CRACKER OR SNACK FOOD PRODUCT AND METHOD FOR ITS MANUFACTURE

Abstract

A baked shelf-stable cracker or snack product comprising a) a body comprising at least 60% by weight wheat flour, from 5 to 22% by weight fat, 0.7 to 7% by weight leavening agent and up to 5% by weight water, in each case based on the total weight of said body; and b) a surface dusting, on at least one surface of the body, of a particulate material, the particulate material comprising at least 30% by weight, based on the total weight of the particulate material, of wheat endosperm particles. The surface dusting is present on the product in an amount of at least 0.5%> by weight, based on the total product weight. Also provided is a process of making the cracker or snack product.

Claims

1. A baked shelf-stable cracker or snack product, comprising: a. a body comprising at least 60% by weight wheat flour, from 5 to 22% by weight fat, 0.7 to 7% by weight leavening agent and up to 5% by weight water, in each case based on the total weight of said body, and b. a surface dusting, on at least one surface of the body, of a particulate material, the particulate material comprising at least 30% by weight, based on the total weight of the particulate material, of wheat endosperm particles; wherein said surface dusting is present on the product in an amount of at least 0.5% by weight, based on the total product weight.

2. A cracker or snack product according to claim 1, wherein the wheat flour is present in said body in an amount of at least 65% by weight, based on the total weight of the said body.

3. A cracker or snack product according to claim 1, wherein the particulate material comprises semolina, the semolina having a particle size such that less than 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 315 m, and at least 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 600 m; or wherein the particulate material comprises wheat flour, the wheat flour having a particle size such that at least 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 315 m, and at least 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 200 m.

4. (canceled)

5. (canceled)

6. A cracker or snack product according to claim 1, wherein the particulate material comprises as wheat endosperm particles a mixture of wheat endosperm particles obtainable by combining (i) a semolina having a particle size such that less than 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 315 m, and at least 20% pass through a silk gauze sieve with mesh openings of 600 m; and (ii) a wheat flour having a particle size such that at least 20% by weight of the particles pass through a silk gauze sieve with mesh openings of 315 m.

7. A cracker or snack product according to claim 1, wherein the particulate material comprises at least 50% by weight, based on the total weight of the particulate material, of wheat endosperm particles; and wherein at least 65% by weight of the starch content of the product is contributed by wheat flour in the product; and wherein the surface dusting comprises from 0.5 to 30 wt % of the total product weight.

8. (canceled)

9. (canceled)

10. (canceled)

11. A cracker of snack product according to claim 1, having a fracturability of at least 28 events.

12. A cracker or snack product according to claim 1, wherein the flour has a protein content and protein quality such that the degree of softening of the flour is from 80 Brabender Units to 145 Brabender Units; and wherein at least a major proportion of the flour in said body of said product is flour having a protein content of from 8.5 to 13.5% by weight based on the total flour weight.

13. (canceled)

14. A baked shelf-stable cracker or snack product comprising wheat flour in an amount of not less than 60% of the total weight of the product, wherein the product has a surface dusting comprising a particulate material as defined in claim 1, and wherein the product has a fracturability of at least 28 events, and wherein the product has an open cellular structure having an averaged total area of cells in cross-section is at least 40% of the total cross-sectional area of the product.

15. (canceled)

16. (canceled)

17. A cracker or snack product according to claim 1, wherein the thickness of the product is such that the height of a stack of ten products is from 60 to 120 mm; and wherein the snack product has a width in the range of from 30 to 60 mm and a length in the range of from 30 to 70 mm.

18. (canceled)

19. A cracker or snack product according to claim 1, wherein the particulate material comprising at least 30% by weight based on the total weight of the particulate material, of wheat endosperm particles, and wherein the particulate material further comprises one or more starchy materials selected from the group consisting of maize flour, rice flour, oat flour and rye flour, tapioca flour, potato flour, potato granules, potato flakes, vegetable powders and/e starches from those materials.

20. (canceled)

21. (canceled)

22. A process for making a shelf-stable cracker or snack product comprising preparing a dough comprising at least 50 parts by weight wheat flour, from 5 to 15 parts by weight fat, 0.3 to 5 parts by weight leavening agent and from 15 to 30 parts by weight water, forming the dough into a dough sheet, cutting dough pieces from the sheet and baking the dough pieces to a water content of not more than 5% by weight to obtain a baked shelf-stable snack product, wherein before or after said cutting of dough pieces from the sheet, a dusting of a particulate material comprising wheat endosperm particles is delivered onto a surface of the dough, whereby the baked product has a visible surface dusting comprising wheat endosperm particles.

