Low-sugar, medium viscosity malted flours and process for making the same

Abstract

Low-sugar, medium viscosity malted flours and methods of making the malted flours are described. Methods of making the low-sugar, medium viscosity flours by treating with Beta-amylase free malt is disclosed. The present disclosure also describes generation of Beta-amylase free malt. The Beta-amylase free malt is used to generate low-sugar, medium viscosity malted flours.

Description

LOW-SUGAR, MEDIUM VISCOSITY MALTED FLOURS AND PROCESS FOR MAKING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application 63 / 650,072 filed May 21, 2024, U.S. Provisional Application 63 / 650,110, filed May 21, 2024, and U.S. Provisional Application 63 / 650,130 filed May 21, 2024, which are incorporated by reference herein in its entirety.BACKGROUND

[0002] Malt is a cereal grain that has been made to germinate by soaking in water and then stopped from germinating further by drying with hot air in a process known as malting. A common malting process has multiple stages including steeping, germination, kilning and roasting grain to convert it into malt. Germination and sprouting involve a number of enzymes to produce the changes from seed to seedling. The malting process is halted when the desired enzymes are optimal. Among other things, the enzymes generated during the malting process convert starch to sugars such as maltose, maltotriose and maltodextrins. Malt with active enzymes is called “diastatic malt”. Malt with inactive enzymes is called “nondiastatic malt”.

[0003] C 'onsumers are asking for label friendly alternatives to maltodextrin in food and beverage applications. While there is a desire to create label-friendly alternatives, there is also a desire for such alternatives to have similar functionality as that of maltodextrin .SUMMARY

[0004] This disclosure relates to malted flours and methods of making malted flours. The disclosure also relates to a [3-amylase free malt, method of making the [3-amylase free malt and use of the [3-amylase free malt for making the malted flours. The disclosure also relates the use of the malted flours generated by the methods described herein.

[0005] The present disclosure provides method of treating a flour comprising treating a slurry comprising a flour with a [3-amylase free (BAF) malt to generate a malted flour, wherein the malted flour comprises less than 5wt% of sugars, preferably less than 5wt% of maltose. Preferably, the method generates a low-sugar, medium -viscosity (LS / MV) malted flour.

[0006] The disclosure also provides malted flour comprising a sugar content of less than 5wt%, preferably less than 4wt%, less than 3wt%, less than 2wt%, or less than lwt%, or less than 0.5wt%. The disclosure further provides food product and / or food ingredients comprising the LS / MV malted flour.

[0007] The disclosure also provides a method for of making a malt from a grain comprising steeping, germinating, and kilning the grain, wherein the germinating step comprises inactivating P-amylase enzyme in the malt to generate a BAF malt.

[0008] The disclosure also provides a malt comprising a-amylase enzymes and P-amylase enzymes, wherein the P-amylase enzyme is substantially inactivated or totally inactivated, wherein the malt is a grain malt, preferably a cereal grain malt.

[0009] Representative features of the present invention are set out in the following clauses, which stand alone or may be combined, in any combination, with one or more features disclosed in the text of the Specification.

[0010] The present invention is as set out in the following clauses:

[0011] Clause 1 : A method of treating a flour comprising: treating a slurry comprising the flour with a P-amylase free (BAF) malt to generate a malted flour, wherein the malted flour is a low sugar malted flour, preferably the malted flour is a low sugar, medium viscosity (LS / MV) malted flour, wherein the malted flour comprises less than 5wt% of sugars, preferably less than 5wt% of maltose.

[0012] Clause 2: The method of claim 1, wherein the flour comprises corn, wheat, rice, rye, potato, tapioca, beans, roots, oats, barley, sorghum, millet, ancient grains and / or combinations thereof, preferably the flour is a rice flour.

[0013] Clause 3: The method of any one of the preceding clauses, wherein treating the slurry comprises: a. heating the slurry to BAF malt enzyme activity temperature, preferably between about 45°C and 55°C; b. treating the slurry with the BAF malt, wherein the amount of the BAF malt added is between about 0.01wt% and about 0.5wt% amt of malt based on weight of the flour added, preferably the amount of the BAF malt added is between about 0.01wt% and about 0.2wt%;c. cooking the slurry to form a cooked flour suspension, preferably the slurry comprises between 5wt% and 20wt% of the flour based on the weight of the slurry, wherein the slurry is cooked to a temperature of at least 80°C, preferably about 95°C; and d. drying the flour suspension to generate the malted flour.

[0014] Clause 4: The method of anyone of the preceding clauses, wherein the method further comprises treating the cooked flour composition with the BAF malt prior to the drying step.

[0015] Clause 5: The method of any one of the preceding clauses, wherein the cooked flour composition is treated with the BAF malt after the cooking step without treating the slurry with the BAF malt prior to the cooking step.

[0016] Clause 6: The method of any one of the preceding clauses, wherein a cooked composition comprising the malted flour at 10 wt% d.s. based on the weight of the composition is a soft gel when incubated for 15 minutes at 4°C and / or is a delayed soft gel when incubated overnight at 4°C.

[0017] Clause 7 : The method of any one of the preceding clauses, wherein the malted flour comprises a viscosity of between about 200 mPa.s and about 2000 mPa.s, when measured at 20°C at a shear rate of 100(l / s), wherein the viscosity is measured in a cooked malted flour composition of 10wt% d.s.

[0018] Clause 8: The method of any one of the preceding clauses, wherein the BAF malt is from cereal grains, preferably from barley, wheat, rye, oats, rice, sorghum, millet, corn and combinations thereof, preferably from barley.

[0019] Clause 9: The method of any one of the preceding clauses, wherein the drying comprises drum drying, freeze drying, spray drying, hot air drying, oven drying and fluidized bed drying and combinations thereof.

[0020] Clause 10: A malted flour comprising a sugar content of less than 5wt%, preferably less than 4wt%, less than 3wt%, less than 2wt%, or less than lwt%, or less than 0.5wt%, wherein a cooked composition comprising the malted flour at 10 wt% d.s. based on the weight of the composition is a soft gel when incubated for 15 minutes at 4°C and / or is a delayed soft gel when incubated overnight at 4°C.

[0021] Clause 11 : The malted flour of clause 10, wherein the malted flour comprises a maltose content of less than 5wt%, preferably less than 4wt%, less than 3wt%, less than 2wt%, or less than lwt%, or less than 0.5wt% flour.

[0022] Clause 12: The malted flour of any one of clauses 10-11, wherein the flour is selected from corn flour, wheat flour, rice flour, rye flour, potato flour, tapioca flour, beans flour, flour from roots, oat flour, barley flour, sorghum flour, millet flour, flour from ancient grains and combinations thereof, preferably rice flour.

[0023] Clause 13: The malted flour of any one of clauses 10-12, wherein the malted flour composition has viscosity range of between about 200 mPa.s and about 2000 mPa.s, wherein the viscosity is measured in a malted flour composition comprising 10wt% of dry solids of the malted flour.

[0024] Clause 14: The malted flour of any one of clauses 10-13, wherein the malted flour has a dextrose equivalent (DE) of less than five as measured by by Schoorl's method, based on the reduction of copper (II) sulphate solution.

[0025] Clause 15: The malted flour of any one of clauses 10-14, wherein the storage modulus of the malted flour is higher than the loss moduli, preferably the storage modulus to loss modulus ratio (G7G”) is between 0.5 and 2, when measured at an angular frequency of 100 (rad / s).

[0026] Clause 16: A food product, comprising the malted flour, preferably malted rice flour, of any one of clauses 10-15.

[0027] Clause 17: The food product of clause 16, wherein the food product is a medicinal product, an emulsion, a dairy product, an ice-cream product, a convenience food, a snack-based filling, and / or combinations thereof.

[0028] Clause 18: The food product of any one of clauses 16-17, wherein the malted flour is a thickening agent, a texturizer, a fat replacer, a skimmed milk replacer, a whey powder replacer and combinations thereof.

