Manufacturing method of eco-friendly twin-crunchy snack using jeju special products including whole grain baking sheet with cream filling and jelly filling derived from jeju citrus, hallabong, green tea, udo peanut, and apple mango, and snack manufactured thereby

Abstract

The present invention relates to a method for manufacturing a Twin Basak snack utilizing Jeju specialty products, and more specifically, to a method for manufacturing a Twin Basak snack using whole grains as the main ingredient and by a baking method without deep-frying, comprising cream fillings and jelly fillings utilizing Jeju specialty products such as Jeju tangerines, Hallabong oranges, green tea, Udo peanuts, and apple mangoes. The method for manufacturing a Twin Basak snack according to the present invention comprises the steps of: preparing whole grain powder through a two-step pretreatment process including washing whole grains with hot water at 40 to 50°C and far-infrared irradiation and cold air cooling; preparing dough by adding Jeju volcanic bedrock water and tangerine dietary fiber powder extracted from Jeju tangerine juice by-products to the whole grain powder and performing vacuum kneading and low-temperature aging; preparing a baking snack sheet having a moisture content of 2 to 4 weight% through a three-step temperature gradient baking process after molding the dough and coating it with a surface treatment solution mixed with Jeju tangerine juice and Jeju volcanic bedrock water; preparing a cream filling and a jelly filling, respectively, using a specialty product concentrate prepared by low-temperature vacuum concentrating Jeju specialty product raw materials; and preparing a Twin Basak snack by interposing the cream filling or the jelly filling between the baking snack sheets. According to the present invention, a whole grain snack with excellent texture can be manufactured using only a baking method without deep-frying, an eco-friendly manufacturing process can be realized through the upcycling of Jeju tangerine by-products, and a high-quality Jeju-specialized snack product can be provided that includes a filling material that preserves the unique flavor and functional components of Jeju specialty products to the maximum extent.

Description

Technology Field

[0001] The following embodiments relate to snacks utilizing Jeju specialty products and technology for an eco-friendly manufacturing method utilizing them. Background Technology

[0003] The snack food industry is seeing a continuous increase in demand for low-calorie, high-nutrient functional snacks, driven by growing consumer interest in health. Conventional snack products have mostly been manufactured using a deep-frying method in which wheat flour is used as the main ingredient and the product is deep-fried in high-temperature cooking oil. While this deep-frying method is effective in providing a crispy texture to the product, concerns have been continuously raised that the high levels of trans fat and saturated fat can lead to adult diseases such as obesity and cardiovascular disease.

[0004] Accordingly, snack manufacturing technologies using a baking method to replace deep-frying have been developed; however, conventional snack products produced by baking have the disadvantage of having inferior texture and lacking flavor compared to deep-fried products. In particular, for baking snacks made primarily from whole grains, there was a technical limitation in that it was difficult to ensure uniform quality during the molding and baking processes due to the coarse texture and low binding strength characteristic of whole grains.

[0005] Meanwhile, Jeju Special Self-Governing Province possesses a variety of high-quality specialty products, including tangerines, Hallabong oranges, green tea, Udo peanuts, and apple mangoes. These products contain large amounts of functional components such as polyphenols, flavonoids, and vitamin C, making them highly valuable as food ingredients. However, conventional snack manufacturing technologies have utilized Jeju specialty products merely as simple flavor additives; no technology has been developed to utilize them to enhance the texture and structural characteristics of snacks while preserving the unique functional components of these products to the fullest extent.

[0006] Furthermore, it is known that the amount of citrus by-products generated annually during the Jeju tangerine juicing process amounts to tens of thousands of tons; however, technologies for recycling these by-products into food ingredients have been very limited, and most of them have been treated as waste, becoming a cause of environmental pollution. Accordingly, there has been a demand for the development of upcycling technologies to utilize Jeju tangerine by-products as food ingredients.

[0007] Furthermore, conventional snack filling manufacturing technology used a high-temperature concentration method, which resulted in the destruction of the raw materials' inherent flavor and functional components by heat; additionally, preservation technology to prevent oxidation of the fillings was also inadequate. Prior art literature

[0009] Korean Registered Patent 10-2552974 Korean Registered Patent 10-2896145 Korean Published Patent 10-2025-0102833 Korean Registered Patent 10-2445110 The problem to be solved

[0010] The present invention has been devised to solve the problems of the prior art as described above, and the problem to be solved by the present invention is as follows.

[0011] First, the present invention aims to provide a method for manufacturing a whole-grain-based snack that can achieve an excellent crispy texture using only a baking method without deep-frying.

[0012] Second, the present invention aims to provide a whole grain pretreatment method that ensures the hygienic safety of whole grain raw materials through a pretreatment process including far-infrared irradiation and stepwise hot air drying, while simultaneously improving processing suitability in subsequent grinding and dough processes.

[0013] Third, the present invention aims to provide an eco-friendly snack manufacturing method that realizes the upcycling of Jeju tangerine by-products by utilizing tangerine dietary fiber powder extracted from Jeju tangerine juice by-products as a binding material for dough.

[0014] Fourth, the present invention aims to provide a method for producing a baking snack sheet of uniform quality after baking by removing air bubbles in the dough and completing the hydration of whole grain powder through a vacuum dough and low-temperature aging process.

[0015] Fifth, the present invention aims to provide a baking process that can maintain a crispy texture for a long period of time by precisely controlling the moisture content of a baking snack sheet to 2 to 4 weight percent through a three-stage temperature gradient baking process and a surface coating treatment using Jeju tangerine juice extract.

[0016] Sixth, the present invention aims to provide a method for manufacturing cream and jelly fillers that minimize the loss of unique flavor components and functional components of Jeju specialty products through a low-temperature vacuum concentration method, and to prevent oxidation of the fillers by storing them in a nitrogen-filled airtight container. means of solving the problem

[0018] The present invention provides a method for manufacturing a Twin Basak snack utilizing Jeju specialty products, which is manufactured by baking rather than frying, comprising: a) a pretreatment step of washing and drying whole grains; a1) a step of grinding the pretreated whole grains to produce whole grain powder; b) a dough preparation step of mixing auxiliary materials with the whole grain powder to produce dough; b1) a molding step of extruding the dough into a predetermined shape to produce a molded body; c) a baking step of baking the molded body in an oven at 100 to 200°C to produce a baking snack sheet; c1) a filling material preparation step of producing a cream filling material and a jelly filling material each containing Jeju specialty products; and c2) a bonding step of interposing the cream filling material or the jelly filling material between the baking snack sheets to produce a Twin Basak snack.

[0019] At this time, the pretreatment step comprises: a1) a step of removing surface foreign substances and residual pesticides by washing the whole grains repeatedly 3 to 5 times with hot water at 40 to 50°C; a2) a step of drying the washed whole grains in a hot air dryer at 55 to 65°C until the moisture content becomes 8 to 12 weight%; a3) a step of introducing the first-dried whole grains into a far-infrared irradiation device and irradiating far-infrared rays at 80 to 100°C for 10 to 20 minutes to reduce the number of microorganisms inside the whole grains by more than 99% compared to before far-infrared irradiation; a4) a step of rapidly cooling the far-infrared irradiated whole grains with cold air at 15 to 25°C to adjust the moisture content to 6 to 8 weight%.

[0020] At this time, b) the dough preparation step comprises: b1) a step of preparing a whole grain base by adding 30 to 40 parts by weight of Jeju volcanic bedrock water to 100 parts by weight of the whole grain powder and mixing it once; b2) a step of preparing a multi-grain mixture by adding 15 to 25 parts by weight of brown rice powder, 10 to 20 parts by weight of oat powder, and 5 to 15 parts by weight of barley powder to 100 parts by weight of the whole grain powder to the whole grain base and mixing it twice; b3) a step of adding 3 to 7 parts by weight of tangerine dietary fiber powder extracted from Jeju tangerine juice by-products to 100 parts by weight of the whole grain powder and mixing it to the multi-grain mixture; b4) a step of removing air bubbles in the dough by introducing the mixture with added tangerine dietary fiber powder into a vacuum dough mixer and kneading it for 20 to 30 minutes under vacuum conditions of -0.08 to -0.09 MPa; b5) A step of aging the vacuum-kneaded dough at 4 to 8°C for 12 to 24 hours to complete the hydration of the dough; characterized by including the above step.

[0021] At this time, c) the baking step comprises: c1) a step of spray-coating a surface treatment solution, prepared by mixing Jeju tangerine juice and Jeju volcanic bedrock water in a 1:1 weight ratio, to a thickness of 0.1 to 0.3 mm on the surface of the molded body before placing it into an oven; c2) a step of removing moisture from inside the molded body by placing the molded body coated with the surface treatment solution into an oven preheated to 150 to 160°C and baking it for 5 to 8 minutes; c3) a step of manufacturing a baking snack sheet by raising the temperature of the first-baked molded body to 170 to 180°C and baking it for 8 to 12 minutes; c4) a step of adjusting the moisture content of the second-baked baking snack sheet to 2 to 4 weight% by lowering the temperature of the second-baked baking snack sheet inside the oven to 120 to 130°C and drying it for 3 to 5 minutes; c5) a step of cooling the third-dried baking snack sheet with cold air at 15 to 25°C for 5 to 10 minutes; It is characterized by including

[0022] At this time, d) the step of manufacturing the filling material comprises: d1) a step of preparing a specialty product raw material by selecting and washing one or more Jeju specialty product raw materials among Jeju tangerines, green tea, Hallabong, Udo peanuts, and apple mangoes; d2) a step of preparing a specialty product concentrate by introducing the specialty product raw material into a low-temperature vacuum concentrator at 55~65℃ and concentrating it for 20~40 minutes under vacuum conditions of -0.08~-0.09 MPa; d3) a step of manufacturing a cream filling material by whipping a total of 100 parts by weight of a cream filling mixture, comprising 20~25 parts by weight of the specialty product concentrate, 55~60 parts by weight of vegetable cream, 10~12 parts by weight of Jeju organic raw sugar, and 8~10 parts by weight of purified water, at 5~10℃; d4) a step of manufacturing a jelly filler by mixing 33 to 38 parts by weight of the specialty product concentrate, 2 to 4 parts by weight of agar powder, 1 to 3 parts by weight of pectin, 30 to 35 parts by weight of Jeju volcanic bedrock water, and 22 to 28 parts by weight of Jeju organic raw sugar, dissolving a total of 100 parts by weight of the jelly filler mixture at 70 to 80°C, and then cooling and gelling at 15 to 25°C to manufacture the jelly filler; d5) a step of storing the cream filler and the jelly filler in nitrogen-filled sealed containers, respectively, to prevent oxidation until immediately before filling; characterized by including these steps. Effects of the invention

[0024] The method for manufacturing a Twin Basak snack using Jeju specialty products according to the present invention has the following effects.

[0025] First, the present invention can significantly reduce the content of trans fat and saturated fat by manufacturing snacks using only a baking method without deep-frying, and can provide health functional snacks rich in nutritional components such as dietary fiber, minerals, and vitamins by using whole grains as the main ingredient.

[0026] Second, the present invention can reduce the number of microorganisms in whole grain raw materials by more than 99% compared to before far-infrared irradiation by applying a two-stage pretreatment process including far-infrared irradiation, while simultaneously improving the grinding efficiency in the subsequent grinding process, thereby ensuring the hygienic safety and processing suitability of the raw materials at the same time.

[0027] Third, the present invention can realize high-value upcycling of tangerine by-products that were previously treated as waste by utilizing tangerine dietary fiber powder extracted from Jeju tangerine juice by-products as a binding material for dough, and through this, can contribute to the reduction of agricultural waste in the Jeju region.

[0028] Fourth, the present invention can effectively remove air bubbles in the dough and complete the hydration of whole grain powder by applying a vacuum dough process carried out under vacuum conditions of -0.08 to -0.09 MPa and a low-temperature aging process carried out at 4 to 8°C for 12 to 24 hours, thereby enabling the stable production of a baking snack sheet with uniform pores and a dense texture after baking.

[0029] Fifth, the present invention can precisely control the moisture content of a baking snack sheet to 2-4 weight% by applying a three-stage temperature gradient baking process consisting of a first baking at 150-160°C, a second baking at 170-180°C, and a third drying at 120-130°C, thereby maintaining the crispy texture of the snack for a long period of time.

[0030] Sixth, the present invention can minimize the loss of unique flavor components and functional components of Jeju specialty products, such as Jeju tangerines, Hallabong, green tea, Udo peanuts, and apple mangoes, due to heat by applying a low-temperature vacuum concentration method of 55 to 65°C, and can stably produce a jelly filler with excellent elasticity by applying a dual gelling agent system using agar powder and pectin.

[0031] Seventh, by utilizing Jeju volcanic bedrock water as dough water and water for manufacturing fillers, the present invention can secure differentiation as a regionally specialized product that actively utilizes the clean natural resources of the Jeju region in snack manufacturing. Brief explanation of the drawing

[0033] Figure 1 is a flowchart showing the entire process of the method for manufacturing a Twin Basak snack using Jeju specialty products according to the present invention. FIG. 2 is a flowchart showing the detailed process of the pretreatment step (a) according to the present invention. FIG. 3 is a flowchart showing the detailed process of the dough preparation step (b) according to the present invention. FIG. 4 is a flowchart showing the detailed process of the baking step (c) according to the present invention. FIG. 5 is a flowchart showing the detailed process of the filler manufacturing step (d) according to the present invention. Specific details for implementing the invention

[0034] Embodiments are described in detail below. However, various modifications may be made to the embodiments, and thus the scope of the patent application is not limited or restricted by these embodiments. It should be understood that all modifications, equivalents, and substitutions to the embodiments are included within the scope of the rights.

