HK1185766B - Methods of making snack food products and products made thereby - Google Patents

Description

Method of making snack food products and products made thereby

The present application is a divisional application of the following applications: the application date is 2006, 10, 4, application number 200680045507.2 entitled method of making snack food and products made thereby.

This application claims priority from U.S. provisional application 60/723,880 filed on day 10/4 of 2005 and U.S. provisional application 60/820,743 filed on day 7/28 of 2006, the entire contents of which are incorporated herein by reference.

Technical Field

The present invention relates to a method of making low fat, fat free or full fat snack food products, and products made according to the method, wherein the food pieces are subjected to enzymatic and/or cationic treatment and/or special cooking and/or drying techniques to impart texture, flavor and other characteristics of conventional full fat products to the snack food products.

Background

Snack foods are typically made by frying sliced vegetable pieces in hot oil such that the moisture content of the sliced food pieces is reduced to a very low level and the fat content is multiplied. Such products generally have a crisp character, which significantly increases their sensory enjoyment. The fat content of conventional fabricated potato or apple chips is typically about 30-40% by weight, and some believe that such fat percentages are unhealthy if such products are consumed in large quantities in place of low-fat foods and for extended periods of time. Despite the market acceptance of such products, the consumer's desire to reduce the amount of their fat consumed limits this acceptance.

Furthermore, the conventional methods generally used require that the food be fried at high temperatures, which can result in the production of potentially harmful by-products. Reports of such by-products in recent years have raised concerns for fried and baked goods, particularly those containing high fat and carbohydrate content. The formation of acrylamide, which is generally proportional to browning of high fat and high carbohydrate containing foods, has raised a high level of concern in the food industry regarding the deleterious effects of this particular processing by-product.

To address these problems, attempts have been made to reduce the fat content of snack foods and more recently to find ways to minimize the formation of potentially harmful substances (e.g., acrylamide, etc.).

In recent years, "light" chips have been manufactured using synthetic oils/fats that are substantially indigestible by the human body, such as OLESTRA^TM. The limited acceptance of these products is due in part to reports of adverse gastrointestinal side effects and FDA requirements for warning signs attached to these foods that suggest that such fat substitutes may cause gastrointestinal side effects such as diarrhea, abdominal cramps, and/or inhibit the absorption of some nutrients.

Products such as potato chips and apple chips are generally manufactured using conventional frying methods, and snack foods manufactured using other nutritious vegetables and fruits (e.g., carrot, pumpkin, parsnip, yucca, pear, etc.) have not successfully entered the market due to the lack of suitable processing methods.

Efforts have been made in the past to reduce fat in snacks such as potato chips.

Roan (us patent 4,058,631) discloses a method of making fried food products in which a food material is treated with an aqueous solution of an enzyme, such as alpha-amylase, for a sufficient time to allow the enzyme to penetrate and coat the surface of the food product, and then the food product is deep fried. Roan states that when the surface of a starchy food material is covered with an aqueous solution of alpha-amylase prior to frying, the food absorbs less fat during frying than when it is not treated with the enzyme, and the taste of the fried food is improved.

Dreher et al (U.S. patent 4,756,916) disclose a process for making low oil potato chips which includes washing potato chips with an aqueous solution, applying oil to the washed chips to coat the chips with oil. Oil-coated potato pieces (oil-coated potatoes) are arranged in a single layer on an endless conveyor belt, blanched at about 160 DEG F to about 212 DEG F, and then baked at an elevated temperature of at least about 390 DEG F but below the smoke point of the oil to partially dry the potato pieces by reducing the moisture content of the pieces to about 10 to 20 wt%. Drying is then accomplished by reducing the moisture content of the partially dried potato pieces to about 2wt% or less at a lower temperature of about 290 ° F to 320 ° F to produce a product having an oil content of about 10 to 25 wt%.

Laufer (us patent 5,292,540) discloses a process for making potato chips comprising the steps of: the potatoes are washed to remove skin impurities, sliced, baked at about 250 ° F to 500 ° F for about 6 to 12 minutes, and heated in a microwave oven for about 2 to 7 minutes.

Yamashita (U.S. patent No. 5,312,631) discloses a method for preventing crop slices from sticking to each other during the drying and cooking steps, which comprises washing or soaking the slices with a starch hydrolase solution or an acidic or alkaline aqueous solution. The sections were blanched prior to enzyme treatment.

Zussman (U.S. Pat. No. 5,370,898) discloses a cooking process that does not involve oil-cooked chips (foodchicopproducts). The food pieces are washed with water to remove extractable surface starch, fed into an oven in layers, and baked in a fluidized bed of hot air or hot steam. The baking process is a multi-step process whereby the food pieces are subjected to high pressure in the first zone for several minutes to ensure that the individual food pieces are separated. The pressure is then reduced in a second zone for a second period of time. Similarly, the pressure is reduced in a third zone for a predetermined period of time to complete cooking of the food product. The chips are then air dried (chips) or dried in a dryer.

Lewis et al (us patent 5,441,758) disclose the preparation of low or no fat potato chips or strips by a process which comprises cutting potatoes into slices or strips, blanching the sliced potatoes, and treating the potato slices with a high temperature amylase during or after blanching to prevent the potato slices from sticking together later in the process. Then, the potato chips are dehydrated to the water content of 12% -30%, and are baked under the conditions of 140-220 FC to reduce the water content to about 2%. The use of high temperature amylases is necessary to enable the enzyme to remain effective in processing and not to be inactivated by the blanching step.

Petelle et al (us patent 5,470,600) disclose a process for making fat free potato chips which comprises first cooking potato slices in a three zone primary oven (threezoneprimaryoven) which first heats the potato slices by radiation and then subjects the potato slices to two successive forced air heating (forcedairyheating) steps to reduce the moisture content of the potato slices to near the final moisture content. Petelle et al further disclose independently controlling the duration of each of the three zones of the potato chips while forcing air into the upper and lower surfaces of the potato chips in the primary furnace to achieve a moisture content of about 15wt% which approaches the final moisture content, and independently controlling the duration of the potato chips in a dielechter using a dielectric heater (dielecuter) having a wavelength of about 65.8 feet and a frequency of about 15mhz to achieve a final moisture content of about 7wt% and to cause the potato chips to be successively stacked (piledup) in two subsequent forced air heating steps and dielectric heating steps.

Benson et al (U.S. patent 5,603,973) discloses a process for making potato chips without the use of oil wherein whole potatoes are cut into discrete pieces and washed to remove starch and debris from the surface of the chips. The potato chips were discharged in a single layer, and water on the chip surface was removed by air-blowing and air-extracting the same. Alternatively, the potato chips can be preheated by washing them in warm water at about 130 ° F. The potato slices are fed onto a heated conveyor belt into the infrared region and exposed to high intensity infrared radiation for a short period of time (less than 25 seconds) to blanch the potato slices and inhibit the deleterious enzymatic action that occurs naturally. In the subsequent step, the potato pieces were bumped with dry air up and down to reduce the moisture content to less than 35 wt%. Potato pieces are stacked in a multi-layer stack and dried in flowing air until the water content is about 0.5% to 2%.

Wiedersatz (U.S. patent 5,858,431) discloses a process for making fat free snack chips which comprises preparing a sheet of food material, subjecting it to a high intensity air knife treatment (airknife treatment) to remove surface moisture, and then subjecting it to hot air fluidized bed impingement, including in a plurality of dual zone hot air fluidized bed impingement ovens operating under different predetermined conditions. In a preferred embodiment, the chips are exposed to a dual zone hot air fluidized bed impingement oven, the first oven having a conveyor belt which transports potato chips at a speed of 2.5 to 3.0 feet per minute to the oven and operates at 500 to 525 ° F (zone 1) and 450 to 500 ° F (zone 2), and the second oven having a conveyor belt which transports potato chips at a speed of 1.5 to 2.0 feet per second to the oven and operates at 350 to 400 ° F (zone 1) and 300 to 350 ° F (zone 2). The first impingement oven of the preferred embodiment removes about 50-60% of the moisture per sheet, while the second impingement oven of this embodiment removes about 20-30% of the remaining moisture. The chips may then be oiled and/or seasoned and passed through a combination of microwave and hot air dryers to remove residual moisture (entrainedmoisture) without scorching the chips.

Xu et al (U.S. patent publication No. 2002/0004085) discloses a process for producing potato consumer products comprising: (a) treating potatoes with an effective amount of one or more exogenous enzymes selected from the group consisting of amyloglucosidase, glucose oxidase, laccase, lipase, maltogenic amylase, pectinase, pentosanase, protease, and transglutaminase, and (b) processing the enzyme-treated potato product to produce a potato product. In one embodiment, blanching of the potato product may be performed prior to the enzyme treatment. The processing step may include frying or baking.

Despite the many advances in the processing of snack and chip-type foods, there remains a need for improved products and processes for their manufacture characterized by improved crispness, mouthfeel and flavor properties, reduced fat content and overall improved nutritional profile (nutritional profile), including reduced exposure to environments that can form harmful by-products, all resulting from viable, efficient, controllable processes that are economically and practically controllable to produce at the output levels required for product marketization in efficient production environments with abundant fuels. There is also a need to eliminate the conventional frying process traditionally used to produce full fat and certain reduced fat snacks and to control the amount of fat in these products to provide a predetermined amount of fat. Further, there is a need for snack foods made from certain vegetables, nuts, grains, etc., and methods for making the same, which have not been previously possible.

Summary of The Invention

A first embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) contacting the food pieces with a solution containing one or more enzymes such that the solution covers the surfaces thereof;

(c) then blanching the plurality of food pieces for a time sufficient to inactivate enzymes on the surface of the food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(d) reducing the initial water content to a final water content of about 0.5 to 10 wt%.

A second embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) contacting the food pieces with a solution containing one or more cations to coat the surfaces thereof with the solution;

(c) then blanching the plurality of food pieces for a time sufficient to inactivate enzymes on the surface of the food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(d) reducing the initial water content to a final water content of about 0.5 to 10 wt%.

A third embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) then blanching the plurality of food pieces for a time sufficient to inactivate enzymes on the surface of the food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(c) reducing the initial moisture content to a final moisture content of about 0.5-10 wt% moisture content by exposing the food pieces to a first moisture content reducing process which reduces the initial moisture content to an intermediate moisture content of about 10-80 wt% moisture content, and then exposing the food pieces to a second moisture content reducing process which reduces the intermediate moisture content to the final moisture content. In other possible processes, the second moisture content reducing process may include the step of frying the food items in oil or an oil substitute.

A fourth embodiment of the invention is directed to snack foods comprising a food cut or food shaped piece wherein each food piece has a predetermined fat content of less than 1 to about 35 weight percent, an average force to break (average force of fracture) of 12N or less, and an average Young's modulus of about 3.5N/mm or greater.

A fifth embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) blanching a plurality of food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(c) reducing the initial water content to a final water content of about 0.5-10 wt%, which is achieved by the following steps: the pieces are dried in one or more steps, at least one of which is performed in a rotary dryer, a fluid bed dryer, a vibrating fluid bed dryer, or the like, or combinations thereof, while controlling the temperature, airflow, and movement (momentum) of the pieces to cause the pieces to continue to be heated uniformly.