[0029] Clause 19: Use of a malted flour of any one of clauses 10-15 wherein the food product is a medicinal product, an emulsion, a dairy product, an ice-cream product, a convenience food, a snack-based filling, and / or combinations thereof.

[0030] Clause 20: A food ingredient comprising a malted flour of any one of clauses 10- 15.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The drawings illustrate generally, by way of example, but not by way of limitation, various aspects discussed herein.

[0032] FIG. 1 shows a plot of RVA viscosities of medium viscosity malted rice flours prepared in the lab and pilot plant.

[0033] FIG. 2 shows a plot of viscosities versus shear rates of medium viscosity malted rice flours.

[0034] FIG. 3 shows a plot of storage and loss moduli of 10% medium viscosity malted rice flours prepared in the lab at 4°C.

[0035] Fig. 4 shows a plot of storage and loss moduli of 10% medium viscosity malted rice flours prepared in pilot plant at 4°C.

[0036] Fig. 5 shows a plot of influence on viscosity of 10% medium malted rice flours from temperature range from 20 to 90°C.DETAILED DESCRIPTION

[0037] Reference will now be made in detail to certain aspects of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0038] This disclosure relates to low sugar malted flours and methods of making low sugar malted flours. In one aspect, the malted flours disclosed herein relate to low sugar and mediumviscosity (LS / MV) malted flours. The LS / MV malted flours comprise gelling ability in an aqueous composition. The MV malted flours can form a soft gel or a delayed soft gel in aqueous composition when incubated overnight at 4°C. The disclosure also relates to the use of the low sugar, MV malted flours generated by the methods described herein. The LS / MV malted flours can be used in applications, for example, in yogurts.

[0039] The disclosure also relates to a P-amylase free malt, method of making the P- amylase free malt and use of the P-amylase free malt for making the low sugar malted flours.

[0040] The term “malt” as used herein relates to a traditional malt powder derived from a grain, preferably a cereal grain and is a diastatic malt with a-amylase enzyme activity and P- amylase enzyme activity. Malt is made by steeping, germinating, kilning and roasting.

[0041] The term “P-amylase free malt” or “BAF malt” or “BAF malt powder” as used herein relates to a malt, e.g., a diastatic malt, that includes the enzymes, a-amylase and P-amylase, however, the activity of the P-amylase enzyme has been substantially or totally inactivated.Preferably, the activity of the P-amylase enzyme is not detectable. The BAF malt still has a- amylase enzyme activity. The terms “P-amylase free malt” or “BAF malt” or “BAF malt powder” will be used interchangeably.

[0042] The terms “malted flour” or “low sugar malted flour” or “LS malted flour” as used herein relate to a flour that has been treated by a BAF malt. Malted flour may include the outer bran, germ, inner endosperm, etc. The malted flour generated by using the BAF malt has low sugar content, preferably low maltose content. The malted flour generated by using a BAF malt includes less than 5wt% of sugars, or preferably less than 2wt% of sugars, or preferably less than lwt% of sugars, or preferably less than 0.5wt% of sugars in the malted flour. The terms “malted flour” and “low sugar malted flour” or “LS malted flour” will be used interchangeably.

[0043] The terms “malted rice flour” or “low sugar rice malted flour” or “LS malted rice flour” as used herein relate to a rice flour that has been generated by using the BAF malt. Malted rice flour may include the outer bran, germ, inner endosperm, etc. The malted rice flour generated by using the BAF malt has low sugar content, preferably low maltose content. The malted rice flour treated with a BAF malt includes less than 5wt% of sugars, or preferably less than 2wt% of sugars, or preferably less than lwt% of sugars, or preferably less than 0.5wt% of sugars in the malted rice flour. The terms “malted rice flour” and “low sugar malted rice flour” or “LS malted flour” will be used interchangeably.

[0044] Malt

[0045] The malt used herein is from a grain, preferably a cereal grain. Cereal grains can include, for example, barley, wheat, rye, oats, rice, sorghum, millet and com. Other cereal grains may also be used and are within the scope of this description. In one aspect, the present description relates to a barley malt. Malt as used herein is formulated as a powder.

[0046] The malt generated at germination of cereal grain can include enzymes, for example, amylases, protease and cellulases, etc. A malt can be added to a flour suspension to solubilize flour components. A natural malt can include about 10wt% of sugars. Malts generally include a-amylases and P-amylases. The P-amylases hydrolyze starch into maltose. A malted flour malted with a traditional malt can include large amounts of sugar, e.g., maltose, due to the hydrolysis of starch into maltose by P-amylase. a- Amylase catalyzes the cleavage of a- 1,4- glycosidic bonds of starch to generate oligosaccharides of varying lengths with a-configuration and a-limit dextrins, which constitute the branched oligosaccharides. P-amylases are generally responsible for producing maltose, the predominant sugar in conventionally made malted flour.The present invention advantageously includes a malt, preferably a diastatic malt, in which the P- amylase enzyme activity has been substantially or completely inactivated. Preferably, the activity of the P-amylase enzyme is not detectable in the BAF malt described herein.

[0047] By substantially or completely inactivated, it is meant that the P-amylase activity in the BAF malt is more than 60% inactivated compared to the P-amylase activity from a malt in which the P-amylase has not been inactivated. Preferably, P-amylase activity in the BAF malt is more than 70%, or preferably more than 80%, or preferably more than 90%, or preferably more than 95%, or preferably more than 97%, or preferably more than 98%, or preferably more than 99% inactivated relative to the P-amylase activity in which the P-amylase has not been inactivated.

[0048] The P-amylase activity in the BAF malt can be reduced to less than 40 Units / gram (U / g), or less than 20 U / g, or less than 10 U / g, or less than 5U / g, or less than 1 U / g, or less than 0.5 Units / g, or not detectable using the method of Beta- Amylase Activity Test (Megazyme K- BETA3 10 / 10, Medallion Labs, 9000 Plymouth Ave. N., MN 55427).

[0049] In one aspect, the BAF malt of the present description includes a-amylase activity with little or undetectable P-amylase activity. In one aspect, the BAF malt of the present description includes P-amylase activity of less than 10 U / g, or preferably less than lU / g.

[0050] The BAF malt includes most or all of the a-amylase activity relative to the a- amylase activity in a traditional diastatic malt, e.g., the malt prior to inactivation. The BAF malt includes at least 50%, or preferably at least 60%, or preferably at least 70%, or preferably at least 80%, or preferably at least 90%, or preferably at least 95%, or preferably at least 98%, or preferably at least 99% of the a-amylase activity relative to the a-amylase activity in the traditional diastatic malt, e.g., malt prior to inactivation. The amount of a-amylase activity after the heat treatment can be at least 50CU / g, or at least 75Cu / g, or at least 100 CU / g, or at least 125CU / g using the Alpha- Amylase Activity Test (AO AC 2002.01, Medallion Labs, 9000 Plymouth Ave. N., MN 55427).

[0051] Method of making BAF malt

[0052] Malting process can include the steps of steeping, germination, kilning and roasting, which can take several days to acquire a malt and / or a malt powder. In one aspect, the present description relates to a method of making a BAF malt, preferably a barley BAF malt. Malts can be from a variety of cereal grains. Cereal grains can include, for example, barley, wheat rye, oats, rice, sorghum, millet and corn.

[0053] The method of making a BAF malt can include solubilizing a malt powder, e.g., a traditional malt powder, preferably a barley malt powder. The malt is preferably a diastatic malt that includes both the P-amylase activity and a-amylase activity. The diastatic malt powder is solubilized to an aqueous slurry of between about 5wt% and about 50wt%, preferably between about 10wt% and about 40 wt%, or preferably between about 15wt% and about 30wt%, or preferably between about 15wt% and about 25wt%, or preferably about 20wt%. By aqueous, it is meant liquid such as water, milk, skimmed milk, and the like. The liquid may be pH adjusted.

