U.S. patent application number 10/896208 was filed with the patent office on 2006-01-26 for method for making a rolled snack food product having a light crispy texture.
Invention is credited to Thomas George Crosby, Geoffrey Thomas Ley, V. N. Mohan Rao, Dianne Renee Ripberger.
Application Number | 20060019013 10/896208 |
Document ID | / |
Family ID | 35657503 |
Filed Date | 2006-01-26 |
United States Patent
Application |
20060019013 |
Kind Code |
A1 |
Crosby; Thomas George ; et
al. |
January 26, 2006 |
Method for making a rolled snack food product having a light crispy
texture
Abstract
A method for making a cooked rolled snack food from a starch
based dough. The starch based dough is admixed with a small average
particle size monoglyceride. The dough is then rolled and cooked in
hot oil. The fatty acid chain is disposed within the helical
amylose molecules in the starch-based dough and provides structural
support within the helix. This support helps control inward
expansion of the rolled dough snack during frying.
Inventors: |
Crosby; Thomas George;
(Frisco, TX) ; Ley; Geoffrey Thomas; (Dallas,
TX) ; Rao; V. N. Mohan; (Plano, TX) ;
Ripberger; Dianne Renee; (Plano, TX) |
Correspondence
Address: |
CARSTENS & CAHOON, LLP
P O BOX 802334
DALLAS
TX
75380
US
|
Family ID: |
35657503 |
Appl. No.: |
10/896208 |
Filed: |
July 21, 2004 |
Current U.S.
Class: |
426/549 |
Current CPC
Class: |
A23L 19/19 20160801;
A23L 7/122 20160801; A23L 7/13 20160801 |
Class at
Publication: |
426/549 |
International
Class: |
A21D 10/00 20060101
A21D010/00 |
Claims
1. A method for making cooked rolled snack pieces having a
monoglyceride, said method comprising the steps of: a. mixing a
starch-based material comprising amylose with monoglyceride and
water to form a starch based dough; b. forming said starch based
dough into a plurality of uncooked snack pieces; c. rolling said
uncooked snack pieces to make a plurality of rolled snack pieces,
wherein each rolled snack piece further comprises: an inner facing
surface; an outer facing surface; and d. cooking said rolled pieces
to make a plurality of cooked rolled snack pieces.
2. The method of claim 1 wherein said starch-based material at step
a) comprises corn masa.
3. The method of claim 1 wherein said amylose at step a) comprises
at least about 40% of said starch-based material by weight.
4. The method of claim 1 wherein said monoglyceride at step a)
comprises between about 0.15% and about 3% by weight of said cooked
rolled snack pieces.
5. The method of claim 1 wherein said starch-based material at step
a) comprises potato flakes.
6. The method of claim 1 wherein said starch-based material at step
a) comprises potato granules.
7. The method of claim 1 wherein said monoglyceride at step a)
comprises a powder having an average particle size less than about
150 microns.
8. The method of claim 1 wherein said monoglyceride at step a)
comprises a fatty acid chain having at least 8 carbons.
9. The method of claim 1 wherein said mixing at step a) forms a
lipid-carbohydrate complex.
10. The method of claim 1 wherein said forming at step b) comprises
sheeting and cutting said starch based dough.
11. The method of claim 1 wherein said forming at step b) comprises
extruding and cutting said starch based dough.
12. The method of claim 1 wherein said forming at step b) comprises
cutting said starch-based dough into a shape having at least 3
sides.
13. The method of claim 1 wherein said b) comprises cutting said
starch-based dough into a hexagonal shape.
14. The method of claim 1 wherein said snack chips said rolling at
step c) comprises between one and two full turns.
15. The method of claim 1 wherein said rolling at step c) at least
a portion of said inner facing surface and at least a portion of
said outer facing surface are adjacent and thereby forms an overlap
area.
16. The method of claim 14 wherein said outer facing surface and
said inner facing surface substantially mate together in said
overlap area.
17. The method of claim 1 wherein said rolling at step c) creates
an inner diameter of between about 0.125 inches and about 0.30
inches.
18. The method of claim 1 wherein said rolling at step c) creates
an outer diameter of between about 0.25 inches and about 0.50
inches.
19. The method of claim 1 wherein said cooking at step d) comprises
toasting.
