Process for a legume based instant fried noodle

Abstract

The present invention relates to a process for the production of a legume based instant fried noodle. In particularly the invention relates to a process for the production of a legume based instant fried noodle using sprouted legume flour, cereal flour, and wheat gluten.

Description

[0001] Process for a legume based instant fried noodle.

[0002] The present invention relates to a process for the production of a legume based instant fried noodle. In particularly the invention relates to a process for the production of a legume based instant fried noodle using sprouted legume flour selected from the group of mung bean, chickpea, lentil, or a combination, cereal flour, and wheat gluten.

[0003] It is already known to have a legume-based noodle. The noodles are using legume flour in an amount less of 20wt%. It is well known that legume flour is a good source of plantbased protein (>20wt%) but it possesses inherent bitterness, off-notes, beany taste, chalkiness, and mostly non-gelatinized form of starch granules (closed cell structure). The manufacturing of dried instant noodles with higher inclusion of legume flour (>25%) using lamination technology has been challenging. It shows dough rheological and machinability issues like sticky dough, poor sheeting or sheet breakage, and in the finished noodles issues like strand stickiness, hard texture and rawness / off-flavor. Instant oil-fried noodles typically have a richer taste, and a more appealing, crispy texture compared to instant air-dried noodles. The frying process enhances flavor through Maillard reactions, giving the noodles a savoury, slightly roasted profile. Additionally, instant oil-fried noodles rehydrate more quickly and evenly during cooking, improving convenience and mouthfeel.

[0004] Therefore, in order to provide nutritional benefits of higher amounts of protein and fiber in instant fried noodles it is hence essential to explore a process having good machinability, good rheology of the noodle dough and having a pleasant taste.

[0005] Summary of the invention

[0006] The object of the present invention is to improve the state of the art and to provide an improved or at least an alternative solution to overcome at least some of the inconveniences described above. The object of the present invention is achieved by the subject matter of the independent claims. The dependent claims further develop the idea of the present invention.

[0007] Particularly, the object of the present invention is to provide a process for the production of a legume based instant fried noodle having good machinability and rheology, higher in protein nutritional value and fiber compared to grain based instant fried noodles and still having good sensory attributes like texture, flavor and a shelf life of at least 9 months of the product. Accordingly, the present invention provides in a first aspect a process for the production of a legume based instant fried noodle comprising 10 to 80wt% of legume flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting legume selected from the group of mung bean, chickpea, lentil, or a combination thereof and milling the sprouted legume to obtain sprouted legume flour; b) Mixing the sprouted legume flour, cereal flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; c) Sheeting and slitting the dough to obtain noodle strands; d) Steaming the noodle strands from step c); e) Cutting and folding the noodle strands from step d); f) Pre-drying to remove moisture before frying; g) Frying in the oil; h) Cooling.

[0008] In a second aspect the invention relates to a legume based instant fried noodle comprising sprouted legume flour, cereal flour, Kansui salts and wheat gluten, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition and wherein the sprouted legume flour is selected from the group of sprouted chickpea flour, sprouted lentil flour, sprouted mung bean flour or combinations thereof, preferably roasted sprouted chickpea flour, roasted sprouted lentil flour, roasted sprouted mung bean flour, or combinations thereof.

[0009] It has been surprisingly found by the inventors that by using a sprouted legume flour to substitute cereal flour, and wheat gluten existing lamination technology has acceptable to good machinability and good sensory attributes in terms of dough sheeting, dough sheeting breakage, noodle formation, texture of noodle (not firm, chewy), good flavor profile (no raw, no beany flavor and / or bitter off note flavor of the legumes) and the obtained instant fried noodle has due to the sprouting a higher protein and higher fiber content compared to nonsprouted legume flour and a beneficial digestive property.

[0010] Detailed Description of the invention In a first aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 10 to 80wt% of legume flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting legume selected from the group of mung bean, chickpea, lentil, or a combination thereof and milling the sprouted legume to obtain sprouted legume flour; b) Mixing the sprouted legume flour, cereal flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; c) Sheeting and slitting the dough to obtain noodle strands; d) Steaming the noodle strands from step c); e) Cutting and folding the noodle strands from step d); f) Pre-drying to remove moisture before frying; g) Frying in the oil; h) Cooling.

