CN1295444A - Dough composition for making semi-finished products and starchy snack food produced from the semi-finished products - Google Patents

Abstract

Starchy snack food products with improved flavor and sensory properties are made by extruding a semi-finished product. The dough for making the intermediate consists essentially of (1) a mixed flour comprising (a) a starch-based flour comprising at least about 10% rice flour, (b) less than about 8% sugar, (C) at least about 0.5% salt, (d) a leavening agent comprising sodium bicarbonate, (e) an emulsifier comprising a monoglyceride, and (2) water. Starch and/or gluten may optionally be added to the meal to provide a different degree of crispness to the finished product. Can be made into full-fat, low-fat or fat-free products. Embossing may be used to control swelling, surface oiliness and fat exudation. The meal is preconditioned and the dough is extruded under low shear and high moisture conditions. The dough composition develops sufficient viscosity upon heating and cooling to allow dough processing at temperatures and work inputs below that which would result in substantial reduction of starch and/or discoloration and loss of flavor components in the ingredients. The rapid drying method used to dry the extrudate improves productivity without sacrificing the desired product properties. Drying of the extrudate is carried out at a temperature of from about 175 ° F (79.4 ℃) to about 200 ° F (93.3 ℃) for from about 1 hour to about 4 hours at a relative temperature of at least about 20%. The semifinished product can be packaged immediately after drying and does not require tempering.

Description

The starchiness snack food that is used to make half-finished dough composition and produces with these semi-finished product

Technical field

The present invention relates to be used to prepare half-finished dough composition and with the starchiness snack food of this semi-finished product preparation.The present invention also relates to be used to prepare process of semi-finished.

Background of invention

Many method and compositions that are used to make expanded starchiness snack food are known technically.Also carried out many years though process these snacks, still relate to many problems in the process of reproduction, the product quality is produced in regeneration in narrow (with measurable) scope, and local flavor has consistent quality with expansion rate to guarantee the product of producing.The problem relevant with the semi-finished product swelling properties, for example, semi-finished product are when fried, absorb the amount of fat and the quality local flavor of finished product snack etc. in the expansion process, the prescription of splitting fermentation group has increased importance, and the expanded snack that this dough formula is produced contains the quality and the local flavor of less fat and improvement than traditional expanded snack.

The condition of known extrusion process (temperature of extrusion cylinder for example, screw rod shape, screw speed, the water content of dough before the hot-working) can influence the quality of half-finished expanding volume and change finished product snack.Be typically, half-finished swelling properties of extruding changes with the change of machinery input in the processing, thereby has changed the quality of final products.The method that another influence is expanded is to apply the heat input the machinery in extruding is imported.

The control of these machined parameters provides bigger operability and control of final products quality etc., the final products of the semi-finished product production of processing with this mode still can not satisfy desired whole feature, low fat for example, fragility, chewiness, melt the oral cleaning of control and local flavor in the oral cavity of control.Final products are tending towards lacking fragility and hard, tight and the nature of glass or hollow and foam-like.This also is the feature (for example, the born of the same parents chamber of big opening, uneven born of the same parents chamber, thin and/or cracked born of the same parents' locular wall) of these products owing to born of the same parents' cell structure causes.Product also trends towards coarse surface texture.Differential expansion and/or big air chamber that fried back forms owing to half-finished expansion are important, because the quality of final products is relevant with bulk density with the volume that expands.Semi-finished product expand the product form produced to a great extent with the composition of dough, composition functional and to add the degree etc. of starch gelatinization in man-hour relevant in the dough.

There is several method can be used to produce traditional expanded snack.In a method, dough is that the mixture by powder/starch/water forms.The ratio to the starch of ungelatinized of gelatinization is adjusted to when fried in the dough, and half-finished expansion is about 1.6 times of original size at least, but is not more than 3.0 times.Be used to produce the half-finished equipment of this type and do not introduce shearing in fact, therefore, the character of the dough of extruding does not change with the original handler that enters basically.Another kind of processing method has been used the have higher screw speed high temperature, short time extrusion of (300-400 rev/min), about 285 of the temperature during operation (140.6 ℃).

Have been found that a problem that forms extrudate with conventional method and prescription relates to extruding and boils to the influence of content of starch than higher material.Unfortunately, machinery and the heat condition during extruding can destroy heat sensitive powder and the desirable character of starch.These character (peak viscosity and final viscosity) are important to the extrudate that obtains, and are low-fat because the semi-finished product born of the same parents cell structure that this extrudate produces when drying should be able to make expanded finished product snack, and are crisp, chewy, yet quality is light.The extruding condition that uses generally also can destroy the amount (for example corn, rice, wheat, potato) of desirable volatile flavor thing and/or the colored component of powder and starch.

Though carried out effort to improving semi-finished product, so that final products have desirable sensory qualities, still there are important disadvantages in known prescription and method, promptly the finished product snack lacks the expansion of uniform born of the same parents chamber and has bad quality.

The present invention has alleviated more aforesaid problems by prescription and unique processing conditions of dough, and prescription comprises specific starch matrix composition, and processing conditions comprises hot prehydration and follows extrude dough under the low shearing condition of high-moisture.

The simple declaration of figure

Fig. 1 is the cross section (amplifying 75 times) of typical commercially available extruded product, with the porous of SEM demonstration.

Fig. 2 is the cross section (amplifying 75 times) of typical commercially available extruded product, with the porous of SEM demonstration.

Fig. 3 is the cross section (amplifying 200 times) of typical commercially available prod, shows born of the same parents' locular wall with SEM.

Fig. 4 is the cross section (fried in triglyceride fat) (amplifying 75 times) of the product of making according to the present invention, with the porous of SEM demonstration.

Fig. 5 is the cross section (fried in triglyceride fat) (amplifying 75 times) of the product of making according to the present invention, with the porous of SEM demonstration.

Fig. 6 is the cross section (fried in triglyceride fat) (amplifying 200 times) of the product of making according to the present invention, with born of the same parents' locular wall of SEM demonstration.

Fig. 7 is the cross section (fried in stodgy fat) (amplifying 75 times) of the product of making according to the present invention, with the porous of SEM demonstration.

Fig. 8 is the cross section (fried in stodgy fat) (amplifying 75 times) of the product of making according to the present invention, with the porous of SEM demonstration.

Fig. 9 is the cross section (fried in stodgy fat) (amplifying 200 times) of the product of making according to the present invention, with born of the same parents' locular wall of SEM demonstration.

Summary of the invention

The invention provides and be used to prepare the intermediate composition dough composition of (after this being called " semi-finished product ").The present invention also relates to be used to produce half-finished processing conditions.The expanded snack food that the present invention also provides full-cream, low fat or do not have fat, this snack has crisp quality, and improved flavor can not stick to one's teeth with long chewiness.Born of the same parents' cell structure of final products, expanded level and quality are all by being used to produce half-finished prescription and/or processing conditions is controlled.

One embodiment of the invention are squeezable doughs, this dough is grouped into by following one-tenth basically: (1) mixed powder, this mixed powder comprises (a) and contains starch matrix meal component at least about 10% crude rice powder, (b) be less than about 8% sugar, (c) at least about 0.5% salt, (d) from about 0.2% to about 1.0% leavening, this leavening comprises sodium acid carbonate, (e) from about 0.1% to about 1.5% emulsifying agent contains monoglyceride and (2) water at least about 0.3% in this emulsifying agent.The amylose content of preferred rice meal is at least about 10%.Except rice meal, composition preferably comprises one or more and is selected from native starch, the starch of ungelatinized, the starch that boils starch and modified starch etc. of ungelatinized, these starch derive from stem tuber and cereal, for example farina, tapioca, cornstarch, oat starch, rice starch and wheaten starch.Starch is added to the final products that can make production in the dough composition has in various degree fragility.The water imbibition index (WAI) of powder and starch is less than 3.0.Except powder and starch, also can add gluten in the dough composition.When adding gluten, emulsifying agent also should comprise the diacetyl tartrate monoglyceride.

Another embodiment relates to the semi-finished product of following method preparation, and this method comprises (1) extrude dough under the low shearing condition of high-moisture; (2) moisture of reduction extrudate.Adopt these processing conditions to produce semi-finished product with dough composition and have, gelatinization point from about 75.2 (24 ℃) to about 203 (95 ℃); The peak viscosity time was at least about 6 minutes; Peak viscosity is from about 10 quick viscosity units (RVU) to about 140 quick viscosity units; With final viscosity from about 120 quick viscosity units to about 350 quick viscosity units.Semi-finished product comprise from about 7% to about 14% moisture and about 3 to about 8 water imbibition index, preferably from about 4 to about 6 water imbibition index.

Another embodiment relates to expanded fried product, its gelatinization point from about 77 (25 ℃) to about 203 (95 ℃), the peak viscosity time was from about 3 minutes to about 7 minutes, peak viscosity from about 11 quick viscosity units to about 55 quick viscosity units and final viscosity from about 130 quick viscosity units extremely of about 20 quick viscosity units.Snack food has light, and is crisp, chews character, improved flavor and fat content from about 11% to about 32%.The water content of fried snack is lower than about 3%.Submember can comprise sugar, spices, local flavor material and pigment.

