U.S. patent application number 16/591979 was filed with the patent office on 2020-03-26 for quick-cook grains and pulses.
The applicant listed for this patent is The Quaker Oats Company. Invention is credited to Gary MOORE, Waleed YACU.
Application Number | 20200093170 16/591979 |
Document ID | / |
Family ID | 45218906 |
Filed Date | 2020-03-26 |
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United States Patent
Application |
20200093170 |
Kind Code |
A1 |
MOORE; Gary ; et
al. |
March 26, 2020 |
Quick-Cook Grains and Pulses
Abstract
A method for making a quick-cook grain or pulse via flat plate
compression or gun puffing by controlling the porosity of the grain
or pulse. Further, the grain or pulse made in accordance with this
invention retains the texture, flavor and appearance of the
original grain or pulse.
Inventors: |
MOORE; Gary; (Chicago,
IL) ; YACU; Waleed; (Chicago, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Quaker Oats Company |
Chicago |
IL |
US |
|
|
Family ID: |
45218906 |
Appl. No.: |
16/591979 |
Filed: |
October 3, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14883260 |
Oct 14, 2015 |
10485260 |
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16591979 |
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13303378 |
Nov 23, 2011 |
9161559 |
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14883260 |
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61416468 |
Nov 23, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23L 7/178 20160801;
A23L 11/10 20160801; A23L 7/183 20160801; A23V 2002/00 20130101;
A23L 7/196 20160801; A23P 30/32 20160801 |
International
Class: |
A23P 30/32 20060101
A23P030/32; A23L 7/178 20060101 A23L007/178; A23L 11/10 20060101
A23L011/10; A23L 7/183 20060101 A23L007/183; A23L 7/196 20060101
A23L007/196 |
Claims
1. A method of processing whole kernel grains to make quick-cook
grains by controlling the porosity of the grains while maintaining
the identity of the grains comprising the steps of: introducing
de-hulled whole kernel grains, having a moisture content of about
8-18%, between two heated devices; compressing the whole kernel
grains between the heated devices for about 1-5 seconds; heating
the whole kernel grains between the heated devices and causing the
water within the grains to reach a superheated condition;
instantaneously reducing the whole kernel grains to atmospheric
pressure to create a slightly puffed grains with a reduced bulk
density; and discharging the slightly puffed whole kernel grains
from the heated devices; wherein the slightly puffed whole kernel
grains have a bulk density between 260-700 g/L and a final moisture
content below about 14% and an a.sub.w less than about 0.65.
2. The method of claim 1 wherein the heated devices are at least
two heated flat plates.
3. The method of claim 2 wherein the flat plates have a temperature
of about 150-250.degree. C. and the pressure exerted on the grain
is about 500 to about 1000 psig.
4. The method of claim 2 wherein after compressing, starch in the
whole kernel grains is partially gelatinized.
5. The method of claim 2 wherein after compressing starch in the
whole kernel grains is fully gelatinized.
6. The method of claim 2 wherein the following steps are performed
prior to the step of introducing the whole kernel grains between
the flat plates: mixing the de-hulled whole kernel grains with
ingredients selected from the group consisting of water, flavor,
nutrients, antioxidants and mixtures thereof to create a grain
mixture; cooking the grain mixture under pressure to partially or
fully gelatinize starch in the grains and arrive at a cooked grain
mixture with a final moisture content of about 30-40%; and drying
the cooked grain mixture.
7. The method of claim 6 wherein the cooked grain mixture is dried
to about 11-13% moisture and subsequently stored.
8. The method of claim 6 wherein the cooked grain mixture is dried
to about 12-18% when proceeding immediately to the compressing
between the flat plates.
9. The method of claim 1 wherein the heated devices are at least
two counter-rotating parallel rolls.
10. The method of claim 1 wherein the heated devices are at least
two mated non-flat plates.
11. A method of processing pulses to make quick-cook pulses by
controlling the porosity of the pulses while maintaining the
identity of the pulses comprising the steps of: introducing whole
pulses having a moisture content of about 8-18% between two heated
devices; compressing the whole pulses between the heated devices
for about 1-5 seconds to gelatinize starch contained in the pulse;
instantaneously reducing the pulses to atmospheric pressure to
create a slightly puffed pulse with a reduced bulk density;
discharging the slightly puffed pulses from the heated devices;
wherein the pulse has a bulk density between 260-700 g/L, the final
moisture content is below about 14% with an a.sub.w less than about
0.65.
12. The method of claim 11 wherein the heated devices are at least
two counter-rotating parallel rolls.
13. The method of claim 11 wherein the heated devices are at least
two mated non-flat plates.
14. A method of processing grains to control the porosity of the
grains while maintaining the identity of the whole grains
comprising the steps of: introducing whole kernel grains having a
moisture content of about 8-14% into a gun puffing chamber and
sealing the chamber; raising the pressure of the chamber to reach a
pressure of about 80-175 psig at a temperature of about
162-192.degree. C. until the moisture of the whole kernel grains
reaches a moisture content of about 14-30%; instantaneously
reducing the whole kernel grains to atmospheric pressure to create
slightly puffed grains with reduced bulk density; and dehydrating
the whole kernel grains to reach a moisture content below about 14%
and an a.sub.w less than about 0.65.
15. The method of claim 14 wherein the moisture content of the
whole kernel grains following dehydration is about 10-13%.
16. The method of claim 14 wherein the moisture content of the
whole kernel grains following dehydration is about 3-5%.