A sixth embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) blanching a plurality of food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(c) the initial moisture content is reduced to an intermediate moisture content of about 10-80 wt% moisture content, while controlling the temperature, airflow and movement of the food pieces to cause the food pieces to continue to be heated uniformly, and then exposing the food pieces to a second moisture content reducing process that reduces the intermediate moisture content to a final moisture content.

A seventh embodiment of the present invention is directed to a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) then blanching the plurality of food pieces for a time sufficient to inactivate enzymes on the surface of the food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(c) reducing the initial moisture content to a final moisture content of about 0.5 to 10wt% by any of the preceding embodiments by (i) not applying a solution containing an enzyme or a cation, or (ii) contacting the food item with a combination comprising one or more enzymes and one or more cations in any feasible manner such that it covers the surface of the food item.

In any of the above embodiments, a frying step and/or a drying step using a vacuum dryer, a vacuum belt dryer, or the like may be added as the reduction step, preferably as the final drying step.

An eighth embodiment of the present invention is a snack food made from vegetables, fruits, nuts, cereals and other consumable ingredients (consubbliengedients) and any combination thereof, and methods for their production, where the commercial production of such snacks, or the production of healthier snacks, has not previously been feasible.

Additional features of the invention will be apparent from the description of the preferred embodiment which follows, and by reference to the accompanying drawings.

Detailed Description

In a preferred embodiment, the present invention provides snack food processed in such a manner that a plurality of food cuts or food shapes have the taste, texture and/or appearance of a product made by conventional production including the step of frying (typically at temperatures greater than about 300F.) a food item. Preferably, the snack food made according to the present invention has at least one, preferably at least 3, preferably at least 5 of the following characteristics: a crispy texture, a fat content of less than about 0.5wt%, a moisture content of greater than about 0.5wt%, a ratio of weight percent moisture to weight percent fat of at least about 12, the food item breaking at less than or equal to about 12N and an average Young's modulus of greater than or equal to about 3.5N/mm.

In another preferred embodiment, the present invention provides snack food products and methods of producing the same and/or cooking such that multiple food cuts or food shapes are obtained that (i) have new and/or unique tastes, textures and/or profiles, or (ii) have less fat and/or are considered healthier versions of currently existing products, or (iii) are made from vegetables, fruits, cereals, nuts, legumes or any other consumable ingredient and combinations thereof, wherein producing such products has not previously been feasible due to lack of suitable production and/or cooking methods.

Surprisingly, it has been found that the present invention can maintain the desirable high quality, taste, texture, appearance and consumer acceptance of high fat snacks by subjecting the raw materials to certain treatments followed by cooking under conditions that inhibit, optionally minimize and/or control contact with fats (e.g., oils or oil substitutes) and limit the production of potentially harmful by-products. Furthermore, contrary to known conventional frying methods, pieces of food can be infused (infused) with a predetermined amount of fat in a 'fully controlled environment' during the production process. In addition to allowing precise control of the amount of fat desired to be incorporated into the product of the invention, the present invention completely avoids the use of large amounts of hot oil or oil substitutes and avoids the need to maintain, filter and ultimately in most cases dispose of the fat used in the manufacturing process.

In addition, the present invention avoids the use of defatting agents (defaters) in the production of similar low fat snack foods.

The term "food item" is meant to include virtually any food item. Preferably, the food piece may be a food cut or food shaped piece that can be formed or reshaped directly from the stock state. These include potatoes, beets, pumpkins, squash, tomatoes, mushrooms, zucchini, carrots, eggplants, apples, pears, bananas, berries, cereals, beans, nuts, seeds, rutabaga, plantains, taros, okra, onions, parsnip, yams, sweet potatoes, yucca, papayas, mangoes, pineapples, and the like. These include pureed, sliced, diced, ground (powdered) or pulvered (pulverzed) fruits, vegetables, legumes, cereals, nuts, beans, seeds, and the like, which include the following products: such as beans, rice, corn, wheat, etc. The aforementioned products and ingredients may be made into food pieces (sheets), food slices (slices) or food pieces (pieces) by extruding or sheeting prepared dough or mixtures or the like, alone or in combination. The dough or mixture thus prepared is then extruded or cut into the desired shape. There are many variations on this basic process and flour or dough can be made into shapes suitable for the process. See, for example, U.S. Pat. No. 3,600,193 (mixing corn flour with flavorings); 3,922,370 (mixing water, rice and rice flour); and 3,348,950 (mixing corn, sucrose, water and corn grits), which are incorporated herein by reference in their entirety. In general, the process of the present invention can be used for all fried foods or foods that cannot be fried. Forms of food products may include, for example, sticks, strips, sheets, chips, rolls, wafers, and flakes, among others. The shredded food product may be in the form of bars (bars) or cereal or used as an ingredient in cereal flakes (granolas), cereal bars (granolabars) or yoghurt, cereal additives, travel high calorie foods (trailmixees) and miscellaneous snacks (snackmixes), etc.

For example, tortilla products or chips (beans) can be prepared by first forming a composition of water and corn or legume flour, or cooked tortillas or legumes, and cooking in a conventional tortilla oven (tortillovens). Tortillas or beancurd sticks or doughnuts (rounds) can be treated and processed with the present invention to produce fat-free or low-fat snack products that have the crispy texture and taste of fried foods but are not fried in oil or oil substitutes. Generally, the process of the present invention can be used with all snack foods that are conventionally fried to give a crispy texture and a traditionally fried taste.

In another embodiment, the sheeted or extruded dough or mixture described herein may be made from a potato mixture or other starch material alone or in combination with other ingredients and then processed in accordance with the teachings of the present invention to provide a crisp finished product without the need for frying.

Preferred pieces of food are derived from fruits and/or vegetables having a solid inner mass that is exposed when sliced and which breaks when the slice is bent. In a preferred embodiment, the food pieces are derived from potatoes such as are commonly used to produce potato chips. In a preferred embodiment, the food pieces comprise potato substrate. The potato substrate may simply be any kind of farm-grown potatoes (e.g., raw potatoes). These species include, but are not limited to, Bintje, RussetBurbank, Yukongold, Kennebec, Norchip, Atlantic, sheppody, Sebago, RedPontiac, RedWarba, IrishCobbler "BC", NorgoldRusset "BC", Norland, Atlantic, WhiteRose, Superior, Centerial Russet, Keswick "NB 1", Greenoutain, LaSoda, RedLaRouge, RedOrnorland, RedBlodLiss, Yellowsi, RubyCrescore and Australian Crescore, Russian blue, Peruvianblue, Superior, Katahdin and sweet potato species such as Beauregagard, Jenewal, Newold, Junceel, Excel, Exampal, Bankward, Banewire, Bankwarville, and sweet potato species (e.g., Beauuregard, Jenewcastle, European, Bandwidth, Banewire, Bankwarville, and others.

According to a first and/or second embodiment of the present invention, there is provided a method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes;

(b) contacting the food item with a solution comprising one or more enzymes and/or one or more cations, such that the solution covers the surface thereof;

(c) then blanching the plurality of food pieces for a time sufficient to inactivate enzymes on the surface of the food pieces, wherein the food pieces have an initial moisture content after the blanching step; and

(d) reducing the initial water content to a final water content of about 0.2 to 10 wt%. According to additional embodiments, the final moisture content is preferably about 0.5 to 5.0 wt%.

Several embodiments of the present invention can achieve an intermediate moisture content of about 10 to 80wt%, preferably about 10 to 50wt%, and more preferably about 15 to 35 wt%. The food pieces are then exposed to a second moisture content reducing process to reduce the intermediate moisture content to a final moisture content. The intermediate and final drying steps may be further divided into smaller steps or combined into one step.

Suitable enzymes, forms of enzymes, commercial availability thereof, etc. that may be used in the present invention are selected from the group consisting of U.S. patent 4,058,631; U.S. Pat. nos. 5,312,631; and one or more of the enzymes listed in U.S. patent 7,056,544, which is incorporated herein by reference in its entirety. Preferably, the enzyme is different from a high temperature enzyme, such as the high temperature amylase described in U.S. patent 5,441,758. However, such enzymes may be used in the present invention under certain circumstances, and the use of high temperature enzymes is not excluded here. Preferred enzymes of the invention include amylases, cellulases, invertases, pectinases and amyloglucosidases, with amylases being most preferred. Preferably, the concentration of the one or more enzymes in the solution is about 0.1 to 5 wt%.

According to the present invention, the enzyme solution may further comprise one or more cations, or the solution may comprise cations without the enzyme. The term "cation-generating compound" is intended to include compounds that generate cations in solution by dissociation of cations from anions under room temperature or under heating. Suitable cation-generating compounds of the present invention include, but are not limited to, alkali metal salts, such as lithium, sodium, and/or potassium salts; alkaline earth metal salts, such as magnesium and/or calcium salts; an aluminum compound; and group VA metals such as nitrogen, phosphorus, and/or bismuth compounds (e.g., ammonium). More preferably this group of compounds: calcium salts, magnesium salts, potassium salts, aluminum compounds and nitrogen compounds, of which calcium salts are most preferred. Preferably, the concentration of the one or more cations in the solution is from about 0.1 to 5wt%, more preferably from about 0.2 to 2.5 wt%.

Contacting the food item with an enzyme solution or a cation solution without the enzyme, optionally including cations as described above, provides the snack food with various improved properties. The term "improved property" is defined herein as any property of the snack food that is altered by the action of one or more enzymes and/or cations as compared to a snack food without treating the food item with such a solution. The improved properties include, but are not limited to, increased crispness, decreased stickiness, increased firmness of raw and/or blanched materials, decreased browning due to enzymatic and/or maillard reactions (Maillar reactions), increased color brightness, increased color retention, increased color enhancement, decreased color fading, increased hardness (stiffness), increased rough or smooth appearance, improved taste, and decreased fat content. Many of these terms are more fully described in U.S. patent 7,056,544, the contents of which are incorporated herein by reference. Other terms are defined as conventional meanings known to those skilled in the art.

It will be appreciated that the crispness and/or firmness can be increased in a measurable manner such that, for example, when a certain crispness or firmness is desired for a certain processing purpose or for the production of a particular finished snack food, the crispness or firmness can be controlled by varying the amount of contact with one or more enzymes and/or cations.

Improved properties can be obtained by comparing snack foods produced by the process of the present invention with snack foods produced by prior art processes. Techniques for measuring such improved properties achieved using the techniques of the present invention will be described herein. Organoleptic qualities (organoleptics) can be evaluated using procedures already established in the food industry and include, for example, using a trained panel of organoleptic evaluators. Other methods include, for example, texture analysis and comparison as disclosed below.

Preferably, the food item is contacted with the enzyme solution (with or without cations), or the cationic solution, for about 0.5 to 45 minutes, more preferably about 0.5 to 15 minutes, and most preferably about 0.5 to 5 minutes.

