U.S. patent application number 14/256243 was filed with the patent office on 2014-10-23 for expanded products with high protein content.
This patent application is currently assigned to MGPI PROCESSING, INC.. The applicant listed for this patent is MGPI PROCESSING, INC.. Invention is credited to Sukh D. BASSI, Girish M. GANJYAL, Clodualdo C. MANINGAT, Kyungsoo WOO.
Application Number | 20140314932 14/256243 |
Document ID | / |
Family ID | 37010665 |
Filed Date | 2014-10-23 |
United States Patent
Application |
20140314932 |
Kind Code |
A1 |
GANJYAL; Girish M. ; et
al. |
October 23, 2014 |
EXPANDED PRODUCTS WITH HIGH PROTEIN CONTENT
Abstract
High protein expanded products are produced by extrusion with
unique blends of ingredients, such as wheat protein isolates,
modified wheat starch, salts, gums and moisture. The mixture is
extruded in a twin-screw extruder with the temperatures in the
range of 50 to 140.degree. C., screw speeds of 250 to 450 rpm and
with a back pressure of 350 to 1200 psi for different recipes. A
range of expanded wheat crisps and other expanded products with
wheat protein contents ranging from 30 to 90% are obtained from
this process. The expanded products have good cell structure with
varying cell sizes when viewed under a microscope. This process can
be used to develop a varied range of products such as, wheat
crisps, wheat curls, wheat loops etc. The products may be used in
nutritional or health bars and other comestible having a high
protein and low carbohydrate content.
Inventors: |
GANJYAL; Girish M.;
(Atchison, KS) ; WOO; Kyungsoo; (Shawnee, KS)
; BASSI; Sukh D.; (Atchison, KS) ; MANINGAT;
Clodualdo C.; (Platte CIty, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MGPI PROCESSING, INC. |
Atchison |
KS |
US |
|
|
Assignee: |
MGPI PROCESSING, INC.
Atchison
KS
|
Family ID: |
37010665 |
Appl. No.: |
14/256243 |
Filed: |
April 18, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11115441 |
Apr 27, 2005 |
8741370 |
|
|
14256243 |
|
|
|
|
60663339 |
Mar 18, 2005 |
|
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Current U.S.
Class: |
426/559 |
Current CPC
Class: |
A23L 7/117 20160801;
A23L 7/17 20160801; A23P 30/20 20160801; A23V 2002/00 20130101;
A23J 3/18 20130101; A23V 2200/3322 20130101; A23V 2002/00 20130101;
A23V 2250/5118 20130101; A23V 2250/5486 20130101; A23V 2002/00
20130101; A23L 33/185 20160801 |
Class at
Publication: |
426/559 |
International
Class: |
A23L 1/18 20060101
A23L001/18; A23J 3/18 20060101 A23J003/18 |
Claims
1. An expanded food product comprising: a wheat protein isolate in
an amount ranging from 50% to 75% by weight, the isolate being
formed by dissolving wheat gluten in an aqueous solution and
isolating the wheat protein components, the isolate having a
protein content of at least 85% by weight; an oxidized starch in an
amount ranging from 19% to 49% by weight, the starch being oxidized
by converting hydroxyl groups on a starch to carbonyl and carboxyl
groups; wherein the product contains no appreciable added fiber;
wherein the cell structure of the product has a substantially
uniform distribution of cell sizes and cell wall thicknesses; and
wherein mixing of product ingredients has occurred to substantial
homogeneity such that there is no appreciable transition of protein
to starch.
2. The product of claim 1, further comprising a cross-linked
hydroxypropylated starch, the starch being made by reacting a
starch with propylene oxide and crosslinking the product.
3. The product of claim 2, wherein the cross-linked
hydroxypropylated starch is present in an amount ranging from 8% to
38% by weight.
4. The product of claim 1, further comprising a non-fibrous RS4
resistant starch made by a process of crosslinking by
phosphorylation.
5. The product of claim 2, further comprising a non-fibrous RS4
resistant starch made by a process of crosslinking by
phosphorylation.
6. The product of claim 1, further comprising a non-fibrous
reversibly-swellable RS4 resistant starch made by a process of
swelling followed by crosslinking by phosphorylation.
7. The product of claim 2, further comprising a non-fibrous
reversibly-swellable RS4 resistant starch made by a process of
swelling followed by crosslinking by phosphorylation.
8. The product of claim 1, further comprising an oxidized
non-fibrous reversibly-swellable RS4 resistant starch made by a
process of swelling followed by crosslinking by phosphorylation
followed by oxidation.
9. The product of claim 1 in which the wheat protein isolate is
present in an amount ranging from 65% to 75% by weight.
10. The product of claim 1 in which the wheat protein isolate has a
protein content of at least 90% by weight.
11. The product of claim 1 having a final moisture level of less
than 8%.
12. An expanded food product comprising: a wheat protein isolate in
an amount ranging from 50% to 75% by weight, the isolate being
formed by dissolving wheat gluten in an aqueous solution and
isolating the protein components; a cross-linked hydroxypropylated
starch in an amount ranging from 8% to 38% by weight, the starch
being made by reacting a starch with propylene oxide and
crosslinking the product; wherein the product contains no
appreciable added fiber; wherein the cell structure of the product
has a substantially uniform distribution of cell sizes and cell
wall thicknesses; and wherein mixing of product ingredients has
occurred to substantial homogeneity such that there is no
appreciable transition of protein to starch.
13. The product of claim 12, further comprising a non-fibrous RS4
resistant starch made by a process of crosslinking by
phosphorylation.
14. The product of claim 12, further comprising a non-fibrous
reversibly-swellable RS4 resistant starch made by a process of
swelling followed by crosslinking by phosphorylation.
15. The product of claim 12, further comprising an oxidized
non-fibrous reversibly-swellable RS4 resistant starch made by a
process of swelling followed by crosslinking by phosphorylation
followed by oxidation.
16. The product of claim 12 in which the wheat protein isolate is
present in an amount ranging from 65% to 75% by weight.
17. The product of claim 12 in which the wheat protein isolate has
a protein content of at least 90% by weight.
18. The product of claim 12 further comprising an oxidized
starch.
19. The product of claim 17, wherein the oxidized starch is present
in an amount ranging from 19% to 49% by weight.
20. The product of claim 12 having a final moisture level of less
than 8%.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/115,441, filed Apr. 27, 2005, which claims
the benefit of priority to U.S. Provisional Application No.
60/663,339, filed Mar. 18, 2005, both of which are hereby
incorporated by reference in their entireties to the extent not
inconsistent with the disclosure herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention pertains to expanded food products with high
protein content and the method of making the same.
[0004] 2. Discussion of the Related Art
[0005] It is problematic that current manufacturing practices are
unable to accommodate certain food ingredients for use in making
expanded food products which are suitable for certain needs. By way
of example, such low carbohydrate diets as the popular Atkins diet
and variations thereof have created a significant demand for food
with high protein and reduced carbohydrates. It is a technological
challenge to increase protein content in certain categories of
traditional foods, particularly in expanded products such as
breakfast cereals and crispy snacks. Expanded food products are
traditionally made using extrusion technology and contain a
significant amount of starch to accommodate proper expansion. The
starch generally imparts desired organoleptic qualities in the
final food product.
