Manufacturing method for whole wheat dry pasta
By milling durum wheat kernels without separating bran and endosperm fractions and controlling drying conditions, the method produces whole wheat pasta with enhanced taste, texture, and color using existing equipment, addressing the issues of bitter taste and gritty texture in durum wheat pasta production.
Patent Information
- Application Number
- JP2021120437
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2021-07-21
- Publication Date
- 2025-10-24
- Estimated Expiration
- 2041-07-21
AI Technical Summary
Existing methods for producing whole wheat durum pasta require additional equipment or reconfiguration to address issues like bitter taste, gritty texture, and dark color, which are caused by the hard outer husk of durum wheat, and existing methods using existing equipment result in suboptimal taste, texture, and color.
A method involving milling durum wheat kernels without separating the bran and endosperm fractions, followed by mixing with water to form a hydrated dough, extruding, and drying at specific moisture and temperature conditions to produce durum wheat whole wheat flour with controlled particle sizes and ash content, ensuring excellent taste, texture, and color.
The method produces durum wheat whole wheat pasta with improved taste, texture, and color using existing production equipment without additional equipment, achieving optimal sensory qualities.
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Abstract
Description
[Technical Field]
[0001] The present invention relates to a method for producing whole wheat dry durum pasta. [Background technology]
[0002] With growing health awareness, there is an increasing demand for foods made with whole wheat flour, which is rich in nutrients such as dietary fiber, vitamins, and minerals, and similar high-yield wheat flour.In addition, needs related to SDGs and food waste are expected to increase, and there is a demand for foods with less production loss (discarded or converted into animal feed). Durum whole wheat dried pasta, which uses whole durum wheat flour as the raw material, has issues such as a unique bitter taste, a gritty texture, the unpleasant feeling of the wheat husk stinging the lips and inside the mouth, and a dark reddish color, and some kind of pre-processing equipment has been required to improve these issues. Durum wheat has a hard outer husk (wheat bran), and even when milled, the husk tends to remain large, adversely affecting texture and taste. Patent documents 1 to 3, for example, propose a method for improving this undesirable characteristic by separating a fraction with less husk from a fraction with more husk by sieving or other methods, and then subjecting only the fraction with more husk to special processing such as fine grinding, moist heat treatment, or dry heat treatment. However, these methods require the reconfiguration of manufacturing equipment or the introduction of processing equipment. Patent document 4 also discloses a technology using whole wheat flour obtained by blending whole wheat flours prepared by mixing predetermined amounts of fine and coarse fractions having predetermined particle sizes. While this method can be implemented using existing manufacturing equipment, it requires the preparation of two types of whole wheat flour and the installation of equipment for storing and mixing them. Therefore, there is a need for a method for producing whole wheat dry durum pasta that does not require additional preparation equipment and can be produced using existing production equipment. [Prior art documents] [Patent documents]
[0003] [Patent Document 1] Patent Publication No. 2007-082542 [Patent Document 2] Patent Publication No. 2007-125003 [Patent Document 3] Patent Publication No. 2019-129712 [Patent Document 4] Patent Publication No. 2015-195759 Summary of the Invention [Problem to be solved by the invention]
[0004] The problem to be solved by the present invention is to provide durum wheat whole grain dried pasta that has excellent taste, texture and color using existing production equipment, without requiring additional preparation equipment. [Means for solving the problem]
[0005] Therefore, the present inventors conducted extensive research to solve the above-mentioned problems, and as a result, they discovered a method for producing whole wheat durum flour pasta, which comprises the steps of milling durum wheat kernels without separating the bran fraction and the endosperm fraction to obtain durum wheat whole wheat flour, mixing the durum wheat whole wheat flour with water to obtain a hydrated dough, extruding the hydrated dough to obtain noodle dough, a preliminary drying step of drying the noodle dough until the moisture content is 16 to 22% by mass, and a main drying step of drying the noodle dough at an average ambient temperature of 62 to 83°C until the moisture content is 13% by mass or less, wherein the durum wheat whole wheat flour has a 50% particle size diameter (median diameter, D50) of 90 μm or more in its volume-based particle size distribution, and a 