In an alternative embodiment, other nutrients including vitamins and minerals such as vitamin a, vitamin B6, vitamin B12, vitamin C, vitamin D, thiamin, riboflavin, niacin, folic acid, phosphorus, magnesium, copper, calcium, zinc, iron, and the like, may be added to the product of the present invention by injecting the vitamins and minerals into the food item, or by spraying the food item with a compound containing any desired vitamins and/or minerals, either before or after cooking. This procedure increases the nutritional value of the product, enabling the manufacture of healthier snack foods. In an alternative embodiment, the flavor enhancer and flavor mixture, such as salt (NaCl), sugar, vanilla extract, fruit extract, vegetable extract, and the like, or combinations thereof, can be infused into the snack food by dipping or soaking the food cut pieces with salt, sugar, vanilla, fruit, vegetable, and the like, thereby adding these flavor components to the food pieces in the blanching step and/or in a separation step after or before the blanching step, thereby incorporating these flavors into the food cut pieces. Alternatively, the food cuts may be immersed in an aqueous or other concentrated flavor extract. In another embodiment, the snack food of the present invention can be coated with chocolate, caramel, syrup and coatings made from fruit or vegetables or other similar coverings, thus creating a new savory snack that is free of or contains low or high amounts of fat.

Preferably any predetermined amount of digestible and/or synthetic fat, such as oil or oil replacer, can be added and/or mixed or blended with the dough or mixture prior to cooking, or can be used in any process before, during or after the pre-cooking step, such as spraying on the food pieces. Preferably, the oil is a fatty acid free edible oil, such as canola oil, sunflower oil or safflower oil, which may be applied to the vegetable pieces by spraying the oil onto the food pieces or by dipping (flash dipping) the food pieces into the oil or by other feasible methods, such as applying hot scalding water or spraying onto the conveyor belt or tray before and/or after the food pieces are placed on the conveyor tray or belt. In an alternative embodiment using an oil, although food grade oils or oil substitutes may be used, preferred oils are unrefined oils and oils with a low smoke point, preferably extra virgin olive oil, hemp seed oil, walnut oil, sesame oil, linseed oil, coconut oil, unrefined canola oil, semi-refined canola oil, unrefined peanut oil, safflower oil, sunflower oil, high oleic sunflower oil, unrefined corn oil, soybean oil, unrefined sesame oil, flavoring oils (flavorinfroses), emulsified vegetable shortening, and the like, synthetic oils such as OLESTRA^TMAnd the like. Alternative oils having health benefits, e.g. SMARTBALANCE^TMAnd ENOVA^TMEtc. may be used alone or in combination with other of the above-mentioned natural or synthetic oils.

Preparation of food articles

Food articles are cut, formed or trimmed from a food material or combination of food materials. For raw vegetables or raw plant material, the pieces of food are preferably washed and optionally peeled and cut. Preferred vegetables (e.g., potatoes, vegetables, fruits or other food products) are preferably cut into pieces (chips), bars or strips, sticks, laces (shoestings), waves (wavcutchips), curls (crinklecutes), waffles (waflecutes), straight pieces (strightcutips), bars, and the like, of a suitable size and shape for potato chip-based food products. After cutting, shaping or trimming, the finished food pieces are preferably contacted with an aqueous solution (e.g., water) to remove free starch. The removal of free starch is advantageous for optimal use of the enzyme and for reducing the amount of enzyme used, plus free starch leaves a powdery appearance after drying of the potato chip-type food product.

Enzyme treatment and/or cation treatment

The prepared food item may be contacted with an enzyme solution or a cationic solution, more preferably an enzyme and cationic solution. When subjected to an enzymatic treatment, it is preferred to use an enzyme content that produces one or more of the improved properties described herein and/or provides at least one of the following advantages: increase the crispness of the finished product, reduce the stickiness and improve the colour. Without being limited by theory, it is believed that the cations increase enzyme activity, decrease time in solution, and make the cut food pieces harder or stronger, making them easier to process. Moreover, cations can reduce enzymatic browning and facilitate the nutritional formulation of the snack food.

Suitable contact with the enzyme or cation for improving the specific properties of the snack food depends on the enzyme or cation. Suitable contacting with the enzyme or cation can be determined by one skilled in the art according to methods known in the art. When both the enzyme treatment and the cation treatment are carried out, it is preferable to carry out the treatment simultaneously using a single solution, although the treatment may be carried out using an enzyme solution and then a cation solution separately, or using a cation solution and then an enzyme solution. The salt and/or flavouring ingredient may be added in any solution.

The enzyme used in the process of the invention may be in any form suitable for the purpose, for example as a dry powder, agglomerated powder or granules, especially as a dust-free granule, a liquid, especially a stable liquid or a protected enzyme. Granulates and agglomerated powders may be prepared by conventional methods, for example, by spraying the enzyme onto a carrier in a fluid bed granulator. The carrier may consist of a particle core having a suitable particle size. The carrier may be soluble or insoluble, for example, a salt (e.g., NaCl or sodium sulfate), a sugar (e.g., sucrose or lactose), a sugar alcohol (e.g., sorbitol), starch, rice, corn grit, or soy. The enzyme may be contained in a sustained release formulation. Methods for preparing sustained release formulations are known in the art. The liquid enzyme preparation may be stabilized according to known methods by adding nutritionally acceptable stabilizers, such as sugars, sugar alcohols or other polyols, and/or lactic acid or other organic acids.

In a preferred embodiment, the enzymatic and/or cationic treatment is carried out before blanching. In an alternative embodiment, the enzymatic and/or cationic treatment is performed simultaneously with the blanching process, or as an additional treatment after blanching. In the case of certain shaped food pieces (e.g., sheet-like products made from a combination of food materials or dough), the enzymatic and/or cationic treatment can be performed after the food forming piece has undergone the initial baking step in the conventional production of such products.

Blanching

Several embodiments of the present invention include the step of blanching the food item. Preferably, the food piece is blanched for a period of time sufficient to accomplish any of: 1) inactivating any enzymes naturally growing on the surface of the food pieces, and/or inactivating any enzymes added during the above-described enzyme treatment step; 2) gelatinizing at least a portion of the naturally occurring starch; 3) removing excess free sugar to reduce Maillard browning and the potential for acrylamide formation; and 4) improving texture and taste. Generally, the food pieces are preferably blanched by immersion in an aqueous solution preferably containing from about 0.5% to about 8%, more preferably from about 2% to about 5%, and most preferably about 3% by weight of one or more of the cations described above. In a preferred embodiment, the cation is selected from NaCl, KCl, MgCl₂And CaCl₂. Blanching may be preferred inAt a temperature of about 60 ℃ to 120 ℃, more preferably about 70 ℃ to 100 ℃. In an alternative embodiment, blanching may be performed by exposure to steam (atmospheric or high pressure) for preferably about 15 seconds to 10 minutes, more preferably about 40 seconds to 3 minutes, depending on the amount of blanching desired. Alternatively, any known blanching method may be used in accordance with the present invention, such as microwaves, resistance heating, super heated steam, infrared heating, and the like.

If desired, the food pieces are then preferably drained or transported under an air curtain (air) to remove excess water. In alternative embodiments, any known method of removing excess surface water may be used. Salt may be added before, during or after blanching. Any salt suitable for food use can be used, but NaCl, KCl, MgCl are preferred₂And CaCl₂And the like.

The blanching step may be inapplicable and/or unnecessary for use in certain food forming pieces, such as sheet products made from a combination of food materials or dough.

Reduction of water content

The moisture in the food item is preferably reduced to a final moisture content of about 0.5 to 10wt%, preferably about 0.5 to 5 wt%. This reduction in water content can be achieved by several different methods.

In one embodiment of the invention, the moisture content reducing step comprises cooking the food item in one or more dryers or ovens independently selected from the group consisting of: forced air convection ovens (forcedarconvectional ovens), fluidized bed dryers/ovens, vibrating fluidized bed dryers/ovens, impingement dryers/ovens (impact dryers/ovens), pulsed fluidized bed dryers/ovens (e.g., AeroPulse dryers), rotary dryers/ovens, drum dryers/ovens, spiral drum dryers/ovens, tray ovens (tray), stationary dryers/ovens, spiral roasters/dryers (e.g., fmcspiral roto-louvvre dryers/dryers), microwave dryers/ovens, infrared dryers/ovens, ultra-hot airless dryers, vacuum belt dryers, and resistance dryers, or any similar drying/cooking device.

In one embodiment, the food item cooks at about 160 ° F to 400 ° F, more preferably about 275 ° F to 325 ° F, for about 0.5 to 40 minutes.

In another embodiment of the invention, the reduction in moisture content comprises allowing the food pieces to stand at a first temperature for a first period of time and then allowing the food pieces to stand at a second temperature for a second period of time. Preferably, the food pieces are allowed to stand at a first temperature for a first period of time, such as, but not limited to, about 160F to 400F, preferably about 275F to 375F for about 0.5 to 40 minutes, to reduce the initial moisture content to an intermediate moisture content of about 10 to 80wt%, and are allowed to stand at a second temperature for a second period of time, such as, but not limited to, about 160F to 375F, preferably about 275F to 350F, and more preferably about 300F to 325F for about 4 to 35 minutes, preferably about 5 to 12 minutes, and more preferably about 6 to 11 minutes, to reduce the intermediate moisture content to a final moisture content of about 0.5 to 10%. In a preferred embodiment, the second temperature is lower than the first temperature.

In other preferred embodiments, the first stage of the process comprises drying the food pieces in a rotary dryer, tumble dryer, screw drum dryer, fluid bed dryer/oven or vibrating fluid bed dryer/oven to remove up to 30wt%, preferably up to 50wt%, and most preferably up to 90wt% of the initial moisture content, and then the second stage reduces the moisture content to a final moisture content of about 0.5 to 10% moisture content. Preferably, the drying step is carried out at a temperature of about 160 ° F to 400 ° F, preferably 275 ° F to 350 ° F, more preferably about 300 ° F to 325 ° F, for about 2 to 40 minutes, more preferably about 5 to 25 minutes, and more preferably about 6 to 18 minutes.

In other preferred embodiments, the moisture content may be reduced in one or more drying steps to a final moisture content of about 0.5-10% using a rotary dryer, a tumble dryer, a screw drum dryer, a fluidized bed dryer/oven, or a vibrating fluidized bed dryer/oven. No additional cooking step is used in this embodiment. The same temperature and time conditions as described above may be used in one or more stages of this embodiment.

Another embodiment of the present invention is to use a screw roaster/dryer for drying/cooking. The drying principle and product performance of this method is similar to that of rotary ovens and drum drying, except that the internal screw can precisely control the drying time in the vessel. Typically, in a spiral roaster/dryer, drying air is passed through perforated plates or screens wrapped around the spiral flights into the product bed between the spiral flights. The precise control of the drying time in the container in combination with the use of this method may lead to higher product quality, process effectiveness and increased process efficiency, as well as previously unavailable or desirable output levels.

In any of these stages, the food pieces may be contacted with air at an air velocity of about 200 to 15,000 feet per minute. According to additional and alternative embodiments of the invention, lower wind speeds may be used depending on the food item to be prepared and/or the equipment used. The process further controls the contact of the product in the temperature and air flow by selectively increasing and/or decreasing the air velocity, thus optimizing the quality of the final product. The temperature and air flow of the controlled drying process is continuously adjusted, which advantageously maintains the product temperature at a temperature below that which can cause browning and charring (browning) until the product reaches a target moisture content. Controlling the different temperature and air velocity zones can optimize texture, color and taste, as well as the economic efficiency of the process.

