Starch Compositions Made Using Saturated Steam

Abstract

Disclosed herein is a method for processing starch by applying a hot aqueous fluid to the starch in an amount of up to about 45% (wt % of starch). Depending on the type of fluid, a process for agglomerating the starch or for pre-cooking or pregelatinizing the starch may be used. This method is useful when applied to native and modified starches, and is particularly useful for pregelatinizing or agglomerating thermally inhibited starches having a moisture content of less than about 2% (wt % of starch).

Description

[Technical field]

[0001] Disclosed herein is a method for processing starch or flour products using limited amounts of water, which can be applied as saturated steam. In at least some embodiments, the method is applied to anhydrous starch or flour products to obtain one or more of agglomerated products, pre-cooked products, and pregelatinized products. [Background technology]

[0002] Starch is a polymer made by plants to store glucose. Starch is mainly present in certain plant organs, such as seeds or tubers. Plant organs can be ground to form flour, and starch can be separated from the flour to obtain essentially pure starch. Although other parts of flour, such as protein, can affect the function of flour in food, starch in flour essentially behaves like isolated starch. Therefore, for convenience, references to starch in this specification include references to essentially pure starch and flour, unless otherwise stated. For example, this specification may refer to flour, which means a product that contains starch and more than about 1% protein, or it may refer to an essentially pure starch product with less than about 1% protein.

[0003] Starch is a common food ingredient that is granular in its native form. Native starch is insoluble in water and settles out of slurries easily. However, when heated in an aqueous fluid (e.g., during cooking), the starch granules hydrate, swell, and eventually fragment to release the starch polymers amylose and amylopectin. The aforementioned process is called gelatinization, and the final product is called gelatinized starch.

[0004] Each of the gelatinization stages may be useful in the food preparation process. In some food preparation processes, it may be useful to have uncooked starch that is cooked during processing. In other food processes, it may be useful to use pre-cooked starch. Pre-cooked starch at least starts the gelatinization process, so that the pre-cooked starch is easier to fully cook when subsequently processed, in some cases eliminating the need for further cooking of the starch. For example, pre-cooked starch may be more likely to swell during cooking, or more easily disperse or swell in cold water, or more soluble in cold water, or some combination of these attributes, compared to uncooked starch. Starch that is pre-cooked to the point of gelatinization and can be recovered as a solid product and used in the food preparation process is called pregelatinized starch. For simplicity, in this specification, the term pre-cooked starch refers to starch that has been pre-cooked to any extent, including pre-cooking the starch until it is fully pregelatinized.

[0005] Starch can also be modified to provide a consistent and predictable texture during the food preparation process. Many starch modifications, including chemical, physical, and enzymatic modifications, are known and commonly used in the art. For the same reasons that native starches are pre-cooked or pregelatinized, it is also common, and sometimes useful, to pre-cook or pregelatinize modified starches.

[0006] Both native and modified starches are commonly pre-cooked (and pregelatinized) using a variety of methods. Two are drum drying or spray drying, which use large amounts of water. For example, the first step in drum drying or spray cooking is to create a starch slurry that is a two-phase composition, meaning that there are two states of matter; that is, in the starch slurry there is a solid phase of starch and a liquid phase of liquid water or other aqueous liquid. During drum drying or spray drying, the starch or flour is cooked, but the excess water must be evaporated, which is energy intensive.

[0007] The methods disclosed herein improve upon conventional pre-cooking techniques by using a single-phase process, meaning that all aqueous fluids used to cook the starch are absorbed by the starch, so that only a single solid starch phase is present during the cooking process. The aqueous fluid can be applied as hot water or hot aqueous liquid, or as saturated steam. The single-phase system cooks the starch in less water than is required to drum-dry or spray-cook the starch. The methods described herein are applicable to both native and modified starches, and are useful for pregelatinizing starch. In a preferred embodiment, the methods described herein can be applied to thermally inhibited starch, including to thermally inhibited starch in its anhydrous state, to pregelatinize the thermally inhibited starch. Also disclosed herein is a pre-cooked starch made according to the methods described herein. [Brief description of the drawings]

[0008] [Figure 1] Photograph of thermally inhibited waxy cassava starch that was drum dried and stained and viewed at 100x magnification under polarized light. [Diagram 2] Photograph of thermally inhibited waxy cassava starch that was spray dried and dyed and viewed at 100x magnification under polarized light. Summary of the Invention [Problem to be solved by the invention]

[0009] In any of the embodiments described herein, the starch is treated with a method (which is a single-phase method) that includes providing starch and applying a hot aqueous fluid to the starch in an amount of up to about 45% (weight % of starch). In some embodiments, the hot fluid is applied as water or an aqueous liquid having a temperature at or near the boiling point of water. In at least some embodiments of the methods disclosed herein, the hot aqueous liquid has a temperature of from about 70°C to about 75°C to about 80°C to about 85°C to about 90°C to about 95°C to about 99°C to about 70°C to about 99°C to about 95°C to about 90°C to about 85°C to about 80°C to about 75°C. In other embodiments, the hot aqueous fluid is applied as saturated steam and has a temperature of greater than about 100° C., or greater than about 110° C., or greater than about 120° C., or greater than 100° C., or greater than about 110° C., or greater than about 120° C., or from about 100° C. to about 200° C., or to about 190° C., or to about 180° C., or to about 170° C., or to about 160° C., or to about 150° C. In at least some embodiments, the hot aqueous fluid is applied to a starch having a moisture content of less than about 2% (by weight).

[0010] In various embodiments of the methods described herein, the hot aqueous fluid can be applied to the starch in different amounts to achieve different effects. In some embodiments, the hot aqueous fluid is applied to the starch in an amount of about 10% to about 20%, or about 10% to about 15% (by weight) of the starch. In such embodiments, the hot aqueous fluid creates an agglomerated starch, which is a composition that includes one or more glued starch granules. In some embodiments, the present disclosure discloses a method for agglomerating starch by applying saturated steam to the starch in an amount of about 10% to 20%, or about 10% to 15%. In other embodiments, the present disclosure discloses a method for agglomerating starch by applying a hot aqueous liquid to the starch in an amount of about 10% to about 20%, or about 10% to about 15%, where the liquid has a temperature of about 70° C. to about 75° C. to about 80° C. to about 85° C. to about 90° C. to about 95° C. to about 99° C. to about 70° C. to about 99° C. to about 95° C. to about 90° C. to about 85° C. to about 80° C. to about 75° C. In at least some embodiments, the moisture is applied to a starch having a moisture content of less than about 2% (by weight).

[0011] In other embodiments, the hot aqueous fluid is applied to the starch in an amount of from about 20%, or from about 25%, or from about 30%, or from about 35% to about 45%, or from about 40% (by weight of starch). In such embodiments, the hot aqueous fluid pre-cooks the starch. In some described embodiments, this process pregelatinizes the starch.

