High-protein and high-fiber whole wheat coarse grain pre-cooked noodle and steaming and drying pre-cooking process thereof

Abstract

The application relates to a high-protein and high-fiber whole wheat coarse grain pre-cooked noodle and a steaming and drying pre-cooking process, which is prepared from 35-45 parts of whole wheat flour, 20-30 parts of coarse grain compound powder, 8-12 parts of plant protein fortifier, 5-8 parts of compound dietary fiber matrix, 0.4-0.8 parts of auxiliary agent and 30-38 parts of drinking water. The whole wheat coarse grain health pre-cooked noodle with high protein, high fiber, light carbohydrate, reduced sugar, low fat, low GI is prepared by combining a vacuum dough-making process, high-temperature steaming, three-stage gradient drying and low-temperature ripening integrated pre-cooking process. The prepared product has a protein content of 18-22%, a dietary fiber content of 12-16%, a digestible carbohydrate content of 25-30%, a fat content of less than 3% and a GI value of less than 45. The noodle is tough and smooth, has a quick rehydration speed, is not cooked and not muddy soup after long-time boiling. The process is stable, the parameters are controllable and the process is suitable for industrial production, fills the technical blank of the sugar-controlled and fat-reduced whole wheat coarse grain pre-cooked noodle, has significant nutritional innovation, process innovation and industry popularization value.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a high-protein, high-fiber whole wheat pre-made noodle and its steaming and drying pre-made process. Background Technology

[0002] Pre-cooked noodles have the advantages of short rehydration time of about 2-3 minutes, a taste close to fresh noodles, and room temperature storage, making them very suitable for modern fast-paced life.

[0003] With the increasing awareness of healthy eating among the public, staple food products that are low in sugar and fat, high in protein, and high in dietary fiber have become the mainstream consumer choice. Traditional noodles are mainly made of refined wheat flour, with a carbohydrate content of 70-75%, protein of only 7-10%, and dietary fiber of 2-3%, resulting in problems such as nutritional deficiencies, rapid glycemic index, and weak satiety.

[0004] Most existing whole grain noodles are simply a mixture of mixed grain powders without nutritional optimization. They generally have a rough texture, are easy to break, have poor rehydration properties, and produce cloudy soup when steamed or boiled. Commercially available instant noodles mostly use frying or a single hot air drying process. Fried noodles have a fat content as high as 18-22%, while hot air dried noodles rehydrate slowly and have a hard texture. Neither can achieve the integration of low GI, high protein, high fiber, and reduced sugar.

[0005] Currently, the industry lacks a dedicated process for integrated steaming and drying of whole wheat and whole grain pre-made noodles, as well as a lack of whole wheat and whole grain nutritious noodles suitable for people who are trying to lose weight, control their blood sugar, or are fitness enthusiasts. Therefore, developing pre-made whole wheat and whole grain noodles with scientific formulas, innovative processes, excellent taste, and healthy nutrition is of great practical significance. Summary of the Invention

[0006] The purpose of this invention is to address the industry pain points of existing refined noodles, such as high carbohydrate content, low nutrition, and rapid glycemic index, as well as the rough texture, easy breakage, poor rehydration, and simple processing of existing whole grain noodles. There is a lack of whole wheat whole grain nutritious noodles suitable for people who want to lose weight, control blood sugar, or exercise. This invention provides a high-protein, high-fiber, low-GI whole wheat whole grain pre-made noodle and its steaming and drying pre-made process.

[0007] The objective of this invention is achieved as follows: a high-protein, high-fiber whole-wheat pre-made noodle, by weight, is made from the following raw materials: 35-45 parts whole wheat flour, 20-30 parts coarse grain compound powder, 8-12 parts plant protein fortifier, 5-8 parts compound dietary fiber matrix, 0.4-0.8 parts auxiliary agent, and 30-38 parts drinking water; the coarse grain compound powder is a mixture of oat flour, buckwheat flour, quinoa flour, and konjac flour in a weight ratio of 5-7:2-3:1-2:1; the plant protein fortifier is a mixture of soy protein isolate, gluten, and chickpea flour in a weight ratio of 4-6:3-4:1-2; the compound dietary fiber matrix is ​​a mixture of inulin, resistant starch, and oat fiber powder in a weight ratio of 2-3:2-3:1-2; and the auxiliary agent is a mixture of edible alkali and salt in a weight ratio of 0.1-0.3:0.3-0.5.

[0008] In this invention, the resistant starch is selected from one or more resistant starches contained in potatoes, bananas, rice, and corn.