17. The method of claim 14 wherein the prior to the step of
introducing the raw whole kernel grain into the gun puffing
chamber, the raw grain is preheated to increase the temperature of
the whole kernel grain to about 120.degree. C.
18. The method of claim 14 wherein the method of processing the
whole kernel grains also includes pre-hydrating and tempering the
whole kernel grains to bring the moisture content to about 13-25%
and then preheating the grains to bring the temperature of the
grains to about 90.degree. C. prior to introducing the grains into
the gun puffing chamber.
19. A method of processing whole pulses to control the porosity of
the whole pulses while maintaining the identity of the whole pulses
comprising the steps of: introducing whole pulses having a moisture
content of about 8-14% into a gun puffing chamber and sealing the
chamber; raising the pressure of the chamber to reach a pressure of
about 80-175 psig at a temperature of about 162-192.degree. C.
until the moisture within the whole pulses reaches a moisture
content of about 14-30%; instantaneously reducing the whole pulses
to atmospheric pressure to create a slightly puffed whole pulses
with a reduced bulk density; and dehydrating the whole pulses to
reach a moisture content below about 14% and an a.sub.w less than
about 0.65.
20. The method of claim 19 wherein the moisture content of the
pulses following dehydration is about 10-13%.
21. The method of claim 19 wherein the moisture content of the
whole pulses following dehydration is about 3-5%.
22. The method of claim 19 wherein the prior to the step of
introducing the whole pulses into the gun puffing chamber, the
whole pulses are preheated to increase the temperature of the
pulses to about 90.degree. C.
23. The method of claim 19 wherein the method of processing also
includes tempering the whole pulses to bring the moisture content
to about 13-25% and then preheating the pulses to bring the
temperature of the whole pulses to about 90.degree. C. prior to
introducing the pulses into the gun puffing chamber.
24. A method of processing split pulses to control the porosity of
the split pulses while maintaining the identity of the split pulses
comprising the steps of: introducing split pulses having a moisture
content of about 8-14% into a gun puffing chamber and sealing the
chamber; raising the pressure of the chamber to reach a pressure of
about 80-175 psig at a temperature of about 162-192.degree. C.
until the moisture within the whole pulses reaches a moisture
content of about 14-30%; instantaneously reducing the split pulses
to atmospheric pressure to create slightly puffed split pulses
having a reduced bulk density; and dehydrating the split pulses to
reach a moisture content below 14% and an a.sub.w less than about
0.65.
25. The method of claim 24 wherein the moisture content of the
pulses following dehydration is about 10-13%.
26. The method of claim 24 wherein the moisture content of the
split pulses following dehydration is about 3-5%.
27. The method of claim 24 wherein prior to the step of introducing
the split pulses into the gun puffing chamber, the split pulses are
preheated to increase the temperature of the pulses to about
90.degree. C.
28. The method of claim 24 wherein the method of processing also
includes tempering the split pulses to bring the moisture content
to about 13-25% and then preheating the pulses to bring the
temperature of the split pulses to about 90.degree. C. prior to
introducing the pulses into the gun puffing chamber.
29. The quick-cook grains produced by the methods of claims 1 and
12.
30. The quick-cook pulses produced by the methods of claims 11, 19
and 24.
Description
[0001] This application claims priority to U.S. Provisional
Application No. 61/416,468, filed on Nov. 23, 2010, which is
incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a method of
processing grains and pulses to control their porosity while
retaining their original identity.
BACKGROUND OF THE INVENTION
[0003] Whole grains play an important role in a healthy and
balanced diet. Consumption of whole grains provide many health
benefits including lowering the risk of chronic diseases such as
diabetes and heart disease. Whole grains have also been found to
promote weight management and may protect against cancer.
[0004] Pulses also play an important role in a healthy and balanced
diet. Because of their high protein content, pulses such as kidney
beans and lentils are sometimes used as meat substitutes and are
heavily consumed by vegetarians and vegans for this reason. Pulses
are also low in fat, high in dietary fiber, and rich in
antioxidants.
[0005] Although grains and pulses provide many health benefits,
they are not consumed as frequently as they should be by the
average American due to the substantial preparation time needed to
cook these foods. In general, a whole grain with its bran layer
intact and no modifications made to its structure will cook on the
stovetop in about 35 to 45 minutes. Mature pulses must be soaked
and then cooked thoroughly before they can be eaten, which can be
very time consuming (from one hour to overnight preparation).
[0006] Although attempts have been made to provide the consumer
with a quick-cooking grain or pulse, these attempts are either
expensive to commercially produce due to efficiency or result in a
product that is overly puffed, thereby compromising the original
texture, flavor and appearance of the original grain and resulting
in consumer skepticism. Further, the current technologies that are
used to make quick-cooking grains and pulses have many
disadvantages. For instance, most of these technologies require
pre-cooking with a large amount of water and then removing the
water at great expense and poor efficiencies. Another method
involves pre-hydrating in the case of grains and pulses to a high
moisture and then freeze drying to remove moisture while retaining
a porous, reduced density whole particle. Once again, this process
is expensive and inefficient when performed on a commercial scale.
Additionally, grains can be pre-cooked in an extruder and
subsequently formed into grain-like shapes, but these methods
change the appearance of the grain and leave it looking
unnatural.
[0007] In light of the foregoing, a need exists in the field for
efficient methods for efficiently and cost-effectively making
quick-cooking whole grains and pulses wherein the identity of the
caryopsis does not change significantly during processing.
Therefore, not only the taste, but also the appearance of the
caryopsis is acceptable to the consumer.
