Quick-Cook Grains and Pulses

Abstract

A method for making a quick-cook grain or pulse via flat plate compression or gun puffing by controlling the porosity of the grain or pulse. Further, the grain or pulse made in accordance with this invention retains the texture, flavor and appearance of the original grain or pulse.

What is claimed is: 
     
         1 . A method of processing whole kernel grains to make quick-cook grains by controlling the porosity of the grains while maintaining the identity of the grains comprising the steps of:
 introducing de-hulled whole kernel grains, having a moisture content of about 8-18%, between two heated devices;   compressing the whole kernel grains between the heated devices for about 1-5 seconds;   heating the whole kernel grains between the heated devices and causing the water within the grains to reach a superheated condition;   instantaneously reducing the whole kernel grains to atmospheric pressure to create a slightly puffed grains with a reduced bulk density; and   discharging the slightly puffed whole kernel grains from the heated devices;   wherein the slightly puffed whole kernel grains have a bulk density between 260-700 g/L and a final moisture content below about 14% and an a w  less than about 0.65.   
     
     
         2 . The method of  claim 1  wherein the heated devices are at least two heated flat plates. 
     
     
         3 . The method of  claim 2  wherein the flat plates have a temperature of about 150-250° C. and the pressure exerted on the grain is about 500 to about 1000 psig. 
     
     
         4 . The method of  claim 2  wherein after compressing, starch in the whole kernel grains is partially gelatinized. 
     
     
         5 . The method of  claim 2  wherein after compressing starch in the whole kernel grains is fully gelatinized. 
     
     
         6 . The method of  claim 2  wherein the following steps are performed prior to the step of introducing the whole kernel grains between the flat plates:
 mixing the de-hulled whole kernel grains with ingredients selected from the group consisting of water, flavor, nutrients, antioxidants and mixtures thereof to create a grain mixture; 
 cooking the grain mixture under pressure to partially or fully gelatinize starch in the grains and arrive at a cooked grain mixture with a final moisture content of about 30-40%; and 
 drying the cooked grain mixture. 
 
     
     
         7 . The method of  claim 6  wherein the cooked grain mixture is dried to about 11-13% moisture and subsequently stored. 
     
     
         8 . The method of  claim 6  wherein the cooked grain mixture is dried to about 12-18% when proceeding immediately to the compressing between the flat plates. 
     
     
         9 . The method of  claim 1  wherein the heated devices are at least two counter-rotating parallel rolls. 
     
     
         10 . The method of  claim 1  wherein the heated devices are at least two mated non-flat plates. 
     
     
         11 . A method of processing pulses to make quick-cook pulses by controlling the porosity of the pulses while maintaining the identity of the pulses comprising the steps of:
 introducing whole pulses having a moisture content of about 8-18% between two heated devices;   compressing the whole pulses between the heated devices for about 1-5 seconds to gelatinize starch contained in the pulse;   instantaneously reducing the pulses to atmospheric pressure to create a slightly puffed pulse with a reduced bulk density;   discharging the slightly puffed pulses from the heated devices;   wherein the pulse has a bulk density between 260-700 g/L, the final moisture content is below about 14% with an a w  less than about 0.65.   
     
     
         12 . The method of  claim 11  wherein the heated devices are at least two counter-rotating parallel rolls. 
     
     
         13 . The method of  claim 11  wherein the heated devices are at least two mated non-flat plates. 
     
     
         14 . A method of processing grains to control the porosity of the grains while maintaining the identity of the whole grains comprising the steps of:
 introducing whole kernel grains having a moisture content of about 8-14% into a gun puffing chamber and sealing the chamber;   raising the pressure of the chamber to reach a pressure of about 80-175 psig at a temperature of about 162-192° C. until the moisture of the whole kernel grains reaches a moisture content of about 14-30%;   instantaneously reducing the whole kernel grains to atmospheric pressure to create slightly puffed grains with reduced bulk density; and   dehydrating the whole kernel grains to reach a moisture content below about 14% and an a w  less than about 0.65.   
     
     
         15 . The method of  claim 14  wherein the moisture content of the whole kernel grains following dehydration is about 10-13%. 
     
     
         16 . The method of  claim 14  wherein the moisture content of the whole kernel grains following dehydration is about 3-5%. 
     
     
         17 . The method of  claim 14  wherein the prior to the step of introducing the raw whole kernel grain into the gun puffing chamber, the raw grain is preheated to increase the temperature of the whole kernel grain to about 120° C. 
     
     
         18 . The method of  claim 14  wherein the method of processing the whole kernel grains also includes pre-hydrating and tempering the whole kernel grains to bring the moisture content to about 13-25% and then preheating the grains to bring the temperature of the grains to about 90° C. prior to introducing the grains into the gun puffing chamber. 
     
     
         19 . A method of processing whole pulses to control the porosity of the whole pulses while maintaining the identity of the whole pulses comprising the steps of:
 introducing whole pulses having a moisture content of about 8-14% into a gun puffing chamber and sealing the chamber;   raising the pressure of the chamber to reach a pressure of about 80-175 psig at a temperature of about 162-192° C. until the moisture within the whole pulses reaches a moisture content of about 14-30%;   instantaneously reducing the whole pulses to atmospheric pressure to create a slightly puffed whole pulses with a reduced bulk density; and   dehydrating the whole pulses to reach a moisture content below about 14% and an a w  less than about 0.65.   
     
     
         20 . The method of  claim 19  wherein the moisture content of the pulses following dehydration is about 10-13%. 
     
     
         21 . The method of  claim 19  wherein the moisture content of the whole pulses following dehydration is about 3-5%. 
     
     
         22 . The method of  claim 19  wherein the prior to the step of introducing the whole pulses into the gun puffing chamber, the whole pulses are preheated to increase the temperature of the pulses to about 90° C. 
     
     
         23 . The method of  claim 19  wherein the method of processing also includes tempering the whole pulses to bring the moisture content to about 13-25% and then preheating the pulses to bring the temperature of the whole pulses to about 90° C. prior to introducing the pulses into the gun puffing chamber. 
     
     
         24 . A method of processing split pulses to control the porosity of the split pulses while maintaining the identity of the split pulses comprising the steps of:
 introducing split pulses having a moisture content of about 8-14% into a gun puffing chamber and sealing the chamber;   raising the pressure of the chamber to reach a pressure of about 80-175 psig at a temperature of about 162-192° C. until the moisture within the whole pulses reaches a moisture content of about 14-30%;   instantaneously reducing the split pulses to atmospheric pressure to create slightly puffed split pulses having a reduced bulk density; and   dehydrating the split pulses to reach a moisture content below 14% and an a w  less than about 0.65.   
     
     
         25 . The method of  claim 24  wherein the moisture content of the pulses following dehydration is about 10-13%. 
     
     
         26 . The method of  claim 24  wherein the moisture content of the split pulses following dehydration is about 3-5%. 
     
     
         27 . The method of  claim 24  wherein prior to the step of introducing the split pulses into the gun puffing chamber, the split pulses are preheated to increase the temperature of the pulses to about 90° C. 
     
     
         28 . The method of  claim 24  wherein the method of processing also includes tempering the split pulses to bring the moisture content to about 13-25% and then preheating the pulses to bring the temperature of the split pulses to about 90° C. prior to introducing the pulses into the gun puffing chamber. 
     
     
         29 . The quick-cook grains produced by the methods of  claims 1  and  12 . 
     
     
         30 . The quick-cook pulses produced by the methods of  claims 11 ,  19  and  24 .