[0035] Specific structural or functional descriptions of the embodiments are disclosed for illustrative purposes only and may be modified and implemented in various forms. Accordingly, the embodiments are not limited to the specific disclosed forms, and the scope of this specification includes modifications, equivalents, or substitutions that fall within the technical concept.

[0036] Terms such as "first" or "second" may be used to describe various components, but these terms should be interpreted solely for the purpose of distinguishing one component from another. For example, the first component may be named the second component, and similarly, the second component may be named the first component.

[0037] When it is stated that a component is "connected" to another component, it should be understood that it may be directly connected to or coupled with that other component, or that there may be other components in between.

[0038] The terms used in the embodiments are for illustrative purposes only and should not be interpreted as intended to be limiting. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this specification, terms such as "comprising" or "having" are intended to indicate the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0039] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the embodiments pertain. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in this application.

[0040] The advantages and features of the present invention and the methods for achieving them will become clear by referring to the embodiments described below in detail together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below but may be implemented in various different forms. These embodiments are provided merely to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims.

[0041] In the embodiments of the present invention, unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the present invention pertains. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an ideal or overly formal sense unless explicitly defined in the embodiments of the present invention.

[0042] In describing the present invention, if it is determined that a detailed description of related prior art could unnecessarily obscure the essence of the invention, such detailed description is omitted. Where terms such as "comprising," "having," or "consisting of" are used in this specification, other parts may be added unless "only" is used. Where a component is expressed in the singular, it includes cases where it is included in the plural unless specifically stated otherwise.

[0043] In interpreting the components, they are interpreted to include a margin of error even in the absence of a separate explicit statement.

[0044] The features of each of the various embodiments of the present invention may be combined or combined with one another, either partially or wholly, and as will be fully understood by those skilled in the art, various technical interlocking and operation are possible, and each embodiment may be implemented independently of one another or together in an interlocking relationship.

[0046] The detailed description of the drawings of the present invention is as follows.

[0047] Detailed description of Fig. 1

[0048] FIG. 1 shows the overall process flow of a method for manufacturing a Twin Basak snack using Jeju specialty products according to the present invention, and illustrates a series of sequential processes from a pretreatment step (a) to a final combining step (c2).

[0049] Referring to FIG. 1, the method for manufacturing a Twin Basak snack according to the present invention is broadly composed of a pretreatment step of whole grain raw materials (a), a step of grinding the pretreated whole grains to produce whole grain powder (a1), a dough preparation step of mixing auxiliary materials with the whole grain powder to produce dough (b), a molding step of extruding the dough into a predetermined shape to produce a molded body (b1), a baking step of baking the molded body in an oven to produce a baking snack sheet (c), a filling material preparation step (c1) of producing a cream filling material and a jelly filling material containing Jeju specialty products, respectively, and a bonding step (c2) of interposing the cream filling material or the jelly filling material between the baking snack sheets to complete the Twin Basak snack.

[0050] In FIG. 1, each step is indicated by a square box, and the start and end of the process are indicated by an oval. Connections between steps are indicated by arrows to clearly show the sequential direction of the process. The final product, the Twin Basak snack, is indicated by a double-bordered square to distinguish it as the final output. The entire process illustrated in FIG. 1 is configured as a non-fried baking method that does not include any deep-frying treatment, and all processes from the pretreatment step (a) to the joining step (c2) are designed to be feasible with equipment available to small and medium-sized enterprises. The detailed processes of the pretreatment step (a) and the dough manufacturing step (b) are separately illustrated in FIG. 2 and FIG. 3, respectively, and the detailed processes of the baking step (c) and the filling material manufacturing step (d) are separately illustrated in FIG. 4 and FIG. 5, respectively.

[0052] Detailed description of Fig. 2

[0053] FIG. 2 shows the detailed process flow of the pretreatment step (a) according to the present invention, and four detailed steps from washing the whole grain raw material to rapid cooling are shown sequentially.

[0054] Referring to FIG. 2, the pretreatment step (a) consists of four steps: a hot water washing step (a1), a primary hot air drying step (a2), a far-infrared irradiation step (a3), and a rapid cooling step (a4).

[0055] In the hot water washing step (a1), whole grains are washed repeatedly 3 to 5 times with hot water at 40 to 50°C to remove surface foreign substances and residual pesticides. As shown in FIG. 2, the washing temperature and number of washes must be performed within the range specified in the present invention. If the washing temperature is less than 40°C or exceeds 50°C, or if the number of washes is less than 3 times or exceeds 5 times, the balance between the efficiency of removing residual pesticides and preventing starch gelatinization is disrupted.

[0056] In the first hot air drying step (a2), the washed whole grains are introduced into a hot air dryer at 55 to 65°C and dried until the moisture content reaches 8 to 12% by weight. The drying temperature and target moisture content shown in FIG. 2 are pretreatment conditions to optimize the microbial reduction efficiency in the subsequent far-infrared irradiation step, and if the moisture content is less than 8% by weight or exceeds 12% by weight, the microbial reduction effect by far-infrared irradiation may be reduced.

[0057] In the far-infrared irradiation step (a3), the first dried whole grains are introduced into a far-infrared irradiation device and irradiated with far-infrared rays at 80 to 100°C for 10 to 20 minutes, thereby reducing the number of microorganisms inside the whole grains by more than 99% compared to before the far-infrared irradiation. The far-infrared irradiation conditions shown in FIG. 2 are critical conditions for simultaneously achieving the effect of reducing microorganisms and preventing browning of the whole grains.

[0058] In the rapid cooling step (a4), the whole grains irradiated with far-infrared rays are rapidly cooled with cold air at 15 to 25°C to adjust the moisture content to 6 to 8 weight percent. As shown in the final output box of FIG. 2, the pre-treated whole grains are supplied to the subsequent grinding step (a1) in a state that simultaneously satisfies two quality criteria: a moisture content of 6 to 8 weight percent and a reduction of more than 99% of microorganisms.

[0060] Detailed description of Fig. 3

[0061] FIG. 3 shows the detailed process flow of the dough manufacturing step (b) according to the present invention, with five detailed steps sequentially shown from whole grain base manufacturing to low-temperature aging.

[0062] Referring to FIG. 3, the dough preparation step (b) consists of five steps: a whole grain base preparation step (b1), a multi-grain mixture preparation step (b2), a citrus dietary fiber powder addition step (b3), a vacuum dough preparation step (b4), and a low-temperature aging step (b5).

[0063] In the whole grain base manufacturing step (b1), 30 to 40 parts by weight of Jeju volcanic bedrock water are added to 100 parts by weight of whole grain powder and mixed once to produce a whole grain base. The content range of Jeju volcanic bedrock water shown in FIG. 3 is a critical range for securing the appropriate moisture content of the dough and maintaining moldability, and if it falls outside this range, the physical properties of the dough deteriorate.

[0064] In the multi-grain mixture preparation step (b2), 15 to 25 parts by weight of brown rice powder, 10 to 20 parts by weight of oat powder, and 5 to 15 parts by weight of barley powder are added to the whole grain base and mixed a second time to 100 parts by weight of whole grain powder to prepare the multi-grain mixture. The content range of each grain powder shown in FIG. 3 is a range to achieve a balance between sufficient content of functional ingredients and maintenance of dough processability.

[0065] In the step of adding tangerine dietary fiber powder (b3), 3 to 7 parts by weight of tangerine dietary fiber powder extracted from Jeju tangerine juice by-products are added to the multi-grain mixture for every 100 parts by weight of whole grain powder and mixed. The tangerine dietary fiber powder shown in FIG. 3 functions as a natural binding material to improve the binding strength of the dough, and at the same time serves as a key material for realizing the upcycling of Jeju tangerine juice by-products.

[0066] In the vacuum kneading step (b4), the mixture containing citrus dietary fiber powder is fed into a vacuum mixer and kneaded for 20 to 30 minutes under vacuum conditions of -0.08 to -0.09 MPa to remove air bubbles from the dough. The vacuum level and kneading time shown in FIG. 3 are critical ranges for achieving a balance between air bubble removal efficiency and preservation of the dough structure.

[0067] In the low-temperature aging step (b5), the vacuum-kneaded dough is aged at 4 to 8°C for 12 to 24 hours to complete the hydration of the dough. As shown in the final output box of FIG. 3, in the dough manufacturing completion step, a dough is produced in which two quality conditions of complete removal of air bubbles and complete hydration are simultaneously satisfied, and this dough is supplied to the subsequent molding step (b1).

[0069] Detailed description of Fig. 4

[0070] FIG. 4 shows the detailed process flow of the baking step (c) according to the present invention, and five detailed steps from surface treatment liquid spray coating to cold air cooling are shown sequentially.

[0071] Referring to FIG. 4, the baking step (c) consists of five steps: a surface treatment liquid spray coating step (c1), a first baking step (c2), a second baking step (c3), a third drying step (c4), and a cold air cooling step (c5).

[0072] In the surface treatment solution spray coating step (c1), before placing the molded body into the oven, a surface treatment solution mixed with Jeju tangerine juice and Jeju volcanic bedrock water in a 1:1 weight ratio is spray-coated onto the surface of the molded body to a thickness of 0.1 to 0.3 mm. The mixing ratio and coating thickness of the surface treatment solution shown in FIG. 4 are critical ranges for simultaneously ensuring surface quality after baking and preventing structural damage to the molded body.

[0073] In the first baking step (c2), the molded body coated with the surface treatment solution is placed in an oven preheated to 150–160°C and baked for 5–8 minutes to gradually remove moisture from inside the molded body. The first baking temperature shown in FIG. 4 is a temperature range designed to induce the gradual removal of internal moisture while preventing rapid hardening of the surface of the molded body.

[0074] In the second baking step (c3), the molded body baked in the first step is heated to 170–180°C and baked again for 8–12 minutes to induce the Maillard reaction and complete the baking snack sheet. The second baking temperature shown in FIG. 4 is a critical temperature range to simultaneously achieve optimal expression of the Maillard reaction and inhibition of acrylamide formation.

[0075] In the third drying step (c4), the second-baked baking snack sheet is dried for 3 to 5 minutes at a temperature of 120 to 130°C in an oven to adjust the moisture content of the baking snack sheet to 2 to 4 weight%. The third drying condition shown in FIG. 4 is a critical condition for precise control of the final moisture content to maintain the long-term crispness of the product.

[0076] In the cold air cooling step (c5), the tertiarily dried baking snack sheet is cooled with cold air at 15 to 25°C for 5 to 10 minutes. As shown in the final output box of FIG. 4, a baking snack sheet is produced that satisfies two quality conditions: a moisture content of 2 to 4 weight% and the completion of cooling at the completion of the baking step, and this baking snack sheet is supplied to the subsequent combining step (c2).

[0078] Detailed description of Fig. 5

[0079] FIG. 5 illustrates the detailed process flow of the filling material manufacturing step (d) according to the present invention, showing five detailed steps ranging from the preparation of specialty raw materials to nitrogen filling and sealed storage. In particular, FIG. 5 clearly shows a structure in which the cream filling material manufacturing path (d3) and the jelly filling material manufacturing path (d4) branch off and then merge, indicated by a diamond-shaped branching symbol.

[0080] Referring to FIG. 5, the filling material manufacturing step (d) consists of a specialty raw material preparation step (d1), a low-temperature vacuum concentration step (d2), branching steps (d3 and d4) for manufacturing cream filling or jelly filling, and a nitrogen-filled sealed storage step (d5).

[0081] In the specialty product raw material preparation step (d1), one or more Jeju specialty product raw materials among Jeju tangerines, green tea, Hallabong, Udo peanuts, and apple mangoes are selected and washed to prepare specialty product raw materials. As shown in FIG. 5, there are five types of Jeju specialty products available in this step, and they can be used as a single raw material or a combination of multiple raw materials, allowing for the composition of various product lineups.

[0082] In the low-temperature vacuum concentration step (d2), the specialty product raw material is introduced into a low-temperature vacuum concentrator at 55 to 65°C and concentrated for 20 to 40 minutes under vacuum conditions of -0.08 to -0.09 MPa to produce a specialty product concentrate. The low-temperature vacuum concentration conditions shown in FIG. 5 are critical conditions to minimize the loss of the unique flavor components and functional components of the specialty product due to heat.

[0083] As can be seen from the diamond-shaped branching symbol in FIG. 5, the specialty concentrate is branched into a cream filler manufacturing path (d3) or a jelly filler manufacturing path (d4) depending on the type of filler to be intended. In the cream filler manufacturing step (d3), a total of 100 parts by weight of a cream filler mixture, comprising 20 to 25 parts by weight of specialty concentrate, 55 to 60 parts by weight of vegetable cream, 10 to 12 parts by weight of Jeju organic raw sugar, and 8 to 10 parts by weight of purified water, is whipped at 5 to 10°C to produce the cream filler. In the jelly filler manufacturing step (d4), a total of 100 parts by weight of a jelly filler mixture comprising 33 to 38 parts by weight of specialty concentrate, 2 to 4 parts by weight of agar powder, 1 to 3 parts by weight of pectin, 30 to 35 parts by weight of Jeju volcanic bedrock water, and 22 to 28 parts by weight of Jeju organic raw sugar is dissolved at 70 to 80°C and then cooled and gelled at 15 to 25°C to produce the jelly filler. The content of each component of the cream filler and jelly filler shown in FIG. 5 is clearly limited based on a total of 100 parts by weight, and it has been confirmed through experimental examples that if the content of each component deviates from the range specified in the present invention, the physical properties and sensory quality of the filler are significantly degraded.

[0084] In the nitrogen-filled sealed storage step (d5), the cream filling and the jelly filling are each stored in nitrogen-filled sealed containers to prevent oxidation until just before filling. As shown in the final output box of FIG. 5, in the filling manufacturing completion step, the cream filling and the jelly filling are each stored in a nitrogen-filled sealed state, and in the combining step (c2) shown in FIG. 1, they are combined with a baking snack sheet to complete the final Twin Crispy Snack.

