CA1324022C - Process for preparing flour from jerusalem artichoke tubers - Google Patents
Process for preparing flour from jerusalem artichoke tubersInfo
- Publication number
- CA1324022C CA1324022C CA000544021A CA544021A CA1324022C CA 1324022 C CA1324022 C CA 1324022C CA 000544021 A CA000544021 A CA 000544021A CA 544021 A CA544021 A CA 544021A CA 1324022 C CA1324022 C CA 1324022C
- Authority
- CA
- Canada
- Prior art keywords
- tubers
- macerating
- homogenate
- jerusalem artichoke
- heating
- 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 - Fee Related
Links
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23K—FODDER
- A23K20/00—Accessory food factors for animal feeding-stuffs
- A23K20/10—Organic substances
- A23K20/163—Sugars; Polysaccharides
-
- 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
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S426/00—Food or edible material: processes, compositions, and products
- Y10S426/804—Low calorie, low sodium or hypoallergic
Abstract
ABSTRACT OF THE DISCLOSURE
Novel processes are provided for the preparation of useful materials from tubers of Jerusalem artichoke or similar inulin-containing plants. One process provides for the preparation of flour from such tubers by the steps of first macerating the tubers to a pumpable, fluid homogenate, then heating the pumpable, fluid homogenate to a designated temperature, then subjecting the heated, pumpable, fluid homogenate to spray-drying, and finally recovering a flour comprising a mixture of monosaccharides, small oligosac-charides and large oligosaccharides. Another process provides for the preparation of a flour from tubers of Jerusalem artichoke or similar inulin-containing plants, by the steps of first macerating the tubers to a homogenate, then adding a food-grade acid either before, during or after the macerating step to provide an acidified, pumpable, fluid homogenate of such tubers, then heating the acidified, pumpable, fluid homogenate to a designated temperature, then subjecting the heated, acidified, pumpable homogenate to spray-drying in a stream of hot gas, and finally recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
Novel processes are provided for the preparation of useful materials from tubers of Jerusalem artichoke or similar inulin-containing plants. One process provides for the preparation of flour from such tubers by the steps of first macerating the tubers to a pumpable, fluid homogenate, then heating the pumpable, fluid homogenate to a designated temperature, then subjecting the heated, pumpable, fluid homogenate to spray-drying, and finally recovering a flour comprising a mixture of monosaccharides, small oligosac-charides and large oligosaccharides. Another process provides for the preparation of a flour from tubers of Jerusalem artichoke or similar inulin-containing plants, by the steps of first macerating the tubers to a homogenate, then adding a food-grade acid either before, during or after the macerating step to provide an acidified, pumpable, fluid homogenate of such tubers, then heating the acidified, pumpable, fluid homogenate to a designated temperature, then subjecting the heated, acidified, pumpable homogenate to spray-drying in a stream of hot gas, and finally recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
Description
~32~022 This invention relates to a process for the preparation of flour-like solids and fructooligosaccharides-rich flour-like solids from inulin derived from tubers of Jerusalem artichoke, and similar plants.
Inulin occurs as a starch-like carbohydrate in the roots of members of the family ComPositae, es~pecially Jerusalem artichoke. Jerusalem artichoke (Helianthus tuberosus), a native plant of Canada, grows well in northern climates and its tubers can yield per area greater amounts of carbohydrates than wheat or corn. Major carbohydrates in the Jerusalem artichoke tubers are fructose polymers (fructans) which consist of one terminal ~lucose and 2 to 35 fructose units (abbreviated GF2-35).
Inulin (high molecular weight fructans) has heretofore been isolated as a white amorphous hy~roscopic powder having a specific ~ravity of 1.35. It is less soluble in cold water than in hot water. It decomposes to caramel when heated to about 178-C. or higher, or when boiled with alkali. Furthermore, it hydrolyzes to fructose when heated -with dilute acids.
The fructan-rich tubers are normally harvested in fall or in sprin~ after wintering in the ground. A hectare of the Jerusalem artichoke field produces about 40 to about 50 tons of the tubers or about 6 to about lO tons of the fructans. The present cost of the tubers production is *
132~022 estimated to be S55 (Canadian)/ton. Although the technology has been developed for cultivation and harvesting of the Jerusalem artichoke tubers and improvement of the tuber quality, the tubers are currently being produced only on a small scale for use as a vegetable in raw or cooked forms.
However, the tubers have commercial potential'to produce the several commercially-interesting products.
One product that may be produced is fructose. Fructose is at least 1.3 times sweeter and also less cariogenic than sucrose. The ingestion of normal amounts of fructose by man does not require insulin, or stimulate the release of insulin, unlike glucose or glucose-releasing sweeteners (eg.
sucrose). Thus, fructose is suitable for consumption by diabetics and calorie-conscious people who can en~oy the same sweetness with 30% less calories. Furthermore, fructose crystallizes less rapidly than sucrose (thus giving a smoother texture in high sugar foods); chelates metal ions (responsible for off-flavor); and enhances the inherent aroma of fruit and vegetable foods.
At present, a glucose syrup of 55% fructose content is commonly used in food products, including soft drinks (carbonated beverages). Such syrup is generally produced from corn starch via elaborate and lengthy processes:
saccharification of starch by ~-amylase and glucoamylase;
~2~022 enzymic transformation of glucose to 42~ fructose;
chromatographic enrichment to 95% fruceose; and blending of the two to produce 55X fructose. In comparison, production of high fructose syrup from the fructans in the Jerusalem artichoke tubers would be simpler as hydrolysis of the fructans produces a syrup containing up to 80~% fructose.
In fact, US Patent No. 4,613,377 issued September 23, 1986 to H. Yamazaki et al provides novel, highly useful, sweet syrups consisting of fructose and various amounts of fructooligosaccharides by the partial or substantially complete hydrolysis of fructans. The process includes first providing an aqueous solution containing inulin from Jerusalem artichoke tubers or chicory roots. Then a warm aqueous solution of fructans is passed through a column of a strong acid cation-exchange resin (proton form), thereby providing an effluent having a pH of about 2.0 to about 3Ø
The effluent is then hydrolyzed by heatin8 at a temperature of about 70C. to about 100 C., and the hydrolyzate is passed through a column of an anion-exchange resin, thereby providing an effluent having a pH of about 6.5 to about 7.0 thereby providing an effluent having a pH of 2.0 to 3Ø
The effluent is then hydrolyzed by heating at a temperature of 70 to 100 C., and the hydrolyzate is passed throu8h a column cont~ining from 6.5 to 7.0 resin, thereby providing an effluent having a pN of 6.5 to 7Ø Optionally, after ,~
, 132~022 the hydolysis step, the hydrolyzate is decolorized by contact with activated or granular charcoal. The effluent is then concentrated to a syrup containing less water than the effluent, e.g. one containing 40 to 70% solids.
Another useful product is fructooligosaccharides.
Recent Japanese studies show that small size' fructooligosaccharides, e.8. GF2_4 or F2-4, though not utilized by humans and animals, selectively stimulate growth of "beneficial" bacterial bifidobacteria in humans in the lower intestine. When the bifidobacteria utilize these carbon sources, acetic and lactic acids are produced, thereby making the intestine environment more acidic. At such an acidic pH, the acids (particularly acetic acid) inhibit growth of "unfavorable" intestinal bacteria e.g.
Escherichia coli and Clostridium perfingens which produce toxic, malodorous smelling substances, e.g. ammonia, amines, hydrogen sulfide, skatole and indole. Amines contribute to high blood pressure and can also react with nitrite to form carcinogenic nitrosamines. These unfavorable bacteria also possess hi8h activity of B-glucuronidase uhich regenerates toxic or carcinogenic substances from the B-glucuronides, detoxification products from the liver. The acids ~enerated by bifidobacteria) retard not only the growth of these bacteria but also intestinal absorption of ammonia and amines by protonation and stimulate bowel movement.
~,.. . .
132L~22 Bifidobacteria provide the hosts with vitamins (Bl, B6, B12, pantothenic and nicotinic acids), degrade nitrosamines, and stimulate intestinal immunity against infection. Decline of the bifidobacteria population is commonly observed in unhealthy or elderly humans. Clinical studies have shown that oral administration of fructooligosaccha~ides increases the biofidobacteria population in the lower intestinal tract; reduces the population of "unfavorable" bacteria; and reduces constipation, blood lipids in hyperlipidemia, blood pressure, blood cholesterol and production of intestinal toxic substances. Fructooligosaccharides exist in many plants e.g. onion, asparagus, rye and banana but at relatively low levels.
Mei~i Seika Ltd. of Japan has commercialized fructooligosaccharides production from sucrose by the action of Aspergillus n er B-fructofuranosidase (GF-- GF2 + GF3 +
GF4, etc.). Fructooligosaccharides are now widely used as an ingredient in food (drinks, confectionaries, preserves, dairy products, etc.) in Japan. As a feed ingredient, fructooligo- saccharides have been used to reduce diarrhea, to improve weight gain and feed efficiency in piglets after weaning and also to reduce fecal odour of pets.
The process used by Mei~i Seika to prepare fructo-oligosaccharides yields a large amount of glucose (e.g. 50%) in addition to fructooligosaccharides. Removal of glucose -132~22 is necessary to prepare dry powder or glucose-free products, which requires a relatively expensive chromatographic process. On the other hand, it is possible to prepare dry powder (which contains greater than 50% fructooli~o-saccharides) by partially hydrolyzing the Jerusalem artichoke fructans either with acid or with endo inulinase.
Furthermore, a major monosaccharide generated from the Jerusalem artichoke fructans is fructose rather than glucose.
A major problem in commercialization of the Jerusalem artichoke tuber products is that the fresh tubers are available for only 3-4 months in a year. A year-round production requires the storage of the tubers. Although mechanical refrigeration and proprietary "liquid storage"
techniques are effective in storing the tubers, the methods are expensive in terms of capital and the requirement of space and transport of the tubers into and out of storage.
Although dehydration of the tuber slices permits inexpensive storage, the dehydration process proposed heretofore is slow and expensive. Furthermore, the extraction of the fructans from the dried slices requires either rehydration or energy-intensive grinding, and the recovery of the fructans is far from complete (e.g. 50%). At present, there is no rapid and economic method for processing a larger amount of the tubers to avoid the high cost of storage.
1324~22 It has been observed tha~ many people who regularly eat Jerusalem artichoke tubers as a vegetable benefit from similar effects as observed with fructooligosaccharides.
However, these benefits are not available all year round because of difficulty in storing the tubers economically.
These effects should increase when the fructans are converted to s~aller fructooligosaccharides which are ~ore efficiently utilized by bifidobacteria.
It is known that the solids (20% of the tuber weight) in the Jerusalem artichoke tubers consist of 60-80%
fructans; 8-12% proteins; 4-6% fibre; and 4-8% ash rich in potassium.
It is therefore desirable to provide Jerusalem artichoke in the form of a flour-like solid, having substantially the same content of fructans, proteins, fibre and ash as aforesaid. Unlike the tubers, the flour-like solid would be readily available to consumers throughout the year and should find 8reater food applications (e.g. baked foods, e.g. bread and pizza crust). Unlike the syrup, the flour-like solid can be used in dry formulations and is easier to dispense. The flour-like solid would be an ideal source of low calorie food. For diabetics, obese or elderly people, the fructooligosaccharides-rich flour-like solid is an ideal food in~redient. For pets. the fructooligo-saccharides-rich flour-like solid can be added to their . . .
foods to control fecal odour and maintain health, as fructooligosaccharides also reduces production of putrefactive substances in the intestine of the pet, For piglets, the flour-like solid can be added to the milk replacer to reduce diarrheas of bacterial origin.
Jerusalem artichoke flour-like solid is-currently produced on an experimental basis by drying the sliced tubers at 50-80C for several hours and "hammer" milling the dried (hardened) slices. This method is slow and energy intensive, and may also generate undesirable color and off-flavor partly due to the oxidation of tuber phenolic acids by polyphenol oxidase.
Canadian Patent 358,340 issued June 9, 1936 by J.W.
Reavell provided a process for producing fruit and vegetable products. The patented process involved sub~ecting pulp of a predetermined consistency and derived from whole fruit or vegetables, sub~ected to a certain preliminary treatment, to a spray drying operation under carefully regulated conditions. The preliminary treatment involved sub~ecting the whole fruit or vegetable to a mincin~, crushing or chopping operation to provide a pulp. The pulp was then further sub~ected to two or more treatments through disintegrating machines or mills to reduce the pulp to a finely divided condition. The cold, finely divided pulp was passed or pumped to a spraying or atomising apparatus 132~022 wherein the spray produced was brought into direct contact with a heated aeriform or gaseous medium where it was heated for the first time to evaporate the moisture, and to provide a powdered fruit or vegetable product.
U.S. Patent 2,555,356 issued to Marchand related to a method for the preparation of inulin. Previdus procedures for producing inulin are also described therein, which ~enerally involved extracting ground dry Jerusalem artichoke tubers with hot water. The patented process involved centrifugal clarification of the syrupy ~uice pressed from ground Jerusalem artichoke tubers. Dry powder was produced by crystallization from acetone.