[0054] The enzymes in the diastatic malt powder and / or the slurry comprising the diastatic malt powder can be treated with heat to inactivate the P-amylase enzyme activity in the malt. Preferably, the enzymes in the diastatic malt powder and / or the slurry comprising the malt powder are treated at a temperature of at most 95°C, or at most 85°C, or at most 75°C. Preferably, the slurry and / or the enzymes in the malt powder are treated to a temperature between about 60°C and 80°C, preferably between about 68°C and about 72°C.

[0055] The heat treatment can be for a duration of 1 minute to 5 hours depending on temperature. High temperature requires less time while low temperature requires longer heat treatment time.

[0056] The method further includes drying the slurry after the heat inactivation of the P-amylase enzyme activity to obtain the BAF -malt powder. The slurry can be dried by any of the drying processes known in the art. In one aspect, the heat inactivated slurry is dried by freeze drying. The freeze-dried BAF malt may be ground using, for example, a coffee grinder and then passed through a mesh screen, preferably and a 40-mesh screen.

[0057] It will be understood that the heat inactivation is directed to inactivation of the P- amylase enzyme but the method retains the activity of the other enzymes including, for example, a-amylase enzyme activity and thus, the BAF malt produced is a diastatic malt but is a reduced diastatic malt due to the inactivation of the P-amylase enzyme activity.

[0058] Malted flour

[0059] Described herein are low sugar malted flours with desired solubility and viscosity functionalities. In one aspect, the present description relates to low sugar malted flours. Preferably, the low sugar malted rice flours described herein also have a medium viscosity in an aqueous malted flour composition. The low sugar / medium-viscosity (LS / MV) malted flours can have an intermediate gelling ability and can form soft gels or delayed soft gels after incubation overnightat 4oC. Preferably, the LS / MV malted flours can have sufficient gelling ability to form a soft gel or delayed soft gel in aqueous compositions having concentrations of 10 wt% dry solids or lower when incubated at 4°C overnight.

[0060] The malted flour is a clean-label, low sugar flour and has the potential to be labelled as "flour". Dairy customers desire a natural flour ingredient that is whiter than clean label starches to texturize their yoghurts. Culinary customers desire a natural flour ingredient to texturize their dressings and sauces. Beverage customers desire a low-sugar bulking agent for no / low sugar beverages. The LS / MV malted flours may be used in variety of products, for example, food products. Food product can include, for example, a medicinal product, an emulsion, dairy products, ice cream products, convenience foods, or a snack- based filling. Such compositions can offer a more clean-label alternative. LS / MV malted flour with pseudoplastic or shear thinning property can be used in ketchup, salad dressings, mayonnaise, process cheese, cream cheese and the like.

[0061] In one aspect, the present description relates to a LS malted flour. Preferably, the malted flour comprises a sugar content of less than 5wt%, or preferably less than 2wt%, or preferably less than lwt%, or preferably less than 0.5wt% in the malted flour. Sugars, as used herein, can include fructose, galactose, glucose, lactose, maltose and / or sucrose.

[0062] Preferably, the LS malted flour can include a maltose content of less than 5wt%, or preferably less than 2wt%, or preferably less than lwt%, or preferably less than 0.5wt%, or preferably less than 0.3wt%, or preferably less than 0.2wt% in the malted flour.

[0063] The flour that can be malted with the B AF malt can be from a variety of sources, preferably a variety of grains, preferably cereal grain. The flours that can be treated with [3- amylase-free malts include, for example, rice flour, com flour, wheat flour, rye flour, potato flour, tapioca flour, bean flour, flour from roots, e.g. potato, oat flour, barley flour, sorghum flour, millet flour, flour from ancient grains and / or other starch containing flours. Ancient grains can include, for example, amaranth, quinoa, Khorasan wheat (kamut), spelt, freekeh, farro, teff, fonio, einkorn, wild rice and the like.

[0064] It will be understood that the present invention will be described with respect to malted rice flour but other malted flours from other cereal grains are within the scope of this description.

[0065] In one aspect, the present description includes a LS / MV malted rice flour. The malted rice flour can include a sugar content of less than 5wt%, or preferably less than 2wt%,or preferably less than lwt%, or preferably less than 0.5wt% in the malted flour. Sugars, as used herein, can include fructose, galactose, glucose, lactose, maltose and / or sucrose. Preferably, the malted rice flour can include a maltose content of less than 5wt%, or preferably less than 2wt%, or preferably less than lwt%, or preferably less than 0.5wt%, or preferably less than 0.3wt%, or preferably less than 0.2wt% in the malted flour.

[0066] The LS / MV malted rice flour includes a dextrose equivalence (DE) of less than 20, or less than 15 or less than 10, or less than 5, or less than 2, or less than 1. The LS malted rice flour has a DE of at most at most 20, or at most 15, or at most 10. The LS / MV malted rice flour has a DE of between 0.5 and 20, or between 0.5 and 15, or between 0.5 and 10, or between 1 and 5, or most preferably below 1.

[0067] The LS / MV malted rice flour includes a carbohydrate content of at least 70wt%, or at least 80wt%, or at least 85wt%, or at least 90wt%. The LS malted rice flour includes a carbohydrate content of between about 70wt% and 95wt%, or between 75wt% and 95wt%, or between 80 to 95wt%, or between about 85wt% and 95wt%, or between about 80wt% and 90wt% on dry basis of the flour.

[0068] The LS / MV malted rice flour includes a protein content of at least 0.5wt%, or at least lwt%, or at least 2wt%, or at least 4wt%, or at least 6wt%, or at least 8wt%, or at least 10wt%. The malted rice flour includes a protein content of between 2wt% about 12wt%, or between about 4wt% and 12wt%, or between about 6wt% and 12wt%, or between 8wt% and 12wt%, or between 2wt% and 10wt%, or between about 2wt% and 8wt%, or between 2wt% and 6wt% on dry basis of the flour.

[0069] The LS.MV malted rice flour includes a fat content of less than 5wt%, or less than 4wt%, or less than 3wt%, or less than 2wt%, or less than lwt% on dry basis of the flour.

[0070] The LS / MV malted rice flour includes an insoluble fiber content of less than 5wt%, or less than 4wt%, or less than 3wt%, or less than 2wt%, or less than lwt% on dry basis of the flour.

[0071] The LS / MV malted rice flour includes a moisture content of between 6wt% about 14wt%, or preferably between 7wt% and about 13wt%, or preferably between 8-12%, or preferably between 9wt% and 1 lwt% on dry basis of the flour.

[0072] In one aspect, the present description includes a LS / MV malted rice flour with a medium-viscosity. Viscosity, as used herein, is measured by a rheometer, for example, Anton Parr Modular Compact Rheometer (MCR 302e) with a parallel plate geometry. Rheologicalmeasurements were made at 20°C with 10wt% dry solids, as described in the Examples below. The LS / MV malted flour can have a viscosity of at least 200 mPa.s, or preferably at least 300mPa.s, or preferably at least 400mPa.s, or preferably at least 500mPa.s, or preferably at least 600mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C. The LS / MV malted flour can have a viscosity of at most 2000 mPa.s, or preferably at most 1500mPa.s, or preferably at most lOOOmPa.s, or preferably at most 800mPa.s, or preferably at most 700mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C. The LS / MV malted flour can have a viscosity of at most 3000 mPa.s, or preferably at most 2000 mPa.s, or preferably at most 1500mPa.s, or preferably at most lOOOmPa.s, or preferably at most 800mPa.s, or preferably at most 700mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C.

[0073] The LS / MV malted flour can have a viscosity of between about 200mPa.s and about 3000mPa.s, or preferably between about 200mPa.s and about 2000mPa.s, or preferably between about 200mPa.s and about 1500mPa.s, or preferably between about 200mPa.s and about lOOOmPa.s, or preferably between about 200mPa.s and about 900mPa.s, or preferably between about 300mPa.s and about 1500mPa.s, or preferably between about 300mPa.s and about lOOOmPa.s, or preferably between about 200mPa.s and about 800mPa.s, or preferably between about 300mPa.s and about 800mPa.s, or preferably between about 200mPa.s and about 700mPa.s, or preferably between about 300mPa.s and about 700mPa.s, when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C..

