MXPA06004772A - Production of shredded or flaked whole grain-containing composite food products - Google Patents

Abstract

Shredded or flaked whole grain-containing composite food products, such as ready-to-eat cereals, and sweet and savory snacks, are continuously produced by pelletizing cooked, tempered, whole cereal grain particles in the presence of vegetables, fruit, or dairy cheese. In another aspect, an enrobing coating containing chocolate is applied to a baked shredded laminate product of the pelletization, wherein the shredded product may further optionally include fruit added and present during pelletization.

Description

PRODUCTION OF WHOLE GRAIN DISMISSED PRODUCTS Field of the Invention The present invention relates to a process for the production of shredded products, such as snacks and ready-to-eat cereals from whole cereal grains. Background of the Invention Whole cereal grains are nutritious and provide a high dietary fiber content. Historically minced products have been made with whole grain wheat. Generally, in the production of shredded ready-to-eat cereal biscuits and shredded wheat hosts from whole grains, a plurality of shredded layers are laminated one on top of the other, and the laminate is cut, set, and baked. to provide products having a shredded pattern distinctly visible on their opposite major surfaces. The shreds provide visual appeal and a unique crunchy texture and imply a healthy, healthy natural product. Also, shredded provide an increased surface area and deliver a more robust flavor. To prepare wheat for crumbling, whole wheat berries are usually cooked and then tempered, using extended tempering times. Wheat is generally easy to crumble over long periods after baking and tempering, for example up to about 24 hours after tempering. Whole wheat is unique in that it contains gluten which helps to retain water and to provide cohesion and elasticity during machining even after prolonged periods after annealing. However, the same is not true for other grains due to their lack of gluten and their unique chemical composition and changes that occur to grains after cooking and tempering. Starch-based compositions that have little or no gluten, when mixed with water, do not form a dough that is cohesive at room temperature and continuously processable or laminable. The machinability of the dough made from ingredients having little or no gluten can be improved by forming a dough under high temperature conditions, such as by passing the ingredients by steam, as disclosed in US Patents 4,873,093 and 4,843,996 issued to Fazzolare. and collaborators. However, in the production of shredded products from cooked whole grains, tempered, gluten-free, such as corn, oats, rye, and barley, the capacity of shredding into continuous long strips tends to decrease as the tempering times increase or as the time between tempering and shredding increases. For example, cooked corn has a tendency to become hard and rubbery during the cooling and tempering process due, it is believed, to retrogradation of the starch. Also, the storage of tempered corn in wave containers to accommodate mass production processes tends to increase the retrogradation and hardness of the starch. The cooked, tempered cereal grains which become hardened or rubberized tend to fracture during shredding or do not conform to the shredding roller slots to produce shredded, continuous, well-defined weblike sheets. In conventional processes to produce shredded grain, the grain is cooked and then allowed to temper to increase shredding strength. The tempering of cooked grains prior to crumbling has generally been considered necessary to obtain strong, continuous crumbs. In patents US 548,086 and 1,159,045, cooked wheat or similar grains are subjected to tempering times of about 12 hours before crumbling. As described in US Pat. No. 4,179,527, in the manufacture of a whole wheat food product such as shredded wheat, whole wheat is cooked sufficiently to gelatinize the starch. Gelatinization is a function of water penetration in the whole berry, temperature, and time, for a given grain type. According to the US 4 patent, 179,527, the gelatinization of wheat starch involves a destruction of bonds in the crystalline regions of starch granules. Retrogradation is the return of starch molecules to a crystalline structure, which is different from the original crystalline structures, before heating. Tempering allows the gelatinized wheat starch to slowly cool and allow migration of water through the wheat particles to achieve a uniform water distribution within the particles. Retrogradation occurs during tempering. According to US Pat. No. 4,179,527, if the shredding is attempted shortly after baking, the insufficient degree of retrogradation or tempering results in, at best, short non-continuous strips and / or strips that are hard, curled, or suffer from another. physical or texture disadvantage. In US Pat. No. 4,179,527, the time required to temper the whole cooked wheat is substantially reduced by cooling the wheat to a temperature of 1 to about 12 ° C. It is believed that for wheat, tempering allows water distribution and facilitates the development of gluten into a network that provides cohesion to crumble. It is also believed that the retrogradation of wheat starch during tempering or after tempering is slow such that it does not impede crumbling or forms a crystalline structure that allows crumbling in the presence of gluten. The tempering of gluten-free grains, such as corn, oats, rye, and barley also helps distribute water through the starch granules. It is believed that the release of some of the soluble starch during firing and distribution of the starch and water during tempering helps to provide cohesion. However, the amount released may be insufficient for continuous comminution or retrogradation of starch may be too fast and may provide a crystalline structure which prevents the comminution ability in long continuous crumbs. Numerous other processes for producing shredded cereal products with reduced quenching times or without any apparent quenching are also known. Shredded cereal products, whether the tempering is used or not, have also been produced by shredding the cereal in a form other than its cooked berry shape. The international patent publications WO 03/034838 and WO 03/024242, and the publication of patent application US 2004/0166201 disclose the addition of an enzyme to raw materials based on starch to accelerate the retrogradation of starch and thus cut the step of tempering in the production of snack pellets and in the production of shredded cereals. US Patent 6,303,177 and EP Patent Publication 1,132,010 disclose the production of a breakfast cereal containing soybean by extrusion cooking a composition containing a soy material and a cereal grain to obtain a substantially gelatinized mass. A conventional pellet former can be used to form pellets of dough from the cooked dough as it is extruded from the former extruder. The pellet-forming blades cut the extruded dough rope into pellets or pellets for further processing into flake or shredded cereal. The dough balls can be dried at a moisture content of less than 18% and then the dried pellets can be tempered for about 4 to about 10 hours before crumbling. US Patent 5,386,870 discloses fortifying ready-to-eat cereal with beta carotene by adding it to cooked tempered cereal grains prior to forming the pieces. Tempering times may vary from about 2 hours to about 36 hours. The cooked cereal pieces may comprise cooked grains or fragments such as berries or whole wheat semolina, corn cones, oat flakes, and the like. After fortification, the cooked tempered cereal pieces can be formed into pellets to make flakes or can be crumbled into crumb rollers. The US 5 patent, 182,127 and International Patent Publication WO 93/05665 disclose tempering pellets or cooked cereal pieces for ready-to-eat cereals or cereal based snack products by exposing the pellets or pieces to a high intensity microwave field for a brief enough time to improve the distribution of moisture in them but without causing the pellets or pieces to inflate. Pellets or tempered pieces with microwaves can be flaked or crumbled. US Patent 4,528,202 discloses the production of shredded ready-to-eat potato products by combining at least one source of potato starch with water under low temperature conditions and low cutting mixing so as to avoid over-gelatinization of potato starch and to form individual discrete dough pieces or particles, by tempering the dough pieces for at least about two hours to distribute the water substantially uniformly through the dough pieces, by crumbling the dough pieces of dough, and to bake the shredded dough . Processes where hardening is not specifically mentioned or indicated as being optional in the production of cereals from wheat or other grains, is disclosed in patents US 1,189,130, 2,008,024, 1,946,803, 502,378, 897,181, 3,062,657, 3,46,277, 3,732,109 and Canadian patent 674,046. In US 1,189,130, completely moistened bran, such as wheat bran, is blended with up to 50% whole wheat or other gelatinous cereal flour or starch-bearing material, and boiled in cauldrons in a steam replica. The cooked product is dried to a lumpy condition, the lumps are pressed through a bottle mesh and the resulting rice size lumps are then fed through shredding mills. In US Pat. No. 2,008,024, a cereal cake is prepared by vaporizing or boiling wheat alone or with other forms of cereal or food material, by drying the cooked product superficially, and then converting it into a thin ribbed sheet. The shredding rolls are sufficiently separated such that a laminated material with ribs is obtained in place of a shredded product. In US Pat. No. 1,946,803, rice, alone or in combination with bran, is steamed, dried and cooled to a rubbery consistency, milled and optionally tempered to effect a uniform water distribution. This product is then passed between slotted rolls to form long flat slats. These slats are dried to produce a brittle product that is broken and then inflated by toasting. In the patent US 502,378, a grain of cereal is prepared for crumbling by boiling, steaming, soaking or moistening. Depending on the spacing between the rollers, a product in the form of threads, loop, battens, or sheets, and the like, is obtained. In US Pat. No. 897,181, cereal grain or vegetable in whole form is moistened but not baked and passed repetitively between slotted rolls and then baked. Boiled or vaporized of the grain or vegetable, it is disclosed, it produces considerable change in its chemical quality and a number of nutritious soluble elements escapes into the water. In the processes of the patents US 3,062,657, 3,462,277 and 3,732,109, and the Canadian patent 674,046, a shredded product is not produced by means of shredding rolls. In US Pat. No. 3,062,657, flour and water are mixed to form a dough in an extruder. The dough is baked in the extruder and then tempered in the extruder at a lower temperature. The extrudates are cut into pellets to simulate cooked and dried grains such as corn grits, whole wheat berries, shucked grains of oats, rice and the like. The extrudates, it is disclosed, have an ideal moisture content to form flakes. It is generally in the order of 18 to 24% by weight, the moisture being uniformly distributed therethrough so that the need to temper is completely eliminated and the extrudate can be immediately transferred to a flaking operation. It is disclosed that it is further preferable to cool the extrudate before it enters the flake forming device to optimize the flaking properties. In US Patent 3,462,277, a mixture of cereal flour or semolina and water is passed through an extruder to gelatinize the starch while the dough is cooked and transformed into a rubber-like dough. The moisture content of the mixture is 13 to 35%. The continuous U-shaped extrudate is pinched into segments by cutting rollers to form cereal products in canoe form. The separate canoe-shaped pieces are then dried below 15% moisture. US Patent 3,732,109 