Method for granulation and recycling low moisture and high fat treated food product

FIELD: food industry.

SUBSTANCE: treated food product production method envisages compressed air injection into a housing. The housing contains a section in the shape of frustum of cone. The injected air moves downwards through the housing and, having reached the lower end of the housing, flows back upwards and is released from the housing through an outlet hole. The treated food product with a water content of less then 14% (weight) and a lipid content of more then 15% (weight) is injected into the housing, captured by the injected air and milled. Then obtained granulated product is discharged from the lower end of the housing and mixed at least with one other ingredient of the treated food product. Then the treated food product is prepared from them.

EFFECT: invention allows to process the treated food product with a low moisture and a high fat lipids content, to implement a short-duration operation of granulation at one device without moving mechanical parts usage and to use the produced granulated product during treated food products production.

18 cl, 4 dwg, 2 ex, 1 tbl

 

Description

The present invention relates to a method of grinding the processed food product low humidity and high fat content for reuse in food production.

In the manufacture of many types of food some unused portions of processed products remain in the form of scraps, pieces, chips, fragments, etc. after periodic processing or other manufacturing operations. In addition, a commercial product may be rejected small amount of processed food product, and may not correspond with the desired shape or configuration. Ideally, such unused portion and/or a small amount combined with large quantities for use in recycling in future food production. This often requires heat treatment, mechanical grinding, milling or other operations for recycling the treated food product in a more comfortable or stable form, which can lead to difficulties.

The necessary funds for the treatment of dry or low moisture content and high content of lipids processed products in stable storage functional form of food quality for re-use is found. The present invention solves these and other objectives of an effective and economically feasible way.

The present invention provides a method of grinding processed foods with a high content of lipids in functional granulated forms of food quality suitable for reuse. The method allows the processing of short-term operations, which essentially retain the desired functional aspects of processed foods, which are useful for future food production. Grinding can be carried out without the need to contact the processed food product with a high content of lipids with any moving mechanical parts. Essentially, the entire received some processes material processed food product with a high content of lipids can be introduced in the food.

In some embodiments, processed foods with low moisture content and high content of lipids, which may be subjected to processing in a single-stage process, include filled foods, such as foods containing in one part of the ingredient on the basis of grain and other part - filling ingredient with a high content of lipids. In one embodiment, the lipid content of obrabotan the th food product, processed by the method according to the present invention is at least about 15 wt.% and, more specifically, from about 15 to 60 wt.%. Such filled products may include, for example, cakes, pies, pastries, served in the shell, jointly extruded form or in the form of sandwiches. For non-limiting examples include, for example, the products of test taste the creamy filling, the products of dough filled with cheese, products made of dough filled with peanut butter and so on. The completed products can include a completed products from the test in the form of sandwiches, filled glazed products of the test, such as filled or glazed biscuits, snacks and/or crackers, etc. For the purposes of the present description "processed food product" means a finished processed foods, as well as partially processed raw food materials such as cocoa beans.

In one specific embodiment, the single-stage grinding, essentially, granulosum processed foods with low moisture content and high content of lipids containing a powdery material without causing significant or uncontrolled transformations in lipid or powdery contents. Lipid and starch content of foods with low moisture content and the high content of lipids, essentially maintained during the grinding process and, therefore, can be reused in future food production. It can also be used in relatively large quantities in the subsequent lines for the production of food.

In some embodiments, the single-stage grinding of processed foods with low moisture content and high content of lipids is carried out as a grinding process in which compressed air and processed food product with low moisture content and high content of lipids separately fed into the casing, which contains a plot in the form of a truncated cone. After the introduction of the compressed air moving through the casing essentially on a downward trajectory until it reaches its lower end. Then the air rises up from the lower end of the casing in the Central region, until it exits from the housing through the outlet. Food product with low moisture content and high content of lipids separately introduced into the upper end of the casing and the food product is captured by the air moving down through the casing until it reaches the lower end of the casing.

During the movement of the treated food product from the upper end of the casing down to the bottom end of the processed food product is at least physically processed Food product can be dehydrated through the use of heated compressed air, in which it is suspended in a dynamic system with air flow generated in the casing, if the temperature is maintained at a level below the melting temperature of the lipid content of the processed food product. During the same operation, a food product desintegrated into fine particles for an extremely short period of time. A significant number of introduced food product with low moisture content and high content of lipids can be reduced before reaching the lower end of the casing. As such, this abrasion of the food product with low moisture content and high content of lipids can be achieved without the use of a grinding device with movable mechanical parts.

Consequently, in such embodiments, the lower end of the casing is unloaded solid product in the form of particles, including powdered foods, and the air together with a pair of moisture released from the food during processing in the device exits the system through the exhaust pipe. In one particular embodiment, the casing is a structure consisting of two parts, containing the upper casing of cylindrical form, which served separately compressed air and a food product with low moisture content and high content of lipids, the cylindrical casing adjacent contributes through with him, n the life jacket in the shape of a truncated cone, containing the lower end of the whole structure, from which discharged recycled material.