[0006] Starches have unique properties, for example, facilitating
the formation of continuous films under extrusion conditions. The
physico-chemical nature of starch benefits the expansion of food
products by forming a good cell structure matrix with
correspondingly favorable texture in the final expanded products.
Extrusion becomes more difficult, however, when ingredients such as
proteins, dietary fibers and lipids are added. It is difficult to
expand proteins without denaturation in extrusion processing
because protein materials are molecularly less amenable to
expansion that derives from the high temperature and pressure of
extrusion processing. In particular, wheat gluten protein has an
elastic nature that resists expansion and texturizes easily.
[0007] Extrusion processing has long been used to manufacture
expanded food products, but the problem of obtaining non-soy high
protein content has not been resolved. In one example, U.S. Pat.
No. 3,873,748 issued to Schwab et al. describes a method to make
ready-to-eat flake cereal by cooking, extruding, drying and
grinding a basic cereal matrix and then blending the resulting
product with sodium caseinate, rewetting the mixture and extruding
to form pellets, and finally using high pressure rolls to create
the flakes. The resulting cereal contains up to 25 percent (25%)
protein, which is rather low.
[0008] Some success has been obtained using soy proteins. U.S. Pat.
No. 3,852,491 issued to Malzahan et al. describes the use of high
temperature/high pressure (HTHP) extrusion to produce an expanded
cereal containing up to fifty-five percent (55%) soy protein. Soy
protein isolate having up to 80% protein was processed at
temperatures in the range of 220.degree. F. to 355.degree. F. and
at pressures in the range from 1000 to 3000 psig. A product having
a stringy or protein fiber-like texture developed when the
temperature of the extruded dough mass reached 355.degree. F. or
higher. Cereal-like textures were observed only at lower
temperatures. This fiber-like texture that is obtained indicates
the texturization process.
[0009] U.S. Pat. No. 3,965,268 issued to Stocker et al. describes
an expanded soy food product that is obtained by extrusion with
heating of a mixture containing an organic compound and water with
passage from a high pressure zone to a low pressure zone. The
product has an open cell structure and could be used as a meat
substitute, convenience food or pet food ingredient. A
sulfur-containing organic material provides functional expansion
benefit when added to the mixture in an amount ranging from 0.2 to
0.6% by weight of the proteinaceous material. The sulfur-containing
organic material includes sulfur-containing amino acids, lower
alkyl mercaptans, lower alkyl sulfides, lower alkyl disulfides,
thioacids, or their salts.
[0010] U.S. Pat. No. 6,242,033 B1 issued to Sander et al. describes
an extrusion process for making expanded high-protein cereal. Tuber
starch, such as tapioca, is used as an expanding agent. The
products contained protein levels of 50% to a maximum of 70%.
Specific recipes were disclosed, largely using rice flour and
tapioca flour and soy protein isolates with the protein levels
between 50% and 62%.
[0011] If carefully observed all the methods deal with extrusion
processing of recipes which have a significant amount of starch,
which is a critical component in expansion of the product.
Expansion of starches during extrusion also requires a proper
balance of water content with other ingredients and proper
extrusion conditions as are known generally in the art to obtain a
good stable expansion. The unique molecular properties of starches
aid in their expansion. They form continuous films when extruded,
which helps to form very good complete cell structure when
extruded.
[0012] Extrusion becomes difficult when other ingredients such as
proteins and lipids are added into the recipes. Unmodified
proteins, when extruded with starches, disperse into the matrix of
starch. Then the product property may entirely depend on the extent
of dispersion of the proteins into the starch matrix.
[0013] When regular unmodified proteins are used, it is difficult
to extrude them, as it takes more energy to break the disulfide
bonds and arrange them properly in a streamline. For example, when
vital wheat gluten is used in large amounts in the production of
bread dough or other products, the dough becomes too strong and is
difficult to process during mixing, shearing, kneading and molding.
In particular, the elasticity of wheat-based proteins tends to
collapse such products after expansion.
[0014] Most of the high protein products that have been developed
include soy as a main source of protein. During the extrusion
process soy proteins are easier to work with, although if high
levels of soy proteins are used, they adversely affect flavor and
give unacceptable volume and crumb grain properties.
[0015] Wheat gluten is a binary mixture of gliadin and glutenin.
These components can be separated by alcohol fractionation or by
using a non-alcoholic process (as disclosed in U.S. Pat. No.
5,610,277) employing the use of organic acids. Gliadin is soluble
in 60-70% alcohol and comprises monomeric proteins with molecular
weights ranging from 30,000 to 50,000 Daltons. These proteins are
classified as alpha-, beta-, gamma-, omega-gliadins depending on
their mobility during electrophoresis at low pH. Gliadin is
primarily responsible for the extensible properties of wheat
gluten. Glutenin is the alcohol insoluble fraction and contributes
primarily to the elastic or rubbery properties of wheat gluten.
Glutenin is a polymeric protein stabilized with inter-chain
disulfide bonds and made up of high-molecular weight and low
molecular weight subunits. Generally, glutenin exhibits a molecular
weight exceeding one million daltons. Preferred fractionated wheat
protein products comprise at least about 85% by weight protein, and
more preferably at least about 80% by weight of glutenin, all
proteins expressed on N.times.6.25, dry basis.
[0016] Wheat protein isolates are generally derived from wheat
gluten by taking advantage of gluten's solubility at alkaline or
acidic pH values. Wheat gluten is soluble in aqueous solutions with
an acidic or alkaline pH and exhibits a classical "U-shaped"
solubility curve with a minimum solubility or isoelectric point at
a pH 6.5-7.0. By dissolving the gluten, proteins can be separated
from non-protein components by processes like filtration,
centrifugation, or membrane processing followed by spray drying.
Alternatively, wet gluten from wet processing of wheat flour can be
repeatedly kneaded, water washed, and dewatered to get rid of
contaminating starch and other non-protein components, and
subsequently flash dried. These techniques yield a wheat protein
isolate product with elevated protein content that is usually at
least about 85% by weight, and more preferably at least about 90%
by weight (on a N.times.6.25, dry basis). Wheat protein isolates
are less elastic but more extensible than wheat gluten. Examples of
preferred wheat protein isolates include, Arise.TM. 3000, Arise.TM.
5000, Arise.TM. 6000 and Arise.TM. 8000 available from MGP
Ingredients, Inc., Atchison, Kans.
[0017] Wheat protein concentrates are proteinaceous compositions
which preferably have protein contents of at least about 70% by
weight, and preferably at least about 82% by weight (N.times.6.25
dry basis). Wheat protein concentrates may be of different
varieties manufactured by a number of different methods. Vital
wheat gluten is one type of wheat protein concentrate that has a
protein content of at least about 82% by weight (N.times.6.25, dry
basis). Vital wheat gluten is a viscoelastic protein manufactured
by a flash drying method. Additional types of wheat protein
concentrates are manufactured by dispersing wet gluten in an
ammonia solution followed by spray drying. These wheat protein
concentrates exhibit lesser viscoelastic properties than vital
wheat gluten but tend to be more extensible. Examples of the latter
type of wheat protein concentrates include FP 300, FP 600 and FP
800 available from MGP Ingredients, Inc. of Atchison, Kans.
