Extruded puffed high protein grain-based food pieces and methods of making

Abstract

The present disclosure relates to low density, high protein, grain-based ready-to-eat food pieces, compositions including such food pieces, and methods of making such food pieces. The pieces include a grain flour in an amount of about 28% to about 55% by dry weight, about 28% to about 40% by dry weight protein, where at least a portion of the protein ingredients include a protein with a PDCAAS greater of at least 60%, such as pea protein, fava bean protein, or soybean protein, and about 10% to about 35% by dry weight low DE carbohydrate.

Description

EXTRUDED PUFFED HIGH PROTEIN GRAIN-BASED FOOD PIECES AND METHODS OF MAKINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 625,486, filed January 26, 2024, which is incorporated herein by reference.TECHNOLOGY

[0002] The present disclosure generally relates to an extruded high protein, grain based product with low density and methods of making such a product.BACKGROUND

[0003] High protein food products have found popularity among consumers as a way to eat nutritionally dense foods. Consumers want diverse ways to get increased protein into their diets. Thus, there is a need for new high protein food products to satisfy the increasing consumer desire for protein.SUMMARY

[0004] Low density, high protein, grain-based ready-to-eat (RTE) food pieces are provided herein, as well as compositions comprising such food pieces. Food pieces provided herein can consist of a grain flour in an amount of about 30% to about 55% by dry weight of the food pieces; a plant-based protein ingredient in an amount of about 28% to about 40% by dry weight of the food pieces, where the protein ingredient has a protein content of at least 60% protein by dry weight of the protein ingredient and contributes a protein having a PDCAAS of at least 60%; a low dextrose equivalent (DE) carbohydrate in an amount of 10% to about 35% by dry weight of the food pieces, the low DE carbohydrate having a DE of from 1 to about 10; other ingredients, the combined other ingredients included in an amount of up to 20% by dry weight of the food pieces; and amoisture content of up to 5% by weight of the food pieces, where the food pieces have a bulk density range of from 110 to 200 grams per 100 cubic inches.

[0005] In some embodiments, at least a portion of the grain flour can be a whole grain flour. In some embodiments, the grain flour can include oat flour. In some embodiments, the plant-based protein ingredient can be included in an amount of about 50% to about 72% relative to the amount of grain flour.

[0006] In some embodiments, the plant-based protein ingredient can contribute protein in an amount of about 22% to about 36% by dry weight of the food pieces, the protein comprising soybean or pea protein. In some embodiments, the food pieces can have a total protein content of about 28% to about 38% by dry weight of the food pieces.

[0007] In some embodiments, the low DE carbohydrate can be included in an amount of about 12% to about 27% by dry weight of the food pieces.

[0008] In some embodiments, the food pieces can consist of the grain flour in an amount of about 30% to about 50% by dry weight of the food pieces, the grain flour including oat flour or corn flour; the plant-based protein ingredient contributing protein in an amount of about 22% to about 35% by dry weight of the food pieces, the protein comprising soybean or pea protein, where the pieces have a total protein content of about 28% to about 38% by dry weight of the food pieces; the low DE carbohydrate including maltodextrin or soluble fiber in an amount of about 14% to about 25% by dry weight of the food pieces; the other ingredients in an amount of less than 10% by dry weight of the food pieces.

[0009] A composition, that includes a plurality of coated food pieces is also disclosed herein. The coated food pieces comprise food pieces according to any embodiment described herein; and a coating on at least a portion of a surface of at least a portion of the food pieces.

[0010] In some embodiments, the coating can comprise about 10% to about 50% by weight of the coated food pieces. In some embodiments, coated food pieces can have a bulk density of about 150 to about 300 grams per 100 cubic inches.

[0011] Also disclosed is a composition comprising a plurality of food pieces and / or coated food pieces according to any embodiment described herein, and edible components other than the food pieces and / or coated food pieces.

