Title of Invention

A PROCESS FOR CORN FLOUR BISCUITS

Abstract

This invention relates to a process for the preparation of corn biscuits and like bakery products. Corn flour biscuits are prepared using creaming method. Fat, powdered sugar, corn syrup, emulsifiers like glycerol monostearate and sodium steoryl lactylate and essence are creamed to get a homogeneous cream. Baking chemicals, salt and skimmed milk powder dissolved in water are added to above cream and mixed to get a smooth homogeneous cream. Finally a blend of corn flour and dry gluten are added to above cream and mixed to get a crumbly dough. The dough is rested, shaped using rotary moulder and baked. The biscuits are cooled and packed.

Full Text

This invention relates to a process for the preparation of corn flour biscuits and like bakery products. Indian bakery industry is the second largest in terms of turnover and production of biscuits in the world. At present India produces about 1.5 MMT of biscuits and by 2010 A.D. the production of biscuits in the country is expected to go up to 2.5 MMT. In India the turn over of bakery industry is Rs. 5000 crores. India produces 1.5 MMT of biscuits valued at Rs. 3000 crores. The bakery products are becoming more popular even in the rural areas with the market share of 42.75%. The biscuits and cookies are more popular in rural areas. The growth rate of biscuit industry is estimated at 7.0% per annum. The increased production and demand for the biscuits is attributed to their taste, texture and availability in varieties to suit different sections of the population. It is also the cheapest, hygienically processed and packed sweet product available in the market. Biscuit and biscuit like products have been made and eaten by man for many hundreds of years. Biscuit is a chemically leavened bakery product which differs from bread where in it has low moisture content of 1-5%. The principle ingredients of biscuit manufacture are wheat flour, sugar and fat. Water is required at the dough mixing stage but should more probably be regarded as a processing aid rather than as a ingredient since the added water together with that present in flour and other ingredient such as syrup is largely removed during the baking process (Wade, P. Biscuit, cookies and crackers. The principle of the craft, vol.1, Elsevier applied Science, London). Biscuit is a snack item that is generally acceptable by all age groups. Apart from wheat and rice classified as fine cereals, several other grains referred to as coarse cereals and millets which are grown in the country. These include maize (corn), Jowar, Bajra and Ragi. Maize with a production of about 11.5 million tones is prominent among them. Maize, (Zea mays), is grown in many countries in the world and it is also known as corn in USA and Canada. Maize is basically used as feed grain in many developed countries. However in most developing countries substantial quantity is used for food purposes. Maize is rich in starch and bland to taste and hence lends itself as an ingredient in several traditional and bakery products. Although maize contains higher proportion of protein (10-12%), its quality is poorer as compared to that of rice protein due to lower proportion of essential amino acids such as lysine and threonine. Apart from maize, starch derived from maize is converted to syrups, sweeteners and industrial products. Corn flour is generally used in biscuits to dilute or mellow the gluten in bakery products. Reference may be made to the work of Moharram Y.G., Abou Elkier Y.I., and Osman H.O.A, (1989). Weaning foods based on sesame protein. Nahrung 33, 245, wherein seven weaning foods and 2 high protein biscuits were prepared from defatted sesame flour, dried skim milk, together with sucrose and either maize starch or rice flour, the biscuits also contained wheat flour and hydrogenated cotton seed oil. Biscuits made from a formulation that included 7% sesame flour, 2% dried skim milk and 5% maize starch were superior in texture and taste to those made with 4% sesame flour, 5% dried skim milk and 5% rice flour. The drawback is that apart from other cereal and legume flours only 5% corn starch was used in the formulation. Reference may be made to the work of Caramelli G. Patent No. WO 90/07880 A1 (1990), wherein the process for dietetic food