RU2482700C1 - Food product or semi-product manufacture method - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to food industry. The method envisages introduction of a grain component into the product or semi-product composition, such component manufactured by way of soaking grains of one or several cereal crops with subsequent milling of swollen grains. Swollen grains milling is performed in such a way that the temperature of the mass released from chopper does not exceed 60°C. Grains soaking is performed at a temperature of no more than 45°C till a swelling stage whereat a pressing force equal to 0.15-11.0 kgf leads to plastic deformation of no less than 80% of caryopsis.

EFFECT: invention allows to ensure technological control convenience, apply scientifically grounded technological process modes, obtain stable quality of the products with enhanced biological value of the end product.

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Description

The invention relates to the food industry, in particular to the production of food products containing cereal components, and can be widely used in the production of bakery and confectionery products, pasta, pizza, snacks, pancakes, ravioli, breakfast cereals and other products.

During the technological process used in the claimed technical solution, the grain soaked in water is germinated to the initial stage (bioactivation of grain). The final product obtained using the grain mass from germinated grain differs from the traditional one by several times higher content of the complex of vitamins of group B, PP and other trace elements (zinc, potassium, iron, etc.) by an average of 20-40% compared with the traditional end product, and the vitamin E contained in the germ of the grain is more than 10 times. Modern studies have proved the important functional role of dietary fibers for the human body, which provide satiety, play the role of sorbents, linking cholesterol, carcinogens, radionuclides, salts of heavy metals contained in food, removing them from the body and lowering their level in the blood.

According to studies in the product (grain bread from germinated grain) obtained according to this invention, the content of dietary fiber (soluble and insoluble, also called dietary fiber) is up to 22% of the total weight of the product. Enough 200 g of bread from germinated grain to meet the daily norm of dietary fiber for the human body.

The final product obtained using grain mass from germinated grain is characterized by increased nutritional and biological value, which is determined by:

- balance of the amino acid composition of the protein;

- finding micronutrients in a biologically digestible form;

- the synthesis of vitamins and antioxidants that occurs during the germination of grain;

- an increased amount of dietary fiber, a significant part of which is soluble, they are able to be absorbed into human blood and clean vessels.

A known method for the production of grain bread, in which the grain is peeled to remove 50-80% of the fruit shells present in the grain, while maintaining the germ and the aleurone layer. The grain is soaked in water with a temperature of 8-40 ° C for 5-24 hours to a grain moisture content of 30-50%. After that, the crushed grain mass is mixed with the rest of the recipe components. Dough pieces are formed from the fermented dough, which are then proofed and baked (SU 1214054 A1, 1986).

The disadvantage of this method is the wide variation in the values of the parameters of the grain preparation mode, which complicates the control of the technological process and does not provide stable product quality, there are no criteria for the availability of raw materials for the transition to the next stage of the technological process.

Another well-known method for preparing grain bread involves peeling grain, smoothing it, grinding it on a dispersant, kneading dough using crushed grain and the ingredients provided for in the recipe, fermenting it, forming dough pieces, proofing and baking them. Wheat grain is used with an autolytic activity of 170-365 s, a glassiness of 40-70%, a natural mass of 770-800 g / l, peeling is carried out until fruit shells are removed in an amount of 3-7% of the total grain weight, the smoothing is carried out for 20-30 h, using water with a temperature of 8-40 ° C in an amount of at least 50% of the total mass of grain. Grain grinding is carried out on a dispersant containing nozzles installed in the following sequence: a three-blade knife, a matrix with a hole diameter of 4 mm, a twelve-blade knife, a matrix with a hole diameter of 3 mm, a twelve-blade knife and a matrix with a hole diameter of 3 mm Knead the dough for 10-20 minutes until it reaches a consistency of 620-650 units according to the Farinograph, ferment the dough for 60-120 minutes at a temperature of 30-40 ° C, before baking the dough pieces are proofed in a proofer, baking dough semi-finished products are on the hearth or in molds at a temperature of 200-250 ° C for 15-60 minutes (RU 22161175 from 10/18/2000).

The disadvantages of this method are the complexity of hardware control over the technological process, restrictions on the parameters of raw materials, a large variation in the parameters of the grain preparation mode, which together makes this method difficult to apply in practice.

Closest to the proposed method is a method of producing a food product from cereal crops, which involves processing plant materials before the appearance of sprouts and subsequent processing to obtain a finished product, characterized in that the whole fruits of at least two types of crops are used as plant materials cereal fruits before the appearance of sprouts are carried out by locking them in a liquid medium. This method is a prototype (RU 2083116 from 02.14.1996).

