CA2466300A1

CA2466300A1 - Functional fibre product for food applications

Info

Publication number: CA2466300A1
Application number: CA002466300A
Authority: CA
Inventors: Jerome Konecsni; Joe Vidal; Cameron Kupper; Petros Loutas; Martin Reaney
Original assignee: Bioriginal Food and Science Corp
Current assignee: Bioriginal Food and Science Corp
Priority date: 2004-05-04
Filing date: 2004-05-04
Publication date: 2005-11-04

Abstract

This invention is in the field of oiled refining and processing, and in particular the production of a functional fiber flax seed flour product from flax seed for use in foods, beverages and nutritional supplements for humans and animal consumption. The invention includes a functional fiber oilseed product with high amounts of-soluble and insoluble dietary fibers, omega-3 fatty acids, protein, phytosterols, lignans, and antioxidants - and low amounts of digestible carbohydrates, saturated and trans fats; with properties useful in enhancing mixing, sheeting, extrusion, baking, frying, and roasting characteristics of human food and beverage products and animal feed products without adversely affecting palatability or appearance attributes; and with considerable extended shelf life compared to prior art functional fiber products. The invention also includes a process for making the functional fiber oilseed product using high pressure and high temperature mixing and extrusion equipment, and high temperature solvent extraction systems.

Description

FUNCTIONAL. FIB12E PRQDXJCT FOR FOOD APPLICATIONS_ This invention is in the Held of oilseed reining and processing, and in particular the production of a functional fiber flour product for use in foods, beverages and nutritional supplements for standard and special diets for human and animal consumption.
The composition of processed foods is an ongoing concern, both fox professional dietitians, and the general public alike. Changes in lifestyle and eating habits have meant that more and more of the foods consumed by consumers arc commercially pzoeessed rather than freshly prepared. Because of tGds, there is increasing concern and attention paid to the composition of processed foods, xz~ order that foods moot reduirements in terms ofnutritional value and digestability.
There are as well different dietary philosophies. Most of the published food guides available in Western countries recommend a diet high in complex carbohydrates and fiber, low in fat and with modest amounts of protein. Typically, it is recommended that _ individuals derive most of their food energy from complex carbohydrate sources such as . . .. ., . ~ . . .. . - " _ ~ . . , ,.
grains and fruits. These same sources are also relatively high in dietary fiber, as~rvell as being low in saturated and traps fats, forms of fat considered to be mare harmful, especially with respect to cardiovascular disease.
In addition to the conventionally accepted diets, there arc a variety of alternative diet regimes that have emerged in the last few decades. The interest in diet and dieting is primarily based on the fact that increased affluence and decreased physical activity in Western society has led to over consumption of food, the reset of which is a significant rise in obesity and in health problems that arc related to obesity, such as cardiovascular disease anal diabetes. Combined with the increasing costs of providing health care, healthful eati~og is now seen as an important factor not only for individuals concerned with theiu personal lealth, but for those who pay the costs of health like health insurers, and the goven~nent where socialized medicine is in place.
While some weight loss and weight management diets adhere to the premise that food selection should be towards foods with love fat, and the bulk of energy be derived from complex carbohydrates, others have suggested that weight less is possible by aggressively restricting simple carbohydrate intake, and consuming mainly protein and fat. Regardless of the relative merits of any particular diet prngram, it is clear that modern day consumers do make food choices based on the perceived health and dietary benefits of particular foods.
Qne of the factors that have gained i~acreasing attention recently is the role of fiber in diet and health. The U.S. Surgeon General recozxtznends that a person should consume 20 ~-35 gm of fiber daily. The average western diet is well below this value, and people in Canada acrd the U.S. typically consume 10 -15 gm daily.
Fiber comes in two forms, soluble and insoluble, and is differentiated by both their physical characteristics and their physiological effects. . Insoluble fiber is comprised of such things as cellulose and lignans, and is the indigestible portion of foods. Insoluble fiber, as the name suggests is fiber that does not dissolve in water. This type of fiber adds bulk to food, and improves the ease of movemenrt of food through the gastrointestinal tract.
In contrast, soluble fiber is soluble in water. Soluble fiber comprises food constituents such as ~umS or pectin. Soluble fiber has many physio).ogical health benefits:
it coats the lining of the digestive tract, delays the emptying of stozn.ach contextts, axed slaws the rate of sugar absorption. The decay in stomach emptying results in a sensation of being foil, and thus provides a mechanical feedback that serves to limit appetite. Slowing the rate of sugar absorption reduces demand on the endocrine pancreas, the source of the hormone