[0012] Methods of making food pieces are described herein. Such methods include combining under extrusion conditions ingredients to form a dough having a moisture content of about 12% to about 18%; forming the dough from an extrusion die to form dough pieces; puffing and drying the dough pieces to form a plurality of food pieces having a bulk density of 110 to 200 grams per 100 cubic inches and a moisture content of 5% or less by weight to form the plurality of food pieces. The ingredients in a dough can consist of a grain flour in an amount of about 30% to about 55% by dry weight of the dough; a plant-based protein ingredient, comprising pea protein, fava bean protein, soybean protein, canola protein, or chickpea protein, the protein ingredient included in an amount of about 28% to about 40% by dry weight of the dough and having a protein content of at least 60% protein by dry weight of the protein ingredient; a low DE carbohydrate (e.g., maltodextrin or a soluble fiber) in an amount of about 10% to about 35% by dry weight of the dough, the low DE carbohydrate having a DE of 1 to about 10; water; and other ingredients, the combined other ingredients included in an amount of up to 20% by dry weight of the dough. In some embodiments, the puffing is performed by direct expansion during the forming step.

[0013] These and various other features and advantages will be apparent from a reading of the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 shows pictures of inventive food pieces made according to Formulation 1 in Table 1. The food pieces have a rounded morphology and even puffing similar to traditional grain-based RTE cereal.

[0015] Figure 2 shows pictures of inventive food pieces made according to Formulation 2 in Table 1. The food pieces have a rounded morphology and even puffing similar to traditional grain-based RTE cereal.

[0016] Figure 3 shows pictures of comparative food pieces made according to Formulation 3 in Table 1. The food pieces exhibit a less rounded appearance and sharp edges along the inner “o” of the pieces.

[0017] Figure 4 shows pictures of comparative food pieces made according to Formulation 4 in Table 1. The food pieces exhibit irregular puffing, sharp edges, and breakage.

[0018] Figure 5 shows pictures of comparative food pieces made according to Formulation 5 in Table 1. The food pieces exhibit poor puffing, especially radial expansion, and sharp edges.

[0019] Figure 6 shows pictures of cross sections of inventive food pieces made according to Formulation 1 in Table 1. The upper images are cross sections of square-shaped pieces, while the lower images are sphere-shaped pieces. The images on the left show the structure of the cells within the pieces. The images on the right shows individually colored cells identified by a deep learning model that was trained to recognize individual cells according to Example 2.

[0020] Figure 7 shows pictures of a cross section of a piece from a commercially available comparative product, described in Example 2. The image on the left shows the structure of the cells within the piece. The image on the right shows individually colored cells identified by a deep learning model that was trained to recognize individual cells according to Example 2. Irregularly shaped cells and large variations in cell size are apparent in the images. The areas circled in red identify regions left out of the analysis of the image because they appeared to have been intentionally-included in the structure, and did not appear to be part of the cell structure.

[0021] Figure 8 shows pictures of comparative food pieces made according to Formulations 6-12 in Table 3. Food pieces made from Formulations 7-12 exhibit poor puffing and / or sharp edges compared to control (Formulation 6).DETAILED DESCRIPTION

[0022] Consumers continually expect an even greater variety of high protein foods that are suitable for different eating occasions. However, protein ingredients, particularly nonanimal derived protein ingredients, often suffer from bitter taste, astringency, and / or off- flavor / aroma, and have proven difficult to puff or to produce a product that resembles a traditional ready-to-eat (RTE) grain-based breakfast cereal. Thus, while grain-based RTE cereal products are available with supplemental protein content (i.e., protein content beyond that contributed by the grain-based component(s)), such products leverage different formats (e.g., flakes, nugget-type pieces, or twigs) or have structures that are generally denser and often have a harder, crunchier, grittier, and / or glassier texture when attempting to replicate traditional puffed RTE cereal format than traditional RTE grainbased breakfast cereals. Such products also tend to suffer from off-flavors and / or bitterness. The present application describes the discovery of high protein compositions that can be puffed into a low-density, high protein, RTE food piece having a pleasant, crunchy texture resembling traditional grain-based RTE breakfast cereal, and having a pleasant or neutral flavor, even in the absence of flavorants or off-flavor maskers.

[0023] A food piece provided herein is a high protein, low density, and ready-to-eat grainbased food piece. As used herein, the term “high protein” refers to a food piece that includes protein in an amount of about 27% to about 40% by dry weight of the piece (e.g., at least 28% to about 38%) by dry weight of the food piece. The term “low density” refers to a plurality of food pieces that have a bulk density of about 80 to about 200 (e.g., about 90 to about 200, about 110 to about 200, or about 140 to about 180) g / 100 cubic inches. A low density food piece may also be referred to as “puffed.” Low density food pieces resembling RTE breakfast cereal pieces can, for example, have a bulk density of about 110 to about 200 (e.g., about 140 to about 180) g / 100 cubic inches. Low density food pieces resembling cheese puff snack pieces can, for example, have a bulk density of less than 110 (e.g., about 80 to about 100, or about 90 to about 100) g / 100 cubic inches.

