CA1282632C - Continuous production of shelf-stable multi-textured shredded cereal biscuits having a paste filling - Google Patents
Continuous production of shelf-stable multi-textured shredded cereal biscuits having a paste fillingInfo
- Publication number
- CA1282632C CA1282632C CA000500305A CA500305A CA1282632C CA 1282632 C CA1282632 C CA 1282632C CA 000500305 A CA000500305 A CA 000500305A CA 500305 A CA500305 A CA 500305A CA 1282632 C CA1282632 C CA 1282632C
- Authority
- CA
- Canada
- Prior art keywords
- filling
- net
- sheets
- biscuit
- shredded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
- A23L7/122—Coated, filled, multilayered or hollow ready-to-eat cereals
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C15/00—Apparatus for handling baked articles
- A21C15/02—Apparatus for shaping or moulding baked wafers; Making multi-layer wafer sheets
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D13/00—Finished or partly finished bakery products
- A21D13/10—Multi-layered products
- A21D13/16—Multi-layered pastry, e.g. puff pastry; Danish pastry or laminated dough
- A21D13/19—Multi-layered pastry, e.g. puff pastry; Danish pastry or laminated dough with fillings
Abstract
ABSTRACT OF THE DISCLOSURE
The present invention provides a process for the continuous production of microbially shelf-stable paste-filled shredded cereal biscuits having an extended shelf-stable plurality of textures. A first plurality of net-like sheets of cereal dough are continuously laminated, followed by continuous depositing of at least one extrudate rope filling upon the first plurality of net-like sheets. A second plurality of net-like sheets is continuously laminated upon the at least one extrudate rope to obtain a filled laminate. Each of the net-like sheets has a plurality of generally parallel longitudinal strands and a plurality of crosshatchings which are generally perpendicular to the longitudinal strands. The filled laminate is cut to enrobe the filling and the product is baked. The number of crosshatchings of the net-like sheets adjacent to the filling is greater than the number of crosshatchings of the net-like sheets which are further removed from the filling. The use of fewer crosshatchings provides a region of light texture which enhances the impression of a soft or chewy filling. The use of a greater number of crosshatchings in the net-like sheets which are adjacent to the filling: 1) prevents substantial penetration of the filling through the adjacent sheets during deposition of the extrudate rope and during baking, 2) enhances the chewiness of the filling, and 3) reduces lateral movement of the longitudinal strands so as to facilitate consistent deposition of the filling rope in an at least substantially straight line. The region of light texture is preferably limited to the interior layers of the biscuit.
The present invention provides a process for the continuous production of microbially shelf-stable paste-filled shredded cereal biscuits having an extended shelf-stable plurality of textures. A first plurality of net-like sheets of cereal dough are continuously laminated, followed by continuous depositing of at least one extrudate rope filling upon the first plurality of net-like sheets. A second plurality of net-like sheets is continuously laminated upon the at least one extrudate rope to obtain a filled laminate. Each of the net-like sheets has a plurality of generally parallel longitudinal strands and a plurality of crosshatchings which are generally perpendicular to the longitudinal strands. The filled laminate is cut to enrobe the filling and the product is baked. The number of crosshatchings of the net-like sheets adjacent to the filling is greater than the number of crosshatchings of the net-like sheets which are further removed from the filling. The use of fewer crosshatchings provides a region of light texture which enhances the impression of a soft or chewy filling. The use of a greater number of crosshatchings in the net-like sheets which are adjacent to the filling: 1) prevents substantial penetration of the filling through the adjacent sheets during deposition of the extrudate rope and during baking, 2) enhances the chewiness of the filling, and 3) reduces lateral movement of the longitudinal strands so as to facilitate consistent deposition of the filling rope in an at least substantially straight line. The region of light texture is preferably limited to the interior layers of the biscuit.
Description
t ~ 3~ ( CONTINUOUS PRODUCTION OF SHELF-STABLE MULTI-TEXTURED
SHREDDED CEREAL BISCUITS HAVING A PAST~ FILLING
FIELD OF THE INVENTION
Thls inventlon relates to the contlnuous productlon of paste-fllled shredded cereal blscults havlng a shelf stable plurallty Or textures. This lnventlon also relates to paste-filled ready-to-eat shredded cereal biscults having a plurallty of shelf-stable textures.
BACKGROUND OF THE INVENTION
Shredding systems used ln the productlon of shredded wheat are dlsclosed ln U.S. Patents 502,378;
SHREDDED CEREAL BISCUITS HAVING A PAST~ FILLING
FIELD OF THE INVENTION
Thls inventlon relates to the contlnuous productlon of paste-fllled shredded cereal blscults havlng a shelf stable plurallty Or textures. This lnventlon also relates to paste-filled ready-to-eat shredded cereal biscults having a plurallty of shelf-stable textures.
BACKGROUND OF THE INVENTION
Shredding systems used ln the productlon of shredded wheat are dlsclosed ln U.S. Patents 502,378;
2~008,024; 2,013,003; 2,693,419; 4,004,035; and Canadlan Paten~ 674,046. A conventlonal shredding mlll comprlses a palr Or closely spaced rolls or rollers that rotate ln opposlte dlrectlons, wlth at least one of the rolls havlng clrcumferential grooves. Upon passlng between , 2 ~ 3~
the rolls, the wheat ls deformed lnto long lndlvldual strings or shreds. The circumferentlally grooved roll can also be grooved transversely to the clrcumferentlal grooves for the productlon of net-llke sheets. A con-ventlonal 5 lnch dlameter roller for produclng net-llke sheets has 60 transverse erooves equally spaced about the clrcumference whlch produce crosshatchlngs ~n the netted product. When the rollers are held to roll in mutual contact, the shreds or fllaments wlll be falrly separate from each other, though more or less contacting, but when the rollers are sprung sllghtly apart, under pressure, the ad~acent filaments may be unlted to each other by very thln translucent, almost transparent, webs or fins between them.
i5 The shreddlng mllls are typlcally arranged ln a llnear series along a common conveyor, wlth the shreds runnlng longltudlnally or ln parallel wlth the dlrectlon of movement of the conveyor. The sheets or layers of fllaments are deposlted on the conveyor ln super-position, wlth thelr fllaments runnlng ln the same dlrectlon. A typlcal biscuit, for example, may contain up to 21 indlvldual layers of shreds. Upon obtaining the requlslte thickness, the multlple layer web can be cut transversely and longltudlnally into multlple llnes of blscults ln known manner.
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The productlon Or shredded cereal products havlng a frult paste fllling ls taught ln U.S. Patents 2,693,419 and ln U.S. Patent 4,004,035. Accordlng to U.S. Patent 2,693,419 the shred form ls superlor to other cereal forms, such as flakes, purfs, and the llke ln the lt does not become soft and soggy when contalnlng relatlvely hlgh percentages of molsture. Drled frult ls enclosed wlthln cereal shreds to provlde a product whereln the cereal and dried frult are essentlally lo lntegral. After the frult has been enclosed wlthln the cereal shreds, lt ls taught, the cereal may be processed at elevated temperatures wlthout any substantlal adverse affect on the texture and flavor Or the frult.
The shredded ~roduct ls prepared by deposltlng layers of molst, cooked shreds on top of each o~her ln the process of U.S. Patent 2,693,419. Usually about after half Or the shred layers have been lald down, the frult ls deposlted on the shreds and the remalnder of the shred layers ls lald down on top of the fruit. The ~ shreds, it ls taught, may be produced by means of a shredding machine comprised of a serles of shreddlng heads, each of whlch consist of a palr of rolls revolving towArd each other. The cereal elements are forced between the rolls and lnto the grooves contalned thereln to drop ln a contlnuous flow Or shreds onto a 1~8~63~
conveyor belt sltuated beneath the shreddlng ~achlne.
In a partlcular embodlment, ralslns are deposited over the surface of the shred bed ln a prearranged pattern after seven shred layers have been deposlted.
The pattern ls such that upon cuttlng the shreds to form blscults, the raislns wlll be marglnally spaced within the biscuits and otherwlse centered thereln. The shreds are cut into biscuits using blunt edged knives after an equal number of shred layers are deposlted on top of the lo raisins.
The raislns, lt is taught, may be replaced by fruits ln the form of a macerated paste. The paste is preferably incorporated wlthin the shreds in a mass or compact strip to mlnlmlze the surface that lt is exposed to the heat treatment of the biscults.
However, ln the productlon Or shredded filled products from layers of lndlvidual shreds, pastes whlch are deposlted between the two lnnermost layers tend to migrate towards the outer layers during baking thereby dlminlshlng a deslrable textural dlchotomy of a crlspy outslde and a chewy interlor. Loss of textural dichotomy and even exposure of the paste upon the surface is particularly acute in spoon slze or bite size biscuits, which typlcally have a maxlmum dlmenslon of about one inch.
~ 5 Furthermore, contlnuous mass productlon of shredded blscults typlcally lnvolve productlon rates Or up to about 150 to 200 feet of shreds per mlnute, or more.
The contlnuous deposltlng Or a strand or rope of paste onto a bed of shred layers tends to at least periodlcally separate the shreds of the layer upon whlch it ls deposlted. Thls causes penetratlon of the paste lnto other layers or the consequent loss of dual texture. In addltlon, lt causes the paste to be deposited in a non-linear pattern whlch adversely affects the cuttlng operatlon where the cuts are desirably made in the lntervals between the deposits Or fruit paste.
U.S. Patent 4,004,035 teaches the productlon of a shredded blscuit having a lapped zig-zag configuration in which the shreds are disposed on an angle relative to the sides and ends of the blscuits and the shreds Or indlvidual layers are disposed on opposlte or crossing angles. The biscuit, it ls taught, is more rugged than a conventlonal blscult whlch is produced uslng shreddlng mills whlch are arranged ln a linear series across a common conveyor, wlth the shreds runnlng longltudlnally or in parallel with the dlrection of movement of the conveyor.
In the process of U.S. Patent 4,004,035, the :: `
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' 3~
addltlon of a second lapplng devlce allows the lntroductlon of a flavorful fllllng between the laps, resulting ln a filled shredded blscult havlng a lapped zig-zag conflguratlon. Each lapplng devlce ls fed by one or more conventlonal shreddlng mllls comprislng a pair of closely spaced rolls whereln preferably one of the rolls has a smooth circumference and the other has a grooved circumference. Accordlng to U.S. Patent 4,004,035, use of the lapplng devlces reduces the number lo of conventlonal shredding mills needed to produce biscults having a given number of shred layers and provides greater flexlbility ln obtalnlng blscults of various slzes.