Grinding of processed foods with low moisture content and high content of lipids in variants of the present invention provides numerous advantages compared with the known schemes disposal of processed foods with low moisture content and high content of lipids. One of them is that the cost of transportation and disposal of food products are reduced or eliminated. The grinding allows granular food product from the food product with low moisture content and high content of lipids in a relatively low-temperature and short-time operation. Grinding preferably can be performed as a single stage operation, without compromising the desired functional attributes of food material and without the need to carry out various kinds of processing on different equipment. Optionally, the process may be carried out in continuous mode, since compressed air is continuously released from the system after the capture of the food product and bringing it down through the casing to its lower end, where you can unload crushed material of the food product. On the inner walls of the processing device does not remain or is ti leaves no residue, to facilitate cleaning and changeover for processing another type of processed foods. These advantages reduce the complexity of the process, the processing time and the cost of production and maintenance.

Brief description of drawings

Other characteristics and advantages of the present invention will be apparent from the following detailed descriptions of preferred options with reference to the accompanying drawings.

Figure 1 - block diagram of the method for processing and reuse of the treated food product with low moisture content and high content of lipids according to the variant of the present invention.

Figure 2 - schematic view of a system for processing a processed food product with low moisture content and high content of lipids according to the variant of the present invention.

Figure 3 - cross section of cyclone devices used in the processing system of figure 2.

4 is a schematic view of a system for processing a processed food product with low moisture content and high content of lipids in another variant of the present invention.

The elements shown in the drawings are not necessarily true to scale. The elements denoted by the same positions in different drawings represent like components, unless otherwise indicated.

Detailed described the e preferred options

Below follows the description of the preferred variants of the present invention with specific reference to the unique processing of processed foods with a high content of lipids and, more specifically, processed foods with low moisture content and high content of lipids. For the purposes of the present description, the term "low water content", used to describe food material, means food material containing less than about 14 wt.% water in the form of liquid, ice and/or steam. The term "high content of lipids", used to describe food material, means food material containing at least about 15% lipid. As already indicated, "processed food" covers ready processed foods, as well as partially processed food raw materials such as cocoa beans.

Essentially, the processed food product with low moisture content and high content of lipids is subjected to grinding to particles of small size in a short period of time in the grinding operation carried out on a single device. Essentially, the grinding process is carried out in the system of cyclone type, which can operate so that the processed food product with low moisture content and high content of lipids can provide useful physical is economical impact. Shredded food product comes in pellet form (e.g. solid fine powder).

For the purposes of the present description, the term "grinding" means crushing, spraying, rubbing, wear or friction particles to fracture into smaller particles and/or to release fine particles and includes mechanisms associated with the contact between the moving particles and/or between the moving particle and a static surface, and the term "drying" means dehydration, i.e. the reduction of the moisture content.

As shown in figure 1, in this non-limiting illustrative embodiment, the processed food product with low moisture content and high content of lipids collect in the production process or of finished food products (step 1), optional cooled (step 2) and/or cool the process air (step 3), then the food is subjected to grinding (step 4) and the obtained granulated food or processed food product re-use as a food ingredient (step 5).

In optional step 2 processed food product can be pre-cooled before introduction into the cyclone processing device described below, to further prevent the melting of the lipid content in the treated food product. Processed food product cooling is t to the temperature sufficient for cooling the lipid content of the food to a temperature below the melting point of the lipid, in particular, the present lipid having the lowest melting temperature. This helps to preserve the integrity of the lipid part and prevents agglomeration or adhesion of food material to the inner walls of the processing device during grinding. If the room temperature below the melting point of the lipid content of the processed food product, the need to cool the air or supplied food product may be reduced or eliminated. In one embodiment, the temperature of the processed food material with a high content of lipids (step 2) and/or process air (step 3), which will be used for grinding, as described in more detail below, prior to entry into the cyclone processing device is reduced to about 70aboutF (21,1aboutC) or below.

Upon completion of step 4 receive granular food product that is suitable for use in food preparation. For example, the obtained granulated food product after grinding, essentially retains its taste and functional attributes. For example, when a food product with low moisture content and high content of lipids is powdery food product, the residual cu is Halliste content in the food product with low moisture content and high content of lipids, which were after any pre-cooking or other thermal processing, which were subjected to this processed food product, essentially, is maintained during the grinding process according to the present invention and, therefore, functionally available for reuse. It can also be used in relatively large amounts on subsequent food production lines.

The granulated food product can be stably stored for re-use in future food production. The granulated food product can be used as a food ingredient in the production of processed food products of the same type on the production line, with which it was assembled as unused material, or in the production of other types of processed foods, where his taste or functional properties may be desirable or useful.

With reference to figure 2 and 3 below detail the illustrative construction equipment and method of operation for grinding the processed food product with low moisture content and high content of lipids in step 4 of figure 1. Processed food product with low moisture content and high content of lipids, which leads to a cyclone system for added the TCI method of the present invention, can be obtained from commercial food production or other sources of processed food materials with low moisture content and high content of lipids. Processed food product with low moisture content and high content of lipids may be in the form of discrete solid pieces, originally produced, or in the form of sections, portions, fragments, scraps, etc.