discloses the production of a ready-to-eat oatmeal cereal cake by attaching a mixture of oatmeal-water at a boiling temperature of water and super-atmospheric pressure to gelatinize a portion of the starch in the oatmeal. . The mixture then passes through a hole and the extruded product is cut into small pieces. The flake-shaped pieces that are formed are dried at a moisture content of between about 2 to about 6% by weight of water. The dried leaflets are then subdivided, they are mixed with a syrup, they are compacted towards the shape of a sponge cake. The formed cakes are then dried at a moisture content of about 4 to 5% by weight. In Canadian Patent 674,046, a shredded dry oat cereal product is produced without the use of shredding rolls. A dough is baked in a screw extruder, extruded through holes to form a bundle of threads, and the bundle of threads is cut into pieces by a cutting device which may be a pair of rolls. Processes for the production of shredded cereals from cereal grains where considerable tempering is used, as in the conventional process for the production of shredded wheat, are disclosed in US Patents 1,159,045, 1,170,162, 1,197,297, and 4,004,035. In US Patents 1,159,045, 1,170,162, 1,197,297, the whole berry is pulverized such as to allow flavor ingredients to be incorporated into the final product. A dough is formed from flour, flavor, and water. The dough is then cooked, rolled into thick slices and then dried atmospherically for a period of 24 to 40 hours. The dried product is roasted, broken into pea-sized pieces, dried and crumbled. In US Pat. No. 4,004,035, crumbled biscuits are formed by depositing a layer of shredded cereal in a zigzag configuration in a moving band to facilitate cutting of the material. In addition to whole wheat, other foods capable of being comminuted, such as cooked cereal, wheat germinated, defatted soy, other vegetable proteins, fruits, vegetable slurries and their mixtures can be used to produce biscuits. The food was softened by baking and tempering before crumbling. In the production of shredded cereals by shredding rolls, obtaining the cooked cereal in a form that produces continuous shredding is only one of several problems encountered. Cooking to eliminate white centers in the grains is taught in US patents 2,421,216 and 4,734,294. In US 2,421,216, particles of cereal grains such as corn, rye, wheat, bran, rice, or oat groats are composed of defatted soybean particles in the form of semolina, flakes, or food to improve the content of cereal protein by the use of a two stage pressure cooking step. The total cooking period to which the cereal component is subjected should, according to US Pat. No. 2,421,216, be such that the starches are highly hydrolyzed and dextrinized and the particles are surface gelatinized without free starch or white center. The cereal particles, taught, should have a slight adhesive action of the soybean particles added in an intermediate manner. The mixed cereal and soybean meal that is removed from the cooker is dried, then tempered for about 15 to 30 minutes before crumbling in a shredding mill where the soy particles become substantially evenly spread and mixed with the cereal particles and adhere to them by pressure through the crushing rollers. US Patent 4,734,294 discloses a process for the production of comminuted oat food products, such as ready-to-eat breakfast cereals having the crumbled appearance and texture of shredded whole wheat. White strips or dots in the final product, which result from uncooked grain or overcooked grain, are removed by pressure cooking the oats in at least two stages, the amount of water used in the first stage of cooking under pressure being limited to partially gelatinize the starch without extraction of water, soluble starches and gums, substantial to the surface of the oat particles. The amount of water used in the remaining pressure cooking stage or stages is sufficient to remove at least substantially all of the white portions in the oat particles and to provide a water content in the oat particles that is sufficiently high to allow shredded continuously in shredding rolls. Additionally, the amount of water in each of the remaining stages is limited to avoid substantial extraction of water-soluble gums and starches to the surface of the partially cooked oat particle. In US Pat. No. 3,512,990 a dough, made of farinaceous materials such as wheat, corn, oats, rice, potatoes, or legumes, is optionally partially or completely cooked with added moisture, at an approximate moisture content of about 30%. After this baking step, the mixture is made homogeneous by passing it through an extruder or a hammer mill, such as Fitzmill. The milled or extruded product is dried at a moisture content of approximately 22 to 24%. The dry mass is then compacted between two rolls to provide a shredding effect and produce a sheet of dough having regular, diamond-like separate perforations. The dough sheet is then cut into strips, folded to form small biscuits that are closed on three sides and fried. In patents US 987,088, 1,019,831, and 1,021,473, corn or other grain is ground and immersed in a quantity of water that is limited to that which will be taken by the grain during cooking. The purpose of this is to preserve in the baked article the aroma and other properties of the grain that may otherwise be carried or dissipated by the evolution of steam or water vapor. In these processes, the cooked dough is extruded through a perforated plate to obtain filaments. In US Pat. No. 4,310,560 particulate edible materials, including at least one material that acquires surface tack when wetted and a chemical yeast system are contacted with a spray of water and pelletized on a pelletizing disk . The edible material may include starches, such as those derived from wheat, corn, rice, potato, tapioca, and the like, including pre-gelatinized starches. The pellets are heated to a temperature sufficient to effect the reaction of the yeast system to release carbon dioxide to provide the pellets with a porous cellular structure. The present invention provides a method for the continuous, mass production of 100% whole grain food products such as ready-to-eat cereals, and thin, crunchy, crunchy, flake-like snacks from whole grains without gluten or of low gluten content such as corn, barley, rice, rye, oats, triticale, and their mixtures. Cooked, tempered whole grains are continuously crumbly in sheets similar to continuous nets even after prolonged tempering times or after prolonged periods in wave vessels after quenching during which retrogradation of substantial starch may occur. The method of the present invention allows the use of whole grain pieces of fully cooked, tempered, but fracturable, hardened, rubberized, in the continuous production of shredded products while achieving well-defined shreds and a crisp texture and high fiber content. It is believed that in the process of the present invention, fracturing of at least substantially gelatinized, tempered starch granules to release amylose and amylopectin increases the cohesion and softens the whole grain pieces of grain for unexpectedly superior shredding ability towards similar sheets. continuous networks. Shredded whole wheat products having an improved crunchy texture can also be produced using shorter tempering times with excellent shredding ability according to the present invention. SUMMARY OF THE INVENTION The ability to comminute whole grains particles, retrograded, to produce a whole grain shredded food product is unexpectedly improved by agglomerated pellets of whole grain grain particles, cooked, tempered, that have suffered retrogradation to a hard, rubberized, fracturable texture. The results of the formation of pellets in the production of pellets of whole grain having a soft, flexible texture, which can be crumbled into sheets similar to continuous networks, in a mass production base. In embodiments of the invention, the pellet formation can be at a pressure of from about 200 to about 600 psig, preferably from about 400 to about 500 psig. The pelletizing temperature can be controlled to provide a pellet temperature of from about 80 to about 120 ° F, preferably from about 90 to about 110 ° F, for example from about 95 to about 105 °. F, when leaving the pellet maker. Cutting and compaction effort of whole grains or pre-ground whole grains in the pellet former softens and plasticizes the starch matrix and generates enough friction and heat to make the whole grain particles foldable and ready to crumble while avoiding stickiness problems . It is believed that retrogradation of the starch is reversed or starch granules fracture releasing amylose and amylopectin during the pellet formation process. As a result, the grain can crumble for a longer period of time after cooking. The process of the present invention provides versatility in terms of tempering times and post-tempering storage times for the production of nutritious, high-fiber, single-whole grain or multiple whole-grain shredded products. Shredded products include shredded whole grain snacks and ready-to-eat cereals made from one or more whole grains that are gluten-free or low in gluten such as whole grains of corn, oats, barley, rice, triticale, and rye. The process can also be used with whole wheat alone or in combination with other whole grains to provide an improved crunchy texture. In embodiments of the invention, a whole-grain shredded flake-like snack, preferably a 100% whole-grain corn snack, having a substantially uniform crumbled-like appearance and a crumbled, crunchy texture, is obtained by substantially compress a laminate of web-like sheets of the shredded whole grain pellets. Detailed Description of the Invention The present invention provides a method for making shredded whole grain products, such as ready-to-eat cereals, and sweet and savory snacks, such as chips, crackers, wafers, biscuits and other products. The products can be made with 100% whole grains and are an excellent source of nutrition and whole grain fiber. The difficulty with the shredding of cooked and tempered grains, such as corn, is overcome by holding the cooked and tempered grains at high cutting effort. The high cutting effort, it is believed, substantially fractures retrograded starch granules to increase the cohesion for comminution into sheets similar to continuous webs. Whole cooked grains, such as corn and other gluten-free or low-gluten-containing grains have a tendency to become hard and rubbery during the cooling and tempering process due to retrogradation of starch. Cutting and compaction of grains in a pellet former has unexpectedly been found to soften and plasticize the starch matrix and generate friction and heat to make the whole grain particles foldable and easily crumbled without stickiness problems in the shredding rolls. Retrogradation of starch, it is believed, reversed or amylose and amylopectin are released from the fractured starch granules during the pelletizing process. As a result, the grain can crumble for a longer period of time after baking. In addition to using a pellet former, other means, such as double shredding, can be used to cut the cooked, tempered, hardened whole grain particles into smooth, collapsible, cohesive shredded pieces. In the double shred, the hardened particles are first crumbled into discontinuous shreds, and then the discontinuous shreds are comminuted into continuous shreds. However, the use of a pellet former is preferred for more efficient production of continuous crumbs. Various whole grain grains may be used to produce shredded whole grain products such as ready-to-eat breakfast cereals and flake-like shredded snacks according to the present invention. Examples of grains that can be used are whole grains without gluten or low gluten content such as whole grain corn or corn grains, oatmeal or oat groats, barley, rye, rice, triticale, and mixtures thereof. A preferred whole grain for use in the present invention is corn. The corn may be of the yellow, white or blue variety, or mixtures thereof.