It has been found that ln the production of shredded fllled products havlng a total of about 10 layers uslng llnearly arranged shredding mllls havlng a 5 lnch dlameter roller wlth 20 clrcumferential grooves per inch and 60 crosshatchlng grooves, the net-like shred layers possess sufflclent strength so as to permlt contlnuous deposltlng Or a rope of paste ln a straight llne without substantlal penetratlon through the layer upon whlch it ls deposited. However, the baked product has a unlformly dense tex.ture upon bltlng through it.
The present inventlon provldes a contlnuous process 2s for the production of multitextured paste-filled ' ' . :
7 ~ 6~
shredded wheat blscuits uslng shreddlng mills whlch are arranged ln the conventional llnear fashlon whereln each shred layer ls produced from a separate palr of shreddlng rollers. The denslty of the blscuit portion of the product ls varled so as to produce a multitex-tured biscuit. The varlatlon enhances the textural dichotomy of a crlsp blscult and a soft and chewy center fllling. The multlple textures are shelf stable for extended perlods of time.
SUMMARY OF THE INVENTION
The present lnventlon provldes a process for the continuous productlon of a shelf-stable paste-fllled shredded cereal blscult having a plurallty of textures.
A first plurallty of shredded cereal dough layers are continuously laminated, followed by continuous deposltlng of at least one extrudate rope fllllng upon the flrst plurallty of shredded layers. A second plurallty of shredded cereal dough layers ls continuously lamlnated upon the at least one extrudate rope to obtaln a fllled lamlnate. Each Or the layers has a plurallty of generally parallel longitudlnal strands and a plurallty of crosshatchlngs whlch are 8 ~ ~d ~
generally perpendlcular to the longltudlnal strands.
The crosshatchlngs and the longltudlnal strands form an lntegral net-llke sheet. The long~tudlnal strands of each layer and the extrudate ropes are generally S parallel. The fllled lamlnate is cut to enrobe the filllng and the product ls baked.
The number of crosshatchlngs of the lntegral net-llke sheets ad~acen~ to the fllllng ls greater than the number Or crosshatchlngs of the net-llke sheets which are further removed from the filllng. The use of fewer crosshatchlngs provldes a reglon of llght texture whlch enhances the lmpresslon of a so~t or chewy fllllng. The use of a greater number of crosshatchlngs in the net-llke sheets whlch are ad~acent to ~he filllng: 1) prevents substantlal penetratlon of the fllllng through the ad~acent sheets durlng deposition of the extrudate rope and durlng baklng, ~2) enhances the chewiness of the fllllng, and 3) reduces lateral movement of the longltudlnal strands so as to facllitate conslstent deposltlon of the fllllng rope ln an at least substantially stralght llne.
The reglon of light texture is preferably limlted to the lnterlor layers of the blscuit to: 1) enhance the appearance of the biscult, 2) enhance an initial lmpression of crlspness, and 3) provide a more stable . .
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9 ~ 32 bed for the deposltlng Or addltlonal net-llke sheets.
A sugar ls preferably deposlted substantlally uniformly across the flrst plurallty of shredded cereal dough layers prlor to deposltlon of the at least one extrudate rope fllllng to inhlbit molsture mlgratlon from the baked filling to the net-llke sheets.
DETAI~ED DESCRIPTION OF THE INV~NTION
The ready-to-eat paste-fllled shredded cereal blscults Or the present lnventlon have a shelf-stable lo plurallty of textures. The paste fllllng ls enrobed in a plurality of shredded cereal layers whlch provide a reglon of dense texture and enhance the chewlness of the blscult. A plurallty of shredded cereal layers whlch provlde a reglon of llght texture enrobe the reglon of dense texture and enhance textural dlchotomy of a crlsp blscult wlth a soft and chewy filllng. A plurallty of shredded cereal layers whlch provlde a reglon of dense texture enrobes the layers whlch provlde a reglon of llght texture to enhance an inltlal lmpresslon of crlspness, to provlde a multlple texture wlthln the shredded layer portlon of the fllled biscuit, and to enhance the appearance of the blscuit. A sugar ls ' ' ,' ' ~' , ' ' ,' 1 o ~ 3 l preferably deposlted between the fllllng and the ad~acent layers which provide a reglon of dense texture so as to lnhiblt molsture mlgration from the fllllng to the shredded cereal layers.
As used hereln the term "enrobed" does not requlre a complete covering, although such ls preferred. The covering should be at least substantlally complete along each cut edge of the blscult and complete across the maJor dlmenslons of the biscult. Accordlngly, a fllling is considered to be enrobed by a plurallty of baked shredded dough layers ln blscults where fllling ls exposed along portlons of one or more cut edges.
~ach of the layers has a plurallty Or generally parallel longltudlnal strands and a plurallty of crosshatchings generally perpendicular to the longitudlnal strands. The crosshatchlngs and the longltudlnal strands form an integral net-like sheet.
The texture of each region ls controlled by the number of crosshatchlngs ln each layer forming the net-llke sheets. The net-like sheets are preferably unwebbed or webless, i.e. the crosshatchlngs and longltudlnal strands of each layer are not connected by a membrane.
The use of an open space wlthin the area formed by the longitudlnal strands and the crosshatchlngs in the outer 25 layers provldes a more attractlve product.
63~' Addltionally, use Or the open space ln the lnner layers avoids an excesslvely dense texture.
In preparing the shredded fllled blscults Or the present lnventlon, the cereal gralns are cooked and tempered ln known manner to obtain partlcles which are sultable for shredding on shreddlng rolls. Sultable molsture contents of the cereal gralns for shreddlng range from about 28% to about 49%, more typlcally from about 39% to about 43% by welght, based upon the weight of the cereal gralns. The cooked and tempered cereal gralns are transrerred, sultably by means Or belt conveyors to a hopper whlch feeds a screw conveyor. The latter transfers the cereal graln to a series Or shreddlng rolls or mllls vla flow tubes or hoppers.
The shreddlng mllls comprlse a palr of rolls that rotate in opposlte dlrectlons. One Or the rolls has clrcumferentlal grooves and crosshatchlng grooves whlch are transverse to the clrcumferentlal grooves for the production Or an lntegral net-llke sheet. The spaclng between the rolls ls preferably controlled so as to avold the productlon of webblng. Upon passlng between the roll, the cereal graln ls deformed lnto the clrcumferentlal grooves and the crosshatchlng grooves.
Each pair Or rolls produces a cereal dough layer havlng a plurallty of generally parallel longltudlnal strands '' ':; :
12 ~ d f;~
and a plurallty of crosshatchlngs generally perpendlcular to the strands. The longltudlnal strands are produced by the clrcumferential groo~es and run ln parallel wlth the dlrectlon of movement of an underlying conveyor. The crosshatchlngs of the dough layer are produced by the crosshatching grooves and run general'y perpendlcular to the dlrection of movement of the conveyor.
The shredding mil~s are arranged ln a linear serles along the common underlylng conveyor. ~ach of the shredded dough layers or sheets are deposlted on the conveyor ln super-posltlon, with ~helr longitudinal strands runnlng ln the same dlrec~ion.
A first plurality of shredded cereal dough layers are contlnuously lamlnated, then the sugar ls deposlted substantlally uniformly across the flrst plurallty Or shredded cereal dough layers. At least one extrudate rope fllling is then continuously deposited upon the first plurality of shredded dough layers. Each extrudate ls deposited generally parallel to, or in the same dlrectlon as, the longitudlnal strands. Addltlonal sugar may be deposlted at this polnt for contact with the upper surface of each extrudate rope filllng. A
second plurallty of shredded dough layers is then contlnuously lamlnated upon the one or more extrudate 3'~
rope flllings ln super-lmposed posltlon to the flrst plurallty of dough layers to obtain a fllled lamlnate.
The number of crosshatchlngs Or the net-llke sheets ad~acent to the extrudate rope fllllng or flllings should be sufflciently hlgh so as to prevent substantial penetratlon of the fllllng through the net-llke sheets durlng baklng and to provlde a reglon of dense texture surroundlng the fllllng whlch enhances the chewiness of the fllllng. The adJacent net-llke sheets providing the region of dense texture may be one or more sheets whlch are deposlted prlor to and subsequent to deposltion of the at least one extrudate rope fllllng. Preferably t~o or more of such ad~acent net-llke sheets are deposited prlor to depositlng of the extrudate rope so as to provlde a more stable bed upon which the extrudate rope ls deposlted thereby reduclng wavlness ln the deposlted rope fllling.
The first and last shredded cereal dough layers to be deposlted or lamlnated should also have a sufflclent number of crosshatchlngs so as to provlde a reglon of dense texture ln the blscult. The flrst layer whlch ls lald down upon the conveyor belt thereby provides a more stable bed for the deposlting of subsequent shred layers. Addltionally, the outside appearance of the product ls enhanced by the presence of crosshatchings as ls the lnltlal lmpresslon Or crlspness upon eatlng. The number of crosshatchlngs ln thè layers whlch provlde a dense texture ad~acent to the filllng and ln the outermost portlon of the Illllng may be the same or dlfferent. For a 5 lnch dlameter shreddlng roll, the number of crosshatchlngs are sultably about 45 or more, equally spaced about the roll. Flve lnch dlameter rolls ma~ typlcally have: 1) about 18 to 22 clrcumferentlal grooves per lnch, havlng a depth of about 0.018 to 0.024 lnches and a wldth of from about 0.025 to 0.033 inches, and 2) up to about 120 equally spaced crosshatchlng grooves having a wldth of up to about 0.040 lnches, and a depth of 0.002 to o.oo8 lnches less than the depth of the clrcumferentlal grooves. Larger or smaller dlameter rolls may also be used wlth about the same frequency and dlmenslons of grooves as the five lnch dlameter rolls.
The dough layers whlch are deposlted between the layers provldlng a dense texture should have a reduced number of crosshatchlngs so as to provlde a reglon of llght texture in the lnterlor of the blscult.
Typlcally, each of the net-llke sheets whlch provlde a reglon of llght texture have a number of crosshatchlngs whlch ls less than about 50% of the number of crosshatchings of the net-llke sheets whlch are ad~acent to the filling for provldlng the reglon of dense 15 ~ 6~
texture~ The number of crosshatchlngs ln each layer whlch provldes the reglon of llght texture may be the same or dlfferent.
To provlde a textural dlchotomy whlch ls readlly dlscernlble by the consumer, at least 30% of the total number of net-llke sheets should provlde one or more regions of llght texture. Generally, the total number of net-like sheets may range from about slx to about 21, wlth the larger number of sheets being reserved for the larger slzed biscults. For spoon-sized blscuits a suitable number of net-llke sheets ranges rrom about 6 to about twelve.
