Method for preparing multi-layer noodles having coarse grain as middle layer

Abstract

A method for preparing multi-layer noodles having a coarse grain as a middle layer, comprising the following steps: respectively adding water into coarse grain flour and wheat flour and performing kneading to form coarse grain dough and white dough; respectively rolling the coarse grain dough and the white dough into coarse grain dough sheets and white dough sheets by means of a pair of sheet pressing rollers; enabling the coarse grain dough sheets to undergo steam spraying treatment, the temperature of steam being 95-120°C, and the time for the steam spraying treatment is 10-110 s; alternately laying the white dough sheets and the coarse grain dough sheets that have undergone the steam spraying treatment and performing rolling to form a layered dough sheet, wherein the white dough sheets are used as an upper surface layer and a lower surface layer of the layered dough sheet; and cutting the layered dough sheet into layered noodles. The layered noodles are chewy and slightly soft on the inside, and have balanced nutrition and rich taste.

Description

The present invention pertains to the field of pasta products, specifically disclosing a multi-layered noodle production method utilizing coarse grain dough sheets as intermediate layers and wheat-based dough sheets as upper / lower surface layers. The laminated structure is then cut into layered noodles. The resultant noodles demonstrate initial textural firmness upon mastication with internal tenderness, delivering balanced nutritional composition and multidimensional mouthfeel characteristics. BACKGROUND With the increasing demand for healthy diets, coarse grains have gradually gained attention and their importance has been elevated. Although coarse grains can complement the nutritional components of refined grains, their textural properties are relatively inferior compared to refined grains. Noodles are a common staple food in China. However, coarse grains generally exhibit low starch content, resulting in noodles with insufficient viscosity during processing that become friable and prone to disintegration. Conventional noodles are typically made from wheat flour or by incorporating limited amounts of coarse grain flour, mixed with water or fruit / vegetable juices to form dough. Nevertheless, their textural firmness remains inferior to pure wheat-based noodles. Moreover, noodles containing coarse grain flour demonstrate poor cooking resistance and low soak tolerance. Cooked products require immediate consumption to avoid moisture absorption-induced swelling and structural fracture. Millet, being nutritionally dense, is conventionally used for porridge or ground into flour for steamed cakes. Commercially available noodles made from millet flour are virtually absent in the market. The development of millet flour-based noodles while maintaining desirable textural firmness presents a technical challenge requiring further research in this field. SUMMARY To address the aforementioned technical deficiencies in prior art, the present invention provides a multi-layered noodle production method utilizing coarse grains as intermediate layers. This method enables the fabrication of stratified noodles from coarse grain flours, particularly millet flour and wheat flour, achieving both nutritional balance and sustained textural firmness in the final product. The present invention provides the following technical solution: A multi-layered noodle production method using coarse grains as intermediate layers, comprising: S1: Hydrating coarse grain flour and wheat flour separately to form coarse grain dough and white dough; S3: Subjecting coarse grain dough sheets to steam treatment at 95-120°C for 10-110 seconds; S4: Alternately stacking and laminating wheat-based dough sheets with steam-processed coarse grain dough sheets to form a laminated structure, with wheat-based dough sheets serving as upper and lower surface layers; S5: Cutting the laminated structure into layered noodles. In S3, the steam temperature is controlled at 95-112°C with a processing duration of 30-90 seconds. Prior to steam treatment in S3, water spray pretreatment is applied to both upper and lower surfaces of the coarse grain dough sheets. Steps S3-S5 are implemented via a noodle lamination machine, which sequentially includes along the processing direction: a conveyor roller set, steam chamber, lamination roller set, and cutting roller set. The conveyor roller set comprises a wheat dough roller and coarse grain roller. Coarse grain dough sheets are transported by the coarse grain roller through the steam