EXTRUDED FOOD PRODUCT, SIMILAR TO FRIED POTATOES, AND PROCEDURE FOR ITS MANUFACTURE

Abstract

The present invention relates to an extruded French-fry-like food product in the shape of a stick, with improved technological features when the food is subject to frying, obtaining a low-fat French-fry-like food as an end product. The invention also relate to a method for preparing the French-fry-like extruded food product.

Claims

1. An extruded food product, similar to fried potatoes ideal for frying, comprising potato pulp, rice flour, and additives, in which the ratio by weight between the potato pulp and rice flour is 7:3.

2. The food product of claim 1, wherein the potato pulp is a wet potato pulp having a moisture content no greater than 65%.

3. The food product of claim 1, wherein the rice flour comes from rice polishing and from the tips of polished rice.

4. The food product of claim 4, wherein the additive is sodium chloride (table salt).

5. The food product of claim 4, wherein the sodium chloride is present in an amount of 0.005 to 1% w/w.

6. The food product of claim 1, wherein the extruded food product after the frying stage is a low-fat product.

7. The food product of claim 1, wherein the extruded food product after the frying stage presents an oil content of between 5 and 10%.

8. The food product of claim 1, wherein the extruded food product presents a stick-like shape, comparable to traditional French fries.

9. A procedure for obtaining an extruded food product similar to fried potatoes ideal for frying, wherein the procedure comprising the stages of: a) Preparing a moist potato pulp; b) Making the rice flour; c) Mixing in a conventional way the components of a), b), and additives; d) Extruding in a double screw extruder; e) Frying in 100% sunflower seed oil, at a temperature of 160° C.±2° C., for 2 minutes, 15 seconds.

10. The procedure of claim 9, wherein stage a) consists of: i) selecting and calibrating the raw potatoes; ii) pealing and chopping the potatoes; iii) immersing in sodium metabisulfite; iv) grinding and pressing; where the percentage of moisture of the potato pulp does not exceed 65%.

11. The procedure of claim 9, wherein stage b) comprises the grinding of the rice grain from the rice polishing and from the rice tips.

12. The procedure of claim 9, wherein the extruded product obtained (in d) prior to the frying stage (f) can optionally be preserved by cooling at a temperature of 4° C., for prolonged periods of up to 15 days.

Description

DESCRIPTION OF THE INVENTION

[0023] The object of the present Invention is to obtain an extruded food product, similar to stick-like fried potatoes, produced with the advantage of having improvements in the technological characteristics when subjecting the extruded product to the frying process, and obtaining an end product similar to French fries that has a low fat content and is organoleptically acceptable.

[0024] The procedure for obtaining the product of the present Invention comprises the following stages: [0025] a) Manufacture of a wet potato pulp; [0026] b) Manufacture of rice flour; [0027] c) Mixing of the components of a), b), and additives; [0028] d) Extrusion; [0029] e) Preservation (cooling and refrigeration or freezing); and [0030] f) Frying

[0031] FIG. 1 shows the flowchart of the manufacturing process for the product of the present Invention. Below are the detailed process stages.

[0032] a) Manufacture of a Wet Potato Pulp

[0033] For the manufacture of a wet potato pulp, the Pukara variety—created by the Agricultural Research Institute (INIA, by its acronym in Spanish) of the Chilean Ministry of Agriculture, of high domestic consumption, with a good availability and low price, which further presents qualities of maintain its structure during cooking, pleasant taste, and medium mealiness, was used.

[0034] In general, for fried products, it is preferable to utilize potatoes having a high dry matter content (specific gravity>1080, starch content>14%), because they result in products having better texture, greater performance/output, and less oil absorption. In addition, they accumulate less reducing sugar during storage (Cocio P, C. E. (2006). Estudio de la distribuciÓn de aceite en rodajas de papa frita [Study on Oil Distribution on Fried Potato Slices]. Santiago, Chile: Universidad de Chile, School of Chemical and Pharmaceutical Sciences, Department of Food Science and Chemical Technology). Similarly, potatoes containing less than 2% of reducing sugars are required in the manufacture of fried products, in order to minimize the development of browning during processing, as a consequence of non-enzymatic browning reactions, as is the case of the Maillard Reaction (Cocio P, 2006), characteristics present in the potato variety that was used in the present Invention.