2 xz~sulin, ~vhi~h is secreted in response to increased blood sugar levels.
ivTodez-atizag izisulizi levels is known to lead to more stable regulation of blQad sugar, w-ltich. ia~
turn zxzoderates appetite.
Lignans are members of a class of ph.ytochemicals knawrz as phytoestrogens.
Lignans are well known for their antioxidant properties, and have been shown to reduce the incidence of some forms of cancer, as well as to produce cardio-protective effects in humans. In addition, they possess steroid-like properties and are considered to be beneficial in reducing the adverse symptoms ofmenopau,~,e in women.
x0 -1n recent years, there has also become more popular, a variety of diets based an a gezzeral _ theme of low carbohydrate and high prot.~.,in as well as relatively high fat intake. In .
general each of these diets work by switching the body's metabolism from sugar-burning to fat-burning. The typical sources of low carbohydrate foods include meat, eggs, cheese and other similar animal derived proteins, which also have very little dietary fiber content. These protein sources are relatively expensive as compared to plant foods .
sources making these diets more costly than the conventional diet. 1n additiozz, tlxere is i concern about the potential adverse side effects of a prolonged diet lower in dietary fiber and higher in fat than what is customarily recommended by the U.S. Surgeon General and the American Dietetic Association. As a result, there is a market need and a consumer desire for foods that are relatively low in carbohydrates and fats as well, while maintaining the desirable characteristics of high fiber and protein per the new weight loss diets.
'Those who are health conscious are concerned not just about their dietary energy sources, but also of their dietary micronutrient profiles. The vitamin and mineral contents of foods are frequently published on labels (publication is mandatory in the U.S.) in order to allow consumers to make more fully informed choices as to their food selections. One claw of nutrients of note is the omega-3 fatty acid group (OFAs}. Typically found at

3 luglx levels iti fish, OFAs have been shown in cliW cal studies to z-educe the risk of cardiovascular disease, decrease the risks of blood clottmb, ~l~~rease triglyceride levels in the blood, decrease the ,growth of atherosclcrotic plague and help lower blood prcssme.
The American Heart Association recommends that people eat fish three times a week if possible, because of their naturally high levels of OFAs. There are several disadvantages to fish serving as the primary source of OFAs. First, fish is relatively expensive as a protein som~ee, since in many landlocked parts of the world the source of marine hsh is fairly distant. In addition, it is lanown that some types of fish concentrate mercury, which makes repeated and prolonged consumption of fish a potential health risk.
Mercury toxicity in humans is well documented, anal includes symptoms such as neurological and renal damage, as well as developmental defects in fetuses. As a result, it would be desirable to have a food product relatively high in OFA content, but one which is not derived from a fish source and thus avoids the problems associated with consumption of fish.
A further issue with many foods is their instability. Stable food products which do not degrade in quality arc highly desirable in modern times because many foods az~
now stared .for extended periods and shipped over long distances. Instability in foods includes the development of off flavors or odors due to chemical reactions such as oxidation, which can render foods unpalatable and unfit for consumption. Spoilage due to the effect of enzymes or microorganisms can also adversely affect the nutritional value, palatability, and safety of foods. Food products derived from oilseeds arc especially vulnerable to degradation due to oxidation of the oils over time, and the oxidation.
byproducts may render a food product either unpalatable or unsuitable for use.
A problem in prior art processes for producing oilseed products such as functional fiber flax flour has been their inability to produce a product will not undergo oxidative rancidity spoilage during txormal storage periods.

4 Palatability is of primary ixnportance for all food hz~oducts. Humans are very diserinzinating in tlaeir food preferences with regard to taste, color and texture. Therefore, notwithstanding the nutritional benefits of a food, products quite simply hare to be agreeable to the consumer's palate. A problem in prior art processes for producing oilseed products such as functional fiber flax flour has been their inability to produce a product that can be substituted in any significant proportion for wheat or other traditional flours in baked products such as bread, pizza crust, muffins, and the like without adversely affecting the taste, aroma, color and texture of the finished products.
The prior art flax flour, also commonly referred tv as defatted flax meal, adversely affects taste, color, and texture of the finished baked product, and also adversely affects bizzding properties (how the flax flour binds to other baking ingredients such as salt, sugar, shortening, baking powder, sodas, flavorings, milk and whey powders), baking performance (leavings, oven jump and spread), and baking equipment performance (gumming of equipment, bowl pull away, and machinability of the product).
Given the nutritional advantages of using flour pxvducts derived from flax, ttte issue of palatability presents problems far the food product industry seeking wheat flour substitutes that have high fiber, high protein, low saturated and traps fatty acids and low digestible carbohydrate contents. In order to be functional, flax flour must be able to substitute for traditional cereal-derived flours to enhance nutritional composition significantly but without adversely affecting the traditional appearance, taste and texture characteristics and the palatability of the finished extruded, baked, fried, roasted, or cooked food product. It is also most desirable that the inclusion of functional fiber flax 2S flour product not change the handling properties of dough, batter, or slurry (e.g.
rnachinability or baking performance) if it is to be accepted for use in commercial baking processes, otherwise specialized equipment may be required that would increase the cost of production. Therefore, a functional fiber flax flour product will behava in a manner analogous to ixaditioztal flours, sucb. that wheat eb functional fiber flax flour is used to