23. A process according to claim 22, wherein said dusting of a particulate material comprising wheat endosperm particles is delivered onto a surface of the dough sheet and the sheet is subjected to a reducing step in which the sheet passes between opposed reducing rollers and said dusting becomes more firmly adhered to the sheet surface before said cutting step.

24. (canceled)

25. A process according to claim 22, wherein the dusting comprises wheat flour or semolina in an amount not less than 50% by weight based on the total weight of the dusting.

26. (canceled)

27. A process for making a shelf-stable cracker or snack product comprising preparing a dough comprising at least 50 parts by weight wheat flour, from 5 to 15 parts by weight fat, 0.3 to 5 parts by weight leavening agent and from 15 to 30 parts by weight water, fermenting the dough for up to four hours, forming the dough into a dough sheet, cutting dough pieces from the sheet and baking the dough pieces to a water content of not more than 5% by weight to obtain a baked shelf-stable cracker or snack product having a fracturability of at least 28 events, the product having a surface dusting comprising a particulate material as defined in claim 1, and the product having an open cellular structure wherein the averaged total area of cells in cross-section is at least 50% of the total cross-sectional area of the product.

28. A process according to claim 25, wherein the dough is fermented for 10 minutes to 4 hours, and, the dough is subject to a sheeting process without any intervening process step following fermentation.

29. (canceled)

30. A process according to any claim 25, wherein the yeast is present in an amount of 0.3 to 2.6% by weight based on the total dough weight, and wherein the dough comprises at least 20% by weight water.

31. (canceled)

32. A process according to claim 25, wherein said baking step comprises baking at a temperature of 105 C. to 345 C., to a moisture content of not more than 5% by weight based on the total weight of the baked product.

33. (canceled)

34. (canceled)

35. A process according to claim 25, wherein the flour has a degree of softening of less than 145 Brabender Units; and wherein the flour has a degree of softening of not less than 80 Brabender Units; and wherein the flour has a protein content of from 8.5 to 13.5% by weight.

36. (canceled)

37. (canceled)

38. A process according to claim 22, wherein the dough is formed in a continuous sheeting process, the continuously formed sheet being passed between one or more pairs of reducing roller before being continuously delivered to a cutting device where said pieces are cut from the sheet; and wherein the cooked pieces are subjected to an oil application step.

39. (canceled)

40. A process according to claim 22, wherein the thickness of the dough sheet immediately before cutting is from 1 to 2.5 mm; and wherein pieces are cut to a width of from 50 to 80 mm and a length of from 70 to 115 mm.

41. (canceled)

42. (canceled)

43. The cracker or snack product according to claim 3, wherein the wheat endosperm particles are selected from among the group consisting of wheat flour and semolina.

44. The cracker or snack product according claim 7, wherein the surface dusting comprises from 1 to 15 wt % of the total product weight.

45. The cracker or snack product according claim 7, wherein the product has a cellular structure having an average total area of cells when measured in a cross-section through the product of at least 50% of the total cross-sectional area of the product.

46. The process according to claim 23, wherein the sheet is subjected to at least one reducing step prior to application of said dusting.

47. The process according claim 25, wherein the leavening agent is yeast and the dough is subjected to a fermentation step before it is sheeted.

48. The process according to claim 32, wherein the pieces are baked to a moisture content of not more than 5%, and subsequently subjected to a drying step in which the moisture content is reduced to not more than 3% by weight.

Description

DESCRIPTION OF DRAWINGS

[0063] FIG. 1 is a schematic view of an apparatus for use in a process of making a cracker according to a first embodiment according to the invention;

[0064] FIG. 2 is a section through a portion of a cracker according to an embodiment of the invention, as imaged using a C-Cell device as herein described; and

[0065] FIGS. 3a, 3b and 3c are farinograph traces of flours used in Examples 5 to 7 below.

[0066] One form of process for making crackers according to a first and illustrative embodiment of the invention in which a dusting of flour is applied to dough pieces before baking will be described with reference to FIG. 1 which shows an apparatus for use in the continuous manufacture of crackers. Ingredients are mixed with water in a mixer 1, from which the dough obtained is transferred to a fermentation hopper 2. The water may be at slightly above ambient temperature, for example at 25 to 40 C.

[0067] After fermentation, for example for a period of 10 minutes to 2 hours, the dough is transferred to the hopper of a sheeting device 3, from which the dough is expelled in the form of a sheet 4. The dough sheet 4 is fed via a first pair 5 of gauge rollers (reducing rollers) and second gauge roller pair 6 to a flour dusting device 7, from which a dusting of flour is sprinkled onto the upper surface of the continuously moving dough sheet.