[0024] As used herein, the term “ready-to-eat” (“RTE”) refers to a food that does not require further cooking or preparation to be suitable and safe for consumption. A food piece provided herein is typically also shelf stable at room temperature for at least 6 months (e.g., at least 8 months, or 12 months to 18 months) without significant negativeimpact on texture, structure, or flavor when stored in appropriate packaging. A food piece provided herein typically has dimensions that are suitable for a RTE breakfast cereal or a bite sized snack food. A food piece provided herein can also be suitably coated, or it can be used in other products, such as dry snacks, inclusions to be mixed in other products (e.g., yogurt or pudding), snack blends, cold-formed or baked snack bars or clusters.

[0025] A food piece provided herein can include a grain flour in an amount of from about 35% to about 55% (e.g., about 40% to about 50%) by dry weight of the food piece. As used herein, a grain flour refers to a food ingredient obtained by grinding a grain (e.g., wheat, com, rice, oat, barley, and the like). In some embodiments, a grain flour alternative can be substituted in-part or fully for a grain flour. Examples of grain flour alternatives can include seed and / or pseudo grain flour (e.g., sunflower, millet, buckwheat, sorghum), tuber flour (e.g., tapioca flour, potato flour, or the like), or the like, or combinations thereof. A grain flour is not limited to finely ground flours, and can include coarse flours such as com meal and / or corn cones. In some embodiments, a suitable grain flour has a particle size where at least 80% of the particles pass through a U.S mesh #40. In some embodiments, a grain flour has a particle size where at least 50% of the particles pass through a U.S. mesh #60. A grain flour referred to herein can be a whole grain flour or a refined flour, however, a grain flour referred to herein does not refer to isolated and / or extracted starches. In some embodiments, at least a portion of a grain flour (e.g., at least 20%, at least 50%, or at least 80% by weight of the grain flour) included in a food piece can comprise a whole grain flour. In some embodiments, a grain flour can comprise a higher percentage of a food piece by weight than any other ingredient (i.e., grain flour is the “first ingredient”).

[0026] A food piece provided herein includes a plant-based protein ingredient in an amount of about 30% to about 40% by dry weight. A suitable plant-based protein ingredient has at least a portion (e.g., at least 60%, at least 70%, or at least 90%) of its protein content comprising a protein source that has a protein digestibility-corrected amino acid score (PDCAAS) of at least 60%. Examples of such proteins include, without limitation, soybean protein, which typically has a PDCAAS of about 90% to about 100%, pea protein, which typically has a PDCAAS of at least 60%, chickpea protein, which typically has a PDCAAS of at least 70%, quinoa protein, which typically has a PDCAASof at least 60%, and rapeseed protein, which typically has a PDCAAS of at least 80%. PDCAAS of a protein is calculated according to the Food and Agriculture Organization of the United Nations (Joint FAO / WHO Expert Consultation (1990), Protein Quality Evaluation. Report of a Joint FAO / WO Expert Consultation held in Bethesda, MD, USA, 4-8 December 1989. Food and Agriculture Organization, Rome. Section 8. ISBN 92-5- 103097-9).

[0027] In some embodiments, a plant-based protein ingredient comprises a legume protein (e.g., soybean protein, pea protein, chickpea protein, fava bean protein, lentil protein, and the like). In some embodiments, a plant-based protein ingredient can include protein from a non-legume plant source, such as wheat, rice, com, canola, and the like.

[0028] In some embodiments, a plant-based protein ingredient can have a protein content of at least 60% (e.g., at least 65%) by dry weight of the protein ingredient. In some embodiments, a plant-based protein ingredient can have a protein content that consists of soybean protein, pea protein, canola protein, chickpea protein, fava bean protein, or any combination thereof. A plant-based protein ingredient can comprise, for example, legume flours (e.g., soybean flour or the like), protein concentrates (e.g., soybean protein concentrate, pea protein concentrate, fava bean protein concentrate, canola protein concentrate, chickpea protein concentrate, or the like), protein isolates (e.g., soybean protein isolate, pea protein isolate, chickpea protein isolate, or the like), and the like, or any combination thereof.