The fundamental difference between the prototype and the above analogues is the use of the state of the grain itself as a criterion of grain readiness for processing, which is manifested in the appearance of sprouts, and not external parameters of the preparation mode, such as the time and temperature of soaking.

However, this criterion is quite subjective and does not have a quantitative assessment, which does not allow to objectively assess the state of grain during the process and to achieve stable quality of the final product. Subsequent processing is also described in general terms.

The claimed technical solution is aimed at obtaining a comprehensive technical result: ensuring the convenience of technological control, the use of scientifically substantiated modes of the process, obtaining stable product quality with increased biological value of the final product.

The specified technical result is achieved by the process of soaking grain, the end of which should occur when the compressive force leading to plastic deformation of the grain is less than 11 kgf, but more than 0.15 kgf, and the temperature during the soaking should not exceed 45 degrees C, while grinding grain is carried out at a temperature of mass leaving the grinder no more than 60 degrees C.

An important point in the production of products from biologically activated grain is the beginning of biological processes leading to the appearance of a sprout or its “pecking”. The onset of biological processes of germination is “trigger” in nature and begins with a threshold moisture content of the kernel of 20% [1] for raw material. Therefore, the moisture content of biologically activated grain cannot be lower than the specified value.

However, when the grain moisture is increased to 52-55% by raw material, proteolytic processes begin, which leads to the hydrolysis of grain proteins: gliadin, hordein, glutenin, aries, leukosin and others, which significantly impairs the rheological properties of the test mass obtained from grain of this degree of moisture , since a number of proteins are involved in the formation of the gluten skeleton of the final food product. Therefore, the indicated humidity should be considered a threshold limiter on the other side of the range.

When a set of grain moisture changes its structural and mechanical characteristics. Figure 1 shows the dependence of the deformation of the grains on the compression force at different moisture content of the raw material [2]. It is obvious that with increasing humidity, the elastic modulus of the kernel decreases and with large humidity values the kernel loses the properties of a solid and the nature of the dependence of the deformation of the kernel on the compression force changes, a characteristic horizontal section appears on it, which is a sign of plastic deformation (Figure 2), and this the compression force of the caryopsis, leading to its plastic deformation, is decisive for the amount of energy that must be spent on grinding soaked grain. If the compression force required for plastic deformation of the grain is large, then the energy spent on grinding the grain, transferred to the mass of grain, leads to its overheating. Figure 3 shows the dependence of the compression force required for plastic deformation of the grain, on the moisture content of the grain. Figure 4 shows the dependence of the degree of additional heating of the grain mass during grinding on grain moisture. The dependencies shown in Fig.2-4, obtained experimentally when working on this technical solution for wheat grain food grade 3, for other cereal crops, the above dependencies are of a similar nature. Plastic deformation of the caryopsis is characterized by the loss of its original shape, the caryopsis becomes flatter, flattened, and at high humidity values, the plastic deformation of the caryopsis is accompanied by extrusion of the softened endosperm through the shell of the grain.

In laboratory conditions, the force applied to the caryopsis was created using a device having two flat jaws, one of which is stationary, and the second is driven by a screw mechanism with a handle. Using a dynamometer, we measured the force applied to the end of the handle and, knowing the length of the handle and the pitch of the screw mechanism, we recalculated the value of the force on the dynamometer in the compression force of the grain between the jaws. In this case, the correction for the friction force in the screw mechanism was taken into account. The measurement was considered the position when the grain was sandwiched between the lips and did not fall out under its own weight. The movement of the jaws of the device, that is, the magnitude of the deformation of the grain, was also counted based on the angle of rotation of the handle of the screw mechanism relative to its position at the beginning of the measurement. In production conditions, to determine the compression force required for plastic deformation of the grain, you can use a simple method: put the grain on the platform of the electronic balance and, pressing on the grain on top of the hard flat object, notice the indication on the balance indicator when the endosperm was squeezed out of the grain or flattening.