Other equipment, such as any similar type of rotary or drum dryer, "flash dryers," airless or super-heated steam dryers, and the like, such as products manufactured by applied chemical technologies, carrier vision, inc. Or microwaves, infrared, impingement, vibroimpingement, tray ovens, convection ovens, stationary ovens, fluidized or vibrated fluidized bed drying, vacuum drying or vacuum belt drying, etc., each with varying degrees of efficiency and output levels, may be used in the partial or complete dehydration process of the food pieces. The use of a steam iron, such as the product produced by the Lyco company, alone or in combination with any of the above devices, may provide a number of additional alternatives for partial or complete dewatering processes. Where applicable, any of the foregoing arrangements associated with various embodiments of the present invention may be used, e.g., batch or continuous processing equipment, static or vibratory equipment designs, etc.

Moisture sensing devices such as those manufactured by DryingTechnologies, Inc, (i.e., DTI500, DTI5000), etc. may be installed inside a rotary dryer, etc. to ensure proper drying conditions on an automated basis.

In a preferred embodiment, the partially dried food pieces are transferred by a conveyor belt or any other conveying device or method into an impingement oven, a fluid bed dryer/oven, a vibrating fluid bed dryer/oven, a vacuum belt dryer/oven, or any other similar apparatus. After the moisture content is reduced, the resulting snack food can be cooled at room temperature or reduced temperature, and optionally seasoned and/or coated as needed, and packaged for distribution and consumption.

Any flavouring mixture may be applied to the product, preferably using a binder that creates a sticky surface on the product, such as gums, starches, proteins, as is known in the food industry.

To achieve a foaming effect on the surface of the food product similar to the general appearance observed when the food product is fried, the food item is preferably cooked at least 265 ° F after a half reduction in moisture. The food item is then cooked with a high velocity air stream (e.g., air velocity of about 500 to 15,000 feet per minute) at a temperature of about 310F to a final moisture content of about 2 to 5%. When using some types of equipment, such as a vacuum dryer, the final drying may be carried out at a temperature lower than that described above.

After the moisture reduction is complete, the process efficiency can be further improved by treating the food items with an "Equilibrator" system which expels gas from the hot product, giving off heat so that it cools as the final moisture is removed.

The present invention also contemplates reducing the moisture content to an intermediate moisture content by the methods described herein, cooling and storing the wet product at room temperature, refrigerated or frozen conditions, followed by frying, drying or baking the product to obtain the final moisture content. Alternatively, the frying step is followed by a step of reducing the moisture content to an intermediate moisture content.

In addition, the present invention contemplates the rapid frying or baking of any snack food prepared according to the present invention, whether commercially available or retail or home.

The present invention also includes snack food products made by any of the methods described herein.

Other aspects and advantages of the present invention will be understood in view of the comparative examples described below.

Examples

Example 1: potato chips:about 2,333 grams of Yukongold variety potato was cleaned and then cut into pieces having an average piece thickness of 1.90mm to give about 2288 grams of sliced potato. Sliced potatoes were rinsed in cold water (18 ℃/65 ° F) for 15 seconds and drained. The drained potato pieces were then kept in a solution of 0.5% amylase (American labs, Inc. fungal amylase-100,000 SKB/g LotAlli 00517-04) and 1% aqueous calcium chloride (32% aqueous calcium chloride, available from DSM zoo specialties) for 3 minutes before being drained again. After draining, the treated potato pieces were blanched in 93 ℃ (200 ° F) water containing 3% salt (NaCl) (CargillTopFlowSalt) for 1 minute. The blanched potato slices were immersed in cold water for about 15 seconds to stop cooking and then drained. The potato pieces were then placed directly into an impingement oven set at 140 ℃/285 ° F (Model No.1240, lincolnfoodservice products, inc., FortWayne, IN) on a conveyor belt, while IN-bandThe time (minimum) was 13.25 minutes. After drying, the chips were allowed to cool completely and then sealed in a moisture-proof bag to yield 467 grams total chips. The resulting chips were visually observed and determined to be light gold in color, and they had good potato chip taste and crispy texture.

The water content of the samples was analyzed by convection oven method: it was performed by measuring the weight loss resulting from heating a ground sample (4 grams, 3 runs) in a convection oven under controlled conditions (24 hours at 100 ℃). The percent moisture in the sample is reported as percent weight loss, and in this example, the final moisture content is 4.42%.

The samples were analysed for fat using the chloroform extraction method of f.i. shahii (with only minor changes) (see reference provided below):

the samples were ground in a mixer before extraction.

1. Preparing chloroform: methanol (2:1) solution.

2. Placing the weighed 10g of ground sample in a flask; 50ml of chloroform/methanol (2:1) solution were added.

3. Stirred for 1 hour.

4. Pour it through filter paper into a clean flask.

5. The original flask and residual solids were rinsed with a small amount of chloroform/methanol (2:1) solution and the rinse was poured into a new flask.

6. 30-35ml of distilled water was added and mixed.

7. Left to stand at 40 ℃ overnight.

8. The upper layer containing water and methanol after precipitation was removed with a water aspirator and a glass pipette.

9. A new round bottom flask was weighed and recorded.

10. The remaining solution was poured through a filter into a new flask and the remaining chloroform (and fat) was allowed to flow over sodium persulfate to remove residual water. All fats were rinsed into the flask with additional chloroform.

11. Residual chloroform was removed (by evaporation) using a rotary evaporator at 50 ℃ at 80 rpm.

12. The flask was placed in a fume hood overnight to completely evaporate the remaining chloroform.

13. After complete drying, the flasks were weighed, and the fat mass was recorded and determined.

The results show that the samples contain on average about 0.30% fat. After drying, the average final thickness of the sample piece was 1.38mm as measured by measuring the thickness of 10 pieces using a digital caliper.

The "chloroform method" is based on the method described in f.i. shahii, "extraction and measurement of total lipids", current protocol catalysis, john wileyandsons,2003, ppd 1.1.4.

The "psychrometric method" is based on the method described in R.P.Ruis, "gravimetric determination of WaterbyDryingand weighing: MeasuringMoistureusaCovementOven", Current protocols in genomic DNA chemistry, John Wileyandsons,2003, pPA1.1.1.

The texture of the chips was evaluated using a ta. xt2 texture analyzer (TextureAnalyzer) using a 0.25 "diameter ball probe and chip/chip holder (chip/cracker). Each sheet was rested on a cylindrical opening of the plate, the opening having a diameter of 18mm, and the sheet was punctured with a ball probe. The ball probe slides at a speed of 4.0mm/s until a force of 10 grams is measured; the ball probe then punctures the disc at a rate of 1.0 mm/sec. The probe was withdrawn at a rate of 10.0 mm/sec. 25 pieces of sample were used for each test. Analysis of these test pieces gave an average peak force of 379 g, which was in combination withLow oil potato chips (Lightchips) (OLESIRA)^TM325.59 grams force) and low fat KETTLEKRISPS^TM(416.06 grams of force) are statistically similar.The Classic force was a little lower, 254.23 grams.

Test 1: comparison of the potato chip characteristics: the potato chip samples of the invention prepared by the process of example 1 were compared to the current commercial chips:

TABLE 1 comparison of French fries characteristics

Fat analysis by chloroform extraction

Information of nutritional signatures

And (3) testing 2: the density of the chips was measured using a multiplex densitometer (Multipycnometer). A complex densitometer (Quantachromemodel MVP-D160-E) measures volume using a fluid displacement technique. The fluid used in the instrument is helium. Chip volume was determined by measuring the pressure differential while flowing a known amount (known reference volume) of helium into a sample chamber containing the chips. The samples were weighed before measuring the volume. Each chip was broken into 2-4 pieces to make it suitable for placement in a measuring tank. The density was calculated by the following formula:

w = weight of potato chip (g)

Vc = volume of the tank (cm)³)*

VR = reference volume (cm)³)*

P₁= pressure reading of reference

P₂Pressure reading of the cell = cell

*V_cAnd V_REstablishing at instrument calibration

TABLE 2 Density calculation of the hydrometer of potato chips

Example 2 general fat free potato sticks:russet burbank potatoes were peeled and cut into strips (Juliennestylelengthwise) approximately 2mm in height and width. After 540 grams had been cut, the raw potato sticks were rinsed under 65 ° F running water for 15 seconds. The washed rods were then held in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride solution (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato sticks were drained and then blanched in water containing 3% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 90g salt) for 1 minute 30 seconds before being drained again. The blanched potato sticks were placed directly in a perforated aluminum tray and placed in a 140C/285F impingement oven (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 24 minutes. Every 5 minutes, the tray was vibrated to stir the potato sticks to dry evenly. The process yielded approximately 103 grams of fat free potato sticks which were then cooled and packaged. The potato sticks were evaluated by trained sensory professionals and were noted to have a good cooked potato taste, golden color and crispy texture (lightcristiptexture).

Example 3 bulk puffed potato strips:yukongold potatoes were peeled and cut into approximately 2mm thick pieces. These sheets were then cut into strips of about 6mm width. About 750 grams of raw potato strips were rinsed under 65 ° F running water for 15 seconds. The washed strips were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato strips were drained and then blanched in water containing 3% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 90g salt) for 1 minute 30 seconds before being drained again. Placing blanched potato strips directly on a perforated aluminum tray and placing them in a 135C/275F impingement oven (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 27 minutes. Every 5 minutes, the tray was vibrated to agitate the potato strips to dry them evenly. The process resulted in about 129 grams of light texture (light texture) fat free potato strips, about 90% of which were puffed into cylindrical shapes giving them a crisp french fry appearance. Fat-free potato strips were judged by trained sensory professionals to have a very strong buttery flavor, a crispy texture and an attractive appearance.

Example 4 carrot slices:carrots were peeled and cut into pieces about 2mm thick. About 500 grams of carrot pieces were rinsed under 65 ° F running water for 15 seconds. The washed carrot pieces were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated carrot pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ℃ F. (2000g water plus 40g salt) for 1 minute 15 seconds before being drained again. Placing the blanched carrot slices directly into a 135 ℃/275 ° F impingement oven belt (I,ModelNo1240, lincoln hoodserviceproducts, inc., FortWayne, IN). The oven belt speed was set at 15 minutes. The process yielded approximately 120 grams of fat free carrot chips with light texture, bright orange color and good sweet carrot flavor.

Example 5 fat free beet chips:fresh red beets were peeled and cut into pieces about 1.6mm thick. Approximately 590 grams of the chips were rinsed under 65F running water for 15 seconds. The washed chips were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme treated chips were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 1 minute 15 seconds before being drained again. Placing the blanched carrot slices directly into a 135 ℃/275 ° F impingement oven belt (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 15 minutes. The process yielded approximately 130 grams of fat-free beet chips with a crisp texture, deep beet red color and good beet flavor.