[0018] Native starch has often been modified to satisfy specific
needs for food manufacturers. Chemical modifications, such as
hydroxypropylation, cross-linking, and oxidation are commonly used
to enhance shear, temperature, and acidic processing stability, to
improve freeze and thaw stability, and to increase paste clarity
and stability. Starch undergoes structural changes during chemical
modification in some of its glucopyranosyl units in the
molecule.
[0019] Hydroxypropylated starch is formed by reaction with
propylene oxide normally at very low levels of substitution.
Substituted hydroxypropyl groups restrict interaction of starch
chains and prevent junction zone formation. Without cross-linking,
however, hydroxypropylated starch tends to swell excessively during
cooking and form a stringy paste that is unstable against high
shear and acidic processing. Combination of hydroxylpropylation and
cross-linking is an efficient method of modification to improve
storage stability. This type of starch includes Midsol.TM. 46,
available from MGP Ingredients.
[0020] Oxidation of starch by an oxidizing agent such as sodium
hypochlorite is well known. During the oxidation reaction, hydroxyl
groups on starch molecules are oxidized to carbonyl and carboxyl
groups. Cleavage of some of the glycosidic linkages also occurs,
which decreases molecular weight of starch. Oxidized starch
granules tend to swell at lower temperature to a greater extent
than unmodified starch. Other characteristics of oxidized starch
include low and stable viscosity, forming gel of high clarity, and
improved binding and film forming properties. Midsol.TM. Krisp,
available from MGP ingredients, is categorized as this type of
starch.
[0021] Some dietary starches resist digestion by .alpha.-amylase in
the human upper gastrointestinal tract and are termed as resistant
starch (RS). RS is recognized as a type of dietary fiber and is of
particular interest with respect to its health benefits against
colon cancer. A high level of RS in starchy food constitutes a diet
with a low glycemic index, which is thought to be beneficial for
all individuals, especially for type II diabetics. A certain degree
of cross-linking on granular starch leads to the formation of
resistant starch, for example, as reported in U.S. Pat. No.
5,855,946 issued to Seib et al., and limits the digestion by
.alpha.-amylase. This type of starch is supplied by MGP Ingredients
and is commercially available as FiberSym.TM. 70 and FiberSym.TM.
80-ST.
[0022] Functional characteristics of resistant starch may be
modified by preswelling of granular starch before cross-linking,
for example, as described in U.S. Pat. No. 6,299,907 issued to Seib
et al. The preswollen and cross-linked starch granules are capable
of undergoing multiple hot or cold water swelling cycles without
losing the individuality of starch granules. Reversibly swellable
starch products may be modified further by an oxidizing agent.
Oxidized reversibly swellable starch products are characterized by
improved hydrophilic surface properties without undue agglomeration
or clumping. Oxidized reversibly swellable starch displays
stability improvement with hydrophilic polymers such as
hydrocolloids and proteins.
SUMMARY
[0023] The present instrumentalities overcome the problems outlined
above and advance the art by providing, for example, a high protein
expanded food product together with apparatus and methodology for
making the expanded food product.
[0024] Purified and/or modified proteins may be combined with
starch in recipes that are rich in protein content. These
ingredients may be subjected to extrusion processing to form a low
density expanded food product, for example, one having good
expanded cell structure, and a density ranging from about 0.1 to
0.4 g/cc.
[0025] By way of example, high protein expanded products are
produced by extrusion with unique blends of ingredients including
protein isolates, modified starch, salts, gums and moisture. The
mixture of ingredients is extruded in a twin-screw extruder with
the temperatures being in the range of 50.degree. C. to 140.degree.
C., with screw speeds of 250 to 450 rpm and with a back pressure of
350 to 1200 psi for different recipes. A range of expanded food
products, such as crisps, curls, loops and the like, may be
obtained from this process. The protein content is preferably
majority wheat protein and may be entirely wheat protein. Protein
contents may range, for example, from 30% to 75% by weight of the
dry extruded product, and are preferably from 65% to 70%. Some
products may include up to 75% by weight protein, but beyond this
limit the quality of expanded cell structure in the final product
deteriorates and the organoleptic quality of texture is impaired.
Products having majority or exclusive protein contents or up to
40%, 50%, 60%, 70%, or 75% by weight may be produced in any
combination with product densities generally in the range of 0.1 to
0.4 g/cc, e.g., 0.1, 0.15, 0.20, 0.25, 0.30, 0.35, or 0.4 g/cc. The
expanded products have well developed porous cell structure of
varying sizes when viewed under a microscope. The products may be
used in, among other products, cereals, snacks, or other high
protein low carbohydrate products. It is also contemplated that the
products may be incorporated with a blend of other ingredients, for
example, to form a bulky, crunchy constituent in an admixture that
is used to form nutritional or health bars.
[0026] In some embodiments, a wheat protein blend is particularly
preferred and may be provided as a wheat protein concentrate or
isolate. A minority fraction of other protein may be mixed with the
wheat protein, for example soy, rice, whey, corn or potato protein.
The proteins used are preferably isolates with high protein
content. Other ingredients may include native or modified starches
derived from wheat, corn, tubers etc. These starches may be
replaced by flour with high starch content, such as wheat flour,
potato flour and/or tapioca flour. Minor ingredients such as salts,
leavening agents, gums and sulfur-containing products in low
concentrations are typically incorporated to aid in expansion of
the product. A minor quantity of any food grade gum such as
Methocel gum can be added to increase the strength of the dough
melt. The use of sulfurous material, especially sulfides, is
feasible and may benefit the product, but is less preferred due to
a possibility of adverse reactions in consumers who are sensitive
to such materials.
[0027] The process used is a high temperature, high pressure, high
shear, short time cooking system that is also known in some
circumstances as extrusion cooking. A special twin screw profile,
die designs and optimum extrusion conditions may be used to obtain
the desired products in optimal form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 depicts a process equipment schematic illustrating an
extruder system for producing high-protein crisps;
[0029] FIG. 2 provides additional detail with respect to a die
assembly used in the process equipment;
[0030] FIG. 3 provides additional detail with respect to the die
assembly;
[0031] FIG. 4 provides additional detail with respect to the die
assembly;
[0032] FIG. 5 shows a twin screw assembly for use in the process
equipment;
[0033] FIG. 6 shows a twin screw assembly for use in the process
equipment;
[0034] FIG. 7 depicts an assemblage of wheat crisps;
[0035] FIG. 8 depicts a scanning electron microscope picture of the
cell structure of a wheat crisp;
[0036] FIG. 9 depicts a scanning electron microscope picture of the
cell structure of a wheat crisp;
[0037] FIG. 10 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp;
[0038] FIG. 11 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp;
[0039] FIG. 12 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp;
[0040] FIG. 13 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp;
[0041] FIG. 14 depicts an assemblage of wheat crisps;
[0042] FIG. 15 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp; and
[0043] FIG. 16 depicts a scanning electron microscope picture of
the cell structure of a wheat crisp.
DETAILED DESCRIPTION OF THE DRAWINGS
[0044] There will now be shown, by way of example and not by
limitation, an extrusion processing system 100 according to FIG. 1.