Grains of high gluten content can also be comminuted according to the method of the present invention. For example, in embodiments of the invention, whole grain wheat, such as soft whole grain wheat, or wheat berries may be used alone or in combination with one or more grains without gluten or low gluten content. In embodiments of the invention, whole grains, which are at least partially or completely defatted, such as defatted whole wheat berries, may be used alone or in admixture with whole grains of whole fat. In the production of multiple grain products, each whole grain can be used in equal weight percentages or in different weight percentages. The whole cereal grain particles employed may be in the form of unprocessed, whole, raw, grain or berry, or in the form of whole grains pre-cut, pre-ground, or ground. For example, the whole grain particles may be in the form of whole corn kernels, or pre-ground or crushed corn kernels. Whole oat particles may be in the form of semolina or whole oat berries, or pre-ground or pre-cut whole oat semolina. The starch of whole grain particles used in the present invention can be all or essentially all individual, crystalline starch granules, as determined by characterization of starch by light microscopy where a sample is stained with Lugol iodine and observed in a Brightfield Optics team.

In embodiments of the present invention pre-ground or shredded whole grain grains are preferred because they hydrate and cook more quickly than whole grains or whole berries. For example, prior to cooking, whole grains of cereal, such as whole grains of corn, can be pre-milled, ground or crushed to a particle size of less than or equal to about 1/4 inch, preferably less than or equal to about 0.2 inches, for example from about 0.09 to about 0.165 inches. In embodiments of the invention, grinding, pre-milling or grinding of raw whole grains can be achieved using a Fitz mill, Commitrol mill or conventional Urschel mill. For example, a Fitz mill having a mesh of 1/8 inch round holes can be used to obtain a particle size distribution of about: 0.0% in a # 6 mesh, about 14.91% in a # 14 mesh, about 30.43% on a # 20 mesh, about 50.25% on a # 40 mesh, and about 4.41% on the plate. In embodiments of the present invention, whole seeds or crushed seeds or legumes, such as soybeans or soybean grits can be mixed with the cereal grains to improve the protein content of the products of the present invention in an amount that does not adversely affect the crumbling capacity. Exemplary amounts of the seeds or legume that can be used range from up to about 60% by weight, based on the total weight of the whole cereal grains. In preferred embodiments where the whole cereal grains include whole corn, lime is preferably used to improve the flavor and also to improve the functionality and cohesion of the starch. Any food-grade calcium or calcium hydroxide can be used in the present invention. The lime may be added in an amount sufficient to improve the functionality of the starch and reduce the stickiness of the corn-based composition, and to provide a dough taste in the final product. Exemplary amounts of lime that can be used in embodiments of the present invention are from about 0.05 to about 3% by weight, preferably from about 0.1 to about 0.5% by weight, based on the total weight of the whole corn kernels. Shredded whole grain foods such as ready-to-eat cereals, crackers, wafers, biscuits, or snack flakes of the present invention may be whole fat, reduced fat, low fat, or fat free products. As used herein, a reduced fat food product is a product having its fat content reduced by at least 25% by weight of the standard or conventional product. A low-fat product has a fat content equal to or less than three grams of fat per reference quantity or label portion. However, for small reference quantities (that is, reference quantities of 30 grams or less or two tablespoons or less), a low-fat product has a fat content less than or equal to 3 grams per 50 grams of product. A non-fat or zero-fat product has a fat content of less than 0.5 grams of fat per reference quantity and per label portion. For accompanying crackers, such as crackers, the reference amount is 15 grams. For pretzels, or biscuits or wafers, used as snacks, and for cookies, the reference amount is 30 grams. Thus, the fat content of a salty biscuit, wafer, or low fat cookie would therefore be less than or equal to 3 grams of fat per 50 grams or less than or equal to about 6% fat, based on the total weight of the final product. A salty cracker without fat would have a fat content of less than 0.5 grams per 15 grams or less than 3.33%, based on the weight of the final product. A non-fat host having a 32 gram label serving size would have a fat content of less than 0.5 grams per 32 grams or less than about 1.56% by weight, based on the weight of the final product. Oil compositions that can be used to produce shredded whole-fat, reduced-fat, or low-fat products, in accordance with the present invention can include any bitumen or fat blends or compositions useful for baking applications, and can include emulsifi- conventional food grade cantes. Vegetable oils, lard, marine oils, and their mixtures, which are fractionated, partially hydrogenated and / or inter-esterified, are examples of bitumens or fats that can be used in the present invention. Fats, fat substitutes, or synthetic fats, such as sucrose or triacyl glyceride polyesters, low or low calorie edible, partially digestible or non-digestible, which are compatible with the process can also be used. Mixtures of hard and soft fats or bitumens and oils can be used to achieve a desired consistency or melting profile in the oleaginous composition. Exemplary edible triglycerides that can be used to obtain the oleaginous compositions for use in the present invention include naturally occurring triglycerides derived from plant sources such as soy bean oil, palm kernel oil, palm oil, palm kernel oil. rapeseed, safflower oil, sesame oil, sunflower seed oil, and mixtures thereof. Marine and animal oils such as sardine oil, shad oil, babassu oil, lard, and tallow can also be used. Synthetic triglycerides, as well as natural triglycerides of fatty acids, can also be used to obtain the oleaginous composition. The fatty oils can have a chain length of 8 to 24 carbon atoms. Bitumen or solid or semi-solid fats at ambient temperatures of, for example, around 75 to about 95 ° F can be used. Preferred oleaginous compositions for use in the present invention include partially hydrogenated soy bean oil, palm oil, and mixtures thereof. In embodiments of the invention, the amount of bitumen or vegetable fat topically applied to shredded products can be reduced by more than 25 percent by weight to obtain reduced fat products having, for example, less than about 12 percent by weight of fat, preferably less than 10% by weight of fat, based on the total weight of the baked, finished product. To provide a more lubricious feel to reduced fat, low fat or fat-free products, a hydrocolloid gum, preferably guar gum, can be used to compensate for fat reduction as disclosed in US Patent 5,595,774 issued. to Leibfred et al., the disclosure of which is incorporated herein by reference in its entirety. As disclosed in US Pat. No. 5,595,774, hydrocolloid gums are used in effective amounts that provide a lubricious, smooth, non-slippery mouthfeel to the baked product. Exemplary amounts of the hydrocolloid gum, preferably guar gum, which can be used range from about 0.15 to about 1.5% by weight, preferably from about 0.25 to about 0.45% by weight, based on the total weight of berries or whole grains. Other gums that can be used with guar gum include xanthan gum and carboxymethyl cellulose, and gums that form gels such as alginate gum, carrageenan gum, gum arabic, tragacanth gum, pectin, and locust bean gum, and mixtures thereof. Generally, the greater the degree of reduction of bitumen or grease, the greater the amount of rubber used to compensate for the loss of lubricity or loss of softness in the mouth. In the method of the present invention, a whole grain shredded food product can be produced continuously or on a mass production basis by mixing whole grain grain particles with water and baking the whole grain particles to at least substantially gelatinize the starch of the whole grain particles, and temper the cooked whole grain particles. The cooked, tempered whole grain particles can be formed into pellets in a pellet former to obtain pellets of whole grain, the pellet former being under pressure and temperature conditions to provide continuous comminution capability of the pellets of whole grain towards pellets similar to continuous networks. The whole-grain pellets can be crumbled into sheets similar to whole-grain nets, followed by laminating the whole grain-like sheets to obtain a whole-grain laminate. The whole grain laminate can be cut into whole grain pieces, followed by baking the whole grain pieces to obtain a whole grain shredded food product. In embodiments where a shredded, thin flake-like snack is produced, the whole grain laminate can be substantially compressed to obtain a compressed laminate having an appearance similar to shredded mesh, followed by cutting the laminate into pieces and baking the pieces. . The cooking of the grain or berry according to this invention can be done in any standard cooking equipment, such as a rotary cooker, an immersion cooker, or a pressure cooker, such as a Lauhoff pressure cooker. The immersion cooker is usually at around atmospheric pressure or only at 2-3 psig. The pressure cooker is preferred because it quickly achieves complete cooking or gelatinization of the whole grain particles without, or essentially without, white centers. The whole grain particles can be cooked at temperatures and humidities which hydrate and at least substantially gelatinize the internal structure of the grains or berries such that only a pinpoint of white or free starch remains visible in the center of the grain. In embodiments of the invention, the degree of gelatinization can be, for example, about 90%. In preferred embodiments, the starch is essentially 100% gelatinized leaving no visible white center in the whole grain particles. The degree of starch gelatinization can be measured by differential examination calorimetry (DSC). Usually, starch gelatinization occurs when: (a) water in a sufficient quantity, generally at least about 25 to 30% by weight, based on the weight of the starch, is added to and mixed with starch and, (b) the The temperature of the starch-water mixture is raised to at least 80 ° C (176 ° F), preferably to 100 ° C (212 ° F) or more. The gelatinization temperature depends on the amount of water available for reaction with the starch. While the amount of available water is lower, the gelatinization temperature is generally higher. Gelatinization can be defined as the fall (fracture) of the molecular order within the starch granule, manifested in irreversible changes in properties such as granular swelling, native crystalline fusion, loss of birefringence, and solubilization of starch. The temperature of the initial gelatinization stage and the temperature range over which it occurs are governed by the concentration of the starch, the observation method, the granule type, and the heterogeneities within the population of granules under observation. Pasting is the second stage phenomenon that follows the gelatinization in the starch dissolution. It involves increased granular swelling, exudation of molecular components (ie, amylose, followed by amylopectin) from the granules, and eventually, the total fracture of the granules. See Atwell et al, "The Terminology And Methodology Associated With Basic Starch Phenomena" Cereal Foods World, vol. 33, no. 3, pp. 306-311 (March 1988). Exemplary immersion cooking temperatures can vary from around 190 to about 212 ° F. The immersion cooking of the whole grain particles can occur at around 210 ° F at atmospheric pressure using steam for about 30 to about 36 minutes. Cooking may include a "rise time" of between 6.5 and about 8 minutes during which the temperature