[0029] A protein ingredient having at least a portion of the protein content comprising a legume protein can contribute to a texture that closely resembles a traditional grain-based RTE cereal. In contrast, a similarly formulated food piece that includes wheat protein and no legume protein can result in a texture that is harder, more brittle, grittier, and / or glassier than a food piece described herein. A protein ingredient having at least a portion of the protein content comprising a legume protein can contribute to an internal cell structure that exhibits relatively uniform cells (Figure 6 and Example 2) compared to a similarly- formulated product that includes wheat protein and no legume protein (Figure 7 and Example 2).

[0030] A plant-based protein ingredient can contribute protein in an amount of about 18% to about 36% (e.g., about 25% to about 35%) by dry weight of the food piece. In some embodiments a plant-based protein ingredient can be selected to arrive at a total protein content that delivers high quality protein in an amount of at least 10% (e.g., at least 11%, or about 11% to about 15%) by dry weight of a food piece. As used herein, the amount of high quality protein in a food piece can be calculated by multiplying the amount of protein contributed by a protein ingredient by the PDCAAS score. For example, if a protein ingredient contributes a protein content of 20% by weight to a food piece, and the PDCAAS value is 60%, then the amount of high quality protein is about 12% (0.2 x 0.6 = 0.12, or 12%). Total protein in a food piece provided herein ranges from about 28% to about 40% (e.g., about 28% to about 38%, or about 28% to about 36%) by dry weight of the food piece, and includes protein content combined from all of the included ingredients (e.g., protein ingredient and grain flour).

[0031] Although a combination of a grain flour and a plant-based protein ingredient can provide a high protein content that some consumers prefer, the combination was found to be difficult to puff to a desired density and texture resembling a traditional grain-based RTE cereal. It was discovered that including a low dextrose equivalent (DE) carbohydrate (e.g., a DE of less than 20, DE of 18 or less, DE of 16 or less, DE of 11 or less, or DE 1 to about 10) in an amount of about 10% to about 35% (e.g., about 12% to about 28%, or about 14% to about 27%) by dry weight of a food piece resulted in the food piece having not only had a desired low density, but a texture and shape that closely resembled traditional grain-based RTE cereals. That is, a food piece provided herein could be made to resemble traditional puffed grain-based RTE cereals, such as a round puff, a rounded “o” shape, a puffed square, and the like, rather than being limited to formats more generally available in high protein RTE cereals (e.g., nuggets, twigs, flakes, and the like). A suitable low DE carbohydrate can include, for example, maltodextrin or a soluble fiber having an average DE of from 1 to 10 (e.g., 1 to about 9, or 1 to about 6). Surprisingly, although starch typically contributes to puffing in traditional low-density grain-based RTE cereals, isolated / extracted starch ingredient could not replace low DE carbohydrate and, when included with insufficient low DE carbohydrate (e.g., less than 10%), resulted in poor puffing, irregular shapes, and / or sharp edges rather than the preferred rounded edges.

[0032] Density can be adjusted by adjusting the ratios of grain flour, plant-based protein ingredient, and low DE carbohydrate relative to each other. It was observed that density of food pieces generally decreased as carbohydrate DE was decreased. It was also observed that density generally decreased as low DE carbohydrate content was increased in food pieces. Density of food pieces also generally increased as protein ingredient content increased. In some embodiments, the amount of protein ingredient included in a food piece can be adjusted to be included in an amount of about 50% to about 90% (e.g., about 60% to about 85%) by weight relative to the amount of grain flour that is included in the food piece to achieve a preferred density. That is, for every 100 g of grain flour included in formulation for a food piece provided herein, about 50 g to about 90 g of protein ingredient can be included in the formulation.

[0033] Grain flour, plant-based protein ingredient, and low DE carbohydrate comprise at least 80% (e.g., at least 90%) by dry weight of food pieces provided herein. Additional other ingredients can optionally be included in a combined amount of up to 20% (e.g., up to 18%, less than 10%, or up to 7%) by dry weight of a food piece. For example, a sweetener (e.g., sugar, sugar alcohol, high potency sweetener, or the like) can be included to contribute to flavor / sweetness and / or structure or texture; colorants and / or flavorants (e.g., salt, vanilla, cocoa, cinnamon, natural and / or artificial coloring, or the like) to provide a desired appearance or flavor; oil (e.g., canola oil, com oil, olive oil, soy oil, sunflower oil, and the like, or any combination thereof) to provide texture and flavor benefits; animal -derived protein ingredients (e.g., casein or caseinate, whey protein, milk powder, egg, and the like) to provide flavor, texture, and / or nutritional benefits; starch (e.g., corn starch, potato starch, tapioca starch, and the like); and / or minors, such as vitamins, minerals, calcium carbonate, processing aids, and the like.

