Optimization of puff pastry production using whole grain and legume extrusion

Abstract

The present invention aims to improve the value and quality of daily and mostly harmful snacks and replace them with health-oriented products and snacks. Puffed whole grains and legumes can be produced in the industrial phase by designing a formulation with the aim of increasing consumer health and making changes in the production line and supplying high-quality raw materials and their specific processing, and using two extruders with different specifications and other supplementary equipment. The required extruders have two screws with different helices, the length of which is one and one and a half meters. The diameter of the cylinder at the beginning of the extruder inlet is 30 centimeters and at the end of the device is between 2 and 5 millimeters, and the rotation speed of the screws is between (20-60) RPM. The extruder operates with three factors: humidity, temperature and pressure, and the ground material enters the extruder to be subjected to the factors mentioned above. In order to complete the work, the cutter, dryer and dragee sections are installed at the end of the production line. To be clear, puffed rice will create a new generation and style in the puffed food industry, which, by becoming a culture, can have a very positive effect on preventing common diseases in society such as obesity, constipation, fatty liver, cardiovascular diseases, and weak digestive and immune systems. In addition, this product can be distributed in schools, pharmacies, and supermarkets as a healthy and useful snack in the nutrition industry, and can be recommended by various specialists in modern and traditional medicine.

Description

Description of the invention Title of the invention Optimization of puff pastry production using whole grain and legume extrusion Technical background of the relevant invention The present invention relates to the field of human needs in the food industry. Technical problem and stating the objectives of the invention Given that nutrition is an integral part of human life and cannot be eliminated; therefore, the quality of food is effective in the health of the body and soul and in improving the quality of life of individuals, therefore, the use of bioactive and health-giving foods such as fibers, minerals, proteins, and vitamins, especially group (B), is of interest. Currently, there are many problems in the formulation of industrial food products in the country, especially in snacks; therefore, we have discussed the problems in the field of puffed products (puffed), which constitute an important part of people's nutrition today, below. 1- The existence of nutrient-free formulations on the market Most of these compounds are based on corn without bran to gain a lot of volume. The compounds and formulations of bulking products containing high fiber and minerals are very rarely used in society, and this has led to the production of simple, low-quality or harmful food compounds. Because most of these compounds are based on corn without bran and chemical additives to gain a lot of volume. 2- Increase in various diseases due to the use of unhealthy foods Today, the consumption of products such as puffed products (puffs) has increased among teenagers and children as one of the most popular types of snacks, and healthy and wholesome snacks are used much less. The raw materials of puffed products are based on corn with a high percentage of starch and contain additives, palm oil, unnatural and chemical flavors and colors, and a lot of salt. The aforementioned substances cause short-term and long-term problems for the consumer; nutrition experts have also pointed out the direct and indirect negative effects of additives. Long-term use of puffed products (puffs) and puffs leads to allergies and, in addition, increases the risk of cancer. Consuming unhealthy snacks makes it difficult for the body to absorb essential vitamins and proteins, and prevents the absorption of vitamins and proteins when consuming healthy foods; It also leads to false obesity and slowed growth in children, because during the growing years, the role of nutrition affects a person's health and quality of life.Various diseases, including osteoporosis, skin problems, prostate, and diabetes, have become very common in different age groups. Objectives of the invention: 1) Providing healthy snacks to different segments of society, especially children and adolescents. 2) Increasing the consumption of fiber, protein, minerals, and B vitamins in people's diets 3) Effectiveness in preventing the upward trend of diseases such as anemia and osteoporosis, diabetes, and skin problems. 4) Improving the physical development of children in adolescence 5) Production of bulk snacks with very high nutritional value and with specific nutritional and therapeutic purposes based on cereals, legumes and nuts. 6) Using whole grain flour and legumes, which are generally consumed in small quantities, in the formulation of high-consumption foods. 