Flavoured corn and rice puffs and production method thereof

Abstract

The invention relates to flavoured corn and rice puffs and the production method thereof. While producing puffed corn and rice, which is the subject of the invention, the flavouring process is carried out before the puffing process and the sugar percentages that cannot be used before the puffing process are ensured to be usable in the recipe. In the method that is the subject of the invention, there are pre-cooking and drying process steps that require heat treatment before annealing and puffing process steps, thus, all the problems encountered during the production, and which will negatively affect the product quality are eliminated and the aroma is delivered to every part of the product.

Description

[0001] FLAVOURED CORN AND RICE PUFFS AND PRODUCTION METHOD THEREOF

[0002] Technical Field of the Invention

[0003] The invention relates to flavoured com and rice puffs and the production method thereof. While producing puffed com and rice, which is the subject of the invention, the flavouring process is carried out before the puffing process and the sugar percentages that cannot be used before the puffing process are ensured to be usable in the recipe. In the method that is the subject of the invention, there are pre-cooking and drying process steps that require heat treatment before annealing and puffing process steps, thus, all the problems encountered during the production, and which will negatively affect the product quality are eliminated and the aroma is delivered to every part of the product.

[0004] State of the Art

[0005] Today, there is a great demand for foods produced from puffed com and rice. The reason for this is that puffed com and rice are a quality source of carbohydrates and are quite high in terms of nutritional value. The production of these foods, which have high nutritional values and high taste, is not as easy as it seems. In particular, they need to go through extra tough processes to be aromatised.

[0006] In the state of the art, in the production of flavoured puffed com and rice, maize and rice grains, which are first annealed with a certain amount of water, are puffed under high temperature for short periods of time. With the high temperature, the moisture in the grain is evaporated and thus the structure of the endosperm in the grain changes and starch gelatinisation is carried out. The flavouring process of the com and rice puffs obtained is carried out after the aforementioned processes. The reason for this is that the inputs such as flavour and sugar to be added to the annealing water during annealing cause aroma loss during puffing. In addition, with the use of sugar- containing inputs during the annealing process, a sticking problem is encountered in the puffing chambers, which adversely affects the whole process.

[0007] In the state of the art, the flavouring process of puffed com and rice after the puffing process is carried out by flavouring in powder form after the puffing process or by coating the solution prepared with oil-soluble powder flavourings on the surface of the com and rice puffs. The flavouring rate in the powder flavouring process varies between 5-10%. In addition, in both flavouring processes, flavouring is limited to the surface areas of com and rice puffs.

[0008] The mentioned rates are limited to a certain amount so that the application rates of sugar and sugar-containing flavourings used as inputs do not adversely affect the product quality in the methods available in the state of the art for flavouring puffed com and rice. For this reason, the desired amount of sugar and sugar-containing flavouring cannot be used in the production of com and rice puffs.

[0009] The method of flavouring puffed com and rice in the state of the art includes annealing, puffing and flavouring processes to be applied sequentially. The pre-cooking process, which is a very important process step in terms of enriching the aroma and is performed before the annealing and puffing process steps, is not encountered in the state of the art.

[0010] The annealing process step in the methods in the state of the art for flavouring puffed com and rice can be carried out in a long period of time such as 4 hours. Considered in terms of efficiency, this situation causes a great energy and efficiency problem in industrial applications.

[0011] The flavouring process mentioned in the production of flavoured puffed com and rice in the state of the art is restricted such that it can be performed after the annealing and puffing process steps in order not to affect the product quality. Otherwise, inputs such as flavour and sugar to be added to the annealing water during annealing cause loss of aroma during puffing, and especially when sugar-containing inputs are used during the annealing process, a sticking problem occurs in the puffing chambers, which negatively affects the whole process. In the flavouring methods of puffed com and rice after the annealing and puffing process steps, said flavouring process is limited to the surface areas of the puffed com and rice and therefore the flavour quality is adversely affected. In addition, the aforementioned rates are limited to a certain amount so that the application rates of sugar and sugar-containing flavourings used as inputs in the methods in the state of the art do not adversely affect the product quality. In addition, it is not possible to come across the pre-cooking process, which is a very important process step in terms of enriching the aroma and is performed before the annealing and puffing process steps in the flavouring methods in the state of the art. The annealing process step in the methods in the state of the art for flavouring com and rice puffs takes place in a long period of time lasting up to 4 hours and in this case, it causes a yield problem.

