A METHOD OF PRODUCTION GRAIN MASS AND A SYSTEM FOR ITS PRODUCTION

Abstract

An enhancement to food industries and to a method of grain mass production. The method features germinating cleaned grain using shungite water as a liquid medium and grinding germinated grain to particles sized no larger than 300 μm, while the dependence of the time of grain germination on the temperature of the liquid medium is inversely proportional. A system for grain mass production featuring an isothermal chamber for grain germination adapted to maintain constant temperature in which transport containers for grain germination are installed, a container for infusing water with shungite stones equipped with means for supplying shungite water in the transport containers and at least one grain grinder which is capable of grinding germinated grain for obtaining a fine grain mass with particles not larger than 300 μm.

Claims

1. A method of producing grain mass involving the germination of cleaned grain and its grinding, while as grain is used matured grain with preserved seedcase and undamaged hyaline layer while the grain germination is conducted in a liquid medium at the temperature of 10° C. to 38° C. based on water from 11 h to 38 h, depending on the temperature of liquid medium with constant air supply until reaching pH 3.6-7 in the grain and after the germination of grain the water in which grain was germinated is drained and grain is rinsed with water at the temperature of 10 to 21 oC to prepare for milling and then grain is ground to particles no larger than 300 μm and milling the germinated grain is conducted with a simultaneous supply of cooled air and at the temperature of 22° C. to 35° C., not exceeding the temperature of denaturation of the protein of the obtained grain mass as a liquid medium is used water infused on shungite stones for 1 h to 10 days and the dependence of the time of grain germination on the temperature of the liquid medium is inversely proportional.

2. The grain mass production method according to claim 1, grain mass being germinated in containers with shungite stones.

3. The grain mass production method according to claim 1, including a stage of superficial cleaning of grain passing grain through an air tunnel at 90% humidity.

4. The grain mass production method according to claim 1, characterized in that in which milling is conducted to the size of particles not larger than 250 μm.

5. The grain mass production method according to claim 1, in which fine milling is conducted to the size of particles not larger than 150 μm.

6. The grain mass production method according to claim 1, and charactcrizcd in that for germination the grain is placed in shungite-structured water with ratio of no more than 1.2 I for 1 kg of grain.

7. The grain mass production method according to claim 1, grain being selected from at least one of a group including wheat, rye, oat, barley, soy, corn and any combination thereof at the required ratio of components.

8. The grain mass production method according to claim 7, the germination of grain of various cereals and their milling are conducted separately and the obtainment of grain mass from various cereals at the recipe-required ratio is conducted by blending the grain masses obtained from each cereal.

9. The method of production of dough on the basis of grain mass obtained by the method according to claim 1, wherein oxidized mass with pH 5.8-6.2 of the same grain is added as natural yeast, wherein the mass is oxidized naturally for 48 h to 72 h at the temperature of 25° C. to 35° C.

10. A system for the production of grain mass comprising: a module for grain germinating featuring: loading device for loading cleaned grain into transport containers for germinating grain; at least one transport container for portional germinating of grain equipped with means for supplying a liquid water-based medium, draining for used water and a air supply system; isothermal chamber for grain germination in which are installed the transport containers, the chamber being adapted to maintain the temperature of grain germination from 10° C. to 38° C. over the entire volume of each of the transport containers; unloading-loading device for transferring germinated grain from the transport containers to the grinder; a grain grinding module comprising at least one grain grinder; the module for grain germinating further including at least one container for water infusion by shungite stones as a liquid medium, equipped with means for supplying shungite stones infused water in the transport containers for grain germination, wherein the grinder is capable to grind germinated grain to achieve fine grain mass with particles sized no larger than 300 μm and has means for supplying cold air for cooling grain mass in the process of milling to a temperature not exceeding the temperature of protein denaturation.

11. The system for the production of grain mass according to claim 10, the module for grain germinating comprising two or more grinders arranged in series, wherein each subsequent downstream grinders is adapted to grind the mass to a smaller particle size.

