Nabisco Brands, Inc.

Cathryn C Warren

Bernhard H Van Lengerich

Bernhard V Lengerich

The present invention relates to the production of a shelf stable unleavened cookie composition which can be leavened to exhibit a cookie crumb-like structure after baking in a convection, radio frequency, or microwave oven. The cookie composition is prepared by using a cooker extruder to mix ingredients and to heat the ingredients to preferably at least about 200.degree. F. to promote browning and flavor development. The resulting cookie composition has a water activity of less than 0.7, preferably less than 0.6. The cookie composition produced using the cooker extruder is shaped into cookie preforms, and leavened by heating in an oven such as a microwave, convection oven, or a combination thereof. The total moisture content of the cookie mixture is generally less than 10% and preferably less than 8%. Water or a source of water may be admixed with the cookie mixture in an amount sufficient to form a dough-like consistency. The water may be admixed in the extruder after the heating stage to prevent fat separation or alternatively after thc cookie composition has cooled and before use by the consumer. The cookie composition may contain a heat or shear sensitive additive. The additive is admixed with the heat treated cookie composition under conditions such that the additive is not deactivated.

Shelf stable cookie product containing heat and shear sensitive

An extrusion processed cookie is produced having shear sensitive particulates and/or heat sensitive additions uniformly dispersed therein. A dry flour blend, including flour, dry milk solids and salt is added to a blending zone of a cooker-extruder with a fat or shortening. The mixture is blended and heat-treated in a heating zone of the extruder under high temperatures without fat separation to form a heat-treated mass. The heat-treated mass is cooled in a cooling zone followed by the addition of a sugar, heat sensitive and/or shear sensitive ingredient to form a cookie composition. Water is also introduced to the cooling zone in an amount effective to produce a dough-like consistency. The heat-treated cookie composition is extruded and shaped into an unleavened and unexpanded cookie dough piece. The cookie pieces are then leavened by heating in a convection, microwave or radio frequency oven to produce a leavened cookie having a crumb-like structure.

Extrusion baking of cookies containing heat and shear sensitive additives

In the present invention leavened products which exhibit a cookie crumb-like structure and structural integrity are produced using high temperature mixing of ingredients comprising flour and oil to promote browning and flavor development. A heat treated mass produced in a cooker extruder is admixed with ingredients comprising water in a post extrusion mixer. The dough-like mixture produced in the post extrusion mixer is leavened and further browned using post-extrusion baking, such as microwave, dielectric radio frequency, infrared, conductive, or convection baking, frying, or a combination thereof. The shortening or fat content of the dough-like mixture may be from about 12% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture. Separation of oil from the remaining mass and extruder surging and starch gelatinization are avoided preferably by admixing water into heat-treated ingredients comprising flour and oil after the during substantial cooling of the heat-treated ingredients. The extruder and post extrusion mixer are operated at low pressure, generally less than about 20 bars absolute, preferably less than about 10 bars absolute. The relative amount of solid, crystalline or granulated sugar, such as sucrose, subjected to the heat treatment may be used to control the tenderness and crunchiness of the final product.

Production of leavened products using high temperature mixing

The present invention relates to the production of cookies which exhibit a cookie crumb-like structure and structural integrity using a cooker extruder to mix and heat ingredients comprising flour and oil to promote browning and flavor development. The heat treated mass produced in the cooker extruder is admixed with ingredients comprising water in a post extrusion mixer. The dough-like mixture produced in the post extrusion mixer is leavened and further browned using post-extrusion baking, such as microwave, dielectric radio frequency, infrared, conductive, or convection baking, frying, or a combination thereof. The shorting or fat content of the dough-like mixture may be from about 12% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture. Separation of oil from the remaining mass and extruder surging and starch gelatinization are avoided preferably by admixing water into heat-treated ingredients comprising flour and oil after and during substantial cooling of the heat-treated ingredients. The extruder and post extrusion mixer are operated at low pressures, generally less than about 20 bars absolute, preferably less than about 10 bars absolute. The relative amount of solid, crystalline or granulated sugar, such as sucrose, subjected to the heat treatment may be used to control the tenderness and crunchiness of the final product.

Cookie production with extrusion heat treatment and post extrusion

The present invention relates to the production of cookies which exhibit a cookie crumb-like structure and structural integrity using a cooker extruder to mix and heat ingredients comprising flour and oil to promote browning and flavor development. The dough-like mixture produced in the extrusion cooker is leavened and further browned using post-extrusion baking, such as microwave, dielectric radio frequency, infrared conductive, or convection baking, frying, or a combination thereof. The shortening or fat content of the dough-like mixture may be from about 12% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture. Separation of oil from the remaining mass and extruder surging and starch gelatinization are avoided preferably by admixing water into heat-treated ingredients comprising flour and oil after and during substantial cooling of the heat-treated ingredients. The extruder is operated at low pressures, generally less than about 20 bars absolute, preferably less than about 10 bars absolute. The relative amount of solid, crystalline or granulated sugar, such as sucrose, subjected to the heat treatment may be used to control the tenderness and crunchiness of the final product.

Production of cookies with extrusion and post extrusion baking

The present invention related to the production of baked products having a relatively high oil content using a cooker extruder. Ingredients comprising flour and oil are mixed and heated in a cooker extruder to promote Maillard browning and flavor development. The dough-like mixture produced in the extrusion cooker is leavened and further browned using post-extrusion baking, such as microwave, dielectric radio frequency, infrared, conductive, or convection baking, or a combination thereof. The shortening or fat content of the dough-like mixture may be from about 12% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture. Separation of oil from the remaining mass and extruder surging and starch gelatinization are avoided preferably by admixing water into heat-treated ingredients comprising flour and oil after and during substantial cooling of the heat-treated ingredients. The extruder is operated at low pressures, typically less than about 20 bars absolute, suitably less than about 10 bars absolute. The relative amount of cystalline or granulated sugar, such as sucrose, subjected to the heat treatment is used to control the tenderness and crunchiness of the final product.

Growing community of inventors

Ridgewood, NJ, United States of America

Cathryn C Warren