Whole grain chips and a method for manufacturing thereof

Abstract

A food product and a method for manufacturing thereof, in particular, manufacturing of a snack food product obtained by extruding and formed as chips, containing rice and corn grains, a natural flavoring additive with olive oil and rosemary, with cheese, with tomato and basil, with nacho cheese, with paprika and chili, the method including treating the rice and corn grits by purifying them from impurities and subsequent moistening with water, extruding the finished mixture of the grits with simultaneous baking and briquetting with double pressing, applying the flavoring additive on the surface of the chips by spraying.

Claims

1. A composition of whole grain chips comprising: rice grits, corn grits, water, and a flavoring additive, wherein the flavoring additive includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning in the following ratio of components, wt. %: TABLE-US-00010 water 5.0-10.0 rice grits 30.0-44.0 corn grits 30.0-44.0 sunflower oil and/or olive oil 5.0-30.0 a rosemary extract 0.005-0.02 natural seasoning The rest.

2. The composition of claim 1, wherein the natural seasoning comprises at least one of tomato and basil, cheese, nacho cheese, paprika and chili.

3. The composition of claim 1, further comprising a leguminous crop comprising at least one of bean, lentils, pea, chickpea, amarantus, quinoa, and mixtures thereof in an amount of 10.0-15.0 wt. %.

4. A method for manufacturing of whole grain chips composed of rice grits, corn grits, water and a flavoring additive, which includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning, the method comprising: treating the rice and corn grits by purifying them from impurities and subsequent moistening with water; extruding the finished mixture of the grits with simultaneous baking and briquetting with double pressing; applying the flavoring additive on the surface of the chips by spraying, the components for manufacturing of the whole grain chips being taken in the following ratio of the components, wt. %: TABLE-US-00011 water 5.0-10.0 rice grits 30.0-44.0 corn grits 30.0-44.0 sunflower oil and/or olive oil 5.0-30.0 a rosemary extract 0.005-0.02 natural seasoning The rest.

5. The method of claim 4, wherein the natural seasoning comprises at least one of tomato and basil, cheese, nacho cheese, paprika and chili.

6. The method of claim 4, wherein the composition of the chips includes additionally a leguminous crop comprising at least one of bean, lentils, pea, chickpea, amarantus, quinoa, or mixtures in the amount of 10.0-15.0 wt. %.

7. The method of claim 4, wherein the moistening the mixture of the grits is performed in a vertical mixer by feeding a calculated quantity of water, triple mixing for about seven minutes to attain a uniform mixing and a uniform distribution of water with subsequent keeping for about one to six hours for swelling, wherein moisture of the finished moistened mixture of the grits is about 14.5-19.0%.

8. The method of claim 4, wherein extruding the moistened mixture of the grits is performed under pressure of about 120-160 bar between press-forms heated up to a temperature of a top part of the stampof about 250-260 C. and a temperature of a bottom part of the stampof about 260-280 C.

9. The method of claim 4, wherein, at the step of applying the flavoring additive, the sunflower or olive oil is heated up in a separately standing tank with a water jacket to room temperature, is fed by a pump or under gravity into a panning drum, where it is sprayed onto surfaces of the chips using nozzles, while seasoning or other spices, along with the oil, are fed into the panning drum and applied on the chips, which have already been covered with oil.

Description

DETAILED DESCRIPTION

[0017] This disclosure eliminates the disadvantages of the prior art, provides a snack product that is not capable of harming the health of the consumer, and expands a range of the bakery products.

[0018] The technical result of the disclosure resides in the implementation of the said product and the method for manufacturing thereof, as a result of which a new snack product being distinguished by its taste quality is obtained, which is intended for direct consumption as an additional source of fiber, mineral substances and vitamins.

[0019] The said technical result is achieved at the expense of the composition of the whole grain chips, which contain rice grits, corn grits, water, a flavouring additive, characterized in that the flavouring additive includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning in the following ratio of the components, wt. %:

TABLE-US-00001 water 5.0-10.0 rice grits 30.0-44.0 corn grits 30.0-44.0 sunflower oil and/or olive oil 5.0-30.0 a rosemary extract 0.005-0.02 natural seasoning The rest.

[0020] At the same time, the natural seasoning is selected from the group comprising at least one of tomato and basil, cheese, nacho cheese, paprika and chili.

[0021] At the same time, in one of the embodiments of the disclosure, the composition of the chips includes additionally the leguminous crops selected from the group containing bean, lentils, pea, chickpea, amarantus, quinoa, or their mixtures in the amount of 10.0-15.0 wt. %.

[0022] At the same time, the ratio of the different kinds of leguminous crops in the mixture may be, for example, 1:1 or 1:2; 1:3; 1:4 etc.