[0008] The processing methods described and claimed herein create
stable, porous, dry whole kernel products without the need for
hydrating to 60-80% moisture and then removing the moisture back
down to a stable moisture content. This invention also provides a
controlled level of puffing for whole grains or whole pulses.
Current gun puffed grains are highly puffed and lose their original
identity when cooked or soaked in water. They also have a Styrofoam
texture in a dry state. With a reduced level of puffing the whole
grains and pulses retain their identity when cooked and have a more
robust texture when eaten in their dry state. This technology also
enables infusion of liquids into the grain or legume structure.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates generally to a method of
preparing quick-cooking grains and pulses by controlling their
porosity using flat plate compression or gun puffing.
DETAILED DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a processing schematic depicting one aspect of the
instant invention relating to gun puffing to produce quick cook
cereal grains.
[0011] FIG. 2 is a processing schematic depicting one aspect of the
instant invention relating to gun puffing to produce quick cook
pulses.
[0012] FIG. 3 is a processing schematic depicting one aspect of the
instant invention relating to hot plate puffing to produce quick
cook cereal grains.
[0013] FIG. 4 is a processing schematic depicting one aspect fo the
instant invention relating to hot plate puffing to produce quick
cook pulses.
[0014] FIG. 5 is a RVA analysis of oats puffed to the target size
and density in one aspect of the instant invention.
[0015] FIG. 6 is an electron micrograph of a cross section of a
typical unrtreated oat groat.
[0016] FIG. 7 is an electron micrograph (1000.times.magnification)
of the interior of a typical untreated oat groat.
[0017] FIG. 8 is an electron micrograph of the cross section of an
oat groat puffed to the target size and porosity in one aspect of
the instant invention.
[0018] FIG. 9 is an electron micrograph (1000.times.magnification)
of the interior of an oat groat puffed to the target size and
porosity in one aspect of the instant invention.
[0019] FIG. 10 is an electron micrograph (3000.times.magnification)
of the microstructure of an oat groat puffed to the target size and
porosity in one aspect of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention relates to a method of processing
whole grains or pulses to manipulate the internal structure of the
food thereby increasing porosity while retaining the nature
appearance/original identity of the grains or pulses.
[0021] The grains used in accordance with the present invention may
include: cereals such as corn, wheat, rice, oat, barley, sorghum,
millet, rye, triticale, and spelt, and pseudocereals such as
buckwheat and quinoa, and mixtures of these grains. Likewise, the
pulses used in accordance with the present invention may include:
beans such as pinto, navy, kidney, lima azuki, mung and black gram,
dry peas such as garden and protein and chickpea, cowpea, pigeon
pea, black-eyed pea and lentils and mixtures of these pulses.
[0022] Unpuffed grains and pulses have a bulk density of
approximately 800 grams/liter. Bulk density is a secondary
indicator of grain porosity, showing that the grains or pulses have
swollen without gaining weight. The invention described herein
controls the porosity of the grains and pulses and reduces the bulk
density to an optimal level for increased hydration while
maintaining the texture and appearance of the original grains and
pulses.
[0023] "Original identity," "original state" or "raw" as used
herein means the uncooked grains or pulses. "Instantaneously" as
used herein means a time frame of two seconds or less.
[0024] The inventors found that manipulating gun puffing and
flat-plate compression processes (as more fully described below)
produced lightly puffed grains or pulses with novel properties,
including increased moisture penetration rate, decreased
preparation time, and a natural appearance following cooking. For
example, the grains and pulses made in accordance with the present
invention cook in about 1-15 minutes versus the 35 minutes to
potentially hours (between soaking and boiling) for grains and
pulses in their original/raw states.
[0025] One aspect of the present invention, illustrated in FIGS. 3
and 4 includes preparing quick-cooking grains and pulses with
controlled porosity using hot plates. In this method, raw grain or
pulse, having a moisture content of about 8-18% (wet basis,) in the
form of whole kernels of grains or pulses are introduced between
flat plates, compressed and heated. Prior to hot plate compression,
hulls are removed from any grains containing intact hulls. The
kernels are compressed for about 1-5 seconds using flat plates
heated to about 150-250.degree. C. to partially or fully gelatinize
the starch. For slightly puffed products (e.g., bulk density
reduction of 5-35%), only partial gelatinization is required. This
can be advantageous for achieving certain types of texture. For
moderate to highly puffed products (e.g. bulk density reduction of
50-75%), more complete gelatinization of the starch is required to
provide structural integrity. Following compression, the pressure
is reduced to atmospheric pressure almost instantaneously, for
example, less than about 2 seconds. After the pressure is released,
the kernels are discharged from the plates. This rapid pressure
release causes the internal volume of the grain or pulse kernel to
increase due to the controlled pressure and temperature
differential. Moreover, the moderate moisture flash-off and
light/subtle puffing leave the kernels with a reduced bulk density.
For example, the bulk density of the lightly puffed grains may
range from about 260-700 g/L, such as about 350-450 g/L. Further,
the final moisture of the grains is less than about 14% (wet
basis), such as about 7-11%. In an alternative aspect of the
invention, the puffed kernels may be further dehydrated by any
applicable means, such as drying with hot air in a batch or
continuous bed dryer or dried in a fluid bed hot air dryer until a
final moisture of less than 14% and a.sub.w less than 0.65 is
achieved. Equipment that may be used to compress the kernels under
pressure and heat include a rice cake popping machine, wherein the
plates operate within a mold. The pressure in the hot plates during
compression may be between 500-1000 psi. Alternatively, a pair of
heated rolls, such as a pair of cereal flaking rolls, rotating
towards each other may be used to compress and heat the kernels to
lightly puff the kernels.