Figure 2 shows an illustrative system 100 for grinding the cooked food product with low moisture content and high content of lipids according to the variant of the method according to the present invention. The cyclone 101 is a structural casing, consisting of two interconnected areas: the upper cylindrical casing 103 that defines a chamber 104, and the lower housing 105 in the form of a truncated cone that defines the cavity 106. The top and bottom covers are ring-like structures, in which a solid wall or shell covers the inner space. In this illustration, the upper casing 103 has an essentially uniform diameter, and the lower casing 105 beveled to its lower end 112. In a non-limiting embodiment, the taper angle α of the lower housing 105 may be 66-70about(see figure 3). For the purposes of the present description, the term "casing" means a structure that covers the camera, the cavity or space, Bo is her with one hand.

Compressed air 116 and processed food product 102 with low moisture content and high content of lipids separately introduced into the cyclone 101 through the upper casing 103. Processed food product 102 with low moisture content and high content of lipids is discharged in the form of powder 113 solid particles from the lower end 112 of the cyclone 101. The drawing shows additional valve mechanism 111 such as a rotary valve or rotary airlock, which allow to extract the dried, shredded food product from the cyclone without interrupting the continuous operation of the system and minimizing the leakage of air from the cyclone 101. Alternatively, if desired the lower end 112 of the cyclone 101 to establish a cylindrical hollow extension shaft (not shown)to direct the granular product in the receiver or similar device located under the cyclone. In the absence of a valve mechanism at the lower end 112 of the cyclone 101 compressed air, is introduced into the cyclone also be out of the cyclone 101 through the opening 111 at the lower end 112 of the cyclone. This additional loss of air may need to compensate by increasing the flow of inlet air to maintain the required conditions of pressure inside the cyclone, for example, increasing the flow rate to compensate for the loss of air through the bottom of the cyclone, and black the C facing the gas stream 114.

The air and possibly some small amount of water vapor released from the processed food product with low moisture content and high content of lipids during processing into the cyclone 101, is removed from the cyclone as the exhaust gases 114 through the sleeve 107 and the discharge port 109. Small small amount of light debris may be released from the food during processing into the cyclone and be carried away by the flow of exhaust gas 114. The exhaust stream 114, if desired, you can filter and removes these particles and/or washed for the removal of other volatile compounds, or other compounds before discharge into the atmosphere an additional module scrubber, such as a scrubber with a nozzle (see figure 4, item 1141). Screening device 115 will be described in more detail below.

For compressed air 116 into the cyclone 101 mechanism 121 of compressed air such as a blower or air compressor generates air flow of large volume and moving with great speed, which is served by the duct 125 through the condenser 123, where he served in the upper casing 103 of the cyclone 101. The term "compressed air" refers to air, compressed to a pressure greater than atmospheric, for example more an absolute pressure of 14.7 pounds per square inch (101,35 kPa). Heating the compressed air before its introduction into the cyclone 101 usually is gelatelno or not necessary in the versions shown here, although in some situations, as will be described below, it may be useful. Heating of the compressed air is generally undesirable because it may cause melting of any sensitive to heat part of the material processed food product processed in the cyclone. In one embodiment, the compressed air is cooled to a temperature below the glass transition temperature is sensitive to heat part of the edible feed material, before submitting it to the cyclone. In one particular embodiment, the air is cooled to approximately 35-75oF (1,7-23,9aboutC), more specifically approximately 40-70oF (of 4.44 to 21.1oC) and even more specifically about 60 to 70oF (of 15.6 to 21.1oC). In another embodiment, air may be fed into the cyclone at room temperature without heating, if the temperature is below the melting temperature of the lipid part of the processed food product. That is, if the temperature at the outlet of the compressor 121 below the melting temperature of the lipid components of the processed food product, it is possible not to pass air through the condenser 123 in operation, before submitting it to the cyclone. Before applying air without the use of the refrigerator any changes in room temperature and air temperature associated with its compression, preferably track Fridge 123 may be a commercial or industrial heat exchanger or refrigerator or other suitable cooling device, for example, the cooling device capable of lowering the temperature of the continuous stream of process air to the coolant temperature of 10oF (about 6oC).

Compressed air 116 is fed into the chamber 104, essentially tangentially to the inner wall 108 of the upper enclosure 103. This can be done, for example, by directing an air stream 116 on many holes 120 (e.g., 2-8 holes)spaced around the circle and passing through the wall 108 of the upper enclosure 103. On the inner wall 108 of the upper enclosure 103 may be installed deflectors 122 to reject an incoming air stream in a direction essentially tangentially to the inner wall 108, in accordance with the design, which is described, for example, in patent publication U.S. No. 2002/0027173 A1, which is incorporated into this description by reference. Compressed air may be injected into the upper casing 103 of the cyclone 101 in the counterclockwise direction or clockwise.

