Process for producing a new appetizer and product by process of the same

Abstract: The subject invention is a process for production of an appetizer comprising the steps of: a) grinding nixtamalized corn to a particle size that is not perceptible by touch; b) adding between about 1.0 to 1.5 weight percent lime; c) boiling the mixture of corn and lime until the mixture contains between about 34 to 38 weight percent moisture; d) soaking the mixture for between about 12 to 16 hours; and e) adding water to the mixture to obtain a moisture level between about 40 to 50 weight percent, and an appetizer product produced by such process. This invention has the quality of permitting a new product from the nixtamalized corn dough, which is acceptable to the public, and a technology that allows for the accomplishment of the above objective.

Description: This invention is related to the appetizer production industry. More specifically, the invention relates to a process for making a new appetizer based on a nixtamalized corn (corn processed for making tortillas) dough and a product made by this method. BACKGROUND OF THE INVENTION In the appetizer production industry there has been an explosion of new products, from simple roasted peanuts, going through potato chips. The differences among them have to do with many factors -- the raw material starting from which such appetizers are made, the flavor that is added to them, the process of appetizer production, among other factors. For example, we have simple salted potato chips, which may differ according to the frying process. There are peanuts, which may be fried, roasted, only salted, or made with dry and ground chili powder. With the development of food industry technology, new products have appeared. These products are obtained by means of extrusion of some dough of a different composition. This technology permits obtaining products of more homogeneous characteristics and of more varied conformation and dimensions. For example, we have the imitations of slices of potato chips, fried flours, and mixtures of flours and other raw materials, shaped as "churros" (fritters), more or less regular in their shape, and so forth. On the other hand, there are at present, basically, two products made from nixtamalized corn dough - "totopos" (corn tortillas) and the so-called "churritos" (small "churros" or small fritters). "Totopos" may be triangular or round in shape. Until now, there have been no modifications to these types of products made from nixtamalized corn dough. To gain part of the market, a nixtamalized corn dough product different from those already known would be quite desirable. The modifications have consisted in adding new flavors by means of new mixtures of flavors. However, the product conformation has not been altered and this factor of generation of new products has not been developed. Conformation changes, although they mean a certain advantage due to the novelty effect on the public in general, and on children in particular, they also mean new technologies of conformation and manufacture, are necessary to develop. Besides, the product in itself, in spite of having novelty, does not mean it will have acceptance on the market, and important investments are required including research and development of new products and the processes to produce them. Furthermore, tasting panels provide a more precise idea of the acceptance of the new product on the market. SUMMARY OF INVENTION The subject invention is a process for production of an appetizer comprising the steps of: a) adding between about 1.0 percent to 1.5 weight percent lime; b) boiling the mixture of corn and lime until the mixture contains between about 34 to 38 weight percent moisture; c) soaking the mixture for between about 12 to 16 hours; d) grinding nixtamalized corn to a particle size that is not perceptible by touch; and e) adding water to the mixture to obtain a moisture level between about 40 to 50 weight percent. The word nixtamal is a Spanish word. Nixtamalized corn means cooking corn. The lime, calcium hydroxide (CaOH 2 ), is added to prevent cellulose from sticking to the grains of corn. The grain mixture boils at between about 91 to 93 °C or between about 196 to 200 °F. This method permits an appetizer product made from nixtamalized corn dough to be shaped in a wide variety of configurations and dimensions including that of a small taco attractive to the consuming public. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS One of the aspects of this invention consists in a new appetizer made from nixtamalized corn dough that has the shape of a small Mexican "taco" (rolled up tortilla). This "taco" is fried to give it the feature of being crackling, but not too greasy. Some special flavor can also be provided to it with a flavoring composition. Once the product has been defined starting from marketing studies, and once the product has been defined from the first instance, the process for obtaining the same requires multiple tests. Production of a small "taco" from the small raw tortilla meant barriers unlikely to be overcome due to the impossibility of giving a perfect rolling up to the product before frying it. Initially, it was decided roll up of the tortilla while still raw. In the beginning it was thought to use the tortilla with a round conformation. As it turned out, this conformation was too thick in the center, creating problems when frying it since too much grease was retained which was not accepted by the public and creates a higher production cost. To solve the problem, a conformation of a small raw tortilla, a slice of pie (triangular) or the form of a caricature of a heart was used. While the problem was solved quite well, the consistency of the dough was not adequate to provide it a certain superficial adherence. The raw tortilla could not adhere appropriately to the surface of the element with which the rolling up was performed. This consistency did not permit rolling up without breaking the small tortilla. Besides such consistency, an adequate thickness of such small tortilla was sought so that the process would work well. It was found that the optimum thickness should be of approximately 1 mm, and such thickness could vary up to 2 mm. A smaller thickness would mean problems for its conformation and a thickness greater than 2 mm would have frying problems by keeping too much grease or high oil content, a longer frying time, and a harder consistency. The nixtamalization process of the corn and the grinding of the same should be the optimum ones to obtain a good consistency. In this process, the parameters of time and temperature of nixtamalization should be such to obtain in the grain moisture of between about 34 to 38%. It was found that the amount of lime added for nixtamalization should be between about 1.0 and 1.5% in weight with respect to the dry weight of corn. The resting time of the nixtamalization corn will vary between about 12 and 16 hours, the time required to obtain moisture in the grain mixture of between about 48 to 50%. In any case, grinding should be performed such as not to have a sandy consistency to the touch. That is, that the size of the particle should be such that it is not detected by touch. The amount of moisture to be added when grinding, if this is necessary, should be enough in order for there to be 50% moisture in the dough obtained. This resulted in a flexible tortilla with a good characteristic of surface adherence to make rolling up possible. Another feasible option is the utilization of nixtamalized corn flour to shape the small raw tortilla in the defined conformation. Preferred starting conformations of the small raw tortilla include a slice of pie (triangular) or the form of a caricature of a heart. The rheologic features of the dough made from the grinding of nixtamalized corn and that of the dough made from reconstituted nixtamalized corn flour are quite different, since the flour has a greater absorption of water than the dough. The final product should have a percentage of grease of approximately 34% in weight to ensure adequate frying. EXAMPLE 1 (Comparative) The corn was nixtamalized with 0.75% of lime with respect to the dry weight of corn. The boiling time and temperature required to obtain the moisture from 34 to 38% in weight in the grain was too much. The mixture was left resting until it reached room temperature. When grinding the grain down to such a degree that the granules were no longer perceptible to the touch, the dough reaching 50% moisture resulted and was not malleable. The dough was very loose. EXAMPLE 2 (Comparative) The corn was nixtamalized with 2.0% lime with respect to the dry weight of corn. A moisture from 34 to 38% in weight in the grain was obtained and it was left resting until it reached room temperature after boiling. When grinding the grain down to a degree such that the granules were no longer perceptible to the touch, the dough was of adequate consistency resulted, but having unacceptable flavor and color. EXAMPLE 3 The corn was nixtamalized with 1.5% lime with respect to the dry weight of corn. A moisture from 34 to 38% in weight in the grain was achieved. The grain was left resting until it reached room temperature. When grinding the grain down to a degree such that the granules were no longer perceptible to the touch, the dough was of adequate consistency resulted having acceptable flavor and color. EXAMPLE 4 The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn, and boiled to obtain moisture from 34 to 38% in weight in the grain. Once room temperature was reached, the grain was ground down to a degree such that the granules were no longer perceptible to the touch resulting in the dough was of adequate consistency and acceptable flavor and color. EXAMPLE 5 (Comparative) The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn. After boiling