[0026] In another aspect of the present invention, the raw grains
are mixed with ingredients, including, but not limited to water,
flavor, nutrients and antioxidants to create a grain mixture. This
grain mixture is then cooked under pressure, such as in a rotary
cereal cooker in an atmosphere of steam pressure at 15-35 psig
(250-285.degree. F.) for a period of 20-90 minutes to partially or
fully gelatinize the starch and arrive at a cooked grain mixture
with a final moisture content of about 20-50%. Next, the cooked
grain mixture is dried to about 11-13% moisture if being stored or
about 12-18% if being immediately puffed. A moderate temperature,
such as about 82.degree. C. for about 60 minutes, may be used to
dry the cooked grain mixture. This dried cooked grain mixture is
subsequently rehydrated, using water or steam, to about 12-18%
moisture. Following this rehydration step, the grain is tempered to
allow moisture to equilibrate throughout the internal structure of
the grain. Following tempering, the grain is then introduced
between flat plates, compressed and heated as described in more
detail above. The grain has a similar identity to the pre-processed
grain. It still looks like a kernel of oat, rice, etc. but it is in
a somewhat flattened state. Upon cooking in water by the end user,
the kernels absorb water and return to a more rounded shape. It
therefore looks very similar to a non-flat plate kernel that has
been cooked in water to the same final moisture state. "Bumping" is
a process step that has been used for quick rice for a long time.
This is typically done sometime during the quick rice manufacturing
process by putting cooked rice through a pair of rolls to make the
rice kernel thinner. A thinner kernel cooks faster. In aspects of
the invention set for the herein, there is a benefit of faster
cooking due to a puffed internal structure and a flatter
kernel.
[0027] In yet another aspect of the present invention, and as
illustrated in FIG. 1, de-hulled whole kernel grains having a
moisture content of about 8-14% (wet basis) are introduced into a
gun puffing chamber. The chamber is then sealed and the pressure
within the chamber is raised to about 80-175 psig at a temperature
of about 162-192.degree. C. until the moisture content of the
grains reaches about 14-30% (wet basis). This type of puffing
usually takes about 60-120 seconds to complete. This temperature
and pressure increase within the puffing chamber is raised by
injection of saturated steam or superheated steam. The pressure is
then reduced to atmospheric pressure almost instantaneously (less
than about 2 seconds). The grain is exposed to the rapid change in
pressure, either by rapidly opening a lid or a valve at the
discharge of the puffing gun, or by passing the grain kernels and
steam through a venturi nozzle to create the rapid pressure
reduction. Next, the kernels are dehydrated by any applicable
means, such as drying with hot air in a batch or continuous bed
dryer or dried in a fluid bed hot air dryer to reach a final
moisture below about 14% (wet basis) and an a.sub.w of less than
0.65. For quick-cook porridge or side dishes, the final moisture
content of the grains is about 10-13% (wet basis), whereas grains
used as inclusions have a final moisture content of about 3-6% (wet
basis).
[0028] Alternatively, the raw grains may be preheated to increase
the temperature from about 38.degree. C. to about 90.degree. C.
prior to introducing the pre-heated grains into the puffing chamber
as described in more detail above.
[0029] A further aspect of the present invention includes
pre-hydrating and tempering the raw grains prior to pre-heating and
subsequently gun puffing. For example, the grains may be combined
with water via mixing, spraying, steaming or humidifying, to bring
the moisture content to about 13-25% wet basis thereby forming a
hydrated grains. This pre-hydration step could also be used to
introduce other ingredients to the raw grains, including, but not
limited to water, flavor, nutrients and antioxidants to create a
grain mixture. The hydrated grains are tempered for a period of
time sufficient to allow the water to penetrate into the center, or
near the center, of the grains for a period of about 1-12 hours.
The grains are then pre-heated to increase the temperature from
about 38.degree. C. to about 90.degree. C. before introducing the
pre-heated grains into the puffing chamber as set forth in more
detail above. However, in another aspect of this invention, the
grains are puffed without using the pre-heating step.
[0030] A further aspect of the present invention includes a method
for processing quick-cook pulses. In accordance with this
embodiment, dry, whole or split pulses with a moisture content of
about 11-15% (wet basis) are introduced into a gun puffing chamber.
The chamber is then sealed and the pressure within the chamber is
raised to about 80-175 psig at a temperature of about
162-192.degree. C. until the moisture content of the pulses reaches
about 14-30% (wet basis), which may take about 60-120 seconds. This
temperature and pressure increase within the puffing chamber is
raised by injection of saturated steam or superheated steam, or
externally heated to reach target super-atmospheric pressure. The
pressure is then reduced to atmospheric pressure almost
instantaneously. Next, the pulses are dehydrated by any applicable
means, such as drying with hot air in a batch or continuous bed
dryer or dried in a fluid bed hot air dryer to reach a final
moisture below about 14% (wet basis) and an a.sub.w of less than
0.65. Quick-cook pulses made in accordance with the present
invention and used in meals or side dishes typically have a final
moisture content of about 10-13% (wet basis).
[0031] Alternatively, the dry, whole or split pulses may be
preheated to increase the temperature from about 38.degree. C. to
about 90.degree. C. before introducing the pre-heated pulses into
the puffing chamber as described in more detail above.