Example 6 fatty-free European style protection tablets:fresh parsnip root was peeled and cut into pieces about 1.6mm thick. Approximately 500 grams of parsnip blades were rinsed under 65 ° F running water for 15 seconds. The washed windguard sheets were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated parsnip tablets were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 1 minute 15 seconds before being drained again. Placing the blanched parsnip directly on a 135 deg.C/275 deg.F impingement oven belt (Impinger)Model No.1240, LincolnHoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 13 minutes. The process yielded about 120 grams of fat-free, windproof tablets with a crisp texture, a creamy brown color and a good European style flavor.

Example 7: non-fat yucca root (Maniac or cassava) pieces:fresh yucca roots were peeled and cut into pieces about 1.6mm thick. The yucca root pieces were rinsed for about 1000 grams at 65F running water for 15 seconds. The washed yucca root pieces were then held in a solution containing 750 grams of water (43 ℃ C./110 ℃ F.), 7.5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 7.5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme treated yucca pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 1 minute 15 seconds before being drained again. Placing blanched yucca root pieces in apple juice for 2 minutes, then draining, and placing directly in a 135 ℃/275 ° F impingement oven belt (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 14 minutes. This process yielded about 200 grams of fat-free yucca root chips with a crisp texture, white color and good slightly sweet taste.

Example 8 fat-free pineapple slices:fresh pineapple is cored and the core is cut into pieces about 1.6mm thick. About 500 grams of pineapple chips were rinsed under 65 ° F running water for 15 seconds. The washed pineapple chips were then kept in a solution containing 500 g of water (43 ℃ C./110 ℃ F.), 5g of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5g of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme treated pineapple slices were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ℃ F. (2000g water plus 40g salt) for 1 minute 15 seconds before being drained again. Placing the blanched pineapple slices directly into an impact oven belt at 140 ℃/285 DEG F ((S))Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 22 minutes. The process yielded approximately 128 grams of fat free pineapple slices with a crisp texture, bright yellow color and a good cooked pineapple taste.

Example 9 fat free apple pieces:fresh Fuji apples were washed and cut into pieces of about 2.0mm thickness. Approximately 900 grams of apple pieces were rinsed under 65 ° F live water for 15 seconds and then placed in a 1% citric acid solution to stop enzymatic browning. The apple pieces were then held in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated apple pieces were drained and then blanched in water containing 2% Cargill's sea salt and 2% calcium chloride solution (2000g water plus 40g salt and 40g calcium chloride solution) at 87 ℃/190 ℃ F for 1 minute 15 seconds before being drained again. Placing the blanched apple pieces directly into an impingement oven belt at 140 ℃/285 ° F (C)Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 14 minutes. The process yielded approximately 220 grams of fat free apple chips with a crisp texture, light brown and good cooked apple flavor.

Example 10 lipid-free pear slices:fresh d' Anjou pears were washed and cut into approximately 2.0mm thick slices. Approximately 850 grams of the pear chips were rinsed under 65 ° F running water for 15 seconds and then placed in a 1% citric acid solution to prevent enzymatic browning. The pear slices were then kept in a solution containing 500 grams of water (43 ℃/110 ° F), 5 grams of bacterial amylase (lotno. ali05175-04, american laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from dsmfood specialties) for 3 minutes. The enzyme-treated pear slices were drained and then re-drained in water (2000g water) containing 2% Cargill's sea salt and 2% calcium chloride solution at 87 ℃/190 ℉Added 40g of salt and 40g of calcium chloride solution) are blanched for 1 minute and 15 seconds. Placing the blanched pear slices directly into an impingement oven belt at 140 ℃/285 ° F ((S))Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 15 minutes. The process yielded approximately 200 grams of fat-free pear chips with a crisp texture, light brown color and good cooked pear flavor.

Example 11 fat-free purple sweet potato chips:purple sweet potatoes were peeled and cut into pieces about 1.8mm thick. After slicing, 1000 grams of raw sweet potato chips were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then blanched in water containing 2% Cargill's sea salt at 87 ℃ (2000g water plus 40g salt) for 1 minute 30 seconds before draining again. Placing the blanched potato chips directly into an impingement oven belt at 140 deg.C/285 deg.F ((S))Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 14 minutes. The process yielded about 225 grams of fat free sweet potato chips, which were then cooled and packaged. Purple sweet potato chips were evaluated by trained sensory professionals and were noted to have good sweetness, novel deep purple color, and crispy texture.

Example 12 fat-free radish pieces:fresh red radish (redtableradishes) was cut into pieces approximately 1.75mm thick. Approximately 500 grams of radish pieces were rinsed in fresh water at 65 ° F for 15 seconds. The washed radish pieces were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride solution (32% calcium chloride, product of DSMFoodspecialties) for 3 minutes. The enzyme-treated radish pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 45 seconds before being drained again. Placing the blanched radish slices directly into an impingement oven belt at 135 ℃/275 ° F: (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 11.5 minutes. The process yielded approximately 109 grams of fat-free radish slices with a crisp texture, a milky brown color, and an astringent radish flavor.

Example 13 fat-free taro pieces:fresh taro roots were peeled and cut into pieces about 1.6mm thick. About 1000 grams of taro pieces were rinsed under 65 ° F running water for 15 seconds. The washed taro pieces were then kept in a solution containing 750 grams of water (43 ℃ C./110 ℃ F.), 7.5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme treated chips were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 1 minute before being drained again. Placing the blanched taro pieces directly into an impingement oven belt at 135 ℃/275 ° F ((Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 12 minutes. This process yielded approximately 255 grams of fat-free taro pieces with a crisp texture, a milky brown color and retained the natural flour/red dots (specks) in the taro root. The taste was mild, palatable and slightly sweet.

Example 14 fat-free pumpkin slices:fresh squash (about 10 inches in diameter) was cut into four pieces, the seeds removed, and then cut into pieces about 1.8mm thick. About 1000 grams of raw pumpkin slices were rinsed under running water at 65 ° F for 15 seconds. The washed pumpkin slices were then kept in a solution containing 750 grams of water (43 ℃/110 ° F), 7.5 grams of bacterial amylase (lotno. ali05175-04, american laboratories, Inc.), 5 grams of calcium chloride (32% calcium chloride solution, available from dsmfood specialties) for 3 minutes. The enzyme-treated pumpkin slices were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 30 seconds before being drained again. Making blanched pumpkin slices(ii) impingement oven belt placed directly at 135 ℃/275 ° FModel No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 11 minutes. The process yielded about 246 grams of fat free pumpkin chips with a crisp texture, orange/brown color and a mild and pleasant taste.

Example 15 fat free turnip cabbage pieces:fresh rutabaga was peeled and cut into pieces of about 1.6mm thickness. About 500 grams of turnip cabbage pieces were rinsed under 65 deg.F running water for 15 seconds. The washed turnip cabbage pieces were then kept in a solution containing 500 g of water (43 ℃/110 ° F), 5g of bacterial amylase (lotno. ali05175-04, american laboratories, Inc.), 5g of calcium chloride (32% calcium chloride solution, available from dsmfood specialties) for 3 minutes. The enzyme-treated turnip cabbage pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 deg.C/190 deg.F (2000g water plus 40g salt) for 1 minute 10 seconds before being drained again. Placing the blanched turnip cabbage pieces directly into an impingement oven belt at 135 deg.C/275 deg.F (C)Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 12.5 minutes. The process yielded approximately 134 grams of fat free turnip cabbage pieces with a crisp texture, a light brown color and a typical cooked turnip cabbage taste.

Example 16: fat-free summer pumpkin slices:several fresh zucchini (about 2.5 inches in diameter and about 8 inches long) were peeled, cored (about 0.5 inches in diameter), and the resulting zucchini was cut into pieces about 2.0mm thick using a shredder (kitchen mandolin) with a serrated edge. About 1000 grams of raw water segments were rinsed under running water at 65 ° F for 15 seconds. The washed pieces were then kept in a container containing 750 grams of water (43 ℃ C./110 ℃ F.), 15 grams of dry enzyme preparation (LotNo. SI9700, MultizymeII, enzyme development Corp. New York, N.Y.), 10 grams of calcium chloride (32% calcium chloride solution)From dsmfood specialties) for 3 minutes. The enzyme-treated slices of the snake melon were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 45 seconds before being drained again. Placing the blanched sliced fructus Benincasae directly into an impact oven belt at 135 deg.C/275 deg.F (C)Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 18 minutes. The process yielded about 96 grams of fat free water-saving melon pieces with a crisp texture, light yellow/brown and mild and pleasant taste.

Example 17 lipid-free Mushroom chips:several fresh agaricus bisporus (button mushroom) (about 2.5 to 3 inches in diameter of the lid) were cut into pieces about 2.4mm thick using a shredder. The pieces of 500 grams of raw mushroom were rinsed under running water at 65F for 15 seconds. The washed pieces were then kept in a solution containing 750 grams of water (43 ℃ C./110 ℃ F.), 15 grams of dry enzyme preparation (LotNo. SI9700, MultizymeII, enzyme development Corp. New York, N.Y.), 10 grams of calcium chloride (32% calcium chloride solution, available from DSM zoo specialties) for 3 minutes. The enzyme-treated mushroom pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 45 seconds before being drained again. Placing blanched mushroom slices on a sieve plate and placing in a 135C/275F impingement oven (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 22 minutes. This process yielded approximately 64 grams of fat free mushroom pieces with light texture, brown color and a mild and pleasant pungent (pungent) cooked mushroom flavor.

Example 18: fat-free green bean stick:fresh green beans (dark blue variety, blue lakevariety) were washed, trimmed of the ends, and then washed with approximately 1000 grams of raw green beans under running water at 65 ° F for 15 seconds. The washed pods were kept in a dry enzyme preparation containing 750 grams of water (43 ℃ C./110 ℃ F.), 15 grams(LotNo. SI9700, Multizyme II, enzyme development Corp. New York, NY), 10g of calcium chloride (32% calcium chloride solution, available from DSMFood specialties) for 3 minutes. The enzyme-treated pods were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g water plus 40g salt) for 4 minutes before being drained again. Placing the blanched green pods on a sieve plate and into a 135C/275F impingement oven belt (C)Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 28 minutes. The process yielded approximately 172 grams of fat-free green bean sticks with a crisp texture, green and brown color and with a mild pleasant taste.

Example 19 Pre-fat free potato chips in general, holding for 1 week under freezing conditions and then drying/cooking Processing the slices:atlantic variety chips (Atlantic Varietychipping) potatoes were peeled and cut into approximately 1.60mm thick pieces using a Ditodean vegetable slicer with a C2 knife edge. After slicing, 1000 grams of raw potato pieces were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then kept in a solution containing 1000 grams of water (43 ℃ C./110 ℃ F.), 10 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 10 grams of calcium chloride solution (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 60g salt) for 1 minute before being drained again. The blanched potato slices were cooled in ice water and then stored in plastic bags in a 3 ℃ 38 ℃ F. freezer for 7 days. Samples were removed from the freezer, placed monolayer on a metal screen, and industrial Air at 176 ℃/350 ℃ FThe plates were processed in an impingement oven (HeatandControl company, Hayward, CA94545) for 3.5 minutes. The partially dried potato pieces were stacked together to form a1 inch thick bed and then passed through a second Air at 148 ℃/300 ° FThe impingement oven (HeatandControl company, Hayward, CA94545) was reprocessed for 3.5 minutes. This process yielded approximately 200 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture. The preprocessed potato chips are kept for 7 days without influencing the texture or taste of the finished products.

