Title of Invention	A PROCESS AND FORMULATION FOR THE PREPARATION OF HIGH PROTEIN ENRICHED VERMICELLI
Abstract	The present invention relates to a formulation for the preparation of high protein vermicelli comprises the use of various protein sources and emulsifiers. The high protein vermicelli developed possesses creamish yellow colour, firm, discrete and non-sticky strands. The protein content of the developed product ranges from 16-17% when compared to 10-12% of control vermicelli.

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The present invention relates to a process and formulation for the preparation of high protein enriched vermicelli. Pasta products (noodles, spaghetti and vermicelli) which have excellent nutritional and safety quality have been known in world over and are eaten and enjoyed every where. Pasta is the Italian word for paste, a mixture of flour and salt. The use of wheat in pasta products is more wide spread in the world, when compared to bread because pasta products are simpler to make and quick to serve, if dried can be conveniently stored for a relatively long period of time without deterioration. Pasta products comprise vermicelli, noodles, macaroni and spaghetti. These are similar, but differ principally in shape and size. They comprise a) Macaroni- made from semolina and are in the shape of hollow tubes of various sizes and diameters, b) Spaghetti- made either from semolina or flour and are in the form of solid rods generally of small diameters, c) Vermicelli-basically made of semolina and is slightly thicker than spaghetti, and d) Noodles-these are made from wheat flour instead of semolina and are strips, either flat (rolled and cut) or oval (extruded). The pasta products such as noodles, spaghetti and vermicelli are becoming popular world over. Their per capita consumption is about 30 Kg in Italy and Greece and 3- 6 Kg in most of the other countries except UK and Scandinavian countries, where it is less than 2 Kg. In India, however, the per capita consumption of pasta products is as low as 80 gram (Vetrimani.R, Sudha ML and Haridas Rao. P, 1999 Improvement of quality of Pasta products through use of additives- an appraisal, Indian Miller, July -Aug, 11-19). The market survey conducted by US Wheat Associates, New Delhi has revealed that about 30-40% of the household are consuming the pasta products and is expected to increase to 65% by 2005 AD. This suggests that there is a tremendous scope for expansion of pasta industry in the country. The production of vermicelli and noodles was 4.73 lakh tonnes for 1990 and increased to 5.39 lakh tonnes in 1996. It is expected to increase further to 7.0 lakh tons in 2005. Pasta formulations which consist essentially of semolina are frequently low in protein efficiency ratios (PER). The protein efficiency ratio of normal semolina is generally in the range of about 0.75 - O.S.In the past many attempts have been made to formulate "high protein" pasta products that will qualify as a " meat alternative" under government sponsored food programs including school lunch programs in USA; but none of the past products offered to this market have been completely satisfactory and acceptable. In India, most of the durum wheat produced were utilized for the production of vermicelli. The need of the hour for pasta making industries would be the process for development of high protein vermicelli. The need is to exploited and there is a good growth potential for the industries which manufactured the vermicelli. Moreover, the developed process system can be useful to fulfill the nutritional requirements of young children in India. India's wheat production in 1998-99 was 73.2 million tonnes, an 18 per cent increase from 55 million tonnes in 1993-94. The 1998-99 output made India the world's second biggest wheat producer after China. But India has not yet established itself as a regular wheat exporting nation. However, the bumper output in 1998-99 - together with other factors mentioned below - positions India to increase its wheat exports, not withstanding the fact that production in 1999-2000 is expected to have declined by 2.9 per cent. Emulsifiers are used in pasta products to improve machinability of the dough and quality of pasta products. Incorporation of GMS (Glycerol Mono Stearate) upto 1.0% decreased the cooking loss by 6% for both pasta cooked for optimum period as well as that for overcooked pasta. Increasing the quality of GMS to 2% further improvement in the pasta quality was not observed. The enzyme modified lecithin was found inferior to GMS in reducing cooking loss and stickiness, probably because of the high mineral content (8% ash) of the modified lecithin. SSL increased the surface firmness and decreased cutting stress. The cooking quality of spaghetti improved when small quantities of other amylose complexing agents as PGMS (Propylene glycol mono stearate) was added to the dough (Nazarov, Nl, Gaidebko, MV, Lekhter AE and Ob'yakova GS 1975. Surfactants to improve macaroni products. Khlebopek, Kunditer, Prom. 4, 27-28). These emulsifiers also increase the cooking tolerance and strength of the product thus reduces the stickiness. • The effect of different types of gluten on shaghetti cooking was studied and observed. Gluten of medium strength appeared to produce spaghetti of optimum cooking quality (Matsue RR and Irvine GN, 1970. Effects of gluten on the cooking quality of spaghetti. Board of grain commissioners for Canada, Grain Research Laboratory, Winnipeg 2, Manitobe, 173-180) Reference may be made here to Grindstaff et al. 1978. US Pat.No. 4,120,989 and Cox . 