U.S. patent application number 14/029681 was filed with the patent office on 2014-03-27 for crumb manufacture.
This patent application is currently assigned to Crisp Sensation Holding S.A.. The applicant listed for this patent is Crisp Sensation Holding S.A.. Invention is credited to Keith Graham Pickford, Carry Reichgelt, Kees van Doorn.
Application Number | 20140087051 14/029681 |
Document ID | / |
Family ID | 48610382 |
Filed Date | 2014-03-27 |
United States Patent
Application |
20140087051 |
Kind Code |
A1 |
Pickford; Keith Graham ; et
al. |
March 27, 2014 |
CRUMB MANUFACTURE
Abstract
A method of manufacture of a breadcrumb coating for a food
product provides a crumb with an extremely low moisture content
without the need for substantial energy input. The method achieves
such very low moisture content without significant adverse effect
on product quality.
Inventors: |
Pickford; Keith Graham;
(Manchester, GB) ; van Doorn; Kees; (Tilburg,
NL) ; Reichgelt; Carry; (Riethoven, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Crisp Sensation Holding S.A. |
Geneva |
|
CH |
|
|
Assignee: |
Crisp Sensation Holding
S.A.
Geneva
CH
|
Family ID: |
48610382 |
Appl. No.: |
14/029681 |
Filed: |
September 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13331900 |
Dec 20, 2011 |
|
|
|
14029681 |
|
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|
|
Current U.S.
Class: |
426/560 ;
426/473 |
Current CPC
Class: |
A23L 29/25 20160801;
A23P 30/20 20160801; A23K 30/20 20160501; A23L 29/256 20160801;
A23L 29/27 20160801; A23L 7/157 20160801; A23L 29/212 20160801;
A23L 29/238 20160801; A23L 29/231 20160801; A23V 2002/00
20130101 |
Class at
Publication: |
426/560 ;
426/473 |
International
Class: |
A23L 1/176 20060101
A23L001/176 |
Claims
1. A method of manufacture of a crumb, the method comprising:
extruding a dough composition comprising flour, a gelling agent,
optional further ingredients and water to form an extruded
composition, wherein the gelling agent is uniformly distributed
throughout the composition; drying the extruded composition in a
rotary dryer to form a dried composition, wherein the water content
of the dried composition is from about 0.1% to about 1.5% by
weight; and milling the dried composition to form a crumb with a
water content of about 0.1% to about 1.5% by weight.
2. The method of claim 1, wherein the rotary dryer comprises an
inlet; an outlet; a passageway for the extruded composition, the
passageway extending between the inlet and outlet; one or more
drying units comprising a perforated cylindrical tube extending
between the inlet and outlet and a screw extending axially of the
tube, wherein one of the tube and the screw are rotatable to move
extruded composition from the inlet to the outlet; and means for
circulating drying air through the passageway.
3. The method of claim 1, wherein the crumb has a water content
from about 0.3% to about 1.0% by weight.
4. The method of claim 3, wherein the crumb has a water content
from about 0.5% to about 1.0% by weight.
5. The method of claim 4, wherein the crumb has a water content
from about 0.5% to about 0.6% by weight.
6. The method of claim 1, wherein the crumb has a maximum dimension
from about 0.1 mm to about 5 mm.
7. The method of claim 1, wherein the gelling agent is a
hydrocolloid.
8. The method of claim 1, wherein the crumb contains from about
0.06% to about 4% by weight of the gelling agent.
9. The method of claim 7, wherein the crumb contains from about
0.08% to about 3% by weight of the gelling agent.
10. The method of claim 9, wherein the crumb contains from about
0.1% to about 3% by weight of the gelling agent.
11. The method of claim 1, wherein the gelling agent is selected
from the group consisting of natural gums, modified gums, gelatin,
pectin, alginate, arabinogalactan, agar, carrageenan, furcellaran,
modified starch and combinations thereof.
12. The method of claim 7, wherein the hydrocolloid is selected
from the group consisting of natural gums and combinations
thereof.
13. The method of claim 12, wherein the natural gum is selected
from the group consisting of guar gum, locust bean gum, gum arabic,
tragacanth, gum karaya, gum ghatti, xanthan gum and combinations
thereof.
