A short-time low-pollution method for preparing masa flour is provided wherein whole grain is first partially cooked in a hot alkaline treating solution to achieve at least about 15% gelatinization and loosening of the bran fraction of the grain. The partially cooked grain is then debranned and is subjected to a flash dehydration for quickly subdividing and reducing the moisture content of the grain. The dehydrated grain is then milled to create an acceptable masa flour.
Precooked and dehulled corn flour for arepa and tortilla is produced in a continuous process. First, the whole cleaned kernel is wetted and crushed to obtain two fractions. The fine fraction only is air-dried and sieved, while segregating both fractions through aspirations to isolate a floury-grit and hull fraction, incorporating the isolated fractions for animal feed by-product, and further producing an endosperm-germ fraction. The endosperm-germ fraction is conditioned and precooked fraction, cooled, air-dried and stabilized as to moisture content in the flaked material. It is then ground to particulate form, separating and collecting fine particles from coarse particles which are further processed, subjecting only the fine particles to centrifugation to yield an integral arepa flour, and, if desired, admixing the fine flour with lime to make a masa flour.
Corn grit is continuously processed to corn collects, or corn flour, by first treating the corn grit in a conditioner at a basic pH and a temperature in the range of about 180.degree. F. to about 200.degree. F. in the presence of steam and at a relatively low moisture content, i.e., no more than about 15 weight percent, preferably about 14 weight percent for a time period sufficient to effect partial gelatinization. Thereafter the obtained, partially gelatinized corn grit is passed through an extruder to produce corn collets that can be comminuted to corn flour. The corn grit moisture content in the extruder is about 20 to about 25 weight percent, and the corn collets are extruded at an exit temperature in the range of about 200 to 215.degree. F. and a moisture content of about 9 to about 12 weight percent. The extruded corn collets have a dextrin value of about 8 to about 10.
Disclosed are novel methods of producing food compositions by the use of an enzymatic digestion of the component parts of whole portions of cereal grains, and grain materials, to impart advantageous qualities to the resulting flour and dough related products produced therefrom. The present invention specifically relates to the fields of making flour and dough, used for totillas, corn chips, totilla chips, snacks, half-products and related products from the component parts and whole portions of cereal grains, and related materials.
A method of saving water, wastewater, lime, and energy while increasing productivity and enhancing product quality in a nixtamalization process. More specifically, during the grain cook and steep process, the phase-separated supernate is retained for a subsequent batch of grain. In addition, a fresh water rinse stream is recycled as push water.
The present invention provides a germ-based additive for enhancing masa flavor in food products produced from flour for dough which includes the additive. The additive includes alkaline cooked cereal germ. The additive may be milled and may be added to food products in an amount effective for producing a masa flavor without the use of masa flour.
