Patent Application
20120263824
The present invention is generally related to bread mixes having reduced starch content and processes for making the same.
Whole grains or foods made from them contain all the essential parts and naturally-occurring nutrients of the entire grain seed. If the grain has been processed (e.g., cracked, crushed, rolled, extruded, and/or cooked), the food product should deliver approximately the same rich balance of nutrients that are found in the original grain seed. However, traditional refining processes can often times remove some of the bran and germ from the grain, resulting in a loss of dietary fiber, vitamins and minerals.
The demand for the use of whole grains in the production of a variety of food products has recently increased due, at least in part, to the greater amount of nutrients therein as compared to refined baked goods such as white bread. Although the use of whole grains for the manufacture of baked goods has increased, to a majority of consumers the overall taste profile of most whole-grain products suffers, especially in the absence of additional bakery-formulated sugar and salt, or flavoring agents. The addition of such “additives” necessarily increases the cost and dilutes the nutritive value of the final baked good purchased by the consumer.
Accordingly, there remains a need for processes and baking mixes that provide an enhanced concentration of micronutrients, dietary fiber, and/or protein while also eliminating or mitigating the need for addition of sweeteners and/or flavoring agents.
In one aspect, the present invention provides processes for the production of baking mixes for the baking industry. Processes according to certain embodiments of the present invention include a step of sprouting a whole grain to provide a sprouted whole grain. The whole grain to be sprouted naturally includes native amounts of starch, sugar, total vitamin content, and all other native phyto-compounds. After the whole grain has been sprouted to the desired degree, a mash including particulated sprouted whole grain is prepared. The particulated sprouted whole grain can be obtained by crushing, grinding, or the like. At least a portion of the native starch can be enzymatically converted into glucose to provide a sprouted whole grain bread mix having an amount of sugar greater than the amount of native sugar in the whole grain due solely to the conversion of starch to glucose. That is, in certain embodiments the increased amount of sugar is attributed only to the conversion of the native starch to glucose. Beneficially, the resulting bakery mixes eliminate or mitigate the amount of formulated sugar added to bread and other bakery products.
In certain preferred embodiments, the present invention provides processes for the production of bakery mixes including an initial step of cleaning a whole grain to remove foreign material. After an initial cleaning, the whole grain can be soaked for 1-15 hours (e.g., 6-9 hours) in water having a temperature preferably from 20-30° C. to hydrate the whole grain. After the whole grain has been hydrated to the desired degree from soaking in water, the hydrated grain can simply be allowed to sprout from 10-40 hours (e.g., 20-30 hours) to provide a sprouted whole grain. The sprouted whole grain can be cooked in boiling water for at least 15 minutes, pressure cooked (e.g. 30 psi) for about 5-30 minutes (e.g., 10-20 minutes), or boiled and pressure cooked to gelatinize starch present in the whole grain. The cooked whole grain is then further processed in a manner to increase the surface area of the sprouted whole grain. For instance, the surface area of the sprouted whole grain can be increased by grinding, crushing, or extruding the sprouted whole grain to provide a mash. The resulting mash can be fermented for about 1-12 hours (e.g., 2-5 hours) at a temperature ranging from 20 to 60° C. (e.g., 30 to 40° C.) using a budding yeast (e.g., Saccharomyces cerevisiae). Preferably, this fermentation step utilizes Saccharomyces cerevisiaeor with 1-3% yeast solids to which enzyme-active wheat or barley malt (150-230° L) is added so that at least a portion of the gelatinized starch is converted into maltose and dextrins. Through the action of the yeast fermentation step, the pH of the mash is reduced to from 4-6 (e.g., 4.5-5.5). After the addition of the malt and yeast fermentation of the mash, an initial hydrolysis of the mash is performed to hydrolyze starch, primarily, into dextrins and maltose. In certain embodiments, the temperature of the fermented mash is increased to about 45 to 65° C. for 10 to 50 minutes (e.g., 25-35 minutes) to malt-hydrolyze the mash followed by increasing the temperature to about 70 to 80° C. for 10 to 50 minutes (e.g., 25-35 minutes). A subsequent fermentation can be performed to further hydrolyze the dextrins and maltose into glucose. In certain embodiments, for instance, fungal glucoamylase can be added to the fermented and enzyme-hydrolyzed mash to further hydrolyze the dextrins and maltose into glucose. The hydrolysis of the dextrins and maltose into glucose can be carried out at a temperature from about 50 to 70° C. for about 30 minutes to about 4 hours according to certain embodiments of the present invention. After the desired degree of conversion to glucose has been obtained, the mash temperature is preferably increased (e.g., increased to at least 90° C. for about 15 minutes or more) such that certain constituents in the mash are heat-denatured (e.g., to inactivate all enzymes) to provide a sprouted whole grain bread mix having an amount of sugar greater than the amount of native sugar in the whole grain due solely to the conversion of the native starch to glucose.