[0068] The sheet 4 with applied dusting of flour is then passed between gauge rollers 8 and embossing rolls 9 to cutting rolls 10 at which the sheet is cut into pieces 11. The embossing rolls 9 may carry a reverse image of a surface design to be applied to the crackers (such as a decorative design, logo or trade name) and/or may serve as a dockering device to docker the sheet. Whilst the apparatus of FIG. 1 includes separate embossing/dockering and cutting roll sets, it is possible for any two or all three of those steps to be carried out at the same set of rolls, as is known in the art.

[0069] Surplus dough is returned to the hopper of sheeting device 3 via a recycle conveyor (not shown). The cut pieces are carried on a conveyor device 12 into a continuous oven 13. The pieces are cooked during transit through the oven in known manner, and the conditions in the oven are so controlled that on emerging from the oven the baked pieces 14 have a moisture content of not exceeding 5% by weight, preferably not exceeding 3% by weight. If desired the pieces may be baked in oven 13 to a first moisture content, for example 5%, and then further dried to a moisture content of not more than 3% by weight in an additional subsequent RF oven (not illustrated in the drawings), which, if present, is preferably in the form of a continuous oven in which pieces leaving the oven 13 are continuously transported through the RF oven on a conveyor. If desired, the cooked pieces may be subjected to one or more further finishing steps, for example a step in which they are sprayed with oil and/or flavouring. Additional ingredients such as oil and flavouring will be applied in minor amounts, and where present will preferably make up no more than 15% of the total product weight.

[0070] The pairs of gauge rollers each serve to reduce the thickness of the dough sheet. The apparatus of FIG. 1 is described as having three pairs of gauge rollers but it is also possible for the apparatus to have a different number of gauge roller pairs. For example, in some embodiments it has been found preferable to include three pairs of gauge rollers upstream of the dusting device. The optimum number of gauge rollers will in part depend upon the viscoelastic properties of the dough and the selection of an appropriate number of gauge rollers for a given dough will be a routine matter for those skilled in the art.

[0071] Whilst the process shown in FIG. 1 is described with reference to a dusting of flour, the apparatus and process may be carried out using a suitable device for applying a dusting of a particulate material containing larger particulate material such as semolina.

[0072] Optionally, the dough may be subjected to a lamination step. Where present, a lamination step may be provided at any point between sheet formation at sheeting device 3 and the second gauge roll pair 6. At least one pair of gauge rollers should be provided after lamination and before the dusting device.

Methods

[0073] Method for Determining Fracturability Fracturability values stated herein were measured using an Ottawa Cell & Plunger with a square 7070 mm Probe (Stable Micro Systems). The settings for the device were as follows:

Test mode: compression
Test speed: 1 mm/sec
Trigger force: 100 g
Maximum force: 30 kg
Macro: count peaks

[0074] The test is carried out for a sample often biscuits from the same batch. Measured values were obtained by placing one biscuit in the test cell and advancing the probe at the constant test speed vertically downwards onto the biscuit, the process being repeated nine times with a new biscuit each time. For each biscuit, the test generates a plot which shows a peak correlating with each fracture. The events are counted to obtain an event total for each biscuit tested and the average of the 10 event totals so obtained is the fracturability.

[0075] The fracturability links closely with the coarseness of the product. The higher the fracturability of the product the coarser its structure is (more, larger air cells). This can be further corroborated by using brightness as a measure.

Methods for Determining Cell Structure and % Cells

[0076] Samples were analysed using a C-Cell instrument (Calibre Control International Ltd) fitted with a 50 mm focal length lens (available from Tamron Co. Ltd under the model number 23FM50SP) to provide a resolution of 0.0356 mm/pixel. Ten replicate crackers from each sample were randomly selected for C-Cell analysis. All products were cut with a scalpel, then abraded with medium grade sandpaper to expose a flat surface for analysis. The crackers were cut between rows of docker holes. Dust created by the abrasion process was removed prior to analysis. Samples were imaged within 15 minutes of being prepared.

[0077] Samples were placed in the instrument and illuminated obliquely from two sides to reveal the cell structure of the exposed surface. The crackers were held in an upright position (with the prepared cross section pointing upwards, facing the camera) using black plastic supports. (The edges of the black plastic supports were removed from the images prior to analysis.) Grey scale images of each sample were taken, using a brightness scale calibrated against a grey card of standardised reflectance supplied with the C-Cell instrument. The images were analysed to measure the dimensions and cell structure. Several standard measurements were calculated by the instrument software, including the brightness. A list of areas of each cell detected was also output and was used to calculate additional measurements describing the cell size distribution and % cell area in each cracker cross-section. The measurements from each of the ten crackers were used to generate mean values for each parameter.