chamber, then laminated with wheat-based dough sheets via the lamination roller set to form a laminated dough sheet. The laminated dough sheet is cut into dual rows of layered noodles by the cutting roller set. A shaping assembly is disposed below the cutting roller set, comprising: A first shaping plate positioned between the dual rows of layered noodles; Second shaping plates arranged at front and rear sides of the dual rows. The first shaping plate is mounted on a first linear track parallel to the cutting roller set's axis, providing controlled translational movement. The second shaping plates are mounted on second linear tracks perpendicular to the first track, enabling orthogonal motion. A pre-shaping component is interposed between the cutting roller set and the shaping assembly, comprising: A right-side shaping block connected via a first linkage plate A left-side shaping block connected via a second linkage plate The distance D between adjacent ends of the shaping blocks is smaller than the lateral thickness L of the layered noodles. Both linkage plates are guided by third and fourth linear tracks parallel to the cutting roller set's axis, enabling convergent movement of the shaping blocks. A noodle guide plate with through-holes aligned to the cutting roller set's discharge ports is positioned between the cutting roller set and the pre-shaping component. The shaping blocks are spatially registered with corresponding through-holes. The steam chamber comprises opposed upper and lower steam nozzles connected to a steam supply system, configured for bidirectional steam impingement. The beneficial effects of the present invention are as follows. The present invention employs a technical solution involving steam treatment of coarse grain dough sheets followed by alternate stacking and integrated lamination with wheat-based dough sheets to produce layered noodles. This methodology achieves: 1. Enhanced Structural Integrity Surface fusion between wheat-based and coarse grain dough sheets within the layered noodles, demonstrating delamination resistance; Wheat-based dough sheets as upper / lower layers imparting overall textural resilience to the laminated structure. 2.Graded Textural Performance Initial mastication resistance derived from differentiated viscoelastic properties between coarse grain and wheat flours; Progressive transition to internal tenderness during chewing cycles. 3.Nutrition-Sensory Synergy Enhanced nutritional profile through coarse grain incorporation while maintaining complex mouthfeel characteristics; Preservation of structural stability during cooking processes. BRIEF DESCRIPTION OF DRAWINGS In order to more clearly explain the technical solutions in the method for producing multi-layered noodles with coarse grain intermediate layers of the disclosure. 1. FIG. 1: Schematic structure of Embodiment 1. 2. FIG. 2: Cross-sectional view along A-A in FIG. 1. 3. FIG. 3: Operational diagram of cutting rollers, pre-shaping, and shaping components in Embodiment 2. 4. FIG. 4: Assembly of pre-shaping and shaping components. 5. FIG. 5: Operational diagram of noodle guide plates in Embodiment 3. 6. FIG. 6: Cross-sectional view along B-B in FIG. 5. Reference numerals: 1. Coarse grain dough sheet, 2. Wheat-based dough sheet, 3. Laminated dough sheet, 4. Layered noodles, 5. Steam chamber, 6. Lamination roller set, 7. Wheat dough roller, 8. Coarse grain roller, 9. Cutting roller set, 10. Shaping assembly, 11. First shaping plate, 12. Second shaping plate, 13. First linear track, 14. Second linear track, 15. Pre-shaping component, 16. First shaping block, 17. Second shaping block, 18. First linkage plate, 19. Second linkage plate, 20. Third linear track, 21. Fourth linear track, 22. Noodle guide plate, 23. Noodle through-hole, 24. Upper steam nozzle, 25. Lower steam nozzle. DETAILED DESCRIPTION To make the purpose, technical solutions and advantages of the disclosure more clearly, the technical solutions of the disclosure will be described in detail below. Example 1 As shown in FIGS. 1-2, the multi-layered noodle production method is implemented via a noodle lamination machine comprising, sequentially along the processing direction: a conveyor roller set, steam chamber 5, lamination roller set 6, and cutting roller set 9. The conveyor roller set includes a wheat dough roller 7 and a coarse grain roller 8. Coarse grain dough sheets 1 are transported by the coarse grain roller 8 through the steam chamber 5, then laminated with wheat-based dough sheets 2 via the lamination roller set 6 to form laminated dough sheets 3, which are subsequently cut into dual rows of layered noodles 4 by the cutting roller set 