PROCESS FOR PREPARING NOODLES AND ALIMENTARY PASTES AND PREMIXED FLOUR THEREFOR

Abstract: Crystalline α-maltose greatly improves the stability, taste and shelf life of noodles or alimentary pastes, and decreases the amount of water needed in their preparation. Since crystalline α-maltose is useful for binding flour, a satisfactory dough can be obtained with a reduced addition of water. Incorporation of crystalline α-maltose into flour yields a premixed flour for preparing noodles or alimentary pastes, and addition of water thereto gives excellent dough products.

Description: The present invention relates to a process for preparing noodles and alimentary pastes. More particularly, the present invention relates to a process for preparing noodles and alimentary pastes whereby crystalline α-maltose and water are added to flour to prepare a dough, and the dough is then shaped into noodles or alimentary pastes. The invention also relates to a premixed flour containing crystalline α-maltose; such flour facilitates the preparation of noodles and alimentary pastes. Throughout the present invention all parts and percentages are given by weight or by weight/weight. Noodles and alimentary pastes are prepared by adding water to flour, and shaping the resultant dough into noodles and alimentary pastes. For example, "Udon (white wheat noodle)" is generally prepared by adding 35-50 parts of water and a small amount of salt to 100 parts of flour, and shaping the resultant dough into noodles. Since the noodles or alimentary pastes prepared in this manner are perishable, their shelf-life must be improved so that they possess a higher commercial value. In the past, hydrogen peroxide was used as a food preservative in noodles and alimentary pastes. Addition of hydrogen peroxide is, however, prohibited because it is not advisable from a safety viewpoint. Since noodles and alimentary pastes are consumed in large quantities almost every day, several methods for preserving noodles and alimentary pastes much more safely have been desired and proposed. For instance, Japanese Patent Laid-Open No. 90642/77 discloses a method wherein edible organic acids are used to improve the preservation of noodles and alimentary pastes. Japanese Patent Laid-Open No. 2647/82 and No. 29258/82 disclose methods wherein ethyl alcohol is used to improve the preservation of noodles and alimentary pastes. These methods, however, have certain drawbacks in that they use excessively large amounts of preservative to obtain a desirable preservation and this may effect the taste of the resultant noodles and alimentary pastes. The Applicants have performed investigations into the use of saccharides to improve the preservation of noodles and alimentary pastes while not adversely affecting their taste qualities. As a result, they have found that crystalline α-maltose facilitates the preparation of noodles and alimentary pastes having improved shelf-life and taste qualities. Accordingly, the present invention provides a process for preparing noodles or alimentary pastes, wherein incorporation of crystalline α-maltose reduces the amount of water used in preparation, the said process comprising adding crystalline α-maltose and water to flour to prepare a dough, and shaping the resultant dough into noodles or alimentary pastes. In the conventional preparation of a dough by adding water to flour, for example, not less than approximately 32% of water against the wheat flour is required when the dough is for Udon, and not less than approximately 28% of "Kansui (a kind of aqueous alkaline solution containing potassium carbonate, sodium carbonate, potassium phosphate and sodium phosphate)" is required when the dough is for "Chuka-men (Chinese yellowish wheat noodle)". The present invention is based on the finding that crystalline α-maltose will bind flour in the presence of water and reduces the amount of water required for preparing noodles or alimentary pastes. Accordingly, the use of crystalline α-maltose in the preparation of dough facilitates reduction of the amount of water needed to prepare noodles or alimentary pastes. This greatly facilitates the production of low-moisture-content noodles and pastes that so far have been difficult to prepare. Crystalline α-maltose has a weak but not negligible sweetening power, and it is preferably added in an amount of less than 10%, preferably 0.5 - 8%, against flour. The crystalline α-maltose may be, for example a crystalline α-maltose powder as disclosed in Japanese Patent Laid-Open No. 35800/86, or that sold by Hayashibara Co., Ltd., Okayama, Japan, under the trade name of "FINETOSE"®. Noodles and alimentary pastes as referred in the present invention include Udon, "Soba (buckwheat noodle)", Chuka-men, "Kishimen (wide, long