[0074] In one aspect, the LS / MV malted rice flour changes when viscosity versus shear rate is measured from 0.1 to 100 (1 / s) as shown in FIG. 2 and described in Examples below. The LS / MV malted rice flour can be considered a shear thinning fluid. The viscosity vs shear rate changes by at least 2-fold, or at least 3 fold, or at least 4 fold, or at least 5 fold, or at least 7 fold, or at least 8 fold, or at least 9 fold, or at least 10 fold when measured from a shear rate of 0.1 to a shear rate of 100 (1 / s). The viscosity vs shear rate changes by less than 100-fold, by less than 50 fold, or by less than 40 fold, or by less than 30 fold, or less than 20 fold when measured from a shear rate of 1 to a shear rate of 100 (1 / s).

[0075] The LS / MV malted rice flour advantageously comprises intermediate gelling capability and can form soft gels. In one aspect, the LS / MV malted rice flour forms a soft gel at10wt% of dry solids after 15 minutes at 4°C or after storage in the refrigerator (4°C) overnight. The rheological analysis of the MV malted rice flour can demonstrate that a soft gel is formed.

[0076] Modulus of rigidity is the ratio of shear stress to the shear strain, which can be used to measure the strength of the gel. The crossover point (G'=G”) quantifies the balance between storage and loss modulus. This point is also called as gel point which represents the transition from liquid-like to solid-like behavior during gelation process. In one aspect, the LS / MV malted rice flour forms a soft gel at 10wt% of dry solids within 15 minutes at 4°C or a delayed soft gel when incubated overnight at 4°C.

[0077] In one aspect, the LS / MV malted rice flour composition at 10% d.s. was incubated between two plates with 1 mm gap for 15 minutes at 4°C. If a gel was formed within 15 minutes, it could be measured by the instrument. Gelation is influenced by the concentration of malted rice flour, temperature and time. In one aspect, when used at low concentration, e.g., 1-4 wt%, LS / MV malted flour may also form a delayed soft gel when incubated overnight at room temperature or lower. The desired gel strength requirement can be dependent on applications and can be measured by the G’ and G”. In one aspect, the LS / MV malted flours might be used in yogurts, ice cream and the like as described below. The G7G” ratio of candies could be. In one aspect, a higher G7G” ratio can be achieved by a drying process to increase dry solids before packaging.

[0078] The rheological analysis of the LS / MV malted rice flour can demonstrate that a soft gel is formed and / or a delayed soft gel is formed. In one aspect, the ratio of storage modulus to loss modulus is at least about 0.5: 1, or at least 1 : 1, or at least 1.2: 1, when measured at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at most 4: 1, or at most 2: 1, or at most 1 : 1 at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at between 0.5: 1 and 4: 1, or between 0.6: 1 and 2: 1, or between 0.6: 1 and 1.5: 1, or between 0.8: 1 and 1.4: 1 when measured within 15 minutes at 4°C, at an angular frequency of 100 (rad / s).

[0079] Method of making malted flour

[0080] The methods described herein can generate a low sugar malted flour of various prototypes such as a low viscosity (LV), a medium viscosity (MV) and / or a high viscosity (HV) malted flour. In one aspect, the present description relates to generating a LS malted flour, preferably a LS / MV malted rice flour.

[0081] In one aspect, the present description includes a method of treating a flour. The method includes making a malted flour, preferably a LS / MV malted rice flour. The methodincludes preparing a slurry with a flour. The slurry can include corn flour, wheat flour, rice flour, rye flour, potato flour, tapioca flour, bean flour, flour from roots, oat flour, barley flour, sorghum flour, millet flour, flour from ancient grains and / or combinations thereof.

[0082] In one aspect, the slurry is a rice flour slurry. The amount of flour in the slurry can be, for example, between about 5wt% and about 40wt%, or preferably between about 5 wt% and about 30wt%, or preferably between about 5 wt% and about 25wt%, or preferably between about 5 wt% and about 20wt% dry solids (d.s.) in the slurry. The slurry is made with an aqueous liquid, preferably the liquid is water.

[0083] The method of generating a LS / MV malted rice flour includes heating the slurry to a temperature that is workable for an enzyme or enzymes to hydrolyze starch or starch and protein in flour. The slurry can be heated to a temperature between about 40°C and about 60°C, or preferably between about 40°C and about 50°C, or preferably between about 45°C and about 55°C, or preferably between 46°C and about 50°C, or preferably about 48°C.

[0084] The method may further comprise adjusting the pH of the slurry. The slurry may be pH adjusted to a desirable pH ranging from about 3.5 to 6.0 or preferably between 4.5 to 6.0, or preferably between pH 5 and about pH 6, or preferably between about pH 5.3 and pH 5.7, or preferably to about pH 5.5. The pH can be adjusted using acid solutions such as hydrochloric acid. Other acid solutions may be used and are within the scope of this description. The method may further include gently mixing the slurry after the pH adjustment.

[0085] In one aspect, the method of generating a LS / MV malted rice flour includes treating the slurry with a BAF malt. The BAF malt may be added to the slurry, prior to cooking, and / or added to a cooked flour suspension. Preferably, the method includes treating the slurry with a BAF malt prior to cooking the slurry. The amounts of BAF malt used and the incubation time with the BAF malt can vary depending on the desired viscosity of the malted flour as further described below. It will be understood that “BAF malt” as used herein refers to a powder but the BAF malt in other forms may also be used, for example, in a solution. The BAF malt can be derived from cereal grains, preferably from barley, wheat, rye, oats, rice, sorghum, millet, corn and combinations thereof. In one aspect, the BAF malt is a barley BAF malt. Addition of the BAF malt powder prior to cooking can reduce the viscosity of the flour slurry during and after cooking. Reducing the viscosity during cooking can be advantageous when higher dry substance content, e.g., 10wt% or higher, of flour is present in the slurry. Without addition ofBAF-malt before heating, the high viscosity of flour when the wt% d.s. is greater may stop the stirring paddle during cooking, which results in unevenly cooked flour.

[0086] In one aspect, the method of generating a LS / MV malted flour includes treating the flour slurry with the BAF malt powder. The slurry can be heated to a temperature that is workable for enzymes in the BAF malt, preferably between 40°C and about 50°C, or preferably between 45°C and about 55°C, or preferably between 46°C and about 50°C, or preferably about 48°C. The amount of BAF-malt powder added to the heated slurry to generate a LS / MV malted flour can be between about 0.001wt% to about 0.75wt% of the dry flour base, or preferably between 0.01wt% and 0.75wt%, or preferably between 0.01wt% and 0.6wt%, or preferably between 0.01wt% and 0.5wt%, or preferably between 0.05wt% and 0.4wt%, or preferably between 0.05wt% and 0.3wt%, or preferably between 0.05wt% and 0.2wt%, or preferably between 0.05wt% and 0.15wt%, or preferably about 0.1 wt% of dry base. The rice slurry may be incubated with the BAF malt at a temperature between about 45°C and about 75°C, or preferably between about 48°C and about 70°C. The slurry can be incubated with the BAF malt for at least about 10 minutes, or preferably at least about 15 minutes, or preferably at least about 30 minutes. The slurry can be incubated with the BAF malt for at most about 60 minutes, or preferably at most about 40 minutes, or preferably at most about 20 minutes. In one aspect, the slurry can be incubated at 48°C for about 15 minutes. Other combinations of temperature and time in the ranges described above are also within the scope of this description.

