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WO2004071200A1 - Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide - Google Patents

Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide Download PDF

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Publication number
WO2004071200A1
WO2004071200A1 PCT/US2003/003422 US0303422W WO2004071200A1 WO 2004071200 A1 WO2004071200 A1 WO 2004071200A1 US 0303422 W US0303422 W US 0303422W WO 2004071200 A1 WO2004071200 A1 WO 2004071200A1
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WO
WIPO (PCT)
Prior art keywords
com
flour
pressure
precooked
kernel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2003/003422
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English (en)
Inventor
Manuel J. Rubio
Felipe A. Rubio
Francisco Arroyo
Roberto Contreras
Francisco Sosa
Miguel A. Arce
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to PCT/US2003/003422 priority Critical patent/WO2004071200A1/fr
Priority to MXPA05008306A priority patent/MXPA05008306A/es
Priority to AU2003216172A priority patent/AU2003216172A1/en
Publication of WO2004071200A1 publication Critical patent/WO2004071200A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A23L7/13—Snacks or the like obtained by oil frying of a formed cereal dough
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/40—Products characterised by the type, form or use
    • A21D13/42—Tortillas
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/198—Dry unshaped finely divided cereal products, not provided for in groups A23L7/117 - A23L7/196 and A23L29/00, e.g. meal, flour, powder, dried cereal creams or extracts