20. The method of claim 1 wherein said cooking at step d) comprises
toasting followed by frying.
21. The method of claim 1 wherein said cooking at step d) comprises
frying.
22. The method of claim 1 wherein said uncooked snack chips are
fried in oil at between about 300.degree. F. and about 400.degree.
F.
23. The method of claim 1 wherein said cooked rolled snack pieces
after step d) further comprise: about 0.05% to about 3.0% by weight
monoglyceride; about 25% to about 34% by weight oil; about 0.8% to
about 2.0% by weight moisture; about 60% to about 80% by weight
starch-based component; and about 0% to about 8% by weight
seasoning.
24. A snack piece made by the method of claim 1.
25. A dough comprising: about 40% to about 50% corn masa; about 45%
to about 60% water; and less than about 3% of a monoglyceride.
26. The dough of claim 25 wherein said monoglyceride comprises a
powder having an average particle size of less than about 150
microns.
27. A method for making cooked rolled snack pieces, said method
comprising the steps of: a. mixing a starch-based material
comprising amylose with a particulate triglyceride and a liquid
monoglyceride and water to form a starch based dough; b. forming
said starch based dough into a plurality of uncooked snack pieces;
c. rolling said uncooked snack pieces to make a plurality of rolled
snack pieces, wherein each rolled snack piece further comprises: an
inner facing surface; an outer facing surface; and d. cooking said
rolled pieces to make a plurality of cooked rolled snack
pieces.
28. The method of claim 1 wherein said starch-based material at
step a) comprises corn masa.
29. The method of claim 1 wherein said amylose at step a) comprises
at least about 40% of said starch-based material by weight.
30. The method of claim 1 wherein said liquid monoglyceride and
said triglyceride at step a) comprises between about 0.15% and
about 3% by weight of said cooked rolled snack pieces.
31. The method of claim 1 wherein said starch-based material at
step a) comprises potato flakes.
32. The method of claim 27 wherein said starch-based material at
step a) comprises potato granules.
33. The method of claim 27 wherein said particulate triglyceride at
step a) comprises a powder having an average particle size less
than about 150 microns.
34. The method of claim 27 wherein said monoglyceride at step a)
comprises a fatty acid chain having at least 8 carbons.
35. The method of claim 27 wherein said mixing at step a) forms a
lipid-carbohydrate complex.
36. The method of claim 27 wherein said forming at step b)
comprises sheeting and cutting said starch based dough.
37. The method of claim 27 wherein said forming at step b)
comprises extruding and cutting said starch based dough.
38. The method of claim 27 wherein said forming at step b)
comprises cutting said starch-based dough into a shape having at
least 3 sides.
39. The method of claim 27 wherein said b) comprises cutting said
starch-based dough into a hexagonal shape.
40. The method of claim 27 wherein said snack chips said rolling at
step c) comprises between one and two full turns.
41. The method of claim 27 wherein said rolling at step c) at least
a portion of said inner facing surface and at least a portion of
said outer facing surface are adjacent and thereby forms an overlap
area.
42. The method of claim 27 wherein said outer facing surface and
said inner facing surface substantially mate together in said
overlap area.
43. The method of claim 27 wherein said rolling at step c) creates
an inner diameter of between about 0.125 inches and about 0.30
inches.
44. The method of claim 27 wherein said rolling at step c) creates
an outer diameter of between about 0.25 inches and about 0.50
inches.
45. The method of claim 27 wherein said cooking at step d)
comprises toasting.
46. The method of claim 27 wherein said cooking at step d)
comprises toasting followed by frying.
47. The method of claim 27 wherein said cooking at step d)
comprises frying.
48. The method of claim 27 wherein said uncooked snack chips are
fried in oil at between about 300.degree. F. and about 400.degree.
F.
49. The method of claim 27 wherein said cooked rolled snack pieces
after step d) further comprise: about 0.05% to about 3.0% by weight
particulate triglyceride and liquid monoglyceride; about 25% to
about 34% by weight oil; about 0.8% to about 2.0% by weight
moisture; about 60% to about 80% by weight starch-based component;
and about 0% to about 8% by weight seasoning.
50. A snack piece made by the method of claim 27.
51. A dough comprising: about 40% to about 50% corn masa; about 45%
to about 60% water; and less than about 3% of a liquid
monoglyceride and a particulate triglyceride.