[0087] The method further comprises cooking the flour slurry to form a cooked flour suspension. The cooking of the slurry can inactivate the BAF malt. Preferably, the slurry is cooked to a temperature of at least 80°C, preferably at least 85°C, or preferably at least 90°C, or preferably at least 95°C to inactivate the BAF malt and to cook the flour suspension. Cooking may be conducted by any of the known methods in the art including using steam jacketed kettle, heating coil heat exchanger, a jet cooker, a drum dryer, etc. In one aspect, the slurry may be cooked in a jet cooker. The jet-cooker temperature may be at least about 90°C, or preferably at least 100°C, or preferably at least 110°C, or preferably at least 120°C or preferably at least 135°C, or preferably from about 90°C to about 135°C. Jet-cooking residence time is at least about 30 seconds, preferably for at least about Iminutes, or preferably at least about 5 minutes or higher. Cooking as described results in inactivating theenzymes and forming a cooked flour composition. After j et-cooking, the temperature can be held at about 90°C for about 20 minutes in a jacketed heating tank.

[0088] Once the reaction is complete and the desired viscosities or dextrose equivalent (DE) is reached, the enzyme(s) is inactivated by methods known in the art such as addition of heat or a low / high pH or both. Rapid Visco Analyser (RVA) method for viscosity measurement can be used to determine the desired final viscosity. The RVA viscosity can be measured using RVA (Model 4800, Perkin Elmer, Shelton, CT, USA) according to standard starch pasting test in deionized water for 13 minutes.

[0089] The B AF malt is inactivated when heated to a temperature of greater than 80°C, or preferably at 85°C or greater. The BAF malt can be inactivated when heated for at least 10 minutes, or preferably for at least 15 minutes.

[0090] The cooked suspension can be cooled to a temperature between about 40°C and about 80°C, or preferably 40°C and about 70°C, or preferably between 45°C and about 55°C, or preferably about 48°C. Cooling may be conducted by any of the known methods in the art including cooling exchanger, cooling coil, cooling j acketed stainless-steel tank, and the like. In one aspect, for freeze-drying, the cooked rice flour composition can be cooled to room temperature and then transferred to a freeze-drying flask and placed in a freezer overnight. The frozen malted rice composition was freeze-dried in a freeze-dryer. In one aspect, in the pilot plant, after holding the temperature at 90°C for 20 minutes to inactivate the enzymes, the cooked flour composition was kept above 60°C in a holding tank for spray drying.

[0091] In one aspect, the treating with BAF malt is conducted until a dextrose equivalent (“DE”) of less than 20 is achieved, or preferably less than 15, or preferably less than 10, or preferably less than 8, or preferably less than 5, or preferably less than 2, or preferably less than 1.

[0092] Once the reaction is complete and the desired viscosities or dextrose equivalent (DE) is reached, the enzyme(s) is inactivated, if needed, by methods known in the art such as addition of heat or a low / high pH or both. Rapid Visco Analyser (RVA) method for viscosity measurement can be used to determine the desired final viscosity. The RVA viscosity can be measured using RVA (Model 4800, Perkin Elmer, Shelton, CT, USA) according to standard starch pasting test in deionized water for 13 minutes. The BAF malt may be inactivated by heating the slurry to a temperature of greater than 80°C, or preferably at 85°C or greater. The BAF malt canbe inactivated by heating the slurry for at least 10 minutes, or preferably for at least 15 minutes, or preferably for at least 15 minutes.

[0093] In one aspect, the method further includes drying the BAF malt treated suspension to generate the malted flour. A variety of drying process are known in the art and all are within the scope of this description. The treated slurry can be dried, for example, by drum drying, freeze drying, spray drying, flash drying, fluidized bed drying and combinations thereof.

[0094] The LS / MV malted flour is dried to obtain a flour with a moisture content of less than 12wt%, or preferably less than 10wt%, or preferably less than 8wt%, or preferably less than 6wt%, or preferably less than 4wt%.

[0095] In one aspect, the method, optionally, may further include a second BAF malt treatment. If performing the second BAF malt treatment, the method can include cooling the cooked suspension to a temperature that is workable for an enzyme or enzymes to hydrolyze starch or starch and protein in flour and treating the cooled flour suspension with a second addition of BAF malt incubation. The cooked suspension can be cooled to a temperature between about 40°C and about 80°C, or preferably 40°C and about 70°C, or preferably between 45°C and about 55°C, or preferably about 48°C. Cooling may be conducted by any of the known methods in the art including cooling exchanger, cooling coil, cooling j acketed stainless-steel tank, etc. The method may include, optionally, treating the cooled flour suspension with a second addition of BAF malt into a reaction tank with agitation. The cooled, cooked rice flour suspension is treated with the second addition of BAF malt at a temperature between about 40°C and about 55°C, or preferably between about 46°C and about 50°C, or preferably at about 48°C. The pH of the suspension may be adjusted as described above. The cooled flour suspension may be treated with the second addition of BAF malt for between about 1 minutes and 30 minutes, or preferably between about 1 minutes and 20 minutes, or preferably between about 1 minutes and 10 minutes, or preferably between about 5 minutes and 20 minutes. If treated with a second addition of BAF malt, the amount of BAF malt added in the second addition to the cooled suspension can be at least about 0.001wt%, or at least about 0.005wt%, or at least about 0.008wt% or at least 0.01wt%. Preferably, the amount of BAF malt added is between 0.00 lwt% and 0.1 wt%, or preferably between 0.00 lwt% and 0.7wt%, or preferably between 0.001wt% and 0.6wt%, or preferably between 0.002wt% and 0.5wt%, or preferably between 0.002wt% and 0. lwt%, or preferably between 0.003wt% and 0.05wt%, or preferably between 0.004wt% and 0.02wt%, or preferably about 0.01wt% of the dry flour base. Theamount of BAF malt added to the cooled flour suspension and the incubation time of the suspension with the BAF malt can vary and can be dependent on the desired end use. Increasing the amount of BAF malt and / or increasing the incubation time can result in decreasing the viscosity and / or the gelling ability of the malted flour.

[0096] The amount of sugar in the medium -viscosity malted flour can be as described above and, for example, be less than 5wt%, or preferably less than 4wt%, or preferably less than 3wt%, or less than 2wt%, or less than lwt%, or less than 0.5wt% of the weight of the malted flour.

[0097] The LS / MV malted rice flour can have a desirable light color. CIELAB color space ("Lab-Farbraum") can be used to measure the color of malted flour. The LS / MV malted rice flour has a higher lightness (L) and lower yellowness (b) than label friendly and functional starch and other starches in the Lab Color Space.

[0098] In one aspect, the method generates a LS / MV malted rice flour with a viscosity of at least 200 mPa.s, or preferably at least 300mPa.s, or preferably at least 400mPa.s, or preferably at least 500mPa.s, or preferably at least 600mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C. In one aspect, the method generates a LS / MV malted rice flour with a viscosity of at most 2000 mPa.s, or preferably at most 1500mPa.s, or preferably at most lOOOmPa.s, or preferably at most 800mPa.s, or preferably at most 700mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20°C.

[0099] In one aspect, the method generates a LS / MV malted rice flour with a viscosity of between about 200mPa.s and about 2000mPa.s, or preferably between about 200mPa.s and about 1500mPa.s, or preferably between about 200mPa.s and about lOOOmPa.s, or preferably between about 200mPa.s and about 900mPa.s, or preferably between about 300mPa.s and about 1500mPa.s, or preferably between about 300mPa.s and about lOOOmPa.s, or preferably between about 200mPa.s and about 800mPa.s, or preferably between about 300mPa.s and about 800mPa.s, or preferably between about 200mPa.s and about 700mPa.s, or preferably between about 300mPa.s and about 700mPa.s, wherein the viscosity is measured at 20°C at 10% d.s in water and at a shear rate of 100 (1 / s) using a rheometer as described below in Examples.