[0086] The present invention provides a method for manufacturing a Twin Basak snack utilizing Jeju specialty products, which is manufactured by baking rather than frying, comprising: a) a pretreatment step of washing and drying whole grains; a1) a step of grinding the pretreated whole grains to produce whole grain powder; b) a dough preparation step of mixing auxiliary materials with the whole grain powder to produce dough; b1) a molding step of extruding the dough into a predetermined shape to produce a molded body; c) a baking step of baking the molded body in an oven at 100 to 200°C to produce a baking snack sheet; c1) a filling material preparation step of producing a cream filling material and a jelly filling material each containing Jeju specialty products; and c2) a bonding step of interposing the cream filling material or the jelly filling material between the baking snack sheets to produce a Twin Basak snack.

[0087] At this time, the pretreatment step comprises: a1) a step of removing surface foreign substances and residual pesticides by washing the whole grains repeatedly 3 to 5 times with hot water at 40 to 50°C; a2) a step of drying the washed whole grains in a hot air dryer at 55 to 65°C until the moisture content becomes 8 to 12 weight%; a3) a step of introducing the first-dried whole grains into a far-infrared irradiation device and irradiating far-infrared rays at 80 to 100°C for 10 to 20 minutes to reduce the number of microorganisms inside the whole grains by more than 99% compared to before far-infrared irradiation; a4) a step of rapidly cooling the far-infrared irradiated whole grains with cold air at 15 to 25°C to adjust the moisture content to 6 to 8 weight%.

[0088] At this time, b) the dough preparation step comprises: b1) a step of preparing a whole grain base by adding 30 to 40 parts by weight of Jeju volcanic bedrock water to 100 parts by weight of the whole grain powder and mixing it once; b2) a step of preparing a multi-grain mixture by adding 15 to 25 parts by weight of brown rice powder, 10 to 20 parts by weight of oat powder, and 5 to 15 parts by weight of barley powder to 100 parts by weight of the whole grain powder to the whole grain base and mixing it twice; b3) a step of adding 3 to 7 parts by weight of tangerine dietary fiber powder extracted from Jeju tangerine juice by-products to 100 parts by weight of the whole grain powder and mixing it to the multi-grain mixture; b4) a step of removing air bubbles in the dough by introducing the mixture with added tangerine dietary fiber powder into a vacuum dough mixer and kneading it for 20 to 30 minutes under vacuum conditions of -0.08 to -0.09 MPa; b5) A step of aging the vacuum-kneaded dough at 4 to 8°C for 12 to 24 hours to complete the hydration of the dough; characterized by including the above step.

[0089] At this time, c) the baking step comprises: c1) a step of spray-coating a surface treatment solution, prepared by mixing Jeju tangerine juice and Jeju volcanic bedrock water in a 1:1 weight ratio, to a thickness of 0.1 to 0.3 mm on the surface of the molded body before placing it into an oven; c2) a step of removing moisture from inside the molded body by placing the molded body coated with the surface treatment solution into an oven preheated to 150 to 160°C and baking it for 5 to 8 minutes; c3) a step of manufacturing a baking snack sheet by raising the temperature of the first-baked molded body to 170 to 180°C and baking it for 8 to 12 minutes; c4) a step of adjusting the moisture content of the second-baked baking snack sheet to 2 to 4 weight% by lowering the temperature of the second-baked baking snack sheet inside the oven to 120 to 130°C and drying it for 3 to 5 minutes; c5) a step of cooling the third-dried baking snack sheet with cold air at 15 to 25°C for 5 to 10 minutes; It is characterized by including

[0090] At this time, d) the step of manufacturing the filling material comprises: d1) a step of preparing a specialty product raw material by selecting and washing one or more Jeju specialty product raw materials among Jeju tangerines, green tea, Hallabong, Udo peanuts, and apple mangoes; d2) a step of preparing a specialty product concentrate by introducing the specialty product raw material into a low-temperature vacuum concentrator at 55~65℃ and concentrating it for 20~40 minutes under vacuum conditions of -0.08~-0.09 MPa; d3) a step of manufacturing a cream filling material by whipping a total of 100 parts by weight of a cream filling mixture, comprising 20~25 parts by weight of the specialty product concentrate, 55~60 parts by weight of vegetable cream, 10~12 parts by weight of Jeju organic raw sugar, and 8~10 parts by weight of purified water, at 5~10℃; d4) a step of manufacturing a jelly filler by mixing 33 to 38 parts by weight of the specialty product concentrate, 2 to 4 parts by weight of agar powder, 1 to 3 parts by weight of pectin, 30 to 35 parts by weight of Jeju volcanic bedrock water, and 22 to 28 parts by weight of Jeju organic raw sugar, dissolving a total of 100 parts by weight of the jelly filler mixture at 70 to 80°C, and then cooling and gelling at 15 to 25°C to manufacture the jelly filler; d5) a step of storing the cream filler and the jelly filler in nitrogen-filled sealed containers, respectively, to prevent oxidation until immediately before filling; characterized by including these steps.

[0092] Detailed description of the invention

[0093] Technical reasons, critical significance, and specific implementation methods for each stage

[0094] Detailed description of the invention

[0095] Reason for Material Selection and Technical Significance

[0096] whole grains

[0097] The whole grains used as the main ingredient in this invention are unrefined grains containing the germ, endosperm, and bran layer, and are rich in nutrients such as dietary fiber, B vitamins, vitamin E, iron, magnesium, and zinc compared to refined grains. Conventional snack products use refined wheat flour as the main ingredient, resulting in the removal of most nutritional components; however, by using whole grains as the main ingredient in this invention, it is possible to provide nutritionally superior snack products. Furthermore, the dietary fiber contained in whole grains promotes the growth of beneficial intestinal bacteria and has the effect of suppressing blood sugar spikes, making them suitable as functional snack materials for the health management of modern people. Moreover, whole grains possess the characteristic of being able to express a savory flavor through baking alone without deep-frying, thus demonstrating high technical compatibility with the non-fried baking process of this invention.

[0098] Brown rice powder, oat powder, and barley powder

[0099] In this invention, by forming a multi-grain mixture by combining whole grain powder with brown rice powder, oat powder, and barley powder, the aim is to resolve the nutritional imbalance associated with the use of a single grain and to provide a complex combination of the functional components possessed by each grain. Brown rice powder contains gamma-oryzanol and phytic acid, providing antioxidant effects; oat powder contains a large amount of beta-glucan, making it effective for cholesterol reduction and blood sugar control; and barley powder contains beta-glucan and proanthocyanidins, contributing to the improvement of gut health. By combining these three grain powders, each possessing different functional components, it is possible to provide a snack product with significantly enhanced functionality and nutritional diversity compared to the use of a single grain.

[0100] Jeju volcanic bedrock water

[0101] The Jeju volcanic bedrock water used in this invention as dough water and water for manufacturing fillers is clean groundwater naturally purified while passing through the volcanic rock strata unique to Jeju Island, and it is rich in mineral components such as calcium, magnesium, potassium, and silica. When Jeju volcanic bedrock water, which has a higher mineral content compared to ordinary purified water, is used as dough water, effects such as promoting gluten formation in the dough and improving the physical properties of the dough can be expected. Furthermore, the use of Jeju volcanic bedrock water was selected to reinforce the identity of the snack product according to this invention as a product specialized for the Jeju region, while simultaneously conferring eco-friendly value through the utilization of Jeju's clean resources. Tangerine dietary fiber powder (tangerine juice byproduct)

[0102] The tangerine dietary fiber powder used as a binding material for the dough in this invention is extracted from by-products generated during the Jeju tangerine juicing process, namely the peel, pulp residue, and seeds remaining after juicing. Although tens of thousands of tons of Jeju tangerine juicing by-products are generated annually, most have been treated as waste; however, this invention aims to realize an eco-friendly manufacturing process by introducing the concept of upcycling to recycle these by-products into food materials. Tangerine peel contains a large amount of pectin, which has the effect of improving the binding strength of the dough, thereby allowing for the replacement of chemical binders. Furthermore, the tangerine dietary fiber powder contains flavonoid components such as hesperidin and narirutin, which can additionally impart antioxidant functionality.

[0103] Jeju tangerines, Hallabong oranges, green tea, Udo peanuts, and apple mangoes

[0104] The Jeju specialty products used as the main raw materials for the filling in this invention are high-quality agricultural products cultivated in the pristine natural environment of Jeju Island, each possessing unique flavor and functional components. Jeju tangerines are rich in Vitamin C and hesperidin, providing immune-boosting and antioxidant effects; Hallabong tangerines were selected as a material to enhance the palatability of the filling due to their higher sugar content and richer flavor compared to tangerines. Jeju green tea contains catechin and theanine, providing antioxidant and antibacterial effects, and can satisfy diverse consumer preferences by imparting a distinctive bitter flavor to the filling. Udo peanuts, a specialty of the Udo region in Jeju, were selected as a suitable material for enhancing the flavor of the cream filling because they have higher protein and unsaturated fatty acid content and a strong nutty flavor compared to regular peanuts. Apple mangoes are rich in beta-carotene and Vitamin A, offering excellent functionality, and their distinctive sweet flavor significantly improves the palatability of the filling. In this way, by utilizing various Jeju specialties possessing different functional ingredients and flavors as filler materials, it is possible to create multiple product lineups that satisfy the diverse tastes of consumers.

[0105] Agar powder and pectin

[0106] In the present invention, agar powder and pectin, used as gelling agents for jelly fillers, play a role in controlling the physical properties of the jelly filler through different gelling mechanisms. Agar powder is a polysaccharide composed of agarose and agaropectin that forms a thermoreversible gel; however, when used alone, it has the disadvantage of making the jelly excessively hard and brittle. Pectin is a polysaccharide derived from fruits that forms a gel under acidic conditions and in the presence of sugar; however, when used alone, it has the disadvantage of lacking elasticity in the jelly. In the present invention, by using agar powder and pectin in combination, the disadvantages of the two gelling agents are mutually compensated for, and a jelly filler possessing both appropriate hardness and elasticity can be manufactured. Furthermore, since both gelling agents are naturally derived materials, they can replace chemically synthesized gelling agents, thus aligning with an environmentally friendly manufacturing process.

[0108] Technical rationale and critical significance of each stage

[0109] (a) Preprocessing step

[0110] (a) Technical significance of the preprocessing step

[0111] The pretreatment step for whole grains is essential to ensure the hygienic safety of the raw materials and to improve processing suitability during subsequent grinding and dough-making processes. Whole grains can become contaminated with foreign substances, pesticide residues, and microorganisms on their surface during harvesting and distribution; failure to effectively remove these contaminants can lead to serious issues regarding the hygienic safety and quality of the final product. Furthermore, since the moisture content of whole grains directly affects grinding efficiency and dough properties, it is crucial to adjust the moisture content to an appropriate range during the pretreatment stage.

[0112] (a1) Critical significance of washing with hot water at 40~50℃

[0113] The washing temperature of whole grains is set to 40–50°C based on the following technical grounds. If the washing temperature is below 40°C, the solubility of oily foreign substances and residual pesticides on the surface of the whole grains is low, resulting in a significant decrease in washing efficiency. On the other hand, if the washing temperature exceeds 50°C, the starch on the surface of the whole grains begins to gelatinize, causing the grain particles to clump together, which makes it difficult to achieve uniform drying in the subsequent drying process. Therefore, limiting the washing temperature to 40–50°C is a critical condition for simultaneously ensuring washing efficiency and preventing starch gelatinization. In addition, repeating the washing process 3 to 5 times is intended to completely remove surface foreign substances and residual pesticides that are not removed by a single wash. Since the removal rate of residual pesticides is insufficient with fewer than 3 washes, and washing with more than 5 washes excessively increases the water absorption of the whole grains, thereby unnecessarily increasing energy consumption in the subsequent drying process, it is optimal to limit the number of washes to 3 to 5.

[0114] (a2) Critical significance of hot air drying at 55~65℃ and moisture content of 8~12 wt%

[0115] The primary drying temperature was set to 55–65°C to achieve a balance between preserving the nutritional components of whole grains and drying efficiency. If the drying temperature is below 55°C, the drying time becomes excessively long, which reduces production efficiency and increases the risk of microbial growth. If the drying temperature exceeds 65°C, heat-sensitive B vitamins and enzyme components contained in the whole grains are destroyed, resulting in a loss of nutritional components. The target moisture content after primary drying was set to 8–12% by weight because if the moisture content is less than 8% by weight, the internal tissue of the whole grains shrinks excessively during the subsequent far-infrared irradiation stage, leading to reduced particle size uniformity during grinding, and if the moisture content exceeds 12% by weight, the microbial reduction effect caused by far-infrared irradiation is not sufficiently manifested.

[0116] (a3) Critical significance of far-infrared irradiation at 80–100°C for 10–20 minutes

[0117] The far-infrared irradiation step was introduced to effectively reduce residual microorganisms inside whole grains that cannot be removed by hot air drying alone. Far-infrared rays penetrate deep into the whole grains and generate heat by vibrating the moisture within the microbial cells, thereby effectively killing the microorganisms. The far-infrared irradiation temperature was set to 80–100°C because the killing effect on heat-resistant microorganisms inside the whole grains is insufficient below 80°C, and if it exceeds 100°C, the starch on the surface of the whole grains gelatinizes, reducing processing suitability during the grinding process. The far-infrared irradiation time was set to 10–20 minutes because the microbial reduction effect falls short of the target of 99% or more below 10 minutes, and if it exceeds 20 minutes, the color of the whole grains turns excessively brown, which may degrade the appearance quality of the product.

