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

Abstract

Low-sugar, high-viscosity malted flours and methods of making the malted flours are described. Methods of making the low-sugar, high 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, high-viscosity malted flours.

Description

PT-1852-WO-PCT [3] LOW SUGAR, HIGH-VISCOSITY MALTED FLOURS AND PROCESS FOR MAKING THE SAME CROSS-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] Consumers 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 β-amylase free malt, method of making the β-amylase free malt and use of the β-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 β-amylase free (BAF) malt to generate a malted flour, whereinPT-1852-WO-PCT [3] the malted flour comprises less than 5wt% of sugars, preferably less than 5wt% of maltose. Preferably, the method generates a low-sugar, high-viscosity (LS / HV) 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 1wt%, or less than 0.5wt%. The disclosure further provides food product and / or food ingredients comprising the LS / HV 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 β-amylase enzyme in the malt to generate a BAF malt.

[0008] The disclosure also provides a malt comprising α-amylase enzymes and β-amylase enzymes, wherein the β-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 β-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, high viscosity (LS / HV) 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 45oC and 55oC; 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 onPT-1852-WO-PCT [3] 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 80oC, preferably about 95oC; 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 forms a strong gel when incubated for 15 minutes at 4oC.

[0017] Clause 7: The method of any one of the preceding clauses, wherein the malted flour comprises a viscosity of at least about 2000 mPa.s, when measured at 20oC at a shear rate of 100(1 / 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 1wt%, 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 forms a strong gel when incubated for 15 minutes at 4oC.

[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 1wt%, or less than 0.5wt% flour.PT-1852-WO-PCT [3]

[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 of at least 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 (G’ / G”) is greater than 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.PT-1852-WO-PCT [3]

[0032] FIG.1 shows a plot of RVA profiles of 10% of rice flour, LS / HV malted rice flours (HV-sample#1 and HV-sample #20).

[0033] FIG.2 shows a plot of the viscosities versus shear rates for 10% of LS / HV malted rice flours (HV-sample#1 and HV-sample #2).

[0034] FIG. 3 shows a plot of the storage and loss Moduli of LS / HV malted rice flours (HV-sample#1 and HV-sample #2).

[0035] Fig.4 shows a plot of the influence of temperature on viscosity of LS / HV malted rice flours (HV-sample#1 and HV-sample #2). DETAILED DESCRIPTION

[0036] 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.

[0037] 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 high- viscosity (LS / HV) malted flours. The LS / HV malted flours comprise gelling ability in an aqueous composition. The HV malted flours can form a strong gel in an aqueous composition in 15 minutes at 4oC. The disclosure also relates to the use of the LS / HV malted flours generated by the methods described herein. The LS / HV malted flours can be used in food applications.

[0038] The disclosure also relates to a β-amylase free malt, method of making the β- amylase free malt and use of the β-amylase free malt for making the low sugar malted flours.

[0039] 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 α-amylase enzyme activity and β- amylase enzyme activity. Malt is made by steeping, germinating, kilning and roasting.

[0040] The term “β-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, α-amylase and β-amylase, however, the activity of the β-amylase enzyme has been substantially or totally inactivated. Preferably, the activity of the β-amylase enzyme is not detectable. The BAF malt still has α-PT-1852-WO-PCT [3] amylase enzyme activity. The terms “β-amylase free malt” or “BAF malt” or “BAF malt powder” will be used interchangeably.

[0041] 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 1wt% 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.

[0042] 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 1wt% 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.

[0043] Malt

[0044] 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 corn. 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.

[0045] 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 α-amylases and β-amylases. The β-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 β-amylase. α-Amylase catalyzes the cleavage of α-1,4- glycosidic bonds of starch to generate oligosaccharides of varying lengths with α-configuration and α-limit dextrins, which constitute the branched oligosaccharides. β-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 β-PT-1852-WO-PCT [3] amylase enzyme activity has been substantially or completely inactivated. Preferably, the activity of the β-amylase enzyme is not detectable in the BAF malt described herein.