52. The dough of claim 51 wherein said triglyceride comprises a
powder having an average particle size of less than about 150
microns.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a method for making an
improved rolled snack food and more particularly to a method for
making a rolled snack food having a light and crispy texture.
[0003] 2. Description of Related Art
[0004] Conventional tortilla snack piece products are prepared from
corn masa dough made from a traditional nixtamalization process.
The masa dough is then compressed between a pair of counter
rotating sheeter/cutter rollers that are located closely together,
thereby providing a pinch point through which the dough is formed
into sheets and cut into a desired shape. Often the desired snack
piece shape is that of a triangle. After the dough is cut, the
snack pieces are transported towards and through a toaster oven for
an increased stiffness for insertion into the fryer. The toasted
snack pieces are then passed through a proofing stage where the
snack pieces are exposed to ambient air to equilibrate moisture
throughout the snack piece. The snack pieces are then fried in hot
oil before being routed into a seasoning tumbler where flavored
seasonings or salts are added to the snack pieces. The snack pieces
are then sent to be packaged.
[0005] Snack pieces made from this process typically have a
substantially flat geometry, even if the snack pieces have a curl
as a result of the frying process. However, there are advantages
for snack pieces to have to other geometries. For example, a rolled
snack piece can be more easily placed into a consumer's mouth,
resulting in a bite-sized or more easily consumable snack.
Moreover, the bulk density of rolled snacks is higher than the bulk
density of snacks having a substantially flat geometry. As a
result, less packaging can be used to contain the same weight of
rolled snacks. Accordingly, a need exists for a rolled snack
food.
[0006] A rolled snack food can be made by rolling the cut dough
pieces following sheeting before the pieces are toasted. One such
apparatus for rolling pieces of dough is disclosed is U.S. Pat. No.
6,393,974. Unfortunately, texture problems that do not occur in
prior art flat snack pieces arise during cooking of rolled dough
pieces. For example, when prior art substantially flat snack pieces
are cooked in hot oil, steam within the dough can cause the snack
pieces to expand mostly outward. This outward expansion creates
voids within the snack piece. These voids help create a lighter,
crispier texture.
[0007] In a rolled snack piece, however, the expansion occurs
radially, both inward and outward. When the rolled snack piece is
placed into the fryer, the moisture in contact with the hot oil in
the outer portion of the fried snack piece turns to steam causing
both inward and outward radial expansion of the snack piece. The
inward expansion of the rolled snack food, upon insertion into the
fryer, closes off the inner portion of the rolled snack food. Thus,
frying oil does not fully permeate the rolled snack piece. This
inhibits oil displacement of water. Corn masa becomes hard and
unpalatable at low oil levels. As a result, the inner portion of
the snack piece has an undesirably hard texture. Moreover, inward
radial expansion further compresses the inner portion of the snack
piece which increases the particulate density, and decreases any
voids that help provide a lighter, crispier texture. A higher
particulate density means there are fewer voids to provide a
lighter, crispier texture. As a result, a hard texture is created
throughout the inner portion of the rolled snack food. Hence, a
need exists for a method to control inward expansion of a rolled
snack food during frying.
[0008] In addition, while the moisture content upon leaving the
toast oven in a prior art substantially flat masa-based snack piece
is between about 25% and about 35% moisture, the moisture content
of a rolled dough snack piece, upon leaving the toast oven, is
about 45% to 50% moisture. There is a larger temperature gradient
within a rolled snack piece that makes it more difficult to remove
water uniformly. This is due, in part, to the decreased surface
area that the rolled dough has exposed in the toast oven. For
example, as the rolled snack piece passes through the toast oven,
the temperature of the inner part of a rolled snack piece is lower
than the temperature of the outer, exposed part. This results in
uneven moisture removal, and higher moisture contents near the
inner portion of the rolled snack piece. As indicated above,
because the inner portion of the snack piece is closed off during
frying, it is difficult to remove the moisture by oil displacement
in the inner portion of the snack piece. Higher moisture contents
in the finished snack piece product can contribute to a harder
texture.
[0009] Consequently, the need exists for a rolled snack piece
having a light, crispy texture. Moreover, a need exists for the
light, crispy texture to be substantially uniform throughout the
cross-section of the rolled snack piece.