[0011] In a preferred aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 10 to 80wt% of mung bean flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting mung bean; b) Milling the sprouted mung bean to obtain sprouted mung bean flour; c) Mixing the sprouted mung bean flour, wheat flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; d) Sheeting and slitting the dough to obtain noodle strands; e) Steaming the noodle strands from step d); f) Cutting and folding the noodle strands from step e); g) Pre-drying to remove moisture before frying; h) Frying in the oil; i) Cooling. In a preferred aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 30 to 80wt% of mung bean flour by weight of the total composition, 15 to 45wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 2 to 10wt% of wheat gluten by weight of the total composition, and 10 to 20wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting mung bean; b) Milling the sprouted mung bean to obtain sprouted mung bean flour; c) Mixing the sprouted mung bean flour, wheat flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; d) Sheeting and slitting the dough to obtain noodle strands; e) Steaming the noodle strands from step d); f) Cutting and folding the noodle strands from step e); g) Pre-drying to remove moisture before frying; h) Frying in the oil; i) Cooling.

[0012] In a preferred aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 10 to 80wt% of legume flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting legume selected from the group of mung bean, chickpea, lentil, or a combination thereof and milling the sprouted legume to obtain sprouted legume flour; b) Roasting the sprouted legume flour; c) Mixing the roasted sprouted legume flour, cereal flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; d) Sheeting and slitting the dough to obtain noodle strands; e) Steaming the noodle strands from step d); f) Cutting and folding the noodle strands from step e); g) Pre-drying to remove moisture before frying; h) Frying in the oil; i) Cooling. In a preferred aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 10 to 80wt% of mung bean flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting mung bean; b) Milling the sprouted mung bean to obtain sprouted mung bean flour; c) Roasting the sprouted mung bean flour; d) Mixing the roasted sprouted mung bean flour, wheat flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; e) Sheeting and slitting the dough to obtain noodle strands; f) Steaming the noodle strands from step e); g) Cutting and folding the noodle strands from step f); h) Pre-drying to remove moisture before frying; i) Frying in the oil; j) Cooling.

[0013] In a preferred aspect the present invention pertains to a process for the production of a legume based instant fried noodle comprising 30 to 80wt% of mung bean flour by weight of the total composition, 15 to 45wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 2 to 10wt% of wheat gluten by weight of the total composition, and 10 to 20wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting mung bean; b) Milling the sprouted mung bean to obtain sprouted mung bean flour; c) Roasting the sprouted mung bean flour; d) Mixing the roasted sprouted mung bean flour, wheat flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; e) Sheeting and slitting the dough to obtain noodle strands; f) Steaming the noodle strands from step e); g) Cutting and folding the noodle strands from steps f) or g); h) Pre-drying to remove moisture before frying; i) Frying in the oil; j) Cooling. In a second aspect the invention relates to a legume based instant fried noodle comprising sprouted legume flour, cereal flour, Kansui salts and wheat gluten, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition and wherein the sprouted legume flour is selected from the group of sprouted chickpea flour, sprouted lentil flour, sprouted mung bean flour or combinations thereof, preferably roasted sprouted chickpea flour, roasted sprouted lentil flour, roasted sprouted mung bean flour, or combinations thereof.

[0014] In a preferred aspect the invention relates to a legume based instant fried noodle comprising 10 to 80wt% of sprouted legume flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 0.5 to 10wt% of wheat gluten by weight of the total, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition and wherein the sprouted legume flour is selected from the group of sprouted chickpea flour, sprouted lentil flour, sprouted mung bean flour, or combinations thereof, preferably roasted sprouted chickpea flour, roasted sprouted lentil flour, roasted sprouted mung bean flour, or combinations thereof.

[0015] In a preferred aspect the invention relates to a legume based instant fried noodle comprising 10 to 80wt% of sprouted mung bean flour by weight of the total composition, preferably roasted sprouted mung bean flour, 5 to 70wt% of wheat flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 0.5 to 10wt% of wheat gluten by weight of the total composition, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition.

