FIELD OF INVENTION
The present invention relates to a flax seed rich, nutritious dough based food product and
a process for the preparation thereof.
The present invention particularly relates to a dough based food product containing flax
seeds wherein roasted whole flax seeds and coarsely ground roasted flax seeds are
combined in a specific predetermined proportion and a process for the preparation
thereof.
BACKGROUND OF THE INVENTION
Consequent to increase in health consciousness, nutritious food products have gained
importance, especially in recent times. Flax is making its mark in the world's food supply
as a functional food. Functional foods deliver a health boost beyond what might be
expected from their traditional nutrient content .Flax fits this description perfectly, being
rich in omega-3 fatty acid, alpha-linolenic acid (ALA), fibre; lignans and protein. Health
experts prescribe these nutrients and other compounds for better health. In view of this,
health-conscious consumers raise the demand for flax and flax-enriched foods as they
become more aware of the potential benefits of flax in reducing the risk of chronic
diseases such as heart disease, stroke etc. The health enhancing foods, unfortunately, tend
to have very different sensory / eating qualities, which are mostly not liked by the
consumers. This is a big hindrance towards development and popularization of functional
foods. This invention, therefore, proposes the formulation and processing of a flax seed
containing dough based food product which is sufficiently nutritious and at the same
time has excellent eating qualities which can be enjoyed by the consumers.
Attempts have been made in the prior art to develop flax seed rich dough based food
products, but they all suffer with the problem of poor shelf stability, particularly in
tropical conditions. This is because of the susceptibility of the polyunsaturated fatty acids
contained in flax seeds to oxidation which leads to development of rancid / foul smell in
the products.
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While flax seeds have so many health benefits, the oil extracted from the seeds lacks
many of the nutrients (like fibres, lignins, protein, minerals and vitamins). Moreover, due
to the high level of polyunsaturated fatty acids, flaxseed oil is much more susceptible to
lipid oxidation leading to the development of rancid / foul smell. Thus enhancing stability
of the oil is important for prolonging shelf-life. This problem is greatly reduced when
whole flax seeds are used. Also, whole flax seeds impart crunchy texture to the baked
foods which makes it fun and easy to eat.
However, when whole flax seed is used in the preparation of foods, its availability for
digestion is reduced. On the other hand, when ground flax seed is used, the availability
for digestion improves, but it is comparatively more susceptible to develop oxidative
rancidity (than whole flax seed) due to the exposure of the high level of polyunsaturated
fatty acids, contained therein, to heat and oxygen during production of the food and
during subsequent storage and handling.
Therefore, there is a long felt need in the prior art to solve the problem of stability, shelf
life and taste of food products containing flax seeds.
OBJECT OF THE INVENTION
Therefore, it is an object of the present invention to provide dough based food product
containing flax seeds wherein whole roasted flax seeds and ground roasted flax seeds are
used in the specific predetermined proportion.
It is further object of the present invention to provide food product containing flax seeds
having improved stability and shelf life.
It is further object of the present invention to provide consumer friendly food product
containing flax seeds having good taste and aesthetic appeal.
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It is further object of the present invention to provide food product containing flax seeds
comprising specific blend of spices in specific proportion and a natural antioxidant in
specific level which further enhances the stability.
Yet another object of the present invention is to provide a process for the preparation of
food product containing flax seeds wherein the ground roasted flax seeds and whole
roasted flax seeds are added at different stages of the process that ensures proper blending
in the dough and gives the biscuits its characteristic texture, finish and taste.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is provided a food product
comprising the whole roasted and ground roasted flax seeds, an antioxidant, a blend of
spices and food additives wherein the whole roasted flax seeds and ground roasted flax
seeds are present in a ratio of from about 60:40 to about 90:10.
According to further aspect of the present invention there is provided a process for the
preparation of dough based food product comprising the steps of:
(i) creaming stage wherein ground flax seeds, an antioxidant, a blend of spices
and other food additives are mixed and then water is added,
(ii) dough making stage wherein to the mixture of step (i), whole roasted flax
seeds and other food additives are added and mixed for 30 minutes.
DETAILED DESCRIPTION
It has been surprisingly found by the present inventors that the stability and shelf life of
the food product containing flax seeds is improved when flax seeds are roasted at a
specific temperature for a specific time.
It is further found that use of part of ground roasted flax seeds at the time of creaming