Method for Obtaining Farinograph Traces and Determination of Degree of Softening

[0078] A farinograph trace is obtainable using standard methods in commercially available standard testing apparatus routinely used in the baking industry. Measurements of farinograph traces herein were made using a Farinograph (trade mark) manufactured by Brabender GmbH and Co. KG of Duisburg, Germany, and having an attached mechanical continuous chart recorder which operates at a speed of 10 mm/min. Measurements were carried out with the speed of rotation of the mixing blades at 63 rpm using a 300 g bowl. Flour (300 g) was equilibrated to room temperature before use. The method used was that of International Association for Cereal Science and Technology (ICC) Standard Method No. 115/1 except that no adjustment was made to the weight for any moisture that may be present in the flour and mixing was carried out to a consistency of 600 (+/20) BU instead of 500 BU, mixing to 600 BU being common practice in the United Kingdom when carrying out this measurement method. The temperature of water used to fill the burette and subsequently added to the flour to form the dough is 30 C. (+/0.5 C.).

Example 1

[0079] A cracker was made using the ingredients and quantities listed in the table below.

TABLE-US-00001 Ingredient % Wheat Flour 67% Palm Oil 7% Yeast 1% Salt 1% Water (25 to 40 C.) 24%

[0080] The yeast and water were mixed using a Z-blade mixer and mixed slowly for 60 seconds. The flour (with a protein content of 10.6% by weight and a degree of softening of 130), palm oil and salt were then added and mixing continued for 180 seconds at high speed. The temperature of the dough after mixing is around 30-32 C. The dough is left to stand for between 15 and 90 minutes. The dough is then placed in the hopper of a sheeter and formed into a sheet which is optionally passed through a lamination device where lamination is carried out to a maximum of three layers. The sheet is passed through a series of three pairs of reducing rollers. After emerging from the second pair of reducing rollers the sheet is passed under a dusting device from which wheat flour is sprinkled onto the upper surface of the dough sheet. The sheet then passes through a further pair of gauge rollers which serves to increase the adhesion between the dusted wheat flour and the sheet. On emerging from the gauge rollers the thickness of the sheet is 1.7 mm. The sheet is then passed between cutter rollers at which pieces are cut from the sheet, the pieces having dimensions of 65 mm by 105 mm. The pieces were baked in a travelling oven at a temperature of 200-235 C. for 6 to 8 minutes at which time they had a moisture content in the range of 3%. The resulting products were crackers characterised by, as compared with conventional crackers, an open texture, variable crumb size, many large air cells and a relatively hard and crunchy outer crust. The flour dusting was present in an amount of about 1% by weight, based on the total weight of the cracker product.

[0081] The proportion of the cracker section occupied by air cells was at least 50%, as determined by the C Cell instrument using the method described above using measurements for ten crackers. FIG. 2 is an image of a section through a part of a product of Example 1 obtained using the C Cell instrument, and shows the open structure with multiple open cells of varying sizes.

Example 2

[0082] Further crackers were made according to the process described in Example 1 except that the wheat flour in the flour dusting device was replaced by durum semolina. The semolina was present in an amount of about 5% by weight, based on the total weight of the cracker product.

Example 3

[0083] Further crackers were made according to the process described in Example 1 except that the flour dusting device was omitted so that the products had no flour dusting.

Sensory Evaluation

[0084] The cracker products of Examples 1 (wheat flour dusting), Example 2 (semolina dusting) and Example 3 (no dusting) were assessed by a trained sensory panel of 12 members using QDA (quantitative descriptive analysis) in comparison with a commercially available standard cream cracker product. QDA is one of the main descriptive analysis techniques used in sensory evaluation.

[0085] Bread flavour intensity scores were rated on a scale of 1 to 100:

TABLE-US-00002 Product Score Standard cracker 32 Example 3 (no dusting) 50 Example 1 64 Example 2 65

[0086] The crackers of Examples 1 and 2 were perceived as having a statistically significantly stronger bread flavour than the Standard cracker and the cracker of Example 3. Whilst the cracker of the Example 3 had a greater bread flavour than the Standard cream cracker, the flavour was perceived even more strongly in the crackers of Examples 1 and 2. The mean intensity scores of the Standard cracker and the cracker of Example 3 were statistically significantly different at the 5% level (p<0.05) from each other and from the crackers of Examples 1 and 2. The difference in bread flavour intensity score between the crackers of Examples 1 and 2 was not statistically significant.

