PRODUCTION OF STABILIZED WHOLE GRAIN FLOUR AND PRODUCTS THEREOF

• US 20090238935A1
• Filed: 06/15/2007
• Published: 09/24/2009
• Est. Priority Date: 06/16/2006
• Status: Active Grant

• Current Assignee: Intercontinental Great Brands LLC (Mondelez International, Inc.)
• Original Assignee: Kraft Foods Global Brands LLC (Mondelez International, Inc.)
• Inventors: Zhou, Ning, Zimeri, Jeanny E., Levine, Harry I., Gabriel, Sarwat, Epperson, Charles W., Howey, Edward D., Haynes, Lynn C., Gannon, Diane, Manns, James, Cassone, Domenico, Slade, Louise, Mihalos, Mihaelos N.
• Granted Patent: US 8,173,193 B2
• Time in Patent Office: Days
• US Class Current: 426/331
• CPC Class Codes: A21D 13/02 Products made from whole meal; Products containing bran or rough-ground grain

Abstract

A stabilized bran component and a stabilized whole grain flour containing the component are produced by subjecting a bran-enriched coarse fraction which contains bran, germ and starch to grinding or milling to reduce grittiness of the coarse fraction without substantially damaging the starch due to abrasion. The coarse fraction may be stabilized by heating to substantially reduce the lipase and lipoxygenase activity of the coarse fraction without substantial gelatinization of the starch. High levels of natural antioxidants and vitamins are retained while avoiding substantial acrylamide formation during the stabilization. The stabilized coarse fraction or stabilized bran component may be combined with a fine fraction which contains predominantly endosperm to obtain a stabilized whole grain flour. The stabilized whole grain flours and the stabilized bran component exhibit extended shelf life and may be used for making baked goods, such as cookies, with desirable oven spread, and a non-gritty mouthfeel.

Claims

1. A method for making a stabilized whole grain flour comprising:

a. subjecting a coarse fraction comprising bran, germ and starch to grinding or milling to reduce grittiness of the coarse fraction without substantially damaging the starch, the amount of bran being at least about 50% by weight, based upon the weight of the coarse fraction,

b. stabilizing the coarse fraction by heating the coarse fraction to substantially reduce the lipase activity of the coarse fraction, and

c. combining the stabilized coarse fraction with a fine fraction comprising endosperm to obtain a stabilized whole grain flour.

2. A method as claimed in claim 1 wherein said stabilizing of the coarse fraction avoids substantial production of acrylamide, while also avoiding substantial loss of tocopherols, thiamin and riboflavin, and maintaining an antioxidant free radical scavenging capacity of not less than about 150 micromoles Trolox equivalents per gram.

3. A method as claimed in claim 1 wherein said coarse fraction is subjected to said grinding or milling before said stabilizing of the coarse fraction.

4. A method as claimed in claim 1 wherein said coarse fraction is subjected to said grinding or milling after said stabilizing of the coarse fraction.

5. A method as claimed in claim 1 wherein the amount of starch is from about 15% by weight to about 35% by weight, based upon the weight of the coarse fraction.

6. A method as claimed in claim 1 wherein before said grinding or milling the coarse fraction has a particle size distribution of at least about 75% by weight having a particle size of greater than or equal to 500 microns, less than or equal to about 5% by weight having a particle size of less than 149 microns, and about 15% by weight to about 25% by weight having a particle size of less than 500 microns but greater than or equal to 149 microns, and the coarse fraction is ground or milled to obtain a ground or milled fraction or bran component with at least about 40% by weight of the fraction having a particle size greater than or equal to 149 microns, and less than or equal to about 35% by weight having a particle size greater than or equal to 500 microns.

7. A method as claimed in claim 6 wherein said ground or milled fraction or bran component has a particle size distribution of about 0.5% by weight to about 5% by weight greater than or equal to 841 microns, about 10% by weight to about 30% by weight less than 841 microns but greater than or equal to 500 microns, about 25% by weight to about 70% by weight greater than or equal to 149 microns but less than 500 microns, and less than or equal to about 60% by weight less than 149 microns, said percentages adding up to a total of 100% by weight.

8. A method as claimed in claim 1 wherein the fine fraction is not subjected to stabilization, in order to avoid substantial gelatinization of starch, and stabilization of the coarse fraction by heating avoids substantial gelatinization of starch contained in the coarse fraction.

9. A method as claimed in claim 1 wherein the lipase activity is reduced to less than about 3 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized coarse fraction.

10. A method as claimed in claim 1 wherein said stabilizing of the coarse fraction avoids an acrylamide content of greater than about 150 ppb, based upon the weight of the stabilized coarse fraction.

11. A method as claimed in claim 1 wherein said stabilization comprises heating at a temperature of from about 100°

C. to about 140°

C.