and thin wheat noodle)", "Won Ton (Chinese flour dumplings with pork, served in soup)", "Jiaoz (Chinese fried or steamed dumplings stuffed with minced meat)", "Shao-mai (Chinese steamed dumplings stuffed with minced shrimp or crab)", "Harumaki (Chinese oblong fried dumplings stuffed with minced pork or shrimp)", macaroni and spaghetti. More particularly, the present invention is of advantage for preparing low-moisture-content noodles and alimentary pastes including fresh noodles, partially dried noodles, steamed noodles and boiled noodles because their stability, preservation and taste qualities are improved; as well as in preparing partially-dried, completely-dried and instant noodles because the amount of water that must be removed in drying is reduced. Any flour can be used in the present invention so long as a dough can be prepared therefrom. For example, one or more varieties of wheat flour, barley flour, rice flour, corn flour, "Sobako (buckwheat flour)", starch and protein flour can be used. The wording "adding crystalline α-maltose and water to flour to obtain dough" includes any process whereby dough can be prepared from flour by using crystalline α-maltose and water. For example, crystalline α-maltose may be added to flour and the resultant mixture kneaded with an appropriate amount of water into a dough. Alternatively, an appropriate amount of water may be added to flour and the resultant mixture kneaded with crystalline α-maltose into a dough. In the former case, for example, flour is added with less than 10% of crystalline α-maltose, preferably 0.5 - 8%, against the flour, to prepare a premixed flour. The premixed flour is kneaded with water into a dough which is then shaped into noodles or alimentary pastes. In the latter case, flour is mixed with an insufficient amount of water and the mixture is added with the prescribed amount of crystalline α-maltose and formed into a low-moisture-content dough which is then shaped into noodles or alimentary pastes. Of course, a dough may be prepared by adding crystalline α-maltose together with water to flour. The methods described above can be practiced in conventional manner without using any particular apparatus. In addition the tap water and well water, aqueous solutions such as saline solution, Kansui, organic acid solutions and aqueous alcohol may be used in the present invention. In the preparation of noodles or alimentary pastes, if necessary, conventional food sub-material(s) such as food preservatives, coloring agents, stabilizers, improvers, nutrients and seasonings can be used in combination with flour and/or water. In the case of preparing premixed flour, one or more varieties of these sub-materials, preferably, those in powder form, can be advantageously added thereto. For instance, edible organic acids such as acetic acid, malic acid, fumaric acid and lactic acid; and alcohols such as ethyl alcohol, propylene glycol and glycerin; amino acids such as glycine and alanine; salts such as common salt, acetate, citrate, sodium carbonate, potassium carbonate, calcium oxide, calcium hydroxide, calcium carbonate, dibasic sodium phosphate and tribasic potassium phosphate; and natural preservatices such as garlic extract, Japanese apricot extract, fermented milk and egg white lysozyme can be used as food preservative. We have found that by using crystalline α-maltose according to the present invention in the preparation of low-moisture-content fresh noodles, these preservatives become approximately 2 - 5 times more effective than when used in conventional manner. In other words, a similar preservation can be attained with a concentration of about 1/2 - 1/5 as with conventional concentrations. This facilitates the preparation of high-commercial-value noodles or alimentary pastes without the worry of causing alteration of their taste qualities by the preservatives. Noodles or alimentary pastes prepared according to the present invention have the following characteristics: 1) The addition of water can be reduced. Crystalline α-maltose improves the activity of binding of flour and its processibility. Excellent noodles and alimentary pastes can be prepared even when the amount of added water is reduced. Conventional preparation of noodles and pastes wherein a relatively large amount of water is added requires a drying step prior to shaping, while the pressnt invention requires no drying step. In the preparation of partially-dried-, completely-dried and instant-noodles, the energy and time for drying is decreased because the amount of water to be removed is less. 2) Stable fresh noodles can be obtained The use of crystalline α-maltose retards the change in physical properties with the passage of time. 3) The addition of water into noodles and alimentary pastes can be reduced, then noodles and alimentary pastes with an improved preservative quality can be prepared. Combination with preservatives and/or improvers extremely improves these effects. Specifically, a combination with preservatives improves synergistically the preservation. 