In another aspect, the present invention provides bakery mixes (e.g., wet and-dry-bread mixes). Bread mixes according to embodiments of the present invention can include sprouted whole grain particulates, in which the bread mix has a starch content of less than 50% by weight calculated on a dry basis and a glucose content ranging from 10-75% by weight calculated on a dry basis in the absence of the addition of formulated sugar. That is, the glucose content of the final mix is due entirely to the conversion of native starch into glucose, not the addition of non-native sugar or sugar derived from non-native starch or saccharides.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.
As used herein, the term “whole grain(s)” can include cereal grains that consist of the intact and unrefined, ground, cracked or flaked fruit of the grains whose principal components—the starchy endosperm, germ and bran—are present in the same relative proportions as they exist in the intact grain. In certain embodiments, the term “whole grain” can include intact and unrefined starch-containing edible seeds including cereal grains such as barley, corn, millet, rice, rye, oats, sorghum, spelt, triticale, wheat, and other edible seeds including buckwheat, wild rice, quinoa, amaranth, teff, and combinations thereof.
In one aspect, the present invention provides processes designed to create wet- and dry-mixes from sprouted whole grains. In certain embodiments of the present invention, the processes can transform inherent grain micronutrients (including vitamins, minerals, antioxidants, etc), dietary fiber, and protein, and convert a desired amount of starch to a desired amount of glucose to provide mixes have decreased starch content and an increased glucose content as compared to traditional processes utilized for making bread mixes. Accordingly, embodiments of the present invention eliminate or at least mitigate the amount of formulated sugar that is traditionally added to baking mixes in bakeries to provide a desirably tasting baked good. In other words, the conversion of at least a percentage of a whole grain's native starch into glucose can effectively replace or mitigate the addition of formulated sugar in bread and other bakery products.
Beneficially, resulting bakery mixes produced from processes according to certain embodiments of the present invention eliminate or mitigate the amount of formulated sugar added to bread and other bakery products. Moreover, an equally “sweet” tasting bread product can be provided without the addition of formulated sugar, while also providing an increased concentration of micronutrients.
As shown in
In certain embodiments, the whole grain is preferably initially cleaned by removing non-grain material by using air aspiration and/or water washing, for example, followed by soaking the cleaned whole grain prior to the sprouting step to hydrate the whole grain. Preferably the whole grain is soaked in excess water having a temperature from 20-40° C. (e.g., 20-30° C.) for several hours (e.g., 1-20 hrs, 3-10 hrs, or 6-9 hrs). After the whole grain has been soaked in water for the desired time (e.g., desired level of hydration is obtained), the whole grain can be removed or separated from the water and allowed to germinate for about 12 to about 40 hours depending on a user's desired degree of germination. In certain embodiments, the sprouting step comprises allowing the whole grain to sprout from 12 to 30 hours, from 15 to 25 hours, or from 20 to 25 hours. The sprouting step beneficially enhances the nutritional profile and enhances nutrient bioavailability.
