RU2375934C2 - Formed product production method, device for production of formed product and formed product - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention concerns food-processing industry and can be used at manufacture formed products out of bread raw material. Method provides for preliminary processing, mixing and moisturising of mixture components. After that mixture is formed, cut, dried, conditioned, fried and semiproduct is cooled. Mixing and moisturising of mixture components is performed at water temperature 45-50°C till mixture with dry substances content 62-65 wt % is produced. Forming is performed by mixture thermal and mechanical processing during 15-20 minutes at 75-85°C and at pressure 8-13 MPa. Drying is performed at 75-85°C during 40-45 minutes before semiproduct is cut. Device contains at least one device for preliminary mixture components processing, mixer, turn-screw extruder with possibility of thermal and mechanical processing temperature parametres self regulation, blower for drying of wet semiproduct, cutting device, moisturiser, frying device and cooling device.

EFFECT: invention allows to decrease formed products cost.

6 cl, 1 dwg, 1 ex

Description

The invention relates to the food industry, in particular to molded products from bread raw materials - rye, and in particular to a method for the production of a molded product and to an installation intended for the production of a molded product.

Changing the lifestyle and, accordingly, the diet of modern man involves the widespread use of instant products. At the same time, an increase in the number of consumers for whom the determining factor in choosing food products is not only their taste, but also nutritional value, entails the need to switch to health food products. Given these two trends, the demand for instant foods and / or ready-made breakfasts and / or ready-made breakfasts and / or snacks with a high content of protein and dietary fiber has grown particularly significantly.

The basis for the production of instant foods and / or ready-made breakfasts and / or snacks is the cooking process of the raw materials, which ensures that the starch present in the raw material is converted to a gelled state, which makes the product quickly digestible while improving its taste and other organoleptic properties. With the use of extrusion in the production of molded products, virtually unlimited reserves appeared in the creation and improvement of product formulations, including basic product formulations, which are semi-finished products (extrudates) of a porous, fibrous or homogeneous structure that have not passed the cooking stage. Moreover, the quality of the finished product depends not only on the correct selection of the components of the recipe mixture, but is also closely related to the parameters of the process and the characteristics of the equipment used.

Known shaped snacks (company “Gebruder Buhler AY Maschinefabrik", Switzerland), which are pre-gelatinized products of various shapes with a final moisture content of 9-10% [1]. The raw materials for the production of such snacks are gelatinized, partially gelatinized or non-gelatinized products from grain, potatoes and starch. The size of the granules of the feedstock is less than 200 microns. The technological scheme of production includes the following main stages, which are carried out using appropriate equipment: mixing (in a mixing plant), gelatinization (in a cooking extruder under the influence of heat, moisture and pressure), extrusion (molding); cutting; vibration drying, preliminary and final drying; cooling, packaging. Frying in oil and, if necessary, aromatizing are carried out immediately before eating. The described snacks, therefore, cannot be used as a “ready breakfast”, as require additional cooking. In addition, the technology for their manufacture requires the use of additional special equipment for preliminary gelatinization of starchy raw materials before extrusion, and the extruder used has a sufficiently large volume and requires constant monitoring and maintenance of the specified extrusion parameters.

Also known are snacks from grain raw materials and potatoes of various shapes and sizes (chips, sticks, straws, circles, etc.) of the company “Veke Danish, Ltd”, Denmark, which are made on the basis of dry mashed potatoes, starch, flour, etc. [2]. The line for their production has a capacity of 250 kg / h for the finished product and includes the following basic equipment for the implementation of various stages of product production: mixer in the form of a batch mixer; a device for molding in the form of an extruder — a gelatinizer and an extruder — a continuous molding machine; cutting device; a vibration dryer for drying and a continuous dryer for final drying, a fryer in the form of a continuous apparatus (productivity 200-300 kg / h); dragee device. The described production method and the corresponding production line make it possible to obtain a molded product that is completely ready to eat, however, they do not provide for food snacks having a significantly different taste due to the use of various additives of plant origin at the stage of mixing the raw materials. In addition, the disadvantages described above with respect to the process, equipment used and the use of breadcrumbs, rye malt and extruded rye flour as raw materials remain unresolved.