[0035] The potatoes were first subjected to selection and calibration, differentiating them between large and small, as per Table 3.

TABLE-US-00003 TABLE 3 Size established for Differences in Caliber Length (cm) Width (cm) Large Potato 13 ± 2 6 ± 2 Small Potato  8 ± 2 4 ± 2

[0036] After calibration, the potatoes were taken to a mechanical peeler (HOBART, 80 kg/h capacity, engine model 60 25 H.P ⅓ with 1450 RPM). This allowed removing the superficial potato skin by means of an abrasive mechanism, which further has a water stream that allows extracting the wastes from the operation (skin). After peeling, the potatoes were submerged in a container that had a sodium metabisulfite solution (Na.sub.2O.sub.5S.sub.2) at a concentration of 6 g/l, so as to stop the enzyme browning during the entire process, preventing the generation of dark or brown areas caused by enzymatic reactions. In the solution, the potatoes were chopped, thereby favoring the action of the additive and its subsequent pulping. Then, the potatoes were pressed to decrease moisture in the potato pulp and reach a moisture content of less than 65%.

[0037] As a variation to the wet potato pulp manufacturing stage, after selection and calibration and before peeling, the potatoes were subjected to a thermal treatment conducted in a steel autoclave. Working conditions considered a pressure of 15 psi, and a temperature close to 120° C., during 7 minutes. After the autoclave processing stage, the potatoes were peeled and chopped. The chopped potatoes were inserted in the semi industrial SKYMSEN blender where, given their high consistency, it was necessary to add 25% of water to make blending easier and to create the paste.

[0038] As another variation to the potato puree manufacturing stage, after selection, calibration, and peeling in the mechanical HOBART peeler, just as in the first way of executing the wet pulp manufacturing stage, the peeled potatoes were submerged in a container with a sodium metabisulfite solution (Na.sub.2O.sub.5S.sub.2) at a concentration of 4 g/l. In the solution, the potatoes were removed and inserted in a potato chopper, obtaining 10 mm thick segments and allowing for an easier action of the additive. The chopped potatoes were inserted in a grinder. To reduce the particle size, additionally a semi industrial SKYMSEN blender was used. Afterwards, the pressing was done in the same way as in the first variation for obtaining the wet potato pulp. In this circumstance, a maximum moisture of 65% was established. [0039] b) Manufacture of Rice Flour

[0040] For the present Invention, white rice flour was used (from the rice polishing), rice flour, and polished rice tip flour.

[0041] Regarding the rice kernels, there is little difference in terms of functionality in the use of broken fractions in comparison with rice ground from whole kernels: however it is often more expensive. The low fat rice flour adds crunchiness to the paste in the coating, a reduction in oil capture, a delayed transmission of moisture, and prolonged maintenance time (Eliasson & Ann-Charlotte (Jul. 16, 2004). Starch in Food—Structure, Function and Applications. Obtained from Elsevier: http://app.knovel.com/hotlink/toc/id:kpSFS FA002/starch-in-food-structure/starch-in-food-structure). The processing quality of these flours largely depends on the inherent chemical profile of each sample and, also on its method of manufacture and the degree of gelatinization.

[0042] In order to obtain rice flour and rice-tip flour, the rice kernel was ground in two machines. In the tests conducted with the first mixture of wet potato pulp of the process, the rice grinding was carried out by means of a mill (BRABENDER Quadromat Junior, with a capacity of 100 g per minute).

[0043] In the tests conducted with the wet potato pulp mixtures, from the two variations, an electric mill (ROMER LABS, model 2A) was used. [0044] c) Mixing of the Components

[0045] The mixing stage comprises incorporating in a semi industrial mixer (VENTUS, model B50A MIXER, 50 liter capacity) the ingredients corresponding to the wet potato pulp, the rice flour, and the additional ingredients, according to the different formulations tested, in order to achieve the mixture and homogenization of the ingredients in a standard way.

[0046] These additional ingredients include additives such as sodium chloride and sodium metabisulfite. [0047] d) Extrusion

[0048] Each of the mixtures obtained through the different formulations was subjected to the extrusion process, thereby arriving at a semi industrial development of the product.