[0012] In another embodiment, the present specification discloses a method of pre-cooking starch, comprising applying saturated steam to the starch in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40% (wt % of starch).In another embodiment, the present specification discloses a method of pregelatinizing starch, comprising applying saturated steam to the starch in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40% (wt % of starch).

[0013] In other embodiments, the present specification discloses a method of pre-cooking starch, comprising applying a hot aqueous liquid to the starch in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40% (by weight % of starch). In yet other embodiments, the present specification discloses a method of pregelatinizing starch, comprising applying saturated steam to the starch in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40% (by weight % of starch). In embodiments using a hot aqueous liquid, the liquid has a temperature of from about 70°C, or from about 75°C, or from about 80°C, or from about 85°C, or from about 90°C, or from about 95°C to about 99°C, or from about 70°C to about 99°C, or from about 95°C, or from about 90°C, or from about 85°C, or from about 80°C, or from about 75°C.

[0014] In any of the embodiments described herein, after agglomeration, pre-cooking or pregelatinization, the agglomerated, pre-cooked or pregelatinized starch may be dried to have a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or to about 12% (by weight of starch), or up to the equilibrium moisture content of native starch.

[0015] In various embodiments, the starch provided to be agglomerated, pre-cooked, or pregelatinized is from any suitable plant source, including, but not limited to, corn, waxy corn, rice, glutinous rice, tapioca, waxy tapioca, potato, waxy potato, pea, chickpea, lentil, fava bean, quinoa, sago, and mixtures thereof.

[0016] In various embodiments, the starch that is agglomerated, pre-cooked, or pregelatinized is a native starch.

[0017] In various embodiments, the starch that is agglomerated, pre-cooked, or pregelatinized is a modified starch. The modified starch may be modified using any method known in the art that is used to modify starch. Common starch modifications include adipic acid or anhydride, POCl 3 , or cross-linking using sodium trimetaphosphate. Other chemical modifications include the addition of chemical moieties to starch using propylene oxide, e.g., acetic acid, acetic anhydride, succinic acid, octenyl-succinic acid, etc. The modified starch does not have to be edible to be used in the processes disclosed herein, and can have, for example, cationic, anionic, and silicon-based moieties added. The starch can be hydrolyzed using acid or base or enzymes. The starch can be oxidized. The starch can be physically modified using various heat and moisture processes, such as having annealing, thermal inhibition, or other types of heat moisture treatment. In at least some embodiments, the starch that is agglomerated or pre-cooked or pregelatinized using the processes described herein is a modified starch, preferably a thermally inhibited starch having a moisture content of less than about 2% (by weight of starch).

[0018] For modified starches that are agglomerated, pre-cooked, or pregelatinized, any process that modifies starch can be used to provide the base material. In at least some methods, the starch is modified in the same reactor that is used to agglomerate, pre-cook, or pregelatinize the starch. Examples of useful reactors include fluidized bed reactors (also called fluidized bed reactors) and hollow tube reactors such as the CoriMix reactor available from Loedige. The modification reaction may involve reacting the base starch with reactants in the gas phase. In hollow tube reactors, the reactants may be liquids, but are applied to the starch in amounts less than that required to form a slurry (i.e., in a single-phase process where the starch absorbs all the liquid). In such a single-phase process, the moisture content of the starch increases and the starch may appear wet or in the form of a starch cake, but the starch remains a powdery material and does not disperse in the liquid. Depending on the reactor layout, the starch may be modified and pre-cooked, or modified and pregelatinized, or modified and agglomerated in the same reactor or in a continuous manner in a series of reactors. In other embodiments, the starch may be batch-processed, modified and pre-cooked, or modified and pregelatinized, or modified and agglomerated in one or more reactors.

[0019] In at least some embodiments, the base starch that is agglomerated or pre-cooked or pregelatinized is a thermally inhibited starch. The thermal inhibition process changes the functionality of the starch so that it behaves in aqueous solution like a chemically crosslinked starch. Various methods are known for thermally inhibiting starch. Useful methods are described in WO 2020-139997, which is incorporated herein in its entirety. Generally, thermally inhibited starch is made by steeping native starch in a liquid containing a buffering agent, typically a salt of an organic acid or base. The starch is steeped to transfer the buffering agent to the starch granules. The buffered starch is then pH adjusted to have a pH in the range of about 4 to about 9.5, depending on the buffer used. The buffered, pH adjusted starch is then dehydrated to have a moisture content of less than about 2% (weight % of starch) and heated to a temperature of about 100°C to about 200°C for a time sufficient to obtain the desired degree of thermal inhibition. The resulting thermally inhibited starch is essentially anhydrous and is dehydrated to a moisture content of less than 2% and then further heated above the boiling point of water for a time sufficient to thermally inhibit the starch.

[0020] In some embodiments, the methods described herein apply a hot aqueous fluid to the essentially anhydrous thermally inhibited starch obtained at the end of the thermal inhibition process. In other embodiments, the thermally inhibited starch is cooled to allow the starch to absorb moisture from the atmosphere prior to using the agglomeration and pre-cooking methods described herein. In various embodiments of the methods described herein for agglomerating, pre-cooking, or pregelatinizing thermally inhibited starch, a hot aqueous fluid is applied to a thermally inhibited starch starting material having a moisture content of less than about 2% (by weight of starch).

[0021] In various embodiments described herein, the hot aqueous fluid is applied to the thermally inhibited starch in an amount to obtain a thermally inhibited agglomerated starch, or in an amount to obtain a thermally inhibited starch that has been pre-cooked or pregelatinized, or in an amount to obtain a thermally inhibited agglomerated starch that has been pre-cooked or pregelatinized and agglomerated.

[0022] Referring first to the flocculation process, in any embodiment, the present specification describes a method for thermally inhibiting agglomerated starch, which means that the starch is flocculated and then the flocculated starch is thermally inhibited. The starch starting material may be a native starch or may be a pregelatinized starch. If pregelatinized, the starch may be pregelatinized (preferably pregelatinized) using the methods described herein. In any embodiment described herein, the method for thermally inhibiting agglomerated starch includes providing starch and applying a hot aqueous fluid to the starch in an amount of about 10% to about 20%, or about 10% to about 15% (weight % of starch), the hot aqueous fluid including a buffer and an acid or base. The hot aqueous fluid flocculates the starch and adjusts the pH of the starch to a pH of about 4.0 to about 9.5. The method further comprises dehydrating the agglomerated, buffered, pH adjusted starch to a moisture content of less than about 2% (by weight of starch) and heat treating the dehydrated starch agglomerates at a temperature of about 100° C. to about 200° C. for up to about 20 hours, thereby thermally inhibiting the starch agglomerates to obtain a thermally inhibited agglomerated starch. In some embodiments of the method described in this paragraph, the starch is buffered and pH adjusted by applying a hot aqueous liquid to the starch to obtain a starch having a pH in the range of about 4.0 to about 7.0, more preferably in the range of about 4.0 to about 4.5 to about 6.5, or to about 5.5.