the mixture, 25% moisture in weight in the grain was obtained. Upon cooling to room temperature, the grain was ground down to a degree such that the granules were no longer perceptible to the touch. Water was added to 50%. The dough was of loose consistency, could not be handled and fell apart. A small tortilla could not be formed. EXAMPLE 6 (Comparative) The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn. 40% moisture in weight in the grain was obtained. After reaching room temperature, the grain was ground to a degree such that the granules were no longer perceptible to the touch. Water was added to 50%, resulting in a dough of chewing gum consistency that could not be handled, did not adhere to any surface, and could not form a small tortilla. EXAMPLE 7 The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn. After heating over a period of time, 34% moisture in weight in the grain was obtained. After reaching room temperature, the grain was ground to a degree such that the granules were no longer perceptible to the touch. Water up to 50% was added, resulting in dough of adequate consistency for forming the small tortilla. EXAMPLE 8 The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn and boiled to obtain 38% by weight moisture in the grain mixture. After cooling to room temperature, the grain was ground down to a degree such that the granules were no longer perceptible to the touch and water was added up to 50% by weight. The dough was of adequate consistency for forming the small tortilla resulted. EXAMPLE 9 The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn and boiled to obtain 38% by weight moisture in the grain mixture. The grain was left resting until it reached room temperature. The grain was ground down to a degree such that the granules were no longer perceptible to the touch. Water was added up to 45% by weight. This resulted in dough of adequate consistency to form a small tortilla and perform rolling up of the same. EXAMPLE 10 (Comparative) The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn, and the boiling time required to obtain 38% moisture in weight in the grain. When grinding the grain down to a degree such that the granules were no longer perceptible to the touch, water was added up to 40% by weight. This resulted in dough of fragile and dry consistency for forming the small tortilla and for performing rolling up of the same. EXAMPLE 11 (Comparative) The corn was nixtamalized with 1.0% lime with respect to the dry weight of corn. After heating to obtain 38% moisture in weight in the grain, the grain was ground to a degree such that the granules were no longer perceptible to the touch and water was added up to 50% by weight. This resulted in a dough of chewing gum consistency with an excessive gelatinization of starch, which caused multiple problems to form a small tortilla and perform rolling up of the same. EXAMPLE 12 (Comparative) Nixtamalized corn flour was reconstituted by adding water up to 50%. This resulted in dough of adequate consistency to form the small tortilla and perform rolling up of the same.

Claims: A process for production of an appetizer comprising the steps of: a) adding lime in a quantity between 1.0 to 1.5 weight percent with respect to the dry weight of corn; b) boiling the mixture of corn and lime until the mixture contains between 34 to 38 weight percent moisture; c) soaking the mixture for 12 to 16 hours; and d) grinding the nixtamalized corn to a particle size that is not perceptible by touch; and e) adding water to the mixture to obtain a moisture level between 40 to 50 weight percent. The process according to claim 1, characterized in that , in addition to the nixtamalized corn, a nixtamalized corn flour reconstitution is used, which confers to the mixture a final moisture of 40 to 50 weight percent. The process according to claim 1 or 2, characterized in that the final moisture is conferred to the dough by adding water during the grinding of the nixtamalized corn. The process according to claim 1 or 2 characterized in that the final moisture is conferred to the mixture by adding water after grinding. The process according to any of the preceding claims characterized in that a dough is obtained and the shape conferred to the dough is that of a slice of pie. The process according to any of claims 1 to 4 characterized in that a dough is obtained and the shape conferred to the dough is that of a caricature of the heart. The process according to any of claims 1 to 4 characterized in that a dough is obtained, a shape conferred to the dough, and the shaped dough is fried. An appetizer obtainable by the process of any of claims 1 to 7.

Inventors: RODRIGUEZ ESPIRIDION VALDES, SANCHEZ EFRAIN JOEL PENA, RODRIGUEZ, ESPIRIDION VALDES, SANCHEZ, EFRAIN JOEL PENA
Applicants: CENTRAL IMPULSORA S A DE C V, CENTRAL IMPULSORA, S. A. DE C.V.
Application year: 2001
Main classification: A23L1
IPC codes: A21D13, A23L1, A21D2