[0049] The mixed feedstock was inserted at one end of the extruder and was extracted at the other end, at high pressure and temperature. Upon exiting the extruder, the mixture was shaped by means of a nozzle and eventually cut into approximately 12 cm long strips. The extrusion tests were carried out in a double screw BUHLER extruder, with a 1 meter run (screw length) and an 8 mm square matrix.

[0050] The extrusion conditions were adapted for each formulation. For the parameters of temperature, pressure, and screw speed, overall ranges were established, which encompass all formulations. The temperature range of the extruder outlet was 50-60° C., the screw speed was 175-210 RPM, and the pressure was set in a range between 25-40 bar.

[0051] The extruder used in the tests can be complemented with a vacuum generator that, in its turn, causes the effect of a decrease in pressure inside the conveyor cavity, thereby allowing a partial extraction of the moisture generated during the process, resulting in a decrease in moisture in the end product. [0052] e) Preservation

[0053] Upon exiting the extruder, the product has a temperature of about 60° C. and, as practically any food product, tends to begin its deterioration phase. For this reason, the mechanism used for its preservation was storage at a refrigeration temperature of 4° C. [0054] f) Frying

[0055] During frying, foods absorb between 5% and 40% by weight of oil, and release part of their lipids into the frying oil. Thus, the oil composition and stability can change during the frying process. The reactions between the frying oil and the proteins and carbohydrates of the foods contribute to the emergence of desirable and undesirable aromas (Frankel, E. (1998), Frying Fats. On Lipid Oxidation. In The Oily Press (pages 227-248). Dundee, Scotland). There are also changes inside their structural formation, such as modification in the cells, changes in phases of some components, or protein degradation during the frying process.

[0056] In the present Invention, this thermal treatment was applied to all samples with the help of an electric fryer (VENTUS CORP, model VFS-102) with adjustable thermostat. The means of immersion was 100% sunflower seed oil, which presents good behavior at high temperatures. The frying conditions were set at 160° C.±2° C., for 2 minutes 15 seconds.

Formulation Examples

[0057] The basic formulation used in the present Invention is made up of 70% wet potato pulp and 30% rice flour.

[0058] The object of the present Invention is to obtain a product that is similar to stick-like fried potatoes, comparable to traditional French fries in taste, appearance, and aroma, factors that make the product pleasant and appetizing, for subsequent commercialization. To this end, it was necessary to incorporate additives: table salt was therefore used (sodium chloride).

[0059] The formulations done in the extruder, subjected to acceptability studies and proximal analyses, are shown in Table 4 where the basic formulation is used as control to observe the changes generated by the additives at different concentrations.

TABLE-US-00004 TABLE 4 Formulations without Application of Vacuum in the Extrusion Process Example Potato (%) Rice (%) Salt (%) 1 (Control) 70 30 — 2 70 30 0.1 Not added (—).

[0060] Measurement of Physical and Chemical Properties

[0061] Moisture Determination

[0062] The moisture determination was carried out for each of the feedstock and extruded products. Three equipment were used: air oven, infrared moisture analyzer, and a moisture analyzer with halogen lamp. [0063] Wet Potato Pulp

[0064] First, there is the traditional moisture determination method, in an air oven. 2 to 5 g were measured and placed in an oven at 103±2° C. for 3 hours. Then, the sample was weighed every 10 minutes until it reached a constant weight (A.O.A.C, 1990). The method is based on the gravimetric determination of mass low of a dried sample, until reaching a constant mass. This mechanism was used for the wet potato pulp samples and their corresponding mixtures. The average moisture of the wet potato pulp in the formulations of the present Invention is 66.2% [0065] Rice Flour

[0066] The moisture determination in rice flour was carried out with an infrared moisture analyzer (KERN, model MLS-D). The oven was regulated at 105° C.; this methodology is based on NCh 841.Of 78 “Alimentos—DeterminaciÓn de humedad′ [Foods—Moisture Determination]. 2 to 3 grams were weighed until reaching a constant weight. The machine records variations of 0.001 g. The average moisture of the rice flour in the formulations of the present Invention is 12.0% [0067] Extruded Product

[0068] The moisture determination of the extruded product, after exiting the extruder, was done in a moisture analyzer HC103 METTLER TOLEDO 0.01%, which operates with a halogen lamp and an infrared sensor that record the variations in weight, at 105° C. 1±0.02 grams of the sample was weighed in the analyzer, previously homogenized, thus starting the drying process that ends when the instrument detects a constant mass. This analysis is based on the gravimetric principle of moisture percentage calculation by a difference in weight. The average moisture of the extruded formulations is approximately 40%.