Example 20 New sweet Potato cereals-general chips of sweet potatoes:the fresh sweet potato cereal, regular sweet potato, is peeled and cut lengthwise into strips about 0.75-1 inch thick, and then the strips are cut into pieces about 2mm thick. After slicing, about 1000 grams of raw potato pieces were washed in fresh water at 65 ° F for 15 seconds. The washed splits were then blanched for 1 minute at 87 ℃/190 ℃ F. in water (5000g cold water plus 50g salt, 25 g calcium chloride) containing 1% Cargill's sea salt and 0.5% calcium chloride solution (32% calcium chloride solution, available from DSM poood specialties) before draining. Placing the blanched sweet potato pieces directly on an aluminum sieve and placing in a 140 deg.C/285 deg.F impingement oven (Model No.1240, Lincoln HoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 17 minutes. Every 5 minutes, the sweet potato pieces were uniformly dried by shaking with a sieve to stir. This process yielded about 284 grams of fat free sweet potato pieces, which were cooled and packaged. Sweet potato pieces were evaluated by trained sensory professionals and were noted to resemble cereal grains, having a good sweet nut taste, golden brown color and crispy texture when placed in a bowl and eaten with milk. The product can keep crisp texture in a bowl for 7-8 minutes.

Example 21: initial drying with infrared heaters and then final drying in an impingement oven Fat-free potato chips:atlantic variety crumb potatoes were peeled and cut into approximately 1.60mm thick pieces using a Ditodean vegetable slicer with a C2 knife edge. After slicing1000 grams of raw potato pieces were rinsed under running water at 65 ° F for 15 seconds. The washed pieces were then kept in a solution containing 1000 grams of water (43 ℃ C./110 ℃ F.), 10 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 10 grams of calcium chloride 32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 60g salt) for 1 minute before being drained again. The blanched potato slices were placed on a conveyor belt and allowed to run in an infrared heating unit for 30 seconds. The partially dried pieces were then immediately placed into an industrial Air at 176 ℃/350 ℃ FThe oven was kept in an impingement oven (HeatandControl company, Hayward, CA94545) for 3 minutes. The partially dried potato pieces were then stacked together to form a1 inch thick bed and then passed through a second Air at 148 ℃/300 ° FThe impingement oven (HeatandControl company, Hayward, CA94545) was reprocessed for 3 minutes. This process yielded approximately 200 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

EXAMPLE 22 general No-Dry with microwave initial drying followed by Final drying in an impingement oven Fat potato chips:atlantic variety crumb potatoes were peeled and cut into approximately 1.60mm thick pieces using a Ditodean vegetable slicer with a C2 knife edge. After slicing, 1000 grams of raw potato pieces were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then kept in time in a solution containing 1000 grams of water (43 ℃ C./110 ℃ F.), 10 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 10 grams of calcium chloride solution (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 60g salt) for 1 minute before being drained again. Blanching potato slicesPlaced on a plastic tray and placed in a microwave oven (AmaraRadarRange, Model No. RS415T,1500Watts, AmanaApplinaces, manufactured by Amana, IA) under full power operation for 1 minute. After microwave drying, the partially dried pieces were placed directly into an industrial Air at 176 ℃/350 ℃ FThe strips of an impingement oven (HeatandControl company, Hayward, CA94545) were held for 1.5 minutes. The potato slices were then stacked together to form a1 inch thick bed, and then passed through a second Air at 148 ℃/300 ° FThe impingement oven (HeatandControl company, Hayward, CA94545) was reprocessed for 1.5 minutes. This process yielded approximately 200 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 23 bulk puffed Potato chips made by steam blanching instead of immersion blanching Hit (lincoln impact) complete:yukongold potatoes were peeled and cut into approximately 2mm thick pieces. These sheets were then cut into strips of approximately 6mm wide and 6cm long. About 750 grams of raw potato strips were rinsed under 65 ° F running water for 15 seconds. The washed strips were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato strips were drained and then blanched with steam in an M-6Dixie vegetable blancher/cooler (Dixiecanning company, AthensGeorgia,30603) for 30 seconds. Placing the blanched potato strips directly on a perforated aluminum tray and into a 135C/275F impingement oven (Model No.1240, LincolnFaoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 27 minutes. Vibrating the disk every 5 minutesTo agitate the potato strips to dry them uniformly. The process yielded about 129 grams of fat free potato strips with a light texture, about 90% of the potato strips being puffed into a cylindrical shape giving them a crisp french fry appearance. Fat-free potato strips were judged by trained sensory professionals to have a very strong buttery flavor, a crispy texture and an attractive appearance.

Example 24 impingement oven for initial drying followed by pulsed fluidized bed dryer for Final drying Drying a typical fat-free potato chip:atlantic variety crumb potatoes were peeled and cut into approximately 1.60mm thick pieces using a Ditodean vegetable slicer with a C2 knife edge. After slicing, 1000 grams of raw potato pieces were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then kept in a solution containing 1000 grams of water (43 ℃ C./110 ℃ F.), 10 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 10 grams of calcium chloride solution (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (3000g cold water plus 60g salt) for 1 minute before being drained again. The blanched potato slices were placed directly on a belt of an impingement oven at 176/350F and dried for 1 minute to reduce the moisture content to 50%, and then the slices were stacked into a 3 inch thick bed and placed in a 148/300F commercial ovenPulsed-air fluidized processor (Aeroglide corporation, Raleigh, NC27626) for 5 minutes. This process yielded approximately 200 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 25: wave or ripple fat-free potato chips:atlantic potato species were peeled and cut into pieces about 2mm high at the thickest and about 1.65mm thick at the thinnest with a kitchen knife equipped with a corrugated blade, in contrast to the currently marketed "WA (WA)" namevy) "or" Ripple "chips have similar appearance, shape and thickness. After slicing, 500 g of raw potato pieces were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then held in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 5 grams of calcium chloride solution (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched by direct steam contact for 30 seconds in an M-6Dixie vegetable blancher/cooler (Dixie cooking company, athens georgia,30603) under atmospheric conditions. Placing the blanched potato strips directly in an impingement oven at 140 ℃/285 ° F (Model No.1240, LincolnFaoodServiceproducts, Inc., FortWayne, IN). The oven belt speed was set at 24 minutes. The process yielded approximately 110 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 26: puffing the potato chips:yukongold potatoes were peeled and cut into approximately 2mm thick pieces. About 750 grams of raw potato strips were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then kept in a solution containing 500 grams of water (43 ℃ C./110 ℃ F.), 5 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.) and 5 grams of calcium chloride (32% calcium chloride solution, available from DSMFoodspecialties) for 3 minutes. The enzyme-treated potato pieces were drained and then blanched in water containing 2.5% Cargill's sea salt (3000g water plus 75g salt) at 87 ℃/190 ° F for 1 minute 30 seconds before being drained again. Placing the blanched potato pieces directly on a conveyor belt and passing through an impingement oven at 140 ℃/285 ° F ((I, model No.1240, lincolnfoodservice products, inc., FortWayne, IN). The oven belt speed was set for 9 minutes for the first pass, and then the potato chips were set for 6 minutes for the second pass. The process yields about 13About 90% of 5 grams of fat free potato chips with a crisp texture were puffed into a pillow-like, hollow, thicker shape. The puffed fat-free potato chips are judged to have a very strong butter flavor, a crispy texture and an attractive appearance by trained sensory professionals.

Example 27 fat-free sweet potato chips:organic Japanese sweet potatoes (organic Japanese sweet potatoes) were peeled and cut into pieces about 1.8mm thick. After slicing, 1000 grams of raw sweet potato chips were rinsed under 65 ° F running water for 15 seconds. The washed pieces were then blanched in water containing 2% Cargill's sea salt at 87 ℃/190 ° F (2000g cold water plus 40g salt) for 1 minute 30 seconds before draining. Placing the blanched pieces directly into an impingement oven at 140 ℃/285 ° F (C)I, model No.1240, lincolnfoodservice products, inc., FortWayne, IN). The oven belt speed was set at 14 minutes. The process yielded approximately 230 grams of fat free sweet potato chips, which were cooled and packaged. The sweet potato chips were evaluated by trained sensory professionals and were noted to have a good sweet, bright orange and crispy texture.

Example 28: a rotary or drum dryer is used in the first step of the cooking process:crumb potatoes were cleaned, peeled, cut into pieces about 1.55mm thick, and then cleaned and exposed to a solution containing bacterial amylase (lotno. ald105175-04, american laboratories, Inc.) and calcium chloride solution (32% calcium chloride solution, available from dsmfood specialties). Next, the enzyme treated potato pieces were drained and then blanched in water containing 87 ℃/190 ° F2% Cargill sea salt before being drained again. The blanched potato slices are then cooled and stored. Several potato slice samples were tested using an OmniMark moisture analyzer (available from DenverEquis company) before and after the dehydration step. The analyzer shows that the water content of the enzyme-treated raw potato pieces is 80-85% before drying after blanching.

The potato slices were then stacked in a drum dryer (from SprayDynamics) and partially mass dehydrated at about 300 ℃ F. for about 10 minutes. The partially dehydrated pieces were removed from the rotary dryer and visually inspected for quality, color, texture, degree of breakage, odor, and taste. Surprisingly, all potato chips have excellent texture, color, taste, odor, and even more surprisingly, the extent of chipping, sticking, or other visual defects is minimal, if any. Drying was uniform and all pieces had similar color and consistent degree of dehydration.

The test is repeated for about 5 to 14 minutes at about 275 DEG F to 350 DEG F for a plurality of dehydration times. The visual results were all as surprisingly good as in the first test and did not change over several tests.

After about 5 to 14 minutes of dehydration, the resulting snack food has a moisture content of about 40% to 70%.

To further test the efficiency of the present teachings, additional tests were performed using a drum dryer (manufactured by SprayDynamics). Potato pieces that were not enzyme treated were placed in a drum dryer in the same manner as described above and partially dried at 300 ° F for up to about 12 minutes. After the dehydration step, the process has given less desirable results and the color, texture, quality, taste or odor of the sheet is considered less than ideal. Drying is not uniform. Some of the pieces dry to be similar and/or as hard as the dehydrated potatoes. However, the other sheets are completely or partially wet or even completely or marginally burnt. It is believed that the use of enzyme treatment can significantly improve food products with high starch content, as the enzyme treatment may degrade the sugar on the surface of the food pieces.

The pre-treated dehydrated potato slices of potatoes processed according to the teachings of the present invention are then used to make potato chips having the same texture, crunchy (crunchiness), color, taste and mouthfeel as conventional deep fried potato chips. Pretreated potato pieces (pretreated dehydrated potato pieces) cooked at a temperature of about 300 ° F for about 8 minutes (having a moisture content of about 51%) were used in the following tests.

