Biscuit made with malt by-product flour and enriched with Pacific white shrimp (Litopenaeus vannamei) by-products.

Description

/ 6 Biscuit made with malt residue flour and enriched with Pacific white shrimp (Litopenaeus vannamei) residue. Field of invention

[001] The present invention consists of using two types of residues that are very rich in nutrients (brewery waste and shrimp farming waste) that are not yet fully exploited by industrial centers, being discarded as waste and / or sold as low value-added input for animal feed production industries.

[002] Waste from both shrimp farming and breweries comes from processing, malt from breweries and shrimp from shrimp farming. Waste generation is a problem not only for one industry but for everyone who depends on the planet and who must use methods that reduce waste production or use technology that transforms this waste into a high-value product where investments can be made.

[003] With the residue from malt and shrimp it is possible to dehydrate and make flours rich in nutrients and applicable in the food industry, the combination of the two flours is fundamental to adding nutritional value to the product.

[004] As if a trend towards fast-consumption foods was conceived in the development of a biscuit formulation enriched with two flours, one from brewery residue and the other from Litopenaeus vannamei shrimp residue. The malt residue flour is rich in fiber and carbohydrates, making it a good alternative for controlling the texture and moisture of the product, in addition to providing functional properties due to its high fiber content. The shrimp residue flour is rich in natural antioxidant compounds such as astaxanthin and canthaxanthin, which will act as a natural additive to prevent oxidation and rancidity. The combination of the two residues in the biscuit formulation, besides encouraging the use of residue as a raw material, generates a positive result in terms of environmental impact. Fundamentals of the invention

[005] Document BR 10 2022 012297 0 A2 reveals the characterization and valorization of malt residue flour as an ingredient for the manufacture of bakery products. Petition 870240109871, dated 12 / 23 / 2024, page 6 / 19 / 6 The previously cited document deals with the development of technological solutions for utilizing waste from beer production, specifically malt spent grains, which are removed during the filtration stage. Binary mixture compositions of malt residue flour and wheat flour are proposed with adequate technical specifications for food safety after microbiological, physicochemical, nutritional, and sensory analysis (color, flavor, odor, and texture). These compositions contain a binary mixture of malt residue flour and wheat flour. The flour products exhibit food safety, nutritional properties, sensory characteristics, and purchase intent that differentiate them from the control products, and can be used in the baking industry. The previously cited document differs from this present invention by not using malt flour for the same purpose, and shrimp residue flour is also not included in the formulation.

[006] Studies on the development of savory biscuits using by-products from the beer industry have already been found. Food and Nutritional Security Journal (Online), 2020-08, Vol.27, p.e020023 DOAJ Directory of Open Access Journals. This study evaluated the technological potential of incorporating malt bagasse flour into savory appetizer-type biscuits. First, malt bagasse flour (MBF) was produced, then biscuit development tests were carried out with applications of 0% (FP), 25% (F25) and 50% (F50) of MBF replacing wheat flour. Results showed that the MBF produced had 16% protein and higher water and oil absorption and water solubility indices when compared to wheat flour. The incorporation of FBM (Fragrance-Based Biomass) into biscuit formulations promoted an increase in ash, protein, and lipid content, while also decreasing moisture and carbohydrate content, and causing sensory changes according to the percentage of FBM applied.Biscuits with 25% FBM had higher acceptability (>70%) compared to biscuits with 50% FBM (<70%). Finally, the byproduct of the brewing industry proved to be a possible input for the development of new products intended for human consumption, in addition to encouraging environmental care. This study is very similar to the present invention but has a structure with different formulations, and does not contain astaxanthin enrichment using shrimp waste, a characteristic exclusive to the present invention with two industrial wastes. Petition 870240109871, dated 12 / 23 / 2024, page 7 / 19 / 6 Brief description of the drawings

[007] Figure 1 shows the flowchart for the production of malt flour.

[008] Figure 2 shows the flowchart for the production of shrimp shell flour.