in the form of biscuits, which are high in fibre, low in calories, contain wheat meal 40-60, sugar 10-16, refined vegetable oil 10-16, glucomannan 5-25, maize meal 5-10, honey 0.1-2.0 and other baking chemicals. The drawback is that the formulation contains only 5-10% maize meal and also it is a cooked product. Reference may be made to the work of Oliveira S.P., and Reyes F.G.R. (1990). Biscuits with a high content of corn fibre: preparation, chemical and technological characterization, and acceptability. Clienciae Tecnologiade Alimentos, 10, 273 wherein biscuits were prepared with equal quantities of wheat flour and the high-fibre corn material. The drawback is that a by product of corn grain into flakes was used to increase the fibre content in the biscuits. Reference may be made to the work of Ambrister W.L., and Setser C.S. (1994). Sesnsory and physical properties of chocolate chip cookies made with vegetable shortening or fat replacers at 50 and 75% levels. Cereal Chem. 71, 344, wherein sensory and physical properties of cookies made with vegetable shortening or protein-based, lipid based, and carbohydrate based fat substitutes at 50 and 75% levels were studied. Cookies with fat replaced by acid-treated corn starch had the most rounded contours. The control cookies were significantly more fracturable than all cookies with fat substitutes, except for that with 50% poly dextrose. The drawback is that the cookies contain wheat flour and also only 10-20% corn starch. Reference may be made to the work of Akpapunam M.A., and Darbe J.W. (1994). Chemical composition and functional properties of blends of maize and bambara groundnut flours for cookie production. Plant Foods for Human Nutrition, 48, 147, wherein cookies with acceptable sensory characteristics was prepared with combination level of 75% corn flour and 25% bambara groundnut meal. The drawback is that the cookies contain only 25-35% corn flour apart from containing ground nut meal. Reference may be made to the work of Schobar T.J., O'Brien CM., McCarthy, D., Damedde A., and Arendt E.K. (2003). Influence of gluten-free flour mixes and fat powders on the quality of gluten-free biscuits. European-Food-Research and Technology, 216, 369, wherein acceptable quality biscuits were prepared with brown rice flour (70), corn starch (10), potato starch (10) and soy flour (10). The drawback is that the biscuits contain only 4-6% corn starch. Reference may be made to the work of Chae Yong Suk, Choe Hyuk Jun and Park Kyong Jun. Patent No.KR9514655, (1995), wherein a process and formulation for 'composite for grain biscuit' is described. The drawback is that the formulation contains only 5-40% corn meal and also contains several other ingredients. Objects of the Invention The main object of the present invention is to provide a process for the preparation of corn flour biscuits which obviates the drawbacks as detailed above. Yet another object of the present invention is to provide a process for modifying dough characteristics suitable for biscuit making using dry gluten. Another object of the present invention is to provide a process for the preparation of corn flour biscuits containing up to 70% corn flour. Still another object of the present invention is to provide a process for the preparation of biscuits wherein the surface characteristics and texture of biscuits is improved due to addition of glycerol monostearate and sodium stearoyl lactylate in combination. Summary of Invention Accordingly, the present invention provides a process for the preparation of corn flour biscuits and like bakery products which comprises of the following ingredients: Ingredients Weight corn flour 92-98 kg dry gluten 8-12 kg sugar (sugar powder) 42-48 kg fat 23-27 kg skimmed milk powder 1.8-2.2 kg GMS 0.4-0.6 kg SSL 0.4-0.6 kg corn syrup 2.5-3.5 kg common salt 0.9-1.1 kg ammonium bicarbonate 0.6-1.0 kg sodium bicarbonate 0.4-0.6 kg acid calcium phosphate 0.4-0.6 kg Vitamins and minerals thiamine hydrochloride 4.0-5.0 g riboflavin 1.4-1.6 g nicotinic acid 18-22g vitamin A (As acetate or palmitate) 3- 8 g vitamin D 0.02-0.04 g butylated hydroxyl anisole 4-5 g flavors 180-240 g water 10-20 kg total dry matter 158-167 kg moisture in biscuits 3.9-4.50 kg (2.5 g/ 97.5 g dry matter) total weight 162.0-171.60 kg production loss (1.0%) 1.62-1.72 kg