U.S. Patent 2.834,694 patented May 13, 1958 by Hill provided a process for preparing fructose polymers from inulin or inulin-containing plants. The patented process involved first extractin~ slices of the inulin-containing plant with an organic extraction solvent. The residual inulin in the extracted slices was then extracted with warm water followed by precipitation of the inulin. Then the inulin was hydrolyzed with heat in the presence of a weak acid.
An ob~ect therefore of one aspect of the present invention is to provide a rapid method for producin~ a flour-like solid from Jerusalem artichoke tubers or similar plants which retains all of the above-mentioned components . ~
of dietary value, so that it can be used in food and also serve as a starting material for production of fructose and fructooligosaccharides.
An object of another aspect of the present invention is to prepare a fructose-rich, sweeter flour-like solid from Jerusalem artichoke tubers.
Accordingly to a broad aspect of the present invention, the novel process includes the steps of wet maceration of the tubers of Jerusalem artichoke or similar inulin-containing plants to a pumpable fluid of sufficient fineness so as to pass through a spray nozzle, preferably under pressure, and then drying such pumpable fluid, i.e. by subjecting that fluid to spray drying in a stream of hot gas, so that a free-flowing flour may be recovered.
Thus, by one broad aspect of this invention, a process is provided for the preparation of a flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of: (a~
macerating the tubers to a homogenate; (b) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging respectively from 30 seconds to 20 minutes;
(c)subjecting the heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
By one variant thereof, the macerating step includes the steps of: (i) washing the Jerusalem artichoke tubers; (ii) dicing the washed Jerusalem artichoke tubers;
B
1~2~22 (iii) macerating the diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating the medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80~ by weight S li~uid.
The dicing step preferably provides cubes of 1 cm in size. The maceration should preferably take place to provide a pumpable fluid having at least 80% by weight water therein. It should preferably be carried out in two stages, namely first to a maximum particle size of 3.2 mm, and then to a finer particle size of 0.03-0.05 mm. The macerating step may be carried out under an atmosphere of nitrogen or carbon dioxide.
The time, temperature and pressure for the heating step are interdependent: the interdependence may be from 30 secs. at 130C at super-atmospheric pressure to 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried out by steam injection.
The flour produced according to this aspect of the present invention preferably comprises 60-80% fructans, 8-12%
proteins, 4-6% fibre and 4-8% ash rich in potassium.
There are many advantages to the process of this aspect of this invention. Compared to the dried tuber slices, the wet tubers can be more readily reduced to fine particles, thus utilizing less energy. Unlike the tuber slices, the resulting homogenate can be subjected to spray-drying, thus permitting rapid and substantially-complete drying. Rapid heating between homogenization and spray-drying is essential B
....
in the process of this aspect of the invention to inactivate tuber polyphenol oxidase, thereby to reduce production of color and off-flavor. Discoloration can be further reduced by using nitrogen or carbon dioxide blanketing during maceration.
The process rapidly converts the Jerusalem artichoke to a stable product of 1/5 the original weight. With appropriate uses of macerators, heater and spray-dryers, it is possible to carry out the entire process continuously within 15 minutes.
Since the flour from Jerusalem artichoke can be readily stored in a stable state at room temperature, such flour is an ideal starting material for commercial production of fructose and fructooligosaccharides throughout the year, and thus being independent of season.
It is known that the fructans from Jerusalem artichoke tubers or similar inulin-containing plants can be hydrolyzed by endoinulinase to produce fructooligosaccharides.
However, enzymic hydrolysis is generally slow unless high concentrations of the enzyme are used. This increases the holding time of macerated tubers when the enzyme is included in processing of the fresh tubers. For enzymic production of fructooligosaccharides, it would be more economical first to reduce the tubers to a flour as above described and then to use such flour as a starting material.
Thus, according to another aspect of this invention, then, a process is provided for the preparation of flour, which comprises the steps of: (a) macerating the tubers of Jerusalem artichoke or similar inulin-containing plants to a homogenate; (b) adding a non-toxic food-grade acid either ' B
before, during or after the macerating step to provide an acidified homogenate of such tubers; (c) heating such acidified homogenate; (d) subjecting the heated homogenate to spray-drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
As in the process of the first aspect of the invention, the macerating step preferably includes the steps of: (i) washing Jerusalem artichoke tubers; (ii) dicing the washed artichoke tubers; (iii) macerating the diced washed artichoke tubers to medium sizes; and (iv) further macerating the medium size macerate of artichoke tubers to fine sizes.
While any non-toxic food-grade acid, e.g. tartaric acid, citric acid, fumaric acid, lactic acid, malic acid or hydrochloric acid can be used, acetic acid is preferred. The acetic acid is preferably added to provide a pH of 3.5 to 5.5.
As in the process of the first aspect of this invention, the dicing step preferably provides cubes of 1 cm size. The maceration should take place to provide a pumpable fluid having at least 80% by weight water therein. It should be carried out in two stages, namely first to a maximum particle size of 3.2 mm and then to a finer particle size of 0.03-0.05 mm.
The amount of the above-described acid added is inversely related to the temperature, e.g. 1/100 by volume acid is added when the temperature is 90C at atmospheric pressure, or 1/3200 by volume of acid is added when the temperature is 130C at super-atmospheric pressure.
,,, As noted above, the time, temperature and pressure for the heating step are interdependent: 30 secs. at 130C at super-atmospheric pressure, or 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried out by steam injection.
The flour formed preferably comprises 3~ monosac-charides, 50-60% small fructooligosaccharides and 47-37~ large oligosaccharides.
According to this embodiment of this invention, a flour is produced by carryinq out an acid hydrolysis step prior to the spray-drying step during the production of the flour-like solid. A small amount (e.g. 1/3200 to 1/100 parts) of glacial acetic acid is added to one part of the tuber either before, during or after maceration. Acid addition can be achieved on a continuous basis. The acidified homogenate is heated for an appropriate length of time, either by transporting it through a heated tube of the required length, or by direct steam injection. Heating temperatures under 100C (e.g. 95C) should be used at atmospheric pressure, but higher temperatures, eg. 100C to 130C, may be used under super-atmospheric pressure. Use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructooligosaccharides generation, since it is known that the reaction rate doubles for every 10C rise in temperature. Although any non-toxic, food grade acid can be used, acetic acid is preferred because it is volatile and thus can be removed during spray-drying, requiring no post-treatment, e.g. neutralization. The '~ B
presence of proteins and fiber in the homogenate facilitate the drying of hydrolyzed fructans, (fructose, glucose and fructooligosaccharides).
Such flour which, however, is substantially free of discoloration, may be produced by maceration in a steam environment and carryinq out an acid hydrolysis step prior to the spray-drying step.
In contrast to enzymic hydrolysis, acid-catalyzed hydrolysis of the fructans proceeds much more rapidly at elevated temperatures, as taught in the above identified Yamazaki et al U.S. Patent No. 4,613,377.
In the accompanying drawings, Figure 1 is a flow diagram of a process of one embodiment of this invention for the production of a flour-like solid from Jerusalem artichoke tubers; and Figure 2 is a flow diagram of a process of another embodiment of this invention for the production of a sweeter, fructose-rich, flour-like solid from Jerusalem artichoke tubers.
As seen in Figure 1, the first step involves washing the tubers in a washing zone 101. Then the tubers are subjected to a staged reduction of size. The first step in such staged reduction in size involves conveying the tubers, as shown by 102 to a dicing zone 103 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a suitable dicing apparatus, e.g. that known by the trade-mark URCHELLTM, or an equivalent, commercially-available apparatus.
The next step in such staged reduction in size involves conveying the diced tubers, as shown by 106 to a macerating zone 107 where the diced product is subjected to maceration, in a suitable macerating apparatus, e.g. that known by the trade-mark FITZMILLTM Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size). Any equivalent, commercially-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILLTM.
The final step in such staged reduction in size involves further wet macerating the preliminarily macerated product produced above, e.g. by passing it, as shown by 108, through a second maceration zone 109, through a suitable macerating apparatus, e.g. that known by the trade-mark VIBRIOREACTORTM Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 to 0.05 mm.
This provides a macerated homogenate in the form of a pumpable fluid having at least 80% by weight liquid (water) therein. This macerated homogenate is then conveyed, as shown by 110, to a heating zone 111 where it is heated for an inter-related period of time and temperature. Examples of suitable such interrelationships of time and temperature range from 10 minutes at 90C at atmospheric pressure to 15 seconds at 150C
at super-atmospheric pressure. This heating is essential to complete the inactivation of enzymes and thus to prevent 17 132~0~2 enzyme decolorization during the spray drying steps. The heating preferably is carried out in a tube by steam injection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time, pasteurizer, or tubular heat exchanger or a scraped surface heater known by the trade-mark CONTHERMrM may be used.
The heated homogenate is then conducted, as shown by 112 to a spray-drying zone 113 where it is spray-dried. Any commercially-available spray drying apparatus may be used.
However, the spray drying procedure preferably used involves pumping the heated macerate through a high pressure pump at a pressure of 1500 to 1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a inverted tear drop co-current spray dryer known by the trade-mark ROGERSTM. The spray dryer has an inlet temperature of 150C to 220C and an exit temperature of 70C to 90C.
The presence of proteins and fiber in the homogenate facilitate the production, as shown by 114, of the flour at zone 115, in spite of the deliquescence of hydrolyzed fructan.
As seen in Figure 2, and as in the first steps of the process of Figure 1, the first step involves washing the tubers at a washing zone 201. Then the tubers are subjected to a staged reduction of size. The first step in such staged reduction in size involves conveying the tubers, as shown by 202, to a dicing zone 203, where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in an URCHELLTM dicer or equivalent commercially-available apparatus.
The next step in such staged reduction in size involves conveying the diced tubers, as shown by 206 to a macerating zone 207 where the diced product is subjected to maceration, e.g. in a FITZMILLTM Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size). Any equivalent, commerically-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILLTM.
The final step in such staged reduction in size involves further wet macerating the macerated product produced above, e.g. by passing it as shown by 208 through a second maceration zone 209, e.g. a VIBRIOREACTORTM Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 - 0.05 mm.
A small amount (e.g. 1/1000 to 1/100 parts) of glacial acetic acid is added to one part of the tuber either before tas shown at 220 at step A), or during (as , g sho~n at 221 and 222 at macerating steps B), or after maceration (as shown at 223 at step C), or at any two or three of steps A, B, and C. Acid for such purpose is fed from acid source 224. Acid addition can be achieved on a continuous basis. After acid additioD/maceration, an acidified macerated homogenate is provided in~ the form of a pumpable fluid with a liquid (water) content of at least about ~0% by weight.
The acidifled, homogenate is then led, as shown at 210, to a heating zone 211, where it is heated for an interrelated period of time and temperature. Suitable such interrelationships of time and temperature range from about 10 minutes at about 90-C. at atmospheric pressure ~o about 15 seconds at about 150-C. at superatmospheric pressure.
This heating is essential to complete the inactivation of enzymes and to prevent enzyme discolorization durin~ the spray drying step. The heating preferably is carried out in a tube with steam in)ection at about 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used.
Use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructoolieosaccharides generation since it i~ known that the reaction rate doubles for every IO-C. rise in temperature. Thus the quantity of acid is inversely proportional to the temperature, varying erom about 1/1000 to about 1/100 parts per part of heated, acidified macerate. Although any non-toxic, food-grade acid can be used, acetic acid is preferred because it is volatile and thus can be removed during spray~drying, requiring no post-treatment, e.g. neutralization.
The heated, acidified, homogenate is then conducted, as shown by 212 to a spray drying zone 213, where it is spray-dried. Any commercially-available spray drying apparatus may be used. However, the spray drying procedure used involves pumping the heated macerate through a high pressure pump at a pressure of about 1500 to about 1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a ROGERS
inverted tear drop co-current spray dryer. The spray dryer had an inlet temperature of about 150-C. to about 220-C. and an exit temperature of about 70-C. to about 90-C.
The presence of proteins and fiber in the homogenate facilitate the production as shown by 214 of the fructose-rich flour-like hydrolyzed solid fructans (fructose, glucose and fructooligosaccharides) in a sweeter, fructose-rich flour-like solid zone 215.
An example of the acetic acid treatment of macerated Jerusalem artichoke tubers to provide fructooligosaccharides includes the step of heating a macerated homogenate of the ,g~
,~", ,, , . , , . _................... ...
Jerusalem artichoke tubers by steam in~ection to 950c. 1/100 parts by volume of glacial acetic acid was then added at zero time. The mixture was heated at 95C for either minutes or 60 minutes, and then was spray-dried to a flour-like solid. The results are shown below in Table 1.
Degree of Hydrolysis of Jerusalem Artichoke Tuber Fructans Acetic acid treatment Reducing su~ar/total fructose 0Q minutes 0.02 20 minutes 0.11 60 minutes 0.29 The samples of flour-like solid were analyzed for reduclng sugars by the 3,5-dinitrosalicylate method and for total fructose by the cysteine-carbazole-sulfuric acid method. Higher ratios of reducing su8ar to total fructose indicate greater degrees of hydrolysis. Complete hydrolysis results in the ratio of 1.3. A ratio of 0.02 corresponds to monosaccharide content of 2%; a ratio of 0.11 corresponds to a fructooligosaccharides content of 91%; and a ratio of 0.29 corresponds to a fructooligosaccharides content of 78%.