7) Variety of formulations of puffed puff pastry products produced with the aim of increasing nutritional value 8) No use of any permitted or unauthorized chemical additives to make snacks puffy. 9) Relatively long shelf life without adding preservatives 10) Restoring the bran separated from the grain to its essence and using its properties A description of the state of the prior art and the history of developments related to the claimed invention. The search and efforts of manufacturers to produce functional products, so-called superfoods, as well as food-medicines, became an incentive for further research to achieve technical knowledge and greater production and diversity in this group of products. The use of foods rich in fiber and containing minerals and B vitamins that were previously less used, such as various types of cereal bran, and its return to the household basket is very necessary, given the countless digestive problems of humans. Therefore, the use of whole roasted flour of cereals, legumes and nuts, which is referred to as sweigh, was revived, and thus, the relevant bran was added to whole flours, cereals such as barley and wheat, and after applying the cooking and roasting process, sweigh of cereals and beans was obtained. In this way, the properties of bran, which is high in fiber and vitamins and minerals, are added to the final product, and during the cooking process, the absorption inhibitors are inactive and better absorption by the body takes place. This product contributes significantly to society in reducing the problems mentioned. In this regard, in order to make Suyiq more convenient and easier to use and deliver these nutrients and minerals to children's bodies, and even more convenient for consumption by young people and adults, we decided to transform this product into a bulk product (puffed Suyiq) and offer it in the snack market as a healthy snack and an alternative to unhealthy puffed rice. In order to identify the patent records, we examined the Iranian Intellectual Property Database and came across several similar cases. We will explain the similar cases in detail below. ●Declaration No. 139550140003011274 entitled "Production of functional snack products from almond meal based on extrusion technology" This food is a combination of corn flour, corn grits and almond meal. In this process, first the oil is extracted from the almonds by cold pressing and then ground into powder using a hammer mill. Then the corn flour and corn grits are mixed with almond meal in an extruder under temperature and humidity with a moisture content of between 12 and 16 percent and after 15 minutes of mixing, they are packaged in polyethylene bags. The samples are stored in the refrigerator for 24 hours to reach moisture balance. To dry the product, the samples are placed in a hot air stream and finally, the product is packaged in thick polyethylene bags. The above invention is based on almond meal, corn flour and corn grits, but in my invention the raw material is whole grains and legumes including whole wheat flour and whole rice and legumes. In the puffed puff pastry processing method, the bran and puff pastry processing steps are also carried out as a precursor in addition to the conventional extrusion processing. ●Declaration 139350140003006597 titled Functional bulk formulation and product containing sprouted millet flour In this invention, first the seeds are washed and soaked for 6 hours at 20°C and germination takes place within 3 days. The germinated seeds are dried using an oven and then ground. The millet flour is mixed with corn flour and corn grits and after mixing for 15 minutes, it is packed in polyethylene bags. Then the samples are stored in the refrigerator for 24 hours. They are also dried in the presence of hot air. Finally, the product is packed in polyethylene bags. In this invention, the food used is millet, but in my invention, the raw material is the bran of whole grains, nuts, and seeds. In this invention, the germination process is used and they are ground, but in my invention, the germination process is not done, and in the method of processing puffed bran, the bran and bran processing steps are also carried out as a precursor in addition to the conventional extrusion processing. Declaration 139750140003006861 titled Functional Barley and Sage Snack In this invention, which I have registered, the product is based on barley and alfalfa sprouts, but in the new invention, the use of different food sources such as whole grain sprouts and legume sprouts has been expanded. For the first time in our country, we have been able to produce a bulk product with a combination of legume sprouts and the pre-processing stage of legumes has been added to