[0016] In a preferred aspect the invention relates to a legume based instant fried noodle comprising 30 to 80wt% of sprouted legume flour by weight of the total composition, 15 to 45wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 2 to 10wt% of wheat gluten by weight of the total composition, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition and wherein the sprouted legume flour is selected from the group of sprouted chickpea flour, sprouted lentil flour, sprouted mung bean flour, or combinations thereof, preferably roasted sprouted chickpea flour, roasted sprouted lentil flour, roasted sprouted mung bean flour, or combinations thereof.

[0017] In a preferred aspect the invention relates to a legume based instant fried noodle comprising 30 to 80wt% of sprouted mung bean flour by weight of the total composition, preferably roasted sprouted mung bean flour, 15 to 45wt% of wheat flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 2 to 10wt% of wheat gluten by weight of the total composition, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition.

[0018] The term “sprouting” is a germination process by which seeds or spores put out shoots. The sprouting comprises process steps of steeping, germination and kilning. The term “steeping” is a hydration process of legume grains. This allows the legume, preferably legume grains, to hydrate and swell while pre-activating enzymes and to remove impurities and any other contaminants. The ratio between legume and water is 1:1 to 1 :10, preferably 1 :2 to 1:5, preferably 1 :2 to 1:4, preferably 1 :3. The steeping is done at a temperature between 20 to 30°C for 10 to 24 hours. Water will be reduced before germination, preferably water will be reduced by decanting.

[0019] The germination is done at a temperature between 25 to 35°C for 24 to 72 hours. The germination process increase the free glutamic acid and aspartic acid, which impart the savoury taste. Additionally free reducing sugars and proline amino acids were released, which is beneficial for Maillard reactions. The term “kilning” is a heating step. Kilning is done at a temperature between 90 to 140°C for 1 to 6 hours, preferably 90 to 120°C for 1 to 4 hours. Kilning inactivates microbial growth and enzyme activity and trigger Maillard reactions.

[0020] The term “legume” according to this invention is selected from the group of chickpea, lentil, mung bean or combinations thereof, preferably mung bean. In an embodiment the legume based instant fried noodle does not comprise soybean.

[0021] The term “legume flour” according to this invention is selected from the group of mung bean flour, chickpea flour, lentil flour or combinations thereof, preferably mung bean flour. In an embodiment the legume based instant fried noodle does not comprise soybean flour. In an embodiment the legume based instant fried noodle comprises 10 to 80wt% of legume flour by weight of the total composition selected from the group of mung bean flour, chickpea flour, lentil flour or combinations thereof, preferable 10 to 75wt%, preferably 20 to 80wt%, preferably 20 to 75wt%, preferably 25 to 80wt%, preferably 25 to 75wt%, preferably 30 to 80wt%, preferably 30 to 75wt%, preferably 40 to 80wt%, preferably 40 to 75wt%, preferably 50 to 80wt%, preferably 50 to 75wt%, preferably 60 to 80wt%, preferably 60 to 75wt% by weight of the total composition. In an embodiment the legume based instant fried noodle comprises 10 to 80 wt% of mung bean flour by weight of the total composition, preferable 10 to 75wt%, preferably 20 to 80wt%, preferably 20 to 75wt%, preferably 25 to 80wt%, preferably 25 to 75wt%, preferably 30 to 80wt%, preferably 30 to 75wt%, preferably 40 to 80wt%, preferably 40 to 75wt%, preferably 50 to 80wt%, preferably 50 to 75wt%, preferably 60 to 80wt%, preferably 60 to 75wt% by weight of the total composition. In an embodiment the lentil flour is green lentil flour, red lentil flour, or a combination thereof.

[0022] The term “sprouted legume flour” according to this invention is selected from the group of sprouted mung bean flour, sprouted chickpea flour, sprouted lentil flour or combinations thereof, preferably sprouted mung bean flour. In an embodiment the legume based instant fried noodle does not comprise sprouted soybean flour. In an embodiment the legume based instant fried noodle comprises 10 to 80wt% of sprouted legume flour by weight of the total composition selected from the group of sprouted mung bean flour, sprouted chickpea flour, sprouted lentil flour or combinations thereof, preferable 10 to 75wt%, preferably 20 to 80wt%, preferably 20 to 75wt%, preferably 25 to 80wt%, preferably 25 to 75wt%, preferably 30 to 80wt%, preferably 30 to 75wt%, preferably 40 to 80wt%, preferably 40 to 75wt%, preferably 50 to 80wt%, preferably 50 to 75wt%, preferably 60 to 80wt%, preferably 60 to 75wt% by weight of the total composition. In an embodiment the legume based instant fried noodle comprises 10 to 80 wt% of sprouted mung bean flour by weight of the total composition, preferable 10 to 75wt%, preferably 20 to 80wt%, preferably 20 to 75wt%, preferably 25 to 80wt%, preferably 25 to 75wt%, preferably 30 to 80wt%, preferably 30 to 75wt%, preferably 40 to 80wt%, preferably 40 to 75wt%, preferably 50 to 80wt%, preferably 50 to 75wt%, preferably 60 to 80wt%, preferably 60 to 75wt% by weight of the total composition.