12. The system for the production of grain mass according to claim 10, the grinder comprising a container, at least one lowerable grid basket and at least two rotating levers arranged in the in grid basket ending with scraping knives touching the internal surfaces of the grid basket, a lifting device for lowering and lifting the grid basket and the knives, wherein a rotating mechanism of the levers comprises a motor and a three-dimensional planetary gear box driven by a cog belt.

13. The system for the production of grain mass according to claim 12, the transport container for the portional germination of grain comprising a grid basket for grain identical with the grid basket of the grinder.

14. The system for the production of grain mass according to claim 10, the internal walls of the transport container for grain germination being covered by cages with shungite stones, said cages being from 2 to 6 cm wide.

15. The system for the production of grain mass according to claim 10 further comprising a module for surface cleaning of the grain.

Description

SHORT DESCRIPTION OF DRAWINGS

[0049] More specifically the method of production of grain mass and the system for the production of grain mass according to the invention are explained by preferable versions of execution presented as examples not limiting the scope of the invention, with references on the attached drawings in which:

[0050] FIG. 1—a schematic depiction of the system for obtaining grain mass according to the invention.

[0051] FIG. 2—a general image of the transport container for grain germination (in section);

[0052] FIGS. 3 and 4—a general image of the grain grinder (in section) with a lifted basket (FIG. 4) and lowered basket (FIG. 3);

THE BEST VERSION OF EXECUTION OF THE INVENTION

[0053] The method of production of grain mass according to the invention features the germination of grain and its subsequent grinding. As grain is used cleaned mature grain with preserved seedcase and undamaged hyaline layer (capable of germination).

[0054] In addition, if necessary, the method can include the stage of germination and the stage of superficial cleaning grain and/or cleaning grain off mechanical inclusions. The methods of cleaning grain themselves are known. For example, the cleaning off the superficial layer can be conducted by humid blowing passing grain through an air tunnel at 90% humidity. Before cleaning by running water grain is subjected to hulling with removing a part of the superficial layer of grain's bran covering at the rate of 5% of the initial mass of grain preserving the integrity of the hyaline layer. The known method described in WO0222268 A1 can be applied.

[0055] Usable are grain of wheat of soft and hard kinds, rye, barley, dinkel wheat, einkorn (Triticum monococcum)), corn, oat, soy, rice, buckwheat and their mixes in proportions prescribed by recipe. The superficial cleaning and germination of various grains are conducted separately by parallel flows taking into account the specifics of activation of the germ of each of the components.

[0056] The grain germination is conducted in containers in a liquid medium while according to the invention as a liquid medium is used shungite stone-infused water. The infusion of water is conducted in separate containers where shungite stones are placed in the quantity of 5 to 50% of the weight of the water, preferably—10% of the water weight. Water is infused for 1 h to 10 days, preferably 24 to 72 h, at the temperature of 10 to 80° C.

[0057] As a liquid medium can be used liquid medium with recipe-required properties (drinking water, activated water, water with added extracts of various plants and so on, serum and such) whose use is required by the technological regulations for the purpose of improving the physical properties of the prospective product, for example dough and accordingly to increase the porosity of the grain bread made from this dough, for instance. To increase the biological value of grain it is possible to add to the water medium various nutritional components (nutritional biological additives, salts). In addition, the liquid medium can contain also extracts of medicinal plants in various blends and proportions.

[0058] It is preferable to germinate grain with a rate of no more than 1.2 liters of shungite-infused water for 1 kg of grain.

[0059] The germination is conducted equally over the entire volume of grain germinated at the temperature of the liquid medium of 10° C. to 38° C., from 11 h to 38 h, depending on the temperature of the liquid medium with constant air supply while the dependence of the time of germination and liquid medium is inversely proportional, that is the higher is the temperature the faster grain germinates. Approximate dependence of time of grain germination on the liquid medium temperature is presented in chart 1.

