Miriamchen 0426
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Texture
Virtually every aspect of the manufacturing process of instant mashed potatoes is aimed at replicating the texture of homemade mashed potatoes. From analyzing the moisture and starch content of the potatoes at the beginning of production, to preparation in the home, it is crucial that the ideal texture is obtained.(1) Texture profile analysis (TPA) is a method designed to standardize the sensory description of food texture using set characteristics. (2) Using modern technology, samples are tested and quantified for their hardness, gumminess, cohesiveness, adhesiveness, and springiness. (3)
Consumers demand that instant mashed potatoes are light and fluffy, as if they prepared from scratch at home. Extracellular starch however occurs when starch cells rupture during thermal processing, resulting in an undesirable, gummy consistency (1). As these unwanted starch molecules are ultimately the greatest contributor to the texture of mashed potatoes, several measures are taken to ensure a desirable product. The initial processing of the potatoes has the largest impact on the finished product. Methods of production vary slightly, but the greatest factors are temperature and time cooking in water. (3)
Food additives are used to extend the shelf life of the product, but they also add to its texture. Monoglycerides and triglycerides are primarily used just before drying to form a starch complex, essentially protecting the starch granules. They also act as an emulsifier. Mashed potatoes are considered a dispersed system of potato cells suspended in a continuous liquid phase of varying composition, typically milk or butter that is added at the time of preparation (1). Mono and triglycerides act to maintain these permanent dispersions. Sodium acid pyrophosphate is another food additive most often found in dairy products. Valued for its emulsification properties, it binds with calcium to create a matrix of casein micelles that homogenize fat molecules. (4)
Along with the production of instant mashed potatoes, equal consideration is given its reconstitution. Just as the temperature and moisture content was given great consideration at the beginning of the process, the quantity of milk and butter added, as well as heating instructions plays a major role in the consumer’s final product. If the product is to be frozen, all the parameters of the TPA except cohesiveness have been found to increase Higher temperatures are associated with lower TPA score and an increased firmness, most likely as a result of the gelatinization of starch molecules (3).
References:
1. M Lamberti, A Geiselmann, B Conde-Petit, F, Escher. Starch transformation and structure development in production and reconstitution of potato flakes. LWT - Food Science and Technology, Volume 37, Issue 4, June 2004, Pages 417-427, ISSN 0023-6438, http://dx.doi.org/10.1016/j.lwt.2003.10.015.
2. Bourne M.C. (1978). Texture profile analysis: Food acceptability. Istituto Sperimentale per la Valorizzazione Tecnologica dei Prodotti Agricoli, Milan (Italy).
3. (http://www.sciencedirect.com/science/article/pii/S0023643803002020)Canet, Wenceslao (2005) Dolores Alvarez, Maria Fernández, Cristina Estrella Tortosa. The effect of sample temperature on instrumental and sensory properties of mashed potato products. International Journal of Food Science & Technology. Vol 40, Issue 5. ISSN - 1365-2621Blackwell Science Ltd. http://dx.doi.org/10.1111/j.1365-2621.2004.00945.x. DOI: - 10.1111/j.1365-2621.2004.00945.x
4. Gupta, S. K., Gupta, S. K., Karahadian, C., & Lindsay, R. C. (04/01/1984). Effect of emulsifier salts on textural and flavor properties of processed cheese’s. Journal of dairy science: American Dairy Science Association]. doi:10.3168/jds.S0022-0302(84)81367-3
General production methods: There are several different variations when it comes to processing of instant mashed potatoes, from the choice of potatoes to the choice of packaging material (U.S. Patent No. 8,017,173, 2011). Instant mashed potatoes are usually made from potato flakes, though some may also use potato granules. There are several controversy over the methods of conventional production of potato flakes and the conventional production may not “allo[w] potato processors to produce suitable flakes from potatoes” (U.S. Patent No. 6,066,353, 2000). The general production of potato flakes is summarized below. The general production process usually consists of three main steps. The first step involves removal of undesirable particles, peeling/cleaning of the potatoes and also inspection. When potatoes arrive at a manufacturer, the first thing is to get rid of the stones, sand, and other particles from the potatoes to avoid damage on the other machineries (Potato flakes, n.d.). Then the manufacturers would wash the peeled potatoes and inspect them to determine their quality. Further unwanted particles on the potatoes are then removed by hand (Potato flakes, n.d.). The second step includes cutting, blanching, cooling, cooking and transferring the product into the drum dryer. After the inspection of the potatoes, a Hydro cutter cuts the potatoes into smaller pieces so they can go through the dosing equipment (Potato flakes, n.d.). Then the potatoes are transferred into a blancher; after the blancher the potatoes are placed into a cooler then into a cooker where they are cooked until they become mashed (Potato flakes, n.d.). After cooking is complete, additives are added. . –Insert additives details- The main purpose of cooking is to inactivate enzymes that soften the intercellular bonds to create the right texture for the flakes (U.S. Patent No. 8,017,173, 2011). However, this method of blanching, cooling and cooking might not be the best way to prepare the potato flakes. U.S. Patent No. 6,066,353 (2000) states that ‘blanching, cooling and cooking’ method might promote retrogradation of starch and make the formation of a machineable sheet more difficult. On the other hand, Lamberti et al. (2004) argues that the blanching and cooling step prior to cooking the potatoes have a positive influence on the texture of the final product. The potato mash is then transferred into a drum dryer and spread out equally as thin sheets by the rollers. –Insert drum drying details- The third step involves the drying, transporting, and packaging of the potatoes. After the drum dryer, the thin film of potato mash is scraped off and transported by airflow to the Mill sifters - the purpose of these mill sifters is to create uniform flakes (Potato flakes, n.d.). Then finally, the potato flakes are packaged in the packaging machines. Most instant mashed potatoes have a shelf life of 12 months from production date, and it should be stored in a cool and dry area free from odours (Potato granules and potato flakes manufacturer, n.d.).