[0023] In addition, the said technical result is achieved due to the method for manufacturing of the whole grain chips, according to which the raw materials composition includes the use of rice grits, corn grits, water and the flavouring additive, which includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning; treating the rice and corn grits by purifying them from impurities and subsequent moistening with water; extruding the finished mixture of the grits with simultaneous baking and briquetting with double pressing; applying the flavouring additive on the surface of the chips by spraying, the components for manufacturing of the whole grain chips being taken according to the above said qualitative and quantitative composition.

[0024] At the same time, moistening the mixture of the grits is performed in the vertical mixers by feeding there a calculated quantity of water, triple mixing during 7 minutes with the purpose of uniform mixing and a uniform distribution of water with subsequent keeping during 1-6 hours for swelling, while moisture of the finished moistened mixture of the grits is 14.5-19.0%.

[0025] At the same time, extruding the moistened mixture of the grits is performed under pressure of 120-160 bar between the press-forms heated up to the temperature of a top part of the stamp250-260 C. and the temperature of a bottom part of the stamp260-280 C.

[0026] At the same time, at the step of applying the flavouring additive, the sunflower or olive oil is heated up in a separately standing tank with a water jacket to room temperature, it is fed by a pump or under gravity into a panning drum, where it is sprayed onto the surface of the chips using the nozzles, while the seasoning or other spices, along with the oil, are fed into the panning drum and they are applied on the chips, which have already been covered with oil.

IMPLEMENTATION OF THE DISCLOSURE

[0027] The uniqueness of the new product obtained by the claimed method (the whole grain chips) is that it is manufactured from the whole rice and corn grits, thereby the product has a high percentage (up to 60%) of the content of food fibers, and also, in one of the embodiments of the disclosure, it contains leguminous crops, which contain a lot of vegetable protein and vegetable fiber.

[0028] The product is a brittle product manufactured from the corn and rice grains with the addition of the flavouring mixture based on sunflower or olive oil with natural seasoning, with the possible addition of leguminous crops and (or) their mixtures, salt and protein powder. It is possible to add natural food flavours (flavouring substancesspices and condiments) to give a peculiar aroma and taste, it is possible to add natural food dyes to give a colour.

[0029] Extruding, which the treated (purified from impurities and moistened) grain is exposed to, is a complex physical and chemical process, which includes: thermal treating the product under pressure; a mechanochemical deformation of the product; an explosion of the product in a shock discharging front.

[0030] When extruded, the water in the grain boils at the high temperature, the grain bursts (swells) and, due to the high pressure, it is immediately formed into a briquette. As a result of thermal treating, the taste quality of the product is improved (a pleasant odour and taste), because various aromatic substances, etc. are formed, the enzyme activity to digest it increases significantly, the nutritional value of the product almost doubles.

[0031] Corn and rice enjoy an excellent reputation due to their nutritional value for the human nutrition. In addition, they also contain the coarse indigestible food fibers that help to remove toxins and slags from the body. The swollen rice grains have a beneficial effect on the intestinal peristalsis, normalize metabolism and they are the suppliers of the complex carbohydrates, which saturate and replenish the energy reserves for a long time. The product does not contain gluten, GMOs, artificial food dyes and flavours, preservation agents and it is a perfect supplement to nutrition.

[0032] The chips are manufactured in the form of the brittle light bars of various shapes. Depending on the technical peculiarities of the equipment, the shape of the product can be square, triangular, round (of different diameters), hearts-shaped or the product can have other shapes.

[0033] The product may contain vitamin or vitamin and mineral complexes (premixes).

[0034] The whole grain chips are covered with the flavouring additive on both sides.

[0035] The examples of the composition of specific products are given and the method manufacturing thereof is described in detail to serve evidence of the possibility of the implementation of the disclosure.

Example 1

[0036] The whole grain corn-rice chips with paprika and chili.

TABLE-US-00002 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 44.00 corn grits 30.00 sunflower oil 5.00 a rosemary extract 0.005 natural seasoning with paprika and chili 15.995 Total 100.00

Example 2

[0037] The whole grain corn-rice with nacho cheese.

TABLE-US-00003 The raw materials The raw materials name consumption, in wt. % water 10.00 rice grits 30.00 corn grits 44.00 sunflower oil 10.00 a rosemary extract 0.02 natural seasoning with nacho cheese 4.98 Total 100.00

Example 3

[0038] The whole grain corn-rice chips with cheese.

TABLE-US-00004 The raw materials The raw materials name consumption, in wt. % water 7.00 rice grits 40.00 corn grits 30.00 sunflower oil 15.00 a rosemary extract 0.01 natural cheese seasoning 7.99 Total 100.00

Example 4

[0039] The whole grain corn-rice chips with tomato and basil.