of the grain in the tub or cooking vessel rises from room temperature to the cooking temperature. But preferably, before firing, the whole grain particles are added to hot water at a temperature of 170 to 190 ° F in the cooker. The whole grain particles can be added to the hot water in a rotary cooker, for example, over a period of time from about 50 to about 100 seconds. The amount of water used in the dip cooking step can vary from about 28% by weight to about 70% by weight based on the total weight of the grains or berries and added water. The cooked grain moisture content, after draining may vary from about 29% by weight to about 60% by weight, preferably from about 29% by weight to about 42% by weight. In preferred embodiments, where pressure cooking with direct steam injection is employed, the pressure cooking temperatures may be at least about 235 ° F, preferably at least about 250 ° F, most preferably around from 268 to around 275 ° F. The pressure cook pressures of the invention may vary from about 15 to about 30 psig, preferably from about 20 to about 28 psig with cooking times ranging from about 15 minutes to about 30 minutes, preferably from around 20 to around 25 minutes. Pressure cooking may include a "rise time" as in dip cooking of between 6.5 and about 8 minutes during which the temperature of the bean in the pan or cooking vessel rises from room temperature to the cooking temperature . But preferably, before firing, the whole grain particles are mixed with hot water at a temperature of about 170 to 190 ° F in the pressure cooker. The whole grain particles can be added to hot water, or vice versa, in a rotary cooker, for example, over a time period of about 50 to about 100 seconds. Other ingredients such as salt, and lime in the case of cooking corn grains, can be added in the cooker with the water as a pre-mix or added separately. Pressure cooking is preferred over immersion cooking because it provides better control over obtaining a desired water content in the cooked whole grain particles and reduces or eliminates the need to dry the whole grain particles to achieve a content of moisture desired to crumble. Generally, in pressure cooking all the added water is absorbed or taken up by the whole grain particles. In addition, water vapor that is injected directly into the pressure cooker is condensed and taken up by the whole grain particles, generally in an amount of about 1% by weight to about 3% by weight, based on the weight total of cooked whole grain particles. Generally, draining water after pressure cooking is not necessary because all or substantially all of the water and water vapor added are taken up by the cooked whole grain particles. The amount of water added in the pressure cooking step, not including the steam condensate, may vary from about 12% by weight to about 30% by weight based on the total weight of the grains or berries and water added. The moisture content of the cooked grain, which includes water inherently present in the raw grain, after draining if necessary, can vary from about 29% by weight to about 42% by weight, preferably about 33% by weight to about 38% by weight, based on the weight of the cooked whole grain particles. During cooking, moisture tends to collect in grain particles or berries. This moisture can increase the stickiness of the cooked grain and can cause handling problems when the grain is transferred to another appliance. Mixing the grain in the cooking vat at low rotation speeds provides for even cooking and reduces lumping.

After draining any excess cooking water and steam condensate formed during cooking, the cooked whole grain particles can be discharged from the rotary cooker and optionally transferred to a dryer and surface cooler. In embodiments of the invention, the cooked whole grain particles can be dried and cooled to a temperature of less than about 125 ° F, for example from about 60 to about 85 ° F. The drying and cooling of the surface facilitates the flow of the cooked grains as individual, discrete pieces. The dry, cooked whole grain particles can have a moisture content of about 29% by weight to about 42% by weight, preferably from about 33% by weight to about 38% by weight for crumbling capacity in shredded, strong, continuous. In preferred embodiments, the cooked whole grain grain particles are passed through a lump splitter to break up lumps or large agglomerates of the whole grain particle particles. The degreed whole grain grain particles can then be co-milled to obtain smaller agglomerates of whole grain grain particles by passing them through a mesh, for example a 1-inch square mesh. The co-milled agglomerates may vary in size from about the size of a golf ball to a granular size, preferably less than about 0.5 cm in diameter.

After cooking, the starch granules of the cooked whole grain particles are no more crystalline in nature and are swollen or larger in size, as determined by characterization of light microscopy starch using Lugol iodine. The cooked particles may contain swollen granules as well as groups of agglomerated starch. The whole cooked cereal grain particles can then be transported to a wave vessel or semolina container for tempering. The cooked whole grain particles can then be hardened or cured for a period of time sufficient to provide a uniform distribution of water through the cooked whole grain particles. The tempering may be conducted at a temperature of less than about 125 ° F, preferably from about 75 to about 100 ° F, more preferably from about 80 to about 90 ° F. Tempering times may vary from about 0.5 to about 5 hours, preferably from about 1 to about 4 hours. The step of tempering or curing can be achieved in one or more stages. The tempered whole grain particles may be in agglomerated form, with the agglomerates varying in size from around golf ball sizes to granular sizes, preferably less than about 0.5 cm in diameter. In embodiments where a hydrocolloid gum is used, as disclosed in US Pat. No. 5,595,774, the hydrocolloid gum, preferably guar gum, in dry, particulate, or powder form, can be physically mixed or mixed with the particles. of whole grain cooked, tempered. Batch or continuous blenders or physical mixers or mixers can be used to mix the gum and the cooked, tempered whole grain particles or agglomerates to coat them with the gum in a substantially homogeneous manner. The dried gum sticks or adheres to the wet, cooked, tempered grains, thus at least partially coating the grains without creating a sticky surface that would hinder or interfere with the comminution. After pelletizing and shredding the grains or berries, the rubber coating or the particles are incorporated into and into the individual strands or web-like sheets formed by shredding rolls. The cooked, tempered whole grain particles can be transferred by means of conveyor belts to a pellet former to form them into pellets for crumbling. When entering the pellet maker, the tempered whole grain particles can be in the form of agglomerates. The agglomerates fed to the pellet former may vary in size from about golf ball size to granular size, and may preferably be less than about 0.5 cm in diameter. They may have a temperature of less than about 125 ° F, preferably from about 75 to about 100 ° F, more preferably from about 80 to about 90 ° F. Upon entry to the pellet former, the tempered whole grain particles can be retrograded, with the starch being the main granule, the starch granules being swollen, and some agglomerated starch groups present, as determined using starch characterization by microscopy light with iodine from Lugol. Commercially available pellet extruders or formers, such as Bonnet or Wenger pellet formers, can be employed to produce crumbly whole grain pellets from the agglomerates of cooked, tempered whole grain particles in the present invention. The pellet former may be equipped with a solid or flight cut screw conveyor for transporting and cutting the tempered whole grain particles from the inlet end to the outlet end and through the outlet die plate. Cooling jackets are preferably used to control the temperature of the agglomerates in the pellet former and to control the temperature of the pellets coming out of the pellet former. The cooling jackets help to remove heat generated by the action of shear stress occurring in the pellet former and die plate as the agglomerates are forced through the die plate openings. The pellet former may be equipped with an internal blade installed on the upstream side of an outlet die plate, and an external blade installed on the downstream side of the die die plate to form the whole grain agglomerates in a rope or rod which is cut into pellets of whole grain. In embodiments of the invention, the die plate may have a plurality of holes or openings each having a diameter of about 3/16 of an inch to about 5/16 of an inch. The open area of the die plate, or the total area of the openings as a percentage of the die plate area, can vary from about 14% to about 55%, preferably from about 25% to about 45%. %, more preferably from about 38% to about 42%. The whole grain pellets can be produced with diameters to crumble in conventional comminution equipment. For example, the pellets can have a cut length of about 1/8 of an inch to about 1/4 of an inch, and a diameter of about 3/16 of an inch to about 5/16 of an inch of diameter imparted by the openings of die According to the method of the present invention, the pelletizing pressure, as measured on the die plate, may be from about 200 to about 600 psig, preferably from about 400 psig to about 500 psig. . The pressures and temperatures employed preferably result in no or substantially no expansion of the extrudate leaving the die orifices. Also, the temperature of the pellets leaving the pellet former should be sufficiently low such that any increase in temperature caused by the comminution operation does not result in damaging the shreds to the shred rollers or downstream compaction rollers. Generally, the temperature of the shredded product outside the shredding rolls can be up to about 120 ° F to about 130 ° F without substantial bonding problems. The pelletizing temperature can be controlled by the use of cooling jackets to provide a pellet temperature of about 80 ° F to about 120 ° F., preferably from about 90 ° F to about 110 ° F, for example from about 95 ° F to about 105 ° F, when leaving the pellet former die plate. In embodiments of the invention, cooling air can be supplied at the outlet of the plate to cool the pellets that come out to help avoid sticking problems. The pellets that come out of the pellet former have a cohesive, foldable, smooth texture. The formation of pellets is thought to reverse the retrogradation of the tempered whole grain particles. High cutting effort in the pellet former is believed to substantially fracture the retrograded starch granules and release amylose and amylopectin to increase the cohesion for crumbling into sheets similar to continuous webs. Although the starch entering the pellet former may be primarily granular, it may be very different in the pellets leaving the pellet former. The starch of the whole grain pellets produced by the pellet former is mainly agglomerated starch and fragmented starch with only a small population of individual pellets, as determined using starch characterization by light microscopy with Lugol iodine. Upon exiting the pellet former, pelletizing should not be so extensive, and the pellets should not be allowed to settle or overly temper, such as to induce retrogradation of substantial starch or pellet hardening which can prevent comminution. The whole grain pellets may preferably be immediately or rapidly, for example within about 20 minutes, preferably within about 10 minutes, conveyed to the comminution operation such that they avoid any substantial hardening or skin formation in the pellets. soft, foldable In embodiments of the invention, the whole grain pellets can be transferred via conveyor belts and / or bar elevators to a feed tank that feeds a screw conveyor. The latter can transfer the whole grain pellets to a series of rollers or crushing mills by means of flow