[0012] Due to the limitations and inadequacies of the solutions in the state of the art, and the facts that the flavouring process of com and rice puffs in the state of the art can only be carried out after the annealing and puffing process steps in order not to affect the product quality, otherwise, the inputs such as flavour and sugar to be added to the annealing water cause loss of aroma at the time of puffing and the adhesion problem appears in the puffing chambers, which adversely affects the whole process, the aforementioned flavouring methods are limited to the surface areas of the com and rice puffs in the flavouring methods of com and rice puffs performed after the annealing and puffing process steps, the pre-cooking process, which is a very important process step in terms of enriching the aroma and is performed before the annealing and puffing process steps in the flavouring methods in the state of the art is absent, the aforementioned rates are limited to a certain amount such that the application rates of sugar and sugar-containing flavours used as inputs in the methods in the state of the art do not adversely affect the product quality, and the annealing process step in the methods in the state of the art for flavouring com and rice puffs is carried out in a long period of time lasting up to 4 hours causing efficiency problems, it has been necessary to develop flavoured com and rice puffs and the production method thereof in which the flavouring process is carried out before the puffing process while producing puffed corn and rice, and for this reason, the sugar and flavours that cannot be used before the puffing process are used in the product recipe without causing any decrease in product quality, the sticking problem in the puffing chambers caused by flavouring inputs is eliminated, the flavouring is not limited to the surface areas of com and rice puffs, the pre-cooking process step, which is a very important process step in terms of enriching the flavour, is applied, the application rates of sugar and sugar-containing flavours used as inputs are not limited to a certain amount, and the implementation time of the annealing process step in the flavoured puffed com and rice production methods is shortened.

[0013] Brief Description and Aims of the Invention

[0014] The invention describes flavoured com and rice puffs and the production methods thereof. While producing puffed com and rice, which is the subject of the invention, the flavouring process is carried out before the puffing process and the sugar percentages that cannot be used before the puffing process are ensured to be usable in the recipe. In the method that is the subject of the invention, there are pre-cooking and drying process steps that require heat treatment before annealing and puffing process steps, thus, all the problems encountered during the production, and which will negatively affect the product quality are eliminated and the aroma is delivered to every part of the product.

[0015] An aim of the invention is to ensure that the aforementioned flavouring process step in flavoured com and rice puffs can be carried out before the annealing and puffing processes in order not to cause a sticking problem and loss of aroma in the puffing chambers. In the present invention, flavouring can be carried out before the annealing and puffing processes, together with the pre-cooking and drying process steps that take place before the annealing and puffing process steps in the method that is the subject of the invention. Another aim of the invention is to enable the flavouring of corn and rice puffs to be carried out without being limited to the surface areas of the com and rice puffs. The flavouring of com and rice puffs without being limited to their surface area is provided with the pre-cooking and drying process steps that take place before the annealing and puffing process steps in the method mentioned in the present invention.

[0016] With the invention, the ratio of sugar and sugar inputs used in flavouring com and rice puffs is increased to 15-20% by mass compared to the final product. Increasing the ratio of sugar and sugar inputs used in flavouring com and rice puffs up to 15-20% by mass compared to the final product is achieved by the flavoured com and rice puff production method, which is the subject of the invention.

[0017] Another aim of the invention is to increase the productivity in the production of flavoured com and rice puffs. Increasing the productivity in flavoured com and rice puffs production methods is achieved by performing the annealing process step in a short time such as 1 hour in the flavoured puffed com and rice production method, which is the subject of the invention.

[0018] With the invention, com and rice puffs with different texture and flavour development are obtained. Obtaining flavoured com and rice puffs with different textures is provided with the aroma development caused by the Maillard reaction provided by the precooking process step in the flavoured puffed com and rice production method, which is the subject of the invention.

[0019] Detailed Description of the Invention

[0020] The invention relates to flavoured com and rice puffs and the production method thereof. While producing puffed com and rice, which is the subject of the invention, the flavouring process is carried out before the puffing process and the sugar percentages that cannot be used before the puffing process are ensured to be usable in the recipe. In the method that is the subject of the invention, there are pre-cooking and drying process steps that require heat treatment before annealing and puffing process steps, thus, all the problems encountered during the production, and which will negatively affect the product quality are eliminated and the aroma is delivered to every part of the product.

[0021] Production method of flavoured corn and rice puffs, which is the subject of the invention, comprises the process steps of:

[0022] I. entering the sugar input to be 15-20% by mass compared to the final product in line with the type of corn and rice grains to be used in the annealing water, and cooking the resulting mixture at 90-100°C for 30-40 minutes, thus completing the first heat treatment step,

[0023] II. drying the grain mixture, the cooking process of which has been completed, at 100-120°C for 40-60 minutes, thus completing the second heat treatment step,

[0024] III. applying the annealing process at 25-30°C to the dried mixture obtained as a result of the second process step with the adjustment of the amount of water to be added in line with the type of grain used,

[0025] IV. obtaining the final product, flavored com and rice puffs, as a result of applying the puffing process step to the annealed mixture.

[0026] The first heat treatment step and the second heat treatment steps, which are mentioned in the I. and II. process steps and require heat treatment, are the precooking and drying process steps, respectively, and are performed before the annealing and puffing process steps in the method that is the subject of the invention. By performing the pre-cooking and drying process steps before the annealing and puffing process steps in the method that is the subject of the invention, it is ensured that the aromatisation of puffed corn and rice is not limited to the surface areas of the com and rice puffs. In addition, by performing the pre-cooking and drying process steps before the annealing and puffing process steps in the method of the invention, the sticking problem is prevented and the aroma loss to be experienced is prevented. In addition, with the method that is the subject of the invention, the ratios of sugar and sugar inputs used in the flavouring of com and rice puffs are increased up to 15-20% by mass compared to the final product.