12. A method as claimed in claim 11 wherein said coarse fraction which is subjected to said stabilization has a moisture content of from about 9% by weight to about 14% by weight, based upon the weight of the coarse fraction.

13. A method as claimed in claim 1 wherein said coarse fraction comprises at least about 60% by weight bran, and at least about 10% by weight germ, based upon the weight of the coarse fraction, and said fine fraction comprises at least about 90% by weight endosperm on a solids basis, and has a particle size distribution of less than about 10% by weight having a particle size of greater than or equal to 500 microns, less than or equal to about 80% by weight having a particle size of less than 149 microns, and about 20% by weight to about 65% by weight having a particle size of less than 500 microns but greater than or equal to 149 microns.

14. A method as claimed in claim 1 wherein the stabilized, ground coarse fraction has a starch melting enthalpy of greater than about 4 J/g, based upon the weight of starch in the stabilized ground coarse fraction, as measured by differential scanning calorimetry (DSC), at a peak temperature of from about 65°

C. to about 70°

C., and a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 200%.

15. A method as claimed in claim 1 wherein said stabilization includes treating said coarse fraction with an edible alkali metabisulfite in a stabilizing amount.

16. A method as claimed in claim 1 wherein said stabilized whole grain flour has a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

17. A method as claimed in claim 1 wherein said stabilized whole grain flour has a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve, about 20% by weight to about 40% by weight on a No. 60 (250 micron) U.S. Standard Sieve, about 10% by weight to about 60% by weight on a No. 100 (149 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

18. A method as claimed in claim 1 wherein said stabilized whole grain flour has a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 85%, a free fatty acid content of less than about 10% by weight of total flour lipids at three months or less than about 3,000 ppm, based upon the weight of the stabilized whole grain flour, and a hexanal content of less than about 10 ppm after 1 month accelerated storage at 95°

C., based upon the weight of the stabilized whole grain flour.

19. A method as claimed in claim 1 wherein said stabilized whole grain flour is produced continuously and said stabilization of the coarse fraction is conducted in from about 0.25 minutes to about 12 minutes.

57. A method as claimed in claim 1 wherein said stabilized whole grain flour is a stabilized whole grain wheat flour.

58. A method as claimed in claim 1 wherein said stabilized whole grain flour is a stabilized whole grain corn flour, a stabilized whole grain oat flour, or a stabilized whole grain rice flour.

66. A method as claimed in claim 57 wherein the amount of starch is from about 10% by weight to about 40% by weight, based upon the weight of the coarse fraction.

20. A method for making a stabilized whole grain flour comprising:

a. comminuting whole cereal grains to obtain ground whole cereal grains,

b. subjecting the ground cereal grains to a separation operation to obtain a coarse fraction comprising bran, germ, and starch, and a fine fraction comprising endosperm, said coarse fraction having a bran content of at least about 50% by weight, based upon the weight of the coarse fraction,

c. grinding the coarse fraction to obtain a ground fraction having a particle size distribution of at least about 40% by weight having a particle size of greater than or equal to 149 microns, and less than or equal to about 35% by weight having a particle size greater than or equal to 500 microns,

d. stabilizing the ground fraction by heating to reduce the lipase activity to less than about 3 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized ground fraction, while avoiding an acrylamide content of greater than about 150 ppb, based upon the weight of the stabilized ground fraction, and

e. combining the fine fraction with the stabilized ground fraction to obtain a stabilized whole grain flour with a lipase activity of less than about 1.5 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized whole grain flour and an acrylamide content of less than about 45 ppb, based upon the weight of the stabilized whole grain flour.

21. A method for making a stabilized bran component comprising:

a. subjecting a coarse fraction comprising bran, germ and starch to grinding or milling to reduce grittiness of the coarse fraction without substantially damaging the starch, the amount of bran being at least about 50% by weight, based upon the weight of the coarse fraction, and

b. stabilizing the coarse fraction by heating the coarse fraction to substantially reduce the lipase activity of the coarse fraction, the stabilized, ground coarse fraction having a particle size distribution of at least about 40% by weight of the fraction having a particle size of at least 149 microns, and less than or equal to about 35% by weight having a particle size greater than or equal to 500 microns.

22. A method as claimed in claim 21 wherein said stabilizing of the coarse fraction avoids substantial production of acrylamide, while also avoiding substantial loss of tocopherols, thiamin and riboflavin, and maintaining an antioxidant free radical scavenging capacity of not less than about 150 micromoles Trolox equivalents per gram.

23. A method as claimed in claim 21 wherein said coarse fraction is subjected to said grinding or milling before said stabilizing of the coarse fraction.