Detailed Description Of The Invention

Main points of the present invention are following factors: shearing and processing conditions in the anti-extruder of prescription energy of (1) dough composition; (2) steam the pre-hydration powder of G﹠W with injecting; (3) extrude dough is to obtain to have certain viscoelastic semi-finished product; (4) dry extrudate; (5) fried semi-finished product are to obtain having certain viscoelastic final products.The key character of snack food of the present invention is unique born of the same parents' cell structure, the quality of low fat and final products.These factors can be used separately or any being used in combination to obtain desirable dough, semi-finished product and/or final snack food.

The character that obtains final snack at first is the semi-finished product that preparation is suitable for.Semi-finished product are to form with including specific the starch matrix batching (being powder and/or starch) and the dough preparation of water.The selection of starch matrix batching is to carry out in the ability that different temperatures increases dough viscosity according to their retentiveness and they.This specific starch matrix batching, employed steam boils and higher water content in advance during in conjunction with extruding, compares with normally used boiling extruder, can use lower heat energy and mechanical energy during the preparation semi-finished product.

Extruding can destroy starch, makes final products present irregular expansion, has reduced chewiness, and fusing fast is higher fatty acid in the oral cavity, greasy outward appearance and shortage local flavor (the effusion local flavor owing to the destruction of born of the same parents chamber in extruder die).But the destruction (for example, the batching is functional and the loss of local flavor) that produces has been compensated in the specific batching combination among the present invention in extrusion process.

A. definition

" mixed powder " used herein is meant the whole dough mixture of ingredients except that anhydrating." mixed powder " comprises composition and other composition, for example liquid emulsifier of all doing.

" extrudate " used herein is meant the wet dumpling piece that just come out from extruder.

Wet snack chip in the middle of " semi-finished product " used herein are meant, this sheet volume energy when fried expands big.Semi-finished product comprise sheet, ring-type and the complicated shape that can expand, for example, and hull shape, letter, numeral, symbol, animal, flower, spirality, twist shape, taper, multiaspect shape, tubular, broken shape and star etc.

" final products " used herein are meant the edible immediately product that semi-finished product produce after fried.

Term used herein " fat " and " oil ", except that other have now fixed, can exchange use.Term " fat " and " oil " comprise edible fatty material in general sense, comprise digestible and stodgy fat, oil, and fat substitute, but be not restricted to these.

Term used herein " water " is meant the water that is added in the dough ingredients.The intrinsic water that originally was present in the dough ingredients is not included in this term " water ".

Term used herein " moisture " is meant whole water of existence, and it comprises the water and the water that joins in the dough ingredients of intrinsic existence in the dough ingredients.

The supposition unit that " viscosity unit (RVU) fast " used herein uses when being viscosity measurement roughly is equivalent to centipoise.

" gelatinization point " used herein is meant the beginning temperature, when this temperature, and 1 ℃ of every rising, viscosity rises greater than 2 quick viscosity units, and assay method is to carry out according to quick viscosity analytical method herein.

" peak viscosity " used herein is meant when measuring with quick viscosity analytical method herein, the high viscosity in the heating process.

" the peak viscosity time " used herein reaches the needed time of peak viscosity when being meant the quick viscosity assay that Clicks here.

" final viscosity " used herein is meant when the quick viscosity analytical method of using is herein measured, cooled final peak viscosity.

Unless otherwise provide, all percentage and ratio are all by weight.

B. dough

Particular importance of the present invention aspect is a dough.Dough is made up and is formed by water and mixed powder, and mixed powder comprises the starch matrix powder composition that (1) contains crude rice powder; (2) sugar; (3) salt; (4) leavening; (5) emulsifying agent.The composition of dough has material impact to the finished product snack; 2 remarkable influence are: (1) processes the ability of dough in extruder, and it is thin, crisp that the dumpling piece that shapes can keep when fried, the snack food of shaping; (2) quality and the flavor characteristic of final snack food.

1. starch matrix powder composition

A rice meal that important component is a ungelatinized of dough.Rice meal is used for the source combination with other starch matrix powder.The source of other starch matrix powder that is suitable for comprises, for example, and tapioca starch, oatmeal, wheat flour, the naked barley powder, (non-masa) corn flour of non-masa, peanut powder and dehydrated potato powder are (for example, the potato block and the particle of dehydration, potato of smashing to pieces and the potato that does).Rice meal can mix to make the snack of different compositions, quality and local flavor.Particularly preferred starch matrix powder composition is the mixture of non-masa corn flour and rice meal.

Optional starch matrix powder composition comprises the powder with following viscoelastic properties: (a) gelatinization point from about 91.4 (33 ℃) to about 203 (95 ℃), preferably from about 122 °F (50 ℃) to about 194 °F (90 ℃), more preferably from about 123 °F (50.6%) to about 185 °F (85 ℃) and most preferably from about 158 °F (70 ℃); (b) the peak viscosity time is from about 3 minutes to about 10 minutes, preferably from about 4.8 minutes to about 7.0 minutes; (c) peak viscosity is from about 100 quick viscosity units to about 360 quick viscosity units, preferably from about 146 quick viscosity units to about 350 quick viscosity units with more preferably from about 180 quick viscosity units to about 205 quick viscosity units; (d) final viscosity is from about 150 quick viscosity units to about 350 quick viscosity units, preferably from about 220 quick viscosity units to about 345 quick viscosity units with more preferably from about 230 quick viscosity units to about 340 quick viscosity units.The water imbibition index (WAI) of starch matrix powder composition is less than 3.0, preferably from about 1.5 to about 2.7, and more preferably from about 1.7 to about 2.5.

Mixed powder of the present invention comprises from about 60% to about 99%, and preferably from about 70% to about 95% and more preferably from about 75% to about 91% starch matrix powder.

At least about 10%, preferably from about 15% to about 50%, more preferably from about 20% to about 40% and most preferably from about 22% to about 30% starch matrix powder composition is a rice meal, and the remainder of starch matrix powder is other powder.In preferred embodiments, the amylose content of rice meal is at least about 10%.Particularly preferred mixed powder comprises from about 10% to about 25% rice meal, and remainder is the non-masa corn flour of degreasing.

Starch

Also can use starch in the dough composition of the present invention.The starch that adds is to be used in combination with above-mentioned starch matrix powder.As hope more crisp quality is arranged, then should add starch in the dough formula.The starch example that is suitable for comprises native starch, the starch of ungelatinized, and the starch that boils and the modified starch of ungelatinized, these starch derive from stem tuber and cereal, for example farina, tapioca, cornstarch, oat starch, rice starch and wheaten starch.Also can use the starch part gelatinization or gelatinization.But when using the starch of pre-gelatinization, should combine with diacetyl tartrate monoglyceride (DATEM).Have been found that and pre-gelatinization can make final products present coarse sand with the starch part gelatinization.Surprisingly, with the diacetyl tartrate monoglyceride with pre-gelatinization and the starch part gelatinization in conjunction with the time can reduce coarse sand greatly.

The water imbibition index of starch that is used for the present invention is less than 3.0, and preferred water imbibition index is from about 1.5 to about 2.7, preferred water imbibition index from about 1.7 to about 2.5.

Mixed powder comprises from about 0.5% to about 30%, preferably from about 1% to about 20%, and more preferably from about 2% to about 10% and from about 3% to about 7% starch most preferably.

Be surprised to find, use starch matrix powder composition and not necessarily combine, dough is not ruptured when extruding with starch.Powder and starch have the preferred viscoplasticity of desired water imbibition exponential sum to guarantee: (1) is water distribution uniformly; (2) aquation of appropriate batching; (3) in the early stage increase viscosity of extrusion process; (4) can keep viscosity in the temperature of extruder with under shearing.

The dough that contains a large amount of separate sources starch matrix materials for example is used to form the dough of product of the present invention, and normal condition is that starch competition in the dough absorbs moisture when extruding.When heating, some starch comparatively fast absorbs moisture than other starch.The starch that lacks suitable aquation, the starch of particularly pre-gelatinization can make fried product become densification, coarse sand and sticking to one's teeth.Because the different water imbibition indexes of powder and starch, some composition is than the easier hydration of other composition, and it is light that this can make fried product have, bulk, hollow structure and comparatively fast thawing in the oral cavity.The gelatinization of starch and disengage the dumpling piece that amylose helps to form viscosity.It has been generally acknowledged that the amylose that disengages in the gelatinization process is not enough to withstand processing conditions (for example, heat in the extruder and shearing), these conditions are essential to producing the semi-finished product that can form uniform expanded fried snack.

Adding has different viscoelastic powders and starch can be stablized dough and provide production to have the method for structure-improved and quality product.For example, because powder has different peak viscosity and different peak viscosity time with starch, it is stable that structure of dough can keep.Because of the water-retaining property difference of batching, therefore in fried step, the water-retaining property of powder and starch makes the inside evaporation of moisture from dough again.Consequently form multi-layered product with homodisperse space.Therefore, in fried step, frying oils can enter in the hollow structure of extrude dough.This can guarantee the inside of dough be boil with fat be homodisperse.When the fat composition that includes Nondigestible fat was used for fried final products, the even distribution of the formation in this even dispersion space and fat was a particular importance.This is can make fat deposition because of big with uneven void space.The fried snack of Chan Shenging has bad quality and greasy and/or wax shape mouthfeel like this.