[0010] Several prior art solutions were tried in an attempt to
satisfy this need. For example, one prior art solution for
softening a fried dough involves using a potato or rice starch.
When these starches are heated and fried at high moisture contents,
the starch binds tightly to itself resulting in a glassy, hard
texture. This glassy texture typically allows for rapid breakdown
of the snack during mastication. Unfortunately, when potato or rice
starch was added to the masa used in the rolled snack piece, the
rolled snack pieces expanded radially inward, forcing the rolled
snack piece to close up upon frying, and made the product bind so
tightly that breakdown failed to occur during mastication. Thus,
adding potato or rice starch, rather than resulting in a softer
texture, resulted in a highly undesirably hard texture.
[0011] Other prior art softening compounds such as dextrins and
lecithins failed to survive the frying process and resulted in
excessive browning of the rolled snack pieces. Moreover, strong off
flavors also became apparent. Fully hydrogenated, high melting
vegetable oil (less than 5 iodine value) was also tried. Such oil
provides voids in the food products creating less hardness,
however, the hardstock leached directly into the oil due to its
inability to complex with the starch in the masa. Moreover, oil
quality was negatively impacted. Hence, a need exists for a method
of making a fried, rolled snack piece having a light, crispy
texture. The method should be conducive to cooking in hot oil, yet
not severely impact oil quality. Moreover, the method should avoid
excessive browning and off-flavors.
SUMMARY OF THE INVENTION
[0012] The proposed invention is a method for making a rolled snack
food having a light, crispy texture. In one aspect, monoglyceride
with a judicious choice of particle size distribution, is mixed
with a starch-based dough. In another aspect, a particulate
triglyceride is mixed with a starch-based dough followed by
addition of a liquid monoglyceride.
[0013] The dough is formed into snack food pieces. In one
embodiment, the snack food pieces are rolled, toasted, and fried in
hot oil. It is theorized that the lipid-carbohydrate complex
created from the starch amylose component helps to stabilize the
starch and control inward expansion of the rolled snack piece
during frying. By controlling inward expansion, the inner portion
of the rolled snack piece can be permeated with hot oil, allowing
more uniform cooking.
[0014] Hence, in one aspect, this invention produces a method that
provides a bite-sized rolled snack food having a light, crispy
texture. In addition, the invention provides a rolled snack food
having a higher bulk density than prior art substantially flat
snack food products thereby requiring less packaging. The above as
well as additional features and advantages of the present invention
will become apparent in the following written description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 is a schematic representation of one embodiment in
the new process.
[0017] FIG. 2 is a perspective schematic representation of one
embodiment of the rolled snack piece of the present invention.
[0018] FIG. 3a is an illustration of the chemical structure of a
monoglyceride and an amylose helix complex.
[0019] FIG. 3b is an alternative perspective representation of FIG.
3a.
DETAILED DESCRIPTION
[0020] An embodiment of the innovative invention will now be
described with reference to FIG. 1. FIG. 1 is a schematic
representation of one embodiment in the new process. A starch based
material 110, a monoglyceride 120, and water 130 are mixed 140
together in a continuous batch, or other mixer. The starch-based
material can comprise corn masa made from a standard nixtalization
process, a dry corn masa mix, potato flour, potato flakes, potato
granules, corn flour, and mixtures thereof. However, any
starch-based material comprising amylose including, but not limited
to, corn, rice, tapioca, potato, and mixtures thereof can be used.
As used herein, a monoglyceride is defined as a solid particulate
monoglyceride having a reduced average particle size of less than
about 400 microns and more preferably less than about 150 microns,
and most preferably less than about 75 microns. Preferably, in one
embodiment, the monoglyceride is added with only trace amounts of
diglycerides and triglycerides. In one embodiment, the
monoglyceride is a fully saturated (hydrogenated) monoglyceride. An
example of an acceptable monoglyceride comprises Dimodan HS.RTM. 75
available from Danisco of New Century, Kans. In an alternative
embodiment, the monoglyceride is partially hydrogenated.