[0032] A further aspect of the present invention includes
pre-hydrating and tempering the dry, whole or split pulses prior to
pre-heating (as described in the immediately preceding paragraph)
and subsequently gun puffing. For example, the pulses may be
combined with water via mixing, spraying, steaming or humidifying,
to bring the moisture content to about 13-25% wet basis thereby
forming a hydrated pulses. This pre-hydration step could also be
used to introduce other ingredients to the raw pulses, including,
but not limited to water, flavor, nutrients and antioxidants to
create a legume mixture. These hydrated pulses are tempered for a
period of time sufficient to allow the water to penetrate into the
center, or near the center, of the grain, typically 1-12 hours. The
pulses are then pre-heated to increase the temperature from about
38.degree. C. to about 120.degree. C. before introducing the
pre-heated grains into the puffing chamber as set forth in more
detail above. In an alternative aspect of the present invention it
is possible to lightly puff the pre-hydrated pulses without
pre-heating the pulses.
[0033] FIG. 5 shows the result of RVA analysis of five (5)
different oat samples processed at puffing gun pressures ranging
from 110 psig to 160 psig. In this aspect of the instant invention,
the RVA curves show that the degree of cook and starch modification
are subject to the processing pressure, and therefore the level of
starch modification can be controlled. The preferred level of
modification for whole oats falls within the range demonstrated by
110-150 psig.
[0034] FIG. 8 illustrates the porous structure of a puffed oat made
in accordance with the present invention compared to the non-porous
structure of an oat as shown in FIG. 6. FIG. 9 shows that a large
portion of the starch granules have been gelatinized and plated up
against the oat cell wall structure, compared to un-gelatinized
starch granules within the oat cell walls in FIG. 7. FIGS. 5 and 10
show that some of the starch granules in the lightly puffed oat are
not gelatinized and therefore, during subsequent cooking by the
consumer to provide a texture more similar to cooked native whole
oats.
[0035] The following examples further illustrate the present
invention.
[0036] Various grains were tested using the flat plate compression
methods described above. The results below are taken from two
trials conducted of the subject matter described in the present
application. Tests were conducted using a rice cake popping machine
manufactured by LEM Machine Company or Ideal Snacks Company. These
grains are identified in the chart below, along with testing
parameters and characteristics of the grains following flat plate
compression.
TABLE-US-00001 Sample Uncooked Uncooked Uncooked Cooked Cooked
A-Grade Brown Long Grain A-Grade Brown Oat Rice White Rice Oat Rice
Initial MC 9.11 10.83 12 10.83 8.40 (%) Pre- 90 130 NA 170 270
Hydration Time (Min.) Pre-hydrated 14.7 13.9 12 13.2 12.1 Moisture
(%) Top Plate 230 210 210 220 210 Temp. (.degree. C.) Bottom 240
220 220 230 220 PlateTemp. (.degree. C.) Hydraulic 1000 1500 1500
2500 2500 Pressure (PSI) Bake Cycle 11 9 12 12 8 Time (Sec.)
TABLE-US-00002 Uncooked Cooked Cooked Uncooked Cooked Cooked Easton
Easton Easton Sample Navy Bean Navy Bean Navy Bean Lentil Lentil
Lentil Initial MC (%) 11.4 16.0 11.1 Pre-hydration 220 150 325 250
295 280 Time (Min.) Pre-hydrated 16.5 14.0 16.0 14.7 11.7 14.6
moisture (%) Top Plate Temp. 220 220 220 220 220 220 (.degree. C.)
Bottom Plate 225 225 225 225 225 225 Temp. (.degree. C.) Air Supply
85 85 85 85 85 85 Pressure (PSI) Bake Cycle Time 4.0 4.0 5.0 5.5
4.5 4.5 (Sec.) Bake Time (Sec.) 1.0 1.0 2.0 2.5 1.5 1.5 Final
Moisture 5.0 4.1 9.4 4.8 Too sticky Too sticky (%)
[0037] The grains processed in accordance with the methods of the
present invention demonstrated a dramatic decrease in preparation
time compared to the grain in its original state, while maintaining
the identity of the grain. Pulses processed in accordance with the
methods of the present invention demonstrated a dramatic decrease
in preparation time compared to raw pulses.
[0038] Various grains and pulses were tested using the gun puffing
described above. Below are results from various trials
performed:
TABLE-US-00003 Non-Hydrated Black Kidney Beans Hydrated Black
Kidney Beans Time in Pre- 10 10 10 10 10 10 10 10 10 10 Heater (s)
Puffing Gun 100 130 150 170 100 85 130 160 190 80 Pressure (PSI)
Barrel Temp. (.degree. F.) 347 347 347 347 347 347 347 347 347 347
Final Bulk Density 1020- 700 700 575 860 1080 680 600 600 1150
(G/2048 cc cup) 1100
[0039] Hydration procedure: 750 g of water, 15 kg of black kidney
beans, equilibrated over night.
TABLE-US-00004 Non-Hydrated Rice Rice Hydrated with Water Rice
Hydrated with Vinegar Time in Pre- 20 20 20 20 20 20 20 20 20 20 20
Heater (s) Puffing Gun 108 90 100 98 130 115 95 103 100 135 95
Pressure (PSI) Final Bulk 330 900 500- 800 300 280- 740- 600 600-
300 710 Density 600 450 770 700 (G/2048 CC Cup)
[0040] Hydration with water: 750 g of water into 15 kg of rice,
equilibrated over night. Hydration with vinegar: 800 g of vinegar
(5% acetic acid) into 15 kg of rice, equilibrated over night.