[0046] By substantially or completely inactivated, it is meant that the β-amylase activity in the BAF malt is more than 60% inactivated compared to the β-amylase activity from a malt in which the β-amylase has not been inactivated. Preferably, β-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 β-amylase activity in which the β-amylase has not been inactivated.

[0047] The β-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).

[0048] In one aspect, the BAF malt of the present description includes α-amylase activity with little or undetectable β-amylase activity. In one aspect, the BAF malt of the present description includes β-amylase activity of less than 10 U / g, or preferably less than 1U / g.

[0049] The BAF malt includes most or all of the α-amylase activity relative to the α- 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 α-amylase activity relative to the α-amylase activity in the traditional diastatic malt, e.g., malt prior to inactivation. The amount of α-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 (AOAC 2002.01, Medallion Labs, 9000 Plymouth Ave. N., MN 55427)

[0050] Method of making BAF malt

[0051] 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.

[0052] 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 aPT-1852-WO-PCT [3] diastatic malt that includes both the β-amylase activity and α-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.

[0053] The enzymes in the diastatic malt powder and / or the slurry comprising the diastatic malt powder can be treated with heat to inactivate the β-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 95oC, or at most 85oC, or at most 75oC. Preferably, the slurry and / or the enzymes in the malt powder are treated to a temperature between about 60oC and 80oC, preferably between about 68oC and about 72oC.

[0054] 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.

[0055] The method further includes drying the slurry after the heat inactivation of the β-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.

[0056] It will be understood that the heat inactivation is directed to inactivation of the β- amylase enzyme, but the method retains the activity of the other enzymes including, for example, α-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 β-amylase enzyme activity.

[0057] Malted flour

[0058] 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 high-viscosity in an aqueous malted flour composition. The low sugar / high-viscosity (LS / HV) malted flours can form a strong gel after about 15 minutes at 4oC at 10%. Preferably, the LS / HV malted flours can have gelling ability to form a strong gel in an aqueous compositions having concentrations of 10 wt% dry solids or lower after about 15 minutes at 4oC.PT-1852-WO-PCT [3]

[0059] The LS / HV 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 / HV 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 / HV malted flour with pseudoplastic or shear thinning property can be used in ketchup, salad dressings, mayonnaise, process cheese, cream cheese and the like. The LS / HV malted rice flour advantageously comprises gelling capability to form a strong gel, which may be useful in jelly candies such as gum drops, orange slices, and jellybeans.

[0060] 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 1wt%, or preferably less than 0.5wt% in the malted flour. Sugars, as used herein, can include fructose, galactose, glucose, lactose, maltose and / or sucrose.

[0061] Preferably, the LS malted flour can include a maltose content of less than 5wt%, or preferably less than 2wt%, or preferably less than 1wt%, or preferably less than 0.5wt%, or preferably less than 0.3wt%, or preferably less than 0.2wt% in the malted flour.

[0062] The flour that can be malted with the BAF malt can be from a variety of sources, preferably a variety of grains, preferably cereal grain. The flours that can be treated with β-amylase-free malts include, for example, rice flour, corn 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.

[0063] 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.

[0064] In one aspect, the present description includes a LS / HV 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 1wt%, or preferably less than 0.5wt% in the malted flour. Sugars, as usedPT-1852-WO-PCT [3] herein, can include fructose, galactose, glucose, lactose, maltose and / or sucrose. Preferably, the LS / HV malted rice flour can include a maltose content of less than 5wt%, or preferably less than 2wt%, or preferably less than 1wt%, or preferably less than 0.5wt%, or preferably less than 0.3wt%, or preferably less than 0.2wt% in the malted flour.

[0065] The LS / HV 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 0.1 and 10, or between 0.1 and 5, or between 0.1 and 2, or between 0.1 and 1, or most preferably below 1.

[0066] The LS / HV 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.