[0021] Following mixing 140, the dough can be formed 150 into
uncooked snack pieces. Forming 150 the dough can be achieved by
compressing the dough between a pair of counter rotating
sheeter/cutter rollers that are located closely together, thereby
providing a pinch point through which the dough is formed into
sheets and cut into a desired chip shape. The dough can be cut into
any desired shape including, but not limited to, circles,
triangles, squares, rectangles, pentagons, and hexagons or any
other polygon. In an alternative embodiment, forming of the dough
comprises extruding the dough and cutting the extruded dough into a
desired shape. After the dough has been cut into a plurality of
uncooked snack pieces, the dough pieces are rolled 160 by using
known methods in the prior art. (see U.S. Pat. No. 6,393,974)
[0022] FIG. 2 is a perspective schematic representation of one
embodiment of the rolled snack piece of the present invention. The
rolled snack piece comprises an inner facing surface 205 and an
outer facing surface 210. The rolled snack piece is in the shape of
a spiral having an overlap area. As used herein, an overlap area is
created when at least a portion of the inner facing surface 205 is
adjacent to at least a portion of the outer facing surface 210. The
snack piece can be rolled into a spiral having an overlap area of
varying lengths.
[0023] In the embodiment shown, the dough is rolled about one and
one-half full turns. Although the inner portion 220 and outer
portion 250 can substantially mate together in the overlap area, it
can be desirable to have a gap (not shown) in the overlap area
between the inner portion 220 and outer portion 250 to allow for
expansion and oil contact during frying.
[0024] The rolled snack piece can also have varying inside and
outside diameter ratios. As used herein, an inner diameter or
inside diameter is defined as the average distance between opposing
inner facing surfaces. As used herein, the outer diameter or
outside diameter is defined as the average distance between
opposing outer surfaces. In the embodiment shown, the rolled snack
piece has an inner diameter of between about 0.125 inches and about
0.30 inches and an outer diameter of between about 0.25 inches and
about 0.50 inches. It should be noted that the snack piece can be
rolled into a spiral having a plurality of turns and the inside and
outside diameters can be changed accordingly.
[0025] Referring back to FIG. 1, the rolled pieces are then cooked
180 to make a plurality of cooked rolled snack pieces. In one
embodiment, cooking 180 comprises first toasting 170 the rolled
snack pieces in a triple pass toast oven for about 30 to about 120
seconds at about 450.degree. F. to about 750.degree. F. In this
embodiment, the toasted 170 rolled snack pieces are then fried 180
in hot oil. In an alternative embodiment, rolled snack pieces are
sent directly to the fryer for cooking 180. Following cooking 180,
the rolled snack pieces, in one embodiment, comprise a moisture
content of between about 0.8% and about 2.0%.
[0026] The rolled snack pieces can be seasoned 190 in a tumbler,
topping unit, or other seasoning device known to those in the art.
In one embodiment, following cooking, the cooked, rolled snack
piece comprises between about 0.05% to about 3.0% monoglyceride,
about 25% to about 34% oil, about 0.8% to about 2.0% moisture,
about 60% to about 80% of a starch-based component, and about 0% to
about 8% seasoning.
[0027] It has been surprisingly found that the addition of
monoglyceride having a reduced average particle size of less than
about 400 microns, more preferably less than about 150 microns and
most preferably less than about 75 microns provides for a
substantially uniform light, crispy texture throughout the cross
section of the cooked, rolled snack pieces. Without being limited
to any specific theory, there are three theories as to why
monoglyceride addition achieves this purpose. It is believed that
these three theories either independently or in tandem explain the
way in which the monoglyceride functions.
[0028] One theory is that the monoglyceride functions to inhibit
inward expansion of the starch based material during frying. Starch
is typically made up of amylose and amylopectin molecules. Amylose,
primarily consisting of .alpha.-1,4 linked glucose rings is a
straight chain helical molecule. Amylopectin, on the other hand, is
a highly branched molecule that comprises both .alpha.-1,4 and
.alpha.-1,6 linked glucose rings. It is theorized that the amylose
helix collapses as a result of expansion that occurs during frying.
Voids formed during frying near outer surfaces create inward
expansion forces and cause the amylose helix near inner
less-exposed surfaces to collapse.