1979. US Pat.No. 4,158,069 discloses the method of preparation of enriched wheat macaroni. In these patents, the macaroni is prepared using whey protein concentrate as one of the ingredient. The draw back in these patents is that the end product is macaroni but not vermicelli and also formulation used in the present invention is also different. Reference may be made here to Kim et al.1992. The improvement of spaghetti quality made from bread wheat flour. Journal of the Korean Society of Food and Nutrition. 21(3) 270-278 wherein the effect of steam treatment after extrusion of the spaghetti from flour of 51 varieties of hard red winter wheat (HRW), 2 varieties of hard white winter wheat (HWW) or commercial durum wheat is compared with spaghetti made from farina of HRW and HWW. Steam treated spaghetti was stronger than control spaghetti. Steam treatment affected quality of hard wheat farina spaghetti more than that of durum spaghetti. The drawback is that the product is spaghetti and not high protein vermicelli. Reference may be made here to Lee., U.S. Pat. No. 4,840,808 (1989) wherein a method for preserving colour of vegetable pasta products is described. Colour is enhanced by the addition of a cation such as magnesium, zinc, copper, calcium and aluminum cations to the pasta mixture. In addition, the patent discloses the presence of salt and glycerol monostearate to the pasta mixture. Salt provides flavour. GMS functions as an emulsifier or lubricant or flow modifier, which reduces the viscosity of alimentary paste, making extrusion easier. It is reported that the use of GMS reduces the pressure within the extruder. The drawback is that final product is not mainly focussed on the protein enrichment of vermicelli.. Reference may be made here to Lee et al., U.S. Pat.No. 6,022,575 (2000) which discloses the method to prevent starch retrogradation in pasta products. In addition, the patent also states the use of additives such as propylene glycol alginate to further improve anti-retrogradation properties of cooked pasta. The cooked product is coated with an edible acid like lactic acid and edible oil could be peanut oil, coconut oil, sunflower oil and the like. Pasta of this invention includes products made from semolina, flour from durum wheat, other flours such as oat flour, rice flour or any other cereal flour. The drawback is that wheat products from semolina and other cereal flours are used and not whey protein concentrate to enrich the vermicelli. Reference may be made here to Sowbhagya et al., U.S. Pat. No. 6,083,551 (2000) which discloses the process for the preparation of noodles/vermicelli from maize (corn,. Zea mays L.) . The draw back is that the raw material used was maize not wheat. Reference may be made here to Gum et al., U.S.Pat.No.5,817,356(1998) wherein a process for the preparation of a fully cooked shelf stable or refrigerated acidified pasta product is described. The mixed dough is encapsulated with edible acid and then steam to gelatinise surface of pasta. The steamed pasta is treated with water and second steaming is done till it is substantially cooked. The pasta is coated with edible oil to inhibit sticking and is finally packed. The drawback is that the pasta ingredients used in this invention may be one Or more of durum semolina, durum flour, regular wheat flour, whole wheat flour, corn flour or any mixture thereof and the formulation used in the present invention is different. Reference may be made here to Hahn et al., US 5,945,144(1999) wherein a calcium fortified pasta and the process for preparing the same is described. The pasta product contains about 75% wheat flour, water and at least 800 mg to 8,000mg of calcium per pound of the product. The pasta product additionally comprises a gelling agent, a vitamin, a flavoring agent, a vegetable, egg white or egg yolk or combination thereof. The drawback is that the pasta product is prepared from wheat flour and the formulation does not contain whey protein concentrate. Also, the additives used in this invention are different. References may be made here to Zhu Enjun et al CN 1341382(2002) wherein the processing conditions for the production of konjak starch vermicelli is described. This patent discloses a food processing method for the production of boil-proof-health care konjak starch vermicelli made by adding konjak fine flour and other auxiliary material in the market starch with various types through the vermicelli production process. The starch vermicelli thus produced possesses smooth surface, transparent and uniformity in fineness and has certain health care function. The drawback here is that konjak flour was used for vermicelli preparation and not semolina from durum wheat, whey protein concentrate and additives used