TABLE-US-00005 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 44.00 corn grits 44.00 sunflower oil 5.00 a rosemary extract 0.01 natural seasoning with tomato and basil 1.99 Total 100.00

Example 5

[0040] The whole grain corn-rice chips with olive oil and rosemary.

TABLE-US-00006 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 30.00 corn grits 32.00 olive oil 30.00 a rosemary extract 0.005 natural seasoning with olive oil and rosemary 2.995 Total 100.00

Example 6

[0041] The whole grain corn-rice chips with pea.

TABLE-US-00007 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 30.00 corn grits 30.00 pea 15.00 olive oil 15.00 a rosemary extract 0.01 natural seasoning with salt and rosemary 3.99 protein powder 1.00 Total 100.00

Example 7

[0042] The whole grain corn-rice chips with bean.

TABLE-US-00008 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 30.00 corn grits 30.00 bean 10.00 olive oil 15.00 a rosemary extract 0.01 natural seasoning with salt and rosemary 4.99 protein powder 5.00 Total 100.00

Example 8

[0043] The whole grain corn-rice chips with chickpea and quinoa.

TABLE-US-00009 The raw materials The raw materials name consumption, in wt. % water 5.00 rice grits 30.00 corn grits 30.00 chickpea 5.00 quinoa 5.00 olive oil 15.00 a rosemary extract 0.01 natural seasoning with salt and rosemary 4.99 protein powder 5.00 Total 100.00

[0044] The method for manufacturing of the product involves the following steps: [0045] treating the raw materials; [0046] composing the mixture; [0047] extruding and briquetting; [0048] applying the flavouring additive; [0049] packaging and labelling the product.

[0050] Treating the raw materials.

[0051] Treating the raw materials involves the following operations: [0052] screening the grain; [0053] washing the grain; [0054] moistening.

[0055] Screening.

[0056] The corn and rice grits, and the leguminous crops, if they are envisaged by the recipe, are screened with the purpose of removal of the impurities differing from the grits by the width, thickness and the aerodynamic properties. The raw materials are passed through the grain purification unit BSH-1 or Almaz (it is possible to use the separators of other brands and other manufacturers) with the magnetic detectors and the sieves with the different diameters of the cells, depending on the kind of the grits.

[0057] Washing.

[0058] The corn and rice grits, and the leguminous crops are washed separately, if they are envisaged by the recipe, at the wash machine KVD-1 (it is possible to use the wash machine of another brand and another manufacturer), intended for clearing a surface of grits and leguminous crops, if they are envisaged by the recipe, and separating them from the impurities differing by the hydrodynamic properties.

[0059] Moistening.

[0060] Moistening is an important technological operation that influence on the quality of the finished product. Moistening the grits is performed in mixers, both of the vertical and horizontal types. The amount of the water required for moistening depends on the kind of the grits and their initial moisture, and it is 2.8-3.5% of the weight of the loadable grits. Moisture of the treated raw materials should be 14.5-19%.

[0061] Moisture occurs by loading the corn and rice grits into the mixer, feeding there the calculated amount of water, triple mixing during 7 minutes with the purpose of uniform mixing and a uniform distribution of water with subsequent keeping during 30-60 hours for the grits swelling.

[0062] After the end of the process of moistening, the corn and rice grits should be kept during 1-6 hours, depending on the quality of the used grits.

[0063] Composing the mixture.

[0064] The mixture of the grits is composed from the treated raw materials according to the approved recipes, depending on the kind of the product.

[0065] Extruding and briquetting.

[0066] The manufacture of the product is performed at a special equipment and it involves extruding the mixture of the grits and simultaneous baking and briquetting with double pressing the obtained product. The technological parameters at this step are the temperature of the top and bottom stamps and the heating-up time. These parameters depend on the processable mixture of the grits and are:

[0067] The temperature of the top part of the stamp is 250-260 C.;

[0068] The temperature of the bottom part of the stamp is 260-280 C.;

[0069] The time of baking is 6-8 seconds;

[0070] The pressure is 120-160 bar.

[0071] Applying the flavouring additive from the vegetable oil and the natural seasoning on the whole grain chips.

[0072] The vegetable oil (high oleic sunflower or olive oil) is heated up in the separately standing tank with the water jacket to room temperature, and it is fed by the pump or under gravity into the panning drum, where it is sprayed onto the surface of the chips using the nozzles. The seasoning or other spices, along with the oil, are fed into the panning drum and they are applied on the chips, which have already been covered with oil.

[0073] This is followed by the steps of packaging and labeling, transporting and storing.

[0074] The given examples of a specific implementation allow determining an optimal ratio of the components for the whole grain chips and obtaining a wholesome product with the high organoleptic characteristics of quality and with a high nutritional value suitable for functional nutrition.