Gluten

Also can add gluten in the dough composition of the present invention.When adding gluten in dough composition, composition preferably also comprises emulsifying agent diacetyl tartrate monoglyceride.Gluten can strengthen the cohesive and the viscoplasticity of dough.Have been found that with the combination of diacetyl tartrate monoglyceride and can promote the functional of gluten.The gluten that adds in the dough composition of the present invention does not comprise the gluten that originally was present in the powder.Gluten strengthens the gas maintenance performance of dough and the ability that dough stands mechanical treatment with the binding energy of diacetyl tartrate monoglyceride.This being combined with helps its shape of product maintenance.

The gluten that adds, the typical case account for mixed powder about 0.2% to about 2.0%, preferably from about 0.4% to about 1.2%, more preferably from about 0.5% to about 1.0%.

2. sugared

Preferably comprise sugar in the dough composition of the present invention.Sugar can not only influence local flavor, and helps to improve the rheological characteristic of dough.In addition, sugar also improves the color and the quality of finished product snack.Mixed powder of the present invention comprises and is less than about 8% sugar, preferably from about 2.5% to about 4%, and 3% sugar more preferably from about.

3. salt

Preferably comprise salt in the dough composition of the present invention.Though also not really understand, think that salt has functional (promptly changing the physical property of dough) and have sense organ (promptly helping to strengthen local flavor) in the finished product snack in dough.Term salt used herein comprises sodium chloride, potassium chloride and calcium chloride, but be not restricted to these.

Comprise at least about 0.5% in the mixed powder of the present invention, preferably from about 1.0% to about 5%, more preferably from about 1.5% to about 3% salt.Salt preferably is less than sugar in the dough composition.

4. leavening

Dough composition of the present invention also comprises leavening.The leavening that exists in the mixture is from about 0.2% to about 1.0%, preferably from about 0.3% to about 0.8%, and more preferably from about 0.4% to about 0.6%.Leavening at least about 0.2%, be sodium acid carbonate preferably at least about 0.5%.

Be surprised to find, sodium acid carbonate and diacetyl tartrate monoglyceride are used in combination the fermentation that can strengthen leavening than independent use sodium acid carbonate.Other general leavening also can be used in combination with sodium acid carbonate.Particularly preferred leavening comprises alkali carbonate and alkali metal hydrogencarbonate, for example sodium carbonate or potash and calcium carbonate, and other leavening, for example aluminum phosphate sodium though can use, is not preferred yet.

Preferred leavening be big particle or outsourcing capsule to prevent emergent gas in extruder, this can make product promptly expanded before fried.Preferred granular size is from about 0.0035 inch (0.088 a millimeter) to about 0.0098 inch (0.250 millimeter).

Leavening also can be encapsulated in low-melting fat or the shortening, can disengage under frying temperature like this.

5. emulsifying agent

Having a kind of composition in the emulsifying agent that dough composition comprises at least is monoglyceride.Monoglyceride can be the monoglyceride that replaces, for example acetylizad monoglyceride, the ester of monoglyceride or diglyceride.Emulsifying agent also can add and comprise the diacetyl tartrate monoglyceride, polyglycereol monoesters, the glyceryl monoacetate of aliphatic acid and two acid esters, stearoyl-2-calcium lactate, stearoyl-2-sodium lactate and their mixture.Emulsifying agent helps to control the amount that is absorbed fat by semi-finished product when fried, controls half-finished expansion when fried, and starch breaks and lubricated extruder barrel when reducing extruding.In practice of the present invention, have been found that emulsifying agent is added to be particularly conducive in the dried ingredients mixture to prevent that the starch hydration is too fast.Like this, starch can lessly be subjected to the influence of mechanical shearing in extruder barrel.

Particularly preferred emulsifying agent is the diacetyl tartrate monoglyceride.Really the cutter reason is also not really clear though act on, and thinks when fried, and the interaction energy of emulsifying agent and leavening strengthens the effectiveness of leavening.Particularly preferred emulsifier mixture comprises the monoglyceride of diacetyl tartrate monoglyceride and distillation.This mixture is specially adapted to comprise the composition of pre-gelatinized starch and gluten (if use).The typical monoglyceride that uses is a powdery, and diacetyl tartrate monoglyceride and/or emulsifying agent mix with fat, and this fat is selected from oil, shortening, stodgy fat and their mixture.

The diacetyl tartrate monoglyceride is the fatty acid ester of glycerine, and it is diacetyl tartaric acid and has 12 to get to the fatty acid esterification of about 22 carbon atoms.Aliphatic acid can be saturated or unsaturated.The iodine number of diacetyl tartaric acid monoglyceride is from about 50 to about 110.Preferred iodine number from about 70 to about 85.The diacetyl tartaric acid monoglyceride is the mixture of monoglyceride and diglyceride.The diacetyl tartrate monoglyceride can be with oily, and shortening and/or stodgy fatty premixed are to increase its flowability.

Also can use low-molecular-weight polyglycerol ester in the dough composition of the present invention.These polyglycereol mainly are two glycerine or triglycerin.During glycerol polymerization, the polyglycereol of formation is a mixture.What most preferably use among the present invention is two monoglycerides, and it is the mixture of polyglycereol monoesters, and wherein dominant polyglycereol is two glycerine.The preferred aliphatic acid that is used to prepare ester is the saturated and undersaturated aliphatic acid that contains from 12 to 22 carbon atoms.Most preferred two monoglycerides are two glycerine monopalmitates.

Also can use saturated and undersaturated fatty acid glycerine one acid esters and the diglyceride that contain 12 to 22 carbon atoms in the dough composition of the present invention.Preferred monoglyceride is the monoglyceride of distillation, for example, from soybean oil, rape seed oil, cotton seed oil, sunflower oil, palm oil, palm olein, safflower oil, corn oil, those that peanut oil and their mixture obtain.Preferred distillation monoglyceride comprises and derives from a little bigger oil, rape seed oil, and the distillation monoglyceride of palm oil and their mixture, but be not restricted to these.

Typical commodity monoglyceride contains the diglyceride and the triglyceride of different amounts.For example, the glycerine one of distillation and two acid esters comprise about 90% monoglyceride, but not the glycerine one and two acid esters of distillation comprise about 30% monoglyceride.The two may be used in the dough formula of the present invention.

Stearoyl-2-sodium lactate or stearoyl-2-calcium lactate is from stearic acid, and the interaction of the lactic acid of 2 molecules and NaOH or calcium hydroxide obtains.

Mixed powder of the present invention comprises from about 0.1% to about 1.5%, preferably from about 0.3% to about 0.7%, and more preferably from about 0.5% to about 0.6% emulsifying agent.The monoglyceride that emulsifying agent comprises is at least about 0.3%.Though the use amount of emulsifying agent can be up to 1.5%, consequently make final products have hard quality.

6. water

Another key character of dough of the present invention is its water content.The preparation of dough is normally in when extruding is added to water mixed powder in the preconditioned device.Term used herein " water " is meant the water that is added in the dough ingredients.The water of intrinsic existence in the dough ingredients for example is present in the water in powder and the starch, and is not included in the term " water ".In powder and the starch amount of the water of intrinsic existence usually from about 3% to about 18% (their humidity is about 3% to about 18%)." humidity " used herein is meant whole moisture of existence.

Dough ingredients of doing and emulsifying agent and the water formation dough that combines.Dough of the present invention comprises from about 18% to about 70% moisture, and this is difference with the moment of processing.The amount of the moisture that exists in the dough changes in extrusion process.Be typically, the water content of dough of the present invention in the preconditioned device be from about 18% to about 35%, preferably from about 19% to about 30%, and more preferably from 24% to about 28%.The water content of dough before when extruding and exhaust is from about 30% to about 58%, preferably from about 35% to about 52%.The water content of the dough that comes out from extruder is from about 20% to about 40%, preferably from about 25% to about 35%, and more preferably from about 26% to about 34%, most preferably from about 30%.

7. other composition

Also can add other composition in the dough composition of the present invention, local flavor material for example, spices, medicinal herbs, pigment and/or flavoring, vitamin, mineral matter and oil.The composition of doing normally is added to dried dough ingredients before extruding.But, also can spray from the teeth outwards in the fried back of snack food.

Vitamin, mineral matter and other nutraceutical adding are in order to improve the nutritive value of extruding snack food.Vitamin and/or mineral matter can be added in the dough, and/or add together with flavoring in fried back.

8. the rheological equationm of state of mixed powder

Mixed powder of the present invention can bring quality and the structure that dough is wished, it has particular rheological properties matter, and this rheological equationm of state makes dough keep stable in extrusion process.The peak viscosity that mixed powder of the present invention has is from about 100 quick viscosity units to about 360 quick viscosity units, preferably from about 145 quick viscosity units to about 215 quick viscosity units with more preferably from about 150 quick viscosity units to about 210 quick viscosity units.The final viscosity of mixed powder is preferably from about 100 quick viscosity units to about 450 quick viscosity units.The gelatinization point of mixed powder from about 91.4 (33 ℃) to about 203 (95 ℃), preferably from about 122 °F (50 ℃) to about 203 °F (95 ℃), more preferably from about 140 °F (60 ℃) to about 176 °F (80 ℃), the peak viscosity time was from about 3 minutes to about 10 minutes.