The above-described methods for the production of molded products, as well as installations for implementing these methods also have another common drawback - the increased complexity of the design of the extruder used as a molding device, and its high cost.

The closest known to the claimed installation and method for the production of the molded product is the installation for the production of molded fried products based on dried mashed potatoes and starch, as well as the method that is implemented using this installation [3]. The installation includes such basic elements as a mixing chamber with a mixing device, a cylinder with a screw and an output extrusion head, a cutting mechanism, an exposure conveyor, a frying tank, and a cooling device.

In the described installation, the extruder used requires constant monitoring and regulation of the main parameters of the extrusion process (temperature, pressure, etc.). In addition, at the exit of the molding matrices mounted on the extruder, a sufficiently high humidity of the extrudate can lead to sticking of portioned pieces in the subsequent cutting.

Closest to the claimed molded product according to the composition of the components is a molded potato product containing dried mashed potatoes, starch, flavorings based on plant materials, salt, water [4]. Potato starch is used as starch, and dried onions, garlic, and beets are used as flavoring additives. However, the possible formulations of the described potato product do not imply the use of plant materials not only as flavoring additives, but also as one of the types of basic raw materials. This limits the possibility of creating potato products of new formulations enriched with useful substances contained in non-potato plant materials.

Thus, the analysis of the prior art in this field shows that despite the already existing variety of finished molded products, as well as the intensive development of the production of finished products in the form of a fried molded product, the issue of how to develop balanced formulations of useful substances products, as well as improving production methods and equipment for their production.

Based on the foregoing, the invention is based on the task of creating high-quality molded products of a wide taste range, including ready-to-eat, with valuable nutritional properties, as well as a method and installation for their production. Among the main technical results provided by the present invention, the following can be distinguished: expanding the range of finished molded products, including using non-traditional vegetable raw materials for this area, increasing the nutritional value of products, improving their organoleptic properties, reducing the cost of molded products through the use of baking waste production - breadcrumbs, reducing the cost of operating technological equipment.

The problem is solved in the inventive method of manufacturing a molded product, including pre-processing, mixing and moistening the components of the mixture, obtaining a wet semi-finished product by molding a mixture of components, cutting, drying, conditioning and frying the semi-finished product, cooling and, if necessary, panning the finished product. In this case, mixing and moistening the components of the mixture is carried out at a water temperature of 45-50 ° C until a mixture with a solids content of at least 65 wt.% Is formed, molding is carried out by thermomechanical processing of the mixture of components for 15-20 s at a temperature of 75-85 ° C and a pressure of 8-13 MPa, before cutting the semi-finished product, the wet semi-finished product is dried at a temperature of 20-25 ° C for 1-3 minutes.

Pre-treatment of the components of the mixture is preferably carried out by grinding and sieving or by preliminary thermomechanical processing, grinding and sieving of at least one component of the mixture.

Practice shows that mixing is not a simple mechanical process; this process contributes to the intensification of thermal and mechanical processes due to an increase in the interaction surface between product particles. The quality of the mixture - porosity, elasticity, humidity, taste, aroma, color is influenced not only by the quality and quantity of the raw material to be laid, but also by the preparation technology: the intensity and duration of mixing, the temperature inside the mass. One of the most important factors in obtaining a mixture is the moisture content. The higher the humidity of the mixture, the faster, more evenly moistened are the particles of breadcrumbs, rye malt, extrusion rye flour and other components. However, there are humidity limits above which extruded products poorly retain their shape and uniform consistency and swell and crumble during subsequent heat treatment.

A study of the influence of the duration of mixing on the structural and mechanical properties of the mixture revealed that with an increase in the duration of the mixing process to a certain limit, the density of the dough decreases and its viscosity increases. As the density decreases, its microstructure changes - the content of air bubbles increases and, accordingly, the porosity of the finished fried molded product. Three types of batches are known and traditionally used, depending on the temperature of the water:

- warm kneading on water with a temperature of 55-65 ° C,

- hot kneading on water with a temperature of 75-85 ° C,

- cold kneading on water with a temperature of 20-25 ° C.

The most common is warm kneading. However, the studies of the authors showed that the optimal temperature of the process of mixing the components is between the temperature limits of cold and warm kneading and is 45-50 ° C, and the optimum dry matter content in the wetted mixture of components ready for extrusion is from 62 to 65 wt.%. At the indicated values of kneading temperature and humidity of the mixture, the duration of mixing is selected in the range from 5 to 15 minutes.