[0034] Food pieces provided herein typically have a moisture content of 5% or less (e.g., about 1% to about 4%, or about 2% to about 3.5%) by weight.

[0035] In addition to a texture very similar to traditional grain-based RTE cereals, the described puffed food pieces can be made to closely visually resemble traditional grainbased RTE cereals, with rounded appearance rather than sharp edges from cutting or irregular shapes due to irregular expansion. Example 1 and Figures 1 and 2 show examplesof puffed food pieces made according to the formulations described herein in sphereshaped puffs, o-shaped puffs, and puffed squares. Such food pieces have rounded surfaces and uniform expansion. In contrast, food pieces made with ingredients outside the described ranges can exhibit poor puffing, sharp edges, and / or irregular puffing. See, e.g., Formulations 3-5 in Example 1 and Figures 3-5).

[0036] In some embodiments, a food piece provided herein can have a coating on at least a portion of a surface of the food piece. For example, a sugar-based, sugar alcohol-based, or fat-based coating can be applied on at least a surface of a food piece to modify the taste, texture, bowl life (e.g., in a bowl of milk), nutritional profile, and / or appearance of the food piece. In another example, a food piece can be sprayed with oil and a dry seasoning (e.g., cinnamon, sugar, chili, oregano, cocoa powder, or the like, or any combination thereof) can be dusted onto the surface.

[0037] Also provided herein are compositions comprising a plurality of food pieces provided herein. In some embodiments, a composition can contain edible components other than the food pieces provided herein. For example, a composition can comprise dried fruit, nuts, confectionery pieces, other grain-based pieces, protein-based pieces, or the like. In some embodiments, a composition can comprise coated food pieces provided herein. A composition comprising coated food pieces can contain pieces that are partially or entirely coated and, in some cases, uncoated pieces as well as coated pieces. A coating in a composition of coated food pieces provided herein can typically comprise about 10% to about 50% (e.g., about 30% to about 50%) by weight of the composition.

[0038] Methods of making food pieces are also provided. Generally, food pieces are produced by combining ingredients under extrusion conditions to form a dough. As used herein, the term “extrusion conditions” refers to subjecting a composition to heat, pressure, and shear in an extruder (e.g., single screw extruder, twin screw extruder, triple screw extruder, ring extruder, or the like). For example, a co-rotating, intermeshing, twin screw extruder can be used in a method provided herein. Manufacturers for co-rotating twin screw extruders include, for example, Coperion, Wenger, Clextral, Berstorff, APV, Baker Perkins, Buhler, and Leistritz.

[0039] In some embodiments, food pieces provided herein can be extruded in a twin screw extruder with a barrel temperature of at least 180° F (e.g., about 220° F to about 350° F). As used herein, the term “barrel temperature” refers to the maximum temperature of a heated barrel of an extruder. In some embodiments, extrusion conditions can comprise a specific mechanical energy (SME) of about 60 to about 150 Wh / kg. In some embodiments, extrusion conditions can comprise a die pressure of about 720 to about 2200 (e.g., about 1000 to about 1500) psi.

[0040] A dough is typically made in a continuous fashion by feeding ingredients into an extruder during an extrusion process. In some embodiments, dry ingredients can be combined to produce a dry mix prior to being combined with water or other aqueous ingredients and, optionally, oil to produce a composition suitable for extrusion. In some embodiments, dry ingredients and a portion of water can be combined in a preconditioner prior to being fed into an extruder.

[0041] The dough generally contains the ingredients described above with regard to the food pieces. That is, the dough consists of a grain flour in an amount of about 30% to about 55% by dry weight of the dough, a plant-based protein ingredient in an amount of about 30% to about 40% by dry weight of the dough, a low DE carbohydrate in an amount of about 10% to about 35% by dry weight of the dough, and optionally other ingredient in a combined amount of up to 20% by dry weight of the dough.

[0042] A dough produced in a method provided herein includes a moisture content of from about 8% to about 20% (e.g., about 12% to about 18%) by weight of the composition.