The preferred gelatinization point of starch matrix powder composition is from about 91.4 °F (33 ℃) to about 203 °F (95 ℃), preferably from about 122 (50 ℃) to about 194 (90 ℃), more preferably from about 122 (50 ℃) to about 176 (80 ℃); The peak viscosity time is from about 3 minutes to about 10 minutes, and peak viscosity is about 350 quick viscosity units extremely from about 100 quick viscosity units to about 360 quick viscosity units and final viscosity from about 150 quick viscosity units.

The batching of doing and the rheological characteristic of mixed powder are to measure with the quick viscosity analytical method of setting forth herein, and wherein these batchings are at first carried out hydration according to described method before mensuration.

C. half-finished preparation

1. extruding

Be used to produce process of semi-finished of the present invention and decide with used starch matrix dough composition, said composition under the condition of lower shear-mixed, high-moisture and control temperature gelatinization to form hollow matrix relatively uniformly.Half-finished preparation is with batch mixes, then with boiling extruder boiling batching.The combination of the heat of preconditioned device and machinery heat allows this method that extrudate is produced under the condition than conventional method milder.This combination not only can make extrudate be lower than 220 °F (104.4 ℃) in temperature, and preferably be lower than 200 °F (93.3 ℃) and produce, and the also less destruction of the starch in the semi-finished product.The final products of producing with the semi-finished product of the method processing of setting forth herein have obvious improved flavor and quality than the final products with traditional semi-finished product production.In general, produce process of semi-finished and be included in mixing and pre-hydration batching in the preconditioned device, wherein mixture is partly boiled; Mixture is sent in a section of extruder, mixture forms dough shape denseness herein; Mixture is at high-moisture, and low pressure fully boils under the low shearing condition; Remove steam by vacuum; The cooling dough is shaped dough with punch die or postforming equipment; Extrudate with dry wet.

Before in being added to the preconditioned device, with traditional ribbon-type blender or continuous mixer in batches together with whole batch mixes, also can after getting togather, the premix of perhaps will preparing burden directly be added in the extruder producing continuously in the speed adding preconditioned device of batching with metering.

Be applicable to that extruder of the present invention comprises single screw rod boil extruder and double screw extruder.The screw rod of double screw extruder can be homodromal or reverse rotation.Preferred extruder is to use the sort of boiling extruder twin-screw and that have die orifice that dough is shaped at the outlet of extruder place.Preferred extruder pattern comprises dough preconditioned parts and is equipped with the extruder of outlet, and the exit has a corrugated die orifice hole to make dough surface form zigzag.All porose so that steam and/or water can join in the dried amyloid material to form dough on preconditioned parts and the extruder.

The method for optimizing for preparing product of the present invention comprises the preconditioned parts.The preconditioned parts can inject steam from vapour source.The purpose of preconditioned parts is the hydrations that guarantee material, and part is boiled, and neutralizes and has appropriate viscosity.In addition, preconditioned is with the combination of starch matrix powder and particular emulsifier can boost productivity (productive rate of extrudate) of comparing with the conventional extruded method.

The preconditioned device preferably comprises two blades, and the size ratio of blade is 2: 1.Except the preconditioned device, be used for extruder of the present invention and can have four major function sections, the further segmentation of each section.These four major function sections are: the first, transmit section; The second, boiling section, the 3rd, exhaust section; The 4th, cooling section.

The semi-finished product of dough of the present invention and extruding are by starch matrix being prepared burden emulsifying agent, water and the preparation of steam injection preconditioned device.Starch matrix material and emulsifying agent enter the preconditioned device with logistics respectively, and running water and steam enter from the hole of preconditioned device.About 212 of the temperature of the steam that injects (100 ℃) to about 350 (176,7 ℃).The time that stops in the preconditioned device is from about 1 to about 4 minutes, this with the mixing speed in the amount of product and the preconditioned device (rev/min) and different.The preconditioned device is equipped with the blade (1 times and 2 times) of two counter-rotatings.The preconditioned device is that operation becomes uniform dough with mixing of materials under low shearing condition.Mixed material in the preconditioned device is that part is boiled.The processing temperature of mixture from about 120 (48.9 ℃) to about 200 (93.3 ℃), preferably from about 140 (60 ℃) to about 185 (85 ℃), more preferably from about 160 (71.1 ℃) to about 180 (82.2 ℃).The moisture of the mixture that comes out from the preconditioned device preferably from about 18% to about 35%.The selection of powder and starch can make dough have desirable viscoplasticity, and such dough joins and can significantly reduce dough in the extruder boil needed mechanical energy and heat energy in extruder.Use has specific viscoelastic starch matrix batching can play the effect that reduces the amount of fats/oils in the final finished.

By screw rod dough is sent to the boiling section then, in the heating of this section with add entry.Preferred extruder is around there being heating/cooling infrastructure, makes dough in indirect/cooling when the length of extruder is advanced.Dough adds entry to set up high moisture environments when advancing by the boiling section.The moisture of dough is preferably from about 28% to about 70%, preferably from about 30% to about 50%, and temperature from about 80 (26.7 ℃) to about 220 (104.4 ℃).The temperature of boiling section is from about 170 °F (76.7 ℃) to about 200 °F (93.3 ℃) preferably, more preferably from about 180 °F (82.2 ℃) to about 190 °F (87.8 ℃).Most of boiling of dough and gelatinization are to produce in the boiling section of extruder.The operation of screw rod makes dough ingredients stand low shearing in this section in the boiling section.Speed when producing desirable the shearing usually is about 120 rev/mins to about 180 rev/mins, preferred 130 rev/mins, and more preferably from about 140 rev/mins.The time of staying in the boiling extruder outlet that exports to die orifice of preconditioned device (promptly from) is usually from about 1 to about 2 minutes, preferably from about 1.25 to about 1.5 minutes.

By screw rod dough is sent to the exhaust section then, goes down except that moisture in about 5 inches vacuum to about 18 inches of mercury at this section.

After this, dough mixture is through cooling section, dough was cooled to from about 80 °F (26.7 ℃) to about 190 °F (87.8 ℃) before the outlet of extruder place, preferably from about 100 (37.8 ℃) to about 180 (82.2 ℃), more preferably from about 110 (43.3 ℃) to about 160 (71.1 ℃).At the pressure of cooling section end from about 400 pounds/square inch to about 1400 pounds/square inch, preferably from about 500 to about 1000 pounds/square inch.

The dough of the extrusion molding that comes out by die orifice space and die orifice hole from extruder is cut into snack chip.The pressure of die orifice is from about 200 to about 1000 pounds/square inch, temperature before dough comes out from die orifice is about 180 °F (82.2 ℃) to about 220 °F (104.4 ℃), preferably from about 180 °F (82.2 ℃) to about 215 °F (101.7 ℃), more preferably from about 190 °F (87.8 ℃) to the moisture from about 20% to about 45% of about 200 (93.3 ℃) ° extrudates, preferably from about 25% to about 35%, more preferably from about 30%.

The design of die orifice and shape can influence the quality of half-finished expansion rate and final products.Have been found that as extruding be longitudinally, the direct product that pushes out from die orifice must have indentation, ripple or embossing (after this being called the embossing technology) without the extruding post processing.As the die orifice hole is ripple, then squeezes out corrugated.Preferably, form zigzag but also can push the back at product with producing zigzag extruding die orifice.The internal structure of the final products of Xing Chenging and surface are particularly suitable for reducing the wax shape of final products and greasy outward appearance the greasy mouthfeel that fried snack brings in comprising the composition of Nondigestible fat like this.The extruded product that these embossing technology of phase credit are produced from the die orifice hole helps to control the expanded and density of final products, half-finished expansion ratio and final products surface oil quantity and/or surperficial greasy outward appearance.This technology all is effective to two dimension (for example sheet, flat shell) dilated product and three-dimensional (for example Wan Qu shell, taper, pincushion) dilated product.The amount of the expansion of three-dimensional expansion product and the fat of absorption mainly is subjected to the control of selected given shape, and embossed surface then helps to control the amount of the fat that the product of two-dimensional swelling draws when fried.The product of three-dimensional expansion, for example curl shape has a plurality of surface grooves fat can be got rid of well; This has just reduced the amount of surface fat.Can have again simultaneously and significantly reduce the greasy pleasant impression that traditional snack often has.The product of two-dimensional swelling is relatively thin and have a big area of plane.These products are drawn relatively large fat usually when fried.Total performance is the oral cavity greasy feeling when chewing.The present invention applies embossing with die orifice to the surface when extruding or extruding back (back is shaped) and expands with control and draw fat.Can make snack chip form many different shapes by the shape of regulating the extruder hole.

2. dry

After the shaping, dry extrudate is to form semi-finished product.Can form semi-finished product with traditional dry technology, still, during according to the dry extrudate of practice of the present invention, can improve final half-finished quality greatly.Its reason is not clear, but may be that this helps to control the migration of water, thereby significantly reduces in dry run half-finished destruction because the batching in the composition has different retentivenesses and specific rheological characteristic.