4) When fresh noodles are boiled, they float easily and hardly scorch on the bottom of a pot. The yield of boiled noodles is satisfactory. 5) The noodles and pastes can be heated easily, and their starch content pregelatinizes easily. Accordingly, the time to steam and boil noodles and alimentary pastes is cut approximately by 1/5 - 1/2. This greatly shortens the cooking time for fresh noodles, partially-dried-, completely-dried- and instant-noodles, therefore is advantageous for preparing "Yonakisoba (Chuka-men cooked and served at a yatai, a roofed mobile stall with cooking facilities hawking on the streets of cities)" and "Tachiguisoba (Udon and Soba cooked and served at a yatai in a transportation station)". 6) The Noodles and pastes are excellent in taste qualities. The noodles and pastes are excellent in appearance, texture and taste. In the preparation of boiled-, steamed- and instant-noodles, incorporation of maltose retards degradation of the starch ingredient in the products and thereby prolongs their shelf lives. The following Experiments further illustrate the present invention. Experiment 1 Effects of saccharides on noodles and pastes Two thousand parts of hard wheat flour was placed in a mixer, and added with 480 parts of Kansui. The mixture was kneaded in a mixer for two minutes, and then added with 80 parts of one saccharide listed in Table I. The resultant was kneaded for eight minutes into dough. According to conventional method, the dough was folded, aged, rolled, cut into long strips, and shaped into fresh Chuka-men. All the saccharides were compared on their processibility of flour as well as on stability and taste qualities of the Chuka-men. As control, a Chuka-men ( Control I) was prepared similarly as in the above, expect that 560 parts of Kansui was mixed in place of saccharides for ten minutes. Another Chuka-men (Control II) was prepared by admixing 560 parts of Kansui and 20 parts of propylene glycol for ten minutes in place of saccharides. As to processibility, the Chuka-mens were compared with the Controls on the adhesiveness of the dough on the roller, the homogeneity of rolled dough and the width uniformity of the noodle prepared. As to stability, the noodles were allowed to stand immediately after preparation at 5°C over a period of 1 day or 14 days, and then compared with the Controls on extensibility, hardness and apparent springiness. The noodles, after boiled and cooked, are compared with the Controls on appearance, palatability and taste qualities by a panel consisting of ten men and ten women. In the Experiment, the noodles were compared with Control II using the hitherto most popular formulation, the noodles equal to Control II was graded as "Good", the noodles superior to control II was graded as "Excellent", and the noodles inferior to Control II was graded as "Passable". The results were as shown in Table I. As evident from the results, it was found that crystalline α-maltose exceeded other saccharids in processibility, stability and taste qualities. Experiment 2 Effects of water on the processibility of noodles using crystalline α-maltose Two thousand parts of hard wheat flour was added with 80 parts of crystalline α-maltose powder to prepare Chuka-men while varying the amount of Kansui from 26 - 18% against the wheat flour. The processibility of the Chuka-men was evaluated similarly as in Experiment 1. The results were as shown in Table II. The Control in Experiment II without adding crystalline α-maltose required 28% of Kansui to obtain a passable processibility. As evident from the results in Table II, in the Experiment wherein 4% of crystalline α-maltose against wheat flour is used, it was found that a satisfactory processibility was attained with not less than 20% of Kansui against wheat flour, specifically, an excellent processibility was attained with not less than 22% of Kansui. This reduces extremely the addition of water and improves the preservation of fresh noodles, as well as in the preparation of partially-dried-, completely-dried-and instant-noodles, facilitates the drying and/or dehydration and contributes to shorten the time to produce the noodles. Experiment 3 Effects of crystalline α-maltose on the improvement of preservation of fresh noodles Chuka-men was prepared with 28% or 22% of Kansui and 0% or 4% of crystalline α-maltose against wheat flour together with either preservative listed in Table III. The preservative was added to the wheat flour prior to its use. The