The extrusion processing system 100 may be used to produce
low-density expanded food products that have a high protein content
and a well developed expansion cell structure. By way of example,
one type of commercially available extruder that may be adapted for
use in extrusion processing system 100 is the model TX57.TM.
extruder from Wenger Manufacturing, Inc. of Sabetha, Kans. The
particular type of extruder system in use may be scaled up or down,
for example, in a scale-up to larger systems, such as the Wenger
model TX85.TM. or TX144.TM. extruder. A recipe of ingredients 102
passes through a hopper 104 and into a preconditioner 106. The
ingredients may be dry, in which case liquids 108 also pass into
the preconditioner 106. The preconditioner 106 may contain, for
example, a conventional single screw (not shown) fitted with
paddles to assist mixing of the ingredients that is actuated by
motor 110. The mixture of ingredients passes from the
preconditioner 106 through tube 112 and into extruder barrel
114.
[0045] The extruder barrel 114 may include a plurality of
cylindrical head sections, such as sections 116, 118, 120. The
respective cylindrical head sections are joined by flanges, such as
flange 122. An actuator, such as motor 124, rotates a dual screw
assembly 126, which is shown in broken view through cylindrical
head section 164. Counter-rotation of the screws 128, 130 of twin
screw assembly 126 subjects the ingredients 102 to internal
extrusion processing within the extruder barrel 114.
[0046] It will be appreciated that thermal process control is
improved by the use of jacketed cylindrical head sections 116, 118,
120, to control temperature in respective zones. For example,
cylindrical head section 118 may constitute one such zone 131 in
which a pump 132 under control of controller 134 circulates
refrigerated coolant in response to a sensed temperature T from
thermocouple 136. The thermocouple 122 may penetrate cylindrical
head section 118 to contact ingredients 102 as they are being
processed, while the coolant (not shown) is circulated within
jacket 138 and does not contact ingredients 102. In like manner,
each of the cylindrical section heads 116, 118, 120 may be
allocated into one or more cooling zones depending upon the nature
of jacketed construction.
[0047] Cylindrical head section 120 terminates in a die assembly
138, which shapes extruded ingredients 140, which are cut by cutter
assembly 142 to form expanded product segments 144 falling on
conveyor 146. The expanded product segments 144 may be in any form
that may be produced through a die extrusion process, such as
crisps, loops, or belts. Expansion of expanded product segments 144
occurs because the internal working pressure inside cylindrical
head section 120 is greater than ambient pressure outside
cylindrical head section 106, and this circumstance flashes the
expanded product 140 when extruded ingredients 140 exit the die
assembly 138. The ensuing expansion of volatile components creates
a suitable cell structure in the expanded ingredients for use as an
expanded product. In turn, conveyor 146 advances the expanded
product segments 144 into dryer 148 and product finishing machinery
150. By way of example, the dryer 148 may operate at 70.degree. C.
to 90.degree. C. for 6 to 10 minutes. The product finishing
machinery 150 may include any type of product finishing machinery
known in the art. By way of example, the product finishing
equipment 150 may include a fluidized bed that is used to coat the
expanded product segments 144 with flavorings, bulk packaging
equipment, retail product packaging equipment, and downstream
processing equipment that uses the expanded product segments 144 as
an ingredient for other products.
[0048] FIG. 2 is a midsectional view that provides additional
detail with respect to die assembly 138 which, for example, may be
in a configuration used to make wheat crisps according to the
dimensions discussed. As shown in the embodiment of FIG. 2, the die
assembly 138 may contain 2 to 1 Y-adapter 200 that contains
channels 202, 204 communicating dough 206 to a central opening 208
that itself communicates into breaker plate 210. The central
opening 208 of breaker plate 210 separates the adapter from die
plate 220 as an interim space communicating the channels 202, 204
with extrusion holes 214, 216. The central opening has a diameter
and an axis that is normal to the diameter between the adapter 200
and the die plate 220, where the diameter and the axis are
sufficient to avoid premature expansion of dough 206 prior to
passage through die plate 220. Depending upon process flow
conditions, the run of the diameter may, for example, be at least
ten times larger than the run of the axis, or this may be twenty or
thirty times larger. A cylinder 218 is positioned into die plate
220.
[0049] FIG. 3 shows die assembly 138 in perspective view. By way of
example, the holes 214, 216 might include 10 to 30 small openings
in size from 1.5 to 4 mm, depending on the desired product nature
when the interior opening 208 has a diameter of about 1 centimeter.
It is generally the case that as holes 212, 214 increase in size
the number of holes should be correspondingly reduced, and the
number of holes may be increased when the holes have a smaller
diameter. This is to provide a flow restriction that increases the
backpressure to facilitate expansion downstream from die assembly
126.
[0050] FIG. 4 shows the die assembly 138 with cutter 142 installed
on cylinder 218 to sweep blade 400 across face 402 of die plate 220
for cutting of extrudate.
[0051] FIG. 5 provides additional detail with respect to one
embodiment of extruder barrel 114 for use as shown in FIG. 1. This
embodiment is shown in FIG. 5 as extruder barrel 114' in an
assembly view with respect to screw assembly 126'. The
configuration as shown is particularly preferred for use in
processing ingredients that are high in protein, especially wheat
gluten. The various screw elements may be purchased on commercial
order, for example, from Wenger Manufacturing of Sabetha, Kans.,
and assembled as shown in FIG. 5. Conventional screw elements that
are in use on Wenger extruders and which may be included in the
screw assembly 126' include, for example, conveying screw sections,
cut-flight screw sections, forward lobes, reverse lobes, neutral
lobes. The various sections A, B, C shown in FIG. 5 are arranged to
provide good mixing and cooking of a dough mixture with high
protein content, such that the starch gelatinizes and forms a film,
but the protein is not texturized and is dispersed uniformly in the
starch. These goals may be accomplished in the extruder profile
set-up for expanded products by use of a simplified screw assembly
that makes limited use of cut-flight screws and reverse lobes.
Thus, the barrel length, for wheat products in particular, may be
shorter than for most conventional set-ups. Section A may, for
example, correspond to section 116 of FIG. 1 and the remaining
sections B and C may be added in sequence.
[0052] Dual screw assembly 126' is a twin screw assembly formed of
screws 500, 502. A first mixing/conveying section 504 resides
beneath mixer-preconditioner 112 (see FIG. 1) and includes an
offset mixer arrangement where screw 500 has approximately two
flights 506 for each flight 508 on screw 502 over interval 510.
This interval 510 accepts dough 206 from the preconditioner 106
(shown in FIG. 1) and completes the mixing process. The remainder
511 of mixing/conveying section 504 is generally a conveying
section that is equally flighted on opposed screws 500, 502, for
example, as a 1/2 pitch conveying section, towards a forward lobe
512 and a reverse lobe 513 on screw 500. The lobes 512, 513 are
opposed to complimentary lobes 512', 513' on screw 502 such that
forward lobe 512 is opposed to reverse lobe 512' and reverse lobe
513 is opposed to forward lobe 513'. The lobes 512, 512', 513, 513'
provide resistance to flow of dough 206 to assure good working and
mixing over mixing/conveying section 504.