[0069] Measurement of Organoleptic Properties [0070] 1. Oil Absorption

[0071] Oil absorption is one of the main parameters evaluated in the present Invention, with the aim of proving that the obtained product corresponds to a product that is an alternative to fried potatoes and has low fat content.

[0072] The oil absorption determination of the fried samples was done following the Bouchon method (Bouchon, P. A. (2003). Structure Oil-Absorption Relationships during Deep-Fat Frying. Journal of Food Science, 68(9), 2711-2716). The total oil content was determined by solvent extraction, using the Soxhlet technique (AOAC, 1984). The potato sticks were ground, thereby obtaining homogeneity in the samples, from which 5 grams, approximately, were weighed and transferred to an extraction thimble. A 250 ml ball was dried and weighed prior to adding 130 ml petroleum ether. The extraction lasted 4 hours, using the Soxhlet machine. The solvent was removed in a rotary evaporator. The ball containing the extracted oil, was placed to dry until obtaining a constant weight, by heating in an air oven at 105° C. The samples were analyzed in duplicate and the results were expressed as percentage of oil, on a dry basis.

[0073] Oil absorption is influenced by a series of factors and cofactors that increase or decrease the values thereof. In the case of fried potatoes, the greatest oil retention occurs on the surface and in holes or capillaries inside the crust (Aguilera J. M. & Gloria H. (1997). Determination of oil in fried potato products by differential scanning calorimetry. Journal of Agriculture Food Chemistry). When dealing with a product similar to a fried potato, the surface imperfections are influenced during the shaping process, during the extrusion, and so it is expected that during frying the oil retention takes place on the product surface.

[0074] Observing the results obtained in Table 5, the formulation with 0.1% salt presents a 65% decrease in oil absorption with regard to the similar products. This could be due to that the mass transfer is characterized by the loss of moisture and the gain in oil, phenomena that operate in countercurrent. Salt, or sodium chloride, is a hygroscopic compound that retains the available water particles, thereby causing the water molecules inside the food to participate in the solvation of the ions coming from the salt, thus achieving a decrease in the water activity (a.sub.w) of the formulation. For this reason, when there is a decrease in moisture loss, a decrease in oil absorption would be generated. This result is extremely important because it directly influences the characteristics that are sought in developing the product.

TABLE-US-00005 TABLE 5 Oil Absorption for the Formulations developed in the Present Invention vs Control % of oil % of oil % of oil % of oil on a wet on a skimmed on a dry on a dry Examples basis moisture basis basis skimmed basis 1 (Control) 20.58 25.91 20.58 22.03 2 (0.1% salt) 7.09 7.64 7.20 7.76 [0075] 2. Proximal Determination

[0076] Proximal analyses were done on the extruded product, in order to learn about the most significant components thereof. The analyses were carried out at the premises of the CECTA-USACH Laboratory, accredited by the INN under the standard NCh-ISO 17025 LE: 1164. The components to be considered were: moisture content (PQM 001 revision 06, 2014, based on NCh 841. Of 78); proteins (PQM 002, revision 07, 2015, based on PTR-711.02-173 ISP, 2009); lipids (PQM 003, revision 05, 2012 based on procedure PTR-701.04-156 from ISP, 1998); ashes (PQM 004, revision 05, 2012 based on NCh 842.0f 78); raw fiber (PQM 005, revision 06, 2014 based on AOAC, 962.09, 2010); non-nitrogenous extracts, (PQM 006, revision 01, 2014, based on Schmindt-Hebbel, pages 32-1981); and energy, (PQM 007, revision 01, 2014, based on Schmindt-Hebbel, 1981).

[0077] The proximal analysis of the product similar to fried potatoes was done, taking into account moisture content, proteins, lipids, ashes, and non-nitrogenous extract (NNE), according to the official methodologies. The analyses were carried out at the premises of the CECTA-USACH Laboratory, accredited by the INN under the standard NCh-ISO 17025 LE: 1164 at the Universidad de Santiago de Chile.

[0078] The data collected in Table 6 ratify that the salt, being a hygroscopic compound that captures water particles, allows reaching the highest values of moisture for the developed formulations. The non-nitrogenous extract, which represents the fraction of soluble carbohydrates, presents a decrease in the formulation with salt. This value can be due to a lack of homogenization in the sample taking.