[0009] The present invention discloses a pre-processing technology for steaming and drying high-protein, high-fiber whole wheat noodles, which includes: raw material pretreatment → vacuum kneading → maturation → multi-stage rolling → cutting and shaping → high-temperature steaming → three-stage gradient drying → low-temperature maturation → aseptic packaging → finished product.

[0010] The pre-processing technology of steaming and drying of the present invention includes the following steps: 1) Pre-treatment of raw materials: After passing the powder through a 120-mesh sieve, mix it evenly; 2) Vacuum mixing: Under vacuum conditions of -0.08 to -0.09 MPa, the pretreated powder, additives, and drinking water are mixed evenly, stirred for 15 to 20 minutes, and then matured at room temperature for 25 to 35 minutes. 3) Multi-stage calendering: Five continuous calendering passes are used to reduce the thickness of the strip to 1.2~1.5mm; 4) Strip forming: Strip width 1.2~1.8mm, length 200~240mm; 5) High-temperature steaming: Steam at 98~105℃ for 8~12 minutes to achieve a starch gelatinization degree ≥95%; 6) Three-stage gradient drying: First stage temperature 45-50℃, humidity 85-90%, drying time 25-35 min; Second stage temperature 55-60℃, humidity 70-75%, drying time 30-40 min; Third stage temperature 65-70℃, humidity 55-60%, drying time 20-30 min; After three-stage gradient drying, the moisture content of the strips is 10-12%. 7) Low-temperature aging: Aged at 30~35℃ for 4~6 hours; 8) The finished noodle product is obtained through aseptic sealing packaging.

[0011] In this invention, step 5) involves steam steaming, preferably with a steam pressure of 0.1~0.15 MPa.

[0012] The positive effects of the raw material ratio used in this invention are as follows: 1) Whole wheat and coarse grain base: Whole wheat flour retains the nutrients of the bran, and when combined with oats, buckwheat, quinoa and konjac powder, it increases the content of B vitamins and minerals. Konjac powder also plays a natural role in retaining water and thickening. 2) Fiber matrix: Through the synergistic effect of inulin, resistant starch, and oat fiber powder as a complex dietary fiber matrix, it not only ensures a high fiber content, but also improves the rough texture commonly found in whole grain noodles through inulin and resistant starch, resulting in a dietary fiber content of >15%. 3) Nutritional fortification logic: The protein source uses soy protein isolate as a high-quality plant protein, wheat gluten as a gluten protein to enhance elasticity, and chickpea flour as an amino acid complement to construct a high-protein and balanced amino acid system, so that the protein content is >20%; 4) Process adaptability: The proportion of functional additives in the formula takes into account the needs of subsequent vacuum kneading and high-temperature steaming processes, which helps to maintain the processing stability of the dough and the rehydration performance of the noodles.

[0013] The positive effects of the process employed in this invention are as follows: 1) Vacuum kneading: Kneading dough under negative pressure can remove air bubbles from the dough, making the gluten network denser, thereby improving the chewiness and cooking resistance of the noodles; 2) High-temperature steaming: The starch is fully gelatinized by steaming with saturated steam at 98~105℃. The starch gelatinization degree is ≥95%, which is the key difference between pre-cooked noodles and fresh noodles. This means that the noodles can reach the best eating state after simple reheating, such as boiling in boiling water for 1~2 minutes or microwaving, and the texture is smoother. 3) Three-stage gradient drying: The gradient strategy of low temperature and high humidity → medium temperature and medium humidity → high temperature and low humidity can effectively prevent the surface of the noodles from cracking and ensure that the moisture diffuses evenly from the inside to the outside, avoid breakage, and ensure the product quality. 4) Low-temperature maturation: The maturation step after drying is 30~35℃ for 4~6 hours, which helps to further balance the internal moisture of the noodles, release internal stress, and make the noodles more stable in taste.

[0014] The product manufactured using this invention has a protein content of 18-22%, dietary fiber of 12-16%, digestible carbohydrates of 25-30%, fat content ≤3%, and a GI value ≤45. The noodles are chewy, smooth, rehydrate quickly, do not become mushy even after prolonged cooking, and do not cloud the broth. This invention features a stable process with controllable parameters, making it suitable for industrial production. It fills a technological gap in whole-wheat pre-made noodles for sugar control and fat reduction, and possesses significant nutritional, technological, and industry promotion value.