TABLE-US-00001 CHART 1 Approximate dependence of time of grain germination on the liquid medium temperature Liquid medium temperature Germination time, hours 40-35° C. 11-13 35-30° C. 14-18 30-25° C. 19-24 25-20° C. 25-27 20-15° C. 28-32 15-10° C. 33-38

[0060] Respectively, the time of readiness of germinated grain can be adjusted by means of decreasing or increasing the temperature of the liquid medium.

[0061] Grain is germinated until it reaches the humidity according to the kind of grain until saturation of grain and reaching pH 3.6-7 in grain. For various kinds of grain water saturation is different and presented as achieving a certain percentage of humidity of grain's weight as follows:

[0062] Wheat—45%

[0063] Rye—51-53%

[0064] Einkorn—55%

[0065] Corn—55%

[0066] Buckwheat—50%

[0067] Oat—52%

[0068] Germination is understood as biological activation of grain in which the germ is fully activated and a sprout appears on it while the grain is saturated by humidity and swells, a root is starting to form but the intensive process of hydrolysis of starch, endosperm and protein of the aleuronic layer has not yet started, that is the baking properties of grain do not deteriorate to a critical level on which the content of gluten decreases sharply.

[0069] At the time of germination the quantity of gluten in grain decreases and at the same time are activated and increase the quantities of enzymes, antioxidants and vitamins.

[0070] A study showed that in germinated grain the quantity of gluten decreases by 75% off its initial content there.

[0071] It is preferable to germinate grain in containers with shungite stones.

[0072] After the germination of grain the water in which grain was germinated is drained and grain is rinsed with water at the temperature of 10 to 21° C. to prepare for milling. As water for rinsing germinated grain it is preferable to use shungite-infused water. The infusion of water is conducted as described above for obtaining shungite water for grain germination.

[0073] Then grain is ground to particles no larger that 300 μm and milling the germinated grain is conducted with simultaneous supply of cooled air and at the temperature of 22° C. to 35° C., not exceeding the temperature of denaturation of the protein of the obtained grain mass. Grain is ground to various sizes of particles: from 250 to 300 μm—course milling, to 250 μm—medium milling, to 150 μm—flour milling.

[0074] From the obtained grain mass is prepared dough adding additional ingredients depending on the recipe of the end product. In one version of the execution of the invention as natural yeast is added oxidized mass with pH 5.8-62 of the same grain. From the obtained mass is separated a part which is oxidized naturally for 48 h to 72 h at the temperature of 25° C. to 35° C.

[0075] The claimed method of production of grain mass is executed by means of an equipment system for producing grain mass according to the invention comprising a module of superficial grain cleaning (optional), a module of grain germination, a module of grain grinding and loading-unloading devices (FIG. 1) installed in the line of the technological process.

[0076] The superficial grain cleaning module is optional and can be executed as equipment for grain cleaning on an industrial scale 5000 kg/h where grain is rinsed with water with a supply of pressured air in an air tunnel at 90% humidity whereby grain is cleaned of superficial layer. The superficial grain cleaning module can feature a hulling machine 11 for the removal of the germ cover's superficial layer particles without damaging the integrity of the seedcase's hyaline layer and preserving its germ, a device for rinsing grain's surface and a device for cleaning grain off mineral and organic inclusions 1. Equipment for grain cleaning is known from practice, for instance from WO0222268 A1.

[0077] The Grain Germination Mode Features:

[0078] At least one container for water infusion 4 on the basis of shungite stones as a liquid medium. This container is equipped by a device of fresh water supply, shungite stones 5, a means of supply of shungite stone structured water in transport containers for grain germination (for example a pump 6 and pipe 14). It is preferable to use shungite stones with carbon content of 35 to 80%. The quantity of shungite stones in a container of 5 to 50% of the water weight. It is possible to use shungite stones in pieces of various sizes. The best results are obtained using shungite stones in pieces preferably sized 1 to 10 cm. It is preferable that the internal walls of the container for water infusion be covered with shungite stones sized 3 to 10 cm. The container has a scale for unloading any quantity of water from 1 to 500 liters. It is preferable that the container is connected to a device supplying fresh purified water through a mechanic filter. The quantity of loaded water in the container for grain germination can be determined automatically.