9. The steam chamber 5 contains opposed upper steam nozzle 24 and lower steam nozzle 25, both connected to a steam supply system. In this embodiment, the coarse grain flour is millet flour. Production Steps S1: Hydrate millet flour and wheat flour separately with water to form coarse grain dough and white dough with medium firmness; S2: Process the coarse grain dough and white dough through a roller pressing assembly to form coarse grain dough sheets 1 and wheat-based dough sheets 2. The wheat-based dough sheets 2 are wound onto the wheat dough roller 7, while the coarse grain dough sheets 1 are wound onto the coarse grain roller 8; S3: Prior to entering the steam chamber 5, water spray pretreatment is applied to both upper and lower surfaces of the coarse grain dough sheets 1 from the coarse grain roller 8 via external water spray nozzles, achieving surface hydration. Subsequent steam treatment at 98°C for 45 seconds through upper steam nozzle 24 and lower steam nozzle 25 induces surface gelatinization. The combined pretreatment and steam treatment enhance interfacial viscosity between the gelatinized surfaces of coarse grain dough sheets 1 and wheat-based dough sheets 2, while creating a gradient structure with a non-gelatinized intermediate layer to prevent delamination; S4: The steam-processed coarse grain dough sheets 1 undergo natural cooling before reaching the lamination roller set 6. The lamination roller set 6 alternately stacks and compresses wheat-based dough sheets 2 with coarse grain dough sheets 1 to form a three-layer laminated dough sheet 3, where wheat-based dough sheets 2 constitute upper / lower layers and the gelatinized surfaces of coarse grain dough sheet 1 bond firmly with adjacent layers under pressure. Alternative configurations include five-layer or seven-layer structures; S5: The laminated dough sheet 3 is processed through the cutting roller set 9, yielding dual rows of spaced layered noodles 4. Technical Effects The layered noodles 4 exhibit: Structural integrity through interfacial fusion between wheat-based dough sheets 2 and coarse grain dough sheets 1; Enhanced textural resilience from wheat-based outer layers; Graded chewing resistance: initial firmness transitioning to internal tenderness, attributed to differentiated viscoelastic properties between millet and wheat flours; Nutritional enhancement with complex mouthfeel characteristics. Example 2 As shown in FIGS. 1-4, this embodiment shares essential features with Example 1, with the key distinction being the sequential arrangement of a pre-shaping component 15 and a shaping assembly 10 below the cutting roller set 9. Pre-shaping Component Configuration The pre-shaping component 15 comprises a first shaping block 16, second shaping block 17, first linkage plate 18, and second linkage plate 19. The first shaping block 16 is positioned on the right side of the layered noodles 4 and connected via the first linkage plate 18, while the second shaping block 17 is positioned on the left side of the layered noodles 4 and connected via the second linkage plate 19. The distance D between adjacent ends of the shaping blocks 16,17 is smaller than the lateral thickness L of the layered noodles 4. Both linkage plates 18,19 are guided by third 20 and fourth 21 linear tracks parallel to the cutting roller set's 9 axis, enabling convergent movement of the shaping blocks. In this embodiment, the first shaping block 16 and second shaping block 17 have identical heights. The first linkage plate 18 is thicker than the second linkage plate 19, with a clearance slot provided on the first linkage plate 18 to accommodate the second linkage plate 19 during convergent movement. Both shaping blocks 16,17 feature arcuate cross-sections, with their centers aligned to the central axis of the layered noodles 4. Operational Mechanism The first linkage plate 18 and second linkage plate 19 perform rapid reciprocating motion. During convergent movement: The first shaping block 16 and second shaping block 17 approach each other to compress the intermediate layer of descending layered noodles 4, creating arcuate indentations on both sides of the noodles. During divergent movement: The shaping blocks 16,17 retract to allow unobstructed descent of the layered noodles 4. Shaping Assembly Configuration The shaping assembly 10 comprises a first shaping plate 11 and second shaping plates 12. The first shaping plate 11 is positioned between the dual rows of layered noodles 4, while the second shaping plates 12 are located at the front and rear sides of the dual rows. The first shaping plate 11 is mounted on a first linear track 13 parallel to the cutting roller