The flour-like solid can be used as a startin~ material for commercial production of fructose and fructooligo-saccharides. Both the Jerusalem artichoke flour-like solid and the fructooligosaccharides-rich flour-like solid. when mixed with wheat or other flour, can be used in baked foods (e.g. bread and pizza crust). These flours contain considerable amounts of carbohydrates which are fermentable by yeast. Since wheat flour is low in ~-amylase, commercial production of leavened products usually requires supplementation of oC-amylase or sucrose to yi'eld adequate gassing power of yeast durin baking. Use of the flour-like solid from Jerusalem artichoke tubers will reduce the amount of such supplementation. Fructans and fructooligo-0 saccharides in the products will not add calories to aconsumers' diet as they cannot be metabolized by humans, but do stimulate growth of "beneficial" intestinal bacteria.
Thus, the flour-like solid can be used as an ingredient of foods for people who are prone to obesity, diabetes, constipation, and diseases related to high cholesterol and high blood pressure. The flour-like solid also provides proteins, fiber and potassium which are important dietary components. The flour-like solid ensures availability of these dietary substances to the consumers at reasonable costs all year-round.
The fructooligosaccharides-rich, flour-like solid can be applied as an agent to be used in milk replacers for piglets. The neonatal piglet depends on mother's milk containing immunoglobulins which confer passive immunity a~ainst disease until weaning at 3-5 week~ of a~e. On an ~, . :
average, I - 2 piglets per litter of 8-10 are lost between bir~h and weaning primarily because of the inability of the piglet to obtain sufficient immunoglobulin-rich milk leading to susceptibility to bacterial disease (e.g. e. coli scour).
This results from problems at lactation, extra large litters, competition within the litter, poor hursing sows, etc. Clearly a milk replacer which can supplement mother's milk is beneficial to pig breeders. Inclusion of the fructooligosaccharides-rich flour in the milk replacer will suppress growth of harmful bacteria including E. Coli (major cause of diarrhea) by stimulating growth of beneficial bacteria (e.g. Streptococcus and Lactobacillus). Sweetness due to monosaccharides and low molecular weight fructo-oligosaccharides will increase palatability of the milk replacer.
Thus, in the countries having a climate similar to that of Canada, Jerusalem artichoke can be an alternative crop to wheat, potatoes or tobacco which can be competitively grown and which has the potential to ~enerate new products.
i- ~
~' ';' -132~22 - SD ~ -SUPPLE~ENTARY DISCLOSURE
The Principal Disclosure provided two alternative processes for the preparation of useful products from tubers of Jerusalem art.choke or similar plants. The first process was for the preparation of a flour-like solid from such tubers, by carrying out the steps of: (a) macerating the tubers to a homogenate; (b) heating the macerated homogenate; and (c) sub~ecting the heated macerated homogenate to spray-drying, thereby to produce a flour-like product.
~he second process was for the preparation of a fructose-rich, flour-like solid having increased sweetness from such tubers by carrying out the steps of: (a) macerating the tubers to a homogenate; (b) adding a food-grade acidulant either before, during or after the maceration step to provide an acidified, homogenate of the tubers; (c) heating the acidified, homogenate; and (d) subjecting the heated, acidified, homogenate to sprsy-drying, thereby to produce a fructose-rich, flour-like solid of increased sweetness.
It is known that Jerusalem artichoke tubers contain polyphenols and active polyphenol oxidases which catalyze the oxidation of the polyphenols to the cDrresponding quinones in the presence of oxygen. The resultin~ reactive quinones couple with amino acids and proteins, generating brown coloration (discoloration).
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Inulin occurs as a starch-like carbohydrate in the roots of members of the family ComPositae, es~pecially Jerusalem artichoke. Jerusalem artichoke (Helianthus tuberosus), a native plant of Canada, grows well in northern climates and its tubers can yield per area greater amounts of carbohydrates than wheat or corn. Major carbohydrates in the Jerusalem artichoke tubers are fructose polymers (fructans) which consist of one terminal ~lucose and 2 to 35 fructose units (abbreviated GF2-35).
Inulin (high molecular weight fructans) has heretofore been isolated as a white amorphous hy~roscopic powder having a specific ~ravity of 1.35. It is less soluble in cold water than in hot water. It decomposes to caramel when heated to about 178-C. or higher, or when boiled with alkali. Furthermore, it hydrolyzes to fructose when heated -with dilute acids.
The fructan-rich tubers are normally harvested in fall or in sprin~ after wintering in the ground. A hectare of the Jerusalem artichoke field produces about 40 to about 50 tons of the tubers or about 6 to about lO tons of the fructans. The present cost of the tubers production is *
132~022 estimated to be S55 (Canadian)/ton. Although the technology has been developed for cultivation and harvesting of the Jerusalem artichoke tubers and improvement of the tuber quality, the tubers are currently being produced only on a small scale for use as a vegetable in raw or cooked forms.
However, the tubers have commercial potential'to produce the several commercially-interesting products.
One product that may be produced is fructose. Fructose is at least 1.3 times sweeter and also less cariogenic than sucrose. The ingestion of normal amounts of fructose by man does not require insulin, or stimulate the release of insulin, unlike glucose or glucose-releasing sweeteners (eg.
sucrose). Thus, fructose is suitable for consumption by diabetics and calorie-conscious people who can en~oy the same sweetness with 30% less calories. Furthermore, fructose crystallizes less rapidly than sucrose (thus giving a smoother texture in high sugar foods); chelates metal ions (responsible for off-flavor); and enhances the inherent aroma of fruit and vegetable foods.
At present, a glucose syrup of 55% fructose content is commonly used in food products, including soft drinks (carbonated beverages). Such syrup is generally produced from corn starch via elaborate and lengthy processes:
saccharification of starch by ~-amylase and glucoamylase;
~2~022 enzymic transformation of glucose to 42~ fructose;
chromatographic enrichment to 95% fruceose; and blending of the two to produce 55X fructose. In comparison, production of high fructose syrup from the fructans in the Jerusalem artichoke tubers would be simpler as hydrolysis of the fructans produces a syrup containing up to 80~% fructose.
In fact, US Patent No. 4,613,377 issued September 23, 1986 to H. Yamazaki et al provides novel, highly useful, sweet syrups consisting of fructose and various amounts of fructooligosaccharides by the partial or substantially complete hydrolysis of fructans. The process includes first providing an aqueous solution containing inulin from Jerusalem artichoke tubers or chicory roots. Then a warm aqueous solution of fructans is passed through a column of a strong acid cation-exchange resin (proton form), thereby providing an effluent having a pH of about 2.0 to about 3Ø
The effluent is then hydrolyzed by heatin8 at a temperature of about 70C. to about 100 C., and the hydrolyzate is passed through a column of an anion-exchange resin, thereby providing an effluent having a pH of about 6.5 to about 7.0 thereby providing an effluent having a pH of 2.0 to 3Ø
The effluent is then hydrolyzed by heating at a temperature of 70 to 100 C., and the hydrolyzate is passed throu8h a column cont~ining from 6.5 to 7.0 resin, thereby providing an effluent having a pN of 6.5 to 7Ø Optionally, after ,~
, 132~022 the hydolysis step, the hydrolyzate is decolorized by contact with activated or granular charcoal. The effluent is then concentrated to a syrup containing less water than the effluent, e.g. one containing 40 to 70% solids.
Another useful product is fructooligosaccharides.
Recent Japanese studies show that small size' fructooligosaccharides, e.8. GF2_4 or F2-4, though not utilized by humans and animals, selectively stimulate growth of "beneficial" bacterial bifidobacteria in humans in the lower intestine. When the bifidobacteria utilize these carbon sources, acetic and lactic acids are produced, thereby making the intestine environment more acidic. At such an acidic pH, the acids (particularly acetic acid) inhibit growth of "unfavorable" intestinal bacteria e.g.
Escherichia coli and Clostridium perfingens which produce toxic, malodorous smelling substances, e.g. ammonia, amines, hydrogen sulfide, skatole and indole. Amines contribute to high blood pressure and can also react with nitrite to form carcinogenic nitrosamines. These unfavorable bacteria also possess hi8h activity of B-glucuronidase uhich regenerates toxic or carcinogenic substances from the B-glucuronides, detoxification products from the liver. The acids ~enerated by bifidobacteria) retard not only the growth of these bacteria but also intestinal absorption of ammonia and amines by protonation and stimulate bowel movement.
~,.. . .
132L~22 Bifidobacteria provide the hosts with vitamins (Bl, B6, B12, pantothenic and nicotinic acids), degrade nitrosamines, and stimulate intestinal immunity against infection. Decline of the bifidobacteria population is commonly observed in unhealthy or elderly humans. Clinical studies have shown that oral administration of fructooligosaccha~ides increases the biofidobacteria population in the lower intestinal tract; reduces the population of "unfavorable" bacteria; and reduces constipation, blood lipids in hyperlipidemia, blood pressure, blood cholesterol and production of intestinal toxic substances. Fructooligosaccharides exist in many plants e.g. onion, asparagus, rye and banana but at relatively low levels.
Mei~i Seika Ltd. of Japan has commercialized fructooligosaccharides production from sucrose by the action of Aspergillus n er B-fructofuranosidase (GF-- GF2 + GF3 +
GF4, etc.). Fructooligosaccharides are now widely used as an ingredient in food (drinks, confectionaries, preserves, dairy products, etc.) in Japan. As a feed ingredient, fructooligo- saccharides have been used to reduce diarrhea, to improve weight gain and feed efficiency in piglets after weaning and also to reduce fecal odour of pets.
The process used by Mei~i Seika to prepare fructo-oligosaccharides yields a large amount of glucose (e.g. 50%) in addition to fructooligosaccharides. Removal of glucose -132~22 is necessary to prepare dry powder or glucose-free products, which requires a relatively expensive chromatographic process. On the other hand, it is possible to prepare dry powder (which contains greater than 50% fructooli~o-saccharides) by partially hydrolyzing the Jerusalem artichoke fructans either with acid or with endo inulinase.
Furthermore, a major monosaccharide generated from the Jerusalem artichoke fructans is fructose rather than glucose.
A major problem in commercialization of the Jerusalem artichoke tuber products is that the fresh tubers are available for only 3-4 months in a year. A year-round production requires the storage of the tubers. Although mechanical refrigeration and proprietary "liquid storage"
techniques are effective in storing the tubers, the methods are expensive in terms of capital and the requirement of space and transport of the tubers into and out of storage.
Although dehydration of the tuber slices permits inexpensive storage, the dehydration process proposed heretofore is slow and expensive. Furthermore, the extraction of the fructans from the dried slices requires either rehydration or energy-intensive grinding, and the recovery of the fructans is far from complete (e.g. 50%). At present, there is no rapid and economic method for processing a larger amount of the tubers to avoid the high cost of storage.
1324~22 It has been observed tha~ many people who regularly eat Jerusalem artichoke tubers as a vegetable benefit from similar effects as observed with fructooligosaccharides.
However, these benefits are not available all year round because of difficulty in storing the tubers economically.
These effects should increase when the fructans are converted to s~aller fructooligosaccharides which are ~ore efficiently utilized by bifidobacteria.
It is known that the solids (20% of the tuber weight) in the Jerusalem artichoke tubers consist of 60-80%
fructans; 8-12% proteins; 4-6% fibre; and 4-8% ash rich in potassium.
It is therefore desirable to provide Jerusalem artichoke in the form of a flour-like solid, having substantially the same content of fructans, proteins, fibre and ash as aforesaid. Unlike the tubers, the flour-like solid would be readily available to consumers throughout the year and should find 8reater food applications (e.g. baked foods, e.g. bread and pizza crust). Unlike the syrup, the flour-like solid can be used in dry formulations and is easier to dispense. The flour-like solid would be an ideal source of low calorie food. For diabetics, obese or elderly people, the fructooligosaccharides-rich flour-like solid is an ideal food in~redient. For pets. the fructooligo-saccharides-rich flour-like solid can be added to their . . .
foods to control fecal odour and maintain health, as fructooligosaccharides also reduces production of putrefactive substances in the intestine of the pet, For piglets, the flour-like solid can be added to the milk replacer to reduce diarrheas of bacterial origin.
Jerusalem artichoke flour-like solid is-currently produced on an experimental basis by drying the sliced tubers at 50-80C for several hours and "hammer" milling the dried (hardened) slices. This method is slow and energy intensive, and may also generate undesirable color and off-flavor partly due to the oxidation of tuber phenolic acids by polyphenol oxidase.
Canadian Patent 358,340 issued June 9, 1936 by J.W.
Reavell provided a process for producing fruit and vegetable products. The patented process involved sub~ecting pulp of a predetermined consistency and derived from whole fruit or vegetables, sub~ected to a certain preliminary treatment, to a spray drying operation under carefully regulated conditions. The preliminary treatment involved sub~ecting the whole fruit or vegetable to a mincin~, crushing or chopping operation to provide a pulp. The pulp was then further sub~ected to two or more treatments through disintegrating machines or mills to reduce the pulp to a finely divided condition. The cold, finely divided pulp was passed or pumped to a spraying or atomising apparatus 132~022 wherein the spray produced was brought into direct contact with a heated aeriform or gaseous medium where it was heated for the first time to evaporate the moisture, and to provide a powdered fruit or vegetable product.