[0023] The roasting is done between a temperature range of 80-160°C for 1 to 8 hours, preferably between a temperature range of 90 to 160°C for 1 to 8 hours, preferably between a temperature range of 90 to 140°C for 1 to 8 hours, preferably between a temperature range of 90 to 120°C for 1 to 8 hours, preferably between a temperature range of 90 to 120°C for 1 to 6 hours. The term “roasted sprouted legume flour” according to this invention means a type of flour that has been sprouted and roasted before being ground into a fine powder. The roasting process enhances the flavor and aroma of the legume. In an embodiment the roasted sprouted legume flour is selected from the group of roasted sprouted mung bean flour, roasted sprouted chickpea flour, roasted sprouted lentil flour, or combinations thereof. The term “roasted sprouted mung bean flour” according to this invention is a type of flour that has been sprouted and roasted before being ground into a fine powder. The roasting process enhances the flavor and aroma of the mung bean.

[0024] The term “cereal flour” according to this invention means at least one ingredient of wheat flour, oat flour, corn flour, rice flour, barley flour, millet flour or combinations thereof, preferably wheat flour. In an embodiment the cereal flour is standard refined wheat flour. In an embodiment the legume based instant fried noodle comprises 5 to 70 wt% of cereal flour by weight of the total composition, preferable 10 to 70wt%, preferably 5 to 65wt%, preferably 10 to 65wt%, preferably 15 to 65wt%, preferably 15 to 60wt%, preferably 15 to 55wt%, preferably 15 to 50wt%, preferably 15 to 45wt%, preferably 15 to 40wt%, preferably 20 to 60wt%, preferably 20 to 55wt%, preferably 20 to 50wt%, preferably 20 to 45wt%, preferably 20 to 40wt% by weight of the total composition. In an embodiment the legume based instant fried noodle comprises 5 to 70 wt% of wheat flour by weight of the total composition, preferable 10 to 70wt%, preferably 5 to 65wt%, preferably 10 to 65wt%, preferably 15 to 65wt%, preferably 15 to 60wt%, preferably 15 to 55wt%, preferably 15 to 50wt%, preferably 15 to 45wt%, preferably 15 to 40wt%, preferably 20 to 60wt%, preferably 20 to 55wt%, preferably 20 to 50wt%, preferably 20 to 45wt%, preferably 20 to 40wt% by weight of the total composition.

[0025] In an embodiment the spouted legume flour, roasted sprouted legume flour or the cereal flour or combination thereof has a particle size of 50 to 400 pm. A finer particle size could mean a high chance of starch to be damaged in the flour leading to higher water absorption. The dough would become sticky and causes operation issues. In addition, the noodle would turn sticky, starchy and non-elastic. A flour with a large particle size, on the other hand, needs longer water absorption time and often forms large dough lumps.

[0026] In an embodiment a legume based instant fried noodle comprising an amount of protein of at least 10wt% by weight of the total composition, preferably at least 11wt%, preferably at least 12wt%, preferably between 10 to 17wt%, preferably between 11 to 17wt%, preferably between 10 to 16wt%, preferably between 11 to 16wt%, preferably between 12 to 17wt%, preferably between 12 to 16wt% by weight of the total composition. In an embodiment the legume based instant fried noodle comprises 0.5 to 15 wt% of wheat gluten by weight of the total composition, preferable 1 to 15wt%, preferable 2 to 15wt%, preferable 3 to 15wt%, preferable 1 to 10wt%, preferably 2 to 10wt%, preferably 2 to 8wt%, preferable 3 to 10wt% by weight of the total composition.