production loss due to aerating agents 0.8-1.2 kg yield of biscuit per 100 kg blend of 161.8-168.64 kg corn flour and dry gluten and the said process comprises the steps of: a) sieving of corn flour and dry gluten either manually or mechanically to pass through 60-80 mesh; b) blending of sieved corn flour, dry gluten with said vitamin and mineral premix for a time period of 8 to 12 minutes; c) creaming of sugar, fat, corn syrup and flavors separately, for a period of 10 to 15 minutes; d) mixing of aqueous solutions of skimmed milk powder, common salt, sodium bicarbonate, ammonium bicarbonate, calcium carbonate and acid calcium phosphate to the cream as obtained in step (c) for a period of 8 to16 minutes to get a homogeneous cream; e) adding of the blend as obtained from step [b] to the cream as obtained in step [d] to get a crumbly dough; f) mixing the dough for a period of 6 to 10 minutes; g) resting the dough for a time period of 20 to 30 minutes; h) shaping of dough obtained in step [g] so as to obtain a biscuit; i) baking of biscuit obtained in step [h] at a temperature of 180 to 220 degree C for a time period of 4 to 6 minutes; j) cooling of the baked biscuits obtained from step [h] at room temperature for a time period of 6 to12 minutes. In an embodiment of the present invention commercial corn flour may contain 0.15 - 0.55% total ash, 9.5 -12.5% protein, 1 - 3% ether extractable (fat). In yet another embodiment of present invention dry gluten may contain 74 - 84% protein content. In still another embodiment of present invention 90 -100 parts of corn flour may be blended with 6 -16 parts dry gluten. In another embodiment of the present invention emulsifiers may be selected from Glycerol monostearate (GMS), and Sodium stearoyl lactylate (SSL) to an extent of 0.2 - 0.6%. In a further embodiment of the present invention corn biscuits may have sensory score of 12.0 -16.0 for texture, 10.0 -15.0 for taste and 60.0 - 68.0 for overall quality. The different operations in the process of the present inventions are given below. Corn flour biscuits are prepared using creaming method. Fat, powdered sugar, com syrup, emulsifiers and essence are creamed to get a homogeneous cream. Baking chemicals, salt and skimmed milk powder dissolved in water are added to above cream and mixed to get a smooth homogeneous cream. Finally a blend of corn flour and dry gluten are added to above cream and mixed to get a crumbly dough. The dough is rested, shaped using rotary moulder and baked. The biscuits are cooled and packed. Sieving of corn flour, dry gluten and scaling Corn flour and dry gluten is sieved to remove impurities. Corn flour and dry gluten is weighed according to formulation. Blending Corn flour and dry gluten are blending in required proportions Weighing of ingredients Ingredients are weighed according to the formulation Creaming Fat, powdered sugar, corn syrup, emulsifiers and essence are to be creamed so as to thoroughly blend the components and aerate the mixture Mixing Skimmed milk powder, common salt, ammonium bicarbonate, sodium bicarbonate, calcium carbonate and acid calcium phosphate are dissolved in water separately added to the cream and mixed into a homogenous cream. Dough mixing Blend of wheat flour and soy protein concentrate is added to cream and mixed to form a homogeneous dough Resting The dough is rested for about 20-30 min Shaping of dough The dough is shaped in a rotary biscuit moulder using a circular die of about 50 mm biscuit diameter. Baking Biscuits are baked in continuous tunnel type oven at 180-220°C for a period of 4-6 min. Cooling Biscuits are cooled to room temperature. Packaging Biscuits are packed in metallised polyester/poly laminate. Novelty of the process 'The novelty of the process is that biscuits are prepared without using wheat flour. Different additives in various combinations are used to get the desired dough characteristics and good textural characteristics of biscuits. Novel inventive step Use of dry gluten and combination of glycerol monostearate and sodium stearoyl lactylate brought in desired dough characteristics. These additives also improved the textural characteristics and mouthfeel of biscuits. The following examples are given by way of illustration and should not be construed to limit the scope of present invention. Example 1 