U.S. Patent 2,555,356 issued to Marchand related to a method for the preparation of inulin. Previdus procedures for producing inulin are also described therein, which ~enerally involved extracting ground dry Jerusalem artichoke tubers with hot water. The patented process involved centrifugal clarification of the syrupy ~uice pressed from ground Jerusalem artichoke tubers. Dry powder was produced by crystallization from acetone.
U.S. Patent 2.834,694 patented May 13, 1958 by Hill provided a process for preparing fructose polymers from inulin or inulin-containing plants. The patented process involved first extractin~ slices of the inulin-containing plant with an organic extraction solvent. The residual inulin in the extracted slices was then extracted with warm water followed by precipitation of the inulin. Then the inulin was hydrolyzed with heat in the presence of a weak acid.
An ob~ect therefore of one aspect of the present invention is to provide a rapid method for producin~ a flour-like solid from Jerusalem artichoke tubers or similar plants which retains all of the above-mentioned components . ~
of dietary value, so that it can be used in food and also serve as a starting material for production of fructose and fructooligosaccharides.
An object of another aspect of the present invention is to prepare a fructose-rich, sweeter flour-like solid from Jerusalem artichoke tubers.
Accordingly to a broad aspect of the present invention, the novel process includes the steps of wet maceration of the tubers of Jerusalem artichoke or similar inulin-containing plants to a pumpable fluid of sufficient fineness so as to pass through a spray nozzle, preferably under pressure, and then drying such pumpable fluid, i.e. by subjecting that fluid to spray drying in a stream of hot gas, so that a free-flowing flour may be recovered.
Thus, by one broad aspect of this invention, a process is provided for the preparation of a flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of: (a~
macerating the tubers to a homogenate; (b) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging respectively from 30 seconds to 20 minutes;
(c)subjecting the heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
By one variant thereof, the macerating step includes the steps of: (i) washing the Jerusalem artichoke tubers; (ii) dicing the washed Jerusalem artichoke tubers;
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1~2~22 (iii) macerating the diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating the medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80~ by weight S li~uid.
The dicing step preferably provides cubes of 1 cm in size. The maceration should preferably take place to provide a pumpable fluid having at least 80% by weight water therein. It should preferably be carried out in two stages, namely first to a maximum particle size of 3.2 mm, and then to a finer particle size of 0.03-0.05 mm. The macerating step may be carried out under an atmosphere of nitrogen or carbon dioxide.
The time, temperature and pressure for the heating step are interdependent: the interdependence may be from 30 secs. at 130C at super-atmospheric pressure to 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried out by steam injection.
The flour produced according to this aspect of the present invention preferably comprises 60-80% fructans, 8-12%
proteins, 4-6% fibre and 4-8% ash rich in potassium.
There are many advantages to the process of this aspect of this invention. Compared to the dried tuber slices, the wet tubers can be more readily reduced to fine particles, thus utilizing less energy. Unlike the tuber slices, the resulting homogenate can be subjected to spray-drying, thus permitting rapid and substantially-complete drying. Rapid heating between homogenization and spray-drying is essential B
....
in the process of this aspect of the invention to inactivate tuber polyphenol oxidase, thereby to reduce production of color and off-flavor. Discoloration can be further reduced by using nitrogen or carbon dioxide blanketing during maceration.
The process rapidly converts the Jerusalem artichoke to a stable product of 1/5 the original weight. With appropriate uses of macerators, heater and spray-dryers, it is possible to carry out the entire process continuously within 15 minutes.
Since the flour from Jerusalem artichoke can be readily stored in a stable state at room temperature, such flour is an ideal starting material for commercial production of fructose and fructooligosaccharides throughout the year, and thus being independent of season.
It is known that the fructans from Jerusalem artichoke tubers or similar inulin-containing plants can be hydrolyzed by endoinulinase to produce fructooligosaccharides.
However, enzymic hydrolysis is generally slow unless high concentrations of the enzyme are used. This increases the holding time of macerated tubers when the enzyme is included in processing of the fresh tubers. For enzymic production of fructooligosaccharides, it would be more economical first to reduce the tubers to a flour as above described and then to use such flour as a starting material.
Thus, according to another aspect of this invention, then, a process is provided for the preparation of flour, which comprises the steps of: (a) macerating the tubers of Jerusalem artichoke or similar inulin-containing plants to a homogenate; (b) adding a non-toxic food-grade acid either ' B
before, during or after the macerating step to provide an acidified homogenate of such tubers; (c) heating such acidified homogenate; (d) subjecting the heated homogenate to spray-drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
As in the process of the first aspect of the invention, the macerating step preferably includes the steps of: (i) washing Jerusalem artichoke tubers; (ii) dicing the washed artichoke tubers; (iii) macerating the diced washed artichoke tubers to medium sizes; and (iv) further macerating the medium size macerate of artichoke tubers to fine sizes.
While any non-toxic food-grade acid, e.g. tartaric acid, citric acid, fumaric acid, lactic acid, malic acid or hydrochloric acid can be used, acetic acid is preferred. The acetic acid is preferably added to provide a pH of 3.5 to 5.5.
As in the process of the first aspect of this invention, the dicing step preferably provides cubes of 1 cm size. The maceration should take place to provide a pumpable fluid having at least 80% by weight water therein. It should be carried out in two stages, namely first to a maximum particle size of 3.2 mm and then to a finer particle size of 0.03-0.05 mm.
The amount of the above-described acid added is inversely related to the temperature, e.g. 1/100 by volume acid is added when the temperature is 90C at atmospheric pressure, or 1/3200 by volume of acid is added when the temperature is 130C at super-atmospheric pressure.
,,, As noted above, the time, temperature and pressure for the heating step are interdependent: 30 secs. at 130C at super-atmospheric pressure, or 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried out by steam injection.
The flour formed preferably comprises 3~ monosac-charides, 50-60% small fructooligosaccharides and 47-37~ large oligosaccharides.
According to this embodiment of this invention, a flour is produced by carryinq out an acid hydrolysis step prior to the spray-drying step during the production of the flour-like solid. A small amount (e.g. 1/3200 to 1/100 parts) of glacial acetic acid is added to one part of the tuber either before, during or after maceration. Acid addition can be achieved on a continuous basis. The acidified homogenate is heated for an appropriate length of time, either by transporting it through a heated tube of the required length, or by direct steam injection. Heating temperatures under 100C (e.g. 95C) should be used at atmospheric pressure, but higher temperatures, eg. 100C to 130C, may be used under super-atmospheric pressure. Use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructooligosaccharides generation, since it is known that the reaction rate doubles for every 10C rise in temperature. Although any non-toxic, food grade acid can be used, acetic acid is preferred because it is volatile and thus can be removed during spray-drying, requiring no post-treatment, e.g. neutralization. The '~ B
presence of proteins and fiber in the homogenate facilitate the drying of hydrolyzed fructans, (fructose, glucose and fructooligosaccharides).
Such flour which, however, is substantially free of discoloration, may be produced by maceration in a steam environment and carryinq out an acid hydrolysis step prior to the spray-drying step.
In contrast to enzymic hydrolysis, acid-catalyzed hydrolysis of the fructans proceeds much more rapidly at elevated temperatures, as taught in the above identified Yamazaki et al U.S. Patent No. 4,613,377.
In the accompanying drawings, Figure 1 is a flow diagram of a process of one embodiment of this invention for the production of a flour-like solid from Jerusalem artichoke tubers; and Figure 2 is a flow diagram of a process of another embodiment of this invention for the production of a sweeter, fructose-rich, flour-like solid from Jerusalem artichoke tubers.
As seen in Figure 1, the first step involves washing the tubers in a washing zone 101. Then the tubers are subjected to a staged reduction of size. The first step in such staged reduction in size involves conveying the tubers, as shown by 102 to a dicing zone 103 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a suitable dicing apparatus, e.g. that known by the trade-mark URCHELLTM, or an equivalent, commercially-available apparatus.
The next step in such staged reduction in size involves conveying the diced tubers, as shown by 106 to a macerating zone 107 where the diced product is subjected to maceration, in a suitable macerating apparatus, e.g. that known by the trade-mark FITZMILLTM Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size). Any equivalent, commercially-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILLTM.
The final step in such staged reduction in size involves further wet macerating the preliminarily macerated product produced above, e.g. by passing it, as shown by 108, through a second maceration zone 109, through a suitable macerating apparatus, e.g. that known by the trade-mark VIBRIOREACTORTM Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 to 0.05 mm.
This provides a macerated homogenate in the form of a pumpable fluid having at least 80% by weight liquid (water) therein. This macerated homogenate is then conveyed, as shown by 110, to a heating zone 111 where it is heated for an inter-related period of time and temperature. Examples of suitable such interrelationships of time and temperature range from 10 minutes at 90C at atmospheric pressure to 15 seconds at 150C
at super-atmospheric pressure. This heating is essential to complete the inactivation of enzymes and thus to prevent 17 132~0~2 enzyme decolorization during the spray drying steps. The heating preferably is carried out in a tube by steam injection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time, pasteurizer, or tubular heat exchanger or a scraped surface heater known by the trade-mark CONTHERMrM may be used.
The heated homogenate is then conducted, as shown by 112 to a spray-drying zone 113 where it is spray-dried. Any commercially-available spray drying apparatus may be used.
However, the spray drying procedure preferably used involves pumping the heated macerate through a high pressure pump at a pressure of 1500 to 1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a inverted tear drop co-current spray dryer known by the trade-mark ROGERSTM. The spray dryer has an inlet temperature of 150C to 220C and an exit temperature of 70C to 90C.
The presence of proteins and fiber in the homogenate facilitate the production, as shown by 114, of the flour at zone 115, in spite of the deliquescence of hydrolyzed fructan.
As seen in Figure 2, and as in the first steps of the process of Figure 1, the first step involves washing the tubers at a washing zone 201. Then the tubers are subjected to a staged reduction of size. The first step in such staged reduction in size involves conveying the tubers, as shown by 202, to a dicing zone 203, where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in an URCHELLTM dicer or equivalent commercially-available apparatus.
The next step in such staged reduction in size involves conveying the diced tubers, as shown by 206 to a macerating zone 207 where the diced product is subjected to maceration, e.g. in a FITZMILLTM Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size). Any equivalent, commerically-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILLTM.
The final step in such staged reduction in size involves further wet macerating the macerated product produced above, e.g. by passing it as shown by 208 through a second maceration zone 209, e.g. a VIBRIOREACTORTM Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 - 0.05 mm.
A small amount (e.g. 1/1000 to 1/100 parts) of glacial acetic acid is added to one part of the tuber either before tas shown at 220 at step A), or during (as , g sho~n at 221 and 222 at macerating steps B), or after maceration (as shown at 223 at step C), or at any two or three of steps A, B, and C. Acid for such purpose is fed from acid source 224. Acid addition can be achieved on a continuous basis. After acid additioD/maceration, an acidified macerated homogenate is provided in~ the form of a pumpable fluid with a liquid (water) content of at least about ~0% by weight.
The acidifled, homogenate is then led, as shown at 210, to a heating zone 211, where it is heated for an interrelated period of time and temperature. Suitable such interrelationships of time and temperature range from about 10 minutes at about 90-C. at atmospheric pressure ~o about 15 seconds at about 150-C. at superatmospheric pressure.
This heating is essential to complete the inactivation of enzymes and to prevent enzyme discolorization durin~ the spray drying step. The heating preferably is carried out in a tube with steam in)ection at about 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used.
Use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructoolieosaccharides generation since it i~ known that the reaction rate doubles for every IO-C. rise in temperature. Thus the quantity of acid is inversely proportional to the temperature, varying erom about 1/1000 to about 1/100 parts per part of heated, acidified macerate. Although any non-toxic, food-grade acid can be used, acetic acid is preferred because it is volatile and thus can be removed during spray~drying, requiring no post-treatment, e.g. neutralization.
The heated, acidified, homogenate is then conducted, as shown by 212 to a spray drying zone 213, where it is spray-dried. Any commercially-available spray drying apparatus may be used. However, the spray drying procedure used involves pumping the heated macerate through a high pressure pump at a pressure of about 1500 to about 1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a ROGERS
inverted tear drop co-current spray dryer. The spray dryer had an inlet temperature of about 150-C. to about 220-C. and an exit temperature of about 70-C. to about 90-C.
The presence of proteins and fiber in the homogenate facilitate the production as shown by 214 of the fructose-rich flour-like hydrolyzed solid fructans (fructose, glucose and fructooligosaccharides) in a sweeter, fructose-rich flour-like solid zone 215.
An example of the acetic acid treatment of macerated Jerusalem artichoke tubers to provide fructooligosaccharides includes the step of heating a macerated homogenate of the ,g~
,~", ,, , . , , . _................... ...
Jerusalem artichoke tubers by steam in~ection to 950c. 1/100 parts by volume of glacial acetic acid was then added at zero time. The mixture was heated at 95C for either minutes or 60 minutes, and then was spray-dried to a flour-like solid. The results are shown below in Table 1.