The basis for obtaining extrusion products of a porous, uniform structure is the phenomenon of deformation of dispersed particles of a heterophase melt of biopolymers and its subsequent formation. Therefore, the choice of the type and parameters of the subsequent thermomechanical treatment, in particular extrusion, of a moistened mixture of components also has an equally important influence on the key functional properties of the finished molded product.

The thermoplastic extrusion process is usually carried out at a temperature of 120-150 ° C. Despite the high thermal load, due to the short duration of its impact, the destruction of the nutrients of the product does not occur. Nevertheless, the proposed significant reduction in thermal load to 78-85 ° C allows you to save nutrients in an even larger volume and at the same time not only does not reduce, but even improves the organoleptic properties of the finished product.

At the exit of the extruder, the molded semi-finished product, as a rule, has a sufficiently high humidity, which can lead to adhesion or deformation of the molded semi-finished product during cutting and subsequent transportation to drying. The proposed original inclusion of an additional stage of drying the molded moist prefabricated product before cutting allowed to significantly simplify the cutting process and significantly improve the appearance of the finished product. During the drying process, surface moisture is removed from the formed moist semi-finished product by blowing with air, the temperature of which is selected in the range of 20-25 ° C. The duration of the drying stage is set within 1-3 minutes.

Thus, the proposed method provides a high quality product both in terms of organoleptic characteristics and nutritional value.

The problem is also solved in the proposed installation for the production of the molded product, which includes a device for pre-processing the components of the mixture, a mixer, a device for molding, a cutting device, a moisture leveling device, a frying device, a cooling device and, if necessary, a coating device, and as a device for molding includes a twin-screw extruder, made with the possibility of self-regulation of temperature parameters for thermomechanical processing, and additional However, the device includes a blower for drying the wet semi-finished product, located behind the extruder.

As noted above, one of the most important stages of the production of the molded product is the stage of thermomechanical processing, in particular thermoplastic extrusion, a moistened mixture of components, on which the basic properties of the finished product are laid. In turn, the design features of the extruder working bodies are influenced by the extrusion process.

The proposed installation for the production of molded product as a molding device, as mentioned above, includes a twin screw extruder. This extruder was specifically designed to provide the claimed thermoplastic extrusion parameters of wetted materials in the production of gelled extruded semi-finished products.

The extruder has lower specific indicators of the consumed resources (energy, water, etc.) and small dimensions in comparison with the known ones. For its operation in a steady-state operating mode to maintain the above temperature parameters of the extrusion process, water cooling and additional heating are provided. Thus, the original design of the extruder provides the ability to control the temperature during the extrusion process. The extruder design also allows for quick change of molding matrices to obtain a semi-finished product of various shapes.

Directly behind the extruder and in front of the cutting device in the proposed device is placed blower, providing air circulation. The removal of surface moisture from the semi-finished product allows avoiding the sticking of the semi-finished product at subsequent stages, primarily during the cutting process, and to obtain a product that is uniform in shape and size.

The problem is finally solved in the inventive molded product containing basic bread raw materials, malt, at least one additive selected from additives based on raw materials from rye flour and flavoring additives based on plant materials, salt and water. Moreover, in the product, at least one of the listed components is subjected to preliminary thermochemical processing by extrusion in the following ratio of components, wt.%:

Rye bread crumbs 80-85 Rye fermented malt 0.5-2 Extruded rye flour 3-5 Flavoring Additive 1-3 Salt 0.5-1 Water 5-10

In addition, as an additive based on plant materials, the product may contain an additive selected from the group: dried onions, dried garlic, dried beets, dried carrots, dried herbs, bell peppers, hot peppers, cinnamon. Moreover, the list of possible additives based on plant materials is not limited to the above additives and may include other aromatic plant materials.

The inventive molded product relates to porous products obtained by molding a mixture of components by thermomechanical processing, in particular by thermoplastic extrusion, and can be used as breakfast cereals, snacks, etc.