14. The method of claim 1, wherein the extruded pellets are dried
in the rotary dryer by employing a counter current stream of hot
air having a temperature in the range of 120.degree. C.-160.degree.
C.
15. A crumb, comprising: milled farinaceous particles of an
extruded composition comprising flour; a gelling agent uniformly
distributed throughout the crumb; and optional further ingredients;
wherein the total water content of the crumb is from about 0.1% to
about 1.5% by weight.
16. The crumb of claim 15, wherein the crumb has a water content
from about 0.3% to about 1.0% by weight.
17. The crumb of claim 16, wherein the crumb has a water content
from about 0.5% to about 0.6% by weight.
18. The crumb of claim 15, wherein the crumb has a maximum
dimension from about 0.1 mm to about 5 mm.
19. The crumb of claim 15, wherein the crumb contains from about
0.06% to about 4% by weight of the gelling agent, and the gelling
agent is a hydrocolloid.
20. A crumb, comprising: milled farinaceous particles of an
extruded composition comprising flour; a gelling agent uniformly
distributed throughout the crumb; and optional further ingredients;
wherein the total water content of the crumb is less than 1.5% by
weight.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of prior application Ser.
No. 13/331,900 filed on Dec. 20, 2011, entitled CRUMB MANUFACTURE,
now pending, the disclosure of which is incorporated by reference
herein in its entirety.
BACKGROUND
[0002] This invention relates to a process for manufacture of
crumb. The invention also relates to crumb manufactured by the
process and food products coated with the crumb. The invention
relates particularly, but not exclusively, to crumb which includes
a hydrocolloid or other gelling agent in order to impart water
resistant characteristics.
[0003] Conventional breadcrumb may have a water content of about 4%
to 12% and becomes soggy immediately upon immersion into water.
Such crumb is inevitably for use in moist environments,
particularly for coating microwaveable products.
[0004] WO99/44439 describes a process for manufacture of breadcrumb
by extrusion of a dough mixture incorporating a gelling agent,
particularly a hydrocolloid, to form pellets which are dried and
milled. WO2010/001101 discloses a process wherein crumb is extruded
with a gelling agent and dried to a moisture content of 2% or is
dried in a fluid bed dryer at around 90.degree. C. for fifteen
minutes. Use of a fluid bed dryer may be undesirable due to
creation of a large amount of airborne dust. Fluid bed dryers are
designed to dry products as they float on a cushion of air or gas.
The air or gas used in the process is supplied to the bed through a
special perforated distributor plate and flows through the bed of
solids at a velocity sufficient to support the weight of particles
in the fluidised state. Bubbles form and collapse within the
fluidised bed of material promoting intense particle movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic view of drying apparatus for use in
accordance with an embodiment of the invention.
[0006] FIG. 2 is a cross-sectional view of a dryer for use in
accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0007] According to a first aspect of the present invention, a
method of manufacture of a crumb comprises:
[0008] extruding a dough composition comprising flour, a gelling
agent, optional further ingredients and water to form an extruded
composition, wherein the gelling agent is uniformly distributed
throughout the composition;
[0009] drying the extruded composition in a rotary dryer to form a
dried composition, wherein the water content of the dried
composition is from about 0.1% to about 1.5% by weight; and
[0010] milling the dried composition to form a crumb with a water
content of about 0.1% to about 1.5% by weight.
[0011] The present method offers the advantage that it enables the
manufacture of a crumb with an extremely low moisture content
without the need for substantial energy input. Furthermore, the
method achieves such very low moisture content without significant
adverse effect on product quality. Alternative drying techniques
would typically achieve such very low moisture content at the cost
of e.g. heat induced defects. The crumb according to the present
invention offers the advantage that it is substantially more water
resistant than crumb having a moisture level of about 2.0 wt %
and/or crumb that does not contain a gelling agent. The high water
resistance of the crumb obtained by the present method is
particularly beneficial if this crumb is used in the manufacture of
coated food products that are distributed in frozen form and that
have to be heated before consumption.
[0012] Percentages and other quantities referred to in this
specification are by weight, unless indicated otherwise.
