic), accounts to absorption/utilization of glucose/insulin. Not enough insulin is produced to meet the body's needs, especially when the person is overweight. Often the body is resistant to the effects of insulin as the receptors are deactivated. In most cases, insulin-replacement injections are not initially required.

The combination of dietary measures, weight reduction and oral medication can keep the condition under control for a period of time, but most people with Type II diabetes ultimately require insulin injections.

One of the complications of Type I and Type II diabetes is production of abnormal glycated compounds. Glycation and glycoxidation, a sequential process, is often encountered in uncontrolled

Type I and Type II diabetics. This involves the surface protein of LDL, and its component apolipoprotein B, which contributes to atherogenicity. Glycated and glycoxidated products are chemotactic to monocytes. The monocytes in the vascular cells infiltrate to macrophage, and form foam cells in the vascular collagen, facilitating adhesion of lipoproteins, suppressing immune complexes and resulting in atherosclerotic plaques. Lysine-fructose in blood is an indicator of the extent of glycation before and after treatment. Carbomethoxy lysine in serum is an indicator of the extent of glycoxidation--before and after treatment.

In patients with Type II diabetes, there is an imbalance between oxidants and antioxidants leading to endothelial dysfunction, which can predispose the patients to atherosclerosis and target organ damage.

The levels of lipid peroxidation are high with simultaneous decrease in those antioxidants such as superoxide dismutase, Vitamin E, glutathione peroxidase, methionine reductase and nitric oxide.

The long-term complications of the disease usually are a decreased life expectancy, neuropathy, and an increased rate of blindness (by 25 times), an increased rate of kidney disease (by 17 times) and an increased rate of heart disease (2 times) in comparison to nondiabetics. Type I and Type II diabetics are always associated with hypercholesterolemia and hyperlipidemia.

As stated above, diabetes may be controlled with insulin and in some cases through careful diet.

However, the blood sugar levels will still fluctuate (sometimes dramatically), in patients undergoing insulin or diet therapy. Furthermore, in cases where the diabetes is severe, patients find it necessary to constantly monitor their glucose levels to prevent associated illnesses. Diabetic patients are forced to inject insulin which ultimately leads to bruising in certain areas. Furthermore, additional medical complications often arise from diabetes such as arteriosclerosis, hyperlipidemia, retinal damage, neurological damage, fatigue and weakness.

Therefore, there is a need for a safe and effective treatment for diabetes with minimal side effects and without the invasive procedures, such as injections. In addition, there remains a need for a treatment which addresses other medical ailments which often accompany diabetes, to insure that patients remain in the best health possible. The present invention fulfills these and other needs.


In some instance, conventional therapy for diabetes is to administer one or more injections per day of various forms of insulin while monitoring blood glucose levels. Near normal blood sugar levels are difficult if not impossible to achieve using conventional therapy. There exists a great need for additional therapy for diabetes to control serum glucose level. It has now been surprisingly found that ingesting stabilized rice bran derivatives control serum glucose levels in mammals. As such, in one

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aspect, the present invention relates to methods for reducing serum glucose level in mammals by ingesting a stabilized rice bran derivative, such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction or mixtures thereof. In one embodiment, the rice bran derivative is ingested in an amount of about 10 grams to about 100 grams per day total, preferably in at least 2 doses.

In another aspect, the present invention relates to methods for managing hyperglycemia in mammals, by ingesting a stabilized rice bran derivative such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction and mixtures thereof.

In still other aspects, the present invention relates to a diabetic food supplement kit comprising a stabilized rice bran derivative, such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction and mixtures thereof, a non-rice consumable, and instructions for the use of the components of the kit. Additional embodiments will be apparent to those skilled in the art with reference to the following detailed description.


I. Glossary

As used herein the term "apolipoprotein B" or "apoprotein B" or "Apo B" refers to the protein component of the cholesterol transport proteins. Cholesterol synthesized de novo is transported from the liver and intestine to peripheral tissues in the form of lipoproteins. Most of the apolipoprotein B is secreted into the circulatory system as VLDL.

As used herein the term "arteriosclerosis" is a degeneration of the walls of the arteries due to the formation of foam cells and aortic streaks which narrow the arteries. This limits blood circulation and predisposes an individual to thrombosis.

As used herein the term "enzyme treated stabilized rice bran derivative" refers to an enzyme treated stabilized rice bran made by mixing a stabilized rice bran with an aqueous solution in a 15% to about a

35% aqueous slurry w/w; adding an enzyme to the aqueous rice bran slurry to convert starch to dextrin, and then directly drying the dextrin solution to form an enzyme treated stabilized rice bran derivative.

The enzyme treated stabilized rice bran comprises about 20% to about 30% total dietary fiber.

As used herein the term "GRAS" means generally regarded as safe with respect to food additives.

As used herein the term "hypercholesterolemia" is a condition with elevated levels of circulating total cholesterol, LDL-cholesterol and VLDL-cholesterol as per the guidelines of the Expert Panel Report of the National Cholesterol Educational Program (NCEP) of Detection, Evaluation of Treatment of high cholesterol in adults (see, Arch. Int. Med. (1988) 148, 36-39).

As used herein the term "hyperglycemia" refers to an excess of glucose in the bloodstream. It can occur in a variety of diseases due to insufficient insulin in the bloodstream and excessive intake of simple carbohydrates.

As used herein the term "hypoglycemia" refers to a deficiency of glucose in the bloodstream. If sever, this can lead to a hypoglycemic coma.

As used herein the term "hyperlipidemia" or "hyperlipemia" is a condition where the blood lipid parameters are elevated in the blood. This condition manifests an abnormally high concentration of fats. The lipids fractions in the circulating blood are, total cholesterol, low density lipoproteins, very low density lipoproteins and triglycerides.

As used herein the term "lipoprotein" such as VLDL, LDL and HDL, refers to a group of proteins found in the serum, plasma and lymph and are important for lipid transport. The chemical composition of each lipoprotein differs in that the HDL has a higher proportion of protein versus lipid, whereas the

VLDL has a lower proportion of protein versus lipid.

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As used herein the term "stabilized rice bran derivative insolubilized fraction" refers to a fraction during a partitioning process. Specifically, after the stabilized rice bran aqueous slurry is enzymatically treated, it is then pumped into a horizontal centrifuge where the insoluble fraction precipitates out of the aqueous solution. The insoluble fraction is collected and then dried, and subsequently ground into a powder. This powder is the insoluble portion. The constituent parts and their percentages are listed in

Tables I and IV.

As used herein the term "stabilized rice bran derivative solubilized fraction" refers to a fraction during a partitioning process. Specifically, after the stabilized rice bran aqueous slurry is enzymatically treated, it is then pumped into a centrifuge where the insoluble fraction precipitates out of the aqueous solution. The aqueous material is pumped to a dryer and then dried. This dried aqueous portion produces the soluble fraction. The constituent parts and their percentages are listed in Tables I and V.

As used herein the term "triglyceride" means a lipid or neutral fat consisting of glycerol combined with three fatty acid molecules.

II. Detailed Description

In harvested rice, also known as rough rice, the kernel is completely enveloped by the rice hull. The milling process removes the hull, which yields brown rice. The outer brown layer is then removed by an abrasive milling process to generate white rice. The separated brown layer is designated rice bran.

Rice bran is the mesocarp, i.e., the portion between the hull and rice grain, obtained by milling or polishing brown rice. It constitutes about 10% of rough rice. It is generally used as an animal feed. It contains about 18-24% fat, about 25% dietary fiber, about 14% protein and about 45% total carbohydrates besides several potent micronutrients. It is rich in B-complex vitamins, vitamin E and its isomers, minerals like potassium, magnesium, and phosphorous besides several potent antioxidants.

Stabilized rice bran can be commercially purchased or prepared using various methods. Most stabilization methods of rice bran result in inactivation of the lipases which are present, inactivation of the peroxidases, and inactivation of the microorganisms, while still maintaining the high levels of antioxidants in the rice bran. For a general discussion of stabilization and processing see, Rice Science and Technology, edited by W. E. Marshall and James I Wadswoth, (1994) pages 390-404.

Under normal conditions when brown rice is milled to rice, the oil in the bran and the lipases also in the bran come into mutual contact, resulting in rapid degradation of the rice oil to free fatty acids and glycerol. The rice bran becomes unpalatable and is no longer suitable for foodstuffs. However, if the lipases are inactivated, the rice bran is thereby stabilized and the adverse effects on the bran are avoided.

There are many suitable means to stabilize or inactivate the lipase in rice bran, however most commercial systems utilize moisture-added or dry extrusion methods. These systems are selected because of their relatively low energy requirements, low capital costs and ease of operation.

Stabilization by dry extrusion utilizes shear, friction, and pressure to generate the heat required to inactivate the lipase.

The temperature of the bran must reach a temperature of a minimum of 130 DEG -140 DEG C. for up to 3 seconds to assure inactivation of the lipase. Acceptable extrusion stabilization can be achieved under less harsh conditions by adding water or steam. The lipase is more heat sensitive at higher moisture and can therefore be inactivated at somewhat lower extrusion temperatures.

Residual peroxidase activity is generally used as the standard measure to make sure that lipase activity has been deactivated in stabilized rice bran. Peroxidase is generally considered to be more heat stable than lipase, and peroxidase activity assays are easier and more reliable than the assays for lipase. The process conditions required to inactivate peroxidase as well as lipase can also cause modification to or loss of antioxidants in the bran. This can lead to fewer fatty acids, but the bran can be subject to oxidative rancidity. In addition, because the rice bran is susceptible to mold, yeast and bacteria, the stabilization process must effectively reduce the microbiological load of the bran.

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In addition to moisture added and extrusion techniques for stabilization, freezing and refrigeration of the rice bran result in economically viable processes to stabilize rice bran. Preferably, processes used to stabilize rice bran minimize the free fatty acid content, while maintaining high levels of antioxidants.

Food grade stabilized rice bran is typically finely granulated, light tan in color and possesses a relatively bland flavor with a nutty, toasted overtones.

Stabilized rice bran is available commercially from Producers Rice Mill Inc. (Stuttgart, Ark.),

Riceland Foods (Stuttgart, Ark.), Riviana Foods, Inc. (Houston, Tex.), Uncle Ben's Inc. (Houston,

Tex.) and The RiceX Company (El Dorado Hills, Calif.). Due to different stabilization processes, stabilized rice bran will differ in composition and stabilization characteristics when derived from different manufacturers.

In order to generate the rice bran derivatives for use in the present invention, the rice bran is first stabilized, and then it is further separated into at least two fractions. These include, but are not limited to, a stabilized rice bran soluble derivative and a stabilized rice bran insoluble derivative. Preferably, the separation into the rice bran derivatives includes a nonchemical process i.e., an enzymatic process.

In this process, partitioning or fractionation preferably proceeds as outlined hereinafter.

The stabilized rice bran is made into about a 15% to about a 35% slurry, preferably, 20-25% slurry with potable water. An enzyme, which can include, but is not limited to, a dextranase, a maltase, a

.alpha.-amylase, and various other carbohydrate cleaving enzymes, is added to the batch converting the starch to dextrins. The slurry is heated to about 150 DEG F. to about 200 DEG F. using for instance, a steam injection cooker, a heat exchanger, or other heating method. The slurry is then pumped to a horizontal centrifuge wherein the insoluble fraction is separated. The insoluble fraction is collected and then dried on a belt dryer, and subsequently ground into a powder. This powder is the stabilized rice bran insoluble fraction. The aqueous material is pumped to a drum dryer and then dried. This dried aqueous portion produces the stabilized rice bran solubilized fraction.

The enzyme treated stabilized rice bran can be generated using the rice bran slurry as described above.

As such, in another aspect, the present invention relates to the process for making an enzyme treated stabilized rice bran derivative, comprising: admixing stabilized rice bran with an aqueous solution to form about a 15% to about a 35% aqueous rice bran slurry, preferably a 20% to about a 30% aqueous rice bran slurry w/w; adding an enzyme to the aqueous rice bran slurry to convert starch to dextrin, thereby forming an enzyme treated slurry, and then directly drying the enzyme treated slurry to form an enzyme treated stabilized rice bran derivative.

In a preferred embodiment of the foregoing process, after the enzyme is added to the slurry, the slurry is heated to about 100 DEG F. to about 200 DEG F. Preferably, the slurry is heated to about 150 DEG

F. to about 200 DEG F. The slurry is then dried, wherein the drying is accomplished by a process such as belt drying, spray drying, drum drying and air drying. The drum drying process is preferred.

These stabilized rice bran derivatives are also available commercially from The RiceX Company of

California. For the purpose of the invention, stabilized rice bran is available as RiceX.TM. Stabilized

Rice Bran. The insoluble derivative is available as RiceX.TM. Fiber Complex and the soluble derivative is available as RiceX Ricelin.TM. from The RiceX Company, El Dorado Hills, Calif.

The stabilized rice bran derivatives can take a variety of forms. They can be a powder, a food, a food supplement, a medical food, a liquid, a beverage, an emulsion or mixture thereof. In addition, they can be incorporated into other edible materials. To incorporate the rice bran derivative into the diet of a mammal various options include, but are not limited to, simply sprinkling the derivative on another food substance (i.e., salad, bread, cereal, etc.) being a major ingredient in a multigrain ready to eat cereal, incorporating it into a baked product (breads, muffins, waffles, etc), pasta, healthy dessert and snacks (athletic bar, healthy drink, etc.) and high fiber foods.

Stabilized rice bran contains about 18-23% fat, about 23-35% dietary fiber, about 12-16% protein, about 8-36% total carbohydrate and many potent mnicrocomponents. Rice bran solubles contains about

15-40% fat, preferably 23-30% fat; about 0% to 25% dietary fiber, preferably about 0-20% dietary fiber; about 0% to 15% protein, preferably 6-9% protein and 25% to about 80% carbohydrates, preferably about 27-66% simple carbohydrate and is a water soluble fraction. Stabilized rice bran

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insoluble derivative contains about 5%-20% fat, preferably 11-16% fat; about 40-65% dietary fiber, preferably 40-60% dietary fiber, and about 10-30% protein, preferably 18-22% protein (see, Table I)

>;tb;TABLE I

>;tb;COMPOSITION (est.)

>;tb; RiceX .TM. Stabilized Rice Bran

>;tb; Fat 18-23%

>;tb; Protein 12-16%

>;tb; Total Dietary Fiber 23-35%

>;tb; Soluble Fiber 2-6%

>;tb; Carbohydrates 8-36%

>;tb; Ash 7-10%

>;tb; Moisture 4-8

>;tb; RiceX Ricelin .TM.

>;tb; Fat 23-30%

>;tb; Protein 6-9%



>;tb; Ash 3-7%

>;tb; Moisture 2-7%

>;tb; RiceX .TM. Fiber Complex

>;tb; Fat 11-16%

>;tb; Protein 18-22%


>;tb; Soluble Fiber 0-12%


>;tb; Ash 8-12%

>;tb; Moisture 1-6%

With reference to Tables IV, V, VI and VII in Example 4, these derivatives have been shown to have at least seventy-five (75) potent anti-oxidants. The major antioxidant vitamin E and its isomers known as tocopherols (T and tocotrienols (T3) are collectively called tocols. A tocol rich substance is a mixture containing one or more compounds selected from tocopherols (T, tocotrienols (T3), and tocotrienol-like (T3 -like) compounds.

Antioxidant in stabilized rice bran derivatives include, but are not limited to, .gamma.-oryzanol, .beta.carotene, several known flavanoids, phytosterols, lipoic acid, and ferulic acid. Some of these compounds are present in high concentration, much more than in any of the known natural sources. It is believed that antioxidants particularly tocols, play a crucial role in significantly correcting certain metabolic disorders singularly or synergistically as discussed below.

The stabilized rice bran soluble derivative is a powdered emulsion of soluble stabilized rice bran and germ, and is easily digested and absorbed by the body. It can be taken by itself with a small amount of water to dissolve it in the mouth. It can also be mixed into liquids such as juice or hot driks.

Additionally, it is appropriate for use in baked goods and other foodstuffs as discussed above. There are a significant number of nutrients which have been discovered in rice bran solubles (stabilized rice bran solubilized derivatives).

The stabilized rice bran insoluble derivative binds bile acids thereby lowering serum cholesterol levels and decreases triglyceride levels thereby helping in the metabolism of cholesterol. It contains many highly potent antioxidants such as .beta.-carotene, .alpha., .beta., .gamma., and .delta. tocopherols and tocotrienols, phytate, oryzanols, glycosides and numerous phytosterols and polyphenols. The rice bran insoluble derivative can also be mixed into liquids such as juice or hot drinks. Additionally, it is appropriate for use in baked goods and other foodstuffs as discussed above.

The enzyme treated stabilized rice bran derivative can also be mixed into liquids such as juice or hot drinks. Additionally, it is appropriate for use in baked goods and other foodstuffs as discussed above.

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In one aspect, the present invention relates to a method for controlling serum glucose level in mammals comprising ingesting a stabilized rice bran derivative, such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction or mixtures thereof. The preferred mammal is a human individual. In a preferred embodiment, the glucose level is elevated due to diabetes mellitus, such as Type I and Type II diabetes. The rice bran derivative is ingested in an amount of about 10 grams to about 100 grams per day total, preferably in at least 2 doses. Preferably, the rice bran derivative is ingested in an amount of about 10 grams to about 40 grams per day total, and more preferably, in an amount of about 15 grams to about 30 grams per day total.

It is presently preferred to take the stabilized rice bran derivative orally. Although the optimum dosage would be determined by the physician taking into account the age, weight and general health of the subject. As discussed above, the daily dosage can also be ingested in one or several treatments over a period of time, such as by way of single or multiple doses per day or from sustained release compositions.

The present invention is based on the discovery that persons with Type I and Type II diabetes who ingest products containing rice bran derivatives, which is any substance derived from rice bran including, but not limited to, enzyme treated stabilized rice bran, rice bran solubles and rice bran insolubles, have significantly reduced serum glucose levels, thereby controlling blood glucose levels.

In another aspect, the present invention relates to methods for managing hyperglycemia in mammals.

The method comprises ingesting a stabilized rice bran derivative such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction and mixtures thereof. The rice bran derivative can be administered alone or, more usually, in the form of a foodstuff comprising a therapeutically effective amount of the active agent in combination with an inert GRAS.

In still another aspect, the present invention relates to a diabetic food supplement kit. The kit comprises a stabilized rice bran derivative, such as an enzyme treated stabilized rice bran, a solubilized fraction, an insolubilized fraction and mixtures thereof, a non-rice consumable, and instructions for ingesting the derivatives. The non-rice consumable can be a carrier for the stabilized rice bran derivative. In addition, the kit also contain instructions for use.

The non-rice consumable can be any of many ways to incorporate the rice bran derivative into the diet of a mammal. These include, but are not limited to, simply sprinkling the derivative on another food substance (salad, bread, cereal, etc.) being a major ingredient in a multigrain ready to eat cereal, incorporating it into a baked product (breads, muffins, waffles, etc), pasta, healthy dessert and snacks

(athletic bar, healthy drink, etc.) and high fiber foods. The non-rice consumable can be various food formulations as well, including, but not limited to, carriers and excipients. The rice bran derivatives can also be used in association with other therapeutic agents including, for example, antibiotics or antiviral agents.

Management of Hyperglycemia Diabetes Mellitus and Related Disorders

Stabilized rice bran derivatives are very effective hypoglycemic agents and therefore helpful as nutritional supplements in the management of Diabetes Mellitus (Type I and Type II), hyperglycemia, and related conditions. These biological effects are due to the synergistic effects of the multiple bioactive components present in stabilized rice bran derivatives (see, Table IV-VI). The mechanisms that are effecting glucose maintenance exert their effect differently, with some effecting glucose absorption, utilization and excretion. While not being bound to any particular theory, it is believed that the mechanisms of action of the individual bioactive components in the stabilized rice bran derivatives include, but are not limited to, the following:

1. The role of B vitamins:

a. Niacin is present in significant quantities in stabilized rice bran derivatives. Niacin is involved in supplying intracellular energy, through nicotinamide adenine dinucleotide (NAD) utilization in the pancreatic .beta.-cells thereby effecting blood glucose levels.

b. Pyridoxin is a vital component for the prevention of diabetic neuropathy.

c. Thiamin and biotin are very important metabolic factors in glucose control.

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d. Therefore, B vitamins in stabilized rice bran derivatives improve glucose absorption at the systemic level and/or improve peripheral utilization of glucose thereby aiding in the control of postprandial glycemnia.

2. Inositol has a modulatory role in the regulation of insulin exocytosis thus helping in the insulin secretory process.

3. The non-starchy polysaccharide and ligins present in stabilized rice bran derivatives enhance the immune complexes and activate the insulin receptors on erythrocytes, thereby enhancing the peripheral utilization of glucose.

4. Stabilized rice bran derivatives are rich in hemicelluloses, which increase peripheral blood lymphocytes, thereby reducing the neurological complications of diabetes.

5. The antioxidants such as tocopherols, tocotrienols, .gamma.-oryzanol, polyphenols (especially ferulic acid and lipoic acid), and other minor antioxidants present in stabilized rice bran derivatives are free radical scavengers, that can ameliorate the complications of diabetes such as atherosclerosis, hyperlipidemia, retinopathy, glycation, glycoxidation, kidney damage and neuropathy. .gamma.-

Oryzanol improves capillary blood circulation and has a neuro-regulatory effect.

6. The non-starchy polysaccharides present in the soluble fraction of stabilized rice bran derivatives form a micelle in the intestine, which can facilitate slow absorption and release of glucose into circulation thereby helping to maintain postprandial glucose levels.

7. The protein, fiber and fat of stabilized rice bran derivatives also help in the management of hyperglycemia and associated conditions which are significant health management issues in individuals with diabetes.

III. EXAMPLES

Example 1

This example illustrates a clinical evaluation of stabilized rice bran derivatives in subjects with diabetes mellitus. Moreover the effect of RiceX Stabilized Rice Bran, RiceX Ricelin (stabilized rice bran soluble derivative) and RiceX Fiber Complex (stabilized rice bran insoluble derivative) on blood glucose and lipid human subjects with diabetes mellitus (Type I) and non-insulin dependent diabetes mellitus (Type II) was evaluated. This clinical evaluation was carried out at the Advanced Medical

Research center at Madison, Wis. and at the Armed Forces Institute of Pathology, Rawalpindi,

Pakistan.

MATERIAL AND METHODS:

A. Product Description

RiceX Stabilized Rice Bran, RiceX Ricelin and RiceX Fiber Complex are products rich in fiber, nonstarchy polysaccharides, complex carbohydrates, proteins, fats, B-complex vitamins, and potent antioxidants such, as .beta.-carotene, vitamin E (Tocopherols and Tocotrienols), .gamma.-oryzanol, phytosterols, and polyphenols.

>;t

>;tb;B. Product Codes

>;tb; Product A: RiceX Stabilized Rice Bran;

>;tb; Product B: RiceX Ricelin;

>;tb; Product C: RiceX Fiber Complex

C. Subjects

Subjects selected were individuals with clinically established cases of diabetes mellitus (Type I or

Type II), male or female, between the age of 20-65 years, with ideal body weight (+20%), and no diagnosed complications. The subjects were under glycemic control with either oral hypoglycemic agents, or insulin therapy or both. All the subjects were on National Cholesterol Education Program

(NCEP) step-1 diet.

D. Dosage and Duration

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The subjects were initially screened and randomly assigned to the RiceX product regimen. Test product was provided to each subject in two equally divided doses of 10 grams each, one taken before breakfast and one taken before dinner in milk/fruit juice/water beverage. The total dosage of 20 grams per day was provided to each subject every day for eight weeks.

E. Study Protocol

The products were given at random either in sequence, or individually for eight weeks. When subjects were evaluated on more than one product a washout period of four weeks with a cellulose placebo to replace treatment was used before switching to the next product. An initial fasting blood sample was drawn before each product regimen, and a final fasting blood sample was drawn at the end of each product regimen. These blood samples were used for the measurement of glycemic and lipid parameters. Physical parameters such as body weight, body mass index, height, medications, and diet were measured and recorded for each subject. Blood glucose levels were monitored every morning before breakfast and every evening before dinner, by the subjects drawing capillary blood and using a glucometer. Any significant change, like sudden hypoglycemic episodes were managed by reducing the medications as well as the rice bran products on which the subjects were maintained, as recommended by the study a physician.

F. Biochemical Analysis

The initial and final blood samples of all the subjects before and after the treatment of each product were collected and stored at -80 DEG C. until analyzed. These samples were analyzed for glycosylated hemoglobin, glucose, insulin, total cholesterol, LDL-Cholesterol, HDL-Cholesterol, Apo B, and triglycerides. All methods used were AOAC approved methods.

G. Statistical Analyses of the Data

All the parameters were statistically analyzed, using changes from baseline values (0-time) to the end of study according to analyses of variance (Yanagava et al., Biometrics, 40:301-311, 1984.) These data were compared among the three products.

Results

Table II summarizes the study of both Type I subjects on glycemic and lipidemic parameters, while

Table III provides the data for the Type II subjects.

H. Type I Study

A total of 45 subjects with clinically established Type I diabetes mellitus were randomly treated with

RiceX rice bran products either in sequence or singularly as mentioned above. A total of 22 subjects were treated with product A, 26 subjects with product B and 20 subjects with product C. The pooled averages of the data on glycemic and lipid parameters of the three products are given in Table II.

I. Type II Study

A total of 41 subjects with clinically established Type II diabetes mellitus were randomly treated with

RiceX Rice Bran products either singularly or in sequence as given in the protocol. A total of 23 subjects were treated with product A, 31 subjects with product B and 26 subjects with product C. The pooled averages of the data on glycemic and lipid parameters of all the three products are given in

Table III.

J. Glycemic control

The results showed that there was a statistically significant (p=0.05) reduction in the glycosylated hemoglobin, by 11% when RiceX Ricelin was provided and by 10% when RiceX Fiber Complex was provided to the Type I subjects for eight weeks. A similar statistically significant (p=0.05) reduction in glycosylated hemoglobin in Type II subjects was shown. RiceX Ricelin consumption for eight weeks led to a 10% reduction in glycosylated hemoglobin, while RiceX Fiber Complex consumption for eight

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weeks lead to an 11% reduction. Fasting serum glucose indicated a statistically significant (p>;0.5) reduction of 33%, when compared to the initial values, after eight weeks consumption of RiceX Ricelin in both Type I and Type II subjects. The RiceX Fiber Complex also showed a decrease in the fasting glucose levels of venous blood analysis of 19% and 22% in Type I and Type II respectively, when compared to initial time values.

Type I subjects who consumed or RiceX Ricelin for eight weeks showed a decrease of 16% and 14% respectively for fasting glucose and glucose measured a 1/2 hour before dinner (monitored by glucometer). While RiceX Fiber Complex consumption showed a decrease of 10% and 17% respectively for serum fasting glucose and serum glucose measured a 1/2 hour before dinner

(monitored by glucometer).

In Type II subjects a decrease of 8% and 5% in fasting glucose and glucose 1/2 hr before dinner

(monitored by glucometer) with RiceX Ricelin consumption for eight weeks was observed. A 10% reduction in both the parameters with RiceX Fiber Complex was observed.

These data on glycemic parameters indicate that RiceX products significantly control and manage blood glucose levels in diabetes mellitus. More specifically, the reduction of glycosylated hemoglobin indicated that, in these subjects, consumption of RiceX Ricelin and RiceX Fiber Complex aided in increased control of blood glucose.

K. Lipid Parameters

Total cholesterol, LDL-Cholesterol, Apo B, and triglycerides of Type I subjects who consumed RiceX

Fiber Complex for eight weeks were reduced 10%, 16%, 10%, and 7% respectively, when compared to zero-time values. There was no change in HDL-Cholesterol.

A greater reduction in lipid parameters was seen in Type II subjects than that noted in Type I subjects.

Total cholesterol, LDL-Cholesterol, Apo B, and triglycerides were reduced by 12%, 15%, 10% and 8% respectively when compared to zero-time values. There was no change in HDL-Cholesterol concentrations after the consumption of RiceX Fiber Complex. These results indicate that the RiceX

Fiber Complex significantly controls hyperlipidemia.

>;tb;TABLE II

>;tb;Results of Type I (IDDM) Subjects

>;tb; Product A (n = 22) Product B (n = 26) Product C

>;tb; (n = 20)

>;tb; Before After % Change Before After % Change

>;tb; Before After % Change

>;tb;Glycemic parameters

>;tb;Phlebotomy Data

>;tb;Glycosylated Hb (%) 10.91 10.92 0 11.25 10.06 -11 11.32

>;tb; 10.23 -10

>;tb;Fasting Serum Glucose 172.00 157.99 -9 174.16 116.97 -33 162.78

>;tb; 131.56 -19

>;tb;(mg/dl)

>;tb;Serum insulin 49.36 49.71 0 52.75 54.86 4

>;tb; 52.03 51.99 0

>;tb;Glucometer Data

>;tb;Fasting Glucose 159.45 154.95 -3 162.5 137.23 -16 164.95 147.85

>;tb; -10

>;tb;(mg/dl)

>;tb;Glucose 1/2 hr. before 175.00 165.91 -5 168.12 145.35 -14 175.35

>;tb; 144.95 -17

>;tb;dinner (mg/dl)

>;tb;Lipid Parameters

>;tb;Serum Total Cholesterol 181.91 180.07 -1 174.27 166.14 -5 185.82

>;tb; 167.74 -10

>;tb;(mg/dl)

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>;tb;Serum LDL-Cholesterol 137.71 134.16 -3 130.79 122.35 -6 134.41

>;tb; 113.55 -16

>;tb;(mg/dl)

>;tb;Serum Apo B 88.15 86.15 -2 85.69 81.708 -5/ 84.37 75.96

>;tb; -10

>;tb;(mg/dl)

>;tb;Serum Triglycerides 135.36 134.85 0 134.07 130.13 -3 129.76

>;tb; 120.58 -7

>;tb;(mg/dl)

>;tb;Serum HDL-Cholesterol 37.65 37.62 0 38.73 38.07 -2 39.29

>;tb; 39.57 0

>;tb;(mg/dl)

>;tb;TABLE III

>;tb;Results of Type II (NIDDM) Subjects

>;tb; Product A (n = 23) Product B (n = 31) Product C (n =

>;tb; 26)

>;tb; Before After % Change Before After % Change

>;tb; Before After % Change

>;tb;Glycemic parameters

>;tb;Phlebotomy Data

>;tb;Glycosylated Hb (%) 10.22 10.63 4 10.69 9.65 -10 10.700

>;tb; 9.51 -11

>;tb;Fasting Serum Glucose 158.11 142.28 -10 158.18 106.52 -33 145.42

>;tb; 113.65 -22

>;tb;(mg/dl)

>;tb;Serum insulin 49.42 49.98 0 48.48 50.31 4

>;tb; 49.45 49.94 0

>;tb;(microunits/ml)

>;tb;Glucometer Data

>;tb;Fasting Glucose 120.13 121.71 1 128.45 118.16 -8 129.12

>;tb; 115.73 -10

>;tb;(mg/dl)

>;tb;Glucose 1/2 hr. before 120.17 129.91 8 129.68 123.61 -5 134.54

>;tb; 120.96 -10

>;tb;dinner (mg/dl)

>;tb;Lipid Parameters

>;tb;Serum Total Cholesterol 182.81 172.79 -5 181.14 171.1 -6 186.04

>;tb; 164.58 -12

>;tb;(mg/dl)

>;tb;Serum LDL-Cholesterol 146.02 134.97 -8 143.18 131.48 -8 146.46

>;tb; 124.77 -15

>;tb;(mg/dl)

>;tb;Serum Apo B 95.56 94.23 -1 94.92 92.27 -3 95.00 85.62

>;tb; -10

>;tb;(mg/dl)

>;tb;Serum Triglycerides 143.75 139.13 -3 138.85 135.47 -2 143.01 131.24

>;tb; -8

>;tb;(mg/dl)

>;tb;Serum HDL-Cholesterol 36.23 36.21 0 34.42 34.33 0

>;tb; 33.64 33.54 0

>;tb;(mg/dl)

Example 2

This example illustrates the synthesis of enzyme treated stabilized rice bran.

Twelve hundred pounds of stabilized rice bran was mixed with five hundred seventy gallons of water to form a water extract. The mixture was allowed to agitate for thirty minutes. Two hundred and forty

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grams of .alpha.-amylase were added and allowed to mix for ten minutes. Thereafter the mixture was pumped through a heat exchanger set at about 190 DEG F. and allowed to travel through a pipe coil for

25 minutes. The mixture was then dried on a drum dryer to a moisture level below 5%.

Example 3

This example illustrates the synthesis of stabilized rice bran insoluble and soluble derivatives.

Twelve hundred pounds of stabilized rice bran was mixed with five hundred seventy gallons of water to form a water extract. The mixture was allowed to agitate for thirty minutes. Two hundred and forty grams of a-amylase were added to the mixture and allowed to mix for ten minutes.

Thereafter the mixture was pumped through a heat exchanger set at 190 DEG F. and allowed to travel through a pipe coil for 25 minutes. The mixture was then pumped to a horizontal decanting centrifuge set at 3,600 RPM and fed at a rate of two gallons per minute. The soluble fraction of the rice bran was separated from the insoluble fraction in the centrifuge.

Thereafter the soluble fraction was dried on a drum dryer to 2.8% moisture. The insoluble fraction was also dried on a drum dryer to 4% moisture. This process yielded 550 lbs. of dried rice bran insolubles and 420 lbs. of dried rice bran soluble concentrate. The chemical composition of the two products are set forth in Tables IV and V respectfully.

Example 4

This example sets forth Tables IV-VII which tabulates components of stabilized rice bran derivatives.

>;tb;TABLE IV

>;tb;RiceX .TM. FIBER COMPLEX

>;tb; MACRONUTRIENTS

>;tb; Protein 20.5%

>;tb; Fat 13.4%

>;tb; Total Dietary Fiber 49.5%

>;tb; (Soluble Fiber 0-1%)

>;tb; Carbohydrates 3.0%

>;tb; Ash 10.0%

>;tb; Moisture 3.5%

>;tb; MICRONUTRIENTS

>;tb; Water Soluble Vitamins (mg/100 Grams) Average

>;tb; Thiamine 2.00

>;tb; Riboflavin 0.19

>;tb; Niacin 30.55

>;tb; Pantothenic Acid 1.90

>;tb; Vitamin B6 1.67

>;tb; Biotin 0.011

>;tb; Minerals (mg/100 Grams) Average

>;tb; Sodium 16.0

>;tb; Calcium 92.5

>;tb; Magnesium 1223.3

>;tb; Potassium 1670.0

>;tb; Vitamin E and Other "Tocol's" Average

>;tb; (mg/100 Grams)

>;tb; .alpha.-Tocopherol 0.74

>;tb; .tau.-Tocopoherol 0.40

>;tb; .delta.-Tocopherol 0.43

>;tb; Total Tocopherols 1.19

>;tb; Tocopherols


>;tb; .beta.-Carotene 1.55


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>;tb; Total TOCOLS 3.73

>;tb; Vitamin A and Other Carotenoids Average

>;tb; (.mu.g/100 Grams)

>;tb; .alpha.-Carotene TBD

>;tb; .beta.-Carotene TBD

>;tb; Lycopene TBD

>;tb; Pre-Lutein TBD

>;tb; Lutein TBD

>;tb; Zeaxantin TBD

>;tb; Pre-Cryptoxanthin TBD

>;tb; Cryptoxanthin TBD

>;tb; .beta.-Cryptoxanthin TBD

>;tb; Total CAROTENOIDS TBD

>;tb; .tau.-Oryzanol (mg/100 Grams) Average

>;tb; 174.1

>;tb; Phytosterols (mg/100 Grams) Average

>;tb; Sitosterol 146.46

>;tb; Brassicasterol 13.20

>;tb; Campesterol 90.40

>;tb; Stigmesterol 67.15

>;tb; Total PHYTOSTEROLS 317.2

>;tb;TABLE V

>;tb;RiceX RICELIN .TM.


>;tb; Protein 7.5%

>;tb; Fat 26.5%



>;tb; Ash 5.0%

>;tb; Moisture 3.0%


>;tb; Water Soluble Vitamins Average


>;tb; Thiamine 3.64


>;tb; Niacin 76.6



>;tb; Biotin 0.015


>;tb; Sodium 15.75

>;tb; Calcium 8.33



>;tb; Vitamin E and Other Average

>;tb; "Tocol's" (mg/100 Grams)





>;tb; .alpha.-Tocotrienol 4.90

>;tb; .beta.-Tocotrienol 0.36

>;tb; .tau.-Tocotrienol 4.48

>;tb; .delta.-Tocotrienol 0.30

>;tb; Total Tocotrienols 10.0


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>;tb; Vitamin A and Other Average

>;tb; Carotenoids (.mu.g/100 g)

>;tb; .alpha.-Carotene TBD

>;tb; .beta.-Carotene TBD

>;tb; Lycopene TBD

>;tb; Pre-Lutein TBD

>;tb; Lutein TBD

>;tb; Zeaxantin TBD

>;tb; Pre-Cryptoxanthin TBD

>;tb; Cryptoxanthin TBD

>;tb; .beta.-Cryptoxanthin TBD

>;tb; Total CAROTENOIDS TBD


>;tb; 248.1






>;tb; Total PHYTOSTEROLS 385.0

>;tb;TABLE VI

>;tb;RiceX .TM. STABILIZED RICE BRAN


>;tb; Protein 14.5%

>;tb; Fat 20.5%


>;tb; (Soluble Fiber 2-6%)


>;tb; Ash 8.0%

>;tb; Moisture 6.0%


>;tb; Water Soluble Vitamins Average


>;tb; Thiamine 2.65


>;tb; Niacin 46.87



>;tb; Biotin 0.014


>;tb; Sodium 8.0

>;tb; Calcium 39.7



>;tb; Vitamin E and Other Average

>;tb; "Tocol's" (mg/100 Grams)





>;tb; .alpha.-Tocotrienol 7.56

>;tb; .beta.-Tocotrienol 0.41

>;tb; .tau.-Tocotrienol 5.36

>;tb; .delta.-Tocotrienol 0.31

>;tb; Total Tocotrienols 13.60


>;tb; Vitamin A and Other Average

>;tb; Carotenoids (.mu.g/100 Grams)

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>;tb; .alpha.-Carotene 0.4

>;tb; .beta.-Carotene 37.0

>;tb; Lycopene 2.3

>;tb; Pre-Lutein ND

>;tb; Lutein 63.8

>;tb; Zeaxantin 18.4

>;tb; Pre-Cryptoxanthin 7.4

>;tb; Cryptoxanthin ND

>;tb; .beta.-Cryptoxanthin ND

>;tb; Total CAROTENOIDS 129.3


>;tb; 245.15






>;tb; Total PHYTOSTEROLS 302

>;tb;TABLE VII

>;tb;Antioxidants in RiceX .TM. STABILIZED RICE BRAN

>;tb; A. .tau.-Oryzanol: (ppm)

>;tb; (2206-3000)

>;tb; Cycloartenyl Ferulate

>;tb; 24-Methylene Cycloartanyl

>;tb; Ferulate

>;tb; Campesteryl Ferulate

>;tb; .beta.-Sitosteryl Ferulate

>;tb; Stigmasteryl Ferulate

>;tb; B. Tocopherols & Tocotrienols:

>;tb; (220-320 ppm)

>;tb; .alpha.-Tocopherol

>;tb; .beta.-Tocopherol

>;tb; .tau.-Tocopherol

>;tb; .delta.-Tocopherol

>;tb; .alpha.-Tocotrienol

>;tb; .beta.-Tocotrienol

>;tb; .tau.-Tocotrienol

>;tb; Tocotrienols (Artifacts)

>;tb; C. Phytosterols: (2230-4400 ppm) 4-

>;tb; Demethylsterols, 4-Methyl Sterol &

>;tb; Brassino Steroids

>;tb; .beta.-Sitosterol

>;tb; Campesterol

>;tb; Stigmasterol

>;tb; .DELTA.5 Avinsterol

>;tb; .DELTA.7 Stigmastenol

>;tb; Isofucosterol

>;tb; .beta.-Amyrin

>;tb; Gramisterol

>;tb; Citrostadienol

>;tb; Obtusifoliol

>;tb; Branosterol

>;tb; 28-Homotyphasterol

>;tb; 28-Homosteasternoic Acid

>;tb; 6-Deoxycastasterone

>;tb; D. Amino Acids: (ppm)

>;tb; Tryptophan (2100)

>;tb; Histidine (3800)

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>;tb; Methionine (2500)

>;tb; Cystine (336-448)

>;tb; Cysteine (3200)

>;tb; Arginine (10800)

>;tb; E. Polyphenols:

>;tb; .alpha.-Lipoic Acid

>;tb; Ferulic Acid

>;tb; Methyl Ferulate

>;tb; p-Coumaric Acid

>;tb; p-Sinapic Acid

>;tb; F. Flavones and Proanthocyanidins

>;tb; Iso Vitexin

>;tb; Flavone Glycosides

>;tb; Olegomeric

>;tb; Proanthocyanidins

>;tb; G. Other Antioxidants: (ppm)

>;tb; Inositol/Myo Inositol

>;tb; (1200-1880)

>;tb; Phytic Acid/Phytates

>;tb; (1500-1710

>;tb; Biotin (0.1-0.22)

>;tb; Choline (930-1150)

>;tb; H. Carotenoids: (0.9-1.6 ppm)

>;tb; .alpha.-carotene

>;tb; .beta.-carotene

>;tb; Lycopene

>;tb; Lutein

>;tb; Zeasanthine

>;tb; I. Phospholipids:

>;tb; Phosphatidyl Choline

>;tb; Phosphatidyl Ethanolamine

>;tb; Lysolecithin

>;tb; J. Enzymes:

>;tb; Glutathione Peroxidase

>;tb; Methionine Reductase

>;tb; Super Oxide Dismutase

>;tb; Polyphenol Oxidase

>;tb; Aspartate Amino Transferase

>;tb; Isoenzyme

>;tb; AAT-1

>;tb; AAT-2

>;tb; Coenzyme Q10

>;tb; K. Polysaccharides:

>;tb; Cycloartenol Ferulic Acid

>;tb; Glycoside

>;tb; Diferulic Acid Complex

>;tb; Diferulic Acid + 3

>;tb; Glucose + 2

>;tb; Calcium ions complex

>;tb; L. Metal Chelators: (ppm)

>;tb; Magnesium (6250-8440)

>;tb; Calcium (303-500)

>;tb; Phosphorous (14700-17000)

>;tb; M. B-Complex Vitamins: (ppm)

>;tb; Thiamine (22-31)

>;tb; Riboflavin (2.2-3.5)

>;tb; Niacin (370-660)

>;tb; Pantothenic Acid (36-50)

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>;tb; Pyridoxine (29-42) All publications, patents and patent applications mentioned in this specification are herein incorporated by reference into the specification in their entirety for all purposes.

Although the invention has been described with reference to preferred embodiments and examples thereof, the scope of the present invention is not limited only to those described embodiments. As will be apparent to persons skilled in the art, modifications and adaptations to the above-described invention can be made without departing from the spirit and scope of the invention, which is defmed and circumscribed by the appended claims.Data supplied from the esp@cenet database - Worldwide

Claims:


What is claimed is:

1. A method for controlling serum glucose in a mammal, said method comprising:

ingesting a therapeutically effective amount of a stabilized rice bran solubilized fraction, wherein said stabilized rice bran solubilized fraction is free of a stabilized rice bran insolubilized fraction, thereby reducing serum glucose in said mammal.

2. A method for controlling serum glucose in a mammal, said method comprising:

ingesting a therapeutically effective amount of a stabilized rice bran insolubilized fraction, wherein said stabilized rice bran insolubilized fraction is free of a stabilized rice bran solubilized fraction, thereby reducing serum glucose in said mammal.

3. A method in accordance with claim 1 or 2, wherein said mamnmnal is a human.

4. A method in accordance with claim 1 or 2, wherein said mammal is suffering from diabetes mellitus.

5. A method in accordance with claim 4, wherein said diabetes mellitus is Type I.

6. A method in accordance with claim 4, wherein said diabetes mellitus is Type II.

7. A method in accordance with claim 1, wherein said stabilized rice bran solubilized fraction comprises about 0% to about 20% total dietary fiber w/w.

8. A method in accordance with claim 2, wherein said stabilized rice bran insolubilized fraction comprises about 40% to about 60% total dietary fiber content w/w.

9. A method in accordance with claim 1 or 2, wherein said fraction is ingested in an amount of about

10 grams to about 100 grams per day total.

10. A method in accordance with claim 9, wherein said amount is ingested in at least 2 doses.

11. A method in accordance with claim 9, wherein said amount is about 10 grams to about 40 grams per day total.Data supplied from the esp@cenet database - Worldwide

2059/2197

417.

US6309680 - 10/30/2001

PELLETIZATION PROCESS


Inventor(s): LIM BEE GIM (SG); HO DAC THANG (CH)

Applicant(s): NESTEC SA (US)


IP Class: A23L1/10

E Class: A23L1/238; A23J3/18


Priority Number: WO1999EP01133 (19990223); SG19980000488 (19980305)

Family: US6309680

Equivalent: WO9944437; EP1059849; CA2314952; TR200002550T; RU2228057;

NO20004330; AU754247

Abstract:


A process for the production of a fermenting material which includes the steps of forming a dough by adding water to a dried gluten in an amount of from at least 19% to 60% by weight, pelletizing the dough to form pellets, and sterilizing the pellets by steam treatment. The gluten may be rice gluten, corn gluten, wheat gluten or combinations thereof. Also, a fermenting material obtained by this process. This fermenting material can be inoculated with a microorganism and fermented to form a fermention product that can be used as a food sauce, flavoring or seasoning additive.Claims:


What is claimed is:

1. A process for the production of a fermenting material which comprises:

forming a dough by adding water to a dried gluten in an amount of from 19% to 60% by total weight of the dough;

pelletizing the dough to form pellets; and

sterilizing the pellets by steam treatment to form the fermenting material.

2. The process according to claim 1, which further comprises adding water to the dough before sterilizing the pellets to adjust the moisture content to from 25% to 50% by weight based on the weight of the pellets.

3. The process according to claim 1, wherein the gluten is wheat gluten and which further comprises devitalizing the wheat gluten before adding water to the dried gluten.

4. The process according to claim 3, wherein the devitalization is carried out at a temperature of from

60 DEG C. to 200 DEG C. over a period of from 5 seconds to 3 hours.

5. The process according to claim 4, wherein the devitalization is carried out using a dry heat treatment using hot air or by contact with a hot surface or hot air in a drier, oven, or stem jacketed vessel.

2060/2197

6. The process according to claim 4, wherein the devitalization is carried out by means of a fluidized bed drier.

7. The process according to claim 4, wherein the devitalization is carried out by means of superheated steam.

8. The process according to claim 1, further comprising adding wheat to the dried gluten in an amount of as high as 90% by weight of the wheat and dried gluten before adding the water to the dried gluten.

9. The process according to claim 3, further comprising adding wheat to the dried gluten in an amount of as high as 90% by weight of the wheat and dried gluten before devitalizing the wheat gluten.

10. The process according to claim 8, wherein the wheat to be added is wheat flour or wheat bran.

11. The process according to claim 1, wherein the dough is pelletized by passing through a screw press, a meat mincer, or a pellet mill.

12. The process according to claim 1, wherein the pellets have a cylindrical or spherical shape and an average diameter of from 1 mm to 10 mm.

13. The process according to claim 1, wherein more than one type of gluten is used to produce the dough.

14. The process according to claim 1, wherein the dried gluten is vital wheat gluten, corn gluten, or rice gluten.

15. A process of preparing a fermentation product which comprises:

preparing a substrate by mixing at least one carbohydrate source with pellets produced according to the process of claim 1;

inoculating the resulting substrate with a fermentation microorganism; and

fermenting the inoculated substrate.

16. The process according to claim 15, wherein the microorganism is Aspergillus.

17. The process according to claim 15, which further comprises adding at least one additional substrate comprising a protein source.

18. The process according to claim 15, which further comprises hydrolyzing the fermented substrate for at least one day.

19. The process according to claim 15, wherein moromi is produced by the fermenting step.Data supplied from the esp@cenet database - Worldwide

2061/2197

418.

WO0101794 - 1/11/2001

POWDER OF UNHULLED CEREAL GRAINS AND METHOD OF

MANUFACTURING THE SAME

URL EPO = http://v3.espacenet.com/textdoc?F=3&CY=ep&LG=en&IDX=WO0101794

Inventor(s): TOYOKURA YASUHIRO (JP)

Applicant(s): KURARICH CO LTD (JP); TOYOKURA YASUHIRO (JP)


IP Class: A23L1/10

E Class: A23L1/10M

Application Number: WO2000JP04056 (20000621)


Family: WO0101794


Cited Document(s): US5385083; FR1305849; XP002148190; KR9107321; XP002148191;

KR9204882; JP11009199; JP60120949; JP2076545; JP2308783

Abstract:

Abstract of WO0101794

Provided is a powder of unhulled rice grains having a nutrient value higher than that of a powder of unpolished rice grains, being excellent in digestive and absorptive properties, and providing a good foodstuff. The powder is manufactured by immersing unhulled rice grains in water for a predetermined time, followed by roasting the grains for a predetermined time and subsequently powdering the roasted grains. The powder can be manufactured from other cereal grains such as barley, wheat, rye and oat than rice.Claims:

Claims of WO0101794

CLAIMS 1. A powder of unhulled cereal grains prepared by the following steps of:

impregnating unhulled cereal grains with water;

roasting said impregnated grains; and

powdering said roasted grains.

2. A powder of unhulled cereal grains claimed in claim 1 wherein said cereal grains comprise at least one cereal selected from the group of rice, barley, wheat, rye and oats.

3. A method of manufacturing a powder of unhulled cereal grains, comprising the steps of:

impregnating unhulled cereal grains with water for apredetermined time;

roasting said impregnated grains for a predetermined time; and

pulverizing the roasted grains into fine powder.

4. A method of manufacturing a powder of unhulled cereal grains claimed in claim 3 wherein said cereal grains comprise at least one cereal selected from the group of rice, barley, wheat, rye and oats.

2062/2197

5. A method of manufacturing a powder of unhulled cereal grains according to claim 3, wherein the unhulled cereal grains are roasted until the roasted grains are colored brown.

6. A method of manufacturing a powder of unhulled cereal grains according to claim 3, wherein the unhulled cereal grains are roasted until the roasted grains are colored black.Data supplied from the esp@cenet database - Worldwide

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419.

WO0106874 - 2/1/2001

SOLUBLE COMPOSITION BASED ON CAROB GERM


Inventor(s): WEBER-TRIPIER NADINE (CH); MONTAGNE DIRK-HEIN (CH)

Applicant(s): NESTLE SA (CH); WEBER TRIPIER NADINE (CH); MONTAGNE DIRK HEIN

(CH)


IP Class: A23L1/305

E Class: A23L1/0526; A23C11/10; A23L1/305A; A23L1/29F; A23L1/305C; A23L2/66

Application Number: WO2000EP06052 (20000629)


Family: WO0106874


Cited Document(s):

Abstract:

WO9854986; FR2720604; EP0904784; XP002126009; NL9300536


The invention concerns a soluble composition for non-allergenic drink to be reconstituted, designed for infant feeding comprising a protein source consisting of carob germ flour or a mixture of rice proteins and carob germ flour, a carbohydrate source, a fat source and additives. The invention also concerns the method for obtaining said soluble composition.