set's 9 axis, enabling controlled translational movement. The second shaping plates 12 are mounted on second linear tracks 14 perpendicular to the first track 13, providing orthogonal motion capability. Shaping Process During operation: The second shaping plates 12 translate along the second linear tracks 14 toward the first shaping plate 11.The first shaping plate 11 and second shaping plates 12 clamp the layered noodles 4.The first shaping plate 11 moves along the first linear track 13, while both plates perform shaping action to transform the arcuate-indentated noodles 4 into circular cross-sections.The indentations combined with rotational kneading cause the wheat-based outer layers 2 to form a circumferential seal encapsulating the coarse grain core 1.After the first shaping plate 11 retracts, the second shaping plates 12 reset, allowing the circular layered noodles 4 to drop. Technical Effects When cooking the circular layered noodles 4, the wheat-based outer layers 2 come into contact with hot water, transferring heat through conduction to cook the inner coarse grain layers 1. Compared to pure wheat noodles, these layered noodles offer: 1 .More balanced nutrition with multi-dimensional taste and texture; 2.Enhanced structural firmness and reduced water absorption compared to blended flour noodles.This design combines the advantages of both wheat-based and coarse grain noodles Example 3 As shown in FIGS. 1-6, this embodiment shares essential features with Example 2, with the key distinction being the addition of a noodle guide plate 22 between the cutting roller set 9 and pre-shaping component 15. The guide plate 22 is provided with noodle through-holes 23 aligned to the discharge ports of the cutting roller set 9, where first and second shaping blocks 16, 17 are spatially registered with corresponding through-holes. The upper ends of the first shaping block 16 and the second shaping block 17 are arranged adjacent to the lower end of the noodle through - hole 23. After the layered noodles 4 are cut by the cutting roller set 9, they fall into the noodle through - hole 23 of the noodle discharge plate 22. The cross - section of the noodle through - hole 23 is in an inverted - cone shape with a larger top and a smaller bottom, which facilitates the entry of the layered noodles 4, provides rough guidance for them, and prevents the layered noodles 4 from twisting. As a result, the pre - shaping component 15 can effectively and precisely extrude and shape the layered noodles 4. Although the embodiments of the disclosure have been shown and described above, it is to be understood that the above-described embodiments are exemplary and cannot be construed as limiting, and that changes, modifications, substitutions and modifications may be made to the above-described embodiments by those of ordinary skill in the art within the scope of the disclosure.

Claims

l.A method for preparing multi-layered pasta with coarse grain intermediate layers, comprising:(a) separately hydrating coarse grain flour and wheat flour to form coarse grain dough and wheat-based dough;(b) rolling said doughs into coarse grain sheets (1) and wheat sheets (2);(c) steam-treating the coarse grain sheet (1) at 95-120°C for 10-110s via bidirectional steam impingement;(d) alternately laminating the steam-treated sheet (1) with wheat sheets (2) to form a composite sheet (3) with wheat layers as outer surfaces;(e) cutting the composite sheet (3) into layered noodles (4).2.The method according to claim 1, wherein the steam treatment in step (c) is performed at 95-112°C for 30-90s.3.The method according to claim 1, further comprising pre-spraying water on upper / lower surfaces of the coarse grain sheet (1) prior to steam treatment.4.The method according to claim 1, implemented via a noodle-making machine comprising:conveyor roller set with wheat dough roller (7) and coarse grain roller (8);steam chamber (5) with opposed upper / lower nozzles (24,25);lamination roller set (6);cutting roller set (9) forming dual rows of noodles (4).5.The method according to claim 4, further including a shaping assembly (10) below the cutting roller set (9), comprising:central shaping plate (11) between noodle rows;front / rear shaping plates (12) with orthogonal linear motion guides.6.The method according to claim 5, further including a pre-shaping component (15) with:opposing shaping blocks (16,17) having adjustable lateral compression; linkage plates (18,19) with parallel linear motion guides.7.The method according to claim 6, further including a guide plate (22) with 5 alignment holes (23) between cutting roller set (9) and pre-shaping component (15).8.The method