tubes or feeder tanks. An example of such a screw conveyor is that made by Screw Conveyor Corporation, 704 Hoffman Street, Hammond, Indiana, 46327 United States. The moisture content of the whole grain crumb pellets can vary from about 29% by weight to about 42% by weight, preferably from about 33% by weight to about 38% by weight, based on the weight of the pellets, to crumble into strong, continuous crumbs. Any conventional grinding system can be used in the present invention. A conventional grinding system for making a wafer or cake can be employed in producing the shredded products such as ready-to-eat cereals, biscuits, and snack flakes according to the present invention. The conventional milling system may comprise a pair of closely spaced rollers rotating in opposite directions with at least one of the rollers having circumferential grooves. When passing between the rollers, the mass is formed into long single strings or threads. A circumferentially grooved roller can also be transversely grooved to the circumferential grooves for the production of a network-like sheet. When the sheets are formed, the sheets are comprised of shredded or interwoven yarns. When the rollers are held together tightly, the threads or filaments partially separate from each other but are more or less connected. When the rollers are rotated slightly apart under pressure, the adjacent filaments may be joined together by very thin webs or fins that stretch between them. When passing between the rollers, the mass is deforms towards the circumferential grooves and the optional transverse grooves. Each pair of rolls produces a dough layer having a plurality of substantially parallel longitudinal strands and optionally a plurality of transverse plumets generally perpendicular to the strands. The transverse plumeados and the longitudinal strands form a lamina similar to an integral network. The texture of each layer can be controlled by the number of transverse plumeados in each layer forming the sheets similar to networks. The sheets similar to networks of preference are not in network or without network, that is to say, the transverse plumeados and the longitudinal strands of each layer are not connected by a membrane. The use of an open space within the area formed by the longitudinal strands and the transverse plumeados in the outer layers provide a more attractive product. Additionally, the use of open space in the inner layers avoids an excessively dense texture. The longitudinal strands are produced by circumferential grooves and can run in parallel with the direction of movement of an underlying conve The transverse plumeados of the dough layer are produced by the transverse grooves and can run generally perpendicular to the direction of movement of the conve The shredding mills can be arranged in linear series along an underlying conve Each layer or sheet of dough can be deposited on the convein superposition, with its longitudinal strands running in the same direction. Conventional comminution systems that can be used in the process of the present invention are disclosed in US Pat. Nos. 502,378.; 2,008,024; 2,013,003; 2,693,419; 4,004,035; and 6,004,612; and the patent US 674,046. The first and the last or more layers of shredded dough to be deposited or laminated may have a number of transverse plumets such as to provide a region of denser texture or greater density in the cake or flake. The first layer that is placed on the conveyor belt preferably has a sufficient number of transverse plumets to provide a more stable bed for depositing subsequent crumbling layers. Additionally, the external appearance of the product is enhanced by the presence of transverse plumeados as well as the first impression of crispness when eating. For a shred roll 5 inches in diameter, the number of cross hatches can be about 45 or more, equivalently spaced around the roll. Rollers five inches in diameter can generally have: (1) about 10 to 22 circumferential grooves per inch, and (2) up to about 120 equidistant transverse grooves. Rollers of larger or smaller diameter can also be used with around the same frequency of slits as the rollers of diameter of five inches. The layers of dough that are deposited between the outer layers providing a denser texture or higher density can have a decreased number of transverse plumets such as to provide a lighter texture region or lower density inside the flake. The number of transverse plumeados in each layer can be the same or different. In embodiments of the invention, at least 30 percent of the total number of web-like sheets can provide one or more regions of dense texture or higher density. In preferred embodiments, each layer has the same number of transverse plumets. In embodiments of the invention, for increased duration, crispness, and visual appearance, 120 transverse plots for a roll of five inches in diameter are preferred. The depth of the circumferential and transverse grooves of the shredding rolls may be from about 0.010 inches to about 0.023 inches, preferably from about 0.016 inches to about 0.021 inches. For example, in preferred embodiments the transverse slit depth may be about 0.018 inches and the circumferential slit depth may be about 0.021 inches. Slit depths of less than about 0.010 inches tend to require too many layers to achieve a desired weight per piece. The weblike sheets when they are laminated on one another, do not necessarily line up exactly such that one layer is superimposed exactly on another layer. While the number of layers is greater, it is more likely that the openings in a weblike sheet will be at least partially covered by the shreds of another web-like sheet. Thus, increasing the number of layers to achieve a given piece weight tends to result in a denser lamination and loss of shred integrity when compressed in compression rolls. The use of slit depths greater than about 0.023 inches tends to result in too dense a laminate which is difficult to bake to a crunchy, flake-like texture. Generally, the total number of web-like sheets can vary from three to 21 depending on the type and size of the shredded product. For example, large size ready-to-eat breakfast cereal biscuits or hosts may contain from about 6 to 21 network-like sheets, preferably from 8 to 12 web-like sheets. Cupcakes or hosts of ready-to-eat cereal of smaller size can contain from 3 to 7, preferably from 4 to 6 sheets similar to nets. The snack flakes of the invention may have from 3 to 7, preferably from 3 to 5., most preferable 4, sheets similar to networks. If the number of sheets is less than three, continuous production, consistent, tends to be interrupted. The laminate tends to stick or slide on the compression band or roll under substantial compression of a laminate which is relatively thin prior to compression. Additionally, with too few layers, the baked product tends to be too fragile for handling in bulk production equipment or for soaking. If the number of sheets or layers is greater than seven, before compression to achieve a desirable thickness, similar to flake, the laminate becomes too dense and difficult to bake to a crunchy texture. In addition, excessive compression may result in a loss of distinctive, crumbled appearance. In embodiments of the invention for producing shredded whole grain snack flake, or a crisp, thin, ready-to-eat breakfast cereal, the whole grain laminate can be compressed according to the method and apparatus of US Pat. No. 6,004,612 issued to Andres i and collaborators for "Production of Shredded Snacks with Chip-Like Appearance and Texture", the disclosure of which is incorporated herein by reference in its entirety. The apparatus and method of US Pat. No. 6,004,612 can be used to obtain a whole grain shredded flake like snack having a substantially uniform shredded netlike appearance and a crunchy, shredded texture by substantially compressing a laminate of grain-like lamellae whole grain pellets obtained in accordance with the present invention. As disclosed in US Pat. No. 6,004,612, the co-pressure substantially reduces or eliminates air pockets or spaces between layers and improves adhesion between layers such as to prevent the development of an inflated, cushioned, or thick cake or cookie-like appearance. Although the laminate undergoes substantial compression, flake-like, deflated, substantially flat products exhibit a net-like appearance, shredding substantially uniform to their larger surfaces. Additionally, individual shredding layers can be discerned visually in the baked product when it is broken down and observed in cross section. The strength of the laminate is sufficient to continuously undergo cutting, transfer, and packaging operations during mass production without tearing or breaking. Shredded flake-like snacks are strong enough to soak in and out of creams or sauces without breaking. Additionally, the flakes have a whole grain appearance, with portions of the husk or fiber of the whole grains being visually apparent in numerous locations on the surface of shredded snack flakes. In embodiments of the invention, prior to compression, the thickness of the whole grain laminate can generally vary from about 0.070 inches to about 0.250 inches. Generally, the thickness of the laminate is reduced by at least about 35%, generally from about 45% to about 60% of its thickness prior to compression. As disclosed in US Pat. No. 6,004,612, compression of the laminate to substantially reduce its thickness can be achieved by passing it between at least one pair of counter-rotating compression rollers while being supported on and transported by a conveyor belt. Where more than one pair of compression rolls are employed, the total thickness reduction can be roughly equally divided between the pairs of rolls. The use of a single pair of counter-rotating compression rolls is preferred to achieve substantial compression of the laminate. Supporting the laminate on a web while being compressed helps avoid excessive stretching and tearing or gluing of the laminate during compression and transport through the rolls. As disclosed in the patent 6, 004,612, each pair of counter-rotating rollers can comprise an upper roller that makes contact with the upper surface of the laminate, and a lower roller that makes contact with the lower surface of the conveyor belt supporting the laminate. The pinch or space between the counter-rotating rollers and their relative rotational speeds are set such that they substantially compress the laminate while avoiding: 1) substantial gluing of the laminate to the upper roller, or 2) substantial movement or sliding of the laminate relative to the band. , any of which would substantially disrupt or distort the shredding pattern of the laminate as it is compressed. The lower roller helps to maintain the linear speed of the conveyor belt driven separately as the upper roller compresses the laminate against the upper surface of the belt. The speeds of rotation of the upper and lower rollers of a pair of counter-rotating rollers can be at least substantially the same, or essentially the same, depending on the relative diameters of the rollers. If rolls of different diameters are used, their speeds of rotation, or angular velocities, can be adjusted such that they provide at least substantially the same linear velocity. As disclosed in US Pat. No. 6,004,612, the laminate is compressed by the counter-rotating rolls without cutting the laminate or without molding the laminate into individual pieces. The reduction in compression or thickness is at least substantially uniform across the width of the laminate. The compression provides a thin compressed laminate, baked, but similar to dough, and helps prevent inflation or expansion upon subsequent baking. The thickness of the compressed laminate coming out of the pinch of the compression rollers is such as to provide a thin flake-like appearance when baking. In embodiments of the present invention, generally the thickness of the compressed laminate can vary from about 0.035 inches to about 0.120 inches, preferably from about 0.050 inches to about 0.100 inches, for example, from about 0.060 inches to around 0.080 inches.