[0053] A second conveying section 516 provides conveying,
compacting and some additional mixing between equivalently flighted
sections 518, 520. Sections 518, 520 each have relatively open
flights 521 proximate reverse lobe 513, such that the ratio of
flights is approximately 4:5 comparing interval 522 against the
remainder 511. In the interval 524, flights 526 narrow to
approximate the same spacing that persists over the remainder 511.
In effect, the flighting on interval 522 is widened to gather,
compact and convey ingredients after the chocking effect of forward
lobe 512 and reverse lobe 513, while the flighting on interval 524
is narrowed to provide additional working force against forward
lobe 528 and reverse lobe 528'. The lobes 528, 528' provide flow
resistance for increased upstream compacting effect in conveying
section 516.
[0054] A working section 530 contains opposed equivalently spaced
offset cut-flights 532, 534. By way of example, these may be cut
flights having a 0.75 inch pitch. Working section 530 imparts shear
to work the dough 206. The use of cut-flights in this position
imparts significant working effect that tends to break-down gluten
bonds. The flights 532, 534 on working section 530 are spaced more
narrowly together than are flights 526 over interval 524, for
example, to compare in an approximate axial run ratio of 3:2. This
is followed by conveying section 536, which carries the dough 206
towards forward lobe 538 and reverse lobe 539, which are opposed to
reverse lobe 538' and forward lobe 539'. Lobes 538, 538', 539, 539'
provide resistance to assure good upstream working conditions. A
second working section 540 repeats the cut-flight arrangement of
working section 530 and passes dough 206 to a lobe system 542
including sequentially a forward lobe 544, reverse lobe 546, and
forward lobe 548. These lobes 544, 546, 548 on screw 500 are
opposed to complimentary lobes including reverse lobe 544', forward
lobe 546', and reverse lobe 548' on screw 502. The lobe system 542
discharges the dough 206 into cone section 550, which passes dough
206 to die assembly 138 for extrusion of ingredients as shown in
FIG. 1.
[0055] It will be appreciated that working section 530 primarily
works the dough 206 and conveying section 536 primarily conveys the
dough 206, although there is some overlap of functionality between
the sections 530, 536. The action of conveying with significantly
less work in the conveying section 536 gives the dough time to
relax during which intermolecular bonds may be established. This
relaxation may be enhanced by the insertion of an additional
conveying section (not shown) where the lobes 544, 546 may be
replaced with an additional length of conveying section 536. This
substitution does two things. First, the additional conveying time
permits the dough 206 to undergo increased relaxation. Second,
elimination of lobes 544, 544', 546, 546' imparts less work to the
relaxed dough. This concept benefits dough with increased protein
contents, for example, when the protein content exceeds 60% by
weight.
[0056] FIG. 6 provides additional detail with respect to one
embodiment of extruder barrel 114 for use as shown in FIG. 1. This
embodiment is shown in FIG. 6 as extruder barrel 114'' in an
assembly view with respect to screw assembly 126''. The various
sections N, B', C', D' shown in FIG. 6 are arranged to provide good
mixing and cooking of a dough mixture with high protein content,
such that the starch gelatinizes and forms a film, but the protein
is not texturized and is dispersed uniformly in the starch. These
goals may be accomplished in the extruder profile set-up for
expanded products by use of a simplified screw assembly that makes
limited use of cut-flight screws and reverse lobes. Thus, the
barrel length may be shorter than for most conventional set-ups.
Section A' may, for example, correspond to section 116 of FIG. 1
and the remaining sections B', C' and D' may be added in sequence.
Screw assembly 126'' is identical to screw assembly 126' of FIG. 5,
except a conveying section 516' includes a longer run in interval
524', to permit enhanced dough relaxation as compared to conveying
section 516 over interval 524 in FIG. 5.
[0057] It will be appreciated that dough 206 may have relatively
high or relatively low protein contents within the prescribed
range, and that doughs with higher protein content must be worked
differently than doughs with lower protein contents. This may be
done, for example, by extending the length of conveying section
516' as shown in FIG. 6 to afford relatively more relaxation time
to dough with higher protein content. The shorter run of conveying
section 516 is amenable to dough with lower protein content.
Alternatively, the interval 516 could have been extended with
additional cut flight sections, such as cut flights 532, 534. These
cut flights impart a tremendous amount of working of the dough 206
and may be added for lower protein content doughs. In this manner,
the precise construction of the screw assembly 126 may be adjusted
on an empirical basis to impart proper working of the dough that is
appropriate to any given recipe on the basis of protein and/or
starch content.
[0058] Operation of the screw assembly 126 and the die assembly 138
in extrusion system 100 may provide significant benefits as
compared to the prior art. The high protein dough is worked
properly to avoid texturization while allowing good mixing and
cooking. This is done in part by using conveying screw elements on
interval 536 to relax the dough intermittently between the cut
flight intervals 530, 540 and the lobe interval 542, all of which
work the dough 206. Dough 206 exiting from cone section 550 passes
through the die assembly 138. The die assembly 138 complements the
screw assembly 126 for these purposes by avoiding long transitions
or venturis that are typically used to make texturized products.
The dough passes to the Y-adapter 200 for passage through the
openings 202, 204 and eventually through the respective openings
214, 216 in die plate 220. By way of example, the die assembly 138
as shown and described is set up to form wheat crisps, which are
generally small spheres with diameters ranging from 2 mm to 6
mm.
[0059] Die assembly 138 may be changed to form curls, loops or roll
products by providing fewer openings than for the wheat crisps.
Technical differences may exist between system setups for extruding
crisps versus other forms of shaped extrudate, such as curls,
loops, and rolls. Wheat crisps are relatively small, whereas the
curls, loops and rolls are increasingly larger in size. The larger
forms utilize a correspondingly larger die opening, so there is
less system backpressure at the die assembly 126. The use of lower
backpressure makes the product more difficult to expand. Expansion
is also more difficult with higher protein content. Where the
extruded product has a diameter of more than about 1 to 1.5
centimeters, it is increasingly difficult to extrude product having
good overall appearance and superior organoleptic qualities as
protein content rises much above the level of 60% by weight.
[0060] A recipe may include, for example, protein, such as wheat
protein concentrate, wheat protein isolate, e.g., with protein
contents between 85% to 95%, such as Arise 5000, 6000, 8000 and
Gliadin. Hydrolyzed wheat gluten such as HWG2009 from MGP
Ingredients may also be used. The hydrolyzed wheat gluten has a
protein content greater than 75% (N.times.5.7 db) and softens the
dough mixture while increasing the extensibility of the dough.
Starch may include a modified starch with the ability to maintain
product crispness and stability such as Midsol Krisp.TM., Midsol
46.TM.; or unmodified starch such as Regular Midsol 50.TM., potato
starch, rice starch, corn starch or tapioca starch; or a
starch-containing flour such as wheat, potato, rice, or tapioca
flour. Modified RS starch, such as such as FiberSym70.TM. and
FiberSym80.TM., may be added to increase total dietary fiber (TDF)
of the recipe. Leavening agents, such as calcium aluminum
phosphate, may be added. Dough softeners and strengtheners such as
cellulose methyl-cellulose (CMC), sodium stearoyl-2-lactylate
(SSL), polysorbate 60 etc. may be added. Antioxidants, such as,
BHA, BHT or TBHQ, may be added within levels that are permitted in
context of Food and Drug Administration regulations.