[0023] Following thermal inhibition, the thermally inhibited starch may be remoistened using any known technique. In some embodiments, the thermally inhibited agglomerated starch is remoistened by washing the thermally inhibited agglomerated starch with sufficient water to form a slurry, followed by drying the thermally inhibited agglomerated starch to a moisture content of from about 4%, or from about 6%, or from about 8% to about 15%, or to about 12% (by weight of starch).

[0024] In other embodiments, the present specification describes a method for agglomerating thermally inhibited starch, meaning that the starch is thermally inhibited and then agglomerated using the methods described herein. In such embodiments, the starting thermally inhibited starch is thermally inhibited to any desired degree using any known thermal inhibition process. The degree of thermal inhibition can be measured using a micro-visco-amylograph test, which measures the change in viscosity over time of an aqueous starch slurry of a defined pH and starch solids content as the slurry is heated.

[0025] In any of the embodiments described herein, the thermally inhibited starch used as the starting material to obtain the agglomerated thermally inhibited starch has a viscosity of about 2000 MPa * Less than s or 1500MPa * In at least some embodiments, the starting thermally inhibited starch has a hot peak viscosity (measured using the Micro-Visco-Amylograph test defined herein) of less than about 300 MPa. * s or less, b) about 300 MPa * s~about 800MPa * s, and c) about 800 MPa * s~approx. 1600MPa * s. The peak high temperature viscosity of the composition is in the range selected from the group consisting of:

[0026] In any embodiment, the present disclosure describes a method comprising applying saturated steam to a thermally inhibited starch in an amount of about 10% to about 20% (wt % of starch), or about 10% to about 15% to obtain an agglomerated thermally inhibited starch, and optionally drying the agglomerated thermally inhibited starch to a moisture content of up to about 15%, or about 4%, or about 6%, or about 8% to about 15%, or about 12% (wt % of starch), or to the equilibrium moisture content of native starch. Preferably, the thermally inhibited starch starting material has a moisture content of less than about 2% (wt % of starch).

[0027] In any embodiment, the present disclosure describes a method comprising applying a hot aqueous liquid to a thermally inhibited starch in an amount of about 10% to about 20%, or about 10% to about 15% by weight of the starch to obtain an agglomerated thermally inhibited starch, and optionally drying the agglomerated thermally inhibited starch to a moisture content of up to about 15%, or about 4%, or about 6%, or about 8% to about 15%, or about 12% (by weight of starch). In embodiments using a hot aqueous liquid, the liquid has a temperature of about 70°C to about 75°C to about 80°C to about 85°C to about 90°C to about 99°C to about 70°C to about 99°C to about 95°C to about 90°C to about 85°C to about 80°C to about 75°C. Preferably, the thermally inhibited starch starting material has a moisture content of less than about 2% (by weight of starch).

[0028] Referring now to the process of pre-cooking and pregelatinizing thermally inhibited starch, the starch starting starch material is a thermally inhibited starch that has been thermally inhibited using any process and to any desired degree of thermal inhibition. The starting thermally inhibited starch may be an agglomerated thermally inhibited starch or a thermally inhibited agglomerated starch.

[0029] In any embodiment, the present specification describes a method comprising applying saturated steam to a thermally inhibited starch in an amount of from about 20%, or from about 25%, or from about 30%, or from about 35% to about 45%, or from about 40% (wt % of starch) to obtain a pre-cooked or pregelatinized thermally inhibited starch, which is optionally then dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (wt % of starch), or to the equilibrium moisture content of native starch. Preferably, in such an embodiment, the thermally inhibited starch starting material has a moisture content of less than about 2% (wt % of starch).

[0030] In any embodiment, the present specification describes a method comprising forming thermally inhibited starch agglomerates by applying saturated steam to the thermally inhibited starch in a first amount, which is up to about 45% (wt % of starch), and pregelatinizing the agglomerated thermally inhibited starch by applying saturated steam to the thermally inhibited agglomerated starch in a second amount, which is greater than the first amount but up to about 45% (wt % of starch), and optionally the pregelatinized agglomerated thermally inhibited starch is then dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (wt % of starch). Preferably, in such an embodiment, the thermally inhibited starch starting material has a moisture content of less than about 2% (wt % of starch).

[0031] In any embodiment, the present specification describes a method comprising applying a hot aqueous liquid to a thermally inhibited starch in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40% (by weight of starch) to obtain a pre-cooked or pregelatinized thermally inhibited starch, which is optionally then dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (by weight of starch), or to the equilibrium moisture content of native starch. Preferably, the thermally inhibited starch starting material has a moisture content of less than about 2% (by weight of starch). In embodiments using a hot aqueous liquid, the liquid has a temperature of from about 70°C, or from about 75°C, or from about 80°C, or from about 85°C, or from about 90°C, or from about 95°C to about 99°C, or from about 70°C to about 99°C, or from about 95°C, or from about 90°C, or from about 85°C, or from about 80°C, or from about 75°C.

[0032] In any embodiment, the present disclosure describes a method comprising forming thermally inhibited starch agglomerates by applying a hot aqueous liquid to the thermally inhibited starch in a first amount, the first amount being up to about 45% (wt % of starch), and pre-cooking or pregelatinizing the agglomerated thermally inhibited starch by applying a hot aqueous liquid to the thermally inhibited agglomerated starch in a second amount, the second amount being greater than the first amount but up to about 45% (wt % of starch), and optionally the pre-cooked or pregelatinized agglomerated thermally inhibited starch is then dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (wt % of starch). Preferably, the thermally inhibited starch starting material has a moisture content of less than about 2% (wt % of starch). In embodiments using a hot aqueous liquid, the liquid has a temperature of from about 70°C, or from about 75°C, or from about 80°C, or from about 85°C, or from about 90°C, or from about 95°C to about 99°C, or from about 70°C to about 99°C, or from about 95°C, or from about 90°C, or from about 85°C, or from about 80°C, or from about 75°C.

[0033] Advantageously, the described methods for agglomerating, pre-cooking, and pregelatinizing thermally inhibited starch allow saturated steam or hot aqueous liquid to be applied to the thermally inhibited starch after the heating stage of the thermal inhibition process. Thus, in some embodiments, the processes for thermally agglomerating, pre-cooking, and pregelatinizing starch can be applied to thermally inhibited starch without the need to move the thermally inhibited starch from where it was thermally inhibited to a different reactor. In some embodiments, the hot aqueous fluid can be applied to the thermally inhibited starch without cooling the starch to absorb at least some ambient moisture. In any embodiment, the hot aqueous fluid can be applied to a thermally inhibited starch having a moisture content of less than about 2% (weight % of starch).