Definitions

  • the present invention relates to a pressurized and acid precooking process for the production of com flour and, more particularly, to one that achieves continuous partial and pressurized cooking and removal of the com bran with an acidic reducing agent as a food processing aid used during the manufacture of an instant com flour for the elaboration of arepas, tortillas, and snacks.
  • the production of high-quality masa flour can be achieved by conventional techniques only if the food-grade com has the following characteristics: uniformity in kernel size and hardness, a low number of stress-cracks and kernel damage, and ease of pericarp removal during the lime-water cooking process. It is known that the hard-endosperm com (U.S. No.2: USFGC. 1996) should be partially cooked before it is formed into the end products, so as to cause it to be a precooked com flour.
  • White-kernel com may contain: 11.0-11.5% moisture, 72.2-73.2% starch, 9.8-10.5% protein, 3.7-4.0% fat and 2.1-2.3%) ash and crude fiber.
  • a dry-milled corn sample might yield, on a dry weight basis, 74.8-76.2% total endosperm, 18.9-20.5% germ and 3.3-6.3% bran.
  • the mature dent kernel (Watson, 1987) has four separable components, on a dry weight basis: tip cap (0.8-1.1%), pericarp or bran (5.1-5.7%), endospem (81.1-83.5%), and germ (10.2-11.9%).
  • the separated bran includes the pericarp, tip cap, aleurone layer and adhering pieces of starchy endosperm as well.
  • Nixtamalized com flour is produced by the steps of alkaline cooking of com, washing, milling the nixtamal, and drying, thereby producing com masa flour. This flour is sieved and blended for different product applications and it is usually supplemented with additives before packaging for commercial table or packaged-tortilla and snack production. Although the pericarp or bran is partially removed during the alkaline-cooking and washing process steps, there is still fiber left from the com kernel (U.S. Patent 4,513,018). Nixtamalized com flour or masa flour typically contains from 7-9% total dietary fiber or bran with 6-8% mainly consisting of insoluble fiber on a dry basis (Sustain, 1997).
  • the cell walls or non-starch polysaccharides are the major com dietary fiber components and are composed of hemicellulose (heteroxylan or pentosan and ⁇ -glucan: 4.4-6.2%), cellulose (2.5-3.3%) and some lignin (0.2%).
  • the com pericarp makes up 5-6% of the kernel dry weight.
  • This pericarp also contains 90% insoluble fiber (67% hemicellulose and 23% cellulose) and only 0.6% soluble- fiber (soluble-arabinoxylan and ⁇ -glucan). It is estimated that dietary fiber in both bran (4.9%) and endosperm (2.6%) make up 80% of the total dietary fiber.
  • the com insoluble fiber is mainly found in the bran and endosperm (aleurone and starchy), which make up 68% of the total dietary fiber (9.5% in a dry-weight basis). Unlike com endosperm (com grits), in which soluble fiber amounts to 12% of the total fiber (4.1%), in whole wheat, soluble fiber represents 22% of total fiber (about 20% of the flour water-uptake is bound to the soluble pentosan fraction).
  • Properly processed industrial com or masa flour simplifies the production of tortilla products, because the customer eliminates management techniques required for wastewater treatment, securing, handling and processing com into masa for tortillas and snacks.
  • an instant com flour might have the following quality and cost limitations: high cost, lack of flavor, and poor texture in tortillas or snacks prepared from masa flour.
  • Tortillas are the main edible com product in North and Central America. It is a flat, round, unleavened and baked thin-pancake (flat-combread) made from fresh masa or com dough prepared from industrial nixtamalized com flour (NCF). It should be mentioned that a tortilla, when manually or mechanically elaborated and without additives of any kind, has a maximum shelf life of 12 to 15 hours at room temperature. Afterwards they are spoiled by microorganisms and become hard or stale due to a physicochemical change in the starch constituent of either stored or reheated tortillas (starch retrogradation). It is known that tortillas, even when kept under conditions in which no moisture is lost (as in a plastic package), nevertheless become stiff with time and break or crumble easily when bent.
  • hard- endosperm com is processed with dry milling technology without wastewater and it is further converted into a precooked, degermed and debranned flour for traditional com foods. Its consumption is mainly in the form of an "arepa", which is a flat or ovoid-shaped, unleavened, and baked thick-pancake made from dry-milled com flour.
  • corn meal and com flour are used for different bakery and pancake mixes as well as snack foods.
  • Com flour processors can generate added value from their industrial operations in one of three approaches: developing new products from new hybrids, increasing the yield of traditional products from com, and improving process efficiency at a lower unit cost.
  • this has been done by methods and using an apparatus in which the grain is cooked and/or steeped in a lime-water solution such as those disclosed in U.S. Patents Nos. 2,584,893, 2,704,257, 3,194,664, and 4,513,018.
  • These prior art methods for the industrial production of masa flour involve accelerated lime cooking and steeping times with large amounts of solids losses ( ⁇ 1.5 to 3.0%) in the liquid waste or wastewater ( " nejayote " ).
  • essential nutrients such as vitamins and some amino acids are lost, depending on the severity of the cooking, washing and drying operations.
  • Another object is to achieve this objective using an industrial method and apparatus involving a pressure and acid precooking with sulfites for a partial hydrolysis of com cell-walls and proteins along with a water diffusion effecting a controlled starch granule and protein swelling with a reduced com loss during the production of precooked com flours.