Traditional is comparing dry at low temperatures method than the drying of the air under the higher temperature, and bigger to the semi-finished product injury, low temperature drying is removed moisture lentamente consistently from extrudate.In addition, traditional drying means is subjected to the restriction of capacity of equipment.Be typically: the productive rate of (1) extrudate is fixed, and/or the ability of (2) drier is that the bed thickness of fixing or have only very little changing capability and (3) drying equipment is conditional (promptly usually from about 1 inch to about 6 inches).Because these restrictions, extrudate is dried to desirable target moisture just needs high temperature air.This can make semi-finished product have bad attribute.These bad attributes comprise the big and/or uneven internal voids of formation, face crack, and internal break and stress cracking, but be not restricted to these.These bad shortcomings can be produced later presenting sometime at semi-finished product.

In the all-mass attribute, used dehydration technique is the quality that can seriously change an attribute of final products during the processing semi-finished product.Quality is determined that by half-finished swelliong power it is by interior moisture content, the distribution of moisture, controls such as distribution of half-finished space and pore size.These character height depend in the drying stage moisture and how to remove.

Extrudate is through two tangible drying stages: (1) constant rate drying period; (2) falling rate drying period.Time in each stage determines total rate of drying and influences semi-finished product character.The drying parameter of external environment condition (for example, the temperature of drying medium air, relative humidity, the bed of flow velocity and extrudate is thick) also influences the rate of drying of product.At constant rate drying period, all ambient parameter is important to obtaining maximum drying all.But at falling rate drying period, temperature is main drying parameter, and relative humidity, air velocity is less important parameter with bed thick (it is relevant with air velocity) to the rate of drying that obtains to wish.

The constant rate of drying phase is such time period, at this section in the period, equals for the evaporation rate of moisture evaporated on the extrudate surface or can get on except that the speed of moisture from the surface faster than external environment condition.The falling-rate periods of drying phase is restricted diffusion period, during this period, is subjected to the restriction of the speed of moisture from the product diffusion inside to the surface from the amount of product surface moisture evaporated.The falling-rate periods of drying phase is a time period, at this moment between in, the speed that extrudate is fed to moisture the surface internally is not enough to keep the speed from surface removal moisture.Moisture diffusion speed in the extrudate is being controlled the speed that moisture is fed to product surface.

Require extrudate dry as quickly as possible, make the semi-finished product of generation have minimum bad attribute simultaneously.Improving dry temperature can accelerate to remove moisture from extrudate.Improve baking temperature and not only can increase the removal that surface moisture was transmitted and followed to heat, it also improves the diffusion rate of moisture from extrudate inside to its surface.Therefore, the temperature of drying medium (air) becomes the control parameter that obtains desirable rate of drying in the falling-rate period of drying, the speed that described speed is produced by extrudate, and drying energy and bed thickness retrain.Though have been found that improve air themperature can be in rational time (for example being less than 1 hour) produce satisfied semi-finished product, extrudate has stood uneven drying (for example, having the gradation of moisture in the semi-finished product).This can make the bad stress characteristics (for example, crackle) of formation in the semi-finished product and be lower than desirable expansion and handling properties.

Can be controlled by the migration of control moisture by the bad shortcoming that drying produces, can be guaranteed that like this moisture distributes equably in semi-finished product.Half-finished preparation method of the present invention is: (1) improves baking temperature: (2) improve the relative humidity of the air that is used for dry extrudate; Not necessarily, (3) are concocted semi-finished product at elevated temperatures and are not further removed moisture.

Be surprised to find that extrudate of the present invention can use the rapid dry process drying.Preferably extrudate is dried to desirable moisture scope being less than in about 4 hours, more preferably in about 2 hours and most preferably in about 1 hour.The semi-finished product that form according to the extrudate of drying of the present invention can expand and have minimum physical imperfection suitably when fried, these defectives can produce bad quality, outward appearance, or processing attribute.Semi-finished product can be after drying fried immediately or packing.

For can dry extrudate is to produce semi-finished product of the present invention in general hot air dryer, the major part in the drying time of extrudate should be at falling rate drying period.This just requires careful operation drying parameter to be avoided producing any physical property shortcoming in semi-finished product, and these shortcomings can make final products produce bad quality, outward appearance or processing attribute.In addition, the throughput rate of extrudate, the working ability of drying equipment and the relation between the rate of drying must optimizations.

The air themperature of dry extrudate preferably is lower than about 200 °F (93.3 ℃), most preferably is lower than about 180 °F (82.2 ℃).When used air drying temp is higher than about 180 °F (82.2 ℃) when at falling rate drying period, should carefully operate drying parameter to avoid in semi-finished product, producing any physical property shortcoming.When adopting higher air drying temp promptly about 190 (87.8 ℃) to about 200 (93.3 ℃) to produce semi-finished product of the present invention, then can reduce the tendency that produces the semi-finished product shortcoming with higher relative humidity.Preferred relative temperature is from about 20% to about 70%, and preferred relative humidity especially preferably uses 30% to 40% from about 25% to about 50%.Can reduce dry intensity and the not too big drying capacity that influences with higher relative temperature.Not bound by theory, can think that the relative humidity that improves drying medium can reduce dry fierce degree, but the speed of not really influence drying, this is because semi-finished product are the falling rate drying periods that are in dry control diffusion.Think that also improving relative humidity also can significantly reduce the wet-bulb temperature of dry air and the difference between the surface of semi-finished temperature.Therefore also reduced dry intensity.Rate of drying can not be subjected to too much influence, because for the moisture holding capacity of drying medium, removing moisture from extrudate is to be subjected to moisture to control to its surface from the diffusion inside of the dry extrudate of part.

In dry run or after dry run is finished, can not necessarily concoct to avoid defective semi-finished product.Blending or maintenance semi-finished product are not significant removal moisture in the part-time in dry run, but allow moisture spread internally to be increased to the amount of moisture on surface at a certain temperature.Some dried shortcoming, crackle for example also can be avoided by keeping half-finished temperature to be higher than about 120 (48.9 ℃) long as far as possible time after drying.This additional time under being higher than environment temperature helps to reduce the gradation of moisture that is present in the semi-finished product, and this is owing to promote the result of the diffusion of moisture in semi-finished product after drying.Therefore, because residual moisture is in poised state, the counter stress less sensitivity that ftractures.

The method for optimizing that reduces the moisture of extrudate is to make baking temperature from about 175 (79.4 ℃) to about 200 (93.3 ℃), preferably from about 180 °F (82.2 ℃) to about 190 °F (87.8 ℃), with relative humidity from about 20% to about 40%, preferred about 25%, dry about 1.0 preferably from about 1.5 to about 4 hours.As meet drying principles and don't produce shortcoming, then also can be less than 1.0 hours drying time.The drying equipment that is used for dry extrudate of the present invention is the forced hot air comvection dryer.Preferably make extrudate on porose conveyer belt, pass through drier, make air pass through the extrudate bed.Drier can be divided into some dry sections, the drying parameter in each district (1) temperature wherein, and (2) relative temperature and (3) time of staying all can be controlled.Single district drier, two or more multi-region drier and/or to have the drier of two conveyer belts to make extrudate all be operable by dry section etc. back and forth.

Extrudate also can carry out drying (as predrying and drying steps) with two step seasonings.Before main drier, can seal in second drier or predrying device.The function of predrying device is before entering main drier, at constant rate drying period, gets on to remove original moisture as much as possible from extrudate.The final extrudate moisture of predrying device is between about 20% to about 25%.Owing to had less moisture, can reduce the temperature of main drier.This decrease of temperature can be avoided half-finished destruction.

Preferred two step method is included in about 180 (82.2 ℃) predrying extrudate to about 200 (93.3 ℃) temperature, reaches about 20% to about 25% up to the moisture of extrudate, not necessarily concocts pre-dried extrudate then.After predrying/blending, the dry extrudate of part about 180 °F (82.2 ℃) to about 190 °F (87.8 ℃) further dry when sufficiently long chien shih moisture be reduced to and be less than about 14%.Common about 1 to about 2 hours enough.After this, semi-finished product (i.e. the extrudate of Ganing) can be higher than about 100 °F (37.8 ℃), preferably concoct the sufficiently long time to reach balance at 100 °F (37.8 ℃) to the temperature of about 120 (48.9 ℃).As fried be carrying out sometime afterwards, semi-finished product also can packed when drier comes out while hot, blending is to carry out in packing.

Extrudate of the present invention can carry out drying with various forms of drying equipments.Hot-air impacts stove has more effective heat to transmit than forced air convection formula utensil.Also can use infrared dryer, particularly early stage at constant rate drying period.Microwave and radio-frequency seasoning device are specially adapted to falling rate drying period.These driers have promoted moisture to be diffused into the surface of extrudate internally.Concerning the people of skilled this technology,, can determine to use any of these drying means or their combination as long as meet above-mentioned principle.

Half-finished water content of the present invention is from about 7% to about 14%, preferably from about 8% to about 12%, and more preferably from about 9% to about 11%.The semi-finished product of moisture outside this scope, when fried, dilatancy significantly reduces, and makes final products have fine and close and glassy state quality, and this does not meet cating quality.Not fried immediately after drying as semi-finished product, then moisture further can be reduced to and be less than about 12% to guarantee little stability.It is about 12% that moisture is higher than, and water is active to be increased approximately more than 65%, and this can induce microbial growth.