[0034] The thermally inhibited starch resulting from the methods described herein, whether agglomerated, precooked, or pregelatinized, or some combination thereof, can be washed and dried to obtain the desired final moisture content, rewetted in a single-phase process to obtain the desired moisture content, or cooled and rewetted under ambient conditions without the use of a washing or single-phase rewet step.

[0035] In any embodiment, the starch may be dried, agglomerated, pre-cooked, or pregelatinized in the same reactor, or the same type of reactor, or in a different reactor, or a different type of reactor.

[0036] In any embodiment, the starch may be dried, agglomerated, pre-cooked, or pregelatinized in a continuous process or in batch.

[0037] Useful reactors for agglomerating, pre-digesting, or pregelatinizing starch are closed reactors in which hot aqueous fluids can be applied to the starch. Useful reactors include fluidized bed reactors, which can be set up to agglomerate, pre-digest, or pregelatinize starch in batches or can be configured to process starch in a continuous process. A fluidized bed (or fluidized bed reactor) is a hollow vessel with a port for injecting gas into the vessel to disperse powdery materials such as starch within the vessel's space so that the starch takes on fluid-like properties. Various gases can be injected, including air, saturated steam, or dispersing liquid, and these can be injected in amounts that provide the weight percentage of aqueous fluid to starch. The gas can be heated and / or the hollow vessel of the fluidized bed reactor can be jacketed or provided with other heating mechanisms so that the temperature of the aqueous fluid and starch is maintained at the levels described herein.

[0038] Other suitable reactors include hollow tube reactors with blades that press the material against the inside of the hollow tube, or screw-like or other devices that rotate or otherwise force the material through the length of the reactor. Such reactors include various openings that allow starch, or steam, liquid aqueous solutions, liquid water, or other materials to enter the hollow tube. In carrying out the methods described herein, the flow rates of starch, aqueous fluids, etc. into and through the hollow tube are metered so that the weight percentage of aqueous fluid to starch is at the levels described herein. Such reactors may be jacketed or equipped with other mechanisms for heating the materials within the hollow tube such that the temperatures of the fluids and starch are maintained at the levels described herein. In at least some embodiments, useful reactors are ring bed or ring dryer type reactors. Such reactors of this type are available from a variety of suppliers, including, but not limited to, Lodige Process Technology, Paderborn, Germany, GEA Barr-Rosin, Hudson, Wisconsin, USA, or Bepex International LLC, Minnesota, USA. Useful reactors may be known in the art by names such as Horizontal Ploughshare Mixers, Littleford Agitated Vacuum Dryers, CoriMix mixers, etc. The foregoing list is intended to be illustrative and not limiting with respect to the types of reactors.

[0039] Also disclosed herein is starch made using any of the processes described herein. In at least some embodiments, the starch obtained by the described methods is pregelatinized starch or pregelatinized thermally inhibited starch. In a preferred embodiment, the starch made by the methods described herein is pregelatinized in a hollow tube reactor. Starch pregelatinized in a hollow tube can be distinguished from starch pregelatinized using methods such as drum drying and spray cooking by viewing the starch in solution under magnification due to the different levels of shear applied to the starch during pregelatinization. The shear applied during pregelatinization tears the starch particles, resulting in many fragmented particles and generally providing starch granules with jagged edges.

[0040] Drum drying is a relatively high shear process. A photograph of drum dried pregelatinized thermally inhibited starch (magnified 100 times using a polarizing filter) is presented in FIG. 1. Spray cooking is a relatively low shear process compared to the drum drying process. FIG. 2 presents a photograph of spray cooked pregelatinized thermally inhibited starch. In comparison to FIG. 1, the starch in FIG. 2 generally has intact particles with relatively smooth peripheries or edges. The processes for pregelatinizing starch and for pregelatinizing thermally inhibited starch described herein apply different shear than drum drying and spray drying because with the described processes, shear is applied to the thermally inhibited starch in a system where all aqueous fluid is absorbed by the starch during cooking and shearing. In contrast, in both drum drying and spray cooking, the starch is cooked and sheared in a slurry with the solid starch phase of the starch dispersed in a separate liquid phase. Using the methods described herein to apply shear during gelatinization provides pregelatinized and thermally inhibited starches that have a differentiated texture and appearance than starches pregelatinized and thermally inhibited using spray drying compared to thermally inhibited starches pregelatinized using drum drying.

[0041] In some embodiments, the present specification describes pregelatinized thermally inhibited starches and pregelatinized agglomerated thermally inhibited starches made according to the process of any of the preceding claims. The agglomerated pregelatinized starches described herein disperse well in aqueous solutions, at least because the aqueous solutions destroy the ability of the binder to hold the agglomerated starch granules together. (Without being bound by theory, it is believed that during the agglomeration process described herein, a small amount of starch is partially cooked and becomes water soluble, and this solubilized starch is believed to be capable of binding separate starch granules together when dried.) When the starch agglomerates are added to water, the water dissolves the bonds between the granules, causing and resulting in the destruction of the surface tension forces that would otherwise hold the starch particles together, tending to disperse the starch.

[0042] Additionally, in preferred embodiments of the methods described herein, the flocculation or pregelatinization process does not destroy the desired functionality of the starch used in the process. In at least some embodiments, the pregelatinized flocculated thermally inhibited starch provides viscosity in cold aqueous solutions, i.e., no additional heating is required. In any embodiment described herein, the thermally inhibited starch that has been flocculated, pregelatinized, or both using the processes described herein has 6% starch and a pH of 6, and can be heated to a viscosity of about a) about 300 MPa * s or less, b) about 300 MPa * s~about 800MPa * s, and c) about 800 MPa * s~approx. 1600MPa * The starch slurry is provided having a viscosity in the range selected from the group consisting of:

[0043] Also described herein are food compositions comprising starches made using the methods described herein. In some embodiments, the starch is pregelatinized or agglomerated, or both. In other embodiments, the starch is a thermally inhibited starch that is pregelatinized or agglomerated, or both, according to the methods described herein. In yet other embodiments, the starch is agglomerated and then thermally inhibited or pregelatinized, or both. In any embodiment of the food composition described herein, the composition comprises a starch and a second component, and the starch is used in any amount, for example, from about 1% to about 99% by weight of the food composition.

[0044] In any embodiment, the food composition comprises a sweetener as a second component.Useful sweeteners include, but are not limited to, dextrose, allulose, tagatose, fructose, glycerol, sucrose, erythritol, rebaudioside (A, B, J, M, etc.), glucosylated stevia glycoside, and corn syrup, including high fructose corn syrup.Sweeteners can be provided in the form of solid, or powder, or liquid, or syrup.