90% particle size diameter of 60 μm or less in its volume-based particle size distribution. The present inventors have found that it is possible to provide durum wheat whole wheat flour dried pasta with excellent taste, texture and color by using the above-mentioned production method, wherein the 50% particle size in a volume-based particle size distribution (median diameter, D50) is 90 μm or more and the 90% particle size in a volume-based particle size distribution is 600 μm or less, and the ash content of the fraction of particle sizes of 280 μm or more of the durum wheat whole wheat flour is 1.4 to 6.0 mass%, and the a* value in the CIELab color system is 10.0 or more but less than 14.0. That is, the present invention is as follows. [1] The following process milling durum wheat grains without separating the bran and endosperm fractions to obtain durum wheat whole grain flour; A step of mixing the durum wheat whole grain flour with water to obtain a hydrated dough; a step of extruding the hydrated dough to obtain noodle dough; a preliminary drying step of drying the noodle dough until the water content is 16 to 22% by mass; A method for producing dried durum wheat whole grain pasta further comprising a main drying step of drying the noodle dough at an average ambient temperature of 62 to 83°C until the water content is 13% by mass or less, wherein the durum wheat whole grain flour has a 50% particle size (median size, D50) of 90 μm or more in its volume-based particle size distribution and a 90% particle size of 600 μm or less in its volume-based particle size distribution, and the durum wheat whole grain flour has an ash content of 1.4 to 6.0% by mass in the fraction having particle sizes of 280 μm or more. [2] The method of [1], further comprising the step of dehulling the durum wheat kernels before milling the durum wheat kernels without separating the bran fraction and the endosperm fraction to obtain whole durum wheat flour. [3] A dried pasta containing durum wheat whole wheat flour, in which the 50% particle size (median size, D50) in the volume-based particle size distribution is 90 μm or more, and the 90% particle size in the volume-based particle size distribution is 600 μm or less, The dried pasta described above, wherein the ash content of the fraction of the durum wheat whole wheat flour with a particle size of 280 μm or more is 1.4 to 6.0 mass%, and the a* value in the CIELab color system is 10.0 or more and less than 14.0. [4] A method for producing cooked durum wheat whole wheat pasta, comprising a step of cooking the dry durum wheat whole wheat pasta obtained by the method described in [1] or [2] or the dry durum wheat whole wheat pasta described in [3]. [Effects of the Invention]
[0006] According to the present invention, it is possible to provide durum wheat whole grain dried pasta with excellent taste, texture and color using existing production equipment, without the need for additional preparation equipment. DETAILED DESCRIPTION OF THE INVENTION
[0007] (Manufacturing method of whole wheat dry durum wheat pasta) The method for producing durum wheat whole grain dried pasta of the present invention comprises the steps of milling durum wheat kernels without separating the bran fraction and the endosperm fraction to obtain durum wheat whole grain flour, mixing the durum wheat whole grain flour with water to obtain a hydrated dough, extruding the hydrated dough to obtain a noodle dough, a preliminary drying step of drying the noodle dough until the moisture content is 16 to 22% by mass, and a main drying step of drying the noodle dough at an average ambient temperature of 62 to 83°C until the moisture content is 13% by mass or less, wherein the durum wheat whole grain flour has a 50% particle size (median size, D50) of 90 μm or more in its volume-based particle size distribution and a 90% particle size of 600 μm or less in its volume-based particle size distribution, and the ash content of the durum wheat whole grain flour fraction having a particle size of 280 μm or more is 1.4 to 6.0% by mass.
[0008] (a) Preparation of durum wheat whole wheat flour The manufacturing method of the present invention comprises milling durum wheat grains without separating the bran and endosperm fractions to obtain whole durum wheat flour. Generally, durum wheat whole wheat flour is obtained by optionally conditioning selected durum wheat grains and then grinding them whole using a grinder such as a pin mill, hammer mill, mortar grinder, or airflow grinder to produce flour containing all of the wheat grains, including the epidermis, germ, and endosperm; alternatively, by optionally conditioning selected durum wheat grains and then grinding them multiple times using a roll mill to fractionate them into a fine fraction of the endosperm (wheat flour, hereinafter referred to as the "endosperm fraction"), a germ fraction, and a coarse fraction containing the outer layer of the endosperm (wheat bran), and then mixing the endosperm fraction, germ fraction, and wheat bran fraction in the composition ratio of the durum wheat grain.