5 replace a portion of the traditional flour, existing pracassinb techniques and conditions may still be employed to produce finished products that will be accepted by consumers.
An additional requirement for a functional fiber flax product is that it should have relatively low oil content. Prior art methods often use a solvent extraction step to remove residual oil .remaining after crushing. However, the use of many solvents preclude;;
certification of the resulting product as an 'brganic" product. As the demand for certified organic food products increases, a higher value flax flour product would be one processed without the use o;f solvents. While it is possible to use alcohols that have been certified I O as "organic", the use of alcohol increases the costs of production. A, problem in prior art processes for producing oilseed products such as fluzctionaI fiber flax hour has been their inability to produce a product with low levels of oils and which are not highly susceptible to oxidative rancidity and spoilage.
1t is an object of the present invention to provide an altered functional fiber flax flour product that overcomes pxoblerxis in the prior art. It is a further object of the present .
invention to provide such an altered fu.nckional $ber flak flour product such that it can be substituted in significant proportions for conventional cereal-derived flours without adversely affecting palatability, baking perfozmance or the appearance and palatability of the finished food product. It is a Farther object of the present invention to prnvide such an altered fiwetional fiber flax flour product with extended stability and shelf life in ambient storage conditions.
It is a further object of the present invcxxtion to provide an altered functional fiber flax flour product with high levels of soluble and insoluble dietary fibers, omega-3 fatty acids, protein, and lignans, and low levels of digestible carbohydrate, saturated and traps fats.
It is a further object of the present invention to provide a process that comprises a high pressure and high temperature extruding step between two separate oil expelling steps for G

produein,~ the altered functional fiber t7av flour product.
In one embodiment, the invention provides a stable high fiber altered functional fiber flax floor product that has useful and superior qualities with respect to palatability, machinability, and handling characteristics rxrhen used in baking, extrusion, and cooking processes. The raw material feed stock used is golden flax seed, rather than the traditional brown flax seed. The functional fiber flax Geed flour product is thus light in color, and has reduced off flavors. The altered functional fiber flax flour product has a reduced content of omega-3 fatty acids and net carbohydrate compared to prior art flax 20 flours, arid increased levels of Lignans, protein and fiber compared to prior art flax flours.
The functional fiber flax flour product is stable, with an extended shelf life under ambient storage and handling conditions compared to prior art flax flour, and can be used in significant proportions as a substitute far wheat and other flours, without adversely affecting palatability, machinability, and handling characteristics to produce baked and extruded foods with increased fiber, increased protein, and decreased carbohydrate levels.
Such processed food products also contain nutritionally desirable and elevated levels of omega-3 and lignans not found in most conventional baked and processed food products.
The process used to obtain the functional fiber altered flax flour product of the invention includes an ext~rusioz~ step after the flax has been through a first expeller press. Extrusion involves subjecting th.e initial flax Seed cake exiting the first expeller press to high presswes 30 - 40 bar in a screw extruder Which raises the temperature of the pz~aduct to as high as X30 ° C and forcing the product out through a die, forming pellets. In conventional food processing, such extruders are mad for that purpose, palletizing material into a final foz~n for sale as dog food and the like. In the present process the 1>xgh temperatures and pressures in tloe extruder appear to fracture the oil cells andlor perhaps alter the fiber in such a way that the benefits of the product are achieved.