[0043] The dough can then be extruded from an extrusion die to form dough pieces. In some embodiments, the dough can puff directly upon extrusion from the extrusion die and portioned (e.g., cut) to form puffed dough pieces, and the puffed dough pieces can be dried to a final density of 80 to 200 (e.g., 110 to 200) g per 100 cubic inches. However, in some embodiments, the dough can be indirectly puffed and dried after the dough pieces are formed (e.g., using a fluid bed drier or a puffing gun) to achieve the desired final density and moisture content.

[0044] In some embodiments, food pieces provided herein can have average diameter of from about 8 mm to about 20 mm (e.g., from about 10 mm to about 15 mm). However, the size of a food piece can be adjusted for the desired use of the food piece or to provide a manufacturing advantage. For example, the size of a food piece can be adjusted to provide a desired size for eating as a stand-alone RTE breakfast cereal or snack, or for use as a component in a snack bar or snack mix. In another example, the size of a food piece can be adjusted to result in a desired drying time during manufacturing. Piece size can be adjusted using known methods, such as die opening size and / or die opening shape selection, rate of extrusion, and / or cutter speed. For example, cutter speed can be reduced to form elongated puffed pieces, such as pieces resembling churros or snack straws or sticks.

[0045] In some embodiments, a food piece can be dried to a moisture content of less than 8% (e.g., about 1% to about 7%, less than 6%, or about 2% to about 4%) to produce dried food pieces. Drying can be performed using any suitable method and equipment, such as a belt dryer.

[0046] In some embodiments, food pieces provided herein can be packaged and sold as a food product without any other components. Such packaged food pieces can be intended to be eaten as a food product alone or in combination with other food products. For example, food pieces can be packaged and sold as a stand-alone snack, alone or as part of a RTE breakfast cereal. In some embodiments, a food piece can be adhered with one or more edible components, such as another food piece, nut pieces, fresh or dried fruit pieces, seeds, coconut, grain, and the like, to form a cluster or bar. A food piece and one or more edible components can be adhered to each other using any appropriate method and ingredients (e.g., edible binders and the like). For example, a cluster can be produced using a combination of a food piece and rolled oats adhered using a honey-based binder or slurry. Clusters can be provided as a food product alone or as part of a food product, such as a snack mix, ready to eat cereal, or oatmeal mix.

[0047] It is to be understood that food pieces provided herein can be used for either sweet or savory applications in food. Food pieces disclosed herein can provide a benefit of being a high protein stand-alone food product or provide added protein in combinationwith other components in food products while also providing an improved texture and flavor over other known high protein pieces.EXAMPLESExample 1

[0048] Samples were prepared according to Table 1. Minors included salt, calcium carbonate, vitamins, soluble corn fiber, sugar, flavor, and tripotassium phosphate. The formulations were extruded on a twin screw extruder, to make a dough with a moisture content of about 12% to about 20%, and puffs were made by direct expansion of the dough from the extruder. The moisture of the puffs directly from the extruder (prior to further drying or processing) was about 6% to about 8%. Conditions included a screw speed of about 220 rpm, a barrel temperature of about 250° F, a specific mechanical energy of about 95-110 Wh / kg, and a die pressure of about 1300-2000 psi. Formulation 1 was formed into both sphere-shaped puffs and square-shaped puffs, producing uniform, regular, rounded pieces. Formulation 2 was formed into “o”-shaped puffs, which were also uniform, regular, and consistently rounded on the surfaces. Formulations 1 and 2 had acceptable flavor and texture with a pleasant, clean taste, a crunchy / crispy texture with little to no toothpacking, with Formulation 2 having a softer texture than Formulation 1. Formulations 1 and 2 closely resembled traditional grain-based RTE cereal in appearance and eating experience. Formulation 3 included a higher grain content, lower protein content, and lower low DE carbohydrate content than inventive food pieces described herein. Formulation 3 produced product with a higher density and a grittier texture than typically associated with traditional grain-based RTE cereals. Formulation 3 also had a slightly salty taste. Formulation 4 included a grain flour content and protein content intermediate between Formulation 3 and inventive food pieces described herein, and even lower low DE carbohydrate content than Formulation 3. Formulation 4 had much higher density and a harder, grittier, and sandier texture than typically associated with traditional grain-based RTE cereals. Formulation 4 also had earthy flavor attributes. In addition, pieces made with formulation 4 exhibited sharp edges rather than the rounded appearance of pieces made from Formulations 1 and 2. Formulation 5 included a grain flour content and maltodextrin content that was similar to inventive food pieces described herein, but aprotein content that was higher than inventive food pieces described herein. Formulation 5 had much higher density and a crunchier texture than typically associated with traditional grain-based RTE cereals. Formulation 5 also exhibited bitterness and astringency.Table 1Example 2