Entered air 116, essentially, can be further cyclone compression in the chamber 104 and the cavity 106. Due to the centrifugal force present in the environment of the cyclone, it is believed that the pressure closer to the outer edges of the cavity 106 is substantially above atmospheric while the pressure near the Central axis of the cavity 106 below atmospheric. As shown in figure 3, as not ogran is to provide illustrations, after the introduction at the top of the casing 103 compressed air 116 in a spiral or otherwise moves essentially along a large downward trajectory as a whirlwind 13 in the upper casing 103 and the lower conical casing 105 until it reaches the lower end 112. This illustration near the lower end 112 of the cavity 106 defined by the internal wall 123 of the lower housing 105, the downward air flow changes its direction of motion and the air (along with a pair of moisture released from the food product processed in the cyclone 101) twisted back up a small whirlwind 15, which takes place essentially within a larger vortex 13. Small whirlwind 15 rises from the lower end 112 of the lower housing 105 in the Central area 128, located approximately near the Central axis 129 of the cyclone 101 and essentially within a larger vortex 13. Small whirlwind 13 flows up to the exit from the housing through the sleeve 107 and then through the outlet 109.

Optional under the lower end 112 or inside it, you can install the tool, breaking the vortex (not shown)to facilitate the transition of a large vortex 13 in small whirlwind 15. There are various designs breakers vortex for cyclones, for example box-shaped casing at the bottom of the conical casing.

Processed food product 102 with low moisture content and high content of lipids Department is but is introduced into upper enclosure 103. Put processed food product with low moisture content and high content of lipids falls under the influence of gravity down into the chamber 104 until it is captured by the vortex 13 in the cyclone 101. Preferably, the processed food product with low moisture content and high content of lipids is introduced into upper enclosure 103 in such orientation that he fell in cyclonic vortex 13 generated within cyclone 101, in which it is located in the space between the sleeve 107 and the inner wall 108 of the upper enclosure 103. This technology feeder to minimize the amount of processed food product with low moisture content and high content of lipids, which may initially fall into the extreme inner or outer radial portions of the vortex, where the cyclonic forces acting on a food product, can be weaker. As indicated above, the feed material can be pre-cooled before introduction into the cyclone 101 by storing the feed material in a suitable cooling unit 1020 or by transporting through him, with such a cooling device may be a commercial or industrial heat exchanger or cooler. Captured food moves in a whirlwind 13 air descending in a spiral or other way down through the lower casing 105, until he reached the em lower end 112 of the lower housing 105. During this downward path effects grinding of food can occur at various appropriate times and in different places on a downward path of food through the cyclone. Without being bound to any theory it is believed that the possible differential pressure, Coriolis forces, cavitation explosions and collisions between particles of food that are captured in high-speed flow of compressed air, can actively destroy the physical structure of the material. Alternative or additional centrifugal force in the vortex can force to press the food product to the inner walls 108 and 123 of the casing. These modes abrasion individually or in combination, or other modes of abrasion that may occur in the cyclone, which may not be fully understood, lead to crushing (grinding) of the food product and its drying. As a result, during such movement of the food product and packaging from the upper casing 103 down to the lower end 112 of the lower housing 105 processed food product is physically processed favorable way. The device 101 does not require mechanical moving parts to effect the grinding of the processed food product.

In another embodiment of the present invention, the output of the solid powder product 113 may prostiutes, for example, sieve, screen or similar suitable mechanism 115 DL the separation/sorting of particles for sorting and separation of finer fractions of the crushed food 1130 in solid powder product 113 from the coarser fraction 1131 product, to the size of the particles meet the criteria without exceeding a predefined size, suitable for processing after grinding. Coarser (larger particle size) fraction 1131 may be returned in the upper casing of the cyclone for additional processing therein. You can use a conveyor (not shown) for transporting the returned coarser material feeding mechanism 127 or other input means in the upper casing 103 of the cyclone 101. In addition, the input means 127 may be inclined conveyor, screw feeder, etc. (see figure 4, item 1270), which transports the feed material into the chamber 104 of the cyclone 101 through the upper casing 103.

It is obvious that the sleeve 107 can be operated to move up and down in different vertical positions within the cyclone 101. Essentially, the lower is the sleeve 107 relative to the cavity 106, the smaller the combined total of the cyclone 101 will be available for air circulation. Because the amount of air supplied to the cyclone remains constant, this reduction in volume leads to an increase in the rate of air flow and increased cyclone effect in the cavity 106 and, therefore, entered the food will be reduced and to circulate in the chamber 104 and the cavity 106 longer. The rise of sleeve 107 leads essentially to the opposite effect. For this podawa the constituent material and data for operating conditions the vertical position of the sleeve 107 can be adjusted to improve the efficiency of the process and increase the yield of products.

In addition, the exhaust pipe 109 you can install the valve 126 to control the amount of air that can extend from the Central section of the low pressure cavity 106 in the atmosphere, which can affect flow rate and gradient forces in the cyclone 101. In addition to the additional valve device 101 typically has no moving parts, in particular, in relation to the grinding action takes place inside the device.

In continuous flow Packed processed food product in the cyclone 101 is achieved continuous output 113 chopped food material. Not limiting example of a commercial device that can operate in continuous mode, processing of food products by the method according to the present invention, a device WINDHEXE, manufactured by Vortex Dehydration Systems, LLC, Hanover Maryland, USA. Description of a device of this type is shown in patent publication No. 2002/0027173 A1, which is incorporated into this description by reference.

Cyclone system 100 creates mechanical energy for disintegration and granulation processed food. The food coming out of the cyclone 101, takes the form of a flowable powder consisting of solid particles, resembling flour.