The number of shredded cereal dough layers or net-llke sheets for provldlng a dense texture in the first plurallty of dough layers may be the same or dlfferent from the number provldlng a dense texture ln the second plurallty of dough layers. Llkewlse, the number of layers for provlding a region of light texture may be the same or dlfferent in the flrst ~lurallty than in the second plurallty of dough layers. It is generally preferable to provide the same total number of shredded dough layers ln the flrst plurality as ln the second plurallty so as to provide a pleasing symmetrical appearance.
Deposlting of the sugar substantially unlformly ', ;, '' 1 6 ~ 6~3~
across the first plurallty of shredded dough layers may be accompllshed by any sultable means placed between the polnt of appllcatlon of the at least one extrudate rope fllling and the palr of shreddlng rolls which produces the shredded dough layer upon whlch the extrudate rope or ropes are deposlted.
The sugar should be a humectant sugar for lnhibltlng molsture mlgration from the baked filllng to the net-llke sheets Or the biscuit. Exemplary of humectant sugars are fructose, aqueous solutlons thereof~ llquld brown sugar, corn syrup, and granulated brown sugar. Granulated humectan~ sugars are preferred because of the dlfflculties involved ln spraylng a sugar solutlon wlthln a conflned area at relatlvely low mass flow rates. The preferred granulated sugar is granulated brown sugar.
The granulated sugar ls suitably applied by means of a gravimetric topping device comprislng a hopper whlch feeds a rotatlng drum for disbursing the materlal ~ upon the dough layer below lt. The sugar ls suitably deposlted at a rate which provldes from about 4% to about 10% by welght of sugar, based upon the total weight of the fllled blscuit.
The fllllng is deposlted by means of an apparatus ~5 placed between adJacent palrs of shredding rolls. The 3'~
filling is suitably applied by extrusion through a nozzle so as to form an extrudate rope which i8 contlnuously deposited upon the flr~t plurallty of dough layers. The apparatus should have a means for controlling and directing the flow of the filling so as to provlde a straight and uni~orm extrudate upon a substrate whlch moves at substantlally the same linear rate aq the extrudate.
The number of extrudate ropes which are deposlted generally ranges rrom about one to five or more, depending upon the width of the shredding roll and the deslred biscuit size. A conventional 5 inch diameter shredding roll typically has a width of between about 5 to about 6 lnches. Typically, about 5 spoon slze or bite size biscults may be produced within thls width thereby calling for the depositlon of five extrudate ropes.
Each Or the extrudate ropes may be supplled by separate apparatus. However, it is preferable to utilize a single appa~atus for depositlng multiple rows of paste such as disclosed in commonly assigned, Canadia~ P~tent No. 1,247!,45~ , in the names of Ralph Do Lee and Nicholas R. Pollfroni fo~ PASTE
SPREADER APPARATUS POR SHREDDED WHEAT.
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18 ~ 3 Paste is supplied by means of a pump to a paste conduit portion whlch is connected to a paste outlet portion. The outlet portlon lncludes a plurality of outlet orlflces whlch each comprlse a nozzle member. The mass flow and dlrectlon of flow of the paste from each nozzle ls indlvidually controllable.
The mass flow rate of the extrudate rope fllling ~rom each nozzle should be sufflclent to provlde typically at least about 15% by weight filllng ln the biscult, based upon the weight of the flnal product.
The fllled laminate i8 cut transversely and longltudlnally to the dlrectlon of flow of the product lnto multiple lines of filled biscult preforms uslng known cuttlng devices. The filled laminate i~ sultably flrst cut transversely and then longitudinally with respect to the longltudinal ~trands of each shredded dough layer. In producing rectangularly shaped biscuits, it is preferable ~o cut the blscult so that lts longest dlmension ls transverse to the longitudinal strands and the extrudate rope. This provldes greater tolerance for cutting between the extrudate rope flllings without cuttlng through the extrudate rope.
The longltudinal cuts are suitably made about mldpoint 19 ~ 3~
between adJacent extrudates.
The cutting can be completely through the lamlnate to form the indlvldual blscult shapes prior to baking.
However, cutting partially through the filled laminate to form biscult shapes, followed by baking and separating the baked partially cut lamlnate into indlvidual biscuits in known manner is preferred. This procedure provldes easier control of the orlentatlon of a cut product as it passes through the oven.
The cuttlng edges of the transverse and longitudinal cutters should preferably be blunt so as to form an at least substantially integral seam along each edge of the biscuit preform. The cutting should be such so as to at least substantlally prevent the appearance of the filling ln the baked, flnal product.
The fillings used in the filled shredded biscuits Or the present invent~on may be a fruit paste filling, a meat filling, a cheese fllling, or the llke which is not adversely affected by the baking of the biscuit portion.
Meat filllngs and cheese filllngs are intended for products to be eaten as a snack whereas fruit paste fillings are lntended for ready-to-eat breakfast cereals or as snacks. Exemplary of frult paste filllngs whlch may be used are raisin paste fillings, strawberry, apple, aprlcot, banana, fig, peach, pear, prune, and ,:. ' , .
.; : ,' , mixtures thereof. They may lnclude seasonlngs such as clnnamon or the like. The fllllngs may contaln artirlclal and/or natural flavorlngs.
The fllllng should be formulated to provlde a mlcroblally shelf stable product havlng a water actlvltv Or less than about 0.7. Filllngs havlng a hlgher water activlty may be used wlth a sultable preservatlve, such as sodlum ben~oa~e. Pastes havlng a water activlty of less than about 0.6 prlor to baklng are preferred so as to assure the attalnment of a mlcroblally safe baked product and to lnhlblt molsture mlgration to the baked dough layers.
The ~llling should provlde an impresslon of molstness and be soft and chewy ln the baked product under proper packaglng and storage condltlons. Fruit paste fllllngs comprlslng dehydrated frult and glycerln or other edlble humectant polyols and/or sugars may be used. Glycerln levels ranging from about 5% to about 25%, preferably rrom about 8% to about 12% by welght, ~ based upon the total welght of the filllng have been found to provlde a deslrable molst, soft or chewy texture ln the baked product wlthout adversely affecting taste. Suitable frult paste flllings typically have a water content of at least about 12% by weight of the extrudate rope fllling, as determined by Karl-Flscher 21 ~ j32 analysLs.
The cereal gralns whlch are used ln preparlng the shredded cereal dough layers may be wheat, oats, rlce, corn, barley, rye, combinatlons thereof, and the like.
The cut, fllled lamlnate ls drled, baked and toasted ln conventlonal equipment. Sultable ovens for drying, baklng and toastlng the cut fllled lamlnate lnclude Proctor & Schwartz, Werner-Lehara, Wolverlne and spooner ovens contalnlng forced alr and gas flred burners and a conveyor.
Temperature proflles used ln the oven for drylng, baking and toastlng of the blscult preforms are generally withln the range of about 200F to about 6000F. The total tlme ~or drying, baklng and toasting lS should be such so as to avold brownlng. It depends upon the number of shred layers, the slze Or the shredded product, the fllllng, and the type of oven. The total time for drying, baking and toasting typically ranges from about 5 mlnutes to about lO minutes.
The flnal product sultably has an average moisture content of about 6% to about 12%, more preferably from about 7% to about 8% by welght, based upon the welght of the flnal product, as determlned by a Karl-Fischer molsture analysls. The water actlvlty Or the final product should be less than about 0.7, preferably less :, ' ' .
22 ~ 8~ 3'~
than about 0.6 when properly packaged. Wlth proper packaglng, the filllng and the shredded cereal portlons of the product reach equilibrlum with respect to water actlvltles wlthin about two weeks.
The color of the final baked product should be a substantially unlform ofr-white to llght golden tan color. The baked product can be topped wlth salt or other flavoring or spray oll by top and/or bottom spraylng in conventlonal manner.
The cereal portion Or the filled biscult may contaln one or more addltives at the usual levels of concentratlon. Exemplary thereof ls a sugar such as sucrose, salt, malt, flavorlng, food colorant, emulsifler such as Myvatex (a blend of dlstllled lS monoglycerldes manufactured by Eastman Xodak), vltamlns and/or mlnerals.
The present lnvention ls further lllustrated ln the followlng examples. All percentages, parts, and proportions are by welght and all temperatures are ln F
unless otherwise indicated:
Cooked, tempered wheat berrles, fortlfied wlth vitamlns and minerals and havlng a molsture content of :, ', . ,, . . : :
23 1'~ 8~ Z
about 43% by weight are shredded ln elght shreddlng mllls arranged in a llnear series along a common conveyor. Each shreddlng mlll comprlses a palr of counterrotating 5 lnch diameter rolls held ln mutual contact for the production of net-like sheets. One of the rolls of each palr contains clrcumferentlal grooves and crosshatching grooves whlch are transvere to the circumferentlal grooves. The number of clrcumferentlal grooves are about 20 per lnch, equally spaced along an about 5 1/4 inch portion of the width of the roller.
Each groove is about 1/40 of an inch wlde. The crosshatching grooves are about 1/30 of an inch wide and are equally spaced about the clrcumference of the roller. The depths of the circumferential grooves and crosshatchlng grooves are 0.020 inches and 0.018 inches, respectively. On one set of rollers the number of equally spaced crosshatchings is 20 whereas on the other set the number of crosshatchlngs ls 60. The linear arrangement of the shreddlng rollers or rolls is:
D D L D S F D L L D
where D represents a palr of rollers wlth a 60 crosshatching roller, L represents a palr of rollers wlth a 20 crosshatching roller, S indicates sugar ....... .
, .
. .
' ~, ' .
24 ~ 2 deposltion, and F represents flller deposltlon. The order of lamlnation, or deposlting is from le~t to right.
The sugar whlch ls deposlted is granulated brown sugar. It ls dlspersed substantlally unlformly across the top of the approxlmately 5 1/4 lnch wlde fourth shredded dough layer by means of a gravlmetric feeder having a rvtatlng perforated drum whlch spans the width of the dough layer. The granulated brown sugar is supplied to the drum by means of a hopper. The speed of rotation of the drum ls adJusted to deposit the sugar at a mass flow rate which provldes a sugar content ln the baked biscuit of about 5% by welght, based upon the welght of the fllled blscuit.
The flller paste ls ground and then pumped, by means of a posltlve displacement pump to a paste spreader whlch dlvides the paste lnto flve extrudate ropes, of about 1/4 lnch diameter. The ropes flow from nozzles at substantially the same mass flow rate onto the underlylng lamlnated shredded dough layers ln a substantially stralght llne. The lamlnate is movlng at a rate of about 150 feet per mlnute. The mass flow rate and dlrection of flow ls adjustable for each extrudate rope. The flows arè ad~usted to provide a fllllng content in the filled biscuit of about 22% by welght, 2 5 ~ B~3'~
based upon the total weight of the fllled blscult. The five extrudate ropes are deposlted upon the underlying superlmposed lamlnates ln a dlrectlon generally parallel to the strands formed by the clrcumferential groovesO
The deposlted extrudate ropes are spaced about one lnch apart.