An acceptable value of the compressive force required for plastic deformation of the grain is not more than 11 kgf, since with high deformation forces the degree of additional heating of the grain mass during grinding starts to increase sharply and begins to exceed 30 degrees C. This degree of heating of the grain mass is critical for some applications, in particular for the manufacture of bakery products, since grain cooling before grinding is carried out in practice with cold water, the temperature of which in the average is 12 degrees C. The final temperature of the test mass is 37 degrees C, which is the maximum technological limit for the dough used for the production of bakery products. In addition, the operation of the grinder (for example, a dispersant) on grain with a high value of the compressive force required for plastic deformation of the grain leads to irrational energy consumption and rapid wear of the working body. However, for the manufacture of other products, the temperature of the crushed grain mass may not be a critical parameter, and here the limitation is the heating of the grain mass above 60 degrees C. Exceeding this temperature in combination with the acidity of the medium, pH 4.3-4.6 causes inactivation of α-amylase enzymes and β-amylases that hydrolyze starch into dextrins and simple sugars and determine such important test parameters as sugar-forming and gas-forming ability, as well as the biochemical composition of the product [3]. With a short-term exposure to temperatures above 60 degrees C, partial destruction of the tertiary and quaternary structure of the protein also begins, which is the biological degradation of the raw material. When soaking the grain, a similar undesirable effect is achieved by prolonged exposure to grain of the environment with a temperature above 45 degrees C, which leads to the blocking of the biological processes of grain germination.

Therefore, the establishment of the threshold value of the compression force of the grain, which leads to its plastic deformation of not more than 11 kgf, achieved at a grain moisture content of more than 20% in terms of raw material, satisfies the conditions of the “trigger” mechanism for the onset of sprout formation and provides acceptable structural and mechanical properties of grain from the point of view of it subsequent processing. The grains of even one batch are different from each other, therefore, it has been experimentally established that at least 80% of the grains of the processed batch must reach the threshold strain force. In this case, of course, there is no need to control the entire batch, it is enough to take 10-15 grains from the lower, middle and upper parts of the tank for soaking.

A grain moisture limit of more than 55% corresponds to a compression force leading to plastic deformation of the grain, less than 0.15 kgf. Therefore, the phase of the soaking of the grain must be completed when the specified state of grain is reached.

The “compression force required for plastic deformation of the grain” parameter allows you to integrally evaluate the result of the soaking phase of grain, which depends on many parameters: temperature, time, grain type, degree of cleaning, application of stratification methods and other factors, which greatly simplifies the process of technological control and makes it objective. Although there is a certain dependence between the compression force necessary for the plastic deformation of the grain and its moisture content, the nature of this curve varies depending on the type of grain, temperature, and soaking conditions. So, for example, figure 3 shows two curves of the compression force required for plastic deformation of the grain versus grain moisture for two types of grain: soft wheat and durum wheat. The latter is characterized by a significantly greater vitreous and crystallinity of the structure of the caryopsis. Since the grinding operation follows after soaking in this method, the structural and mechanical properties of the grain are crucial for the operation of the grinder, and the compression force required for plastic deformation of the grain is used as the most informative and significant factor as a criterion for the readiness of the grain for grinding after soaking.

For each specific application of this method, the necessary amount of compression force required for plastic deformation of the grain is selected from technological considerations, which is then used as a control during the manufacturing process.

The regime of grain germination under these conditions provides an increase in the content of vitamins and other biologically valuable substances, partial hydrolysis of starch before the stage of intensive reduction of gluten.

Description of graphic images

Figure 1 shows the dependence of the deformation of the caryopsis on the compression force at different moisture content of the raw material, curve 1 - for humidity 15%, 2 - 15.8%, 3 - 16.7% with a glassiness of 50%.

Figure 2 shows the curve of the deformation of the grains from the compression force with the plot of plastic deformation at a humidity of 45%.

Figure 3 shows the dependence of the compression force required for plastic deformation of the grain from moisture grain.

Figure 4 shows the dependence of the degree of additional heating of the grain mass during grinding on grain moisture.

The method can be illustrated by the following examples of its implementation.

Example 1: Production of whole grain bread from a mixture of wheat and rye.

For the manufacture of this food product, the main raw material is used entirely consisting of a grain component, which is prepared from wheat and rye in a ratio of 4: 1. The grain purified from foreign impurities is washed on an MM3-500 grain washing machine and soaked in a container of water at a temperature of 35 degrees C. Thermostatic mode is not required. It is possible to add grains of other cereal crops: bare oats, barley up to 10% of the total weight of dry grain. Next, the grain is washed every 12 hours, pouring fresh water at a temperature of 25 degrees C. The amount of water (by weight) is taken twice as much as the amount of grain. Soaking is carried out until when at least 80% of the kernels undergo plastic deformation with a compression force of 4-5 kgf. Then the grain is washed in cold water with a temperature of 14-16 degrees C and crushed on a dispersant L3-15, controlling the temperature of the test mass exiting the dispersant, which should not exceed by 15 degrees C the temperature of the grain loaded into the dispersant, that is, the final temperature of the crushed grain mass should not exceed 30 degrees C. With higher heating of the test mass, replace the worn cutting device of the dispersant with a new one. Salt is added to the resulting test mass in a proportion of 1.8% by weight of dry grain, pressed baker's yeast in a proportion of 4% by weight of dry grain, water as needed. Kneading is carried out for 10-12 minutes on a dough mixer L4-HTV or similar.

