Corn Lime water Cook and steep it Wash and drain MASA FLOW DIAGRAM CORN COOKING AND HARDNESS 1 Optimum Hardness level required 2 Hard corn requires longer cook time a More tolerant to handling ID: 832729
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MASA PROCESSCorn + Lime + waterCook an
MASA PROCESSCorn + Lime + waterCook and steep itWash and drainMASAFLOW DIAGRAMCO
RN COOKING AND HARDNESS1.Optimum Hardn
RN COOKING AND HARDNESS1.Optimum Hardness level required2.Hard corn requires longe
r cook timea.More tolerant to handling
r cook timea.More tolerant to handling3.Soft corns cook quickly retain pericarpa.
Corn overcooked to remove pericarpb.D
Corn overcooked to remove pericarpb.Dry matter losses increase significantlyMETHOD
S OF DETERMINING HARDNESS1.Subjective
S OF DETERMINING HARDNESS1.Subjectivea.Transmitted lightb.Proportion of hard sta
rch2.Floatation and density3.Others
rch2.Floatation and density3.OthersPERICARP (SKIN) REMOVAL1.Corn variety2.Env
ironment3.Lime quality can be critical
ironment3.Lime quality can be critical4.Heating âtime / temperature / agitatio
n5.Washing methodsCHANGES DURING THE
n5.Washing methodsCHANGES DURING THE CORN MASA PRODUCTIONCOOKINGoTemp/Time prof
ile = 175â212F / 35-55âoStar
ile = 175â212F / 35-55âoStart hydration, from 12-16% �= 35-42%
oLoosen pericarpoDenature protein and
oLoosen pericarpoDenature protein and Slight starch gelatinizationOvercooked corn
Undercooked cornProper CookOvercooked
Undercooked cornProper CookOvercooked cornCOOKING (CRITICAL FACTORS)oNixtamalMoi
stureoTemperature and time profileoL
stureoTemperature and time profileoLime quality and concentrationoEven heat dist
ributionoConsistent and repeatable coo
ributionoConsistent and repeatable cooking conditions (continuous vs batch)BENEFIT
S OF ALKALINE COOKINGoRemoval of Peric
S OF ALKALINE COOKINGoRemoval of PericarpoPartial solubilizationof protein and s
tarchoFlavor and tasteoHigher Calciu
tarchoFlavor and tasteoHigher Calcium and release of NiacinWASHINGoWater Temp =
150-170FoLime removaloForeign mat
150-170FoLime removaloForeign material removaloLowers corn temperatureoProm
ote even properties of the bulkWASHING
ote even properties of the bulkWASHING (CRITICAL FACTORS)oResidual Lime.oWater T
emperature.oEven application of washin
emperature.oEven application of washing water.oAdequate/homogeneous removal of exc
ess lime and foreign material.oAdequa
ess lime and foreign material.oAdequate drainage.Adequate washingPoor washingSTE
EPINGoTemp / Time profile = 140-150F
EPINGoTemp / Time profile = 140-150F / 2.5-4 hoursoComplete hydration to about
37-42% moisture (promotes even prope
37-42% moisture (promotes even properties)oPartial gelatinization of starchoIm
proves colorSTEEPING (CRITICAL FACTORS)
proves colorSTEEPING (CRITICAL FACTORS)oTemperatureoTimeoNixtamalMoistureoEv
en steeping conditionsGRINDINGoHigh s
en steeping conditionsGRINDINGoHigh speed hammer millingoTemperature = 140-150F
oParticle size reductionoShearing ef
oParticle size reductionoShearing effectoStarch damageoAdditional cookingGRIN
DING (CRITICAL FACTORS)oAssure consist
DING (CRITICAL FACTORS)oAssure consistent particle size reduction.oAvoid developme
nt of excessive heat.oHammer wear.oE
nt of excessive heat.oHammer wear.oEfficiencyDRYINGoSmall particlesoHigh �
000;temperature 580FoShort timeoAdd
000;temperature 580FoShort timeoAdditional cookingoPartial gelatinization and r
etro gradation of starch.DRYING (CRIT
etro gradation of starch.DRYING (CRITICAL FACTORS)oAir temperatureoAir flow rat
e (particle residence time)oTemperatur
e (particle residence time)oTemperature âTime profile550 â700 Mcal/MT6 â
8 KWH/cwtSIEVINGoSegregation of par
8 KWH/cwtSIEVINGoSegregation of particlesoHomogenization of flouroAssure cons
istency of flour properties (adequate p
istency of flour properties (adequate particle size distributionoEfficiencyREMILLI
NG (DRY MILLING)oAssure consistent par
NG (DRY MILLING)oAssure consistent particle size reductionoHammer wearoEfficienc
yADDITIVESExtend the shelf lifeoPota
yADDITIVESExtend the shelf lifeoPotassium SorbateoCalcium PropionateoFumaric
AcidoSodium PropionateoColor Aidso
AcidoSodium PropionateoColor AidsoPhosphoric AcidoTitanium DioxideTexturizers
oCMCoGuarrGumoEnzymesSTARCH GELA
oCMCoGuarrGumoEnzymesSTARCH GELATINIZATIONïLoss of native structureoSwel
lingoMeltingïDepends on water and
lingoMeltingïDepends on water and heatïStarch granules are in a protein matr
ix that limits swelling (hard corns)ï
ix that limits swelling (hard corns)ïPartial gelatinizationoIncreases water abs
orption and solubilityïComplete gela
orption and solubilityïComplete gelatinizationoDisrupts whole structure and beco
mes solubleoUsually due to heat, water
mes solubleoUsually due to heat, water, shearing, alkali/acid and mechanical energy
STARCH RETROGRADATIONoOpposite to gel
STARCH RETROGRADATIONoOpposite to gelatinizationoAffects masa propertiesoAffect
s friability of chipsoForm backbone of
s friability of chipsoForm backbone of tortillas and chipsTortillas vs ChipsMoistu
re @ 50%Moisture 2-3%Oil 21 to 30%D
re @ 50%Moisture 2-3%Oil 21 to 30%During frying, only 20% was absorbed by the ch
ips, and80% remained on the chip's surf
ips, and80% remained on the chip's surface. During cooling,about 64% of the total o
il content was absorbed by thechips, a
il content was absorbed by thechips, and 36% remained on the chip's surfaceThank y