[0067] The LS / HV malted rice flour includes a protein content of at least 0.5wt%, or at least 1wt%, 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.

[0068] The LS / HV 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 1wt% on dry basis of the flour.

[0069] The 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 1wt% on dry basis of the flour.

[0070] The LS / HV 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 11wt% on dry basis of the flour.

[0071] In one aspect, the present description includes a LS / HV malted rice flour with a high viscosity. Viscosity, as used herein, is measured by a rheometer, for example, Anton Parr Modular Compact Rheometer (MCR 302e) with a parallel plate geometry. Rheological measurements were made at 20oC with 10wt% dry solids, as described in the Examples below. The LS / HV malted flour can have a viscosity of at least 2000 mPa.s, or preferably at leastPT-1852-WO-PCT [3] 2200mPa.s, or preferably at least 2400mPa.s, when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20oC. The LS / HV malted flour can have a viscosity of at most 10,000mPa.s, or preferably at most 8000mPa.s, or preferably at most 5000 mPa.s, or preferably at most 4000 mPa.s, or preferably at most 3000 mPa.s, when measured at a shear rate of 100 (1 / s) by a rheometer. The LS / HV malted flour can have a viscosity of between about 2000mPa.s and about 6000mPa.s, or preferably between about 2000mPa.s and about 5500mPa.s, or preferably between about 2000mPa.s and about 5000mPa.s, or preferably between about 2000mPa.s and about 4500mPa.s, when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20oC.

[0072] In one aspect, the LS / HV 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 / HV malted rice flour can be considered a shear thinning fluid. The viscosity vs shear rate changes by at least 50 fold, or at least 100 fold, or at least 200 fold when measured from a shear rate of 0.1 (1 / s) to a shear rate of 100 (1 / s). The viscosity vs shear rate changes by at most 1000 fold, or by at most 500 fold, or by at most 400 fold, or by at most 300 fold, or by at most 250 fold when measured from a shear rate of 0.1(1 / s) to a shear rate of 100 (1 / s).

[0073] The LS / HV malted rice flour advantageously comprises gelling capability to form a strong gel. The high viscosity of the LS / HV malted rice flours can advantageously be used to generate a strong gel even at lower concentrations, e.g.5wt%. Thus, the use of lower concentration of flour to achieve high viscosity can result in cost reduction. 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 / HV malted rice flour forms a strong gel at 10wt% of dry solids, or preferably at 15wt% of dry solids, or preferably at 20wt% or dry solids, or preferably at 25wt% of dry solids within 15 minutes at 4oC.

[0074] In one aspect, the LS / HV 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. The LS / HV malted flour can form a strong gel at 10 wt% dry solids or higher at 4ºC. In one aspect, when used at low concentration, e.g., 1-4 wt%, LS / HV malted flour may also form less firm or weak gel at room temperature. The desired gel strengthPT-1852-WO-PCT [3] requirement can be dependent on applications and can be measured by the G’ and G”. When the G’ / G” ratio of the tested hydrogels was determined to be 10, which is similar to the properties reported for naturally occurring tissues, these hydrogels are potentially viable in tissue engineering applications. In one aspect, the LS / HV malted flours might be used in jelly candies such as gum drops, orange slices, and jellybeans. The G’ / G” ratio of candies could be higher than 10. In one aspect, a higher G’ / G” ratio can be achieved by a drying process to increase dry solids before packaging. The jelly candies can be considered a strong gel.

[0075] The rheological analysis of the LS / HV malted rice flour can demonstrate that a strong gel is formed. In one aspect, the storage modulus of the HV malted rice flour is higher than the loss modulus at 10% dry substance within 15 minutes at 4oC, (See FIG.3). The ratio of storage modulus to loss modulus is at least 2:1, or at least 3:1, or at least 5:1 when measured at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at most 10:1, or at most 7:1, or at most 6:1 at an angular frequency of 100 (rad / s). The ratio of storage modulus to loss modulus is at between 2:1 and 8:1, or between 3:1 and 8:1, or between 4:1 and 7:1, or between 4:1 and 6:1 when measured within 15 minutes at 4oC, at an angular frequency of 100 (rad / s).