[0045] In an optional embodiment, the food composition comprises a gum or gum-like material as a second component. Useful gums and gum-like materials include, but are not limited to, gelling starch, gum arabic, xanthan gum, tara gum, konjac, carrageenan, locust bean gum, gellan gum, guar gum, and mixtures thereof.

[0046] In any embodiment, the food composition comprises oil, or fat, or aqueous component as the second component. Useful oils include, but are not limited to, vegetable oils such as corn oil, olive oil, canola oil, sunflower oil, rapeseed oil, palm oil, coconut oil, etc. Useful fats (other than vegetable oils) include, for example, animal fats and dairy fats. Useful aqueous components include, for example, water, milk, syrup, or other carbohydrate-containing liquids, or acidic liquids, or basic liquids.

[0047] In any embodiment, the food compositions comprising one as described herein may further comprise a variety of other flavors, seasonings, and colorants commonly used in food compositions.

[0048] In any embodiment, the food composition is an aqueous composition in which the cold water swelling starches are useful including, but not limited to, dressings, including pourable dressings and spoonable dressings, pie fillings and cream fillings, including fruit fillings (and other similar fruit preparations whether or not used in pies), white and cheese sauces, gravies, imitation and light syrups, puddings, custards, yogurt, sour cream, pasta, beverages including dairy-based beverages, glazes, soups, and baby foods.

[0049] References herein to "waxy starch" mean low amylose starch, i.e., less than about 5% or less than about 3% or essentially 0% amylose. Depending on the plant source, the ratio of amylose to amylopectin may vary. However, plants can be bred such that essentially all the starch produced is amylopectin. Such species may be referred to in the art as waxy species, e.g., waxy corn or glutinous rice. Generally, waxy plant species are bred to produce less than about 5% amylose (by weight), more commonly essentially 0% amylose.

[0050] References herein to "native" starch refer to starch that has not been modified, for example, using physical, chemical, or enzymatic processes. In general, native starch and native flour can be identified by microscopic examination of the starch (or starch within flour) because native starch has a crystalline structure that produces a Maltese orthogonal-like diffraction pattern when viewed under polarized light. In contrast, gelatinized (and pregelatinized) starch has no crystallinity and therefore no discernible diffraction pattern when viewed under polarized light.

[0051] The term "pregelatinized" starch and its grammatical variations are terms known in the art and are used herein according to their full meaning in the art. To facilitate understanding of the technology described herein, without limiting the full understanding of the meaning of the term pregelatinization, the following characteristics of pregelatinized starch are referenced: Pregelatinized starch is pre-cooked to break the native granular structure of the starch. The pregelatinization process can be applied to native or modified starches, including thermally inhibited starches. The starch is pregelatinized so that it can provide its intended function, for example, to provide viscosity to an aqueous solution without further cooking. In this sense, pregelatinized starch can be referred to in the art as instant starch or cold water swelling starch or cold water soluble starch or pre-cooked starch. Whether a starch is pregelatinized can be determined by viewing the starch under polarized light. Granular starch exhibits a Malta orthogonal diffraction pattern. Non-granular starch does not. Also, at ambient pressure, starch will gelatinize at different temperatures depending at least on the plant source and whether and how the starch is modified, however, generally at ambient pressure, starch will gelatinize at temperatures between 60°C and 80°C.

[0052] Reference to "precooked starch" means that the starch is processed such that it is heated to any temperature up to the point where it is fully pregelatinized and then recovered in solid form. Precooked starch may be partially pregelatinized or fully pregelatinized.

[0053] References herein to "saturated steam" are to steam at a temperature above the vaporization point of its liquid state at the absolute pressure at which the temperature is measured. For example, under normal (sea level) environmental conditions, water has a vaporization point (also known as a boiling point) of about 100° C. Saturated steam composed of water has a temperature above about 100° C. under normal environmental conditions.

[0054] Reference herein to "thermally inhibited" starch means a starch made by a process that modifies the functionality of native starch so that it functions in aqueous solution like a chemically crosslinked starch. The extent to which a starch is thermally inhibited can be assessed using a micro-visco-amylograph test. Such a test (defined below) measures how the viscosity of a starch slurry changes over time as the slurry is heated. Thermally inhibited starches can be made to have different degrees of inhibition. For example, starches are referred to herein as being lightly, moderately, and highly inhibited. In practice, thermally inhibited starches are selected for food applications based on the processing conditions used to make the food application. More specifically, the inhibited starch is selected to be most likely to provide a constant viscosity throughout the process of making the food product. For example, when more severe food processing conditions are used, a more highly thermally inhibited starch is used.

[0055] Within this specification, "lightly", "moderately" and "highly" inhibited thermally inhibited starches are described according to the highest viscosity during the heating stage ("peak hot viscosity") using the Micro-Visco-Amylograph test at pH 6. Although not required to meet the definition of thermally inhibited, in a preferred embodiment, the thermally inhibited starch has no viscosity break during the heating stage of a Visco-Amylograph or Micro-Visco-Amylograph manufactured by Brabender® GmbH & Co. KG. Also, with reference to various preferred embodiments, the slurry may have "no viscosity break" since the viscosity remains constant at the peak viscosity or increases in viscosity while the slurry is held at 95°C for 15 minutes and the spindle speed is 75 RPM. In this context, as used herein, "lightly thermally inhibited starch" refers to a starch that has a viscosity of 800 MPa or less. * Over s ~ 1600MPa * "Moderately heat-inhibited starch" has a peak high-temperature viscosity of 300 to 800 MPa. * The "highly thermally inhibited starch" has a peak high temperature viscosity of 300 MPa. *Brabender Visco-Amylograph or Micro-Visco-Amylograph generally has a peak high temperature viscosity of Brabender Units (BU) MPa * Viscosity measurements may be reported using s, or cmg.

[0056] Reference herein to the "Micro-Visco-Amylograph Test" refers to the following test: An aqueous slurry of starch is obtained by mixing 6% (by weight) starch with an aqueous solution that is buffered and pH adjusted to pH 6. The slurry is heated and stirred to a temperature of about 50°C to about 95°C using a Brabender Visco-Amylograph or Micro-Visco-Amylograph machine rotating at a speed of 75 rpm and a rate of 6°C / min, and the slurry is held at 95°C for 15 minutes. The combination of heating from 50° to 95° and holding at 95° is referred to herein as the "cooking phase" of the Micro-Visco-Amylograph Test. A useful attribute of the slurry for determining the degree of inhibition is the peak hot viscosity, which is the highest viscosity achieved during the cooking phase of the test. The Micro-Visco-Amylograph Test may be terminated when the cooking phase is completed. Although not necessary to this definition, the Micro-Visco-Amylograph Test may be continued after completing the cooking phase of the test. Generally, during this stage, the slurry is cooled under ambient or controlled conditions until the slurry approaches ambient temperature and the final steady state viscosity (or gelled composition), referred to herein as the "cooling stage." The cooling stage can be carried out for any desired period of time, but is typically completed within about 30 minutes after heating is stopped, which is about 1 hour total from the start of the test.