The fllllng ls prepared by a process comprlslng admlxlng macerated ralsins wlth glycerln to obtaln a smooth paste having a glycerln content of about 10~ by weight and a water activity of about 0.55.
The fllled lamlnate comprising the eight shredded dough layers, the sugar, and the five extrudate ropes ls first cut transversely to the ropes at about 3/4 inch intervals and then longitudlnally at about 15/16 inch intervals. Blunt-edged cutters are used to seam the layers together to form rectangularly shaped blscult preforms of about 15/16 of an inch by about 3/4 of an inch. The cutting is such so as to approximately center each extrudate rope between a 15/16 lnch interval. The filled biscuit preforms are dried, baked, and toasted ln a gas-flred zone oven for about 7 mlnutes at temperatures ranging from inlet to outlet withln the range of about 200~F to about 6000F, and separated into lndividual filled blscults to obtaln a produc~ havlng a water actlvity of about 0.4 and an average molsture 26 ~ 32 content of about 7.2g by welghtj based upon the total welght of the blscult, as determlned by Karl-Fischer moisture analyses.
The filled shredded blscults are properly packed and permltted to equlllbrate for about two weeks. The blscults exhlblt a pleasant appearance. ~pon bltln8 through the blscults, they provlde a crlsp lnltlal texture, followed by a llght texture whlch gradually turns to a soft and chewy texture.
lo EXAMPLE 2 Fllled shredded blscults are produced as ln Example 1 except the llnear arrangement Or the shreddlng rolls 1 s :
D D L L D S F D L L D D
where D, L, S, and F are deflned as above.
Fllled shredded blscults are produced as ln Example 1 except an apple paste filling is used lnstead Or the raisln paste fllling and lts flow is ad~usted to provide .
' , . . ~ ' ~ , ' ' ' 27 ~ j3'~
a filllng content ln the fllled blscult of about 28% by weight, based upon the total weight of the fllled blscult. The apple paste fllling comprlses hlgh fructose corn syrup, sugar, glycerin, apples, modlfied food starch, apple julce, natural flavor, mallc acld, sodlum alginate, pectin, splces, and sodium benzoate.
The water activlty of the fllllng ls about 0.73 and its water conten~ ls about 23% by welght as determlned by Karl-Flscher moisture analysls. The filled biscult preforms are drled, baked and toasted to obtaln a product havlng a water actlvlty of about o.6 and molsture content of about 10% by welght, based upon the total weight of the biscult, as determlned by Karl-Flsher molsture analyses.
lS The fllled shredded biscuits are properly packaged and permitted to equilibrate for about two weeks. The blscults exhiblt a pleasant appearance. Upon bltlng through the blscuits, they provlde a crlsp inltial texture, followed by a llght texture whlch gradually turns to a soft and chewy texture.
Fllled shredded blscuits are produced as ln Example 1 except a strawberry paste fllling ls used instead of '~, ` , , ~ 3'~
rllllng. The strawbe y comprises glycerln, strawberrles, hlgh fructose corn odified food starCh, natural flavor, pectin, mallc acld, sodlum alginate, and sodlum benzoate. The water actlvlty of the fllllng ls about 0.66 and its water content ls about 22% by wel8ht 9 by Karl-Fischer moistur filled b~scult preforms are dried, ba~ed and toasted to obtain a product having a water actlvity of about -55 mOlsture content of a th total welght of determlned by Karl-Fischer molsture anal~sesO
The filled shredded blscuit5 are properly packed and permitted to equ~llbrate for about two weeks- The lS ibit a pleasant aPPearan biscults, theY provide texture, followed by a llght texture whlch graduallY
to a soft and cheWY tex .
.
the rolls, the wheat ls deformed lnto long lndlvldual strings or shreds. The circumferentlally grooved roll can also be grooved transversely to the clrcumferentlal grooves for the productlon of net-llke sheets. A con-ventlonal 5 lnch dlameter roller for produclng net-llke sheets has 60 transverse erooves equally spaced about the clrcumference whlch produce crosshatchlngs ~n the netted product. When the rollers are held to roll in mutual contact, the shreds or fllaments wlll be falrly separate from each other, though more or less contacting, but when the rollers are sprung sllghtly apart, under pressure, the ad~acent filaments may be unlted to each other by very thln translucent, almost transparent, webs or fins between them.
i5 The shreddlng mllls are typlcally arranged ln a llnear series along a common conveyor, wlth the shreds runnlng longltudlnally or ln parallel wlth the dlrectlon of movement of the conveyor. The sheets or layers of fllaments are deposlted on the conveyor ln super-position, wlth thelr fllaments runnlng ln the same dlrectlon. A typlcal biscuit, for example, may contain up to 21 indlvldual layers of shreds. Upon obtaining the requlslte thickness, the multlple layer web can be cut transversely and longltudlnally into multlple llnes of blscults ln known manner.
, . ' ' : ' ' ' : . . . .
The productlon Or shredded cereal products havlng a frult paste fllling ls taught ln U.S. Patents 2,693,419 and ln U.S. Patent 4,004,035. Accordlng to U.S. Patent 2,693,419 the shred form ls superlor to other cereal forms, such as flakes, purfs, and the llke ln the lt does not become soft and soggy when contalnlng relatlvely hlgh percentages of molsture. Drled frult ls enclosed wlthln cereal shreds to provlde a product whereln the cereal and dried frult are essentlally lo lntegral. After the frult has been enclosed wlthln the cereal shreds, lt ls taught, the cereal may be processed at elevated temperatures wlthout any substantlal adverse affect on the texture and flavor Or the frult.
The shredded ~roduct ls prepared by deposltlng layers of molst, cooked shreds on top of each o~her ln the process of U.S. Patent 2,693,419. Usually about after half Or the shred layers have been lald down, the frult ls deposlted on the shreds and the remalnder of the shred layers ls lald down on top of the fruit. The ~ shreds, it ls taught, may be produced by means of a shredding machine comprised of a serles of shreddlng heads, each of whlch consist of a palr of rolls revolving towArd each other. The cereal elements are forced between the rolls and lnto the grooves contalned thereln to drop ln a contlnuous flow Or shreds onto a 1~8~63~
conveyor belt sltuated beneath the shreddlng ~achlne.
In a partlcular embodlment, ralslns are deposited over the surface of the shred bed ln a prearranged pattern after seven shred layers have been deposlted.
The pattern ls such that upon cuttlng the shreds to form blscults, the raislns wlll be marglnally spaced within the biscuits and otherwlse centered thereln. The shreds are cut into biscuits using blunt edged knives after an equal number of shred layers are deposlted on top of the lo raisins.
The raislns, lt is taught, may be replaced by fruits ln the form of a macerated paste. The paste is preferably incorporated wlthin the shreds in a mass or compact strip to mlnlmlze the surface that lt is exposed to the heat treatment of the biscults.
However, ln the productlon Or shredded filled products from layers of lndlvidual shreds, pastes whlch are deposlted between the two lnnermost layers tend to migrate towards the outer layers during baking thereby dlminlshlng a deslrable textural dlchotomy of a crlspy outslde and a chewy interlor. Loss of textural dichotomy and even exposure of the paste upon the surface is particularly acute in spoon slze or bite size biscuits, which typlcally have a maxlmum dlmenslon of about one inch.
~ 5 Furthermore, contlnuous mass productlon of shredded blscults typlcally lnvolve productlon rates Or up to about 150 to 200 feet of shreds per mlnute, or more.
The contlnuous deposltlng Or a strand or rope of paste onto a bed of shred layers tends to at least periodlcally separate the shreds of the layer upon whlch it ls deposlted. Thls causes penetratlon of the paste lnto other layers or the consequent loss of dual texture. In addltlon, lt causes the paste to be deposited in a non-linear pattern whlch adversely affects the cuttlng operatlon where the cuts are desirably made in the lntervals between the deposits Or fruit paste.
U.S. Patent 4,004,035 teaches the productlon of a shredded blscuit having a lapped zig-zag configuration in which the shreds are disposed on an angle relative to the sides and ends of the blscuits and the shreds Or indlvidual layers are disposed on opposlte or crossing angles. The biscuit, it ls taught, is more rugged than a conventlonal blscult whlch is produced uslng shreddlng mills whlch are arranged ln a linear series across a common conveyor, wlth the shreds runnlng longltudlnally or in parallel with the dlrection of movement of the conveyor.
In the process of U.S. Patent 4,004,035, the :: `
.
:, ' , '`
' 3~
addltlon of a second lapplng devlce allows the lntroductlon of a flavorful fllllng between the laps, resulting ln a filled shredded blscult havlng a lapped zig-zag conflguratlon. Each lapplng devlce ls fed by one or more conventlonal shreddlng mllls comprislng a pair of closely spaced rolls whereln preferably one of the rolls has a smooth circumference and the other has a grooved circumference. Accordlng to U.S. Patent 4,004,035, use of the lapplng devlces reduces the number lo of conventlonal shredding mills needed to produce biscults having a given number of shred layers and provides greater flexlbility ln obtalnlng blscults of various slzes.
It has been found that ln the production of shredded fllled products havlng a total of about 10 layers uslng llnearly arranged shredding mllls havlng a 5 lnch dlameter roller wlth 20 clrcumferential grooves per inch and 60 crosshatchlng grooves, the net-like shred layers possess sufflclent strength so as to permlt contlnuous deposltlng Or a rope of paste ln a straight llne without substantlal penetratlon through the layer upon whlch it ls deposited. However, the baked product has a unlformly dense tex.ture upon bltlng through it.
The present inventlon provldes a contlnuous process 2s for the production of multitextured paste-filled ' ' . :
7 ~ 6~
shredded wheat blscuits uslng shreddlng mills whlch are arranged ln the conventional llnear fashlon whereln each shred layer ls produced from a separate palr of shreddlng rollers. The denslty of the blscuit portion of the product ls varled so as to produce a multitex-tured biscuit. The varlatlon enhances the textural dichotomy of a crlsp blscult and a soft and chewy center fllling. The multlple textures are shelf stable for extended perlods of time.
SUMMARY OF THE INVENTION
The present lnventlon provldes a process for the continuous productlon of a shelf-stable paste-fllled shredded cereal blscult having a plurallty of textures.
A first plurallty of shredded cereal dough layers are continuously laminated, followed by continuous deposltlng of at least one extrudate rope fllllng upon the flrst plurallty of shredded layers. A second plurallty of shredded cereal dough layers ls continuously lamlnated upon the at least one extrudate rope to obtaln a fllled lamlnate. Each Or the layers has a plurallty of generally parallel longitudlnal strands and a plurallty of crosshatchlngs whlch are 8 ~ ~d ~
generally perpendlcular to the longltudlnal strands.