[0061] It will be appreciated that the starch may be provided as
flour that has a high starch content and so may be used to replace
the starch. By way of example, such flours include wheat, potato,
and tapioca flour.
[0062] The ingredients may be premixed in a blender and fed into
the extruder mixer/preconditioner 106 where moisture may be added,
such as from 15% to 20% by weight of the ingredients, to provide a
total moisture content ranging from about 25% to 30% by weight when
the in situ water content of dry flour and starch is also
considered. The ingredients are introduced into the extruder
barrel, which may be formed in any number of sections 116, 118, 120
and operated in a predetermined sequence of temperatures, for
example, as described in the recipes below. The temperature
preferably increases along the length of the extrusion barrel.
Where the protein content is less than about 40%, the late stages
of extrusion are preferably at about 100.degree. C. or less to
avoid defunctionalizing the starch. Higher protein contents benefit
from the use of higher temperatures, such as late stage
temperatures of 110.degree. C. or 120.degree. C. As the dough
passes though the extruder, it is mixed well and cooked to a
desired level.
[0063] Passage through die assembly 126 provides a desired shape
and texture. Drying of the extruded product in dryer 134 imparts a
final moisture level of 5 to 8%, whereupon the product may be
bagged or subjected to other downstream processing. Products
reported in the examples below had low density, good uniformity,
and good cell structure, which imparts a crisp texture in the
product.
[0064] Wheat crisps with protein contents ranging from 40 to 70%
have been developed according to working examples set forth below.
These examples set forth preferred materials and methods and should
not be narrowly construed. Along with the wheat crisps, curls and
loops/rolls were developed with protein contents in the range of 30
to 70%. For wheat crisps, generally the protein content can be as
much as 75% with excellent cell structure and texture. For other
expanded food products, for example, including wafers, loops,
rolls, and the like, the protein content may be less, such as up to
60% or 65% protein, in which case the remainder of the recipe
contains additional starch to compensate for less protein. In this
context, the starch may be any starch, such as high expanding
starch, oxidized starches, etc.
[0065] Wheat protein isolates such as Arise.TM. 5000, 6000 and
8000, which are products of MGPI, and modified starches such as
Midsol Krisp.TM., Midsol 46.TM., FiberStar.TM. 70 and 80, SRS.TM.
and Oxy-SRS.TM., which also are products of MGPI were used. Any
other wheat protein isolates which would have a proper blend of
gliadin and glutenin to provide the right amount of extensibility
and elasticity to give proper strength to the expanding dough melt
in the extruder may be used in the same manner. Other starches
which have good expansion ability can be used.
[0066] Other minor ingredients used were salts that may generate
expansion gas or prevent caking or clumping of dough, e.g., calcium
carbonate (CaCO3) or sodium bicarbonate along with sodium aluminum
phosphate, calcium aluminum phosphate or sodium aluminum sulfate.
These minor ingredients may be used, either alone or in
combinations, as an aid to expansion by way of releasing carbon
dioxide. Any other salts which can aid in expansion can be used.
Along with the above ingredients, a minor quantity of any food
grade gum such as Methocel gum may be added to increase the
strength of the dough melt. Different dough softeners that are
commonly used in the commercial baking industry, such as SSL and/or
Datem, may be used to assist the expansion of higher protein crisps
by making the high protein dough softer. The concentrations of
minor ingredients may vary as a matter of product formulation.
[0067] Vinegar is preferably but optionally added, and especially
improves flow of the dough through the extruder when the dough
contains higher protein levels above 60%. Again, vinegar is a
preferred ingredient at these higher protein levels, but not a
necessary one that must be used in all embodiments.
Example 1
Wheat Protein+Modified Wheat Starch
A. Extrusion Conditions
[0068] Extrusion Profile: #2
[0069] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0070] die assembly 126: 47-47-79-74.degree. C.
[0071] Extrusion Pressure: 5460.2 kPa
[0072] Extrusion Motor Load: 85%
[0073] Extruder Speed: 385 rpm
[0074] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Recipe
TABLE-US-00001 [0075] Ingredient Percent Wt. Arise 8000 .TM. 50
Midsol Krisp .TM. 48.61 Sodium Bicarbonate 0.5 Sodium Aluminum
Phosphate 0.25 Sodium Aluminum Sulfate 0.25 Calcium Aluminum
Phosphate 0.25 CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar
2%
C. Final Product Properties
TABLE-US-00002 [0076] Property Value Moisture Content 2.31 Bulk
Density (g/cc)-(lb/ft.sup.3) 0.1249-7.8 Protein (N .times. 6.25 as
is) 42.66 TDF 1.1
Example 2
Wheat Protein+Modified Wheat Starch
[0077] a. Extrusion Conditions
[0078] Extrusion Profile: #2
[0079] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0080] die assembly 126: 45-91-95-98.degree. C.
[0081] Extrusion Pressure: 6190 kPa
[0082] Extrusion Motor Load: 60%
[0083] Extrusion Speed: 325 rpm
[0084] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00003 [0085] Ingredient Percent Wt. Arise 8000 .TM. 60
Midsol Krisp .TM. 38.296 Sodium Bicarbonate 0.5 Sodium Aluminum
0.25 Phosphate Sodium Aluminum Sulfate 0.25 Calcium Aluminum 0.25
Phosphate BHA 0.002 BHT 0.002 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00004 [0086] Property Value Moisture Content (% wb) 2.63
Bulk Density (g/cc) - (lb/ft.sup.3) 0.141-8.790 Protein (N .times.
6.25 as is) 57.29 TDF (%) 1.1
[0087] FIG. 7 shows a plurality of wheat crisps made according to
this example. FIG. 8 shows a SEM micrograph at 50 .mu.m
magnification showing a substantially uniform cell structure in a
wheat crisp. By "substantially uniform" it is meant that the cell
structure has a substantially uniform distribution of cell sizes
and cell wall thicknesses throughout a unit volume, and that mixing
of ingredients has occurred to substantial homogeneity such that
there is little or no apparent transition of protein to starch
material visible at this magnification. FIG. 9 shows a
substantially uniform cell structure at 250 .mu.m
magnification.
Example 3
Wheat Protein+Wheat Flour
A. Extrusion Conditions
[0088] Extrusion Profile: #2
Extrusion Temperature in cylindrical head sections 102, 104, 106,
and die assembly 126: 45-92-95-92.degree. C.
[0089] Extrusion Pressure: 7200 kPa
[0090] Extrusion Motor Load: 64%
[0091] Extrusion Speed: 350 rpm
[0092] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00005 [0093] Ingredient Percent Wt. Arise 8000 .TM. 60
Wheat Flour (high protein) 38.296 Sodium Bicarbonate 0.5 Sodium
Aluminum 0.25 Phosphate Sodium Aluminum Sulfate 0.25 Calcium
Aluminum 0.25 Phosphate BHA 0.002 BHT 0.002 Water 15% Vinegar
2%
C. Final Product Properties
TABLE-US-00006 [0094] Property Value Moisture Content (% wb) 1.75
Bulk Density (g/cc) - (lb/ft.sup.3) 0.192-12.00 Protein (N .times.