24. A method as claimed in claim 21 wherein said coarse fraction is subjected to said grinding or milling after said stabilizing of the coarse fraction.

25. A method as claimed in claim 21 wherein the amount of starch is from about 15% by weight to about 35% by weight, based upon the weight of the coarse fraction, and before said grinding or milling the coarse fraction has a particle size distribution of at least about 75% by weight having a particle size of greater than or equal to 500 microns, less than or equal to about 5% by weight having a particle size of less than 149 microns, and about 15% by weight to about 25% by weight having a particle size of less than 500 microns but greater than or equal to 149 microns, and the coarse fraction is ground or milled to obtain a ground or milled fraction or bran component with at least about 40% by weight of the fraction having a particle size greater than or equal to 149 microns, and less than or equal to about 35% by weight having a particle size greater than or equal to 500 microns.

26. A method as claimed in claim 25 wherein said ground or milled fraction or bran component has a particle size distribution of about 0.5% by weight to about 5% by weight greater than or equal to 841 microns, about 10% by weight to about 30% by weight less than 841 microns but greater than or equal to 500 microns, about 25% by weight to about 70% by weight greater than or equal to 149 microns but less than 500 microns, and less than or equal to about 60% by weight less than 149 microns, said percentages adding up to a total of 100% by weight.

27. A method as claimed in claim 21 wherein stabilization of the coarse fraction is by heating which avoids substantial gelatinization of starch contained in the coarse fraction.

28. A method as claimed in claim 21 wherein the lipase activity is reduced to less than about 3 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized coarse fraction.

29. A method as claimed in claim 21 wherein said stabilizing of the coarse fraction avoids an acrylamide content of greater than about 150 ppb, based upon the weight of the stabilized coarse fraction.

30. A method as claimed in claim 21 wherein said stabilization comprises heating at a temperature of from about 100°

C. to about 140°

C.

31. A method as claimed in claim 30 wherein said coarse fraction which is subjected to said stabilization has a moisture content of from about 9% by weight to about 14% by weight, based upon the weight of the coarse fraction.

32. A method as claimed in claim 21 wherein said coarse fraction comprises at least about 60% by weight bran, and at least about 10% by weight germ, based upon the weight of the coarse fraction.

33. A method as claimed in claim 21 wherein the stabilized, ground coarse fraction has a starch melting enthalpy of greater than about 4 J/g, based upon the weight of starch in the stabilized ground coarse fraction, as measured by differential scanning calorimetry (DSC), at a peak temperature of from about 65°

C. to about 70°

C., and a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 200%.

63. A method for making a stabilized bran component as claimed in claim 21 wherein said stabilized bran component is a stabilized wheat bran component.

64. A method for making a stabilized bran component as claimed in claim 21 wherein said stabilized bran component is a stabilized corn bran component, a stabilized oat bran component, or a stabilized rice bran component.

65. A method for making a stabilized bran component as claimed in claim 21 wherein the amount of starch is from about 10% by weight to about 40% by weight, based upon the weight of the coarse fraction.

34. A stabilized bran component comprising a ground or milled, heat-treated coarse fraction comprising bran, germ and starch, the amount of bran being at least about 50% by weight, based upon the weight of the coarse fraction, the stabilized, ground coarse fraction having:

a. a particle size distribution of at least about 40% by weight of the fraction having a particle size of at least 149 microns, and less than or equal to about 35% by weight having a particle size greater than or equal to 500 microns,

b. a lipase activity of less than about 3 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized bran component,

c. an acrylamide content less than or equal to about 150 ppb, based upon the weight of the stabilized bran component,

d. a starch melting enthalpy of greater than about 4 J/g, based upon the weight of starch in the stabilized ground coarse fraction, as measured by differential scanning calorimetry (DSC), at a peak temperature of from about 65°

C. to about 70°

C., and

e. a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 200%.

35. A stabilized bran component as claimed in claim 34 wherein the amount of starch is from about 15% by weight to about 35% by weight, based upon the weight of the coarse fraction.

36. A stabilized bran component as claimed in claim 34 wherein said ground or milled fraction or bran component has a particle size distribution of about 0.5% by weight to about 5% by weight greater than or equal to 841 microns, about 10% by weight to about 30% by weight less than 841 microns but greater than or equal to 500 microns, about 25% by weight to about 70% by weight greater than or equal to 149 microns but less than 500 microns, and less than or equal to about 60% by weight less than 149 microns, said percentages adding up to a total of 100% by weight.

37. A stabilized bran component as claimed in claim 34 wherein said coarse fraction comprises at least about 60% by weight bran, and at least about 10% by weight germ, based upon the weight of the coarse fraction.