Chuka-men was compared on preservation with Control I and Control II prepared similarly as Experiment 1. All the tests exhibited an excellent processibility. The products were investigated on preservation as follows. A fresh Chuka-men was placed on tray and then allowed to stand at 25°C while measuring daily on viable bacterial count to determine the number of days required to reach the criterion defined by All Japan Federation of Manufactures Association (less than 3 x 10⁶ counts/g) and also the number of days when the noodles were free of mould growth. The results were as shown in Table III. As evident from the results in Table III, the noodle prepared with 22% of Kansui and 4% of crystalline α-maltose was more preservative than that prepared with 28% of Kansui in conventional manner. For instance, comparison with samples of Test No.1 and Test No.7 revealed that incorporation of crystalline α-maltose reduced the amount of water to prepare noodles and prolonged the number of days required to reach the criterion by 2 days and the number of days when the noodles were free of mould growth by 1 day. In case of using a food preservative, for example, ethyl alcohol, comparison with samples of Test No.1 and Test No.3 revealed that incorporation of 2% of ethyl alcohol prolonged the shelf life of noodle by 2 days. This was comparable to a preservation attained by using 2% ethanal in place of crystalline α-maltose. By comparing these samples with a sample wherein 22% of Kansui and 4% of crystalline α-maltose were incorporated. Alternatively, by checking the difference in the number of days between Test No.1 and No.3 and that between Test No.1 and No.8, it can be understood that in comparison with samples of Test No.1 and Test No.3 the shelf life was prolonged by seven days, while in comparison with samples of Test No.1 and Test No.8 the shelf life was prolonged by 7 days. Alternatively, it was found that incorporation of crystalline α-maltose reduced the amount of Kansui for preparing noodles, and prolonged the shelf life of the noodles by 1 - 2 days, and that incorporation of ethyl alcohol without crystalline α-maltose prolonged the shelf life of noodles by two days. In addition, incorporation of crystalline α-maltose reduced the amount of Kansui, and prolonged synergistically the shelf life by seven days in combination with ethyl alcohol. Accordingly, it was found that the combination of crystalline α-maltose and food preservative reduced the amount of Kansui and could halved the amount of the food preservative than in case of using it in the conventional process for noodles while maintaining their preservative ability equivalent to that of the conventional products. For instance, comparison with samples of Test No.4 and Test No.10 as to glycine, comparison with samples of Test No.5 and Test No.11 as to vinegar, and comparison with samples of Test No.6 and Test No.12 as to calcium oxide revealed that the food preservatives exhibited preservative ability equivalent to or more than that of conventional products even when the food preservatives were halved than that used in conventional process. This facilitated the preparation of noodles without affecting their taste qualities with food preservatives. The present invention is illustrated further by the following Examples. Example 1 Chuka-men Two thousand and eighty parts of a premixed flour, prepared by the method in Example 5, was placed in a mixer, and then admixed with small amounts of coloring agents, 20 parts of ethyl alcohol and 480 parts of Kansui. The mixture was kneaded in the mixer for ten minutes into dough which was then placed in noodle processing machine and prepared into Chuka-men in usual manner. This noodle exceeded conventional Chuka-men in processibility, stability and preservation. The time to boil the noodles was shortened approximately to 2/3 of that to boil conventional products, and the cooked noodle was tasty. The products can be favourably processed into boiled noodle or instant noodle in conventional manner. Example 2 Udon Two thousand parts of medium hard flour, 40 parts of common salt, 10 parts of vinegar and 590 parts of water were kneaded for two minutes in a mixer. To the mixture was added 80 parts of crystalline α-maltose, and the resultant was kneaded for eight minutes into dough which was then placed in noodle processing machine and prepared into Udon in usual manner. This noodle exceeded conventional Udon in processibility, stability and preservation, and was process into partially- or completely-dried-noodle. The noodle was boiled easily in less time, approximately 3/4 of that to boil conventional products, and the cooked noodle was excellent in taste qualities. The products can be favourably processed into partially-dried-noodle