[0029] FIG. 3a depicts an illustration of a monoglyceride 300a and
an amylose helix 360a. A monoglyceride 300a typically comprises a
glycerol 310a and a fatty acid chain 340a. A diglyceride would have
a fatty acid chain attached to the oxygen adjacent to second carbon
atom 314a of the glycerol molecule 310a, or attached to the third
glycerol carbon 316a. Similarly a triglyceride would have a fatty
acid chains attached to each of the oxygens attached to the second
and third glycerol carbons 314a 316a.
[0030] FIG. 3b is an alternative perspective representation of FIG.
3a. As shown in FIG. 3b, an amylose molecule 360b forms a single
helix. It is believed that a lipid-carbohydrate complex is formed
when the monoglycerides long hydrophobic fatty acid chain 340b is
inserted into the amylose starch helix 360b. It is believed that
the fatty acid chain 340b of the starch monoglyceride complex
effectively builds bridges of support inside the amylose helix
360b. This bridging may prevent the amylose starch from collapsing
due to inward expansion forces during frying. Therefore, the
monoglyceride is contributing to the structural integrity of the
masa or other starch-based material matrix by forming a
lipid-carbohydrate complex. A hydrogenated monoglyceride has a
better chance to complex due to the linear nature of the molecule.
Unsaturated fatty acid molecules especially those having a cis
configuration, can have kinks that lower their ability to complex
with the linear form of the amylose helix. Thus, in an embodiment
comprising a partially hydrogenated monoglyceride, a trans rather
than a cis configuration at the double bond is preferred to permit
a better interaction with the starch.
[0031] Particulate diglycerides and triglycerides may work, but are
less desirable because they are not as effective as the
monoglyceride. Hence, using an emulsifier having significant
amounts of particulate glycerides other than monoglyceride lowers
efficiency and results in increased costs. In sum, blends of
monoglycerides with other glycerides can be used, but may be less
desirable.
[0032] Similarly, other emulsifiers can be used including, but not
limited, lysolecithin (lysophosphatidyl choline powder), succinic
acid esters of monoglyceride, diacetlylated tartaric acid esters of
monoglyceride (DATEM), stearoyl lactylate, and its salts (stearoyl
2-lactylate, sodium stearoyl 2-lacylate, calcium 2-lactylate).
[0033] The second theory is that monoglyceride "lubricates" the
dough. The lubrication takes place both within the dough
(intra-lubrication) and outside the dough (inter-lubrication). The
inter-lubrication allows for better release from the roller and
from the cutter. Further, the inter-lubrication may provide a small
gap in the overlap area that allows for better oil contact within
the overlap area during frying. Further, the inter-lubrication
provided by the monoglyceride also prevents the rolled dough piece
from sticking to itself in some portions at the overlap area,
allowing oil in the fryer to contact the dough piece in the overlap
area.
[0034] Intra-lubrication may be the result of the melted
monoglyceride formed in the toast oven. The melted monoglyceride
may create a series of voids throughout the rolled dough piece.
These voids provide an area for steam to be created when the dough
is fried. The steam can then escape permitting oil to enter these
voids.
[0035] The third theory is that monoglyceride changes the thermal
transfer properties of the dough. Addition of the monoglyceride may
impact the rate in which water leaves the starch during frying, or
affect the amount of unbound or free water that exits the
starch-based dough during frying. For example, the monoglyceride
interaction may displace free water from the starch and the polar
end of the monoglyceride will be more likely to hold the bound
water in the system. Thus, rate of moisture removal and final
amount of moisture in the fried chip can be affected by the
monoglyceride. The longer dough is fried, the harder it becomes. A
shorter fry dwell time results in a more tender, less hard chip.
Prior to adding the monoglyceride to the rolled dough, a fry dwell
time of three minutes in oil at 360.degree. F. was required to
achieve a chip having a moisture content of less than 2% by weight.
Addition of the monoglyceride reduced the dwell time to about one
minute. Thus, a chip having a light, crispy texture resulted.