[0076] Method of making malted flour

[0077] The methods described herein can generate a low sugar malted flour of various prototypes such as a low viscosity (LV), a medium viscosity (HV) and / or a high viscosity (HV) malted flour. In one aspect, the present description relates to generating a LS / HV malted rice flour.

[0078] In one aspect, the present description includes a method of treating a flour. The method includes making a malted flour, preferably a LS / HV malted rice flour. The method includes 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.

[0079] 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.

[0080] The method of generating a LS / HV malted rice flour includes heating the slurry to a temperature that is workable for an enzyme or enzymes to hydrolyze starch or starch andPT-1852-WO-PCT [3] protein in flour. The slurry can be heated to a temperature between about 40oC and about 60oC, or preferably between about 40oC and about 50oC, or preferably between about 45oC and about 55oC, or preferably between 46oC and about 50oC, or preferably about 48oC.

[0081] 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.

[0082] In one aspect, the method of generating a LS / HV 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 of BAF-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.

[0083] In one aspect, the method of generating a LS / HV 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 40oC and about 50oC, or preferably between 45oC and about 55oC, or preferably between 46oC and about 50oC, or preferably about 48oC. The amount of BAF-malt powder added to the heated slurry to generate a LS / HV 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%, orPT-1852-WO-PCT [3] preferably between 0.05wt% and 0.15wt%, or preferably about 0.1wt% of dry base. The rice slurry may be incubated with the BAF malt at a temperature between about 45oC and about 75oC, or preferably between about 48oC and about 70oC. 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 48oC for about 15 minutes. Other combinations of temperature and time in the ranges described above are also within the scope of this description.

[0084] 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 80oC, preferably at least 85oC, or preferably at least 90oC, or preferably at least 95oC 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 90oC, or preferably at least 100oC, or preferably at least 110oC, or preferably at least 120oC or preferably at least 135oC, or preferably from about 90oC to about 135oC. Jet-cooking residence time is at least about 30 seconds, preferably for at least about 1minutes, or preferably at least about 5 minutes or higher. Cooking as described results in inactivating the enzymes and forming a cooked flour composition. After jet-cooking, the temperature can be held at about 90ºC for about 20 minutes in a jacketed heating tank.

[0085] 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.

[0086] The BAF malt is inactivated when heated to a temperature of greater than 80oC, or preferably at 85oC or greater. The BAF malt can be inactivated when heated for at least 10 minutes, or preferably for at least 15 minutes.PT-1852-WO-PCT [3]

[0087] The cooked suspension can be cooled to a temperature between about 40oC and about 80oC, or preferably 40oC and about 70oC, or preferably between 45oC and about 55oC, or preferably about 48oC. Cooling may be conducted by any of the known methods in the art including cooling exchanger, cooling coil, cooling jacketed 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 90ºC for 20 minutes to inactivate the enzymes, the cooked flour composition was kept above 60ºC in a holding tank for spray drying.

[0088] 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.

[0089] 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 80oC, or preferably at 85oC or greater. The BAF malt can be inactivated by heating the slurry for at least 10 minutes, or preferably for at least 15 minutes, or preferably for at least 15 minutes.

[0090] 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.

[0091] The LS / HV 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%.

[0092] 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 hydrolyzePT-1852-WO-PCT [3] 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 40oC and about 80oC, or preferably 40oC and about 70oC, or preferably between 45oC and about 55oC, or preferably about 48oC. Cooling may be conducted by any of the known methods in the art including cooling exchanger, cooling coil, cooling jacketed 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 40oC and about 55oC, or preferably between about 46oC and about 50oC, or preferably at about 48oC. 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 0.001wt% and 0.1wt%, or preferably between 0.001wt% 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 0.1wt%, 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. The amount 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.