[0013] In a preferred embodiment the rotary dryer comprises an
inlet; an outlet; a passageway for the extruded composition; the
passageway extending between the inlet and outlet; one or more
drying units each comprising a perforated cylindrical tube
extending between the inlet and outlet and a screw extending
axially of the tube, wherein one of the tube and the screw are
rotatable to move extruded composition from the inlet to the
outlet; and means for circulating drying air through the
passageway.
[0014] The rotary dryer may comprise at least four drying units
assembled in a rotary cage located within a closed housing.
[0015] The apertures in the perforated cylindrical tubes are
selected to be smaller than at least 90 wt % of the particles of
the extruded composition. Preferably the dimension of the apertures
in the perforated cylindrical tube is in the range of about 1 mm to
about 5 mm.
[0016] The extruded composition is preferably dried in the rotary
dryer using a countercurrent hot air stream. The countercurrent hot
air stream typically has a temperature of 100.degree.
C.-160.degree. C., more preferably of 130.degree. C.-150.degree.
C., most preferably about 140.degree. C. Flow rates of hot air
employed in the present method are typically in the range of about
6 to about 15 m/s, preferably of 8-10 m/s.
[0017] This invention utilises a gelling agent, particularly a
hydrocolloid, dispersed uniformly in a rigid extruded farinaceous
matrix structure which when dried to a water content of 1.5% by
weight or lower reduces hydration and swelling of the hydrocolloid
upon exposure to moisture thus creating a water resistant barrier.
The farinaceous matrix advantageously comprises low gluten wheat
flour.
[0018] Without wishing to be bound by theory it is believed that
upon exposure to moisture the gelling agent hydrates at the surface
of the crumb or elsewhere in contact with moisture but cannot
expand within the structure of the crumb. This may result in
formation of a barrier to passage of water into the body of the
crumb.
[0019] Preferably the particles have a maximum dimension between
dust having a dimension of about 0.1 mm and about 5 mm. Crumb
having a substantial absence of fine particles or dust may be used
for outer coating of products. The dust may be used in the coating
process as a predust or as an infill between larger particles.
[0020] Preferably, the water content of the dried composition and
crumb is from about 0.3% to about 1%, more preferably about 0.5% to
about 1%, most preferably about 0.5% to about 0.6%.
[0021] Crumb made by the method of this invention has the advantage
of moisture resistance during cooking or reheating in a thermal,
microwave or combined thermal and microwave oven. The crumb finds
particular application for use in products which are frozen for
storage before use. Uniform distribution of the gelling agent,
especially a hydrocolloid, throughout the crumb imparts water
resistance to the entire body of the crumb, and not to a
superficial outer layer which may become damaged in use.
[0022] Reduction of the water content of the crumb below 1.5%
confers an unexpected degree of moisture resistance to the crumb.
Thus, the crumb can be used to produce a crumb coated food product
which is crisp and has a crunchy texture. Without wishing to be
bound by theory, it is believed that reduction of the water content
as claimed reduces the rate of re-hydration of the gelling agent in
contact with water, prolonging the period during which the crumb
remains crisp. This is particularly important in crumb coated
microwaveable products because steam emitted from the core of the
product passes through the coating, making conventional crumb
coated products soggy and unpalatable. The very low water content
of the crumb further provides the unexpected advantage that the
crumb exhibits a low pick-up of oil during frying.
[0023] The gelling agent is preferably a hydrocolloid which forms a
gel or otherwise increases in viscosity when mixed with water.
Preferred hydrocolloids produce a milled extrudate which retains
shape when stirred in water having a temperature of 20.degree. C.
for a period of 60 seconds. The hydrocolloid provides a degree of
water resistance reducing any tendency to pick up moisture from
adjacent layers of the food product or surrounding materials.
Typically, hydrocolloid is contained in the milled extrudate in a
concentration of about 0.06% to about 4%, more preferably about
0.08% to about 3%, and most preferably about 0.1% to about 3% by
weight.
[0024] Examples of hydrocolloids that may be used include natural
gums, modified gums, gelatin, pectin, alginate, arabinogalactan,
agar, carrageenan, furcellaran, modified starch and combinations
thereof. Preferably the hydrocolloid is selected from natural gums
and combinations thereof.
