Cereals processing technology Edited by Gavin Owens ©2001 Woodhead Publishing Ltd. Published by Woodhead Publishing Limited Abington Hall, Abington Cambridge CB1 6AH England www.woodhead-publishing.com Published in North and South America by CRC Press LLC 2000 Corporate Blvd, NW Boca Raton FL 33431 USA First published 2001, Woodhead Publishing Limited and CRC Press LLC ß 2001, Woodhead Publishing Limited The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publishers cannot assume responsibility for the validity of all materials. Neither the authors nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. 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Woodhead Publishing Limited ISBN 1 85573 561 X CRC Press ISBN 0-8493-1219-1 CRC Press order number: WP1219 Cover design by The ColourStudio Project managed by Macfarlane Production Services, Markyate, Hertfordshire ([email protected]) Typeset by MHL Typesetting Limited, Coventry, Warwickshire Printed by TJ International, Padstow, Cornwall, England ©2001 Woodhead Publishing Ltd. Contents List of contrib utors 1 Introduction W. G. Owens, Satake Centre for Grain Process Engineering, University of Manchester Institute of Science and Technology Part I Cereal a nd flo ur production 2 Cereal production methods E. J. Evans, University of Newcastle 2.1 Introduction 2.2 Varietal selection 2.3 Crop establishment 2.4 Crop nutrition 2.5 Weed control 2.6 Disease control 2.7 Pest control 2.8 Harvesting and grain storage 2.9 References and further reading 3 Wheat , corn and coars e grai ns mi lling W. G. Owens, Satake Centre for Grain Process Engineering, University of Manchester Institute of Science and Technology 3.1 Introduction 3.2 The evolution of modern flour milling 3.3 The flour milling process ©2001 Woodhead Publishing Ltd. 3.4 Recent developments in flour milling 3.5 On-line process measurement 3.6 Automation and its role within the milling industry 3.7 Milling research 3.8 Optimisation of processes 3.9 The future 3.10 References 4 Biotechnol ogy, cereal and cere al products quality R. J. Henry, Southern Cross University, Lismore 4.1 Introduction: productivity, product quality and safety 4.2 Herbicide resistance 4.3 Disease resistance 4.4 Improved nutritional properties 4.5 Improved processing qualities 4.6 Improved cereal quality control 4.7 Examples of transformed wheat and barley 4.8 Examples of transformed rice and maize 4.9 Future trends 4.10 Sources of further information and advice 4.11 References Pa rt II Cereal pro ducts 5 Rice production B. S. Luh, University of California, Davis 5.1 Introduction 5.2 Rice grain quality indicators 5.3 Rice cultivation, including genetic modification 5.4 Processing issues 5.5 Rice snack foods 5.6 Rice noodles, parboiled and quick-cooking rice 5.7 Canned and frozen rice 5.8 Extruded rice 5.9 Shredded rice 5.10 Baby foods 5.11 Puffed rice cake Õ 5.12 Rice Krispies 5.13 Future trends 5.14 Sources of further information 5.15 Acknowledgements 5.16 References ©2001 Woodhead Publishing Ltd. 6 Pasta pr oduction B. A. Marchylo and J. E. Dexter, Canadian Grain Commission, Winnipeg 6.1 Introduction 6.2 History of pasta processing 6.3 Pasta-making process 6.4 Advances in drying technology 6.5 Raw material selection 6.6 The future 6.7 References and further information 7 Asian noodle proces sing D. W. Hatcher, Canadian Grain Commission, Winnipeg 7.1 Introduction 7.2 Noodle diversity 7.3 White salted noodles 7.4 Alkaline noodles 7.5 Instant noodles 7.6 Buckwheat noodles 7.7 Future of the industry 7.8 Summary 7.9 General sources of information 7.10 References 8 Breakfa st cere als R. B. Fast, Consultant, Robert B. Fast Associates Inc., Poultney 8.1 Introduction 8.2 The industry and its structure 8.3 Recent trends and technology developments 8.4 The future of the industry 8.5 Sources of further information 8.6 References 9 Mal ting G. Gibson, Consultant, Cowan & Linn, Glasgow 9.1 Introduction 9.2 The UK malting industry 9.3 Basic malting process 9.4 Barley intake, wet bin storage, and drying 9.5 Dry barley storage 9.6 Malting plant 9.7 Malt storage 9.8 Automation 9.9 The future of the malting industry 9.10 Further reading ©2001 Woodhead Publishing Ltd. 9.11 References 10 Breadm aking S. P. Cauvain, Campden and Chorleywood Food Research Association, Chipping Campden 10.1 Introduction 10.2 Bread dough development 10.3 Breadmaking processes 10.4 The character of bread 10.5 Bread flavour 10.6 Bread types 10.7 What determines bread quality? 