Although the thickness of the laminate is substantially reduced, a substantially uniform comminuting pattern is visually apparent to the opposite major surfaces of the baked product. Additionally, at least substantially all, or all of the individual shredding layers are generally visible to the naked eye by decomposing a baked piece perpendicular to its larger surfaces. For example, if a baked piece is split by about half, a cross-sectional view of each piece can generally reveal the same number, or substantially the same number, of shredded layers or network-like sheets as were present prior to compression. The moisture content of the laminate prior to compression and after compression is generally at least substantially the same. The moisture contents of the pre-roll and post-roll can vary from about 29% by weight to about 42% by weight, preferably from about 33% by weight to about 38% by weight. The starch from the laminates can be in the form of agglomerated starch groups with virtually no individual starch granules, as determined using starch characterization by light microscopy with Lugol iodine. The whole grain laminates of shredded dough strands, layers or weblike sheets can then be cut, and grooved using conventional equipment, such as rotary cutters and slot formers. The seating of the laminate is not necessary to prevent inflation or fermentation. A non-seated piece is preferred because it is more similar to flake in appearance. Also, the seating of a compressed laminate tends to produce excessively dense portions that are difficult to bake without burning. The cutting operation can partially or completely cut the whole grain laminates into strips. The grooving operation can completely cut or incise the strips such as to provide cut strips of ready-to-eat cereal biscuits or unbaked snacks with the unbaked biscuits or snacks lightly connected to each other. In embodiments of the invention, the non-compressed or compressed whole grain laminate may be cut at the edge and then partially cut into pieces configured by a rotary cutter without substantial generation of waste or recycle material. Then, the partially cut laminate can be cut longitudinally in the direction of movement of the conveyor belt, and then transversely in the direction of movement of the conveyor belt without substantial generation of waste or recycle material. After baking and before or after adding oil to the strips, the transport movement, etc., breaks the cut strips to provide individual pieces of shredded product such as ready-to-eat cereals, biscuits, wafers, or flake-like snacks. . The figure of the shredded products can be square, round, rectangular, elliptical, parallelepiped, triangular and the like. Figures that minimize or eliminate waste or recycle are preferred. A most preferred figure for flake-like snack is a triangular or substantially triangular shape. As disclosed in US Pat. No. 6,004,612, to essentially eliminate debris, triangles can be formed using a rotary cutter that cuts the compressed laminate such that the base of each triangle is parallel to the longitudinal axis or direction of movement of the laminate. To reduce breakage during and after cutting, the laminate is preferably cut such that the apex or tip of a triangle in one row does not touch or intersect the apex or tip of another triangle located in an adjacent row. In preferred embodiments, the cutter can cut the laminate into a plurality of longitudinal rows of pieces of triangular shape such that the apex of a triangular piece of a row is located at or intersects about the midpoint of the base of a piece triangular of an adjacent row as shown in US 6 patent, 004,612. As disclosed in US Patent 6,004,612, it is also preferable to form or cut triangular pieces with rounded, blunt or flat corners such as to eliminate sharp points that may break during the rotary cutting or subsequent slotting or transfer of the cutting laminate. For example, the vacuum can be used to lift and transfer a partially cut laminate from one conveyor belt to another. The presence of substantial amounts of broken spots can plug the vacuum equipment. One or more, preferably all corners or apexes of the triangular pieces can be rounded, flattened or blunt. For example, to obtain flattened or blunt corners in a substantially equilateral or isosceles triangular shaped piece, each corner may be formed, cut, or configured at least substantially parallel to its opposite side or at least substantially perpendicular to an adjacent side by the cutter rotary. The cut whole grain laminate can be dried, baked and roasted in conventional equipment. Suitable ovens for drying, baking and toasting the cut laminate include Proctor &; Schwartz, Werner-Lehara, Wolverine and spoon ovens containing burners driven by forced air and gas and a conveyor. The laminates can be roasted to improve the flavor and brown the edges of the shredded products. The baking of compressed laminates does not inflate or ferment them substantially and provides a thin, substantially flat flake-like appearance. Temperature profiles used in the oven to dry, bake and toast laminated pre-forms can generally be in the range of about 200 to about 600 ° F.