[0027] Obtaining flavoured com and rice puffs with different textures is provided with the aroma development caused by the Maillard reaction provided by the pre-cooking process step in the flavoured puffed com and rice production method, which is the subject of the invention. The aroma development caused by the Maillard reaction provided by the pre-cooking process step occurs as a result of the changes in the structure of amylose and amylopectin, especially due to starch gelatinisation. In addition, aroma components consisting of phenolic components, which are formed with the cooking of cereals, contribute to the aforementioned aroma development and to obtain com and rice puffs with different texture structures. As a result of all these, nitrogenous polymeric components are formed with the effect of sugar in the environment during the explosion process.

[0028] An analysis of the textures of the flavoured com and rice puffs produced by the method according to the invention, compared to of those produced by the methods mentioned in the state of the art, was carried out.

[0029] Table 1. The results of the analysis of the textures of the flavoured com and rice puffs produced by the method according to the invention, compared to of those produced by the methods mentioned in the state of the art. As a result of the fracture hardness analyses made, it was understood that the flavoured com and rice puffs obtained by the method that is the subject of the invention were sensorially weaker and softer than the flavoured com and rice puffs produced by the aforementioned methods in the state of the art. The fracture hardness of flavoured com and rice puffs produced by methods mentioned in the state of the art is higher than those obtained by the method of the invention, and for this reason, com and rice puffs in the state of the art have a denser and harder structure in sensory sense compared to flavoured com and rice puffs obtained by the method of the invention. Table 2. The results of the comparison of the process parameters in the method of the invention with the process parameters related to the production method of flavoured rice and com puffs in the state of the art.

[0030] Considering that the annealing process step in the methods in the state of the art for flavouring com and rice puffs takes place in a long time period lasting up to 4 hours, and this situation causes a big yield problem when considered industrially, a substantial yield problem is avoided by carrying out the annealing process step in the flavoured puffed com and rice production method that is the subject of the invention in as little as 1 hour. In addition, unlike the method for flavouring com and rice puffs in the state of the art, all reaction temperatures applied until the final product is obtained in the flavoured puffed corn and rice production method that is the subject of the invention are lower. With the method performed at lower temperatures, energy losses are prevented.

[0031] In another embodiment of the invention, the production method of flavoured com and rice puffs that is the subject of the invention com and rice puffs, which is the subject of the invention, comprises the process steps of: i. entering the sugar input to be 15-20% by mass compared to the final product in line with the type of com and rice grains to be used in the annealing water, and cooking the resulting mixture at 90-100°C for 30 minutes, thus completing the first heat treatment step, ii. drying the grain mixture, the cooking process of which has been completed, at 100°C for 1 hour, thus completing the second heat treatment step, iii. applying the annealing process at 25-30°C to the dried mixture obtained as a result of the second process step with the adjustment of the amount of water to be added in line with the type of grain used, iv. obtaining the final product, flavored com and rice puffs, as a result of applying the puffing process step to the annealed mixture.

Claims

CLAIMS1. Production method of flavoured com and rice puffs, comprising the process steps of:I. entering the sugar input to be 15-20% by mass compared to the final product in line with the type of com and rice grains to be used in the annealing water, and cooking the resulting mixture at 90-100°C for 30- 40 minutes, thus completing the first heat treatment step,II. drying the grain mixture, the cooking process of which has been completed, at 100-120°C for 40-60 minutes, thus completing the second heat treatment step,III. applying the annealing process at 25-30°C to the dried mixture obtained as a result of the second process step with the adjustment of the amount of water to be added in line with the type of grain used,IV. obtaining the final product, flavored com, and rice puffs, as a result of applying the puffing process step to the annealed mixture.

2. A method according to claim 1 , comprising the steps of: i. entering the sugar input to be 15-20% by mass compared to the final product in line with the type of com and rice grains to be used in the annealing water, and cooking the resulting mixture at 90-100°C for 30 minutes, thus completing the first heat treatment step, ii. drying the grain mixture, the cooking process of which has been completed, at 100°C for 1 hour, thus completing the second heat treatment step, iii. applying the annealing process at 25-30°C to the dried mixture obtained as a result of the second process step with the adjustment of the amount of water to be added in line with the type of grain used, iv. obtaining the final product, flavored com, and rice puffs, as a result of applying the puffing process step to the annealed mixture.

3. Flavoured com and rice puffs produced with the method of Claim 1 or 2, wherein fracture hardness is 800-950 g.F.Flavoured corn and rice puffs, comprising 15-20% sugar by mass compared to the final product. Flavoured com and rice puffs according to Claim 4, wherein fracture hardness is 800-950 g.F.

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