TABLE-US-00005 Non-Hydrated Kilned Kilned A-Grade Oats Kilned
A-Grade Oats A-Grade Oats Hydrated with Water Hydrated with Vinegar
Time in Pre- 20 20 20 20 20 20 20 20 20 20 20 Heater (s) Puffing
Gun 140 115 100 170 180 140 110 105 135 150 165 Pressure (PSI)
Final Bulk 550- 750 840 400 290 520 700 780 540 400 290 Density 600
(G/2048 CC Cup)
[0041] Hydration with water: 750 g of water into 15 kg of oats,
equilibrated over night. Hydration with vinegar: 800 g of vinegar
(5% acetic acid) into 15 kg of oats, equilibrated over night.
TABLE-US-00006 Non-Hydrated Green Green Oats Hydrated Green Oats
Hydrated Oats with Water with Vinegar Time in Pre- 20 20 20 20 20
20 20 20 20 20 20 Heater (s) Puffing Gun 150 125 100 90 150 125 100
175 150 125 100 Pressure (PSI) Final Bulk 400 600 720 800 400 600
760 280 400 630 770 Density (G/2048 CC Cup)
[0042] Hydration with water: 750 g of water into 15 kg of oats,
equilibrated over night.
[0043] Hydration with vinegar: 800 g of vinegar (5% acetic acid)
into 15 kg of oats, equilibrated over night.
TABLE-US-00007 Non-Hydrated Red Kidney Beans Hydrated Red Kidney
Beans Time in Pre- 10 10 10 10 10 10 10 10 10 10 Heater (s) Puffing
Gun 100 130 150 170 80 100 80 130 160 115 Pressure (PSI) Puffing
Gun 347348 342 365 372 342 -- -- 360 370 -- Temp. (.degree. F.)
Final Bulk 1020 650 530 580 1220 810 1060 580 580 600 Density
(G/2048 cc cup)
[0044] Hydration with water: 750 g of water into 15 kg of beans,
equilibrated over night.
TABLE-US-00008 Non-Hydrated Wheat Wheat Hydrated with Water Wheat
Hydrated with Vinegar Time in Pre- 20 20 20 20 20 20 20 20 20 20
Heater (s) Puffing Gun 125 115 105 95 105 120 100 120 95 135
Pressure (PSI) Final Bulk 300 500 823 820 600 400 600 450 400 430
Density (G/2048 CC Cup)
[0045] Hydration with water: 750 g of water into 15 kg of wheat,
equilibrated over night.
[0046] Hydration with vinegar: 800 g of vinegar (5% acetic acid)
into 15 kg of wheat, equilibrated over night.
[0047] Overall, the grains and pulses of the present invention
exhibit about a 2 to 5-fold increase in volume using the processing
methods set forth herein.
[0048] The specific grains and pulses were subsequently cooked.
These cooking parameters and observations are set forth in the
tables below.
[0049] Red and black kidney beans: In evaluating the sample, each
sample was weighed. 1 tablespoon of margarine and water were
brought to a boil in a medium saucepan. The sample was stirred in
and the heat was turned down to medium and boiled, stirring
occasionally, for 15 minutes. The mixture was subsequently reduced
to a low temperature, covered and simmered for 15 minutes. Lastly,
the mixture was removed from the heat and stood (with lid on for 5
minutes). The texture and flavor were then evaluated. The results
of one such test are as follows:
TABLE-US-00009 Sample Set #1- 175 g + Sample Water Cook time Simmer
Rest time # 710 g water wt in g wt in g in minutes time, min. in
minutes Comments 1 Unhydrated 175 750 15 15 5 Excess water, good
appearance red kidney (large portion of intact full beans), bean,
80 psi undercooked chalky texture, flavor ok, needed more cook or
simmer time 2 Unhydrated 175 750 15 15 5 Excess water, good
appearance, red kidney cooked texture al dente or slightly bean,
100 psi undercooked, flavor has moderate smoky note, higher
percentage of loose seed coat skins separated from the bean 3
Unhydrated 175 750 15 15 5 Excess water but more sauce-like red
kidney due to loss of a large portion of the bean, 130 psi bean
identity, strong smoky or toasted flavor, not good for side dish,
may be ok in a soup mix 4 Unhydrated 175 750 15 15 5 Excess water
but more sauce-like red kidney due to loss of a large portion of
the bean, 170 psi bean identity, strongest smoky or toasted flavor,
not good for side dish, may be ok in a soup mix for the right
flavor system 5 Water 175 750 15 15 5 Excess water, good appearance
hydrated red (large portion of intact full beans), kidney bean,
cooked texture ok, maybe al dente 80 psi to some, flavor good,
smoky notes either very slight or none 6 Water 175 750 15 15 5
Excess water, good appearance but hydrated red fewer attached seed
coats than kidney bean, sample #5, cooked texture ok, flavor 100
psi has slight smoky flavor 7 Water 175 750 15 15 5 Excess water
but more sauce-like hydrated red due to loss of a large portion of
the kidney bean, bean identity, strong smoky or 130 psi toasted
flavor, not good for side dish, may be ok in a soup mix 8 Water 175
750 15 15 5 Excess water but more sauce-like hydrated red due to
loss of a large portion of the kidney bean, bean identity,
strongest smoky or 170 psi toasted flavor, not good for side dish,
may be ok in a soup mix for the right flavor system 9 Unhydrated
175 710 15 15 5 Excess water, good appearance black bean, (large
portion of intact full beans), al 100 psi dente texture 10
Unhydrated 175 710 15 15 5 Excess water, fair appearance, soft
black bean, texture, potentially too soft 130 psi depending on
individual preferences 11 Unhydrated 175 710 15 15 5 Excess water
but more sauce-like black bean, due to loss of a large portion of
the 170 psi bean identity, most toasted flavor, not good for side
dish, may be ok in a soup mix 12 Water 175 710 15 15 5 Excess
water, good appearance hydrated black (large portion of intact full
beans), al bean, 100 psi dente texture but softer than sample #9 13
Water 175 710 15 15 5 Excess water, fair appearance, soft hydrated
black texture, potentially too soft bean, 130 psi depending on
individual preferences 14 Water 175 710 15 15 5 Excess water but
more sauce-like hydrated black due to loss of a large portion of
the bean, 170 psi bean identity, most toasted flavor, not good for
side dish, may be ok in a soup mix
[0050] Another set of red and black kidney beans was tested with a
slightly adjusted method of preparation. In evaluating the second
set of samples, each sample was weighed. The sample, 1 tablespoon
of margarine and water were brought to a boil in a medium saucepan.