[0100] In one aspect, the method generates a LS / MV malted rice flour with a viscosity versus shear rate measured from 1 to 100 (1 / s) changes as shown in FIG. 2 and described in Examples below. The LS / MV malted rice flour can be considered a shear thinning fluid. Themethod generates a LS / MV malted rice flour with a viscosity vs shear rate that changes by at least 2-fold, or at least 3 fold, or at least 4 fold, or at least 5 fold, or at least 7 fold, or at least 8 fold, or at least 9 fold, or at least 10 fold when measured from a shear rate of 0.1 to a shear rate of 100 (1 / s). The viscosity vs shear rate changes by less than 100-fold, by less than 50 fold, or by less than 40 fold, or by less than 30 fold, or less than 20 fold when measured from a shear rate of 1 to a shear rate of 100 (1 / s).

[0101] The method may further comprise forming a soft gel with the LS / MV malted rice flour. The LS / MV malted rice flour using the method described herein can advantageously comprise intermediate gelling capability In one aspect, the ratio of storage modulus to loss modulus is at least about 0.5: 1, or at least 1 : 1, or at least 1.2: 1, when measured at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at most 4: 1, or at most 2: 1, or at most 1 : 1 at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at between 0.5: 1 and 4: 1, or between 0.6: 1 and 2: 1, or between 0.6: 1 and 1.5: 1, or between 0.8: 1 and 1.4: 1 when measured within 15 minutes at 4°C, at an angular frequency of 100 (rad / s).

[0102] In one aspect, the LS / MV malted rice flours can be used as a food ingredient in a variety of food products. The products made using the above MV malted rice flours will be natural and clean-label functional ingredients. It may be labelled as a malt or a malted flour or malted flours. The products comprising the LS / MV malted flours may provide viscosities, creaminess, mouthfeel, gelling, emulsifying and other functionalities. The MV malted flour can be used as an ingredient in a wide variety of applications in bread, pastry, meats, dry soup mixes, bakery mixes, frosting mixes, spice mixes, condiments, gravy mixes, sauce mixes, frozen dairy foods, fat mimetics, whipped products, protective coatings, agglomeration aids, low or reduced-in-calorie foods, low or reduced-in-fat foods, beverages, fat replacers, skimmed milk replacers, whey powder replacers, flavor carrier, seasoning carrier, etc.

[0103] In one aspect, the LS / MV malted flour can be a low-sugar, clean-label flour texturizer and / or thickening agent. In one aspect, the LS / MV malted flour can be a low sugar or sugar-free thickening agent. In one aspect, the LS / MV can be a low sugar binding agent.

[0104] In one aspect, if the G7G’ was less than 1, the solution could be stored in the refrigerator for up to a month, preferably for a week, most preferable for overnight to form a delayed gel. These properties could be user-friendly in processing. A yogurt liquid, for example,may be deposited through pipe to cups without blockage during processing. The yogurt liquid turns to soft gel in refrigerator.

[0105] According to various aspects, a use of a low sugar, LS / MV malted flour includes use in food products such as, but not limited to, beverages, beverage mixes, infant food, medicinal products, food emulsions, convenience foods, bakery, dairy, and snack-based fillings or food products. Beverages and beverage mixes can include instant mixes for hot or cold beverages, flavored milk including chocolate milk, cocoa malt beverages, carbonated soft drinks, fruit juices, sports beverages, nutrition beverages, and infant formula. Dairy can include ice cream, yogurt, sour cream, whip cream, and non-dairy vegan alternatives. Convenience foods include but are not limited to salad dressings (pourable and spoonable), sauces (instant and prepare), condiments, puddings, bars, cereals, coatings for cereal, spreads, low-fat spreads, icings, hard candies, soft candies, gummy products, and dry mix seasonings. Bakery can include cookies, cakes, muffins, crackers, pastries, and laminated baked products.

[0106] In an example, the ability of the LS / MV malted flour of the present invention to be incorporated at high dry substance percentages and function as a texturizer / thickening agent ensures that the mouth feel of a consumable can be tailored accordingly meaning that the LS / MV malted flour ingredient of the present invention can be used in numerous consumables.

[0107] In one aspect, the LS / MV malted flour as described herein can be used as at least a partial replacement of maltodextrin in food applications and in many cases can be used as a full replacement of maltodextrin in food applications. Such LS / MV malted flour can be an effective maltodextrin replacement in any food application in which maltodextrins are currently used. The LS / MV malted flour demonstrates similar functionality (e.g., pH, solubility, and viscosity) as maltodextrin making it a suitable replacement for maltodextrin in food applications. Such replacement allows for consumer-friendly labelling as malted flours may be more well received by some consumers as compared to maltodextrin.

[0108] Further, such malted flour additionally has the capability to replace maltodextrins in flavor encapsulation applications wherein a flavor emulsion is created and spray dried, to convert a liquid flavor into a solid. In these applications maltodextrins may be used alongside a lipophilic starch, or alternately used alone to create a flavor emulsion. Maltodextrins are typically used in this space due to their ability to form matrices that positively contribute to encapsulation. The malted flour described herein can replace maltodextrins in this space due to their bland flavor, low viscosity, and low cost.

[0109] Additionally, LS / MV malted flours can replace maltodextrin in plating oil-based flavors. Preferably, the malted flour as described herein can be used for instant sauces (e.g., dry mix that is reconstituted to a sauce form by the consumer), prepared sauces, dry mix seasoning, and flavor encapsulation. Such malted flours can be added in varying amounts and consistently demonstrate similar taste and functionality as maltodextrin.

[0110] The invention is further described in detail by reference to the following experimental examples. These examples are provided for purposes of illustration only and are not intended to be limiting unless otherwise specified. Thus, the invention should in no way be construed as being limited to the following examples, but rather should be construed to encompass any and all variations which become evident as a result of the teaching provided herein.EXAMPLESExample 1: Method of making the B-amylase free malt

[0111] Light-colored barley malt (Prairie Malt ULC, Lot BIG22XMB00035) was obtained from Boortmalt North America. In the lab, barley malt grains were ground to coarse particles using a coffee grinder for 1 minute. The coarse particles were transferred to a 40-mesh sieve. After shaking, the overs on the 40-mesh sieve were discarded. The rest was ground and passed through 60 mesh screen (61% yield). Rice flour: Honeyville long grain rice flour was purchased from The Honeyville Mill.

[0112] Methods:

[0113] Preparation fine beta-amylase-free malt:

[0114] Deionized water (200 ml) in a metal beaker was heated to reach 68-70°C on the hot plate (Fisher brand Isotemp Advanced stirrer hotplate). Fine Prairie Malt ULC (50 g) was added into a beaker to form 20% solution. The malt aqueous slurry was treated at 68-70°C for 30 min to inactivate P amylase without significant impacting a-amylase activity. After heat treatment, the malt aqueous slurry was quickly cooled to about room temperature. The malt aqueous slurry was transferred into a freeze-drying flask and placed in the freezer overnight. The frozen malt slurry was freeze-dried in a freeze-dryer.

[0115] Alpha-amylase activity test: Alpha-amylase activity was determined by the Medallion lab using the reference AO AC 2002.01.

[0116] Beta-amylase activity test: Beta-amylase activity was determined by the Medallion lab using the reference of Megazyme K-BETA3.

[0117] Table 1 (below) shows the results from the heat treatment of the traditional malt. The P-amylase enzyme activity is reduced to below detectable limits in the treated barley malt, while 77.6% of alpha-amylase was retained after the process (Table 1). The barley malt powder resulting from the heat treatment is the BAF malt powder used in the experiments below.Table 1* Alpha-amylase activity was determined by the Medallion lab using the reference AO AC 2002.01.#Beta-amylase activity was determined by the Medallion lab using the reference of Megazyme K-BETA3.Example 2-Method of making low sugar, medium-viscosity (LS / MV) malted flour (Lab092822)

[0118] Long grain rice flour was obtained from Honeyville Grain Mill (Honeyville, UT 84314, USA). It contains 21.74% amylose, 81.5% carbohydrate, 7.24% protein, 1.4% fat, 2.0% soluble fiber, 0.6% insoluble fiber and 0.55% ash analyzed by Medallion Labs (Minneapolis, MN 55427).