The sprouted whole grain, according to certain embodiments of the present invention, can be cooked at an elevated temperature in water in order to further hydrate the sprouted whole grain and to gelatinize the whole grain's starch. For instance, the sprouted whole grain can be cooked in water at a temperature from 30 to 100° C. (e.g., 50-100, 70-100, 90-100, or 90-99° C.). The cooking time can vary depending on the desired degree of gelatinization of the whole grain's starch and the temperature at which cooking is carried out. For example, cooking times can vary from 5-60 minutes (e.g., 5-45 minutes, 5-30 minutes, or 10-20 minutes). In certain preferred embodiments, the sprouted whole grain is cooked for about 10-15 minutes in near boiling (e.g. 97-99° C.) or boiling water (100° C.).
Alternatively, the sprouted whole grain can be pressure cooked (e.g. 10-30 psi, 15-25 psi above atmospheric conditions) for 5-60 minutes (e.g., 5-45 minutes, 5-30 minutes, 10-30 minutes, or 8-10 minutes) at an elevated temperature (e.g., 115-142° C.) to gelatinize the sprouted whole grain's starch. According to certain embodiments, the sprouted whole grain can be pressure cooked in elevated temperatures as previously described.
In certain preferred embodiments, the sprouted whole grain (either before or after cooking) can be physically manipulated to form particulates thereof. The sprouted whole grain can be milled, crushed, or extruded such that the surface area of the sprouted whole grain is increased. The physically manipulated sprouted whole grain typically provides particulated sprouted whole grain that can be added to water (or vice versa) to provide a mash including the particulated sprouted whole grain. The resulting mash can be subjected to a fermenting step and the addition of an enzyme-active malt to convert more than 50% (e.g., 50-100%, 70-99%, 75-95%) of the gelatinized starch (due to the cooking operation) into maltose and dextrins and to lower the mash pH to a desirable level (e.g., between 4.5 and 5.5). A percentage (e.g., 1-100%, 50-100%, 80-100%, 90-100%) of the maltose and dextrins can be enzymatically hydrolyzed further into glucose.
According to certain embodiments of the present invention, the resulting sprouted whole grain mixes can have a starch content from 1-10% (e.g., 1-8%, 2-6%, 3-5%) by weight calculated on a dry basis. Moreover, the resulting mixes can include a glucose content of from 10-90% (e.g., 25-85%, 45%-80%, 55-70%, or 60-70%) by weight calculated on a dry basis in the absence of the addition of formulated sugar or other formulating additives. Additionally, the resulting mixes can have a total vitamin content ranging from 10-75% (e.g., 10-60%, 30-60% or 40-60%) larger than the native total vitamin content of the starting whole grain. As such, resulting mixes produced according to certain embodiments of the present invention provide an enhanced concentration of micronutrients, dietary fiber, and protein while also eliminating or mitigating the need for addition of sweeteners and/or flavoring agents.
In certain preferred embodiments, processes for the production of baking mixes (e.g., bread mixes) include a particular sequence of processing steps as illustrated in
After the whole grain has been cleaned to the desired extent, the whole grain can be subjected to a water soaking step 20. In the soaking step 20, the whole grain can be soaked for 1-15 hours (e.g., 3-12 hours or 6-9 hours) in excess water having a temperature from 15-40° C. (e.g., 20-40° C., or 20-30° C.) to facilitate hydration of the whole grain. After soaking in excess water, the whole grain (which has been hydrated to the desired degree) is separated from the water and undergoes a sprouting step 30 in which the whole grain is allowed to germinate/sprout for 10-40 hours (e.g., 15-30 hours, 20-30 hours). Soaking and germinating the whole grain beneficially hydrates the grain, enhances grain nutrient profile, enhances grain nutrient bioavailability, generates enzymes, and begins hydrolysis of the whole grain's starch.
In certain embodiments, the soaking water is changed once or twice during the soaking period. Harder, more dense whole grains (e.g., hard spring or winter wheat) can be soaked for a longer period of time than softer-textured grain that hydrates more quickly. After proper hydration, the whole grain is drained and allowed to germinate, or sprout, for 21-24 hr. If greater transformation of the grain is desired, germination time can be extended. Germination enhances the grain nutrient profile as it increases most vitamins, increases many essential amino acids, and increases bioavailability of many micro- and macro-nutrients.