The crosshatchlngs and the longltudlnal strands form an lntegral net-llke sheet. The long~tudlnal strands of each layer and the extrudate ropes are generally S parallel. The fllled lamlnate is cut to enrobe the filllng and the product ls baked.
The number of crosshatchlngs of the lntegral net-llke sheets ad~acen~ to the fllllng ls greater than the number Or crosshatchlngs of the net-llke sheets which are further removed from the filllng. The use of fewer crosshatchlngs provldes a reglon of llght texture whlch enhances the lmpresslon of a so~t or chewy fllllng. The use of a greater number of crosshatchlngs in the net-llke sheets whlch are ad~acent to ~he filllng: 1) prevents substantlal penetratlon of the fllllng through the ad~acent sheets durlng deposition of the extrudate rope and durlng baklng, ~2) enhances the chewiness of the fllllng, and 3) reduces lateral movement of the longltudlnal strands so as to facllitate conslstent deposltlon of the fllllng rope ln an at least substantially stralght llne.
The reglon of light texture is preferably limlted to the lnterlor layers of the blscuit to: 1) enhance the appearance of the biscult, 2) enhance an initial lmpression of crlspness, and 3) provide a more stable . .
~ - ' ' . ' .
," .' ' ~ ' .
9 ~ 32 bed for the deposltlng Or addltlonal net-llke sheets.
A sugar ls preferably deposlted substantlally uniformly across the flrst plurallty of shredded cereal dough layers prlor to deposltlon of the at least one extrudate rope fllllng to inhlbit molsture mlgratlon from the baked filling to the net-llke sheets.
DETAI~ED DESCRIPTION OF THE INV~NTION
The ready-to-eat paste-fllled shredded cereal blscults Or the present lnventlon have a shelf-stable lo plurallty of textures. The paste fllllng ls enrobed in a plurality of shredded cereal layers whlch provide a reglon of dense texture and enhance the chewlness of the blscult. A plurallty of shredded cereal layers whlch provlde a reglon of llght texture enrobe the reglon of dense texture and enhance textural dlchotomy of a crlsp blscult wlth a soft and chewy filllng. A plurallty of shredded cereal layers whlch provlde a reglon of dense texture enrobes the layers whlch provlde a reglon of llght texture to enhance an inltlal lmpresslon of crlspness, to provlde a multlple texture wlthln the shredded layer portlon of the fllled biscuit, and to enhance the appearance of the blscuit. A sugar ls ' ' ,' ' ~' , ' ' ,' 1 o ~ 3 l preferably deposlted between the fllllng and the ad~acent layers which provide a reglon of dense texture so as to lnhiblt molsture mlgration from the fllllng to the shredded cereal layers.
As used hereln the term "enrobed" does not requlre a complete covering, although such ls preferred. The covering should be at least substantlally complete along each cut edge of the blscult and complete across the maJor dlmenslons of the biscult. Accordlngly, a fllling is considered to be enrobed by a plurallty of baked shredded dough layers ln blscults where fllling ls exposed along portlons of one or more cut edges.
~ach of the layers has a plurallty Or generally parallel longltudlnal strands and a plurallty of crosshatchings generally perpendicular to the longitudlnal strands. The crosshatchlngs and the longltudlnal strands form an integral net-like sheet.
The texture of each region ls controlled by the number of crosshatchlngs ln each layer forming the net-llke sheets. The net-like sheets are preferably unwebbed or webless, i.e. the crosshatchlngs and longltudlnal strands of each layer are not connected by a membrane.
The use of an open space wlthin the area formed by the longitudlnal strands and the crosshatchlngs in the outer 25 layers provldes a more attractlve product.
63~' Addltionally, use Or the open space ln the lnner layers avoids an excesslvely dense texture.
In preparing the shredded fllled blscults Or the present lnventlon, the cereal gralns are cooked and tempered ln known manner to obtain partlcles which are sultable for shredding on shreddlng rolls. Sultable molsture contents of the cereal gralns for shreddlng range from about 28% to about 49%, more typlcally from about 39% to about 43% by welght, based upon the weight of the cereal gralns. The cooked and tempered cereal gralns are transrerred, sultably by means Or belt conveyors to a hopper whlch feeds a screw conveyor. The latter transfers the cereal graln to a series Or shreddlng rolls or mllls vla flow tubes or hoppers.
The shreddlng mllls comprlse a palr of rolls that rotate in opposlte dlrectlons. One Or the rolls has clrcumferentlal grooves and crosshatchlng grooves whlch are transverse to the clrcumferentlal grooves for the production Or an lntegral net-llke sheet. The spaclng between the rolls ls preferably controlled so as to avold the productlon of webblng. Upon passlng between the roll, the cereal graln ls deformed lnto the clrcumferentlal grooves and the crosshatchlng grooves.
Each pair Or rolls produces a cereal dough layer havlng a plurallty of generally parallel longltudlnal strands '' ':; :
12 ~ d f;~
and a plurallty of crosshatchlngs generally perpendlcular to the strands. The longltudlnal strands are produced by the clrcumferential groo~es and run ln parallel wlth the dlrectlon of movement of an underlying conveyor. The crosshatchlngs of the dough layer are produced by the crosshatching grooves and run general'y perpendlcular to the dlrection of movement of the conveyor.
The shredding mil~s are arranged ln a linear serles along the common underlylng conveyor. ~ach of the shredded dough layers or sheets are deposlted on the conveyor ln super-posltlon, with ~helr longitudinal strands runnlng ln the same dlrec~ion.
A first plurality of shredded cereal dough layers are contlnuously lamlnated, then the sugar ls deposlted substantlally uniformly across the flrst plurallty Or shredded cereal dough layers. At least one extrudate rope fllling is then continuously deposited upon the first plurality of shredded dough layers. Each extrudate ls deposited generally parallel to, or in the same dlrectlon as, the longitudlnal strands. Addltlonal sugar may be deposlted at this polnt for contact with the upper surface of each extrudate rope filllng. A
second plurallty of shredded dough layers is then contlnuously lamlnated upon the one or more extrudate 3'~
rope flllings ln super-lmposed posltlon to the flrst plurallty of dough layers to obtain a fllled lamlnate.
The number of crosshatchlngs Or the net-llke sheets ad~acent to the extrudate rope fllllng or flllings should be sufflciently hlgh so as to prevent substantial penetratlon of the fllllng through the net-llke sheets durlng baklng and to provlde a reglon of dense texture surroundlng the fllllng whlch enhances the chewiness of the fllllng. The adJacent net-llke sheets providing the region of dense texture may be one or more sheets whlch are deposlted prlor to and subsequent to deposltion of the at least one extrudate rope fllllng. Preferably t~o or more of such ad~acent net-llke sheets are deposited prlor to depositlng of the extrudate rope so as to provlde a more stable bed upon which the extrudate rope ls deposlted thereby reduclng wavlness ln the deposlted rope fllling.
The first and last shredded cereal dough layers to be deposlted or lamlnated should also have a sufflclent number of crosshatchlngs so as to provlde a reglon of dense texture ln the blscult. The flrst layer whlch ls lald down upon the conveyor belt thereby provides a more stable bed for the deposlting of subsequent shred layers. Addltionally, the outside appearance of the product ls enhanced by the presence of crosshatchings as ls the lnltlal lmpresslon Or crlspness upon eatlng. The number of crosshatchlngs ln thè layers whlch provlde a dense texture ad~acent to the filllng and ln the outermost portlon of the Illllng may be the same or dlfferent. For a 5 lnch dlameter shreddlng roll, the number of crosshatchlngs are sultably about 45 or more, equally spaced about the roll. Flve lnch dlameter rolls ma~ typlcally have: 1) about 18 to 22 clrcumferentlal grooves per lnch, havlng a depth of about 0.018 to 0.024 lnches and a wldth of from about 0.025 to 0.033 inches, and 2) up to about 120 equally spaced crosshatchlng grooves having a wldth of up to about 0.040 lnches, and a depth of 0.002 to o.oo8 lnches less than the depth of the clrcumferentlal grooves. Larger or smaller dlameter rolls may also be used wlth about the same frequency and dlmenslons of grooves as the five lnch dlameter rolls.
The dough layers whlch are deposlted between the layers provldlng a dense texture should have a reduced number of crosshatchlngs so as to provlde a reglon of llght texture in the lnterlor of the blscult.
Typlcally, each of the net-llke sheets whlch provlde a reglon of llght texture have a number of crosshatchlngs whlch ls less than about 50% of the number of crosshatchings of the net-llke sheets whlch are ad~acent to the filling for provldlng the reglon of dense 15 ~ 6~
texture~ The number of crosshatchlngs ln each layer whlch provldes the reglon of llght texture may be the same or dlfferent.
To provlde a textural dlchotomy whlch ls readlly dlscernlble by the consumer, at least 30% of the total number of net-llke sheets should provlde one or more regions of llght texture. Generally, the total number of net-like sheets may range from about slx to about 21, wlth the larger number of sheets being reserved for the larger slzed biscults. For spoon-sized blscuits a suitable number of net-llke sheets ranges rrom about 6 to about twelve.
The number of shredded cereal dough layers or net-llke sheets for provldlng a dense texture in the first plurallty of dough layers may be the same or dlfferent from the number provldlng a dense texture ln the second plurallty of dough layers. Llkewlse, the number of layers for provlding a region of light texture may be the same or dlfferent in the flrst ~lurallty than in the second plurallty of dough layers. It is generally preferable to provide the same total number of shredded dough layers ln the flrst plurality as ln the second plurallty so as to provide a pleasing symmetrical appearance.
Deposlting of the sugar substantially unlformly ', ;, '' 1 6 ~ 6~3~
across the first plurallty of shredded dough layers may be accompllshed by any sultable means placed between the polnt of appllcatlon of the at least one extrudate rope fllling and the palr of shreddlng rolls which produces the shredded dough layer upon whlch the extrudate rope or ropes are deposlted.
The sugar should be a humectant sugar for lnhibltlng molsture mlgration from the baked filllng to the net-llke sheets Or the biscuit. Exemplary of humectant sugars are fructose, aqueous solutlons thereof~ llquld brown sugar, corn syrup, and granulated brown sugar. Granulated humectan~ sugars are preferred because of the dlfflculties involved ln spraylng a sugar solutlon wlthln a conflned area at relatlvely low mass flow rates. The preferred granulated sugar is granulated brown sugar.
The granulated sugar ls suitably applied by means of a gravimetric topping device comprislng a hopper whlch feeds a rotatlng drum for disbursing the materlal ~ upon the dough layer below lt. The sugar ls suitably deposlted at a rate which provldes from about 4% to about 10% by welght of sugar, based upon the total weight of the fllled blscuit.
