Food or edible material: processes – compositions – and products – Products per se – or processes of preparing or treating... – Basic ingredient is starch based batter – dough product – etc.
Reexamination Certificate
1999-11-17
2001-06-26
Corbin, Arthur L. (Department: 1761)
Food or edible material: processes, compositions, and products
Products per se, or processes of preparing or treating...
Basic ingredient is starch based batter, dough product, etc.
C426S473000, C426S523000, C426S560000, C426S573000, C426S637000
Reexamination Certificate
active
06251465
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to methods for producing sheetable potato dough from raw potato stock and, in particular, processes for making potato dough based products incorporating raw potato stock in place of dehydrated potato flakes, resulting in improved flavor characteristics.
2. Description of Related Art
There are many advantages in the food processing industry to developing products that can be made using a dough as the starting material for the product. A dough product might be sheeted, formed, cut, extruded, or shaped if necessary. For example, tortilla chips use as a starting material a corn or masa based dough which is pressed through a sheeter device and then cut into individual chip shapes. The masa is sufficiently cohesive that it can be pressed into a thin sheet and placed onto a conveyor without tearing, and is thus referred to as a “sheetable” dough. Typically, cookie and cracker type snacks start as a flour based dough which is extruded and cut or sheeted and cut. Methods for producing wheat flour and corn flour based doughs that are suitable for sheeting and extruding are well known in the industry.
Potato based doughs typically use potato flour or dehydrated potato flakes as a starting material. Potato dough made from raw potatoes is not used in applications requiring sheeting or extruding, because the properties of the dough are not acceptable for this purpose. Specifically, potato dough made from raw potato products tends to adhere to processing equipment surfaces yet it does not maintain adequate cohesion for sheeting or extruding. Past attempts at making a sheetable potato dough from raw potato stock have failed, resulting in a dough that is of a paste consistency which is not suitable for forming into pressed sheets for cutting or forming.
Potato flour and potato flakes start with a raw potato product which is cooked and then dehydrated to a dry flour or flake consistency, thereby leaching many of the sugars and homogenizing the raw material. Unfortunately, much of the potato flavor is lost in such process. Consequently, when such flour or flakes are used as a starting material, flavor additives are typically incorporated to produce an edible end product, such as a chip like snack. However, a potato flour or potato flake based product has yet to be developed that closely emulates a potato chip made from raw potato stock.
Accordingly, a need exists for a process that incorporates as a starting material raw potato product into potato dough that results in a potato based product that is suitable for extruding and sheeting. By introducing the raw potato stock into the starting dough, the flavor of the end product should be greatly enhanced. The raw potato stock should replace dehydrated potato flour or flakes, thus providing a more natural potato product. At the same time, the process should produce a potato dough gel having handling properties suitable for use with standard food processing, sheeting, extruding and cutting devices.
SUMMARY OF THE INVENTION
The proposed invention comprises methods for preparing potato based products using a potato dough comprising raw potato stock. Despite the use of raw potato stock as a base ingredient in the potato dough, the dough is suitable for sheeting, extruding, and cutting, with similar processing characteristics to potato doughs based on potato flour or flakes. This is accomplished using several controlled processing steps in combination.
One embodiment of the invention starts with chip stock potatoes which are peeled and cut into quarter-inch slabs. The slabs of raw potatoes are then subjected to a controlled dehydration at 195° C. to a moisture content of between about 40 and 60%. The partially dehydrated slabs are then cooled and placed in a high-shear processor. The high-shear processor is used to chop the slabs, thereby acting as a mechanical cooker, to a controlled temperature and time end-point. This produces a flowable gel which is allowed to cool, for example, for 30-60 minutes to about 40-45° C. in one embodiment. An emulsifier containing oleic acid can be blended into the gel along with potato flakes or other starchy materials. Sugars, corn syrup, and salts can also be added. The dough is then mixed for a short period of time while adding water in order to develop a particulate, as opposed to lumpy, dough texture with an approximate moisture content of between 30-50%. This dough can then be pressed between rollers in a sheeting device, sheeted to thickness, and then cut to form a chip product. This chip product may then be form-fried or otherwise baked or fried to the desired end-point moisture level.
The end result is a formed potato-based product with enhanced potato flavor. This invention is particularly unique in its ability to utilize raw potato stock resulting in a sheetable potato dough. For the purposes of this application, a sheetable dough is a dough readily suitable for use in industry standard dough sheeting devices.
The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description.
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Bello Anthony Bamidele
Friend Christopher Patric
Petrofsky Keith Eric
Cahoon Colin P.
Carstens, Yee & Cahoon
Corbin Arthur L.
Recot Inc.
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