[0119] Preparation of medium -viscosity low-sugar malted rice flour using beta-amylase- free malt in the lab:

[0120] Deionized water (480 g) was weighed into a 600 ml beaker and placed on the hot plate. While stirring, Honeyville long grain rice flour (60 g, moisture 9.34%) was added gradually to water. The slurry was heated to 48±2°C. The pH of the slurry was adjusted to 5.5±0.2 using 1% NaOH / HCI solutions. After pH adjustment, continue mixing of the slurry at a gentle speed.The beta-amylase-free Malt (moisture 2.52%, 0.06 g or 0.1% of the weight of the rice flour as is) was added to rice slurry. After enzyme conversion at 48±2°C for 15 min to lower the viscosity, the slurry was heated to 95°C and cooked for 15 minutes and then cooled to 48±2°C. The beta- amylase-free malt (moisture 2.52%, 0.06 g or 0.01% of the weight of the rice flour as is) was gradually into the rice flour slurry while mixing. The enzyme reaction was carried out for 15 minutes. After enzyme conversion, the reaction was terminated by heating the rice flour slurry at 85-87°C for 15 minutes. The rice flour slurry was cooled to room temperature. It was then transferred to a freeze-drying flask and placed in a freezer overnight. The frozen malt slurry was freeze-dried in a freeze-dryer.Example 3 - Making LS / MV malted flour at pilot plant (HAM083123SD)

[0121] Rice flour slurry preparation: Long grain rice flour (RF-100080) from Producers Rice Ingredients (14.4 lbs, moisture 11.9%) was weighed and added to jacketed stainless steel tank. Water was added so that the total slurry weight was 118.4 lb. While stirring, the slurry was heated to 48±2°C.

[0122] Adjustment of pH: Check the pH and the temperature of the slurry. Adjust pH to 5.5±0.2 using 1% NaOH / HCI solutions. After pH adjustment, continue mixing of the slurry at a gentle speed.

[0123] Initial enzyme conversion and cooking: Barley P-amylase-free Malt (0.025% BAF malt on weight of rice flour as is) was added gradually to rice flour slurry. After enzyme conversion at 48±2°C for 15 min to lower slightly the viscosity, the slurry of rice flour is jet- cooked at about 90-93°C. Jet-cooking residence time was about 1 minute. Time for all the slurry to pass through the jet cooker was 27 minutes. The cooked rice flour slurry was hold at 90°C for 20 minutes to make sure all enzymes in malt were inactivated.

[0124] Drying of malt treated flour: The BAF malt treated rice flour was spray-dried.Example - 4 Making LS / MV malted flour in the lab using Thermomix (Vorwerk® International) (Lab042424).

[0125] Long Grain Rice Flour (RF-100080) was from Producers Rice Ingredients (moisture 10.75%). Beta-amylase-Free Barley Malt (moisture 6.08% or 93.92% d.s.) at 68-70°C for 30 minutes.

[0126] Rice flour slurry preparation: Sample 224.1 g (200 g d.s.) of long grain rice flour with moisture of 10.75% (RF-100080, Producers Rice Ingredients, Stuttgart AR 72160) wasweighed into a Thermomix (Vorwerk® International). Water (1775.9 g) was added to make a 10% rice flour aqueous slurry.

[0127] Adjustment of pH: The pH of the flour slurry was adjusted to 5.5±0.2 using 1% NaOH / HCI solutions while mixing.

[0128] Initial enzyme reaction and cooking: The flour slurry was added with 0.213 (0.2 g d.s.) or 0.1% of beta-amylase free malt on rice flour base while mixing to reduce the viscosity during cooking of flour slurry. The rice flour was held at 48-52°C and 70-75°C for 15 minutes.

[0129] Termination of Reaction: After 15 min hydrolysis, the reaction was terminated by heating the rice flour slurry at 93-97°C for 15 minutes.

[0130] The rice flour slurry was cooled to room temperature. It was then transferred to a freeze-drying flask and placed in a freezer overnight. The frozen malt slurry was freeze-dried in a freeze-dryer.

[0131] Sample was ground in coffee grinder and passed through 40 mech screen (g). The moisture content was 1.8%.Example 5 - Making LS / MV malted flour at pilot plant (HAM042723B)

[0132] Rice flour slurry preparation: Long grain rice flour (RF-100080) from Producers Rice Ingredients (13 lb, moisture 11.9%) was weighed and added to jacketed stainless steel tank. Water was added so that the total slurry weight was 104.1 lb. While stirring, the slurry was heated to 48±2°C.

[0133] Adjustment of pH: Check the pH and the temperature of the slurry. Adjust pH to 5.5±0.2 using 1% NaOH / HCI solutions. After pH adjustment, continue mixing of the slurry at a gentle speed.

[0134] Initial enzyme conversion and cooking: Barley P-amylase-free Malt (0.025% BAF malt on weight of rice flour as is) was added gradually to rice flour slurry. After enzyme conversion at 48±2°C for 15 min to lower slightly the viscosity, the slurry of rice flour is jet- cooked at about 113-114°C. Jet-cooking residence time was about 1 minute. Time for all the slurry to pass through the jet cooker was 15 minutes. The cooked rice flour slurry was hold at 90°C for 20 minutes to make sure all enzymes in malt were inactivated.

[0135] Drying of malt treated flour: The BAF malt treated rice flour was spry-dried.

[0136] Table 2 shows a summary of BAF malt used for Examples 2-5Table 2

[0137] Sugar profile by HPLC test: Sugar profile by HPLC test was analyzed by the Medallion lab using the reference of AO AC 977.20.

[0138] Rheological measurements

[0139] To prepare the sample for rheology, samples were cooked using a Rapid Viscosity Analyzer (RVA), e.g., RVA (Model 4800, Perkin Elmer, Shelton, CT, USA). The samples were suspended in deionized (DI) water at 10% dry solids (ds). The total suspension weighed 30.0 g. The RVA method settings are heating sample from 50°C to 95°C with spindle speed at 160 rpm in 4 min and 42 sec, cooking at 95°C for 2 min and 30 sec with spindle speed at 160 rpm, cooling down to 50°C in 3 min and 48 sec, and holding at 50°C for 2 min. Once complete, 2mL of the RVA paste was used for rheology testing. Anton Parr Modular Compact Rheometer (MCR 302e) with a parallel plate geometry was use d for rheology.

[0140] To measure storage (G’) and loss moduli (G”), right after cooking the sample 10% dry substance in the RVA, about 2 mL of the sample was pipetted onto the parallel plate base that was set to a temperature of 4°C. A PP50 sandblasted geometry was set to a 1 mm gap, the pasted sample was trimmed, and the method was started. The rheology method included a 15-minuterecovery period. A shear sweep from 100 to 0.5 rad / s is then measured at 1% shear strain. Using the same instrumental setting, viscosities versus shear rates from 0.1 to 100 1 / s at 20°C were analyzed at 10% and 20°C. A temperature ramp from 20-90°C at 20 1 / s shear rate was performed.

[0141] 1. Sugar content of rice flour treated with a traditional barley malt

[0142] Sugar profiles of traditional malt (1% on flour bases)-hydrolyzed rice flour at different reaction time was shown in Table 3. The rice flour was treated for the reaction times indicated in Table 3 The sample with 0 min hydrolysis means that the sample was drawn before addition of traditional barley malt. Table 3 shows that the amount of maltose in the rice flour increases with the incubation time when treated with a traditional malt. The presence of the [3- amylase enzyme activity in the traditional malt results in the hydrolysis of starch leading to increased amounts of maltose as the reaction time increases. The sugar content of malted rice flour was 16.6% after hydrolyzed the cooked rice flour using 1% barley malt at 48±2°C for 15minutes. The high sugar content is undesirable for a texturizer. The sugar was nearly all contributed by maltose, the hydrolyzed product of starch by beta-amylase.Table 30143] Sugar profile by HPLC test was analyzed by the Medallion lab using the reference of AO AC 977.20.