Then the dough is divided into pieces according to the weight of the selected baking form, on any type of dough divider or manually, give the dough piece a round shape on any type of dough rounder or manually and put into baking molds coated with vegetable oil.

Proofing of the blanks is carried out at a temperature of 40-45 degrees C and a humidity of 80% for 25-35 minutes, baking is carried out at a temperature of 220-240 degrees C for 25-40 minutes depending on the weight of the product with steam supply at the beginning and end of baking.

After baking, the finished products are removed from the molds, cooled and packaged.

Example 2. The production of pasta.

Durum wheat grains, cleaned of impurities, are washed with an MM3-500 grain washing machine and soaked in containers, pouring water at a temperature of 45 degrees C. Thermostatic mode is not required. Subsequently, the grain is washed every 12 hours, pouring fresh water at 35 degrees C. The amount of water (by weight) is taken twice as much as the amount of grain. Soaking is carried out until when at least 80% of the kernels undergo plastic deformation with a compression force of 11 kgf. Then the grain is washed in cold water with a temperature of 14-16 degrees C and crushed on an MPTM-300 disperser with an additional knife-grate section, controlling the temperature of the test mass exiting the dispersant, which should not exceed 60 degrees C. With higher heating of the test mass, the worn cutting replace the dispersant apparatus with a new one. Obtained in the form of a test mass, the grain component is mixed with wheat grits for the production of pasta in accordance with GOST 12307 in a ratio of 1: 1 in the required quantity on a dough mixer TMM-60 or similar. To adjust the final humidity of the dough to 32%, add water to increase humidity or pasta to reduce it. The resulting dough is loaded into a pasta press “Mercury PM-50”, extrusion is carried out through a die of the “ears” type. Macaroni is dried in an oven to a moisture content of not more than 19%. Drying to a nominal moisture content of 14-15% is carried out in cardboard boxes at the packaging site in the natural environment. Packing is carried out on a vertical packaging machine of any type.

Example 3. Crust (base) for pizza.

Pizza crust consists entirely of a grain component made from wheat grain. Wheat grain, cleaned of impurities, washed on a grain washing machine MM3-500 and soaked in containers with water at a temperature of 35 degrees C. Thermostatic mode is not required. Considering the fact that for a pizza base, the formation of a bulk blank is not essential, as for bread, the soaking phase is carried out until at least 80% of the grains undergo plastic deformation with a compression force of 0.15 kgf. The grain is washed and crushed, as in example 1, after cutting, the dough pieces are placed in turn into the ZANUSSI HPZF45 press chamber and baked until the crumb structure is formed. Next, the pizza crust is transferred to the layout of the filling or frozen and packaged as a semi-finished product for retail sale.

Bibliographic data

1. Physiology of initiation of seed germination. N.V. Obrucheva, O.V. Antipova, Journal of Plant Physiology, 1997, Volume 44, No. 2, pp. 287-302.

2. Technologies of grain processing industries. Butkovsky V.A., Merko A.I., Melnikov E.M., M., Intergraph service, 1999., p. 9.

3. Technology of baking production. Auerman L.Ya., S.-P., 2009, 9th edition, p.21.

4. Patent SU 1214054 A1, 1986

5. Patent RU 22161175 from 10/18/2000.

6. Patent RU 2083116 dated 02.14.1996.

Claims (1)

A method of manufacturing a food product or a semi-finished product, characterized in that it comprises introducing into the composition of the product or a semi-finished product a grain component, which is obtained by soaking the grains of one or more cereal crops with subsequent grinding of the swollen grain, while grinding is carried out in such a way that the temperature of the mass leaving the grinder does not exceed 60 ° C, and soaking is carried out at a temperature of not more than 45 ° C until such a stage of swelling at which a compression force of 0.15-11.0 kgf leads to plastic deformation of at least 80% of grains.

Images