[0087] Seventeen assessors were asked to taste the cracker of Example 1 and the Standard cracker and indicate their liking on a 9 point scale, for appearance, flavour, texture. They were also asked to indicate their overall preference.

[0088] There were statistically significant differences between the Standard cracker and the cracker of Example 1 in appearance, texture and flavour liking. There was also a statistically significant preference for the cracker of Example 1.

Example 4

[0089] The process of Example 1 was used to produce a dusted sheet of thickness 1.7 mm except that the sheet was fed between different cutter rollers to obtain smaller pieces, of 45 mm by 50 mm. The pieces were baked to obtain bite-size snack products with a flavour and texture reminiscent of bread.

Example 5

[0090] Crackers were made using the method described in Example 1 using a wheat flour with added gluten giving a total protein content of 13.5% by weight (based on the weight of the flour plus gluten) and a degree of softening of 95 BU as determined from the farinograph trace shown in FIG. 3a.

TABLE-US-00003 Ingredient % by weight Wheat Flour 65% Gluten 2% Palm Oil 7% Yeast 1% Salt 1% Water 24%

[0091] The product was found to have a fracturability of 37 events, and had an open, coarse structure with a significant number of large air cells, resulting in an attractive open eating texture.

Example 6

[0092] Crackers were made using the method described in Example 1 using a wheat flour with flour protein content of 13% by weight and a degree of softening of 70 (see the farinograph trace of FIG. 3b). The product had a fracturability of 24 events. The lower fracturability as compared with the product of Example 4 was reflected in a less open texture as compared with the cracker of Example 5.

Example 7

[0093] Crackers were made using the method described in Example 1 using a wheat flour with flour protein content of 8.6% by weight and a degree of softening of 145 as determined from the farinograph trace of FIG. 3c. The product so obtained had a fracturability of 25 events.

Example 8

[0094] Crackers were made using the method described in Example 1 using a wheat flour with flour protein content of 10.6% by weight and a degree of softening of 130. The pieces had a final sheet thickness of 2.4 mm.

[0095] The fracturability of the resultant crackers was 18 events, and had a commensurately less open structure than the products of Examples 6 and 7. It is believed that the relatively high thickness of the dough pieces limited the degree of expansion of the dough pieces. By comparison, the samples made using the same flour and method in Example 1, in which the dough pieces were 1.7 mm thick, had a fracturability of 36.

Further Sample Evaluation

[0096] Samples of the products of Examples 1, 3, 5, 6, 7 and 8 were analysed using the C-cell structure method and fracturability method described above. The measured values of brightness, the area of air cells as % based on total cross-sectional area of the product, and fracturability are given in the table below where the data is calculated as an average based on ten replicate samples. Two conventional cracker-type products were also examined using the same techniques.

TABLE-US-00004 Fracturability % Total Air Example (No. of events) Cells Brightness Example 1 36 54.4 96.2 (wheat flour dusting) Example 3 36 54.4 96.2 (no dusting) Example 5 37 52.0 95.2 Example 6 24 52.5 111.4 Example 7 25 51.0 104.8 Example 8 18 52.2 103.8 Standard cracker 2.5 49.1 118 Gran Cereale Croccanti 7.5 56.3 102

[0097] The cell brightness gives an indication of the coarseness of the structure (range of cell sizes). Lower numbers represent darker products. The darker the colour, the coarser the product (larger air cells). There is a generally negative correlation between fracturability and the brightness/coarseness. The data shows that the stronger protein flour of Example 6 gives the finest structure, followed by the weakest flour (Example 7). As the fracturability gets higher, the coarseness of the product increases. The products of Examples 1, 3 and 5 have lower brightness (implying the presence of deep cells within the product matrix) and higher fracturability (indicative of open cells and/or blisters associated with a hard and crunchy crust). Overall, these attributes are indicative of a more open and bread-like cell structure.

[0098] By comparison, the commercial crackers examined were found to have fracturability values well below those preferred in accordance with the present invention. The standard cracker has a high wheat flour content, but is made by a very different process, namely a sponge and dough process including a long fermentation of up to 18 hours, with further processing steps being required between fermentation and sheeting. In contrast, preferred crackers of the invention are made by a simple process in which a shorter fermentation step is used and, if desired, the dough may be sheeted immediately after fermentation without any intervening processing of the dough.