[0057] References herein to a "single-phase process" refer to a process in which water (aqueous solution) is added to starch or flour in an amount such that all of the solution is absorbed by the starch or flour such that there is only a solid phase in the mixture, although the solid phase may appear wet and be present as a cake or chunk of material. Here, phase refers to a state of matter, and thus the system has a single phase since all liquid or gas (vapor) has been absorbed and only a single solid phase of starch is present. A single-phase process is distinguished from a process in which excess water is added which creates a slurry in which there are two distinct states of matter: a solid (starch) phase and a liquid phase.

[0058] In terms of usage, the specification refers to thermally inhibited agglomerated starch, which is an agglomerated starch that is subsequently thermally inhibited. The specification also refers to agglomerated thermally inhibited starch, which in turn refers to agglomerated thermally inhibited starch.

[0059] The use of "about" to modify a number is meant to include the stated number plus or minus 10%. Legally permitted recitations of values ​​in the claims mean approximately that value. The use of about in the claims or specification is not intended to limit the entire range of equivalents covered.

[0060] The indefinite article "a" or the definite article "the" is intended to mean one or more, unless the context clearly dictates otherwise.

[0061] While particular embodiments have been illustrated and described, those skilled in the art, after reading the foregoing specification, may effect modifications, substitutions of equivalents, and other types of alterations in the methods and techniques of the present invention. Each of the above aspects and embodiments may also include or incorporate such variations or aspects as disclosed with respect to any or all of the other aspects and embodiments.

[0062] The technology is also not limited with respect to the embodiments described herein, which are intended as single illustrations of individual embodiments of the technology. As will be apparent to those skilled in the art, many modifications and variations of the technology can be made without departing from its spirit and scope. Functionally equivalent methods within the scope of the technology will be apparent to those skilled in the art from the foregoing description, in addition to those recited herein. Such modifications and variations are intended to be included within the scope of the appended claims. It is to be understood that the technology is not limited to methods, complexes, reagents, compounds, compositions, labeled compounds, or biological systems, which may, of course, vary. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. It is also to be understood that the terms used herein are for the purpose of describing embodiments only, and are not intended to be limiting. Thus, it is intended that the specification be considered as illustrative only of the breadth, scope, and spirit of the technology, as indicated solely by the appended claims, definitions thereof, and any equivalents thereof. No language in the specification should be construed as indicating any non-claimed element as essential.

[0063] The embodiments illustratively described herein may be suitably practiced in the absence of any element(s), limitation(s) not specifically disclosed herein. Thus, for example, terms such as "comprising", "including", "containing" and the like are to be read expansively and without limitation. Additionally, the terms and expressions used herein are used as terms of description and are not to be limited, and there is no intention to exclude any equivalents of the features or portions thereof shown and described in the use of such terms and expressions, but it is recognized that various modifications are possible within the scope of the claimed technology. Additionally, the phrase "consisting essentially of" will be understood to include those elements specifically recited, as well as additional elements that do not materially affect the basic and novel characteristics of the claimed technology. The phrase "consisting of" excludes any elements not specified.

[0064] In addition, where features or aspects of the disclosure are described in terms of a Markush group, one of skill in the art will recognize that the disclosure is also described in terms of any individual members or subgroups of members of the Markush group. Each of the narrower species and subgroups falling within the generic disclosure also form part of the technology. This includes describing the concept of the technology with a condition or negative limitation that removes any subject matter from the genus, regardless of whether the excised material is specifically described herein.

[0065] As will be understood by those skilled in the art, for any and all purposes, in view of providing a specifically written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of those subranges. Any recited range can be easily recognized as fully describing and allowing the same range to be divided into at least one half, one third, one quarter, one fifth, one tenth, etc. As a non-limiting example, each range discussed herein can be easily divided into a lower third, a middle third, and an upper third, etc. Also, as will be understood by those skilled in the art, all words such as "up to," "at least," "greater than," "less than," etc. refer to a range that includes the recited numbers and can be divided into the subranges discussed below. Finally, as will be understood by those skilled in the art, a range includes each individual member, and each separate value is incorporated herein as if it were individually described herein.

[0066] The technology disclosed herein can be better understood with reference to the following embodiments, which are provided for purposes of illustration and are not intended to be limiting in any way.

[0067] 1. A method for processing starch, comprising: providing starch; and applying a hot aqueous fluid to the starch in an amount up to about 45% (by weight of the starch).

[0068] 2. The method of claim 1, wherein the hot aqueous fluid is applied to the starch in an amount of about 10% to 20% or about 10% to 15%, the method flocculating the starch, and the hot aqueous fluid is a binder.

[0069] 2. The method of claim 1, wherein the hot aqueous fluid is applied in an amount of from about 20% to about 25% to about 30% to about 35% to about 45% to about 40%, and the hot aqueous fluid is pre-cooked and optionally the starch is pregelatinized such that the starch does not exhibit a Malta orthogonal diffraction pattern when viewed under polarized light.

[0070] 4. The method of claim 1, further comprising drying the agglomerated or pre-cooked starch to have a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (by weight).

[0071] 5. The method according to any one of claims 1 to 4, wherein the starch is from the group consisting of corn, waxy corn, rice, glutinous rice, tapioca, waxy tapioca, potato, waxy potato, pea, chickpea, lentil, fava bean, quinoa, sago, and mixtures thereof.

[0072] 6. The method according to any one of claims 1 to 5, wherein the hot aqueous fluid is applied to the native starch.

[0073] 7. The method according to any one of claims 1 to 6, wherein a hot aqueous fluid is applied to the modified starch, preferably the modification being thermal inhibition.

[0074] 8. The method according to any one of claims 1 to 7, wherein the starch has a moisture content of less than 2% (by weight), and optionally the starch is a thermally inhibited starch.

[0075] The hot aqueous fluid is applied to the starch in an amount of about 10% to 20% or about 10% to 15%, the starch being a native starch, and the method further comprises applying the hot aqueous fluid to the starch further comprising a buffer and an acid or base such that after applying the hot aqueous fluid, the starch is an agglomerated starch, the agglomerated starch being buffered and pH adjusted to a pH of about 4.5 to about 9.5, preferably the starch is adjusted to a pH of about 4.5 to about 7.0, more preferably 9. The method of claim 1, further comprising: adjusting the starch to a pH of about 4.5 to about 5.5; dehydrating the agglomerated, buffered, pH adjusted starch to a moisture content of less than about 2% (by weight of starch) to provide a starch agglomerate; and heat treating the anhydrous or substantially anhydrous starch agglomerate at a temperature of about 100° C. to about 200° C. for up to about 20 hours, thereby thermally inhibiting the starch agglomerate to obtain a thermally inhibited agglomerated starch.