The palletized flax seed cake then is pressed again its a second expellcr press where more oil is removed, such that the final altered flax cake has au oil content of about 10°/,.
Depending on the situation the final altered flax cake then can be micronizcd to further kill microorganisms although the high temperatures in the extruder do substantially kill all bacteria and the like that might be present. The double pressed final altered flax seed cake in any event is than milled into the final altered functional fiber flax flour product of the invention.
Simply double pressing the flax seed without extruding could bring the oil content of the 1 U final cake down to 1 U%, however the flax flour resulting there from does not have the beneficial and improved properties of stability, palatability, and machinability demonstrated by the fuz~ctioz~al. fiber altered flax flour product of the invention.
Beneficially, the extraction process does not use any solvents such as axe commonly used when attempting to decrease oil content. This allows for the altered flax flour product manufactured by the present process to receive an "organic" certification, and reduces the costs of produ~aion that would be added by processing with solvents such as alcohol that are certified as "organic." Organic foods are becoming az~creasingly desirable and foods so cerrif~ed are typically of higher value.
Oilseed crops such as flax are recognized as producing seeds with several nutritional characteristics desirable for humans and animals. These include the presence of high levels of fiber, both soluble and insoluble, protein, and low levels of digestible carbohydrates. In addition, like other plant sources, the fat content is mainly in the farm of unsaturated fats, which are more desirable in terms of human health. Flax also contains significant levels of omega--3 fatty acids (OFAs), which have been shown through medical research to have a number of beneficial effects on cardiovascular health in humans, and lignans like secoisolariciresinol diglycoside (SDG). 'Ufhen consumed, SDG is converted in the body to the mammalian lignans enterolactone and enterodiol.
These compounds have been shown to provide health benefits, reducing the risks of cancer and heist disease. In woman, lignans have the potential to reduce the unfavorable symptoms of menopause, as well as reduce the incidence of hom,one-related cancers.
In addition, dietary choices have changed over time, and with concerns about obesity and the role of carbohydrates, consumers are seeking out sources of food that are low in simple carbohydrate but high in protein. Furkher, tlae benefits of fiber are also well-documented such that consumers increasingly seek foods with fiber when making choices related to diet.
1 U As a result, the present invention is directed towards producing a functional fiber flax seed flour product that combines the aforementioned health benefits, and which can be used in place of a portion of the wheat flour in baking processes and as a substitute for other sources of fiber aztd protein in food products. The method further provides for a product that is stable and which has an extended shelf life, making it more amenablt to storage and transport.
The Altered functions~l fiber flax fl«ur product:
The final milled altered functional fiber flax flour product has characteristics consistent with the ability of the flour to be used in the production of batter, dough or slung.
Parameters that define the suitability of a flour product for such applications include the water holding and binding properties, mixing ability, texture of the mixed product, the ability to withstand mixing without a loss of structural integrity of the flour particles, the color, favor and the texture that the flour product imparts to the final baked and processed food products in which it is included. Consistency in these patarneters is important to commercial bakers and food processors as it permits standardized recipes to be used, which will yield predictable quality in finished products.