[0093] The amount of sugar in the high-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 1wt%, or less than 0.5wt% of the weight of the malted flour.

[0094] The LS / HV 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 / HV 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.PT-1852-WO-PCT [3]

[0095] In one aspect, the method generates a LS / HV malted rice flour with a viscosity of at least 2000 mPa.s, or preferably at least 2200mPa.s, or preferably at least 2400mPa.s, when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20oC. In one aspect, the method generates a LS / HV malted rice flour with a viscosity of at most 8000 mPa.s, or preferably at most 7000mPa.s, or preferably at most 6000mPa.s, or preferably at most 5000mPa.s, or preferably at most 5000mPa.s when measured at a shear rate of 100 (1 / s) by a rheometer in a composition having 10% dry solids in water at 20oC.

[0096] In one aspect, the method generates a LS / HV malted rice flour with a viscosity of between about 2000mPa.s and about 8000mPa.s, or preferably between about 2000mPa.s and about 7000mPa.s, or preferably between about 2000mPa.s and about 6000mPa.s, or preferably between about 2000mPa.s and about 5500mPa.s, or preferably between about 2000mPa.s and about 5000mPa.s, or preferably between about 2000mPa.s and about 4500mPa.s, or preferably between about 2000mPa.s and about 4000mPa.s, wherein the viscosity is measured at 20oC at 10% d.s in water and at a shear rate of 100 (1 / s) using a rheometer as described below in Examples.

[0097] In one aspect, the method generates a LS / HV malted rice flour with a viscosity versus shear rate measured from 0.1 to 100 (1 / s) changes as shown in Figure 2 and described in Examples below. The LS / HV malted rice flour can be considered a shear thinning fluid. The method generates a LS / HV malted rice flour with a viscosity vs shear rate that changes by at least 50 fold, or at least 100 fold, or at least 200 fold when measured from a shear rate of 0.1 (1 / s) to a shear rate of 100 (1 / s). The viscosity vs shear rate changes by at most 1000 fold, or by at most 500 fold, or by at most 400 fold, or by at most 300 fold, or by at most 250 fold when measured from a shear rate of 0.1(1 / s) to a shear rate of 100 (1 / s).

[0098] The method may further comprise forming a strong gel with the LS / HV malted rice flour. The LS / HV malted rice flour using the method described herein can advantageously comprise gelling capability to form a strong gel within 15 minutes at 4oC. In one aspect, the LS / HV malted rice flour forms a strong gel at 10wt% of dry solids, or preferably at 15wt% of dry solids, or preferably at 20wt% or dry solids, or preferably at 25wt% of dry solids after storage for 15 minutes at 4oC. Gelation is influenced by the concentration of malted rice flour, temperature and time. HV malted flour can form a strong gel at 10 wt% dry solids or higher at 4ºC. However, when used at low concentration, e.g., 1-4%, HV malted flour can also form less firm or weak gel at room temperature. The gel strength requirement is depending on applications and can bePT-1852-WO-PCT [3] measured by the G’ and G”. The LS / HV malted rice flour may be used for jelly candies such as gum drops, orange slices, and jellybeans. The G’ / G” ratio of candies could be higher than 10. Such a high G’ / G” ratio can be achieved by a drying process before package since the drying process increases the percent dry solids. The rheological analysis of the HV malted rice flour can demonstrate that a strong gel is formed. In one aspect, the storage modulus of the HV malted rice flour was higher than its loss modulus at 10% dry substance, indicating a gel was formed (See FIG.3).

[0099] In one aspect, the LS / HV malted flour has a storage modulus (G’) greater than 100 Pa, preferably greater than 200 Pa, or preferably greater than 300 Pa, or preferably greater than 400 Pa when measured at an angular frequency (rad / s) of 100 and at 10wt% of d.s. of malted rice flour at 4oC. The ratio of storage modulus to loss modulus (G’ / G”) is greater than 1, or greater than 1.1, or greater than 1.2, or greater than 1.3, or greater than 1.4, or greater than 1.5 when measured at an angular frequency (rad / s) of 100 and at 10wt% of d.s. of malted rice flour at 4oC.