[0079] At least one container for portional grain termination 7 as a transport container with wheels with a capacity of 50 to 300 kg of grain. It is preferable that the container for grain germination have four driving wheels. It is preferable be made of stainless steel. The container's bottom has a drainage tap 8 for draining residual water after germination. On the sides can be hands thanks to which this container can be lifted and turned over for unloading. In the sample version shown in FIG. 2, the transport container 7 features a grid basket 9 with holes, made of stainless still into which grain is loaded. This grid basket is identical to the grinder's basket as described more specifically below. After germination this basket 9 is transferred together with the germinated grain from the transport container to the grinder's container.

[0080] The number of containers needed for grain germination 7 is calculated considering the total quantity of the end product produced from the grain mass for a given day (shift) taking into account the requirements of dry grain per unit of the end product. Each transport container 7 is equipped with a device for air supply (not shown in the figure) as a tube connectible to a pressured air source whose lower end is in the container's bottom and the upper end with a device for connection to a pressured air source. This source can be for instance a compressor with a necessary level of pressure of air. The air supply system for the germinating grain can be executed also as removable perforated tube connected with a flexible pipe for pressured air supply installed in the container before loading grain for germination. Such perforated tube can have the form of a horizontal spiral. The perforated tube can have a vertical sleeve which is a connector between the perforated tube and flexible pipe. The flexible pipe for pressured air supply can be one of the exit of the traditional pressured air pumping system which includes a compressor and a central flexible pipe connected to it with the number of exits according to the number of the germination containers. Each exit can be equipped with a nozzle with lateral perforation.

[0081] In the preferable version the internal walls of the germination container 7 be covered with nets of shungite rocks 2 to 6 cm wide.

[0082] The germination module features also a loading device 15 for loading cleaned grain to the transport germination containers. Preferably this module should include a silo 12 for containing grain with a capacity of, for example, 50 t, equipped by a dosing unit 2, for example a drum feeder, rotary feeder, electronic scale et cetera adjusted for loading a certain amount of grain into the germination containers, for example by a vacuum transporter 3. It is preferable that silo have devices for controlling grain's humidity. In the sample version of the invention execution, shown in FIG. 1, at the exit of silo 12 is installed grain cleaning module 1.

[0083] The grain germination module 1 comprises also an isothermal chamber 13 for grain germination where are located transport containers 7 for grain germination and the chamber is capable of maintaining the temperature in the entire volume of each of the transport containers. The germination containers 7 can be located in one or several rows inside the isothermal chamber 13. Over the first or over each germination container 7, or over a group of such containers are located pipes for air supply connected to a pressured air source and pipes for water supply 14 connected to container 4 or water infusion containers as well as transport sleeve 15 for feeding grain from grain storage silo 12. Isothermal chamber 13 is equipped with equipment for maintaining temperature according to required parameters from 10° C. to 38° C.

[0084] For example, air conditioners (not shown in the drawings). Each group of germination containers has a control module for air temperature at a given moment. The data is sent to the central unit of command of temperature in the isothermal chamber which commands the air conditioners located round the isothermal chamber. The isothermal chamber may have rails and/or guideways on which the transport germination containers move and could be connected with each other and make up one or several chains/sequences. In the beginning of a sequence the transport germination containers are loaded with a certain quantity of cleaned grain and shungite water and then the loaded transport containers progress into the isothermal chamber at a speed defined by the required time for grain germination at a required temperature. The movement of the transport containers is achieved by known means, for instance transport paths, belt conveyor or other conveyors.

[0085] The isothermal chamber can be of tunnel-type whose length is chosen so that in can contain the number of germination containers as required by the technological process. A tunnel isothermal chamber is known for example from WO0222268 A1.