it. Providing a solution to an existing technical problem along with an accurate, sufficient, and integrated description of the invention The claimed invention is "Optimization of puff pastry production using bran and grain extrusion," which consists of the following materials: Given that all bulk snacks are corn-based and may be made from imported genetically modified corn, and most have coatings containing synthetic colors and flavors that are sometimes problematic for health, and that a large portion of these products' fans are children and adolescents, the existence of evidence and evidence of the effects of misuse of these snacks indicates an increase in diseases due to unhealthy diets, and therefore the production of healthy and functional snacks is very necessary in today's society. For this purpose, in order to prevent and eliminate existing problems, we have started producing puffed sweeg, which is of particular importance. sweeg means roasted flour, which consists of flour and grain bran. In my invention, whole wheat, whole barley, whole rice, lentils, chickpeas, cowpeas, and sesame are used to make sweigh. In order to produce 100 grams of puffed sweigh, whole grains (40%-60%), legumes (20%-30%), oil (15%-20%), and nuts and flavorings (10%-15%) are mixed together or produced separately. Puffed rice has good nutritional properties, including phosphorus, iron, manganese, magnesium, and molybdenum, as well as protein and B vitamins. In terms of treatment, it is useful for regulating blood pressure, helping to treat diabetes and reduce blood sugar, helping to build bones, promoting children's growth, and helping to repair the skin. Of course, it is considered an innovative and very important product for preventing anemia. Manufacturing process: -First stage: The raw materials must pass through a filter to remove impurities (sieving). -Second stage: The materials are soaked in water for 12 hours and washed. -Third stage: The materials are dried and ground. -Fourth stage: The raw materials are formulated, mixed, and fed into the extruder. -Fifth stage: In the extruder, three factors of temperature, humidity, and pressure are applied to the material to obtain a slurry. Two screws are designed in the extrusion chamber, the length of the screws is about one meter, and at the beginning of the inlet, the diameter of the screws is 30 cm and the outlet of the opening is 5 mm, and its rotation speed is (20-40) Rpm. Inside the extruder, the materials are heated and roasted at a temperature of (90-150) degrees Celsius; otherwise, the shelf life of the product decreases and the contamination of the raw material increases and it is not easily digested. Also, the initial moisture of the product is between 5 and 15 percent, and during the process, we increase the moisture by 20%-25% for better performance of the device, but the final moisture of the product is 6 to 9 percent. Also, the amount of pressure as a third factor is between (200-250) MPa. -Sixth step: The material goes to the grinding machine to be powdered. -Seventh step: The materials are transferred back to the extruder so that the bulking process can take place. When they exit the extruder, they puff up due to contact with air and are shaped with different molds. The product is divided into smaller pieces with a cutter installed at the end of the machine. -Eighth step: After this step, the puffed rice straws are placed in a tunnel dryer to dry better and reach a moisture content of about 2%. Step 9: In the final stage, a coating machine sprays a flavoring containing spices and liquid oil onto the product, making it pleasant and delicious. Explanation of shapes, maps and diagrams Figure 1- Production process A clear and precise statement of the advantages of the claimed invention over prior inventions. Producing a bulk snack called Puffed Whole Grains and Beans for the first time in the country and including grains as an important nutritional source in the people's food basket Low cost Used for all ages Increasing the health level of consumers by delivering fiber, protein, minerals and B vitamins to the body Returning the bran separated from the grain to its essence and using its properties Increase product shelf life Increase the digestibility and absorption of nutrients from legumes and whole grains through a designed process and utilize the energy hidden in the seeds. Promoting the physical development of children Description of at least one implementation method for implementing the invention - Method of processing bulk products based on corn grits: Corn grits moistened in the primary mixer with 17% moisture. Extrusion process (23% moisture increase, motor speed or screw speed 60-70 rpm, average temperature 160°C, pressure 160 pascals in 3 to 5 seconds). Product exits as a bulk snack with about 10% moisture. Transfer by conveyor to the dryer. Drying in a layer dryer (temperature 