2064/2197

420.

WO0121016 - 3/29/2001

CALCIUM FORTIFIED CEREAL PRODUCT AND METHOD OF

PREPARATION


Inventor(s): LEUSNER STEVEN J (US); CREIGHTON DEAN W (US)

Applicant(s): GEN MILLS INC (US); LEUSNER STEVEN J (US); CREIGHTON DEAN W (US)


IP Class: A23L1/10; A23L1/304; A21D2/02

E Class: A21D2/36; A21D2/02; A23L1/10B; A23L1/304; A21D2/14B; G06F9/44W

Application Number: WO2000US24032 (20000830)


Family: WO0121016


Cited Document(s): US5945144; WO9639053; US5514387; WO9848648; XP002076604;

XP000972684

Abstract:


Light cooked cereal dough products are provided that are fortified with at least a 0.3 % calcium at least a portion of which is supplied by CaCO2 exhibiting reduced discoloration such as RTE cereals and grain based snacks. The dried cereal finished products are fabricated from cooked cereal doughs that can comprise rice and/or corn and minor levels of other conventional cereal ingredients and calcium carbonate. The cooked cereal doughs additionally essentially comprise effective amounts of calcium sequestrants. Methods of preparing such calcium fortified cooked cereal compositions and dried cereal finished food products essentially comprise: A) providing a lightly colored calcium fortified cooked cereal dough or mass containing at least 0.3 % calcium (dry weight basis) at least a portion of which is supplied by calcium carbonate and sequestrants; B) forming the lightly colored calcium fortified cereal dough into pieces, and, C) drying the pieces to form the present rice based finished food products fortified with high levels of calcium.Description:

Description of WO0121016

CALCIUM FORTIFIED CEREAL PRODUCT

AND METHOD OF PREPARATION


The present invention is directed generally to food products and to their methods of preparation. In particular, the present invention is directed to improved

Ready-To-Eat cereal products fortified with a nutritionally fortifying ingredient such calcium and to processes for making such improved fortified cereal products.

Background

Ready-To-Eat ("RTE") breakfast cereal have long been fortified with various vitamins and mineral.

Health and nutrition interests have recently focused upon increasing the calcium content of foods and

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in RTE cereals in particular. The present invention provides improvement in the mineral fortification of cooked cereal products such as Ready-To-Eat cereals. More specifically, the present invention provides improvements in providing lightly colored RTE cereals fortified such as rice and/or corn based with high levels of calcium that are not discolored.

For adults, recent medical studies have indicated that a diet containing the U. S. recommended daily allowance(RDA) of calcium might be effective in preventing or mitigating osteoporosis, and also possibly high blood pressure and colon cancer. Calcium is also of particular nutritional value in growing children to support bone growth. There is therefore great public interest in the consumption of food products that will supply the recommended daily allowance of calcium.

In view of the desire for introducing more calcium into diets, especially children's diets, it would be desirable if such RTE cereal products were fortified with supplemental calcium to provide a significantly nutritionally enhanced product. By significantly nutritionally enhanced is meant a product having at least 10% of the current recommended daily allowance ("RDA") or at least100 mg of calcium per serving (typically 25 to 35g of product) of RTE cereal.

Calcium can be added in limited amounts to RTE cereal products. However, at higher levels of calcium fortification, the presence of such high amounts of calcium can adversely interfere with other desired characteristics. For example, high levels of added calcium materials could negatively affect the taste, texture and density of the RTE cereal products. More importantly, for lightly colored cereals such as than that are rice and/or corn (maize) based, calcium fortification can result in development of offcolors.

RTE cereal products fabricated from rice and/or corn based cooked cereal doughs such as RiceChex",

CornChex', or Honey NutChexT", (a rice and corn based RTE cereal) are very popular. Such rice and/or corn base products are popular in part due to their light coloration and light airy texture. The combination of their rice and/or corn flavor as well as their light color and texture are particularly pleasing. A good description techniques for forming such RTE cereal products is given is US

2,600,532 entitled"Method for

Manufacture of Cereal Food Products" (issued June 17, 1952 to D. Hule et al.) and

2,743,685entitled"Apparatus for Manufacturing a Cereal Food Products (issued May 1, 1956 to D.

Hale et al.) each of which is incorporated herein by reference.

In view of the current interest in providing RTE cereals having high levels of calcium fortification, it would thus be desirable to provide RTE cereal products fabricated from rice and/or corn based cooked cereal doughs fortified with supplemental calcium to provide a significantly nutritionally enhanced product. Calcium carbonate at40% dry weight calcium is potentially a good ingredient to employ to provide desired calcium fortification. Unfortunately, however, RTE cereal products fabricated from lightly colored cereal doughs such as but not limited to rice and/or corn based cooked cereal doughs fortified with high levels of calcium supplied by calcium carbonate can develop an undesirable green or grey discoloration.

One technique for addressing this discoloration is to add coloring agents or other colored ingredients to mask or darken the cereal. However, it would be desirable to provide RTE cereal products that exhibit the familiar and desirable light color which nonetheless posses high levels of calcium fortification. Another technique to provide RTE cereal products that are naturally darker such as those that are wheat based. The dark brown color of the wheat-based products naturally masks any discoloration that can occur.

It would thus be desirable to be able to calcium fortify RTE cereal products fabricated from lightly colored cooked cereal doughs to provide high levels of calcium fortification while minimizing discoloration and maintaining a light coloration.

The present invention is directed towards the provision of improved R-T-E cereal products fortified with high calcium levels of superior appearance and reduced discoloration. The present invention resides in part in the additionally including particular levels of sequestrants into a lightly colored cooked cereal dough formulation, cooking the calcium and sequestrant containing cereal ingredients to

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form cooked cereal doughs of reduced discoloration and forming such cooked cereal doughs into finished RTE cereal products.

The present invention further resides in part in the selection of calcium material of particular type and size to provide the desired calcium fortification.


In its product aspect, the present invention provides light cooked cereal compositions such as cooked cereal doughs fortified with at least a 0.3% calcium at least a portion of which is supplied byCaCO2 that exhibit reduced discoloration and further provides dried finished cereal food products fabricated therefrom such as RTE cereals and grain based snacks.

The dried cereal finished products are fabricated from lightly colored cooked cereal doughs that can comprise rice and/or corn and minor levels of other conventional cereal ingredients and at least 0.3% calcium

(dry weight basis) cereal supplied in part by calcium carbonate. The cooked cereal doughs additionally essentially comprise effective amounts of calcium sequestrants. Notwithstanding high concentrations of the calcium, the finished fortified cereal products are not only organoleptically desirable but also almost indistinguishable from their unfortified counterparts especially in terms of color appearance.

In its method aspect, the present invention resides in as methods for preparing such calcium fortified cooked cereal compositions and dried cereal finished food products.

In the preferred embodiment, the methods of providing finished products essentially comprise the steps of:

A. Providing a lightly colored calcium fortified cooked cereal dough or mass containing at least 0.3% calcium (dry weight basis) at least a portion of which is supplied by calcium carbonate and sequestrants;

B. Forming the lightly colored calcium fortified cereal dough into pieces; and,

C. Drying the pieces to form the present rice based finished food products fortified with high levels of calcium.


The present invention relates to cooked cereal doughs containing defined levels calcium at least partially provided by calcium carbonate, to finished dried cooked cereal dough based products prepared therefrom such as RTE cereals, and to methods for the preparation of the doughs and finished products.

Each of these product constituents, as well as methods for their preparation and use are described in detail below.

Throughout the specification and claims, percentages are by weight and temperatures in degrees

Fahrenheit, unless otherwise indicated.

The present invention is particularly suitable for providing calcium fortified lightly colored cooked cereal dough of equivalent color to doughs not fortified with the levels of calcium herein. Cooked cereal doughs can be simply characterizedas"light"or"dark"on the familiar Hunter color scale wherein pure white has a value of100 and pure black has a value of zero. A ricebased RTE cereal typically will have a color value of between about 55 to 63 depending in part upon the degree of toasting. A cornbased cereal can have a Hunter color value ranging from about 55 to 60. A 50: 50 rice and corn blend

RTE cereal can have an intermediate value. By "lightly colored"cooked cereal dough or finished product herein is meant a product having a color value ranging above 51, or more practically, about 60 to 90 on the

Hunter color scale. In contrast, a darker cooked cereal dough such as prepared from whole red wheat can have a

Hunter color value of about 40 to 50.

Useful herein to measure the color of an cereal product is a spectrophotometer such as a LabScan XE spectrophotometer manufactured by HunterLab, 11491 Sunset

Hills Road, Reston, Virginia USA 22090. The spectrophotometer measures color on an L, a, and b axis.

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The L axis measures the light to dark on a scale of 0100,0 being the darkest and 100 the lightest. The a and b axes measure the color hue. The measurement procedure is the manufacturer's recommended procedure.

In one preferred embodiment of providing lightly colored cooked cereal doughs and finished products therefrom, the principle essential component of the present cereal compositions is rice and/or corn. The rice component can be provided from whole grain rice or brown rice, or, preferably from white or polished rice.

The rice component can be provided by whole rice pieces such as whole white rice, cut rice grain pieces, rice flour or other rice ingredients, e. g., blends of variously sized rice components. The rice component can also include blends of white rice, e. g., rice flour, and rice bran, if desired. The corn

(maize) component can be similarly provided by whole grain, corn, corn grits, corn cones, corn flours, and mixtures thereof. When corn is the sole or principal grain ingredient, mesa corn (i. e. alkaline treated) can be selected to provide its distinctive flavor. In preferred embodiments, the rice and/or corn ingredient (s) comprise about 40 to 97% (dry weight basis) of the cooked cereal dough. In more preferred embodiments, the rice and/or corn ingredients comprise about 75 to 95% (dry weight basis) of the cooked cereal dough. For best results the rice and/or corn ingredients comprise about 80 to 95% of the present cereal products.

In still other variations, the present lightly colored cooked cereal doughs can comprise white wheat, especially those white hard wheat varieties that have recently become more widely available such as, but not limited to, from the species Tritium aestivium. In such wheat containing products preferably the wheat content ranges from about 1 to 30 with the balance of the cereal ingredients being supplied by the lightly colored rice and/or corn.

In still other variations, the lightly colored cooked cereal dough can comprise those bleached wheat grains and grain products such as whole flours that are described in copending commonly assigned

USSN 09/392,699 filed September 9,1999 by Lloyd Metzger (attorney docket 5274)entitled"Bleached

Grain and Grain Products and

Methods of Preparation"which is incorporated herein by reference. In that application, cereal grains such as whole grain wheat kernels (whether hard or soft, red or white and especially hard white) are bleached with hydrogen peroxide to bleach or whiten the bran layer.

Bleached whole grain kernels and milled grain products such as whole flours are provided having the white color and bland flavor of conventional white or patent flour.

In other less preferred embodiments, the principal rice and/or corn ingredient is partially substituted or blended with other or supplemental starchy cereal components. The supplemental starchy cereal component can optionally further comprise any conventionally employed starchy cereal or, synonymously, farinaceous material, for use in a ready-to-eat cereal. Exemplary suitable starchy cereals include cereal grains, cut grains, grits or flours from wheat, corn, oats, barley, rye, triticale or other cereal grains and mixtures thereof. The flours can be whole flours or, preferably flour fractions such as with the germ fraction or husk fraction removed. Of course, the R-T-E cereal art is well developed and the skilled artisan will have no difficulty selecting suitable farinaceous materials for use herein.

Care however, must be taken to insure that the selection of type and amount of cereal components is made so as to provide a lightly colored cooked cereal dough.

In certain embodiments, the rice and/or corn ingredient comprises at least 50% of the cooked cereal dough (dry weight basis). In less preferred embodiments having higher levels of supplemental cereal ingredients, the rice ingredient is present in the cooked cereal dough at levels ranging from about 10% to less than 50% (dry weight basis).

Calcium

The present cooked cereal doughs and finished food products fabricated therefrom further essentially comprise a calcium ingredient to provide the desired calcium enrichment wherein at least a portion of the calcium is supplied by calcium carbonateCaCO2.

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Good results are obtained when the products comprise sufficient amounts of calcium ingredients to provide the total calcium content (including both native calcium associated with ingredients, with water, and added calcium) of the composition to provide at least 10% of the current recommended daily requirement of calcium per serving. Generally, the cooked cereal dough compositions comprise at least about100mg per 33g serving (dry basis) (i. e., about 0.3% by weight, dry basis) of calcium, preferably about0.30% to 1% (by weight, dry basis), and more preferably about 0.5% to 1% calcium.

Higher calcium concentrations in the cooked cereal dough are desired when sugar coated RTE cereal pieces are provided. Sugar coating generally comprises about20% to 35% of the finished product.

Thus, to provide the desired levels of calcium (e. g., 0.3%) in the finished product, e. g., a sugar coated

RTE cereal, the concentration of calcium in the base piece, must be higher to compensate for the sugar coating.

At least a portion of the calcium level is essentially supplied by calcium carbonateCaCO2. Calcium carbonate comprises about40% calcium. While expensive, food grade calcium carbonate obtained by chemical reaction processes is desirable due to low levels of impurities, a good, inexpensive source of calcium carbonate from natural sources is ground limestone.

Care should be exercised in selecting sources of ground limestone that are low in trace metals, especially such heavy metals such as lead. In particular, it is desirable that the ground limestone has trace metal concentrations of less than 10 PPM. Useful levels of calcium carbonate range from about

0.75% to 15% in the finished product. Such calcium material levels insure that the calcium content in the finished product ranges from about 100 mg per serving.

If desired, the cooked cereal doughs and finished products prepared therefrom can further comprise supplemental calcium fortification from other less desirable insoluble calcium ingredients. Useful herein to supply the supplemental calcium levels are calcium ingredients that provide at least 20% of their weight of calcium. Useful herein to provide the supplemental calcium fortifications above that provided by CaC02 are insoluble mineral calcium salts, particularly calcium phosphate salts. Such calcium phosphate salts provide high levels of calcium and are relatively inexpensive.

Moreover, such calcium phosphate salts can be used to provide calcium at high fortification levels with an acceptable taste. Calcium phosphate is generally available as a monobasic (CaH4(P04) 2 H20), dibasic(CaHP04-2H20) or tribasic (Ca3(P04) 2) salts. Preferred for use herein is tricalcium phosphate,Ca3 (P04) 2, ("TCP") because of its high weight percentage of calcium (about38%).

A useful tricalcium phosphate starting material is also known as tribasic calcium phosphate or tricalcium orthophosphate and is available in food chemicals codex grade from Monsanto or Rhone

Poulenc, having the general formula 3Ca3(P04) 2-Ca (OH) 2. This product provides assayed calcium content of from 34 to 40% by weight. Less preferred but nonetheless useful herein is anhydrous dicalcium phosphate, also known as anhydrous dibasic calcium phosphate, having a formula ofCaHP04. An anhydrous dicalcium phosphate material is also available from Stauffer in food chemical codex grade, providing an assay calcium content from about 30 to about 31.7% calcium by weight. Other calcium phosphate hydrates also can be useful, including, but not limited to, calcium pyrophosphate, calcium hexametaphosphate and monobasic calcium phosphate.

The skilled artisan will appreciate that whileCacao, and these calcium phosphate salts are characterized herein as insoluble, of course, some small percentage will dissolve in water depending in part upon the temperature and pH.

Soluble calcium salts typically are expensive and contain low weight percentages of calcium. While calcium chloride is an exception to this generalization, addition of significant calcium levels supplied by calcium chloride imparts an unacceptable bitter flavor to cooked cereal dough. In addition, by adding sufficient amounts of many of these soluble calcium salts to achieve the desired fortification level, the finished product may exhibit an undesirably dry texture and gritty mouth feel. Thus, in highly preferred embodiments, the present food products are essentially free (i. e., less than0.1%) of added soluble calcium salts.

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The insoluble calcium ingredient regardless of source or type is further preferably characterized by a particularly fine particle size. Such a fine or flour form of the calcium ingredient provides a particle size such that the average particle size is less than 25pm.

Selection of such a fine particle size allows for inclusion of the particulate material without imparting an undesirable gritty mouthfeel.

Even more preferred for use herein are calcium ingredients having a mean particle of less than 15 pm and for best results less than 10Hm. A good material, for example, is ground limestone of high purity having an average particle size of 3.8 pm available from Pluess

Stauffer (California), Inc. (Lucerne Valley, California).

Sequestrant

It has been unfortunately found that fortification of lightly colored cooked cereal doughs with calcium carbonate at the levels of calcium fortification herein can undesirably result in the development of an off color in the cooked cereal dough. Depending in part upon the particular grain ingredients the off color can be green or grey in color. While not wishing to be bound by the proposed theory, it is speculated herein that the calcium carbonate partially dissolves in the hydrated cereal

ingredients during the cooking step. It is further

speculated that upon dissolution, divalent calcium ions

react with a phytic acid constituent in grains leading to

development of the off color.

The present cooked cereal doughs and finished food products fabricated therefrom further essentially

comprise effective amounts of a calcium sequestrant to prevent discoloration of the lightly colored cooked

cereal doughs. Addition of the sequestrant herein binds

up the dissolved calcium ions preventing reaction with the phytic acid.

Suitable materials for use herein as the calcium

sequestrants useful herein include phosphate salts such

as sodium hexametaphosphate ("SHMP"), trisodium

phosphate, disodium phosphate, tetrasodium pyrophosphate, polyphosphates; edible organic acids such as ascorbate,

citric, malic, maleic, tartaric, succinic, oxalic,

citric, fumaric; ethylenediaminetetraacetate ("EDTA"),

and mixtures thereof.

SHMP is the preferred calcium sequestrant primarily

because SHMP can bind up to six Ca++ ions and thus is

much more effective on a weight basis than the useful

organic acid sequestrants. Thus, in preferred form at least a portion of the sequestrant is supplied by

SHMP.

Especially preferred for use as the sequestrant is a mixture of sodium ascorbate and sodium hexametaphosphate("SHMP") in a 1 to 5: 1 weight ratio.

The organic acids can be added in pure form or, preferably as their water-soluble salts, e. g. sodium citrate.

Good results are obtained when the sequestrant (s) ranges for example, about 0.005% to0.05%, preferably about 0.025% to 0.05% (dry weight basis).

The problem of discoloration is evident whenCaC02 is used to provide calcium mineral fortification, but surprisingly, not with the calcium phosphate salts described above. Again while not wishing to be bound by the proposed theory, it is speculated that these materials have enough ionic phosphorous when partially dissolved to complex with any divalent calcium ions sufficiently to prevent significant discoloration in the grain based cooked cereal dough. Thus, in a less preferred embodiment wherein the

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lightly colored calcium fortified cooked cereal doughs are free ofCaC02, sequestrant addition can also be and preferably is avoided.

Moisture

The present cooked cereal dough food products herein range in moisture broadly from about 1 to35% moisture.

The amount of moisture depends, in part, upon the particular cereal ingredients, desired intermediate or finished products, cooking equipment and drying techniques employed.

The cooked cereal dough products generally has a moisture content of about22% to 35% moisture, preferably about 26% to29%. Cereal pellets and/or half products generally range in moisture from about 10% to 18% moisture. Half products that are shipped to separate locations for further processing into finished products such as fried snacks preferably range from about 10% to14% moisture to provide shelf stable products. Pellets used in RTE cereal plants that are typically further processed in short order and thus that do not require shelf stability can range from about 10% to18% moisture.

Finished dried RTE cereals can have moisture contents of about 2% to 5% while fried snack products can be 1% to 3% moisture.

Within this broad moisture range, particular preferred moisture ranges can be selected in important part upon the particular cooking technique and equipment selected. For extruder cookers, e. g., twin screw extruders, the preferred moisture content ranges from about 22 to28%. When batch pressure cookers are employed such as is described inthe'532 and/or'685 patents the moisture content is generally higher and ranged from about 26 to30%, and most preferably about26-28%.

Supplemental Ingredients

In more preferred embodiments, if desired, the present cereal dough composition can additionally include a variety of materials designed to improve the aesthetic, organoleptic or nutritional qualities of the cereal.

These adjuvant materials can include vitamin and/or mineral fortification, colors, flavors, high potency sweetener (s), and mixtures thereof. The precise ingredient concentration in the present cereal composition will vary in known manner. Generally, however, such materials can each comprise about0.01% to about2% dry weight of the cereal composition.

One especially useful material is common salt.

Desirably, the salt comprises about 0.1 to 4%, preferably about 0.5 to 3.0% of the cereal composition.

The present cooked cereal dough products can optionally additionally comprise minor amounts such as

1% to30%, preferably about 1% to12%, of one or more supplemental starchy cereal components. The starchy cereal component can comprise any conventionally employed starchy cereal or, synonymously, farinaceous material, for use in a ready-to-eat cereal. Exemplary suitable starchy cereals include cereal grains, cut grains, grits or flours from wheat, rice, corn, oats, barley, rye, triticale or other cereal grains and mixtures thereof.

The flours can be whole flours or flour fractions such as with the germ fraction or husk fraction removed or, alternatively, brans. For those embodiments to be fabricated into puffed cereal pieces the supplemental ingredient can for example comprise pure starches or pure modified starches to assist in providing desired puff volumes. Of course, the R-T-E cereal art is well developed and the skilled artisan will have no difficulty selecting suitable farinaceous and/or starchy materials (e. g., potato starch) for use herein.

If desired, the present cooked cereal dough food products can additionally comprise about0.1% to about 20% (dry weight), preferably about 1% to10%, and most . preferably about5% to10% by weight sugar (s) or, synonymously herein, nutritive carbohydrate sweetening agents. Such materials are also well known in the R-T-E cereal art. Useful herein as the sugar component is sucrose. However, the sugar (s) component can additionally comprise conventional fructose, maltose, dextrose, honey, fruit

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juice solids, brown sugar, and the like. In addition to providing desirable sweetness, the sugar component additionally beneficially affects the cereal color and texture. Better results are obtained, especially for R-T-E cereal products, when the sugar (s) component comprises from about 1% to about

10% by weight of the composition.

In a preferred embodiment for ready-to-eat cereals, the present cereal compositions are further essentially defined in part by low fat levels, i. e., the present cereals do not comprise added or absorbed fat. Thus, the total fat or lipid component is quite low. The fat content results from the native fat associated with the starchy cereal component (s). Permissible low fat additions can also result from adding emulsifiers and from vitamin or flavor addition. However, the total fat content of the cereal compositions should be less than about3%, preferably less than about2%. Preferably, the

R-T-E cereal is substantially free of any fat or oil incorporated into the cooked cereal dough.

Such"added fat"is to be distinguished from"absorbed fat"that is picked up during deep fat frying used to prepare finished snack products herein.

It is also desirable to vitamin fortify the present

R-T-E cereals, especially selected B vitamins, e. g., riboflavin. Conventional methods and techniques of vitamin fortification can be used herein. Due in part to their heat sensitivity, vitamin fortification is typically practiced by topical application to the R-T-E cereal and such a technique is preferred herein.

More heat tolerant vitamins can be added to the other cereal ingredients that form the cooked cereal dough.

Method ofPreparation

In the preferred embodiment, the present methods essentially comprise a first step of providing a light colored cooked cereal composition such as a cereal dough or cereal mass containing calcium and sequestrant each within the herein their respective specified ranges.

Cooked cereal dough can be prepared by blending various dry cereal ingredients together with water and cooking to gelatinize the starchy components and to develop a cooked flavor. Preferably, a preblend of wet ingredients is made and combined with a preblend of the dry ingredients. The cooked cereal material or mass can also be mechanically worked to form cooked cereal dough.

The cooking and mechanical work can occur simultaneously or sequentially. The dry ingredients can also include various cooked cereal dough additives such as sugar (s), salt and mineral salts, and starches. In addition to water, various liquid ingredients such as corn (maize) or malt syrups can be added. A cooked cereal mash is quite similar to cooked cereal dough except that larger sized particles such as whole grains or cut grains are cooked rather than cereal flour ingredients.

The calcium carbonate and the sequestrant (s) can be added in whole or in part to either the dry or wet blend.

Surprisingly, in a preferred variation add calcium carbonate and sequestrant at each added at least in part, and preferably entirely to the wet ingredients to insure that the sequestrant is more intimately admixed with the calcium.

Moreover, while the invention finds particulars dried pellets or half products. These half products are useful intermediate products. Finished grain based snack products are usually provided by the deep fat frying or other puffing of the pellets (e. g., hot air or microwave heating) of partially dried half products fabricated from cooked cereal doughs. An advantage of half products is that they can be produced in bulk in one location and thereafter fried in one or more finish operations to form the finished snack products. Not only are shipping costs reduced due to the reduced volume of the half products compared to the finished products but also breakage of the finished product is reduced. Also, the present invention can be used to provide pretzel snack products fortified with calcium.

The cereal dough cooking step can be practiced using a batch, atmospheric cooker and a low pressure extruder cooker especially those equipped with a conditioner precooker, or a twin screw extruder. The cereal is cooked with steam and sufficient amounts of added water for times and at temperatures sufficient to gelatinize the cereal starch and to develop desired levels of cooked cereal flavor.

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Forming intoDesirably Shaped and Sized Pieces

The present methods further essentially comprise the step of forming the cooked cereal dough or mass into individual pieces of desirable shape and size.

Conventional techniques and equipment can be employed to practice this step and the skilled artisan will have no difficulty in selecting those suitable for use herein.

For example, the dough having a moisture content of about25% to30% is first partially dried to a partially dried dough having a moisture content of about12% to20%. The partially dried dough can then be fed to piece forming apparatus that form the partially dried dough into individually shaped and sized pieces.

The present cereal compositions can be fabricated into any of a variety of common R-T-E cereal or snack forms including, shreds, biscuits, flakes, rings, or any common R-T-E cereal or cereal based snack product form, shape or size. The present cereal compositions can also be formulated and fabricated so as to provide puffed cereals of various shapes and sizes such as"biscuits".

Especially desirable for use herein are biscuits, especially toasted biscuits. Especially for flakes, the forming step can first involve a substep of shaping the dough into pellets and then a finish substep of shaping the pellets into a final desired shape such as flakes.

For example, the cooked cereal dough can be fed to a pellet former to form pellets. In the preparation of R

T-E cereals in flake form, the pellets can be sized to have a pellet count of about 35 to 50 per lOg and a moisture content of 16 to20%. In the preparation of a flaked R-T-E cereal, the pellets can be partially dried to moisture contents of about 18 to 20%. The pellets can then be formedinto"wet"flakes having a thickness of about 380 to 635pm (0.015 to 0.025 inch), preferably while warm 76.6 to 87.8 C (170 to190 F) to form desirably shaped and sized wet flakes.

In still another variation, the dough can be sheeted . to form sheets of dough (e. g., 25 to 800 microns in thickness) and the individual pieces formed by cutting the sheet into individual pieces or by stamping out shaped pieces from the dough sheet.

In still another variation, the cooked cereal dough can be extruded through a die imparting a desired peripheral shape to form an extrudate cooked cereal dough rope. The dough rope can be cut to form individual shaped pieces.

In still another variation, the cooked cereal dough can be fed to a biscuit forming device (see, for example,

U. S. 5,342,188, entitled"Device For Crimping and Cutting

Dough Ropes, issued August 30,1994 to C. E. Zimmermann, which is incorporated herein by reference) which forms the dough into biscuit shaped individual pieces.

In another preferred variation, the cooked cereal dough is formed intoindividual"O"shaped pieces or rings, biscuits, shreds, figurines, letters, spheres or flakes or other geometric shapes, nuggets, or even irregular shapes.

Drying To Form Finished Pieces

The present methods further comprise the step of drying the shaped and sized individual pieces to form finished cereal products fortified with calcium.

The skilled artisan will appreciate that the drying step depends importantly in part upon the desired end product. For example, for end products in the form of puffable half products or pellets for snack production, the drying step can be practiced to provide a"finish" moisture content of about 10 to 15%.

However, when the desired end product is an R-T-E cereal, drying the pellets to these moisture contents may only be an intermediate or substep prior to, for example, flaking the dried pellets toform"wet"flakes. These"wet" flakes can then be subjected to a finish or final drying step wherein the pieces are dried to final dried moisture contents of 1 to4% such as by toasting.

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In still another variation, the dough can be extruded under conditions of temperature and pressure so as to puff and expand(the"direct expansion"technique) and sectioned or cut into individual pieces to form individual expansions puffed R-T-E cereal or snack pieces.

In certain embodiments, the cooked cereal dough can be puffable such as by deep fat frying, microwave heating, gun puffing, jet zone heating, etc.

In another variation, the drying step can involve heating the pieces under conditions that not only dry the piece but also cause the piece to expand to form dried and puffed or flaked finished pieces. For example, pellets can be gun puffed to form dried puffed R-T-E cereal products. The wet flakes can be toasted to dry, expand and tenderize to form finished R-T-E cereal flakes.

In still another variation, the pieces or pellets can be deep fat fried to form dried puffed fried finished cereal products fortified with calcium. Such dried puffed fried finished cereal pieces are especially desirable as calcium fortified snack products. Such products can absorb about 5 to 35% of frying fat during the drying and puffing step.

The dried cereal pieces, however realized, can optionally be provided with a topical sugar coating and subsequently dried to remove the moisture added by the sugar coating solution to form presweetened

R-T-E finished cereal pieces. In other variations, an oil topical coating optionally with salt and/or flavors, is applied to form finished dried snack products. Both conventional sugar coatings and coatings employing high potency sweeteners, especially aspartame and potassium acesulfame, are known and can be used to provide presweetened cereals for use herein.

If employed, the topical sweetening is applied in sufficient amounts such that after drying to remove added moisture associated with the sugar coating solution, the sugar coating is present in a weight ratio of sugar coating to cereal base of about 1: 100 to about 50: 100, preferably 10: 100 to about 40: 100 and for best results about 25: 100 to about 35: 100. Typically, the sugar coating solution will have a blend of sugars and will comprise about 4 to 20% moisture. When higher amounts of the sugar coating solution, particularly for those solutions employing higher moisture levels, the slurry coated cereal pieces may be subjected to a final drying step to remove the added moisture from the sugar coating to provide finished dried products having a moisture content of about 1 to5%.

The R-T-E cereal pieces so prepared can then be conventionally packaged for distribution and sale.

In still other variations, the present finished dried food products are admixed with other dry snack ingredients (e. g., peanuts, pretzels, and other cereal pieces) to form a mixed aggregate snack product.

The finished dried R-T-E cereal and cereal based snack products fabricated from the calcium fortified cooked cereal doughs herein are useful as nutrient fortified food products. Surprisingly, the finished R-

T

E cereal and cereal-based snack products provided herein are remarkably similar to their unfortified counterparts, even though containing the added calcium ingredient.

Good flavor, good texture and other favorableorganoleptic attributes characterize the products.

Notwithstanding their highly acceptable taste, appearance and texture attributes, the products are nonetheless characterized as having high levels of calcium. The present finished products are remarkably free of the undesirable discoloration heretofore associated with finished light colored dried cereal products high in calcium content. The cooked cereal doughs and finished products prepared therefrom can each further be characterized by a Hunter value of greater than 60. If desired, the finished products can also be subjected to a toasting step.

The products can be packaged and distributed in conventional form.

Thus, since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing

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description, and all changes, which come within the meaning and range of equivalency of the claims, are intended to be embraced therein.Data supplied from the esp@cenet database - Worldwide

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421.

WO0156393 - 8/9/2001

WATER-DISPERSIBLE COATING COMPOSITION FOR FRIED FOODS AND

THE LIKE


Inventor(s): STEVENS CHEREE L B (--); STEVENS JOHN F (--); CARR D MICHAEL (--)

Applicant(s): ADVANCED FOOD TECHNOLOGIES (US)


IP Class: A23B7/16

E Class: A23L1/00P8B4; A23L1/217


Priority Number: US20000180666P (20000207)

Family: WO0156393

Equivalent: CA2398845; AU776363

Cited Document(s): US5928693; US5885639; US5849351; US5965189

Abstract:


A coating composition for foods contains high level of rice (e.g., as flour) and dextrin, and little or no cornstarch, with the rice and dextrin components on a percentage weight basis together comprising from about 25 % to 70 % of the total weight of the solids content of the coating composition, and ratios of rice to dextrin between about 1.0:1 to 5:1. The high amounts of both rice and dextrin substantially increase the coated product's crispness and holding time after either complete initial cooking or secondary reconstitution in conventional or microwave oven after limited initial cooking (e.g., parfrying) and freezing, while maintaining excellent appearance, taste, tenderness, and tooth compaction characteristics, and also are highly cost-advantageous. The composition also may contain potato starch and seasonings, coloring agents, leavening agents, and stabilizing agents, and may be applied as a dry mix of ingredients or in slurry form.Description:


WATER-DISPERSIBLE COATING COMPOSITION FOR FRIED FOODS AND THE LIKE


The present invention relates to a water-dispersible coating composition for food substrates, and more particularly to a food coating which is applied prior to cooking, e. g., parfrying or finish frying, has a substantially clear appearance on such foods after frying or parfrying and subsequent reconstitution, and substantially increases both crispness and tenderness while greatly prolonging the holding time of the food, while maintaining good taste and tooth compaction characteristics desirable to the final consumer.


The process and procedure of preparing and applying coatings to the outer surfaces of food items prior to freezing and finish cooking, especially potato products, are generally well known in the art. Such coatings have been applied to various potato products, and particularly to potato strips which are to

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become french fries, in an effort to obtain one or more of the following objectives: 1) improved visual appearance of the finished (cooked) product; 2) improved eating characteristics, especially surface crispness, of the cooked product; and 3) extended holding time during which the finished product can be held under a heat lamp or the like while maintaining acceptable or improved post-preparation characteristics for consumption by a final consumer.

The industry has for some time used coatings for food product substrates, such as potatoes, which are applied as a slurry or batter and which form a generally clear coat after they dry or are parfried.

Such"clear coats"are important because of their ability to at least partially maintain the original food substrate's natural appearance to the consumer while imparting increased surface crispness to the food product following final preparation. Further, such coatings increase the holding time or postpreparation time during which the product can be maintained at preferred post-preparation characteristics (e. g., under a heat lamp) prior to consumption by a consumer: To this end, food coatings have been developed previously that were applied to potato strips that were then at least briefly deep-fried ("parfried") and frozen for storage prior to finish cooking and consumption.

However, developing a substantially clear coat for potato substrates which increases the surface crispness and inner tenderness of the final prepared product, and maintains these qualities over an extended period of time has presented significant difficulty to the formulators. Prior art demonstrates that various dry mix coating compositions which can be mixed with a liquid to form a slurry have been developed which when placed on potato substrates achieved at least some of the above-mentioned objectives. Most or even all of the prior art potato substrate coatings, however, require the use of cornstarch,especally modified cornstarch which has been chemically crosslinked. Use of cornstarchbased prior art coatings does impart increased crispness, but it also increases the overall formulation costs for the coating composition.

Furthermore, due to the substantial amount of cornstarch which is required in such prior art coating compositions to obtain the desired crispness, an undesirable cereal flavor is introduced into the final coated product.

In view of the rising cost of the cornstarch component used in known coating compositions, many prior art compositions have included leavening ingredients that incorporate acids and/or salts to help increase crispness of the final product, as an alternative to or adjunct for the cornstarch component.

However, it has been shown that the use of such leavening ingredients results in a non-continuous surface coating causing a spotty covering and appearance upon the final coated product. Further, such leavening ingredients also cause an undesirable excess of oil to transfer into both the surface coating composition and overall final potato substrate product when the food is deep-fried. The result of this transfer is a flaky, oily looking, and oily tasting final product which is considered inferior within the food coating industry.

An additional difficulty for the coating formulator has been that when the prior art coatings are placed onto food substrates which have previously been immersed in an aqueous medium for blanching, etc., reconstitution of the coated final product within a gradient heat oven (convection or conventional type) or within a microwave oven, changes the characteristics of the coating composition such that it fails to achieve the crispness and holding time objectives required by the food industry. Furthermore, some coatings of the prior art become tough and leathery from gradient heat oven reconstitution, and they become soft and rubbery following microwave reconstitution.

Due to the shortcomings of prior art coating compositions for food substrates, and particularly, potato substrates, there is a definite need within the food industry for a coating composition which is substantially clear when placed upon food substrates, provides increased crispness, and increases holding time while still maintaining the desired eating characteristics for the final consumer. Further, there is a need within the food industry for a coating composition which reduces the adherence of food item pieces to one another during processing, especially during the processing step of parfrying the coated food pieces. In addition, there is a need for a coating composition which also allows products to be reconstituted in a gradient heat oven as well as a microwave oven without sacrificing the benefits of improved outer crispness, appearance, and holding time. Also, there is a need for a coating composition which produces less tooth compaction after cooking and holding time prior to consumption by the final consumer. Furthermore, all of these shortcomings of the prior art must also be overcome in such a

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manner that the overall cost of the coating composition is reduced in order to be truly beneficial commercially.

With reference to prior patents illustrating the prior art coatings referenced above,

U. S. Patent No. 5,141,759 to Sloan et al. discloses a coating composition that contains cornstarch along with potato starch and rice flour in order to allegedly achieve a substantially clear and crisp potato coating having an extended holding time.

U. S. Patent No. 5,965,189 to Stevens etal. describes a coated potato product having increased crispness and holding time through use of a coating having cornstarch in conjunction with corn flour and a low-solubility dextrin. This patent further claims that such coating composition is essentially non-allergenic.

U. S. Patent No. 5,976,607 to Higgins etal. discloses the use of a substantial amount of modified cornstarch in a potato substrate coating to increase crispness of the final coated potato product, along with an amount of rice flour that serves to reduce or balance the crispness characteristic imparted through use of the modified cornstarch.

U. S. Patent No. 5,997,918 toMelvej discloses a food coating composition for use on potatoes which contains a high percentage of cornstarch in relation to rice flour in order to obtain a coating composition which is said to impart increased crispness and holding time to the final cooked potato substrate product.

U. S. Patent No. 5,095,435 to Sloan etal. discloses a process for preparing frozen coated potato products in which an aqueous starch slurry comprised of a combination of modified ungelatinized potato starch, modified ungelatinized corn starch, rice flour, and other optional ingredients such as flavorings and seasonings are utilized to allegedly improve the crispness of the final cooked coated potato product while maintaining the tenderness of the interior of the cut potato. The'435 patent also states that its disclosed coating, when placed upon a potato strip that is frozen, allows the potato product to be reconstituted within a conventional oven producing an acceptable product without decreased flavor characteristics.


In accordance with the present invention, it has now been discovered that a very desirable waterdispersible coating composition for food substrates may be achieved which is less expensive than prior art coatings and yet yields a substantial improvement over prior art coatings in both appearance and eating characteristics, including crispness, holding time, and tooth compaction, which allows the food to be reconstituted or finishcooked in practically any manner, i. e., in deep fat fryers, gradient heat ovens or microwave ovens, after freezing and/or storage. It has been discovered that such substantial improvements can be accomplished with a coating composition that contains a surprising high level of both a rice component and a dextrin component, which are present (considered together as a combination) on a percentage weight basis of from as low as about 25% up to about 70% of the solids content forming the overall coating composition, preferably between about 35% to 50%.

In particular, the rice component of the rice/dextrin combination preferably comprises at least about

25%, desirably about 27-28%, and most preferably up to about 30% by weight of the solids content of the various ingredients other than water which form the coating composition of the present invention.

The dextrin component of the rice/dextrin combination preferably comprises at least about 20% of the total solids content weight of this combination of ingredients, and most preferably about 25% to 35%.

(Theterm"solids content"being used to mean dry or generally dry substances and also those which are soluble or suspended in an aqueous or other liquid.)

By using such a relatively high concentration of rice and dextrin, a substantially clear coating composition is created which imparts significantly increased crispness and holding time to the final coated product without the use of cornstarch, which prior art coatings relied upon to impart the desired crispness to the final coated substrate product.

It is believed that the coating of the present invention imparts an increased crispness to the final finishcooked coated substrate product, regardless of whether or not any cornstarch is present within the composition, and preferably without this relatively expensive ingredient.

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In particular, it has been discovered that the ratio of rice to dextrin should preferably be at least about

1: 1 and up to about 5: 1, more preferably, between about

1.5: 1 and 5: 1, and most preferably between at least about 2: 1 to 3.5: 1, to achieve the best improvement according to the invention.

It has also been discovered that while the rice component is most advantageously comprised of rice flour, the particular form or type of rice flour and/or of dextrin used in accordance with the invention does not significantly change the benefits obtained. The benefits of the present invention are derived from the amount and relationship of the rice component (e. g., rice flour) and dextrin component, which together, as a combination, largely cause the overall improvement in crispness and holding time of the coated substrate product after final preparation and when the food is finish-cooked and ready for consumption. Short-grain, medium-grain, and/or long-grain rice flour and derivatives thereof (for example, starch) can be used in formulating therice"component"of the present coating composition, and potato dextrin, tapioca dextrin, and/or corn dextrin, of either low or high solubility, and derivatives thereof, can be used in, or as, the dextrin component of the riceflour/dextrin combination used in the coating composition of the present invention.

The key to obtaining the present invention's benefits lies in the total and relative amounts of the two primary ingredient types (rice flour, etc. and dextrin), including the weight ratio relationship they have to one another. While the dextrin component may actually be used in an amount higher than the rice component, the results are not as favorable as those obtained by use of the preferred relationship of rice component being present at a somewhat higher level than that of the dextrin component. Unlike prior art coating compositions, the present invention's use of high overall percentage and particular relative amounts and ratios of rice and dextrin provides for increased crispness and holding time for a product which is cooked or reconstituted in practically any conventional way, including deep-frying, gradient ovens, or microwave ovens, without sacrificing appearance, flavor, or tooth compaction characteristics desirable to consumers of the final coated end product.

It is believed that the present invention's novel combination and ratio relationship of rice flour etc., and dextrin creates a lattice structure or matrix that enhances crispness and holding time by allowing moisture to easily escape from the potato substrate while allowing heat to enter the internal structure, without destroying the strength of the overall lattice. It is further believed that use of a very low solubility and very low molecular weight dextrin component in the rice dextrin combination allows for the production of an open lattice structure which uniformly coats the potato substrate, i. e., the potato strip, and that the dextrin component produces spot weld points within the lattice produced by the riceflour/dextrin combination, to increase its overall strength. Such a phenomenon does not occur with other carbohydrates, such as cornstarch, potato starch,O ! wheat f ! our, because they tend to form a continuous film and thereby seal-over the surface of the finished fry, which does not let moisture escape while allowing heat to enter.

By trapping-in the moisture, it is believed that prior art coating compositions utilizing cornstarch, potato starch, or wheat flour tend to weaken due to the moisture's ability to change the configuration of the film's continuous phase structure, which in turn causes the potato product to quickly wilt or become limp quickly after reconstitution.

The present invention's combination of rice flour and dextrin in the preferred weight and ratio relationships significantly increases crispness and holding time of the final coated product because the overall coated potato structure can release moisture while retaining heat, while the integrity of the open lattice structure enrobing the substrate remains intact.

In addition, it has been discovered that the coating formulation of the present invention not only improves the crispness and holding time of the final product substantially when reconstituted by deep fat frying after parfrying and freezing, but also provides significantly increased crispness and holding time of the final product even when it is reconstituted by gradient heating or microwave heating methods. Unlike prior art coating compositions, the present invention's inventive use of high amounts and specified weight ratio relationships for the rice and dextrin components provides increased crispness and holding time of the coated food substrate when reconstituted in basically any manner, including conventional gradient ovens, convection ovens, or microwave ovens without sacrificing

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appearance, flavor, or tooth compaction characteristics desirable to end consumers of the final finishcooked coated potato substrate product. Such a discovery allows for"take home"or"delivery"capabilities for a wide range of such coated products, which could not previously be done successfully due to the attendant marked degradation in taste, appearance, and organoleptic qualities.

Further, the dry mix coating composition of the present invention may even be applied to the food product in its dry form rather than as a slurry or batter, and the dry coated product may be frozen directly, without parfrying or other such precooking, and will produce a crisp, tender, and appealing final product with an extended holding time.

Such an application and procedure is believed to never have been possible using other coating compositions currently known, and it also provides the extended holding times noted above, not only under heat lamps and the like but even at ambient room temperatures, after which the product may simply be reheated to serving temperatures, by use of essentially any heating source such as conventional ovens or microwave devices.

It is well known within the art that the cornstarch component of prior art coating compositions is expensive and significantly increases the overall cost of the final coated product. The present invention substantially reduces the cost of coating compositions for food substrates by removing or minimizing the use of the expensive cornstarch component. Furthermore, it has also been discovered that the present invention may advantageously be utilized on many different types of food product substrates in addition to potatoes. For example, the benefits of the present invention may also be obtained by using it on vegetables, such as mushrooms, broccoli, cauliflower, egg plant, etc., or as a coating for meats, such as seafood (including shrimp, fish, etc.), chicken, and the like.

Finally, it has also been discovered that other ingredients may be added to the present coating composition without detracting from its discovered benefits. Such ingredients include cornstarch, potato starch, leavening ingredients (either an acid or carbonate or both), coloring agents (dextrose, corn syrup solids, whey, etc.), stabilizers such as methylcellulose gums, and flavors such as sugar and salt. It should be noted that, of the foregoing, low-amylose content potato starch is preferred because it contains approximately 30% amylose, unlike modified cornstarch, which has a much higher amylose content of around approximately 50% to 70%.

It is believed that the low-amylose potato starch ingredient which may be incorporated within coatings based on the present invention acts as a carrier for the riceflour/dextrin combination. Further, it is believed that the low-amylose potato starch acts as an adherent for the riceflour/dextrin combination by creating a film over the substrate, e. g., potatoes. Upon parfrying of the food substrate, the lowamylose potato starch component bursts and opens to allow for the rice flour/dextrin combination to further adhere to the food substrate, and contemporaneously form the previously noted open lattice structure with its spot weld points all around the food substrate. In addition, the low-amylose potato starch, after bursting open, restructuralizes and realigns itself along the lattice structure created by the riceflour/dextrin combination, to further improve the strength, resultant crispness, and resultant holding time imparted to the coated substrate.

Although not necessary, the coating composition of the present invention may include cornstarch if desired. For example, 10% or even more of cornstarch ingredients known for their crisping function when used in clear coats for french fries may be used to reduce the amount of the low-amylose potato starch component within the present coating composition to considerably less than 50%, e. g., 40% or even somewhat less.

However, the addition of the expensive cornstarch component will not increase the crispness or holding time characteristics to a level greater than that of the present invention's novel rice and dextrin combination.

These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification and claims.


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In one example of the present invention, fresh whole Russet Burbank potatoes are washed in water, peeled, and cut into1/4 inch byV4 inch strips of about21/2 to 3 inches in length. The strips are then blanched at180 F for 15 minutes and subsequently dipped into a water solution of sodium chloride

(2%) and Sodium Acid Pyrophosphate (SAPP 0.5%) held at140 F for 40 seconds. The potato strips are then removed from thewater/salt/SAPP solution and allowed to drip dry before placement into a standard convection oven at150 F for 18 minutes to further dry, but not dehydrate, the strips.

Such drying reduces the moisture of the potato strips approximately 12%.

Next, a dry-mix coating composition comprising a combination of 30% by weight of a medium-grain rice flour and 15% of a tapioca dextrin further in combination with

47% modifiedungelatinized low-amylose potato starch, sugar, a leavening agent (sodium acid pyrophosphate and sodium bicarbonate), table salt, and corn syrup solids is dispersed into water at55 F to form aslurry, such that the dry-mix coating combination constitutes about 30% to 50%, preferably

35% to 45% of thetotal slurry composition based upon the total weight of the water and dry-mix components. Next, the coating composition slurry is stirred in a Kitchen-Aids mixer at a paddle blade speed of two for five minutes and then allowed to rest in a non-agitated state for 20 minutes prior to placing the coating composition slurry upon the potato strips.

The water-dispersible coating composition of the present invention, in the form of aslurry, is then placed upon the pre-cut potato strips by immersion of the strips within the slurry for a period of ten seconds. Following the immersion step, the now coated potato strips are then parfried for 50 seconds in a fryer containing soybean oil heated to a temperature of 365 F. It was observed during the parfrying step that the coating composition of the present invention did not cause the coated potato strips to stick together, decreasing production time and loss due to unacceptable products, also known as rejects.

The parfried coated potato strips are then removed from the fryer and placed on wire racks, which are then placed into a chest freezer to quickly bring the temperature of the parfried strips down to15 F within 25 minutes. After that, the frozen, coated, and parfried potato strips are placed into plastic bags and held for a period of at least 72 hours in a frozen stateof-10 to 10 F before evaluations are conducted to assess the quality of the coated product in relation to the objects of the present invention.

After 72 hours, the frozen parfried coated potato strips are then evaluated against commercially available potato strips coated with commercially available cornstarchbased compositions that do not contain high percentage levels and relative ratios of rice flour and dextrin, like that of the present invention.

Table 1 below describes the ingredient make-up for the coating composition of the present invention used in the tests as well as that of the prior art formulation used for the post-72 hour evaluatory test. In other respects, the potato strips were of the same type and were coated, parfried, frozen and reconstituted in the same manner.

TABLE 1

EMI9.1

>;tb; Present >;SEP; Invention >;SEP; Ingredient >;SEP; Prior >;SEP; Art

>;tb; 0.0% >;SEP; Cornstarch >;SEP; 15.9

>;tb; 30% >;SEP; Medium >;SEP; grain >;SEP; rice >;SEP; flour >;SEP; 15%

>;tb; 15% >;SEP; Tapioca >;SEP; dextrin >;SEP; 5%

>;tb; 46.9%Ungelatinized, >;SEP; modified >;SEP; 56%

>;tb; potato >;SEP; starch

>;tb; 1 >;SEP; % >;SEP; Sodium >;SEP; acid >;SEP; pyrophosphate >;SEP; 1. >;SEP; 0%

>;tb; 0.7% >;SEP; Sodium >;SEP; bicarbonate >;SEP; 0. >;SEP; 7%

>;tb; 2% >;SEP; Sugar >;SEP; 2%

>;tb; 4% >;SEP; Salt >;SEP; 4%

>;tb; 0.2% >;SEP; Xanthan >;SEP; gum >;SEP; 0.2%

>;tb; 0.2% >;SEP; Corn >;SEP; syrup >;SEP; solids >;SEP; 0. >;SEP; 2%

>;tb;

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Following preparation and parfrying, it was noted that 10% to 15% of the coated fries utilizing the prior art coating composition stuck together after completion of the parfrying step. It is well known within the food coating industry that limits are set as to the maximum allowable number of fry strips that can be stuck together, i. e., rejects, to achieve maximum cost savings. However, coated potato strip substrates utilizing the present invention in either wet (slurry) or dry form did not stick together during or after completion of the parfrying step, or during finish-cooking (reconstitution or as a single step) by deep-frying. Thus, it was established that a further benefit of the present invention, unlike that of the prior art, is a reduction of unusable reject coated substrates, with a corresponding increase in production efficiency.

Other evaluatory tests were conducted to assess the coating of the present invention against currently available coating compositions. A sensory evaluation was completed on fully prepared (finish-cooked) and ready-to-eat coated food products, to contrast and compare the degree of crispness, degree of toughness, and amount of tooth compaction (amount of product retained in the teeth after chewing), both immediately after finish frying and after the sample products were placed under a heat lamp containing two 250-watt bulbs for ten minutes. Panelists were selected and made aware of sample-coat identification, but not as to the make-up of the composition they were evaluating.