[0027] “Starch” according to this invention has two main polysaccharides amylose and amylopectin. Starches granules can be isolated from a wide variety of plant sources, consisting of tuberous root, tuber and seeds. Based on the botanical origin, starch granules come in different shapes, sizes and have varying ratios of amylose / amylopectin. Starch according to this invention is a native starch, pre-gelatinized starch or cold swelling starch or combination thereof, preferably a native starch. The starch according to the invention is selected from the group consisting of maize, waxy maize, high amylose maize, wheat, tapioca, rice, potato, cassava or combinations of these. In an embodiment the legume based instant fried noodle comprises 1 to 20 wt% of starch by weight of the total composition, preferable 2 to 20wt%, preferably 1 to 15wt%, preferably 2 to 15wt, preferable 1 to 10wt%, preferable 2 to 10wt% by weight of the total composition.

[0028] The term “kansui salts” comprises a mixture of alkaline salts comprising sodium chloride, sodium carbonate, potassium carbonate or sodium phosphate or a combination thereof. In an embodiment the legume based instant fried noodle comprises 0.2 to 3.5wt% of kansui salts by weight of the total composition. In a preferred embodiment the kansui salts are dissolved in water to obtain a kansui solution. The term “kansui solution” comprises a mixture of 1 to 15wt% of alkaline salts comprising sodium chloride, sodium carbonate, potassium carbonate or sodium phosphate or a combination thereof based on the total amount of the solution in 85 to 99wt% of water based on the total amount of the solution, preferably the kansui solution comprises 3 to 7wt% of alkaline salts and 93 to 97wt% of water based on the total amount of the solution.

[0029] The term “oil” according to this invention is selected from the group of palm oil, sunflower oil, high oleic oils, high oleic sunflower oil (HOSO), ground nut oil, rice bran oil, mustard oil, soybean oil or a combination thereof, preferably palm oil or high oleic sunflower oil or combination thereof.

[0030] The dough mixing time is between 10 to 40 minutes, preferably 15 to 30 minutes. A twin speed mixer is used. The mixing speed is between 50 to 120 rpm. High speed mixing (between 100 to 120 rpm) is recommended during the time the kansui solution is dosed to avoid localized dosing and to ensure homogeneity. For addition of small ingredients like calcium carbonate, fortificant (vitamin and / or mineral) it is recommended to make a pre-blend with flour before addition. The amount of water added has a big influence on dough formation. The moisture content of the dough after mixing should be between 20 to 40%, preferably between 25 to 35%. If too much water is added the dough will be too soft and sticky. If too less water is added the noodle will be brittle, doughy and hard-centered due to insufficient gelatinisation during steaming as degree of gelatinisation depends on moisture content of dough.

[0031] The term “sheeting” is a process step wherein the dough is passed through a series of rollers to obtain a final sheet of desired thickness which will then determine the noodle strand thickness. By sheeting the dough a network is developed as pressure is applied. In addition, the sheeting removes entrapped air from the dough and therefore reduces porosity and result in less oil uptake.

[0032] The slitter / cutter called “kiriha” consists of a pair of grooved cylinders which cut and separate the dough sheet into strands that are trapped in the grooves. These strands are immediately removed by a comb-like scraper, called “kasuri” which is attached in between the two rollers. The width of the noodle strand is determined by Kiriha groove width.

[0033] The purpose of steaming is to gelatinize the starch in order to eliminate the raw and doughy taste on the end-product. Steaming time and temperature along with steam pressure affect product quality and are known to the person skilled in the art. Good steaming results to obtain at least 80% starch gelatinisation is giving a better association of starch granules and protein matrix as well as better continuity of protein network. The steaming time is between 0.5 to 15 minutes, preferably 0.5 to 7 minutes. A saturated steam is used. If steaming is insufficient, the final noodle will have a gritty center, doughy and raw wheat after taste (cereal note). Noodle strands coming out of the steamer are hot and tend to stick to the steamer mesh conveyor. This can lead to poor cutting and folding down the line. Therefore, the strands are cooled and slightly dried up using fans or blowers / air knives at the exit of steamer tunnel.