Other factors that arc import.a.tlt in baking processes and food preparation arc the binding properties of a flour or fiber ingredient, i_e. how well it binds ~o ;~~rcar in~trcclie;ncs like Salt, sugar, shortening, baking powder, sodas, flavorings, milk, whey powders and the like, baking performance, and interaction with baking equipment. Equipment gumming, S bowl pull away and machinability of the product are important considerations, especially in commercial baking operations. Water absorption is also a significant concern in co'mrnercial processes including baking and extrusion. Bread typically achieves water absorption levels of 65% to 68%, while water absorption in cakes ranges above 30%. A
functional fiber flax flour that can achieve similar or better water absorption levels as compared to traditional flours will be desirable as increased water absorption, while maintaining taste and texture, allows a baked product to be produced at lower cost.
An important requirement for flour products is that of palatability.
Palatability includes factors such as taste, flavor and color. Additionally, far a flour to be considered palatable by consumers, it must also provide for a finished baked product with certain characteristics of texture. Some of the desirable texture characteristics include case of chewing, the graininess of the baked product, and the size and uniformity of the air spaces that develop in a product during the baking process.
2U In the present case, the altered functio~xal Mbar flax flour product produced by the described process from golden flax seed yields a flour product with properties that make it useful in the production of products such as baked goods, pasta, and other processed food.5. Golden flax seed feed stock, as opposed to the more common brown flux seed, produces a light colored flour product without the taste associated with brawn flax seed.
1'relizninary tests with the functional fiber flax seed flour product have shovsm that it is possible to replace about 25% of the wheat flour that would nonnafly be used in bread with the altered functional fiber flax flour product of the invention, without significantly affecting the taste or appearance of the finished product. In some foods it has been possible to replace up to 40% of the wheat flour with the altered functional fiber flax flour product, while in other foods like pizza crust, currently th.e upper limit appears to be ~ubstaniially Iesv than 25°/...
While golden flax seed is the preferred feedstock, it is also contemplated that a range of altered funetiorAal fiber flax flour products can be obtained by using feedstock of varying proportions of golden and brown flax seeds. The product could be tailored in color and taste to suit the preferences of the end user.
The altered funeNonat fiber flax flour product of the present invention advantageously has a higher water absorption capacity than wheat flour does, and so increased water is used in formulations when the functional 'fiber flax seed flour is blended with wheat flour. To achieve the same consistency of dough, approximately 1.5 to 2 times as much water must be added for each part of functional fiber flax seed flour product as would be used for the si~aailar amount of wheat :hour. Where 25% of the wheat flour is replaced with flax seed flour, this would allow an additiazzal 10-25% water be added as compared to a recipe where only wheat flour was used. The ability to absorb more water allows for a Beater amount of a baked product containing the functional fiber flax seed flour product to be produced from the same amount of starting dry materials.
24 Although the changes are presently undefined, the processing method including high pressure and high temperature extrusioxx has apparently caused changes in the crushed flax seed cake, such that the functional fiber flax seed flour produced from the cake has novel properkies that permit iLw use a flour replacement in baking, extnision and processing without significantly affecting the taste or appearance of the finished products, and without adversely affecting baking, extrusion or processing performance.
Thus, the present invention provides a stable altered functional fiber flax flour product that can be used to produce, in a conventional baking process, baked goods with the nutritional advantages of flax such as increased levels of fiber, proteirx, and increased ligzzaz~ anal decreased levels of digestible carbohydrate. While the azncga-3 fatty acid content of the product of the invention i ; less than that of conventional fl~a.~; flour, the product allows the production of finished baked, extruded, and processed foods with a significant level of beneficial omega-3 fatty acid. Prior art baked, extruded, and processed foods contained no omega-3 fatty acids.
It is anticipated that the method of the invention could be practiced using oilseeds other than flax seed to obtain some advantage.
The functional fiber flax seed flour produced by the present method has been fbrthcr characterized. The results of these analyses show that a functional fiber flax send flour can be produced with lpwer level of digestible carbohydrate, higher level of fiber, and In addition to the features listed above, the functional fiber flax seed flour product 1 S produced by the process of the invention contains significant amounts of nutrients such as calcium, copper, iron, magnesium, niacin, potassium, phosphorous, riboflavin, thiamine and zinc, and is relatively low in sodium.
DESC'RIPT10N OF TAE DRAWINGS:
Whiic the invention is claimed in the concluding portions hereof; preferred embodiments arc provided in the accompanying detailed description which may be best understood in conjunction with the accompanying diagrams where like parts in each of the several diagrams are labeled with like numbers, and where:
Pig. 1 is a flowchart representation of the method of the invention of producing a stable oilseed functional fiber floor product.

Yroduc.tinn of a Stable ~ltcxeci .functional flbcr flax flour l~rodr~ct yr:ith hovel Properties Fig. 1 provides a flowchart .iJ.lustration of the steps comprising the process of the invention. The individual steps are as follows.
Step 7 - Flax Feedstock: Light colored or golden flax seed from storage bins is weighed, and then f~i via a rate controlled auger into a seed conditioner. If the flax seed has moisture content greater than 10% it is first dried in a conventional heated-air seed dryer.
A control mechanism regulates the speed of the auger, such that a continuous flow process is achieved.
Step 2 - Conditioning: The flax seed .feedstock is then passed through a seed conditioner where the moisture content is reduced to approximately 8% by stirring and heating the flax seed to about 35 - 50°C. Such seed conditioners are known in the oilseed processing art.
Step 3 - First Pressin t-u, o expel a first portioxt of oil:
Typically flax seed has oil content of about 40%. After conditioning, the flax seed is pressed in a first expeller press, as is Jv~owz~ in the art, to remove a first portion of oil from the flax seed. The vil is collected for conventional use, and the initial flax calve exiting the first expeller press has oil cozztent of about 16 -1$% by weiglxt.
The pressure and friction of the first expeller presser raises the temperature of the initial flax cake to about 60°C.

C'oz,ventinzlal flax hour or meal is typically made by grinding this initial.
fi7.ax cake into flour, However ttirtlzer steps are required to produce the altered functional t~bez- flax flour product. of the invention.
Stc 4 - Extrudin The initial flax cake exiting the first expeller press is then passed through an extruder to produce pellets. The cxttttder used by the present inventor is an lnsta-Proe~o Model 2000RC Extruder manufactured by Insta-Pro~ International, a division of Triple "F", inc.
of Des Moines, lows, U.S.A. The manufactewcr advertises that the extruder is capable of cooking, expanding, sterilizing, dehydrating and texturizing a wide range of products, and states that by creating heat through friction, the Insta-Pro dry extrusion process allows for high heat, sham-cook time producing high quality feed and food.
The Insta-Prod Model 2000RC Extruder is a rotating screw type extruder with a 5%4 inch screw rotating in a 5 5/16 inch barrel. The Model 2000RC Extruder cazz raise the .
temperatzr.re of the product being extruded to well over 200 ° C. The screw rotates at about G 15 rpxxx. The cake leaves the extruder through the exit orifice as an altered flax cake in the form of pellets.
The temperature of the initial flax cake may fall somewhat when moving from the first expeller press to the extntder, but the screw extruder raises the temperature of the flax cake in the extruder to about 100°C. No oil is removed during the extrusion step, however it appears that some structural changes take place in the flax cake during this step that beneficially alter the properties of the flax cake. It appears that extrusion fractures the oil cells, alters I;he structure of the fiber, or induces some similar alterations in the cake_ 1n any event, the product produced from the extruded seed cake has a longer shelf life than conventional flax flour, and exhibits impraved baking pcrtbrmance.