Degree of Hydrolysis of Jerusalem Artichoke Tuber Fructans Acetic acid treatment Reducing su~ar/total fructose 0Q minutes 0.02 20 minutes 0.11 60 minutes 0.29 The samples of flour-like solid were analyzed for reduclng sugars by the 3,5-dinitrosalicylate method and for total fructose by the cysteine-carbazole-sulfuric acid method. Higher ratios of reducing su8ar to total fructose indicate greater degrees of hydrolysis. Complete hydrolysis results in the ratio of 1.3. A ratio of 0.02 corresponds to monosaccharide content of 2%; a ratio of 0.11 corresponds to a fructooligosaccharides content of 91%; and a ratio of 0.29 corresponds to a fructooligosaccharides content of 78%.
The flour-like solid can be used as a startin~ material for commercial production of fructose and fructooligo-saccharides. Both the Jerusalem artichoke flour-like solid and the fructooligosaccharides-rich flour-like solid. when mixed with wheat or other flour, can be used in baked foods (e.g. bread and pizza crust). These flours contain considerable amounts of carbohydrates which are fermentable by yeast. Since wheat flour is low in ~-amylase, commercial production of leavened products usually requires supplementation of oC-amylase or sucrose to yi'eld adequate gassing power of yeast durin baking. Use of the flour-like solid from Jerusalem artichoke tubers will reduce the amount of such supplementation. Fructans and fructooligo-0 saccharides in the products will not add calories to aconsumers' diet as they cannot be metabolized by humans, but do stimulate growth of "beneficial" intestinal bacteria.
Thus, the flour-like solid can be used as an ingredient of foods for people who are prone to obesity, diabetes, constipation, and diseases related to high cholesterol and high blood pressure. The flour-like solid also provides proteins, fiber and potassium which are important dietary components. The flour-like solid ensures availability of these dietary substances to the consumers at reasonable costs all year-round.
The fructooligosaccharides-rich, flour-like solid can be applied as an agent to be used in milk replacers for piglets. The neonatal piglet depends on mother's milk containing immunoglobulins which confer passive immunity a~ainst disease until weaning at 3-5 week~ of a~e. On an ~, . :
average, I - 2 piglets per litter of 8-10 are lost between bir~h and weaning primarily because of the inability of the piglet to obtain sufficient immunoglobulin-rich milk leading to susceptibility to bacterial disease (e.g. e. coli scour).
This results from problems at lactation, extra large litters, competition within the litter, poor hursing sows, etc. Clearly a milk replacer which can supplement mother's milk is beneficial to pig breeders. Inclusion of the fructooligosaccharides-rich flour in the milk replacer will suppress growth of harmful bacteria including E. Coli (major cause of diarrhea) by stimulating growth of beneficial bacteria (e.g. Streptococcus and Lactobacillus). Sweetness due to monosaccharides and low molecular weight fructo-oligosaccharides will increase palatability of the milk replacer.
Thus, in the countries having a climate similar to that of Canada, Jerusalem artichoke can be an alternative crop to wheat, potatoes or tobacco which can be competitively grown and which has the potential to ~enerate new products.
i- ~
~' ';' -132~22 - SD ~ -SUPPLE~ENTARY DISCLOSURE
The Principal Disclosure provided two alternative processes for the preparation of useful products from tubers of Jerusalem art.choke or similar plants. The first process was for the preparation of a flour-like solid from such tubers, by carrying out the steps of: (a) macerating the tubers to a homogenate; (b) heating the macerated homogenate; and (c) sub~ecting the heated macerated homogenate to spray-drying, thereby to produce a flour-like product.
~he second process was for the preparation of a fructose-rich, flour-like solid having increased sweetness from such tubers by carrying out the steps of: (a) macerating the tubers to a homogenate; (b) adding a food-grade acidulant either before, during or after the maceration step to provide an acidified, homogenate of the tubers; (c) heating the acidified, homogenate; and (d) subjecting the heated, acidified, homogenate to sprsy-drying, thereby to produce a fructose-rich, flour-like solid of increased sweetness.
It is known that Jerusalem artichoke tubers contain polyphenols and active polyphenol oxidases which catalyze the oxidation of the polyphenols to the cDrresponding quinones in the presence of oxygen. The resultin~ reactive quinones couple with amino acids and proteins, generating brown coloration (discoloration).
~,,;
2~
- SD ~ -In the past, it was suggested that such discoloration could be prevented by passage of sulfur dioxide or by the addition of sodium metabisulfite to a macerate of Jerusalem artichoke tubers. While this technique is suitable to prevent discoloration, such added compounds generate off-flavors in products, corrosion in equipment and their use is prohibited in some countries, It was also suggested that such discoloration could be prevented by the addition of ascorbic acid, which prevents discoloration by reducing the quinones. However, this technique is not suitable because relatively large amounts of ascorbic acid are required, thus increasing the cost of production.
It was also suggested in the Principal Disclosure that the macerating step cGuld be carried out under a blanket of carbon dioxide or nitrogen. This procedure is not always practical or economic.
Accordin~ly it is an ob~ect of an aspect of the invention as now provided by the present Supplementary Disclosure to provide an improvement to the processes described and claimed in the Principal Disclosure to minimize or even to prevent the discolor-ation of the Jerusalem artichoke tuber products.
It has now been found in one specific embodiment of the invention provided by this Supplementary Disclosure, that .~. 1, 2~
- SD ~g -the discoloration of the Jerusalem artichoke tuber products during maceration can effectively be prevented by in~ecting steam to the diced tubers before they reach the macerator.
Thus by one broad aspect of the invention provided by the present Supplementary Disclosure, a process is provided including the steps of wet maceration of the~tubers of Jerusalem artichoke or similar plants in an environment of steam to a pumpable fluid of sufficient fineness so as to pass through a spray nozzle or spinning disc, preferably under pressure, and drying such pumpable fluid, i.e. by subjecting it to spray drying in a stream of hot gas, so that a free-flowing, flour-like solid is recovered.
The above-described process provided for the preparation of a flour-like solid from Jerusalem artichoke tubers or similar plants thus comprises the steps of: (a) macerating the tubers to a homogenate in an environment of steam; (b) heating the homogenate; and (c) sub~ecting the heated homogenate to spray-drying, thereby to produce a flour-like product. In such process, the macerating step preferably includes the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; (c) passing the diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating apparatus where the diced, washed Jerusalem artichoke tubers are macerated to medium sizes; and (d) further maceratin6 the ' ' ' - SD ~ -medium sized, macerated Jerusalem artichoke tubers, still in an environment of steam, to fine sizes, thereby to provide a pumpable fluid homogenate of at least 80% by weight water.
By another broad aspect of the invention provided by the present Supplementary Disclosure, a process is provided for the preparation of a sweeter, fructose-rich, flour-like solid from tubers of Jerusalem artichoke or similar plants which comprises the steps of: (a) macerating the tubers to a homogenizate in an environment of steam; (b) adding a non-toxic food-grade acidulant either before, during or after the macerating step to provide an acidified, homogenate of the tubers; (c) heating the acidified homogenate; and (d) subjecting the heated, acidified homogenate to spray-drying, thereby to produce a sweeter, fructose-rich flour-like solid. In such process the macerating step preferably includes the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers;
(c) passing the diced, washed Jerusalem artichoke tubers along with steam to a macerating apparatus where the diced, washed Jerusalem artichoke tubers are macerated to medium sizes; and (d) further macerating the medium sized, macerated Jerusalem artichoke tubers, still in an environment of steam, to fine sizes, thereby to provide a pumpable fluid homogenate of at least 80~ by weight water.
SD ~ 132~022 According to the invention now provided by the present Supplementary Disclosure, it has been found that macerating the Jerusalem artichoke tubers in an environment of steam is unexpectedly useful for several reasons. Firstly, the steam environment reduces discoloration by displacing oxygen-containing air to the inlet of the macerator.
Secondly, the heat in the steam inactivates oxidases.
Thirdly, the moisture generated from condensation of the steam provides lubrication for the macerating step (thereby eliminating the need of adding water.) Thus, by another aspect of this invention, a process is provided for the preparation of a flour from the inulin in tubers of Jerusalem artichoke tubers or similar inulin-containing plants, which comprise the steps of: (a) maceratingthe tubers to a homogenate in an environment of steam; (b) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging, respectively from 15 seconds at super atmospheric pressure to 10 minutes at atmospheric pressure; (c) subjecting the heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
In one variant thereof, the macerating step comprising the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; (c) passing the diced, washed Jerusalem artichoke tubers in an en~ironment of steam to a macerating ~one where the diced, ~4 1324022 SD ~-washed Jerusalem artichoke tubers are macerated to medium sized homogenate; and (d) further macerating the medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
As in the Principal Disclosure, the dicing step preferably provides cubes of 1 cm in size. The maceration should preferably take place to provide a pumpable fluid having at least 80% by weight water therein. It should preferably be carried out in two stages, namely first to a maximum particle size of 3.2 mm, and then to a finer particle size of 0.03-0.05 mm. The macerating may also be carried out under an atmosphere of nitrogen or carbon dioxide.
As in the Principal Disclosure, the time, tempera-ture and pressure for the heating step are interdependent: in this Supplementary Disclosure, they range from 15 secs. at 150C at super-atmospheric pressure to 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried 0 out by steam injection.
The flour produced according to this aspect of the Supplementary Disclosure is comprised of a mixture of mono-saccharides, small oligosaccharides and oligosaccharides, preferably comprising 3% monosaccharides, 50-60% small fructooligosaccharides and 47-37% large oligosaccharides, in which:
dp = 1 ranges from 8.3 to 46.~
dp = 2 ranges from 18.9 to 29.0 dp - 3 ranges from 9.3 to 13.0 ` B
~o 132~022 SD s~
dp = 4 ranges from 5.9 to 11.8 dp = 5 ranges from 4.1 to 9.4 dp = 2-5 ranges from 48.3 to 56.7 and dp = >5 ranges from 4.9 to 38.7.
By another aspect of the invention, provided by the present Supplementary Disclosure, a process is provided for the preparation of flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of: (a) macerating the tubers to a homo-genate; (b) adding a non-toxic, food-grade acidulant either before, during or after the macerating step to provide an acidified homogenate of the tubers; (c) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure; (d) subjecting the heated homogenate to spray drying in a stream of hot gas;
and (e) recovering a flour comprising a mixture of monosac-charides, small oligosaccharides and large oligosaccharides.
As in the Principal Disclosure, the step of macerating the tubers to a homogenate preferably takes place in an environment of steam. In addition, the macerating step preferably comprises the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; ~c) passing the diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where the diced, washed Jerusalem artichoke tubers are macerated to a homogenate; and (d) further macerating the medium sized, P~
30 1~24022 - SD S~a -macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
As in the Principal Disclosure, the dicing step preferably provides provides cubes of 1 cm in size. As in the Principal Disclosure, the macerating to medium sizes preferably provides solids having a maximum size of 3.2 mm, and preferably to fine sizes provides solids having a size of 0.03 - 0.05 mm.
As in the Principal Disclosure the acidulent is acetic acid, which is added to provide a pH of 3.5-5.5, and the amount of acid added is inversely related to the temperature.
As in the Principal Disclosure, 1/100 by volume acid is preferably added when the temperature is 90C. at atmos-pheric pressure, or 1/1000 by volume of acid is preferably added when the temperature is 150C. at super-atmospheric pressure. As in the Principal Disclosure, the temperature of heating is inversely related to the time ranging from 150C.
to 90C. for 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure, respectively. As in the Principal Disclosure, the heating is preferably carried out by steam injection.
As in the Principal Disclosure, flour which, however, is substantially free of discoloration, may be produced by carrying out an acid hydrolysis step prior to the spray-drying step. A small amount (e.g. 1/3200 to 1/lO0 1~
SD ~b 1~24022 parts) of glacial acetic acid is preferably added to one part of the tuber either before, during or after maceration in order to provide a pH of 3.5-5.5. As in the Principal Disclosure, acid addition can be achieved on a continuous basis, and the acidified homogenate may be heated for an appropria'e length of time, either by transporting it through a heated tube of the required length, or by direct steam injection. As in the Principal Disclosure heating tempera-tures under 100C (e.g. 95C) can be used at atmospheric pressure, but higher temperatures, eg. 100C to 150C, may be used under super-atmospheric pressure. As in the Principal Disclosure, the use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructose generation, since it is known that the reaction rate doubles for every 10C rise in temperature. Although any non-toxic, food-grade acidulant, e.g. tartaric acid, citric acid, fumaric acid, lactic acid, malic acid or h~vdrochloric acid can be used, acetic acid is preferred since it is volatile and thus can be removed during spray-drying, and requires no post-treatment, e.g. neutrali-zation. The presence of proteins and fiber in the homogenate facilitate the drying of hydrolyzed fructans, (fructose, glucose and fructooligosaccharides).
The flour which, however, is substantially free of discoloration, may be produced by maceration in a steam environment and carrying out an acid hydrolysis step prior to the spray-drying step.
1~
~ 132~022 SD ~c In the drawings accompanying the present Supplementary Disclosure, Figure 3 is a flow diagram for the production of a flour-like solid from Jerusalem artichoke tubers according to an embodiment of the invention as now provided by the present Supplementary Disclosure; and Figure 4 is a flow diagram for the production of a sweeter, fructose-rich, flour-like solid from Jerusalem artichoke tubers according to another embodiment of the invention as now provided by the present Supplementary Disclosure.