stage and part of whole roasted flax seeds at the time of dough making stage ensures
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proper blending in the dough and gives the biscuits its characteristic texture , finish and
taste.
Flax is a high quality food. It is rich in omega-3 fatty acid (alpha-linolenic acid); fibre;
lignans, proteins, minerals and vitamins.
Flaxseeds are rich in polyunsaturated fats (70 %) comprising of the balanced levels of
two essential fatty acids ( EFA) - omega -3 and omega -6 fatty acids , which are essential
to life. Since the body cannot produce them, consumption of essential fatty acids is
necessary. WHO recommends that essential fatty acids make up at least 3% daily calorie
consumption. These healthful fats play a significant role in improving human health.
The EFAs are believed to have important role in normal functioning of all tissues of the
body, formation of healthy cell membranes, aiding the body's absorption of vital nutrients
regulation of cholesterol, triglycerides, blood pressure, blood clotting , immune and
inflammatory responses, reducing risk of coronary heart disease and stroke development
and functioning of the brain, eye and nervous system.
Flax seed contains soluble and insoluble fibre. Soluble fibre can lower blood cholesterol
levels, while insoluble fibre is important for regulating bowel movements and preventing
constipation, helping digestion by increasing bulk and reducing the time that waste
remains in the body. Fiber enhances our body's ability to use other dietary nutrients. Flax
is also low in available carbohydrate and is a Low GI Food (which means that flax seed
cause blood glucose and insulin levels to rise slowly).
Flax seed provides up to 800 times more lignans than most other foods in a vegetarian
diet. Lignans are believed to have antioxidant, phytoestrogenic and anti-carcinogenic
properties.
Flax seed contains 20 % protein of high quality.
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Flax seeds contain zinc, iron, vitamin E, carotene, B-group vitamins, magnesium,
calcium, sulfur, phosphorous, manganese, silicon, copper, nickel, molybdenum,
chromium, and cobalt. Flaxseed is very high in potassium content.
According to present invention, the following techniques are adopted to solve the
problem of stability, shelf life and taste.
1. Use of only roasted Flax seeds:
Flax seed is roasted at a specific temperature for a specific time. This enhances the
stability and/or shelf life of the final product. Roasted flaxseed also tastes better than non-
roasted flaxseed. Sensory analysis indicated that roasted flaxseed showed significantly
higher flavor and texture scores compared to unroasted flaxseed. Roasted flaxseed has a
unique nutty flavor, with a very pleasant crunchy texture. The time and temperature
required for the roasting is critical - any deviation in either of the parameters from the
specific levels will lead to under roasting (hence less stability) or over roasting (leading
to burnt flavor and bitterness).
It has been found that when the temperature used for roasting the flax seeds is 180 to
220°C, the end product has a significantly enhanced flavor and stability characteristics
compared to other temperature.
According to present invention the flax seeds are kept for roasting for 20 to 30 minutes,
which ensures a sufficient roasting of the flax seeds to enhance the stability without
leading to bitterness of over-roasted product.
2. Use of a combination of whole and ground Flax seeds:
Roasted whole flax seeds and coarsely ground roasted flax seeds are used in a specific
predetermined proportion to establish a balance of the stability and availability for
digestion. This proportion is very critical - any other proportion will lead to suboptimal
product stability as well as the textural and other sensory parameters.
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According to present invention, the whole roasted flax seeds and ground roasted flax
seeds are particularly present in a ratio of from about 60:40 to about 90:10.
According to present invention the whole roasted flax seeds and ground roasted flax
seeds are more particularly present in a ratio of from about 60 : 40 to about 70: 30.
3. Use of a natural anti -oxidant
Flax seed itself contain some antioxidants but availability of the same in the whole or
coarsely ground flax seed is limited for protection of the oil which is much more
abundant than the former. This necessitates addition of extra antioxidant. Synthetic
antioxidants can be used for the purpose but they are considered as harmful chemicals
and their uses as well as the quantities are restricted by many governments. Some of them
also impart undesired taste and flavor to the finished products.
Similarly, many of the natural anti oxidants (mostly extracts of different materials of
plant origin) affects the color, taste and flavor of the finished product. This is highly
undesirable and has significant hindrance towards popularizing the functional foods. The
natural anti oxidant and the spice blend which are used in this invention is free from such
drawbacks.
It has been found that use of a particuarly selected natural antioxidant, namely
tocopherol (vitamin E) at a specific level protects the oil from development of rancidity.
The quantity of this anti oxidant is very critical - a level less than the specific quantity
will significantly affect the stability of the finished product. This antioxidant, being an
important vitamin, enhances the nutritional quality of the finished product, apart from