[0049] Samples from Formulation 1 (Table 1) were compared to a commercially available RTE breakfast cereal containing, including a sugar-based coating, 51% grain ingredient (wheat flour, oatmeal flour, maize flour), sugar, wheat protein, maltodextrin, molasses, oat fiber, acacia gum, salt, barley malt extract, and minors (minerals, raising agent, natural flavors, natural colors, and vitamins). No legume protein was included in the commercially available RTE breakfast cereal. The commercially available RTE breakfast cereal had a bulk density of about 262 g / 100 cubic inches. It was estimated that the coating of the commercially available RTE breakfast cereal comprised about 24% by weight of the product (as sugar content), resulting in an uncoated piece estimated to have a total protein content of about 29% (20-24% from wheat protein ingredient), about 67% grain flour, and maltodextrin at less than 7%. See, Table 2. Formulation 1, in contrast, contained significantly less grain flour (40-46% in Formulation 1 vs about 67% in the uncoatedcommercially available product), a similar protein content from a plant-based protein ingredient (20-30% in Formulation 1 vs about 20-24% in the uncoated commercially available product), though the commercially available product included wheat protein and no legume protein, and a maltodextrin content that was significantly higher (14-18% in Formulation 1 vs less than 7% in the uncoated commercially available product).Table 2

[0050] The commercially available product had a harder, glassier, grittier texture than Formulation 1 that had been coated with a sugar-based coating. In addition, the internal cell structure of both the square-shaped and sphere-shaped puffs of Formulation 1 and the commercially available product were compared. The commercially available product had 2 holes that appeared to be intentionally-included in the structure (see, Figure 7, circled inred), which were excluded from analysis. Samples of each of the two Formulation 1 puffs and the commercially available product were cross-sectioned with a razor blade to expose an internal section perpendicular to the extrusion direction and glued to an aluminum stub, keeping the surfaced exposed by the cross section facing upward for imaging. Once the glue solidified, the samples were imaged with a scanning electron microscope. To capture the entire sectional view of the internal structure, a tiled scan with a total of more than 100 images were collected for each section at a magnification of 200X. Overall morphology of Formulation 1 appeared to have a more uniform cell structure than the commercially available product. See, Figure 6.

[0051] A deep learning model was trained to recognize individual cells within the cell structure of the cross-sectioned pieces. Cell size was calculated as a base 10 logarithm based on the number of pixels included in the area of each identified cell within the images. Cell size analysis showed that the mean cell size in the commercially available product was 2.14 (approximately 582 pm2) with a standard deviation of 0.59. Many of the cells in the commercially available product appeared to merge together to form very large, irregular cells, while others were very small. In contrast, the cell structure of both the square-shaped and sphere-shaped pieces of Formulation 1 appeared to be larger and more uniform, with a mean cell size of 2.80 (approximately 966 pm2) ± 0.49 (SD) and 2.67 (approximately 1576 pm2) ± 0.40 (SD) for the sphere- and square-shaped pieces, respectively.Example 3

[0052] Samples were prepared according to Table 3 to compare the use of a low DE carbohydrate to starch. Minors included salt, calcium carbonate, vitamins, soluble com fiber, sugar, flavor, and tripotassium phosphate. The formulations were extruded on a twin screw extruder, to make a dough with a moisture content of about 12% to about 20%, and puffs were made by direct expansion of the dough from the extruder. The moisture of the puffs directly from the extruder (prior to further drying or processing) was about 6% to about 8%. Conditions included a screw speed of about 220 rpm, a barrel temperature of about 250° F, a specific mechanical energy of about 95-140 Wh / kg, and a die pressure of about 1300-2000 psi. Formulation 6 was similar to Formulation 1 in Table 1, andproduced uniform, regular, rounded pieces. The maltodextrin used had a DE of 1; the pea protein ingredient was approximately 80% protein by dry weight. Formulation 7 was the same as Formula 6, except that about half of the maltodextrin was replaced with com starch. Formulation 7 could produce pieces having a desired target density, but had undesirably sharp edges rather than the round appearance of Formulation 6. Formulations 8-11 contained no maltodextrin and up to 20% com starch. Formulations 8-11 failed to achieve a density of less than 200 g / 100 cubic inches, with Formulations 8 and 9 also forming irregular pieces, and Formulations 10 and 11 exhibiting sharp edges rather than a rounded shape. Formulation 12 contained no maltodextrin and 25% corn starch. Formulation 12 could produce pieces having a desired target density, but had undesirably sharp edges rather than the round appearance of Formulation 6.Table 3

[0053] The implementations described above and other implementations are within the scope of the following claims. One skilled in the art will appreciate that the present disclosure can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation.