To assess the quality of products such as breakfast cereals and snacks, characteristics such as stiffness, brittleness, porosity, pore wall thickness, size distribution, extrudate expansion index, bulk density and solubility, smell, taste and many other parameters are used. When evaluating the consumer properties of products, the number of parameters is limited, as a rule, to five main ones: rigidity, fragility, taste, expansion index and bulk density.

Ensuring the high quality of products both in terms of individual parameters and in their totality depends both on the method of production of the product and on the correct choice of components of the recipe mixtures.

For example, studies of the expansion index of the extrudates of a porous macrostructure obtained on the basis of mixtures of components of various structures show that, in addition to explosive evaporation of moisture, the composition of the extrudable mixture also has a significant effect on its value. Based on experimental data, those skilled in the art have found that increasing the percentage of extruded rye flour in the extrudable mixture increases the density of the extrudate. However, the proposed composition of the product due to the original selection of components and the use of the production method proposed in the framework of the present invention and the corresponding installation allows to obtain a highly porous product with organoleptic and physico-chemical parameters that are highly appreciated.

Based on the proposed composition, an almost unlimited number of molded products can be obtained that are diverse in taste and nutritional value. So, as sources for obtaining components based on raw materials from legumes, peas, soy, oats, wheat, corn, barley and other legumes can be used.

Significantly improves the quality of the finished product using components that have undergone preliminary thermomechanical processing, in particular by thermoplastic extrusion. Pre-extrusion can be subjected to one or several components: the main rye raw materials, fermented rye malt. This allows you to improve the taste of the finished product and its nutritional value.

The invention will be described below in more detail and explained with reference to graphic materials and examples. It should be noted that the above examples and graphic materials do not limit all possible forms of implementation of the invention and are intended only to illustrate the advantages and advantages of the claimed objects.

The drawing shows a simplified block diagram of one embodiment of the inventive installation for the production of a molded product using the proposed method.

The installation includes the following main blocks: a device 1 for the production of dry mashed potatoes, including an extruder (schematically shown as a single block), a crusher 2, a sieve 3, a dispenser 4, a mixer 5, an extruder 6 with molding dies 7, a blowing device 8, a cutting device 9, a distributor 10, a dryer 11, a conveyor 12, a feeder 13, a moisture equalizer 14, a roasting oven 15, a cooling device 16, a coating machine 17, a packaging machine 18.

With the exception of the extruder 6 of the original design, all other elements and blocks of the proposed installation, including an additional blower introduced into the installation, can be selected by specialists in this field from a number of traditionally used and, if necessary, upgraded accordingly taking into account the above parameters of the proposed method production of a molded product. The operating principles and design of these elements and blocks are also well known to those skilled in the art. In this regard, in detail the design and operation principles of each element or unit of the claimed installation in the framework of the present invention will not be described.

The proposed method of manufacturing a molded product using the proposed installation in the form of implementation depicted in the drawing is explained below in one of the possible examples.

Example 1

A rectangular shaped product is made, which includes: rye crumbs, rye malt, extruded rye flour, dried onions, salt, water.

Rye crumbs are crushed in a hammer mill 2 and sifted through a sieve 3 with a hole size of 0.5-0.6 mm.

Dry onions are crushed on a hammer mill 2 and sieved through a sieve with a hole size of 0.5-0.6 mm.

Rye malt, extruded rye flour, salt is sieved through a sieve 3 with a hole size of 0.5-0.6 mm.

Through the dispenser 4, all components of the recipe mixture are loaded into the mixer 5, mixed and then through the dispenser 4 serves water with a temperature of 50 ° C. Mixing of all components in the mixer 5 is carried out for 10 minutes to obtain a homogeneous friable mass, the solids content of which is 65%.

On the extruder 6, a molding matrix 7 is pre-installed with a 4 mm rectangular hole. The chamber is preheated to a temperature of 35-40 ° C.

The humidified mixture from the mixer 5 is fed into the extruder 6 through the loading window. The mixture moves in the chamber of the cylindrical body of the extruder 6 from the loading window to the molding head 7 as a result of the rotational movement of the screw. The mixture is subjected to thermochemical treatment in the body of the extruder 6 for 12 min at a pressure of 12 MPa and a temperature of 80 ° C. While maintaining the temperature in the extruder 6 is carried out by creating a pressure controlled at the inlet of the finished product.

At the exit of the molding matrix 7 of the extruder 6, a molded rectangular-shaped tape 4 mm wide is obtained.