6.25 as is) 61.50 TDF (%) 1.0
[0095] FIG. 10 shows a SEM micrograph at 200 .mu.m magnification
showing a substantially uniform cell structure in a wheat crisp
produced in this example. FIG. 11 shows a substantially uniform
cell structure at 200 .mu.m magnification from a different locus in
the wheat crisp.
Example 4
Wheat Protein+Potato Starch
A. Extrusion Conditions
[0096] Extrusion Profile: #2
[0097] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0098] die assembly 126: 45-90-95-92.degree. C.
[0099] Extrusion Pressure: 6890 kPa
[0100] Extrusion Motor Load: 73%
[0101] Extrusion Speed: 350 rpm
[0102] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00007 [0103] Ingredient Percent Wt. Arise 8000 .TM. 60
Potato Starch 38.296 Sodium Bicarbonate 0.5 Sodium Aluminum 0.25
Phosphate Sodium Aluminum Sulfate 0.25 Calcium Aluminum 0.25
Phosphate BHA 0.002 BHT 0.002 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00008 [0104] Property Value Moisture Content (% wb) 1.77
Bulk Density (g/cc) - (lb/ft.sup.3) 0.169-10.58 Protein (N .times.
6.25 as is) 59.84 TDF (%) 0.8
[0105] FIG. 12 shows a SEM micrograph at 200 .mu.m magnification
showing a substantially uniform cell structure in a wheat crisp
produced according to this example. FIG. 13 shows a substantially
uniform cell structure at 500 .mu.m magnification in the wheat
crisp.
Example 5
Wheat Protein+Modified Wheat Starch
A. Extrusion Conditions
[0106] Extrusion Profile: #2
[0107] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0108] die assembly 126: 45-45-73-77.degree. C.
[0109] Extrusion Pressure: 7567.5 kPa
[0110] Extrusion Motor Load: 76%
[0111] Extrusion Speed: 350 rpm
[0112] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00009 [0113] Ingredient Percent Wt. Arise 8000 .TM. 60
Midsol 46 .TM. 38.61 Sodium Bicarbonate 1.0 Sodium Aluminum 0.5
Phosphate Sodium Aluminum 0.5 Sulfate Calcium Aluminum 0.5
Phosphate CoviOx (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00010 [0114] Property Value Moisture Content 3.25 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.138-8.651 Protein (N .times. 6.25
as is) 57.12 TDF 1.12
Example 6
Wheat Proteins+Modified Wheat Starch
A. Extrusion Conditions
[0115] Extrusion Profile: #2
[0116] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0117] die assembly 126: 45-91-94-94.degree. C.
[0118] Extrusion Pressure: 645 kPa
[0119] Extrusion Motor Load: 63%
[0120] Extrusion Speed: 400 rpm
[0121] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00011 [0122] Ingredient Percent Wt. Arise 8000 .TM. 35
Arise 6000 .TM. 35 Midsol Krisp 27.496 Sodium Bicarbonate 1.0
Sodium Aluminum 0.5 Phosphate Sodium Aluminum Sulfate 0.5 Calcium
Aluminum 0.5 Phosphate BHA 0.002 BHT 0.002 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00012 [0123] Property Value Moisture Content (% wb) 2.75
Bulk Density (g/cc) - (lb/ft.sup.3) 0.175-10.95 Protein (N .times.
6.25 as is) 59.92 TDF (%) 1.8
[0124] FIG. 14 shows a plurality of wheat crisps made according to
this example. FIG. 15 shows a SEM micrograph at 500 .mu.m
magnification showing a substantially uniform cell structure in a
wheat crisp. FIG. 16 shows a substantially uniform cell structure
at 500 .mu.m magnification.
Example 7
Wheat Protein+Modified Wheat Starches
A. Extrusion Conditions
[0125] Extrusion Profile: #2
[0126] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0127] die assembly 126: 46-46-74-72.degree. C.
[0128] Extrusion Pressure: 7439.7 kPa
[0129] Extrusion Motor Load: 71%
[0130] Extruder Speed: 400 rpm
[0131] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00013 [0132] Ingredient Percent Wt. Arise 8000 .TM. 60
Midsol Krisp .TM. 33.61 Fibersym 70 .TM. 5.0 Sodium Bicarbonate 0.5
Sodium Aluminum 0.25 Phosphate Sodium Aluminum Sulfate 0.25 Calcium
Aluminum 0.25 Phosphate CoviOx .TM. (Vitamin E) 0.14 Water 15%
Vinegar 2%
C. Final Product Properties
TABLE-US-00014 [0133] Property Value Moisture Content 2.32 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.217-13.57 Protein (N .times. 6.25
as is) 51.36 TDF 4.75
Example 8
Wheat Protein+Modified Wheat Starches
A. Extrusion Conditions
[0134] Extrusion Profile: #2
[0135] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0136] die assembly 126: 46-46-74-78.degree. C.
[0137] Extrusion Pressure: 6786.2 kPa
[0138] Extrusion Motor Load: 70%
[0139] Extruder Speed: 400 rpm
[0140] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00015 [0141] Ingredient Percent Wt. Arise 8000 .TM. 60
Midsol Krisp .TM. 28.61 Fibersym 70 .TM. 10.0 Sodium Bicarbonate
1.0 Sodium Aluminum 0.5 Phosphate Sodium Aluminum Sulfate 0.5
Calcium Aluminum 0.5 Phosphate CoviOx (Vitamin E) 0.14 Water 15%
Vinegar 2%
C. Final Product Properties
TABLE-US-00016 [0142] Property Value Moisture Content 1.88 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.227-14.19 Protein (N .times. 6.25
as is) 51.61 TDF 7.54
Example 9
Wheat Protein+Modified Wheat Starches
A. Extrusion Conditions
[0143] Extrusion Profile: #2
[0144] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0145] die assembly 126: 46-46-77-81.degree. C.
[0146] Extrusion Pressure: 8601.05 kPa
[0147] Extrusion Motor Load: 81%
[0148] Extrusion Speed: 400 rpm
[0149] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00017 [0150] Ingredient Percent Wt. Arise 8000 .TM. 64.36
Midsol Krisp .TM. 26.35 Midsol 46 .TM. 7.92 Sodium Bicarbonate 0.5
Sodium Aluminum 0.25 Phosphate Sodium Aluminum Sulfate 0.25 Calcium
Aluminum 0.25 Phosphate CoviOx (Vitamin E) 0.14 Water 15% Vinegar
2%
C. Final Product Properties
TABLE-US-00018 [0151] Property Value Moisture Content 1.98 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.2098-13.1 Protein (N .times. 6.25
as is) 56.27 TDF 1.27
Example 10
Wheat Protein+Modified Wheat Starch
A. Extrusion Conditions
[0152] Extrusion Profile: #2
[0153] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0154] die assembly 126: 48-48-72-78.degree. C.