The mixture was subsequently reduced to a low temperature, covered
and simmered for the target simmer time. Lastly, the mixture was
removed from the heat and stood (with lid on for 2 minutes). The
texture and flavor were then evaluated. The results of one such
test are as follows:
TABLE-US-00010 Sample Set #2- 175 g + Sample Water Cook time Simmer
Rest time # 473 g water wt in g wt in g in minutes time, min. in
minutes Comments 15 Unhydrated red 175 473 0 20 2 Moderate amount
of excess water, kidney bean, 80 very good appearance, (large psi
portion of intact full beans), undercooked texture, flavor ok 16
Unhydrated red 175 473 0 20 2 Moderate amount of excess water,
kidney bean, good appearance, undercooked 100 psi texture, needed
about 10' more of simmer time, flavor ok 17 Unhydrated red 175 473
0 20 2 Moderate amount of excess water, kidney bean, fair
appearance, slightly 130 psi undercooked and fragmented bean
creates more of a mushy texture, flavor is strong smoky 18 Water
hydrated 175 473 0 20 2 Small amount of excess water, red kidney
very good appearance, bean, 80 psi undercooked texture, needed
about 10' more of simmer time, flavor ok 19 Water hydrated 175 473
0 20 2 Small amount of excess water, red kidney good appearance,
slightly bean, 100 psi undercooked texture, needed about 5' more of
simmer time, flavor ok 20 Water hydrated 175 473 0 20 2 Small
amount of excess water, fair red kidney appearance, cook texture ok
but bean, 130 psi fragmented bean creates more of a mushy texture,
flavor tastes smoky 21 Unhydrated 175 473 0 7 2 Excess water, good
appearance black bean, 100 (large portion of intact full beans),
psi al dente texture, probably better with more cook time 22
Unhydrated 175 473 0 7 2 Excess water, fair appearance, soft black
bean, 130 texture, potentially too soft psi depending on individual
preferences 23 Unhydrated 175 473 0 7 2 Excess water but more
sauce-like black bean, 170 due to loss of a large portion of the
psi bean identity, most toasted flavor, not good for side dish, may
be ok in a soup mix 24 Water hydrated 175 473 0 7 2 Excess water,
good appearance black bean, 100 (large portion of intact full
beans), psi al dente texture but softer than sample #21, best
texture and appearance of samples #24-26 25 Water hydrated 175 473
0 7 2 Excess water, fair appearance, soft black bean, 130 texture,
potentially too soft psi depending on individual preferences 26
Water hydrated 175 473 0 7 2 Excess water but more sauce-like black
bean, 170 due to loss of a large portion of the psi bean identity,
most toasted flavor, not good for side dish, may be ok in a soup
mix
[0051] With respect to the rice samples prepared via gun puffing in
accordance with this invention, the samples were subsequently
evaluated by the following cooking procedures: the target amount of
rice was weighed and then added to sauce pan along with a
pre-measured amount of water. The mixture was heated to a boil,
reduced to low heat, covered with a lid and simmered for a target
cook time (as shown in the tables below). The mixture was
subsequently removed from the heat and stood (with the lid on the
pan) for a target rest time (as shown in the tables below). Lastly,
the samples were evaluated for texture and flavor. The results of
one such test are as follows:
TABLE-US-00011 Sample Set #1- 100 g + Density Sample Water Cook
time Rest time # 180 g water g/L wt in g wt in g in minutes in
minutes Comments 27 Unhydrated 400 100 180 5 3 two different
textures, one that is soft brown rice, 98 and almost mushy and a
second of al psi, 800 g/2 L dente due to non-uniformity of density
within sample, bland but maybe slight toasted note 28 Water
hydrated 370 100 180 5 3 same texture as #27, bland but maybe brown
rice, 95 slight toasted note psi, 740 g/2 L 29 Vinegar hydrated 355
100 180 5 3 same texture as #27, different flavor brown rice 95psi,
than #27 & #28, very slight sour note, 710 g/2 L less toast
notes
[0052] With respect to the oat samples prepared via gun puffing in
accordance with one aspect of this invention, the oats were cooked
and tested in a similar manner compared to the rice described
above. The results of one such test are as follows:
TABLE-US-00012 Sample Set #1- 100 g + Density Sample Water Cook
time Rest time # 400 g water g/L wt in g wt in g in minutes in
minutes Comments 30 Kiln oat 288 100 400 15 3 very little loose
water; soft, mushy, unhydrated porridge like, with individual whole
140 psi, 550- kernels still visible, strong toasted 600 g/2 L
flavor, breaks down with stirring 31 Kiln oat water 260 100 400 15
3 very little loose water; soft, mushy, hydrated 140 psi, porridge
like, with individual whole 520 g/2 L kernels still visible, strong
toasted flavor, breaks down with stirring 32 Kiln oat vinegar 270
100 400 15 3 very little loose water; soft, mushy, hydrated 135
psi, porridge like, with individual whole 540 g/2 L kernels still
visible, less toasted flavor and also has a mild sour taste, 33