Claims

What is claimed is:

1. A composition comprising a plurality of food pieces, the food pieces consisting of: a. a grain flour in an amount of about 30% to about 55% by dry weight of the food pieces; b. a plant-based protein ingredient in an amount of about 28% to about 40% by dry weight of the food pieces, comprising pea protein, fava bean protein, chickpea protein, canola protein, or soybean protein, the protein ingredient having a protein content of at least 60% protein by dry weight of the protein ingredient; c. maltodextrin in an amount of 10% to about 35% by dry weight of the food pieces, the maltodextrin having a DE of from 1 to about 10; d. other ingredients, the combined other ingredients included in an amount of up to 20% by dry weight of the food pieces; and e. a moisture content of up to 5% by weight of the food pieces, wherein the food pieces have a bulk density range of from 110 to 200 grams per 100 cubic inches.

2. The composition of claim 1, wherein at least a portion of the grain flour is a whole grain flour.

3. The composition of claim 1 or 2, wherein the grain flour comprises oat flour or com flour.

4. The composition of any one of claims 1-3, wherein the plant-based protein ingredient is included in an amount of about 50% to about 72% relative to the amount of grain flour.

5. The composition of any one of claims 1-4, wherein the plant-based protein ingredient contributes protein in an amount of about 22% to about 36% by dry weight of the food pieces, the protein comprising soybean or pea protein.

6. The composition of any of claims 1-5, wherein the food pieces have a total protein content of about 28% to about 38% by dry weight of the food pieces.

7. The composition of any one of claims 1-6, wherein the maltodextrin is included in an amount of about 12% to about 27% by dry weight of the food pieces.

8. The composition of any one of claims 1-7, wherein the food pieces consist of: a. the grain flour in an amount of about 30% to about 50% by dry weight of the food pieces, the grain flour comprising oat flour or com flour; b. the plant-based protein ingredient contributing protein in an amount of about 22% to about 35% by dry weight of the food pieces, the protein comprising soybean or pea protein, wherein the food pieces have a total protein content of about 30% to about 38% by dry weight of the food pieces; c. the maltodextrin in an amount of about 14% to about 25% by dry weight of the food pieces; d. the other ingredients in an amount of less than 10% by dry weight of the food pieces.

9. A composition, comprising a plurality of coated food pieces, the coated food pieces comprising: a. the plurality of food pieces according to any one of claims 1-8; and b. a coating on at least a portion of a surface of at least a portion of the food pieces.

10. The composition of claim 9, wherein the coating comprises about 10% to about 50% by weight of the coated food pieces.

11. The composition of claim 10, wherein the coated food pieces have a bulk density of about 150 to about 300 grams per 100 cubic inches.

12. The composition, comprising a plurality of food pieces according to any one of claims 1-8, and edible components other than the food pieces.

13. A method of making a plurality of food pieces, comprising: a. combining under extrusion conditions ingredients to form a dough having a moisture content of about 12% to about 18%, the ingredients consisting of: i. a grain flour in an amount of about 30% to about 55% by dry weight of the dough; ii. a plant-based protein ingredient, comprising pea protein, fava bean protein, soybean protein, canola protein, or chickpea protein, the protein ingredient included in an amount of about 30% to about40% by dry weight of the dough and having a protein content of at least 60% protein by dry weight of the protein ingredient; iii. maltodextrin in an amount of about 10% to about 35% by dry weight of the dough, the maltodextrin having a DE of 1 to about 10; iv. water; and v. other ingredients, the combined other ingredients included in an amount of up to 20% by dry weight of the dough; b. forming the dough from an extrusion die to form dough pieces; c. puffing and drying the dough pieces to form a plurality of food pieces having a bulk density of 110 to 200 grams per 100 cubic inches and a moisture content of 5% or less by weight to form the plurality of food pieces.

14. The method of claim 13, wherein the puffing is performed by direct expansion during the forming step.