[0015] Therefore, this invention is highly suitable for fitness enthusiasts who are pursuing a high-protein, high-fiber, and low-GI diet while controlling blood sugar and losing fat. It solves the problems of traditional whole-grain noodles being unpalatable, prone to breaking, and nutritionally unbalanced. Detailed Implementation

[0016] Example 1, Standard Optimal Formula: Ingredients: By weight, 40 parts whole wheat flour, 12 parts oat flour, 6 parts buckwheat flour, 4 parts quinoa flour, 2 parts konjac flour, 5 parts soy protein isolate, 3 parts wheat gluten, 1 part chickpea flour, 2 parts inulin, 2 parts resistant starch, 1 part oat fiber powder, 0.2 parts baking soda, 0.4 parts salt, 35 parts drinking water; Process: Steam at 100℃ for 10 minutes; Dry at 48℃ / 58℃ / 68℃; Mature at 32℃ for 5 hours; Indicators: Protein 20.5%, Dietary Fiber 14.2%, Digestible Carbohydrates 27.8%, Fat 2.6%, GI value 42. Target Audience: People on sugar-controlled / diabetic diets (low GI value ≤45, high fiber to slow blood sugar rise), fitness and weight loss groups (high protein provides satiety, low fat ≤3%), healthy staple food substitutes (replacing refined white noodles or high-oil instant noodles).

[0017] Example 2, High-Fiber Sugar-Control Formula: Ingredients: By weight, 38 parts whole wheat flour, 14 parts oat flour, 6 parts buckwheat flour, 4 parts quinoa flour, 2 parts konjac powder, 5 parts soy protein isolate, 3 parts wheat gluten, 1 part chickpea flour, 3 parts inulin, 3 parts resistant starch, 1 part oat fiber powder, 0.2 parts edible alkali, 0.4 parts salt, and 36 parts drinking water; Process: Steam at 100℃ for 10 minutes; Dry at 48℃ / 58℃ / 68℃; Mature at 32℃ for 5 hours; Indicators: Dietary fiber 15.8%, GI value 40, suitable for people controlling blood sugar.

[0018] Comparative Example 1: Regular whole wheat noodles: 11% protein, 6% dietary fiber, 68% digestible carbohydrates, GI 69, with a rough texture and easy breakage.

[0019] Comparative Example 2, Fried Instant Noodles: 21% fat, 8% protein, 1.5% dietary fiber, high in oil and carbohydrates, and nutritionally unbalanced.

[0020] This invention allows for the addition of humectants and multivitamins as needed. Adding small amounts of yeast extract or natural spices can also be considered to diversify the product's flavor. For different whole grain flour particle sizes, such as the colloidal properties of konjac flour, the rolling thickness and steaming time can be fine-tuned to balance rehydration speed and texture.

[0021] Nutritional composition comparison table of the product of this invention with ordinary refined noodles and traditional whole grain noodles Nutritional indicators Product of this invention Ordinary refined noodles Traditional whole grain noodles protein 18~22% 7~10% 10~12% Dietary fiber 12~16% 2~3% 5~8% Digestible carbohydrates 25~30% 70~75% 65~70% Fat ≤3% 1~2% 1~3% GI value ≤45 70~75 65~70 The formula of this invention, through compound additives, enhances protein and dietary fiber while retaining the texture of whole wheat grains.

[0022] Formula Ingredient Function Analysis: Whole wheat flour 35-45 parts + coarse grain compound powder 20-30 parts. Whole wheat flour provides basic wheat aroma and B vitamins; the coarse grain compound powder (oat + buckwheat + quinoa + konjac) introduces active ingredients such as β-glucan and rutin, while konjac provides colloidal support and improves water retention. Soy protein isolate: gluten: chickpea flour = 4-6:3-4:1-2. Soy protein increases protein content; gluten compensates for insufficient gluten network in coarse grains, enhancing chewiness; chickpea flour provides plant protein and improves flavor. Inulin: resistant starch: oat fiber powder = 2-3:2-3:1-2. Inulin and resistant starch act as prebiotics, while oat fiber powder increases water retention; the three work synergistically to achieve high fiber and low glycemic index, lowering the noodle's GI value. Baking soda and salt adjust pH, strengthen the gluten network, inhibit enzymatic browning, and extend shelf life.

[0023] The core of the process of this invention lies in the process of first cooking and then drying, which is different from traditional fresh noodles and ensures the consistency of taste after reheating.

[0024] The purpose of vacuum kneading at -0.08 to -0.09 MPa is to allow water molecules to quickly penetrate into the flour particles under negative pressure, forming a more uniform and dense gluten network. This is a key step that solves the problems of uneven water absorption and brittle dough that are often caused by high-fiber and high-protein formulas.

[0025] The purpose of steaming at 98~105℃ is to fully gelatinize the starch using saturated steam, with a gelatinization degree of ≥95%. This step directly determines the elasticity and smoothness of the noodles after rehydration, avoiding the undercooked or mushy phenomena that are common in traditional dried noodles. The gelatinization degree is the ratio of gelatinized starch to total starch. The goal of a gelatinization degree of ≥95% is to achieve almost complete gelatinization, resulting in good elasticity and smoothness, easy digestibility, and rapid rehydration.