Half-finished gelatinization point from about 75.2 (24 ℃) to about 203 (95 ℃); The peak viscosity time is at least about 6 minutes, preferred about 7 minutes; Peak viscosity is from about 10 quick viscosity units to about 140 quick viscosity units, preferably from about 11 quick viscosity units to about 120 quick viscosity units, more preferably from about 13 quick viscosity units to about 100 quick viscosity units with most preferably from about 31 quick viscosity units to about 65 quick viscosity units; With final viscosity from about 120 quick viscosity units to about 350 fast viscosity units, preferably from about 127 quick viscosity units to about 265 quick viscosity units, more preferably from about 133 quick viscosity units to about 250 quick viscosity units with most preferably from about 149 quick viscosity units to about 152 quick viscosity units.

Half-finished water imbibition index typical case is from about 3 to about 8, and preferably from about 4 to about 6 and more preferably from about 5 to about 5.5.

The preparation of D. expanded fried snack food

1. fried

Half-finished fried can be continuous or in batches.It is about 3% that the moisture requirement of fried back final products is less than, preferably from about 1% to about 3%, and more preferably from about 1.5% to about 2.5%.Not bound by theory, the hardness of finished product increases with the decline of water content.Too low as water content, the quality that then forms product can be too hard.

When needing, semi-finished product are at fried back reusable heat air, and superheated steam or inert gas heating are to be reduced to desired horizontal with moisture.This is a kind of fried and bake the step that combines.

Snack food is preferably with continuous fried method preparation.In the method, snack chip is in the oil that is immersed in below the moving belt.The design of continuous fried device should make semi-finished product not swim on the surface of oil.Can reduce expansion like this.Another important continuous fried device parameter is flowing of oil.With respect to semi-finished product, preferably use the flow velocity of lower oil.The too high meeting of flow velocity of the oil by fried device makes the finished product hardening.Not bound by theory, can think that this is owing to heat transmission too much from oil to semi-finished product.The heat transmission of this increase is to cause owing to oily fast moving has from the teeth outwards reduced surface boundary layer.

Snack chip is fried to the triglyceride oil of about 390 (198.9 ℃) in temperature about 360 (182.2 ℃), more preferably about 380 of You temperature (193.3 ℃).The preferred fried time of staying more preferably from about 15 to about 20 seconds, perhaps made the time of staying be enough to make moisture to be reduced to desired level from about 10 to about 30 seconds.When the fat composition that uses comprises stodgy fat, the temperature of fried oil need improve at least 5 °F to 15 °F, and preferred oily temperature is about 380 °F (193.3 ℃) to about 390 °F (198.9 ℃) ± be higher than 15 of triglyceride fats (8.3 ℃) to 20 °F (11.1 ℃).The definite fried time is that temperature and the half-finished initial moisture by oil is determined.The people of skilled this technology is easy to determine the relation of fried time and temperature.Final products fried in comprising the fat composition of Nondigestible fat more preferably were cooled to 130 °F (54.4 ℃) to 140 °F (60.0 ℃) within about 5 minutes within about 10 minutes.

The snack food of making of this method typically contains 11% to about 32% the fat of having an appointment, and these are different with the shape of final snack food.Fried snack food preferably contains has an appointment 13% to about 30%, more preferably from about 15% to about 20% fat.As require further to reduce fat mass, can adopt the purge step in fried back.

2. fatty and oily

Fried can carrying out in traditional triglyceride oil or carry out in stodgy material on demand for example set forth in following patents, the United States Patent (USP) 3,600,186 (transferring P﹠G) of mandate on May 12nd, 1970 Mattson etc.; Awarded United States Patent (USP) 4,005,195 (transferring P﹠G) on January 25th, 1977 in Jandacek etc.; The United States Patent (USP) 4,005,196 (transferring P﹠G) of mandate on January 25th, 1977 Jandacek etc.; Authorized the United States Patent (USP) 4,034,083 (transferring P﹠G) of Mattson on July 5th, 1977; Authorized the United States Patent (USP) 4,241,054 (transferring P﹠G) of Volpenhein etc. on December 23rd, 1980, these patents are listed as that this is for reference.Friedly also can in the mixture of traditional triglyceride oil and nondigestible oil, carry out.

Unless otherwise prescribed, term herein " fat " and " oil " can exchange use.Term " fat " or " oil " are meant edible fat material in general sense, comprise natural or synthetic fat and oil or their mixture, they comprise triglyceride, soybean oil for example, corn oil, cotton seed oil, sunflower oil, palm oil, coconut oil, Tower rape oil, fish oil, lard or tallow oil, these fat and oil can be partially or completely hydrogenation, or other modification, and have the nontoxic fat-yielding material similar in appearance to triglyceride, be called stodgy fat herein, these fat can be that part is stodgy or stodgy fully.Fat low in calories and edible stodgy fat, oily or fatty substitute etc. all is included within this term.

Term " stodgy fat " is meant those part or all of stodgy edible fat materials, and for example, polyol fatty acid polyesters is as OLEAN ^TM

Term " fat " or " oil " also relate to similar performance in 100% of triglyceride nontoxic fat-yielding material.Term " fat " or " oil " generally include fat substitute, and these fat substitutes can be partially or completely stodgy.

" polyalcohol " is meant and contains at least 4, preferably contain the polyhydroxy-alcohol of 4 to 11 hydroxyls.Polyalcohol comprises sugar (being monose, disaccharide and trisaccharide), sugar alcohol, other sugar derivatives (being APG), polyglycereol, for example diglycerol and triglycerin, pentaerythrite, sugar ether, for example sorbitan and polyvinyl alcohol.The specific sugar that is suitable for, the example of sugar alcohol and sugar derivatives comprises wood sugar, arabinose, ribose, xylitol, antierythrite, glucose, methylglycoside, mannose, galactolipin, fructose, D-sorbite, maltose, lactose, sucrose, gossypose and maltotriose.

" polyol fatty acid polyesters " is meant the polyalcohol with at least 4 aliphatic acid ester groups.Containing 3 or the polyol fatty acid ester that is less than 3 ester groups digests in enteron aisle usually, by intestinal absorption, but those contain 4 or more the polyol fatty acid ester of many fatty acid ester base is stodgy basically and be not to be absorbed by the body therefore to the product of digestion as common triglyceride fat or oil.The whole esterifications of unnecessary alcohol radical polyalcohol, but the disaccharide molecule preferably contains no more than 3 nonesterified hydroxyls, its objective is nondigestible.Typically, hydroxyl groups, almost whole, be esterification for example at least about 85%.For sucrose polyfatty acid esters, about 7 to 8 hydroxyls that are typically polyalcohol are esterifications.

The fatty acid radical typical case that polyol fatty acid ester contains is contained at least 4 carbon atoms and how to 26 carbon atoms.These fatty acid radicals can be from natural or synthetic aliphatic acid.These fatty acid radicals can be saturated or unsaturated, comprise the isomeric compounds position or how much, for example, and suitable or anti-isomeric compound, and all ester group can be identical, maybe can be the mixture of different aliphatic acid.

Also can be with liquid stodgy oil in the practice of the present invention.The complete fusing point of liquid stodgy oil is lower than about 98.6 °F (37 ℃), comprises liquid polyol fatty acid polyester (consulting the United States Patent (USP) 4,005,195 of authorizing Jandacek on January 25th, 1977); The ester of liquid tricarballylic acid (consulting the United States Patent (USP) 4,508,746 of authorizing Hamm on April 2nd, 1985); The diester of liquid dicarboxylic acids, for example derivative of malonic acid and butanedioic acid (consulting the United States Patent (USP) 4,582,927 of authorizing Fulcher on April 15th, 1986); Liquid alpha-branched chain carboxylic acids's triglyceride (consulting the United States Patent (USP) 3,579,548 of authorizing Whyte on May 18th, 1971): the liquid ether and the ether-ether (consulting the United States Patent (USP) 2,962,419 of authorizing Minich November 29 nineteen sixty) that contain the neopentyl part; The fatty acid polyether of liquid polyglycereol (consulting the United States Patent (USP) 3,932,532 of authorizing Hunter etc. on January 13rd, 1976); Liquid alkyl glycoside fatty acid polyester (consulting the United States Patent (USP) 4,840,815 of authorizing Meyer etc. on June 20th, 1989); The hydroxypolycarboxylic acid's that two ether connects liquid polyesters (for example citric acid or isocitric acid) (consulting the United States Patent (USP) 4,888,195 of authorizing Huhn etc. on December 19th, 1988); The alkoxylated polyol of various liquid esterifications comprises the ester of the polyalcohol of liquid epoxides chain extension, (consults the United States Patent (USP) 4,861,613 of authorizing White etc. on August 29th, 1989 as the propoxylated glycerol of liquid esterification; The United States Patent (USP) of mandate on March 21 nineteen ninety-five Cooper etc. was authorized the United States Patent (USP) 5,589,217 of Mazurek and the United States Patent (USP) 5,597,605 of authorizing Mazurek on January 28th, 1997 on December 31st, 5,399,729,1996); The ethoxylation sugar of liquid esterification and sugar alcohol ester (consult Ennis etc. United States Patent (USP) 5,077,073); The APG of the ethoxylation of liquid esterification (consulting the United States Patent (USP) 5,059,443 of authorizing Ennis etc. on October 22nd, 1991); The oxyalkylated polysaccharide of liquid esterification (consulting the United States Patent (USP) 5,273,772 of authorizing Cooper on December 28th, 1993); The alkoxylated polyol of the liquid esterification that connects (consulting the United States Patent (USP) 5,374,446 that the United States Patent (USP) of authorizing Ferenz June 27 nineteen ninety-five on December 20th, 5,427,815 and 1994 was authorized Ferenz etc.); The polyalkylene block copolymers of liquid esterification (consulting the United States Patent (USP) 5,308,634 of authorizing Cooper on May 3rd, 1994); The polyethers that contains out oxa-cyclopentane unit of liquid esterification (consulting the United States Patent (USP) 5,389,392 of authorizing Cooper February 14 nineteen ninety-five); Liquid oxyalkylated polyglycereol polyester (consulting the United States Patent (USP) 5,399,371 of authorizing Harris March 21 nineteen ninety-five); The polysaccharide of liquid part esterification (consulting the United States Patent (USP) 4,959,466 of authorizing White September 25 nineteen ninety); And liquid dimethyl silicone polymer (for example liquid polysiloxanes of Dow Corning).Patents of all above-mentioned relevant liquid nondigestible oils are listed as that this is for reference.The fat of solid nondigestible or other solid material can be added in the liquid stodgy oil to prevent passive oil loss.Particularly preferred stodgy fat composition comprises those of setting forth in following patents, the United States Patent (USP) 5,490,995 of mandate Corrigan in 1996; The United States Patent (USP) 5,480,667 of mandate Corrigan in 1996 etc.; The United States Patent (USP) 5,451,416 of nineteen ninety-five mandate Johnston etc.; The United States Patent (USP) 5,422,131 of authorizing Elsen etc. with nineteen ninety-five.Nineteen ninety-five authorizes the United States Patent (USP) 5,419,925 of Seiden to set forth the mixture of triglyceride low in calories and polyol polyester, and it can use herein, but more easily digestion fat may be provided.