[0086] The system also includes loading-unloading devices for reloading germinated grain from the transport containers to the mill. For example, from one side of the isothermal chamber can be located means for lifting and overturning the transport containers for unloading germinated grain to the belt conveyor for feeding germinated grain to the grinding module. In the sample version shown in FIG. 1 move only grid basket 9 with germinated grain—from transport container 7 to grinder's containers 16.

[0087] Grain Grinding Module

[0088] This module is executed as at least one grain grinder/mill 17. Grain grinder 17 is adjusted to grind germinated grain for achieving fine grain mass with particles sized not more than 300 μm and has means for cold air supply for cooling grain mass in the milling process to the temperature not exceeding that of protein denaturation −35° C.

[0089] The grinding module can feature several grinders 17 located in a row while each subsequent, in the production line, grinder is adjusted to grind the obtained mass to particles of a smaller size. For example, the first grinder of this sequence grinds to particles sized 750 μm, the second 350 μm and the third 250 μm. In the sample version of the execution of the system (FIGS. 3 and 4) grinder 17 comprises container 16, grid basket 9 and at least two rotating levers 18 in it ending with scraping knives 19 touching the internal surfaces of grid basket 9. The rotating mechanism can turn, for instance, engine 21, three-dimensional planetary gear box 22 driven by a cog belt. The grinder has lifting means 20 for lowering and lifting grid basket 9 and knives system. Grid basket 9 is preferably made of stainless still, for example in the shape of a sieve and has many holes of determined sizes and cutting edges. As container 16 of the grinder a transport container for dough kneading, a bowel, can be used made of stainless steel. The rotation of levers with the scraping knives leads to the grinding of germinated grain in the grid basket as a result of the scraping effect of knives and holes of the basket. The sized of obtained particles depends on the size of the holes.

[0090] The system can also be equipped with loading-unloading devices installed in the places of reloading as required by the technological process.

[0091] The system also can include an electronic unit of command of the system's processes and devices. Such electronic command block can be connected with various sensors, for instance sensors of temperature in the isothermal chamber.

[0092] The grain mass production system operates as follows.

[0093] Matured grain with seedcase and undamaged hyaline layer, cleaned and rinsed, is loaded into a transport container for germination and filled with shungite stones infused water as a liquid medium.

[0094] The number of containers needed for grain germination is calculated considering the total quantity of the end product produced from the grain mass for a given day (shift) taking into account the requirements of dry grain per unit of the end product. Before loading the cleaned and rinsed grain into the container is installed a perforated tube of the air supply system with a sleeve for subsequent connection to the flexible pipe of pressured air feed from a compressor.

[0095] The prepared germination containers are placed in the isothermal chamber.

[0096] In the isothermal chamber is maintained equal permanent temperature all over the volume of the germinating grain during a determined time until the required stage of germination. This stage of germination is determined by the aggregate indices of saturation of grain by water.

[0097] This stage (state) of germinated grain can be determined by a quick empiric method—pressing a swollen grain by two fingers without special effort when the germinated grain brought to the required condition is easily flattened and the germ pops out together with the white endosperm mass.

[0098] For ensuring the germination process the grain mass is regularly fed with air, for instance, by adding air to the germination container by means of the pressured air supply system.

[0099] When grain reaches the required stage of germination the surplus liquid medium, if left in the germination container, is drained through the drainage tap.

[0100] The germinated grain is then rinsed with cold drinking water off the residues of the acidic liquid medium in which grain was germinated.

[0101] Then the germinated grain is reloaded into grain grinding module 3. In our sample we use three grain grinders.

[0102] The finished grain mass enters the transport container for the collection of obtained grain mass, for instance into a standard bowel as shown in the sample or to a belt or screw conveyor (not shown in the drawing) for further feeding to the technological place of processing into the end product.