[0034] Seasoning means that flavor or flavors are added by a spraying or within a seasoning bath. Cutting and folding occur after steaming the noodle strands. Cutting means that the noodle strands are cut to a desired length and folded. At this stage, the noodle is still quite flexible but is able retain its shape.

[0035] Pre-drying is used to reduce the wet cake moisture content by 2 to 10%. In addition after pre-drying an oil up take reduction by 1 to 8%, preferably 2 to 4% is achieved. A predrying step is done at a temperature between 50 to 120°C within 15 to 500 sec, preferably at a temperature between 60 to 100°C within 30 to 400 sec. In a preferred embodiment the noodles are pre-dried.

[0036] Frying is a process wherein moisture from cakes is removed to a desired level and doughy taste is eliminated in the end product. Steamed or pre-dried noodle cakes are conveyed to the fryer buckets which pass through the hot oil bath. The Frying in oil is done at temperatures between 110 to 170 °C and a frying time between 30 to 200 seconds, preferably at temperatures between 130 to 165 °C and a frying time between 40 to 150 seconds. After oil frying the final moisture in the product is less than 10wt%, preferably between 2 to 10wt% by weight of the total composition. The final product has a water activity < 0.6.

[0037] In an embodiment the legume based instant fried noodle has an amount of oil in the range of 10 to 30wt% by weight of the total composition, preferably between 12 to 28wt%, preferably between 13 to 25wt%, preferably between 13 to 19wt% by weight of the total composition.

[0038] Cooling means that the temperature of the noodle after frying in the oil is reduced. It is desirable to have the noodle cake temperature the same as or close to room temperature before wrapping, preferably between 20 to 30°C, more preferably between 20 to 25°C. Otherwise, there may be condensation of water vapour in the packet of noodles, which may lead to mould growth. A side from condensates, hot cakes also cause expansion of air within the pack, subsequently causing difficulty in secondary packaging.

[0039] In an embodiment the process for the production of a legume based instant fried noodle does not include a transglutaminase, gamma-aminobutyric acid (GABA), konjac flour, guar gum, cross-linked hydroxypropyl starch, egg, or a combination thereof. The process for the production of a legume based instant fried noodle does not include light-induced germination. Those skilled in the art will understand that they can freely combine all features of the present invention disclosed herein. In particular, features described for different embodiments of the present invention may be combined. Where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred to in this specification.

[0040] Examples

[0041] Example 1 : Process

[0042] Legume (mung bean) grains are sprouted. In a steeping step the legume is hydrated at a 1 :3 ratio of legume to water for 12 hours at a temperature of 25°C. The amount of water is reduced be decanding before the hydrated legume is germinated for 48 hours at a temperature of 30°C. In the following kilning step the legume is heated and dried at a temperature of 100°C for 3 hours followed by milling to obtain a sprouted legume flour. Optionally the sprouted legume flour is roasted using a drum dryer at a temperature at 130°C for 4 hours. Standard instant fried noodle manufacturing process involves mixing of sprouted legume flour, cereal flour (wheat flour), wheat gluten and kansui solution in a batch mixer. Noodle line used for the production is from CCK supplier. Dough from mixer is passed through rollers to form two sheets thereafter compounding the two dough sheets into one, reducing dough sheet to a desired thickness through a series of rollers. The final sheet is passed through the Kiriha to slit the dough sheet and form the noodle strands, which are then steamed in a tunnel.

[0043] The steamed noodles are cut, folded and moulded into pre-dryer. The pre-dryer removes moisture before frying and helps to reduce the oil uptake. The pre-dried noodle cakes are discharged from pre-dryer to frying bucket, which are then passed through a fryer where noodle cakes are fried, and moisture is removed. After which, the cakes are cooled to ambient temperature before packing. This process describes a fried noddle.

[0044] Below table shows details of all the process steps with the process parameters:

[0045] Examples 2 to 6:

[0046] Examples 5 and 6 are prepared according to example 1 , wherein example 6 use roasted sprouted legume flour (sprouted mung bean flour). Comparison examples 2 only use wheat flour and no legume flour (mung bean flour). Comparison example 3 use legume flour which was not sprouted and / or roasted. Comparison example 4 use only 4wt% of sprouted legume flour (mung bean flour).