[0036] The amount of monoglyceride used in the dough is one
variable of the invention that must be controlled for a number of
reasons. First, monoglyceride is not very elastic. Thus, dough
rolling becomes more difficult when the monoglyceride is used at
higher levels. For example, if high levels (e.g. more than about 3%
by finished product weight) of monoglyceride are used, the dough,
after it is sheeted and cut, can retain shape memory. As a result,
rolled uncooked snack pieces have a tendency to unroll as higher
amounts of monoglyceride are used. Second, the melting temperature
of monoglyceride powder is about 150.degree. F. In one embodiment,
the toast oven is operated at over 450.degree. F. Thus, if too much
monoglyceride is used, it has a tendency to melt and cause rolled
dough piece to unroll in the toast oven. Moreover, if a particle
size of monoglyceride above 400 microns is used, distribution
throughout the dough can be impacted. This can result in
monoglyceride beading out of the dough and onto the belt in the
toast oven. As a result, there may be a shortage of monoglyceride
when needed in the fryer to control expansion, provide for
lubrication, or impact the thermal transfer properties of the
dough. Third, using high levels of monoglyceride increases the cost
of snack product production. Fourth, high levels of monoglyceride
can alter the texture or even the taste of a finished product. For
example, high concentrations of monoglycerides are known to give an
oily mouth feel and off flavors. Moreover, as discussed above,
monoglycerides tend to lubricate the dough and allow more moisture
to escape during frying. Too much moisture escape during frying
results in reduced blistering of the chip surface. Less blistering
results in a harder texture and less desirable look in a tortilla
chip embodiment. Moreover, the resulting fried chip would have an
oil soaked appearance. Fifth, a high level of monoglyceride can
result in monoglyceride leaching into the oil, affecting oil
quality. Thus, any addition of monoglyceride must proceed with
caution.
[0037] As discussed above, there are numerous disadvantages
associated with increased levels of monoglyceride. Many of these
disadvantages, however, are greatly reduced or not apparent when
using lower concentrations of monoglyceride. It has surprisingly
been found that a lower concentration of monoglyceride can
contribute to sufficient structural integrity of the starch-based
material if the average particle size of the monoglyceride is at or
below about 400 microns, more preferably below about 150 microns
and most preferably at or below about 75 microns. Using 400 micron
monoglyceride required a monoglyceride of 2.3% by weight of the
finished product to soften the snack pieces to desired levels. A
monoglyceride having an average particle size of less than about
150 microns and more preferably less than about 75 microns provides
monoglyceride having an increased surface area, allowing even lower
levels of monoglyceride to be used. Moreover, better mixing of the
monoglyceride throughout the dough matrix can occur, increasing the
monoglyceride availability to the starch molecule.
[0038] Thus, a monoglyceride concentration of less than about 3%,
more preferably less than about 1%, and most preferably between
about 0.15% and about 0.75% by weight of finished product can be
used with monoglycerides having smaller particle sizes. Hence, in
one aspect, the present invention provides a method for making a
rolled snack food having a light and crispy texture. By using a
lower concentration of monoglyceride as disclosed in the present
invention, a rolled snack piece does not have the tendency to
unroll in the toast oven, undesirable texture and off-flavors are
minimized, and the cost of producing the rolled snack piece can be
reduced. Moreover, oil quality is not substantially impacted.
[0039] In another aspect of the invention and referring to FIG. 1,
it is believed that a particulate triglyceride can be used in place
of the solid particulate monoglyceride 120. As used herein, a
particulate triglyceride is defined as a triglyceride having a
reduced average particle size of less than about 400 microns and
more preferably less than about 150 microns, and most preferably
less than about 75 microns. A liquid monoglyceride could then be
applied, for example by a spray, to the dough during mixing 140 to
produce similar textural effects in a rolled snack piece. For
example, it is believed that the overall functionality (expansion
control, lubrication, thermal transfer properties) can be enhanced
in this manner. For example, both the particulate triglyceride and
liquid monoglyceride provide lubrication. In one embodiment, a
particulate monoglyceride is used. The particulate triglyceride may
provide better void space functionality and liquid monoglyceride
provides better starch interaction that results in expansion
control. Thus, the texture of the snack piece can be controlled by
changing the particulate size and/or concentration of the
triglyceride, while keeping the starch interaction constant, and
vice-versa. Such optimization may be more difficult with only
monoglyceride. The liquid monoglyceride and particulate
triglyceride added should be less than 3% by weight of the finished
product.
[0040] While this invention has been particularly shown and
described with reference to a preferred embodiment, it will be
understood by those skilled in the art the various changes in form
and detail may be made therein without departing from the spirit
and scope of the invention.
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