[0118] (a4) Critical significance of cold air cooling at 15–25°C and moisture content of 6–8 wt%

[0119] The rapid cold air cooling step after far-infrared irradiation is performed to rapidly lower the temperature of the whole grain raised by far-infrared irradiation, thereby preventing further thermal decomposition of internal components of the whole grain due to residual heat and adjusting the moisture content to an optimal level for the subsequent grinding process. The cold air temperature is set to 15–25°C because excessive cooling below 15°C can cause condensation on the surface of the whole grain, potentially causing the moisture content to exceed the target value, while cooling above 25°C is slow, potentially leading to component loss due to residual heat. The final moisture content is set to 6–8% by weight because if the moisture content is less than 6% by weight, excessive dust is generated during grinding and wear on the grinding device increases, and if it exceeds 8% by weight, aggregation of the whole grain powder occurs after grinding, making uniform mixing difficult during dough preparation.

[0121] (b) Dough preparation step

[0122] (b) Technical significance of the dough preparation step

[0123] The dough preparation step is a step of uniformly mixing multiple powder raw materials, including whole grain powder, with liquid raw materials to produce a moldable dough, and is a key process that has a decisive influence on the texture, consistency, and structural stability of the final product. In particular, since whole grain powder has a lower gluten-forming ability compared to refined wheat flour, separate technical means are required to secure the binding power of the dough, and in the present invention, this problem is solved through a composite process that combines the addition of citrus dietary fiber powder, vacuum kneading, and low-temperature aging.

[0124] (b1) Critical significance of 30–40 parts by weight of Jeju volcanic bedrock water

[0125] Adding 30 to 40 parts by weight of Jeju volcanic bedrock water to 100 parts by weight of whole grain powder as dough water is because if less than 30 parts by weight is added, the moisture content of the dough is insufficient, causing cracks to occur during molding and the texture of the product to become excessively dense after baking; if more than 40 parts by weight is added, the dough becomes excessively runny, failing to maintain its molded shape and degrading the texture of the product after baking. The calcium and magnesium ions contained in Jeju volcanic bedrock water combine with the protein components of the whole grain powder to improve the structural stability of the dough, an effect that is difficult to expect when using ordinary purified water.

[0126] (b2) Critical significance of 15~25 parts by weight of brown rice powder, 10~20 parts by weight of oat powder, and 5~15 parts by weight of barley powder

[0127] The reason the brown rice powder is limited to 15 to 25 parts by weight per 100 parts by weight of whole grain powder is that the functional effect of gamma-oryzanol derived from brown rice is not sufficiently expressed when the amount is less than 15 parts by weight, and when the amount exceeds 25 parts by weight, the binding strength of the dough decreases due to the high fat content of the brown rice powder. The reason the oat powder is limited to 10 to 20 parts by weight is that the functional effect of beta-glucan derived from oats is insufficient when the amount is less than 10 parts by weight, and when the amount exceeds 20 parts by weight, the viscosity of the dough increases excessively due to the high beta-glucan content of the oat powder, thereby increasing the extrusion resistance during the molding process. The reason the barley powder is limited to 5 to 15 parts by weight is that the effect of imparting the unique flavor of barley is negligible when the amount is less than 5 parts by weight, and when the amount exceeds 15 parts by weight, the unique bitter taste of barley becomes strong, thereby reducing the palatability of the product.

[0128] (b3) Critical significance of 3 to 7 parts by weight of citrus dietary fiber powder

[0129] The reason for limiting the amount of citrus dietary fiber powder to 3 to 7 parts by weight per 100 parts by weight of whole grain powder is that if it is less than 3 parts by weight, the binding strength enhancement effect due to the pectin component contained in the citrus dietary fiber powder is not sufficiently expressed, causing the product to easily crumble after baking, and if it exceeds 7 parts by weight, limonene, a component with a characteristic bitter taste of citrus, lowers the palatability of the product and at the same time excessively increases the viscosity of the dough, thereby reducing processability during the molding process.

[0130] (b4) Vacuum kneading -0.08~-0.09 MPa, critical significance of 20~30 minutes

[0131] The vacuum level of the vacuum kneading process was set to -0.08 to -0.09 MPa because, at a vacuum level below -0.08 MPa, the removal of air bubbles in the dough is insufficient, resulting in the formation of uneven pores in the texture of the product after baking, and high vacuum conditions exceeding -0.09 MPa promote the evaporation of moisture in the dough, causing the moisture content of the dough to deviate from the design range. The kneading time was set to 20 to 30 minutes because, if it is less than 20 minutes, uniform mixing between the dough ingredients is not achieved, and if it exceeds 30 minutes, the particle structure of the whole grain powder is destroyed due to excessive kneading, which can degrade the texture of the product.

[0132] (b5) Critical significance of low-temperature aging at 4–8°C for 12–24 hours

[0133] The low-temperature fermentation temperature of the dough was set to 4 to 8°C because below 4°C there is a risk that part of the dough will freeze and the hydration rate of the whole grain powder will become excessively slow, reducing economic efficiency, and above 8°C there is an increased risk of microbial growth during fermentation. The fermentation time was set to 12 to 24 hours because if it is less than 12 hours, the hydration of the whole grain powder is not sufficiently completed, resulting in an uneven internal texture of the product after baking, and if it is fermented for more than 24 hours, it only increases production time without changing the physical properties of the dough, thereby reducing economic efficiency.

[0135] (c) Baking step

[0136] (c) Technical significance of the baking step

[0137] The baking stage is a step in which heat is applied to the molded dough to remove moisture and form the structure of the product through the gelatinization of starch and denaturation of protein, and it is a key process that determines the texture, color, and flavor of the final product. In the present invention, by introducing a three-stage temperature gradient baking process rather than single-temperature baking, moisture inside the molded body is removed step by step, and different chemical reactions in each temperature range are optimally controlled to produce a high-quality baking snack sheet.

[0138] (c1) Critical significance of a 1:1 mixture of tangerine juice and volcanic bedrock water surface treatment solution, with a coating thickness of 0.1–0.3 mm

[0139] The mixing ratio of tangerine juice and Jeju volcanic bedrock water in the surface treatment solution was set to a 1:1 weight ratio because if the ratio of tangerine juice exceeds 1, the proteins on the surface of the molded body are excessively denatured by organic acids derived from tangerines, causing the surface to crack after baking, and if the ratio of volcanic bedrock water exceeds 1, the concentration of tangerine juice is diluted, making the functional effect imparted by the surface coating negligible. The coating thickness was set to 0.1 to 0.3 mm because if it is less than 0.1 mm, the coating layer is too thin and is lost during baking, and if it exceeds 0.3 mm, the moisture in the coating layer evaporates rapidly during baking, forming bubble marks on the surface of the molded body and degrading the appearance quality.

[0140] (c2) Critical significance of the first baking at 150~160℃ for 5~8 minutes

[0141] The first baking temperature was set to 150–160°C because, at temperatures below 150°C, the moisture inside the molded body does not sufficiently evaporate, causing cracking and deformation of the product due to rapid moisture evaporation during subsequent second high-temperature baking; and if the temperature exceeds 160°C, the surface of the molded body hardens excessively, blocking the evaporation path of internal moisture and causing the problem of moisture remaining inside the product. The first baking time was set to 5–8 minutes because, at less than 5 minutes, the first removal of moisture inside the molded body is insufficient, and if it exceeds 8 minutes, the coating layer of the surface treatment solution is lost due to excessive drying of the surface of the molded body.

[0142] (c3) Critical significance of secondary baking at 170–180℃ for 8–12 minutes

[0143] The secondary baking temperature is set to 170–180°C to optimally induce the Maillard reaction and caramelization reaction. The Maillard reaction is a reaction between reducing sugars contained in whole grains and amino acids, which becomes activated at temperatures above 170°C to impart a distinctive golden color and nutty flavor to the product. If the secondary baking temperature is below 170°C, the Maillard reaction does not proceed sufficiently, resulting in a deterioration of the product's color and flavor; if it exceeds 180°C, the Maillard reaction proceeds excessively, raising concerns about the generation of harmful substances such as acrylamide. The secondary baking time is set to 8–12 minutes because the Maillard reaction proceeds insufficiently at less than 8 minutes, and excessive browning and carbonization of the product occur if it exceeds 12 minutes.

[0144] (c4) Critical significance of tertiary drying at 120–130℃, 3–5 min, moisture content of 2–4 wt%

[0145] The third drying temperature was set to 120~130℃ to finally remove residual moisture after the second baking to the target range, while minimizing the impact on the color and structure of the already formed product. The target moisture content after the third drying was set to 2~4% by weight because if the moisture content is less than 2% by weight, the product becomes excessively dry, increasing the rate of breakage due to impact, and if it exceeds 4% by weight, the deterioration of texture due to moisture absorption during storage proceeds rapidly, shortening the shelf life of the product.

[0146] (c5) Critical significance of rapid cooling at 15–25°C for 5–10 minutes

[0147] The rapid cooling temperature of the baking snack sheet was set to 15 to 25°C because excessive cooling below 15°C can cause thermal shock due to the temperature difference between the baking snack sheet and the cold air, which may result in cracking of the product, and if it exceeds 25°C, the cooling speed is insufficient, which may lead to over-drying of the product due to residual heat. The cooling time was set to 5 to 10 minutes because if it is less than 5 minutes, the temperature of the center of the baking snack sheet does not drop sufficiently, which may cause the filling to melt during the subsequent filling bonding process, and if it exceeds 10 minutes, production efficiency decreases.

[0149] (d) Filler manufacturing step

[0150] (d) Technical significance of the filler manufacturing stage

[0151] The filling material manufacturing step involves producing cream and jelly filling materials that possess physical properties suitable for combination with baking snack sheets, while preserving the unique flavor and functional components of Jeju specialty products to the maximum extent. In this invention, a low-temperature vacuum concentration method is applied instead of the conventional high-temperature concentration method, and by manufacturing the cream and jelly filling materials through separate processes, it is possible to construct multiple product lineups that satisfy the diverse tastes of consumers.

[0152] (d1) Technical Significance of Sorting and Washing of Specialty Raw Materials

[0153] The sorting stage of Jeju specialty raw materials is an essential step carried out to ensure quality uniformity; it plays a role in minimizing quality variations in the filler by removing damaged, spoiled, or immature materials. The grading standards for each specialty product presented by the Jeju Agricultural Research and Extension Services are applied as the selection criteria, and the quality of the final product is guaranteed by using only superior grade raw materials based on sugar content, acidity, appearance, and size.

[0154] (d2) Critical significance of low-temperature vacuum concentration at 55–65℃, -0.08–-0.09 MPa, 20–40 min

[0155] The low-temperature vacuum concentration temperature was set to 55–65°C to achieve a balance between the preservation of heat-sensitive flavor and functional components contained in Jeju specialty products and concentration efficiency. If the concentration temperature is below 55°C, the rate of water evaporation is slow, significantly reducing concentration efficiency; if it exceeds 65°C, heat-sensitive functional components such as Vitamin C, hesperidin, and catechin decompose, degrading the functionality of the filler material. The vacuum level was set to -0.08–-0.09 MPa to enable efficient concentration even at low temperatures by lowering the boiling point of water under reduced pressure conditions. This is because the reduced pressure effect is insufficient below -0.08 MPa, reducing the benefits of low-temperature concentration, while high vacuum conditions exceeding -0.09 MPa excessively increase equipment maintenance costs. The concentration time was set to 20–40 minutes because concentration to the target concentration is not achieved within 20 minutes, and if it exceeds 40 minutes, the loss of flavor components due to prolonged heating increases.

[0156] (d3) Total 100 parts by weight of cream filler, critical significance of whipping at 5~10℃

[0157] The whipping temperature of the cream filling is set to 5 to 10°C because at excessively low temperatures below 5°C, the fat components of the vegetable cream solidify excessively, making it difficult to incorporate air and resulting in insufficient volume of the whipped cream; and if the temperature exceeds 10°C, the fat components of the vegetable cream do not solidify sufficiently, which reduces the shape retention after whipping and causes the filling to flow out during the injection process. The cream filling is specified as a total of 100 parts by weight to ensure a clear balance between the components when setting the content range of each component. If the content of the specialty product concentrate exceeds 25 parts by weight, the stability of the cream decreases due to an increase in moisture content, and if it is less than 20 parts by weight, the unique flavor of the specialty product is not sufficiently expressed.

[0158] (d4) Total 100 parts by weight of jelly filler, 2-4 parts by weight of agar and 1-3 parts by weight of pectin, dissolution at 70-80°C, cooling at 15-25°C, critical significance of gelation

[0159] The melting temperature of the jelly filler was set to 70–80°C because below 70°C, the agar powder does not completely dissolve, resulting in an uneven texture of the product after gelation, and above 80°C, the ester bonds of pectin are hydrolyzed, reducing the gel-forming ability. The cooling gelation temperature was set to 15–25°C because below 15°C, the gelation speed is too fast, causing gelation to be completed before the filler injection process, making process control difficult, and above 25°C, the gelation speed is slow, reducing production efficiency. The amount of agar powder was limited to 2–4 parts by weight because below 2 parts by weight, the hardness of the gel is insufficient, causing the filler to flow down after bonding with the baking snack sheet, and above 4 parts by weight, the gel becomes excessively hard, resulting in a crumbly texture when consumed. The reason for limiting the amount of pectin to 1 to 3 parts by weight is that if it is less than 1 part by weight, the effect of imparting elasticity by pectin is negligible, and if it exceeds 3 parts by weight, an off-flavor characteristic of pectin occurs, which may lower the palatability of the product.