[0047] Comparison examples 2 and 4 have the lowest protein and fiber content in the final composition. Comparison example 3 using not sprouted legume does not have good process and product features as dough sheeting, dough sheeting breakage, noodle formation and has the highest rating regarding beany flavor, which is negative perceived by the consumer.

[0048] Example 5 using sprouted mung bean flour has good process and product features and is a noodle high in protein and high in fiber. The best example is example 6 using a roasted sprouted mung bean flour.

Claims

Claims1. A process for the production of a legume based instant fried noodle comprising 10 to 80wt% of legume flour by weight of the total composition, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, 0.5 to 10wt% of wheat gluten by weight of the total composition, and 10 to 25wt% of oil by weight of the total composition, the process comprising the steps of: a) Sprouting legume selected from the group of mung bean, chickpea, lentil, or a combination thereof and milling the sprouted legume to obtain sprouted legume flour; b) Mixing the sprouted legume flour, cereal flour, wheat gluten and optionally other dry ingredients with the Kansui salts and water to form a dough; c) Sheeting and slitting the dough to obtain noodle strands; d) Steaming the noodle strands from step c); e) Cutting and folding the noodle strands from steps d); f) Pre-drying to remove moisture before frying; g) Frying in the oil; h) Cooling.

2. A process for the production of a legume based instant fried noodle as claimed in claim 1 , comprising 30 to 80wt% of legume flour by weight of the total composition, 10 to 60wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 0.5 to 10wt% of wheat gluten by weight of the total composition.

3. A process for the production of a legume based instant fried noodle in any one of claims 1 to 2, comprising 40 to 80wt% of legume flour by weight of the total composition, 15 to 40wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 0.5 to 10wt% of wheat gluten by weight of the total composition.

4. A process for the production of a legume based instant fried noodle in any one of claims 1 to 3, wherein the legume is mung bean.

5. A process for the production of a legume based instant fried noodle in any one of claims 1 to 4, wherein the cereal flour is wheat flour, oat flour, corn flour, rice flour, barley flour, millet flour or combinations thereof, preferably wheat flour.

6. A process for the production of a legume based instant fried noodle in any one of claims 1 to 5, wherein the kansui salts comprises a mixture of sodium chloride, sodium carbonate, potassium carbonate, sodium phosphate or a combination thereof.

7. A process for the production of a legume based instant fried noodle in any one of claims 1 to 6, wherein the kansui salts are added as a solution of 1 to 10wt% of sodium chloride, sodium carbonate, potassium carbonate and sodium phosphate (based on the total amount of the solution) in 90 to 99wt% of water (based on the total amount of the solution).

8. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 7, wherein the instant noodle is fried in the oil at a temperature between 110 to 170 °C and a frying time between 30 to 200 seconds.

9. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 8, wherein the steaming is done by using saturated steam within 0.5 to 15min.

10. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 9, wherein pre-drying is done at a temperature between 50 to 120°C and 15 to 500sec.

11. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 10, wherein the sprouted legume flour is further roasted between a temperature range of 80-160°C for 2 to 8 hours after step a) and before step b).

12. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 11 , wherein the sprouting comprises the following process steps: xi) Steeping to hydrate the legumes with water at a legume-water ratio between 1 :1 to 1 :10 at a temperature between 20 to 30°C for 10 to 24 hours;xii) Germination at a temperature between 25 to 35°C for 24 to 72 hours; xiii) Kilning at a temperature between 90 to 140°C for 1 to 6 hours.

13. A process for the production of a legume based instant fried noodle as claimed in any one of claims 1 to 11 , wherein the process does not include a transglutaminase, gamma-aminobutyric acid, konjac flour, guar gum, cross-linked hydroxypropyl starch, egg, or a combination thereof.

14. A legume based instant fried noodle comprising 10 to 80wt% of sprouted legume flour by weight of the total composition selected from the group of sprouted mung bean flour, sprouted chickpea flour, sprouted lentil flour, or a combination thereof, 5 to 70wt% of cereal flour by weight of the total composition, 0.2 to 3.5wt% of Kansui salts by weight of the total composition, and 0.5 to 10wt% of wheat gluten by weight of the total composition, wherein the legume based instant fried noodle has an amount of protein of at least 15wt% by weight of the total composition and an amount of fiber of at least 2.5 wt% by weight of the total composition.

15. The use of the composition as claimed in claim 14 for preparing a food product.

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