Processing device 101 may remain relatively clean, since the processed material is not who meet the tendency to stick in the form of a plaque to the inner walls of the processing device, used for grinding food in granular form. This can facilitate any required transition to processing of another type of material on the same device. In the same technological scheme of processing of the processed food product with low moisture content and high content of lipids, the compressed air in the cyclone is compressed air at a gauge pressure of about 10 psi (about 68,95 kPa) to about 100 psig (about 689,5 kPa), more specifically from about 20 pounds per square inch (about 137,9 kPa) to about 35 pounds per square inch (about 241,3 kPa), and more specifically, from about 26 pounds per square inch (about 179,2 kPa) to about 32 pounds per square inch (about br220.6 kPa). The volume flow of compressed air supplied to the cyclone, is in the range from about 500 ft3/min (about 14,16 m3/min) to about 10,000 ft3/min (about 283,17 m3/min), more specifically from about 1000 ft3/min (about 28,3 m3/min) to about 6,000 ft3/min (about 169,9 m3/min), and still more specifically from about 1500 ft3/min (about 42,5 m3/min) to about 3000 ft3/min (about 84,9 m3/min).

The feed rate of the processed food product with low moisture content and high content of lipids may vary, but generally can range from about 1 to 300 lbs/m is n (about 0,454-136,0 kg/min), more specifically, from about 50 to 150 pounds/min (about 22,7-68,0 kg/min) for cyclone (maximum) diameter of from 1 to 10 feet (of 0.3048-3,048 m). The diameter of the cyclone can be from about 1 to 10 feet (of 0.3048-3,048 m) and, more specifically, from about 1 to 6 feet (of 0.3048-1,8288 m).

Processed food product with low moisture content and high content of lipids can be processed in the above-described cyclone device within a very short period of time. In one embodiment, after the introduction of processed food product with low moisture content and high content of lipids in the cyclone granulated food product out of the processing device through about 15, and more specifically through from about 1 to 5 C. Volatile components can also be controlled by directing the exhaust gases from the cyclone through the scrubber, etc. after their exit from the cyclone.

Essentially, the entire processed food product with low moisture content and high content of lipids can go as recycled product in such a short period of time. The above temperature and time used in the milling processed food product with low moisture content and high content of lipids, low enough to prevent any significant undesirable changes in the structure of starch or other physico-chemical the definition of attributes, related to food processing, which can occur during grinding, as described above. Any content of the starch present in the food product with low moisture content and high content of lipids (before granulation)essentially remains unchanged during the grinding carried out according to the present invention. Under normal grinding, essentially, used moving parts, providing abrasion material, which leads to the formation of localized heat. Intensive or incorrectly increase the heat may increase the risk of degradation of the desired functional characteristics of food.

In one embodiment, the processed food product with low moisture content and high content of lipids was used as the material fed to the grinding process and, essentially, when you enter into the cyclone 101 of the system 100 contains at least about 15 wt.%, and more specifically, from about 15 to about 60 wt.% lipids, and less than about 14 wt.% moisture, and more specifically, from about 1 to about 14 wt.% the moisture. Compressed air is supplied to the cyclone usually without heating or at least heated to a temperature below the melting temperature of the lipid component of the processed food material. In one embodiment, the food material is processed in a refrigerated or, at least, not hot, for example, if the tempo is the atur 65-75 aboutF (about 18-24aboutC) or below. Crushed (powdered) part obtained in the process of food product essentially contains 1-14 wt.% the moisture.

You may need draining compressed air before it is introduced into the cyclone in conditions of high relative humidity (over 50%)to the processed material could be used up in granular form and do not form a sticky or viscous mass into a cyclone. The air can be dried conventional cooling coil or similar device used for drying of process air (see figure 4, component 1231). The desiccant 1231 air may be a commercial General purpose, such as Model MDX 1000, manufactured by the company Motivair, Amherst, NJ, USA.

The heat exchanger (cooler) 123, dehumidifier 1231 and the heater 1232, which is not usually used in specific embodiments of the present invention, are devices of the subsystem represented by the module 1233 air preparation shown in figure 4. As shown in figure 4, to selectively control air flow through the various devices of the module 1233 can be used control valves and other devices.

Shredded food product obtained by grinding, preferably has a commercially applicable particle size. In one embodiment, the dried shredded food is already installed, obtained by processing the processed food product with low moisture content and high content of lipids according to the variant of the present invention, in essence, may have an average particle size from about 1 micron to about 1000 microns, and more specifically, from about 2 μm to about 1000 μm. In one embodiment, the fraction of solid powder of edible product obtained at the bottom of the cyclone, contained at least 50% shredded food product with an average particle size of from about 1 μm to about 1000 μm.

The granulated food product obtained by the variants of the present invention, edible and can be used in a variety of foods for different purposes. The granulated food product preferably has no unpleasant taste or smell and can easily be processed with the dough, processed meat and other processed food without quality loss. For example, the granulated food product according to variants of the present invention is an economical replacement for the original ingredients used in such food products. This granular food product is able to add taste and function without harmful effect on such foods. The granulated food product obtained by the variants of the present invention, is usually stable during storage and can be used to attached the Oia taste and/or functional properties of manufactured food product after many months of storage, this granulated food product, for example, in a period of twelve months or more.