[0144] 2. Sugar content of rice flour treated with a BAF malt from barley

[0145] The beta-amylase-free malt was used to produce medium -viscosity malted rice flour and it contained 0.45% total sugars. Such a low sugar product may be used for low-sugar orsugar-free products (Table 4). When the beta-amylase-free malt was used to produce a medium viscosity malted rice flour, the total sugar content was 0.58% in the spray-dried product, which proved that the low sugar technology can be scaled up (Table 3). Prairie malt ULC and traditional barley malt had total sugars of 9.84% and 8.73% respectively, which are too high for texturizers (Table 4).Table 4

[0146] Analysis of LS / MV malted flour: The LS / MV malted rice flour was analyzed anc the results summarized in the Table 5 below.Table 5

[0147] Detailed RVA and rheological measurements are shown in FIG’s. 1 to 5.

[0148] The RVA profiles of samples are shown in FIG. 1. Sample 1 showed a small viscosity peak at temperature at about 66°C, which might be caused by solubilization of starch for increase of viscosity and temperature increase for viscosity decreasing. Viscosity of sample 2 decreased at about 70°C, which was likely caused by temperature increase. Sample 3 showed a peak viscosity like uncooked starch. Sample 3 was prepared using 0.1% BAF malt and only cooked once in the lab. Some starch may not be fully cooked during preparation which caused high peak viscosity during RVA testing. Sample 4 showed a relative stable viscosity during testing.

[0149] Viscosities versus shear rate showed that all 4 samples were shear thinning fluids (FIG. 2). The sample with higher viscosity exhibited more decrease of viscosity during the shear sweep. The samples prepared in the lab (sample 1 and 3) had higher viscosities than the samples prepared in the pilot plant (sample 2 and 4).

[0150] The G’ and G” of the lab prepared samples (1 and 3) are shown in FIG. 3. The ratios of G7G” of samples 1 and 3 were higher than 1, indicating gels were formed for samples 1 and 3 during rheological measurements.

[0151] The G’ and G” of the samples of pilot prepared samples (2 and 4) are shown in FIG. 4. The ratios of G7G” of samples 2 and 4 were less than 1, indicating gels were not formed for samples 2 and 4 during rheological measurements. However, when the samples 2 and 4 were cooked in RVA and stored in refrigerator for two weeks, both samples formed gels. Since samples 2 and 4 did not form a gel during incubation in rheometer for 15 minutes but formed gels after incubation in the refrigerator for two weeks, they were called delayed soft gels in this invention.

[0152] Temperature influences of medium malted flours from 20 to 90°C are shown in FIG. 5. All sample were susceptible to temperature increase. When temperature increased, viscosities of medium viscosity malted rice flours decreased.

[0153] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.

[0154] Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range were explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0155] Unless expressly stated, ppm (parts per million), percentage, and ratios are on a by weight basis. Percentage on a by weight basis is also referred to as wt% or % (wt) below.

Claims

CLAIMSWhat is claimed is:

1. A method of treating a flour comprising: treating a slurry comprising the flour with a P-amylase free (BAF) malt to generate a malted flour, wherein the malted flour is a low sugar, medium viscosity (LS / MV) malted flour, wherein the LS / MV malted flour comprises less than 5wt% of sugars, preferably less than 5wt% of maltose.

2. The method of claim 1, wherein the flour comprises com, wheat, rice, rye, potato, tapioca, beans, roots, oats, barley, sorghum, millet, ancient grains and / or combinations thereof, preferably the flour is a rice flour.

3. The method of any one of the preceding claims, wherein treating the slurry comprises: a. heating the slurry to BAF malt enzyme activity temperature, preferably between about 45°C and 55°C; b. treating the slurry with the BAF malt, wherein the amount of the BAF malt added is between about 0.01wt% and about 0.5wt% amt of malt based on weight of the flour added, preferably the amount of the BAF malt added is between about 0.01wt% and about 0.2wt%; c. cooking the slurry to form a cooked flour suspension, preferably the slurry comprises between 5wt% and 20wt% of the flour based on the weight of the slurry, wherein the slurry is cooked to a temperature of at least 80°C, preferably about 95°C; and d. drying the flour suspension to generate the malted flour.

4. The method of any one of the preceding claims, wherein the method further comprises treating the cooked flour composition with the BAF malt prior to the drying step.

5. The method of any one of the preceding claims, wherein the cooked flour composition is treated with the BAF malt after the cooking step without treating the slurry with the BAF malt prior to the cooking step.

6. The method of any one of the preceding claims, wherein a cooked composition comprising the malted flour at 10 wt% d.s. based on the weight of the composition is a soft gel when incubated for 15 minutes at 4°C and / or is a delayed soft gel when incubated overnight at 4°C.

7. The method of any one of the preceding claims, wherein the malted flour comprises a viscosity of between about 200 mPa.s and about 2000 mPa.s, when measured at 20°C at a shear rate of 100(l / s), wherein the viscosity is measured in a cooked malted flour composition of 10wt% d.s.

8. The method of any one of the preceding claims, wherein the BAF malt is from cereal grains, preferably from barley, wheat, rye, oats, rice, sorghum, millet, com and combinations thereof, preferably from barley.

9. The method of any one of the preceding claims, wherein the drying comprises drum drying, freeze drying, spray drying, hot air drying, oven drying and fluidized bed drying and combinations thereof.

10. A malted flour comprising a sugar content of less than 5wt%, preferably less than 4wt%, less than 3wt%, less than 2wt%, or less than lwt%, or less than 0.5wt%, wherein a cooked composition comprising the malted flour at 10 wt% d.s. based on the weight of the composition is a soft gel when incubated for 15 minutes at 4°C and / or is a delayed soft gel when incubated overnight at 4°C.

11. The malted flour of claim 10, wherein the malted flour comprises a maltose content of less than 5wt%, preferably less than 4wt%, less than 3wt%, less than 2wt%, or less than lwt%, or less than 0.5wt%.

12. The malted flour of any one of claims 10-11, wherein the flour is selected from corn flour, wheat flour, rice flour, rye flour, potato flour, tapioca flour, beans flour, flour from roots, oat flour, barley flour, sorghum flour, millet flour, flour from ancient grains and combinations thereof, preferably rice flour.

13. The malted flour of any one of claims 10-12, wherein the malted flour composition has viscosity range of between about 200 mPa.s and about 2000 mPa.s, wherein the viscosity is measured in a malted flour composition comprising 10wt% of dry solids of the malted flour.

14. The malted flour of any one of claims 10-13, wherein the malted flour has a dextrose equivalent (DE) of less than five as measured by by Schoorl's method, based on the reduction of copper (II) sulphate solution.

15. The malted flour of any one of claims 10-14, wherein the storage modulus of the malted flour is higher than the loss moduli, preferably the storage modulus to loss modulus ratio (G7G”) is between 0.5 and 2, when measured at an angular frequency of 100 (rad / s).

16. A food product, comprising the malted flour, preferably malted rice flour, of any one of claims 10-15.

17. The food product of claim 16, wherein the food product is a medicinal product, an emulsion, a dairy product, an ice-cream product, a convenience food, a snack-based filling, and / or combinations thereof.

18. The food product of any one of claims 16-17, wherein the malted flour is a thickening agent, a texturizer, a fat replacer, a skimmed milk replacer, a whey powder replacer and combinations thereof.

19. Use of a malted flour of any one of claims 10-15 wherein the food product is a medicinal product, an emulsion, a dairy product, an ice-cream product, a convenience food, a snack-based filling, and / or combinations thereof.

20. A food ingredient comprising a malted flour of any one of claims 10-15.

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