Both the final product of the present invention and that of the prior art were flashfrozen using conventional freezing techniques and then subsequently deep fat fried to completion, known as finish frying, within a fryer containing soybean oil heated to a temperature of350 F for 21/2 minutes. Such finish frying of frozen coated and parfried potato strips would be essentially similar to that done for french fries served in a typical food service restaurant. Sensory evaluation sheets containing five-point hedonic and numeric scales to assess the above-mentioned characteristics were then completed after a sampling of the potato products embodying the prior art and others embodying the present invention.

Panelists also evaluated visual characteristics of each sample as well.

Those characteristics included surface roughness of the coating, amount of coating present on the substrate, and uniform application of the coating over the surface of the substrate.

In all of the evaluatory categories, each of the panelists concluded that at least one full hedonic unit separation occurred in a more positive direction for coatings in accordance with the present invention, over that of the prior art sample. Panelists also concluded on a numeric scale of one to five, with one being the highest positive value, that the coating composition ranked number one in comparison to the prior art coating composition. In addition, panelists concluded that the coating sample representative of the present invention had surface roughness and amount and uniformity of coating characteristics which were equal or superior to the prior art sample.

It was also discovered during the sensory tests that the finish-cooked coated potato product of the present invention could be allowed to stand under a heat lamp for a period of at least about 45 minutes, or even allowed to stand at ambient room temperatures for up to about one and one-half hours, and then placed within an 1100watt microwave oven on a paper towel and reheated once again back to serving temperature, at a which point it would once again become a crisp, tender, and hot final product.

Samples made in accordance with the prior art, which underwent even an extended holding time under a heat lamp prior to the same reheating procedure were noted as being limp and rubbery, producing an unsatisfactory final product after the second reconstitution. The ability to stand at room temperature for an extended interval (and thus cool down to that temperature) and then become hot, tasty, crisp, and tender by heating in a microwave oven has until now been unheard of, and clearly brings a totally new dimension and capability to the"fast-food"industry, and particularly with respect to the take-out food business.

In view of the results of the microwave oven test, a further test was completed in which samples of the final coated potato substrate product of the present invention and samples of prior art coated products were placed into a gradient oven (conventional oven) upon a single layer tray, and heated to a temperature of450 F for a period of 15 minutes. The resultant baked final product of the present invention was hot, crisp, and tender, unlike the prior art samples, which were hot, but unsatisfactorily limp, chewy, and leathery.

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Comparative composition tests were also completed, to evaluate each of the individual components of the present invention against a currently available prior art coating composition. The compositions, evaluation criteria, and results are reproduced below.

Test Constituents

Example1

CONTROL 1: DRY MIX COATING WITHOUT HIGH RICE FLOUR/DEXTRIN

COMBINATION MIXED WITH WATER TO FORM A SLURRY (TO

DEMONSTRATE THE PRIOR ART)

Control 1 Ingredients : 56% potato starch, 15% medium grain rice flour,

5% tapioca dextrin,1 % sodium acid pyrophosphate, 0.7% sodium bicarbonate,2% sugar, 4% salt,

0.2% xanthan gum, 0.2% corn syrup solids, and 15.9% cornstarch.

CONTROL 2: DRY MIX COATING WITH HIGH RICE FLOUR/DEXTRIN

COMBINATION CONTAINING HIGH RICE AND MODERATE DEXTRIN

LEVELS MIXED WITH WATER TO FORM A SLURRY (TO DEMONSTRATE ONE

EMBODIMENT OF THE PRESENT INVENTION)

Control 2 Ingredients : 41.9% potato starch, 35% medium grain rice flour, 15% tapioca dextrin, 1% sodium acid pyrophosphate, 0.7% sodium bicarbonate,2% sugar, 4% salt, 0.2% xanthan gum, 0.2% corn syrup solids, and 0.0% cornstarch.

[Note that Controls 1 and 2 utilize 42% dry mix coating and 58% water to form the final waterdispersible coating composition.]

TEST 1: DRY MIX COATING WITH HIGH RICE/DEXTRIN COMBINATION

HAVING EQUAL AMOUNTS OF RICE FLOUR AND DEXTRIN, MIXED WITH

WATER TO FORM A SLURRY (TO DEMONSTRATE ANOTHER EMBODIMENT

OF THE INVENTION)

Test 1 Ingredients : 46.9% potato starch, 22.5% medium grain rice flour,

22.5% tapioca dextrin, 1% sodium acid pyrophosphate, 0.7% sodium bicarbonate,2% sugar, 4% salt,


TEST 2: DRY MIX COATING WITH HIGH RICE/DEXTRIN COMBINATION

HAVING LESS RICE FLOUR THAN DEXTRIN, MIXED WITH WATER TO FORM

A SLURRY (TO DEMONSTRATE ANOTHER EMBODIMENT OF THE

INVENTION)

Test 2 Ingredients : 46.9% potato starch, 15% medium grain rice flour,

30% tapioca dextrin,1% sodium acid pyrophosphate, 0.7% sodium bicarbonate, 2% sugar, 4% salt,


Test Preparation Procedures

Both the final products of the present invention and that of the prior art were deep fat fried to completion, known as finish frying, from a previously parfried and frozen state, using a conventional deep-fat fryer containing soybean oil heated to a temperature of 350 F for21/2 minutes. Such finish frying would be essentially similar to that done for coated food products served in a typical food service restaurant. Sensory evaluation sheets containing a five-point hedonic scale to assess the abovementioned characteristics were then completed after a sampling of the potato products embodying the prior art and others embodying the present invention. The five-point hedonic scale was followed by a numeric scale of one to five, with one being the highest positive numeric value to rate and determine the overall best sample.

Evaluatory Criteria and Procedures

After samples of the prior art and present invention coatings were completed, panelists completed evaluatory sheets ascertaining various appearance, texture, and flavor characteristics of each sample.

Appearance characteristics for evaluation included surface roughness, amount of coating, and coating uniformity. Texture characteristics evaluated included initial crispness, toughness, and tooth compaction, andre-evaluation of these same characteristics after the samples had been placed under a heat lamp for a period of ten minutes. Flavor characteristics included an evaluation as to whether the final coated product had a good, fair, or poor potato flavor and whether or not a foreign flavor was present.

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Discussion of the Results

In view of Tests 1 and 2, it was shown that Control 2, utilizing aslurry-form coating in accordance with the present invention, achieved significantly increased crispness and holding time as compared to the coating of the prior art represented by

Control 1. Tests 1 and 2 also demonstrated that it was possible to use the dextrin component in an amount equal to or even greater than the rice flour component in the present invention's high riceflour/dextrin combination while still obtaining increased crispness and holding time compared to that of the prior art coating composition of

Control 1. However, these tests also demonstrated that high rice/dextrin formulas made with either an equal ratio of rice flour to dextrin (Test 1) or less rice flour than dextrin (Test 2) produced a final coated produce having a comparatively rough and less uniform visual appearance than whe ; i the ratio of these components favors a greater amount of rice flour to dextrin in combinations according to the present invention.

Since the coated products of Test 1 and Test 2 were somewhat rougher than those of Control 2, one would have expected that either of these test products would have had increased crispness, greater than that of Control 2. However, this was not the case. It was determined that the coated products of Test 1 and Test 2 had slightly less or equal crispness and holding time as compared to those of Control 2, but did not have the superior visual appearance characteristics of Control 2, which are required or at least greatly desired by the food industry. However, it should be noted that Test 1 and Test 2 did produce a final product that had greater crispness and holding time than Control 1 (the prior art), indicating that products made in accordance with Test 1 and Test 2 could function acceptably as alternative embodiments of the present invention. Thus, an example of the preferred embodiment of the present invention can be seen in Control 2.

Those seeking substantially clear, smooth, and"invisible"coatings for food products, especially potato substrate products, without producing a dark, opaque, oily, broken, or rough surface texture, but having very desirable qualities and extended holding periods would prefer the coating of Control 2.

Similar tests have also been done on potato strips of essentially the same type which were dry-coated with ingredient mixes of the same formulations after the strips were similarly treated, blended, and superficially dried. In some of these tests, the drycoated strips were parfried, frozen, and then reconstituted, while in other tests, the drycoated strips were simply frozen and later finish-fried directly to a ready-to-eat status. In all such tests, much the same kind of improvements were observed in crispness, tenderness, flavor, and other such hedonic qualities, and essentially the same surprisingly extended holding times were provided, both under heat lamps and merely at room temperature. Also, there was little or no clumping of the dry-coated strips, either during freezing or subsequent deep frying.

The above description of the new and inventive coating formulation and related processes and procedures is considered that of the preferred embodiments only.

Modifications of the invention may occur to those skilled in the art and to those who make or use the invention after learning of these preferred embodiments. Therefore, it is to be understood that the embodiments described above are merely illustrative and should not be used to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.Data supplied from the esp@cenet database - Worldwide

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422.

WO0164044 - 9/7/2001

NUTRITIONAL FOOD BAR FOR SUSTAINED ENERGY


Inventor(s): MODY SEEMA K (US)

Applicant(s): WARNER LAMBERT CO (US); MODY SEEMA K (US)


IP Class: A23G3/00

E Class: A23L1/164C; A23L1/164B; A23G3/00


Priority Number: US20000186646P (20000302)

Family: WO0164044

Equivalent: WO0164044; CA2368475

Cited Document(s): US5413805; US3431112; US3992556; US4623546; EP0348196;

US4543262; US4859475; US3582336; US4871557

Abstract:


A nutritional food bar for providing sustained energy to the consumer is provided. The bar has a core, a coating, and comprises a mixture of vitamins, minerals, proteins, carbohydrates and fats. The core is a non-baked grain-based core comprised of at least one extruded rice crisp and at least one toasted puffed rice crisp. The coating is a confectioner's coating which is selected from chocolate and compound coatings.

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423.

WO0184953 - 11/15/2001

FOOD PRODUCTS FORTIFIED WITH CALCIUM AND METHOD OF

PREPARATION


Inventor(s): BALLMAN DARRYL J (US); CREEDON SEAN W (US); GEOFFRION JAMES

W (US); HEDE THOMAS D (US); LANGENFELD MATHEW F (US); TRAUTZ JONATHAN E

(US)

Applicant(s): GEN MILLS INC (US); BALLMAN DARRYL J (US); CREEDON SEAN W (US);

GEOFFRION JAMES W (US); HEDE THOMAS D (US); LANGENFELD MATHEW F (US);

TRAUTZ JONATHAN E (US)


IP Class: A23L1/10; A23L1/164; A23L1/18

E Class: A21D2/02; A23L1/10B; A21D13/08



Family: WO0184953

Equivalent:

Abstract:

WO0184953; CA2408015


Cooked cereal dough products are provided that are fortified with at least a 0.65 % calcium (dry weight basis) at least a major portion of which is supplied by calcium phosphate salts having a median particle size of 2 to 15 mu m. Dried cereal finished products such as Ready-to-Eat breakfast cereals are fabricated from cooked cereal doughs that can comprise even lightly colored cereal materials such as rice and/or corn (maize) and minor levels of other conventional cereal ingredients and calcium phosphate. Methods for preparing such calcium fortified cooked cereal compositions and dried cereal finished food products essentially comprise: (a) providing a calcium fortified cooked cereal dough or mass containing at least 0.65 % calcium (dry weight basis) at least a portion of which is supplied by calcium phosphate; (b) forming the lightly colored calcium fortified cereal dough into pieces; and (c) drying the pieces to form the present rice based finished food products fortified with high levels of calcium. Preferred are puffed RTE cereal pieces prepared by direct expansion from a twin screw cooker extruder.Claims:


WHAT IS CLAIMED IS : 1. Calcium fortified cooked cereal food product, comprising:

A. a cooked cereal dough product having a moisture content having a moisture content of about 1% to

30%; and,

B. sufficient amounts of a calcium phosphate salt to provide a total calcium content of at least 0.65%

(dry weight basis).

2. The food product of claim 1 wherein the cooked cereal dough is in the form. of pieces ranging from about 0.1 to 5 gram in weight.

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3. The food product of claim 2 wherein the pieces having a moisture content of about 2to5%.

4. The food product of claim 4 wherein the pieces having a density of about 0.2 to 0.4 g/cc.

5. The food product of claim 1 wherein at least a portion the calcium phosphate salt is tricalcium phosphate.

6. The food product of claim 5 additionally comprising calcium carbonate.

7. The food product of claim 6 wherein the weight ratio of calcium phosphate salt to calcium carbonate is greater than 1 :1.

The food product of claim 5 wherein the calcium phosphate salt has an median particle size ranging from about 2 to 15 microns.

8. The food product of claim 3 wherein the food product is a ready-to-eat cereal in the form of a flake, shred, biscuit, shredded biscuit, shredded mini biscuit, ring, alphanumeric, figurine, sphere or mixtures thereof.

9. The food product of claim 8 wherein the calcium phosphate salt is present in sufficient amounts to provide a total calcium content of at least 1.5% (dry weight basis).

10. The food product of claim 9 wherein the calcium phosphate salt is present in sufficient amounts to provide a total calcium content of at least 3% (dry weight basis).

11. The food product of claim 2 wherein the food product is in the form of a dough having a moisture content of about 25% to30%.

12. The food product of claim 2 wherein the food product is in the form of cooked cereal dough pellets or half products having a moisture content of about 10% to 18%.

13. The food product of claim 2 wherein the food product is in the form of cooked cereal dough R-T-E cereals having a moisture content of about 3% to5%.

14. The food product of claim 13 additionally comprising a sugar coating.

15. The food product of claiml. wherein dough is a light colored cooked cereal dough comprising about 40% to 97% rice, corn (maize), oat, and mixtures thereof.

16. The food product of claim 15 wherein the light cooked cereal dough comprises about40% to97% rice.

17. The food product of claim 15 wherein the light cooked cereal dough comprises about40% to97% corn.

18. The food product of claim 4 wherein the calcium phosphate salt has an median particle size of about 5 to 12 microns.

19. The food product of claim 18 wherein the calcium phosphate salt is tricalcium phosphate.

20. The food product of claim 1 wherein the cooked cereal dough is substantially free of a calcium sequestrant (such as is selected from the group consisting of phosphate salts, edible organic acids,

EDTA and mixtures thereof).

21. A method of providing calcium fortified cooked cereal dough products, essentially comprise the steps of:

A. providing a cooked calcium fortified cereal dough or mass having a moisture content of about 10 to35% moisture, and sufficient amounts of a calcium phosphate salt to provide a total calcium content

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of at least 0.8% (dry weight basis) having an median particle size of about 2 to 15 microns; B. forming the calcium fortified cereal dough or mass into calcium fortified cereal dough pieces; and,

C. drying the calcium fortified cereal dough pieces to form the finished cooked cereal dough products fortified with high levels of calcium.

22. The method of claim 21 additionally comprising up to about 0.5% of the calcium carbonate.

23. The method of claim 22 wherein at least a portion of the calcium carbonate is supplied by ground limestone.

24. The method of claim 23 wherein the calcium carbonate has an median particle size of no larger than

15 microns.

25. The method of claim 20 wherein the cooked cereal dough is lightly colored and comprises corn, rice, oats and mixtures thereof.

26. The method of claim 20 wherein the food product is in the form of cooked cereal dough pellets or half products having a moisture content of about10% to 18%.

27. The method of claim 20 wherein the food product is in the form of cooked cereal dough R-T-E cereals having a moisture content of about 3% to5%.

28. The method of claim 25 wherein the light cooked cereal dough comprises about40% to 97% rice, corn (maize) and mixtures thereof.

29. The method of claim 28 wherein the light cooked cereal dough comprises about 40% to97% rice.

30. The method of claim 20 drying the cooked cereal dough to a moisture content of10% to 20% prior to forming into pieces.

31. The method of claim 20 wherein the forming and drying steps are practiced simultaneously.

32. The method of claim 20 comprising insoluble calcium material in a quantity sufficient to bring the total calcium content of the food product composition to from about 0. 1% to 10% by weight (dry basis).

33. The method of claim 20 wherein the dough comprises about 5% to 10% sugar.

34. The method of claim 20 additionally comprising the step of toasting.

35. The method of claim 20 additionally comprising the step of applying a sugar topical coating.

36. The method of claim 31 additionally comprising the step of applying a sugar topical coating.

37. The method of claim 20 wherein the forming and drying steps are practiced by direct expansion from a twin screw extruder.

38. The method of claim 20 steps A, B, and C are each practiced in with the same twin screw cooker extruder.

39.-The method of claim 38 wherein the calcium is supplied by tricalcium phosphate, dicalcium phosphate and mixtures thereof and comprises about 1% to 3.5% of the cooked cereal dough.

40. The method of claim 40 wherein the finished cooked cereal dough products have a density of about

0.2 to 0.5 g/cc.

41. The method of claim 41 wherein the calcium has an median particle size of about 4 to 10 microns.

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42. The method of claim 20 wherein step A includes admixing the calcium phosphate with dry cereal ingredients and water and cooking to form the calcium fortified cooked cereal dough.

43. The method of claim 40 wherein the finished cooked cereal dough products are in the form of spheres.

44. The method of claim 20 wherein at least a portion of the drying step is practiced by gun puffing pellets having a moisture content of about 10 to14%.

45. The method of claim 20 wherein the cooked cereal dough comprises about 1% to about 40% of a soy ingredient. 46. The method of claim 43 wherein the calcium content of the cooked cereal dough ranges from about5% to 10% and additionally comprising the step of applying a topical sugar coating to the puffed finished cereal dough products.

47. The method of claim 20 wherein the drying step comprises deep fat frying.

48. The method of claim 21 wherein the phosphate salts, comprises tricalcium phosphate.

49. The method of claim 47 wherein the cooked cereal dough comprises about 0.01% to1% of a leavening agent.

50. The food product prepared by the method of claim 20.






56.. The food product prepared by the method of claim 26.













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69. The food product prepared by the method of claim 39.Data supplied from the esp@cenet database -

Worldwide

2090/2197

424.

WO0195744 - 12/20/2001

OLD RICE IMPROVEMENT AND NUTRITION RICE MANUFACTURING

METHOD


Inventor(s): KIM SOON JA (KR)

Applicant(s): KIM DO YOUNG (KR); KIM SOON JA (KR)


IP Class: A23L1/182

E Class: A23L1/182

Application Number: WO2001KR00857 (20010524)

Priority Number: KR20000035460 (20000610)

Family: WO0195744

Cited Document(s):

KR20000138

KR85003494; KR96030812; JP9299047; JP64002544; KR99001987;

Abstract:


Disclosed are clean rice containing a glutinous rice ingredient and a method for producing the same.

The clean rice is produced by dipping rice in a solution of glutinous rice powder dissolved in water to coat and impregnate the solution on and into the rice, and polishing and drying the resulting rice. The clean rice containing a glutinous rice ingredient can provide a glutinousness for a desirable flavor of rice without being mixed with separate glutinous rice in cooking the rice.Description:


OLD RICE IMPROVEMENT AND NUTRITION RICE

MANUFACTURING METHOD

Technical Field

2091/2197

The present invention relates to a method for improving old rice and producing nutritional rice, and more particularly, the present invention relates to clean rice containing an ingredient of glutinous rice which is highly beneficial to the human body and a method for producing the same, the clean rice being produced by coating and impregnating a solution of glutinous rice powder dissolved in water on and into rice.

Background Art

As well known, rice is the preeminent food for the bulk of the global community. In these days, it has been recognized that, when boiling and eating rice, the rice can serve not only as means for simply making a living but also as supplementary means for promoting health. That is to say, by boiling and eating rice which contains an ingredient good for health, a person can spontaneously ingest the ingredient good for health.

Also, since glutinous rice has a high degree of glutinousness, when it is desired to ameliorate flavor of rice or make rice glutinous, rice is boiled in a state wherein it is mixed with a small amount of glutinous rice. In particular, if rice is boiled in a state wherein the rice gets stale or a quality of the rice is deteriorated due to damages by blight and harmful insects or defects in storage, the rice cannot be properly cooked and flavor of the rice can be impaired. Therefore, in this case, it is the norm that the rice is boiled while being mixed with glutinous rice. As a consequence, a method for fully satisfying fastidious taste of a person has been demanded. By progressing this standpoint, a base for changing wholehearted-to-feed nourishment which is currently pointed out as a problem, to adjustable nourishment, can be defined. On this basis, by producing nutritional rice for all of the global community, it is possible to lay a cornerstone of healthy rice development for all human beings.

Further, it is possible to emerge from a wholehearted-to-feed viewpoint for the principal food, and instead, it is possible to develop functional rice capable of adjusting faculty of the human body and rendering a nourishing meal.

Disclosure of the Invention

Accordingly, the present invention has been made in an effort to solve the problems occurring in the related art, and an object of the present invention is to convert old rice into rice having the same glutinousness as new rice, by coating and impregnating a solution of glutinous rice powder dissolved in water on and into the old rice, while polishing the old rice, employing a technique for polishing rice by making use of a wet-type rice polishing machine, and to allow delicious and glutinous flavor of the rice to be obtained by boiling the rice as it is without the need of mixing the old rice with separately prepared glutinous rice.

In order to achieve the above object, according to one aspect of the present invention, there is provided clean rice containing a glutinous rice ingredient, characterized in that a solution which is prepared by dissolving glutinous rice powder in water, is coated on a surface of rice to a predetermined fine thickness, and is deeply impregnated into the rice which includes an albumen.

According to another aspect of the present invention, there is provided a method for producing clean rice containing a glutinous rice ingredient, comprising the steps of: dissolving glutinous rice powder of

1 weight part into water of 3 to 8 weight parts and thereby preparing an aqueous solution of the glutinous rice powder; polishing rice while coating and impregnating the aqueous solution of the glutinous rice powder on and into the rice of 500 to 2,000 weight parts using a wet-type rice polishing machine; and drying the rice on and into which the aqueous solution of the glutinous rice powder is coated and impregnated.

By the features of the present invention, by coating and impregnating an ingredient of glutinous rice which is known to be highly beneficial to the human body, on and into rice, employing a technique for polishing rice by making use of a wet-type rice polishing machine, a person can spontaneously ingest the ingredient of glutinous rice. By this method, it is possible to convert, with glutinous rice of 10 Kg, old rice of 10,000 Kg into rice of good quality, having the same flavor and glutinousness as glutinous rice.

Brief Description of the Drawings

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The above objects, and other features and advantages of the present invention will become more apparent after a reading of the following detailed description when taken in conjunction with the drawings, in which:

FIG. 1 is an enlarged cross-sectional view illustrating clean rice in accordance with an embodiment of the present invention.

Best Mode for Carrying Out the Invention

Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawing.

First, glutinous rice is prepared and finely crushed. At this time, it is preferred that the glutinous rice is crushed to maximum fine powder having a size of no greater than30pm. Thereafter, by mixing the powder with water, the glutinous rice powder is dissolved in water, whereby an aqueous solution of the glutinous rice powder is prepared.

When rice of 10,000 Kg is to be polished, 40 litters of water and glutinous rice powder of 10 Kg are mixed with each other at a ratio which does not induce a saturated state.

Thereupon, after brown rice is prepared and before a next process for polishing the brown rice is implemented, the brown rice having a moisture content of less than 14% is stored in a reserve tank, and, at the same time, the prepared aqueous solution of the glutinous rice powder is primarily sprayed on the brown rice for about an hour using a water pump to impregnate the aqueous solution into the brown rice thereby to artificially raise a moisture content of the brown rice up to15%.

Then, in the course of polishing the rice, the prepared aqueous solution of the glutinous rice powder is secondarily sprayed on the rice using a wet-type rice polishing machine, whereby the rice is polished in a state wherein its moisture content is raised up to 16-17%.

Next, by air-drying the rice, production of clean rice according to the present invention, on and into which the aqueous solution of the glutinous rice powder is coated and impregnated, is completed. At this time, in order to avoid quality deterioration due to a great moisture content, the rice can be dried using a heatedair dryer for a predetermined period of time in a state wherein a temperature is adjusted to20 C, whereby production of clean rice according to the present invention, on and into which the aqueous solution of the glutinous rice powder is coated and impregnated, is completed.

In the clean rice produced in this way, the aqueous solution of the glutinous rice powder is coated on a surface of the rice to a fine thickness and is deeply impregnated into the rice which includes an albumen.

Preferably, a mixing ratio between the rice and the glutinous rice powder is from 2000: 1 to 500: 1 by weight. More preferably, a mixing ratio between the rice and the glutinous rice powder is from 1500: 1 to 800: 1 by weight. At this time, it is preferred that an amount of water which is required for dissolving 1 weight part of the glutinous rice powder is 3-8 weight parts.

In the present invention, due to the fact that an glutinous rice ingredient which is highly beneficial to the human body, is contained in the clean rice, it is possible to take a meal which has an elevated nutritive value, a savory odor and a high degree of glutinousness.

On the other hand, according to the present invention, in place of the glutinous rice powder, a variety of ingredients which are obtained from other grain and are beneficial to the human body, can be used.

In other words, by making an aqueous solution of grain powder and then producing clean rice by using the method according to the present invention, ingredients of grain can be adequately contained in rice.

Industrial Applicability

As described above, according to the present invention, it is possible to enjoy delicious and glutinous flavor of rice in a country where rice is regarded as the staple food. Namely, since flavor of rice, a nutritive value and an odor are improved or enhanced, an income of a farm household can be raised due to rice consumption increase. Further, it is possible to contribute to health promotion of a people.Data supplied from the esp@cenet database - Worldwide

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425.

WO8303184 - 9/29/1983



Inventor(s): BLACKWOOD GRAEME CHARLES (GB)



IP Class: A23L1/10

E Class: A23L1/182; A23L1/16; A23L1/105B

Application Number: WO1983GB00077 (19830316)


Family: WO8303184

Equivalent: EP0103604; FI834056; ES8402704; PT76367; IT1161643; GR77156

NL279192; US3950543; DE2362530; FR1519391; US1363193; Cited Document(s):

JP50012289

Abstract:


A rapid cooking food product, especially a rice or a pasta is produced by treating the food product with a starch degrading enzyme under starch degrading conditions. The enzyme is an enzyme which attacks either the 1,4-glucoside links or the 1,6-glucoside links in the starch molecules and is preferably alpha amylase or pullulanase or a mixture thereof. Rice that can be cooked merely by pouring on boiling water and leaving it to stand can be produced by the process.Description:



This invention relates to rapid cooking foodstuffs, for example starchy cereal grains such as rice, wheat, oats, etc., and flour products such as pastas.

Numerous attempts have previously been made to produce a form of rice that cooks in a considerably shorter time than that which is normally required for cooking rice, whether it be husked, dehusked, milled, unmilled, parboiled or non-parboiled rice. The majority of these attempts have revolved around disrupting the structure of the rice grain to allow easy and rapid access of cooking water into the grain.

These methods which have normally been either mechanical or physical have for example involved crushing or flaking the rice grains, expanding or puffing the rice grains by heating water contained therein under pressure then rapidly releasing the pressure, or producing surface cracks in the grains by drying them.It hasalse been proposed to produce a fast cooking rice by steeping rice grains in water or a chemical solution, for example sodium chloride, for a substantial period prior to drying.

These prior methods have produced fast cooking rices that differ in terms of speed, convenience of preparation, organoleptic characteristics of taste, texture and mouthfeel, appearance in the dry and cooked form and the presence of chemicals in the end product.

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It is particularly desirable to produce a satisfactory rice product that can be cooked merely by covering the rice grains with boiling water.

This invention provides a process for producing a rapid cooking starchy foodstuff such as, for example, cereal grains and pasta, which comprises subjecting the foodstuff to the action of one or more starch degrading enzymes under starch degrading conditions.

The starch degrading enzymes are those that attack the 1,4-glucoside links or the 1,6-glucoside links.

As examples of those enzymes that attack the 1,4-glucoside links there may be mentionedamylase (an endoamylase),ss -amylase (an exoamylase) and amylomaltase, which enzymes have the Enzyme

Numbers 3.2.1.1., 3.2.1.2., and 2.4.1.3., respectively. As enzymes that attack the 1,6-glucoside links there may be mentioned pullulanase, isoamylase anddextrine-l,6-glucosiddase, which enzymes have the Enzyme

Numbers 3.2.1.41., 3.2.1.68., and 3.2.1.33, respectively.

These enzymes all serve to degrade the starch granules in the starchy foodstuff by breaking the linkages in and between the individual starch molecules of the starch granule.

The enzymes, for example those described hereinbefore may be used singly or in combination but preferablya amylase or pullulanase or a mixture thereof are used.

The enzymes are usually operative at a temperature within the range of from about 200C to1200 and can be used under pH conditions ranging from approximately 3 to 9. Individual enzymes of a given type, however, depending on their source, will normally operate at optimum efficiency under fairly narrow process conditions within the ranges specified, these conditions normally being specified by the manufacturer.

The enzymes may be used in any concentration above the minimum concentration at which the enzyme activity is so slow as to be negligible but is preferably not used in a concentration of more than

30 thousand enzyme units per kilogram of foodstuff to be treated although this is merely an economic limit since concentrations greatly in excess of this could be used without producing any advantage.

Preferably the'concentration of enzymes used is such that the enzyme treatment to produce a desired product can be continued for a period within the range of from 5 minutes to 24 hours, preferably from

30 minutes to 4 hours.

The period of exposure to the enzyme is related to the concentration of enzyme used and is primarily determined by the amount of degradation required, the higher the concentration of enzyme the shorter the period of exposure needed to achieve a given degree of degradation. The treatment is carried out until a desired proportion of the links in and between the individual starch molecules forming the starch granule are broken.

The exact proportion desired to be broken depends on the nature of the product desired but it is necessary to strike a balance between the desired rapid cooking time and the need to retain the desired organoleptic and other characteristics of the product. After treatment the product is dried to a moisture content at which the product has adequate stability against spoilage to enable satisfactory packaging, storage and distribution.

If desired, enzyme activity can be removed at any one of several stages following the action of the enzyme on the starch grains by the use of conventional technigues, e.g. pH adjustment and raising to high temperatures.

Rice grains to be treated according to the invention may be in any form such as for example, paddy, cargo, brown, white or parboiled rice grains. Other cereals that can be treated are for example wheat and oats, and cereal flour products such as pasta, for example macaroni and spaghetti.

It is possible to combine the enzyme treatment of the invention with a parboiling treatment of paddy or cargo rice whereby the enzyme is added to any steeping stage of the various parboiling processes.

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If it should be desired to obtain extremely rapid contact of the enzyme with the centre of the cereal product, especially when rice is treated, it is possible to subject the grains to a conventional technigue such as vacuum infiltration and/or rolling to produce cracks in the surface of the grain.

Although the enzyme treatment alone produces a product that can be cooked very much more quickly than the corresponding untreated product, (in the case of rice, for example, the cooking time can be reduced to 6 minutes or less) the cooking time of the foodstuff can be considerably further reduced if, during or after the enzyme treatment, the foodstuff is contacted with an electrolyte, especially a common food approved electrolyte such as, for example, sodium or potassium chloride or sodium or potassium iodide or sodium glutamate.

Very quick cooking can be achieved by heating the product after the enzyme treatment, for example for a period of about 5 minutes in water with or without an electrolyte such as one of those described above.

The treatment of the invention in addition to providing a rapid cooking foodstuff, for example rice that can be cooked in under 10 minutes and especially in under 5 minutes and more ideally can be cooked merely by pouring boiling water over the grains, also provides a rice with a lower starch content per rice grain and which may therefore be described as being a "dietrice".

The following Examples ilustrate the invention. In the Examples the references to "enzyme units" are references to the amount of enzyme that under standard conditions has a standard effect. In the case of pullulanase the standard conditions are that on 2% pullulan concentration and a temperature of

450C,pH 7.0 and over a reaction period of 30 minutes one enzyme unit hydrolyses pullulan liberating reducing carbohydrate with a power equivalent tol micromole of glucose per minute. For amylase the enzyme unit is defined as the amount of enzyme that breaks down 5.26 grams of solublestarch per hour under standard conditions of temperature 370C pH 5.6 and calcium 0.0043 m. All the enzymes used in these Examples were obtained from NOVO Industri A/S. The pH in all the following examples was approximately 6.5 but no attempt was made to control the pH.

EXAMPLE 1

100 grams of parboiled rice was soaked for 4 hours at 300C, in 500 mls. of water containing 7.5 grams

(6000 enzyme units) of powdered pullulanase. Preferably throughout the soaking period the mixutre was stirred. At the end of the soaking period the excess liquid was drained off, at which time the hydrated rice had a weight of 212 grams. The rice was then dried to a moisture content at which the product was stable, that is to say to a water activity (Aw) less than 0.5. Rice produced by this process could be cooked in boiling water within 10 minutes and the cooked rice showed no tendency to clumping, being fluffy and consisting of separate grains.

EXAMPLE 2

200 grams of parboiled rice was soaked for 2 hours at 450C in 1 litre of water containing 4,800 units of pullulanase and 720 units of bacterialci -amylase. At the end of the period of incubation 20 grams of salt was added and the mixture boiled for 5 minutes. The excess water was drained off and the rice dried overnight at 300C to an

Aw >; 0.5. The product could rehydrated and made ready for eating by pouring on boiling water and leaving to stand for 3-5 minutes.

EXAMPLE 3

200 grams of parboiled rice was soaked for 2 hours at 450C in 800 ml of water containing 4,800 units of pullulanase and 1,200 units of fungal a- amylase. The mixture was incubated with stirring. At the end of the period of incubation 20 grams of salt was added and the mixture boiled for 2 minutes.

Excess water was drained off and the rice dried at 300C for 24 hours to anAw >; O.S.

The rice could be cooked by adding boiling water and leaving to stand for 5 minutes.

EXAMPLE 4

200 grams of parboiled rice was soaked for 2 hours at 450C in 800 ml of water containing 1,200 units of bacterialamylase. At the end of the period of incubation 30 grams of salt was added and the mixture

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boiled for 5 minutes. Excess water was drained off and the rice dried at 300C for 24 hours to an Aw >;

0.5. The rice could be cooked by pouring on boiling water and leaving to stand for 3-5 minutes.

EXAMPLE 5

Three samples of wheat were taken:

1. Was soaked overnight at room temperature.

2. Was parboiled for1 hours

3. Was not pretreated;

Samples 1 and 2 were dried overnight at400C.

200 grams of each sample were soaked in 800 ml of water containing 4,800 units of pullulanase and

1,200 units of bacterial a-amylase for 2 hours at 450C. At the end of the incubation period 20 grams of salt was added to each sample followed by boiling for 5 minutes. The samples were dried overnight at

400C. The cooking times were:

1.li hours.

2. 45 minutes.

3. 1 hour.

Untreated wheat had to be cooked forlh hours to reach a similar texture.

EXAMPLE 6

200 grams of spaghetti was soaked for 20 minutes at 450C in 800 ml-of water containing either:1.

4,800 units of pullulanase and 600 units of bacterial

a-amylase, or 2. 1,200 units of bacterial a-amylase.

At the end of the incubation period the spaghetti was dried in a fluid bed drier at 500C. Each spaghetti produce was cooked after 3 minutes in boiling water.

EXAMPLE 7

Example 2 was repeated except that milled, non-parboiled rice was used and the boiling period was reduced to 1 minute. The product could be cooked in less than 5 minutes in boiling water, it was however more sticky than when parboiled rice was used.

EXAMPLE 8

100 g of parboiled rice was soaked for 2 hours at 450C in 500 ml of water containing 4,800 units of pullulanase and 250 units of bacterial a-amylase. Excess liquid was drained off and the rice dried at30

C for 24 hours to an Aw >; 0.5. The rice could be cooked by boiling for 6 minutes.

EXAMPLE 9

100 g of brown rice was soaked for 4 hours at 500C in 500 ml of water containing 8,000 units of pullulanase. At the end of the period of incubation 10 g of salt was added and the product boiled for 2 minutes. The rice was dried to an Aw >; O.5 and could subsequently be cooked by boiling for 15 minutes compares with an untreated standard which required 30 minutes to achieve a similar texture.

EXAMPLE 10

500 g of paddy rice was placed under vacuum and 5 litres of water containing 5,000 units of pullulanase was then added. The treatment was continued for 2 hours at 500C. The rice was then parboiled and milled using conventional processes. This rice was found to be cooked in 13 minutes in boiling water compared with 18 minutes required to obtain the equivalent texture in a standard parboiled rice, which has been produced by the sameparboiling and milling method but with a pretreatment of 2 hours in water at 500C without enzyme.

EXAMPLE 11

240 units of Termamyl 120L, a high temperature active bacteriala-amylase, was added to 1 kg of water at 900C.

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This was then mixed with 1 kg of milled, parboiled rice and the temperature was increased to 950C for a period of 25 minutes. After this time 750 ml of water containing 0.1% citric acid was added and the mixture boiled for 8 minutes. The rice was then drained, and dried on a fluid bed drier at approximately

1100C until a moisture content of about 12% was achieved. The rice could be cooked by pouring on boiling water and leaving for 5 minutes.

EXAMPLE 12

To 1 litre of water at 900C, containing 240 units of

Termamyl 120L, 1 kg of milled, non-parboiled (white) rice was added. After 20 minutes at this temperature, any excess water was drained and the rice was steamed for 8 minutes. The rice was then dried on a fluid bed drier at1100C until approximately 122 moisture. This rice could be cooked in a similar manner to the produce of

Example 11.Data supplied from the esp@cenet database - Worldwide

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426.

WO8501860 - 5/9/1985

COATED FOODSTUFFS AND METHOD FOR PREPARING


Inventor(s): GERMINO FELIX J (US); AMATO VINCENT V (US)

Applicant(s): GERMINO FELIX J (--); AMATO VINCENT V (--)

IP Class 4 Digits: A23B; A21D

IP Class: A23B9/00; A21D15/08

E Class: A23L1/164B; A23L1/182B; A23L1/36B2



Family: CA1234716

Equivalent: EP0161268; IT1178175

US3784714; US3471304; US2468078; US2279203; US4160848; Cited Document(s):

US4299848; US4423082

Abstract:


A method for coating foodstuffs such as crisp rice with alkaline metal salts of stearic acid and the coated foodstuff. The food may be coated by immersion or spraying of a stearate dispersed in a carrier fluid onto the food. On heating, the stearate forms a substantially continuous film over the food, which retains the crunchy texture of the coated food in the presence of moisture.Description:


COATED FOODSTUFFS AND METHOD FOR PREPARING

This application relates to food products in general and more specifically, to a coated food product and a method for preparing such a coated food product which will retain its textural character in the presence of moisture.

Food products which are normally crunchy in nature and have a firm texture and chewy nature when fresh and recently prepared, have a tendency to become soggy and suffer a loss of texture through the passage of time and exposure to moisture-laden air. Good packaging techniques can generally extend the shelf life of such products.

However, once the package is opened a food product with a chewy texture and crunchy characteristic begins deteriorating immediately. Measures such as the addition of amounts of sucrose and other sugar alcohols to a granola mixture could, if mixed in the right proportions, retain the chewy characteristics of a granola mix bar for some time.

However, such formulations are ineffective in the retention of the crunchy characteristics of individual food particles in a mixture of other foodstuffs having contrasting characteristics. Thus, a food product with dual texture characteristics is not possible by the teachings of the prior art.

2099/2197

In attempting to prolong the shelf life and original character of various food products, many different coatings have been attempted. Foods have been coated with oil, dough, sugar, and fats, among other coatings. All of the above have been found unsatisfactory for one reason or another but primarily because of discontinuities in the film formed on the object being coated. In general, these coatings are permeable to moisture nonhydrophobic and merely delay the change in textural characteristics by only a short time at best.


Therefore, an object of the subject invention is a method for coating foodstuffs or food products in a manner which will maintain the crunchy and chewy textural characteristics of a food product in the presence of moisture.

Another object of the subject invention is a method of developing within grains the crunchy character of nuts.

Yet another object of the subject invention is a coated food product such as grains and nuts which are insensitive to water.

A still further object of the subject invention is a coating composition which, when applied to food products provides a crunchy, chewy character to the food product.

Further objects are attained in accordance with the present invention wherein there is provided a coating composition and a method for applying that coating composition to food products such as grains and nuts, which coating composition provides a measure of insensitivity to moisture in a food product. A continuous film or coating of an alkaline metal salt of stearic acid such as zinc stearate calcium stearate or magnesium stearate is applied to the food product, such as nuts and grain, in a manner which retains the original texture of that food product in the presence of moisture. Surprisingly enough, the taste of the original food product is not affected by the coating. A food product such as crisp rice may be coated by dissolving the stearate in hard fat and then applying the stearate and fat blend while hot to the crisp rice.In the alternative, the rice may be first coated with fat and then the zinc stearate may be dusted onto the fat coated rice and heated.

The novel features of the invention both as to the product and the method of making the product together with further objectives and advantages thereof will be better understood from the following description in which the presently preferred method and composition of the invention is set forth.


The coating composition of the subject invention comprises a metal salt of stearic acid such as zinc stearate, calcium stearate, or magnesium stearate in a carrier of fat or oil. The stearate used should be a uniform fine particle powder of high purity and food grade quality. The carrier may be a hydrogenated or partially hydrogenated fat or oil such as those as will be disclosed in the forthcoming examples.

Where the product itself can provide, or be the source of, the oil, as in some nuts, then the addition of the fat or oil becomes unnecessary, and the stearate need only be dusted on the product prior to heating.

In certain cases, the stearate may simply be dusted on perse, or dispersed in a suitable carrier and sprayed on.The heating step found in each of the examples is important for achieving a continuous or substantially continuous film over the food product being coated. As a result, the temperature and time of heating should be closely controlled in order to achieve the necessary water insensitivity and repellant properties. The method and coating composition of the subject invention will become more evident from the following examples.

EXAMPLE I.

In each of the experiments in the following table rice is heated in a pan coating apparatus. To the rice is added the oil and the mixture is agitated. After the rice becomes fully coated with the oil the zinc stearate is dusted onto the coated rice and then dried in an oven at 3000 F. for seven minutes. A simple taste test showed no evidence of off flavors or added flavor.

Rice Hydrogenated Fat Zinc Stearate Water Absorbed 1. 500g 0 0 32 ml 2. 500g 50g10g 18 ml 3.

500g 50g 20g 14 ml 4.500g 50g 30g 7 ml 5. 500g 50g 0 28 ml 6. 500g 0 30g 14 ml

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The above samples were evaluated for water absorption properties. The greater the amount of water absorbed the less effective the coating properties seem to be. In this evaluation 10.8 grams of the coated rice is dispersed in 300 ml of water and stirred for five minutes.

The solids are removed and the water volume noted. The difference noted in the water volume comprises an indication of the relative amounts of water absorption by the rice.

Thus, samples 1 and 5 show the least degree of coating, therefore,- a maximum water gain by the rice

EXAMPLE II

250g wheat flakes

25g hydrogenated palm oil

lOg zinc stearate

The wheat flakes were coated with the above ingredients using the method of Example I. The coated product was evaluated according to the method outlined in

Example I. The control product, i.e., the uncoated wheat flakes, absorbed 35 ml of water in the evaluation method of

Example I, while the test product, i.e., the coated product, absorbed 22 ml of water showing a relatively high degree of protection from moisture. No evidence of off taste or added tastes were noted.

EXAMPLE III

750g granola mix

75g fat

30g zinc stearate

The granola mix in this example was coated with zinc stearate in the same method as set forth in

Example 1. The resulting coated product was insensitive to moisture. The taste of the resulting product appears unaffected.

EXAMPLE IV.

Two grams of crisp rice coated as in Example I, sample No. 2 are mixed into cupcake batter mix. Two grams of uncoated crisp rice are also mixed into a cupcake batter mix for use as a control. The product is baked and tested for textural characteristics. The cupcakes containing the control uncoated rice tastes very gummy whereas the cupcakes containing the coated rice product is crunchy and firm, with no change in taste.

EXAMPLE V.

Ice cream mixes are blended with crisp rice, both coated according to the subject invention and uncoated. The ice cream blend is immediately frozen. Twenty-four hours later the ice cream blend containing the coated rice is firm and crunchy whereas the control product having the uncoated crisp rice has lost its textural properties being gummy and gel-like. The taste of the ice cream having the coated rice is not different from that of a fresh batch of uncoated crispy rice and ice cream.

EXAMPLE VI.

A granola bar mix is prepared according to the following:

Ingredients

5.5 crisp rice

8.0 chocolate chips

31.5 syrup matrix

52.5 granola mix

Syrup Matrix Ingredients

18.44 corn syrup

5.0 sugar

0.4 salt

2.7 shortening

3.6 honey

1.5 water

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The dry mix was heated to 100 F. and mixed with syrup matrix which had been preheated to 170 F.

The bars were formed as known in the art and evaluated for taste and texture. The bars containing coated rice at 5.5% level had a higher bulk density than control produt containing 9% crisp rice. In fact, the granola bar mix prepared from the uncoated rice had one third less volume than that prepared from the coated bar. A granola bar mix having98 uncoated rice is prepared according to the above recipe and procedure to form a control.The granola bars are formed, cooled and allowed to age for twentyfour hours. The granola bar containing the rice coated according to the subject invention is firm and crunchy whereas the control product has become gummy in that period of time. The taste of the granola bar did not appear to be affected by the coated crisp rice.

EXAMPLE VII.

The following coated cereal samples were prepared by heating the rice, pouring melted fat into a pan until the rice is fully coated, adding the zinc stearate and drying in a 3000 F. oven for seven minutes:

ZINC

CEREAL FAT STEARATE 7. 500 g 102 Rice 25 g 17D Fat 20 g

(Durkee's Soy

Base) 8. 500 g 102 Rice 50 g 17D Fat 20 g

(Durkee's Soy

Base) 9. 500 g 102 Rice 50 g 17D Fat 30 g

(Durkee's Soy

Base) 10. 500 g 102 Rice 50 g Paramount 20 g

XX (Durkee's

Palm Base) 11. 500 g 102 Rice 50 g 17D Fat 10 g 12. 500 g 108 Rice 25 g 17D Fat 20 g 13. 500 g 108

Rice 25 g 17D Fat 10 g 14. 108 Rice 25 g 17D Fat 30 g 15. 250 g Grainfield 25 g 17D Fat 10 g

Wheat Flakes 16. 250 g Natural Grain 75 g 17D Fat 15 g

Granola 17. 750 g Natural Grain 75 g 17D Fat 30 g

Granola

In the following sample 35 grams of fat was first

poured into the pan to coat the rice and then the zinc

stearate was added to the coated rice. The remainder of

the fat was then added to form double fat coating on the

rice.

18. 500 g 102 Rice 50 g Paramount 15 g

XX (Durkee's

Palm Base)

In the following sample, the zinc stearate was

mixed with a shellac and then sprayed onto the fat

coated rice: 19. 500 g 102 Rice 50 g 17D Fat 10 g

In the following sample, the rice is coated with 25

grams of fat addition to the pan and the zinc stearate

is then added. The balance of the fat is mixed with the

flavor and sprayed onto the coated rice to form a double

coated rice product having the zinc stearate in the

first coating and the flavor in the second and outer

coating: 20. 500 g 102 Rice 50 g 17D Fat 20 g

One tablespoon of each samples 2 through 20 coated as set forth above, is blended with four fluid ounces of vanilla ice cream and placed in a freezer set at 200 F.

Each ice cream cup is.hermetically sealed before being placed in the freezer. Control samples of four fluid ounces of vanilla ice cream with a tablespoon of crisp uncoated rice is likewise placed in a freezer in sealed containers.

A "tastetest is conducted every forty-eight hours by taking a spoonful of each sample and comparing the texture of the coated cereal in each sample as compared to the uncoated control samples. In these tests, the uncoated control samples produces a soft, mushy cereal whereas each of the coated rice product samples produces a variety of firm and chewy textures comprising the cereal and the ice cream.

In each taste test, no evidence of a taste attributable to the coating is found.

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Moisture absorption tests are performed on sample no. 7 the above coated samples and compared to a control uncoated rice product according to the procedure outlined in

Example I. Sample 7 is found to absorb 25 ml of water, while samples 8 and 10 absorb 12.5 ml of water. The control uncoated rice product absorbs 50 ml of water, which shows in comparison to the uncoated samples, a high resistance to the absorption of moisture as the result of coating with zinc stearate according to the subject invention.

The following examples, with duplicate ingredients and coating, and prepared according to the procedure utilized in preparing example 4 of Example I, are subjected to a variety of times and temperatures in the baking step, as indicated.

Hydro

genated Zinc Water

Rice Fat StearateTemp. (F0.) Time Absorbed 21. 500 g 50 g 30 g 2500 7 min. 31 ml 22. 500 g 50 g 30 g 2600 7 min. 30 ml 23. 500 g 50 g 30 g 2650 7 min. 12 ml 24. 500 g 50 g 30 g 3000 7 min. 7 ml

It becomes apparent that heating at about 2650 F. and above for the required period of time is necessary to achieve a substantially continuous film over the food product. The time required is that which is necessary to bring all components up to the required temperature. Thus, this time might vary with different ovens or different volumes being baked.

EXAMPLE VIII

As a further example, calcium stearate was dusted onto raw macadamia nuts which were then heated at

3600F for 8 minutes. Toasted macadamia nuts were likewise dusted and hated at3500F for 5 minutes.

The coated nuts were placed with uncoated control nuts in a high humidity enclave at 7580% R.H.

After 48 hours, the coated product was firm and crunchy, but the uncoated product was soft and not crunchy. No off flavors or additional flavors were noted.

EXAMPLE IX

Calcium stearate was dusted onto toasted coconuts which had first been heated and mixed with melted

Durkee KCS fat. The dusted nuts were placed in an oven at 3500F for 7 minutes alongside control nuts.

The coated nuts were crisp and crunchy in water, while the control nuts were soft and soggy. No difference was noted in flavor.

With the above examples, it should be noted that the stearate may be applied in any number of ways such as being dusted onto fat coated rice, as in Examples 1 through 6 and then heated at temperatures above 2650 F. or coated with a fat containing zinc stearate and then heated at temperatures above 2650

F. as shown in Examples 7-20. In the alternative, if the product to be coated is capable of exuding oil upon heating or by other means it may only be necessary to dust the heated product with the stearate of choice. Thus, it is important to note that the invention comprises the coating of a stearate such as calcium stearate, magnesium stearate or zinc to the food product in a manner which obtains a substantially continuous film over the food product.By such a process, not only can grains be given the crunchy character of nuts, but this crunchy character can be retained over a longer period of time and in the presence of moisture as well. In addition, by the method and product of the subject invention food products containing a dual texture, such as liquid or semi-liquid products with crunchy nuggets contained therein, or ice cream with crunchy particles within is possible.

It should also be noted, as shown in Example XII, that the stearate provides for a lighter extrudate, as well as apparently lubricating the extrusion process for a more even extrusion flow with less screw wrap.

EXAMPLE X

In the following example, crisp rice is coated with magnesium stearate in the manner set forth in

Example

IX. The coated rice is mixed with caramel prepared according to any of several recipes known in the art. The addition of the coated rice to the caramel provides a high bulk and a crunchy character with no off taste. When the caramel is mixed with uncoated rice, the mixture soon becomes soggy and loses its crunchy character entirely.

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EXAMPLE XI

Haystacks were prepared according to the following recipe:

Grams Ingredient

50 granulated sugar

25 brown sugar

100 corn syrup

60 condensed milk

20 Paramount C crystals

10 butter

1.5 salt

Mix the above ingredients thoroughly and heat to 2480F; add the following:

20 Invert sugar

100 Fondant

1.5ml butterscotch flavor

50 crisp rice (coated

with calcium stearate

as in Example IX)

80 small pecan pieces

Mix thoroughly while still hot and let cool. The haystack candy formed from the cooled mixture above was crunchy, firm and did not impart a gummy or off taste to the product.