90-100°C, residence time 10-15 minutes until reaching 2% moisture. Entry into the glazing machine using warm palm oil and flavors and preservatives with the help of compressed air spray into the drum and the machine rotates on the surface of the snack as a coating. Transfer by conveyor. Weighing and packaging. -Method and stages of processing puffed rice from whole grains and legumes First step: Cereal bran processing: The bran is fed into an extruder with a moisture content of 6%, the extrusion process (17% moisture increase, motor speed or screw speed of 20-25 rpm, average temperature of 120°C, pressure of 250 MPa for 10 to 15 seconds, the bran is extruded in the form of granules and cooled to 30°C, ground with a mesh of 0.5, weighed and packaged. Second stage: Processing of sevighs (roasted flour): Mixing cereal flour such as wheat, barley and rice with processed bran (output product of stage 1) or legumes such as chickpeas, lentils and beans in the primary mixer or a combination of these. Extrusion process (increase moisture to 17%, motor speed or screw speed 30-40 rpm, medium thermal shock 130°C, pressure 200 MPa for 7-10 seconds). Exit from the extruder with 8% moisture. Drying in a layer dryer (temperature 90-100°C, residence time 15-20 minutes until moisture reaches 2%. Grinding with 0.5 mesh. Weighing and packaging. Third stage: Final processing of puffed snack (bulked product): Mixing all processed ingredients (output product of stage 1 + processed whole grain snacks of output product of stage 2) or legumes (chickpea flour, lentils and beans) or combining them with sprouts in the primary mixer. Extrusion process (23% moisture increase, motor speed or screw speed 60-70 rpm, average temperature 150°C, pressure 180 pascals for 5 to 7 seconds). Output of the product as a bulk snack with a moisture content of about 8%. Output of the product as a bulk snack. Transfer by conveyor belt to the dryer. Drying in a layer dryer (temperature 90°C, residence time 15-20 minutes until reaching 2% moisture content. Entry into the glazing machine (dragee) and adding the flavor combination (natural edible flavors + liquid sunflower oil + salt) by spraying compressed air into the drum and rotating the machine. On the surface of the snack as a coating, transported by conveyor belt, weighed and packaged by adding nitrogen gas inside the packages. Explicit mention of the industrial application of the invention The claimed invention is related to the field of human needs, sub-sector of food industry. It can be used in the food industry and household use, and its consumption is safe for all individuals and age groups, which increases the level of health of the community.

Claims

Claims What is claimed: Claim 1) The claimed invention is "Formulation and production of puffed puffs using whole grain and legume extrusion," where the puffed puff formulation includes whole grains including whole wheat, whole barley, whole rice (40 to 60 percent), legumes including lentils, chickpeas, and beans (20 to 30 percent), liquid oil (15 to 20 percent), and natural flavoring (10 to 15 percent). Claim 2) According to claim 1, to produce puffed sevigh, first whole grains, bran and legumes are separately roasted and then roasted. The roasted materials are transferred to an extruder to bulk them up. At this stage, the materials puff up and are shaped into desired shapes with different molds and divided into smaller pieces with a cutter. Then the sevighs are fed into a tunnel dryer until their moisture content reaches about 2%. In the next stage, the sevighs are fed into a dragee machine and the flavor combination (natural permitted flavors, sunflower oil and salt) is coated on the surface of the product by air spray. Finally, the sevighs are weighed and placed in packages containing nitrogen gas. Claim 3) According to claim 2, for processing cereal flour, first cereal flours such as wheat, barley and rice are mixed with bran or legumes such as chickpeas, lentils and beans (with a moisture content of 17%). Then, this mixture is extruded in an extruder at a temperature of 170 ° C, a pressure of 200 MPa and a screw speed of 30 to 40 rpm for 7 to 10 seconds until the moisture content of the samples reaches 8%. After that, the samples are placed in a tray dryer at a temperature of 90 to 100 ° C for 15 to 20 minutes until the moisture content is reduced to 2%. Finally, the samples are ground and sieved with a 0.5 mesh, then weighed and packaged. Claim 4) According to claim 2, in the extrusion process, the temperature is set between 90 and 150 degrees Celsius, the humidity is 20 to 25 percent, and the pressure is 200 to 250 MPa. The initial moisture content of the product is between 5 and 15 percent, which is increased to 20 to 25 percent during the process to improve the performance of the device. Finally, the final moisture content of the product is set to 6 to 9 percent.