[0160] (d5) Technical significance of nitrogen-filled sealed storage

[0161] Storing cream and jelly fillers in nitrogen-filled airtight containers is intended to prevent the oxidation of unsaturated fatty acids and functional ingredients within the fillers. As an inert gas, nitrogen does not react with the filler components, and by replacing the oxygen in the container with nitrogen, the deterioration of filler quality caused by oxidation can be effectively prevented. In particular, since fillers derived from Udo peanuts have a high content of unsaturated fatty acids, which can lead to the rapid development of off-flavors due to oxidation, nitrogen storage is an essential process for maintaining the freshness of the fillers.

[0163] (b1) Additional detailed description of the forming step and (c2) the joining step

[0164] In the molding step described in the present invention, the process of extruding the dough into a predetermined shape adopts a screw extrusion method, and the external shape of the Twin Basak snack is determined according to the shape of the extrusion die. Since the dough temperature during extrusion molding directly affects the molding precision, it is preferable to perform molding while maintaining the temperature of the previously performed low-temperature aged dough at 4 to 8°C. It is preferable to set the thickness of the molded body to 2 to 4 mm, because if it is less than 2 mm, deformation may occur due to excessive shrinkage of the molded body during baking, and if it exceeds 4 mm, the problem of moisture remaining inside may occur because the baking snack sheet is not dried uniformly. In the bonding step, a nozzle spraying method or a roller coating method may be used to interpose the filling material between the baking snack sheets, and it is preferable to set the coating thickness of the filling material to 1 to 3 mm. If the coating thickness of the filling material is less than 1 mm, the flavor of the filling material is not sufficiently expressed, and if it exceeds 3 mm, the weight ratio of the baking snack sheet to the filling material becomes unbalanced, which may reduce the structural stability of the product.

[0165] Examples and Comparative Examples

[0166] Pretreatment Step Examples and Comparative Examples

[0167] Examples 1 to 3 and Comparative Examples 1 to 4: Pretreatment conditions according to whole grain washing temperature and frequency

[0168] In order to determine the optimal conditions according to the washing temperature and number of washes in the whole grain pretreatment step according to the present invention, Examples 1 to 3 and Comparative Examples 1 to 4 were set with different washing temperatures and number of washes as shown in Table 1 below.

[0169] Example 1 was set to a washing temperature of 40°C and three washes, Example 2 to a washing temperature of 45°C and four washes, and Example 3 to a washing temperature of 50°C and five washes. Comparative Example 1 was set to a washing temperature of 25°C (room temperature water) and three washes, Comparative Example 2 to a washing temperature of 35°C and two washes, Comparative Example 3 to a washing temperature of 55°C and five washes, and Comparative Example 4 to a washing temperature of 60°C and three washes.

[0170] [Table 1] Pretreatment conditions according to washing temperature and frequency

[0171] division Washing temperature (°C) Washing frequency (times) note Example 1 40 3 Within the scope of the present invention Example 2 45 4 Within the scope of the present invention Example 3 50 5 Within the scope of the present invention Comparative Example 1 25 3 Washing temperature below the lower limit Comparative Example 2 35 2 Washing temperature and frequency below the lower limit Comparative Example 3 55 5 Washing temperature upper limit exceeded Comparative Example 4 60 3 Washing temperature upper limit exceeded

[0172] After washing was completed, subsequent pretreatment was performed on all examples and comparative examples under the same conditions (hot air drying 60°C, moisture content 10 wt%, far-infrared irradiation 90°C for 15 minutes, cold air cooling 20°C).

[0174] Examples 4 to 6 and Comparative Examples 5 to 8: Pretreatment conditions according to far-infrared irradiation temperature and time

[0175] In order to verify the temperature and time conditions in the far-infrared irradiation step according to the present invention, Examples 4 to 6 and Comparative Examples 5 to 8 were set with different far-infrared irradiation temperatures and times as shown in Table 2 below.

[0176] Example 4 was set to a far-infrared irradiation temperature of 80°C and an irradiation time of 20 minutes, Example 5 to a far-infrared irradiation temperature of 90°C and an irradiation time of 15 minutes, and Example 6 to a far-infrared irradiation temperature of 100°C and an irradiation time of 10 minutes. Comparative Example 5 applied only hot air drying without far-infrared irradiation, Comparative Example 6 was set to a far-infrared irradiation temperature of 70°C and an irradiation time of 20 minutes, Comparative Example 7 was set to a far-infrared irradiation temperature of 110°C and an irradiation time of 10 minutes, and Comparative Example 8 was set to a far-infrared irradiation temperature of 90°C and an irradiation time of 25 minutes.

[0177] [Table 2] Pretreatment conditions according to far-infrared irradiation temperature and time

[0178] division Irradiated temperature (°C) Investigation time (minutes) note Example 4 80 20 Within the scope of the present invention Example 5 90 15 Within the scope of the present invention Example 6 100 10 Within the scope of the present invention Comparative Example 5 - - Far infrared not applied Comparative Example 6 70 20 Below the lower limit of the inspection temperature Comparative Example 7 110 10 Exceeding the upper limit of the inspection temperature Comparative Example 8 90 25 Exceeding investigation time limit

[0179] Examples and Comparative Examples of Dough Preparation Steps

[0180] Examples 7 to 9 and Comparative Examples 9 to 12: Dough preparation conditions according to multi-grain mixture composition

[0181] In order to determine the optimal conditions for the composition of a multi-grain mixture in the dough preparation step according to the present invention, Examples 7 to 9 and Comparative Examples 9 to 12 were established with different contents of each grain powder as shown in Table 3 below. All figures in Table 3 below are parts by weight per 100 parts by weight of whole grain powder.

[0182] Example 7 was set with 15 parts by weight of brown rice powder, 10 parts by weight of oat powder, 5 parts by weight of barley powder, 30 parts by weight of Jeju volcanic bedrock water, and 3 parts by weight of tangerine dietary fiber powder. Example 8 was set with 20 parts by weight of brown rice powder, 15 parts by weight of oat powder, 10 parts by weight of barley powder, 35 parts by weight of Jeju volcanic bedrock water, and 5 parts by weight of tangerine dietary fiber powder. Example 9 was set with 25 parts by weight of brown rice powder, 20 parts by weight of oat powder, 15 parts by weight of barley powder, 40 parts by weight of Jeju volcanic bedrock water, and 7 parts by weight of tangerine dietary fiber powder.

[0183] Comparative Example 9 was set to 10 parts by weight of brown rice powder, 8 parts by weight of oat powder, 3 parts by weight of barley powder, 30 parts by weight of Jeju volcanic bedrock water, and 3 parts by weight of tangerine dietary fiber powder. Comparative Example 10 was set to 30 parts by weight of brown rice powder, 25 parts by weight of oat powder, 20 parts by weight of barley powder, 40 parts by weight of Jeju volcanic bedrock water, and 7 parts by weight of tangerine dietary fiber powder. Comparative Example 11 was set to 20 parts by weight of brown rice powder, 15 parts by weight of oat powder, 10 parts by weight of barley powder, 35 parts by weight of Jeju volcanic bedrock water, and 1 part by weight of tangerine dietary fiber powder. Comparative Example 12 was set to 20 parts by weight of brown rice powder, 15 parts by weight of oat powder, 10 parts by weight of barley powder, 35 parts by weight of Jeju volcanic bedrock water, and 10 parts by weight of tangerine dietary fiber powder.

[0184] [Table 3] Dough preparation conditions according to multi-grain mixture composition (Unit: parts by weight, based on 100 parts by weight of whole grain powder)

[0185] division brown rice powder oat powder barley powder Volcanic bedrock water Citrus dietary fiber note Example 7 15 10 5 30 3 Within the scope of the present invention Example 8 20 15 10 35 5 Within the scope of the present invention Example 9 25 20 15 40 7 Within the scope of the present invention Comparative Example 9 10 8 3 30 3 Grain powder below the lower limit Comparative Example 10 30 25 20 40 7 Grain powder exceeds limit Comparative Example 11 20 15 10 35 1 Below the lower limit of citrus dietary fiber Comparative Example 12 20 15 10 35 10 Exceeding the upper limit of citrus dietary fiber

[0186] Examples 10 to 12 and Comparative Examples 13 to 16: Dough quality according to vacuum dough and low-temperature aging conditions

[0187] To verify the vacuum dough and low-temperature aging conditions according to the present invention, Examples 10 to 12 and Comparative Examples 13 to 16 were established with different vacuum levels, dough times, aging temperatures, and aging times as shown in Table 4 below. In all examples and comparative examples, the dough composition was set to be the same as in Example 8.

[0188] Example 10 was set to a vacuum of -0.08 MPa, a dough time of 30 minutes, an aging temperature of 8°C, and an aging time of 24 hours. Example 11 was set to a vacuum of -0.085 MPa, a dough time of 25 minutes, an aging temperature of 6°C, and an aging time of 18 hours. Example 12 was set to a vacuum of -0.09 MPa, a dough time of 20 minutes, an aging temperature of 4°C, and an aging time of 12 hours.

[0189] Comparative Example 13 was set to no vacuum kneading (atmospheric pressure kneading), kneading time 25 minutes, aging temperature 6℃, and aging time 18 hours. Comparative Example 14 was set to a vacuum degree of -0.06 MPa, kneading time 25 minutes, aging temperature 6℃, and aging time 18 hours. Comparative Example 15 was set to a vacuum degree of -0.085 MPa, kneading time 25 minutes, and no aging (resting at room temperature for 1 hour). Comparative Example 16 was set to a vacuum degree of -0.085 MPa, kneading time 25 minutes, aging temperature 15℃, and aging time 18 hours.

[0190] [Table 4] Vacuum Dough and Low-Temperature Fermentation Conditions

[0191] division Vacuum level (MPa) Dough time (minutes) Aging temperature (°C) Aging time (time) note Example 10 -0.08 30 8 24 Within the scope of the present invention Example 11 -0.085 25 6 18 Within the scope of the present invention Example 12 -0.09 20 4 12 Within the scope of the present invention Comparative Example 13 atmospheric pressure 25 6 18 Vacuum dough not applied Comparative Example 14 -0.06 25 6 18 Below the lower limit of vacuum level Comparative Example 15 -0.085 25 Room temperature (approx. 20℃) 1 Low-temperature aging not applied Comparative Example 16 -0.085 25 15 18 Exceeding the upper limit of aging temperature

[0192] Baking Step Examples and Comparative Examples

[0193] Examples 13 to 15 and Comparative Examples 17 to 20: Surface treatment solution composition and 3-step baking temperature and time conditions

[0194] In order to verify the surface treatment solution conditions and the 3-step baking temperature and time conditions in the baking step according to the present invention, Examples 13 to 15 and Comparative Examples 17 to 20 were established with different conditions as shown in Table 5 below. In all examples and comparative examples, the dough was prepared under the same conditions as in Example 11, and the thickness of the molded body was set to 3 mm.

[0195] Example 13 was set with a surface treatment solution coating thickness of 0.1 mm, a first baking at 150°C for 8 minutes, a second baking at 170°C for 12 minutes, and a third drying at 120°C for 5 minutes. Example 14 was set with a surface treatment solution coating thickness of 0.2 mm, a first baking at 155°C for 7 minutes, a second baking at 175°C for 10 minutes, and a third drying at 125°C for 4 minutes. Example 15 was set with a surface treatment solution coating thickness of 0.3 mm, a first baking at 160°C for 5 minutes, a second baking at 180°C for 8 minutes, and a third drying at 130°C for 3 minutes.

[0196] Comparative Example 17 was set to no surface treatment solution coating and single-temperature baking at 175°C for 20 minutes. Comparative Example 18 was set to a surface treatment solution coating thickness of 0.2 mm and single-temperature baking at 175°C for 20 minutes. Comparative Example 19 was set to a surface treatment solution coating thickness of 0.2 mm, first baking at 140°C for 7 minutes, second baking at 165°C for 10 minutes, and third drying at 125°C for 4 minutes (below the lower limit of the first and second baking temperatures). Comparative Example 20 was set to a surface treatment solution coating thickness of 0.2 mm, first baking at 165°C for 7 minutes, second baking at 190°C for 10 minutes, and third drying at 140°C for 4 minutes (above the upper limit of the first, second, and third baking temperatures).

[0197] [Table 5] Surface treatment solution composition and 3-step baking conditions

[0198] division Coating thickness (mm) 1st baking 2nd baking 3rd drying note Example 13 0.1 150℃, 8 minutes 170℃, 12 minutes 120℃, 5 minutes Within the scope of the present invention Example 14 0.2 155℃, 7 minutes 175℃, 10 minutes 125℃, 4 minutes Within the scope of the present invention Example 15 0.3 160℃, 5 minutes 180℃, 8 minutes 130℃, 3 minutes Within the scope of the present invention Comparative Example 17 Micoting - 175℃, 20 minutes - Single-temperature baking, no coating applied Comparative Example 18 0.2 - 175℃, 20 minutes - Single-temperature baking Comparative Example 19 0.2 140℃, 7 minutes 165℃, 10 minutes 125℃, 4 minutes Below the lower limit of the baking temperature Comparative Example 20 0.2 165℃, 7 minutes 190℃, 10 minutes 140℃, 4 minutes Exceeding the baking temperature limit

[0199] Examples and Comparative Examples of Filler Manufacturing Steps

[0200] Examples 16 to 18 and Comparative Examples 21 to 24: Cream filler composition conditions

[0201] In order to determine the optimal composition conditions of the cream filler according to the present invention, Examples 16 to 18 and Comparative Examples 21 to 24 were established with different contents of each component as shown in Table 6 below. All figures in Table 6 below are based on 100 parts by weight of the total cream filler, and Hallabong concentrate was used as the Jeju specialty raw material.