While the above described Insts-Praet% Model 2000RC Extruder has been used to carry out the process, it is contenaplated other extruders could as well be Lutilized to carry out the extruding step. It is also contemplated extruding such that the temperature of tlae flax cake in the extruder is raised to between 80 and 130 ° C could provide satisfactory results.
Step 5 - Second Pressin t~pel a second portion of oil:
The flax cake pellets are then passed through a second expeller press, where a second portion of oil is expelled. 'fhe oil content of the final altered flax cake exiting the second x0 expeller press is about 10% by weight. It is contemplated that further pressing, or pressing under higher pressures could reduce the oil content of the final altered flax cake tQ about 6% or less.
Step 6 - Milling:

The final altered flax cake can then be micronized with infrared ovens or the like, as is lmown izt the art The high temperatures of the extrusion process however kills substantially all bacteria gad the like, so for many applications microtuzation may not be required. Similarly other prior art operations such as providing a I00%
nitrogen 20 atmosphere during expelling or like operations to reduce oxidation could also be incorporated.
In any event, whether micronized or not, the final altered flax calve is then milled conventionally into the altered flax .flour product of the invention. The final altered flax 2S cake is milled to mesh sizes of 20, 40, 60, 80, and finer mash [ Canadian Standards]. For most applications, the finished functional fiber flax seed flour product will be ~auilled so as to comprise at least 20% of 8U mesh and finer particles.
Results It appears th~.t tllC ComblIlattOrr uI' ht~r~ pr«w~e and high temperature iti tine extension process is effective to produce changes in the resulting flax seed cake. While the precise chemical and structural changes that occur dining processing axe trot fully understood, it is clear that the process results in modification of the functionality of the fiber and perhaps of other constituents. These modifications result i.n an altered functional fiber flax seed flour prnduct with novel properties that are amenable for use as a substitute for wheat and other cereal-derived flours in baked goodh acrd other processed food products, and that has a substantially longer shelf life stability than prior art mulled flax flours. As x0 a result, an altered functional fiber flax flour product can be produced which retains the nntxitional benefits of flax seed, while acquiring novel properties that permit the functional fiber flax seed flour so produced to be useful in baking operations, ar for use in other flour-containing processed food products including pasta and cereals.
Flax seed meal or flour produced by prior art crushing xnethads do not have tl2e necessary properties required to function as an adequate substitute for traditional cereal-derived flours, and do not allow the nutritional benefits of flax seed to be readily enjoyed in cozxumon foods.
It is expected that the reduced levels of omega-3 fatty acids in the altered functional fiber flax flour product of the present invention result fxozn more complete extraction of the oil From the flax seed, as compared to a traditionally Willed flax seed meal or flour (Table 1 ).
In addition, it is thought that the enhancement of the lit;zran content of the finished product contributes to the stability of the product, as lignans are well known as antioxidants. An advantage here is that no artif cial additives axe necessary to produce a stable product with the desired functional characteristics, and so the product is capable of designation as an "organic" food product, increasing the value of the functional fiber flax flour so produced.
1 C~

Claims

CLAIMS:

What is claimed is:

1. An altered functional fiber flax flour product produced by pressing golden flax seed to remove a first portion of oil and produce initial flax cake, extruding the initial flax cake at a temperature between 80 and 130 ° C to produce an altered flax cake, pressing the altered flax cake to remove a second portion of oil and produce final altered flax cake, and milling the final altered flax cake.

2. A process for producing an altered functional fiber flax flour product comprising the steps of:

pressing golden flax seed to remove a first portion of oil and produce an initial flax cake;

extruding the initial flax cake such that a temperature of the initial flax cake rises to between 80 and 130 ° C thereby producing an altered flax cake;

pressing the altered flax cake to remove a second portion of oil and produce a final altered flax cake; and milling the final altered flax cake to produce the altered flax flour product.