More coated crisp rice could be added and the amount of pecan pieces further decreased, with only minimal effects on taste and texture. Thus with more inexpensive coated rice and less costly pecan pieces, better cost control can be achieved without sacrificing quality.

Each of the above Examples I through XI shows no evidence of extraneous tastes being added to the product on coating by the composition and method of the subject invention. The taste can be affected greatly by the quality, nature and amount of the fat or oil used to initially coat the product. Thus, it is possible to achieve a different taste sensation by the selection of the fat or oil, as desired. Should no additional taste be desired then the oil or fat selected for use should be bland and substantially tasteless, as those used in the accompanying examples.

EXAMPLE XII.

Two pounds of calcium stearate are blended with 100 pounds of flour. The flour is formed of 95 parts wheat flour, 5 parts sucrose. The flour/stearate mixture is blended with water to yield a dough with a moisture content of 17%. The dough is heated in an extruder and forced through the extruder die orifice or opening where it is flash dried and toasted. An identical product was made without the addition of calcium stearate. The product to which calcium stearate was added had a less dense, i.e., more expanded product, experienced more uniform cutting at the die face, extruded easier with no screw wrap and provided a finished product which was water resistant. The control product, i.e., no stearate, absorbed water quickly to become soggy and difficult to extrude in an efficient manner.

EXAMPLE XIII.

Two kg of fresh potato chips are placed in a pan of oil heated to 3000 F. To the oil is added calcium stearate at a 4% level. The chips are removed, dried, and allowed to stand at 850F and408 RH. After

24 hours, the product was still firm and crunchy, whereas the control (no stearates added) was soft and soggy.

EXAMPLE XIV.

Two kg. of extruded rice and corn blend are prepared with two percent calcium stearate as set forth in

Example XII. The extrudate is placed in a heated enrober and blended with 80 grams of heated fat. 80 grams of magnesium stearate are dusted onto the fat coated extrudate and then the entire coated extrudate is heated to approximately 3600F for one minute. The finished product, having both internal and external stearates was very hydrophobic, being so much so that it floated on water.

2104/2197

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.Data supplied from the esp@cenet database - Worldwide Claims:


We Claim:

1. A food product having a substantially continuous

coating of an alkaline metal salt of stearic acid.

2. The food product of claim 1 wherein said alkaline

metal salt of stearic acid is selected from the group

of zinc stearate, magnesium stearate, and calcium

stearate.

3. The food product of claim 1 wherein the food product

has a coating selected from the group of partially

hydrogenated fat and partially hydrogenated oil.

4. The food product of claim 1 wherein said alkaline

metal salt of stearic acid is dispersed in a suitable

carrier means.

5. The food product of claim 2 wherein said initial

coating provides no additional taste to said food

product.

6. The food product of claim 1 wherein the food product

is selected from the group of crisped rice, cereal

grain flakes, granola mix, potato chips, corn chips,

and nuts.

7.- A food product having a first and a second component,

said first component having a soft moist texture, said

second component being a food item having a crunchy

texture and being immersed in said first component,

said second component being coated with a stearate

selected from the group of zinc stearate, magnesium

stearate, and calcium stearate for providing

resistance to moisture in said first component and

thereby retaining a dual texture in said food product

for a longer period of time.

8. The food product of claim 5 whereby said stearate

forms a substantially continuous film over said second

component.

9. The food product of claim 5 wherein said second

component comprises said stearate dusted over said

food item and heated, said food item having previously

been coated with an oil.

10. The food product of claim 5 wherein said second

2105/2197

component is selected from the group of crisp rice,

wheat flakes, granola mix, potato chips, corn chips,

and nuts.

11. The food product of claim 5 wherein said first

component is selected from the group of baked goods,

ice cream and confections.

12. A method for preparing a food product having crunchy

characteristics and which is resistant to moisture

comprising the steps of:

i. contacting the food product with an alkaline

metal salt of stearic acid to form a

discontinuous film about said food product,

and

ii. heating said food product to a temperature and

for a time sufficient to form a substantially

continuous film about said food product for

retaining said crunchy characteristics in the

presence of moisture, without affecting taste.

13. The method of claim 10 wherein prior to contacting the

food product said stearate is first mixed with a

carrier means.

14. The method of claim 10 wherein said stearate is dusted

onto the food product coated with a material selected

from the group of partially hydrogenated fats and

partially hydrogenated oils.

15. The method of claim 13 wherein said stearate and

carrier means mixture is sprayed onto said food

product to form said coating.

16. The coated food product formed by the method of claim

12.

17. The method of claim 12 further including the step of

adding said coated food product to a second food

product of dissimilar textural properties to form a

dual texture food which will retain said dual texture

over a long period of time.

18. -A method for preparing a food product, comprising the

steps of:

(1) forming a dough;

(2) blending with said dough a stearate selected

from the group of calcium stearate, magnesium

stearate, and zinc stearate;

(3) placing said blended dough in an extruder;

(4) forcing said blended dough through an extruder

orifice to form an extrudate; and

(5) cutting said extrudate into discrete pieces

and drying by heating to form a finished

product.

19. The method of claim 1 wherein said extrudate is coated

with a stearate selected from the group of magnesium

stearate, calcium stearate, and zinc stearate for

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greater moisture resistance.

20. The food product formed by the method of claim 18.

21. A method for preparing a food product, comprising the

steps of:

a) forming a dough;

b) blending with said dough a stearate selected

from the group of calcium stearate, magnesium

stearate, and zinc stearate;

c) forming said dough into discrete pieces and

drying by heating to form a finished product

having said metal salt of stearic acid

distributed throughout said product for

maintaining the texture of said product.Data supplied from the esp@cenet database - Worldwide

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427.

WO8702224 - 4/23/1987

PREPARATION OF SAUCES


Inventor(s): FONTENEAU JEAN-LUC (FR); GERMON JEAN-PIERRE (FR)

Applicant(s): FLEURY MICHON SA (FR)


IP Class: A23L1/39; A23L1/04; A23L1/313

E Class: A23L1/0526; A23L1/39

Application Number: WO1985FR00284 (19851010)

Priority Number: WO1985FR00284 (19851010)

Family: WO8702224


FR2158323; US3300319; US3266908; US3598614; GB1355907; Cited Document(s):

US3300318; US4423084

2108/2197

Abstract:


Methods for the preparation of edible compositions of sauces and seasonings which comprise, as essential ingredient, a combination of rice starch and carob flour, which combination is intended to impart to said compositions desired consistency, unctuousness and stability characteristics. A method for preparing ready-cooked packaged food products of the type meat-in-sauce or fish-in-sauce, by means of the formulated sauce or seasoning compositions is also disclosed.Claims:


REVENDICATIONS

1. Procédé de préparation d!une composition de sauce ou d'assaisonnement qui comprend

le chauffage d'environ 1,5 à 2,5 parties en poids d'une graisse à1200C environ,

l'addition d'environ 1,5 à 2,5 parties en poids d'amidon de riz à la graisse chauffée afin qu'un premier mélange soit formé,

la cuisson du premier mélange à 1200C,

l'addition d'environ 70 à 90 parties en poids d'au moins un liquide tel que l'eau, l'huile, le jus de cuisson de viande, le jus de cuisson de poisson, le vin, le vinaigre ou un jus de légumes, au premier mélange afin qu'un second mélange soit formé,

le gonflement de l'amidon de riz. par contact avec le liquide afin que le second mélange soit épaissi,

le chauffage du second mélange épaissi à ébullition,

l'addition d'environ 0,3 à 1 partie en poids de farine de caroube et d'environ 4 à 26,7 parties en poids d'au moins un aromate ou un épice afin qu'un troisième mélange soit formé,

la cuisson du troisième mélange pendant un temps suffisant pour que la sauce ou l'assaisonnement voulu soit obtenu, et

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le mélange de la sauce ou de l'assaisonnement afin qu'une composition homogène soit obtenue.

2. Procédé selon la revendication 1, dans lequel la graisse et l'amidon de riz sont présents en quantités

égales.

3. Procédé selon l'une des revendications 1 et 2, dans lequel le premier mélange est cuit pendant 2 à 8 minutes environ.

4. Procédé selon l'une quelconque des revendications 1, 2 et 3, dans lequel au moins deux des liquides sont ajoutés au premier mélange.

5. Procédé selon l'une quelconque des revendi cations 1 à 4, dans lequel le liquide comprend une partie d'aromates ou d'épices, alors que le reste d'aromates ou d'épices est ajouté avec la farine de caroube dans le second mélange à l'ébullition.

6. Procédé selon l'une quelconque des revendications 1 à 5, comprenant en outre la réduction de la température du second mélange à 1000C environ après l'addition du liquide.

7. Procédé selon l'une quelconque des revendications 1 à 6, dans lequel le temps total de cuisson à partir du moment auquel le liquide est ajouté jusqu'au moment auquel la sauce ou l'assaisonnement voulu est obtenu, est d'environ 10 à 30 minutes.

8. Procédé selon l'une quelconque des revendications 1 à 7, dans lequel le mélange de la sauce ou de l'assaisonnement est assuré par un dispositif électrique de mélange.

9. Procédé de préparation d'un produit alimentaire emballé, qui comprend

la préparation d'au moins un ingrédient alimentaire cru de viande, de poisson ou de légumes, par nettoyage puis enlèvement des parties non comestibles ou indésirables de l'ingrédient alimentaire,

la découpe de l'ingrédient alimentaire à une ou plusieurs dimensions prédéterminées,

la cuisson de l'ingrédient 'alimentaire au degré voulu dans un fluide à base d'eau ou d'huile,

la décantation du fluide à base d'eau ou d'huile afin que les jus de cuisson 'de l'ingrédient alimentaire cuit soient récupérés,

la préparation d'une sauce ou d'un assaisonnement par

addition d'environ 70 à 90 parties en poids des jus de cuisson à un premier mélange d'environ 1,5 à 2,5 parties en poids d'une graisse et d'environ 1,5 à 2,5 parties en poids d'amidon de riz après cuisson du premier mélange à gonflement de l'amidon de riz par contact avec le liquide afin que le second mélange épaississe,

chauffage du second mélange épaissi à l'ébullition,

addition d'environ 0,3 à 1 partie en poids de farine de caroube et d'environ 4 à 26,7 parties en poids d'au moins un aromate ou épice afin qu'un troisième mélange soit formé,

cuisson du troisième mélange pendant un temps suffisant pour qu'une sauce ou un assaisonnement voulu soit obtenu, et

mélange de la sauce ou de l'assaisonnement afin qu'une composition homogène soit obtenue,

la disposition de parties pesées prédéterminées de l'ingrédient alimentaire cuit dans un paquet ou récipient,

l'addition d'une quantité prédéterminée de la sauce ou de l'assaisonnement dans le récipient,

la fermeture étanche du paquet ou récipient afin qu'un produit alimentaire emballé de façon étanche soit formé,

la pasteurisation du produit afin que les bactéries éventuelles soient détruites, et

le stockage du produit refroidi dans des conditions réfrigérées jusqu'à réchauffage ultérieur et service.

10. Procédé de préparation d'un produit alimentaire emballé, qui comprend

la préparation d'au moins un ingrédient alimentaire cru de viande, de poisson ou de légumes, par nettoyage puis enlèvement des parties non comestibles ou indésirables de l'ingrédient alimentaire,

la découpe de l'ingrédient alimentaire à une ou plusieurs dimensions prédéterminées,

la cuisson de l'ingrédient alimentaire au degré voulu dans un fluide à base d'eau ou d'huile,

la décantation du fludie à base d'eau ou d'huile afin que les jus de cuisson soient récupérés de l'ingrédient alimentaire cuit,

la préparation d'une sauce ou d'un assaisonnement par

2110/2197

addition d'environ 70 à 90 parties en poids des jus de cuisson à un premier mélange d'environ 1,5 à 2,5 parties en poids d'une graisse et d'environ 1,5 à 2,5 parties en poids d'amidon de riz après cuisson du premier mélange à1200C afin qu'un second mélange soit formé,

gonflement de l'amidon de riz par contact avec le liquide afin que le second mélange épaississe,

chauffage du second mélange épaissi à l'ébullition,

addition d'environ 0,3 à 1 partie en poids de farine de caroube et d'environ 4 à 26,7 parties en poids d'au moins un aromate ou épice afin qu'un troisième mélange soit formé,

cuisson du troisième mélange pendant un temps suffisant 'pourqu'une sauce ou un assaisonnement voulu soit obtenu, et

mélange de la sauce ou de l'assaisonnement afin qu'une composition homogène soit obtenue,

l'addition d'une quantité prédéterminée de la sauce ou de l'assaisonnement dans le récipient,

la disposition de portions pesées prédéterminées de l'ingrédient alimentaire cuit dans un paquet ou récipient,

la fermeture étanche du paquet ou récipient afin qu'un produit alimentaire emballé de manière étanche soit formé,

la pasteurisation du produit afin que les bactéries éventuelles soient détruites, et

le stockage du produit refroidi dans des conditions réfrigérées jusqu'à réchauffage ultérieur et service.

11. Procédé selon l'une des revendications 9 et 10, dans lequel les ingrédients alimentaires sont obtenus à l'état congelé et sont dégelés avant préparation.

12. Procédé selon l'une quelconque des revendications 9 à 11, dans lequel l'ingrédient alimentaire est cuit en étant sauté dans l'huile chaude à 1800C environ, par mijotage dans l'eau bouillante à environ

1000C ou par une combinaison de telles cuissons.

13. Procédé selon l'une quelconque des revendications 9 à 12, dans lequel l'ingrédient alimentaire est cuit pendant 7 minutes à 2 heures.

14. Procédé selon l'une quelconque des revendications 9 à 13, dans lequel l'ingrédient alimentaire est emballé dans des récipients de matière plastique à base de polyéthylène haute densité recouvert par thermosoudage d'un film de matière plastique à deux couches comprenantune couche d'un polyamide liée à une couched'un polyéthylène de densitémoyenne, la face du polyamide du film étant tournée vers l'ingrédient alimentaire.

15. Procédé selon l'une quelconque des revendications 9 à 14, dans lequel les paquets ou récipients sont soudés hermétiquement sous un vide compris entre 400 et 600 torr (millimètres de mercure).

16. Procédé selon l'une quelconque desrevendica tions 9 à 15, dans lequel l'étape de pasteurisation comprend l'immersion des paquets ou récipients étanches dans un bain d'eau chaude à une température comprise entre 90 et 1060C et pendant un temps compris entre 30 minutes et 2 heures.

17. Procédé selon l'une quelconque des revendications 9 à 16, dans lequel les produits emballés sont stockés en étant réfrigérés à une température -comprise entre 0 et 70C pendant un temps compris entre

4 et 8 semaines.

18. Procédé selon l'une quelconque des revendications 9 à 17, dans lequel les produits emballés sont réchauffés par immersion dans l'eau bouillante ou par chauffage par des micro-ondes.

19. Procédé selon l'une quelconque des revendications 9 à 18, dans lequel toutes les étapes de traitement sont complètement automatisées dans une chaîne continue de production.

20. Procédé d'amélioration de la consistance, de l'onctuosité et de l'uniformité d'une composition de sauce ou d'assaisonnement qui comprend

l'addition d'amidon de riz à la composition en quantité suffisante pour qu'il joue le rôle d'un agent

épaississant principal, et

l'addition de farine de caroube à la composition en quantité suffisante pour qu'elle joue le rôle d'un agent liant,

les quantités relatives d'amidon de riz et de farine de caroube étant telles que le rapport pondéral de l'amidon de riz à la farine de caroube est compris entre 2,5/1 et 5/1 environ.

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21. Procédé selon la revendication 20, dans lequel la quantité d'amidon de riz est comprise entre environ 1,5 et 2,5 % du poids de la composition globale, et la quantité de farine de caroube est comprise entre environ 0,3 et 1 % du poids de la composition globale.Data supplied from the esp@cenet database - Worldwide

2112/2197

428.

WO8800797 - 2/11/1988

RICE CAKE MACHINE


Inventor(s): PELS MICHAEL (AU)

Applicant(s): REAL FOODS PTY LTD (AU)

IP Class 4 Digits: A23L; A21B

IP Class: A23L1/10; A23L1/18; A21B1/42; A21B5/02

E Class: A23L1/18C2; A21B5/02

Application Number: WO1987AU00239 (19870729)

Priority Number: AU19860007177 (19860729)

Family: WO8800797

Cited Document(s): US4328741; AU4821285; FR1087548

Abstract:


The production of a cooked rice cake, or other grain-food products, including the steps of introducing a mixture for the product into a heated mould cavity, compressing the mixture while cooking, momentarily venting steam from the cavity, sharply increasing the cavity during popping of the grain, pausing with said increasing cavity to permit setting of the product, and then opening the mould cavity and removing the product.Description:


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DESCRIPTION

RICECR2KE MACHINE

TECHNICAL FIELD

This invention relates to a cooking machine, particularly useful in cooking rice cakes, sometimes known as rice wafers. These rice cakes are a puffed rice crispbread type product. The invention is also suitable for the cooking of other forms of grain food.

BACKGROUND ART

Automatic machines for the making of rice cakes are known and incorporate a mould formed by a generally cylindrical continuous, upright side wall with open ends closed by respective end walls reciprocally movable towards and away from each other and which closely fit within the cylindrical wall. Heating elements are included and serve to control the temperature within a predetermined operating range. An uncooked rice mixture is introduced into the mould and crushed before cooking.

After a short period to allow for cooking the top end wall is withdrawn at a constant rate until it clears the side wall, and subsequently the cooked rice cake is ejected, or removed, fromthe mould.

There is a relatively high rejection rate of products from the existing process, due to a deterioration in appearance and texture in some instances. The product is in the shape of a cylindrical cake and the appearance of its upper marginal edge portion is often unacceptable, as well as its texture. This effect appears to result from a sudden drop in pressure upon the cake as the top end wall leaves the side wall.


The present invention has its basis in the theory that a better product should be obtainable with strictly controlled pressure maintained in the mould during cooking, with substantial reduction thereof before the top end wall is completely withdrawn from the mould. As it has been found that at a pedictable point in the cooking cycle the rice seeds "pop", or explode, provision should be made to accommodate this phenomenon.

It is therefore an object of the present invention to provide a cooking machine for rice cakes which will provide a a consistently good product.

In accordance with the present invention there is provided a method of producing a cooked grain-food product such as a rice cake, comprising introducing a cookable mixture for the product into the cavity of a heating mould, applying compression to said mixture by reducing the volume of said cavity, maintaining said compression for a first period of time, momentarily increasing the volume of said cavity for the venting of steam, maintaining heating of said mixture for a second predetermined period of time, sharply increasing the volume of said cavity at the completion of said second period, pausing in the increase of said volume for a third predetermined period of time before opening said cavity, and then removing the cooked product from said mould.

The invention also provides a cooking machine for a grain-food product, such as a rice cake, comprising a mould defining a cooking cavity and having a tubular side wail and first and second end walls for closing the ends of said side wall;

power means for independently moving said first and second end walls along the axis of said side wall for variation of the volume of said cooking cavity;

heating means for said mould; a three-position solenoid controlled fluid valve controlling said power means for movement of said first end wall; and

an electronic control circuit for controlled energizing of said fluid valve to effect a pause during retraction of said first end wall from said cavity.

In the above described machine it is preferred that the end walls include the heating elements. The second end wall preferably includes an outer tapered periphery which, by interference, sealsagainst a cooperative lip at one end of the side wall with movement of the second end wall towards the lip.

The cross-sectional shape of the end walls will correspond to the cross-sectional shape of the tubular side wall as well as the shape of the rice cake which will generally have a circular or rectanguTar body.

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It is also preferred that the first end wall when fully retracted be sufficiently external of the moulding cavity so as to allow access thereto by a cookable mixture supply tool which, under the control of the control means, provides a measured quantity of cookable mixture to the moulding cavity at the commencement of each cycle.

Another preferred feature is the ability of the second end wall to be raised to a position flush with the entry to the cavity so as to allow quick and easy removal of the cooked product after the cooking cycle.

In the above described method, especially in the case of cooking rice cakes, it is preferred that immediately after the introduction of the cookable mixture end walls of the moulding volume are pressured together so as to evenly crush the cookable mixture in a heated state so as to fuse together the individual components. The end walls are then "bounced" by being momentarily separated and brought back together in a relative position so as to produce a moulding cavity of a size suitable for the cooking cycle. The purpose of bouncing is to vent steam generated from moisture in the mixture.

The expansion of the moulding cavity after the cooking period is preferably obtained by quick separation of end walls defining the moulding cavity to a relative position defining a larger moulding cavity. This larger moulding cavity is maintained for a short period of time, of from 0.3 to 0.5 seconds, followed by a further quick separation of the end walls. In this final separation the first end wall is completely removed from the moulding cavity while the second end wall is advanced through the side wall so as to allow easy removal of the cooked product.


By way of example only, one preferred form of the invention will now be described with reference to the accompanying drawings, in which:

Fig 1 shows by diagram the basic operational stages of the machine; and

Fig 2 is a diagrammatic representation of a cooking machine according to this invention.

MODES FOR CARRYING OUT THE INVENTION

The basic components of the cooking machine shown in Fig. 1 are a bottom end wall 1, top end wall 2 and an upright tubular side wall 3.

Preferably in a cross-section all of the walls 1, 2 & 3 are circular. As will be seen in the diagram both of the end walls 1 and 2 fit neatly and closely within the tubular side wall 3. Thus when the end walls 1 and 2 are in, for example, respective positions Al and 82, there is defined between the three walls 1, 2

& 3 a small moulding cavity 7 in which a suitable mixture may be initially compressed and heated.

Aswil be later described both the end walls 1 and 2 can be moved in various positions axially of the generally cylindrical side wall 3. This movement is produced by pneumatic cylinders.

A further basic component of the device is the food mixture supply mechanism 4. As will be later described mechanism 4 provides a dual purpose, firstly the supply of mixture to be cooked and secondly the removal of cooked rice cakes from the machine. Mechanism 4 is reciprocally movable in a generally horizontal direction and again this movement is provided by pneumatic devices. It will be appreciated that the gap shown between the side wall 3 and the end walls 1 and 2 is exaggerated for the benefit of clarity of the drawing. In practice this gap will be in the order of some hundredths of a millimeter.

Towards the bottom of end wall 1 is a tapered sealing surface 5.

When the end wall 1 is in position Al (as shown), the tapered surface 5 seals against the internal lip 6 of the side wall 3. This interference sealing between the end wall 1 and side wall 3 not only provides a positive seal at the bottom of the moulding volume but also provides a rigid abutment preventing further movement of the end wall 1 beyond the position

Al.

A further basic component of the cooking device is a microprocessor control device (shown in Fig. 2) which receives various signals from a thermo couple indicating temperature within the cavity 7, proximity switches indicating the relative position of movable components, and electronic clocks

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providing predetermined timing periods. As later described the microprocessor control device maintains the desired cooperation of component movements and cooking cycle. The cooking temperature is maintained between200"C and220cm.

In operation the device commences in the general state as shown in

Fig. 1. Heating elements within the end walls 1 and 2 raise the temperature of these components until the predetermined temperature is reached within the cavity 7. The mixture supply mechanism 4 then moves above the moulding cavity and introduces a controlled quantity of rice mixture by dropping it upon the floor of the cavity 7 provided by the end wall 1. Upon retraction of the mechanism 4 the end wall 2 is forced down by a pneumatic cylinder so as to compress the rice mixture at a predetermined pressure for from 3 to 5 seconds for initial cooking. During this compression step the rice mixture is fused to form more or less a unit structure. The end wall 2 is then "bounced" by momentarily raising and relowering to position 82 to vent steam via the clearance between the end wall 2 and the side wall

3.The rice mixture is then further cooked within the moulding cavity 7 for a predetermined period of from 3 to 5 seconds.

The end wall 2 is then rapidly moved to position 83 where it pauses for another predetermined period of from 0.3 to 0.5 seconds, and preferably 0.4 seconds. This movement is timed to occur at the predicted time of "popping" of the rice grain in the mixture. During this pause at position 83 the volume of the cavity is somewhat larger than it was during the cooking period and the expanded cooked rice cake takes up that volume and then sets.

Expansion of the rice occurs rapidly due to the "popping" effect of the grain and it is believed that the improved quality of appearance and crispness throughout the rice cake that is achieved is due to precise control of the volume of the cavity 7 at this critical stage and the timing of the end wall movement with the "popping" of the grain. After the pause the end wall 2 is quickly withdrawn from the cavity 7 to positionB1 and the end wall 1 is raised to its position A2.

The set and cooked rice cake is then ejected by the horizontal movement of mechanism 4 and thereafter it positions itself for introduction of new rice mixture and a repeat of the above cycle.

During the whole cycle the earlier mentioned heating elements will be periodically energised under control from the controldevice so as to keep the temperature within an operating range of from200"C to220"C.

The manner in which the machine is automatically controlled by the electronic control circuit 8 is shown in Fig. 2. Although not shown in this drawing heating coils are embedded in the upper end wall mould 2 and the lower end wall mould 1, while a thermo couple is connected- to the tubular side wall

3. It should be understood that the heating coils and the thermo couple are also connected to the control circuit 8.

A pneumatic cylinder 9 controls the movement of the upper end wall 2 while a pneumatic cylinder 10 controls movement of the lower end wall 1. A further pneumatic cylinder 11 controls movement of the supply mechanism 4.

Solenoid valves 12 responsive to the control circuit 8 control operation of the cylinders 9, 10 & 11.

The cylinder 11 also, through the mixture supply unit 13, controls dispensing of cookable mixture to the cavity 7 of the mould. A proximity switch 14, connected with the control circuit 8, serves to sense the position of the top end wall 2 within the cavity 7.

In order to achieve the necessary complex movement of the top end wall 2 the cylinder 9 is controlled through a special solenoid valve 15 which is of a 3-positional type having a closed centre or exhaust centre.

A suitable solenoid for this purpose is that marketed by SMC Model No.

VF5420. The control circuit 8 is programmed whereby all movement of the end walls 1 and 2 is precisely controlled. The necessary timing apparatus for timing of pauses in the movement of the top end wall 2 and the cooking periods, are incorporated within the control circuit 8.

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Whereas a preferred embodiment has been described in the foregoing passages it should be understood that other forms, refinements and modifications are feasible within the scope of this invention.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1. A method of producing a cooked grain-food product such as a rice cake, comprising introducing a cookable mixture for the product into the cavity of a heating mould, applying compression to said mixture by reducing the volume of said cavity, pausing for a first period of time, momentarily increasing the volume of said cavity for the venting of steam, maintaining heating of said mixture for a second predetermined period of time, sharply increasing the volume of said cavity at the completion of said second period, pausing in the increase of said volume for a third predetermined period of time before opening said cavity and then removing the cooked product from said mould.

2. A method according to Claim 1, wherein said mixture is introduced by dropping onto the floor of said cavity, and said floor is elevated upon opening of said cavity to facilitate removal of said cooked product

3. A method according to Claim 1 or 2, wherein said third period of time is between 0.3 and0.5 of a second.

4. A method according to Claim 1, 2 or 3, wherein each of said first and second periods of time is between 3 and 5 seconds while said heating of said mixture is maintained at from200"C to220or.

5. A cooked product, such as a rice cake, whenever produced by the method of any one of the preceding claims.

6. A cooking machine for a grain-food product, such as a rice cake, comprising a mould defining a cooking cavity and having a tubular side wall and first and second end walls for closing the ends of said side wall;

power means for independently moving said first and second end walls along the axis of said side wall for variation of the volume of said cooking cavity;

heating means for said mould;

a 3-position solenoid controlled fluid valve controlling said power means for movement of said first end wall; and

an electronic control circuit for controlled energizing of said fluid valve to effect a pause during retraction of said first end wall from said cavity.

7. A cooking machine according to Claim 6, wherein said power means are pneumatic cylinders controlled by solenoid valves energized under control of said control circuit.

8. A cooking machine according to Claim 6 or 7, wherein the axis of said tubular side wall is substantially vertical, and said first end wall is movable downwardly into said cavity.

9. A method of producing a cooked grain-food product substantially as hereinbefore described with reference to the accompanying drawings.

10. A cooking machine for a grain-food product substantially as hereinbefore described with reference to the accompanying drawings.Data supplied from the esp@cenet database - Worldwide

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429.

WO8801137 - 2/25/1988

NON-AQUEOUS PROCESSING OF RICE


Inventor(s): MYERS MARSHALL J (US); OPELLA JERRY (US); CAMPBELL CLIFFORD

(US); BROOKS LESTER ALAN (US)

Applicant(s): UNCLE BEN S INC (US)


IP Class: A23L1/182

E Class: A23L1/182C


Priority Number: CA19870545016 (19870820); US19860898236 (19860820)

Family: AU599542

Equivalent: EP0278000; US4810519; CA1323241

Cited Document(s): US2616808; US3870804; US3532508; US3582352; US3706573;

US3600192; US4649055; US3914454; US3828017; JP48002781B; JP60164431; JP5786261;

JP5643332B; JP5978656; JP5911169; US6054650

Abstract:

Abstract not available for WO8801137


A process which comprises treatment of rice grains by contact with a non-aqueous media, organic liquid or liquified gas which is substantially inert to water and the rice grain being treated, permitting only the transfer of heat to effectuate desired food processing such as gelatinization, parboiling, cooking, frying, baking, roasting or the like, and a product made by that process.Claims:


What is claimed is:

1. A method for gelatinizing rice which comprises the steps of: (a) hydrating a rice sample by steeping said rice sample in water at a temperature and for a period of time, said temperature and period of time being sufficient for said rice to obtain a desired moisture content which permits a desired degree of gelatinization of starch in said rice; and (b) heating said hydrated rice without steaming by contacting said hydrated rice under pressure for a period of time with a non-aqueous process medium heated to and maintained at a temperature, said period of time and temperature being sufficient for heat contained in said process medium to be transferred to said rice in order to effect said desired degree of gelatinization of said starch, said process medium being suitable for use in food processing and comprising a non-aqueous organic liquid or liquified gas which is substantially inert to water.

2. The method of claim 1 wherein the rice sample is hydrated to a moisture content in the range of 20% to 50%, by weight.

3. The method of claim 1 wherein the rice sample is hydrated to a moisture content of 30% to 40%.

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4. The method of claim 1 wherein the rice sample is hydrated to a moisture content of about 30%.

5. The method of claim 1 wherein the process medium is maintained at a temperature in the range of

110 DEG C. to 170 DEG C.



7. The method of claim 1 wherein said process medium is a liquified hydrocarbon gas or liquid hydrocarbon, for use.

8. The method of claim 7 wherein said process medium is liquified butane or hexane.

9. The method of claim 7 wherein said process medium is liquified trichlorofluoromethane or trichlorofluoroethane.

10. The method of claim 7 wherein said process medium is liquid rice bran oil.

11. The method of claim 7 wherein said process medium is liquid vegetable oil.

12. The method of claim 7 wherein said process medium is liquid mineral oil.

13. The method of claim 1 wherein said rice sample is a variety of paddy rice, brown rice or white rice of long, medium, or short grain or wild rice.

14. The method of claim 13 wherein said rice sample is selected from the group consisting of

Newbonnet paddy rice, Starbonnet brown rice, Lemont brown rice and L202 brown rice.

15. The method of claim 13 wherein said rice sample is a mixture of Lemont and L202 brown rice in a

1:1 weight ratio.


Starbonnet white rice, Newbonnet white rice and Lemont white rice.

17. The method of claim 1 wherein the period of time to effect said desired degree gelatinization is in the range of four to thirty-two minutes.

18. The method of claim 1 wherein said rice sample is gelatinized at least 40%.

19. The method of claim 18 wherein the rice sample is hydrated to a moisture content in the range of

20% to 50%, by weight.

20. The method of claim 19 wherein the rice sample is hydrated to a moisture content of 30% to 40%.

21. The method of claim 19 wherein the rice sample is hydrated to a moisture content of about 30%.





24. The method of claim 19 wherein said process medium is a liquified hydrocarbon gas or liquid hydrocarbon, for use.

25. The method of claim 24 wherein said process medium is liquified butane or hexane.

26. The method of claim 25 wherein said process medium is liquified trichlorofluoromethane or trichlorofluoroethane.

2119/2197

27. The method of claim 24 wherein said process medium is liquid rice bran oil.

28. The method of claim 24 wherein said process medium is liquid vegetable oil.

29. The method of claim 24 wherein said process medium is liquid mineral oil.

30. The method of claim 19 wherein said rice sample is a variety of paddy rice, brown rice or white rice of long, medium, or short grain or wild rice.


Newbonnet paddy rice, Starbonnet brown rice, Lemont brown rice and L202 brown rice.

32. The method of claim 30 wherein said rice sample is a mixture of Lemont and L202 brown rice in a

1:1 weight ratio.


Starbonnet white rice, Newbonnet white rice and Lemont white rice.

34. The method of claim 19 wherein the period of time to effect heat treatment is in the range of four to thirty-two minutes.

35. The method of claim 1 wherein said process medium is a non-aqueous organic liquid.

36. A method for heat treating rice undergoing food processing which comprises heating a hydrated, uncooked rice sample by contacting said rice sample under pressure for a period of time with a nonaqueous process medium heated to and maintained at a temperature, said period of time and temperature being sufficient for heat contained in said process medium to be transferred to said rice in order to effect a desired degree of gelatinization of said rice, said process medium being suitable for use in food processing and comprising a non-aqueous organic liquid or liquified gas which is substantially inert to water.

37. The method of claim 36 wherein said process medium is a non-aqueous organic liquid.Data supplied from the esp@cenet database - Worldwide

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430.

WO8806425 - 9/7/1988

APPARATUS AND METHOD FOR PRODUCING CRACKERS OF GRANULAR

MATERIAL


Inventor(s): VAN DEN BERGHE RENE (BE)

Applicant(s): BERGHE RENE VAN DEN (BE)


IP Class: A61B5/02

E Class: A23L1/18C2; A21B5/02

Application Number: WO1988BE00005 (19880222)


Family: WO8806425

Equivalent: EP0359740; US5102677; BE1000311

Cited Document(s): BE904631; FR2201406; DE3019798; US3949660; EP0006575; FR2577760

Abstract:


Apparatus and method for producing shaped products from granular materials, in particular food products from cereals such as rice, corn, wheat or the like, which are pressure-baked and afterwards expanded in a heatable mold defined in a fixed upper mold and a movable lower mold (punch).

Preferably the mold comprises a peripheral mold element which is individually movable. Driving means are provided for actuating the movable punch which are in the form of two aligned, separately controlled hydraulic cylinders of which one cylinder defines a precise expansion and the other cylinder controls the compression in combination with separate end switch means.

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431.

WO9000355 - 1/25/1990

PROCESS FOR PAR-BOILING RICE


Inventor(s):

ADRIAN (US)

MCILROY DAVID (BE); JACOPS LUC (BE); KEMPEN JEF (BE); TRIM


IP Class 4 Digits: A23B; A23L; B02B

IP Class: A23B9/00; A23L1/182; B02B1/08

E Class: A23L1/182; A23L1/10H2



Family: AU616994

Equivalent: EP0352939; US5130153; PT91173

Cited Document(s):

US2546456

US3558327; GB2186178; GB794744; US2828209; EP0170404;

Abstract:



According to the present invention, there is provided a process for par-boiling rice, comprising the steps of: (a) treating the rice with water at a temperature up to its boiling point to increase its water content to 17 to 28%; (b) steaming the soaked rice at a temperature from 100 to 125 DEG C to increase its water content to 19 to 30%; (c) heating the steamed rice, in a sealed vessel, under pressure and using dry heat, to a minimum temperature of approximately t DEG C, wherein t = 195 - 2.5 M and M is the moisture content of the steamed rice in %, for from 1 to 5 minutes; (d) reducing the pressure on the rice over a period of 1 to 10 minutes to atmospheric pressure, thereby allowing water to evaporate from the heated rice to reduce its temperature to approximately 100 DEG C and its water content to 17 to 24%; and (e) drying the partially dried rice to microbiological stability. The product of the present invention has better consumer appeal than conventional par-boiled rice.Claims:


1. A process for par-boiling rice, comprising the steps of:

(a) treating the rice with water at a temperature up to its boiling point to increase its water content to

17 to 28%;

(b) steaming the soaked rice at a temperature from 100 to 125 DEG C to increase its water content to

19 to 30%;

(c) heating the steamed rice, in a sealed vessel, under pressure and using dry heat, to a minimum temperature of approximately t DEG C, wherein t = 195 - 2.5 M and M is the moisture content of the steamed rice in %, for from 1 to 5 minutes;

(d) reducing the pressure on the rice over a period of 1 to 10 minutes to atmospheric pressure, thereby allowing water to evaporate from the heated rice to reduce its temperature to approximately 100 DEG

C and its water content to 17 to 24%; and

(e) drying the partially dried rice to microbiological stability.

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2.The process of claim 1, wherein in step (c) the rice is held at t DEG C for a further 1 to 5 minutes.

3. The process of claim 1 or claim 2, wherein after step (d) and before step (e), the rice is tempered by being held at a water content of 17 to 24% for up to one hour.

4. The process of any one of claims 1 to 3, wherein in step (a) the water is at a temperature of 50 to 95

DEG C and the treatment is carried out to increase the water content of the rice to between 20 and 24%.

5. The process of any one of claims 1 to 4, wherein during the steaming step (b), the water content of the rice is increased to 22 to 30%.

6. The process of any one of claims 1 to 5, wherein steps (a) and (b) are combined.

7. The process of any one of claims 1 to 6, wherein the dry heating step (c) is carried out by applying microwave energy to the steamed rice in a sealed vessel under pressure.

8.Par-boiled rice which, when cooked for about 18 minutes in boiling water, is less sticky, thinner and longer grained and less coloured than conventional par-boiled rice cooked under the same conditions.

9. Par-boiled rice obtainable by a process according to any one of claims 1 to 7.

10. Apparatus for producing par-boiled rice comprising

(a) means for treating the rice with water at a temperature up to its boiling point to increase its water content to 17 to 28%;

(b) means for steaming the soaked rice at a temperature from 100 to 125 DEG C to increase its water content to 19 to 30%;

(c) means for heating the steamed rice, in a sealed vessel, under pressure and using dry heat, to a minimum temperature of approximately t DEG C, wherein t = 195 - 2.5 M and M is the moisture content of the steamed rice in %, for from 1 to 5 minutes;

(d) means for reducing the pressure on the rice over a period of 1 to 10 minutes to atmospheric pressure, thereby allowing water to evaporate from the heated rice to reduce its temperature to approximately 100 DEG C and its water content to 17 to 24%; and

(e) means for drying the partially dried rice to microbiological stability.Data supplied from the esp@cenet database - Worldwide

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432.

WO9102464 - 3/7/1991

METHOD OF PRODUCING PRESSURIZED RICE AND CONTAINER FOR

COOKING THE SAME


Inventor(s): HAYASHI RIKIMARU (JP)

Applicant(s): INOUE TADASHI (JP)


IP Class: A23L1/10

E Class: A23L1/182; A23L1/10H2; A23L1/01D; A47J27/088



Family: US5405635


Cited Document(s): JP1013955; JP56072655

Abstract:


A method of producing pressurized rice characterized in that washed and polished rice is put into a solution in a pressurizing chamber as such or after being put into a sealed container, and a high pressure is applied to the pressurizing chamber for a suitable time. The present invention provides also a container for cooking the pressurized rice in a microwave oven. The container is constituted of a container body, a cover for the container body and a partition housed inside the container body, wherein the partition has a large number of steam passages and is disposed inside the container body in such a manner as to divide the inside of the container body into an upper portion for storing the pressurized rice and a lower portion for storing steaming water. Thus the pressurized rice can be obtained easily and cooked to a state suitable for eating by heating it for a short period without losing much the taste and nutrients. The use of this container serves cook and steam rice effectively by heating in a microwave oven and a satisfactory cooking state can be obtained within an extremely short period.Description:


FIELD OF INDUSTRIAL APPLICATION

The present invention relates to a method of preparing pressure-treated rice and containers for cooking the rice in a microwave oven.

PRIOR ART AND PROBLEMS INVOLVED

When to be eaten, rice must usually be treated by the following steps.

a. Washing

b. Steeping

c. Boiling

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d. Standing as boiled

Rice is washed in the washing step a., and water is allowed to fully penetrate into the rice in the steeping step b. These steps require about one hour. The boiling step c. and the step d. of allowing the rice to stand as boiled require about 50 minutes. Thus, the entire process takes about 1 hour and 50 minutes.

Accordingly, the cooking process requires much labor and time before eating and is cumbersome especially to unmarried persons. Rice could be cooked in a shortened period of time by omitting the step b. of steeping and the step d. of standing, but this is usually undesirable since the rice would then taste very poor.

To ensure savings in labor and time for cooking rice, rice is retorted or otherwise processed and prepared as enclosed, for example, in pouches. More specifically, rice is cooked by the steps a. to d. and enclosed in packets in units of one to several meals. When purchased and heated again in a household microwave oven, the processed rice is ready for eating. The rice can therefore be cooked with reduced labor in a shortened period of time. However such processed food is preserved after having been heated and needs to be heated again for eating. This not only results in a greatly impaired taste but also seriously breaks down nutrients such as vitamins and calcium.


An object of the present invention is to overcome these problems of the prior art and to provide a method of preparing rice which is eatable with reduced labor and time and which is so treated as not to impair the taste, flavor and nutrients, the invention further providing utensils needed for the preparation.

To fulfill the above object, the present invention provides a method of preparing pressure-treated rice characterized by placing washed polished rice into water within a pressure chamber and applying a high pressure to the pressure chamber for a suitable period of time.

The present invention further provides a method of preparing pressure-treated rice characterized by placing washed polished rice into an enclosing container along with a suitable amount of water and hermetically sealing off the container with air removed from its interior, immersing the container into a liquid, and applying a high pressure to the liquid for a suitable period of time to subject the container in the liquid to the pressure uniformly from outside.

The present invention also provides a container for cooking pressure-treated rice in a microwave oven characterized in that the cooking container comprises a container body, a closure for the container body, and a partition provided inside the container body, the partition having a multiplicity of steam ports and being disposed in the interior of the container body for dividing the interior into an upper portion for accommodating the rice therein and a lower portion for accommodating therein water for steaming the rice.

In the method of the present invention for preparing pressure-treated rice, washed polished rice is placed into water within a pressure chamber, which is then subjected to a high pressure for a suitable period of time, or washed polished rice and a suitable amount of water are placed into an enclosing container, which is then hermetically sealed off with air removed from inside the container and immersed in a liquid, followed by application of a high pressure to the liquid for a suitable period of time, so that the high pressure applied for the suitable period of time denatures the polished rice as a characteristic effect of the high pressure. (Denaturation under high pressure is described in detail in

"High Pressure Use in Food," published by San-Ei Shuppan Co., on Jul. 15, 1989.) The denaturation breaks down the three-dimensional molecular structure of raw starch, rendering the starch readily decomposable. The denatured rice is not greatly different from usual polished rice in appearance, has high hardness and is more similar to uncooked polished rice than cooked rice. Since the pressure applied acts on the rice throughout its interior instantaneously, the rice is denatured substantially uniformly in its entirety including the interior of the grains. Especially because rice must be cooked thoroughly without leaving any uncooked interior portion, the pressure treatment is more advantageous than the heat treatment which requires some time for the heat to reach the inner portion of the grains

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from the surface. In the case where polished rice is placed into water within the pressure chamber, which is then subjected to a high pressure for the preparation of the treated rice, the rice is placed directly into the pressure chamber, with the result that the rice can be treated by a simple procedure and can be dried easily after the pressure treatment. In the case where polished rice and water are placed into the enclosing container, which is then hermetically sealed off and immersed in a liquid for the application of high pressure, this method of preparation serves to prevent the contamination of the treated rice with bacteria or microorganisms. Further in this case, various liquids are usable for immersing the enclosing container therein. This is advantageous, for example, for inhibiting the corrosion of the inner surface of the pressure treatment apparatus.

Preferably, the pressure to be applied is not lower than 1000 atm to not higher than 9000 atm. At pressures lower than 1000 atm, sufficient denaturation will not take place, with the result that the treated rice fails to become suitable for eating when heated for a short period of time. Pressures exceeding 9000 atm necessitate a very great pressure apparatus, whereas it is not particularly desired to shorten the heating time more than is achievable by a pressure of 9000 atm. Further use of a pressure of at least 2000 atm serves to sterilize rice. The application of a pressure of at least 4000 atm inactivates the enzyme of rice, preventing rice from decaying inside the enclosing container and from producing a gas due to decay.

The container of the present invention for cooking the pressure-treated rice comprises a partition disposed within the container body and having a multiplicity of steam ports for dividing the interior of the container body into an upper portion for accommodating the rice therein and a lower portion for accommodating therein water for steaming the rice. When the container is heated in a microwave oven, therefore, the pressure-treated rice placed in the upper portion is boiled with boiling water present in the upper portion and thereafter steamed with the vapor released from the water remaining in the lower portion, whereby the treated rice is softened thoroughly within a short period of time owing to its unique nature.

The partition of the container is disposed inside the container body, preferably with its peripheral edge substantially in contact with or positioned close to the container body so as to restrict the flow of steam inside the container. This obviates the likelihood that the steam will escape through a clearance between the partition and the container body to reach the top portion of the container without coming into contact with the pressure-treated rice, whereby the rice can be steamed very effectively.

Alternatively, the partition can be disposed inside the container body with the top edge thereof substantially in contact with or positioned close to the closure so as to restrict the flow of steam inside the container, whereby the same effect as above can be achieved.

Other objects and advantages of the present invention will become more apparent from the following description of embodiments with reference to the accompanying drawings.


The drawings show the embodiments of the invention.

FIG. 1 is a diagram showing a pressure treatment apparatus for use in preparing pressure-treated rice;

FIG. 2 is a perspective view of an enclosing container for use in preparing the pressure-treated rice;

FIG. 3 is a perspective view showing another enclosing container; and

FIG. 4 to 6 are views in vertical section showing different containers for use in cooking the pressuretreated rice in a microwave oven.

EMBODIMENTS

The following description should be understood merely as describing some embodiments of the present invention. The present invention can be modified variously without departing from the scope thereof as defined in the appended claims.

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First, a description will be given of two exemplary methods of preparing pressure-treated rice.

I. In the case where polished rice is placed directly into pressure chamber

Polished rice is treated by the following sequence of steps.

a. Polished rice is washed and thereafter placed into water within a pressure chamber. The rice is washed in the same manner as when rice is cooked usually.

b. For a suitable period of time, the pressure chamber is subjected to a high pressure which is in the foregoing range. The pressurizing time is usually 20 minutes to 50 minutes although varying with the hardness and like properties of the rice.

c. After the application of pressure, the rice is withdrawn from the pressure chamber and dried in the air to remove the water deposited on the surface. This can be done at room temperature or in a hot atmosphere which will not affect the composition of the rice.

d. When required, the pressure-treated rice is thereafter enclosed in containers in an amount of one meal (e.g. 140 g) to several meals or larger in each container. The containers can be bags, rigid plastics or metal cans or other suitable ones. It is advantageous to place the rice into the bag as evacuated to a vacuum or to place a deoxidizer thereinto along with the rice for the prevention of degradation of the rice with time.

II. In the case where polished rice and water are placed into enclosing container, followed by pressurization

a. Polished rice is placed into a plurality of enclosing containers in an amount of one meal (e.g. 140 g) to several meals in each container, or a larger amount of polished rice is placed into one container.

b. Water is poured into the container. To be suitable, the amount of water is about twice the volume of the rice.

c. The air in the container is removed, and the container is sealed off. Preferably, the air is removed by inserting a tube connected to a vacuum pump into the container. Preferably, the container is sealed off at a portion thereof remoter from its one end than the tube.

d. The container is immersed in hot water at 20 DEG to 50 DEG C. for about 10 minutes. This step permits water to penetrate into the rice with greater ease but can usually be omitted.

e. The container is placed into a pressure chamber. The pressure chamber is filled with distilled water, a liquid containing antioxidant or some other suitable liquid for pressure treatment. The pressure to be applied and the pressurizing time are the same as in the first method. Although the pressurizing time can be shortened when the pressure liquid is used at 30 DEG to 50 DEG C., a satisfactory result is available usually at room temperature.

f. After the application of pressure, the container is withdrawn from the pressure chamber. In this state, the water in the container has almost entirely penetrated into the grains of rice. When required, the surface of the container is dried to remove the liquid.

When the rice is placed directly into the pressure chamber or into the enclosing container in either of the above methods, chopped vegetables, meat, mushroom or the like can be suitably added to the rice, whereby the rice can be given improved taste and flavor when cooked.

Next, a pressure treatment apparatus for use in the above methods will be described. FIG. 1 schematically shows the apparatus. The pressure treatment apparatus comprises a pressurizing assembly 1, hydraulic unit 2, unit 3 for circulating water of constant temperature and water jacket 10.

The pressurizing assembly 1 comprises a container side wall 4 and a container upper wall 9 which form a pressure chamber 6 inside thereof, a high-pressure piston 5 movable into and out of the pressure chamber 6, a low-pressure piston 8 positioned under and integral with the high-pressure piston 5, and a low-pressure cylinder 7 for driving the low-pressure piston 8.

For operation, the low-pressure piston 8 is urged upward inside the low-pressure cylinder 7 by the hydraulic unit 2. With this movement, the high-pressure piston 5 integral with the low-pressure piston 8 is also urged upward inside the pressure chamber 6. The high-pressure piston 5 thus urged gives an increased pressure to the pressure chamber 6 which is filled with water or pressure liquid. The internal pressure of the pressure chamber 6 is dependent on the ratio between the low-pressure piston 8 and the high-pressure piston 5 in the area to be subjected pressure, and the pressure of the hydraulic unit is amplified in corresponding relation with the ratio and applied to the pressure chamber. In the present example, the pressure is amplified ten times and a high pressure can be quickly produced. The container side wall 4 is surrounded by the water jacket 10, through which constant-temperature water from the water circulating unit 3 is circulated, so that the internal temperature of the pressure chamber

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6 can be adjusted, for example, to about 60 DEG C. by controlling the temperature of the circulating water.

Various other pressure treatment apparatus are usable which have a pressure chamber and adapted to exert a high pressure on a liquid in the pressure chamber.

FIGS. 2 and 3 show examples of enclosing containers in the form of a bag for accommodating the polished rice to be placed into the pressure chamber. The bag 20 of FIG. 2 is made of vinyl chloride or like usual material for enclosing containers and has a receptacle portion 22 surrounded by a sealed portion 21 formed by fusion, adhesion or otherwise. Formed immediately inwardly of one side of the sealed portion 21 is a linear thin-wall portion 23 for opening the bag. The thin-wall portion 23 can be of various forms, for example, in the form of a continuous line or broken line, or can be omitted. A partition portion 25 is provided inwardly of the thin-wall portion 23. The partition portion 25 is formed by joining together the opposed sheet portions of the container, for example, by fusion or adhesion in the form of a discrete line, with one or a plurality of minute spaces 26 left unjoined which are smaller than the grain size of the polished rice. The drawing shows the container as sealed along its entire periphery after the pressure-treated rice has been placed into the receptacle portion 22 with the sealed portion 21 partly left unclosed.