The fllllng is deposlted by means of an apparatus ~5 placed between adJacent palrs of shredding rolls. The 3'~
filling is suitably applied by extrusion through a nozzle so as to form an extrudate rope which i8 contlnuously deposited upon the flr~t plurallty of dough layers. The apparatus should have a means for controlling and directing the flow of the filling so as to provlde a straight and uni~orm extrudate upon a substrate whlch moves at substantlally the same linear rate aq the extrudate.
The number of extrudate ropes which are deposlted generally ranges rrom about one to five or more, depending upon the width of the shredding roll and the deslred biscuit size. A conventional 5 inch diameter shredding roll typically has a width of between about 5 to about 6 lnches. Typically, about 5 spoon slze or bite size biscults may be produced within thls width thereby calling for the depositlon of five extrudate ropes.
Each Or the extrudate ropes may be supplled by separate apparatus. However, it is preferable to utilize a single appa~atus for depositlng multiple rows of paste such as disclosed in commonly assigned, Canadia~ P~tent No. 1,247!,45~ , in the names of Ralph Do Lee and Nicholas R. Pollfroni fo~ PASTE
SPREADER APPARATUS POR SHREDDED WHEAT.
.
,' , ' :, . .' :
18 ~ 3 Paste is supplied by means of a pump to a paste conduit portion whlch is connected to a paste outlet portion. The outlet portlon lncludes a plurality of outlet orlflces whlch each comprlse a nozzle member. The mass flow and dlrectlon of flow of the paste from each nozzle ls indlvidually controllable.
The mass flow rate of the extrudate rope fllling ~rom each nozzle should be sufflclent to provlde typically at least about 15% by weight filllng ln the biscult, based upon the weight of the flnal product.
The fllled laminate i8 cut transversely and longltudlnally to the dlrectlon of flow of the product lnto multiple lines of filled biscult preforms uslng known cuttlng devices. The filled laminate i~ sultably flrst cut transversely and then longitudinally with respect to the longltudinal ~trands of each shredded dough layer. In producing rectangularly shaped biscuits, it is preferable ~o cut the blscult so that lts longest dlmension ls transverse to the longitudinal strands and the extrudate rope. This provldes greater tolerance for cutting between the extrudate rope flllings without cuttlng through the extrudate rope.
The longltudinal cuts are suitably made about mldpoint 19 ~ 3~
between adJacent extrudates.
The cutting can be completely through the lamlnate to form the indlvldual blscult shapes prior to baking.
However, cutting partially through the filled laminate to form biscult shapes, followed by baking and separating the baked partially cut lamlnate into indlvidual biscuits in known manner is preferred. This procedure provldes easier control of the orlentatlon of a cut product as it passes through the oven.
The cuttlng edges of the transverse and longitudinal cutters should preferably be blunt so as to form an at least substantially integral seam along each edge of the biscuit preform. The cutting should be such so as to at least substantlally prevent the appearance of the filling ln the baked, flnal product.
The fillings used in the filled shredded biscuits Or the present invent~on may be a fruit paste filling, a meat filling, a cheese fllling, or the llke which is not adversely affected by the baking of the biscuit portion.
Meat filllngs and cheese filllngs are intended for products to be eaten as a snack whereas fruit paste fillings are lntended for ready-to-eat breakfast cereals or as snacks. Exemplary of frult paste filllngs whlch may be used are raisin paste fillings, strawberry, apple, aprlcot, banana, fig, peach, pear, prune, and ,:. ' , .
.; : ,' , mixtures thereof. They may lnclude seasonlngs such as clnnamon or the like. The fllllngs may contaln artirlclal and/or natural flavorlngs.
The fllllng should be formulated to provlde a mlcroblally shelf stable product havlng a water actlvltv Or less than about 0.7. Filllngs havlng a hlgher water activlty may be used wlth a sultable preservatlve, such as sodlum ben~oa~e. Pastes havlng a water activlty of less than about 0.6 prlor to baklng are preferred so as to assure the attalnment of a mlcroblally safe baked product and to lnhlblt molsture mlgration to the baked dough layers.
The ~llling should provlde an impresslon of molstness and be soft and chewy ln the baked product under proper packaglng and storage condltlons. Fruit paste fllllngs comprlslng dehydrated frult and glycerln or other edlble humectant polyols and/or sugars may be used. Glycerln levels ranging from about 5% to about 25%, preferably rrom about 8% to about 12% by welght, ~ based upon the total welght of the filllng have been found to provlde a deslrable molst, soft or chewy texture ln the baked product wlthout adversely affecting taste. Suitable frult paste flllings typically have a water content of at least about 12% by weight of the extrudate rope fllling, as determined by Karl-Flscher 21 ~ j32 analysLs.
The cereal gralns whlch are used ln preparlng the shredded cereal dough layers may be wheat, oats, rlce, corn, barley, rye, combinatlons thereof, and the like.
The cut, fllled lamlnate ls drled, baked and toasted ln conventlonal equipment. Sultable ovens for drying, baklng and toastlng the cut fllled lamlnate lnclude Proctor & Schwartz, Werner-Lehara, Wolverlne and spooner ovens contalnlng forced alr and gas flred burners and a conveyor.
Temperature proflles used ln the oven for drylng, baking and toastlng of the blscult preforms are generally withln the range of about 200F to about 6000F. The total tlme ~or drying, baklng and toasting lS should be such so as to avold brownlng. It depends upon the number of shred layers, the slze Or the shredded product, the fllllng, and the type of oven. The total time for drying, baking and toasting typically ranges from about 5 mlnutes to about lO minutes.
The flnal product sultably has an average moisture content of about 6% to about 12%, more preferably from about 7% to about 8% by welght, based upon the welght of the flnal product, as determlned by a Karl-Fischer molsture analysls. The water actlvlty Or the final product should be less than about 0.7, preferably less :, ' ' .
22 ~ 8~ 3'~
than about 0.6 when properly packaged. Wlth proper packaglng, the filllng and the shredded cereal portlons of the product reach equilibrlum with respect to water actlvltles wlthin about two weeks.
The color of the final baked product should be a substantially unlform ofr-white to llght golden tan color. The baked product can be topped wlth salt or other flavoring or spray oll by top and/or bottom spraylng in conventlonal manner.
The cereal portion Or the filled biscult may contaln one or more addltives at the usual levels of concentratlon. Exemplary thereof ls a sugar such as sucrose, salt, malt, flavorlng, food colorant, emulsifler such as Myvatex (a blend of dlstllled lS monoglycerldes manufactured by Eastman Xodak), vltamlns and/or mlnerals.
The present lnvention ls further lllustrated ln the followlng examples. All percentages, parts, and proportions are by welght and all temperatures are ln F
unless otherwise indicated:
Cooked, tempered wheat berrles, fortlfied wlth vitamlns and minerals and havlng a molsture content of :, ', . ,, . . : :
23 1'~ 8~ Z
about 43% by weight are shredded ln elght shreddlng mllls arranged in a llnear series along a common conveyor. Each shreddlng mlll comprlses a palr of counterrotating 5 lnch diameter rolls held ln mutual contact for the production of net-like sheets. One of the rolls of each palr contains clrcumferentlal grooves and crosshatching grooves whlch are transvere to the circumferentlal grooves. The number of clrcumferentlal grooves are about 20 per lnch, equally spaced along an about 5 1/4 inch portion of the width of the roller.
Each groove is about 1/40 of an inch wlde. The crosshatching grooves are about 1/30 of an inch wide and are equally spaced about the clrcumference of the roller. The depths of the circumferential grooves and crosshatchlng grooves are 0.020 inches and 0.018 inches, respectively. On one set of rollers the number of equally spaced crosshatchings is 20 whereas on the other set the number of crosshatchlngs ls 60. The linear arrangement of the shreddlng rollers or rolls is:
D D L D S F D L L D
where D represents a palr of rollers wlth a 60 crosshatching roller, L represents a palr of rollers wlth a 20 crosshatching roller, S indicates sugar ....... .
, .
. .
' ~, ' .
24 ~ 2 deposltion, and F represents flller deposltlon. The order of lamlnation, or deposlting is from le~t to right.
The sugar whlch ls deposlted is granulated brown sugar. It ls dlspersed substantlally unlformly across the top of the approxlmately 5 1/4 lnch wlde fourth shredded dough layer by means of a gravlmetric feeder having a rvtatlng perforated drum whlch spans the width of the dough layer. The granulated brown sugar is supplied to the drum by means of a hopper. The speed of rotation of the drum ls adJusted to deposit the sugar at a mass flow rate which provldes a sugar content ln the baked biscuit of about 5% by welght, based upon the welght of the fllled blscuit.
The flller paste ls ground and then pumped, by means of a posltlve displacement pump to a paste spreader whlch dlvides the paste lnto flve extrudate ropes, of about 1/4 lnch diameter. The ropes flow from nozzles at substantially the same mass flow rate onto the underlylng lamlnated shredded dough layers ln a substantially stralght llne. The lamlnate is movlng at a rate of about 150 feet per mlnute. The mass flow rate and dlrection of flow ls adjustable for each extrudate rope. The flows arè ad~usted to provide a fllllng content in the filled biscuit of about 22% by welght, 2 5 ~ B~3'~
based upon the total weight of the fllled blscult. The five extrudate ropes are deposlted upon the underlying superlmposed lamlnates ln a dlrectlon generally parallel to the strands formed by the clrcumferential groovesO
The deposlted extrudate ropes are spaced about one lnch apart.
The fllllng ls prepared by a process comprlslng admlxlng macerated ralsins wlth glycerln to obtaln a smooth paste having a glycerln content of about 10~ by weight and a water activity of about 0.55.
The fllled lamlnate comprising the eight shredded dough layers, the sugar, and the five extrudate ropes ls first cut transversely to the ropes at about 3/4 inch intervals and then longitudlnally at about 15/16 inch intervals. Blunt-edged cutters are used to seam the layers together to form rectangularly shaped blscult preforms of about 15/16 of an inch by about 3/4 of an inch. The cutting is such so as to approximately center each extrudate rope between a 15/16 lnch interval. The filled biscuit preforms are dried, baked, and toasted ln a gas-flred zone oven for about 7 mlnutes at temperatures ranging from inlet to outlet withln the range of about 200~F to about 6000F, and separated into lndividual filled blscults to obtaln a produc~ havlng a water actlvity of about 0.4 and an average molsture 26 ~ 32 content of about 7.2g by welghtj based upon the total welght of the blscult, as determlned by Karl-Fischer moisture analyses.