3. The process of Claim 2 wherein the temperature of the initial flax cake rises to between 80 and 130°C during extrusion.

4. The process of any one of Claims 2 and 3 wherein the initial flax cake has an oil content between 11% and 20% by weight.

5. The process of any one of Claims 2 - 4 wherein the final altered flax cake has an oil content less than 11% by weight.

6. The process of Claim 5 wherein the final altered flax cake has an oil content less than 11% by weight.

7. The process of any one of Claims 2 - 6 wherein at least 20% of the altered functional fiber flax flour product is of a size of 80 mesh or finer.

8. An altered functional fiber flax flour product produced by the process of any one of Claims 2 - 7.

9. A method of baking a baked product comprising replacing a portion of traditional flour with the altered functional fiber flax flour product of Claim 8.

10. The method of Claim 8 further comprising storing the altered functional fiber flax flour product of Claim 1 for a period of at least 15 months prior to baking.

11. The method of any one of Claims 2 and 9 wherein the traditional flour is at least one of wheat flour, soy flour, rye flour, barley flour and oat flour.

12. The method of any one of Claims 8 and 9 wherein the baked product is bread and wherein the portion of traditional flour replaced by the altered functional fiber flax flour product is greater than 15%.

13. The method of Claim 10 wherein the baked product is a muffin, cake, cookie, pasta or other sweet product and wherein the portion of traditional flour replaced by the altered functional fiber flax flour product is greater than 35%

14. A baked or processed product produced by the method of any one of Claims 8 - 12.

15. A functional fiber flax flour product composition comprising: i) a dietary fiber component comprising: a) soluble fiber, b) insoluble fiber, c) prebiotic agent, and d) lignings, ii) a carbohydrate component, which includes the dietary fiber material, iii) a fat component comprising: a) poly-unsaturated fatty acids, b) omega-3 fatty acids, c) omega-6 fatty acids, and d) saturated fatty acids, and iv) lignan precursors.

16. The functional fiber flax flour product composition of claim 15 wherein the fiber component comprises more than 38% by weight.

17. The functional fiber flax flour product composition of claim 15 wherein the fiber component comprises: a) soluble fiber, b) insoluble fiber, c) prebiotic agent, and d) lignins.

18. The functional fiber flax flour product composition of claim 17 wherein the soluble fiber component comprises one-third of the fiber component and the majority of which is mucilage gum.

19. The functional fiber flax flour product composition of claim 17 wherein the insoluble fiber component comprises two-thirds of the fiber component and is primarily composed of non-starch polysaccharides - cellulose and link Q.

20. The functional fiber flax flour product composition of claim 17 wherein the soluble fiber component further comprises a pre-biotic agent.

21. The functional fiber flax flour product composition of claim 15 wherein the protein component comprises more than 38% by weight.

22. The functional fiber flax flour product composition of claim 21 wherein the composition of the protein component is similar to that of soy protein, and is gluten free.

23. The functional fiber flax flour product composition of claim 15 wherein the fat component comprises less than 15% by weight.

24. The functional fiber flax flour product composition of claim 23 wherein the fat component comprises: i) polyunsaturated fats: a) omega-3 fatty acids, b) omega-fatty acids, ii) monounsaturated fats; and iii) saturated fats.

25. The functional fiber flax flour product composition of claim 24 wherein the polyunsaturated fats comprise more than 7.5% by weight and includes omega-3 fatty acid - alpha-linolenic acid (ALA), and omega-6 fatty acid - linolenic acid.

26. The functional fiber flax flour product composition of claim 24 wherein the monounsaturated fats comprise more than 1% by weight.

27. The functional fiber flax flour product composition of claim 24 wherein the saturated fats comprise less than 2% by weight.

28. The functional fiber flax flour product composition of claim 24 wherein the monounsaturated fats comprise - linoleic acid.

29. The functional fiber flax flour product composition of Claim 24 wherein the saturated fats comprise oleic acid.

30. The functional fiber flax flour product composition of claim 15 wherein the lignan precursor component comprises more than 1.5% by weight.

31. The functional fiber flax flour product composition of claim 16 wherein the lignan component comprises: the lignan precursor secoisolariciresinol diglycoside (SDG).

32. The functional fiber flax flour product composition of claim 15 wherein the ratio of soluble to insoluble dietary fiber is about 1:2 to 1:3.