protecting the polyunsaturated oils present in flax seed.
According to present invention a natural anti oxidant is used in the range of 50 - 500
ppm.
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4. Use of a blend of specific spices:
A blend of spices, comprising of cinnamon and nutmeg powder , known to have anti -
oxidant properties, beside imparting pleasant taste and flavor , have been used in a
specific proportion to further enhance the stability. Any change in these proportions was
shown to affect the stability of the finished product.
According to present invention cinnamon and nutmeg powder is used in the ratio of about
30 : 70 to about 50 : 50.
The food ingredients used in the present invention are sugar,
invert syrup, fats and oils, butter, emulsifier, soy flour, salt, flavors, wheat flour,
coarsely ground corn flakes, almond flakes and like.
According to present invention the food product containing flax seeds can be in the form
of biscuit, bread or nutritional bar.
According to present invention the preferred form of food product containing flax seeds
is biscuit.
The process for manufacture of a Flax seed based, nutritious food product, according to
the present invention comprises a creaming stage, a dough making stage, forming stage
and a baking stage.
According to this invention, the flax seeds are first roasted at a specific temperature for a
specific time and then cooled to ambient temperature. A part of the roasted flax seeds is
ground .The ground flax seeds are mixed with an antioxidant, a blend of spices and food
additives in the creaming stage. The roasted whole seeds are added to the mixture along
with other food additives in the formulation at the dough making stage to ensure uniform
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distribution of the flax seeds in the dough. Subsequently, the dough is passed though a
forming stage and is finally baked to get the said finished product.
Preparation of the dough is taken up through a 2 stage mixing process:
1. Creaming stage - wherein the roasted , ground Flax seeds ( 0.5 - 5.0 % ), sugar (
1.0 -14.0%), Invert Syrup ( 0.5- 2.5 %) , Fats & oils (1.0 - 13.0 %) , butter ( 0.5 -
5.0 %), emulsifiers ( 0.5 -1.0 % ), natural antioxidants ( 20 - 400 ppm ), soy flour (
1.0 -4.0% ), spices ( 0.1-1.0 % ) and salt ( 0.1 -0.5 % ) are added in the mixing
machine along with other ingredients like flavors and water and mixed at rpm > 30
for 1 to 10 minutes followed by addition of leavening agents (dissolved in water) and
mixed at speed > 30 rpm speed for 2 minutes to 20 minutes.
2. Dough making stage : wheat flour ( 5.0-25.0% ) along with the remainder (if any )
of the ground roasted Flax seed and roasted whole Flax seeds ( 1.0 -7.5 % ) and
whole wheat flour ( 0.0 - 20.0 % ), coarsely ground corn flakes ( 1.0 -5.0 % ) and
almond bits (0.5-1.0 % ) are added in the creaming stage mass and mixed at RPM <
50 for 3 minutes to 30 minutes.
This unique process of mixing roasted, ground flax seed and food additives and addition
of the same at the creaming stage and the roasted whole flax seeds at the dough making
stage ensures proper blending in the dough and gives the biscuits its characteristic texture
, finish and taste.
The dough obtained in the process described herein, is then passed through the
subsequent processing stages namely forming and baking.
In the forming stage, the dough described herein, is given the shape and design of the
biscuits, using a rotary moulder - equipment commonly used for the purpose.
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In the baking stage , the shaped dough pieces , thus obtained , are passed through a long
tunnel type , multi zone baking oven and baked at temperatures ranging between 210 -
250 degree centigrade for a period ranging between 4 to 5.5 minutes to get the said
finished biscuits.
The present invention shall now be specifically described by way of illustrative and non-
limiting examples. It shall be understood that many variations and modifications thereto
will be apparent to those skilled in the art without departing from the broadest scope and
ambit of the invention as set forth hereinabove.
Examples:
Example -1 PROCESS FLOW CHART
Preparation of roasted Flax seed. Preparation of roasted & ground flax seed:
Flax seeds are roasted in a rotary roasting machine at a temperature of 220 degree
centigrade for 20 minutes and then cooled to about 30 degree centigrade in a rotary
cooling system.
A portion of the roasted flax seeds are ground in a hammer mill to a powder which passes
through a 16 mesh sieve and stored in air tight containers.
The rest of the material (i.e. roasted whole flax seeds) is also stored in separate
containers.
MIXING PROCESS:
Creaming stage Roasted and ground Flax seeds (2.5 %), sugar (15 %),
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Invert Syrup (1.5 %), Fats & oils (10.0 %), butter (1.0
%), emulsifiers (0.15 %), natural antioxidants (75
ppm), soy flour (2.5%), spices (0.2 %) and salt (0.5 %)
are added in the mixing machine along with other
ingredients like flavors and water and mixed at 20
RPM for 10 minute followed by addition of leavening
agents (dissolved in water) and mixed at speed of 40
RPM for 5 minutes.
MIXING PROCESS:
Dough making stage wheat flour (21 %) along with roasted whole Flax
seeds (5.0%), whole wheat flour (20 %), coarsely
ground corn flakes (4%) and almond flakes (1.0%) are
added in the creaming stage mass and mixed at 40
RPM for 4 minutes.