Preferred stodgy fat is to have the fat-yielding material of similar performance in triglyceride, for example sucrose polyfatty acid esters.A kind of preferred stodgy fatty OLEAN ^TMProduce by P﹠G.These preferred stodgy fat or oil substitute composition are authorized the United States Patent (USP) 5,085,884 of Young etc. and are authorized June 6 nineteen ninety-five in the United States Patent (USP) 5,422,131 of Elsen etc. on February 4th, 1992 and be described.

Other known technically composition also can be added in edible fat and the oil, comprises antioxidant, for example the TBHQ ascorbic acid; Chelating agent such as citric acid and defoamer such as dimethyl polysiloxane.

3. the quality of finished product snack and structure.

Fried food of the present invention has unique quality and structure.The quality of this uniqueness and structure be by native starch matrix powder, and the combination of modified starch adds to be mixed into specific emulsifying agent and to realize under the processing conditions of uniqueness in dough.The combination control starch gelatinization of these factors and the structure of final snack.

The quality of snack of the present invention has four obvious characteristics: the fragility of long period, the lubricity of chewiness and increase and oral cavity melting." fragility " used herein is meant the sensation that begins to sting snack." chewiness " used herein is meant the state that the snack particle size reduces in the process of chewing.When chewiness also can be thought then to chew after beginning to sting, snack kept the ability of fragility." lubricity " and " oral cavity thawing " reduce the relevant with difficulty easily of snack size when chewing.In the oral cavity fast and broken easily food need can think more lubricated and have oral cavity melting rate faster with the food of more time and power when chewing.

These four features are reciprocal.For example, the snack of not wishing to have extruding is because or too hard and solid and can not melt fast in the oral cavity, or because lubricated and can not keep fragility and chewiness when chewing.They have very high fat and greasy feeling usually, particularly use the fried snack of Nondigestible fat.In order to produce fried snack, just may need to sacrifice satisfied chewiness to obtain lubricity from semi-finished product with highly extruding of lubricity.Therefore, problem is just in that to attempt to develop quality light, fried snack lubricated and that in the oral cavity, easily break, but can keep chewiness (do not become soft paste when promptly chewing and stick to one's teeth) simultaneously again and not contain the fat of a large amount.

Traditional extruding snack is compared with product of the present invention is not too gently to be exactly too heavy.A kind of explanation of this quality difference be product physics and internal structure.Traditional extruded product typically has irregular shaping space, the difference of its thickness.This can see from accompanying drawing 1,2 and 3.From Fig. 4,5 and 6 (fried in triglyceride) and Fig. 7,8 and 9 (fried in Nondigestible fat) can see obviously that product of the present invention typically has the space of even size and than conventional extruded product thicker born of the same parents' locular wall arranged.

Another explanation of this quality difference is that two faces of product all are pressed into decorative pattern by the ripple nib.This uniform born of the same parents chamber size relevant with the rheological characteristic of dough and the combination of thickness and embossing make product of the present invention have different structure and more crisp on quality than traditional extruded product, and chewiness and lubricated is more arranged.

The gelatinization point of fried snack of the present invention from about 77 (25 ℃) to about 203 (95 ℃); The peak viscosity time was from about 3 minutes to about 10 minutes; Peak viscosity is from about 11 quick viscosity units to about 55 quick viscosity units, preferably from about 12 quick viscosity units to about 52 quick viscosity units, more preferably from about 17 quick viscosity units to about 48 quick viscosity units; With final viscosity from about 20 quick viscosity units to about 130 quick viscosity units, preferably from about 24 quick viscosity units extremely about 130 quick viscosity units and 122 quick viscosity units more preferably from about.The water imbibition index of finished product snack is from about 3.5 to about 4.5, and preferably from about 3.6 to about 4.0 and more preferably from about 3.8; And about 1: 2 of the scope of expansion ratio (extruding: expansion), preferably from about 1: 1.8.In addition, the finished product snack does not have greasy outer existing and greasy tooth gluing sense.

Analytical method

1. water imbibition index (WAI)

A. do batching, mixed powder and semi-finished product

Usually, term " water imbibition index " is meant the mensuration of the moisture holding capacity of the carbohydrate matrix material that cooking method forms.(consulting R.A.Anderson etc., Gelatinization ofCorn Grits By Roll-and Extrusion-Cooking, 14 (1): 4, Cereal ScienceToday (1969)).

The water imbibition assessment of indices method of sample is as follows:

(1) the weigh weight of centrifuge tube of the sky that is used to measure to the decimal point two.

(2) get the dried sample of 2 grams and put into test tube.Before mensuration, the granular size of measured object is crushed to No. 40 sieves by the U.S. with electric coffee grinder.Then the sample of pulverizing (2 gram) is placed test tube.

(3) add 30 ml waters in test tube.

(4) vigorous agitation water and sample are residual to guarantee the not having block of doing.

(5) test tube is placed in the water-bath of 86 (30 ℃) 30 minutes, when 10 minutes and 20 minutes, repeats to stir.

(6) in 3000 rev/mins of centrifugations 15 minutes.

(7) from test tube, incline and anhydrate, stay gelinite.

(8) weigh test tube and content.

(9) weight of residual gel is calculated the water imbibition index divided by the weight of dry sample:

Water imbibition index=([weight of test tube and gel]-[weight of test tube]) ÷ [weight of dry sample])

B. fried product

With Carver laboratory squeezer (Model ^#C) remove oil from product.Fried product is placed graduated cylinder, and graduated cylinder is placed squeezer and pressurizes until the pressure of removing on the oily product with hand lever is 15000 pounds/square inch.From graduated cylinder, take out product.Then measure and do batching, mixed powder and half-finished water imbibition index with above-mentioned steps (1)-(9).

2. measure rheological characteristic with fast viscosity analyzer (RVA)

Do batching, mixed powder, the rheological equationm of state of semi-finished product and final products with the quick viscosity analysis-e/or determining of RVA-4 type.Fast the viscosity analyzer is originally the activity that is used for measuring fast the germinated wheat alpha-amylose.This viscosimeter is to stir the starch sample simultaneously in heating and cooling to carry out qualitative to starch quality.The viscosity analyzer is directly used in mensuration starch, powder, the viscometric properties that boils of semi-finished product and final products fast.This instrument requires the water of about 2 to 4 gram samples and about 25 grams.Calculate the sample weight (S) that is used for testing and be added to the weight (W) of the water of sample when testing with following formula: $S=\frac{258}{100-M}$

W=25+(3-S)

Wherein S=is in the sample weight (sample mass of correction) of gram

W=is in the quality (being added to the weight of the water in the sample) of the water of the correction of gram

The actual water content % (adding before the entry) of M=tested sample is in percentage (for example 12% is 12, rather than 0.12)

The mixing that water and sample mixture pre-establish when measuring, metering, heating and cooling step.Test provides the data of relevant dough viscosity, thus the quality of explanation powder.

As sample is through fried, removes the oil that is present in the sample with squeezer earlier.Pulverize sample to reduce granular size with electric coffee grinder then.Make sample pass through No. 40 sieves of the U.S. with the bristle paintbrush.The quick viscosity analyzed of viscosity, product quality (for example dilatancy, coarse sand), and between the merit input very strong correlation is arranged.There have Several Parameters to be used for sample to be qualitative.Be used for representing that the key parameter of characteristic of the present invention is a gelatinization point, peak viscosity, peak viscosity time and final viscosity.

Quick viscosity analytical method

A. do batching and mixed powder

(1) measures the moisture (M) of sample from baking oven or Ohaus wetting balance instrument.