33. The functional fiber flax flour product composition of claim 15 wherein the ratio of omega-3 to omega-6 fatty acids is about 3:1 to 4:1

34. The functional fiber flax floor product composition of claim 15 wherein the carbohydrate component is selected from the group consisting of digestible carbohydrate material, non-digestible carbohydrate material, and. mixtures thereof, and wherein the non-digestible carbohydrate material is selected from dietary fiber, non-absorbent carbohydrate material, and mixtures thereof.

35. The functional fiber flax flour product composition of claim 15 wherein the average particle size of the dietary fiber is less than about 250 microns.

36. The functional fiber flax flour product composition of claim 35 wherein the average particle size of the dietary fiber is less than 25 microns.

37. The functional fiber flax flour product composition according to claim 15 having a water absorption value of 200% or higher as determined by the farinograph method, AACC Method 54-21A, and a viscosity of 600 centipoise or more, as determined on a 15% solution with a Brookfield® viscometer at 25° C. and a shear rate of sec^-1.

38. A functional fiber flax flour product composition according to claim 15 that can be mixed with cereal flours in various combinations, water, salt, fat, and yeast to make a bread dough which may be baked into a bread, pizza, or focaccia product.

39. A functional fiber flax flour product composition according to claim 15 that can be mixed with cereal flours in various combinations, egg, water, salt, fat, and baking powder to make a batter which may be baked into a cake, muffin, pancake, waffle or crepe.

40. A functional fiber flax flour product composition according to claim 15 that can be mixed with cereal flours in various combinations, water, salt, fat, and yeast to make a pliable dough which may be boiled and baked into a bagel or bialy.

41. A functional fiber flax flour product composition according to claim 15 that can be mixed with cereal flours in various combinations, water, egg, vegetable powders, and fat to make a mixture which may be extruded and dried to form a stable pasta or noodle product.

42. The bread, pizza, or focaccia product according to claim 38 comprising less than 7.0 grams of digestible carbohydrate per 28.35 gm serving.

43. The bread, pizza, or focaccia product according to claim 38 comprising less than 3.0 grams of digestible carbohydrate per 28.35 gm serving.

44. The cake, muffin, pancake, waffle or crepe product according to claim 39 comprising less than 7.0 grams of digestible carbohydrate per 28.35 gm serving.

45. The cake, muffin, pancake, waffle or crepe product according to claim 39 comprising less than 3.0 grams of digestible carbohydrate per 28.35 gm serving.

46. The bagel or bialy product according to claim 40 comprising less than 7.0 grams of digestible carbohydrate par 28.35 gm serving.

47. The bagel or bialy product according to claim 40 comprising less than 3.0 grams of digestible carbohydrate per 28.35 gm serving.

48. The pasta or noodle product according to claim 41 comprising less than 7.0 grams of digestible carbohydrate per 28.35 gm serving.

49. The pasta or noodle product according to claim 41 comprising less than 3.0 grams of digestible carbohydrate per 28.35 gm serving.

50. The high fiber bread, pizza, or focaccia product according to claim 35 having the cell structure and organoleptic properties comparable to conventional bread, pizza, or focaccia, comprising, per 28.35 gm of bread, pizza, or focaccia product: a) at least 5 gm protein; b) about 7.0 gm and less of digestible carbohydrate; c) up to 1.6 gm of omega-3 fatty acids; wherein the bread, pizza, or focaccia has a water activity (a w) of more than about 0.80 and less than about 0.95.

51. The high fiber cake, muffin, pancake, waffle or crepe product according to claim 39 having the cell structure and organoleptic properties comparable to conventional cake, muffin, pancake, waffle ar crepe, respectively, comprising, per 28.35 gm of said cake, muffin, pancake, waffle or crepe product: a) at least 5 gm protein; b) about 7.0 gm and less of digestible carbohydrate; c) up to 1.6 gm of omega-3 fatty acids;
wherein the cake, muffin, pancake, waffle or crepe has a water activity (a w) of more than about 0.80 and less than about 0.95.

52. The high fiber bagel or bialy product according to claim 40 having the cell structure and organoleptic properties comparable to conventional bread, comprising, per 28.35 gm of bagel or bialy product: a) at least 5 gm protein; b) about 7.0 gm and less of digestible carbohydrate; c) up to 1.6 gm of omega-3 fatty acids; wherein the bagel or bialy has a water activity (a w) of more than about 0.80 and less than about 0.95.

53. The high fiber pasta or noodle product according to claim 41 having the cell structure and organoleptic properties comparable to conventional pasta or noodle, comprising, per 28.35 gm of pasta or noodle product: a) at least 5 gm protein; b) about 7.0 gm and less of digestible carbohydrate; c) up to 1.6 gm of omega-3 fatty acids;
wherein the pasta or noodle has a water activity (a w) of more than about 0.80 and less than about 0.95.