According to embodiments illustrated in
After the cooking step 40, the cooked whole grain can be physically manipulated in a manner to form a mash 50 (with or without water and/or heat) including particulated sprouted whole grain. That is, the cooked whole grain is then further processed in a manner to increase the surface area of the sprouted whole grain. The surface area of the sprouted whole grain can be increased by grinding, crushing, or extruding the sprouted whole grain to provide a particulates of sprouted whole grain to which water can be added (or vice versa) to generate a mash. For instance, the whole grain can be mashed or coarsely ground in order to free various grain components and to increase component surface area, particularly gelatinized starch, in preparation for yeast fermentation and malt-hydrolysis into maltose and dextrins. In certain embodiments, the heating and mashing steps can be combined in modern heating-and extruding devises. The intensity of the grinding will typically depend on the particle size distribution of the fiber-rich bran that is desired for final products.
The mash generated in step 50 is subjected to a yeast fermentation step 60 in which the mash is fermented for 1 to 10 hours (e.g., 2-7 hours, or 2-5 hours) at a temperature ranging from 25 to 50° C. (e.g., 30-50, 30-40, or 35-40° C.) using, preferably, ordinary baker's yeast—Saccharomyces cerevisiae—with 1-3% yeast solids to which enzyme-active wheat or barley malt (150-230° L) is added in order to convert majority or most of the gelatinized starch into maltose and dextrins and to lower the mash pH to between 4-6 (e.g., 4.5-5.5). Preferably, most of the gelatinized starch can be converted into maltose and dextrins and the mash pH is lowered to between 4.5 and 5.5 in order to maximize future conversion to glucose. More or less yeast and more or less-active malt can be formulated but if so, both time and temperature must be appropriately re-balanced.
After the fermentation step 60, the mash is subjected to a second, or “intensified” hydrolysis step 70 in which the temperature of the fermented mash is increased to 45-65° C. (e.g., 45 to 65° C., 55 to 65° C.) for 15-60 minutes (e.g., 20-40, 25-35 minutes) to malt hydrolyze the mash followed by increasing the temperature to about 70-90° C. (e.g., 70-80° C., or 70-75° C.). The fermentation and first hydrolysis steps 60, 70 hydrolyze starch into (primarily) dextrins and maltose. By this point in the process, virtually all of the whole grain's starch has been sufficiently cleaved into dextrins.
In certain embodiments, after much of the starch has been hydrolyzed into maltose and dextrins and the pH lowered to about 5.0, the fermented mash is heated to between 45-60° C. (depending on the malt used) for 1-3 hr in order to enhance the degree of starch conversion to maltose and shorter-chain-length dextrins. The high degree of starch conversion is typically sought so that a subsequent hydrolysis step utilizing glucoamylase will most effectively convert maltose and dextrins to glucose.
Following fermentation and the initial- and intensified- hydrolyses, a second hydrolysis step 80 is performed for 1-4 hours (e.g., 1-3 hours) to convert the maltose and dextrins into glucose via addition of fungal glucoamylase to the fermented and enzyme-hydrolyzed mash. For instance, after most of the gelatinized starch has been converted to maltose and comparatively short-chain dextrins, fungal glucoamylase can be added to the fermented and enzyme-hydrolyzed mash and held for 1-3 hours at 45-65° C. in order to convert the maltose and dextrins to glucose. The time and temperature of incubation depends on the source of the glucoamylase and on the enzyme activity optima. By definition, one glucoamylase unit (GAU) is the amount of enzyme activity that will liberate one (1) gram of reducing sugar as D-glucose per hour under the optimum conditions recommended by the glucoamylase provider. If, for instance, the formulated glucoamylase has an activity of 440GAU/ml, an optimum incubation temperature of 62° C., and the substrate contains 1 Kg of hydrolyzed starch, 1.0 ml of glucoamylase would require an incubation period of 2.5-3.0 hr (60°-65° C.) in order to convert nearly all of the maltose and short-chain dextrins into D-glucose. In all cases the amount of glucoamylase to be formulated will depend on its activity (GAU/ml), on the amount of substrate, and on the desired termination time.