The ingredients used in the preparation of biscuits were as follows: Ingredients Quantity (g) Cornflour 100 Sugar (sugar powder) 45 Fat 25 Skimmed milk powder 2.0 Com syrup 3.0 Common salt 1.0 Ammonium bicarbonate 0.6 Sodium bicarbonate 0.4 Acid calcium phosphate 0.4 Biscuits were prepared using above formulation and processing conditions. Biscuits were evaluated for colour, surface characteristics, texture, taste and overall quality by a trained panel of six judges as per the proforma given in table 2. The water required to make the biscuit dough was 20%. Based on sensory evaluation it was observed that the biscuits were very hard and scored very low for texture and mouthfeel. Table 1. Quality characteristics of biscuits (Table Removed) Table. 2. Reference score card for sensory evaluation of biscuit • You receive set of coded samples • Score them for various characteristics given below • Maximum score is given in brackets you may also use quality description given for each parameter Quality charcteristics (Table Removed) Example 2 Preparation of Blend A Cornflour 100 parts Dry gluten powder 6 parts Corn flour and dry gluten powder were mixed in above proportion for 6-10 min to obtain blend A. Example 3 Preparation of Blend B Cornflour 100 parts Dry gluten powder 9 parts Corn flour and dry gluten powder were mixed in above proportion for 6-10 min to obtain blend B. Example 4 Preparation of Blend C Cornflour 100 parts Dry gluten powder 12 parts Corn flour and dry gluten powder were mixed in above proportion for 6-10 min to obtain blend C. Example 5 Determination of protein quantity and quality Protein content was determined by Micro Kjeldahl method. Corn flour contained 6.8% protein, while blend A contained 11.3% protein. The protein content of blend B and blend C further increased to 13.5 and 14.6% respectively. Protein quality was determined by SDS Sedimentation test. The SDS sedimentation value of corn flour was 15 ml, and for blend A it was 34 ml. SDS sedimentation values were 40 and 50 ml for blend B and blend C respectively. Example 6 Biscuits were prepared as in example 1 except for corn flour was replaced by either of the blends A, B and C. Biscuits were evaluated for colour, surface characteristics, texture, taste and overall quality. The water required to make the biscuit dough decreased to 18% on incorporation of 12 parts of dry gluten in the blend. Based on sensory evaluation it was observed that increase in dry glutein in the blend improved biscuit quality up to 9 parts per 100 parts of corn flour. Further increase in dry gluten content in the blend decreased taste and mouthfeel of the biscuits. Table 3. Quality characteristics of biscuits (Table Removed) Blend A -Corn flour 100 parts and 6 parts dry gluten, Blend B -Corn flour 100 parts and 9 parts dry gluten, Blend C -Corn flour 100 parts and 12 parts dry gluten. *Means followed by different letters differ significantly 12 Example 7 Biscuits were prepared as in example 1 except for corn flour was replaced by blend B and using glycerol monostearate at 0.25 and 0.50% level in the formulation. It was observed that surface characteristics, texture, taste and mouthfeel improved on incorporation of the emulsifier GMS. The improvement was higher when 0.25% of GMS was used in the formulation. Table 4. Quality characteristics of biscuits (Table Removed) Blend B -Corn flour 100 parts and 9 parts dry gluten GMS - Glycerol monostearate *Means followed by different letters differ significantly Example 8 Biscuits were prepared as in example 1 except for com flour was replaced by blend B and using sodium stearoyl lactylate at 0.25 and 0.50% level in the formulation. It was observed that surface characteristics, texture, taste and mouthfeel improved on incorporation of SSL. Table 5. Quality characteristics of biscuits (Table Removed) Blend B -Corn flour 100 parts and 9 parts dry gluten, SSL- Sodium stearoyl lactylate *Means followed by different letters differ significantly Example 9 Biscuits were prepared as in example 1 except for corn flour was replaced by blend B and using any one of the emulsifiers at 0.5% level in the formulation. The emulsifiers used are glycerol monostearate, and sodium stearoyl lactylate. Biscuits were also prepared using combination of 0.25% GMS and 0.25% SSL. It was observed that surface