[0025] Examples of natural gums that may be suitably employed
include guar gum, locust bean gum, gum arabic, tragacanth, gum
karaya, gum ghatti, xanthan gum and combinations thereof.
[0026] Most preferably, the hydrocolloid is selected from guar gum,
locust bean gum, xanthan gum and combinations thereof.
[0027] The extrudate may be cut into pieces upon discharge from the
extruder in order to form pieces of solid farinaceous material.
Preferably the pieces may expand to form rounded pellets or beads
suitable for passage through a dryer before milling. The beads may
have a maximum dimension of 0.5 cm to 1 cm.
[0028] The extruded composition obtained in the present method has
a water content of about 0.1% to about 1.5 wt. %, more preferably
of about 0.3 wt. %.
[0029] Extruded crumb may be manufactured as disclosed in
WO2010/001101, the disclosure of which is incorporated into this
specification by reference for all purposes.
[0030] In a preferred embodiment the dryer comprises an inlet, an
outlet, a passageway for pieces of extrudate, the passageway
extending between the inlet and the outlet, means for circulating
drying air through the passageway and means for mixing the pieces
of the extrudate during passage through the passageway; wherein the
passageway comprises a perforated cylindrical tube extending
between the inlet and outlet;
[0031] apertures in the tube having a maximum dimension arranged to
retain extrudate particles within the tube;
[0032] the means for mixing comprising a screw extending axially of
the tube; and
[0033] one of the tube and screw being rotatable to move extrudate
from the inlet to the outlet.
[0034] Preferably, the screw remains stationary as the tube
rotates. Alternatively, the screw may rotate within a stationary
tube. Rotation of the tube is preferred to cause thorough mixing of
the extrudate particles during passage along the tube. Use of the
apparatus in accordance with this aspect of the invention is
advantageous because the particles are mixed by tumbling rather
than application of a mechanical mixer. This reduces breakage of
the particles and consequent formation of dust.
[0035] The tube may be constructed from wire mesh or perforated
sheet material having apertures sufficiently small to retain the
extrudate pieces. Dust or fine particles are separated from the
pieces by being allowed to fall through apertures in the rotating
tube into a collector at a lower part of the apparatus. For example
a trough may be provided with an Archimedes screw for carrying dust
out of the apparatus. Rotation of the tube has the advantage of
agitating the dust or fine particles, promoting flow of the latter
through the apertures in the tube, providing convenient separation
of the fines from the pieces of extruded composition.
[0036] In particularly advantageous embodiments, a multiplicity of
tubes are mounted in a dryer chamber, ventilation means being
provided to circulate dry heated air within the chamber. Heat
exchangers may be used to heat the air passing into or within the
chamber.
[0037] A vibratory feeder may be used to introduce extrudate into
the or each tube. A vibratory collector may be used to collect the
dried extrudate.
[0038] The dryer chamber may be divided into two or more zones
maintained at different temperatures or humidities. A first zone
may be at a higher temperature, for example in the range from about
120.degree. C. to about 160.degree. C., preferably about
130.degree. C. to about 150.degree. C., more preferably about
140.degree. C. A second zone may be at a lower temperature, for
example in the range from about 80.degree. C. to about 140.degree.
C., preferably about 90.degree. C. to about 120.degree. C., more
preferably about 100.degree. C. The dwell time in the dryer may be
about 45 minutes to 90 minutes, preferably about 60 minutes.
[0039] Another aspect of the invention relates to a crumb
comprising milled farinaceous particles of an extruded composition
comprising flour, a gelling agent uniformly distributed throughout
the crumb and optional further ingredients, wherein the total water
content of the crumb is from about 0.1% to about 1.5% by weight,
more preferably from about 0.3% to about 1%, even more preferably
about 0.5% to about 1%, most preferably about 0.5% to about
0.6%.
[0040] Preferred embodiments of the present crumb have already been
discussed above in relation to the manufacturing method.
[0041] The aforementioned crumb is preferably obtainable by the
method described herein. Most preferably, the crumb is obtained by
said method.