[0100] In the HV malted rice flour, the ratio of G’ / G’ is at least 2, or preferably at least 3, or preferably at least 4 or higher when measured at an angular frequency (rad / s) of 100 and at 10wt% of d.s. of malted rice flour at 4oC. In comparison, in the MV malted rice flour, the ratio of G’ / G’ is at least 1, or preferably at most 2 when measured at an angular frequency (rad / s) of 100 and at 10wt% of d.s. of malted rice flour at 4oC. In the rheological measurement, the solution was incubated in a 15-minute period at 4ºC. Some gel formation requires more time. We found that some MV malted rice flour with the ratio of G’ / G’ less than 1, e.g., 0.5 could form gel if the fluid were incubated at 4ºC preferably overnight, or a week, or two weeks or four weeks. In this case, the gel was delayed. In the HV malted rice flour, strong gel was formed after incubated in a 15- minute period at 4ºC.

[0101] In one aspect, the viscosity of LS / HV malted flour decreases as the temperature increases. The sample prepared in the lab (Lab100322) decreased less than the sample prepared in the pilot plant (HAM083123) between about 20 and 90oC as shown in FIG.4. LS / HV malted flours having a relatively stable viscosity can maintain relative high viscosity at high temperature and can be used in applications that are dependent on maintaining viscosity between 20 and 90oC. In one aspect, the LS / HV malted flour can have a significant decreasing viscosity as the temperature of the composition increases, for example, between about 20 and 90oC as shown in FIG.4. LS / HV malted flours having a less susceptible to temperature increases or decrease can be used in applications that are dependent on relatively stable viscosity between 20 and 90oC, forPT-1852-WO-PCT [3] example, hot beverages. Customers don’t want beverages to become undrinkable (high viscosity or even a weak gel) at room temperature when beverage temperature drops from hot to room temperature.

[0102] The rice flour (unmalted) has the highest RVA final viscosity among three samples. However, the unmalted rice flour also has the highest RVA setback that is the final increase in the viscosity during the cooling phase which is related to the retrogradation of starch (FIG.1). RVA setback is undesirable since it is related to unpourable and unsmooth texture in applications, e.g., dressings and sauces. Advantageously, the LS / HV malted rice flours have lower viscosity (2500 (cP) at 50oC compared to the unmalted rice flour having a viscosity of over 4000(cP) at a temperature of over 80oC at the end of the cooling phase.

[0103] In one aspect, the LS / HV malted rice flours can be used as a food ingredient in a variety of food products. The products made using the above HV 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 / HV malted flours may provide viscosities, creaminess, mouthfeel, gelling, emulsifying and other functionalities. The HV 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.

[0104] In one aspect, the LS / HV malted flour can be a low-sugar, clean-label flour texturizer and / or thickening agent. In one aspect, the LS / HV malted flour can be a low sugar or sugar-free thickening agent. In one aspect, the LS / HV can be a low sugar binding agent.

[0105] According to various aspects, a use of a low sugar, LS / HV 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, softPT-1852-WO-PCT [3] 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 / HV 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 / HV malted flour ingredient of the present invention can be used in numerous consumables.

[0107] In one aspect, the LS / HV malted flour can be used in forming a candy. The strong gel formed can be beneficial for pouring into a mold. The composition can quickly form a strong gel and generate the desired molded shapes in jelly candies such as gum drops, orange slices, and jellybeans. The G’ / G” ratio of candies could be higher than 10. Such a high G’ / G” ratio can be achieved by a drying process to increase G’ / G” ratio before package. The jelly candies can be considered a strong gel.