  • embodiments of wliich include a short-time pressure precooking with a sodium metabisulfite, or sodium hydrogen sulfite or sodium sulfite solution as a processing aid so as to effect a partial hydrolysis of insoluble fiber and protein along with a controlled gelatinization and denaturation, reduced kernel washing and solid loss into wastewater, stabilization of the moisture content to a desired optimum level for grinding, milling and drying the preconditioned kernel to produce a uniform partial cooking, cooling and drying the dry-ground particle, separating and recovering the fine grind so produced from the coarser grind while the latter is further aspirated to partially remove a com bran fraction for feed or integral flour, remilling the isolated coarser grind and further sieving it to obtain an instant com flour for arepas, and admixing only a fine flour with lime to produce a limed-com or masa
  • FIG. 1 there is depicted, in flowchart form, an embodiment of the present invention. It includes a pressure precooker 1 ; a washer 2; a preconditioner 3 with a feeder; a primary mill 4; a furnace 5; a dryer 6; a first cyclone separator 7; a cooler 8; a second cyclone separator 9; a sifter 10; an aspirator system 11; and a secondary mill 12.
  • the pressure precooker 1 whose design is known per se, is fed with cleaned com and a sodium metabisulfite solution along with hot steep-water (60°C to 70°C) recycled from the washer 2 to form an acidic aqueous suspension (com to water ratio of about 1 :0.5 to about 1:1).
  • the solids content of the acidic solution is regulated in the range from about 1.0% to about 3.0%.
  • the com suspension is heated with saturated steam (7 to about 21 psig and 110° to about 114°C) for a period of 17 to 34 minutes.
  • the pressure precooker with the sulfites solution causes a partial acidic hydrolysis that promotes a rapid and uniform diffusion of the cooking water through the bran into the germ, endosperm and their cell-walls made of dietary fiber.
  • Saturated steam and sulfites solution also effect a controlled solubilization and swelling in the com kernel, allowing a 45% to 65% waste solids reduction as well as a 55% to 75% decrease in wastewater effluent (with a lower sewage cost) as compared to the industrially applied lime-cooking process (Alvarez and Ramirez, 1995). This water loss in the precooker is replaced with recycled steep-water from the washer 2.
  • the partially precooked com suspension is then passed to a washer 2 where it is sprayed with steam-heated water at a temperature of about 60° to about 70°C for 30 to 60 seconds, which also serves to increase water absorption and wash off soluble solids into wastewater.
  • the washed corn is thereafter passed to a preconditioner 3, where the precooked kernel is equilibrated to obtain a residual moisture content of about 38% to about 39% for about 30 to about 210 minutes.
  • the preconditioned and washed com is fed through a feeder to a primary mill 4, whose design is known per se, such that the premilled com and hot air coming from a furnace 5, is mixed and partially cooked by an industrial dryer 6 whose design is known per se.
  • the premilled kernel is thereby flash dried at a high-temperature from 180°C to about 230°C for a short time of 5 sec to about 30 sec. Its starchy endosperm is partially gelatinized or precooked to yield a moisture content of 16% to about 18% depending on the granulation being produced.
  • Moisture laden-hot air (130°C to 205°C, and 11% to 13% moisture) is extracted with a first cyclone separator 7 so that further moisture extraction may take place by impelling the drier material through a cooler 8, whose design is known per se, thus further decreasing the moisture content from 16-18% to about 9-12% (similar to incoming com).
  • the precooked dry particle is directed to a sifter 10 where the fine fraction is separated (under 20 to 60 mesh) as instant com flour and the coarser fraction is further separated.
  • the latter coarse fraction is further separated in the aspirator system 11 wherein two fractions are obtained, a light-bran fraction which is isolated as feed or for integral flour with a moisture content between 9% to 12% (representing from about 3% to about 7% of the total weight of incoming com), and a heavy coarser fraction that is remilled in a secondary mill 12.
  • the milled product from secondary mill 12 is recycled to the sifter 10 for further sieving and producing a homogeneous com flour for arepas.
  • the arepa flour can be admixed with food-grade lime (0.15% weight based on precooked flour) to produce a limed-com or masa flour for making tortillas and snack foods.
  • the instant corn flour is preferably rehydrated by mixing with warm water from a 1:1.3 to about 1:1.4 weight ratio to form a corn dough (55% to 60% final moisture) for arepa elaboration.
  • the masa flour made from the present method can be rehydrated with water from a 1 : 1.0 to about 1:1.3 weight ratio for a masa dough (50% to 55% final moisture) used in tortilla or com foods.
  • the novel physicochemical precooking results in a reduction of 45% to 65% in wastewater solids and a 55% to 75% in wastewater overflow, with correspondingly lower sewage and energy costs, as compared to the industrial methods (>5.0%: Sahai and Jackson, 2001).
  • the acid-pressure precooking of the invention allows a 75% reduction in lime use if an instant limed-com or masa flour were produced to improve new flavors in corn-based foods such as tostadas and novel snacks.
  • the rapid high-temperature precooking (110°C-114°C) using a sulfites solution (0.10%-0.20%) not only aids in hydrolyzing the insoluble cell-walls but also effects a controlled gelatinization and denaturation.
  • the instant com flour produced by the novel method may thus comprise a higher than 90% yield of flour per kilogram of corn
  • the debranned and degermed flour produced by a typical arepa process obtains only a 65% to 70% yield, or a 80% to 85% yield for an integral arepa flour (U.S. Pat. No. 6,326,045).
  • the acid-pressure precooked corn flour produced by the present method has a higher nutritional value as compared to the conventional and commercial methods, with a higher dietary fiber and fat content than the commercial arepa or degermed com flours (INCAP, 1961).
  • the following table gives a typical nutrient average composition of precooked flours for corn foods and traditional arepa (Cuevas, 1985):
  • Nutritional profile (g/100 g): Precooked Corn Flours