[0026] Three-stage gradient drying: low temperature and high humidity → medium temperature and medium humidity → high temperature and low humidity. The first stage, at 45~50℃ and high humidity, is a slow-warming stage, allowing internal moisture to migrate outwards and surface moisture to evaporate slowly, preventing the formation of a hard crust (vitrification). The second stage, 55~60℃, medium humidity, is the shaping stage. The noodles shrink as internal moisture migrates to the surface, which is both shaping and shrinking. The third stage involves drying at 65-70℃ with low humidity until the moisture content reaches 10-12%, thus meeting microbial safety standards.

[0027] Low-temperature aging, 30~35℃, 4~6h. Purpose: to redistribute the internal moisture and stress of the noodles evenly, eliminate internal stress during the drying process, and prevent the noodles from breaking during storage or transportation.

[0028] This invention features a strong coupling between the formula and the process. Simply imitating the formula (such as adding a large amount of fiber) without the support of vacuum kneading and gradient drying processes can easily lead to noodles that break and have a rough texture.

[0029] This invention provides a complete solution from nutritional design to processing. It successfully reconciles the seemingly contradictory concepts of health (high protein, high fiber, low GI) and deliciousness / convenience (chewy, quick rehydration), giving it clear functional food attributes and a significant market differentiation advantage.

[0030] The product positioning and advantages of this invention belong to the category of non-fried, ready-to-eat / quick-cooking healthy staple food. It has a short rehydration time and, although similar to instant noodle cakes, is healthier. The core of the process lies in steaming first and then gradually drying, which is fundamentally different from traditional raw or fried instant noodles, ensuring the fresh taste of the noodles after rehydration.

[0031] The core features of this invention are: high nutrition: high protein and high dietary fiber; low GI potential: the combination of complex fiber and resistant starch makes its glycemic response lower than that of ordinary wheat noodles; stable taste: the steaming process locks in the starch structure, making it less prone to becoming soggy after rehydration and retaining the chewy texture of whole grains.

[0032] This invention optimizes the rehydration speed by finely adjusting the calendering thickness and steaming time, taking into account the reheating habits (boiling, soaking) of different groups of people.

[0033] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-protein, high-fiber whole wheat pre-made noodle, characterized in that, By weight, it is made from the following raw materials: 35-45 parts whole wheat flour, 20-30 parts coarse grain compound powder, 8-12 parts plant protein fortifier, 5-8 parts compound dietary fiber matrix, 0.4-0.8 parts auxiliary agent, and 30-38 parts drinking water; The whole grain compound powder is composed of oat flour, buckwheat flour, quinoa flour, and konjac flour mixed in a weight ratio of 5~7:2~3:1~2:1; the plant protein fortifier is composed of soy protein isolate powder, gluten powder, and chickpea flour mixed in a weight ratio of 4~6:3~4:1~2; the compound dietary fiber matrix is ​​composed of inulin, resistant starch, and oat fiber powder mixed in a weight ratio of 2~3:2~3:1~2; and the auxiliary agent is composed of edible alkali and salt in a weight ratio of 0.1~0.3:0.3~0.

5.

2. The pre-processing technology for steaming and drying high-protein, high-fiber whole wheat noodles according to claim 1, characterized in that, Includes the following steps: 1) Pre-treatment of raw materials: After passing the powder through a 120-mesh sieve, mix it evenly; 2) Vacuum mixing: Under vacuum conditions of -0.08 to -0.09 MPa, the pretreated powder, additives, and drinking water are mixed evenly, stirred for 15 to 20 minutes, and then matured at room temperature for 25 to 35 minutes. 3) Multi-stage calendering: Five continuous calendering passes are used to reduce the thickness of the strip to 1.2~1.5mm; 4) Strip forming: Strip width 1.2~1.8mm, length 200~240mm; 5) High-temperature steaming: Steam at 98~105℃ for 8~12 minutes to achieve a starch gelatinization degree ≥95%; 6) Three-stage gradient drying: First stage temperature 45-50℃, humidity 85-90%, drying time 25-35 min; Second stage temperature 55-60℃, humidity 70-75%, drying time 30-40 min; Third stage temperature 65-70℃, humidity 55-60%, drying time 20-30 min; After three-stage gradient drying, the moisture content of the strips is 10-12%. 7) Low-temperature aging: Aged at 30~35℃ for 4~6 hours; 8) The finished noodles are obtained through aseptic sealing packaging.

3. The pre-processing technology for steaming and drying high-protein, high-fiber whole wheat noodles according to claim 2, characterized in that, Step 5) The steam pressure for steam steaming is 0.1~0.15MPa.