[0042] The invention is further described by means of example, but
not in any limitative sense, with reference to the accompanying
drawings.
EXAMPLES
Example 1
[0043] A flour composition was prepared from the following
ingredients as follows:
TABLE-US-00001 Flour mixture 96.4% Sodium bicarbonate (Bex .RTM.
baking powder) 2.0% Glyceryl Monostearate (Abimono SS40P) 0.6% Salt
1.0% 100.0%
A gelling composition was prepared from the following
ingredients:
TABLE-US-00002 Guar gum 67.00% Sodium metabisulphite 33.00%
100.00%
[0044] The gelling composition was hydrated at 3% w/w in 97% water.
This can be done using a paddle mixer but a high shear mixer is
preferred. The hydrated mixture was left to stand for at least 12
hours after mixing.
[0045] The flour composition (150 kg per hour) was mixed with water
(35 kg per hour) to form a slurry. The slurry was fed into a
Clextral.TM. twin-screw extruder was used (alternatively a
Buhler.TM. twin-screw extruder may be used). The hydrated gelling
composition was injected into the extruder barrel in an amount of
7.5% (13.88 kg per hour). The resultant extruded mixture was
chopped into pieces and allowed to expand to form bubble-shaped
pieces having a typical maximum dimension of 0.5 cm to 1.0 cm.
Example 2
[0046] The bubble-shaped pieces of extrudate were fed into the
input of a dryer as shown schematically in FIG. 1.
[0047] The dryer comprised an outer casing (1) defining a chamber
containing twelve gauze tubes (2) each having a diameter of about
30 centimetres and a length of about 11.5 metres. An Archimedes
screw (3) with 57 turns and a pitch of 30 centimetres for each turn
extends coaxially within each tube (2) adjacent the inner surface
of the tube. The tubes are connected by a drive mechanism to a
motor (not shown) and are arranged to rotate around the stationary
Archimedes screws (3). Tumbling of crumb particles (4) against the
surface of the screw causes the particles to move along the tubes
from the inlet (5) to the outlet (6).
[0048] FIG. 2 is a cross-sectional view of the dryer. The casing
(1) encloses an array of twelve or other convenient number of
cylindrical tubes (2) arranged in a cylindrical array (10) for
rotation in the casing about a longitudinal axis. A drive mechanism
(not shown), for example a chain drive, causes the tubes (2) to
rotate about the axes (17) of Archimedes screws (3) (as shown in
FIG. 1). A heat exchanger (11) provides heated air for circulation
within the casing (1). Air is removed from an outlet (12) by a pump
(13), arranged to recirculate air together with fresh air from
inlet (14) to the heat exchanger (11).
[0049] Collector plates (15) located at a lower portion of the
casing (1) beneath the array (10) of cylindrical tubes collects
dust or other fines falling from the cylindrical tubes. Archimedes
screws (16) serve to collect the dust and fines for delivery to an
outlet (not shown).
[0050] An outer casing includes a chamber and an air circulation
system including a heat exchanger to provide dry heated air.
[0051] The chamber is divided into two or more zones. A first zone
may be maintained at a first higher temperature, for example about
140.degree. C. and a second zone may be maintained at a second
lower temperature, for example about 100.degree. C. Any convenient
number of zones may be maintained at temperatures selected to
provide an efficient drying profile to suit the dimensions and
principal characteristics of the particles.
[0052] Each tube may have a diameter of about 30 cm and may
surround a coaxial screw with a pitch of about 30 cm.
[0053] The retention time within the dryer may be adjusted by
varying the rate of rotation of the tubes to provide a throughput
of 1200 kg/hr and a dwell time in the dryer of about 60
minutes.
[0054] A vibratory feeding system may be provided to introduce
undried particles into the tubes. Each tube may be provided with a
separate loading shovel. A vibratory collector may be provided to
collect dried particles for delivery to a mill.
[0055] The dried particles were milled using a roller mill.
[0056] The milled crumb was sieved and fractions were collected
with dimensions of below 0.8 mm, from 0.8-2.0 mm and from 2.0 to
3.5 mm. The water content of the crumb was determined to be 0.5 wt
% to 0.6 wt %.
* * * * *