10.8 Current mixing and processing technologies 10.9 Future trends in breadmaking 10.10 Conclusions 10.11 References ©2001 Woodhead Publishing Ltd. Contributors Chapters 1 and 3 Chapter 4 Dr Gavin Owens Professor Robert J. Henry Woodview Centre for Plant Conservation Ballycullane Genetics Athy Southern Cross University Co. Kildare PO Box 157 Ireland Lismore NSW Tel/fax: +353 507 31623 Australia E-mail: [email protected] Tel: +61 (0)2 6620 3010 Fax: +61 (0)2 6622 2080 Chapter 2 E-mail: [email protected] Dr Eric J. Evans Department of Agriculture Chapter 5 University of Newcastle Newcastle upon Tyne NE1 7RU Emeritus Professor B. S. Luh England Department of Food Science and Technology Tel: +44 (0)191 222 6925 University of California Fax: +44 (0)191 2227811 Davis E-mail: [email protected] CA 95616-8598 USA Fax: +1 530 752 4759 E-mail: [email protected] ©2001 Woodhead Publishing Ltd. Chapter 6 Chapter 9 Dr Jim Dexter and Dr B. A. Mr George Gibson Marchylo 3 Braehead Road Canadian Grain Commission Thorntonhall Grain Research Laboratory Glasgow G74 5AQ 1404-303 Main Street Scotland Winnipeg Manitoba Tel: +44 (0)141 644 3230 Cananda R3C 3G8 Fax: +44 (0)141 644 5398 E-mail: Tel: +1 204 983 3320 [email protected] Fax: +1 204 983 0724 E-mail: [email protected] [email protected] Chapter 10 Dr Stan Cauvain Chapter 7 Campden and Chorleywood Food RA Chipping Campden Dr Dave Hatcher Glos GL55 6LD Grain Research Laboratory England Canadian Grain Commission 1404-303 Main Street Tel: +44 (0)1386 842000 Winnipeg Fax: +44 (0)1386 842100 Manitoba E-mail: [email protected] Canada R3C 3G8 Tel: +1 204 983 5362 Fax: +1 204 983 0724 E-mail: [email protected] Chapter 8 Mr Robert B. Fast 1545 Hillside Road Poultney VT 05764 USA Fax: +1 802 287 9516 ©2001 Woodhead Publishing Ltd. 1 Introduction W. G. Owens, Satake Centre for Grain Process Engineering, University of Manchester Institute of Science and Technology The cereal processing industry may be described as any industry that takes a cereal or a cereal product as its raw material. Most cereal processes produce foodstuffs but a few produce items such as starch for industrial or other uses. Because of the importance of cereals in the human food chain, cereals processing has evolved dramatically from humble beginnings as one of the world’s oldest industries to the sophisticated one we know today. It took many incremental advances to achieve today’s state of the art. This book aims to highlight some of the more recent contributions to this continual evolution. Why are cereals so dominant in the food sector? The answer is simple. Cereals are a versatile and reliable source of food. They are easy to store and may be used to produce a myriad of food products. Cereals processing thus forms a large and important part of the food production chain. It also plays a lesser, but no less important role in the non-food sector. It is for these reasons that ways of improving cereal processing technology and practice need to be addressed on a continual basis. There are many texts available, such as ‘Kent’s Technology of Cereals’ that address the basic issues of cereals processing, but there are few texts available that review the most recent developments in each processing sector. This collection seeks to address this gap. The world is becoming a more competitive place, with trade barriers being removed and transportation becoming more efficient. This coupled with the benefits of scale and efficiency that technological improvements have made possible means that processing facilities are becoming larger and fewer in number. Moreover, these plants are expected to operate with greater levels of reliability over longer operating cycles. Within mainstream processes like flour milling or bread baking, for example, the emphasis is still heavily towards process efficiency and increased scale of operation to curtail processing cost.