As shown in
According to certain embodiments of the present invention, the resulting sprouted whole grain mixes can have a starch content from 1-10% (e.g., 1-8%, 2-6%, 3-5%) by weight calculated on a dry basis. Moreover, the resulting mixes can include a glucose content of from 10-90% (e.g., 25-85%, 45%-80%, 55-70%, or 60-70%) by weight calculated on a dry basis in the absence of the addition of formulated sugar or other formulating additives. Additionally, the resulting mixes can have a total vitamin content ranging from 10-75% (e.g., 10-60%, 25-60%, or 40-60%) larger than the native total vitamin content of the starting whole grain. As such, resulting mixes produced according to certain embodiments of the present invention provide an enhanced concentration of micronutrients, dietary fiber, and protein while also eliminating or mitigating the need for addition of sweeteners and/or flavoring agents.
As shown in
In certain embodiments, a “wet mix” preparation is provided. As discussed above, the water addition during the processing steps is limited so as to not exceed a ratio of about 55:45, water to solids. For example, an enzyme heat-inactivated mash can contain ˜60% water and ˜40% solids prior to any dehydration, and contain ˜24% and ˜25% sugar, respectively. For certain “wet mix” preparations, cooked mashes can simply be packaged at this point without removing any water. However, even though the mash will have been cooked (e.g., for at least 15 minutes at 98° C.-100° C.), after packaging the individual packages (with contents) should be retorted in order to insure their sterile condition will remain indefinitely. For financial reasons related primarily to the cost of shipping, however, in certain embodiments the mash is dehydrated to about 40% moisture (60% solids) in order to reduce shipping costs to a minimum. Because of the water activity and the relative amount of sugars in the solids, the cost of dehydrating the first 10-15% of the water in the mash is comparatively inexpensive, compared to the cost of dehydrating thereafter. That is, dehydrating water from relatively high sugar concentrations becomes increasingly more and more difficult.
In another aspect, the present invention provides bakery mixes (e.g., wet and-dry-bread mixes). Baking mixes according to embodiments of the present invention can include sprouted whole grain particulates, in which the bread mix has a starch content of less than 50% by weight calculated on a dry basis and a glucose content ranging from 10-75% by weight calculated on a dry basis in the absence of the addition of formulated sugar. That is, the glucose content of the final mix is due entirely to the conversion of native starch into glucose, not the addition of non-native sugar or sugar derived from non-native starch or saccharides.
In certain embodiments, the starch content of the mix ranges from 1-20% (e.g. 1-10%, 1-8%, 2-6%, 1-5% or 3-5%) by weight calculated on a dry basis. Moreover, the resulting mixes can include a glucose content of from 10-90% (e.g., 25-85%, 45%-80%, 55-70%, or 60-70%) by weight calculated on a dry basis in the absence of the addition of formulated sugar or other formulating additives. Additionally, the resulting mixes can have a total vitamin content ranging from 10-75% (e.g., 10-60%, 30-60% or 40-60%) larger than the native total vitamin content of the starting whole grain in the absence of formulated vitamin addition. As such, resulting mixes produced according to certain embodiments of the present invention provide an enhanced concentration of micronutrients, dietary fiber, and protein while also eliminating or mitigating the need for addition of sweeteners and/or flavoring agents.
Baking mixes according to certain preferred embodiments include a starch content ranging from 1-10% by weight calculated on a dry basis, a glucose content ranging from 55-70% by weight calculated on a dry basis in the absence of the addition of formulated sugar, and a total vitamin content which is from 15-60 percent larger than a vitamin content of the unsprouted whole grain used for producing the mixes in the absence of formulated vitamin addition.
As illustrated in Table 1, both the hard- and the soft-wheat mashes produced according to one embodiment of the present invention contained 60% water and 40% solids prior to dehydration, and contained 24.05% and 25.42% sugar, respectively. Mashes were dehydrated to 80% solids and 20% water. At 20 percent moisture, the percentage of sugars was 50.83% and 48.09%, respectively, for the soft- and hard-wheat mashes.
1Calculated based on ratio wet:dry weight
2Estimated 90% conversion of starch to D-glucose.
3Calculated by 100 minus sum of all other Component.
4Average sum of total vitamins increased 50% due to sprouting
Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing description. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