Processed food product with low moisture content and high content of lipids, which can be used as the feed material in the process of the present invention, can be obtained from commercial food production or other sources of processed foods with low moisture content and high content of lipids.

In some preferred embodiments, processed foods with low moisture content and high content of lipids contain filled products, including lipid containing filler and grain part, used as a covering on the type of sandwich, closing, wrapping, covering or glazing part.

Lipid containing filling part may contain filling cream containing fat or fat compositions which are edible and "spotting" at normal room temperature. For example, in baked products in different ways were used filling creams that may be present in food products processed according to the present invention. Fill the cream can be used as a layer or "spread" for a sandwich between two pieces of biscuits or crackers or, alternatively, it can be entered in cakes or other food is roducti injection method or co-extrusion, or encapsulation.

Filling creams of this type, for example, as main ingredients can contain fat or fat composition, sugar and flavoring. Fats and fatty composition can be obtained from a variety of sources of edible lipids and may contain various mixtures of oils as fractionated and not fractionated and with different degrees of hydrogenation. Fat or fat composition filling cream may contain fats and oils of animal and/or vegetable origin. The oil or fat composition may have an index of fat content, for example, about 15-43% in dry substance at 70aboutF (21,1aboutC) about 0.7 to 6.0% at 92aboutF (33,3aboutC).

Composition filling of cream, for example, may contain about 30 to 60 wt.% fat or fat content, and the rest can include one or more of the following components: sugar, sweeteners, flavorings, dairy products, processing AIDS and the like, sufficient for spotting Cremonini composition. Appropriate flavorings and extracts are commercially available and include, for example, vanilla, chocolate, coffee, peanut butter, mint, cheese and other Dairy product can be non-fat dry milk. You can use emulsifiers, plasticizers (e.g., lecithin) and/or other those is technological additives. The filling composition may contain spotting RemoveAny composition with a density of from 0.7 to 0.85. Can be and other isolating a composition containing lipids.

Products with the placeholder can contain part based on corn, for example materials based on the test, such as a bread base sandwich or shell for filling foods with filler. Materials on the basis of grain can contain one or more main part of the grain, such as pericarpel or bran (the outer layer of the grain), the endosperm (powdery protein containing starch) or germ (the embryo of the seed). Examples include cereals, flour, coarse grinding, fine grinding flour, starch or gluten, obtained by grinding cereals, such as wheat, corn, oats, barley, rice, rye, sorghum, rape seed, legumes, soybeans, triticale, and various mixtures thereof, as well as various products such grinding cereals, such as bran. In one embodiment, the processed food product with low moisture content and high content of lipids, in essence, may contain on a dry matter 1-99 wt.%, and more specifically, 5 to 95 wt.% ingredient corn-based, and the rest may consist of non-grain agricultural food materials and/or food additives.

In one embodiment, the portion on the basis of grain contains powdery Mat is real, and more specifically, the powdery material obtained from cereals. Powdery material contains the above-mentioned cereals in the form of coarse or fine grinding and tubers, such as potatoes, tapioca, etc. and flour from them. These starch-containing materials can be processed without the formation of unwanted gelatinization or without other undesirable changes. Grinding device described above, allows the use of relatively short-term low-temperature processing, which is believed, contributes to the prevention of transformations of starch (i.e., gelatinization) during processing. If based on the grain part contains the baked dough, such as bread-based, it is not necessary to prepare a special recipe and it may contain flour, water, fat or shortening, sugar, and other standard ingredients of the dough. For products in the form of a sandwich filler bread base can be prepared relatively more rigid than the placeholder, although this is not required.

In one embodiment, the products with the placeholder is collected in line for the production of processed foods as whole pieces, or broken, and/or scrapped parts. These materials can be reduced in a single-stage grinding process according to the variant of the present invention to obtain a granulated product of pishevar the quality, suitable for re-use. For example, a granulated product, essentially preserves the original (i.e. before treatment) lipid and starch structure, which was processed in the food product after cooking, so it remains suitable for the production of fresh food. It can represent, at least partially, of a stable functional replacement of fresh dough ingredients such as flour (grain based), and/or filler ingredients.

Foods with filler, suitable for single-stage processing may include those that are produced by co-extrusion pasty mixture with non-test materials placeholder containing lipids. Product co-extrusion can be obtained using coaxial extrusion head or tube, is inserted into the bore of the extrusion head. Products with filler can also be obtained, conveying a pasty mixture obtained by extrusion, conventional glazing or obsypayu machine for postextrusion fill the placeholder. The pieces obtained by extrusion, can be subjected to fermentation and use. Materials having a low moisture content and high content of lipids, can be collected during the processing of finished food products.

To PR the measures fillers, containing lipids that may be recycled include cream placeholders vanilla, cream placeholders with the taste of chocolate, milk chocolate, cheese, peanut butter, mint, etc. Filling material can also be produced separately pasty mixture for the production of different tastes, of different color or different texture of the cookie.