Example 28A:about 5,000 grams of the pre-treated dehydrated potato pieces were poured onto an open conveyor belt (openingcoveyingbelt) of a fluid bed dryer (made by wittercompany) and further heated at a temperature of about 325 ° F for about 6 minutes. The air velocity is about 300 to 350 cfm. The cooked pre-treated dehydrated potato pieces were then cooled to ambient temperature (80F.). The resulting chips include some air pockets/blisters (blistering) similar to conventional fried chips and have a texture, mouthfeel, taste, color and crunchy feel comparable or superior to corresponding chips made by conventional frying methods. This test yielded about 1,990 grams of fat free potato chips.

Example 28B:in industrial AirApproximately 1,500 grams of pre-treated dehydrated potato pieces were stacked in layers on a conveyor belt of an impingement oven (heatandcontrol company, Hayward, CA94545) to form a1 inch thick bed, which was then processed at 148 ℃/300 ° F for 5.5 minutes. The process yielded approximately 660 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 28C:industrial use at 148 ℃/300 ° FA pulsed gas fluidized bed processor (aeroglide corporation, Raleigh, NC27626) processes about 2,000 grams of pre-treated dehydrated potato pieces in a multi-layer format for 5 minutes. The process yielded approximately 830 grams of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 28D:approximately 1000 grams of the pre-treated dehydrated potato pieces were further processed using a convection oven (Model #6203, lincoln steam' r oven, lincoln pod services products, fort wayne, IN). The potato pieces were placed on a perforated tray and cooked in an oven at 148 ℃/300 ° F for 12 minutes until the product was completely dried. This test yielded about 400 grams of finished fat free potato chips. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 28E:approximately 2000 grams of the pre-treated dehydrated potato pieces were further processed in a fixed tray dryer (national dryer machinery company, Philadelphia, PA) by stacking the potato pieces into layers 3/4 inches thick and drying at 148 ℃/300 ° F for 16 minutes. The test yielded about 810 grams of fat free potato chips. The chips were evaluated by trained sensory professionals and were noted to have a bright gold color, excellent chip taste, and a crisp texture.

Example 29: impingement oven for initial drying, followed by vibrating fluidized bed dryer for final drying Drying a typical fat-free potato chip:scrap potatoes of the Snowden variety were cleaned and cut into approximately 1.60mm thick slices using a ditto dean vegetable slicer with a C3 knife edge. After slicing, the raw potato pieces were rinsed with 65 ° F running water for 3.95lbs. The washed pieces were then held in a solution containing 3000 grams of water (43 ℃/110 ° F), 30 grams of bacterial amylase (lotno. ali05175-04, american laboratories, Inc.), 30 grams of calcium chloride solution (32% calcium chloride solution, dsmfood specialties) for 3 minutes. The enzyme-treated potato slices were drained and then blanched with steam in an M-6Dixie vegetable blancher/cooler (Dixiecanning company, AthensGeorgia,30603) for 40 seconds. The blanched potato slices were placed directly on the belt of a 176C/350F impingement oven and dried for 5 minutes to reduce the moisture content to 36%, then the slices were stacked into a 2 inch thick bed and then placed in a test mode vibratory fluidized bed processor (CarrierVibratin) with drilled holes type trays (Drawledthethypeplate)geeequipment, inc., Louisville, KY40213), and dried/cooked at 160/320 ° F for 2 minutes. The process yielded approximately 1 pound of fat free potato chips, which were cooled and packaged. The chips were evaluated by trained sensory professionals and were noted to have good cooked potato taste, gold color and crispy texture.

Example 30: steam blanching followed by vibratory fluidized bed dryer for completeness of fat free sweet potato slices And (3) drying:common varieties of sweet potatoes were washed, peeled and cut into approximately 1.80mm thick slices using a Dittodean vegetable slicer with a C3 knife edge. After slicing, the raw sweet potato slices were rinsed under 65 ° F live water for 15 seconds at 3.0lbs. The washed pieces were then drained and blanched with steam in an M-6Dixie vegetable blancher/cooler (DixieCanning company, AthensGeorgia,30603) for 50 seconds. The blanched sweet potato slices were rinsed for 3 minutes with a cold water spray, drained, and then stored overnight in plastic bags in a freezer. The blanched sweet potato slices were stacked into a 2 inch thick bed and then placed in a pilot model vibratory fluidized bed processor (carrier vision equipment, inc., Louisville, KY40213) with perforated trays and dried/cooked at 176C/350F for 4 minutes. The temperature of the processor was reduced to 160/320F and the product was cooked for an additional 2 minutes before the temperature of the processor was reduced to 148/300F for 2 minutes of final drying/cooking. The continuous temperature reduction allows control of the drying process, keeping the product temperature below 148 ℃/300 ° F at the final drying stage, when evaporative cooling is not being performed to prevent browning of the product and to control the charring of the natural sugars in the product. This controlled process yielded approximately 0.75 fat free sweet potato chips, which were cooled and packaged. The sweet potato chips were evaluated by trained sensory professionals and were noted to have a good sweet, bright orange and crispy texture.

The above process is repeated several times with sweet potatoes treated with calcium chloride, amylase and a combination of the two to obtain a product with good color, texture and taste.

In addition, pears, apples, squash and various carrots, including yellow carrots, orange carrots, white carrots and purple carrots, can be processed in a similar process as described above to give superior products with good taste, color and texture.

Example 31: steam blanching followed by vibratory fluidized bed dryer for completeness of fat free potato sticks And (3) drying:common brown potatoes (CommonRussetpotatoes) were cleaned, peeled and cut to approximately 2.0mm using a Dittodean vegetable slicer with AS-4 knife edge²And filaments or rods (juiliennesleicerosticks) having an average length of 8 cm. After cutting, the raw potato sticks were rinsed under 65 ° F running water for 15 seconds for 2.80lbs. The washed potato sticks were then drained and held in a solution containing 3000 grams of water (43 ℃ C./110 ℃ F.), 30 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 30 grams of calcium chloride solution (32% calcium chloride solution, manufactured by DSMFoodspecialties) for 3 minutes. The enzyme-treated potato sticks were drained and blanched with steam in an M-6Dixie vegetable blancher/cooler (DixieCanning company, AthensGeorgia,30603) for 55 seconds. The blanched potato sticks were rinsed for 3 minutes with a cold water spray, drained, and then soaked in a solution containing 1000 grams of water, 75 grams of tomato juice, 10 grams of lemon juice, 10 grams of carrot juice plus 10 grams of salt in a pre-cooler and held overnight. The next day the soaked potato sticks were drained and then stacked in a 2 inch thick bed in a pilot model vibrating fluid bed processor with perforated disks (carriervibrancing equipment, inc., Louisville, KY40213) and dried/cooked for 6 minutes at 160 ℃/320 ° F. The temperature of the processor was reduced to 148/300F and the product was cooked for an additional 2 minutes before the temperature of the processor was reduced to 140/285F for 2 minutes of final drying/cooking. The continuous temperature reduction allows control of the drying process, keeping the product temperature below 148 ℃/300 ° F at the final drying stage, when evaporative cooling is not being performed to prevent browning of the product and to control the charring of the natural sugars in the product. This controlled process yielded approximately 0.60 fat free potato sticks which were cooled and packaged. The resulting product was bright gold, had a slightly salty butterpotato taste, and had an excellent crispy texture.

Example 32: using a vibrating fluid bed dryer on fat-free corn meal disks (tortillacichips), and (3) carrying out final cooking:commercially available 6-inch diameter white tortillas were purchased at local food stores and each tortilla was cut into 8 wedges (wedges) or 8 triangles (triangles). Approximately 500 grams of tortilla chips were held in a solution containing 3000 grams of water (43 ℃ C./110 ℃ F.), 30 grams of bacterial amylase (LotNo. ALI05175-04, American laboratories, Inc.), 30 grams of calcium chloride solution (32% calcium chloride solution, manufactured by DSMFoodspecialties) for 3 minutes. The enzyme-treated tortilla chips were drained and stacked into a bed of 11/2 inches thick, then placed in a pilot-mode vibratory fluidized bed processor with perforated trays (carrier vision equipment, inc., Louisville, KY40213), and dried/cooked at 160 ℃/320 ° F for 7 minutes. The process yields about 200 grams of tortilla chips, which are cooled and packaged. Tortilla chips were evaluated by trained sensory professionals and were shown to have a good cooked tortilla taste, light gold color, smooth appearance, and a crispy texture. The samples processed with the procedure of the present invention were more refreshing in texture and exhibited more crunchy and crunchy (crunch) and crunchy texture than the products processed with a similar process but without the enzyme treatment. Samples not treated with enzyme remained harder and less brittle in water for 3 minutes than those made by the process of the present invention.

Example 33: and (5) testing the crispness.Vegetable snack chips are popular for their crunchiness and crunchy feel, which are typical characteristics of traditional fried chips. Crispness and crunchiness can be quantified by an instrument that records the force and hardness required to break the chip before breaking. The ratio of increase in the resistance to increased curvature or deformation is young's modulus (also called elastic modulus). Vickers and Christensen (Vickers, Z.M. and Christensen, CM.1980.relationship shift between young and red sugar and sugar, and the like) found that the Young's modulus and the food crispness are related in instrumental measurementsAnd max. These authors show that it is advantageous to record the sound of a broken chip, as they found that crispness correlates very well with loudness at break. Vickers (Vickers, Z.M.1983.Pleasantnessof food sources Journarof food science48: 783. 786.) observed and emphasized the importance of snack food sounds: the pleasantness of the food sound is extremely related to the "crunchiness" and "crunchy feeling" of the description.

Thus, in order to feel crunchy and creaky, snack foods need to have a suitable hardness, (as reflected in young's modulus) and emit at least a certain level of sound upon breakage. At the same time, the snack food does not require a force sufficient to cause mouth pain or injury. To evaluate crispness, samples were broken on a ta.xtplus texture analyzer (TextureAnalyzer) (stabilized microsystems, Godalming, u.k.) equipped with a TA-101 chip rigger (chiprie) and a 5kg load cell (loadcell). The TA-101 rigging has a tube of diameter 2cm by height 2cm, which supports a chip (chip) in a horizontal position. A 5mm ball was delivered at 1 mm/sec until 5g of resistance (resistance) was felt, then continued for 30mm and the resistance as the chip flexed and broke was recorded. The sound produced at break is recorded using a stable microsystems audio envelope detector (stablemicrosystems audioenveloppe detector).

To demonstrate the crispness/crunchiness of various snack foods, representative samples were analyzed to measure the force and sound levels required to rupture the chips. Analytical method consisting of testing the chip samples listed in Table 3, samples designated A through M, where samples A, B, C, D, L and M were made according to the invention in examples 28, 24, 25, 26, 27 and 5, respectively, and the remaining samples E, F, G, H, I, J and K were purchased at a food store local to Lincoln, Nebraska. Representative discs were selected from each sample, processed and analyzed in a consistent manner to obtain the data in tables 3, 4, 5 and 6.