Dough is rested for 20 minutes

FORMING STAGE Dough is formed into biscuit shape and design using a
rotary moulder

BAKING STAGE The biscuit shaped dough pieces are baked at 230 degree
centigrade for minutes in a 200 ft long tunnel oven,
comprising of 4 zones, to get the finished biscuits.
Example -2 PROCESS FLOW CHART
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Preparation of roasted Flax seed. Preparation of roasted & ground flax seed:
Flax seeds are roasted in a rotary roasting machine at a temperature of 180 degree
centigrade for 30 minutes and then cooled to about 30 degree centigrade in a rotary
cooling system.
A portion of the roasted flax seeds are ground in a hammer mill to a powder which
passes through a 16 mesh sieve and stored in air tight containers.
The rest of the material (i.e. roasted whole flax seeds) is also stored in separate
containers.
MIXING PROCESS
Creaming stage: Roasted and ground Flax seeds (2.88 %), sugar (13.94
%), Invert Syrup (1.63 %), Fats & oils (12.02 %),
butter (1.35 %), emulsifier (0.1%), natural antioxidants
(120 ppm), soy flour (2.88%), spices (0.29 %)
and salt (0.38 %) are added in a horizontal mixing
machine along with other ingredients like flavors and
water and mixed at 30 RPM for 10 minutes followed
by leavening agents dissolved in water and mixed at
speed of 30 RPM for 5 minutes.
MIXING PROCESS
Dough making stage: wheat flour (24.04 %) along with roasted whole Flax
seeds (6.73 %), whole wheat flour (18.08% %),
coarsely ground corn flakes (4.18%) and almond
flakes (0.96%) are added in the creaming stage
mass and mixed at 40 RPM for 4 minutes.

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Dough is rested for 20 minutes

FORMING STAGE Dough is formed into biscuit shape and design using
a rotary moulder

BAKING STAGE The biscuit shaped dough pieces are baked for 5 minutes
in a 100 ft long tunnel oven comprising of 3 zones,
maintained at the temperature of 215 , 250 & 220
degree centigrade respectively, to get the finished
biscuits.
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The terms and expressions in this specification are of description and not of limitation , as
such terms and expressions do not, and arc not intended to , exclude any equivalents of
the features of this invention illustrated and described herein.

According to an aspect of the present invention, there is provided a food product
comprising the whole roasted and ground roasted flax seeds, an antioxidant, a blend of
spices and food additives wherein the whole roasted flax seeds and ground roasted flax
seeds are present in a ratio of from about 60:40 to about 90:10.
According to further aspect of the present invention there is provided a process for the
preparation of dough based food product comprising the steps of:
(i) creaming stage wherein ground flax seeds, an antioxidant, a blend of spices
and other food additives are mixed and then water is added,
(ii) dough making stage wherein to the mixture of step (i), whole roasted flax
seeds and other food additives are added and mixed for 30 minutes