[0076] A hot aqueous fluid is applied to the thermally inhibited starch, and optionally the thermally inhibited starch has a viscosity of about 2000 mPa as measured using the Micro-Visco-Amylograph test. * Less than s or about 1500mPa * s or less, or a) about 300 mPa * s or less, b) about 300 mPa * s~about 300mPa * s, and c) about 800 mPa * s~approx. 1600mPa * 10. The method of claim 1, wherein the cured product has a peak thermal viscosity within a range selected from the group consisting of:

[0077] 11. The method of any one of claims 1 to 10, wherein hot aqueous fluid is applied to the thermally inhibited starch in an amount of about 10% to about 20% or about 10% to about 15% to obtain an agglomerated thermally inhibited starch, and optionally the agglomerated thermally inhibited starch is dried to a moisture content of about 10% to about 15% (by weight of starch).

[0078] 12. The method of claim 1, wherein hot aqueous fluid is applied to the thermally inhibited starch in an amount of from about 20% to about 40%, or from about 25% to about 40%, to obtain a pregelatinized, thermally inhibited starch, and optionally the pregelatinized, thermally inhibited starch is dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or from about 12% (wt %).

[0079] 13. The method of any of claims 1 to 12, further comprising applying a hot aqueous fluid to the thermally inhibited starch in a first amount, the first amount being in the range of up to about 40% (wt % of starch) to form an agglomerated mass of thermally inhibited starch, and applying a hot aqueous fluid to the thermally inhibited agglomerated starch in a second amount, the second amount being greater than the first amount but in the range of up to about 40% (wt % of starch), to pregelatinize the agglomerated thermally inhibited starch, optionally drying the pregelatinized agglomerated thermally inhibited starch to a moisture content of up to about 15%, or from about 4% to about 6% to about 8% to about 15%, or to about 12% (wt %).

[0080] 14. The method of any one of claims 1 to 13, wherein the hot aqueous fluid is applied to a thermally inhibited starch having a moisture content of less than about 2% (% by weight of starch).

[0081] 15. The process according to any one of the preceding claims, wherein the hot aqueous fluid is applied to the starch in one or more of a fluidized bed reactor or a hollow tube reactor.

[0082] 16. The method according to any one of the preceding claims, wherein the starch is agglomerated or pregelatinized and dried in the same reactor.

[0083] 17. The method according to any one of claims 1 to 16, wherein the starch is agglomerated or pregelatinized and dried in different reactors.

[0084] 18. The method according to any one of claims 1 to 17, wherein the hot hydrous fluid has a temperature of from about 70°C to about 75°C to about 80°C to about 85°C to about 90°C to about 95°C to about 99°C, or from about 70°C to about 99°C, or from about 95°C to about 90°C to about 85°C, or from about 80°C to about 75°C.

[0085] 19. The method according to any one of claims 1 to 18, wherein the hot hydrothermal fluid is saturated steam.

[0086] 20. The method according to any one of claims 1 to 19, wherein the hot hydrous fluid has a temperature of greater than about 100°C, or greater than about 110°C, or greater than about 120°C, or from about 100°C to about 200°C, or from about 190°C, or from about 180°C, or from about 170°C, or from about 160°C, or from about 150°C.

[0087] 21. A pregelatinized thermally inhibited starch or pregelatinized agglomeration thermally inhibited starch produced according to the process of any one of claims 1 to 20.

[0088] An aqueous starch slurry having 6% starch solids and a pH of 6 can be heated to about 2000 mPa* Less than s or about 1500mPa * a) a viscosity of less than about 300 mPa * s or less, b) about 300 mPa * s~about 800mPa * s, and c) about 800 mPa * s~approx. 1600mPa * 22. The pregelatinized thermally inhibited starch or pregelatinized aggregation thermally inhibited starch of claim 21 having a viscosity in the range selected from the group consisting of:

[0089] 23. A food product comprising a starch made by the process of any one of claims 1 to 22 and a second edible component, preferably wherein the starch is a pregelatinized heat-inhibited starch or a pregelatinized aggregation heat-inhibited starch.

[0090] The technology disclosed herein can be better understood with reference to the following examples, which are provided for illustrative purposes and are not intended to be limiting in any manner.

[0091] Example 1 - Thermally inhibited and pregelatinized starches and processes for making them The differences between pregelatinized, thermally inhibited starches that have been pregelatinized using one of the drum drying, spray drying, or single phase methods described herein are depicted in the examples below.

[0092] Example 1a - Drum dried pregelatinized thermally inhibited starch Drum drying processes are known in the art and generally work by applying a thin film of starch slurry to a rotating heated drum. The drum cooks the starch in the slurry, pregelatinizes it, and evaporates water from the slurry. The pregelatinized, dried starch is scraped off the drum to provide a final product in the form of flake-like, partially intact, partially sheared starch granules (however, the starch is not granular in the sense that granular starch exhibits a Malta orthogonal starch diffraction pattern when viewed under polarized light, and drum-dried starch does not exhibit a Malta diffraction pattern when viewed under polarized light). The drum-dried starch is generally milled to obtain a specific particle size. Referring to commercially available pregelatinized starch available from Ingredion Incorporated, the coarser grind may have a particle size distribution such that about 55% of the particles (by volume) will settle on a 200 mesh (74 micron pore size) sieve, and the finer grind may have a particle size distribution where up to about 1.0% of the particles will settle on a 500 mesh (25 micron pore size) sieve. In foods, dehydrated drum dried starch may have a pulpy texture that can be reduced by using finer milled drum dried starch products.

[0093] FIG. 1 is a photograph of drum-dried, heat-inhibited waxy cassava starch available from Ingredion Incorporated after staining with iodine. The starch was prepared by hydrating drum-dried, heat-inhibited waxy cassava starch in fruit juice for 33 minutes (7% starch in fruit juice, dry basis). 0.1 g of starch in fruit juice dispersion was then mixed with 0.1 g of iodine solution (calculated as follows: 6.5 g potassium iodide + 1.3 g iodine / 100 mL deionized water, solution from JT Baker). The stained starch was viewed at 100x magnification using a polarizing filter. Referring to FIG. 1, there was no Malta orthogonal diffraction pattern in the starch granules, demonstrating that the starch was pregelatinized. Note that many jagged small features were visible, indicating that the shear from the drum had torn much of the starch apart.