From about 25 samples, 9 pieces were selected for testing. More uniform sheets were selected for measurement because the sheets and the thickness and blistering (blistering) were different. The 9 selected pieces were broken and the force required to break each piece was measured as the probe (moved towards the piece at a uniform speed of 1 mm/sec) broken each piece. An exponential software (Exponentsoftware) was used to generate a plot of force (newtons) vs distance (mm) and determine (1) the initial slope, which is the young's modulus discussed above, (2) the peak value of force required for sheet breakage, and (3) the peak value of sound when the sheet was broken. The mean, standard deviation and coefficient of variation were calculated using Excel spreadsheet software. Samples A, B, C, D, L and M were tasted and found to have good crunchiness and creaky feel before the target test, while samples E-K were measured within the shelf life noted for the original package.

The measurement for each force generates a plot of the distance (mm) traveled by the probe in terms of force (N) vs. Each of the plots depicts the increase in resistance to an applied force as the chip bends under the pressure applied by the probe before the chip breaks. The probe was moved at a constant rate of 1 mm/sec towards the chip. In each case, the increase in tolerance to the applied force suddenly decreased as the chip broke. In most cases, the flakes break and break in a series of breaks. However, the first break was used to measure the peak force required to break the chip. The peaks produced under this method characterize the texture of the chip, i.e., how resistant the chip is to bending before breaking, how bending before breaking, and the distance and force involved in breaking it. These amounts "record" the fracture properties as well as their crunchiness and crunchiness. The sudden loss of tolerance (after the peak of force) was accompanied by a recording of the sound of the chip vibration due to the sudden loss of deformation and stress. As mentioned above, a typical plot includes 2-4 peaks of the main force, and corresponds to several peaks of sound. The slope before each peak is the aforementioned young's modulus, which is a good evaluation parameter for creaky feeling. Since the test specimens were all very brittle, pieces with an average Young's modulus of greater than 3.5N/mm were considered very brittle. Snack foods having a Young's modulus of about 3.5N/mm, more preferably about 4.0N/mm, even more preferably 4.5N/mm, and even more preferably about 5.0N/mm are preferably produced according to the present invention. Preferably, the snack food breaks under a force of about 12N, more preferably about 10N, and more preferably about 9N applied to the sheet, such that the snack food has a crunchy feel, but the force required for the snack food is such that the product is not damaged when consumed.

The test results are shown in tables 3 to 6. The resulting sound levels listed in table 5 have no units because they are relative values.

TABLE 3 average values of maximum force, sound and Young's modulus in the data shown in tables 4 to 6

TABLE 4 maximum power (N)

	Test 1	Test 2	Test 3	Test 4	Test 5	Test 6	Test 7	Testing8	Test 9	Average	% coefficient of variation
												A	1.20	3.77	1.62	2.84	7.39	3.45	5.41	5.29	4.53	3.95	50%
B	4.05	5.65	3.64	5.09	2.19	2.68	5.89	4.64	7.38	4.58	36%
												C	7.47	6.78	2.99	8.60	8.55	4.63	5.51	8.04	7.30	6.65	29%
D	8.14	8.05	7.11	7.76	4.86	6.38	10.37	7.63	3.79	7.12	27%
												E	2.29	5.03	2.54	2.35	3.92	5.96	1.52	2.51	2.60	3.19	46%
F	2.77	1.74	2.19	2.54	1.97	2.80	4.32	2.31	2.71	2.59	29%
												G	4.65	4.30	4.88	3.56	6.44	4.21	4.51	5.81	7.89	5.14	26%
H	9.69	7.43	8.67	9.85	5.87	8.16	4.41	6.64	6.37	7.45	24%
												I	5.56	3.73	6.55	4.19	4.50	8.97	8.72	3.56	5.03	5.65	36%
J	2.06	7.56	6.94	11.94	6.39	2.95	8.12	4.00	6.16	6.23	48%
												K	11.68	9.37	10.75	10.88	7.20	5.97	11.10	8.75	5.87	9.06	25%
L	8.88	8.88	11.22	7.25	10.10	6.35	7.59	6.53	12.13	8.77	23%
												M	2.73	2.02	3.15	4.81	3.64	3.93	5.74	3.30	3.28	3.62	31%

TABLE 5 Sound

	Test 1	Test 2	Test 3	Test 4	Test 5	Test 6	Test 7	Test 8	Test 9	Average	% coefficient of variation
												A	1587	4402	2229	2140	6902	4266	7714	4349	3287	4097	51%
B	4427	3933	4247	4741	1728	3965	5592	2412	2656	3745	33%
												C	6618	7134	5599	7986	8598	5215	2246	5510	4813	5969	32%
D	5211	4778	7179	4753	2436	4804	4158	2361	1577	4140	42%
												E	1293	915	634	583	1198	1432	875	633	782	927	34%
F	389	661	634	1264	1299	1284	2544	1202	1008	1143	55%
												G	2269	1030	880	1462	2242	810	1355	1825	2674	1616	42%
H	1549	1877	819	1132	1839	1571	1181	1041	2020	1448	29%
												1	5558	4560	8370	1698	5257	7193	4318	3479	4537	4997	39%
J	1538	2237	4534	5610	1539	4445	6575	4060	4441	3887	45%
												K	506	1409	1175	1626	1136	935	630	938	1107	1051	33%
L	7600	6965	1175	7909	5915	4004	8198	6015	4132	6944	34%
												M	2806	3791	2668	3527	3171	5403	6226	2593	3638	3758	33%

TABLE 6 Young's modulus (N/mm)

	Test 1	Test 2	Test 3	Test 4	Test 5	Test 6	Test 7	Test 8	Test 9	Average	% coefficient of variation
												A	11.3	18.0	22.2	5.8	6.5	16.0	11.8	15.6	16.5	13.7	39%
B	11.3	8.5	9.6	4.5	5.0	10.6	6.9	8.0	12.4	8.5	32%
												C	19.1	18.4	8.9	28.1	18.6	22.7	17.7	27.2	16.5	19.7	30%
D	14.3	16.0	18.3	16.6	18.1	7.1	22.0	14.0	14.8	15.7	26%
												E	4.9	16.4	5.0	4.1	6.3	5.5	1.1	3.6	4.1	5.7	75%
F	4.8	2.1	5.5	3.1	3.7	6.2	1.0	6.9	4.5	4.2	46%
												G	11.3	13.9	9.0	6.8	21.2	3.1	6.5	8.3	17.0	10.8	53%
H	25.4	19.8	15.8	12.8	13.5	11.9	8.7	13.6	6.6	14.2	40%

I	8.2	2.2	15.0	3.8	21.0	14.4	15.9	3.4	5.8	9.9	68%
												J	3.8	11.9	8.8	13.4	3.6	10.2	23.6	7.2	9.0	10.2	59%
K	21.9	4.7	27.6	22.1	30.2	12.7	24.1	19.2	2.2	18.3	53%
												L	25.6	1.0	22.0	9.8	26.7	23.9	17.4	16.6	26.8	18.9	46%
M	7.0	6.0	5.6	11.2	5.2	7.8	10.2	6.6	6.4	7.3	28%

While the invention has been described with specific embodiments, many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore intended to embrace all such alternatives, modifications and variations that fall within the spirit and scope of the appended claims.

Claims (23)

1. A method of making a snack food comprising:

(a) providing a plurality of food cuts or food shapes prepared from vegetables and fruits;

(b) contacting the food item with a solution comprising an enzyme selected from the group consisting of amylase, amyloglucosidase, and combinations thereof, and one or more cations, such that the solution covers the surface of the food item for 0.5 to 5 minutes;

(c) then blanching the piece of food for a time sufficient to inactivate enzymes on the surface of the piece of food, wherein the piece of food has an initial moisture content after the blanching step; and

(d) reducing the initial moisture content of the food item to an intermediate moisture content of 10-80 wt% by cooking the food item in one or more dryers or ovens at one or more first temperatures of 275 ° F-375 ° F for a first period of time of 0.5-40 minutes, wherein the food item is not fried in oil;

(e) obtaining a snack food having a final moisture content of 0.2-10 wt% by cooking a food piece having an intermediate moisture content in one or more dryers or ovens at a second temperature of 275 ° F-325 ° F for a second period of time of 4-12 minutes, wherein the food piece is not fried in oil and the second temperature is lower than the first temperature; and

(f) optionally, coating a predetermined amount of digestible and/or synthetic oil on the food item and/or snack food to obtain a snack food having a fat content of less than 35wt% and the snack food produced therefrom exhibits one or more properties of a snack food produced by frying the food item in oil, wherein the properties are selected from the group consisting of: texture, fragrance, crispness, creaky feel, color and appearance.

2. The method of claim 1 wherein in step (d) the food item is cooked at 275 ° F to 350 ° F.

3. The method of claim 2 wherein the food item is cooked in a dryer or oven at an air speed of 200 to 15,000 feet per minute.

4. The method of claim 1, wherein in step (d) the food item is cooked at a first temperature for a first period of time to reduce the initial moisture content to 50-70 wt% of the initial moisture content.

5. The method of claim 1, wherein in step (e) the food item is cooked at a temperature of 275 ° F to 300 ° F for 6 to 12 minutes.

6. The method of claim 1, wherein the food item is cooled and stored at room temperature, refrigerated, or frozen after cooking the food item at a first temperature for a first period of time and before cooking at a second temperature for a second period of time.

7. The method of claim 1, wherein the one or more cations are selected from the group consisting of: sodium salts, calcium salts, magnesium salts, potassium salts, aluminum compounds, and nitrogen compounds.

8. The method of claim 1, wherein the one or more cations are selected from the group consisting of: NaCl, KCl, MgCl₂And CaCl₂。

9. The method of claim 8, wherein the concentration of the one or more cations in the solution is 0.1 to 5 wt%.

10. The method according to claim 1, wherein the concentration of the enzyme in the solution is 0.1 to 5 wt%.

11. The method according to claim 10, wherein the food item is exposed to the solution for 0.5 to 5 minutes.

12. The method of claim 1, wherein the food items are cooked in at least one rotary dryer or oven, at least one fluid bed dryer or oven, or at least one microwave dryer or oven.

13. The method of claim 1, wherein the food is selected from the group consisting of beet, zucchini, carrot, eggplant, apple, pear, banana, turnip cabbage, plantain, taro, okra, onion, parsnip, yam, sweet potato, yucca, and potato.

14. The method of claim 1, wherein the food cut pieces are slices, strips, or bars.

15. The method of claim 1, wherein the blanching comprises treating the food cut pieces in an aqueous solution at 60-120 ℃ for 15 seconds to 10 minutes.

16. The method of claim 1, wherein the food item is immersed in cold water after the blanching step.

17. The method of claim 1, further comprising applying a predetermined amount of digestible and/or synthetic oil to the food item.

18. The method of claim 17, wherein the blanching step is performed in a blanching medium comprising a digestible and/or synthetic oil.

19. A method according to claim 17, comprising applying a predetermined amount of digestible and/or synthetic oil to the food item prior to cooking the food item.

20. The method of claim 19, wherein step (d) is performed in a microwave oven.

21. The method of claim 1 comprising coating a predetermined amount of digestible and/or synthetic fat or oil on the snack food.

22. The method of claim 1, wherein in step (d) or (e) the food pieces are fluidized in air by the at least one dryer or oven.

23. The method of claim 1 wherein the snack food has a fat content of less than 0.5 wt%.