[009] Figure 3 shows the flowchart for the production of mixed flour1.

[0010] Figure 4 shows the flowchart for the production of mixed flour2.

[0011] Figure 5 shows the flowchart for the production of mixed flour3.

[0012] Figure 6 shows the flowchart for the production of biscuits enriched with mixed flour.

[0013] Figure 7 shows the flour from the malt residue.

[0014] Figure 8 shows shrimp waste flour

[0015] Figure 9 shows the biscuit enriched with malt flour and shrimp flour. Description of the invention

[0016] The beer industry is growing more and more, which means that the demand for manufacturing inputs should grow. Beer is produced from four basic elements: water, barley malt, hops, and yeast. On average, 2.2 kg of malt is used for every 10 liters of water to make beer; the quantity varies according to the type of beer and the brewer's formula.

[0017] Beer production is divided into processes: milling the malted grain, mixing with water, heating for mashing, boiling, cooling the wort, filtration, clarification, fermentation, and maturation. In the mashing stage, the malted barley grain is hydrolyzed by enzymes, which will act directly on the long-chain compounds, leaving smaller compounds favorable for yeast fermentation. After all carbohydrates, proteins, and lipids have been hydrolyzed into smaller compounds, and after all the sugars and compounds in the grain are available in the wort, the grains Petition 870240109871, dated 12 / 23 / 2024, page 8 / 19 / 6 are removed and destined for disposal in soils, landfills, cattle farms and / or dumped in open dumps, forming a highly complex organic waste, generating an environmental problem, with risks to public health.

[0018] Malt grain residue is the largest residue in production. Besides this residue, there are others generated, but on a much smaller scale than the grain residue. An example of residue formation is during the fermentation stage: yeast consumes hydrolyzed compounds, multiplies in the presence of oxygen, and after consuming all the available oxygen, begins fermentation. The result of its secondary metabolism is the synthesis of alcohol, carbon dioxide, and other compounds that are part of beer. After fermentation, the yeast is decanted; some is used for a new fermentation, and the rest is discarded without any further processing.Both malt residue and fermentation residue can be used to manufacture a new product. Studies by Gurak, Poliana Deyse; Glüger, Helena Dupke used brewer's residue to formulate savory appetizer-type biscuits, while other studies used malt residue to improve the fiber content in the formulation of mixed flours.

[0019] To manufacture flour from malt residue, it is dried at a temperature of 65 °C for 24 hours, then ground. The flour must be sifted and stored in clean, dry packaging protected from light and moisture. Malt flour has a good amount of fiber and a very characteristic and strong flavor. To mask the malt flavor, cooked L. vannamei shrimp shell flour will be used; in addition to adding the shrimp flavor to the flour, it will provide antioxidant functionality due to the astaxanthins present in the shrimp shell.

[0020] Shrimp shell flour is obtained from the carapace of the abdomen, head and tail, which are separated, cleaned with running water and dehydrated in an oven at 65 °C for 24 h, then ground in a knife mill and sifted until a powder is obtained.

[0021] The mixture of malt flour with shrimp shell flour was balanced at 1 / 10 shrimp shell flour to malt flour. In biscuit making, you can use 10-20% mixed flour, preferably 15%, 25-40% wheat flour, preferably 35%, 1-3% baking powder, preferably 1%, 5-8% sugar, Petition 870240109871, dated 12 / 23 / 2024, page 9 / 19 / 6 preferred 7%, 20 - 30% milk, preferred 25%, 6 - 10% margarine, preferred 7%, and 7 - 11% egg whites, preferred 10%.

[0022] The present invention BISCUIT MADE WITH MALT RESIDUE FLOUR AND ENRICHED with PACIFIC WHITE SHRIMP RESIDUE, characterized by containing mixed flour (malt residue and shrimp residue), wheat flour, baking powder, milk, eggs, margarine and sugar.