Preferably baking is carried out in a zone oven using low baking speed to avoid excess curling, separation or warping of the strips during baking. The total type for drying, baking and toasting can be such as to prevent browning (except at the edges of the pieces). It depends on the number of shredded layers, the size of the shredded product and the type of oven. The total time to dry, bake and toast can vary from around 3 minutes to around 10 minutes. After baking, the starch of the products may be in the form of agglomerated starch groups with virtually no starch granules, as determined using starch characterization by light microscopy with Lugol iodine. The color of the final baked product may be a nearly uniform white or gold color. The product can be coated with salt (for example, 0.5 to 2 percent by weight, based on the total product weight) prior to baking. The salt provides flavor and improves the flavor. Some of the salt (NaCl) can be replaced with KCl or other salt substitutes. The fat or bitumen, when used in embodiments of the invention, can be applied, preferably by spraying in the form of oil, to the upper and lower surfaces of baked strips of snacks without having added fat or having only fat inherent in them. the grain of cereal. For example, whole wheat berries generally have an inherent fat content of around 2 to 4% by weight. See, Wheat: Chemistry and Technology, vol. II, Pomeranz, ed. , Amer. Assoc. Of Cereal Chemists, Inc., St. Paul, Minnesota, United States, p.285 (1988). In embodiments of the invention, topical application of oil to baked snacks without added fat can result in baked goods having a total fat content of less than about 12%, preferably less than about 10% by weight . In other embodiments the amount of topically applied oil may be less than about 8% by weight, for example, less than about 6% by weight, based on the weight of the flake-like, shredded snack. The use of a hydrocolloid gum provides for a slippery or soft sense in the mouth and a shiny appearance even without added fat. The shredded whole grain products of the present invention may contain one or more additives (e.g., vitamins, minerals, colorants, flavors, etc.) at effective concentration levels. Exemplary thereof are sugars such as sucrose, fructose, lactose, dextrose, and honey, polydextrose, dietary fiber, seasonings, such as onion, garlic, parsley, and broth, malt, wheat germ, nuts, cocoa, flavors such as fruit flavor, biscuit flavor, cinnamon, and vanilla flavor, acidulants such as citric acid and lactic acid, preservatives such as TBHQ, antioxidants such as tocopherol and BHT, food dyes, emulsifiers such as Myvatex (a physical mixture of distilled monoglycerides manufactured by Eastman Kodak), sodium stearoyl lactylate, lecithin, and polysorbate 60, and vitamins and / or minerals. Examples of suitable vitamins and minerals include B-complex vitamins, soluble iron compounds, calcium sources such as calcium carbonate, vitamin A, vitamin E, and vitamin C. Also, dry skim milk solids (ie, milk powder) ) or soy bean protein can be added in an amount sufficient to create a final protein level of about 10 to about 20 percent. Such additional ingredients may vary up to about 30 percent by weight, based on the total dry weight of the final product. The additives, such as vitamins and minerals, can be mixed dry with an optional hydrocolloid gum and the dried mixture can be mixed with the cooked, tempered whole grain particles. In other embodiments, enrichment with vitamins and minerals and / or other additives can be achieved by physically mixing with the grain and mixed optionally mixed gum. For example, a dry multi-vitamin pre-mix can be added with simultaneous mixing to a rubber-coated grain mixture at the entrance of a screw conveyor to form a homogeneous composition. The resulting composition can be fed or dropped into a feed tank, which supplies the grinding rolls. The grain composition coated with multi-vitamins and optional rubber can then be ground into shred rollers and formed into shredded products. Additives or fillers, particularly those that can adversely affect the crumbling, can also be incorporated into the shredded baked goods of the present invention by depositing them between layers of shreds during the formation of the dough laminate. Sucrose, fructose, lactose, dextrose, polydextrose, fiber, milk powder, cocoa, and flavors are examples of additives that can be deposited. Exemplary fillers for deposition of intermixed layers include fruit paste fillings, skimmed cheese powder fillings, confectionery fillings, and the like. The additives or fillers can be whole fat, fat-free, reduced in fat or low in fat. The additives can also be applied topically to the laminated structure before or after baking. In the production of shredded whole grain snacks, additives are preferably applied topically instead of being applied between layers such that they do not adversely affect a thin, flake-like appearance. Topically applied oil can be used as a vehicle for one or more additives, such as flavors or seasonings. The topical application of additives can be achieved by using conventional dispensing apparatuses such as those disclosed in US Pat. No. 5,707,448 issued to Cordera et al., By "Apparatus for the Application of Particles to Baked Goods and Snacks", the disclosure of the which is incorporated by reference in its entirety. Products of the present invention may have a moisture content of less than about 5% by weight, preferably from about 0.5 to about 3 percent by weight, more preferably from about 1 to 2 percent by weight, based on the total weight of the finished baked product. The final product can be baked at stable shelf humidity or "water activity" of less than about 0.7, preferably less than about 0.6. It can have shelf stability of at least about 2 months, preferably at least around 6 months, when it is stored in its own sealed packages. The following examples further illustrate the present invention where all parts and percentages are by weight and all temperatures are in ° F, unless otherwise indicated. Example 1 The ingredients and their relative amounts that can be used to produce a shredded snack of whole grain corn, similar to flake, thin, crunchy, are: Pre-ground whole yellow corn can be prepared by grinding Fitz type raw whole corn grain using a mesh of 1/8 inch round holes. Water, salt and lime can be pre-mixed and added to a Lauhoff rotary steam boiler. The water temperature can be around 170-190 ° F. Then, the whole Fitz type ground corn can be added to the rotary cooker within about 60-70 seconds. The dough in the cooker can then be heated with steam and cooked for about 23 minutes at a pressure of about 26 psig and a temperature of about 268 ° F to about 275 ° F to completely gelatinize the starch in the cookers. whole grain corn particles. The cooked whole-grain corn particles can then be discharged from the rotary cooker, passed through a lump-breaker, and then co-milled using a 1-inch square mesh to obtain agglomerates of whole corn grain. The agglomerates can then be transported to a semolina tank or curing tank (tempered). The cooked whole grain agglomerates can be tempered in the semolina vat for up to 3 hours, with a target tempering time of about 2 hours. The cooked, tempered whole grain particles can have a moisture content of about 35% by weight to about 38% by weight, preferably about 36.5% by weight to crumble. The hardened whole grain agglomerates can be transferred to a Bennet pellet former having a solid or cut fly screw, internal and external blades, and a die plate having 1/4 or 5/16 inch openings and a die area. open from around 38% to around 42%. The hardened agglomerates can be formed into pellets at a pressure of about 450 psig to about 550 psig. The pellet former cooling unit can be set at about 40 ° F to cool the pellet former jacket such that the pellets leaving the pellet former have a pellet temperature of about 105 ° F to avoid stickiness problems potentials in the shredder, triangular cutter head, and soft compression roll downstream. Air can be introduced into the die cutter to dispense the pellets. The pellets of whole grain obtained from the pellet former are soft, foldable and coherent, and can have a length of about 1/8 to about 1/4 inch and a diameter of about 1/4 to about 5/16 inch. The discrete free-flowing whole grain pellets can then be transported to a wave feed tank to feed four shredding mills that are arranged in a linear array along a common conveyor. Each shredding mill may comprise a pair of counter-rotating rollers held in mutual contact for the production of network-like sheets. The rollers of the four mills can each have a slit depth of about 0.018 to 0.021 inches and 120 transverse slits. The web-like dough sheets produced by the shredding mills can be continuously deposited on a continuous conveyor belt to form a four-layer whole grain laminate having a thickness of about 1/8 inch. The four-layer laminate, while supported on the conveyor belt, can be continuously compressed between smooth, non-slit, stainless steel counter-rotating compression rollers, as disclosed in US Pat. No. 6,004,612. The compression rollers can have the same diameter can be driven by the same traction at the same speed of rotation. The linear speed of each compression roller can be the same and the linear speed of the band can be around 1% slower than the speed linear of the compression rollers. Compression rollers can be moved or maintained in position by the use of air cylinders. Air cylinder pressures of about 60 to 80 psi can be used to maintain a desired space between the rolls as the band and laminate pass continuously between the counter-rotating compression rolls. The space between the upper roller surface and the upper surface of the conveyor belt can be from about 0.06 to about 0.08 inches to obtain a compressed laminate having a thickness of about 0.06 to about 0.08 inches. The moisture content of the pre-compression laminate and the moisture content of the compressed laminate can be from about 35% by weight to about 38% by weight, preferably around 36.5% by weight. The compressed laminate can be transported to an edge cutter to cut the longitudinal edges. The trimmed, compressed laminate can then be transported to a rotary cutter having a plurality of circumferential rows of Teflon-coated triangular cutters or forming elements. The elements can be partially cut or formed into compressed laminate into rows of isosceles triangle figure pre-forms having blunt or flattened corners. The triangular preforms are joined at their peripheries by a thin layer of mass that results from cutting or only partial incision of the compressed laminate. The partially cut compressed laminate may then be cut or slit longitudinally, and then cut transversely in the direction of movement of the laminate to form triangular, pre-shaped dough strips cut. The whole grain compressed laminate can be transferred to a multi-zone strip oven for drying, baking and toasting for about 5 to 7.5 minutes at temperatures ranging from about 200 to about 600 ° F. The baked product leaving the oven may have a final point moisture content of about 2% by weight, based on the total weight of the final product. After leaving the oven, the baked product strips can be oiled and seasoned in a seasoned drum or dumper. Soybean oil can be applied topically as a fine spray to the top and bottom of the pre-shaped baked-up snack strips, followed by the application of sweet or savory seasonings. The pre-formed bake strips can then be transported to packaged in such a way that the cut strips of triangular snacks are easily separated in the incision line by movement, shock, etc., towards individual snack pieces. The snack pieces can be of isosceles triangle shape with blunt or flattened corners. The base can be around 1.7 inches long, and the two sides can each be about 1.6 inches in length. The two blunt side portions perpendicular and adjacent to the base may each be about 0.1 inches long. The blunt side portion parallel to and opposite the base may be about 1/16 inch. Baked snack pieces can have a flake-like, flat, thin appearance and crisp, crunchy texture. The upper and lower major surfaces may have a substantially uniform shredded pattern or shredded or woven appearance and shredded texture. When the baked snack flakes are