[0202] Example 16 was set with 20 parts by weight of Hallabong concentrate, 60 parts by weight of vegetable cream, 10 parts by weight of Jeju organic raw sugar, and 10 parts by weight of purified water. Example 17 was set with 22 parts by weight of Hallabong concentrate, 58 parts by weight of vegetable cream, 11 parts by weight of Jeju organic raw sugar, and 9 parts by weight of purified water. Example 18 was set with 25 parts by weight of Hallabong concentrate, 55 parts by weight of vegetable cream, 12 parts by weight of Jeju organic raw sugar, and 8 parts by weight of purified water.

[0203] Comparative Example 21 was set with 15 parts by weight of Hallabong concentrate, 63 parts by weight of vegetable cream, 12 parts by weight of Jeju organic raw sugar, and 10 parts by weight of purified water (less than the lower limit of concentrate). Comparative Example 22 was set with 30 parts by weight of Hallabong concentrate, 50 parts by weight of vegetable cream, 12 parts by weight of Jeju organic raw sugar, and 8 parts by weight of purified water (more than the upper limit of concentrate). Comparative Example 23 was set with 22 parts by weight of Hallabong concentrate, 58 parts by weight of vegetable cream, 7 parts by weight of Jeju organic raw sugar, and 13 parts by weight of purified water (less than the lower limit of raw sugar). Comparative Example 24 was set with 22 parts by weight of Hallabong concentrate, 53 parts by weight of vegetable cream, 15 parts by weight of Jeju organic raw sugar, and 10 parts by weight of purified water (more than the upper limit of raw sugar).

[0204] [Table 6] Cream Filler Composition Conditions (Unit: parts by weight, based on a total of 100 parts by weight)

[0205] division Hallabong concentrate Vegetable cream Wondang purified water total note Example 16 20 60 10 10 100 Within the scope of the present invention Example 17 22 58 11 9 100 Within the scope of the present invention Example 18 25 55 12 8 100 Within the scope of the present invention Comparative Example 21 15 63 12 10 100 Below the lower limit of the concentrate Comparative Example 22 30 50 12 8 100 Exceeding the upper limit of concentrate Comparative Example 23 22 58 7 13 100 Below the lower limit of raw sugar Comparative Example 24 22 53 15 10 100 Raw sugar limit exceeded

[0206] Examples 19 to 21 and Comparative Examples 25 to 28: Jelly filler composition and gelation conditions

[0207] In order to determine the optimal values ​​for the composition and gelation conditions of the jelly filler according to the present invention, Examples 19 to 21 and Comparative Examples 25 to 28 were established with different content of each component and gelation conditions as shown in Table 7 below. All values ​​in Table 7 below are based on a total of 100 parts by weight of the jelly filler, and Jeju tangerine concentrate was used as the Jeju specialty raw material.

[0208] Example 19 was set with 33 parts by weight of tangerine concentrate, 2 parts by weight of agar powder, 1 part by weight of pectin, 35 parts by weight of Jeju volcanic bedrock water, 29 parts by weight of Jeju organic raw sugar, a dissolution temperature of 70°C, and a gelation temperature of 15°C. Example 20 was set with 36 parts by weight of tangerine concentrate, 3 parts by weight of agar powder, 2 parts by weight of pectin, 33 parts by weight of Jeju volcanic bedrock water, 26 parts by weight of Jeju organic raw sugar, a dissolution temperature of 75°C, and a gelation temperature of 20°C. Example 21 was set with 38 parts by weight of tangerine concentrate, 4 parts by weight of agar powder, 3 parts by weight of pectin, 30 parts by weight of Jeju volcanic bedrock water, 25 parts by weight of Jeju organic raw sugar, a dissolution temperature of 80°C, and a gelation temperature of 25°C.

[0209] Comparative Example 25 was set with 36 parts by weight of tangerine concentrate, 1 part by weight of agar powder, 2 parts by weight of pectin, 35 parts by weight of Jeju volcanic bedrock water, 26 parts by weight of Jeju organic raw sugar (less than the lower limit of agar powder), a dissolution temperature of 75°C, and a gelation temperature of 20°C. Comparative Example 26 was set with 31 parts by weight of tangerine concentrate, 5 parts by weight of agar powder, 4 parts by weight of pectin, 35 parts by weight of Jeju volcanic bedrock water, 25 parts by weight of Jeju organic raw sugar (more than the upper limit of agar powder and pectin), a dissolution temperature of 75°C, and a gelation temperature of 20°C. Comparative Example 27 was set with 36 parts by weight of tangerine concentrate, 3 parts by weight of agar powder, 2 parts by weight of pectin, 33 parts by weight of Jeju volcanic bedrock water, 26 parts by weight of Jeju organic raw sugar, a dissolution temperature of 60°C (less than the lower limit of dissolution temperature), and a gelation temperature of 20°C. Comparative Example 28 was set with 36 parts by weight of tangerine concentrate, 3 parts by weight of agar powder, 2 parts by weight of pectin, 33 parts by weight of Jeju volcanic bedrock water, 26 parts by weight of Jeju organic raw sugar, a dissolution temperature of 85°C (exceeding the upper limit of the dissolution temperature), and a gelation temperature of 20°C.

[0210] [Table 7] Jelly Filler Composition and Gelation Conditions (Unit: parts by weight, based on a total of 100 parts by weight)

[0211] division tangerine concentrate agar powder pectin Volcanic bedrock water Wondang total Dissolution temperature (°C) Gelation temperature (°C) note Example 19 33 2 1 35 29 100 70 15 Within the scope of the present invention Example 20 36 3 2 33 26 100 75 20 Within the scope of the present invention Example 21 38 4 3 30 25 100 80 25 Within the scope of the present invention Comparative Example 25 36 1 2 35 26 100 75 20 Agar powder below the lower limit Comparative Example 26 31 5 4 35 25 100 75 20 Agar and pectin exceeded upper limits Comparative Example 27 36 3 2 33 26 100 60 20 Below the lower limit of the melting temperature Comparative Example 28 36 3 2 33 26 100 85 20 Exceeding the upper limit of the melting temperature

[0212] Experimental Example

[0213] Experimental Example 1: Evaluation of Residual Pesticide Removal Rate and Starch Gelatinization Degree According to Whole Grain Washing Temperature and Frequency

[0214] The residual pesticide removal rate and surface starch gelatinization degree were evaluated for the pretreated whole grains prepared in Examples 1 to 3 and Comparative Examples 1 to 4. The residual pesticide removal rate was calculated as the percentage reduction in residual pesticide content after washing relative to the residual pesticide content of the whole grains before washing, and the surface starch gelatinization degree was measured using a differential scanning calorimeter (DSC). Measurements were repeated three times for each example and comparative example, and the average value was calculated.

[0215] [Table 8] Residual Pesticide Removal Rate and Surface Starch Gelatinization According to Washing Conditions

[0216] division Pesticide residue removal rate (%) Surface starch gelatinization (%) Moisture increase after washing (weight%) note Example 1 92.3 0.8 4.2 Good Example 2 95.7 1.1 5.1 Good Example 3 97.2 1.8 6.8 Good Comparative Example 1 78.4 0.3 3.8 Insufficient removal rate Comparative Example 2 71.2 0.2 3.1 Insufficient removal rate Comparative Example 3 97.5 8.4 7.2 Excessive starch gelatinization Comparative Example 4 97.8 14.7 8.9 severe starch gelatinization

[0217] As shown in Table 8 above, Examples 1 to 3 demonstrated a residual pesticide removal rate of 92% or higher while maintaining a surface starch gelatinization degree of less than 2%, thereby simultaneously achieving washing efficiency and inhibiting starch gelatinization. Comparative Examples 1 and 2 failed to meet hygiene safety standards as their residual pesticide removal rates were only 78.4% and 71.2%, respectively, due to washing temperatures falling below the range of the present invention. Comparative Examples 3 and 4 exceeded the range of the present invention, causing a rapid increase in surface starch gelatinization degrees to 8.4% and 14.7%, respectively. This resulted in aggregation between whole grain particles during the subsequent drying process, which hindered uniform drying. From this, it was confirmed that limiting the washing temperature to 40–50°C and the number of washes to 3–5 times is a critical condition for simultaneously achieving residual pesticide removal and preventing starch gelatinization.

[0219] Experimental Example 2: Evaluation of Microorganism Reduction Rate and Color Change According to Far-Infrared Irradiation Conditions

[0220] The microbial reduction rate and color (L value, a value, b value) were evaluated for the whole grains treated in Examples 4 to 6 and Comparative Examples 5 to 8 above. The microbial reduction rate was calculated as the percentage reduction of the total number of bacteria after irradiation relative to the total number of bacteria before far-infrared irradiation, and the color was measured using a colorimeter. The L value represents lightness (the higher the value, the brighter), the a value represents redness, and the b value represents yellowness.

[0221] [Table 9] Microbial reduction rate and color according to far-infrared irradiation conditions

[0222] division Microorganism reduction rate (%) L value value of a b value note Example 4 99.1 68.4 3.2 18.7 Good Example 5 99.6 67.8 3.5 19.1 Good Example 6 99.8 67.2 3.8 19.6 Good Comparative Example 5 82.3 70.1 2.8 17.4 Insufficient reduction rate Comparative Example 6 94.7 69.5 3.0 18.2 Insufficient reduction rate Comparative Example 7 99.9 58.3 6.7 24.8 Severe browning Comparative Example 8 99.8 60.1 5.9 23.2 browning occurs

[0223] As shown in Table 9 above, Examples 4 to 6 all exhibited a microbial reduction rate of 99% or higher, while maintaining an L value of 67 or higher, thereby simultaneously achieving hygienic safety and maintaining color quality. Comparative Example 5 (no far-infrared radiation applied) failed to meet safety standards with a microbial reduction rate of only 82.3%, and Comparative Example 6 fell short of the target value of 99% with a microbial reduction rate of 94.7% because the irradiation temperature was 70°C, which was below the lower limit of the present invention. In Comparative Example 7, severe browning was observed as the Maillard reaction proceeded prematurely due to the irradiation temperature exceeding the upper limit of 110°C, resulting in a significantly lower L value of 58.3 and a rapid increase in a and b values. In Comparative Example 8, browning occurred because the irradiation time exceeded the upper limit of 25 minutes. From this, it was confirmed that conditions of far-infrared irradiation temperature of 80–100℃ and irradiation time of 10–20 minutes are critical conditions for simultaneously achieving microorganism reduction and color quality maintenance.

[0225] Experimental Example 3: Evaluation of Dough Binding Strength and Moldability According to Multigrain Mixture Composition

[0226] The binding strength (yield stress, Pa) and moldability (extrusion resistance, N) of the doughs prepared in Examples 7 to 9 and Comparative Examples 9 to 12 were evaluated. Binding strength was measured by measuring the yield stress of the dough using a texture analyzer, and moldability was evaluated by the extrusion resistance value through an extrusion die with a diameter of 3 mm.

[0227] [Table 10] Dough binding strength and moldability according to multi-grain mixture composition

[0228] division Yield stress (Pa) Extrusion resistance (N) Whether molding cracks occur note Example 7 1,824 12.3 doesn't exist Good Example 8 2,156 14.7 doesn't exist Good Example 9 2,341 17.2 doesn't exist Good Comparative Example 9 1,203 8.4 generation Lack of binding strength Comparative Example 10 2,387 28.6 doesn't exist Excessive extrusion resistance Comparative Example 11 1,412 9.8 generation Lack of binding strength Comparative Example 12 2,298 19.4 doesn't exist Off-odor occurrence

[0229] As shown in Table 10 above, Examples 7 to 9 had a yield stress of 1,800 Pa or higher, so no cracks occurred during molding, and the extrusion resistance was in the range of 12 to 18 N, maintaining a level achievable by small and medium-sized enterprise (SME) equipment. Comparative Example 9 had a grain powder content below the lower limit of the present invention, resulting in a low yield stress of 1,203 Pa and cracking during molding. Comparative Example 10 had a grain powder content exceeding the upper limit, causing the extrusion resistance to increase excessively to 28.6 N, which is a level difficult to achieve with SME-level extrusion molding equipment. Comparative Example 11 had insufficient binding strength because the citrus dietary fiber powder was below the lower limit, and Comparative Example 12 had an off-flavor derived from limonene because the citrus dietary fiber powder exceeded the upper limit. From this, it was confirmed that limiting the content of each grain powder and citrus dietary fiber powder to within the range of the present invention is a critical condition for securing the binding strength and moldability of the dough.

[0231] Experimental Example 4: Evaluation of Dough Foam Content and Texture Uniformity After Baking According to Vacuum Dough and Low-Temperature Aging Conditions

[0232] The air bubble content (volume%) in the dough and the cross-sectional pore uniformity after baking were evaluated for the doughs prepared in Examples 10 to 12 and Comparative Examples 13 to 16 and the baking snack sheets prepared therefrom. The air bubble content in the dough was measured using X-ray CT, and the cross-sectional pore uniformity was evaluated as the standard deviation (mm²) of the pore area by analyzing cross-sectional images taken with a scanning electron microscope (SEM) using image analysis software.

[0233] [Table 11] Dough Air Foam Content and Texture Uniformity According to Vacuum Dough and Low-Temperature Fermentation Conditions

[0234] division Dough air content (volume%) Cross-sectional pore uniformity (standard deviation, mm²) Moisture content (weight%) after baking note Example 10 1.8 0.012 3.1 Good Example 11 1.5 0.009 2.8 Good Example 12 1.6 0.011 3.0 Good Comparative Example 13 8.7 0.087 4.8 Excessive bubbles Comparative Example 14 5.2 0.054 4.2 Excessive bubbles Comparative Example 15 1.4 0.063 4.5 Incomplete hydration Comparative Example 16 1.5 0.042 4.1 Hydration non-uniformity

[0235] As shown in Table 11 above, Examples 10 to 12 produced baking snack sheets with a uniform texture, maintaining the air content in the dough at less than 2% and having a standard deviation of cross-sectional pore uniformity of 0.012 mm² or less. Comparative Example 13 (vacuum dough not applied) and Comparative Example 14 (vacuum degree below lower limit) had high air content in the dough at 8.7% and 5.2%, respectively, resulting in the formation of an uneven pore structure after baking; consequently, the moisture content after baking exceeded the target range at 4.8% and 4.2%. Comparative Example 15 (low-temperature aging not applied) and Comparative Example 16 (aging temperature above upper limit) had low air content in the dough, but the hydration of the whole grain powder was incomplete, resulting in high standard deviations of cross-sectional pore uniformity of 0.063 and 0.042 mm², respectively. From this, it was confirmed that combining vacuum dough at a vacuum level of -0.08 to -0.09 MPa with low-temperature aging at 4 to 8°C for 12 to 24 hours is a critical condition essential for removing air bubbles from the dough and completing hydration.