48. A food product comprising a stabilized bran component as claimed in claim 34.

67. A stabilized bran component as claimed in claim 34 wherein said stabilized bran component is a stabilized wheat bran component, and the amount of starch is from about 10% by weight to about 40% by weight, based upon the weight of the coarse fraction.

68. A stabilized bran component as claimed in claim 34 wherein said stabilized bran component is a stabilized corn bran component, a stabilized oat bran component, or a stabilized rice bran component, and the amount of starch is from about 10% by weight to about 40% by weight, based upon the weight of the coarse fraction.

38. A stabilized whole grain flour comprising bran, germ and endosperm, wherein only a portion of the endosperm is subjected to heat stabilization and at least a substantial portion of the bran and germ is subjected to stabilization by heating, the stabilized whole grain flour having a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve.

39. A stabilized whole grain flour as claimed in claim 38 wherein the lipase activity is less than about 1.5 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized whole grain flour, and the acrylamide content is less than about 45 ppb, based upon the weight of stabilized whole grain flour.

40. A stabilized whole grain flour as claimed in claim 38 having a particle size distribution of less than about 5% by weight on a No. 35 (500 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

41. A stabilized whole grain flour as claimed in claim 38 having a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve, about 20% by weight to about 40% by weight on a No. 60 (250 micron) U.S. Standard Sieve, about 10% by weight to about 60% by weight on a No. 100 (149 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

42. A stabilized whole grain flour as claimed in claim 38 having a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 85%, a free fatty acid content of less than about 10% by weight of total flour lipids at three months or less than about 3,000 ppm, based upon the weight of the stabilized whole grain flour, and a hexanal content of less than about 10 ppm after 1 month accelerated storage at 95°

C., based upon the weight of the stabilized whole grain flour.

59. A stabilized whole grain flour as claimed in claim 38 which is a stabilized whole grain wheat flour.

60. A stabilized whole grain flour as claimed in claim 38 which is a stabilized whole grain corn flour, a stabilized whole grain oat flour, or a stabilized whole grain rice flour.

43. A stabilized whole grain flour comprising bran, germ and endosperm, the stabilized whole grain flour having:

a. a lipase activity of less than about 1.5 micromole butyrate free acid formed per hour per 0.1 gram of the stabilized whole grain flour,

b. an acrylamide content less than about 45 ppb, based upon the weight of stabilized whole grain flour, and

c. a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

44. A stabilized whole grain flour as claimed in claim 43 having a particle size distribution of less than about 10% by weight on a No. 35 (500 micron) U.S. Standard Sieve, about 20% by weight to about 40% by weight on a No. 60 (250 micron) U.S. Standard Sieve, about 10% by weight to about 60% by weight on a No. 100 (149 micron) U.S. Standard Sieve, and less than about 70% by weight through a No. 100 (149 micron) U.S. Standard Sieve.

45. A stabilized whole grain flour as claimed in claim 43 having a sodium carbonate-water solvent retention capacity (SRC sodium carbonate) of less than about 85%, a free fatty acid content of less than about 10% by weight of total flour lipids at three months or less than about 3,000 ppm, based upon the weight of the stabilized whole grain flour, and a hexanal content of less than about 10 ppm after 1 month accelerated storage at 95°

C., based upon the weight of the stabilized whole grain flour.

46. A stabilized whole grain wheat flour as claimed in claim 43 made from berries comprising whole white wheat berries.

47. A stabilized whole grain wheat flour as claimed in claim 43 made from berries comprising whole red wheat berries.

49. A food product comprising a stabilized whole grain wheat flour as claimed in claim 43.

50. A farinaceous food product comprising a stabilized whole grain wheat flour of claim 43.

51. A biscuit product comprising a stabilized whole grain wheat flour of claim 43.

52. A food product selected from the group consisting of bakery products and snack foods, wherein the food product includes a stabilized whole grain wheat flour of claim 43.

53. A food product as claimed in claim 51 wherein the food product is a bakery product selected from the group consisting of cookies, crackers, pizza crusts, pie crusts, breads, bagels, pretzels, brownies, muffins, waffles, pastries, cakes, quickbreads, sweet rolls, donuts, fruit and grain bars, tortillas, and par-baked bakery products.

54. A food product as claimed in claim 51 wherein the food product is selected from the group consisting of cookies, crackers, and cereal crunch bars.

55. A food product as claimed in claim 54 wherein the food product is a cookie.

56. A food product as claimed in claim 55 wherein the cookie has a cookie spread of at least about 130% of the original prebaked dough diameter, as measured according to the AACC 10-53 bench-top method.

61. A stabilized whole grain flour as claimed in claim 43 which is a stabilized whole grain wheat flour.

62. A stabilized whole grain flour as claimed in claim 43 which is a stabilized whole grain corn flour, a stabilized whole grain oat flour, or a stabilized whole grain rice flour.