Kiln oat vinegar 390 100 350 15 3 small amount of loose water;
pasta al hydrated 105 psi, dente texture, no hard centers, sour 780
g/2 L taste, lightest kiln oat color, lightest toasted flavor of
sample #s 33-35 34 Kiln oat water 350 100 350 15 3 small amount of
loose water; pasta al hydrated 110 psi, dente texture, no hard
centers, 700 g/2 L moderate toasted flavor 35 Kiln oat 375 100 350
15 3 small amount of loose water; pasta al unhydrated dente
texture, no hard centers, darkest 115 psi, 750 g/2 L color of
sample #s 33-35, moderate toasted flavor but stronger than sample
#s 33 and 34
[0053] With respect to the wheat samples prepared via gun puffing
in accordance with this invention, the wheat were cooked and tested
in a similar manner compared to the rice described above. The
results of one such test are as follows:
TABLE-US-00013 Sample Set #1- 100 g + Sample Water Cook time Rest
time # 350 g water wt in g wt in g in minutes in minutes Comments
36 Unhydrated 100 350 12 3 chewy and wheat, 115 psi, undercooked,
too al 500 g/2 L dente, noticeable toasted flavor, darker color
that samples #37 & 38 37 Water hydrated 100 350 12 3 al dente,
and slightly wheat, 105 psi, undercooked, bran 600 g/2 L noticeable
but not offensive, mild to no toasted flavor 38 Vinegar hydrated
100 350 12 3 al dente, and slightly wheat, 105 psi, undercooked,
bran 600 g/2 L noticeable but not offensive, mild to no toasted
flavor, grain by itself is not sour but with excess water is sour
39 Unhydrated 100 250 15.5 5 undercooked wheat, 105 psi, 820 g/2 L
40 Water hydrated 100 250 15.5 5 undercooked, but wheat, 95 psi,
softer than 39 820 g/2 L 41 Vinegar hydrated 100 250 15.5 5
undercooked, but wheat, 95 psi, softer than #39 900 g/2 L 39a
Unhydrated 100 250 5 3 chewy and wheat, 105 psi, undercooked, too
820 g/2 L, al dente, cooked sample noticeable toasted #39 with
flavor, darker color additional cook than #40a & 41a and rest
time added 40a Water hydrated 100 250 5 3 chewy and wheat, 95 psi,
undercooked but 820 g/2 L, softer than #39a, cooked sample bran
noticeable #40 with but not offensive, additional cook mild to no
toasted and rest time flavor added 41a Vinegar hydrated 100 250 5 3
chewy and wheat, 95 psi, undercooked but 900 g/2 L, softer than
#39a, cooked sample bran noticeable #41 with but not offensive,
additional cook mild to no toasted and rest time flavor, excess
added water is sour
[0054] With respect to green oat samples prepared via gun puffing
in accordance with one aspect of the instant invention, the green
oats were cooked and tested in a similar manner compared to the
rice described above. The results of one such test are as
follows:
TABLE-US-00014 Sample Set #1- 100 g + Sample Water Cook time Rest
time # 400 g water wt in g wt in g in minutes in minutes Comments
42 Green oat 100 400 15 3 soft but pasta al unhydrated dente type
texture, 125 psi, with individual 600 g/2 L kernels still visible,
moderate toasted flavor 43 Green oat 100 400 15 3 soft but pasta al
vinegar dente type texture, hydrated 125 with individual psi, 630
g/2 L kernels still visible, moderate toasted flavor along with
sour flavor Sample Set #2- 100 g + Sample Water Cook time Rest time
# 350 g water wt in g wt in g in minutes in minutes Comments 44
Green oat 100 350 15 3 al dente texture, vinegar hulls noticeable,
hydrated sour taste, low toast 100 psi, flavor 770 g/2 L 45 Green
oat 100 350 15 3 most chewy, hulls unhydrated noticeable, 90 psi,
potentially could 800 g/2 L have used a long cook time, low toast
flavor, less toasted flavor than samples #33-35
[0055] Further, the grains and pulses made in accordance with
aspects of this invention may be used in other types of products
where the product developer needs to control the density and
texture of the components. For example, these grains or pulses
could also be used by product developers to make unique
agglomerated products such as snack bars. Grains and pulses made in
accordance with aspects of the present invention can also be used
as a component in a multi-component snack mix.
[0056] It was found that using low temperatures and pressures along
with the extremely rapid/instantaneous depressurization utilized in
the gun puffing and flat plate compression methods described herein
provided unexpected results--grains and pulses with low to
moderately increased porosity, preferred bulk densities and optimal
rehydration properties while retaining the original
identity/appearance of the grain or legume.
[0057] This invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The foregoing embodiments, therefore, are to be considered
in all respects illustrative rather than limiting the invention
described herein. Scope of the invention is thus indicated by the
appended claims, rather than by the foregoing description, and all
changes that come within the meaning and range of equivalency of
the claims are intended to be embraced therein.
* * * * *