The filled shredded blscults are properly packed and permltted to equlllbrate for about two weeks. The blscults exhlblt a pleasant appearance. ~pon bltln8 through the blscults, they provlde a crlsp lnltlal texture, followed by a llght texture whlch gradually turns to a soft and chewy texture.
lo EXAMPLE 2 Fllled shredded blscults are produced as ln Example 1 except the llnear arrangement Or the shreddlng rolls 1 s :
D D L L D S F D L L D D
where D, L, S, and F are deflned as above.
Fllled shredded blscults are produced as ln Example 1 except an apple paste filling is used lnstead Or the raisln paste fllling and lts flow is ad~usted to provide .
' , . . ~ ' ~ , ' ' ' 27 ~ j3'~
a filllng content ln the fllled blscult of about 28% by weight, based upon the total weight of the fllled blscult. The apple paste fllling comprlses hlgh fructose corn syrup, sugar, glycerin, apples, modlfied food starch, apple julce, natural flavor, mallc acld, sodlum alginate, pectin, splces, and sodium benzoate.
The water activlty of the fllllng ls about 0.73 and its water conten~ ls about 23% by welght as determlned by Karl-Flscher moisture analysls. The filled biscult preforms are drled, baked and toasted to obtaln a product havlng a water actlvlty of about o.6 and molsture content of about 10% by welght, based upon the total weight of the biscult, as determlned by Karl-Flsher molsture analyses.
lS The fllled shredded biscuits are properly packaged and permitted to equilibrate for about two weeks. The blscults exhiblt a pleasant appearance. Upon bltlng through the blscuits, they provlde a crlsp inltial texture, followed by a llght texture whlch gradually turns to a soft and chewy texture.
Fllled shredded blscuits are produced as ln Example 1 except a strawberry paste fllling ls used instead of '~, ` , , ~ 3'~
rllllng. The strawbe y comprises glycerln, strawberrles, hlgh fructose corn odified food starCh, natural flavor, pectin, mallc acld, sodlum alginate, and sodlum benzoate. The water actlvlty of the fllllng ls about 0.66 and its water content ls about 22% by wel8ht 9 by Karl-Fischer moistur filled b~scult preforms are dried, ba~ed and toasted to obtain a product having a water actlvity of about -55 mOlsture content of a th total welght of determlned by Karl-Fischer molsture anal~sesO
The filled shredded blscuit5 are properly packed and permitted to equ~llbrate for about two weeks- The lS ibit a pleasant aPPearan biscults, theY provide texture, followed by a llght texture whlch graduallY
to a soft and cheWY tex .
.
Claims (43)
1. A process for the continuous production of a shelf-stable paste-fllled ready-to-eat shredded cereal biscuit comprising:
(a) continuously laminating a first plurality of shredded cereal dough layers, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, (b) continuously depositing at least one extrudate rope filling upon said first plurality of shredded layers, each extrudate rope being deposited generally parallel to said longitudinal strands, (c) continuously laminating a second plurality of shredded cereal dough layers upon said at least one extrudate rope to obtain a filled laminate the number of crosshatchings of the integral net-like sheets adjacent to the at least one extrudate rope filling being greater than the number of crosshatchings of the next net-like sheets further removed from the filling, the crosshatchings of the net-like sheets preventing subtantial penetration of the filling through said adjacent net-like sheets, said further removed net-like sheets providing a region of light texture and said adjacent net-like sheets providing region of dense texture in the filled biscuit, (d) cutting the filled laminate, and (e) baking the cut filled laminate.
(a) continuously laminating a first plurality of shredded cereal dough layers, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, (b) continuously depositing at least one extrudate rope filling upon said first plurality of shredded layers, each extrudate rope being deposited generally parallel to said longitudinal strands, (c) continuously laminating a second plurality of shredded cereal dough layers upon said at least one extrudate rope to obtain a filled laminate the number of crosshatchings of the integral net-like sheets adjacent to the at least one extrudate rope filling being greater than the number of crosshatchings of the next net-like sheets further removed from the filling, the crosshatchings of the net-like sheets preventing subtantial penetration of the filling through said adjacent net-like sheets, said further removed net-like sheets providing a region of light texture and said adjacent net-like sheets providing region of dense texture in the filled biscuit, (d) cutting the filled laminate, and (e) baking the cut filled laminate.
2. A process as claimed in claim 1 wherein, a sugar is deposited substantially uniformly across said first plurality of shredded cereal dough layers prior to deposition of said at least one extrudate rope filling to inhibit moisture migration from the baked filling to the baked net-like sheets.
3. A process as claimed in claim 2 wherein, said sugar comprises granulated brown sugar.
4. A process as claimed in claim 2 wherein, the crosshatchings of the adjacent net-like sheets prevent substantial passage of said sugar through said adjacent net-like sheets.
5. A process as claimed in claim 1 wherein, the number of crosshatchings in each of said further removed net-like sheets is less than about 50 percent of the number of crosshatchings of each of said adjacent net-like sheets.
6. A process as claimed in claim 5 wherein, at least 30 percent of the total number of net-like sheets are said further removed net-like sheets.
7. A process as claimed in claim 6 wherein, the region of light texture contributed by said further removed net-like sheets is limited to the interior of the biscuit.
8. A process as claimed in claim 7 wherein, the total number of net-like sheets is from about 6 to about 21.
9. A process as claimed in claim 1 wherein, said cutting of the filled laminate is first generally transverse to said longitudinal strands and then generally parallel to said longitudinal strands, the parallel cuts being made between adjacent extrudate filling ropes.
10. A process as claimed in claim 1 wherein, the filling is a fruit paste filling, a meat filling, or a cheese filling.
11. A process as claimed in claim 2 wherein, the filling is a fruit paste filling comprising dehydrated fruit, and glycerin, and said filling has a water content of at least about 12 percent by weight of the extrudate rope.
12. A process as claimed in claim 11 wherein, the water activity of the biscuit is less than about 0.6.
13. A process as claimed in claim 11 wherein, the amount of filling in the biscuit is at least about 15 percent by weight, based upon the weight of the final product.
14. A process as claimed in claim 13 wherein, said sugar is deposited in an amount to provide from about 4 percent to about 10 percent by weight of the sugar, based upon the total weight of the filled biscuit.
15. A process as claimed in claim 13 wherein, the dehydrated fruit is ground raisins.
16. A paste-fllled shredded cereal biscuit obtained by the process of claim 1.
17. A paste-fllled shredded cereal biscuit obtained by the process of claim 2.
18. A paste-fllled shredded cereal biscuit obtained by the process of claim 11.
19. A paste-fllled shredded cereal biscuit obtained by the process of claim 15.
20. A ready-to-eat paste-filled shredded cereal biscuit having a shelf stable plurality of textures comprising:
(a) a filling (b) a plurality of shredded cereal layers providing a region of dense texture enrobing said filling, (c) a plurality of shredded cereal layers providing a region of light texture enrobing said region of dense texture, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, the number of crosshatchings of the integral net like sheets which provide the region of dense texture being greater than the number of crosshatchings of the net-like sheets which provide the region of light texture, substantial penetration of the filling through the net-like sheets being prevented by the crosshatchings of the net-like sheets of the region of dense texture.
(a) a filling (b) a plurality of shredded cereal layers providing a region of dense texture enrobing said filling, (c) a plurality of shredded cereal layers providing a region of light texture enrobing said region of dense texture, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, the number of crosshatchings of the integral net like sheets which provide the region of dense texture being greater than the number of crosshatchings of the net-like sheets which provide the region of light texture, substantial penetration of the filling through the net-like sheets being prevented by the crosshatchings of the net-like sheets of the region of dense texture.
21. A cereal biscuit as claimed in claim 20 wherein a sugar is deposited between said filling and said layers providing the region of dense texture to inhibit moisture migration from the filling to the layers.
22. A cereal biscuit as claimed in claim 21 wherein a plurality of shredded cereal layers providing a region of dense texture enrobes said layers providing the region of light texture.
23. A cereal biscuit as claimed in claim 21 wherein the water activity of the filled biscuit is less than about 0.6, and the average moisture content of the filled biscuit is from about 6% by weight to about 12%
by weight.
by weight.
24. A cereal biscuit as claimed in claim 22 wherein the amount of filling is at least about 15% by weight based upon the total weight of the filled shredded biscuit.
25. A cereal biscuit as claimed in claim 24 wherein the amount of said deposited sugar is from about 4% by weight to about 10% by weight, based upon the total weight of the filled shredded biscuit.
26. A cereal biscuit as claimed in claim 25 wherein said deposited sugar is granulated brown sugar.
27. A cereal biscuit as claimed in claim 25 wherein the filling is a dehydrated fruit paste filling.
28. A cereal biscuit as claimed in claim 27 wherein the filling is a raisin paste filling comprising ground raisins and glycerin.
29. A cereal biscuit as claimed in claim 27 wherein the filling is an apple filling.
30. A cereal biscuit as claimed in claim 27 wherein the filling is a strawberry filling.
31. A cereal biscuit as claimed in claim 24 wherein the number of crosshatchings in each of the layers forming the region of light texture is less than about 50% of the number of crosshatchings of each of said layers forming the region of dense texture, and at least 30 percent of the total number of layers provide a light texture.
32. A cereal biscuit as claimed in claim 20 wherein the filling is a meat filling or cheese filling.
33. A ready-to-eat paste-filled shredded cereal biscuit having a shelf stable plurality of textures comprising:
(a) a fruit-paste filling comprising dehydrated fruit and glycerin, (b) a plurality of shredded cereal layers providing a region of dense texture enrobing said filling, (c) a layer of a sugar deposited between at least a portion of said filling and said layers providing the region of dense texture to inhibit moisture migration from said filling to said layers, (d) a plurality of shredded cereal layers providing a region of light texture enrobing said region of dense texture, and (e) a plurality of shredded cereal layers providing a second region of dense texture enrobing said layers providing the region of light texture.
(a) a fruit-paste filling comprising dehydrated fruit and glycerin, (b) a plurality of shredded cereal layers providing a region of dense texture enrobing said filling, (c) a layer of a sugar deposited between at least a portion of said filling and said layers providing the region of dense texture to inhibit moisture migration from said filling to said layers, (d) a plurality of shredded cereal layers providing a region of light texture enrobing said region of dense texture, and (e) a plurality of shredded cereal layers providing a second region of dense texture enrobing said layers providing the region of light texture.
34. A shelf-stable paste-filled ready-to-eat shredded cereal biscuit produced by a continuous process comprising the steps of:
(a) continuously laminating a first plurality of shredded cereal dough layers, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, (b) continuously depositing at least one extrudate rope filling upon said first plurality of shredded layers, each extrudate rope being deposited generally parallel to said longitudinal strands, (c) continuously laminating a second plurality of shredded cereal dough layers upon said at least one extrudate rope to obtain a filled laminate, the number of crosshatchings of the integral net-like sheets adjacent to the at least one extrudate rope filling being greater than the number of crosshatchings on the next net-like sheet further removed from the filling, the crosshatchings of the net-like sheets preventing substantial penetration of the filling through said adjacent net-like sheets, said further removed net-like sheets providing a region of light texture and said adjacent net-like sheets providing regions of dense texture in the filled biscuit, (d) cutting the filled laminate, and (e) baking the cut filled laminate.