The completed products can be, for example, cheese filled, or filled with cream biscuits, crackers, snacks, etc. Filled products that can be recycled include are described in U.S. patent No. 5,612,078; 5,374,438; 4,711,788; 5,015,466 and 5,000,968, which is incorporated into this description by reference. Commercial examples of completed products that can be recycled, are, for example, layered cookies Nabisco OREO®, layered cookies Nabisco NUTTER BUTTER®, cookies Nabisco CIPS AHOY® CREMEWICHES, cheese layered crackers Nabisco CIPS AHOY® COOKIE BARZ®, Nabisco RITZ BITZ® and layered crackers with peanut butter Nabisco RITZ BITZ® and the like.

The granular product obtained by one-step processing of food products with filler, can be used to replace fresh ingredients on the production lines of food products, essentially unlimited. In some embodiments, the granulated product obtained from the dough with a low content is of moisture and a higher content of lipids, can be used in amounts of from 0.1 wt.%, and more specifically, from about 1 to 99 wt.%, instead of fresh flour in batches of dough for bread basis or, alternatively, as an oil containing ingredient.

The following examples are intended to illustrate and not limit the present invention. All percentages are percentages by weight, unless otherwise indicated.

EXAMPLES

Example 1

Layered cookies Nabisco® OREO® (moisture content of 1.5-3.5 percent) was fed to the device WINDHEXE for grinding in a circular vortex air stream. The device WINDHEXE produced by Vortex Dehydration Systems, LLC, Hanover Maryland, USA. Description of a device of this type is shown in patent publication No. 2002/0027173 A1, which is incorporated into this description by reference. Processing device has four inlet ports spaced at equal distance around the top of the device, through which simultaneously served the compressed air stream in a counterclockwise direction.

Tested device WINDHEXE diameter of 2 ft (0,609 m). The diameter refers to the size of the camera casing, which serves compressed air, and processed foods with low moisture content and high content of lipids. The conditions of this experiment are described below. Feed rate biscuits with low moisture content and high content of LIPI the s was set so that to get about 3 pounds (1.36 kg) of solid product per minute and the device was introduced approximately 20 pounds (9,07 kg) of food material. Processed food product with low moisture content and high content of lipids was loaded into a hopper, from which directly fed onto the conveyor belt with a width of 3 inches (76.2 mm), which harbored the device WINDHEXE. The tests were carried out on the device WINDHEXE diameter of 2 ft (0,609 m), which is supplied compressed air with a temperature of 65oF (18,3aboutC)the flow rate of the injected air was 1000 ft3/min (28,3 m3/min), and pressure - 20-35 psig (137,9-241,3 kPa).

The food coming out of the device, had the form of a finely milled powder. This granular food product started to be unloaded from the bottom of the cyclone approximately 2 s after the processed food product with low moisture content and high content of lipids was started to be fed into a processing device. The obtained granulated food product had an average particle size of 5-50 μm and a moisture content of 1.5-3.5%by weight. He was stable when stored and preserved the taste after the grinding process.

RESEARCH REUSED PRODUCT

Studies have been conducted reused product for comparison of ability to about what abode and sensory attributes of cookies, treated with crushed bread base, obtained from cookies subjected to grinding in a cyclone as described above, with cookies with the same number of processed bread base, which was obtained by mechanical grinding layered OREO cookies® to the same particle size. In the test for the studied and reference biscuits in the composition of the test consisted of 5 parts of recycled product to 100 parts of grain base. For the preparation of the corresponding test combined sugar, hot water, cocoa, salt, flavorings and component recycled bread basics and the mixture was stirred for 4 minutes, then was added to liquid vegetable shortening with stirring for 2 minutes, then added the flour and stirring continued for another 6 minutes. The dough is cut into round portions and baked. Received biscuits, processed processed product obtained according to the scheme of the present invention was comparable in terms of machinability and sensory attributes of cookies received from mechanically milled recycled product. It should be understood that the recycled product can be used for other lines of food.

The obtained granulated product during grinding, essentially, has not lost the taste or functionality, and was suitable cachedany ingredient for cooking food. The granular product was also stable during storage of the powder, and was suitable for reuse as an ingredient of the party to produce the same or other product lines.

Additional studies have shown that it is possible to use changes in feed rate and temperature to control the process of granulation and moisture content of the product with low moisture content and high content of lipids.

Example 2

Separate batches of roasted cocoa bean (the moisture content of 1.5 to 3.5 wt.%, lipid 54%) and non-roasted cocoa beans (the moisture content of 1.5 to 3.5 wt.%, lipid 54%) was fed to the device WINDHEXE for grinding in a circular vortex air stream. The cocoa beans are usually called roasted cocoa beans separated from the shell and crushed into smaller pieces. However, as noted above, for this example was conducted in a separate operation, where cocoa beans were made from cacao beans that have not undergone pre-roasting. The device WINDHEXE was the same as the basic configuration described in example 1. Tested device WINDHEXE with a diameter of 3 ft (0,91 m). The diameter refers to the size of the camera casing, which serves compressed air, and processed foods with low moisture content and high content of lipids. The conditions of this experiment the op is Sana below. The feed speed of the cocoa bean was set so that the output to get about 3 lb (1.36 kg) of solid product per minute and the device was introduced approximately 20 pounds (9,07 kg) of food material for each batch of cocoa beans. Cocoa beans are loaded into a hopper from which the screw feed was fed to the device WINDHEXE. The tests were carried out on the device WINDHEXE with a diameter of 3 ft (0,91 m), compressed air is supplied at a temperature of 65aboutF (18,3aboutC)the flow rate of the injected air was 1000 ft3/min (28,3 m3/min), and pressure - 40-55 psi (275,8-to 379.2 kPa). Relevant threads finely ground product started to leave the device in approximately 2 C.

