초록 ▼

A method for producing a shelf-stable protein-based pellet that is capable of expansion into a light, crispy snack cake, while providing a good source of protein and calcium. The method, in preferred embodiments, involves making dough from tapioca and potato starches and a milk protein derivative co

A method for producing a shelf-stable protein-based pellet that is capable of expansion into a light, crispy snack cake, while providing a good source of protein and calcium. The method, in preferred embodiments, involves making dough from tapioca and potato starches and a milk protein derivative consisting of whey protein isolate, milk protein isolate or calcium caseinate. The mixture is extruded, sliced and dried in a series of dyers. The method produces a shelf-stable pellet having a moisture level of approximately 9-13% by weight which is further processed to produce a puffed dairy protein snack product, having a moisture level typically less than 2%.

대표청구항 ▼

1. A method for making a dairy protein based puffed food snack, said method comprising the steps of: a) Mixing dry ingredients comprising starch components and a milk protein component, wherein said starch components comprise potato starch and tapioca starch;b) Adding water to precondition said dry

1. A method for making a dairy protein based puffed food snack, said method comprising the steps of: a) Mixing dry ingredients comprising starch components and a milk protein component, wherein said starch components comprise potato starch and tapioca starch;b) Adding water to precondition said dry ingredients to form a dairy protein based dough having a moisture level of about 25% to about 37%;c) Extruding the dough to form a dough rope wherein said dough comprises a moisture content of about 20% to about 28%, said extruding step comprising a two-step extrusion process having a first extruder and a second extruder;d) Cutting the dough rope into dairy protein based pellets;e) Drying the pellets to between 7% to 15% moisture by weight; andf) Puffing the pellets into a puffed cake using a rice cake popper, thus forming a dairy protein based puffed food snack. 2. The method of claim 1 wherein said milk protein component is chosen from the group consisting of whey protein isolate, calcium caseinate and milk protein isolate. 3. The method of claim 1 wherein both the milk protein component and at least one of the starch components have particle sizes within the range of 8 to 200 microns. 4. The method of claim 1 wherein step a) further compromises mixing salt with said starch and protein components. 5. The method of claim 1 wherein step a) further compromises optionally mixing an emulsifier with said starch and protein components. 6. The method of claim 1 wherein said dough produced by step b) comprises between about 28% and about 34% moisture by weight. 7. The method of claim 1 wherein the first extruder is a twin screw extruder and the second extruder is a single screw extruder, and wherein extrusion in the twin screw extruder comprises a screw speed of between about 155 rpm to about 175 rpm and increasing temperatures of up to 325° F. 8. The method of claim 1 wherein at the output of the extrusion step c), said dough rope contains a moisture content of about 22% to about 26% by weight. 9. The method of claim 1 wherein the drying process of step e) comprises temperatures between about 160° F. to about 175° F. 10. The method of claim 1 wherein the drying process of step e) is a three step process comprising: a shaker dryer stage in which the pellets are dried for approximately 5-11 minutes;a secondary dryer in which the pellets are dried for approximately 20-30 minutes; anda finishing dryer in which the pellets are dried for approximately 60-90 minutes. 11. The method of claim 1, wherein at the output of the drying process e), the pellets comprise a moisture level of 9 to 13%. 12. The method of claim 1 wherein the pellets puffing step f) comprises transferring a bulk amount of the pellets to a rice cake puffing platform and wherein said pellets are volumetrically expanded into a single puffed food product. 13. The method of claim 1 further comprising the step of: g) seasoning the puffed food snack. 14. A method for making a dairy protein based puffed food snack from a shelf-stable pellet used for expansion into said puffed food snack, said method comprising the steps of: a) Mixing dry ingredients comprising potato starch, tapioca starch and a milk protein derivative, said milk protein derivative selected from the group consisting of whey protein isolate, milk protein isolate and calcium caseinate;b) adding water to said dry ingredients of step a) to precondition said dry ingredients to form a dough having a moisture level of about 25% to about 37%; hydrating said dry ingredientsc) extruding said dough using a two-step extrusion process to form a dough rope, the two-step extrusion process comprising a first extruder and a second extruder;d) cutting the dough rope into dairy protein based pellets;e) drying said dairy protein based pellets to a moisture level of approximately 9 to 13%; andf) puffing said dairy protein based pellets using a puffing machine, thus forming a dairy protein based puffed snack food. 15. The method of claim 14 wherein both said milk protein derivative and at least one of said potato starch or tapioca starch comprise a particle size within the range of about 8 to about 200 microns. 16. The method of claim 14 wherein said dough comprises between about 35% to about 45.25% milk protein. 17. The method of claim 1 wherein said dough comprises: a) approximately 21.80%-29.00% tapioca starch;b) approximately 25.00%-37.00% potato starch; andc) approximately 35.00%-45.25% milk protein. 18. The method of claim 1 wherein said dough comprises between about 35% to about 45.25% milk protein. 19. The method of claim 1 wherein said extruding step comprises extrusion through a twin screw extruder at approximately 1000 to 1400 psi. 20. The method of claim 14 wherein said extruding step comprises extrusion through a twin screw extruder at approximately 1000 to 1400 psi. 21. The method of claim 14 wherein the the first extruder is a twin screw extruder and the second extruder is a single screw extruder.