were different. RU 2159050(2000) discloses the method of the production of instant cooking vermicelli. In this patent dough for vermicelli is prepared in water with addition of egg or egg powder, salt, sugar, sodium glutamate, gluten, sodium tri-polyphosphate, potassium carbonate, sodium carbonate and garlic juice. The drawback in this patent is that the raw material and additives used were different from the present invention. References may made here to CN 1332978(2002) wherein the invention relates to the production of general vermicelli to which vegetable components can be added to obtain a natural green fast food vermicelli. The vermicelli apart from containing vegetable components, also contain edible fungus. The drawback of the invention is that raw materials used are different and also edible fungus and vegetables components are added which do not form the ingredients in the present invention. The main object of the present invention is to provide a process and formulation for the preparation of high protein enriched vermicelli.Another object of the present invention is to provide the utilization of newly developed formulation system in vermicelli. Accordingly, the present invention relates to a formulation for the preparation of high protein vermicelli thereof comprising use of 950-980 parts of Durum semolina; 50-60 parts of Whey protein Concentrate; 0.050-0.100 parts of Ascorbic acid; 25-30 parts of vital gluten; 2.5 - 5.0 parts of SSL and 320-350 parts of water. In an embodiment the whey protein concentrate used comprises protein content in the range of 50-68%. In an another embodiment the gluten powder comprises of a protein content in the range of 74-75%. In an another embodiment the wherein high protein enriched vermicelli comprises of following qualitative characteristics: Total solid loss (%) 6.5-7.5 Yellow index value 6.2-6.4 Shear force (g) 63-66 Colour Creamish yellow Strand quality Firm discrete, non-sticky mouth feel. The cooked weight was 82.5g/25g. The cooking loss was 7.5%. The yellow index and shear force were 5.34 and 61 g respectively. (Table 1) Example 2 (5% WPC) Formulation of vermicelli Semolina 950 g Whey protein concentrate 50g Water 330 ml • Weighing of the ingredients, Mixing together semolina and water for 5 min in first speed using Hobart mixer ( Model N50, 59 rpm) and rest for 5 min. • Transferring this mixture to the pasta machine and kneading for 5 min till the formation of lot of coffee bean size dough pieces ( La Monferrina, Italy) • Extruding the vermicelli dough using the die having perforations of 0.7mm diameter. Discarding strands , a few centimeters initially • Extruding, Cutting the strands to 10 -11" length by scissors • Discarding last few centimeters of the strands • Drying extruded vermicelli in hot air oven at 75° C for 3 hours • Cooling vermicelli to room temperature • Packing in polypropylene pouches The characteristics of vermicelli made using the whey protein concentrate (5%) were: creamish colour, Discrete strands and non-sticky. The cooked weight was 88.6g/25g. The cooking loss was 7.7%. The yellow index was 4.19. A shear force of 58g was recorded. This value was lower than the control which shows that the strands did not posses much strength and were fragile. Sensory evaluation of strand quality showed that strands were fragile but without any stickiness (Table 1). Higher value for solid loss, lower yellow index value and fragile nature of strands when compared to control indicated that the quality of vermicelli needs improvement. Example 3 (Combination I) Formulation of vermicelli Semolina 950 g Whey protein concentrate 50 g Ascorbic acid 100mg Gluten 30g Water 330 ml • Weighing of the ingredients, mixing together semolina, whey protein concentrate, additives and water for 5 min in First speed using Hobart mixer ( Model N50, 59 rpm) and rest for 5 min. • Transferring this mixture to the pasta machine and kneading for 5 min till the formation of lot of coffee bean size dough pieces ( La Monferrina, Italy) • Extruding the vermicelli dough using the die having perforations of 0.7 mm diameter. Discarding strands , a few centimeters initially. • Extruding, Cutting the strands to 10 -11" length by scissors • Discarding last few centimeters of the strands • Drying extruded vermicelli in hot air oven at 75° C for 3 hours • Cooling vermicelli to room temperature • Packing in polypropylene pouches Characteristics of vermicelli with whey protein concentrate (5%), ascorbic acid (100ppm) and gluten (3%) were creamy colour and strands were slightly mashy and sticky(Table 1). Cooked weight of 78.0g and cooking loss of 8.2% was observed which was higher when compared with the cooking losses of control and combination II. The yellow index and shear force value were 4.98 and 60.6g respectively (Table 1). Example 4 (Combination II) Formulation of vermicelli Semolina 950 g Whey protein concentrate 50 g Ascorbic acid 100mg Gluten .30g SSL 5g Water 320 ml • Weighing of the ingredients, Mixing together semolina, whey protein concentrate, additives and water for 5 min in First speed using Hobart mixer ( Model N50, 59 rpm) and rest for 5 min. • Transferring this mixture to the