As seen in Figure 3, the first step involves washing the tubers in a washing zone 301. Then the tubers are B
- SD 3~ -subjected to a staged reduction of size. The first step in such reduction in size involves conveying the tubers, as shown by 302, to a dicing zone 303 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a URCHELL
dicer or equivalent, commercially-available apparatus.
The next step in such reduction in size~involves intermixing the diced tubers at 305 with a blanket of steam from steam blanket 304. The next step in such reduction in size involves conveying the diced tubers in an environment of steam, as shown by 306, to a macerating zone 307 where the diced product is sub~ected to maceration, e.g. in a FITZMILL Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size).
Any other equivalent, commerically-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILL.
The final step in such reduction in size involves further wet macerating the preliminarily macerated product produced above while still in an environment of steam, e.g.
by passing it, as shown by 308, through a second maceration zone 309, e.g., a VIBRIOREACTOR Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 - 0.05 mm.
~ ";
~ , ~
~24022 - SD ~ -This provides a macerated homogenate in the form of a pumpable fluid having at least 80% by weight liquid (water) therein. The macerated homogenate is then conveyed, as shown by 310, to a heating zone 311 where it is heated for an interrelated period of time and temperature. Suitable such interrelationships of time and temperatu~e range from 10 minutes at 90'C. at atmospheric pressure to 15 seconds at 150-C. at superatmospheric pressure. This heating is essential to complete the inactivation of enzymes and thus 0 to prevent enzyme decolorization during the spray drying step. The heating preferab~y is carried out in a tube by steam in~ection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time, pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used.
The heated homogenate is then conducted, as shown by 312 to a spray drying zone 313 where it is spray-dried. Any commercially-available spray drying apparatus may be used.
However, the spray dryin8 procedure actually used involves pumping the heated macerate through a high pressure pump at a pressure of 1500-1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a ROGERS inverted tear drop co-current spray dryer. The spray dryer had an inlet temperature of 150-C. to 220-C. and an exit temperature of 70-C. to 90-C.
`' 1324~22 - SD ~ -The presence of proteins and fiber in the homogenate facilitate the production of the flour-like solids, as shown at 314 in a flour-like solid production zone 315, in spite of the deliquescence of hydrolyzed fructan.
As seen in Figure 4, and as in the first steps of the process of Figure 3, the first step involves~washing the tubers at washin~ zone 401. Then the tubers are sub~ected to 8 staged reduction of size. The first step in such reduction in size involves conveying the tubers, as shown by 402, to a dicing zone 403 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a URCHELL dicer or equivalent, commercially-available apparatus.
The next step in such reduction in size involves intermixing the diced tubers, at 405 in an environment of steam from steam source 404. The next step in such reduction in size involves conveying the diced tubers in their environment of steam, as shown by 406, to a macerating zone 407 where the diced product is sub~ected to maceration, e.g. in a FITZMILL Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen ta screen having holes 3.18 mm in size).
~ny equivalent, commercially-available wet hammermill, crusher, ~crew press extractor or disintegratin~ mill or dispenser may be used instead of the FITZMILL.
,.
.
132~22 9~
- SD ~ -The final step in such reduction in size involves further wet macerating the macerated product produced above while it is still in their environment of steam, e.g. by passing it, as shown by 408, through a second maceration zone 409, e.g., a VIBRIOREACTOR Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clea~rance to provide a particle size of 0.03 - 0.05 mm.
A small amount (e.g. 1/1000 to 1/100 parts) of glacial acetic acid is added to one part of the diced tubers either before (as shown at 420 at step A), or during (as shown at 421 and 422 at macerating step B), or after maceration (as shown at 423 at step C), or at any two or three of steps A, B, and C. Acid for such purpose is fed from source 424.
Acid addition can be achieved on a continuous basis. After acid addition/maceration, still in an environment of steam, an acidified homogenate is provided in the form of a pumpable fluid with a liquid (water) content of at least 80%
by weight.
The acidified, homogenate is then led, as sho~n at 410, to a heating zone 411, where it is heated for an inter-related period of time and temperature. Suitable such interrelationships of time and temperature range from 10 minutes at 90-C. at atmospheric pressure to 15 seconds at 150-C. at superatmospheric pressure. This heating is essential to complete the inactivation of enzymes and to ~' .
"
- SD ~ -In the past, it was suggested that such discoloration could be prevented by passage of sulfur dioxide or by the addition of sodium metabisulfite to a macerate of Jerusalem artichoke tubers. While this technique is suitable to prevent discoloration, such added compounds generate off-flavors in products, corrosion in equipment and their use is prohibited in some countries, It was also suggested that such discoloration could be prevented by the addition of ascorbic acid, which prevents discoloration by reducing the quinones. However, this technique is not suitable because relatively large amounts of ascorbic acid are required, thus increasing the cost of production.
It was also suggested in the Principal Disclosure that the macerating step cGuld be carried out under a blanket of carbon dioxide or nitrogen. This procedure is not always practical or economic.
Accordin~ly it is an ob~ect of an aspect of the invention as now provided by the present Supplementary Disclosure to provide an improvement to the processes described and claimed in the Principal Disclosure to minimize or even to prevent the discolor-ation of the Jerusalem artichoke tuber products.
It has now been found in one specific embodiment of the invention provided by this Supplementary Disclosure, that .~. 1, 2~
- SD ~g -the discoloration of the Jerusalem artichoke tuber products during maceration can effectively be prevented by in~ecting steam to the diced tubers before they reach the macerator.
Thus by one broad aspect of the invention provided by the present Supplementary Disclosure, a process is provided including the steps of wet maceration of the~tubers of Jerusalem artichoke or similar plants in an environment of steam to a pumpable fluid of sufficient fineness so as to pass through a spray nozzle or spinning disc, preferably under pressure, and drying such pumpable fluid, i.e. by subjecting it to spray drying in a stream of hot gas, so that a free-flowing, flour-like solid is recovered.
The above-described process provided for the preparation of a flour-like solid from Jerusalem artichoke tubers or similar plants thus comprises the steps of: (a) macerating the tubers to a homogenate in an environment of steam; (b) heating the homogenate; and (c) sub~ecting the heated homogenate to spray-drying, thereby to produce a flour-like product. In such process, the macerating step preferably includes the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; (c) passing the diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating apparatus where the diced, washed Jerusalem artichoke tubers are macerated to medium sizes; and (d) further maceratin6 the ' ' ' - SD ~ -medium sized, macerated Jerusalem artichoke tubers, still in an environment of steam, to fine sizes, thereby to provide a pumpable fluid homogenate of at least 80% by weight water.
By another broad aspect of the invention provided by the present Supplementary Disclosure, a process is provided for the preparation of a sweeter, fructose-rich, flour-like solid from tubers of Jerusalem artichoke or similar plants which comprises the steps of: (a) macerating the tubers to a homogenizate in an environment of steam; (b) adding a non-toxic food-grade acidulant either before, during or after the macerating step to provide an acidified, homogenate of the tubers; (c) heating the acidified homogenate; and (d) subjecting the heated, acidified homogenate to spray-drying, thereby to produce a sweeter, fructose-rich flour-like solid. In such process the macerating step preferably includes the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers;
(c) passing the diced, washed Jerusalem artichoke tubers along with steam to a macerating apparatus where the diced, washed Jerusalem artichoke tubers are macerated to medium sizes; and (d) further macerating the medium sized, macerated Jerusalem artichoke tubers, still in an environment of steam, to fine sizes, thereby to provide a pumpable fluid homogenate of at least 80~ by weight water.
SD ~ 132~022 According to the invention now provided by the present Supplementary Disclosure, it has been found that macerating the Jerusalem artichoke tubers in an environment of steam is unexpectedly useful for several reasons. Firstly, the steam environment reduces discoloration by displacing oxygen-containing air to the inlet of the macerator.
Secondly, the heat in the steam inactivates oxidases.
Thirdly, the moisture generated from condensation of the steam provides lubrication for the macerating step (thereby eliminating the need of adding water.) Thus, by another aspect of this invention, a process is provided for the preparation of a flour from the inulin in tubers of Jerusalem artichoke tubers or similar inulin-containing plants, which comprise the steps of: (a) maceratingthe tubers to a homogenate in an environment of steam; (b) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging, respectively from 15 seconds at super atmospheric pressure to 10 minutes at atmospheric pressure; (c) subjecting the heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
In one variant thereof, the macerating step comprising the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; (c) passing the diced, washed Jerusalem artichoke tubers in an en~ironment of steam to a macerating ~one where the diced, ~4 1324022 SD ~-washed Jerusalem artichoke tubers are macerated to medium sized homogenate; and (d) further macerating the medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
As in the Principal Disclosure, the dicing step preferably provides cubes of 1 cm in size. The maceration should preferably take place to provide a pumpable fluid having at least 80% by weight water therein. It should preferably be carried out in two stages, namely first to a maximum particle size of 3.2 mm, and then to a finer particle size of 0.03-0.05 mm. The macerating may also be carried out under an atmosphere of nitrogen or carbon dioxide.
As in the Principal Disclosure, the time, tempera-ture and pressure for the heating step are interdependent: in this Supplementary Disclosure, they range from 15 secs. at 150C at super-atmospheric pressure to 10 minutes at 90C at atmospheric pressure. The heating step is preferably carried 0 out by steam injection.
The flour produced according to this aspect of the Supplementary Disclosure is comprised of a mixture of mono-saccharides, small oligosaccharides and oligosaccharides, preferably comprising 3% monosaccharides, 50-60% small fructooligosaccharides and 47-37% large oligosaccharides, in which:
dp = 1 ranges from 8.3 to 46.~
dp = 2 ranges from 18.9 to 29.0 dp - 3 ranges from 9.3 to 13.0 ` B
~o 132~022 SD s~
dp = 4 ranges from 5.9 to 11.8 dp = 5 ranges from 4.1 to 9.4 dp = 2-5 ranges from 48.3 to 56.7 and dp = >5 ranges from 4.9 to 38.7.
By another aspect of the invention, provided by the present Supplementary Disclosure, a process is provided for the preparation of flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of: (a) macerating the tubers to a homo-genate; (b) adding a non-toxic, food-grade acidulant either before, during or after the macerating step to provide an acidified homogenate of the tubers; (c) heating the homogenate at a temperature ranging from 150C to 90C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure; (d) subjecting the heated homogenate to spray drying in a stream of hot gas;
and (e) recovering a flour comprising a mixture of monosac-charides, small oligosaccharides and large oligosaccharides.
As in the Principal Disclosure, the step of macerating the tubers to a homogenate preferably takes place in an environment of steam. In addition, the macerating step preferably comprises the steps of: (a) washing the Jerusalem artichoke tubers; (b) dicing the washed Jerusalem artichoke tubers; ~c) passing the diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where the diced, washed Jerusalem artichoke tubers are macerated to a homogenate; and (d) further macerating the medium sized, P~
30 1~24022 - SD S~a -macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
As in the Principal Disclosure, the dicing step preferably provides provides cubes of 1 cm in size. As in the Principal Disclosure, the macerating to medium sizes preferably provides solids having a maximum size of 3.2 mm, and preferably to fine sizes provides solids having a size of 0.03 - 0.05 mm.
As in the Principal Disclosure the acidulent is acetic acid, which is added to provide a pH of 3.5-5.5, and the amount of acid added is inversely related to the temperature.
As in the Principal Disclosure, 1/100 by volume acid is preferably added when the temperature is 90C. at atmos-pheric pressure, or 1/1000 by volume of acid is preferably added when the temperature is 150C. at super-atmospheric pressure. As in the Principal Disclosure, the temperature of heating is inversely related to the time ranging from 150C.
to 90C. for 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure, respectively. As in the Principal Disclosure, the heating is preferably carried out by steam injection.
As in the Principal Disclosure, flour which, however, is substantially free of discoloration, may be produced by carrying out an acid hydrolysis step prior to the spray-drying step. A small amount (e.g. 1/3200 to 1/lO0 1~
SD ~b 1~24022 parts) of glacial acetic acid is preferably added to one part of the tuber either before, during or after maceration in order to provide a pH of 3.5-5.5. As in the Principal Disclosure, acid addition can be achieved on a continuous basis, and the acidified homogenate may be heated for an appropria'e length of time, either by transporting it through a heated tube of the required length, or by direct steam injection. As in the Principal Disclosure heating tempera-tures under 100C (e.g. 95C) can be used at atmospheric pressure, but higher temperatures, eg. 100C to 150C, may be used under super-atmospheric pressure. As in the Principal Disclosure, the use of higher temperature will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructose generation, since it is known that the reaction rate doubles for every 10C rise in temperature. Although any non-toxic, food-grade acidulant, e.g. tartaric acid, citric acid, fumaric acid, lactic acid, malic acid or h~vdrochloric acid can be used, acetic acid is preferred since it is volatile and thus can be removed during spray-drying, and requires no post-treatment, e.g. neutrali-zation. The presence of proteins and fiber in the homogenate facilitate the drying of hydrolyzed fructans, (fructose, glucose and fructooligosaccharides).