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Cereal-Derived Products (AREA)

Abstract

Dans certains modes de réalisation, cette invention concerne des procédés et un appareil servant à produire en continu de la farine de maïs précuite sous pression d'acide et partiellement décortiquée pour tortillas, arepas et autres en-cas, cette farine pouvant être produite par une précuisson sous pression rapide au moyen de métabisulfite de sodium ou au moyen d'une solution de sulfite de sodium ou d'hydrogénosulfite de sodium comme auxiliaire de préparation de l'aliment, afin de réaliser une hydrolyse partielle des fibres et des protéines insolubles en même temps qu'une gelatinisation et une dénaturation régulées, par lavage réduit des grains et par rinçage à l'eau de la fraction solide de maïs, par stabilisation de la teneur en humidité jusqu'à un niveau optimum souhaité pour le broyage, par mouture et séchage des grains préconditionnés, en vue de produire une cuisson partielle, par refroidissement et séchage des particules moulues par voie sèche, par séparation et récupération de la fraction finement moulue produite à partir de la fraction plus grossièrement moulue pendant que celle-ci est ensuite aspirée, pour en extraire partiellement une fraction de son de maïs destinée à faire du fourrage ou de la farine intégrale, par nouvelle mouture de la fraction grossièrement moulue ainsi isolée et ensuite par tamisage de celle-ci, en vue de produire une farine de maïs instantanée pour arepas, et par mélange uniquement de la farine fleur avec de la lime, en vue de produire une farine de maïs et de lime, ou masa, pour tortillas et autres en-cas.
PCT/US2003/003422 2003-02-04 2003-02-04 Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide Ceased WO2004071200A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US2003/003422 WO2004071200A1 (fr) 2003-02-04 2003-02-04 Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide
MXPA05008306A MXPA05008306A (es) 2003-02-04 2003-02-04 Produccion continua de una harina de maiz instantanea para arepas, tortillas y bocadillos, empleando un precocimiento a presion con acido.
AU2003216172A AU2003216172A1 (en) 2003-02-04 2003-02-04 Continous production of an instant corn flour for arepa, tortilla, and snack, using an acid-pressure precooking

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2003/003422 WO2004071200A1 (fr) 2003-02-04 2003-02-04 Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide

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WO2004071200A1 true WO2004071200A1 (fr) 2004-08-26

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PCT/US2003/003422 Ceased WO2004071200A1 (fr) 2003-02-04 2003-02-04 Production continue d'une farine de mais instantanee pour tortillas, arepas et autres en-cas, au moyen d'une operation de precuisson sous pression d'acide

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AU (1) AU2003216172A1 (fr)
MX (1) MXPA05008306A (fr)
WO (1) WO2004071200A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006118778A2 (fr) 2005-05-05 2006-11-09 Investigacion De Tecnologia Avanzada, S.A. De C.V. Production en continu de farine de mais pregelatinisee pour produits laitiers et aliments a base de cereales

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6322836B1 (en) * 2001-01-19 2001-11-27 Manuel J. Rubio Continuous production of an instant corn flour for arepa and tortilla, using an acid-cooking

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6322836B1 (en) * 2001-01-19 2001-11-27 Manuel J. Rubio Continuous production of an instant corn flour for arepa and tortilla, using an acid-cooking

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006118778A2 (fr) 2005-05-05 2006-11-09 Investigacion De Tecnologia Avanzada, S.A. De C.V. Production en continu de farine de mais pregelatinisee pour produits laitiers et aliments a base de cereales
EP1887884A4 (fr) * 2005-05-05 2012-05-30 Invest De Tecnologia Avanzada S A De C V Production en continu de farine de mais pregelatinisee pour produits laitiers et aliments a base de cereales

Also Published As

Publication number Publication date
MXPA05008306A (es) 2006-06-23
AU2003216172A1 (en) 2004-09-06

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