Food or edible material: processes – compositions – and products – Processes – Preparation of product which is dry in final form
Patent
1987-01-14
1989-06-06
Czaja, Donald E.
Food or edible material: processes, compositions, and products
Processes
Preparation of product which is dry in final form
426450, 426452, 426459, 426560, 426620, A23P 112
Patent
active
048371122
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
This invention relates to a continuous process for producing an extruded bran cereal product.
BACKGROUND OF THE INVENTION
In the batch production of ready-to-eat bran cereals wheat bran, flour, water, and other ingredients are mixed together with a flavor syrup, cooked, dumped onto a conveyor, processed by an extruder into strands, and then dried and toasted. The first step of this conventional process is the pressure cooking at about 260.degree. F. for one half hour of, for example, a 100 pound batch of wheat bran, 5 percent wheat flour, 7.5 pounds of an alternate flour and a flavoring material. The cooked mixture is extruded under low shear conditions into bran cereal nuggets or "buds" having a "fibrous" appearance. Products produced by this batch process generally stay crisp in milk for about 2-3 minutes. They then lose crispness and their integrity fairly rapidly, in milk or water. Rapid loss of integrity and crispness aids in use of the bran cereal for baking applications, such as in the production of bran cereal biscuits. However, it also may detract from the eating qualities or mouthfeel of the product when used as a breakfast cereal.
U.S. Pat. No. 4,500,558 to Fulger et al. relates to modification of bran by extrusion. In this patent, hereinafter referred to as the '558 patent, a bran and water feed having a bran to water ratio of from 5.5:1 to 10:1 is extruded in a counter-rotating twin-screw extruder under high temperature and high shear conditions. The modified bran according to this process is made more readily millable and, when milled, possesses a "mouthfeel" with an absence of grittiness and a greater "functionality" in a food product. The production of extruded nuggets is not taught.
U.S. Pat. No. 4,438,146, to Colby et al, relates to a method for preparing cooked wheat products. Here, an apparatus and method for cooking wheat products is shown wherein the products are cooked by extrusion through an extrusion die. The extruder is similar to a conventional twin screw extruding device, and the die plates, shown in FIGS. 2, 3, and 5, cause extrusion of the wheat product into strands.
Ground whole wheat is used and mixed with any desired dry ingredients. The cooked edible product is in expanded form. At column 3, lines 1-3, it is taught that an extrusion aid or lubricant may be added to the dough to modify the extrusion pressures. The preferred extrusion lubricant is an edible oil or fat, the extrusion itself providing the heat necessary for the expansion.
As seen in column 3 at lines 11-16, no external heat source is necessary, and because of steam vaporization upon extrusion, the die face itself is cooled so that the outer face of the die has a temperature in the range of 150.degree. F. to 180.degree. F.
Water and/or moisture containing product is added to the other ingredients in the cooker, the water being present in a range of 14 to 18 percent by weight. It is taught in the '146 patent that the level of moisture is important in relation to the development of heat in the die and to the achievement of the desired expansion. As taught at column 5, lines 39-43, the heating and cooking of the dough is primarily done in the die itself. This is also taught in column 5, lines 33-38, wherein it is stated that the heat generated during cooking in the die can require the temperature to be controlled such as with a water cooling jacket or the like around the body or barrel. Such cooling is to control the temperature range of dough entering the die to between ambient temperature (usually about 68.degree. F.-84.degree. F.) and about 180.degree. F. It is also stated in column 5, lines 27-29 that "cooking of the dough in the body or the barrel is not necessary and is to be minimized."
The dough, as taught in the '146 patent, in passing through the die generates heat sufficient to form steam and cook the dough enough to condition the gluten so that upon extrusion the dough expands in a desired form as determined by the die configuration. It is also taught that in the die itself t
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Calandro Thomas
Straka Robert
Verrico Marsha K.
Czaja Donald E.
Kornutik Richard
Nabisco Brands Inc.
Paden Carolyn
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