[0237] Experimental Example 5: Evaluation of moisture content, hardness, and color of baking snack sheets according to 3-step baking conditions

[0238] The final moisture content (weight%), hardness (N / mm²), and color (L value) of the baking snack sheets prepared in Examples 13 to 15 and Comparative Examples 17 to 20 were evaluated. Hardness was measured by a 3-point bending test using a texture analyzer, and color was measured using a colorimeter.

[0239] [Table 12] Quality characteristics of baking snack sheets according to 3-stage baking conditions

[0240] division Moisture content (weight%) Hardness (N / mm²) L value Acrylamide (μg / kg) note Example 13 3.8 4.2 67.3 98 Good Example 14 3.1 4.8 66.9 112 Good Example 15 2.4 5.3 66.2 127 Good Comparative Example 17 4.9 3.1 64.8 143 Excess moisture, lack of firmness Comparative Example 18 4.6 3.4 65.2 138 Excess fluid Comparative Example 19 5.3 2.8 68.1 87 Excess moisture, lack of firmness Comparative Example 20 2.1 6.8 57.4 284 Browning, excess acrylamide

[0241] As shown in Table 12 above, Examples 13 to 15 maintained an appropriate level of final moisture content within the range of 2–4 wt% and hardness of 4.2–5.3 N / mm², and the acrylamide content was significantly lower than the Ministry of Food and Drug Safety's recommended standard of 1,000 μg / kg. Comparative Examples 17 and 18 applied single-temperature baking, resulting in a moisture content of 4.6–4.9 wt%, which exceeded the target range, leading to low hardness and reduced crispness. Comparative Example 19 had a baking temperature below the lower limit, resulting in a moisture content of 5.3 wt%. Comparative Example 20 had a baking temperature exceeding the upper limit, causing the Maillard reaction to proceed excessively, which significantly lowered the L value to 57.4 and rapidly increased the acrylamide content to 284 μg / kg. From this, it was confirmed that the three-stage temperature gradient baking process and the temperature and time conditions of each stage are critical conditions for ensuring product quality.

[0243] Experimental Example 6: Evaluation of Physical Properties and Sensory Properties According to the Composition of Cream Filler and Jelly Filler

[0244] Physical properties (viscosity or gel hardness) and sensory evaluations (flavor intensity, preference) were performed on the cream fillers and jelly fillers prepared in Examples 16 to 21 and Comparative Examples 21 to 28 above. Viscosity was measured using a rotational viscometer, and gel hardness was measured using a texture analyzer. Sensory evaluation was conducted on 10 food expert panelists using a 5-point scale (1: very poor, 5: very good).

[0245] [Table 13] Evaluation of physical properties and sensory properties according to cream filler composition

[0246] division Viscosity (mPa·s, 10℃) Shape retention rate (%, 25℃ 30 min) Flavor intensity (points) Preference (points) note Example 16 8,420 94.3 3.6 4.1 Good Example 17 9,150 96.1 4.1 4.5 Good Example 18 9,870 97.4 4.4 4.6 Good Comparative Example 21 10,230 97.8 2.3 3.1 Lack of flavor Comparative Example 22 6,840 81.2 4.6 3.4 Poor shape retention Comparative Example 23 8,920 95.3 4.0 3.2 Lack of sweetness Comparative Example 24 9,310 96.2 3.9 3.3 Excessive sweetness

[0247] [Table 14] Evaluation of Physical Properties and Sensory Properties According to Jelly Filler Composition

[0248] division Gel hardness (N / cm²) Elastic modulus (%) Flavor intensity (points) Preference (points) note Example 19 18.4 78.3 3.8 4.2 Good Example 20 22.7 82.1 4.2 4.6 Good Example 21 26.3 84.7 4.4 4.5 Good Comparative Example 25 11.2 61.4 4.1 3.2 Lack of firmness, dripping Comparative Example 26 38.7 71.2 3.8 2.8 Excessive hardness, off-flavor Comparative Example 27 14.3 63.8 4.0 3.0 Agar beauty solution, lack of hardness Comparative Example 28 21.8 68.4 3.4 3.3 Pectin breakdown, loss of elasticity

[0249] As shown in Tables 13 and 14 above, the cream fillers of Examples 16 to 18 exhibited fluidity suitable for the filler injection process with a viscosity in the range of 8,000 to 10,000 mPa·s, and showed excellent stability with a shape retention rate of 94% or higher even after 30 minutes at 25°C. Comparative Example 21 had a concentrate content below the lower limit, resulting in a low flavor intensity of 2.3 points, and thus the specialty flavor characteristics as a product were not expressed; Comparative Example 22 had a concentrate content exceeding the upper limit, and the shape retention rate was significantly reduced to 81.2% due to increased moisture content. The jelly fillers of Examples 19 to 21 maintained an appropriate level where the filler did not flow down after bonding with the baking snack sheet, with a gel hardness in the range of 18 to 27 N / cm², and provided a chewy texture upon consumption with an elastic modulus of 78% or higher. In Comparative Example 25, the agar powder fell below the lower limit, resulting in a low hardness of 11.2 N / cm² and causing the filler to flow out; in Comparative Example 26, the agar powder and pectin exceeded the upper limit, resulting in an excessively high hardness of 38.7 N / cm² and the occurrence of an off-flavor. In Comparative Example 27, the dissolution temperature fell below the lower limit, causing the agar powder to not dissolve completely, resulting in low hardness and the formation of an uneven structure; and in Comparative Example 28, the dissolution temperature exceeded the upper limit, causing the ester bonds of the pectin to hydrolyze, which reduced the elastic modulus to 68.4%. From this, it was confirmed that the content of each component of the cream filler and jelly filler, as well as the manufacturing conditions, are critical conditions for ensuring the physical properties and sensory quality of the filler.

[0251] Results and Discussion

[0252] Preprocessing Step Results and Discussion

[0253] 1. Discussion of Results According to Washing Temperature and Frequency

[0254] According to the results of Experimental Example 1, the effects of washing temperature and frequency on the residual pesticide removal rate and surface starch gelatinization of whole grains were clearly confirmed. In Examples 1 to 3, by setting the washing temperature to a range of 40 to 50°C and applying 3 to 5 washes, the residual pesticide removal rate was excellent at 92.3 to 97.2%, while the surface starch gelatinization rate remained very low at 0.8 to 1.8%. These results are attributed to the fact that hot water at 40 to 50°C effectively dissolved and removed oily foreign substances and residual pesticides from the surface of whole grains, while simultaneously minimizing structural changes in the surface starch by maintaining temperature conditions below the starch gelatinization initiation temperature (approx. 55 to 65°C).

[0255] In contrast, Comparative Example 1 (washing temperature 25℃) and Comparative Example 2 (washing temperature 35℃, washing frequency 2 times) showed residual pesticide removal rates of only 78.4% and 71.2%, respectively, which is about 20 to 25 percentage points lower than the examples of the present invention. This is interpreted to be because the solubility of oily residual pesticides is significantly reduced at low washing temperatures, and the physical cleaning effect is not sufficiently manifested due to insufficient washing frequency. In particular, if the residual pesticide removal rate is less than 80%, it may be difficult to comply with the Ministry of Food and Drug Safety's Maximum Residue Limit (MRL), suggesting that serious problems may arise in ensuring the safety of the final product.

[0256] Meanwhile, in Comparative Example 3 (washing temperature 55℃) and Comparative Example 4 (washing temperature 60℃), the residual pesticide removal rates were 97.5% and 97.8%, respectively, which were similar to those of the example; however, the degree of surface starch gelatinization increased sharply to 8.4% and 14.7%, respectively. This is attributed to the fact that as the washing temperature approached or exceeded the starch gelatinization initiation temperature, the starch particles on the surface of the whole grains absorbed moisture, swelled, and partially gelatinized. In the whole grains where surface starch gelatinization had progressed, inter-particle adhesion increased, causing aggregation where the whole grain particles clumped together during the subsequent drying process. Consequently, problems were observed where drying non-uniformity intensified and particle size uniformity decreased during the final grinding process. Based on the above results, it was confirmed that limiting the washing temperature to 40–50℃ and the number of washes to 3–5 times is the optimal condition for simultaneously ensuring hygienic safety and processing suitability.

[0257] 2. Discussion of Results According to Far-Infrared Irradiation Conditions

[0258] According to the results of Experimental Example 2, it was confirmed that the far-infrared irradiation temperature and time had opposing effects on the microbial reduction rate and the color of whole grains. In Examples 4 to 6, under conditions of a far-infrared irradiation temperature of 80–100°C and an irradiation time of 10–20 minutes, the microbial reduction rate was 99.1–99.8%, achieving the target value of over 99%, and the L value was maintained at 67.2–68.4, indicating excellent preservation of color quality. It is believed that a mechanism was at work in which far-infrared rays uniformly penetrated into the interior of the whole grains, vibrating water molecules within the microbial cells and destroying the cell membranes to effectively kill the microorganisms.

[0259] In Comparative Example 5 (no far-infrared radiation applied), the microbial reduction rate was only 82.3%, clearly confirming that hot air drying alone cannot sufficiently remove heat-resistant microorganisms inside the whole grain. In Comparative Example 6 (irradiation temperature 70℃), the microbial reduction rate was 94.7%, falling short of the target value; this is interpreted as being due to the irradiation temperature of 70℃ not reaching the critical temperature required for the killing of heat-resistant bacteria. On the other hand, in Comparative Example 7 (irradiation temperature 110℃), the microbial reduction rate was 99.9%, the highest level; however, severe browning was observed, with the L value dropping significantly to 58.3 and the redness (a value) and yellowness (b value) increasing rapidly. This is judged to be because the Maillard reaction and caramelization reaction proceeded prematurely at high temperatures above 110℃, damaging the appearance quality of the whole grain. In Comparative Example 8 (irradiation time 25 minutes), as the irradiation time became excessively long, the cumulative heat input increased, causing browning. From the above results, it was confirmed that the conditions of a far-infrared irradiation temperature of 80–100°C and an irradiation time of 10–20 minutes are the only critical range capable of simultaneously achieving microorganism reduction and color quality preservation.

[0261] Results and Discussion of Dough Preparation Steps

[0262] 3. Discussion of Results According to Multigrain Mixture Composition

[0263] According to the results of Experimental Example 3, it was confirmed that the content of each component of the multi-grain mixture had a direct and significant effect on the binding strength and moldability of the dough. In Examples 7 to 9, the yield stress was in the range of 1,824 to 2,341 Pa, and no cracks occurred during molding. The extrusion resistance was in the range of 12.3 to 17.2 N, which is a level that can be stably achieved using general screw extrusion equipment (typically a maximum extrusion force of 25 to 30 N) at the level of small and medium-sized enterprises. This is believed to be because the pectin component contained in the citrus dietary fiber powder within the content range of the present invention interacts with the protein and starch components of the multi-grain mixture to promote the formation of a three-dimensional network structure of the dough, thereby effectively compensating for the structural weakness of whole-grain powder-based dough with low gluten-forming ability.

[0264] In Comparative Example 9 (grain powder content below the lower limit), the yield stress was significantly low at 1,203 Pa, causing cracks during molding; this is interpreted as being due to the failure to form an elastic structure of the dough as a result of the decrease in total solid content. In Comparative Example 10 (grain powder content above the upper limit), the extrusion resistance was 28.6 N, approaching the limit of equipment for small and medium-sized enterprises; it is determined that the main cause was an abnormal increase in dough viscosity due to the excessively high beta-glucan content of the oat powder. In Comparative Example 11 (citrus dietary fiber powder below the lower limit), the binding strength was insufficient because the binding contribution of pectin was not sufficient, and in Comparative Example 12 (citrus dietary fiber powder above the upper limit), a characteristic bitter off-flavor was clearly detected in the sensory evaluation as the concentration of limonene contained in the citrus peel exceeded the critical threshold. In particular, in the case of Comparative Example 12, since the occurrence of off-flavor is expected to have a direct negative effect on the palatability of the final product, it was reaffirmed that strictly limiting the upper limit of citrus dietary fiber powder to 7 parts by weight is essential for product quality control. The above results clearly support the fact that precisely controlling the content of each grain powder and citrus dietary fiber powder within the range specified in the present invention is an essential condition for simultaneously securing the binding power, moldability, and palatability of the dough.

[0265] 4. Discussion of Results According to Vacuum Kneading and Low-Temperature Aging Conditions

[0266] According to the results of Experimental Example 4, the synergistic effect of combining vacuum kneading and low-temperature aging on reducing the air bubble content of the dough and completing hydration was clearly confirmed. In Examples 10 to 12, the air bubble content in the dough was maintained at a very low level of 1.5 to 1.8 volume%, and the standard deviation of the cross-sectional pore uniformity was extremely small at 0.009 to 0.012 mm², allowing for the reproducible production of baking snack sheets with a uniform texture. The final moisture content after baking was also 2.8 to 3.1 weight%, which was stably distributed within the target range of 2 to 4 weight%.