To cook the pressure-treated rice accommodated in the enclosing container, the linear thin-wall portion

23 is opened first. At this time, air is drawn into the vacuum within the container, whereas the rice will not be forced out by an air stream since the rice contained is separated by the partition portion 25. Next, the container is opened along the partition portion 25 or inside thereof to take out the rice. The rice and a suitable amount of water (for example, 1.5 to 1.6 times the volume of the rice) are thereafter placed into a pan or the like and heated in a microwave oven or with gas or electricity. The heating time required for cooking is about 5 to 7 minutes in the case of the microwave oven or about 10 to 12 minutes when gas or electricity is used for heating.

The bag 20 of FIG. 3 has a slanting partition portion 25 extending downward from a position immediately below the midpoint of a linear thin-wall portion 23 toward opposite sides. The bag thus constructed can be opened easily along the partition portion 25 by opening the thin-wall portion 23 and thereafter pulling apart the opposed sheet portions of the bag as held by the hands at the upper end of the partition portion. The partition portion 25 can be so formed that the upper end thereof extends to a position above the thin-wall portion 23. When the thin-wall portion 23 is opened in this case, a space corresponding to the minute space 26 is formed. The partition portion 25 can be of various forms, for example, in the form of a curve or zigzag line.

Next, containers for use in cooking the pressure-treated rice in a microwave oven will be described.

FIG. 4 shows a container 30 comprising a container body 31 in the form of a bowl, a closure 32 for the container body and a partition 33 removaly provided in the container body. These members are made of various resin materials usable for the treatment in the microwave oven to be described below and free of problems as to food sanitation. Examples of such suitable materials are polypropylene, "EVAL" etc. The size of the container body 31 is so determined that the pressure-treated rice can be accommodated in the upper portion 36 thereof on the partition 33 in an amount required for the contemplated use. The upper portion of the present embodiment accommodates about 140 g of rice.

The closure 32 is placed on the container body 31 to cover an upper opening thereof with such airtightness that the steam produced during cooking in the microwave oven can be held within the container while suitably releasing an increase in the internal pressure. The partition 33 is in the form of a shallow bowl and has a side wall which is so shaped as to be substantially in contact with the inner side surface of the container body 31. The bottom wall of the partition divides the interior of the container body into the upper portion 36 for accommodating the pressure-treated rice, and a lower portion 37 for containing water for steaming the rice. The bottom wall of the partition 33 is formed with a multiplicity of steam ports 34 for holding the upper portion 36 and the lower portion 37 in communication with each other therethrough. The lower portion 37 has the depth to be described below so as to accommodate an amount of water sufficient to steam the pressure-treated rice without making the container excessively bulky. When the container is adapted to contain 140 g of the treated rice like the present embodiment, the depth is preferably 2 to 15 mm, more preferably 5 to 8 mm.

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Using the container and a microwave oven, the pressure-treated rice is cooked to a state suited to eating in the following manner. First, the partition is installed in the container body 31, and a suitable amount of the pressure-treated rice is placed into the body. Next, water is placed into the body in an amount slightly excessive relative to the rice, i.e., usually about 1.5 to about 1.6 times the amount of the rice. The higher the temperature of the water, the shorter will be the cooking time, whereas the water may have room temperature. The container is closed with the closure 32 and placed into the microwave oven, which is then operated. Although the operating time varies with the amount of treated rice and the output of the microwave oven, it is suitable to boil 140 g of the treated rice for about 5 to about 7 minutes and steam the rice for about 5 to 10 minutes, for example, when the microwave oven is for household use. The operation of the microwave oven first boils the water, boiling the pressuretreated rice. Since the treated rice has a large amount of water already contained therein, such a supply of water to the rice as is needed in this case for cooking usual rice is unnecessary. When the amount of water decreases below the partition 33 owing to boiling, the rice is steamed with water vapor. The arrangement wherein the peripheral edge of the partition 33 is in contact with the inner side surface of the container body 33 eliminates the likelihood that the steam will escape through a space between the partition and the container body and reach the top portion of the container without coming into contact with the rice. However, a clearance, if present between the partition and the container body, will not impair the substantial function of the present invention although somewhat lowering the efficiency of action of the steam and the uniformity of treatment in the interior of the container. This is also true of the following embodiments. Owing to the foregoing unique nature, the pressure-treated rice is cooked very satisfactorily by the boiling and steaming which are effected for the respective short periods of time already described.

Steam ports can be formed also in the side wall of the partition unlike the above partition. Further the partition may be fixed to the container wall.

FIG. 5 shows another container embodying the present invention for use in cooking the pressuretreated rice. The container 40 comprises a container body 41, a stepped portion 48 formed on the inner surface of the side wall of the body and a partition 43 resting on the stepped portion 48. A handlegauge portion 50 is provided on a side portion of the container body 41. The handle-gauge portion 50 comprises a U-shaped projection 51 projecting from the container body 41 radially outwardly thereof, and a valve 52 provided on the top of the projection 51. The projection 51 has a transparent or semitransparent portion which extends vertically and which is hollow. The top of the hollow portion 53 is positioned above the level of water to be contained in the container body 41, and the bottom of the portion 53 is positioned in the vicinity of the bottom of the container body 41. The hollow portion communicates at the top and the bottom with the interior of the container body. The valve 52 is hinged to the top wall of the projection 51 and openably covers a small hole 54 formed in the top wall. With the present embodiment, a closure 42 is tightly fittable in the opening of the container body 41.

The container 40 is used for cooking the pressure-treated rice also in the same manner as already described. The present embodiment is provided with the handle-gauge portion 50 having the transparent or semitransparent portion, so that the level of water in the handle-gauge portion 50 indicates the amount of water in the container even if the side wall of the container body is opaque. An increase in the vapor pressure during cooking is released through the valve 52. The construction wherein the bottom of the hollow portion 53 is positioned close to the bottom of the container body prevents steam from escaping through the hollow portion to the top portion of the container even if the level of water within the container is lower than the partition.

FIG. 6 shows another container embodying the present invention for use in cooking the pressuretreated rice. The container 60 comprises a container body 61, an outer closure 62, a partition 65 and an inner closure 66. The container body 61 is in the form of a bowl comprising a side wall 610 and a bottom wall 611. A flange 613 is formed around the outer periphery of the body 61 at a position a small distance below a top edge 612 defining an opening. A knob 614 is provided below the flange. A leg

615 extends downward from the lower surface of the bottom wall 611. The lid of the container comprises the outer closure 62 and the inner closure 66. The outer closure 62 comprises a side wall 620 fittable to the opening top edge 612 of the container body in intimage contact therewith, an upper wall

621 extending from the side wall to the central portion, a pressure control valve 630 provided on the upper wall centrally thereof, and fasteners 640 supported by the side wall 620. The upper wall 621 is formed with an annular recessed portion close to its center, and an annular ridge 623 is formed on the

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lower surface of the recessed portion. Steam ports 624 and 625 are formed in the recessed portion respectively on the inner side and the outer side of the ridge immediately adjacent thereto. The upper wall 621 has a central protrusion 626 formed with a hole 627 centrally thereof and steam ports 628 around the hole. The side wall 620 has two guide bores 629 extending therethrough and opposed to each other. The pressure control valve 630 comprises a stem 631 inserted through the hole 627 in the central protrusion of the outer closure, and a disk 632 extending radially from the upper end of the stem. The stem 631 is hollow and has a plurality of grooves 633 communicating with the hollow portion and extending axially of the stem. The stem 631 has opposite ends of an increased diameter for restricting the range of sliding movement of the stem in the hole 627. The fastener 640 comprises a slide portion 641 inserted through the guide bore 629 in the side wall 620, a vertical portion 642 extending downward from the slide portion, and an engaging portion 643 extending from the lower end of the vertical portion radially inwardly of the outer closure. The engaging portion 643 is so disposed as to engage with the flange 613 on the container body 61 when the slide portion 641 is pushed into the guide bore 629 after the outer closure 62 is fitted over the container body 61 with the slide portion 641 pulled out. The partition 65 comprises a side wall 650 and a bottom wall 651 and is in the form of a bowl. The bottom wall 651 is formed with a multiplicity of steam ports 652 and has legs 653 on its lower surface. The legs 653 serve to form a chamber between the partition and the bottom wall 611 of the container body for accommodating water for steaming the rice and have such a length that the chamber has the same depth as the corresponding chamber of the embodiment of FIG. 4. The top edge of the side wall 650 is provided with a flange 654. When the partition 65 is placed into the container body 61, the interior of the container body is divided into an upper portion and a lower portion by the bottom wall 651, with the flange in contact with the side wall 610 of the container body. The inner closure 66 comprises a side wall 660 supportable by the top wall 612 of the container body in contact with the inner surface thereof, and a bottom wall 661 extending from the lower end of the side wall.

Steam ports 662 are formed in the bottom wall close to the outer periphery thereof. The central portion of the bottom wall is in the form of a protrusion 663 which is slightly raised. When the outer closure 62 is closed, the annular ridge 623 comes into contact with the peripheral edge portion of the protrusion

663. Steam ports 664 are formed also in the protrusion 663. The protrusion 663 is centrally formed with a knob 665 extending upward vertically.

The container 60 is used in the following manner. The partition 65 is installed in the container body

61, and the pressure-treated rice and water are placed therein. The inner closure 66 is placed over the partition, and the outer closure 62 is fitted over the closure 66, and is fastened to the container body by the fasteners 640. The container 60 in this state is placed into a microwave oven and heated. When the water in the container boils, the internal pressure of the container builds up, permitting steam to be released through the steam ports 662, 664 of the inner closure and through the steam ports 624, 625,

628 of the outer closure. Upon the increase in the pressure exceeding a certain value, the steam pressure lifts the pressure control valve 630, permitting the release of steam also through the grooves

633 to mitigate the pressure. Accordingly, the weight of the pressure control valve, when adjusted, makes it possible to heat the rice with the internal pressure of the container elevated to a desired value and to cook the rice more satisfactorily than under the usual pressure in a shortened period of time.

When the steam liquefies between the outer closure 62 and the inner closure 66, the resulting water returns downward through the steam ports 662. With the present container, the contact of the top flange 654 of the partition 65 with the side wall 650 of the container body also obviates the likelihood that the steam will escape through a clearance between the partition and the container body to reach the top portion of the container without coming into contact with the pressure-treated rice. Instead of the flange 654, the top edge may be extended so as to contact the lower surface of the inner closure 66 as indicated in broken lines in FIG. 6. Since the bottom wall of the container body has the legs 615, the bottom surface of the container can also be irradiated with microwaves in the microwave oven.Data supplied from the esp@cenet database - Worldwide Claims:


I claim:

1. A method of preparing pressure-treated rice comprising the steps of placing washed polished rice directly into water within a pressure chamber and applying a high pressure to the pressure chamber, the pressure being not lower than 1,000 atm to not higher than 9,000 atm, said pressure being applied for a time sufficient to denature the rice and to produce a rice product having high hardness and which is

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more similar to uncooked polished rice than to cooked rice, said rice product being suitable for eating after being cooked for a short period of time.

2. A method according to claim 1 wherein the pressure is at least 2000 atmospheres.

3. A method according to claim 1 wherein the pressure is at least 4000 atmospheres.

4. A method according to claim 1 wherein said pressure is applied for 20-50 minutes.

5. A method according to claim 1 further comprising removing the pressure-treated rice from the pressure chamber and drying the removed rice.Data supplied from the esp@cenet database -

Worldwide

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433.

WO9306013 - 4/1/1993

BIODEGRADABLE PACKAGING FILM


Inventor(s): AUNG DAVID (CA)

Applicant(s): AUNG DAVID (CA)

IP Class 4 Digits: B65D

IP Class: B65D

E Class: A23L1/00P8E; C08L3/02; A23P1/08E; B65D65/46C; C08J5/18

Application Number: WO1992CA00407 (19920918)


Family: WO9306013


BE657909; WO9014938; US2347849; BE654605; EP0370913 Cited Document(s):

Abstract:


The invention relates to a biodegradable film comprised of starch and water. The film is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50 % or greater. The film may also contain flour and additives. The starch may be corn, tapioca and wheat and the flour may be corn, rice and wheat. Suitable additives that may be used include softening agents, firming agents, anti-caking agents, preservatives, colouring agents, flavouring agents and anti-oxidant agents. The film may be used for wrapping food or forming bags. The invention also relates to a process for preparing the film.Description:


Title: Biodegradable Packaging Film


The invention relates to a water repellent biodegradable film and a process for preparing said film.


Flexible films made from plastic or paper are widely used for packaging a variety of products. Thin plastic film is used to wrap take-out food in commercial outlets and food left-overs in the home.

Plastic-based films are also commonly formed into bags for carrying all manner of products, including food. Disposable plastic film is convenient, easy to use, inexpensive, hygienic, requires no washing and can be discarded after use.

However, these oil-based plastic products are not biodegradable and contribute to litter problems. They are generally disposed of in landfill sites where they accumulate and persist indefinitely as environmental contaminants.

Wood-based wrapping materials, such as waxed paper, are more environmentally friendly but their uses are limited by the properties of paper. Paper products are opaque and can not be stretched like plastic films.

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Paper products are generally folded rather than stretched.

Biodegradable polymers, such as starch, have been incorporated into oil-based plastics. A corn starchbased additive is often used at a concentration of between 6 and 15% of the final product. In the appropriate environment, such as a landfill site, microorganisms digest the starch. Bulk biodegradation occurs at concentrates approaching 50% starch but, as the percentage of starch increases there is a concomitant loss of physical properties of the plastic (See Modern Plastics

Encyclopedia Mid-October 1990 issue p. 178). United

Kingdom patent application No.2,029-,836, discloses a method and composition of materials for preforming starch with a lubricating fluid into pellets for use in the extrusion of biodegradable plastic.However, so called biodegradable plastics are comprised of traditional oilbased plastic polymers loaded with starch or other rapidly decomposing material as a binder. The binding material breaks down rapidly but leaves small particles of the plastic polymer which are not biodegradable. The oilbased plastics blended with biodegradable materials such as starch have not gained commercial acceptance because they are not fully biodegradable and they are expensive to produce.

Natural polymers which can be processed by conventional plastics technology have been obtained as fermentation products from single cell microorganisms.

Biocycle, March 1989, p. 58 discloses the isolation of a biodegradable polymer poly(3hydroxybutyrate-3 hydroxyvalerate). However, the polymer is expensive to produce and can not compete commercially with oil-based plastics.

Water-soluble films for food packaging have been produced from methyl cellulose, hydroxy-propyl cellulose, and hydroxypropylated high-amylose corn starch. United

States Patent No. 3,549,619 to Mark and Mehltretter teaches a method for the preparation of amylose acetate dispersions capable of yielding edible transparent films suitable for packaging of food. The water-soluble food packaging films are produced from high amylose corn starch acetylated with acetic anhydride. The resulting corn starch acetate granules are cooked by steam jets at 1770C to disintegrate the granules. Water-soluble food packaging films are then cast from the resulting amylose acetate aqueous dispersions. It is disclosed that the product is a water-soluble, edible, flexible film which is especially suited to package dry foods intended to be added to liquid prior to use, such as coffee or soup.

There is a need for a biodegradable flexible film which is stretchable, environmentally friendly and prepared by a commercially useful process. In particular there is a need for a water repellent biodegradable film suitable -for wrapping food or forming into bags.


The present invention provides a biodegradable film comprising starch and water, whereby said film- is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50% or greater. Preferably the film is comprised of starch, flour, water and additives, is 0.025 to 0.125 mm thick and has a stretch factor of from 50-100% and the starch is corn, tapioca or wheat starch; the flour is corn, rice or wheat flour; and the additives are softening agents, firming- agents, anti-caking agents, preservatives, colouring agents, flavouring agents and anti-oxidant agents.

The present invention also provides a method of forming a biodegradable film comprising preparing a mixture of starch and water, heating and mixing the mixture to form a viscous liquid; casting said viscous liquid into a film, wherein the relative amounts of the ingredients and the process conditions are selected such that the film is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50% or greater.

The film may be further processed to form a sheet of a predetermined thickness and a water repellent may be coated on the surface of the film by powder or liquid spraying.

The mixture of starch and water used in the method of the invention may be in pellet form. Additives such as softening agents, firming agents, anti-caking agents, preservatives, colouring agents, flavouring agents and anti-oxidant agents may also be added to the mixture of starch and water.

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The water repellent used in the method of the invention may be casein, zein, ethyl cellulose, gluten, glutenin or alginate.

In an embodiment of the method of the invention, a mixture is prepared using starch in an amount of2-

308 by weight and water in an amount of 65-85% by weight. In a second embodiment of the method of the invention, the mixture of ingredients is heated at a temperature of from 175 to1950F and the viscous liquid has a viscosity of from 50-1,000 cps.

In a preferred method of the invention, a biodegradable film is formed by mixing starch in an amount of 2-30% by weight, flour in an amount of0-10% by weight, water in an amount of 65-85% by weight and additives in an amount of 0-15% by weight; feeding the mixture into a cooking reactor; cooking and mixing the mixture in a cooking reactor to form a viscous liquid; feeding said liquid into a casting and pressing mold; casting and pressing said viscous liquid into a film in said casting and pressing mold.

The film may be further processed by the additional steps of feeding the film through a rolling machine, and coating water repellent on the surface of the film by powder or liquid spraying, and cooling and drying the film. Preferably, the mixture is cooked in the cooking reactor at a temperature of from 175 to 1950F and the viscous liquid has a viscosity of from 50-1,000 cps.

The casting and pressing mold has a die temperature of 104-1400F and a pressure of 4,000-30,000 psi.

The water repellent may be selected from the group comprising casein, zein, ethyl cellulose, gluten, glutenin or alginate.

The properties of the film of the invention make it suitable for wrapping foodstuffs. Sheets of the thin film may be used in a similar manner to thin plastic films or waxed paper. The thin film may also be formed into bags suitable for a variety of uses including containing foods and groceries. In particular, the film of the invention may be entirely composed of natural edible ingredients such as starch and flour and accordingly is biodegradable and edible. It will be appreciated that small amounts of additives will not affect the biodegradable nature of the film. Preferably, natural biodegradable and edible additives should be employed.

The film is also flexible and in a preferred embodiment has a thickness of from 0.025 to 0.125 mm, a stretch factor of 50-100%, and is translucent and is water repellent.


The invention will be better understood with reference to the drawings which show a preferred embodiment of the present invention and in which:

Figure 1 is a schematic drawing showing a method for producing a biodegradable thin film;

Figure 2 is a schematic drawing of a casting and pressing mold;

Figure 3 is a schematic side view of another apparatus according to the present invention;

Figure 4a and b are an end view and sectional. view of an outer part of a slide nozzle; and

Figures5a and b are an end view and a sectional view of an inner, nozzle part of the slide nozzle.

DETAILED DESCRIPTION OF INVENTION

The present invention provides a biodegradable film comprised of starch, water and optionally, additives.

The film is sufficiently impermeable, flexible and strong to be used for wrapping food or other organic material.

The film may be translucent so that the contents are readily visible. The film may be used in a similar fashion to thin plastic food wraps or waxed paper to retain the freshness of foodstuffs. It is also contemplated that the thin film could be formed into bags for a range of uses such as fast-food and food wrap, sandwich and lunch bags and grocery bags.

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In a preferred embodiment the film has a moisture content of from 10 to 30%, a thickness of from 1 to

5 mil, a density of from 0.01 to 0.3 g/cc, a stretch factor of at least 50% and is stable over a temperature range of from -20 up to 1400C. The film is preferably comprised of starch, most preferably corn, tapioca or wheat; flour, most preferably corn, rice or wheat; additives; and, water.

A variety of additives may be used in the film depending on the desired results. Examples of suitable additives are provided in Table I. For further lists of suitable additives see, for example, R.S. Igoe,

Dictionarv of Food Ingredients, Van Nostrand Reinhold, New York 2nd

Ed., 1989; and R.J. Lewis Sr. Food Additives Handbook,

Van Nostrand Reinhold, New York, 1989.

Xost preferably, the film has a water repellent coating. The water repellent may be applied by powder or liquid spraying techniques as generally described in R.F.

Bunshah, DepositionTechnoloaies for Film and Coatings; and Finishing Guidebook, Netal Finishing

Magazine, 1988.

Examples of suitable water repellents include casein, zein, ethyl cellulose, glutenin and alginate.

A preferred embodiment of the present invention also relates to a method for producing the abovedescribed film from the ingredients comprising 2-20% starch (particle size 150-250 mesh) 0-15% additives, 0-10% flour and65-85t water. The ingredients are mixed, sieved and cooked in a cooking reactor to form a viscous mixture.

The viscous mixture is formed into a film by the techniques of casting and pressing, and a water repellent may be applied on one or both sides of the film by powder or liquid spraying techniques. The film may be further processed by cooling, cutting to the desired shape and packaging.

Various formulations of natural ingredients may be used in the process as feed materials. The feed materials comprise starch, water and additives. Flour may also be included. The flour and starch are obtained from natural cereal sources, such as corn, tapioca or wheat starch and corn, rice or wheat flour. The particle size of the starch and flour is preferably in the range of 150250 mesh and the moisture content is in the range of 8.015% for flour and 10-23% for starch. As discussed above, a variety of additives may be used depending on the nature of the film to be produced.

The flavouring agent may be one or more of a natural flavour or an artificial flavour, or a combination of natural and artificial flavours. Examples of suitable natural flavouring agents include grapefruit oil, jasmine oil, lemon oil, lime oil, orange oil and rose oil. The desired result as well as the nature of the flavouring agent will determine the actual amount used in any particular incident.

The colouring agent may be a natural or artificial colouring agent or a combination of both. The amount of colouring agent to be added can be determined by visual requirements. Natural colouring agents such as saffron, paprika, beetroot, crocein and carotene are preferably used as colouring agents.

Flavouring and colouring agents are most preferably selected from the relevant list of approved agents, for example those approved by Health and Welfare,

Canada and the Federal Drug Agency, United States.

A preferred process is shown in Figure 1 and described below. The feed materials are fed into a weigh mixer in the following proportions, 2-30% by weight starch, 0-10% by weight flour, 65-85% by weight water and 0-15% by weight additives. The mixture is sifted in a sifter to provide particles of uniform size. The mixture, water, flavouring and colouring agents are held in storage tanks and are fed into an electrically heated cooking reactor 1 (for example, Chester Jenson Co., model 70N5).

The feed materials may be in the form of a pellet, which is formed by cooking the starch and flour in a cooking reactor as detailed below and feeding the resulting viscous liquid into a conventional pellet mill.

Preferably, the pellet has a moisture content of 12 to15%.

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In the cooking phase, the ingredients are mixed by stirring at 50-200 rpm and cooked at 175-1950F, until a viscous liquid mixture results (50-1,000 cps). Most preferably the mixture is cooked at 1800F with a stirring speed of 90 r.p.m. to yield a mixture having a viscosity of 200cps.

The viscous mixture is fed to a casting and pressing mold2 which is water cooled to 104-1400F. The casting and pressing mold isoperated with a mold pressure of 4,000 to 30,000 psi and a liquid pressure of 14-50 psi.

Most preferably the casting and pressing mold is operated with a mold pressure of 10,000 psi and a die temperature of 1100F, and the mold force is completed in 10 seconds.

In the casting and pressing mold the viscous mixture spreads over the countersurfaces of the mold and pressure is applied for 2-30 seconds. During compression the mold is water cooled to cool the film to approximately 1100F.

The warmed water effluent may be recycled for heat exchange.

Figure 2 shows a schematic drawing of a suitable casting and pressing mold. The mold is constructed from polished and tempered stainless steel. The base, top and sides of the mold are at leastF inch thick and the surface may be ground to the desired texture (smooth or rough). To produce the film of the invention, the viscous mixture is pumped, for example at 5,000 psi into the die through apertures such as 5. The mixture spreads out over surface 7. The die is cooled by cool water circulated, for example, at

2 gallons per minute, through inlets 1 and 3. During the pressing phase, hydraulic or pneumatic powered compression is applied to the mold in the direction shown by arrow 6 for approximately 10 seconds.

The formed film may be further processed by feeding through rolling machine 3 to produce a film of even thickness. The sheet may be fed through a rolling machine set at 1-5 mil, at a temperature of from

70-900F, preferably 800F, with teflon or rubber coated steel rollers rotating at approximately 9-150, preferably 100 rpm. The resulting film is fed through cooling chamber 4 for approximately 3 minutes and cooled by cooled forced air at 40-700F.

Preferably, a water repellent is coated onto one or both surfaces of the film. Suitable water repellents include casein, zein, methyl cellulose, glutenin, gluten and alginates such as sodium and calcium alginate and in particular water repellents sold under the trade marks

Algin (Prescott Company), Ethocel (Dow Chemicals), Prolait (Charles Tennant), Modglut (Ogilvie

Mill) and Zein (Freeman Industries). The water repellent may be applied with a spray pressure of from

50-200 psi by powder or liquid spray coating techniques. For example, the water repellent may be applied using a Christy Machine Company tube/core coater, using a nozzle pressure of 100 psi. The film may be coated on one or both sides and the coating may have a thickness of from 0.25-0.75 mil, preferably 0.5 mil.

The film may be cut into the desired shape and size by cutting machine 5. Alternatively the cooling and cutting steps may be carried out in one machine, for example a Greerco multi-zone cooling/cutting machine with an 8 foot capacity. The film may be packed and stacked for shipping, for example in an

Eagle Packaging, Dyna-Pak

Stacking/Packing Machine with a 240 bag per minute capacity.

It will be appreciated that modifications can be made to the embodiment described in connection with

Figure 1, and that such modifications are within the contemplation of the present invention. As an example, the cooking reactor may be an extrusion cooker with a single screw. The extrusion cooker may be used to mix and cook the sifted mixture of feed materials and water and any desired colouring and flavouring agents. In particular, the sifted mixture, water and any colouring and flavouring agents are introduced by means of a volumetric screw feeder (at a temperature of about 131 to 176, preferably

158 to 176) into an extrusion cooker with a single screw rotating at a speed of between about 20-480 rpm. An example of such an extrusion cooker is an extruder typically used for plastics. Blowing agents such as ascorbic acid and sodium lactate may be used in the extrusion process.In the extrusion cooker, the material is mixed and kneaded at a temperature of 176 to 266, preferably 212 to266 F and cooked

2136/2197

at a temperature of 176 to 266, preferably 212 to 2660F. The resultant material can then be injected at a pressure of 1,000 to 4,500, preferably 1,300 to4,000psi, into a flat die where the film is set and cut.

The die may be about 6-48 inches and may have a single blade which is operated at a speed of 60-120 rpm. The die pressure is generally in the range of 10,000 to 35,000 psi. The die may be adjusted to obtain a desired thickness for the film. After the film is set and cut it may be transferred to a coating machine after which it may be dried, preferably in an oven.A circular die can be attached by means of a die-adapter to the extrusion cooker to produce blown film using an air ring cooled oscillator system

(die pressure 2,500 to 4,500psi).

The flexible film may also be formed into containers, packaging blocks, lids, etc in a compression mold using high temperature and pressure.

The following examples are illustrative of the present invention:

Example 1

A range of formulations as shown in Table II were tested, employing the seven basic ingredients of corn starch, tapioca starch, wheat starch, corn flour, potato flour, rice flour and wheat flour to determine the preferred formulations for preparing the flexible film.

The preferred formulations are shown in Table III

The particular formulations shown in Table IV were processed as generally described above to obtain a mixture with particles having a mesh size of 200 and a moisture content of 12% by weight. The ingredients were cooked at 1800F in an electrically heated cooking reactor (model 70 N5, Chester-

Jensen Co.) with a stirring speed of 90 rpm. The ingredients were stirred and cooked to yield a mixture with a viscosity of 200 cps.

The viscous mixture was fed into the casting and pressing mold described above and shown in Figure

2. The viscous mixture was pumped into the casting and pressing mold at a pressure of 5,000 psi and allowed to spread over the countersurfaces of the mold. The extruded material may be introduced into a mold which is shaped and sized to form for example wrapping films, cups lids, boxes, plates, trays, straws and eating utensils. 10,000 psi pressure was applied to the mold for 10 seconds. During compression, cooled water (2 gallons per minute) was pumped into the mold to cool the forming film to about 1100F. The warmed water effluent was recycled for heat exchange. The formed film was fed through a rolling machine equipped with teflon coated steel rollers turning at a speed of 100 rpm and a temperature of 800F.

Water repellent was coated on the formed film by powder or liquid spray coating techniques.

Ethylcellulose was sprayed on the film to a depth of 0.5 mil using a nozzle pressure of 100 psi in a water resistance coating machine (Christy Machine Company, tube/core coater, equipped with powder and liquid dispenser). The film was cooled at 750F for 3 minutes in a Greerco multi-zone cooling/cutting machine with 8 feet capacity.

The films were tested for moisture content (AACC 4416, Sartorius MA 30), thickness (ASTM D-

1005-84, Fowler micrometer), density (ASTM D-792-86, Sartorius B120 S), elongation strength

(ASTM D-638, Chatillon/BG 100), stability (Thermal Conductivity Tester, K. Matic/Rapid K,

Holometrix) and water resistance (ASTM D-870-87) and the results are shown in Table V.

To compare the flexible films of the invention with flexible films of the prior art a variety of flexible films known in the art were tested as described above.

The following commercially available films were tested: aluminum foil(Alcan), paper bags (Dow

Chemical), plastic wrap (First Brand) and plastic bags (First Brand), and the results are shown in Table

VI.

Reference will now be made to Figures 3 - 5, which show an alternative embodiment of the invention.

In Figure 4, there is shown a platform 40 for supporting apparatus. Above this is supported a mixer 42, which is connected to a volumetric feeder 44. The volumetric feeder 44 in turn supplies a hopper 46. A control panel 48 includes the necessary control instrumentation devices.

2137/2197

An extruder 50 has a barrel and screw in known manner, and is driven by a motor 52. The extruder 50 is a single screw extruder, and here is an Engel Model ES55

Injection Molding Machine, as produced by Engel Canada

Inc.

The screw and barrel configuration should be chosen to give desired characteristics. Here, these are: mixing; cooking; pressurising; and expansion. To ensure adequate mixing, a modified barrel profile was used including channels.

The end of the extruder barrel is connected to a mold 54, which is shown, for molding a single article; as detailed below a different mold configuration would be employed for molding sheet or film in accordance with the present invention.

Turning to Figures 4 and 5, these show details of the sliding nozzle seal. This comprises a first nozzle part or nozzle body 82, which is threaded at one end, as indicated at 84, for securing in the end of the barrel body 50. The nozzle body 82 defines a bore 86. As shown in Figure 3, this bore 86 comprises a relatively wide inlet portion 86a with a diameter of 0.75 inches, an immediate portion 86b of slightly narrower diameter, and an upper or outlet end portion 86c of yet narrower diameter. The portion 86c has a diameter 0.5 inches. The overall bore 86 and nozzle body 82 have a length of 3.25 inches.

The nozzle or second part of the nozzle assembly is shown at 88 in Figure 4, and comprises an upper or outlet portion 90, having a hemispherical abutment surface 92 for abutting a corresponding surface of a mold inlet plate. A bore 94 extends from the hemispherical surface 92 through to a short cross bore

95.

The'inlet part 88 has an inlet end portion 96, into which the bore 94 extends. At the lower or inlet end of the inlet portion 96, a screw 98 secures an end member 100. This end member 100 has a diameter of

0.74 inches, and hence is sized to fit within the bore part 86a with a clearance of 0.010 inches. In use, the nozzle part 88 is slidingly mounted in the bore 86, and the end member 100 retains the two elements together.

Although not shown, the inlet plate is provided with a hemispherical recess, corresponding to the end surface 92, and a short bore leading from this into the mold cavity.

To mold or form film or sheet, a die would be used having a narrow slot opening with a width in the range 0.5 - 3 mil, corresponding to the thickness of sheet to be formed. For plain flat film, a straight slot or nozzle would be provided. A circular slot can be provided, in known manner, where it is desired to make a tube. Such a continuous tube can be further processed, again in known manner, to form bags.

To inject material through the mold in known manner, the mold and barrel 50 would be brought together, and pressed together with sufficient force to form a seal.

This causes the nozzle part 88 to be pressed downwards within the nozzle body 82, as viewed in

Figures 3 and 4, bringing the end portion 90 into abutment with the nozzle body82 The lower face of the cylindrical member 100 is spaced by 2.938 inches from an abutment face 102 of the end portion 90.

As this is less than the overall length of the nozzle body 82, this ensures the end member 100 is retained in the bore part 86a and cannot extend beyond it.

A spacing of 2.688 inches between the abutment face 102 and the end member 100 enables the nozzle part 88 to reciprocate in the two bore portions 86b, c between a closed postion and an injection position.

In the closed position, the nozzle member 100 abuts an annular stop between the bore portions 86b, c, and the cross bore 95 is within the bore portion 86c, and hence effectively is closed off. The bore portion 86c and the nozzle end portion 96 have closely similar diameters for this purpose. In the injection position, the abutment surface 102 abuts the top of the nozzle body 82, and the cross bore 95 is located in the bore portion 86b. This enables material to be injected around the end element 100, through the bore parts 86b and c, through the cross bore 95 and bore 94, and through the bore of the inlet plate 70 into the mold cavity 62.

2138/2197

After a predetermined amount of the material has been injected through the mold, the injection is stopped, and the pressure applied by the barrel 50 released. This permits the nozzle part 88 to travel to the closed position, under the influence of the pressure within the nozzle body 82. The cross bore 95 is then located in the narrow bore portion 86c, and hence closed.

To facilitate separation of the various components, and prevent the material used from sticking to the various components, a Teflon coating can be used on surfaces contacting the composition.

Additionally, the inlet plate was coated with Teflon, to facilitate separation from the sliding nozzle 82,

88.

A number of tests have been carried out using this apparatus, to form shaped articles. These were carried out using a mixture using one hundred parts dry material, using formulations comparable to those given in

Table IV without the water listed, two parts per hundred

MAGIC baking soda, and 27 parts per hundred water. The dry ingredients were thoroughly mixed before the water was added. For producing film according to the present invention, the same ingredients as listed in Table IV could be used with the moisture content reduced to 15 25%.

Feeding the equipment may require care, since it is designed for free-flowing material. Bridging can occur in the mixer 42 and/or feeder 44.

Although not shown in detail, the mold can either comprise a simple, straight slit, or alternatively, a circular slit, either of which may have a thickness in the range of 0.5 -3 mil. A straight slit will produce a flat ribbon of material, while a circular slit will produce a tube. The tube can be later processed, after cooling, to form bags, in known manner.

Table VII sets out the set, actual and best temperature figures for forming this sheet material.

As indicated, the temperature in the barrel should increase from a range of 158 - 1760F to 212 -2660F at the nozzle or adaptor 82, 88. The die itself should be maintained at a temperature in the range of 239

- 2930F.

The present invention has been described in detail and with particular reference to the preferred embodiments; however, it will be understood by one having ordinary skill in the art that changes can be made thereto without departing from the spirit and scope thereof.

TABLE I

Function of Suitable

Additive Additives

Softening Syrup, sugar, sorbitol,

glycerol, glucose, sodium

lactate & others

Firming Aluminium & calcium sulphate,

calcium phosphate, chloride,

gluconate & others

Non-sticking Silicate of sodium, calcium,

calcium-aluminum, magnesium

oxide & others

Non-staling Sucrose, sucrose acetate

isobutyrate & others

Anti-oxidant Citric & benzoic acid

derivatives, sorbic acid & BR>;

sorbic sodium, calcium,

potassium salt, ascorbic acid

& ascorbic acid sodium,

calcium salt & others

Expansion Agent Sodium bicarbonate, ascorbic

acid, sodium lactate

2139/2197

TABLE II

TESTINGFORW LATION FOR RIGID MATERIALS

(PERCENT BY WEIGHT)

FLOUR STARCH ADDITIVES WATER

CORN TAPIOCA WHEAT

CORN 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95

POTATO 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95

RICE 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95

WHEAT 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95 0-10 2-20 2-10 75-95

TABLE III

FORMULATIONS FOR FLEXIBLE PACKAGING MATERIALS

(percent by weight)

FORMULATION NO. 1

Corn/rice/wheat flour .... 00 - 05%

Corn starch .... 10 - 20%

Additives .... 05 - 10%

Water... 65 - 85%

FORMULATION NO. 2


Tapioca starch .... 10 - 20%

Additives .... 05 - 10%

Water .... 65 - 85%

FORMULATION NO. 2


Wheat starch .... 10 - 20%

Additives ... 05 - 10%

Water .... 65 - 85%

TABLE IV

FLEXIBLEBIODEGRADABLE/EDIBLE MATERIAL FORMULATIONS

Formulation

Wheat flour .. 1%

Corn starch .. 14%

Wheat gluten .. 1%

Mannitol .. 10%

Sod Alginate .. 5%

Sod Benzoate .. 2%

Water .. 67%

Formulation

Corn flour .. 2%

Tapioca starch .. 16%

Sorbitol .. 8%

Zein .. 1%

Sod Ascorbate .. 1%

Water .. 72%

Formulation

Rice flour .. 1%

Wheat starch .. 18%

Glycerol .. 7%

Casein .. 1%

Sod Benzoate .. 2%

Water .. 71% TABLE V

FLEXIBLE BIODECRADABLE/EDIBLE PACKAGING MATERIALS TEST DATA

EMI20.1

>;SEP; EXPANSION >;SEP; ELONGKTION >;SEP; INSULATION >;SEP; WATER

>;tb; MOISTURE >;SEP; THIC@@NESS >;SEP; DEGREE >;SEP; DENSITY >;SEP; STRENGTH

>;SEP; STRENGTH >;SEP; STADILITY >;SEP; RESISTANT >;SEP; COLOR >;SEP; @@CUR

>;SEP; FLAVOUR

2140/2197

>;tb; 14.50 >;SEP; % >;SEP; 1.5 >;SEP; mil >;SEP; - >;SEP; 0.123@g/cc >;SEP; 50 >;SEP; % >;SEP;

- >;SEP; 266 >;SEP; F >;SEP; good >;SEP; clear >;SEP; neutral >;SEP; neutral

>;tb; 18.25 >;SEP; 2.0 >;SEP; - >;SEP; 0.1190 >;SEP; 50 >;SEP; - >;SEP; 230 >;SEP; good >;SEP; semi >;SEP; neutral >;SEP; neutral


>;tb; 13.45 >;SEP; 1.5 >;SEP; - >;SEP; 0.1162 >;SEP; 60 >;SEP; - >;SEP; 261 >;SEP; good >;SEP; clear >;SEP; neutral >;SEP; neutral

>;tb; 19.12 >;SEP; 3.0 >;SEP; - >;SEP; 0.1274 >;SEP; 50 >;SEP; - >;SEP; 275 >;SEP; good >;SEP; opaque >;SEP; neutral >;SEP; neutral

>;tb; 17.93 >;SEP; 2.0 >;SEP; - >;SEP; 0.1183 >;SEP; 75 >;SEP; - >;SEP; 259 >;SEP; good >;SEP; s#ml >;SEP; neutral >;SEP; neutral

>;tb; 13.04 >;SEP; 1.5 >;SEP; - >;SEP; 0.1226 >;SEP; 50 >;SEP; - >;SEP; 228 >;SEP; good >;SEP; clear >;SEP; neutral >;SEP; neutral

>;tb; 19.57 >;SEP; 3.5 >;SEP; - >;SEP; 0.1327 >;SEP; 100 >;SEP; - >;SEP; 264 >;SEP; good >;SEP; opaque >;SEP; neutral >;SEP; neutral


>;tb;

TABLE VI

COMPATIBLE FLEXIBLE MATERIAL vs.

FLEXIBLE BIODEGRADABLE/EDIBLE PACKAGING MATERIAL TEST DATA

A=Aluminium; P=Paper; Pl=Plastic; B=Bag; W=Wrap; F=Foil

EXPANSION

TEST NO. MOISTURE THICKNESS DEGREE DENSITY

A.F. -- 1.0 mil -- 1.3425

P.B. -- 8.0 mil -- 0.5492

P1.W -- 1.5 mil -- 0.2441

P1.B -- 1.5 mil -- 0.6102

ELONGATION INSULATION

TEST NO. STRENGTH STRENGTH STABILITY

A.F. 00 % -- 1200 F

P.B. 00 % -- 340 F

P1.W 100 % -- 270 F

P1.B 75 % -- 285 F

WATER

TEST NO. RESISTANT COLOR ODOUR FLAVOUR

A.F. good metallic -- -

P.B. poor brown -- -

P1.W good clear -- -

P1.B good clear -- -

TABLE VII

PROCESS PARAMETERS (FLEXIBLE)

Temperature ( F)

Set Actual Best

DIE 203-293 203-293 239-293 (form)

Nozzle 1 176-266 176-266 212-266 (adaptor)

Barrel 2 176-266 176-266 212-266 (cook)

Barrel 3 176-266 176-266 212-266 (mix/knead)

Barrel 4 131-176 131-176 158-176 (feed)Data supplied from the esp@cenet database - Worldwide

Claims:


I Claim: 1. A biodegradable film comprising starch and water, whereby said film is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50% or greater.

2. A film as claimed in claim 1 further comprising flour.

2141/2197

3. A film as claimed in claim 1 wherein said starch is selected from the group comprising corn, tapioca and wheat 4. A film as claimed in claim 2 wherein said flour is selected from the group comprising corn, rice and wheat.

5. A film as claimed in claims 1, 2, 3 and 4 further comprising additives selected from the group consisting of softening agents, firming agents, anticaking agents, preservatives, colouring agents, flavouring agents and anti-oxidant agents.

6. A film as claimed in any one of claim 1 - 5, having one or more of the following properties: a moisture content of from 10 to 30%, a thickness of from 1.0 to 5.0 mil, a density of from 0.10 to 0.3 g/cc, a stretch factor of from 50 to 100%, being transparent, being water repellent and being stable over a temperature range of from -100C to 2800F.

7. A film as claimed in any one'of claims 1 to 6, which is formed from an initial composition comprising: 0 - 5 percent by weight flour; 10 - 20% by weight starch; 5 - 10% by weight additives; and

65 - 85% by weight water.

8. A film as claimed in any one of claims 1 - 6, which is formed from an initial composition comprising: a dry mixture, which comprises 0 - 5 parts by weight flour, 10 - 20 parts by weight starch, and 5 - 10 parts by weight additives; and 15 - 25% by weight water, which composition was processed through an extrusion cooker to form the film.

9. A film as claimed in claims 7 and 8, wherein the flour is selected from corn, rice and wheat flour, and the starch is selected from corn, tapioca and wheat starch.

10. A biodegradable film produced by preparing a mixture of starch and water, heating and mixing the mixture to form a viscous liquid; casting said viscous liquid into a film, wherein the relative amounts of the ingredients and the process conditions are selected such that the film is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50% or greater.

11. A method of forming a biodegradable film comprising preparing a mixture of starch and water, heating and mixing the mixture to form a viscous liquid; casting said viscous liquid into a film, wherein the relative amounts of the ingredients and the process conditions are selected such that the film is impermeable and flexible and of sufficient tensile strength to withstand stretching by a factor of 50% or greater.

12. A method of forming a biodegradable film as claimed in claim 11, wherein the mixture is prepared using starch in an amount of2-308 by weight and water in an amount of 65-85% by weight.

13. A method as claimed in claim 12 wherein said mixture is heated at a temperature of from 175 to

1950F and said viscous liquid has a viscosity of from 50-1,000 cps.

14. A method as claimed in claim 11, 12 or 13, wherein the starch and including some water is in pellet form, with additional water being provided to give the required proportions.

15. A method as claimed in claim 11, 12,13 or 14, which further comprises adding additives selected from the group consisting of softening agents, firming agents, anti-caking agents, preservatives, colouring agents, flavouring agents and anti-oxidant agents.

16. A method for forming a biodegradable film from an initial composition comprising: a dry mixture of flour, starch and additives, which respectively comprise 0 - 5 parts, 10 - 20 parts, and 5 - 10 parts of the dry mixture; and water comprising 15 - 25% per weight of the composition; the method comprising mixing and cooking the initial composition in an extrusion cooker under elevated temperature and pressure conditions, and passing the cooked composition through a slot-shaped die to form the film.

17. A method as claimed in claim 16, wherein the flour is selected from corn, rice and wheat flour, and the starch is selected from corn, tapioca and wheat starch.

2142/2197

18. A method as claimed in claim 16 or 17, wherein the die has a slot width of 0.5 - 3 mil, to form a film of corresponding thickness.

19. A method as claimed in claim 16, 17 or 18, wherein the die has a circular slot, for forming a tubular film.

20. A method as claimed in any one of claims 11 19, which additionally includes forming a layer of water repellent on the surface of the film by powder or liquid spray.

21. A method as claimed in claim 20, wherein water repellent is selected from the group comprising casein, zein, ethyl cellulose, glutenin or alginate.Data supplied from the esp@cenet database -

Worldwide

2143/2197

434.

WO9316604 - 9/2/1993

HIGHLY WATER ABSORBING RICE, METHOD OF MANUFACTURING SAME

AND UTILIZATION THEREOF


Inventor(s): ISHIDA YUKIO (JP)

Applicant(s): ISHIDA YUKIO (JP)


IP Class: A23L1/10

E Class: A23L1/182



Family: WO9316604

Equivalent: EP0585464; FI934589; CA2106771

Cited Document(s): JP60016559; JP57115151; JP59073229U; JP1079412U

Abstract:



In a first stage, by use of hot water, steam and/or pressurized steam, there is prepared water absorbing rice, in which 38-115 parts weight of water is contained per 100 parts weight of rice, and this rice is refrigerated or/and frozen; in a second stage, water is further absorbed into the rice to such an extent that 72-130 parts weight of water is contained per 100 parts weight of rice, thereby obtaining highly water absorbing rice, in a state where the rice grains are hardly pasty. Heretofore, to obtain excessively water absorbing rice, the surface of the rice grains inevitably go pasty so that the rice is ill-tasted and sticky to tend to make the subsequent processing difficult. However, according to the present invention, the highly water absorbing rice can be obtained in the state where the rice grains are almost free of being pasty. The highly water absorbing rice according to the present invention is, even when it is cooked and heated thereafter, solid on the surfaces of the rice grains and soft inside, and gives an excellent taste, thus enabling to supply tasteful cooked rice. Furthermore, this rice, when frozen and dried, is turned to an excellent instantaneously cookable rice.Description:



The present invention relates to a highly water absorbed rice in the state of nearly no gelatinization of rice grains, being preferable as a raw material for a variety of boiled rice products, a method for producing the same and the application of the same.

The present invention relates to boiled rice, processed boiled rice, seasoned boiled rice, molding processed boiled rice, instant dry rice and the like.

2144/2197

PRIOR ART AND PROBLEMS

Water absorbed rice has been produced conventionally by immersing raw rice in water or hot water for a long period of time. However, the water absorption of conventional water absorbed rice is insufficient, so that a relatively larger amount of water has been needed for cooking such rice or preparing fried rice. It is disadvantageous that tasty cooked rice, being overall soft but having slightly hard surface, cannot be obtained for a short time when a greater amount of water is added prior to heating. This represents how difficult it is to determine an appropriate amount of water, specifically that it is extremely difficult to constantly prepare homogeneous and tasty products although a package of such product for one meal is small in volume.

Furthermore, for producing rice ball and the like by using molds, conventionally, rice is once steamboiled and prepared into alpha type, which is then packaged into molds followed by molding under pressure and heating over direct flame to prepare baked rice ball and the like.

However, rice completely prepared into alpha type is already in the form of boiled rice, where the grains stick together due to the starch on the surface, and the rice is packed in molds with much difficulty, and the continuous mechanical production of a greater amount of rice balls is very difficult, which induces troublesome works in machine washing and costs high in terms of economy. In case that the rice prepared into the form of boiled rice is molded under pressure, the grains get mashed if the rice is too strongly compressed and the products if gently steamed again lose the shape immediately, so that such rice has a disadvantage in that the rice cannot be processed widely besides baked rice ball.

PROBLEMS THAT THE INVENTION IS TO SOLVE

A first object of the present invention is to produce a highly water absorbed rice by making rice grains absorb an amount of water necessary for prepare rice grains into boiled rice while maintaining the state of nearly no gelatinization; by further using the highly water absorbed rice, a second object of the present invention is to produce tasty boiled rice products such as a variety of boiled rice products and molded boiled rice, having somewhat hard grain surface and having the inside nevertheless fluffy and touch on teeth for a short period of time, without requiring difficult adjustment of water.

MEANS FOR SOLVING THE PROBLEMS

In accordance with the present invention, the production of a highly water absorbed rice has been successfully achieved by enforcing individual processes such as refrigeration, freezing, freezing after refrigeration or refrigeration after freezing, between first-stage water absorption and second-stage water absorption.

The present invention relates to a highly water absorbed rice produced by making 100 parts by weight of rice absorb 72 to 130 parts, preferably 80 to 125 parts by weight of water while retaining rice grains in the state of nearly no gelatinization.

The highly water absorbed rice of the present invention can be prepared into alpha type and cooked with microwave ovens, ovens and the like for an extremely short time without water addition. The rice is also preferable as a raw material for a variety of processed boiled rice such as rice gruel, rizzotte and the like.

In accordance with the present invention, first-stage water absorption and second-stage water absorption should essentially be required before and after the processes of refrigeration or/and freezing, but the gelatinization of rice grains should be avoided in any of such water absorption. The taste of the rice with gelatinized grain surface, even if cooked, is badly deteriorated because the grain surface is still further gelatinized.

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The present invention is to prepare water absorbed rice with a water content of 38 to 115 parts, preferably 45 to 100 parts by weight to 100 parts by weight of rice by using hot water at 60 DEG C or more, and or steam and/or steam under pressure.

Subsequently, refrigeration or/and freezing process is carried out, but the final water absorption level varies, depending on whether refrigeration process or freezing process is carried out, so that refrigeration process or/and freezing process should preferably be done, depending on the objective water absorption level, namely the use of the highly water absorbed rice.

In the refrigeration process, storage under refrigeration is done at 10 to 0 DEG C for about one day, preferably three days or more. After the refrigeration process, second-stage water absorption is effected using water at about 15 to 25 DEG C, and the final water absorption level is at most about 85 to 100 parts by weight of water to 100 parts of rice. If the water absorbed rice is further immersed in lukewarm water at about 25 to 45 DEG C, up to about 110 parts by weight of water may be then absorbed without the occurrence of grain gelatinization.

In freezing process or rapid freezing process, freezing is effected at - 20 DEG C to - 80 DEG C for 20 minutes or more, preferably one day or more. After the freezing process, second-stage water absorption is effected, and the final water absorption level may be freely modified in the range of 72 to 130 parts by weight of water to 100 parts by weight of rice.

The first-stage water absorption is completed by adding the immersed rice into water preferably at 60

DEG C to 100 DEG C, or by simultaneously or individually processing the rice in steam or steam under pressure, whereby 38 to 116 parts by weight of water is absorbed into 100 parts by weight of rice. In this case, there may be another process comprising once heating the rice at 60 DEG C or more and charging the rice into water at a temperature lower by several centigrade degrees for water absorption, whereby a given amount of water absorption is completed. The water absorbed rice thus processed is transferred to refrigeration or/and freezing processes.

The second-stage water absorption is completed by adding the absorbed rice through refrigeration or/and freezing process into water, lukewarm (hot) water, broth, soup, sauce and the like, at 0 DEG C to 100 DEG C, whereby 72 to 130 parts by weight of water is absorbed into 100 parts by weight of rice. When water at a high temperature is used at the second-stage water absorption, care should be taken so as to complete such immersion for a short time to prevent rice grains from falling into the state of grain gelatinization. As has been described in the previous section, water absorption may be completed by charging the rice once at a raised temperature into water, lukewarm water, broth, soup, sauce and the like at a temperature lower by several centigrade degrees.