(a) continuously laminating a first plurality of shredded cereal dough layers, each of the layers having a plurality of generally parallel longitudinal strands and a plurality of crosshatchings generally perpendicular to said strands, said crosshatchings and said longitudinal strands forming an integral net-like sheet, (b) continuously depositing at least one extrudate rope filling upon said first plurality of shredded layers, each extrudate rope being deposited generally parallel to said longitudinal strands, (c) continuously laminating a second plurality of shredded cereal dough layers upon said at least one extrudate rope to obtain a filled laminate, the number of crosshatchings of the integral net-like sheets adjacent to the at least one extrudate rope filling being greater than the number of crosshatchings on the next net-like sheet further removed from the filling, the crosshatchings of the net-like sheets preventing substantial penetration of the filling through said adjacent net-like sheets, said further removed net-like sheets providing a region of light texture and said adjacent net-like sheets providing regions of dense texture in the filled biscuit, (d) cutting the filled laminate, and (e) baking the cut filled laminate.
35. A shredded cereal biscuit in accordance with claim 34 wherein a sugar is continuously deposited substantially uniformly across said first plurality of shredded cereal dough layers prior to deposition of said at least one extrudate rope filling to inhibit moisture migration from the baked filling to the baked net-like sheets.
36. A shredded cereal biscuit in accordance with claim 34 wherein a sugar is continuously deposited substantially uniformly across said at least one extrudate rope filling prior to the lamination of said second plurality of shredded cereal dough layers to inhibit moisture migration from the baked filling to the baked net-like sheets.
37. A shredded cereal biscuit in accordance with claim 35 wherein the crosshatachings of the adjacent net-like sheets prevent substantial passage of said sugar through said adjacent net-like sheets.
38. A shredded cereal biscuit in accordance with claim 34 wherein the cutting of the filled laminate is first generally transverse to said longitudinal strands and then generally parallel to said longitudinal strands, the parallel cuts being made between adjacent extrudate filling ropes.
39. A shredded cereal biscuit in accordance with claim 34 wherein said filling is a fruit paste filling, a meat filling or a cheese filling.
40. A shredded cereal biscuit in accordance with claim 33 wherein said filling is a fruit paste filling comprising dehydrated fruit and glycerin, said filling having a water content of at least about twelve percent by weight of said extrudate rope, and wherein the water activity of said biscuit is less than about 0.6.
41. A shredded cereal biscuit in accordance with claim 40 wherein the amount of filling in said biscuit is at least about fifteen percent by weight based upon the weight of the final product.
42. A shredded cereal biscuit in accordance with claim 40 wherein said dehydrated fruit comprises ground raisins.
43. A shredded cereal biscuit in accordance with claim 35 wherein said sugar is deposited in an amount to provide from about four percent to about ten percent by weight of sugar, based upon the total weight of the filled biscuit.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US695,059 | 1985-01-25 | ||
| US06/695,059 US4696825A (en) | 1985-01-25 | 1985-01-25 | Continuous production of shelf-stable multi-textured shredded cereal biscuits having a paste filling |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1282632C true CA1282632C (en) | 1991-04-09 |
Family
ID=24791384
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000500305A Expired - Lifetime CA1282632C (en) | 1985-01-25 | 1986-01-24 | Continuous production of shelf-stable multi-textured shredded cereal biscuits having a paste filling |
Country Status (8)
| Country | Link |
|---|---|
| US (2) | US4696825A (en) |
| EP (1) | EP0189348B1 (en) |
| AT (1) | ATE78133T1 (en) |
| AU (1) | AU578997B2 (en) |
| CA (1) | CA1282632C (en) |
| DE (1) | DE3685964T2 (en) |
| ES (1) | ES8706393A1 (en) |
| NZ (1) | NZ214892A (en) |
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|---|---|---|---|---|
| PT108813A (en) * | 2015-09-11 | 2017-03-13 | António De Pinho Ribeiro José | INDUSTRIAL PROCESSING OF VEGETABLE IGUARIAS. |
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| US4940593A (en) * | 1989-04-24 | 1990-07-10 | General Mills, Inc. | Multicolored R-T-E cereal and method of preparation |
| US4948619A (en) * | 1989-04-25 | 1990-08-14 | Nabisco Brands, Inc. | Natural antioxidant system for cereals |
| GB9002949D0 (en) * | 1990-02-09 | 1990-04-04 | Nautech Ltd | Autopilot system |
| US5492710A (en) * | 1994-02-22 | 1996-02-20 | Nabisco, Inc. | Fat free or low fat cookie production |
| IT1269817B (en) * | 1994-05-23 | 1997-04-15 | Barilla Flli G & R | OVEN PRODUCT WITH HIGH YOGURT CONTENT |
| US5595774A (en) * | 1994-12-14 | 1997-01-21 | Nabisco, Inc. | Reduced fat shredded wafers and process |
| CA2226766A1 (en) * | 1997-02-10 | 1998-08-10 | Kraft Foods, Inc. | Filled cereal product |
| DE19741717C1 (en) * | 1997-09-22 | 1999-02-25 | Bahlsen Kg | Process to manufacture long-life baked sandwich products e.g. biscuits and wafers |
| US6004612A (en) * | 1997-12-19 | 1999-12-21 | Nabisco Technology Company | Production of shredded snacks with chip-like appearance and texture |
| US6932517B2 (en) | 2000-10-27 | 2005-08-23 | Ethicon Endo-Surgery, Inc. | Connector incorporating a contact pad surface on a plane parallel to a longitudinal axis |
| US6746707B2 (en) * | 2002-01-08 | 2004-06-08 | General Mills, Inc. | Laminated multi-layered cereal products and methods of preparation |
| US20040108332A1 (en) * | 2002-12-02 | 2004-06-10 | Brient Scott E. | Condiment dispenser having a condiment tap |
| DK1695632T3 (en) * | 2005-02-25 | 2014-02-17 | Barilla Flli G & R | Apparatus and method for making baked goods, especially biscuits, with edible particulate materials |
| US7939122B2 (en) * | 2005-04-29 | 2011-05-10 | Kraft Foods Global Brands Llc | Production of whole grain shredded products |
| US7964233B2 (en) * | 2005-04-29 | 2011-06-21 | Kraft Foods Global Brands Llc. | Production of whole grain shredded products |
| US8367142B2 (en) * | 2005-04-29 | 2013-02-05 | Kraft Foods Global Brands Llc | Production of shredded or flaked whole grain-containing composite food products |
| US20080038427A1 (en) * | 2006-08-09 | 2008-02-14 | The Quaker Oats Company | Method for adding slits to expose fruit filling in a co-extruded bar |
| US8980355B2 (en) * | 2007-11-27 | 2015-03-17 | The Quaker Oats Company | Food product with filling |
| US20090285946A1 (en) * | 2008-05-15 | 2009-11-19 | Kirihara Terry T | High fiber shredded cereal and method of preparation |
| US8926308B2 (en) | 2010-04-21 | 2015-01-06 | Intercontinental Great Brands Llc | Dough extruders and methods |
| US10264804B2 (en) | 2010-10-19 | 2019-04-23 | Intercontinental Great Brands Llc | Heat-stable filling with cereal-derived ingredients |
| IN2014CN02536A (en) | 2011-10-06 | 2015-08-07 | Intercontinental Great Brands Llc |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US502376A (en) * | 1893-08-01 | Fritz ochs | ||
| CA674046A (en) * | 1963-11-12 | The Quaker Oats Company | Shredded cereal product and method of making same | |
| US993922A (en) * | 1908-09-11 | 1911-05-30 | Shredded Wheat Co | Filamentous cereal biscuit. |
| GB191112455A (en) * | 1911-05-23 | 1911-08-10 | Edwin Loring Wallace | Improvements in and relating to Filamentous Cereal Biscuits. |
| US2013003A (en) * | 1931-07-31 | 1935-09-03 | Loose Wiles Biscuit Co | Cereal food |
| US2008024A (en) * | 1933-03-27 | 1935-07-16 | Loose Wiles Biscuit Co | Cereal food products |
| US2693419A (en) * | 1950-04-24 | 1954-11-02 | Gen Foods Corp | Fruited cereal product and process therefor |
| GB1167909A (en) * | 1965-12-21 | 1969-10-22 | Gen Foods Corp | Baked Food Products. |
| US4004035A (en) * | 1975-07-28 | 1977-01-18 | Kellogg Company | Method and apparatus for producing lapped shredded food articles |
-
1985
- 1985-01-25 US US06/695,059 patent/US4696825A/en not_active Expired - Lifetime
-
1986
- 1986-01-17 AU AU52528/86A patent/AU578997B2/en not_active Ceased
- 1986-01-21 EP EP86400108A patent/EP0189348B1/en not_active Expired - Lifetime
- 1986-01-21 AT AT86400108T patent/ATE78133T1/en not_active IP Right Cessation
- 1986-01-21 DE DE8686400108T patent/DE3685964T2/en not_active Expired - Fee Related
- 1986-01-21 NZ NZ214892A patent/NZ214892A/en unknown
- 1986-01-24 CA CA000500305A patent/CA1282632C/en not_active Expired - Lifetime
- 1986-01-24 ES ES551223A patent/ES8706393A1/en not_active Expired
-
1987
- 1987-04-16 US US07/040,479 patent/US4795647A/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| PT108813A (en) * | 2015-09-11 | 2017-03-13 | António De Pinho Ribeiro José | INDUSTRIAL PROCESSING OF VEGETABLE IGUARIAS. |
Also Published As
| Publication number | Publication date |
|---|---|
| US4795647A (en) | 1989-01-03 |
| AU5252886A (en) | 1986-07-31 |
| US4696825A (en) | 1987-09-29 |
| DE3685964D1 (en) | 1992-08-20 |
| EP0189348A3 (en) | 1988-08-17 |
| DE3685964T2 (en) | 1993-02-04 |
| AU578997B2 (en) | 1988-11-10 |
| NZ214892A (en) | 1988-05-30 |
| EP0189348B1 (en) | 1992-07-15 |
| ATE78133T1 (en) | 1992-08-15 |
| ES551223A0 (en) | 1987-07-01 |
| ES8706393A1 (en) | 1987-07-01 |
| EP0189348A2 (en) | 1986-07-30 |
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| MKLA | Lapsed | ||
| MKEC | Expiry (correction) |
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