[0009] Wheat kernels, including durum wheat, generally consist of endosperm, germ, and the outer layer (wheat bran) that covers the endosperm and germ. Although this varies slightly depending on growing conditions and varieties, the composition ratio of endosperm, bran, and germ in a wheat kernel is approximately 83:15:2 (by mass). In the present invention, durum wheat whole grain flour refers to a product containing the above-mentioned components of durum wheat kernels in substantially the same compositional ratios as those described above. Durum wheat kernels may also be used that have been dehulled, as described below. The process of milling durum wheat kernels to obtain whole wheat flour, and methods for obtaining whole wheat flour, generally include a method in which the endosperm, wheat bran, and germ are all milled together without separation (Production Method 1), and a method in which the milled material is fractionated into three fractions, namely, the endosperm fraction, the wheat bran fraction, and the germ fraction, and then mixed to obtain whole wheat flour (Production Method 2). In the present invention, Production Method 1 corresponds to a method for milling durum wheat kernels without separating the bran fraction and the endosperm fraction. Specifically, in Production Method 1, selected wheat kernels are optionally tempered and milled in an impact mill such as a pin mill, hammer mill, or airflow mill, or a mortar-type mill, to obtain whole wheat flour.
[0010] In the present invention, it is preferable to include a step of dehulling durum wheat grains before the step of milling durum wheat grains without separating the bran fraction and the endosperm fraction to obtain durum wheat whole grain flour. In the present invention, dehulling refers to a process of partially removing the outer husk of durum wheat grains by physically scraping them, and the dehulling rate of durum wheat grains (the rate of removal of the outer husk by the dehulling process) by the dehulling process is 3% or less, preferably 1 to 3%. Dehulling tends to improve the texture, color, and taste. Dehulling may be performed, for example, by utilizing friction between wheat grains or by using a commercially available dehulling machine or barley polishing machine.
[0011] In the present invention, the durum wheat grains used to obtain whole wheat flour may be any known grains, and specifically, any durum wheat grains of a variety or brand used for food can be suitably used regardless of place of origin.
[0012] The 50% particle size (median diameter, D50) in the volumetric particle size distribution of durum wheat whole wheat flour is 90 μm or more, and the 90% particle size (D90) in the volumetric particle size distribution is 600 μm or less. D50 is preferably 150 to 350 μm, and more preferably 200 to 350 μm. Durum wheat whole wheat flour with a D50 of less than 90 μm tends to have a less elastic texture and a more crumbly feel. The higher the D50, the better the texture and taste tend to be, but if D90 exceeds 600 μm, the wheat husk tends to catch or prick the lips or inside the mouth, which is a concern. Therefore, D90 is preferably 300 to 600 μm, and more preferably 400 to 600 μm. In this specification, particle size distribution and particle size are based on volume, D50 represents the particle size at 50% of the cumulative total (50% particle size, median diameter) calculated from the smallest particle in a particle size cumulative distribution curve, and D90 represents the particle size at 90% of the cumulative total. Volume-based particle size can be measured by a known laser diffraction / scattering method, and a specific example of such an apparatus can be a particle size distribution analyzer (MT3000, manufactured by Microtrack Bell Co., Ltd.). In the present invention, the ash content of the fraction of durum wheat whole grain flour with a particle size of 280 μm or more is 1.4 to 6.0% by mass, preferably 1.4 to 1.8% by mass. Since the ash content of the endosperm portion of the wheat grain is approximately 0.4% by mass and the ash content of the bran portion is 5.0 to 6.0% by mass, the fraction of durum wheat whole grain flour with a particle size of 280 μm or more in the present invention contains approximately 20 to 100% by mass, preferably approximately 20 to 30% by mass, of a bran-derived fraction.
