Nabisco Technology Company

Nabisco, Inc.

Juan A Menjivar

Joseph A Szwerc

John M Kaiser

Robert M Sauer, Jr

Lisa Alfieri

James W Kelly

Norbert Gimmler

Craig E Rethwill

Bradford A Burns

Corn-based products having a masa flavor, such as tortilla chips and taco shells, and soft tacos are produced using ground corn. The crisp corn based food products have a masa flavor and color, a crisp texture, and chip-like appearance without the gritty, hard texture associated with conventional tortilla chips or taco shells made by steeping whole corn kernels. The liming of continued corn particles reduces steeping time, develops masa flavor, and reduces tackiness to provide a cohesive dough which can be machined in a tortilla sheeter/cutter. Substantially uniform hydration of a coarse ground corn component, such as corn meal, is achieved by admixing and heating the coarse ground corn component with water and lime to at least substantially hydrate the coarse corn particles without substantially gelatinizing the corn starch. The hydrated coarse component may then be subjected to temperatures above the gelatinization temperature to partially gelatinize the corn starch. A fine ground starchy component is admixed and heated with the hydrated course ground component before, after, or simultaneously with gelatinization of the hydrated coarse ground corn component to form a machinable dough or masa. The hydration process avoids undesirable hard, white, raw-tasting spots in the final product.

Masa corn-based food products and method of preparing

The amount of oleaginous or aqueous liquid carrier used as an adhesive or binding agent for the topical application of a particulate composition to the major surfaces of baked good pieces or snack pieces is reduced by separately spraying the liquid composition and dispensing the particulate composition in substantial side-by-side relationship within a rotating drum. The liquid composition causes the particulate composition to adhere to the pieces prior to and without substantial penetration of the liquid composition into the pieces. Highly porous or absorptive products such as reduced fat, low fat, or no-fat crackers or snacks may be transferred hot to the drum. The liquid composition is sprayed substantially coextensively but separately from the dispensing of the particulate composition. The particulate curtain and the liquid spray both extend in the direction of transport of the pieces. The pieces are contacted sequentially by the liquid composition and the particulate composition several times as the pieces are driven up the side of the rotating drum and tumble downwardly as they travel through the drum. The resulting alternating layers of particulate and adhesive compositions promote strong binding of the particulates to the substrate while creating an appearance of visually apparent discrete particulate particles. The products may be dried in the drum by passing heated air through apertures in the wall of the drum. Reduced fat, low fat, and no-fat products having particulate toppings adhered to their top and bottom major surfaces may be produced.

Topical application of particulates for production of reduced fat, low

Mass corn--based products, e.g., tortilla chips and taco shells, are produced by admixing and heating a coarse ground corn component with water and lime to hydrate the coarse corn component at a temperature below the gelatinization temperature of corn starch, admixing the hydrated coarse corn component with a fine ground starchy component, heating the mixture to form a dough, forming the dough into pieces and baking and/or flying the pieces.

Production of masa corn-based products

Oil-based or fat-based carriers or solvents are replaced in whole or in part by a supercritical fluid or high pressure gas as a spray medium or carrier for food additives or food enhancers. Reduced fat, low fat, and even no-fat food products may be produced by topically applying the additive or enhancer using a supercritical fluid as a fat or oil replacement. Post baking or post cooking application of the food additives or enhancers substantially reduces the loss of the additives or enhancers due to heat decomposition or a volatilization in the production of food products such as baked goods, snacks, and nuts. Food additives or enhancers which may be topically applied to the food substrates include flavorants, colorants, moisture barriers, vitamins and minerals, and odorants or fragrances.

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Denville, NJ, United States of America

Juan A Menjivar