[0155] Extrusion Pressure: 9139.9 kPa
[0156] Extrusion Motor Load: 75%
[0157] Extrusion Speed: 400 rpm
[0158] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00019 [0159] Ingredient Percent Wt. Arise 8000 .TM. 70
Midsol Krisp .TM. 28.61 Sodium Bicarbonate 1.0 Sodium Aluminum 0.5
Phosphate Sodium Aluminum Sulfate 0.5 Calcium Aluminum 0.5
Phosphate CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00020 [0160] Property Value Moisture Content 1.96 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.2500-15.61 Protein (N .times. 6.25
as is) 59.67 TDF 1.11
Example 11
Wheat Protein+Modified Wheat Starches
A. Extrusion Conditions
[0161] Extrusion Profile: #2
[0162] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0163] die assembly 126: 46-46-74-74.degree. C.
[0164] Extrusion Pressure: 6336.3 kPa
[0165] Extrusion Motor Load: 72%
[0166] Extruder Speed: 400 rpm
[0167] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00021 [0168] Ingredient Percent Wt. Arise 8000 .TM. 70
Midsol Krisp .TM. 20.61 Fibersym 70 .TM. 5.0 Sodium Bicarbonate 1.0
Sodium Aluminum 0.5 Phosphate Sodium Aluminum Sulfate 0.5 Calcium
Aluminum 0.5 Phosphate CoviOx .TM. (Vitamin E) 0.14 Water 15%
Vinegar 2%
C. Final Product Properties
TABLE-US-00022 [0169] Property Value Moisture Content 2.11 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.2704-16.88 Protein (N .times. 6.25
as is) 60.8 TDF 4.31
Example 12
Wheat Protein+Modified Wheat Starch
A. Extrusion Conditions
[0170] Extrusion Profile: #2
[0171] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0172] die assembly 126: 46-51-75-78.degree. C.
[0173] Extrusion Pressure: 7258.2 kPa
[0174] Extrusion Motor Load: 83%
[0175] Extruder Speed: 400 rpm
[0176] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00023 [0177] Ingredient Percent Wt. Arise 8000 .TM. 75
Midsol Krisp .TM. 19.36 Sodium Bicarbonate 1.5 Sodium Aluminum 0.75
Phosphate Sodium Aluminum Sulfate 0.75 Calcium Aluminum 0.75
Phosphate CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00024 [0178] Property Value Moisture Content 2.23 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.3099-19.35 Protein (N .times. 6.25
as is) 64.80 TDF 1.13
Example 13
Wheat Protein+Rice Protein+Modified Rice Starches
A. Extrusion Conditions
[0179] Extrusion Profile: #2
[0180] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0181] die assembly 126: 46-62-75-69.degree. C.
[0182] Extrusion Pressure: 5326 kPa
[0183] Extrusion Motor Load: 66%
[0184] Extruder Speed: 375 rpm
[0185] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Wheat Crisp Recipe
TABLE-US-00025 [0186] Ingredient Percent Wt. Arise 8000 .TM. 40
RemyPro N80+ .TM. 30 Remyline AX-FG-P .TM. 16.86 Remy B7 .TM. 10.0
Sodium Bicarbonate 1.5 Sodium Aluminum 0.5 Phosphate Sodium
Aluminum Sulfate 0.5 Calcium Aluminum 0.5 Phosphate CoviOx .TM.
(Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00026 [0187] Property Value Moisture Content 2.48 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.2939-18.35 Protein (N .times. 6.25
as is) 60.71 TDF 1.56
Example 14
Wheat Protein+Soy Protein+Modified Wheat Starch
A. Extrusion Conditions
[0188] Extrusion Profile: #2
[0189] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0190] die assembly 126: 47-59-72-68.degree. C.
[0191] Extrusion Pressure: 55550 kPa
[0192] Extrusion Motor Load: 67%
[0193] Extruder Speed: 380 rpm
[0194] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Recipe
TABLE-US-00027 [0195] Ingredient Percent Wt. Arise 8000 .TM. 50.26
Soy Isolate (EX-38 Solae) 20.10 Midsol Krisp .TM. 27.35 Sodium
Bicarbonate 0.5 Sodium Aluminum 0.25 Phosphate Sodium Aluminum
Sulfate 0.25 Calcium Aluminum 0.25 Phosphate Calcium Carbonate 0.9
CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00028 [0196] Property Value Moisture Content 2.77 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.1887-11.78 Protein (N .times. 6.25
as is) 61.35 TDF 1.21
Example 15
Rice Protein+Modified Wheat Starches
A. Extrusion Conditions
[0197] Extrusion Profile: #2
[0198] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0199] die assembly 126: 45-60-72-70.degree. C.
[0200] Extrusion Pressure: 6650.4 kPa
[0201] Extrusion Motor Load: 87%
[0202] Extruder Speed: 325 rpm
[0203] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Recipe
TABLE-US-00029 [0204] Ingredient Percent Wt. RemyPro N80+ .TM.
70.00 Midsol Krisp .TM. 18.61 Midsol 46 .TM. 10.00 Sodium
Bicarbonate 0.5 Sodium Aluminum 0.25 Phosphate Sodium Aluminum
Sulfate 0.25 Calcium Aluminum 0.25 Phosphate Calcium Carbonate 0.9
CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00030 [0205] Property Value Moisture Content 5.45 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.1352-8.44 Protein (N .times. 6.25
as is) 41.09 TDF 2.33
Example 16
Rice Protein+Modified Wheat Starches
A. Extrusion Conditions
[0206] Extrusion Profile: #2
[0207] Extrusion Temperature in cylindrical head sections 102, 104,
106, and
[0208] die assembly 126: 45-62-81-74.degree. C.
[0209] Extrusion Pressure: 8814.6 kPa
[0210] Extrusion Motor Load: 77%
[0211] Extruder Speed: 350 rpm
[0212] Water was added to the dry mix during extrusion through the
extruder barrel. The dry feed rate ranged from 105 to 130 kg/hr,
and water feed rate ranged from 10 to 26 kg/hr. Vinegar was fed
into the extruder preconditioner at approximately 2 kg/hr.
B. Recipe
TABLE-US-00031 [0213] Ingredient Percent Wt. RemyPro N80+ .TM.
80.00 Midsol Krisp .TM. 8.61 Midsol 46 .TM. 10.00 Sodium
Bicarbonate 0.5 Sodium Aluminum 0.25 Phosphate Sodium Aluminum
Sulfate 0.25 Calcium Aluminum 0.25 Phosphate Calcium Carbonate 0.9
CoviOx .TM. (Vitamin E) 0.14 Water 15% Vinegar 2%
C. Final Product Properties
TABLE-US-00032 [0214] Property Value Moisture Content 2.63 Bulk
Density (g/cc) - (lb/ft.sup.3) 0.1852-11.56 Protein (N .times. 6.25
as is) 54.91 TDF 1.68
[0215] Those skilled in the art will appreciate that the foregoing
discussion teaches by way of example, not by limitation. The
disclosed instrumentalities set forth preferred methods and
materials, and may not be narrowly construed to impose undue
limitations on the invention. The scope of the inventor's
patentable inventions is defined by the claims, nothing else.
Furthermore, the inventors hereby state their intention to rely
upon the Doctrine of Equivalents to protect the full scope of their
rights in what is claimed.
* * * * *