[0013] (b) Preparation of hydrated dough and noodle making The production method of the present invention includes a step of mixing the durum wheat whole grain flour with water to obtain a hydrated dough. The hydrated dough can be obtained by a conventional method depending on the type of pasta to be produced. For example, in the case of spaghetti, the hydrated dough can be obtained by adding water to durum wheat whole grain flour so that the moisture content of the resulting dough is about 30 to 35% by mass, and mixing the mixture in a noodle mixer or the like. In the production method of the present invention, in addition to the durum wheat whole grain flour, other commonly used cereal flours may be used as the raw material flour, depending on the intended use and texture improvement. These include common cereal flours such as common wheat, durum wheat, so-called ancient wheats, novel cereals obtained by crossbreeding with wheat, and secondary cereal flours derived from grains such as rice, rye, barley, oats, Job's tears, corn, buckwheat, soybeans, barnyard millet, foxtail millet, and amaranth. Secondary ingredients may also be used, including inorganic salts such as salt, various starches (including modified starches), egg whites, egg yolks, whole eggs, and powders thereof, thickeners, alcohol, emulsified oils and fats, emulsifiers, milk and milk powder, preservatives, flavorings, colorings, spices, nutritional fortifiers such as vitamins and calcium, and protein materials derived from animals and plants. The amount of durum wheat whole grain flour used is not particularly limited, but is preferably at least 80% by mass, more preferably at least 90% by mass, and most preferably 100% by mass, of the total amount of cereal flour contained in the raw material flour.
[0014] The manufacturing method of the present invention also includes a step of extruding the hydrated dough to obtain noodle dough. The obtained hydrated dough can be made into noodles using a standard method appropriate for the type of pasta. For example, this can be done using an extrusion-type noodle-making machine, and preferably, noodles are made using a vacuum extrusion noodle-making method using a vacuum extruder. In the present invention, examples of pasta shapes include, but are not limited to, long pasta such as spaghetti, spaghettini, fedellini, capellini, linguine, and bucatini, and short pasta such as macaroni, penne, conchiglie, farfalle, and fusilli.
[0015] (c) Drying process Dried pasta is generally produced by adding water to raw flour (mainly durum semolina) and extruding the dough through a mold (die) under high vacuum pressure to obtain a shaped dough, which is then dried under controlled humidity until the moisture content is 13% by mass or less. The drying process involves gradually raising the ambient temperature inside the drying chamber, drying at an appropriate temperature over a period of time, and then gradually lowering the temperature back to room temperature. Specifically, the extruded dough (approximately 30-35% moisture) is heated with a heater immediately after extrusion. The process typically involves (1) pre-drying to approximately 20% moisture, (2) reducing the moisture content to 13% or less in the main drying process, (3) stabilizing the moisture gradient inside and outside the dough to homogenize, and (4) cooling it back to room temperature. In industrial continuous production lines, the process progresses by conveying the extruded dough through zones of different temperatures inside the dryer. Heaters are installed at individual locations within the dryer depending on the manufacturing equipment, and the ambient temperature is raised or lowered while humidity is adjusted as needed to adjust the drying level to the target moisture level. Drying times also vary depending on the manufacturing equipment.
[0016] The production method of the present invention comprises a preliminary drying step in which the noodle dough is dried until the water content is 16 to 22% by mass, and a main drying step in which the noodle dough is dried at an average ambient temperature of 62 to 83°C until the water content is 13% by mass or less. The average ambient temperature in the main drying step is preferably 68 to 80°C, and more preferably 70 to 75°C. There are no particular limitations on the ambient temperature or drying time in the preliminary drying step, but for example, the noodle dough is dried at 40°C to 75°C for 30 to 90 minutes until the water content reaches 16 to 22% by mass, and preferably 17 to 21% by mass. It is preferable that the ambient temperature in the preliminary drying step does not exceed 80°C. The drying time in this main drying step depends on the average ambient temperature and production equipment, but is typically 4 to 8 hours at an average ambient temperature of 65°C, and 1.5 to 3 hours at 80°C. In this drying step, the noodle dough is dried until its moisture content is 13% by mass or less, preferably within the range of 10 to 12% by mass.
[0017] By using the drying process of the present invention that satisfies the specified conditions, it is possible to obtain whole wheat dried pasta with excellent taste, texture and color. If the average atmospheric temperature in this drying process exceeds 83°C, the color tends to become darker red and the taste tends to become more bitter, while if it is below 62°C, the texture tends to become more crumbly, less elastic, and less crisp.
[0018] (Dried whole wheat durum pasta) The present invention relates to dried pasta containing durum wheat whole wheat flour, in which the 50% particle size (median size, D50) in a volume-based particle size distribution is 90 μm or more and the 90% particle size in a volume-based particle size distribution is 600 μm or less, wherein the ash content of the fraction of the durum wheat whole wheat flour having particle sizes of 280 μm or more is 1.4 to 6.0 mass%, and the a* value in the CIELab color system is 10.0 or more and less than 14.0.