[0108] In one aspect, the LS / HV malted flour as described herein may be used as at least a partial or full replacement of maltodextrin in food applications at a lower concentration for cost reduction, and in many cases can be used as a full replacement of maltodextrin in food applications. Such LS / HV malted flour can be an effective maltodextrin replacement in any food application in which maltodextrins are currently used. The LS / HV 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.

[0109] Additionally, LS / HV 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.PT-1852-WO-PCT [3] EXAMPLES

[0111] Example 1: Method of making the β-amylase free malt

[0112] 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: Honeywille long grain rice flour was purchased from The Honeyville Mill.

[0113] Methods:

[0114] Preparation fine beta-amylase-free malt:

[0115] 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 β amylase without significant impacting α-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.

[0116] Alpha-amylase activity test: Alpha-amylase activity was determined by the Medallion lab using the reference AOAC 2002.01.

[0117] Beta-amylase activity test: Beta-amylase activity was determined by the Medallion lab using the reference of Megazyme K-BETA3.

[0118] Table 1 (below) shows the results from the heat treatment of the traditional malt. The β-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.PT-1852-WO-PCT [3] Table 1*Alpha-amylase activity was determined by the Medallion lab using the reference AOAC 2002.01.#Beta-amylase activity was determined by the Medallion lab using the reference of Megazyme K-BETA3.

[0119] Example 2-Method of making low sugar, high-viscosity (LS / HV) malted flour in the lab (Lab100322)

[0120] 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).

[0121] Preparation of high-viscosity low-sugar malted rice flour using beta-amylase-free malt in the lab:

[0122] Deionized water (480 g) was weighed into a 600 ml beaker and placed on the hot plate. While stirring, Honeywille 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. The enzyme conversion was carried out at 48±2°C for 15 min. The slurry was heated to 90±2°C (hot plate setting 178^C, 13 min reaching to 90^C) and cooked 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.PT-1852-WO-PCT [3]

[0123] Example 3-Method of making low sugar, high-viscosity (LS / HV) malted flour at pilot plant (HAM083123FD)

[0124] 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.

[0125] 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.

[0126] Initial enzyme conversion and cooking: Barley β-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. The sample was cooled to below 60ºC and transferred to freeze-drying flasks and placed in a freezer. Once the samples were frozen, they were freeze-dried on a freeze dryer.

[0127] Table 2 shows a summary of BAF malt addition, cooking method and percent d.s. during treatments. Table 2

[0128] Sugar profile by HPLC test: Sugar profile by HPLC test was analyzed by the Medallion lab using the reference of AOAC 977.20.

[0129] Rheological measurementsPT-1852-WO-PCT [3]

[0130] 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.

[0131] 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-minute recovery 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 201 / s shear rate was performed. Sugar content of rice flour treated with a traditional barley malt

[0132] 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 β- 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 3PT-1852-WO-PCT [3]

[0133] Sugar profile by HPLC test was analyzed by the Medallion lab using the reference of AOAC 977.20. Sugar content of rice flour treated with a BAF malt from barley

[0134] The beta-amylase-free malt was used to produce high-viscosity malted rice flour. The lab sample (lab100322) contained 0.88% total sugar. The pilot sample contained 0.58% total sugar. Such a low sugar product may be used for low-sugar or sugar-free products (Table 4). When the beta-amylase-free malt was used to produce a high-viscosity malted rice flour in pilot plant, the sugar content was 0.58% in freeze dried product, which proved that the low sugar technology can be scaled up (Table 4). 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 4PT-1852-WO-PCT [3]

[0135] Analysis of LS / HV malted flour: The LS / HV malted rice flour was analyzed and the results summarized in Table 5 below. Table 5

[0136] The unmalted rice flour has much higher final RVA viscosity than HV malted rice flours (FIG.1). However, the unmalted rice flour has the highest RVA setback that is the final increase in the viscosity during the cooling phase which is related to the retrogradation of starch (FIG.1). RVA setback is undesirable since it is related to unpourable and unsmooth texture in applications, e.g., dressings and sauces.