The granular material of each test run were collected and sifted particle size to determine the distribution of particle sizes. Also sifted parties are not fried and roasted cocoa beans that have not undergone processing in the cyclone. The results of the screening are shown in table 1, which shows the percentage of material quantity of a specific party, which remained on the surface of the sieve with the specified cell size, i.e. particles that are too large.

Table 1
The type of party grains Kaka is The size of the screened particles (μm)
+6300+4000+3150+1000+500+250+150+125+100
Unroasted/unhandled4,4744,3872,3998,99-----
Unroasted/
processed in the cyclone
---0,0829,1776,2998,5699,5899,69
Fried/
processed in the cyclone
---0,6643,5596,15 99,82100100

The results in table 1 show that the roasted and unroasted cocoa beans were significantly crushed by processing in the cyclone compared to the untreated material. The corresponding granular products were stable during storage and during processing has preserved sensory attributes such as taste.

Although the present invention described above with reference to specific embodiments of the method and product, it should be understood that the present description can be based on various modifications, changes and adaptations, which are within the inventive concept and scope of the invention defined by the attached claims.

1. A method of obtaining a processed food product, providing
the introduction of compressed air into the casing, which contains a plot in the form of a truncated cone, in which the introduced air is moving towards a downward path through the enclosure, including the conical section, to its lower end and the air has reached the lower end flows back up and exits the enclosure through the outlet;
introduction to the casing of the processed food product containing less than about 14 wt.% water and at least about 15 wt.% lipids, which is captured who entered the ear, moving down through the casing where at least part of the processed food product is ground before reaching the lower end of the casing;
unloading granular product from the lower end of the casing;
combining at least part of the granular product and at least one other ingredient in a processed food product and
the preparation of these processed food product.

2. The method according to claim 1, wherein the granulated product has a particle size of from about 1 to about 1000 microns.

3. The method according to claim 1, in which processed food product contains outer layers containing the ingredient on the basis of grain and an intermediate layer located between the outer layers containing lipids.

4. The method according to claim 1, wherein the processed food product is chosen from the group consisting of cookies, crackers, pastries and desserts.

5. The method according to claim 1, in which compressed air is injected under pressure 68,95-689,5 kPa.

6. The method according to claim 1, in which compressed air is injected under pressure 137,9-241,33 kPa.

7. The method according to claim 1, in which compressed air is injected at a temperature not exceeding 23,9°C.

8. The method according to claim 1, in which compressed air is injected at a temperature not exceeding the melting point of the lipid content.

9. The method according to claim 1, in which the input of compressed air provides (a) compressing ambient air is and, first, the temperature of which exceeds 23,9°C to compression; (b) cooling the compressed air to a second temperature below the first temperature and lower than about 23,9°C and the flow of cooled compressed air into the casing.

10. The method according to claim 1, in which the compressed air supplied from the flow 14,16-weighing 28.32 m3/min

11. The method according to claim 1, in which the compressed air supplied from the flow 42,48-84,96 m3/min

12. The method according to claim 1, in which compressed air is introduced into the cylindrical casing on the inner walls of the cylindrical casing.

13. The method according to claim 1, in which the upper cylindrical casing has a constant diameter size of 0.3048-3,048 m, and the lower casing has the shape of a truncated cone having a maximum diameter in the place in which the bottom cover adjacent to the cylindrical casing, and the maximum diameter of the lower housing, essentially equal to the diameter of the cylindrical casing.

14. The method according to claim 1, in which processed food product contains from about 15 to about 60 wt.% lipid.

15. Processed food product containing a combination of granulated product and at least one other ingredient in a processed food product, and the granulated product obtained by introducing compressed air into the casing containing the plot in the shape of a truncated cone, in which the air moving through the enclosure, including the conical section, by direction of the slow-down trajectory to its lower end and air, under the lower end flows back up and exits the enclosure through the outlet, and by introducing into the casing of the processed food product containing less than about 14 wt.% water and at least about 15 wt.% lipids, which is captured by the air moving down through the casing, and at least part of the processed food product with a high content of lipids is crushed before it reaches the lower end of the casing, and discharge of granular product from the lower end of the casing.

16. The product indicated in paragraph 15, in which processed food product contains outer layers containing the ingredient on the basis of grain, and the Central layer located between the outer layer and containing lipids.

17. The product indicated in paragraph 15, in which the processed food product is selected from the group consisting of cookies, crackers, pastries and desserts.

18. The product indicated in paragraph 15, in which the processed product contains from about 15 to about 60 wt.% lipid.



 

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