according to claim 4, wherein the steam chamber (5) includes upper (24) and lower (25) nozzles connected to a steam supply system.INTERNATIONAL SEARCH REPORT International application No. PCT / CN2024 / 138052A. CLASSIFICATION OF SUBJECT MATTER A23L 7 / 109(2016.01)i; A21C ll / 24(2006.01)i; A21C ll / 00(2006.01)i; A21C 3 / 02(2006.01)i; A21C 9 / 00(2006.01)i According to International Patent Classification (IPC) or to both national classification and IPC B. FIELDS SEARCHED Minimum documentation searched (classification system followed by classification symbols) IPC: A23L A21C Documentation searched other than minimum documentation to the extent that such documents are included in the fields searched Electronic data base consulted during the international search (name of data base and, where practicable, search terms used) CNTXT, CJFD, CNKI, DWPI, VEN, ENTXT, WPABS, WPABSC, ENTXTC: ffiK, W, JI, J±, BR, noodles, dough, layer, multilayer, rooling, steam, vapour C. DOCUMENTS CONSIDERED TO BE RELEVANT Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No. PX CN 117643354 A (INSTITUTE OF BIOTECHNOLOGY AND FOOD SCIENCE, HEBEI ACADEMY OF AGRICULTURE AND FORESTRY SCIENCES) 05 March 2024 (2024-03-05) claims 1-8 1-8 Y Y CN 105380103 A (LI SHAOWE) 09 March 2016 (2016-03-09) description, paragraphs 5-9 CN 209862219 U (HENAN JINGHUA FOOD S&T DEVELOPMENT CO., LTD.) 31 December 2019 (2019-12-31) description, paragraphs 5-12 1-8 1-8 A CN 104684411 A (NISSIN FOODS HOLDINGS CO., LTD.) 03 June 2015 (2015-06-03) claims 1-12 1-8 A A WO 2019088712 A2 (CJ CHEILJEDANG CORP.) 09 May 2019 (2019-05-09) claims 1-14 JP 110591845 A (NISSIN FOOD PRODUCTS LTD.) 16 April 1993 (1993-04-16) claims 1-6 1-8 1-8 | | Further documents are listed in the continuation of Box C. | J | See patent family annex. * Special categories of cited documents: “T” later document published after the international filing date or priority “A" document defining the general state of the art which is not considered date and not in conflict with the application but cited to understand the to be of particular relevance principle or theory underlying the invention “D" document cited by the applicant in the international application “X” document of particular relevance; the claimed invention cannot be “E" earlier application orpatent but published on or after the international considered novel or cannot be considered to involve an inventive step filing date when the document is taken alone “L" document which may throw doubts on priority claim(s) or which is “Y” document of particular relevance; the claimed invention cannot be cited to establish the publication date of another citation or other considered to involve an inventive step when the document is special reason (as specified) combined with one or more other such documents, such combination “O” document referring to an oral disclosure, use, exhibition or other being obvious to a person skilled in tile art means “&” document member of the same patent family “P” document published prior to the international filing date but later than the priority date claimed Date of the actual completion of the international search 11 March 2025 Date of mailing of the international search report 13 March 2025 Name and mailing address of the ISA / CN China National Intellectual Property Administration (ISA / CN) China No. 6, Xitucheng Road, Jimenqiao, Haidian District, Beijing 100088 Authorized officer Telephone No.INTERNATIONAL SEARCH REPORT International application No. Information on patent family members I ’CT / CN2024 / 138052 Patent document cited in search report Publication date (day / month / year) Patent family member(s) Publication date (day / month / year) CN 117643354 A 05 March 2024 None CN 105380103 A 09 March 2016 None CN 209862219 U 31 December 2019 None CN 104684411 A 03 June 2015 HK 1206941 Al 22 January 2016 EP 2880991 Al 10 June 2015 EP 2880991 A4 04 November 2015 EP 2880991 Bl 07 December 2016 TW 201431499 A 16 August 2014 TWI 576053 B 01 April 2017 BR 112015002037 A2 04 July 2017 BR 112015002037 Bl 31 March 2020 HUE 031553 T2 28 July 2017 WO 2014020702 Al 06 February 2014 KR 20150031480 A 24 March 2015 KR 101652650 Bl 30 August 2016 US 2015257418 Al 17 September 2015 US 9723862 B2 08 August 2017 PH 12015500192 Al 06 April 2015 PH 12015500192 Bl 24 April 2019 SG kJ 11201500661 PA 29 April 2015 MX 2015001167 A 13 November 2015 MX 342886 B 17 October 2016 RU 2569963 Cl 10 December 2015 WO 2019088712 A2 09 May 2019 WO 2019088712 A3 27 June 2019 KR 20190049605 A 09 May 2019 KR 102400130 Bl 24 May 2022 JP H0591845 A 16 April 1993 JP 2780881 B2 30 July 1998

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