[0137] The HV malted rice flour viscosity is very high as shown in FIG.2. The viscosities of LS / HV malted rice flour decrease when the shear rate increases from 0.1 to 100 (1 / s). The LS / HV malted rice flour is shown to be a shear thinning fluid. The LS / HV malted flour (Lab 100322) has a viscosity of 333,000 mPa.s at shear rate 0.1 (1 / s) and 2,740 mPa.s at shear rate 100 (1 / s). The pilot plant sample (HAM083123FD) has a viscosity of 588,000 mPa.s at shear rate 0.1 (1 / s) and 2,880 mPa.s at shear rate 100 (1 / s). When used as a viscosifier at shear rate 20 (1 / s) for many applications, HV malted rice flour can be used at a lower concentration to achieve the same viscosity compared to low viscosity viscosifiers for cost reduction. Many foods show shear thinning behaviors including melted chocolate, peanut butter, concentrated tomato juice, ketchup, lotions, paints, mayonnaise, etc.PT-1852-WO-PCT [3]

[0138] The LS / HV malted rice flour advantageously comprises gelling capability to form a strong gel (FIG.3). The LS / HV malted flour (Lab 100322) has a storage modulus (G’) of 292 Pa and loss modulus (G”) of 104 Pa at 100 angular frequencies (rad / s), 10% and 4ºC. The pilot plant sample (HAM083123FD) has a storage modulus (G’) of 412 Pa and loss modulus (G”) of 98 Pa at 100 angular frequencies (rad / s), 10% and 4ºC. The ratios of G’ / G’ for lab sample (Lab 100322) and pilot sample (HAM083123FD) are 2.8 and 4.2 respectively, which are useful for many food applications. The strong gel formed can be beneficial for pouring into a mold. The composition can quickly form a strong gel and generate the desired molded shape in jelly candies such as gum drops, orange slices, and jellybeans. The G’ / G” ratio of candies could be higher than 10. Such a high G’ / G” ratio can be achieved by a drying process to increase dry solids and G’ / G” ratio before package.

[0139] The viscosity of LS / HV malted flour from 20-90°C at 201 / s shear rate was shown in FIG.4. The LS / HV malted flour (Lab 100322) has a viscosity of 5481 mPa.s at 20ºC (shear rate 201 / s) and 3964 mPa.s at 90ºC (shear rate 201 / s). The pilot plant sample (HAM083123FD) has a viscosity of 6191 mPa.s at 20ºC (shear rate 201 / s) and 1652 mPa.s at 90ºC (shear rate 201 / s). Both LS / HV malted flours are susceptible to high temperature. However, The Lab sample (100322) is much more stable in viscosity than the pilot plant sample (HAM083123FD) at temperature from 30ºC to 90ºC. LS / HV malted flours having a less increase in viscosity as the temperature decreases can be used in applications that are dependent on relatively stable viscosity between 20 and 90oC, e.g., hot beverages. Customers don’t want beverages to become undrinkable with high viscosity or even a weak gel at room temperature when the beverage temperature drop from hot to room temperature.

[0140] 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.

[0141] 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 toPT-1852-WO-PCT [3] 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.

[0142] 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

PT-1852-WO-PCT [3] CLAIMS What is claimed is:

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

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.

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 45oC and 55oC; 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 80oC, preferably about 95oC; 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.PT-1852-WO-PCT [3] 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 forms a strong gel when incubated for 15 minutes at 4oC.

7. The method of any one of the preceding claims, wherein the malted flour comprises a viscosity of at least about 2000 mPa.s, when measured at 20oC at a shear rate of 100(1 / 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, corn 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 1wt%, 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 forms a strong gel when incubated for 15 minutes at 4oC.

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 1wt%, 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.PT-1852-WO-PCT [3] 13. The malted flour of any one of claims 10-12, wherein the malted flour composition has viscosity of at least 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 (G’ / G”) is greater than 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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