characteristics, texture, taste and mouthfeel improved on incorporation any of the emulsifier. Very good quality biscuits were obtained by using combination of GMS and SSL Table 6. Quality characteristics of biscuits (Table Removed) Blend B -Corn flour 100 parts and 9 parts dry gluten, GMS (0.5 %), SSL (0.5 %) Combination- GMS (0.25%) and SSL (0.25%), *Means followed by different letters differ significantly Example 10 Physical characteristics of biscuits were determined.according to Gaines C.S., and Tsen C.C. 1980. A baking method to evaluate flour quality for rotary moulded cookies. Cereal Chem. 57, 433. Maximum improvement in biscuit quality was observed on using combination of emulsifiers. Improvement in texture was observed with decrease in breaking force from 2460 to 1440 g. Table 7. Effect of emulsifiers on the physical characteristics of biscuits (Table Removed) Advantages of the process Biscuits are prepared essentially using wheat flour as major ingredient. The unique advantage of the process is that biscuits are prepared using corn flour. Dough handling properties of corn flour improved due to the addition of gluten. The surface characteristics and texture of biscuits improved with addition of glycerol monostearate and sodium stearoyl lactylate. Good quality biscuits are prepared using corn flour We claim: 1. A process for the preparation of corn biscuits and like bakery products which comprises of the following recipe ingredients: Ingredients Weight Cornflour 100 kg Dry gluten 6-12 kg Sugar (sugar powder) 42-48 kg Fat 23-27 kg Skimmed milk powder 1.8-2.2 kg Glycerol monostearte 0.25-0.6 kg Sodium stearoyl lactylate 0.25-0.6 kg Corn syrup 2.5-3.5 kg Common salt 0.9-1.1 kg Ammonium bicarbonate 0.6-1.0 kg Sodium bicarbonate 0.4-0.6 kg Acid calcium phosphate 0.4-0.6 kg Content of other ingredients like vitamins, minerals, butylated hydroxyl anisole, and flavors as herein described. The said process comprising steps of: a) sieving of corn flour and dry gluten manually or mechanically to pass through 60-80 mesh, b) blending of corn flour, dry gluten, and vitamin and mineral premix for a time period of 8-12 min to obtain blend, c) creaming of sugar, fat, corn syrup and flavors for a period of 10-15 min, d) mixing of aqueous solutions of skimmed milk powder, emulsifier, common salt, sodium bicarbonate, ammonium bicarbonate, calcium carbonate and acid calcium phosphate to the cream as obtained in step (c) effected for a period of 8-16 min to get a homogeneous cream, e) adding of blend as prepared in step b) to the cream as obtained in step d) and mixing of dough for a period of 6-10 min, f) resting of dough for a time period of 20-30 min, g) shaping of dough in a rotary moulder for a biscuit diameter of 45-55 mm, h) baking of biscuit carried out for a temperature of 180- 220°C for a time period of 4-6 min, i) cooling of biscuits at room temperature for a time period of 6-12 min, j) packing of biscuits using metallized poly ester/poly laminate pouches. 2. A process as claimed in claim 1, where in corn flour contains 0.15-0.55% total ash, 4.5-8.5% protein, 1-3% ether extractable (fat). 3. A process as claimed in claims 1 and 2, where in dry gluten contains 74-84% protein content. 4. A process as claimed in claims 1 to 3, wherein a combination of emulsifiers like glycerol monostearate and sodium steoryl lactylate are used at 0.2-0.4%.. 5. A process as claimed in claims 1 to 4 wherein corn biscuits will have a sensory score of 16.5-18.0/20.0 for texture, 14.5-16.5/20.0 for taste. 6. A process as claimed in claims 1 to 5, wherein corn biscuits have overall sensory score of 65.0-68.0/80.0. 7. A process for the preparation of corn biscuits and like bakery products as here is described with reference to examples accompanying the specifications.

Documents:

738-DEL-2005-Abstract-(03-05-2011).pdf

738-del-2005-abstract.pdf

738-DEL-2005-Claims-(03-05-2011).pdf

738-del-2005-claims.pdf

738-DEL-2005-Correspondence Others-(03-05-2011).pdf

738-del-2005-correspondence-others.pdf

738-DEL-2005-Description (Complete)-(03-05-2011).pdf

738-del-2005-description (complete).pdf

738-del-2005-description (provisional).pdf

738-del-2005-form-1.pdf

738-del-2005-form-18.pdf

738-del-2005-form-2.pdf

738-DEL-2005-Form-3-(03-05-2011).pdf

738-del-2005-form-3.pdf

738-del-2005-form-5.pdf