EXAMPLE 1

[0103] To produce an end product—wheat grain buns in the amount of 340 kg it is required to take 250 kg of cleaned wheat. We load the clean wheat to a transport container with shungite placed on all the internal walls of the container and fill it with shungite-infused water in the quantity of 300 I. Before that the water is infused with shungite in a container with 30 kg of shungite stones for 48 h at the temperature of 32° C. In the transport container the wheat is germinated with constant air supply from the bottom part of the container at the temperature of 25° C. for 25 h. Upon completing the process of germination the remaining water is drained and germinated grain is rinsed by shungite-infused water with the temperature of 21° C. The obtained quantity of germinated grain of approximately 360 kg is poured to a conveyor belt where containers are placed and so is transported to the grinding module. From the conveyor container the germinated grain is poured into the loading part of the grinder where a container with a basket is where the orifices are for coarse mill and the germinated grain is ground to the size of 250 μm. During milling we supply cooled air at the temperature of 4° C. to maintain the temperature of the obtained mass within 35° C. After the milling is complete the mass is moved to the dough production module where are added 2% of salt, herbs (for instance ground cummin 0.5% and oxidized dough with 8.5 pH in the quantity of 10% of the mass's weight. The oxidized dough is obtained from the same math which we leave to oxidize naturally for 72 h at the temperature of 35° C.

EXAMPLE 2

[0104] To produce an end product — rye bread in the amount of 365 kg it is required to take 250 kg of cleaned rye. We load the clean rye to a transport container with shungite placed on all the internal walls of the container and fill it with shungite-infused water in the quantity of 300 I. Before that the water is infused with shungite in a container with 30 kg of shungite stones for 72 h at the temperature of 30° C. In the transport container the rye is germinated with constant air supply from the bottom part of the container at the temperature of 30° C. for 18 h. Upon completing the process of germination the remaining water is drained and germinated grain is rinsed by shungite-infused water with the temperature of 21° C. The obtained quantity of germinated grain of approximately 385 kg is poured to a conveyor belt where containers are placed and so is transported to the grinding module. From the conveyor container the germinated grain is poured into the loading part of the grinder where a container with a basket is where the orifices are for coarse mill and the germinated grain is ground to the size of 150 μm. During milling we supply cooled air at the temperature of 4° C. to maintain the temperature of the obtained mass within 35° C. After the milling is complete the mass is moved to the dough production module where are added 2% of salt, herbs (for instance ground cummin 0.5% and oxidized dough with 8.5 pH in the quantity of 10% of the mass's weight. The oxidized dough is obtained from the same math which we leave to oxidize naturally for 72 h at the temperature of 35° C.

EXAMPLE 3

[0105] To produce an end product—wheat pasta in the amount of 325 kg it is required to take 250 kg of cleaned wheat. We load the clean wheat to a transport container with shungite placed on all the internal walls of the container and fill it with shungite-infused water in the quantity of 300 I. Before that the water is infused with shungite in a container with 30 kg of shungite stones for 48 h at the temperature of 32° C. In the transport container the wheat is germinated with constant air supply from the bottom part of the container at the temperature of 25° C. for 25 h. Upon completing the process of germination the remaining water is drained and germinated grain is rinsed by shungite-infused water with the temperature of 21° C. The obtained quantity of germinated grain of approximately 360 kg is poured to a conveyor belt where containers are placed and so is transported to the grinding module. From the conveyor container the germinated grain is poured into the loading part of the grinder where a container with a basket is where the orifices are for coarse mill and the germinated grain is ground to the size of 150 μm. During milling we supply cooled air at the temperature of 4° C. to maintain the temperature of the obtained mass within 35° C. After the milling is complete the mass is moved to the dough production module where are added 2% of salt, herbs (for instance ground cummin 0.5% and oxidized dough with 8.5 pH in the quantity of 10% of the mass's weight. The oxidized dough is obtained from the same math which we leave to oxidize naturally for 72 h at the temperature of 35° C.

[0106] The inventions can be used for producing grain mass on an industrial scale from germinated (brought to the initial stage of germination) grain with stable batch-to-batch required properties, with increased nutritional and biological value and high organoleptic indices for end products produced from it such as pastas, bread, including bakery products (hamburger buns, baguettes, bread sticks, pitas, biscuits, dry biscuits, croissants, cookies, pasta and so on).