Process for obtaining solubilized seed extracts for the production of food beverages

Abstract

A process for obtaining solubilised seed extracts for the production of food beverages, which operates entirely in a continuous line and comprises the following sequence of steps: - initial heat treatment of the seeds with the addition of water; - in-line grinding of the seeds treated in the previous step to form a paste; - enzymatic slurry treatment and in-line maintenance for component solubilisation; and - separation of the liquid extract by continuous filtration.

Description

[0001] PROCEDURE FOR OBTAINING SOLUBILIZED SEED EXTRACTS FOR THE PREPARATION OF FOOD BEVERAGES

[0002] DESCRIPTION

[0003] OBJECT OF THE INVENTION

[0004] The present invention falls within the technical field of food product preparation and relates in particular to a continuous line industrial process for obtaining solubilized seed extracts for the production of food beverages, especially designed for milk-substitute beverages of plant origin.

[0005] BACKGROUND OF THE INVENTION

[0006] Worldwide, more and more people are adopting eating habits such as vegetarianism or vegan diets. Among the products whose consumption is increasing the most are plant-based milk substitutes.

[0007] Plant-based beverages are increasingly occupying a place alongside traditional milk in cafes, supermarkets, and kitchens. Like soy and almond varieties, modern oat, spelt, and rice products are particularly in demand among young, urban consumers who value individual taste, health, and fitness, and who demand lactose-free, climate- and animal-friendly foods. Plant-based beverages are sustainable products, resulting in less energy consumption, less agricultural land use, less ocean acidification, and less greenhouse gas emissions.

[0008] Regarding industrial processes for producing plant-based beverages, it should be noted first that there are two main options for the raw material: whole grains or flour. Using grains entails high investment and operating costs for milling equipment, but the raw material is cheaper. Flour, on the other hand, is more expensive, but the investment and operating costs are lower and more flexible.

[0009] Of all the plant-based products from which these beverages are obtained, oats are especially important in terms of production volume, as they also have specific processing requirements.

[0010] The conventional process for obtaining plant-based beverages usually includes the following sequence of stages:

[0011] - Mixing and enzymatic treatment: The flour is mixed with hot water in a processing tank. The hot water causes the starch in the seed to gel, increasing viscosity and optimizing the effectiveness of the enzymatic reaction. After enzyme dosing and high-shear mixing, the subsequent enzymatic reaction breaks down the starch into dextrin or sugar, while rapidly reducing viscosity.

[0012] - Heating and cooling: A recirculation circuit can be added to the process to adjust the temperature appropriate for a second enzymatic reaction that breaks down the dextrin into different saccharides according to the given sweetness profile. In this case, the suspension is first cooled to the optimal reaction temperature. One option could be to deactivate the enzymes just before extraction, which would also be accomplished by heat treatment.

[0013] - One- or two-step extraction: The resulting slurry is introduced into a centrifuge-decanter to remove unwanted fibers and retain the desired starch and p-glucans in the product. A second redilution and extraction step can be added to increase solids and protein yields. The solids from the first step are washed with water, which is then separated and used for the initial mixing process.

[0014] - Final formulation: The extracted oat base is then formulated with various ingredients, such as oil to enhance the mouthfeel, as well as salt or other flavorings. This is achieved using specific high-shear dosing and mixing systems.

[0015] - UHT heat treatment and heat recovery: Oat beverages are sold as ready-to-drink beverages in shelf-stable containers. To achieve this, the beverage undergoes ultra-high temperature (UHT) treatment and is then packaged using aseptic equipment. The direct method, placing the product in direct contact with hot steam, achieves rapid heat transfer and smooth product flow. Alternatively, a safe and economical process is also possible, in which the product is not in contact with the heating media. The choice of method depends on the product properties and production method. Heat recovery equipment can be included to save energy in both processes.

[0016] - Homogenization and aseptic storage: The homogenizer ensures the necessary fine distribution of fat particles and bubbles throughout the product. A deaerator is also used to reduce oxygen in the beverages. Both processes result in an aseptic beverage that can be stored under aseptic conditions before packaging.

[0017] If grains are used as raw material, they must also be milled beforehand.

[0018] The conventional process for producing plant-based beverages requires a large amount of energy in the stages of grinding the seeds, separating solids by centrifugal decantation, and concentrating them from an initial dilution with a high proportion of water, which is added in a ratio of at least 4:1 to the weight of the seeds.

[0019] As already mentioned, one or more enzymatic treatments are required, which are carried out in batch process tanks. That is, a tank is filled with the product to be treated, the treatment is carried out, and the treated product is discharged for further processing. For continuous operation, a series of enzymatic treatment tanks is required, so that there is always one tank receiving the product to be treated and another tank delivering the treated product.

[0020] Since it involves loading and unloading tanks and several stages of enzymatic treatment, it requires a large investment in industrial machinery, the processing times are long and cause qualitative degradation, and it cannot be guaranteed that all seeds are treated under the same conditions and times.

[0021] There is therefore a need for a method for obtaining solubilized seed extracts for the production of plant-based milk substitute beverages that overcomes the aforementioned drawbacks of the current state of the art.

[0022] DESCRIPTION OF THE INVENTION

[0023] The object of the invention is a continuous line process for obtaining solubilized seed extracts for the production of food beverages which, unlike current processes, works in a continuous line rather than in batches.