The flour which, however, is substantially free of discoloration, may be produced by maceration in a steam environment and carrying out an acid hydrolysis step prior to the spray-drying step.
1~
~ 132~022 SD ~c In the drawings accompanying the present Supplementary Disclosure, Figure 3 is a flow diagram for the production of a flour-like solid from Jerusalem artichoke tubers according to an embodiment of the invention as now provided by the present Supplementary Disclosure; and Figure 4 is a flow diagram for the production of a sweeter, fructose-rich, flour-like solid from Jerusalem artichoke tubers according to another embodiment of the invention as now provided by the present Supplementary Disclosure.
As seen in Figure 3, the first step involves washing the tubers in a washing zone 301. Then the tubers are B
- SD 3~ -subjected to a staged reduction of size. The first step in such reduction in size involves conveying the tubers, as shown by 302, to a dicing zone 303 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a URCHELL
dicer or equivalent, commercially-available apparatus.
The next step in such reduction in size~involves intermixing the diced tubers at 305 with a blanket of steam from steam blanket 304. The next step in such reduction in size involves conveying the diced tubers in an environment of steam, as shown by 306, to a macerating zone 307 where the diced product is sub~ected to maceration, e.g. in a FITZMILL Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen (a screen having holes 3.18 mm in size).
Any other equivalent, commerically-available wet hammermill, crusher, screw press extractor or disintegrating mill or dispenser may be used instead of the FITZMILL.
The final step in such reduction in size involves further wet macerating the preliminarily macerated product produced above while still in an environment of steam, e.g.
by passing it, as shown by 308, through a second maceration zone 309, e.g., a VIBRIOREACTOR Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clearance to provide a particle size of 0.03 - 0.05 mm.
~ ";
~ , ~
~24022 - SD ~ -This provides a macerated homogenate in the form of a pumpable fluid having at least 80% by weight liquid (water) therein. The macerated homogenate is then conveyed, as shown by 310, to a heating zone 311 where it is heated for an interrelated period of time and temperature. Suitable such interrelationships of time and temperatu~e range from 10 minutes at 90'C. at atmospheric pressure to 15 seconds at 150-C. at superatmospheric pressure. This heating is essential to complete the inactivation of enzymes and thus 0 to prevent enzyme decolorization during the spray drying step. The heating preferab~y is carried out in a tube by steam in~ection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time, pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used.
The heated homogenate is then conducted, as shown by 312 to a spray drying zone 313 where it is spray-dried. Any commercially-available spray drying apparatus may be used.
However, the spray dryin8 procedure actually used involves pumping the heated macerate through a high pressure pump at a pressure of 1500-1800 psi using a SX type, #66-69 nozzle with 4-16 insert into a ROGERS inverted tear drop co-current spray dryer. The spray dryer had an inlet temperature of 150-C. to 220-C. and an exit temperature of 70-C. to 90-C.
`' 1324~22 - SD ~ -The presence of proteins and fiber in the homogenate facilitate the production of the flour-like solids, as shown at 314 in a flour-like solid production zone 315, in spite of the deliquescence of hydrolyzed fructan.
As seen in Figure 4, and as in the first steps of the process of Figure 3, the first step involves~washing the tubers at washin~ zone 401. Then the tubers are sub~ected to 8 staged reduction of size. The first step in such reduction in size involves conveying the tubers, as shown by 402, to a dicing zone 403 where the tubers are subjected to dicing, e.g. to 1 cm cubes, e.g. in a URCHELL dicer or equivalent, commercially-available apparatus.
The next step in such reduction in size involves intermixing the diced tubers, at 405 in an environment of steam from steam source 404. The next step in such reduction in size involves conveying the diced tubers in their environment of steam, as shown by 406, to a macerating zone 407 where the diced product is sub~ected to maceration, e.g. in a FITZMILL Model M, fitted with a reversible comminuting chamber, operated with its impact edge forward for pulverizing at 1740 R.P.M. to provide a product passing through a #3 screen ta screen having holes 3.18 mm in size).
~ny equivalent, commercially-available wet hammermill, crusher, ~crew press extractor or disintegratin~ mill or dispenser may be used instead of the FITZMILL.
,.
.
132~22 9~
- SD ~ -The final step in such reduction in size involves further wet macerating the macerated product produced above while it is still in their environment of steam, e.g. by passing it, as shown by 408, through a second maceration zone 409, e.g., a VIBRIOREACTOR Model JMM/0/25 (PUC120K) with a cross-cut head operated at a head clea~rance to provide a particle size of 0.03 - 0.05 mm.
A small amount (e.g. 1/1000 to 1/100 parts) of glacial acetic acid is added to one part of the diced tubers either before (as shown at 420 at step A), or during (as shown at 421 and 422 at macerating step B), or after maceration (as shown at 423 at step C), or at any two or three of steps A, B, and C. Acid for such purpose is fed from source 424.
Acid addition can be achieved on a continuous basis. After acid addition/maceration, still in an environment of steam, an acidified homogenate is provided in the form of a pumpable fluid with a liquid (water) content of at least 80%
by weight.
The acidified, homogenate is then led, as sho~n at 410, to a heating zone 411, where it is heated for an inter-related period of time and temperature. Suitable such interrelationships of time and temperature range from 10 minutes at 90-C. at atmospheric pressure to 15 seconds at 150-C. at superatmospheric pressure. This heating is essential to complete the inactivation of enzymes and to ~' .
"
3~
- SD ~ -prevent enzyme discolorization during the spray drying process. The heating preferably is carried out in a tube with steam injection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used~.
Use of higher temperatures will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructose generation since it is 0 known that the reaction rate doubles for every IO-C. rise in temperature. Thus the quantity of acid is inversely proportional to the temperature, varying from 1/1000 to 1/100 parts per part of heated, acidified homogenate.
Although any non-toxic, food-grade acidulant can be used, acetic acid is preferred since it is volatile and thus can be removed during spray-drying, thereby requirin~ no post-treatment, e.g. neutralization.
The heated. acidified. homogenate is then conducted, as shown by 412, to a spray-drying zone 413, where it is spray-dried. Any commercially-available spray drying apparatus may be used. However, the spray drying procedure actually used involves pumping the heated macerate through a high pressure pump at a pressure of 1500-1800 psi using a SX
type, #66-69 nozzle with 4-16 insert into a ROCeRS inverted tear drop co-current spray dryer. The spray dryer had an 132~022 ~ L
- SD ~ -inlet temperature of 150'C. to 220-C. and an exit temperature of 70'C. to 90-C.
The presence of proteins and fiber in the homogenate facilitate the production of the flour-like, hydrolyzed fructans (fructose, glucose or fructooligosaccharides), as shown at 414 in a sweeter, fructose-rich, flour-like solids production zone 415.
Analysis of the composi~ion of soluble carbohydrates in the tubers before and after hydrolysis were made. In order to carry out such analysis, 1 part of glacial acetic acid was added to 100 parts ofthe tubers. Heating at higher temperatures (e.g. IOO-C. to 140-C.), with a 12 minute holding time was carried out prior to spray drying. The results are set out in the following Table 2.
?
132~022 - SD ~e -Table 2 Composition of Soluble Carbohydrates in the Tubers Before And After Hydrolysis Treatments Composition(X) of mono- % of small and oligosaccharides oligosaccharides Acid Heating (temperature) dp=l dp=2dp=3 dp=4 dp=5 dp~6 (dp=2-5) - - 3.2 18.0 14.813.1 11.2 39.5 57.1 + - 9.9 18.3 12.811.0 8.3 39.6 50.4 + +(lOO-C.)8.3 18.9 12.811.8 9.4 38.7 52.9 + +(llO-C.)10.1 20.4 12.911.6 9.4 37.7 54.3 + +(120-C.)14.5 22.7 13.011.3 9.2 29.4 56.2 `+ +(130-C.)26.3 27.2 12.3 9.6 7.6 16.9 56.7 + +(140-C.)46.8 29.0 9.3 5.9 4.1 4.9 48.3 ~' ;
, ~, .. . ..
3~
- SD ~ -As a result of these analysis, it may be concluded that the soluble carbohydrates of the Jerusalem artichoke tubers are comprised of 50 to 60% small FOS ~fructooligo-saccharides) of dp=2-5, the remainder being large FOS (dp >
5). Spray drying results in the production of a free flowing flour. The small FOS are useful in'that they support the growth of beneficial bacteria more efficiently.
The heat treatment (100-C. to 140-C. with a 12 minute holding time) on the acidified Jerusalem artichoke tuber 10 homogenate (1/100 part of glacial acetic acid added to 1 part of the diced tubers) leads to only a slight increase of the small FOS (as compared to acid-treated unheated control) at lOO-C. to 130-C. The small FOS decreases as the heating temperature increases to 140-C. Hydrolysis leads to increased monosaccharides (largely fructose) and disac-charides, and decreased amount of higher FOS; thus hydrolysis leads to increased sweetness and decreased amount of higher FOS. Extensive hydrolysis results in hygroscopic, sticky and clumpy flour.
Heating of sliced (or diced) tubers in an environment of steam reduces discoloration and development of off-flavour.
In summary, it has been found that untreated Jerusalem artichoke flour is a good source of small FOS and other nutrients. The heat treatment of acidified homogenate ~, ,.
132~22 - SD 4~ -increases sweetness. A product of increased sweetness provides a good base for palatable animal feeds. The discolorization (and off-flavour development) can be prevented by the use of an environment of steam.
As a result of the present invention, a number of advantages accrue. The invention provides ~apid conversion of perishable Jerusalem artichoke tubers to stable products, namely unhydrolyzed flour and partially hydrolyzed flour.
The hydrolyzed flour provides a "health" flour for human and animals; a milk replacer ingredient; the starting material for the production of small FOS (with or without the use of enzymes); and the starting material for the production of fructose syrup containing small FOS.
The partially hydrolyzed flour can be used as an animal mik replacer. It can also be used as the flour for leavened baked products.
- SD ~ -prevent enzyme discolorization during the spray drying process. The heating preferably is carried out in a tube with steam injection at 150 p.s.i. However, any equivalent commercially-available heater, e.g. a high temperature, short time pasteurizer, or tubular heat exchanger or CONTHERM scraped surface heater, may be used~.
Use of higher temperatures will permit use of smaller quantities of the acid and also shorten the time of hydrolysis required for fructose generation since it is 0 known that the reaction rate doubles for every IO-C. rise in temperature. Thus the quantity of acid is inversely proportional to the temperature, varying from 1/1000 to 1/100 parts per part of heated, acidified homogenate.
Although any non-toxic, food-grade acidulant can be used, acetic acid is preferred since it is volatile and thus can be removed during spray-drying, thereby requirin~ no post-treatment, e.g. neutralization.
The heated. acidified. homogenate is then conducted, as shown by 412, to a spray-drying zone 413, where it is spray-dried. Any commercially-available spray drying apparatus may be used. However, the spray drying procedure actually used involves pumping the heated macerate through a high pressure pump at a pressure of 1500-1800 psi using a SX
type, #66-69 nozzle with 4-16 insert into a ROCeRS inverted tear drop co-current spray dryer. The spray dryer had an 132~022 ~ L
- SD ~ -inlet temperature of 150'C. to 220-C. and an exit temperature of 70'C. to 90-C.
The presence of proteins and fiber in the homogenate facilitate the production of the flour-like, hydrolyzed fructans (fructose, glucose or fructooligosaccharides), as shown at 414 in a sweeter, fructose-rich, flour-like solids production zone 415.
Analysis of the composi~ion of soluble carbohydrates in the tubers before and after hydrolysis were made. In order to carry out such analysis, 1 part of glacial acetic acid was added to 100 parts ofthe tubers. Heating at higher temperatures (e.g. IOO-C. to 140-C.), with a 12 minute holding time was carried out prior to spray drying. The results are set out in the following Table 2.
?
132~022 - SD ~e -Table 2 Composition of Soluble Carbohydrates in the Tubers Before And After Hydrolysis Treatments Composition(X) of mono- % of small and oligosaccharides oligosaccharides Acid Heating (temperature) dp=l dp=2dp=3 dp=4 dp=5 dp~6 (dp=2-5) - - 3.2 18.0 14.813.1 11.2 39.5 57.1 + - 9.9 18.3 12.811.0 8.3 39.6 50.4 + +(lOO-C.)8.3 18.9 12.811.8 9.4 38.7 52.9 + +(llO-C.)10.1 20.4 12.911.6 9.4 37.7 54.3 + +(120-C.)14.5 22.7 13.011.3 9.2 29.4 56.2 `+ +(130-C.)26.3 27.2 12.3 9.6 7.6 16.9 56.7 + +(140-C.)46.8 29.0 9.3 5.9 4.1 4.9 48.3 ~' ;
, ~, .. . ..
3~
- SD ~ -As a result of these analysis, it may be concluded that the soluble carbohydrates of the Jerusalem artichoke tubers are comprised of 50 to 60% small FOS ~fructooligo-saccharides) of dp=2-5, the remainder being large FOS (dp >
5). Spray drying results in the production of a free flowing flour. The small FOS are useful in'that they support the growth of beneficial bacteria more efficiently.