[0019] The durum wheat whole grain flour contained in the durum wheat whole grain dried pasta of the present invention is as described in the "Method for producing durum wheat whole grain dried pasta" of the present invention. In addition to the above-mentioned durum wheat whole wheat flour, the durum wheat whole wheat dried pasta of the present invention may use, as a raw material flour, other commonly used cereal flours, such as common wheat, durum wheat, so-called ancient wheat, new cereals obtained by crossbreeding with wheat, and secondary cereal flours derived from cereals such as rice, rye, barley, oats, Job's tears, corn, buckwheat, soybean, barnyard millet, foxtail millet, and amaranth, depending on the intended use and the intended texture improvement. Secondary ingredients may also be used, such as inorganic salts such as salt, various starches (including modified starches), egg whites, egg yolks, whole eggs, or powders thereof, thickeners, alcohol, emulsified oils and fats, emulsifiers, milk and milk powder, preservatives, flavorings, colorings, spices, nutritional fortifiers such as vitamins and calcium, and protein materials derived from animals and plants. The amount of durum wheat whole grain flour used is not particularly limited, but is preferably 80% by mass or more, more preferably 90% by mass or more, and most preferably 100% by mass, of the total amount of grain flour contained in the raw material flour.
[0020] The color tone of the pasta was measured using a spectrophotometer CM-3500d (Konica Minolta) with a φ38 mm target mask. Using a jig, the dried pasta was laid out with the noodle strands aligned so that the layer was 13 mm thick, and the layer was covered with a board to prevent light from entering from outside, and the L*, a*, and b* values were measured. The L*a*b* color space is a method of quantifying color tones that was standardized by the International Commission on Illumination (CIE) in 1976 to represent the color of an object, and is also adopted in Japan as part of JIS (JIS Z 8781-4) (hereafter referred to as the "CIELab color system"). The L* value represents lightness, with larger values indicating brighter colors. The a* value is a component in the red-purple and blue-green directions, with larger values indicating stronger red-purple colors. The b* value is a component in the yellow-blue directions, with larger values indicating yellower colors.
[0021] (Method of manufacturing cooked whole wheat durum pasta) The present invention also relates to a method for producing cooked durum wheat whole grain pasta, which comprises a step of cooking the above-mentioned dry durum wheat whole grain pasta of the present invention or the dry durum wheat whole grain pasta produced by the production method of the present invention. For example, durum wheat whole grain dried pasta can be added to boiling water and the boiling time adjusted so that the boiling yield is 200 to 320% to make boiled pasta, or it can be further cooked by frying or stewing with sauce seasonings, etc. [Example]
[0022] EXAMPLES The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.
[0023] Production Example 1: Production of durum wheat whole wheat flour Durum wheat kernels were milled in an airflow mill without separating the bran and endosperm fractions, and particle size was adjusted by changing the mill rotation speed and the sieve openings used when sieving after milling, to obtain durum wheat whole wheat flour with the D50 and D90 values shown in Table 1. The ash content of the fractions of the obtained whole wheat flour with particle sizes of 280 μm or more was in the range of 1.4 to 6.0% by mass.
[0024] Production Example 2: Production of dried pasta 100 parts by mass of the resulting durum wheat whole wheat flour was added with 27 to 32 parts by mass of water and mixed for 10 minutes in a noodle mixer to obtain a hydrated dough. The hydrated dough was extruded into the shape of spaghetti using a macaroni molding machine while the pressure was reduced to a vacuum of approximately -80 kPa (gauge pressure), yielding noodle dough. The noodle dough was placed on a baking sheet and pre-dried in a dryer at 40 to 75°C until the moisture content of the noodles reached 16 to 22% by mass. Further drying was performed under controlled humidity conditions to reduce the moisture content of the noodles to 13% by mass or less, yielding dried pasta with a diameter of 1.7 mm. The average atmospheric temperature during the main drying process was varied to produce dried pasta with different average atmospheric temperatures. The moisture content of the resulting dried pasta was within the range of 10 to 12% by mass.