To remove surface moisture from the molded tape, it is transferred to a blowing device 8, where it is held for 2 minutes at a temperature of circulating air of 20-25 ° C until the tape is not sticky.

At the exit of the blowing device 8, a cutting device 9 is placed, by means of which a semi-finished product formed into a tape is cut into rectangles 25-30 mm long. The thickness of the plates is 0.6-0.7 mm.

The chopped rectangles by means of the spreader 10 are sent for drying to a belt type dryer 11. Drying is carried out for 60 minutes at a temperature of 55 ° C. The moisture content in the product at the outlet of the dryer 11 does not exceed 12 wt.%.

By means of the conveyor 12 and the feeder 13, the dried molded semi-finished product is sent to a moisture equalizer 14, where it is subjected to conditioning (moisture equalization) to improve the structure. The second feeder 13 is designed to move the semi-finished product and load into the frying oven 15. The product is fried at 180 ° C for 10 s in deodorized vegetable oil. The oil level in the fryer 15 is kept constant by adding fresh oil.

From the frying oven 15, the product is sent to a conveyor-type cooling device 16 for cooling and inspection in order to remove excess vegetable oil and substandard plates (undercooked, overcooked, fines, etc.), as well as to give the product a crispy consistency. Cooling is carried out to a temperature of 30 ° C.

Cooled to a temperature of 30 ° C, the product is sent to a coating machine 17, where the flavoring additive is applied to the plates at the rate of 30 g per 1 kg of product.

Finished rectangles of the molded product are sealed in 50 g bags using a packaging machine 18.

A completely ready-to-eat product is obtained having high palatability and nutritional value.

The claimed invention is not limited to the above example and can be repeatedly reproduced in various modifications within the claimed essential features in the production of any capacity in the relevant field of technology.

Literature

1. Prospectus of the company “Gebruder Buhler AY Maschinenfabrik", Switzerland, 1984

2. Prospectus of the company “Beke Danish, Ltd”, Denmark, 1984

3. USSR copyright certificate No. 1311698, BI No. 19, 1987

4. N.M. Makhanov, A.M. Mazur, R. L. Kovganenko and others. Production of potato products // Handbook / VO Agropromizdat, 1987. 244 p.

Claims (6)

1. A method of manufacturing a molded product, including pre-processing, mixing and wetting the components of the mixture, obtaining a wet semi-finished product by forming a mixture of components, cutting, drying, conditioning and frying the semi-finished product, cooling and, if necessary, panning the finished product, characterized in that mixing and moistening the components of the mixture is carried out at a water temperature of 45-50 ° C until a mixture with a solids content of 62-65 wt.% is formed, the formation is carried out by thermomechanical second processing ingredients mixture for 15-20 seconds at a temperature of 75-85 ° C and a pressure of 8-13 MPa, before cutting the semifinished product is carried out predrying of wet semifinished at 75-85 ° C for 40-45 min. 2. The method according to claim 1, characterized in that the preliminary processing of the components of the mixture is carried out by grinding and sieving. 3. The method according to claim 1, characterized in that the preliminary processing of the components of the mixture is carried out by preliminary thermomechanical processing, grinding and sieving of at least one component. 4. Installation for the production of the molded product by the method according to claims 1 to 3, comprising at least one device for pretreating the components of the mixture, a mixer, a molding device, a cutting device, a moisture equalizer, a frying device, a cooling device and, if necessary, a coating device , characterized in that as a device for molding includes a twin-screw extruder made with the possibility of self-regulation of temperature parameters for thermomechanical processing and tionary comprises a wiper for drying a wet semi disposed behind the extruder. 5. The molded product obtained by the method according to claims 1 to 3, containing the main rye bread raw materials, at least one additive selected from additives based on raw materials from legumes and a flavoring additive based on plant materials, salt, water, characterized in that at least one of the components is subjected to preliminary thermomechanical processing by extrusion in the following ratio of components, wt.%:
main raw material - rye bread crumbs 80-85 extruded rye flour 3-5 rye fermented malt 0.5-2 flavoring 1-3 salt 0.5-1 water 5-10 6. The molded product according to claim 5, characterized in that it additionally contains flavoring agents in an amount of 1-3% by weight of the product.