High protein flakes derived from protein pellets
The present invention relates to methods for preparing high protein flakes comprising forming a protein into a protein pellet and introducing the protein pellet and a food component into a cooker. The protein pellet and the food component are cooked in the cooker to give a cooked food product. The food product is then formed into a high protein flake.
1. A method of preparing a flaked cereal product comprising:
providing a first mixture having a protein content of at least 80% by weight;
preconditioning the first mixture to form a dough;
providing the dough to an extruder to form a protein extrudate;
forming a plurality of first pellets from the protein extrudate;
providing the first pellets, at least one grain, a sugar, water, and a starch to a cooker to form a second mixture, wherein the first pellets are provided in an amount of 15% to 30% by weight of the second mixture:
cooking the second mixture;
forming the second mixture into a plurality of second pellets; and
forming the plurality of second pellets into a plurality of flakes.
2. The method of claim 1 , wherein the first mixture includes a vegetable protein and water.
3. The method of claim 1 , further comprising preconditioning the first mixture to form the first mixture into a first dough.
4. The method of claim 1 , wherein upon providing the dough to the extruder a moisture level of about 30% to 60% by weight is obtained.
5. The method of claim 1 , wherein the plurality of first pellets are cylindrically shaped and have a diameter of at least 1 mm and a length of at least 0.5 mm.
6. The method of claim 1 , wherein the plurality of the first pellets have a moisture content of less than or equal to 20% by weight.
7. The method of claim 1 , wherein the plurality of first pellets have a density from about 0.02 g/cm 3 to about 0.1 g/cm 3 .
8. The method of claim 1 , wherein the cooker is a rotary cooker and the second mixture is cooked for a cycle time of about 30 minutes to 90 minutes, at a cooking temperature of 250° F. to 280° F., and at a pressure of 15 psig to 25 psig to a moisture content of 30% to 50% by weight.
9. The method of claim 1 , wherein the plurality of first pellets have a hardness of at least 1000 grams.
10. A method of preparing a flaked cereal product comprising:
forming a plurality of first pellets from a first mixture, each of the pellets having a protein content of at least 80% by weight, and a diameter of at least 1 mm;
providing the plurality of first pellets and at least one of a grain, a sugar, or a starch to a cooker to form a second mixture, wherein the first pellets are provided in an amount of 15% to 30% by weight of the second mixture;
cooking the second mixture;
forming the second mixture into a plurality of second pellets; and
forming the plurality of second pellets into a plurality of flakes.
11. The method of claim 10 , wherein the first mixture includes a vegetable protein and water.
12. The method of claim 10 , further comprising preconditioning the first mixture to form the first mixture into a dough prior to forming the plurality of first pellets.
13. The method of claim 12 , further comprising providing the dough to an extruder prior to forming the plurality of first pellets, wherein a moisture level of about 30% to 60% by weight is obtained.
14. The method of claim 10 , wherein the plurality of first pellets are cylindrically shaped and have a diameter of at least 1 mm and a length of at least 0.5 mm.
15. The method of claim 10 , wherein the plurality of the first pellets has a moisture content of less than or equal to 20% by weight.
16. The method of claim 10 , wherein the plurality of first pellets have a density from about 0.02 g/cm 3 to about 0.1 g/cm 3 .
17. The method of claim 10 , wherein the cooker is a rotary cooker and the second mixture is cooked for a cycle time of about 30 minutes to 90 minutes, at a cooking temperature of 250° F. to 280° F., and at a pressure of 15 psig to 25 psig to a moisture content of 30% to 50% by weight.
18. The method of claim 10 , wherein the plurality of first pellets have a hardness of at least 1000 grams.