[0025] Test Example 1: Evaluation of boiled pasta Each dried pasta was placed in boiling water, and the boiling time was adjusted to achieve a boiling yield of 230%. The boiled pasta was then evaluated by 10 experienced panelists according to the evaluation criteria. Following the test example described in Patent Document 1, Reference Example 1 was prepared using durum wheat whole wheat flour (a conventional product manufactured by Nippon Co., Ltd., used exclusively in-house) and humidity-controlled drying at an average atmospheric temperature of 90°C during the drying process. Each pasta was evaluated as having a good color tone if all evaluation items were 3.0 points or higher and the "a*" value, which indicates the intensity of the color from green to red, was less than 14.0. Furthermore, a rating of "good" for "lip and throat stickiness" was given as an overall rating of "good." The results are shown in Table 1.
[0026] Evaluation criteria table TIFF0007759744000001.tif78138
[0027] Table 1 TIFF0007759744000002.tif99145 TIFF0007759744000003.tif99145 TIFF0007759744000004.tif78132
[0028] A common trend was observed in which the larger the D50, the higher the evaluation of "texture" and "taste." Furthermore, an average ambient temperature that was too high or too low was not good; at 60°C, the evaluation of "texture" was low (Comparative Examples 1 and 2), and at 85°C, the evaluation of "taste," "texture," and "color tone" was low (Comparative Examples 8 and 9). In the reference examples where D50 was small and the average ambient temperature was 90°C, the color of the dried noodles became extremely reddish-black. The best results were obtained when the average ambient temperature was 72°C. When D90 was 604 μm, the wheat husk caught on the lips and inside the mouth, causing pain and discomfort (Comparative Examples 4, 5, and 7).
[0029] Test Example 2: Dehulled durum wheat Hulling is a known method for reducing the unpleasant sensation caused by the outer skin of durum wheat grains. Therefore, durum wheat grains were peeled to a peeling rate (the percentage of outer skin removed by the peeling process) of 2%, and the resulting peeled durum wheat grains were then ground in the same manner as in Production Example 1 to obtain peeled durum wheat whole wheat flour. Dried pasta was produced using this as a starting material in the same manner as in Production Example 2, and the quality of the dried pasta was evaluated in the same manner as in Test Example 1 (average ambient temperature 72°C). The results are shown in Table 2.
[0030] Table 2 TIFF0007759744000005.tif93141
[0031] Compared to Example 5, which used unpeeled durum wheat whole wheat flour, both the texture and taste were improved (Example 10). When dried pasta made from peeled durum wheat whole wheat flour was dried in the temperature range of the present invention, dried pasta of higher quality was obtained.
Claims
1. The following process milling durum wheat grains without separating the bran and endosperm fractions to obtain durum wheat whole grain flour; A step of mixing the durum wheat whole grain flour with water to obtain a hydrated dough; a step of extruding the hydrated dough to obtain noodle dough; a preliminary drying step of drying the noodle dough until the water content is 16 to 22% by mass; A method for producing dried durum wheat whole grain pasta, further comprising a main drying step of drying the noodle dough at an average ambient temperature of 62 to 83°C until the water content of the noodle dough is 13% by mass or less, The durum wheat whole wheat flour has a 50% particle size (median size, D50) in a volume-based particle size distribution of 90 μm or more and 253 μm or less, and a 90% particle size in a volume-based particle size distribution of 600 μm or less; The ash content of the fraction of the durum wheat whole grain flour with a particle size of 280 μm or more is 1.4 to 6.0% by mass. The manufacturing method.
2. 10. The method of claim 1, further comprising the step of dehulling the durum wheat kernels before milling them.
3. A dried pasta containing durum wheat whole wheat flour, wherein the 50% particle size (median size, D50) in a volume-based particle size distribution is 90 μm or more and 253 μm or less, and the 90% particle size in a volume-based particle size distribution is 600 μm or less, The ash content of the fraction of the durum wheat whole grain flour with a particle size of 280 μm or more is 1.4 to 6.0% by mass, The a* value in the CIELab color system is 10.0 or more and less than 14.0, The dried pasta.
4. A method for producing cooked durum wheat whole grain pasta, comprising a step of cooking the dry durum wheat whole grain pasta obtained by the method according to claim 1 or 2 or the dry durum wheat whole grain pasta according to claim 3.
Citation Information
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