[0094] Example 1b - Spray cooked pregelatinized thermally inhibited starch The spray cooking process is known and generally works by passing a starch slurry through a narrow annular opening while using high temperature steam to cook the starch. The steam passes through the circular steam opening and travels radially across the starch slurry flow toward the starch slurry flow. This cooks the starch and simultaneously pregelatinizes it. The pregelatinized starch slurry is then passed through a spray nozzle to collect the starch. The particle size of the spray cooked starch is controlled by the nozzle size, which can be confirmed by visual inspection.

[0095] FIG. 2 is a photograph of spray dried, heat inhibited waxy cassava starch after staining with iodine. Starch was prepared for expansion using the same method as the starch shown in Figure 1 (hydration of drum heat-inhibited waxy cassava starch in juice (7% starch in juice, dry basis) for 33 minutes. 0.1 g of starch in juice dispersion was then mixed with 0.1 g of iodine solution (calculated as follows, 6.5 g potassium iodide + 1.3 g iodine / 100 mL deionized water, solution from J.T. Baker). Referring to Figure 2, there was no Malta orthogonal diffraction pattern present on the starch granules, confirming that the starch was pregelatinized. As can be seen, although irregularly shaped, the starch had a generally smoother surface than the drum-dried, heat-inhibited waxy corn starch of Figure 1. The relatively fewer jagged edges indicated that the spray-cooked starch remained mostly intact, indicating less signs of shearing (fragmentation) than the starch product obtained by the drum drying method.

[0096] Example 1c - Single Phase Pregelatinized Thermally Inhibited Starch (Prophetic Example) In a preferred embodiment of the described method, the thermally inhibited starch is pregelatinized in a single-phase process using a hollow tube reactor, such as the CoriMix reactor available from Gebrueder Lodige Maschinenbau GmbH. Hot water is fed into the reactor to dehydrate the amount of starch described herein. More specifically, water is added to provide sufficient moisture to the starch so that it will pregelatinize with the heat provided by the CoriMix reactor. A preferred process starts with thermally inhibited starch that has not been rewetted and therefore has a moisture content of less than about 2% (wt%), and adds sufficient hot water so that the starch is hydrated to a moisture content of more than 20% or more than 30% up to about 45% (wt%).

[0097] In operation, the CoriMix reactor forces the starch through the length of the hollow tube, applying shear forces to the starch as it gelatinizes. However, unlike drum drying, the starch is not slurried in water and exists in a single phase during the process, so damage to the starch resulting from shear is expected to be less than observed for drum drying. Thus, the product pregelatinized in the single-phase process is expected to have a less jagged and broken appearance than drum-dried pregelatinized heat-inhibited starch and more jagged and broken than spray-cooked pregelatinized heat-inhibited starch. The starch is further expected to provide a viscosity comparable to either spray-dried or drum-dried starch, but a less pulpy texture than finely milled drum-dried heat-inhibited starch, e.g., having about 500 mesh.

Claims

1. A method for processing thermally inhibited starch, comprising: providing thermally inhibited starch; and gelatinizing the thermally inhibited starch by applying a hot aqueous fluid to the starch in an amount of from about 20% to about 40%, or from about 25% to about 40% (by weight of the starch), wherein the temperature of the hot aqueous fluid is from about 70°C to about 99°C, or from about 100°C to about 200°C, and the hot aqueous fluid is applied to the starch in one or more hollow tube reactors.

2. 10. The method of claim 1, further comprising drying the pregelatinized, thermally inhibited starch to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or to about 12% (by weight).

3. 10. The method of claim 1, wherein the hot aqueous fluid is applied in an amount of from about 30%, or from about 35% to about 40%, and the thermally inhibited starch is pregelatinized such that the starch does not exhibit a Malta orthogonal diffraction pattern when viewed under polarized light.

4. 10. The method of claim 1, wherein the starch is from the group consisting of corn, waxy corn, rice, glutinous rice, tapioca, waxy tapioca, potato, waxy potato, pea, chickpea, lentil, fava bean, quinoa, sago, and mixtures thereof.

5. The method described in claim 1, wherein the hot aqueous fluid is applied to a thermally inhibited starch having a moisture content of less than 2% (by weight of the starch).

6. Approximately 2000 mPa when measured using a micro-visco-amylograph test * less than or about 1500 mPa * s or less, or a) about 300 mPa * b) less than about 300 mPa * s~about 800mPa * s, and c) about 800 mPa * s~about 1600mPa * 10. The method of claim 1, wherein the hot aqueous fluid is applied to a thermally inhibited starch having a peak hot viscosity within a range selected from the group consisting of:

7. a. forming thermally inhibited starch agglomerates by applying a hot aqueous fluid to the thermally inhibited starch in a first amount ranging up to about 40% (by weight of the starch); b. pregelatinizing the agglomerated, thermally inhibited starch by applying a hot aqueous fluid to the thermally inhibited agglomerated starch in a second amount greater than the first amount but up to about 40% (by weight of the starch); 10. The method of claim 1, wherein optionally the pregelatinized agglomerated thermally inhibited starch is dried to a moisture content of up to about 15%, or from about 4%, or from about 6%, or from about 8% to about 15%, or to about 12% (by weight).

8. 8. The method of claim 7, wherein the thermally inhibited starch is agglomerated, pregelatinized, and dried in the same reactor.

9. 8. The method of claim 7, wherein the thermally inhibited starch is agglomerated in a reactor different from that in which it is pregelatinized and dried.

10. 10. The method of claim 1, wherein the hot aqueous fluid has a temperature of from about 75°C, or from about 80°C, or from about 85°C, or from about 90°C, or from about 95°C, or to about 99°C, or from about 70°C to about 95°C, or to about 90°C, or to about 85°C, or to about 80°C, or to about 75°C.

11. The method of claim 1 , wherein the hot aqueous fluid is saturated steam.

12. 10. The method of claim 1, wherein the hot aqueous fluid has a temperature of from about 100°C to about 190°C, or to about 180°C, or to about 170°C, or to about 160°C, or to about 150°C.

13. A pregelatinized thermally inhibited starch or a pregelatinized agglomeration thermally inhibited starch made according to the process of any one of claims 1 to 12.

14. An aqueous starch slurry having 6% starch solids and a pH of 6 can be heated to a viscosity of about 2000 mPa without heating the slurry. * Less than or about 1500 mPa * a) a viscosity of less than about 300 mPa * b) less than about 300 mPa * s~about 800mPa * s, and c) about 800 mPa * s~about 1600mPa * 14. The pregelatinized thermally inhibited starch or pregelatinized agglomeration thermally inhibited starch of claim 13, having a viscosity in the range selected from the group consisting of:

15. 13. A food product comprising a pregelatinized, thermally inhibited starch or a pregelatinized, agglomerated, thermally inhibited starch made by the process of any one of claims 1 to 12, and a second edible ingredient.

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