Since the rice grains of the highly water absorbed rice obtained by the two water absorption steps before and after refrigeration or/and freezing processes, in accordance with the present invention, contain a great amount of water in the state of nearly no gelatinization, there can be produced products almost comparable to rice cooked with conventional rice cooking method or to those produced by processing the cooked rice; and at a larger scale, there can be produced novel boiled rice foods conventionally never produced.Because the highly water absorbed rice of the present invention is refrigerated or frozen prior to storage and then processed with heating at another place, whereby tasty boiled rice foods thoroughly prepared into alpha type, can be prepared, industrial merits of the largescale production, such as the large scale preparation of semi-products for the preparation of very hot boiled rice foods at another place, will not be accurately estimated.

Because the highly water absorbed rice of the present invention is in the state of a great amount of water absorption although in the state of nearly no gelatinization, the rice can readily be prepared completely into alpha type for an extremely short time on heating afterwards without almost no addition or no addition of water, which is then prepared into tasty boiled rice having touch on teeth, slightly tough surface and being soft inside. In the highly water absorbed rice of the present invention, a greater amount of water absorption is realized through a relatively high extent of alpha -type preparation via the first heating and a certain degree of aging through refrigeration and freezing without gelatinization.

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Although those of a lower water content, for example, those of a water absorption level of 72 to 110 parts by weight in the highly water absorbed rice of the present invention, are used for preparation of molded boiled rice, they are in the state without gelatinization and therefore can be continuously charged freely at a constant amount into molds, and in heating them, they are just heated as they are with lukewarm (hot) water, steam, steam under pressure, an autoclave, direct flame and the like and then prepared into delicious, molded boiled rice.

As the mold to be used in accordance with the present invention, use may be made of a variety of molds, such as plastic-, or teflon-made molds, metal-made molds processed with teflon, in the forms of rice ball, stick, box and the like. In accordance with the present invention, only one mold may be needed for consistent production from initial stage to final products as molded boiled rice, or an initial mold may be used for pressurizing the water absorbed rice or heating the rice with lukewarm water or in steam for tentative molding, and subsequently taking out the molded rice and transferring the rice into another mold or a molding box for heating the rice with lukewarm (hot) water, steam, steam under pressure, an autoclave, a microwave oven, direct flame or the like to prepare final products.If replacing a mold and/or a molding box, the subsequent mold should be somewhat larger than the initial mold for easy handling, and the one where a molding box is arranged on a plastic plate or an iron plate can achieve satisfactory molding, depending on the initial process or the heater to be used, which is very simple.

If molded boiled rice is prepared with the same mold from the initial stage to the final stage, the transferring thereof is not necessary, so such process is simple, but the highly water absorbed rice expands when the rice is prepared into boiled rice, which may be then prepared into slightly compressed, molded boiled rice. If heating is effected after transferring into a mold or a molding box of a slightly larger size, however, handling is easy, and molded boiled rice at a just appropriate toughness may be prepared due to the expansion of the rice at the preparation of boiled rice. If a mold is replaced with another mold and/or a molding box so as to effect transferring therein, it is needless to say that the operation in mechanical operation and steam cooking is extremely readily made consistent, advantageously, and the washing after use is made extremely easy.

Using as such mold the ones in appropriate forms such as rice ball, box, stick, flat plate, molded rice, sushi, rectangular parallelepipeds, cube, cylinder, funnel and the like, the highly water absorbed rice is poured into the molds, followed by applying a high pressure in continuous manner or a batch-wise manner for molding, or followed by slightly heating the rice at 50 to 100 DEG C with hot water or/and steam to tentatively mold the rice grains at a degree at which the grains might not be separated. It is needless to say that both of them may be used in combination.After the tentative molding, heating is effected in the same mold or after the rice is transferred into another mold and/or a molding box, a laminated package or the like, with steam at 60 to 100 DEG C, steam under pressure at 100 to 110

DEG C, with an autoclave, a microwave oven, direct flame and the like for molding.

In case that pickled ume or a cooked product is inserted as an ingredient into the molded processed boiled rice, about half of the highly water absorbed rice is poured into a mold, into which is then inserted the ingredient followed by pouring the highly water absorbed rice over the ingredient for tentative molding, and subsequently, in the same mold or after transferred into another mold or a molding box, the rice is heated and molded. Alternatively, the ingredient may be inserted between two molded articles separately molded or tentatively molded.

Also, the highly water absorbed rice of the present invention may be stored as it is or as it is immersed in lukewarm water, water, broth, sauce, soup and the like or as it is immersed therein while changing water, or may be refrigerated after draining lukewarm water, water, broth, sauce, soup and the like, or may be refrigerated as it is immersed therein, or may after draining, be frozen, refrigerated after freezing, or frozen after refrigeration; otherwise, the highly water absorbed rice after draining may be stored and/or refrigerated or frozen in the deoxygen state where oxygen is shielded.

In the highly water absorbed rice of the present invention, water is absorbed nearly up to the water absorption level when the rice is boiled, so that the highly water absorbed rice changes into tasty boiled rice only with steam-boiling or heating, advantageously without water adjustment which is the most troublesome work in boiling rice. Because the rice hardly requires water addition at heating, the highly water absorbed rice of the present invention can be used for readily cooking delicious fried rice, dorria,

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paelia and the like if the rice is commercially available as a raw material of fried rice, dorria, paelia and the like together with seasoning materials.When the highly water absorbed rice of the present invention is cooked for preparing rice gruel, furthermore, the rice is turned into tasty gruel for a short period of heating and without gumming the grain surface, which provides an extremely advantageous rice-gruel cooking method. Still furthermore, if the rice is in advance mixed with water, soup, sauce and the like for storage, the rice does not any more absorb water or does not soften unless the temperature is raised, so that the rice turns into fresh boiled rice products such as delicious rice gruel, hotchpotch, rizzotte and the like, with completely different tastes from those processed from conventional alpha -type products, as if the rice was just prepared from so-called raw rice.

Also, the highly water absorbed rice of the present invention is frozen and dried, advantageously obtaining instants dry rice.

Since the highly water absorbed rice of the present invention uniformly absorbs 72 to 130 parts by weight of water to 100 parts by weight of rice, the rice when reconstituted with lukewarm water or heated after water addition may turn into porous instant dry rice if the rice is frozen and dried as it is, advantageously providing boiled rice readily, as if just cooked.

Examples of the present invention will now be explained hereinbelow.

Example 1

Rice was washed and immersed in water for 2 hours, followed by immersion in hot water at 98 DEG C under heating for 45 seconds and subsequent immersion in water at 30 DEG C for 30 minutes, which corresponds to the completion of first-stage water absorption. At the first-stage water absorption, the water absorption level was 86 parts by weight to 100 parts by weight of rice, and the temperature of the product was 29 DEG C.

The resulting water absorbed rice was placed in a freezer at -20 DEG C and frozen for one day.

Then, the frozen water absorbed rice was charged in water at 20 DEG C and heated so as to maintain

20 DEG C for 20-min process of immersion and water absorption.

The resulting water absorbed rice absorbed 114 parts by weight of water to 100 parts by weight of rice, and was highly water absorbed rice without grain gelatinization.

One hundred-fifty grams of the highly water absorbed rice were placed in a plastic container, which was then covered with wrappings, and the rice was processed with a microwave oven for 3 minutes, to prepare fluffy delicious boiled rice.

Example 2

Rice was washed and immersed in water overnight, followed by immersion in hot water at 98 DEG C under heating for 40 seconds and subsequent immersion in water at 30 DEG C for 30 minutes, which corresponds to the completion of first-stage water absorption. At the first-stage water absorption, the water absorption level was 86 parts by weight to 100 parts by weight of rice, and the temperature of the product was 29 DEG C.

The resulting water absorbed rice was placed in a freezer at -3O DEG C and frozen for 5 days.

Then, the frozen water absorbed rice was charged in water at 40 DEG C and heated so as to maintain

40 DEG C for 20-min process of immersion and water absorption. The water addition ratio was 114 parts by weight of water to 100 parts by weight of rice. The water absorbed rice was subsequently further immersed in water at 10 DEG C for 8 minutes to produce highly water absorbed rice.

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The resulting water absorbed rice absorbed 120 parts by weight of water to 100 parts by weight of rice, and was highly water absorbed rice without grain gelatinization.

Using broth seasoned with soy sauce, sushi vinegar and the like instead of water at 10 DEG C as used at the final process in Example 1 or water at 20 DEG C, the water absorbed rice, colored or seasoned, could be obtained. The resulting water absorbed rice was highly water absorbed rice at 120 parts by weight of water to 100 parts by weight of rice, also nearly without grain gelatinization.

Example 3

The water absorbed rice produced at the first-stage of Example 1 was immediately placed in a refrigerator at 5 DEG C for several-day refrigeration.

Then at a second stage, the refrigerated water absorbed rice was placed in water at 20 DEG C and heated so as to maintain 20 DEG C for 30-min process of immersion and water absorption.

The resulting water absorbed rice absorbed 100 parts by weight of water to 100 parts by weight of rice, without grain gelatinization.

Using broth seasoned with soy sauce instead of water at 20 DEG C as used at the second stage in

Example 1, the refrigerated water absorbed rice prepared at the first stage was kept at 20 DEG C at an extent where the refrigerated water absorbed rice did not appear above the water surface, for subsequent 15-min process of immersion and water absorption.

The resulting water absorbed rice absorbed 100 parts by weight of the broth to 100 parts by weight of rice, nearly without grain gelatinization.

Example 4

The two types of highly water absorbed rice obtained in Example 3 (each 50 g), were placed separately in a steamer lined with linen so that the two types of rice might not be mixed up, while 20 g of the ingredients of mixed rice were placed on the seasoned water absorbed rice, followed by steaming for 8 minutes, to produce tasty, simple boiled rice and seasoned boiled rice, without water adjustment.

Example 5

The highly water absorbed rice obtained in Example 3 was poured at an appropriate rate into a teflonmade or plastic-made mold of a rice ball production apparatus, and heated in boiling water for 5 minutes in the state under pressure while the mold was closed with a lid in a forcing-in manner for tentative molding.

Loosing the lid so as to release the pressure while keeping the state as it is, the mold was put into a batch-wise steaming tank, followed by heating with steam at 105 DEG C for 5 minutes, to mold a rice ball.

Taking out the ball from the mold, a firm rice ball was prepared because the pressure from the expansion of the water absorbed rice was also applied, which did not readily break down and which was a very delicious rice ball with a less water content. The water content of the prepared product was

103 parts by weight to 100 parts by weight of rice.

Example 6

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The highly water absorbed rice using broth obtained in Example 3 was poured into a mold of a continuous box-type rice ball production apparatus of a boiled fish paste-plate size, at a level of seven/tenth the volume, on which were placed the cooked ingredients comprising seasoned chicken and vegetables, over which was then poured the highly water absorbed rice, followed by closing the mold with a lid in a forcing-in manner and placing continuously the mold in a steaming tank, which was subsequently heated with steam at 105 DEG C for 5 minutes, to tentatively mold a stick-type rice ball.

Loosing the lid so as to release the pressure while keeping the state as it is, the mold was put into a steaming tank, followed by heating with steam at 105 DEG C for 5 minutes, to produce a stick-type rice ball.

Taking out the ball from the mold, the highly water absorbed rice was prepared into alpha type, and firmly molded under the pressure from the expansion of the water absorbed rice, which did not readily break down. Even if the rice ball was picked up with hands while hot, the ball did not lose its shape.

Example 7

The highly water absorbed rice obtained in Example 3 was poured at an appropriate rate into a teflonmade mold of a rice ball production apparatus, into which was inserted one pickled ume followed by closing the mold with a lid and continuously pressurizing the mold for tentative molding, and subsequently, the tentatively molded rice ball was taken out from the mold, and placed in another metal-made molding box and then placed in a second heating tank, followed by heating with steam under pressure at 110 DEG C for about 10 minutes, to mold a rice ball.

Taking out the ball from the molding box, an overall firm rice ball was prepared.

When direct flame is used at the final stage, the ball is immediately processed into a baked rice ball. In that case, the molding box may be present as it is or the box may be taken out. Even if the ball was resteamed, the ball was still firmly molded, and if picking up the re-steamed ball while hot, the ball did not lose its shape.

Example 8

The highly water absorbed rice obtained in Example 3 was poured at an appropriate rate into a teflonprocessed metal-made mold of a rice ball production apparatus, into which was inserted seasoned eel, followed by pressurizing for tentative molding, and subsequently, the ball was taken out and placed in another mold, followed by firmly closing the mold with a lid and heating in boiling water for about 15 minutes, and then, the ball was taken out from the mold, and a rice-ball-like product with eel placed on top was prepared. Furthermore, freezing the resulting product and re-steaming the product again one month later, the product tasted delicious and could be picked up and eaten with hands while hot.

Example 9

One hundred-twenty grams of cream soup obtained by diluting 100 g of a commercially available white cream soup were mixed with 40 g of the highly water absorbed rice obtained in Example 3 and heated with a microwave oven for 4 minutes, to prepare very delicious rizzotte, being very hot and still having a pasta-like touch on teeth.

Following the same manner, saffron soup and fishes and shell fishes were mixed, and the pot was heated on direct gas flame for 5 minutes, to prepare marvelous paelia.

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Example 10

Fifty grams of the highly water absorbed rice obtained in Example 2 were packaged in a retort bag and stored in a refrigerator for several days, and subsequently, pin holes were opened through the bag, which was heated with a 500-W microwave oven for 1 minute and 30 seconds, and when the bag expanded, the bag was taken out from the microwave oven and left to stand for 1 minute, and the bag was opened to taste the rice, which was comparable to boiled rice produced just by cooking general rice with care. In case the water absorbed rice was immersed in broth, the rice turned into tasty chameshi as in the case above.

Example 11

One hundred-twenty grams of water were added to 50 g of the highly water absorbed rice of Example 1 in a plastic container and heated with a 500-W microwave oven for about 5 minutes, and thus, very delicious rice gruel was prepared with no boiling over due to the short heating time.

Example 12

Fifty grams of the highly water absorbed rice of Example 2, 120 g of broth, chicken and a slight amount of a Chinese cabbage were placed together in a pot and heated on direct flame for about 3 to 4 minutes, to prepare very tasty chicken hotchpotch.

Example 13

The highly water absorbed rice of Example 2 was divided at each weight of 50 g in containers or retort bags and left to stand in a freezer for about 10 days, followed by sealing the containers with wrappings or by opening pin holes in the retort bags, which were then placed as they were in the frozen state in a

500-W microwave oven for 2 minutes and then left to stand for 1 minute for serving, and thus, the rice turned into very delicious simple boiled rice, cha-meshi and the like, as in the case described above.

Example 14

Placing the highly water absorbed rice of Example 1 in a variety of heat resistant containers or plastic containers (microwave oven-safe), storing the containers under freezing or refrigeration, mixing about

10 g of the ingredients of mixed rice in the rice, and sealing the containers with wrappings, prior to heating for several minutes and mixing up, very hot mixed rice may be thus prepared and tasted delicious as in the case described above.

Example 15

In case of the highly water absorbed rices of Examples 1 to 3, any of the rices may be prepared on several-minute heating into simple boiled rice, a variety of mixed rice, cha-meshi, and rice gruel, hotchpotch, rizzotte and the like, with the addition of water or broth, more or less involving the difference in shelf life between storage under freezing and under refrigeration and the slight variation in heating time.

Example 16

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Molding the highly water absorbed rice of Example 1 and subsequently drawing out the rice from molds followed by sufficient freezing and placing the rice in a plastic molding box, and heating the rice with a 500-W microwave oven for about 3 minutes, various forms of firmly molded and tasty articles were produced so readily, by modifying molds for molding and molding boxes for thawing, which articles were molded articles of boiled rice for convenience, which were not broken when the articles were picked up while hot. Depending on the molds, tasty molded articles could be produced only by freezing the products after molding without using molding boxes at thawing.

Example 17

Three kilograms of the highly water absorbed rice obtained in Example 1 were charged in a vacuum refrigerating machine of a single maximum vaporization level of 10 kg (1m x 1m x 2m, an experimental machine of a volume of 2 m>;3;), and frozen at -70 DEG C, followed by adjustment to

20 torr (-740 mmHg), and under heating depending on the quantity of heat, the resulting rice was drying processed overnight, to produce 1.2 kg of dry rice.

One hundred-twenty grams of the resulting dry rice were placed in a heat resistant container, to which was added a sufficient amount of boiling water followed by discarding the hot water 4 minutes later, and the resulting rice was served one minute later, which was very delicious boiled rice.Data supplied from the esp@cenet database - Worldwide

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435.

WO9501730 - 1/19/1995



Inventor(s): NOBLE PETER (GB)

Applicant(s): HILBOROUGH MILL FOODS LTD (GB); PPL MARKETING LTD (GB); NOBLE

PETER (GB)

IP Class 4 Digits: A23P; A23K; A23N

IP Class: A23N17/00; A23P1/14; A23K1/00

E Class: A23K1/00B2; A23L1/00P14B2; A23K1/10C; A23N17/00B; A23P1/14B2



Family: WO9501730


Cited Document(s): FR2691879; FR2292437; GB2149637; EP0169106; GB1306487;

US4332832; NL8600467; WO9305666; DE2604917

Abstract:


A process for converting fresh, low value animal materials into feed products comprises mixing predetermined proportions of fresh, low value animal materials and pumping them through a size reducing means and mixing them in a screw type extruder with starch and protein bearing ingredients such as cereals, cereal substitutes, rice, gluten and root crops to produce a cooked extrudate suitable for use, for example, as a pet food or snack product, which can be specifically tailored to meet all the end consumer's nutritional requirements.Description:



The present invention relates to a process for converting into a feed product, low value materials remaining in an animal processing plant after most of the flesh has been removed from the animal carcasses. Such materials typically include bones with meat attached and other low value products such as offal.

Traditionally this material is sold to renderers who produce from such material meat and bone meal and tallow for use in the animal feeds and cosmetic industries. Due to a restricted demand for such products, however, it is becoming increasingly difficult for meat processing plants to sell their low value material and indeed, in many cases, it is necessary for the processing plant to pay in order to dispose of it.

Off-site processing of this material is also becoming less attractive as the transport of such material is controlled in the UK under the Animal By-Products Order 1992 and equivalent legislation in other EC countries to implement Council Directive 90/667/EEC. The cost of such transport is high since60-80W of the material is water which must be driven off during the rendering process.

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In practice this cost is borne by the meat processing plant.

There exists a substantial and growing technical problem for the meat industry to sell this material at a reasonable price or without incurring a loss.

Accordingly, in the present invention a process is provided which enables the low value material to be processed at the meat processing plant thus eliminating the need for transportation and its associated cost. The process is capable of using a wet feedstock of the low value material and added ingredients and utilises all of the low value material produced, thereby eliminating storage problems prior to collection. The only unusable effluent from the process is water in the form of steam which can be readily recondensed and treated.

Depending on the added ingredients, the product can be adapted to numerous purposes, for example, sale as feed for all livestock, including pets, cattle, pigs, poultry or fish. If the processing plant is handling a single species of animal, there is the added advantage of being able to channel the resultant feedstuff exclusively into feeding different species. This is not the case for rendered meat and bone meal which contains waste material from many species. This process can also be used for production of snacks containing meat and cereals for human consumption, although it should be appreciated that a higher value meat component would be used for this application.

There are in existence various processes for producing extruded and expanded food items from various ingredients. As described in more detail herein it has been found advantageous to use a twin screw extruder.

Such extruders are normally employed with a"dry" feedstock but an example of a prior art process for fish and vegetable waste using such a twin screw extruder is described in EP-A-0 169 106 (Clextral).

The Clextral process teaches that moisture may be vented off half way along the extruder barrel (degassing) in order to reduce the water content of this product. Nevertheless the resulting product has a water content between15-30k at which the product would suffer from the technical problem of not being shelf-stable. The use of the extruder to dry the product as suggested in Clextral is difficult to control in terms of product expansion and uniformity.

Clextral also suggests the use of relatively "soft" waste materials and does not therefore teach any essential preparation.

The present inventors have, however, appreciated that the use of an extruder as a means to significantly reduce water content as taught by Clextral is unsuitable for fresh wet animal by-products and the invention is therefore characterised in that the water content of the feedstock is controlled and the resulting expanded product is subsequently dried as a separate step in the process.

The present process therefore has the significant technical advantage that the moisture content of the material passing through the extruder is accurately controlled by further addition of water to the extruder barrel thus producing a consistent, well formed product.

Although some moisture is removed as steam as the product expands, further drying must be employed to reduce the water content to levels which ensure relatively long term shelf stability.

One of the most attractive end products is pet food.

Therefore the remainder of this description will be directed at a process for the manufacture of pet food, although it should be appreciated that the end product may be suitable for alternative applications. Where the process is carried out alongside a processing plant producing meat for human consumption, there is an added advantage that the potential exists to run recipe combinations which ensure that all of the ingredients will have been passed fit for human consumption. This, together with traceability of the meat back to the origin of the animals, provides a complete account of production methods employed and an appealing quality guarantee to consumers.

An embodiment of the process will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which:

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Figure 1 is a flowchart of the material preparation

stages of the process; and

Figure 2 is a flowchart of the extrusion and packing

stages of the process.

One of the advantages of the process to be described is that it is intended to be operated in or alongside a meat/fish/poultry processing plant taking its input directly from the low value material generated when animals are processed. Preferably these materials should not be stored prior to use, as immediate processing ensures freshness and avoids refrigeration costs. However the process can, if necessary, be used on "imported" materials. The remainder of the description assumes that the process is being carried out in or alongside a meat processing plant.

The ingredients for the process fall into two categories, those which are low value materials from meat production carried out in the meat processing plant, and the added ingredients which include a starch and protein providing component, such as cereals, cereal substitutes, rice, gluten and oil seeds, as well as other optional ingredients added to provide flavour, texture, consistency, colour and nutritional properties.

The process consists of pre-treatment stages illustrated in Figure 1 followed by the cooking and extrusion stage illustrated in Figure 2. In the pre-treatment stages transport of the ingredients and mixtures between the various stages of the process is enclosed and may be carried out using pumps such as those manufactured by

SIMO Industries A/S of Denmark (SIMO), but it will appreciated that alternative means may be used as appropriate. The SIMO pump is essentially a double chambered positive pump which also reduces the size of the material being pumped. This acts as the first stage of a size reduction process essential to the operation.

The low value material ingredients are fed to the process from the meat processing plant. Certain parts of the process are more appropriately carried out in the meat processing plant and others in a separate plant. The division between equipment located in the meat plant and the equipment which should be located in a separate plant is illustrated in Figure 1 by the line 2.

The low value animal material ingredients of the process are various offals and bone with meat attached. These two types of low value material are prepared separately and then combined into a meat paste which is mixed with added dry ingredients and liquid in an extruder. Other special ingredients may be added at other stages during the process.

The offal is cut using a cutter 4 which takes its input directly from the meat plant. This machine will

"slash" the material and facilitate cleaning in a subsequent stage. A suitable cutter is model TV90 manufactured by

Loma Engineering Limited, although any machine capable of cutting the offal into thin strips would be suitable. The temperature of the offal is in excess of 300C which makes it susceptible to rapid deterioration. The process allows prompt treatment of the offal before decay can begin and unpleasant smells develop. This gives an obvious environmental advantage over traditional methods of storing low value material until there is sufficient to be sent to a rendering plant.

The output of offal cutter 4 is delivered to an offal cleaning machine 6. A suitable machine is model

570P manufactured by La Parmentiere of France, although any machine capable of passing a flow of water over the offal and tumbling it in order to clean it would be suitable.

The material entrained in the waste water is discharged into a separate output 7 where it is collected.

The cleaned offal is then fed directly to a drainer 8 to remove excess water which is directed to a separate output 9 and collected. A rotating drainer manufactured by La Parmentiere of France is suitable, although any machine capable of centrifugally (or otherwise) separating water from the offal would also be suitable.

It would also be possible to wash the offal by hand before processing. Ideally the water content of the washed offal will be in the range70-90k which includes both the intrinsic water content of the offal

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and the residual water remaining after the washing process. A press (not shown) may be used to reduce the water content if desired.

The output of the rotating drainer 8 discharges to a weighing system 10a. The weighing system can be a simple "eurobin" which is filled, weighed and tipped into the next stage of the process, or a more complex system employing weighing silos which can automatically discharge predetermined amounts of the ingredients into the process.

The other main low value material used is bone with meat attached which can be derived either or both from the output of a cutting/boning facility at the meat processing plant or as the residue from a mechanically recovered meat process (MRM) used to recover meat adhering to the bones. Where joints have been boned in a boning room they will typically have been chilled and therefore from this source will be cold, typically at 4100C. Bone from MRM will be at a higher temperature in the range 150C to

250C and, as in the case of the offal, can be processed promptly avoiding the need to store and refrigerate. Where boning or MRM operations are not continuous, it is possible to store the bone in a silo 16 to be used in the process during periods where no waste bone is being generated.The bone from all sources is fed via a SIMO pump 14 to a holding silo 16 and from silo 16 is discharged under gravity to the weighing system 10b.

Where alternative sources of bone are used it will be appreciated that several pumps may be needed to supply system 10b. The proportion of the bone, meat, offal and other ingredients in the output mix from the weighing system 10 is determined by the nutritional requirements of the resulting product.

Where, as will normally be the case, the plant is designed to work in conjunction with a particular meat processing plant, the recipe may be tailored to take into account the proportion of bone, meat and offal that is available from processing in that plant. It is also possible to provide a control means for the operator to select one of several different preset proportions. Each preset value being for use with a specific workload of the meat processing plant.Such control means would also control a downstream metering pump 20 and feeder 22 (to be described in greater detail later) which control the relative amounts of the animal derived ingredients and the starch and protein ingredient for extrusion. A suitable control means could include a microprocessor connected to a key pad for operator input and provided with a display to confirm the input and provide operator instructions. The control means would then generate the necessary electrical signals to operate the metering devices by means of a wiring loom connected to suitable transducers.

Where the recipe of the product to be produced requires the addition of wet ingredients such as egg, tripe, vegetables or other types of low value material from the meat processing plant or elsewhere, a further silo 18 is provided. Addition of these extra ingredients at this point of the process allows them to be minced and blended accurately. For other types of ingredients addition direct to the extruder or, for dry ingredients, from a separate silo 25 coupled to the feeder 22, is preferred (to be described in greater detail later).

The next stages of the process reduce the low value ingredients to a finely minced mixture in which the particles of meat and bone are less than a predetermined maximum size. The particle size is important regarding both extrusion efficiency and appearance of the finished product. The maximum size may be in the range 0.3mm to 3mm and preferably the particles have a size range of 0.3mm to 0.5mm.

The size reduction is achieved in three stages in the process being described, although the reader will appreciate that depending on the maximum particle size to be achieved, more or less stages may be necessary or desirable.

The material from weighing system 10a is discharged into a mincer 26 which converts the offal into a free flowing slurry. A suitable mincer is Mincemaster 30 manufactured by K.S., although any machine capable of mincing offal to 6mm pieces would be suitable. The output of mincer 26 is discharged into a mixer/blender 28 which acts to completely homogenise the ingredients prior to pumping to the final size reduction stage. The output from weighing system10b is discharged into a grinder 24 which reduces the particle size to roughly 6mm. A suitable grinder is model Weiler 1109B manufactured by

Weiler, although any machine capable of grinding bone to 6mm would be suitable. The output of grinder 24 also discharges to the mixer/blender 28. A suitable mixer is modelRS1300 manufactured by

Risco Brevetti, although any mixer/blender capable of providing a homogeneous mixture of ground

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bone and offal would be suitable. The output of the mixer/blender 28 is discharged into a pump 30 which transfers the blended material for further size reduction. A suitable pump is model 5070VI manufactured by Altec Waukesha, although any pump capable of pumping a meat and bone mixture to the next stage of the process would be suitable.

If for any reason the plant is to be closed down, provision is made to connect an alternative pipe 32 to the output of pump 30 to enable the ingredients to be temporarily stored or disposed of if necessary.

The output of pump 30 discharges into a micro-cutter 34.

A suitable micro-cutter is modelMCH10 100A manufactured by Stephan. The micro-cutter 34 is set to cut the input mixture down to the required maximum particle size. That material which passes from the micro-cutter 34 is the output A of the mincing means and is fed into a live silo 36 for further processing. The live silo provides a buffer in the system to facilitate continuous production despite variations in the input supply. However it is not intended that the live silo 36 should be used to store material for any prolonged period and typically the time from entering to leaving the live silo will be maintained at a maximum of 60 minutes. It should be appreciated that an alternative system capable of mincing or size reduction and blending into an homogeneous "meat paste" would be suitable.

A metering pump 20 is used to draw the mix from the silo 36 at a predetermined rate. A suitable pump is model V134 manufactured by Altec Waukesha, although any positive pump capable of accurately pumping the meat paste would be suitable. The output of the metering pump 20 is fed to an input of an extruder 38. An alternative waste pipe 39 may be connected to pump 20 in order to divert the mix to disposal means in order to empty the plant or if the extruder cannot accept input.

The input of the extruder 38 is also fed with the input B of feed means for supplying the added ingredients, typically a blend of starch containing cereal, protein containing oil seeds or gluten and other special or minor ingredients such as vitamins, trace elements and salt.

The extrusion process needs a certain amount of water in a barrel of the extruder for cooking to proceed in a controlled fashion and for the final product to be well formed after expansion at the extruder head. The present process therefore provides for control of input moisture content such as to achieve a moisture content of up to 40% coming from the extruder. This figure represents the moisture content before additional moisture (typically 35 ) is lost in the form of steam. The moisture content may be controlled in various ways including monitoring moisture content of the meat paste and making adjustments by addition of further liquid in the form of water, steam or blood.Oil can also be added at the extruder although oil in the extruder barrel may interfere with expansion and is therefore better added later as a coating if required by the nutritional needs of the recipe.

Bulk silo(s) 40 are used to store the major dry ingredients and the minor dry ingredients are added to a hopper 44.

A predetermined quantity of cereals, gluten, oil seeds and minor ingredients, with a particle size in the range of0 to 3mm, are fed to a blender 42 where they are mixed together as a batch. After blending, the contents of blender 42 are transferred to hopper 44 which acts as a buffer in the system to facilitate continuous production.

A suitable blender is a ribbon blade mixer manufactured by APV Baker Ltd. The output from the hopper 44 is fed by a feeder 22 to the extruder 38. A preconditioner (not shown) can be used to treat starch based cereals to increase the extruder capacity, although this is not desirable with gluten based mixtures. The feeder 22 feeds the blended added ingredients via a conditioner or directly to output B at the required rate. A suitable feeder is commercially manufactured by APV Baker Ltd. The metering pump 20 and the feeder 22 are set such that the proportion of blenaed meat paste to blended dry ingredients is in the range 2:1 to 1:10.

Additional liquid ingredients are supplied via metering pumps 48. Water is added in the range 2% to

14%. Steam is added in the range 1% to 5%. Blood can be added in the range 2% to 10%. Oil can be added in the range 1% to 4%.

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These proportions are by volume of the total feedstock post extruder. It is necessary to have at least

25% starch in the extruder barrel in order to provide satisfactory extrusion of this blend of material, however should products of different bulk density be required, the starch content will be varied accordingly.

At the extruder 38, the dry ingredients and the meat paste mixture are combined together. The extruder

38 is a twin screw type. It should also be appreciated that any alternative system capable of mixing and metering dry and wet ingredients and feeding to the extruder would be suitable.

Twin screw extruders are well known in food and pet food processing but they normally operate on a relatively "dry" feedstock with water added to the barrel to control the cooking process. In this process the feedstock has a high water content because of the presence of the meat paste mixture, typically up to 40%, and this is regulated as previously described so that the resulting product has an output moisture content which may be in the range 3540%. For use in this process, however, the extruder is modified. The design of the twin screw extruder allows the feedstock to be intimately mixed and cooked thoroughly. The configuration of the screws is such that clearances are smaller than normally used and consequently the amount of heat produced from friction is sufficient to produce the temperature necessary for adequate cooking and sterilisation.The combination of heat produced from friction and barrel heating allows the cooking temperature in the product to reach 1100C-1400C which also provides sterilisation of the product. The barrel temperature is maintained in the range 150-2500C.

Higher temperatures may cause product burning.

Control of product quality in terms of degree of expansion and texture is achieved by the addition of varying amounts of water direct into the extruder barrel.

It has been found possible to modify for use in this process a Model MPF125 twin screw extruder manufactured by APV Baker Ltd. It will be appreciated that other designs of extruder may, by appropriate adjustment, also be suitable.

The screw configuration, found to give acceptable results, was as follows: 4.5D Feedscrew, 4 x 600

Forward Paddles, 2D Feedscrew, 4 x 600 Forward Paddles, 3 x 600 Reverse Paddles,1D

Feedscrew, 3 x 600 Forward Paddles, 2 x 600 Reverse

Paddles, 0.5D Single Leadscrew, 3 x 600 Forward paddles, 4 x 300 Reverse Paddles, 1D Single

Leadscrew.

In this configuration D represents the barrel diameter and the figures given show the length of the particular sections of the screw in terms of barrel diameter. The second screw is identical to the configuration of the first so that the two screws mesh in a standard manner.

The output from the extruder is normally in the range 2 tonnes per hour to 4 tonnes per hour dependent on operating parameters and recipes, although it must be appreciated that different extruder models will give higher or lower outputs. The product discharged from the extruder 38 passes through a die-plate and cutter 50 where the product is shaped and sized. The extruded and shaped product is conveyed to a drier 52 and then through a coating system 54 to a cooler 56. The drier reduces moisture content to 10-

12% at which the product is shelf stable. In the coating system 54, the hot, dried extrudate may be coated with ingredients such as oil, colour, flavour or vitamins.

The cooled product may then be stored in bulk containers 58 prior to being fed to a packaging line 60.

These steps are typical of the processing of extruded products.

It will be appreciated that a substantial amount of water will be evaporated during the cooking process in the extruder and subsequently in the drier. This steam and the washing water used in the offal cleaning machines 6 and 8 is the only effluent from the process.

The process may be automated and requires minimum operator input.

It will be appreciated that the plant described is capable of producing a complete balanced food for livestock, including pets, poultry and fish, in one continuous process from the meat, poultry or fish

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processing plant to finished product and providing complete traceability throughout.Data supplied from the esp@cenet database - Worldwide Claims:


CLAIMS

1. A process for converting fresh low value animal

material into a feed product comprising the step of

extruding it in a twin screw extruder (38) with a

starch providing ingredient in order to produce an

expanded cooked product, characterised in that the

process further comprises a size reduction step such

that the maximum particle size of the material at

the input of the extruder is in the range of 0.3 to

3mm; in that the water content of the input material

is controlled; and in that the resulting extruded

product is dried as a separate step in the process.

2. A process as claimed in claim 1, wherein the

particle size of the input animal material is in the

range 0.3 to 0.5mm.

3. A process as claimed in claim 1 or 2, wherein the

water content controlling step is regulated to

ensure the water content at the extruder output is

up to 40%.


claims, wherein the low value material is

transferred from an adjacent meat, poultry or fish

processing plant.


claims, wherein the starch providing ingredient is

selected from cereals, cereal substitutes, oil

seeds, rice or root crops.


claims, wherein the proportions of offal and bone

with meat in the low value animal material is

controllable.


claims, wherein the proportions of low value animal

material and starch-providing ingredient is in the

range 2:1 to 1:10.


claims, wherein liquid in the form of one or more of

water, steam, oil or blood is added at the extruder.

9. A plant adapted for carrying out the process as

claimed in any one of the preceding claims.

10. A plant adapted for carrying out processing of fresh

low value animal material into an expanded food

product comprising: mincing means (4, 14, 24, 26,

28, 30, 34) for reducing the maximum particle size

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of said animal material to within the range 0.3 to

3mm at an output (A); feed means (24, 40, 42, 44,

22) for supplying at an output (B) at least one

additional ingredient providing starch; a twin screw

extruder (38) having an input connected to the

outputs (A, B) of the said mincing means and feed

means and an output; liquid supply means (40) for

controlling water content of the input of the

extruder (38); and drying means (52) connected to

the extruder output for drying the extruded expanded

product.Data supplied from the esp@cenet database - Worldwide

2160/2197

436.

WO9512324 - 5/11/1995

PROCESS OF FREEZING SUSHI OR BOILED RICE CONTAINING FOOD


Inventor(s): NARUMIYA TADAOKI (JP); MIKAWA NOBORU (JP)

Applicant(s): MAEKAWA SEISAKUSHO KK (JP); AM PM JAPAN CO LTD (JP); NARUMIYA

TADAOKI (JP); MIKAWA NOBORU (JP)


IP Class: A23B9/10; A23L3/36

E Class: A23L1/182; A23L1/325H; A23L3/36



Family: EP0691815

Equivalent: US6217928; EP0691815

Cited Document(s):

Abstract:

EP0051191; JP57005659; JP63094945; JP56151470; JP58158146


A process for freezing sushi, boiled rice or processed food containing boiled rice is described. The method permits to achieve substantially the same quality after natural thawing or thawing in an electric oven as before the freezing step. In one embodiment the process consists of three steps: Firstly the temperature of the product is reduced to 0 - -4 DEG C, secondly the temperature is reduced until having passed the maximum ice generation temperature range (up to -10 DEG C), lastly the food is cooled to at least -15 DEG C. The temperature gradient and freezing time in the second step being greater than in the first step. In another embodiment of the present invention the freezer temperature is preset to 0 - -10 DEG C. When freezing procedure starts, the temperature of the freezer is reduced to -

15 DEG C within 10 to 20 minutes with a temperature gradient of 1 to 2 DEG C/min., then temperature is changed to -10 to -20 DEG C, and in the third step to -30 to -45 DEG C with a linear temperature gradient of 0.5 to 1 DEG C/min. Freezing time in the second step is about 15 min.Description:




This invention relates to a process of freezing sushi, boiled rice or processed food with boiled rice as the main component.

Among varieties of sushi which can be frozen by a process according to the invention is nigiri-sushi

(or edomae-sushi) 1 as shown in FIG. 19(A). A piece of this food is prepared by forming an adequate amount of boiled rice 1a with vinegar into a mouthful-sized oval piece, putting a piece of fish, shellfish, shrimp, etc. 1b on this rice piece, and then adjusting the overall shape of the food by lightly gripping the same. Another variety of sushi is oshi-sushi 3 as shown in FIG. 19(B). This food is prepared by filling a rectangular wooden frame of about 20 cm.times.10 cm with boiled rice with

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vinegar 3a, putting a piece or pieces of fish, shellfish, shrimp, etc. 3b on the rice, pressing the resultant food from above with a wooden lid for shape adjustment, and then cutting the food into mouthful-sized pieces. A further variety of sushi is inari-sushi 4 as shown in FIG. 19(C). This food is prepared by using aburage (or fried sliced tofu) 4b prepared by frying rectangular sliced tofu in oil after water draining. Each aburage piece 4b is cut into two halves, and these aburage halves are boiled using sweet shoyu. Then, each boiled aburage half is opened from the cut side into a sack-like form, and then boiled rice 4a with vinegar is charged into the open boiled aburage half. In this way, a piece of inari-sushi is obtained. A further variety of sushi is maki-sushi or norimaki 12 as shown in FIG. 19(B). As shown, a piece of this food has a circular sectional profile. This variety may also include futomaki 13. This variety comprises a central ingredient part 12b, 13b which may be a piece or pieces of fish, baked egg, cucumber or like vegetables, etc., a boiled rice part 12a, 13a surrounding the ingredient part and having a predetermined thickness, and paper-like toasted layer 12c, 13c surrounding the boiled rice part. (The norimaki 12 and futomaki 13 are different in that in the norimaki 12 only a single kind of ingredient is used for the central ingredient part, while the futomaki 13 uses a plurality of different ingredients, the former being about 3 cm in diameter and the latter being about 5 cm.)

Particularly, the invention concerns a process of freezing sushi, which permits substantially the same quality as non-frozen sushi to be obtained after natural thawing.

Further, the invention is applicable to a process of freezing boiled rice or processed food, with boiled rice as a main component, permitting substantially the same quality as non-frozen food to be obtained after natural thawing. Among varieties of this type of food, there is boiled cleaned or uncleaned rice as shown in FIG. 20(A). The boiled cleaned rice 5 is prepared by boiling cleaned rice or white rice grains, which are obtained by polishing off surface portions of uncleaned rice after hulling. The boiled uncleaned rice is prepared by boiling uncleaned rice in a high pressure oven. A further variety of the food is sekihan 6 as shown in FIG. 20(B). This food is prepared by boiling or steaming glutinous rice with azuki bean, making the rice itself pink. A further variety of the food is rice cake 7 as shown in

FIG. 20(C). This food is prepared by squeezing steamed glutinous rice into a grain-free state. A further variety of the food is onigiri 8 utilizing boiled rice as shown in FIG. 21(A). This food is a substantially triangular piece of boiled rice 8a formed with both hands or with a wooden frame. If desired, pickled fish egg, pickled plum, etc. may be provided inside. Further, onigiri may have a cover of a paper-like layer 8b. A further variety of the food is takikomi gohan (combination boiled rice) 9 as shown in FIG.

21(B). This is prepared by boiling rice together with sliced meat, vegetables, fish, shellfish, etc. and also with shoyu or like seasoning. A further variety is fried rice prepared by frying boiled rice with slices of meat, vegetables, fish, shellfish,. etc. A further variety of the food is okowa (combination steamed glutinous rice) similar to the takikomi gohan 9. This food is prepared by steaming glutinous rice together with meat, vegetables, fish, shellfish, etc. and also with shoyu or like seasoning.

Sometimes, the materials are steamed while they are wrapped in bamboo bud skin. A further variety of the food is pilaf which is prepared by boiling rice together with meat, vegetables, fish, shellfish, etc. and also with olive oil, Safran or like seasoning. A further variety of the food is ohagi 11 as shown in

FIG. 22(A). This food is a mouthful ball-like boiled glutinous rice piece 11a in sweet boiled azuki bean

11b. A further variety of the food is chirashi as shown in FIG. 21(C), which is prepared by mixing boiled rice with vinegar and sliced fish, baked egg, vegetables such as cucumber, etc. A further variety of the food is beaf bowl or other bowls, which is prepared by filling a bowl with rice and then putting cooked meat, egg, curry, etc. on the rice. There are further varieties of the processed food, the volume of which is mainly occupied by boiled rice, for instance curry rice.


Among recent frozen foods are fresh foods and cooked foods, and boiled rice, rice cake, sushi and the like are not exceptions. These conventional frozen foods, however, have their texture destroyed when they are frozen. Therefore, when they are thawed, a great deal of liquid is produced, giving rise to great differences of smoothness and sense of touch compared to fresh foods.

Particularly, frozen nigiri-sushi presents such problems as escapement of vinegar from the rice ball part, which is made from boiled rice with vinegar and carries a piece of fish or the like, hard rice grains due to loss of stickiness, discoloring of ingredients, loss of taste, etc.

2162/2197

Also, boiled rice or processed food with boiled rice as a main component, when frozen and thawed in the usual way, results in hard rice grains due to loss of stickiness and therefore in unsatisfactory taste, sense of eating, etc.

To solve the above problems, various processes of freezing sushi or boiled rice or the like have been proposed.

For example, Japanese Patent Laid-Open Publication No. Sho 61-260843 (Prior Art Example 1) shows a freezing process in which maki-sushi is frozen quickly in a state of being wrapped in transparent film to a temperature of -40 to -70 DEG C.

Also, Japanese Patent Laid-Open Publication No. Hei 2-100643 (Prior Art Example 2) shows a method of manufacturing frozen sushi in which washed rice is boiled while adding vinegar to additive liquid for extraction of branched cyclodextrine for vinegar escapement prevention and organic phosphate, amino acid, etc. for preventing the hardening and oxidation of the rice to obtain boiled rice with vinegar. Sushi is then prepared with the boiled rice and ingredients, and the sushi thus prepared is frozen momentarily in contact with liquid nitrogen gas in a short period of time (i.e., 18 to 20 min.).

Further, Japanese Patent Laid-Open Publication No. Sho 5-38266 (Prior Art Example 3) shows a process of producing frozen boiled rice including frozen sushi, in which rice boiled in the usual way is cooled down to 25 to 40 DEG C., formed to a predetermined shape, frozen quickly in a freezer preliminarily cooled down to -40 to -50 DEG C. by blowing liquified gas against the rice while maintaining a constant reduced pressure in the freezer, and then frozen continually by passing a maximum ice generation temperature range in a short period of time (i.e., 3 min.), thus obtaining substantially the same temperature of the superficial and central parts of the formed rice.

Prior Art Example 1, however, is a special process of freezing maki-sushi and can not be applied to nigiri-sushi with a piece of fish, shellfish, cooked egg (hereinafter referred to as sushi raw materials) put on a riceball. Bedsides, the process requires wrapping each sushi piece, which is very cumbersome.

Prior Art Example 2 requires especially prepared additives or additive liquids for preventing escapement of vinegar from boiled rice with vinegar and the hardening and oxidation of the boiled rice.

The tastes of such additives cause bitterness, leading to great deterioration of the taste.

In either of the above techniques, a significant problem is posed by the quick freezing sushi when passing the maximum ice generation temperature range (-1 to -5 DEG C.) in a minimum period of time for texture destruction prevention in the freezing process. A freezing curve which is obtainable when quickly passing the maximum ice generation temperature range for quick freezing, for the rice ball part as shown in FIG. 3, does not always provide for good taste, and the quality of food is extremely deteriorated compared to non-frozen sushi.

A further problem which is posed in case of frozen sushi is that the technique of thawing is usually very difficult. This is because the sushi raw material part (e.g., fish piece) and rice ball part require different thawing times when using an electronic oven, for instance, for thawing. Therefore, setting the thawing time for the raw material results in most of the rice ball remaining in the frozen state. If the thawing time is set for the rice ball part, on the other hand, the sushi raw material is excessively heated by the heat of the electronic oven during the thawing of sushi.

Accordingly, a technique for high frequency heating sushi raw materials when wrapped in aluminum foil is disclosed in Japanese Patent Laid-Open No. Sho 63-24864. However, it is practically impossible to separate the sushi raw material part and rice ball part of the frozen sushi. Basically, therefore, a freezing technique which permits sushi obtained by natural thawing to have the same quality as nonfrozen sushi is necessary.

It has been proposed to vacuum seal boiled cleaned rice or the like and water in a resin film bag for steaming under pressure and subsequent freezing and thawing; this is disclosed in Japanese Patent

Laid-Open Publication No. Sho 60-16560. Such a freezing process, in which rice is steamed under pressure when packed with water, is not applicable to onigiri or like processed food.

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Further, what is commonly called a loose rice freezing process, in which boiled rice is frozen in a loose state such that the individual grains are distinct from one another, is disclosed in, for instance,

Japanese Patent Laid-Open Publication No. Sho 62-253350. Such a freezing process provides for rice with individual grains distinct from one another due to lack of stickiness. Such rice, although suitable as the material of pilaf, is unsuited for eating directly after thawing. Further, the rice cannot be sold directly after thawing as a product in shops.

Further, a technique of freezing rice that has been boiled with an organic acid or a derivative thereof is disclosed in Japanese Patent Laid-Open No. Sho 60-172262. According to such a technique, the taste is deteriorated by the additive.


An object of the invention, in view of the above technical problems, is to provide a process of freezing sushi which permits frozen sushi to have substantially the same taste and sense of eating as non-frozen sushi.

Another object of the invention is to provide a process of freezing sushi which permits frozen sushi to have substantially the same taste and sense of eating as non-frozen sushi even after natural thawing.

A further object of the invention is to provide a process of freezing sushi which permits frozen sushi to have substantially the same taste and sense of eating as non-frozen sushi even when individual sushi pieces are frozen without being wrapped one by one but rather while being held in rows in vessels.

A still further object of the invention is to provide a process of freezing boiled rice, such as boiled cleaned rice, boiled uncleaned rice, sekihan rice or rice cake, or processed food utilizing such boiled rice, such as onigiri, combination boiled rice, fried rice, chirashi, ohagi or okowa, which permits the same quality as that before freezing to be obtained after thawing.

A yet further object of the invention is to provide a process of freezing boiled rice obtained in the usual way and/or processed food utilizing such boiled rice, which permits the same taste and sense of eating as before freezing to be obtained after thawing even when the food is frozen and naturally thawed in a packed state or while held in plastic vessels or the like.

Still another object of the invention is to provide a process of freezing boiled rice obtained in the usual way and/or processed food utilizing such boiled rice, without the use of any additive, which permits substantially the same taste and sense of eating before freezing to be obtained after freezing and natural thawing.

Yet another object of the invention is to provide a process of freezing sushi, boiled rice or processed food with boiled rice as main component, which permits the manufacturer to obtain food with good reproducibility and also permits the consumer to obtain good taste and substantially the same quality as fresh processed food before freezing.

To attain the above objects of the invention, there is provided a process of freezing sushi, such as nigiri-sushi, inari-sushi, maki-sushi, etc., which comprises disposing the sushi, while being held alone or mixed in vessels, in a freezer, and then starting freezing. Freezing includes a first freezing step of reducing the temperature of the rice ball part of the sushi from the initial temperature at the start of freezing to the freezing point (0 to -4 DEG C.), a second freezing step of reducing the temperature until passing of a maximum ice generation temperature range from the freezing point to about -10 DEG C. while maintaining the same range for a predetermined period of time, and a third freezing step of reducing the temperature to -15 DEG C. or below, preferably -20 DEG C. or below, more preferably -

30 DEG C. or below, after passing of the maximum ice generation temperature range. The temperature gradient in the first freezing step is set to be greater than the temperature gradient in the second freezing step, and the time of the second freezing step is set to be longer than the time of the first freezing step. More specifically, at least the time of the second freezing step is set to about 15 to 35 min.

2164/2197

In this case, the freezing end temperature in the third freezing step may be -30 DEG C. or below purely from the quality standpoint and may be -15 DEG C. or below without any problem. Because of the need to increase the temperature of the product in a packing step subsequent to the end of freezing, it is suitable to end freezing with the product at a temperature of -20 to -30 DEG C.

Further, the temperature gradient in the third freezing step, after passing through the maximum ice generation temperature range and until reaching -20 to -30 DEG C., is suitably set to be substantially equal to or greater than the temperature gradient in the first freezing step.

Specifically, when freezing sushi at normal temperature, i.e., around 20 DEG C., it is suitable to set the temperature gradient in the first freezing step to about 1 to 2.5 DEG C./min., preferably about 1 to 2

DEG C./min., the temperature gradient in the second freezing step to about 0.5 DEG C./min. or below, preferably 0.3 DEG C./min. or below, and the temperature gradient in the third freezing step to about 1 to 3 DEG C./min., preferably 1.5 to 2.5 DEG C./min.

If the freezing time in the third freezing step down to -20 to -30 DEG C. after passing of the maximum ice generation temperature range is too short, then the intended effect can not be attained. Accordingly, when executing the third freezing step down to -30 DEG C., it is suitable to set the time of this step to about 10 min. or above, preferably 10 to 20 min.

