US-12616213-B1 - Method of manufacture and composition of a dough based item including protein

US12616213B1US 12616213 B1US12616213 B1US 12616213B1US-12616213-B1

Abstract

A method of manufacture and a composition for the technology as disclosed herein, which includes a method of manufacture and composition for a dough tortilla item including protein. The dough tortilla composition as disclosed and claimed herein can be manufactured using a corn masa based flour and/or utilizing other grain based flours such corn, rice, barley. For one implementation of the technology other leguminous based flours or chestnut base flours, or various bean base powder, or cauliflower based powders used individually or in combination with any of the other types of flours described herein. The technology as disclosed and claimed provides a dough based tortilla or other dough based item that is a protein enhanced alternative to conventional tortillas and other dough based products. This invention results in a dough tortilla that has more protein, more complete protein, and fewer carbohydrates than conventional wheat dough tortilla.

Inventors

Shanna Motl
Mike Langham
Russell Thomas
Travis Ellis

Assignees

TYSON FOODS, INC.

Dates

Publication Date: 20260505
Application Date: 20190723

Claims (7)

1 . A composition for a dough based item comprising: a dough mixture comprising, 52% to 75% chilled animal meat derived protein by weight of total mixture; 15% to 32% masa by weight of total mixture; up to 9.3% water by weight of total mixture; and up to approximately 0.7% Salt by weight of total mixture, where the chilled animal meat derived protein is size reduced.
2 . The composition for a dough based item as recited in claim 1 , comprising: 1% to 6% animal Skin by weight of total mixture; and where the 52% to 75% chilled animal meat derived protein is 52% to 60% chicken by weight of total mixture.
3 . The composition for a dough based item as recited in claim 2 , comprising: one or more of a first ingredient that modifies flavor and a second ingredient that increases shelf life.
4 . The composition for a dough based item as recited in claim 2 , where the chicken is approximately 52% by weight of the total mixture; the masa is approximately 32% by weight of the total mixture; the animal skin is approximately 6% by weight of the total mixture; the water is approximately 9.3% by weight of the total mixture and the salt is approximately 0.7% by weight of the total mixture.
5 . The composition for a dough based item as recited in claim 1 , where the composition includes one or more of a cauliflower powder flour; a bean based powder flour; and a tuber based flour.
6 . The composition for a dough based item as recited in claim 5 , where the chilled animal meat derived protein is one or more of ground chicken meat derived protein, ground turkey meat derived protein, ground pork derived protein, ground beef derived protein and ground mutton derived protein.
7 . The composition for a dough based item as recited in claim 6 , where the chilled animal meat derived protein is ground to approximately 3/32 of an inch.

Description

BACKGROUND Field This technology as disclosed herein relates generally to methods of manufacturing and compositions of dough and, more particularly, to methods of mixing ingredients for dough and composition of ingredients for dough. Background In recent years, a trend in food product development has been toward providing products suitable for both quick preparation and convenient consumption. Manufacturers of these food items often produce them in shelf ready configurations and are often provided precooked and frozen. Even though many new products meeting these needs have been introduced commercially in recent years, there remains a need for a greater variety of healthful yet convenient products. The ability to commercially produce and sell any specific food product often depends on whether the product can be produced with economies of scale or other efficiencies while still meeting the other criteria of both quick preparation and convenient consumption. Various bakery products have been developed that provide both quick preparation and convenient consumption, including various precooked pizza doughs, bread sticks, flat breads, pitas and tortillas. However, these doughs and breads don't provide much nutritional value. Dough products, generally speaking, can be difficult to manufacture in a large production environment and filled dough products even more so, can present handling and processing challenges that can be difficult to overcome while achieving the flexibility and processing speeds desirable for economical manufacturing. Dough products, whether filled or unfilled, tend to be sticky at some point during their manufacture, which can cause them to be difficult to handle or require equipment cleaning steps once handled. If fillings or toppings are included in a product, the steps of applying or inserting a filling or topping in a way that minimizes waste or mess can present additional challenges. Preparation of leavened/unleavened dough products may also require the dough to increase in volume upon expansion during a proofing, leavening, or rising step, or when baked. Such expansion will affect oven or proof box space, time, and possibly final packaging size requirements. With these difficulties, little has been produced in the food industry that modifies the basic dough processes in order to improve the nutritional value of the dough item itself. It would be desirable to provide new ways to achieve efficiencies in the manufacture of dough products, including filled dough products, that also improves the nutritional value of the dough product. Tortillas are manufactured commercially by forming a dough, flattening the dough to form dough flats, and baking the flats until they leaven and ultimately set. Representative manufacturing processes include pressing, die cutting and hand cutting. The dough typically comprises flour, a leavening system, and water. In case of a tortilla dough, a corn system includes corn, lime and water. The leavening system comprises a leavening base and one or more leavening acids. The leavening base and leavening acid(s) react to yield carbon dioxide (neutralization reaction), which, along with any other gases present, leavens the dough. A problem that can arise during manufacture of tortillas is inadequate pliability and strength of the dough. Conventionally, modifying the dough to make it more pliable has weakened the dough. Modifying the dough to strengthen it has made it less pliable. Inadequate pliability and strength negatively impact the handling and processing of the dough as well as the properties of the end product tortilla/chip. Inadequate pliability renders the dough more difficult to handle and process. Inadequate strength reduces the ability of the dough to retain gas during handling and processing. With these difficulties, little has been produced in the food industry that modifies the basic dough processes for tortillas and other like items in order to improve the nutritional value of the dough item itself. It would be desirable to have a dough composition having excellent pliability and strength that also has increased nutritional value. It would be desirable to have a method for manufacturing tortillas wherein the tortillas have excellent physical and product properties and increased nutritional value. A better method of manufacturing and a better composition for a tortilla dough item is needed for improving its nutritional value and that is suitable for both quick preparation and convenient consumption. SUMMARY The technology as disclosed herein includes a method of manufacture and composition for a dough tortilla item including protein. Dough is a thick, malleable, sometimes elastic, paste made out of any grains, leguminous or chestnut crops. Dough for a tortilla is traditionally manufactured by mixing corn masa based flour with a small amount of water and/or other liquid, and sometimes includes yeast and/or other leavening agents as well as other ingredient