broken, the four layers of crumbling can be observed with the naked eye in cross section. The snack flakes can be used for hand-to-mouth snacks and can be used to soak without breaking. Example 2 The ingredients and their relative amounts that can be used to produce a shredded snack of whole grain rice, similar to flake, thin, crunchy, are: Pre-milled long-grain brown rice can be prepared by grinding Fitz type long-grain raw brown rice using a mesh of 1/8 inch round holes. Water and salt can be pre-mixed and added to a Lauhoff rotary steam cooker. The water temperature can be around 170-190 ° F. Then, the whole Fitz type ground rice can be added to the rotary cooker within 60-70 seconds. The dough in the cooker can then be heated with steam and boiled for about 20 minutes at a pressure of about 20 psig and a temperature of about 268 to about 275 ° F to completely gelatinize the starch in the particles of water. whole grain rice The cooked whole-grain rice particles can then be discharged from the rotary cooker, passed through a lump-breaker, and then co-milled using a 1-inch square mesh to obtain agglomerates of whole-grain rice. The agglomerates can be transported to a semolina tank or curing tank (tempered). The cooked whole grain agglomerates can be tempered in the semolina vat for 1 to 4 hours, with an objective tempering time of about 2 hours. The cooked, tempered whole grain particles can have a moisture content of about 35% by weight to crumble. The hardened whole grain agglomerates can be transferred to a Bennet pellet former having a solid or cut fly screw, inner and outer blades, and a die plate having 3/16 inch openings and an open die area of about 38% to around 42%. The hardened agglomerates can be formed into pellets at a pressure of about 450 psig to about 600 psig. The pellet-forming cooling unit can be set at about 40 ° F to cool the pellet former jacket such that the pellets emerging from the pellet former have a pellet temperature of about 95 to about 105 ° F for avoid potential stickiness problems in the shredder, triangular cutter head, and soft compression roll downstream. Air can be introduced into the die cutter to disperse the pellets. The pellets of whole grain obtained from the pellet former are soft, foldable and coherent, and can have a length of about 1/8 to about 1/4 inch and a diameter of about 3/16 inch. The discrete free-flowing whole grain pellets can then be minced into a whole grain laminate, compressed, rotatably cut, baked, seasoned, and packaged as in example 1. Example 3 The ingredients and their relative amounts that can be used to produce a crushed whole grain rice snack, similar to flake, thin, crunchy, are: Pre-ground oats can be prepared by grinding Fitz type raw whole grain oats using a mesh of 1/8 inch round holes. Water and salt can be pre-mixed and added to a Lauhoff rotary steam cooker. The water temperature can be around 170-190 ° F. Then, whole Fitz type ground oats can be added to the rotary cooker within 60-70 seconds. The dough in the cooker can then be heated with steam and cooked for about 20 minutes at a pressure of about 20 psig and a temperature of about 268 ° F to completely gelatinize the starch from the whole grain oat particles . The cooked whole grain oat particles can then be discharged from the rotary cooker, passed through a lump splitter, and then co-milled using a 1-inch square mesh to obtain agglomerates of whole grain oats. The agglomerates can be transported to a semolina tank or curing tank (tempered). The cooked whole grain agglomerates can be tempered in the semolina vat for 1 to 4 hours, with a target tempering time of around 2 hours. The cooked, tempered whole grain particles can have a moisture content of about 32% by weight to crumble. The hardened whole grain agglomerates can be formed into pellets and the discrete, free-flowing whole grain pellets can then be crumbled into a whole grain laminate, compressed, rotatably cut, baked, seasoned, and packaged as in Example 2 Example 4 The ingredients and their relative amounts that can be used to produce a shredded snack of 100% whole grains, similar to flake, thin, crunchy, are: Each of the four pre-ground whole grains can be prepared by grinding the whole Fitz type whole grain using a mesh of 1/8 inch round holes. Water and salt can be pre-mixed and added to a Lauhoff rotary steam cooker. The water temperature can be around 170-190 ° F. The four pre-ground whole grains can be added to the rotary cooker within 60-70 seconds. Alternatively, the four pre-ground whole grains can be added separately to the rotary cooker and physically mixed in the cooker with the water-salt solution to obtain a substantially homogenous physical mixture. The dough in the cooker can then be heated with steam and boiled for about 20 minutes at a pressure of about 20 psig and a temperature of about 268 to about 275 ° F to completely gelatinize the starch in the particles of water. whole multiple grains. The cooked whole-grain particles can then be discharged from the rotary cooker, passed through a lump-breaker, and then co-milled using a 1-inch square mesh to obtain agglomerates of whole grain oats. The agglomerates can be transported to a semolina tank or curing tank (tempered). The whole cooked whole grain agglomerates can be tempered in the semolina vat for 1 to 4 hours, with a target tempering time of about 2 hours. Fully cooked, tempered whole grain particles can have a moisture content of about 34.5% by weight to crumble. Whole hardened multiple grain agglomerates can be formed into pellets and discrete, free-flowing whole grain pellets can then be crumbled into a whole multiple grain laminate, compressed, rotatably cut, baked, seasoned, and packaged as in example 2

Claims (21)

1. CLAIMS 1. A method for producing a whole grain shredded food product comprising: a) mixing whole grain grain particles with water and baking the whole grain particles to at least substantially gelatinize the starch of the whole grain particles b) temper the cooked whole grain particles, c) pellet the cooked, tempered whole grain particles in a pellet former to obtain pellets of whole grain, the pellet former being under temperature and pressure conditions for provide continuous shredding of whole grain pellets into continuous web-like sheets, d) shredding whole grain pellets into sheets similar to whole-grain nets, e) laminating whole grain-like sheets to obtain a grain laminate whole, f) cut the whole grain laminate into whole grain pieces, and g) bake the whole grain pieces for to obtain a whole grain shredded food product.
2. 2. A method for producing a whole grain shredded food product according to claim 1, wherein the whole grain particle particles are whole corn grain particles.
3. 3. A method for producing a whole grain shredded food product according to claim 2, wherein the pellet formation reduces retrogradation of the starch of the tempered whole grain particles to increase their shredding.
4. 4. A method for producing a whole grain shredded food product according to claim 2, wherein the whole corn particles are fired with lime and the moisture content of the cooked whole corn grain particles is around 29% by weight to about 42% by weight, based on the weight of the cooked whole grain corn particles. A method for producing a whole grain shredded food product according to claim 2, wherein the pellet formation is at a pressure of about 200 to about 600 psig. 6. A method for producing a whole grain shredded food product according to claim 2, wherein the pelletizing temperature is controlled to provide a pellet temperature of about 80 to about 120 ° F upon exiting the pelletizer. pellets. A method for producing a whole grain shredded food product according to claim 2, wherein the pellet formation is at a pressure of about 400 to about 500 psig, and the pelletizing temperature is controlled to provide a pellet temperature of about 90 to about 110 ° F on leaving the pelletizing die. A method for producing a whole grain shredded food product according to claim 2, wherein the pellets have a length of about 1/8 to about 1/4 inch and a diameter of about 3/16 to about 5/16 of an inch and are produced by extrusion through a pellet forming die having a plurality of apertures. 9. A method for producing a whole grain shredded food product according to claim 8, wherein said extrusion die has an open area of about 25 to about 45%. A method for producing a whole grain shredded food product according to claim 2, wherein said whole corn grain particles are obtained by grinding entire maize grains or seeds to a particle size of about 0.09 to about 0.165 inches A method for producing a whole grain shredded food product according to claim 2, wherein said cooking is conducted at a temperature of at least about 250 ° F. 12. A method for producing a whole grain shredded food product according to claim 2, where said cooking is conducted at a pressure of about 15 to about 30 psig. A method for producing a whole grain shredded food product according to claim 2, wherein said tempering is for about 0.5 to about 5 hours at a temperature of less than about 125 ° F. A method for producing a whole grain shredded food product according to claim 2, wherein said whole grain laminate is compressed to a thickness of about 0.05 to about 0.08 inches and the compressed whole grain laminate is cut into pieces. A method for producing a whole grain shredded food product according to claim 1, wherein said whole grain particles comprise at least one member selected from the group consisting of rye, oats, rice, barley, corn, wheat, and triticale 16. A method for producing a whole grain shredded food product according to claim 15, wherein whole soybean seeds or crushed whole soybean seeds are mixed with said whole grain particles. 17. A method for producing a whole-grain shredded corn snack having a crunchy, crunchy-like texture, comprising: a) crushing whole raw maize seeds or grains, b) mixing the crushed whole raw maize grains, and cooking pressing the crushed whole grains to at least substantially gelatinize starch from the whole grains, c) tempering the whole maize grains, crushed, cooked, d) pelletting the whole maize grains crushed, cooked, tempered, into a pellet former to obtain whole corn kernel pellets, the pellet former being at a pressure of about 200 to about 600 psig, and the pelletizing temperature being controlled to provide a pellet temperature of about 80 to about 120 ° F when leaving the pellet former, e) crumble the pellets of whole corn kernel into slices similar to whole corn kernels, f) laminating the maize-like webs to obtain a whole corn grain laminate, g) substantially compressing the entire maize laminate to obtain a compressed laminate having an appearance similar to shredded network, h) cutting the laminate of whole corn kernel compressed into whole corn kernel pieces, and i) baking whole corn kernel pieces to obtain a crushed corn snack of whole grain having a crumbled texture similar to flake, thin, crunchy, and a similar appearance a shredded flake. 18. A method for producing a whole-grain shredded corn snack according to claim 17, wherein the pellet formation is at a pressure of about 400 to about 550 psig, and the pelletizing temperature is controlled to provide a pellet temperature of about 90 to about 110 ° F upon exiting the pellet former. 19. A method for producing a whole-grain shredded corn snack according to claim 17, wherein the ground, cooked, tempered whole corn grains are in the form of pellets upon entering the pellet former. A method for producing a whole grain shredded corn snack according to claim 19, wherein the agglomerates have a hard texture, and the pellet former produces pellets having a softer, more collapsible texture, for continuous shredding into sheets similar to networks. 21. A method for improving the shredding of whole grains of grain, retrograded, to produce a shredded whole grain food product comprising agglomerated pellets of whole grain particles, cooked, tempered, which have suffered retrogradation to a hard, fracturable texture, to obtain whole grain pellets having a smooth texture, pelletizing, the formation of pellets being at a pressure of about 200 to about 600 psig, and the pelletizing temperature being controlled to provide a pellet temperature of about 80 to about 120 ° F upon leaving the former of pellets.