The heat treatment (100-C. to 140-C. with a 12 minute holding time) on the acidified Jerusalem artichoke tuber 10 homogenate (1/100 part of glacial acetic acid added to 1 part of the diced tubers) leads to only a slight increase of the small FOS (as compared to acid-treated unheated control) at lOO-C. to 130-C. The small FOS decreases as the heating temperature increases to 140-C. Hydrolysis leads to increased monosaccharides (largely fructose) and disac-charides, and decreased amount of higher FOS; thus hydrolysis leads to increased sweetness and decreased amount of higher FOS. Extensive hydrolysis results in hygroscopic, sticky and clumpy flour.
Heating of sliced (or diced) tubers in an environment of steam reduces discoloration and development of off-flavour.
In summary, it has been found that untreated Jerusalem artichoke flour is a good source of small FOS and other nutrients. The heat treatment of acidified homogenate ~, ,.
132~22 - SD 4~ -increases sweetness. A product of increased sweetness provides a good base for palatable animal feeds. The discolorization (and off-flavour development) can be prevented by the use of an environment of steam.
As a result of the present invention, a number of advantages accrue. The invention provides ~apid conversion of perishable Jerusalem artichoke tubers to stable products, namely unhydrolyzed flour and partially hydrolyzed flour.
The hydrolyzed flour provides a "health" flour for human and animals; a milk replacer ingredient; the starting material for the production of small FOS (with or without the use of enzymes); and the starting material for the production of fructose syrup containing small FOS.
The partially hydrolyzed flour can be used as an animal mik replacer. It can also be used as the flour for leavened baked products.
Claims (46)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for the preparation of a flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of:
(a) macerating said tubers to a homogenate;
(b) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging respectively from 30 seconds at super-atmospheric pressure to 20 minutes at atmospheric pressure;
(c) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
(a) macerating said tubers to a homogenate;
(b) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging respectively from 30 seconds at super-atmospheric pressure to 20 minutes at atmospheric pressure;
(c) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
2. The process of Claim 1, wherein said macerating step includes the steps of:
(i) washing said Jerusalem artichoke tubers;
(ii) dicing said washed Jerusalem artichoke tubers;
(iii) macerating said diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
(i) washing said Jerusalem artichoke tubers;
(ii) dicing said washed Jerusalem artichoke tubers;
(iii) macerating said diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
3. The process of claim 2 wherein said dicing step provides cubes of 1 cm in size.
4. The process of claim 3 wherein said macerating to medium sizes provides solids having a maximum size of 3.2 mm.
5. The process of claim 4 wherein said macerating to fine sizes provides solids having a size of 0.03 - 0.05 mm.
6. The process of Claim 1, wherein said heating is carried out by steam injection.
8. The process of claim 1 wherein said heating is for a time of 30 seconds at 130°C at super-atmospheric pressure.
8. The process of claim 1 wherein said heating is for a time of lo minutes at 90°c at atmospheric pressure.
9. The process of claim 1 wherein said macerating steps are carried out under an atmosphere of nitrogen or carbon dioxide.
10. A process for the preparation of flour from tubers of Jerusalem artichoke or similar inulin-containing plants which comprises the steps of:
(a) macerating said tubers to a homogenate;
(b) adding a non-toxic, food-grade acid either before, during or after said macerating step to provide an acidified, homogenate of said tubers;
(c) heating said acidified homogenate at a temperature ranging from 150° to 90°C for a time ranging, respectively from about 15 seconds to about 10 minutes;
(d) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
(a) macerating said tubers to a homogenate;
(b) adding a non-toxic, food-grade acid either before, during or after said macerating step to provide an acidified, homogenate of said tubers;
(c) heating said acidified homogenate at a temperature ranging from 150° to 90°C for a time ranging, respectively from about 15 seconds to about 10 minutes;
(d) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
11. The process of Claim 10, wherein said macerating step includes the steps of:
(i) washing said Jerusalem artichoke tubers;
(ii) dicing said washed Jerusalem artichoke tubers;
(iii) macerating said diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
(i) washing said Jerusalem artichoke tubers;
(ii) dicing said washed Jerusalem artichoke tubers;
(iii) macerating said diced, washed, Jerusalem artichoke tubers to medium sizes; and (iv) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
12. The process of claim 11 wherein said dicing step provides cubes of 1 cm in size.
13. The process of claim 12 wherein said macerating to medium sizes provides solids having a maximum size of 3.2 mm.
14. The process of claim 13 wherein said macerating to fine sizes provides solids having a size of 0.03 - 0.05 mm.
15. The process of Claim 10, wherein said non-toxic, food-grade acid, which is acetic acid is added to provide a pH of 3.5-5.5.
16. The process of claim 15 wherein the amount of acid added is inversely related to the temperature.
17. The process of claim 16 wherein 1/100 by volume acid is added when the temperature is 90°C at atmospheric pressure.
18. The process of claim 16 wherein 1/3200 by volume of acid is added when the temperature is 130°C at super-atmospheric pressure.
19. The process of Claim 11, wherein said heating is carried out by steam injection.
20. The process of claim 10 wherein said heating is for a time of 30 seconds at 130°C at super-atmospheric pressure.
21. The process of claim 10 wherein said heating is for a time of 10 minutes at 90°C at atmospheric pressure.
22. The process of claim 10 wherein said macerating steps are carried out under an atmosphere of nitrogen or carbon dioxide.
CLAIMS SUPPORTED BY THE SUPPLEMENTARY DISCLOSURE
CLAIMS SUPPORTED BY THE SUPPLEMENTARY DISCLOSURE
23. A process for the preparation of a flour from the inulin in tubers of Jerusalem artichoke tubers or similar inulin-containing plants, which comprise the steps of:
(a) macerating said tubers to a homogenate in an environment of steam;
(b) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure;
(c) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
(a) macerating said tubers to a homogenate in an environment of steam;
(b) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure;
(c) subjecting said heated homogenate to spray-drying in a stream of hot gas; and (d) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
24. The process of claim 23 wherein said macerating step comprises the steps of:
(a) washing said Jerusalem artichoke tubers;
(b) dicing said washed Jerusalem artichoke tubers;
(c) passing said diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where said diced, washed Jerusalem artichoke tubers are macerated to medium sized homogenate;
and (d) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
(a) washing said Jerusalem artichoke tubers;
(b) dicing said washed Jerusalem artichoke tubers;
(c) passing said diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where said diced, washed Jerusalem artichoke tubers are macerated to medium sized homogenate;
and (d) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
25. The process of claim 24 wherein said dicing step provides cubes of 1 cm in size.
26. The process of claim 25 wherein said macerating to medium sizes provides solids having a maximum size of 3.2 mm.
27. The process of claim 26 wherein said macerating to fine sizes provides solids having a size of 0.03 - 0.05 mm.
28. The process of claim 23, wherein said heating is carried out by steam injection.
29. The process of claim 28 wherein said heating is for a time of 15 seconds at 150°C at super-atmospheric pressure.
30. The process of claim 28 wherein said heating is for a time of 10 minutes at 90°C at atmospheric pressure.
31. The process of claim 23 wherein said heating step is carried out by steam injection.
32. The process of claim 23 wherein said macerating steps are carried out under an atmosphere of nitrogen or carbon dioxide.
33. A process for the preparation of flour from the inulin in tubers of Jerusalem artichoke or similar inulin-containing plants, which comprises the steps of:
(a) macerating said tubers to a homogenate;
(b) adding a non-toxic, food-grade acidulant either before, during or after said macerating step to provide an acidified homogenate of said tubers;
(c) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure;
(d) subjecting said heated homogenate to spray drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
(a) macerating said tubers to a homogenate;
(b) adding a non-toxic, food-grade acidulant either before, during or after said macerating step to provide an acidified homogenate of said tubers;
(c) heating said homogenate at a temperature ranging from 150°C to 90°C for a time ranging, respectively from 15 seconds at super-atmospheric pressure to 10 minutes at atmospheric pressure;
(d) subjecting said heated homogenate to spray drying in a stream of hot gas; and (e) recovering a flour comprising a mixture of monosaccharides, small oligosaccharides and large oligosaccharides.
34. The process of claim 33 wherein said step of macerating said tubers to a homogenate takes place in an environment of steam.
35. The process of claim 34 wherein said macerating step comprises the steps of:
(a) washing said Jerusalem artichoke tubers;
(b) dicing said washed Jerusalem artichoke tubers;
(c) passing said diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where said diced, washed Jerusalem artichoke tubers are macerated to a homogenate; and (d) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
(a) washing said Jerusalem artichoke tubers;
(b) dicing said washed Jerusalem artichoke tubers;
(c) passing said diced, washed Jerusalem artichoke tubers in an environment of steam to a macerating zone where said diced, washed Jerusalem artichoke tubers are macerated to a homogenate; and (d) further macerating said medium sized, macerated Jerusalem artichoke tubers to fine sizes, while still in an environment of steam, thereby to provide a pumpable, fluid homogenate of at least 80% by weight liquid.
36. The process of claim 35 wherein said dicing step provides cubes of 1 cm in size.
37. The process of claim 35 wherein said macerating to medium sizes provides solids having a maximum size of 3.2 mm.
38. The process of claim 35 wherein said macerating to fine sizes provides solids having a size of 0.03 - 0.05 mm.
39. The process of claim 33, wherein said acidulent is acidic acid, which is added to provide a pH of 3.5-5.5.
40. The process of claim 39 wherein the amount of said acidic acid added is inversely related to the temperature.
41. The process of claim 40 wherein 1/100 by volume acidic acid is added when the temperature is 90°C at atmospheric pressure.
42. The process of claim 40 wherein 1/3200 by volume of acidic acid is added when the temperature is 150°C at super-atmospheric pressure.
43. The process of claim 33, wherein said heating is carried out by steam injection.
44. The process of claim 33, wherein the temperature of heating is inversely related to the time ranging from 150°C
to 90°C for 15 seconds to 10 minutes.
to 90°C for 15 seconds to 10 minutes.
45. The process of claim 44 wherein said heating is for a time of 15 seconds at 150°C at super-atmospheric pressure.
46. The process of claim 44 wherein said heating is for a time of 10 minutes at 90°C at atmospheric pressure.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000544021A CA1324022C (en) | 1987-08-07 | 1987-08-07 | Process for preparing flour from jerusalem artichoke tubers |
| US07/228,266 US4871574A (en) | 1987-08-07 | 1988-08-04 | Process for preparing flour from Jerusalem artichoke tubers |
| JP63194688A JPH01199554A (en) | 1987-08-07 | 1988-08-05 | Production of powder food from girasol tuber |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000544021A CA1324022C (en) | 1987-08-07 | 1987-08-07 | Process for preparing flour from jerusalem artichoke tubers |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1324022C true CA1324022C (en) | 1993-11-09 |
Family
ID=4136226
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000544021A Expired - Fee Related CA1324022C (en) | 1987-08-07 | 1987-08-07 | Process for preparing flour from jerusalem artichoke tubers |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US4871574A (en) |
| JP (1) | JPH01199554A (en) |
| CA (1) | CA1324022C (en) |
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| WO2014172486A1 (en) | 2013-04-16 | 2014-10-23 | Fsk Consulting, Llc | Vegetable based products and uses thereof |
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Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR764076A (en) * | 1932-11-21 | 1934-05-14 | Sveriges Litografiska Tryckeri | Process for obtaining copies from images taken on films or films forming color screens |
| OA01884A (en) * | 1965-05-18 | 1970-02-04 | Rolf Hein | Process for obtaining flour and starch from parts of plants, in particular tubers, roots and fruits. |
| US3497360A (en) * | 1965-10-24 | 1970-02-24 | Virginia H Tintera | Method and composition for production of dietetic bread |
| US4042719A (en) * | 1972-02-25 | 1977-08-16 | Chinoin Gyogyszer Es Vegyeszeti Termekek Gyara Rt | Compositions of low calory content |
| US4283432A (en) * | 1978-12-12 | 1981-08-11 | Mitchell William A | Natural beverage powders from dahlia extracts |
| DK147291C (en) * | 1980-12-23 | 1984-12-24 | Danske Sukkerfab | CONTINUOUS PROCEDURE AND PLANT FOR MANUFACTURING FEEDS FROM A ROOM MATERIAL |
| CA1184418A (en) * | 1983-04-15 | 1985-03-26 | Mary Maclean | Natural coffee |
| DE3508387C1 (en) * | 1985-03-08 | 1986-07-17 | Günter Prof. Dr.-Ing. 1000 Berlin Bärwald | Process for the production of a low-glucose digestion product from plant parts containing inulin |
| US4565705A (en) * | 1985-03-12 | 1986-01-21 | Show-Me Low Calorie Foods, Inc. | Production of Jerusalem artichoke flour |
| JPS61231993A (en) * | 1985-04-09 | 1986-10-16 | Oriental Yeast Co Ltd | Novel baker's yeast and method for baking bread |
-
1987
- 1987-08-07 CA CA000544021A patent/CA1324022C/en not_active Expired - Fee Related
-
1988
- 1988-08-04 US US07/228,266 patent/US4871574A/en not_active Expired - Fee Related
- 1988-08-05 JP JP63194688A patent/JPH01199554A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPH01199554A (en) | 1989-08-10 |
| US4871574A (en) | 1989-10-03 |
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