[0024] The procedure is specifically designed for the case where the food beverages are milk substitutes, and more particularly for the case of oatmeal, although not limited to these options.

[0025] The procedure for obtaining solubilized seed extracts basically comprises the following sequence of successive steps:

[0026] - Heat treatment of seeds with a reduced proportion of water;

[0027] - In-line crushing of the seeds to form a paste;

[0028] - Addition of enzymes to the paste and online maintenance for solubilization of components;

[0029] - Separation of the liquid extract by continuous filtration; and

[0030] - Continuous washing of the separated solids for maximum extraction efficiency, taking advantage of the wash water in the first stage of seed treatment.

[0031] The main difference compared to current treatments is that this is a completely inline process, meaning the seed advances from the beginning without any stage where it undergoes treatment in a reactor or tank to retain it. Furthermore, in the specific case of oats, the seed undergoes a multi-enzyme treatment in a single stage.

[0032] The continuous in-line process, with a single enzymatic treatment stage, reduces processing times, simplifies production plant design, and lowers investment costs. Energy consumption in the milling stage is also significantly reduced, thanks to the pretreatment of hydration and heating that softens the seeds. Energy consumption in the separation of solids is also reduced by using filtration instead of decantation.

[0033] The process allows for an extract with a higher initial concentration because it requires the addition of a much smaller amount of water than current processes. This makes it possible to produce a concentrated extract with much lower energy consumption during the concentration phase. This concentrated extract reduces packaging, storage, and transportation costs, and can be diluted later when the final beverage is prepared.

[0034] PREFERRED EMBODIMENT OF THE INVENTION

[0035] A detailed explanation of a preferred embodiment of the object of the present invention is provided below.

[0036] The continuous online process for obtaining solubilized seed extracts for the production of food beverages described herein comprises the following sequence of steps:

[0037] - Heat treatment of the seeds with water. To achieve this, a screw feeder is used to introduce a continuous quantity of seeds along with a controlled flow of water into the upper part of a vertical mixing tank, into which steam is also injected to control the process temperature. The treated mixture of seeds and water is also continuously extracted from the lower part of the tank, thus ensuring a uniform treatment time for the seeds.

[0038] - in-line crushing of the seeds to form a paste, by means of an in-line shear mill placed at the outlet of the heat treatment tank;

[0039] - enzymatic treatment of the paste, with continuous injection of enzymes into the mixture inlet pipe to the grinder by means of a dosing pump, and on-line maintenance for component solubilization, inside a vertical maintenance tank, with the appropriate volume so that the residence time of the product in the tank is sufficient to complete the enzymatic reactions; and - separation of the liquid extract by continuous filtration, introducing the product into a cylindrical sieve with a scraping system on the sieve wall to prevent clogging, such that the liquid phase passes through the sieve and the solid phase advances to the sieve outlet.

[0040] - washing of the solids in a vertical column through which they descend countercurrently with a flow of wash water. The washed solids are removed from the bottom of the column, and the wash water is recovered from the top for the initial seed treatment stage; and

[0041] - concentration of the obtained extract to achieve the desired final concentration, by means of a forced circulation tubular concentrator.

[0042] The hot hydration pretreatment of the whole seeds facilitates subsequent milling. In the enzymatic treatment, a 2:1 water-to-seed ratio is used for solubilization. The seed paste also receives a single enzymatic solubilization treatment with a combination of several different enzymes, such as alpha-amylase, glucoamylase, protease, or cellulase, acting together and simultaneously.

Claims

CLAIMS 1. Procedure for obtaining solubilized seed extracts for the production of food beverages, characterized in that it operates completely in a continuous line and comprises the following sequence of stages: - initial heat treatment of the seeds with the addition of water; - online crushing of the seeds treated in the previous stage to form a paste; -enzymatic treatment of the paste and online maintenance for component solubilization; and - separation of the liquid extract by continuous filtration.

2. Method according to claim 1, which additionally comprises a final step of washing the separated solids in countercurrent with water in order to increase the extraction yield, taking advantage of the washing water in the addition to the seeds.

3. Method according to claim 1, further comprising a final step of concentrating the extract obtained to obtain a highly concentrated product that is used as a base or ingredient for the production of beverages or other food products.

4. Method according to any of the preceding claims, wherein the seed paste receives a single enzymatic solubilization treatment with a combination of several different enzymes of the alpha-amylase, gluco-amylase, protease or cellulase type, which act together and simultaneously.

5. Method according to any of the preceding claims, wherein in the enzymatic treatment step a water:seed ratio of 2:1 is used for solubilization.

6. Method according to any of the preceding claims wherein the continuous filtration is carried out by means of a self-cleaning sieve.

7. Method according to any of the preceding claims, wherein in the initial heat treatment stage of the seeds with the addition of water, a screw feeder is used to introduce a continuous quantity of seeds together with a controlled flow of water into the upper part of a vertical mixing tank, into which steam is also injected to control the temperature of the process.

8. Method according to any of the preceding claims, wherein in the in-line crushing stage of the seeds, an in-line shear mill placed at the outlet of the heat treatment tank is used.

9. Method according to any of the preceding claims, wherein the enzymes are injected into the inlet pipe to the in-line crusher, and the outlet pipe of the crusher is connected to a vertical maintenance tank, with the appropriate volume so that the residence time of the product in the tank is sufficient to complete the enzymatic reactions of solubilization of components.