[0023] Regarding the mixed flour being formulated in a ratio of 1 / 10 shrimp residue flour and malt residue flour.

[0024] In the formulation of the mixed flour biscuit, 10-20% (malt residue and shrimp residue), 25-40% wheat flour, 1% baking powder, 5-8% sugar, 20-30% milk, 6-10% margarine, and 7-11% egg whites are used.

[0025] Shrimp flour is made from the residue of shells, heads and fins of adult shrimp.

[0026] The milk used to formulate the biscuit is whole cow's milk, standardized to 3% fat. In addition, the margarine contains cream and salt in its formulation. The egg whites are from free-range chickens. Examples of embodiments of the invention

[0027] The biscuit preparation is carried out in three stages. The first stage involves mixing the mixed flour with wheat flour and yeast, homogenizing it with standardized cow's milk at 3% fat. The second stage involves homogenizing the egg white with granulated sugar and margarine with cream in another bowl. The third stage involves mixing the two bowls in an aluminum bowl, shaping the biscuits, and baking them in a preheated oven at 160°C for 7 minutes. Afterward, they are cooled, unmolded, and packaged in clean, dry packaging. Three mixed flour formulations were made, with concentrations of 1 / 100, 1 / 50, and 1 / 10 of shrimp residue flour to malt residue.

[0028] The 1 / 100 flour formulation observed that the smell of the malt residue was stronger than the smell of the shrimp residue. Petition 870240109871, dated 12 / 23 / 2024, page 10 / 19 / 6

[0029] The 1 / 50 flour formulation had a darker color compared to the 1 / 100, but the malt smell was masked by the smell of shrimp residue.

[0030] The 1 / 10 flour formulation had a strong smell of dried shrimp, with the shrimp smell being predominant over the malt residue.

[0031] The biscuit made using 1 / 100 mixed flour, with 25% mixed flour, 25% wheat flour, 8% sugar, 25% milk, 7% margarine and 10% egg white, had a dark brown color, with an intense smell of malt residue and no aroma of shrimp residue. 1. The biscuit made using a 1 / 10 mixed flour ratio, comprising 15% mixed flour, 35% wheat flour, 8% sugar, 25% milk, 7% margarine, and 10% egg whites, resulted in a dark cream color, a shrimp-like smell, and a malty flavor, with the characteristic taste and smell of whole-wheat oat biscuits. 2. The biscuit made using a 1 / 10 mixed flour ratio, with 10% mixed flour, 40% wheat flour, 8% sugar, 25% milk, 7% margarine, and 10% egg whites, resulted in an orange color, a faint shrimp smell, and no malt aroma. The overall flavor resembled that of water and salt cream crackers. Petition 870240109871, dated 12 / 23 / 2024, p. 11 / 19

Claims

CLAIMS 1. BISCUIT MADE WITH MALT RESIDUE FLOUR AND ENRICHED WITH PACIFIC WHITE SHRIMP RESIDUE, characterized by containing mixed flour (malt residue and shrimp residue), wheat flour, baking powder, milk, eggs, margarine and sugar.

2. Biscuit, according to claim 1, characterized by the base ingredients being in the following proportions: mixed flour 10-20% (malt residue and shrimp residue), 25-40% wheat flour, 1-3% baking powder, 5-8% sugar, 20-30% milk, 6-10% margarine, and 7-11% egg whites.

3. Biscuit, according to claim 2, characterized in that the mixed flour is formulated in a ratio of 1 / 10 shrimp residue flour and malt residue flour.

4. Biscuit, according to claim 3, characterized in that the shrimp flour is made from the residue of shells, heads and fins of adult shrimp.

5. Biscuit, according to claim 2, characterized by whole cow's milk being standardized to 3% fat.

6. Biscuit, according to claim 2, characterized by the margarine being made with cream and salted.

7. Biscuit, according to claim 2, characterized by the egg whites of free-range chickens. Petition 870240109871, dated 12 / 23 / 2024, p. 12 / 19

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