and completely-dried-noodle in usual manner. Example 3 Soba Fifteen hundred parts of Sobako, 50 parts of hard wheat flour, 6 parts of crystalline α-maltose and small amounts of coloring agents were mixed in a mixer. The mixture was then added with 1 parts of lactic acid and 61 parts of warm water, and the resultant was mixed for ten minutes into dough which was then placed in noodle processing machine and prepared into Soba noodle in usual manner. This noodle exceeded conventional Soba noodle in processibility, stability and preservation. The noodle could be boiled easily in a shortened time of 4/5 relative to that to boil conventional products. The cooked noodle was excellent in flavor and palatability. The product can be favourably processed into partially- or completely-dried-noodle in usual manner. Example 4 Jiaoz One thousand parts of hard wheat flour, 15 parts of common salt, 25 parts of eggs and 275 parts of water were mixed. The mixture was added with 60 parts of crystalline α-maltose, and the resultant was kneaded for fifteen minutes to obtain a dough. After aging for thirty minutes, the dough was shaped into "jiaoz p'i (fresh dough rolled in circle for folding jiaoz's ingredients)". The jiaoz p'i was excellent in processibility, material stability and preservation, and the jiaoz cooked with the jiaoz p'i had an excellent flavor and palatability. Example 5 Premixed flour for preparing noodles and pastes Two thousand parts of hard wheat flour was mixed with 80 parts of crystalline α-maltose powder. The mixture was packaged as premixed flour for preparing noodles and pastes. The premixed flour can be advantageously used to prepare noodles and pastes wherein the addition of water is reduced. Example 6 Premixed flour for preparing noodles and pastes Two thousand parts of medium hard wheat flour was mixed with 60 parts of crystalline α-maltose and 40 parts of common salt. The mixture was packaged as premixed flour for preparing noodles and pastes. The premixed flour can be advantageously used to prepare noodles and pastes with a reduced addition of water. As obvious from the above, in the preparation of noodles and alimentary pastes, incorporation of crystalline α-maltose exerts an activity of binding flour to improve its processibility, and facilitates the preparation of noodles and alimentary pastes having improved stability, preservation and taste qualities with a reduced addition of water. More particularly, even noodles and alimentary pastes, prepared by using crystalline α-maltose in combination with a food preservative to reduce the addition of water, exert synergistically improved preservative ability and shelf life. In addition, the present invention provides a premixed flour for noodles and pastes wherein crystalline α-maltose is incorporated into flour, specifically, a premixed flour which can be easily prepared into noodles and pastes with a reduced addition of water.

Claims: A process for preparing noodles or alimentary pastes, comprising adding crystalline α-maltose and water to flour to prepare a dough; and shaping the dough into noodles or alimentary pastes. A process according to claim 1, wherein the amount of water to prepare the noodles or alimentary pastes is reduced by incorporating crystalline α-maltose into the flour. A process according to claim 1 or 2, wherein less than 10 w/w % of crystalline α-maltose is added to the flour. A process according to claim 1, 2 or 3, wherein crystalline α-maltose is added to the flour and the mixture is kneaded with water to form the said dough. A process according to claim 1, 2 or 3, wherein a premix of flour and crystalline α-maltose is prepared, and the premix is then kneaded with water to form the said dough. A process according to claim 1, 2 or 3, wherein the flour is kneaded with water and crystalline α-maltose is added to the resultant mixture to form the said dough. A process according to any one of the preceding claims, wherein the noodles and alimentary pastes have a low moisture content. A process according to any one of the preceding claims, wherein the noodles or alimentary pastes further comprise a food preservative. A process according to any one of the preceding claims, wherein the noodles are fresh noodles, partially dried noodles, completely dried noodles, steamed noodles, boiled noodles or instant noodles. A premixed flour for preparing noodles or alimentary pastes, comprising flour and crystalline α-maltose. A premixed flour according to claim 10, for use in preparing noodles or alimentary pastes with reduced quantities of water.

Inventors: MITSUHASHI, MASAKAZU, MIYAKE, TOSHIO, SAKAI, SHUZO
Applicants: KABUSHIKI KAISHA HAYASHIBARA SEIBUTSU KAGAKU KENKYUJO
Application year: 1987
Main classification: A23L1
IPC codes: A23L1