The freezer temperature, i.e., the temperature of the freezing space, will now be described on the basis of the freezing curve. When, for instance, nigiri-sushi, maki-sushi, etc., is disposed in a freezer such that pieces of sushi are held without each being wrapped in rows in vessels and then the freezer is initially cooled to a temperature of about 0 to -15 DEG C., and preferably about -5 to -10 DEG C., the freezing comprises a first freezer temperature reduction step of reducing the freezer temperature from the preliminary cooling temperature to about -30 DEG C. in about 5 to 25 min. from the start of freezing, and a second freezer temperature reduction step of reducing the freezer temperature to a lower temperature. In this case, the temperature gradient in the first freezer temperature reduction step is set greater than the temperature gradient in the second freezer temperature reduction step, and the time until passing of the maximum ice generation temperature range of 0 to -10 DEG C. of the rice part of the sushi is set to 15 to 35 min., preferably 15 to 25 min.

In this case, it is suitable to set the temperature gradient and time of the first freezer temperature reduction step to about 1 to 3 DEG C./min., preferably 1 to 2 DEG C./min., and about 10 to 20 min., respectively, and to set the temperature gradient in the second freezer temperature reduction step to 1

DEG C./min. or below, preferably about 2.0 to 0.5 DEG C./min.

It is to be understood that, in the foregoing description, the temperatures that are set for the first to third freezing steps refer to the temperature of the rice ball part, particularly the central part thereof, while those for the first and second freezer temperature reduction steps refer to the freezer temperature.

When freezing nigiri- or maki-sushi, the freezer is initially cooled down to the above temperature, and then the sushi is disposed while being held in rows in vessels in the freezer for freezing. The freezing in this case comprises a first freezer temperature reduction step of reducing the freezer temperature from the preliminary cooling temperature to about -30 DEG C. in about 15 to 25 min., and a second freezer temperature reduction step of reducing the freezer temperature to a lower temperature. It is suitable in this case to set the temperature gradient in the first freezer temperature reduction step to be greater than the temperature gradient in the second freezer temperature reduction step and set the time until passing

(or of maintenance) of the maximum ice generation temperature range of 0 to -10 DEG C., more specifically -3 to -6 DEG C., to 15 to 25 min., preferably 15 to 20 min.

The temperature gradient will now be described. When freezing nigiri- sushi at normal temperature, i.e., about 20 DEG C., it is suitable to set the temperature gradient in and time of the first freezer temperature reduction step from the preliminary cooling temperature of -10 DEG C. to -30 DEG C. to 1 to 2 DEG C./min. and about 20 min., respectively, and set the temperature gradient of the second freezer temperature reduction step down to -30 to -40 DEG C. or below to 1 DEG C./min. or below, preferably about 0.5 DEG C./min.

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A freezing curve of the rice part of nigiri-sushi is set such that the temperature gradient in the first freezer temperature reduction step is about 2 DEG C./min., the temperature gradient in the second freezer temperature reduction step is about 0.5 to 0.3 DEG C./min. or below, and the temperature gradient of the third freezing step down to -30 DEG C. is about 2 DEG C./min. or below.

With inari-sushi which, unlike nigiri-sushi, has its rice ball enclosed in aburage (or fried sliced tofu) impregnated with boiling juice, the freezing curve is set differently. Specifically, freezing is started after initially cooling the freezer and then disposing the sushi while being held in rows in vessels in the freezer. Freezing comprises a first freezer temperature reduction step of reducing the freezer temperature from the preliminary cooling temperature to about -30 DEG C. in about 5 to 15 min. with a temperature gradient of about 2 DEG C./min., and a second freezer temperature reduction step of reducing the temperature to -45 DEG C. with a temperature gradient of -0.2 to -0.5 DEG C./min.

Thus, the freezing curve that is set for the inari-sushi is such that the temperature gradient in and time of the first freezing step are about 1.2 to 1.5 DEG C./min. and 10 to 20 min., respectively, the temperature gradient in and time of the second freezing step until passing of the maximum ice generation temperature range are about 0.3 DEG C./min. or below and about 20 to 35 min., respectively, and the temperature gradient in the third freezing step down to -30 DEG C. is about 2

DEG C./min.

Experiment results prove that even when the food which has been frozen in such a way is thawed under the worst condition of natural thawing, it is possible to minimize vinegar escapement from boiled rice and changes in the hardness or stickiness. In addition, as for the sushi raw materials such as fish pieces, it is possible to obtain the same character as non-frozen sushi after thawing.

Further, when the vessel top, i.e., top of sushi raw materials, is open, it is suitable to freeze the food in a commonly termed slight air supply space with a minimum of air supplied into the freezer.

Further, a batch freezer or a continuous freezer such as a net conveyor, a movable truck or the like may be used as the freezer.

Aside from sushi, boiled rice or processed food with boiled rice as its main component, for instance onigiri, may be frozen in a similar process.

More specifically, boiled rice or the like is disposed in a non-packed or packed state in a freezer, and then freezing is started. The freezing in this case comprises a first freezing step of reducing the temperature of the food from the initial temperature thereof to the freezing point (0 to -4 DEG C.), a second freezing step of maintaining a commonly termed maximum ice generation temperature range from the freezing point to -5 to -10 DEG C., and a third freezing step of reducing the temperature to -

20 DEG C. or below, preferably -30 C or below, after passing through the maximum ice generation temperature range. The temperature gradient in the first freezing step is set to be greater than the temperature gradient in the second freezing step, and the time until passing of the maximum ice generation temperature range of 0 to -10 DEG C. of the rice part is set to 15 to 35 min., preferably 15 to

30 min., and more preferably 20 to 30 min.

In a specific case of freezing the food at normal temperature, i.e., about 20 DEG C., it is suitable to provide the first freezing step with a temperature gradient of 1.5 to 2.5 DEG C./min., preferably 2 DEG

C./min., for 15 to 25 min., preferably about 20 min., provide the second freezing step with a temperature gradient of about 0.5 DEG C./min. or below, preferably 0.3 DEG C./min. or below, to maintain the maximum ice generation temperature range for about 23 to 37 min., preferably about

30.+-.3 min., and provide the third freezing step down to -30 DEG C. with a temperature gradient of about 1 to 2.5 DEG C./min., preferably 1.5 to 2 DEG C./min.

Again, in this case, if the freezing time of the third freezing step, after passing through the maximum ice generation temperature range and until reaching -30 DEG C., is too short, the intended effect can not be attained. Accordingly, it is suitable to set the time to about 10 min. or above, preferably 10 to 20 min.

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The freezer temperature will now be described on the basis of the freezing curve. A case of freezing boiled rice or the like is considered. In this case, the food is disposed, in a state held in vessels without or after packing, in a freezer, and the freezer is then initially cooled down suitably to about 0 to -10

DEG C., preferably about -5 DEG C. Freezing is then started, and it suitably comprises a first freezer temperature reduction step of reducing the freezer temperature to about -10 to -20 DEG C., preferably about -15 DEG C., in about 10 to 20 min. with a temperature gradient of about 1 to 3 DEG C./min., preferably 1 to 2 DEG C./min., a second freezer temperature reduction step or temperature maintaining step of maintaining a temperature range of about -10 to -20 DEG C., and a third freezer temperature reduction step of reducing the temperature from the temperature in the temperature maintaining step to

-30 to -45 DEG C. with a substantially linear temperature gradient of 0.5 to 1.5 DEG C./min., preferably 0.5 to 1 DEG C./min, the freezing time of the second step being set to 10 to 23 min., preferably 10 to 20 min., and more preferably 15 min.

For such stringent temperature control, a batch freezer is suitably used as the freezer. However, it is possible as well to use a net conveyor or other continuous freezers, such as those of the truck type. In this case, step wise temperature control is possible by using a continuous freezer with partitioned spaces or rooms on the conveyor belt.

When using a continuous freezer with a belt or net conveyor, along which vessels holding food are moved, it is suitable to initially cool the freezer down to about -10 DEG C. and set a freezer temperature reduction step of reducing the temperature from about -10 DEG C. down to -40 DEG C. with a substantially linear temperature gradient of 0.5 DEG C./min.

A suitable freezing curve for boiled rice or the like was formed in this case such that the temperature of the food was reduced from a normal temperature of 23 DEG C. to a maximum ice generation temperature range of the neighborhood of 0 to -3 DEG C. in an initial period of about 20 min. with a temperature gradient of about 1 to 2 DEG C./min., the maximum ice generation temperature range was passed in a subsequent period of about 29 to 38 min. with a slight temperature gradient of 0.3 DEG

C./min. or below, preferably about 0.2 DEG C./min., and the temperature was then reduced to about -

28 DEG C. in a subsequent period of about 30 to 35 min. with a temperature gradient of about 0.5 to 1

DEG C./min., preferably 0.7 DEG C./min.

Experiment results prove that even when using this technique it is possible to obtain boiled rice with substantially the same quality of hardness, stickiness and taste after thawing under the worst condition of natural thawing as boiled rice before freezing.

Further, as described before, when the top of the vessel holding the boiled rice or the like is open, it is suitable to freeze the food in what is commonly called a slight air supply space with air supplied at a minimum rate into the freezer.


The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.

FIG. 1 is a diagram showing a freezing characteristic of nigiri-sushi and futomaki in an example of the process according to the invention;

FIG. 2 is a diagram showing a freezing characteristic of inari-sushi in an example of the process according to the invention;

FIG. 3 is a diagram showing a freezing characteristic of inari-sushi and nigiri-sushi in Comparative

Example 1 in a process of quick freezing;

FIG. 4 is a diagram showing a freezing characteristic of nigiri-sushi in Comparative Example 2 of a process of slow freezing;

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FIG. 5 is a graph showing distributions of measured hardness and stickiness of non-frozen sushi and frozen sushi in the above examples and comparative examples;

FIG. 6 is a perspective view showing a plastic vessel for holding sushi used in an example of the process according to the invention;

FIG. 7 is a flow chart showing a sequence of freezing of boiled rice held in a vessel in an example of the process according to the invention;

FIG. 8 is a diagram showing a freezing characteristic of boiled rice in Example 1 of the process according to the invention based on the flow shown in FIG. 7;

FIG. 9 is a diagram showing a freezing characteristic of boiled rice held in a vessel in Example 2 of the process according to the invention based on the flow shown in FIG. 7;

FIG. 10 is a diagram showing a freezing characteristic of boiled rice held in a vessel in a comparative example of quick freezing based on the flow shown in FIG. 7;

FIG. 11 is a diagram showing a freezing characteristic of boiled rice held in a vessel in a comparative example of slow freezing based on the flow shown in FIG. 7;

FIG. 12 is a diagram showing a freezing characteristic of boiled rice held in a vessel in a comparative example of slow freezing based on the flow shown in FIG. 7;

FIG. 13 is a wave form diagram showing a parameter sample obtained by analysis with a textulometer;

FIG. 14 is a diagram showing two-dimensional distributions of measured hardness and stickiness of non-frozen boiled rice and frozen boiled rice shown in FIG. 8;



FIG. 17 is a table showing results of taste testing of boiled rice samples shown in FIGS. 8 to 13 in examples and Comparative Examples 1 and 2;

FIG. 18 is a diagram showing a freezing characteristic of boiled rice in Example 1 of the process according to the invention based on the flow shown in FIG. 7; and

FIGS. 19(A)-(C) are photographs showing various sushi to be frozen, with FIG. 19(A) showing nigirisushi, FIG. 19(B) showing oshi-sushi, norimaki and futomaki, and FIG. 19(C) showing inari-sushi.

FIGS. 20 to 22 are photographs showing boiled cleaned rice or processed food with boiled rice as the main component, with FIG. 20(A) showing boiled cleaned rice, FIG. 20(B) showing sekihan, FIG.

20(C) showing rice cake, FIG. 21(A) showing onigiri, FIG. 21(B) showing takikomi-gohan, FIG. 21(C) showing chirashi, and FIG. 22(A) showing ohagi.


Preferred embodiments of the invention will now be described as examples with reference to the accompanying drawings. It is to be construed that, unless otherwise specified, the temperature reduction conditions, freezing curves, materials, shapes and relative dispositions of the food to be frozen and so forth described hereinunder are mere examples.

First, 1 wt. part of cleaned rice was boiled with 1.4 wt. parts of cleaned water in a commercially available electric oven. Then, when the rice was cooled down to 40 DEG C., vinegar for boiled rice with vinegar (composed of brewed vinegar, sugar, edible salt, seasonings and amino acid, specifically

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vinegar for sushi sold by Cupie Shokuhin) was added in an amount of about 10% of the boiled rice, and the resultant system was agitated to prepare boiled rice with vinegar at about 25 DEG C.

Then, using this boiled rice with vinegar, nigiri-sushi with ingredients put on rice balls, futomaki and inari-sushi, as shown in FIG. 19, were prepared using well-known sushi-preparing robots at normal temperature. These sushi varieties were each put in a well-known vessel 2 as shown in FIG. 6, made of a packing material of polyethylene, polypropyrene, etc., and open at the top. These vessels holding the sushi were then put on a second and a third shelf of an exclusive food freezing unit (i.e., a batch type air-cooled freezer provided under a trade name "High Power 22" by Maekawa Seisakusho), and then freezing was performed with freezing curves as shown in FIGS. 1 to 4.

The batch type freezer "High Power 22" is constructed such that air flows slightly through the inside and it has five shelves disposed one above another.

FIG. 1 shows a freezing characteristic obtained in Example 1 of the process according to the invention with 10 pieces of sushi, i.e., either nigiri-sushi alone or nigiri-sushi and futomaki. As shown in the

Figure, the freezer was preliminarily cooled down to about -10 DEG C. Then, freezing was started to reduce the temperature to -30 DEG C. in 20 min. with a temperature gradient of 1 DEG C./min., and then the temperature was reduced continually to about -45 DEG C. in 40 min. with a linear downward temperature gradient of 0.5 DEG C./min. With this control characteristic A, a freezing curve of the temperature of the rice ball part of the sushi was produced such that the temperature was reduced from a normal temperature, i.e., 20 DEG C., to a maximum ice generation temperature range in the neighborhood of -1 to -5 DEG C. in an initial period of about 10 to 15 min. from the start of freezing with a temperature gradient of about 1 DEG C./min. The temperature was then held in the maximum ice generation temperature range for a subsequent period of about 25 min., then reduced to -30 DEG C. in a subsequent period of about 10 min. with a temperature gradient of 2.2 DEG C./min. and then reduced to about -42 DEG C. in a subsequent period of 15 min. with a temperature gradient of about -1

DEG C./min.

On the basis of the above freezing characteristic, 20 batches of nigiri-sushi, prepared with fish, cuttlefish or shrimp, 20 batches of futomaki and 20 batches of mixed futomaki and nigiri-sushi were frozen repeatedly.

In Example 2, a permanent preservation process at -20 DEG C. for 24 hr. was provided after the freezing process. In Example 3, alkali water was used instead of water, and 20 batches of nigiri-sushi 1 were frozen repeatedly.

FIG. 2 shows a freezing characteristic of inari-sushi in Example 1 of the process according to the invention. As shown in this Figure, the freezer was initially cooled down to about -10 DEG C., and then freezing of sushi was caused and the temperature reduced down to -30 DEG C. in 10 min. from the start with a temperature gradient of 2 DEG C./min. The temperature was then reduced down to about -50 DEG C. in a subsequent period of 50 min. with a linearly downward temperature gradient of

0.3 DEG C./min. With the above control characteristic B, a freezing curve of the temperature of inarisushi was produced such that the temperature was reduced from normal temperature, i.e., 20 DEG C., to reach the maximum ice generation temperature range in the neighborhood of -1 to -5 DEG C. in an initial period of about 15 to 20 min. from the start of freezing with a temperature gradient of about 1.3

DEG C./min. The temperature was then held in the maximum ice generation temperature range for a subsequent period of about 30 min. and then reduced to about -35 DEG C. in a subsequent period of 15 to 20 min. with a temperature gradient of 2 DEG C./min. Again this experiment was carried out repeatedly for 20 batches.

FIG. 3 shows freezing characteristics of mixed inari-sushi and nigiri-sushi 1 in Comparative Example

1 (quick freezing). As shown in this Figure, as a freezer temperature control characteristic C, the freezer temperature was quickly reduced from a normal temperature, i.e., about 20 DEG C., to about -

40 DEG C. in about 5 min. with an average temperature gradient of 6 DEG C./min. and then held at -40

DEG C. for a period of about 55 min. With this control characteristic C, a freezing curve of the temperature of the rice ball part of the nigiri-sushi 1 was produced such that, with the freezing started from normal temperature of 28 DEG C., the temperature was reduced down to -10 DEG C. by passing a maximum ice generation temperature range in an initial period of about 5 min. with a temperature

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gradient of about 4 DEG C./min. The temperature was then held at that temperature for about 5 min., then reduced to about -40 DEG C. in a subsequent period of about 20 to 30 min. and then held at that temperature for a subsequent period of about 30 min.

In the case of inari-sushi, a freezing curve of the temperature of the rice part was produced such that the temperature was reduced from 28 DEG C. at the start of freezing to reach the maximum ice generation temperature range in the neighborhood of -1 to -5 DEG C. in an initial period of about 7 to

10 min. The temperature was then held in the maximum ice generation temperature range for a subsequent period of about 10 min., then reduced to about -40 DEG C. in a subsequent period of 10 to

20 min. and then held at that temperature for a subsequent period of about 30 min. Again, these freezing experiments were each carried out for 20 batches.

FIG. 4 shows a freezing characteristic of nigiri-sushi in Comparative Example 2 (slow freezing). As shown in this Figure, as a freezer temperature control characteristic D, the freezer temperature was reduced from a normal temperature of about 5 DEG C. to about -12 DEG C. in 5 min. with a linearly downward freezing temperature gradient. The temperature was then continually reduced slowly from -

12 DEG C. to about -30 DEG C. in about 80 to 90 min. with an average temperature gradient of 0.2

DEG C./min. With this control characteristic D, a freezing curve of the temperature of the rice ball part of the sushi was produced such that the temperature was reduced from the start of freezing to reach a maximum ice generation temperature range in the neighborhood of -1 to -5 DEG C. in an initial period of about 25 min., then held in the maximum ice generation temperature range for a subsequent period of about 55 min. and then reduced to about -25 DEG C. in a subsequent period of about 20 to 30 min.

Again, this freezing experiment was carried out for 20 batches.

The frozen sushi, which was obtained in the above way, was covered at the top with a transparent lid and then sealed gas-tight in a vinyled bag at a temperature of 25 DEG C. and under a reduced pressure of 500 mHg, followed by leaving it at normal temperature for about 120 to 180 min. for thawing. After this, the taste and sense of eating were examined together with the stickiness and hardness of rice. The results are shown in FIG. 5.

Referring to FIG. 5, group 10 represents characteristics of non-frozen sushi, group 11 represents characteristics of sushi frozen and thawed in Example 1, group 12 represents characteristics of sushi frozen and thawed in Example 2, group 13 represents characteristics of sushi using rice boiled with alkali water and frozen and thawed in Example 3, group 14 represents characteristics of sushi in

Comparative Example 1 as a process of quick freezing and thawing, and group 15 represents characteristics of sushi frozen in Comparative Example 2 as a process of slow freezing and thawing.

The characteristics of the sushi samples in Examples 1 to 3 are distributed around and not substantially different from the characteristics 10 of the non-frozen sushi. In addition, these sushi samples proved to have good taste and sense of eating when they were actually eaten.

However, the sushi sample with the characteristics of group 14 in Comparative Example 1 of quick freezing was high in hardness, and its taste and sense of eating were not desirable. The sushi sample with the characteristics of group 15 was not good at all when it was actually eaten, due to high value of hardness and low value of stickiness.

It is to be appreciated that, according to the invention, even when sushi or onigiri is frozen without a vinyl package for each piece of the food, by holding plural pieces of the sushi in rows in a vessel, it is possible to obtain substantially the same taste and sense of eating as non-frozen sushi or non-frozen onigiri. This means that the freezing operation can be extremely simplified. In addition, satisfactory quality can be obtained after natural thawing. This means that the frozen food can be directly held on a display table, which is very practical in supermarkets and convenience stores. Further, it is possible to provide sushi processing plants in foreign countries rather than near areas in which the sushi is to be consumed, which is very useful.

Now, a process of freezing and thawing boiled rice will be described with reference to FIG. 7.

First, 600 g of cleaned rice was washed by dipping it in about 1 liter of purified water, agitating it with the hands 15 times from the left and the same number of times from the right and then removing water.

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This washing was done 5 times repeatedly. Then, the washed rice was dipped in 840 milliliters of purified water for 120 min.

As soon as the dipping ended, the rice was boiled and steamed for a total period of 60 min. using a commercially available electric oven.

Then, a sample of the rice was left in a plastic mesh-like vessel for cooling down to 30 DEG C.

Seven rice packs were then prepared by filling a plastic vessel (16 cm.times.11 cm.times.3 cm ) like that for sushi with 200 g of sample. These rice packs were each preserved.

In the above way, 7 bags.times.3 ovens.times.6 ovens of packs were prepared.

Then, the packs were disposed on the second shelf of an exclusive food freezing unit (provided with a trade name "Plus .alpha. Freezer" manufactured by Maekawa Seisakusho) and then frozen such as to produce each of the freezing curves shown in FIGS. 8 to 13.

In this experiment, the commercially available "Plus a Freezer" was modified for use into a cassette rack type batch freezer, the inner temperature of which could be reduced down to -50 DEG C., and through which air could flow slightly.

After freezing, each rice pack was packed by air-purged packing in a vinyl bag and then preserved overnight at -20 to -25 DEG C. Then, it was thawed under the bad thawing condition of normal temperature (left alone at 25 DEG C., room temperature) thawing for 180 to 240 min.

After thawing, analysis with a textulometer (a food physical characteristic measuring instrument manufactured by Zenken Co., Ltd.), water content rate analysis and sensuous taste testing were conducted.

The individual freezing and freezer temperature reduction processes will now be described.

FIGS. 8 and 9 show a product temperature curve and a freezer temperature curve, respectively, in ideal freezing carried out with the above freezer in an embodiment of the invention. FIGS. 10 and 11 are a product temperature curve and a freezer temperature curve, respectively, of quick freezing carried out with the above freezer in a comparative example. FIGS. 12 and 13 are a product temperature curve and a freezer temperature curve, respectively, of slow freezing carried out with the above freezer in a comparative example.

Of the 7 packs noted above, 6 packs (2 packs as physical property analysis samples, one pack as a water content measurement sample, one pack as a taste testing sample, one pack as a temperature measurement sample and one pack as a spare (with less than 200 g of rice)) were subjected to freezing, while the remaining pack was used as contrast and not subjected to freezing.

The product temperature was measured using a "U Logger-L822-T" device (manufactured by Unipulse

Inc.). More specifically, thermocouple terminals "TCT-G-0,32-2000" (manufactured by Unipulse Inc.) were buried in the four corners and center of the pack at a depth of about 1 cm from the boiled rice mass surface such that they were perfectly enclosed in the boiled rice mass. In this state, the temperature measurement was carried out. The results are shown in FIGS. 8 to 12.

Analysis with the textulometer after thawing was carried out by using a textulometer manufactured by

Zenken Co., Ltd. More specifically, three boiled rice grains taken out randomly from the sample pack using a pair of tweezers were held in an analysis cell (or analysis dish), and an arm was brought into contact with the cell with its vertical movement. At this time, the boiled rice was squeezed by the arm, and an electric resistance that was offered when the arm was separated was used to calculate the hardness and stickiness.

Particularly with boiled rice, important parameters are, as shown in FIG. 13, hardness H (first chewing

H1, second chewing H2), stickiness -H (first chewing -H1, second chewing -H2) and adhesion (A3, A4

(first and second chewing)).

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Of the products frozen and thawed on the basis of the individual freezing curves and non-frozen contrast product, two-dimensional graphs of the hardness H1 and stickiness -H1 were formed as shown in FIGS. 14 to 16.

As will be understood from these Figures, substantially the same hardness and stickiness as those of the non-frozen contrast product could be obtained only in the case of freezing on the basis of the ideal curve.

After thawing, the hardness, stickiness, taste and whiteness were evaluated by 5-mark evaluation on the basis of the standards of the Food Agency, the Ministry of Agriculture and Forestry of Japan. The

5-mark evaluation was made in comparison to the non-frozen contrast product (mark 5 representing the highest evaluation). The results are shown in FIG. 17.

As is obvious from the Figure showing evaluation examples, the taste and other characteristics of the products frozen and thawed on the basis of the ideal curve are good even when the products are thawed under the worst condition of natural thawing (at room temperature of 20 to 25 DEG C.), that is, thawed at the glutinization temperature of starch or below.

Moreover, even when the products are left at room temperature of 20 DEG C. for more than 7 hr. after the thawing, the taste deterioration is substantially the same as that of the non-frozen boiled rice or sushi and gives rise to no problems.

Further, in the case of quick thermal thawing at a temperature above the .alpha./.beta. transition point of starch with an electronic oven, hot air, hot water, etc., under good conditions, the taste can not be distinguished from that of rice which has just been boiled.

Further, since it is possible to maintain sufficient quality when the product is thawed by natural thawing, fluctuations of the thawing conditions on the shop side give rise to no problems.

The freezing processes shown in FIGS. 8 to 12 will now be described in detail.

In the case of FIG. 8, the freezer was first preliminarily cooled down to about -5 DEG C.,a and then the temperature was reduced to about -15 DEG C. in 7 min. with a temperature gradient of 1.5 DEG

C./min., then held at the temperature of -15 DEG C. for 15 min. and then continually reduced to about -

42 DEG C. in 40 min. with a linear downward freezing temperature gradient of 0.7 to 0.8 DEG C./min.

With this control characteristic E, a freezing curve of the temperature of boiled rice was produced such that the temperature was reduced from normal temperature of 22 DEG C. to reach a maximum ice generation temperature range of the neighborhood of 0 to -3 DEG C. in an initial period of about 20 to

28 min with a temperature gradient of about 1.3 DEG C., then held in the maximum ice generation temperature range for a subsequent period of about 25 to 30 min. and then reduced to about -25 DEG

C. in a subsequent period of about 10 to 15 min. with a temperature gradient of about 1.6 DEG C./min.

In the case of FIG. 9, the freezer was first preliminarily cooled down to about -5 DEG C., and then the temperature was reduced to about -15 DEG C. in 7 min. with a temperature gradient of 1.2 to 1.5 DEG

C./min., then held at -15 DEG C. for 15 min. and then continually reduced to about -42 DEG C. in 40 min. with a linearly downward freezing temperature gradient of 0.7 to 0.8 DEG C./min. With this control characteristic F, a freezing curve of the temperature of boiled rice was produced such that the temperature was reduced from a normal temperature of 20 DEG C. to reach the maximum ice generation temperature range of the neighborhood of 0 to -3 DEG C. in an initial period of about 20 to

25 min. with a temperature gradient of about 1.2 DEG C., then held in the maximum ice generation temperature range for a subsequent period of about 20 to 25 min. and then reduced to about -20 to -25

DEG C. in a subsequent period of 12 to 17 min. with a temperature gradient of about 1.5 DEG C./min.

FIG. 10 shows a freezing characteristic in another comparative example (quick freezing 2). In this case, the freezer was first preliminarily cooled down to about -37 DEG C., and then the temperature was gradually reduced to about -50 DEG C. With this control characteristic H, the temperature of boiled rice was reduced from a normal temperature of 20 DEG C. to reach the maximum ice generation temperature range of the neighborhood of 0 to -3 DEG C. in an initial period of about 7 min. with a

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temperature gradient of about 2 DEG C., then passed the maximum ice generation temperature range from 0.about.-3 DEG C. to -4.about.-10 DEG C. in a subsequent period of about 10 to 15 min. with a temperature gradient of 0.3 DEG C., then reduced to -30 DEG C. in a subsequent period of about 8 min. with a temperature gradient of about 3 DEG C./min. and then gradually converged to -50 DEG C.

FIG. 11 shows a freezing characteristic in a further comparative example (slow freezing). In this case, the freezer was first preliminarily cooled down to about -2 DEG C., and then the temperature was reduced to about -7 DEG C. in 3 min. with a temperature gradient of 2 DEG C./min., then gradually reduced from -7 DEG C. to -13 DEG C. in 55 min. with a temperature gradient of about 0.1 DEG

C./min., and then reduced continually to about -30 DEG C. in 40 min. with a linearly downward freezing temperature gradient of 0.4 to 0.5 DEG C./min. With this control characteristic I, a freezing curve of the temperature of boiled rice was produced such that the temperature was reduced from a normal temperature of 20 DEG C. to reach the maximum ice generation temperature range in the neighborhood of 0 to -3 DEG C. in an initial period of about 20 to 25 min. with a temperature gradient of 1.2 DEG C./min., then held in the maximum ice generation temperature range in a subsequent period of 35 to 45 min. and then reduced to about -20 to -25 DEG C. in a subsequent period of about 30 min. with a temperature gradient of about 0.7 DEG C./min.

FIG. 13 shows a freezing characteristic of another contrast example (slow freezing 2) based on the flow shown in FIG. 7. In this case, the freezer was first preliminarily cooled down to about -8 DEG C., and then the temperature was reduced to about -18 DEG C. in 8 min. with a temperature gradient of 1.2

DEG C./min., then held at the temperature of -18 DEG C. for 24 min., then gradually reduced to -28

DEG C. in 30 min. with a temperature gradient of about 0.3 DEG C./min., and then held at the temperature of -28 DEG C. for 28 min. With this control characteristic J, a freezing curve of the temperature of boiled rice was produced such that the temperature was reduced from a normal temperature of 23 DEG C. to the maximum ice generation temperature range of the neighborhood of 0 to -3 DEG C. in an initial period of about 20 min. with a temperature gradient of 1.2 DEG C., then reduced to pass the maximum ice generation temperature range in a subsequent period of about 38 min. with a slight temperature gradient of 0.2 DEG C./min. and then reduced to about -28 DEG C. in a subsequent period of about 30 to 35 min. with a temperature gradient of about 0.7 DEG C./min.

In the case of FIG. 8, concerning an example of the invention, it is necessary to produce a freezer temperature curve, which takes about 8 min. for the first freezer temperature reduction step to reduce the freezer temperature down to about -15 DEG C., and about 15 min. for the second freezer temperature reduction step to maintain the temperature of about -15 DEG C., and about 35 to 40 min. for the third freezer temperature reduction step to reduce the freezer temperature to -42 DEG C. with a substantially linear temperature gradient.

In the case of FIG. 9, it is necessary to produce a freezer temperature curve, which takes about 4 min. for the first freezer temperature reduction step to reduce the freezer temperature to about -8 to -10 DEG

C., and 15 to 17 min. for the second freezer temperature reduction step to reduce the freezer temperature gradually from about -8 DEG C. to -15 DEG C., and about 40 to 45 min. for the third freezer temperature reduction step to reduce the freezer temperature to about -37 DEG C. with a substantially linear temperature gradient.

However, changing the freezer temperature in relation to time is unsuitable for continuous freezers, in which vessels are moved with conveyor trucks or pallets moved on a belt conveyor, although there is no problem in the case of batch processing.

In continuous freezing carried out by moving vessels on a net conveyor, as shown in FIG. 19, subsequent to cooling the freezer to about -10 DEG C., a freezer temperature reduction step is provided to reduce the temperature from about -10 DEG C. to -40 DEG C. with a substantially linear temperature gradient of 0.5 C/min.

With this control characteristic K, a freezing curve of the temperature of boiled rice was produced such that the temperature was reduced from normal temperature of 23 DEG C. to reach a maximum ice generation temperature range in the neighborhood of 0 to -3 DEG C. in an initial period of about 20 min. with a temperature gradient of about 1.2 DEG C./min., then caused to pass the maximum ice generation temperature range in a subsequent period of 38 min. with a slight temperature gradient of

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about 0.2 to 0.5 DEG C./min and then reduced to about -28 DEG C. in a subsequent period of about 30 to 35 min. with a temperature gradient of about 0.5 to 1 DEG C./min., preferably 0.7 C/min.

While the invention has been described in connection with boiled rice alone, it will be readily understood that substantially the same taste and sense of eating as those of non-frozen boiled rice are obtainable with processed food with boiled rice as main component, such as onigiri or chirashi.

Further, while boiled rice, curry rice, okowa, etc., which are to be eaten in a hot state, may be thawed using an electronic oven, chirashi, onigiri, etc. to be eaten in a cold state, may be thawed without use of any electronic range or the like. Natural thawing can instead be used to obtain substantially the same taste and sense of eating as those of non-frozen food. Thus, the invention is very beneficial.

It is to be appreciated that, according to the invention, it is only necessary to preserve, for instance, a large amount of factory-boiled rice by freezing in packed vessels or processed into sushi or the like for providing tasty boiled rice, onigiri, sushi, etc. when desired and in necessary amounts. Thus, there is no need for a 24-hour rice boiling system, and it is possible to improve inefficient production of small amounts of various kinds of food. Further, since the food can be preserved, it is possible to eliminate discarding loss, even when the consumption is low.

Further, plants for processing-boiled rice into processed food products may be installed in foreign countries rather than new consumption areas. Thus, the invention is very beneficial.Data supplied from the esp@cenet database - Worldwide Claims:


What is claimed is:

1. A process of freezing a group of sushi, in which at least one of nigiri-sushi, maki-sushi, and inarisushi is frozen, said process comprising:

placing the group of sushi on a vessel, and

disposing the vessel in a freezer and freezing the group of sushi, the freezing comprising:

a first freezing step in which the group of sushi placed on said vessel is disposed in the freezer, and the temperature of a rice ball part of the sushi is reduced from an initial temperature to a freezing point in a range of 0 DEG C. to -4 DEG C.;

a second freezing step in which the temperature is reduced to a temperature in the range from the freezing point to -10 DEG C. and maintained at this temperature for a predetermined period of time until passing of a maximum ice generation temperature range, and

a third freezing step in which the temperature is reduced to -15 DEG C. or below after the passing of the maximum ice generation temperature range;

the first freezing step having a temperature gradient which is set to be greater than the said second freezing step, and said second freezing step being carried out for a time which is set to be longer than the first freezing step.

2. The process according to claim 1, wherein in said third freezing step the temperature is reduced to -

20 DEG C. or below.

3. The process according to claim 2, wherein in said third freezing step the temperature is reduced to -

30 DEG C. or below.

4. The process according to claim 1, wherein the time of said second freezing step is set to about 13 to

35 min.

5. The process according to claim 1, wherein the third freezing step reduces the temperature to from -

20 to -30 DEG C. after the passing of the maximum ice generation temperature range and has a temperature gradient which is at least equal to the temperature gradient of the first freezing step.

6. The process according to claim 1, wherein the temperature gradient in said first freezing step is set to about 1 to 2.5 DEG C./min., the temperature gradient in the second freezing step is set to at most about 0.5 DEG C./min., and the temperature gradient in said third freezing step is set to about 1 to 3

DEG C./min.

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7. The process according to claim 6, wherein the temperature gradient in the first freezing step is about

1 to 2 DEG C./min., the temperature gradient in the second freezing step is at most 0.3 DEG C./min., and the temperature gradient in the third freezing step is about 1.5 to 2.5 DEG C./min.

8. The process according to claim 1, wherein the third freezing step is carried out over a time of at least about 10 minutes until a temperature of -30 DEG C. is reached.

9. The process according to claim 8, wherein the third freezing step is carried out for a time from 10 to

20 minutes.

10. The process according to claim 1, wherein the sushi is disposed in vessels in the freezer with a plurality of sushi pieces held in rows in each vessel, and the freezer then is preliminarily cooled down to about 0 to -15 DEG C. and freezing is started, the freezing comprising a first temperature reduction step in which the temperature of the freezer is reduced from the preliminary cooling temperature to about -30 DEG C. in about 5 to 25 minutes from the start of freezing of the sushi, and a subsequent second temperature reduction step to a temperature lower than -30 DEG C., the temperature gradient in the first temperature reduction step being greater than the temperature gradient in the second temperature reduction step, and the time until passing of the maximum ice generation temperature range of 0 to -10 DEG C. of the rice part of the sushi being set to 15 to 35 min.

11. The process according to claim 10, wherein the freezer is preliminarily cooled to from -5 to -10

DEG C., and the time until passing of the maximum ice generation temperature range of 0 to -10 DEG

C. is from 15 to 25 min.

12. The process according to claim 10, wherein the temperature gradient in the second temperature reduction step is at most 1 DEG C./min.

13. The process according to claim 12, wherein the temperature gradient in the second temperature reduction step is from about 0.2 to 0.5 DEG C./minute.

14. The process according to claim 10, wherein the nigiri-sushi or the maki-sushi is frozen, and after the preliminary cooling down of the freezer, the sushi is disposed in the freezer in vessels with a plurality of sushi pieces held in rows in each vessel, and freezing is then started, the freezing comprising a first temperature reduction step in which the freezer temperature is reduced from the preliminary cooling temperature to about -30 DEG C. in about 15 to 25 minutes, and a subsequent second temperature reduction step in which the freezer temperature is reduced to a temperature below -

30 DEG C., the first temperature reduction step having a temperature gradient greater than the second temperature reduction step, and the time until passing of the maximum ice generation temperature range of 0 to -10 DEG C. of a rice part of the sushi being set to 15 to 25 minutes.

15. The process according to claim 14, wherein the maximum ice generation temperature range is from

-3 to -6 DEG C., and the time until passing of the maximum ice generation temperature range is from

15 to 20 min.

16. The process according to claim 10, wherein the nigiri-sushi or the maki-sushi at room temperature is frozen, the temperature gradient in the first temperature reduction step of reducing the freezer temperature from the preliminary cooling temperature of -10 to -30 DEG C. is set to about 1 to 2 DEG

C./minute and the time of the first temperature reduction step is about 20 minutes, and the temperature gradient in the second temperature reduction step of reducing the freezer temperature to below -30

DEG C. is at most 1 DEG C./minute.

17. The process according to claim 16, wherein in the second temperature reduction step the freezer temperature is reduced to a temperature of -40 DEG C. or below, and the temperature gradient in the second temperature reduction step is about 0.5 DEG C./minute.

18. The process according to claim 10, wherein the freezing is carried out such that the temperature gradient in the first freezing step is about 2 DEG C./minute, the temperature gradient in the second

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freezing step is at most about 0.5 DEG C./minute, and the temperature gradient in the third freezing step is at most about 2 DEG C./minute.

19. The process according to claim 18, wherein the temperature gradient in the second freezing step is at most about 0.3 DEG C./min.

20. The process according to claim 1, wherein the inari-sushi is frozen, and after the preliminary cooling down of the freezer, the sushi is disposed in the freezer in vessels with a plurality of sushi pieces held in rows in each vessel, and freezing is then started, the freezing comprising a first temperature reduction step in which the freezer temperature is reduced from the preliminary cooling temperature to about -30 DEG C. in about 5 to 15 minutes at a temperature gradient of about 2 DEG

C./minute, and a second temperature reduction step in which the freezer temperature is reduced to -45

DEG C. at a temperature gradient of 0.2 to 0.5 DEG C./minute.

21. The process according to claim 1, wherein the inari-sushi is frozen such that the temperature gradient in the first freezing step is about 1.2 to 1.5 DEG C./minute and the time of the first freezing step is from 10 to 20 minutes, the temperature gradient in the second freezing step is at most about 0.3

DEG C./minute and the time of the second freezing step is about 25 to 35 minutes, and the temperature gradient in the third freezing step is about 2 DEG C./min.

22. A process of freezing a group of sushi, in which at least one of nigiri-sushi, maki-sushi, and inarisushi is frozen, said process comprising:

placing the group of sushi on a vessel, and

disposing said vessel in a freezer and freezing the group of sushi, the freezing comprising:

a first freezing step in which the group of sushi placed on said vessel is disposed in the freezer, and a freezer temperature is reduced from an initial temperature at the start of freezing to a freezing point of boiled rice,

a second freezing step in which the temperature is reduced from said freezing point to a maximum ice generation temperature for boiled rice and maintained at said maximum ice generation temperature for a predetermined period of time, said maximum ice generation temperature lying in the range from -4 to

-10 DEG C., and

a third freezing step in which the freezer temperature, after passing the maximum ice generation temperature range, is reduced to at most -20 DEG C., the first freezing step having a temperature gradient greater than the second freezing step, and the time until passing the maximum ice generation temperature range of boiled rice being from 15 to 35 minutes.

23. The process according to claim 22, wherein the sushi is disposed in the freezer in an enclosed state.

24. The process according to claim 22, wherein said freezing point lies in the range from about 0 to -4

DEG C.

25. The process according to claim 22, wherein in the third freezing stage the temperature is reduced to at most -30 DEG C.

26. The process according to claim 22, wherein the time until passing the maximum ice generation temperature range is from 15 to 30 minutes.

27. The process according to claim 26, wherein the time until passing the maximum ice generation range is from 20 to 30 minutes.

28. The process according to claim 22, wherein the sushi is frozen from room temperature, the temperature gradient in the first freezing step is from 1.5 to 2.5 DEG C./minute and the time of the first freezing step is from 15 to 25 minutes, the temperature gradient in the second freezing step is at most about 0.5 DEG C./minute through the maximum ice generation temperature range and the time in the second freezing step is about 23 to 37 minutes, the temperature gradient in the third freezing step is about 1 to 2.5 DEG C./minute and the freezer temperature is reduced in the third freezing step to a temperature in the range from -20 to -30 DEG C.

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29. The process according to claim 28, wherein the temperature gradient in the first freezing step is about 2 DEG C./minute, the time of the first freezing step is about 20 minutes, the maximum ice generation temperature range is from -4 to -10 DEG C., the temperature gradient in the second freezing step is at most about 0.3 DEG C./minute, and the temperature gradient in the third freezing step is 1.5 to 2 DEG C./minute.

30. The process according to claim 22, wherein after the maximum ice generation temperature range has been passed, the time in the third freezing step until a temperature of -30 DEG C. is reached is at least about 10 minutes.

31. The process according to claim 30, wherein the time in the third freezing step until a temperature of -30 DEG C. is reached is from 10 to 20 minutes.

32. A process of freezing boiled rice or processed foods consisting mainly of boiled rice, remaining in a wrapped condition, and disposed in a freezer, comprising preliminarily cooling down a freezer to from 0 to -10 DEG C. and then placing wrapped, clustered boiled rice in the freezer, the freezing comprising:

a first freezing step of reducing the freezer temperature at a temperature gradient of about 1 to 3 DEG

C./minute for about 10 to 20 minutes to a temperature of about -10 to -20 DEG C.,

a second freezing step of maintaining the temperature in the range from about -10 to -20 DEG C. for a time of from 10 to 23 minutes, and

a third freezing step of reducing the freezer temperature at a substantially linear temperature gradient of 0.5 to 1.5 DEG C./minute from the temperature of the second step to -30 to -45 DEG C.

33. The process according to claim 32, wherein the wrapped, clustered boiled rice is disposed in the freezer in a wrapped vessel.

34. The process according to claim 32, wherein the temperature gradient in the first step is 1 to 2 DEG

C./minute, the temperature is reduced in the first step to about -15 DEG C., the second step is carried out for a time of from 10 to 20 minutes, and the temperature gradient in the third step is 0.5 to 1 DEG

C./minute.

35. The process according to claim 34, wherein the second step is carried out for about 15 minutes.Data supplied from the esp@cenet database - Worldwide

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437.

WO9532993 - 12/7/1995

A METHOD FOR PREPARING FINE-GRANULED AND MODIFIED STARCHES


Inventor(s): MAELKKI YRJOE (FI); MYLLYMAEKI OLAVI (FI); TUOMELA RISTO (FI)

Applicant(s): EXAVENA OY (FI); MAELKKI YRJOE (FI); MYLLYMAEKI OLAVI (FI);

TUOMELA RISTO (FI)

IP Class 4 Digits: A23L; C08B

IP Class: A23L1/0522; C08B30/04

E Class: A23L1/09D; A23L1/0522; A23K1/14C; C08B30/04B

Application Number: WO1995FI00302 (19950530)

Priority Number: FI19940002546 (19940531)

Family: WO9532993

Equivalent: EP0767802; US5929231; FI942546; FI96317C; FI96317B

Cited Document(s):

Abstract:

US3537893; EP0378522


The subject of the invention is a method for preparing fine-granuled starch from kernels of oats or rice.

In the method, the kernels are ground and the starch is separated from the starch containing fraction obtained by the milling. An essential feature of the invention is that a suspension of the said fraction or of starch separated from it is treated with a surface-active agent or a lipolytic enzyme for disintegrating compound granules or aggregates of starch granules. Except the particle size, also functional properties of starch are affected. Disintegration of compound granules is enhanced by alkaline conditions and by mixing of the suspension. The fine-granuled starch obtained can be applied in foods and, for instance, for biodegradable plastics and for surface treatment agents. The invention can be included as a part of an integrated fractionation process, in which, in addition to starch, an oil fraction, an enriched fibre fraction, and a surplus fraction suitable for feed, are obtained.Description:


A method for preparing fine-granuled and modified starches

The subject of this invention is separation and purification of fine-granuled and modified starches from oat or rice groats.

Cereal crops used for manufacturing of starch have been so far mainly corn and wheat. As compared to these crops, use of rice for starch manufacture is less common. When used, the raw material consists usually for economical reasons of mechanically or enzymatically damaged kernels of rice.

Despite the properties of rice starch deviate from other cereal starches, its industrial use has remained smaller as compared to other cereal starches. This is partly due to its higher price, partly due to fluctuations in quality deriving of the problems in the quality of raw material said above.

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Barley and rye have been used in the manufacture of starch mainly for finding demand for surplus crops. These starches have no such special properties that would give them an advantage over other cereal starches.

Unlike most other cereal starches, oat starch has a small granule size. The primary granules are usually

3 to 5Um in dimensions and the shape is globular or angular. In the kernels of oats and rice, the starch is for its main part in compound granules. In the endosperm of rice, the starch is totally in compound granules, whereas in oats also individual granules occur. The small granule size makes it possible to use oat starch technologically for several purposes for which rice starch has been used so far. Also the gelatinization properties of native oat starch deviate from other cereal starches, due at least partly to the amount and composition of lipids in the starch granules.

Recovery of oat starch has been earlier presented mainly as a by-product in the preparation of protein or fibre concent rates. In most of these methods, separation is not presented further than until oat flour, or for the removal of starch for enriching the main products. Thus the United States

Patent 4,028,468 describes a process, where oat gum, starch and protein are separated from the bran by wet milling in sodium carbonate solution. Starch is separated by an effective centrifugation of the viscous solution, but any further separation of starch nor the purity of the recovered starch is given. The granule size of starch is said to be 5 to 10clam.. Similarly, the Canadian Patent 1,133,446 describes separation of the endosperm from milled oats, but purification of starch only for testing purposes using laboratory methods.United States Patent 4,211,801 describes separation in an organic solvent, whereby of oat flour free of oat gum is prepared, but separation of starch from it is not described.

Separation and purification of starch are described in detail in the European Patent Application

89.200321.1, and in the corresponding Finnish application 900508. The method is based on wet milling in a solution containing sulfur dioxide, and subsequent sieving and hydrocyclone operations. For achieving the separation of starch from cell walls, enzymes degrading cell wall components such as cellulose, hemicellulose andss-glucan are used. The particle size distribution of the starch obtained using this method is according to the patent specification within limits 4 - 15 m.

Enzymatic steps are also included in processes where starch is further hydrolysed to maltodextrin, as in the United

States Patents 4,996,063 and 5,082,673. These methods are, however, not intended for separation of unhydrolyzed starch.

In a method according to the Canadian Patent 1,179,189, hull-less oat groats are soaked in sulfur dioxide containing water for 24-28 hours at 500C. The inherent enzymatic activity of the kernel decomposes cell wall material, and the endosperm containing starch is separated from the bran by squeezing. In this method, too, no description of starch separation is included.

In the method described in the Finnish Patent 84,775 and in the corresponding European Patent

379,499, oat endosperm is treated in sodium hydroxide solution to decrease the protein content. The patent specification does not give information on the particle size distribution.

The nature of bonds in the compound starch granules of oats or rice and the separation of individual granules from them are not closely described in the scientific literature nor in patents. In the ordinary processes including a treatment in alkaline suspensions, mechanical homogenization, and dry milling, individual granules are only difficultly separated of compound granules. Even after being separated they remain in aggregates consisting of 2 to 10 individual granules.

One compound granule can contain tens of individual granules, and in electron micrographs the compound granule has often a ball shape. Correspondingly, compound granules that are difficultly decomposed occur also in rice starch.

In technological applications where a small granule size is important, it is also important that the granule size distribution is as homogeneous as possible. Examples of such cases are mixing of starch into plastics for preparing biodegradable materials, or in release or surface treatment agents. When classifications are used for achieving finegranuled and homogeneous starches, great losses of material can occur, unless compound granules and aggregates have been effectively decomposed in the process.

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The principal factors affecting functional properties of starches are the ratio of amylose and amylopectin, mechanical damages of the granule, leaching of starch molecules outside the granules, and complexing of starch by lipids. The lipid content of oat starch is inherently higher than that of other cereal starches. This evidently affects, among others, temperature of gelatinization, the amount of starch outside the granules, and freezing-thawing stability. A remarkable part of the lipids of starches is inside the granules. Therefore, treatments with lipid solvents at low temperatures remove only a part of the lipids, and the effect on functional properties remains small.

Extractions in butanol-water mixtures at their boiling temperatures for several hours can remove bound lipids and alter functional properties of the starches. A treatment at high temperatures in the presence of water leads, however, easily to leaching of starch outside the granule, to disintegration of the granule, and to gelatinization of starch.

In the background research for this invention it has now been surprisingly observed, that compound granules and aggregates consisting of several individual granules can be disintegrated by surface active compounds or lipolytic enzymes. This can occur when they are added to suspensions of oat flour or of partly or completely purified starch.

Both anion active, cation active and non ionic surface active compounds can have this effect. The disintegration is enhanced by a simultaneous mixing and by alkaline conditions. It was also noticed, that extracting fats enhances the disintegration of compound granules and aggregates by means of surface-active compounds. The effect is most probably due partly to dispersing or dissolving of compounds binding the particles together, partly to the decrease of interfacial tension and its effect in enhancing water penetration and swelling.

Essential characteristics of this invention are presented in the Claims attached.

When preparing starches for non food purposes, addition of synthetic anion active compounds such as alkyl sulfates or alkyl aryl sulfonates can be used. In preparing starches for food and pharmaceutical purposes, alkali salts of fatty acids or food and pharmaceutical grade non ionic or weakly ionized surface active agents such as those marketed under trade name Tween can be added. Alternatively, the lipids in the starch can be hydrolysed using microbial lipases or extracts of plant or animal products containing lipolytic activity, or by adding enzymes isolated from these. Also an addition ofcat ironic surface active compounds such as cetyl pyridinium chloride leads to disintegration of compound granules and aggregates, and simultaneously a microbicidic effect is achieved.Enzymes and conditions of use have to be selected in such a way, that no remarkable hydrolysis of starch can occur. Other steps in the preparation of starch can be performed by using unit operations and techniques known as such.

However, requirements of the product, the fine-granuled and slowly sedimenting starch, have to be considered in the choice of equipment and process parameters.

The treatments presented above affect not only the disintegration of compound granules and aggregates, but also the functional properties of the starch. Without committing to any mechanism of action it seems possible, that the surface active compounds remove a part of lipids bound in the starch and complexing it. Lipolytic enzymes hydrolyse lipids bound to or adsorbed on the starch thus altering their starch complexing effect. Each of these phenomena can affect the amount of starch outside the granules, and in water absorption, water binding, gelatinization and viscosity properties and the hydrolysability by enzymes.