pasta machine and kneading for 5 min till the formation of lot of coffee bean size dough pieces ( La Monferrina, Italy) • Extruding the vermicelli dough using the dies having perforation of 0.7 mm diameter. Discarding strands , a few centimeters initially • Extruding, Cutting the strands to 10 -11" length by scissors • Discarding last few centimeters of the strands • Drying extruded vermicelli in hot air oven at 75° C for 3 hours • Cooling vermicelli to room temperature • Packing in polypropylene pouches Characteristics of vermicelli with whey protein concentrate (5%), ascorbic acid (100ppm), gluten (3%) and SSL (0.5%) were creamish yellow colour ajid strands were firm discrete and non-sticky(Table 1). Cooked weight 90.5g and Cooking loss of 7.0% was observed which was lowest when compared with the cooking losses of control, combination I and III. The yellow index and shear force value were 6.38 and 65.6g respectively (Table 1). The combination II consisting of additives (whey protein concentrate 5%, ascorbic acid 100 ppm, gluten 3% and SSL 0.5%) produced the best results. As evident from the photograph of the product (Figure 1), the vermicelli made using the combination II had creamy yellow colour and very good quality characteristics in terms of strand quality, cooked weight, low cooking loss and shear force values. Example 5 (Combination III) Formulation of vermicelli Semolina 950 g Whey protein concentrate 50 g Ascorbic acid 100mg Gluten 30g SSL 5g Xylanase 1.2 g Water 320 ml Weighing of the ingredients, Mixing together semolina, additives and water for 5 min in First speed using Hobart mixer ( Model N50, 59 rpm) and rest for 5 min. • Transferring this mixture to the pasta machine and kneading for 5 min till the formation of lot of coffee bean size dough pieces ( La Monferrina, Italy) • Extruding the vermicelli dough using the dies having perforation of 0.7 mm diameter. Discarding strands , a few centimeters initially • Extruding, Cutting the strands to 10 -11" length by scissors • Discarding last few centimeters of the strands • Drying extruded vermicelli in hot air oven at 75° C for 3 hours • Cooling vermicelli to room temperature • Packing in polypropylene pouches Characteristics of vermicelli with whey protein concentrate (5%),ascorbic acid (100ppm), gluten (3%), SSL (0.5%) and xylanase (0.012%)were whitish colour and strands were mashy and sticky (Table 1). Cooked weight of 81.Og, Cooking loss of 8.8% which was the highest when compared with the cooking losses of control, combination I and II. The yellow index and shear force value were 5.0 and 62.3g respectively (Table 1). Table 1. Effect of WPC on physical characteristics of vermicelli (Table Removed) Table 2. Effect of WPC on sensory quality characteristics of vermicelli. (Table Removed) Example 6 Determination of protein content of control vermicelli and vermicelli prepared with combination II was carried out. The results showed that the protein content of vermicelli prepared with combination II was 16% as against the control vermicelli which had 11.5% protein. The results of examples 4 and 6 showed that improved quality vermicelli with 4.5% increased protein content can be prepared by the formulation and processing conditions of example 4. SEM Studies: The control vermicelli, the vermicelli prepared with 5% WPC and the vermicelli prepared with Combination II which produced the best results were selected for the SEM Studies. The cross section of the micrograph of control vermicelli, no area of rupture was observed (Figure 2). However, the cross sections of the micrographs of vermicelli containing 5% whey protein concentrate and vermicelli prepared using combination II showed that the area of rupture in case of the vermicelli containing 5% whey protein concentrate was bigger whereas in vermicelli prepared using combination II, it was very small indicating that the strands had strength and the core was smooth during cooking. The integrity of the protein film which envelopes the strands is very crucial as it affects the cooking quality. The micrographs of control vermicelli showed a continues protein film embedded with starch granules whereas in the case of vermicelli with 5% whey protein concentrate showed a distorted protein film was observed which resulted in rupture of protein network. This could be one of reasons for higher cooking loss in the case of vermicelli with 5% whey protein. The micrographs of vermicelli with combination II showed a continuos, rupture free structure indicating that the improver mix had imparted strength to the protein network in whey protein enriched vermicelli resulting in a product with good cooking quality (Figure 2). We claim: 1. A formulation for the preparation of high protein vermicelli thereof comprising use of 950-980 parts of Durum semolina; 50-60 parts of Whey protein Concentrate; 0.050-0.100 parts of Ascorbic acid; 25- 30 parts of vital gluten; 2.5 - 5.0 parts of SSL and 320-350 parts of water. 2. A formulation for the preparation of high protein vermicelli substantially as herein described with reference to the examples and graphs accompanying this specification

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