[0267] In Comparative Example 13 (vacuum dough not applied, atmospheric pressure dough), the air bubble content in the dough was 8.7 volume%, which is about 5 to 6 times higher than that of the example, and the standard deviation of the cross-sectional pore uniformity was 0.087 mm², indicating the formation of an extremely non-uniform tissue structure. This is attributed to the fact that the dough under atmospheric pressure conditions failed to effectively expel air, leaving a large amount of air bubbles in the dough, which then expanded during the baking process to form a non-uniform pore structure. In Comparative Example 14 (vacuum degree -0.06 MPa), the air bubble content was also 5.2 volume%, which is higher than that of the example, confirming that the efficiency of air bubble removal is significantly reduced when the vacuum degree is less than -0.08 MPa.

[0268] In Comparative Example 15 (low-temperature aging not applied), the air content of the dough was maintained at a low 1.4 volume%, but the standard deviation of the cross-sectional pore uniformity was 0.063 mm², which is about 5 to 7 times higher than that of the example. This is interpreted to be because although air bubbles were removed by vacuum kneading alone, the hydration of whole grain powder particles proceeded incompletely due to the lack of low-temperature aging, resulting in non-uniformity of moisture evaporation per particle during baking. In Comparative Example 16 (aging temperature 15℃), the standard deviation was also high at 0.042 mm², confirming that when the aging temperature exceeds 8℃, the activity of proteolytic enzymes increases, thereby reducing the stability of the dough structure. The above results clearly demonstrate that vacuum kneading and low-temperature aging each show incomplete effects independently, and that combining the two processes under the conditions specified in the present invention is an essential requirement for manufacturing a uniform and stable baking snack sheet.

[0270] Baking Step Results and Discussion

[0271] 5. Discussion of Results Based on 3-Step Baking Conditions

[0272] According to the results of Experimental Example 5, the effect of the three-stage temperature gradient baking process on the moisture content, hardness, color, and harmful substance content of the baking snack sheet was clearly confirmed. In Examples 13 to 15, the final moisture content was 2.4 to 3.8 wt%, which is within the target range; the hardness was 4.2 to 5.3 N / mm², which is maintained at a level where consumers can clearly perceive crispness; and the L value was 66.2 to 67.3, which achieved a golden color. In particular, the acrylamide content was 98 to 127 μg / kg, which is significantly lower than the Ministry of Food and Drug Safety's recommended standard of 1,000 μg / kg, confirming that safety was sufficiently ensured.

[0273] In Comparative Example 17 (uncoated surface treatment solution, single temperature 175°C baking) and Comparative Example 18 (single temperature 175°C baking), the moisture content was 4.9% and 4.6%, respectively, exceeding the target range, and the hardness was low at 3.1–3.4 N / mm², which is judged to significantly reduce the crispness perceived by consumers. This is interpreted to be because in single temperature baking, the surface of the molded body hardens rapidly, causing a crusting phenomenon in which the evaporation path of internal moisture is blocked, resulting in an uneven moisture distribution where the exterior is excessively dried while moisture remains inside. In contrast, in the example applying a three-stage temperature gradient baking, it is judged that uniform and stable drying was achieved by gradually removing internal moisture in the first low-temperature baking, optimally inducing the Maillard reaction in the second high-temperature baking, and precisely controlling residual moisture in the third drying.

[0274] In Comparative Example 19 (baking temperature below the lower limit), the moisture content was highest at 5.3 wt%, confirming that drying was not sufficiently achieved. In Comparative Example 20 (baking temperature above the upper limit), the Maillard reaction proceeded excessively, resulting in a significantly lower L value of 57.4 and a rapid increase in acrylamide content to 284 μg / kg. The acrylamide content in Comparative Example 20 increased to approximately 2 to 3 times that of the example, which is interpreted as a result of the reaction between asparagine amino acids and reducing sugars being accelerated during high-temperature baking. Although the acrylamide content in Comparative Example 20 did not exceed current recommended standards, it was confirmed that minimizing the generation of harmful substances by strictly controlling the baking temperature below the upper limit is desirable from the perspective of food safety. The above results clearly support the fact that the three-stage temperature gradient baking condition specified in the present invention is a critical condition for simultaneously optimizing the texture, appearance, and safety of the product.

[0276] Results and Discussion of Filler Manufacturing Steps

[0277] 6. Discussion of Results Based on Cream Filler Composition

[0278] According to the evaluation results of the cream filling in Experimental Example 6, it was confirmed that the content of specialty concentrate and vegetable cream had a decisive influence on the physical properties and sensory quality of the cream filling. In Examples 16 to 18, the viscosity ranged from 8,420 to 9,870 mPa·s, satisfying the fluidity required for the filling injection process. Furthermore, the shape retention rate after 30 minutes at 25°C was excellent at 94.3 to 97.4%, indicating that the problem of the filling flowing down between the baking snack sheets would not occur. Both exhibited excellent sensory characteristics, with flavor intensity ranging from 3.6 to 4.4 points and preference from 4.1 to 4.6 points. Additionally, a tendency was observed where both flavor intensity and preference improved as the content of the specialty concentrate increased.

[0279] In Comparative Example 21 (concentrate content below the lower limit, 15 parts by weight), the flavor intensity was significantly lowered to 2.3 points, and it was evaluated that the unique flavor characteristics of a product utilizing Jeju specialty products were not sufficiently conveyed to consumers. This is interpreted as being due to the fact that the absolute concentration of flavor components derived from the specialty products fell short of the sensory perception threshold because the concentrate content was excessively low. In Comparative Example 22 (concentrate content above the upper limit, 30 parts by weight), the shape retention rate was significantly lowered to 81.2% due to an increase in moisture content; this is judged to be because the moisture destabilized the fat crystal structure of the vegetable cream, thereby promoting the collapse of the cream's structure. In Comparative Example 23 (raw sugar content below the lower limit), the preference score dropped to 3.2 points due to a lack of sweetness, and in Comparative Example 24 (raw sugar content above the upper limit), the preference score remained at 3.3 points due to a masking effect in which the unique flavor of the specialty products was obscured by excessive sweetness. From the above results, it was confirmed that a composition of 20 to 25 parts by weight of specialty concentrate, 55 to 60 parts by weight of vegetable cream, 10 to 12 parts by weight of Jeju organic raw sugar, and 8 to 10 parts by weight of purified water, based on a total of 100 parts by weight of cream filler, is the critical range that simultaneously optimizes physical properties and sensory quality.

[0280] 7. Discussion of Results According to Jelly Filler Composition and Gelation Conditions

[0281] According to the evaluation results of the jelly filler in Experimental Example 6, it was confirmed that the content of agar powder and pectin and the dissolution temperature had a combined effect on gel hardness, elasticity modulus, and sensory quality. In Examples 19 to 21, the gel hardness ranged from 18.4 to 26.3 N / cm², which was sufficient for the filler to stably maintain its shape between baking snack sheets, and the elasticity modulus was 78.3 to 84.7%, providing a chewy and elastic texture upon consumption. Excellent sensory characteristics were exhibited with flavor intensity of 3.8 to 4.4 points and preference of 4.2 to 4.6 points, and a tendency was observed that gel hardness and elasticity modulus improved together as the content of agar powder and pectin increased.

[0282] In Comparative Example 25 (agar powder content below the lower limit, 1 part by weight), the gel hardness was low at 11.2 N / cm², and the phenomenon of the filling flowing down the side of the baking snack sheet after injection was actually observed. Additionally, the elastic modulus was 61.4%, which was significantly lower than that of the example, so a chewy texture was not exhibited. In Comparative Example 26 (agar powder and pectin content exceeding the upper limit), the gel hardness was excessively high at 38.7 N / cm², and at such a hardness, there is a concern that the filling will crumble hard when the consumer eats the product. Furthermore, in Comparative Example 26, as the pectin content exceeded the upper limit, an off-flavor characteristic of pectin occurred, and the preference score was evaluated as the lowest among all experimental groups at 2.8 points.

[0283] In Comparative Example 27 (dissolution temperature 60°C, below the lower limit), the agar powder was not completely dissolved, and it was visually confirmed that undissolved agar particles remained in the tissue after gelation; consequently, the gel hardness was low at 14.3 N / cm² and the tissue was formed unevenly. In Comparative Example 28 (dissolution temperature 85°C, above the upper limit), the gel hardness itself was 21.8 N / cm², which was similar to the example; however, due to heating at a high temperature, the ester bonds of pectin were hydrolyzed, significantly reducing the contribution to gel formation, resulting in a lower elastic modulus of 68.4%. Additionally, in Comparative Example 28, some loss of flavor components of the citrus concentrate occurred due to heating at 85°C, causing the flavor intensity to decrease to 3.4 points compared to the example. The above results clearly demonstrate that the composition range of 2 to 4 parts by weight of agar powder and 1 to 3 parts by weight of pectin specified in the present invention, along with the process conditions of a dissolution temperature of 70 to 80°C and a gelation temperature of 15 to 25°C, are critical conditions for simultaneously optimizing the physical properties, texture, and sensory quality of the jelly filler.

[0285] Comprehensive Review

[0286] Synthesizing the results of Experimental Examples 1 to 6 above, it was clearly confirmed that in the method for manufacturing Twin Basak snacks using Jeju specialty products according to the present invention, if the conditions in each stage of pretreatment, dough preparation, baking, and filling preparation deviate from the range specified in the present invention, one or more of the product's hygienic safety, physical properties, appearance quality, and sensory characteristics are significantly degraded. In particular, it was confirmed that the process conditions of each stage do not operate independently, but rather there is interdependence between the processes, in which the moisture content of whole grains in the pretreatment stage affects the hydration characteristics in the dough stage, the removal of air bubbles and the completion of hydration in the dough stage affect the tissue uniformity in the baking stage, and the gel hardness and shape stability of the filling affect the structural completeness of the final product. This supports the fact that each process condition of the present invention is based on the organic integrated design of the entire manufacturing process rather than simple individual optimization, and serves as a basis that clearly supports the technical advancement of the present invention. In addition, it was confirmed that the industrial feasibility of the present invention is sufficiently secured, as the manufacturing conditions of all embodiments are within the range feasible with equipment available at the level of small and medium-sized enterprises (hot air dryers, far-infrared irradiation devices, vacuum dough mixers, convection ovens, low-temperature vacuum concentrators, etc.).

Claims

Claim 1 A method for manufacturing a Twin Basak snack utilizing Jeju specialty products, which is produced by baking rather than frying, comprising: a) a pretreatment step of washing and drying whole grains; a1) a step of grinding the pretreated whole grains to produce whole grain powder; b) a dough preparation step of mixing auxiliary materials with the whole grain powder to produce dough; b1) a molding step of extruding the dough into a predetermined shape to produce a molded body; c) a baking step of baking the molded body in an oven at 100~200℃ to produce a baking snack sheet; c1) a filling material preparation step of producing a cream filling material and a jelly filling material containing Jeju specialty products, respectively; c2) a bonding step of interposing the cream filling material or the jelly filling material between the baking snack sheets to produce a Twin Basak snack; wherein the pretreatment step a) comprises: a1) a step of repeatedly washing the whole grains 3~5 times with hot water at 40~50℃ to remove surface foreign substances and residual pesticides; a2) drying the washed whole grains in a hot air dryer at 55~65℃ with moisture a3) a step of first drying the whole grains so that the content becomes 8-12% by weight; a4) a step of introducing the first-dried whole grains into a far-infrared irradiation device and irradiating far-infrared rays at 80-100°C for 10-20 minutes to reduce the number of microorganisms inside the whole grains by more than 99% compared to before far-infrared irradiation; a4) a step of rapidly cooling the far-infrared irradiated whole grains with cold air at 15-25°C to adjust the moisture content to 6-8% by weight; wherein the b) dough preparation step comprises: b1) a step of preparing a whole grain base by adding 30-40 parts by weight of Jeju volcanic bedrock water to 100 parts by weight of the whole grain powder and mixing it first; b2) a step of adding 15-25 parts by weight of brown rice powder, 10-20 parts by weight of oat powder, and 5-15 parts by weight of barley powder to 100 parts by weight of the whole grain powder to the whole grain base and mixing it secondarily Step of preparing a multigrain mixture; b3) Step of adding 3 to 7 parts by weight of tangerine dietary fiber powder extracted from Jeju tangerine juice by-products to the multigrain mixture and mixing, with respect to 100 parts by weight of the whole grain powder;b4) a step of removing air bubbles in the dough by introducing the mixture to which the above tangerine dietary fiber powder has been added into a vacuum mixer and kneading it for 20 to 30 minutes under vacuum conditions of -0.08 to -0.09 MPa; b5) a step of completing the hydration of the dough by aging the vacuum-kneaded dough at 4 to 8°C for 12 to 24 hours; and the above c) baking step comprises: c1) a step of spray-coating a surface treatment solution, prepared by mixing Jeju tangerine juice and Jeju volcanic bedrock water in a 1:1 weight ratio, to a thickness of 0.1 to 0.3 mm on the surface of the molded body before placing it into an oven; c2) a step of removing moisture inside the molded body by placing the molded body coated with the surface treatment solution into an oven preheated to 150 to 160°C and baking it for 5 to 8 minutes; c3) a step of manufacturing a baking snack sheet by raising the temperature of the molded body baked for the first time to 170 to 180°C and baking it for 8 to 12 minutes; c4) A method for manufacturing a Twin Basak snack using Jeju specialty products, characterized by comprising: a step of adjusting the moisture content of the baking snack sheet to 2-4 weight% by lowering the temperature of the baking snack sheet baked the second time in an oven to 120-130℃ and drying it the third time for 3-5 minutes; c5) a step of cooling the baking snack sheet dried the third time with cold air at 15-25℃ for 5-10 minutes. Claim 2 delete Claim 3 delete

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