The invention can be advantageously integrated to processes where cereal materials are fractionated and starch is separated from other components. The conditions and the active ingredients can then be chosen in such a way, that means described in this invention are applied. Operation steps according to this invention can be included in the total process, and objectives of this invention are thus simultaneously achieved. As an example, processing steps now described can be combined in fractionations and treatments which are performed according to the Finnish Patent 84,775 and the

Finnish Patent Application 932,558. Figure 1 attached presents such an integrated process for fractionating oats and further treatment of the fractions.Stages 1 to 6 and 16 to 17 of the figure can then be performed following the methods presented in the Finnish Patent 84,775, stages 7 to 12 according to the Finnish Patent Application 932,558, and stages 13 to 15 according to the method now presented.

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The extraction performed as stage 3 removes the main part of fat, which is of advantage for performing the method now described. In the proteolysis at the stage 7, enzymes can be applied, which besides proteases also contain lipase activity, and can thus affect the starch fraction according to the method now described.

Application of the invention is described in the following examples. As raw material in the examples, oat or fractions separated from it have been used, but the same methods can be applied also for rice or rice starches.

Example 1.

Dehulled oats were milled using a roller mill with uncorrugated rolls, and bran was separated by sieving. 5 kg of the flour obtained was suspended in 100 litres of water, pH of the mixture was adjusted to the value 9.0 with sodium hydroxide, and the mixture was allowed to stand overnight at room temperature. Coarse components were separated from the suspension by sieving it with a vibrating screen having openings of 125Um, performing four subsequent sievings. To the mixture passing the sieves, 100 ml of a 25% solution of sodium dodecyl sulfate was added, and the mixture was blended with a blade mixer overnight at room temperature.Fibre separated was removed by wet sieving using sieves with openings of 75Mm. Starch was further purified by separating larger particles in a hydrocyclone having a diameter of 10 mm, separated from the water by centrifugation, and air dried. In the product obtained, before further classifications, the individual granules made 95% of the particles.

Light absorption coefficient of the dry starch obtained, as measured from a layer thickness of 8.4 g/m2, was 0.97 m2/g, whereas that of the native oat starch, as measured from a layer thickness of 7.5 g/m2, was 0.186 m2/g, and from a layer thickness of 8.9 g/m2 it was 0.162 m2/g.

Example 2.

Five lots, 2 g each, of a starch sieved from oat meal suspended in sodium hydroxide solution, were suspended each in 100 ml of water, and the following additions were made: (a) 0.2 g of sodium dodecyl sulfate (b) 0.2 g of alkyl benzene sulfonate (c) 0.2 g of Tween 20 (d) 0.2 g of cetyl pyridinium chloride (e) no additions.

The lots were stirred with magnetic stirrers overnight at about 300C, after which each lot was subjected to microscopical observation. In lots a, b and c starch was nearly totally disintegrated to individual granules. No clear difference in the effect of these three surface active compounds could be observed.

In lot e, the change from the particle size distribution before the test was slight.

Example 3.

15 g of oat flour, obtained from wet sieving of oat bran after being extracted during 2 hours at 750C with ethanol and subsequent drying, was suspended in 150 ml of distilled water, and 300 mg of lipase produced by Candida cylindrica (Biocatalysts, England) was added to the mixture. This enzyme is an unspecific lipase, which also hydrolyses phospholipids. The mixture was stirred overnight with a magnetic stirrer at ca.300C, and the coarse part was separated by sieving the suspension with a 60Mm sieve. Starch was separated by centrifuging and subjected to microscopy. In the unfractionated starch obtained, the majority of the particles consisted of individual starch granules. In addition about 10% of the mass was in aggregates of 2 to 10 individual granules.A similar result was obtained by using lipase produced by Penicillium cyclopium (Biocatalysts), which is 1,3 specific towards fats, but hydrolyses from phospholipids fatty acids from both positions. The treatment was made in a buffer solution of pH

4.5, in the presence of calcium.

Example 4.

Effect of the treatments to functional properties of the starches was studied by differential scanning calorimetry from the following samples: (a) starch separated from an alkaline solution according to

Example 1, but without a treatment with surface active substances (b) starch prepared according to

Example 3 from ethanol extracted flour, but without any enzymatic treatment (c) starch prepared

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according to Example 3, treated with lipase of Candida cylindrica (d) starch prepared according to

Example 3, treated with lipase of Penicillium cyclopium

Table. Effect of solvent and enzyme treatments on calorimetric properties of starches. Angel = gelatinization enthalpy,

Tp = maximum temperature of the gelatinization endotherm,

AML

AH E = dissociation enthalpy of amylose-lipid complex, Tp = its maximum temperature.

Treatment AHgel J/g Tp, C#HAML,J/g Tp,0C a) alkaline separation 9.4 63.2 0.8 98.9 b)ethanol extraction 6.3 62.3 0.5+0.5 100 + 112c) ethanol extraction, lipase of

C. cylindrica 9.3 62.4 2.4 99.9 d) ethanol extraction, lipase of

P. cyclopium 8.8 62.5 2.5 101

According to the Table, treatments with lipases cause changes in the amylose-lipid complex, which reflects in changes in the functional properties.Data supplied from the esp@cenet database -

Worldwide Claims:


Claims

1. A method for preparation of fine-granuled starch from kernels of oat or rice, in which method the kernels are milled and starch is separated from a milled, starch containing fraction, characterized in that the said fraction or starch isolated from it is treated with a surface active compound or with a lipolytic enzyme for disintegrating starch compound granules or aggregates of granules.

2. A method according to Claim 1, characterized in that the surface active compound used is anion active.

3. A method according to Claims 1 or 2, characterized in that the surface active compound used is sodium dodecyl sulfate or an alkyl benzene sulfonate.

4. A method according to Claims 1 or 2, characterized in that the surface active compound used is an alkali salt of a fatty acid.

5. A method according to Claim 1, characterized in that the surface active compound used is non ionic or weakly ionized.

6. A method according to Claim 1, characterized in that the surface active compound used is cation active.

7. A method according to Claim 1, characterized in that as a lipolytic enzyme a microbial lipase that can hydrolyse lipids in starch is used.

8. A method according to Claim 1, characterized in that as lipolytic enzymes, extracts of plant or animal products containing lipolytic activity, or enzymes separated of that, are used.

9. A method according to Claims 1, 7 or 8, characterized in that the lipase used hydrolyses phospholipids.

10. A method according to any of the foregoing Claims, characterized in that treating with a surface active compound or a lipolytic enzyme, functional properties of the starch are modified.

11. A method according to any of the foregoing Claims, characterized in that before a treatment with a surface active compound or lipolytic enzyme, fat has been removed by extraction with an organic solvent.

12. A method according to any of the foregoing Claims, characterized in that a treatment with a surface active compound or with lipolytic enzymes is a part of a fractionation process of oats or rice, whereby

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in addition of starch a concentrate enriched in respect of dietary fibre is prepared.Data supplied from the esp@cenet database - Worldwide

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438.

WO9608978 - 3/28/1996

FOOD PRODUCTS BASED ESSENTIALLY ON NON-BREAD FLOUR PLANTS

AND METHOD FOR OBTAINING SUCH PRODUCTS


Inventor(s): KOBREHEL KAROLY (FR); NIMBONA COME (BI)

Applicant(s): AGRONOMIQUE INST NAT RECH (FR); KOBREHEL KAROLY (FR);

NIMBONA COME (BI)


IP Class: A23L1/10

E Class: A23L1/16; A23L1/20D4; A23L1/214D; A23L1/164; A21D2/36; A23L1/216B; A23L1/214B

Application Number: WO1995FR01217 (19950921)


Family: WO9608978

Equivalent: EP0782397; FR2724819

JP56021566; JP5015309; JP6007071 Cited Document(s):

Abstract:


Food product based essentially on non-bread flour plants having cohesion characteristics. Such a plant may be a non-bread making cereal, such as sorghun, corn, rice or a plant other than a cereal such as soya bean or manioc. The disclosed product may be obtained by a method comprising the following steps: hydrating flour or semolina essentially from such a plant up to a hydration rate appropriate to obtain a paste; compression of the paste; and drying. Subsequently, it can be baked.Description:

Description of corresponding document: FR2724819

La présente invention a pour objet des produits alimentaires majoritairement à base de plantes à farine non panifiable.

Elle est d'autre part relative à un procédé d'obtention de ces produits.

Les pâtes alimentaires sont traditionnellement prépares à partir de farine de blé dur ( Triticumdurum ).

Dans certains pays on ajoute néanmoins de la farine de blé tendre( Triticum aestivum). Cependant, la farine de blé tendre ne peut être utilisée seule, car elle ne permet pas d'obtenir après cuisson un produit présentant une cohésion.

Cette absence de cohésion se retrouve avec toutes les farines d'autres céréales non-panifiables, telles que le maïs, le sorgho ou le riz mais aussi avec des farines issues de graines de plantes autres que des céréales, telles que le soja ou le manioc.

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Le blé dur, panifiable, ne représente, avec une production mondiale de l'ordre de 30 millions de tonnes, qu'un faible pourcentage de la production mondiale de céréales qui est supérieure à 550 millions de tonnes. De plus, il n'est cultivable que dans un nombre restreint de régions.

Le manque de cohésion des produits obtenus à partir de farines de céréales non panifiables ou d'autres plantes fournissant des farines nutritives, est un problème majeur pour l'alimentation humaine, car il réduit considérablement les possibilités de fabrication de produits faciles à conserver issus de ces plantes ou de ces farines.

Des solutions de différentes natures ont néanmoins été trouvées dans certains pays.

Ainsi, en Europe Centrale, des pâtes sont obtenues en mélangeant du blé tendre avec des additifs tels que des oeufs.

Des pâtes peuvent aussi être obtenues à partir de céréales non panifiables par des procédés de fabrication faisant intervenir la gélatinisation ou la fermentation préalable de l'amidon. Cependant, ces produits sont marginaux et ont des qualités organoleptiques très différentes de celles obtenues à partir de blé dur. Leur utilisation est liée à des habitudes culinaires particulières.

Comme l'indique Faure en 1992 dans une revue des produits de type pâte comprenant des céréales non panifiables, il n'existe pas de produits majoritairement à base de céréales non panifiables et pouvant

être cuits. ( Sorghum andmaize pasta and extruded produts, p. 75-82 in " Utilization of sorghum and millets, Gomez et al. ed. Patancheru, India,

International Crops Research Institute for the Semi-Arid

Tropics).

Le demandeur s'est donc attaché à mettre au point des produits faciles à fabriquer, obtenus à partir de céréales non panifiables, pouvant être stockés sur de longues durées et pouvant être cuits et consommés de la même manière que les pâtes de blé dur. I1 a montré que, contrairement à ce qui est habituellement admis, on peut obtenir des produits présentant une cohésion uniquement à partir de céréales non panifiables, et ce même sans cuisson

La présente invention a donc pour objet un produit alimentaire majoritairement à base de plantes à farine non panifiable, ou farine sans gluten, et présentant une cohésion.

On entend par cohésion la capacité d'un produit à ne former qu'un seul bloc et à conserver sa forme tout en absorbant de l'eau, lors de la cuisson ou d'une surcuisson.

Avantageusement un tel produit est sous forme cuite.

Le terme gluten doit être compris dans le sens utilisé pour le gluten obtenu à partir de farine de blé.(Voir:Mauzé

C. Richard M. et Scotti G. "Guide pratique Contrôle de la qualité des blés" 1972, édité par ITCF Paris;

Dacosta Y.". Le

Gluten de blé et ses applications" 1986, édité par APRIA

Paris).

On entend par plantes à farine non panifiable les plantes qui, à la date de la présente invention, ne pouvaient aboutir, contrairement aux céréales panifiables telles que le blé, à des produits présentant une cohésion.

De telles plantes peuvent être les céréales non panifiables, telles que le sorgho, le maïs ou le riz, ou des plantes autres que des céréales telles que le soja, le manioc, l'igname, la patate douce ou la pomme de terre.

Elles peuvent aussi être le teff, le sarrasin et le poids chiche.

De manière générale toutes les farines obtenues & partir de céréales ou d'autres sources, à l'exception de la farine de blé, sont considérées comme des farines non panifiables, ou farines sans gluten.I1 est possible de fabriquer des produits de type pain avec les farines de seigle et d'orge; néanmoins ils

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présentent des qualités organoleptiques inférieures aux produits obtenus à partir de blé, en particulier une moins bonne viscoélasticité.

De manière préférentielle le produit selon l'invention contient au minimum 80% en poids de farine de plante non panifiable et encore plus préférentiellement au minimum 90%.

Avantageusement, un tel produit comprend un pourcentage proche de 100 % en céréales non panifiables.

Un tel produit peut être avantageusement caractérisé en ce qu'il présente:

- une capacité à absorberl'eau supérieure à 150% et avantageusement supérieure à 200%:

- une résistance proche de 100 % à une surcuisson de cinq minutes après une cuisson conventionnelle l'ayant amené & un état cuit.

Il peut en outre posséder une viscoélasticité, c'est-àdire qu'après compression le produit recouvre en partie son épaisseur d'avant la compression.

Les tests permettant de mesurer les caractéristiques de ces produits sont décrits dans les exemples de mise en oeuvre de1 invention qui suivent.

De tels produits peuvent aussi comprendre des composants, autres que ceux mentionnés ci-dessus, sous forme de poudre, tels que, dans le cadre d'aliments pour animaux, de la poudre d'os, du sang séché, du lait en poudre ou des sous produits de l'abattage.

La présente invention a d'autre part pour objet un procédé d'obtention d'un produit tel que décrit cidessus comprenant les étapes suivantes

- hydratation de farine ou de semoule d'une plante & farine non panifiable jusqu'à l'obtention d'un taux d'hydratation permettant l'obtention d'une pâte,

- compression de la pâte, et

- séchage.

Les produits peuvent alors être cuits, de manière similaire aux pâtes obtenues à partir de blé dur.

Préférentiellement l'hydratation est effectuée par pétrissage. Elle dépend de chaque produit. Elle est avantageusement d'au moins 45% du poids sec, préférentiellement de 55 %, et encore préférentiellement de 60%.

L'hydratation de la farine varie en fonction du type de plante dont elle est issue. Ainsi, le taux d'hydratation doit être compris entre 60 et 70% pour le soja, entre 65 et95b pour le riz, entre 85 et 95% pour le maïs ou le sorgho, entre 95% et 105% pour un gluten de maïs et entre 100 et 110% pour une farine de manioc.

L'hydratation de la farine nécessaire à la mise en oeuvre du procédé selon l'invention doit être déterminée pour chaque farine ou mélange de farines. Elle peut être déterminée par des essais préalables effectués dans un farinographe. Une faible quantité de farine est graduellement hydratée dans un micropétrin dont les bras pétrissent la farine à tester. La mesure du couple du micropétrin permet de déterminer l'hydratation optimale de la farine pour former le produit objet de la présente invention.

Le couple optimal correspond à environ 500 unités

Brabender pour le blé et à 400 unités Brabender pour le riz.

Les conditions de détermination de l'hydratation sont décrites dans"Mauzé et al.: Guide pratique contrôle de la qualité des blés, 1972, éd. ITCF, Paris.

De manière avantageuse, la compression de la pâte est effectuée à une pression minimale de 60 kg/cm2 et préférentiellement d'au minimum 100 kg/cm2. Le temps de pression est de quelques secondes.

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Avantageusement, le séchage est effectué à une température inférieure à45 C et préférentiellement proche d'environ30 C.

Outre les étapes indiquées ci-dessus, le procédé peut aussi comprendre une étape dans laquelle la farine ou la semoule hydratée est pétrie et/ou une étape dans laquelle la pâte est laminée avant d'être comprimée.

L'étape de compression est effectuée préférentiellement à l'aide d'une presse ou d'une extrudeuse.

Le laminage peut quant à lui être mis en oeuvre & l'aide d'un dispositif constitué de rouleaux tournant dans des directions opposées, entre lesquels la pâte est laminée.

L'homme du métier pourra se référer pour la mise en oeuvre de la présente invention et en particulier du procédé au manuel général suivant : Mauzé et al: Guide pratique

Contrôle de la qualité des blés, 1972, ed. ITCF, Paris.

Le procédé objet de la présente invention permet d'obtenir des produits présentant une cohésion après cuisson, sans exercer un quelconque traitement dénaturant.I1 ne modifie donc pas de manière notable la nature biochimique des différents constituants des farines et en particulier n'entraîne pas de dénaturation thermique des protéines ou de l'amidon. Cette absence de dénaturation permet de conserver la qualité des matières premières mises en oeuvre et donc d'obtenir une haute qualité nutritionnelle des produits objets de la présente invention.

On notera que la présente invention va à l'encontre des préjugés de l'homme du métier qui ne pouvait concevoir que des plantes, et en particulier des céréales, définies comme non panifiables permettent d'obtenir des produits alimentaires présentant une cohésion après cuisson.

En outre les produits selon l'invention peuvent être panifiables ou conduire à des produits panifiables.

Le procédé objet de la présente invention permet la production de produits à partir de céréales considéréescomme non panifiables. Ces céréales se trouvent en particulier dans les pays en voie de développement dans lesquels le blé ne peut être cultivé.

La présente inventionrésoud donc un problème important pour ces pays et présente de ce fait un progrès technique essentiel.

Un autre progrès technique important, engendré par l'invention, réside dans l'utilisation des produits objets de la présente invention pour la santé humaine. En effet, il est connu que certaines personnes présentent une intolérance au gluten de blé, appelée maladie coeliaque. La consommation des produits selon l'invention par ces personnes permet de pallier cet inconvénient des pâtes classiques contenant du gluten de blé.

La présente invention est illustrée sans pour autant être limitée par la description et les exemples ciaprès en référence aux dessins annexés sur lesquels:

- la figure 1 représente schématiquement le procédé selon l'invention.

- la figure 2 illustre le gonflement ( en ordonnée) de produits selon l'invention obtenus à partir de maïs, de sorgho et de riz, en fonction du temps de cuisson (en abscisse). Les flèches indiquent le temps de cuisson au bout duquel l'amidon est complètement gélatinisé.

- la figure 3 montre les gonflements des produits cuits obtenus à partir de blé dur ( DW), de blé tendre(BW), de riz (R), de sorgho (S) et de maïs (C).

- la figure 4 illustre les pertes à la cuisson ( en ordonnée) obtenues pour des produits obtenus à partir de riz, de sorgho et de maïs en fonction du temps de cuisson (en abscisse).

- les figures5A à 5E représentent l'évolution de la viscoélasticité. L'épaisseur ( en ordonnée) est mesurée en fonction du temps ( en abscisse) pour des produits obtenus respectivement à partir de blé dur, de blé tendre, de maïs, de sorgho et de riz.

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- les figures 6, 7 et 8 sont des diagrammes illustrant respectivement la compressibilité, la recouvrance et l'index de viscoélasticité des produits objets de la figure 3. Les abréviations sont identiques à celles utilisées dans la figure 3.

Les figures 9, 10, 11 et 12 sont des photographies en microscopie électronique de produits selon l'invention obtenus respectivement à partir de blé dur, de maïs, de riz et de sorgho. Les produits des figures 9A,lOA, llA et 12A ont été obtenus par le procédé selon l'invention comprenant un séchage

à30 avec une humidité relative de 78 à 94 % tandis que les produits des figures 9B,10B, llB et 12B ont été séchés à25 C avec une humidité relative ambiante.

EXEMPLE 1:

Fabrication de produits selon l'invention à Dartir de farines de maïs, de sorgho et de riz.

1. Taille des particules de la farine.

La taille moyenne des particules des farines de maïs, de sorgho et de riz, utilisées pour la préparation des produits de type pâtes selon l'invention est d'environ160pu.

Dans le cas du maïs, des échantillons ayant une taille de particule supérieure, de l'ordre de 200Hm ont

été également préparés. Les produits obtenus avec ces échantillons présentent une capacité d'absorption d'eau supérieure durant la cuisson mais l'aspect des produits n'est pas homogène, même après cuisson.

2. Préparation de produits detvne Dates selon l'invention.

2.1 Hydratation

Afin d'obtenir des produits de qualité, la quantité d'eau à ajouter a été déterminée de manière optimale pour chaque type de matériau de base ( farine ou semoule ).

Pour les farines, les hydratations suivantes, calculées sur une base sèche, ont été utilisées:

- maïs et sorgho : 89,5 %

- riz : entre 70 et 89,5 %

- soja : 64,8 %

- manioc : 105 %

- gluten de maïs : 100 %.

L'influence de l'hydratation sur la qualité des produits finaux dépend de l'origine de la farine utilisée.

Dans la plupart des cas, un écart de plus ou moins 3% par rapport aux valeurs indiquées ci-dessus est acceptable.

Dans le cas du maïs et du sorgho, quand l'écart est de plus ou moins 9,5 % par rapport à l'optimal déterminé, la qualité du produit final n'est plus acceptable.

2.2. Pétrissage

Pour chaque type d'échantillon de farine, la quantité d'eau requise a été ajoutée et le mélange a été effectué pendant dix minutes environ, c'est-à-dire le temps nécessaire pour obtenir un produit de type pâte.

Afin d'effectuer ce mélange, on a utilisé un microfarinographeBrabender, un mixographe ou un pétrin

Mahot.

Avec les deux premiers appareils, on ne peut pétrir que de 10 à 40 g de farine, tandis que le second permet de pétrir un kilogramme.

Les expérimentations ont été effectuées à des températures variant entre la température ambiante ( environ20'C) et37 C. Aucune influence du type d'appareil utilisé aux températures de pétrissage n'a pu

être mise en évidence.

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2.3. Laminage.

Afin d'obtenir le produit sous la forme d'une feuille, la pâte formée est passée deux fois entre des rouleaux ayant un écartement de 2,5 mm et tournant dans des directions opposées.

Cette étape peut néanmoins être omise sans pour autant diminuer la qualité des produits finaux.

2.4. ComPression

Les pâtes laminées sont introduites dans une presse où une pression de 60 à 200 kg/cm2 est appliquée.

La qualité des produits finaux est substantiellement comparable quand les pressions appliquées sont comprises entre 60 et 200 kg/cm2. En utilisant des pressions inférieures à 60 kg/cm2, la qualité des produits finaux a tendance à diminuer.

2.5. Découpage

La pâte compressée est découpée sous la forme de disques ayant des diamètres de 35 mm ou 14 mm et des épaisseurs d'environ 2mm.

La forme des produits peut être différente sans pour autant changer leur comportement.

2.6.Séchaae.

Les produits découpés frais sont mis sur un plateau de type tamis, en acier inoxydable, puis sont exposés dans le séchoir à une température de30'C et une humidité relative comprise entre 90 et 94%.

Après 14 heures, l'humidité relative dans le séchoir est d'environ 80% et l'humidité du produit est d'environ 16%, calculée sur une base sèche.

A ce moment, les produits sont ôtés du séchoir et laissés à l'air libre à la température ambiante.

Après six heures à la température ambiante, l'humidité des produits décroît et atteint 12%.

Les produits séchés sont stockés à température ambiante sans prendre de précaution particulière.

A des températures de séchage supérieures à40 C, la qualité culinaire des produits décroît. De manière similaire, le séchage des produits à des humidités relativement basses, même à faible température, a un effet négatif sur les qualités organoleptiques et plus particulièrement sur la qualité culinaire des produits.

Il doit être noté cependant que, quand les produits étaient séchés à une température élevée( 70-C), l'humidité relative était de 83 %, en raison des caractéristiques techniques du séchoir. Le séchage pourrait être effectué à des températures supérieures si l'humidité relative était maintenue à une valeur suffisamment élevée.

3. Caractérisation des produits obtenus.

La caractérisation des échantillons est effectuée sur des produits de type pâte fabriqués à partir de différents matériaux de base et préparés dans des conditions similaires.

3.1. Caractérisation de la dualité culinaire des produits.

3.1.1. Absorption d'eau.

L'absorption d'eau est mesurée en plongeant les produits dans del'eau bouillante. Après cuisson les produits sont retirés et mis dansl'eau à la température ambiante. Ils sont refroidis, ensuite essuyés et pesés.

L'absorption d'eau est exprimée en pourcentage de l'augmentation de poids des produits durant la cuisson, calculée sur la base de la matière sèche.

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Les résultats représentés sur la figure 2 montrent que l'absorption d'eau des produits provenant de chaque céréale sans gluten, c'est-à-dire de céréales non panifiables ( maïs, sorgho et riz ), augmente progressivement en fonction du temps de cuisson. Le tableau 1 illustre aussi cette propriété par des résultats complémentaires.

La vitesse de gonflement des produits diminue mais le gonflement continue néanmoins après une complète gélatinisation de l'amidon.

Comme le montre la figure 2, l'absorption d'eau des produits atteint des valeurs supérieures à 200 % lors de la gélatinisation complète de l'amidon, c'est-à-dire à un moment où les produits peuvent être considérés comme étant totalement cuits.

On notera néanmoins que l'absorption d'eau dépend aussi de la forme des produits. Dans le cas de disques ayant un faible diamètre, le temps de cuisson est inférieur. Dans ce cas, lorsque la gélatinisation de l'amidon est totale, l'absorption d'eau est considérablement plus importante que dans les produits ayant un diamètre important. Pour cette raison, les résultats concernant l'absorption d'eau ne peuvent être considérés comme absolus et seuls les résultats obtenus avec des produits ayant des tailles similaires peuvent être comparés.

Les résultats présentés sur la figure 3 et dans le tableau 1 comparent les résultats obtenus avec cinq produits céréaliers différents. Ils montrent que l'absorption d'eau des produits obtenus à partir de céréales non panifiables est comparable à l'absorption d'eau de produits obtenus à partir de blé dur. Les valeurs sont similaires pour le maïs et le sorgho. Elles peuvent être supérieures à celles obtenues avec le blé.

Des résultats similaires sont obtenus pour des produits fabriqués à partir de blé dur et de blé tendre.

3.1.2. Résistance à la surcuisson

Le temps de cuisson est défini comme le temps nécessaire pour obtenir une gélatinisation complète de l'amidon de produit plongé dans de l'eau bouillante. Cette détermination est effectuée par une observation visuelle . A cet effet, les produits cuits sont coupés et compressés à la main entre deux pièces de verre synthétique (Plexiglas).

Lorsque le produit est cuit, la ligne de couleur blanche, due à l'amidon non-gélatinisé, disparait.

Les produits obtenus à partir de différentes céréales ou à partir d'autres origines sont cuits dans les conditions habituelles de cuisson de pâtes de blé dur, comme décrit cidessus.

La cuisson a été maintenue pendant cinq minutes après la complète gélatinisation de l'amidon. ( T + 5).

Les produits sont considérés comme résistant à une surcuisson quand, après

T + 5, ils conservent leur forme initiale et sont d'un aspect homogène typique de produits cuits et gonflés.

Au contraire, des produits préparés de manière impropre se désintègrent durant la cuisson ou durant la surcuisson.

3.1.3. Propriétésviscoélastigues.

Les propriétés viscoélastiques ont été déterminées en utilisant unviscoélastographe, telqu'u ilisé pour déterminerles propriétés viscoélastiques de pâtes c zen blé dur.

Selon cette méthode, on applique un poids de 750 g au produit cuit présentant une forme ré ière. Les produits cuits sont coupés afin d'avoir la taille de petits disques ayant un diamètre de 10 mm et une

épaisseur initiale E.

Après une compression de 40 secondes, les produits compressés ont une épaisseur el, et, de O à 40 secondes après que le poids ait été enlevé, uneépar user e2.

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Les formules utilisées pour calculer la compressibilité, la recouvrance élastique et l'index de viscoélasticité, sur la base des valeurs E, el et e2 sont les suivantes

E -e1

Compressibilité (C) =

E e2 -e1

Recouvrance élastique ( ER) =

E - e1

e2 - e1

Index de viscoélasticité (VI) =E . 10

(E - e1)2

Les courbes obtenues pour le blé dur, le blé tendre, le maïs, le sorgho et le riz sont respectivement représentées sur les figures 5A, 5B, 5C,5D et 5E.

Dans ces expériences, lesproduits à base de blé dur ont été préparés dans les mêmes conditions que les produits à base de céréales sans gluten (céréales non panifiables), afin de comparer leurs qualités dans des conditions équivalentes.

On notera cependant que l'hydratation de la semoule de blé dur a été effectuée à une valeur de 49 % sur la base de la matière sèche, correspondant à l'hydratation utilisée habituellement pour préparer des pâtes de blé dur.

La compressibilité des différents produits obtenus est représentée sur la figure 6 tandis que la recouvrance élastique est illustrée sur la figlure 7 et l'index de viscoélasticité des produits cuits sur la figure 8.

De manière générale, la qualité des produits obtenus & base de riz est inférieure à la qualité des produits provenant des autres céréales.

Les produits obtenus à partir de blé dur et de blé tendre présentent des caractéristiques similaires

La qualité des produits obtenus à partir de maïs et de sorgho est comparable ou même supérieure à celle de produits obtenus à partir de blé. Le paramètre le plus intéressant est la recouvrance élastique des produits cuits. Les meilleures valeurs sont obtenues pour le maïs et le sorgho.

3.1.4. Perte à la cuisson.

L'évolution des pertes à la cuisson en fonction du temps de cuisson des produits obtenus à partir de maïs, de sorgho et de riz est illustrée sur la figure 4 et sur le tableau 1.

Le temps de cuisson a été déterminé comme étant de 13 minutes pour les produits obtenus à partir de maïs et de sorgho et d'environ 10 minutes pour les produits obtenus & partir de riz.

Ces résultats montrent qu'au temps de cuisson T, quand les produits sont cuits, les pertes engendrées par la cuisson des produits obtenus à partir de maïs et de sorgho sont légèrement inférieures à 10 % tandis que, pour les produits obtenus à partir de riz, les pertes à la cuisson sont d'environ 12 %. Les produits obtenus à partir de blé dur et de blé tendre dans des conditions similaires présentent un temps de cuisson d'environ 13 minutes.

Comme le montre le tableau 1, les pertes à la cuisson de produits obtenus à partir de blé dur sont similairesb celles des autres produits, bien que les pertes & la cuisson de produits obtenus à partir de blé tendre soient légèrement inférieures. Les pertes à la cuisson de pâtes de blé dur traditionnelles, telles que les spaghettis, sont légèrement inférieures à 15%.

Ceci montre que le procédé objet de la présente invention n'a pas d'effet négatif sur les paramètres caractérisant la qualité des produits de type pâte.

3.2. Coloration des Produits

La coloration des différents produits de type pâte dépend en premier lieu des caractéristiques du matériel de base, plus que de la céréale utilisée. Ainsi, les produits obtenus à partir de maïs blanc et de

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maïs jaune ont d'une part de bonnes qualités culinaires et d'autre part conservent respectivement leur coloration caractéristique claire ou jaune, même après cuisson. Les produits, aussi bien avant cuisson qu'après cuisson, fabriqués à partir de farine de riz ont une coloration similaire aux produits obtenus à partir de maïs blanc.

Les produits obtenus à partir de blé tendre ont une tendance à prendre une coloration sombre.

Les produits séchés obtenus à partir de sorgho peuvent, en fonction du cultivar utilisé, présenter une couleur sombre marron. Cette coloration marron diminue au cours de la cuisson.

Si la couleur du produit n'est pas celle souhaitée, par exemple dans le cas d'une coloration marron importante, l'amélioration peut être obtenue en baissant le pH del'eau utilisée pour l'hydratation jusqu'à une valeur comprise entre 4 et 5, par exemple en ajoutant du vinaigre.

L'amélioration de la couleur des produits cuits peut être aussi obtenue de manière similaire en acidifiant faiblementl'eau de cuisson par exemple en ajoutant quelques gouttes de vinaigre à cette eau.

EXEMPLE 2:

Fabrication à partir de farines de teff, de sarrasin. de pois chiche, de soia,d'igname, de patate douce et deporpre de terre.

1) Matières premières testées:

- céréales ou assimilé aux céréales : teff et sarrasin

- légumineuses: pois chiche, soja

- tubercules ou racines: igname, patate douce, pomme de terre.

2)Préparation des échantillons , et des produits.

Pour le teff, le sarrasin et le pois chiche, on a utilisé des farines du commerce.

Tubercules ou racines: les produits frais sont lavés, épluchés, découpés en petits morceaux puis séchés

à l'étuve & 30-35'C. Les produits séchés (contenant environ 8% d'eau) sont broyés avec un Cyclotec

1093 Sample Mill. La granulométrie de la farine obtenue est d'environ 160pm.

L'hydratation nécessaire pour la fabrication du produit a été déterminée au microfarinographeBrabender (obtention d'une pâte après le pétrissage), comme dans l'exemple 1 pour les céréales sans gluten.

Le procédé de fabrication des produits est le même que celui décrit dans l'exemple 1. Les farines sont hydratées par pétrissage puis les pâtes ainsi obtenues sont compressées (environ 100 kg/cm2) et séchées dans les conditions précédemment décrites.

On a également réalisé des produits à partir de mélanges de farines.

3) Résultats obtenus.

Les résultats de la caractérisation des produits sont présentés dans les tableaux 2, 3 et 4.

Les produits fabriqués à partir de matières premières différentes de celles de l'exemple 1 ont une bonne qualité culinaire.( voir tableaux).

Deux exceptions sont cependant à noter: la pomme de terre et le manioc. Cependant la farine de manioc utilisée est une farine de commerce.

Par contre, les produits préparés à partir de la farine d'igname dans les conditions décrites plus haut, ont une bonne tenue à la cuisson (tableaux 2 et 3).

2192/2197

L'addition de 10% de farine de soja à la farine de pomme de terre a rendu possible l'obtention d'un produit présentant une cohésion mais de moins bonne qualité qu'avec le mélange manioc 90% (farine du commerce) soja 10%.

Dans les mélanges, le soja peut être remplacé par le pois chiche. Cependant, pour obtenir un produit de bonne qualité, on doit rajouter 20% de farine de pois chiche à la farine de manioc ou de pomme de terre. Comme le montre le tableau 2 les teneurs protéiques du manioc et de la pomme de terre sont très faibles. L'addition d'une farine de légumineuse augmente simultanément la teneur protéique et la valeur nutritive des produits.

Dans le cas de l'igname et de la patate douce qui, comme la pomme de terre et le manioc, ne contiennent que très peu de protéines, l'addition de farine d'une légumineuse augmente la teneur protéique du produit, ainsi que sa valeur nutritive, mais l'addition d'autres farines n'est pas nécessaire pour l'obtention de nouveaux produits ayant une qualité culinaire satisfaisante.

A partir des farines amylacées ( pomme de terre, manioc) des produits selon l'invention ont été obtenus

également sans ajout de farine de légumineuse en utilisant des mélanges50%/50% de ces deux amylacées.

En ce qui concerne la mesure de viscoélasticité des produits, le tableau 4 montre que, suivant la charge utilisée, la discrimination entre les produits varie. Si l'utilisation d'une charge de 750g est recommandée pour les variétés de blé dur, les produits selon l'invention à base de farine contenant très peu de protéines, sont mieux différenciés en utilisant une charge de 500g. La plupart des produits obtenus ont une bonne viscoélasticité. Les produits contenant de la pomme de terre ont globalement une moins bonne viscoélasticité.

Etudes en microscopie électroniQue sur les Produits à base de céréales non panifiables.

Les analyses ont été réalisées sur produits cuits à base de blé dur ( figures 9A et 9B),de Maïs ( figures

10A et 10B), de riz ( figures11A et 11B) et de sorgho (figures 12A et 12B). Les produits des figures

9A, 10A, llA et 12A ont été séchés à 30 C, avec une humidité relative de 78 à 94% tandis que ceux des figures 9B, 10B,llB et 12B ont été séchés à 25'C avec une humidité relative ambiante. Les résultats montrent que l'ensemble de traitements, et probablement plus particulièrement la compression, confèrent aux produits une structure organisée. Les produits séchés à3OC présentent néanmoins des microstructures plus homogènes que les produits séchés à25 C à humidité ambiante.Chez les produits obtenus à partir des céréales non panifiables on peut constater l'existence d'un réseau protéique continu.

Conclusion

Ces exemples montrent quel'on peut obtenir des produits de type pâte à partir de différents matériaux de base tels que des farines ou des semoules de céréales sans gluten, ou céréales non panifiables, ( maïs, sorgho, riz) sans ajouter de produits issus du blé ou sans autres additifs. L'ajout d'additifs est cependant possible dans le but de changer le goût ou d'autres caractéristiques organoleptiques des produits.

D'autres matériaux de base ( farine de soja, gluten de maïs, farine de manioc contenant 10 % de farine de soja....) peuvent aussi être utilisés avec succès.

Ces nouveaux produits peuvent être, pour l'alimentation humaine, utilisés après cuisson d'une manière similaire aux pâtes traditionnelles.

Ce procédé peut aussi être utilisé pour texturer différents matériaux de base pour l'alimentation animale. TABLEAU l

ABSORPTION D'EAU ET PERTES A LA CUISSON

Temps de 5 10 15 20 cuisson (min)

EMI19.1

* >;SEP; * >;SEP; * >;SEP; *

>;tb; Gonfle- >;SEP; Perte >;SEP; Gonfle- >;SEP; perte >;SEP; à >;SEP; Gonfle- >;SEP; perte >;SEP;

à >;SEP; Gonfle- >;SEP; perte >;SEP; à

2193/2197

>;tb; ment >;SEP; à >;SEP; la >;SEP; ment >;SEP; la >;SEP; ment >;SEP; la >;SEP; ment >;SEP; la

>;tb; cuisson >;SEP; cuisson >;SEP; cuisson >;SEP; cuisson

>;tb; Maïs >;SEP; 202 >;SEP; 7,5 >;SEP; 231 >;SEP; 10 >;SEP; 256 >;SEP; 12,5 >;SEP; 282 >;SEP;

14,7

>;tb; Sorgho >;SEP; 211 >;SEP; 8 >;SEP; 233 >;SEP; 11 >;SEP; 261 >;SEP; 13,6 >;SEP; 274 >;SEP;

17

>;tb; Riz >;SEP; 154 >;SEP; 12 >;SEP; 164 >;SEP; 13 >;SEP; 181 >;SEP; 15 >;SEP; 206 >;SEP; 20

>;tb; Blé >;SEP; dur >;SEP; 224 >;SEP; 12,8 >;SEP; 240

>;tb; Blé >;SEP; à >;SEP; pain >;SEP; 230 >;SEP; 14 >;SEP; 250

>;tb; * exprimée en % de la matière sèche.

TABLEAU 2

Caractéristiques générales des produits

EMI20.1

Produits >;SEP; Teneur >;SEP; en >;SEP; Hydratation >;SEP; Gonflement >;SEP; Pertes >;SEP;

Couleur >;SEP; des >;SEP; produits

>;tb; protéines. >;SEP; % >;SEP; % >;SEP; Cuisson >;SEP; Crus >;SEP; Cuits

>;tb; Céréales

>;tb; Maïs >;SEP; (M.) >;SEP; 10,4 >;SEP; 89 >;SEP; 282 >;SEP; 8,4 >;SEP; jaune >;SEP; orangé

>;SEP; jaune

>;tb; Sorgho >;SEP; 13 >;SEP; 89 >;SEP; 274 >;SEP; 9,2 >;SEP; brun >;SEP; clair >;SEP; gris >;SEP; rosâtre

>;tb; Riz >;SEP; 7,5 >;SEP; 70-89 >;SEP; 206 >;SEP; 10,4 >;SEP; blanc >;SEP; blanc

>;tb; Blé >;SEP; dur >;SEP; 14,7 >;SEP; 49 >;SEP; 240 >;SEP; 5,1 >;SEP; jaune >;SEP; jaune

>;tb; (cv. >;SEP; Néodur)

>;tb; Blé >;SEP; tendre >;SEP; 10,3 >;SEP; 53 >;SEP; 250 >;SEP; 6,7 >;SEP; jaune >;SEP; brun

>;SEP; jaune >;SEP; brun

>;tb; (cv. Thésée)

Teff 12,0 66 175 10 gris clair brun foncé

Divers

Sarrasin 11,3 50 225 4,5 gris clair brun foncé

Gluten de maïs 60,0 100 - - -

Soja 40 65 224 9,7 jauâtre jaune pâle

Pois chiche 20 46 267 8,2 jaune orangé jaune pâle

(P.C.)

Manioc 0,9 105 - - -

Patate douce 2,0 62 295 10,6 brun pâle brun jaune

(P.d.)

Igname 1,9 82 300 7,8 brun olive brun jaune

Pomme de terre 2,1 60 - - - (P.d.t)

Caractéristiques générales de produits>;/RTI;

EMI21.1

Produits >;SEP; Teneur >;SEP; en >;SEP; Hydratatiobn >;SEP; Gonflement >;SEP; Pertes >;SEP;

Couleur >;SEP; des >;SEP; produits

>;tb; protélines >;SEP; % >;SEP; % >;SEP; Cuisson >;SEP; Crus >;SEP; Cuits

>;tb; Mélanges

>;tb; Gluten >;SEP; M.75% >;SEP; +

>;tb; M.25% >;SEP; 47,6 >;SEP; 94 >;SEP; 152 >;SEP; 4,9 >;SEP; jaune >;SEP; orangé >;SEP; jaune

>;tb; M.75% >;SEP; + >;SEP; gluten

>;tb; M.25% >;SEP; 23,0 >;SEP; 90 >;SEP; 215 >;SEP; 8,5 >;SEP; jaune >;SEP; jaune >;SEP; orangé

>;tb; Manioc >;SEP; 90%

>;tb; + >;SEP; soja >;SEP; 10% >;SEP; 4,9 >;SEP; 85 >;SEP; 251 >;SEP; 11 >;SEP; blanc >;SEP; blanc

>;tb; très >;SEP; pâle

>;tb; Manioc >;SEP; 80% >;SEP; +

2194/2197

>;tb; P.C.20% >;SEP; 4,7 >;SEP; 70 >;SEP; 235 >;SEP; n.d. >;SEP; n.d. >;SEP; n.d.

>;tb;

P.d. >;SEP; 90% >;SEP; +

>;tb; soja >;SEP; 10% >;SEP; 5,8 >;SEP; 63 >;SEP; 252 >;SEP; 9,4 >;SEP; brun >;SEP; pâle >;SEP; brun

>;tb; jaunâtre

>;tb; Igname >;SEP; 90%

>;tb; + >;SEP; soja >;SEP; 10% >;SEP; 5,7 >;SEP; 76 >;SEP; 276 >;SEP; 7,1 >;SEP; brun >;SEP; pâle

>;SEP; brun

>;tb; jaunâtre

>;tb; Maïs >;SEP; 70% >;SEP; +

>;tb; soja >;SEP; 30% >;SEP; 19 >;SEP; 70 >;SEP; 224 >;SEP; 7,5 >;SEP; jaune >;SEP; orangé

>;SEP; blanc

>;tb; très

>;tb; pâle

>;tb; P.d. >;SEP; 50% >;SEP; +

>;tb; Manioc >;SEP; 50% >;SEP; 1,5 >;SEP; 65 >;SEP; 250 >;SEP; 12 >;SEP; gris >;SEP; clair

>;SEP; jaune

>;tb; brun

>;tb; foncé

>;tb; TABLEAU 2 (suite)

Caractéristiques générales de produits obtenus par le procédé

EMI22.1

Produits >;SEP; Teneur >;SEP; Hydratation >;SEP; Gonflement >;SEP; Pertes >;SEP; Couleur >;SEP; des >;SEP; produits

>;tb; prot. >;SEP; % >;SEP; % >;SEP; Cuisson >;SEP; Crus >;SEP; Cuits

>;tb; P.d.t.>;SEP; 50%

>;tb; + >;SEP; manioc >;SEP; 50% >;SEP; 1,5 >;SEP; 65 >;SEP; 230 >;SEP; 14 >;SEP; jaune >;SEP; pâle >;SEP; jaune

>;tb; brun

>;tb; foncé

>;tb; P.d. >;SEP; 50% >;SEP; +

>;tb; P.d.t. >;SEP; 50% >;SEP; 2 >;SEP; 65 >;SEP; 280 >;SEP; 9,5 >;SEP; brun >;SEP; olive >;SEP; brun

>;tb; sombre

>;tb; P.d.t. >;SEP; 90% >;SEP; +

>;tb; soja >;SEP; 10% >;SEP; 5,8 >;SEP; 65 >;SEP; 248 >;SEP; 15 >;SEP; gris >;SEP; rosâtre >;SEP; brun

>;tb; jaunâtre

>;tb; TABLEAU 3

Propriétés viscoélastiques des produits

EMI23.1

Produits >;SEP; Compressibilité >;SEP; Recouvrance >;SEP; Indice >;SEP; de

>;tb; relative >;SEP; viscoélasticité

>;tb; Céréales

>;tb; Maïs >;SEP; (M) >;SEP; 0,232 >;SEP; 0,700 >;SEP; 30

>;tb; sorgho >;SEP; 0,301 >;SEP; 0,605 >;SEP; 17,8

>;tb; Riz >;SEP; 0,141 >;SEP; 0,320 >;SEP; 9,7

>;tb; Bié >;SEP; dur >;SEP; (cv. >;SEP; Néodur) >;SEP; 0,340 >;SEP; 0,607 >;SEP; 17,8

>;tb; Blé >;SEP; tendre >;SEP; (cv.>;SEP; Thésée) >;SEP; 0,347 >;SEP; 0.617 >;SEP; 18,0

>;tb; Teff >;SEP; 0,315 >;SEP; 0,341 >;SEP; 10,9

>;tb; Divers

>;tb; Sarrasin >;SEP; 0,476 >;SEP; 0,172 >;SEP; 3,7

>;tb; Gluten >;SEP; de >;SEP; Maîs >;SEP; (gluten >;SEP; M) >;SEP; - >;SEP; - >;SEP;

2195/2197

Soja >;SEP; 0,295 >;SEP; 0,551 >;SEP; 18,7

>;tb; Pois >;SEP; chiche >;SEP; 0,242 >;SEP; 0,490 >;SEP; 20,3

>;tb; Manioc >;SEP; - >;SEP; - >;SEP;

Patate >;SEP; douce >;SEP; (P.d.) >;SEP; 0,693 >;SEP; 0,478 >;SEP; 6,9

>;tb; Igname >;SEP; 0,600 >;SEP; 0,299 >;SEP; 5,1

>;tb; Pomme >;SEP; de >;SEP; terre >;SEP; (P.d.t.) >;SEP; - >;SEP; - >;SEP; TABLEAU 3 (suite)

Propriétés viscoélastiques des produits

EMI24.1

Produits >;SEP; Compressibilité >;SEP; Recouvrance >;SEP; Indice >;SEP; de

>;tb; relative >;SEP; viscoélasticité

>;tb; Mélanges

>;tb; Gluten >;SEP; M.>;SEP; 75%+Maïs >;SEP; 25% >;SEP; 0,097 >;SEP; 0.313 >;SEP; 33,5

>;tb; Maïs >;SEP; 75% >;SEP; + >;SEP; Gluten >;SEP; M. >;SEP; 25% >;SEP; 0,142 >;SEP; 0,475

>;SEP; 33,6

>;tb; Manioc >;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,592 >;SEP; 0,081 >;SEP; 1,4

>;tb; Manioc >;SEP; 80+ >;SEP; P.C. >;SEP; 20% >;SEP; 0,573 >;SEP; 0,088 >;SEP; 1,5

>;tb; P.d. >;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,458 >;SEP; 0,631 >;SEP; 13,9

>;tb; Igname >;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,559 >;SEP; 0,631 >;SEP; 7.3

>;tb; Maïs >;SEP; 70% >;SEP; + >;SEP; soja >;SEP; 30% >;SEP; 0,173 >;SEP; 0,577 >;SEP; 33,3

>;tb; P.d. >;SEP; 50% >;SEP; + >;SEP; manioc >;SEP; 50% >;SEP; 0,541 >;SEP; 0,149 >;SEP; 2

>;tb; P.d.t. >;SEP; 50% >;SEP; + >;SEP; manioc >;SEP; 50% >;SEP; 0.550 >;SEP; 0,115 >;SEP; 2,1

>;tb; P.d.t. >;SEP; 50% >;SEP; + >;SEP; P.d. >;SEP; 50% >;SEP; 0,542 >;SEP; 0,190 >;SEP; 3,5

>;tb; P.d.t.>;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,672 >;SEP; 0,038 >;SEP; 0,6

>;tb; TABLEAU 4

Effet de la charge sur les mesures de la viscoélasticité des produits

EMI25.1

Produits >;SEP; Charge: >;SEP; 750 >;SEP; g >;SEP; Charge: >;SEP; 500 >;SEP; g

>;tb; C >;SEP; Rr >;SEP; Iv >;SEP; C >;SEP; Rr >;SEP; Iv

>;tb; Patate >;SEP; douce >;SEP; (P.d.) >;SEP; 0,693 >;SEP; 0,478 >;SEP; 6,9 >;SEP; 0,590 >;SEP;

0,434 >;SEP; 10

>;tb; Igname >;SEP; 0,600 >;SEP; 0,299 >;SEP; 5,1 >;SEP; 0,540 >;SEP; 0,600 >;SEP; 9,4

>;tb; P.d.t >;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,678 >;SEP; 0,038 >;SEP; 0,6

>;SEP; 0,193 >;SEP; 0,518 >;SEP; 27

>;tb; Manioc >;SEP; 90% >;SEP; + >;SEP; soja >;SEP; 10% >;SEP; 0,592 >;SEP; 0,081 >;SEP; 1,4

>;SEP; 0,337 >;SEP; 0,439 >;SEP; 13

>;tb; P.d.t. >;SEP; 50% >;SEP; + >;SEP; P.D. >;SEP; 50% >;SEP; 0,542 >;SEP; 0,190 >;SEP; 3,5

>;SEP; 0,352 >;SEP; 0,607 >;SEP; 17,5

>;tb; P.d. >;SEP; 50% >;SEP; + >;SEP; manioc >;SEP; 50% >;SEP; 0,541 >;SEP; 0,149 >;SEP; 2

>;SEP; 0,470 >;SEP; 0,275 >;SEP; 5,8

>;tb; P.d.t. >;SEP; 50% >;SEP; + >;SEP; manioc >;SEP; 50% >;SEP; 0,550 >;SEP; 0,115 >;SEP; 2,1

>;SEP; 0,292 >;SEP; 0,535 >;SEP; 18,3

>;tb; P.d.t. = Pomme de terre

C= compressibilité

Rr = Recouvrance relative

Iv = Indice le viscoélasticité.Data supplied from the esp@cenet database - Worldwide

2196/2197

439.

WO9629889 - 10/3/1996

VITAMIN AUGMENTED RICE COMPOSITE AND METHOD OF MAKING


Inventor(s): COX JAMES P (US); COX ROBERT W DUFFY (US)

Applicant(s): COX JAMES P (US); COX ROBERT W DUFFY (US)


IP Class: A23L1/30; A23L1/36

E Class: A23L1/168; A23L1/10B



Family: WO9629889


US5252351; US2835584; US3431112; US4765996 Cited Document(s):

Abstract:


Vitamin augmented rice composites and methods include ground rice, vitamin, a binding agent, a cross-linking agent for setting the binding agent, an antioxidant, a moisture barrier agent and an aqueous agent. The binding agent is most preferably algin, the cross-linking agent is most preferably a calcium source, the vitamin is most preferably vitamin A, the antioxidant is most preferably vitamin E, the moisture barrier agent is most preferably lard, and the aqueous agent is most preferably water.

2197/2197

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