(2) calculate sample weight (S) and water weight (W).

(3) sample and water are placed in the canister, with blade with clockwise and respectively changeed 10 minutes counterclockwise.The jog blade is 10 times up and down.

(4) canister is put into the tower neutralization running according to the following steps of quick viscosity analyzer: the step time unloaded and keep 50 ℃ of 0-1 minute ladders rise to 95 ℃ remained in 1-4.45 minute 95 ℃ be cooled in 4.75-7.15 minute remained in 50 7.15-11 minutes 50 ℃ 11-13 minute

(5) according to the makers' explanation of quick viscosity analyzer, the test result that obtains to print is for required parameter.

B. semi-finished product

(1) in electric coffee grinder, pulverizes sample to sieving by #40

(2) measure the moisture (M) of sample from baking oven or Ohaus wetting balance instrument

(3) calculate sample weight (S) and water heavy (W)

(4) sample and water are put into canister, insert the #8 rubber stopper, acutely shake 15 seconds to 60 seconds (can draw together down from the periphery of canister) with pivot/blade

(5) sample is inserted quick viscosity analyzer tower, and running according to the following steps: the step time unloaded and keep 25 ℃ of 0-2 minute ladders rise to 95 ℃ remained in 2-6 minute 95 ℃ be cooled in 6-10 minute 25 ℃ remained in 10-11 minute 25 ℃ 11-22 minute

(6) according to the makers' explanation of quick viscosity analyzer, the test result that obtains to print is for required parameter.

C. fried product

(1) product is placed laboratory hydraulic pamp (15000 pounds/square inch of Carver)

(2) product that will press is placed in the electric coffee grinder 15 seconds

(3) measure the moisture (M) of sample with baking oven or Ohaus wetting balance instrument

(4) calculate samples weighed (S) and water heavy (W)

(5) to half-finished quick viscosity analytical method, repeat above-mentioned step (4), (5) and (6).

Embodiment

Explanation the present invention that following examples are more detailed, but do not mean that limitation of the present invention.

1. embodiment 1

Composition	Weight %
Corn flour rice meal tapioca starch modified starch sugar emulsifying agent local flavor material salt leavening adds up to	70.0 12.0 5.0 8.0 2.0 0.8 0.3 1.4 0.5 100.0

With Wenger TX52 prepared in twin-screw extruder dough.Be added in the preconditioned device with the monoglyceride of about 135 Pounds Per Hours speed starch matrix material (dried powders mixture) and powdery distillation.About 115 rev/mins of the screw speed of preconditioned device.10: 90 emulsifier mixture of the diacetyl tartrate monoglyceride of liquid state and the cotton seed oil speed with 20 ml/min is added in the preconditioned device.Water is injected steam with about 0.25 Pounds Per Minute speed adding with about 15 Pounds Per Hours speed.

The product that enters the boiling extruder is about 70% the dry mixture and the composition of 30% water.Extruder is divided into 6 temperature sections.These sections are arranged in series.About 100 of first temperature section (37.8 ℃).Second about 160 of temperature section (77.1 ℃).Third and fourth temperature section is mainly used in and boils, and is about 200 °F (93.3 ℃).The the 5th and the 6th temperature section (cooling and exhaust) is about 80 °F (26.7 ℃).The screw speed of extruder is about 131 rev/mins.

Product comes out from the shelly die orifice with corrugated surface.The moisture of extruded product about 30%.

2. embodiment 2

About 60 minutes of extruded product in temperature about 180 (82.2 ℃) and 20% time further dry embodiment 1 of relative humidity.(for example, OLEAN in stodgy oil then ^_) in 17 seconds of fried down this semi-finished product of temperature about 380 (193.3 ℃).Final moisture of fried product about 2% and final fat content about 26%.

Claims (10)

1. A dough composition consisting essentially of: (1) Mixed powder, the mixed powder contains (a) from 60% to 99% of a starch-based flour ingredient comprising at least 10%, preferably about 20% to 40%, of rice flour; other flour, preferably comminuted non-masa corn flour, Oat flour, tapioca flour, potato flour, peanut flour, wheat flour, rye flour, pastry flour or mixtures thereof: preferably from 0.5% to 30% starch; preferably from 0.2% to 2.0% gluten; wherein said rice flour preferably contain at least 10% amylose; (b) less than 8% sugar; (c) at least 0.5% salt; (d) From 0.1% to 1.5% of emulsifiers containing at least 0.3% monoglycerides, wherein the emulsifiers are preferably diacetyl tartrate monoglycerides, polyglycerol esters, stearic acid-2 - lactates, or mixtures thereof; and (e) from 0.2% to 1.0% of a leavening agent, wherein the leavening agent comprises sodium bicarbonate; and (2) water. 2. The dough composition of claim 1, wherein the gelatinization temperature of the starch-based powder ingredient is from 91.4°F (33°C) to 203°F (95°C); peak viscosity time is from 3 minutes to 10 minutes; peak viscosity is from 100 to 100 minutes Viscosity Units to 360 Rapid Viscosity Units; and Final Viscosities from 150 Rapid Viscosity Units to 350 Rapid Viscosity Units compositions. 3. 2. The dough composition of claim 1 or 2, wherein the starch and starch-based flour ingredients have a Water Absorption Index (WAI) of less than 3. 4. Semi-finished product, its gelatinization temperature is from 75.2°F (24°C) to 203°F (95°C); peak viscosity time is at least 6 minutes; peak viscosity is from 10 rapid viscosity units to 140 rapid viscosity units; final viscosity is from 120 rapid viscosity units to 350 rapid viscosity units; water absorption index from 3 to 8; and moisture from 7% to 14%. 5. A method for producing a semi-finished product with a water absorption index ranging from 3 to 8, comprising the following steps: (a) adding to the preconditioner a mixed meal comprising from 60% to 99% of a starch-based meal containing at least 10% rice flour and the balance being other flours; less than 8% sugar; at least 0.5% salt; from 0.1% to 1.5% emulsifier containing at least 0.3% monoglycerides; from 0.2% to 1.0% leavening agent, where the leavening agent contains sodium bicarbonate ; and non-essential starches; (b) Inject hot steam or water into the preconditioner and process the mixture at a temperature from 120°F (48.9°C) to 200°F (93.3°C) for at least 1 minute to form a partially cooked mixture containing 18% to 35% moisture. Cooked hydrated mixture. c) passing the partially cooked hydrated mixture through a cooking extruder while adding moisture to form a dough comprising 28% to 70% moisture; (d) cooking dough at 80°F (26.7°C) to 220°F (104.4°C) to form cooked dough; (e) passing the cooked dough through a vent zone under pressure from 5 to 18 inches of mercury to reduce the moisture in the cooked dough; (f) cooling the cooked dough; (g) passing the cooked dough from the venting step through a forming zone where the cooked dough is passed through an extrusion die under a pressure of 200 to 1000 psig to form an extrudate; and (h) reducing the moisture content of the extrudate to form a semi-finished product, The emulsifiers therein are pre-blended with oil, shortening, non-digestible fat or mixtures thereof before being added to the pre-conditioner. 6. The method of claim 5, after the drying step (h), further comprising the step of frying the dried semi-finished product to form snack chips, the frying oil temperature is from 360°F (182.2°C) to 390°F (198.9°C), the oil Fry for 15 to 30 seconds in oils containing hydrogenated and unhydrogenated cottonseed oil, soybean oil, corn oil, tallow, olive oil, canola oil, rapeseed oil, peanut oil, nondigestible fats, and their mixture. 7. The method of claim 6, wherein the water or steam of step (b) is injected for 2 to 4 minutes and the processing temperature of the mixture is from 140°F (60°C) to 200°F (93.3°C); the dough of step (d) The cooking temperature is from 160°F (71.1°C) to 190°F (87.8°C); the screw speed of the cooking extruder is from 130 rpm to 180 rpm; Dry from 20% to 40% and temperatures from 175°F (79.4°C) to 200°F (93.3°C) for 1.5 hours to 4 hours. 8. The method of claim 7, wherein the step of reducing extrudate moisture comprises: (a) pre-drying the extrudate at a temperature from 180°F (82.2°C) to 200°F (93.3°C) to a moisture content of from 20% to 25%; (b) drying the pre-dried extrudate at a relative humidity of from 20% to 25% for a time sufficient to reduce the moisture content to less than 12% to form a semi-finished product; and (c) Temper the work in the range of 100°F (37.8°C) to 120°F (48.9°C) long enough for the work to reach equilibrium. 9. Fried snack chips having a fat content from 11% to 32%, a moisture content of less than 3%, a water absorption index from 3.5 to 4.5, and a gelatinization temperature from 77°F (25°C) to 203°F (95°C) ), peak viscosity time from 3 minutes to 10 minutes, peak viscosity from 11 rapid viscosity units to 55 rapid viscosity units, and final viscosity from 20 rapid viscosity units to 130 rapid viscosity units. 10. Mixed powder having a gelatinization temperature from 122°F (50°C) to 194°F (90°C), a peak viscosity time from 3 minutes to 10 minutes, a peak viscosity from 100 rapid viscosity units to 360 rapid viscosity units, and final viscosities from 150 rapid viscosity units to 350 rapid viscosity units.

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