TABLE-US-00006 TABLE 6 Proximal Analysis of a Product similar to Extruded Fried Potatoes Example 1 Example 2 Analysis Control 0.1% salt Moisture (g/100 g) 45.8 51.3 Proteins (% N × 6.25) 4.0 4.3 Lipids (g/100 g) *not detected *not detected Ashes (g/100 g) 0.6 0.8 Raw Fiber (g/100 g) ***not detected ***not detected Non Nitrogenous 49.6 43.6 Extract (g/100 g) Energy (Kcal/100 g) 214 192 *detection limit ≤ 0.52 g/100 g ***detection limit < 0.59 g/100 g Source: CECTA-USACH Laboratory [0079] 3. Sensory Determination

[0080] The sensory assessment of the food product developed represents the preference of the evaluators who expressed it through the attributes of: aroma, stick length, color, taste, and residual oiliness. Once the sticks had been fried, the sensory quality thereof was determined through the methodology of descriptive quantitative analysis (Trinchero & col., 2008), using unstructured scales, 15 cm long. The average values of each descriptor are shown in Table 7. The sensory analysis was done in keeping with UNE-ISO 6658:2008. 25 panelists were recruited, according to Pedrero & Pangborn (1989) for the sensory analysis of the samples of the food product similar to fried potatoes.

[0081] The acceptability of the extruded product, according to an unstructured guideline, was defined from the ranges, in which the measurement unit was centimeters. The rejection area is 0-6.99 cm; the indifference area, 7-7.99; and the acceptability area, 8-15 cm.

[0082] The stick firmness is a characteristic of texture that is related with the starch content and cell structure. No significant differences as to firmness (p<0.05) were observed between the treatments.

[0083] In the residual oiliness and taste values, no significant differences were observed between the treatments.

[0084] As to the attributes of color and aroma, there were significant differences (Table 7). Out of the group of treatments, the one having the greatest evaluation in the scale—considering these two factors—is the one formed by the addition of salt at 0.1%, generating an increase in the sensory aptitudes of the product.

TABLE-US-00007 TABLE 7 Sensory and Statistical Results in the Acceptability Determination (cm) Formulation Example 1 Example 2 Attribute Control 0.1% salt Aroma 6.12.sup.a 7.33.sup.a Color  5.07.sup.bc 8.88.sup.a Stick 6.31.sup.a 6.40.sup.a Firmness Taste 5.61.sup.a 6.35.sup.a Residual 7.17.sup.a 7.61.sup.a Oiliness * Identical letters in the attribute indicate that there are no significant differences (P-value ≥ at 0.05) [0085] 4. Texture Determination

[0086] Texture is regarded as a positive attribute of quality for the formulation of foods. In this study, a soft food texturometer was used (Agrosta® Texturometer Version 2), with the aim of learning more about the food product's characteristics. The texture analysis was conducted on the extruded end product, yet it was necessary to define the working conditions and parameters because there are no standard values, it being a new product and there being no studies of similar products in the market.

[0087] The main characteristic of fried potatoes is their crunchy texture, considered to be one of the most important quality indicators in the end product. This is assessed by the fracturability, which is defined as the first significant drop in the curve, during the first compression cycle, resulting from a high level of hardness and low level of cohesiveness. It refers to the hardness with which the food product crumbles, crunches, or bursts. It is expressed in Newton units of force (Sanchez, M. M. (2016). Texturometria Instrumental: Puesta a punto y aplicaciÓn a la tecnologia de alimentos [Instrumental Texturometry: Set-up and Application in Food Technology]. Michoacan: Instituto Tecnológico Superior de Apatzingán [Higher Technological Institute].

[0088] The texture analysis was carried out by taking 10-12 sticks of each formulation of the present Invention. 4 measurements were made lengthwise to each stick, to have a more precise average of the behavior of the whole stick. This analysis used a penetration speed of mails, a penetration distance of 15 mmm and a cylindrical accessory 5 mm in diameter.

TABLE-US-00008 TABLE 8 Average Fracturability Values of each Treatment Fracturability (kg) Extruded Fried Product 636.85

[0089] The recorded values are not comparable through bibliography, given that they deal with a new food product.