Ratio of mixing- NCC 012 : NCF012 In 20% : 80%
Dough Preparation
Water
Sheet Forming and Shaping
Add water 80% if need more water increase 5-10%, Mixing Time- 5 Minutes
If needed, adjust water to get the perfect dough.
Make the sheet forming and shaping as per your requirement.
Note: If needed 0.1-0.3% Xanthan gum and CMC can be added to flour to increase strength and rollability
Baking
Folding and Frying
Ready To Eat
Bake the sheets to reduce the moisture content before frying.
Then do the frying process.
Then our delicious final product will be ready to eat now.
| Combinations | 1 | 2 | |
|---|---|---|---|
| Ingredient Recipe | Masa Flour Fine grade (Batch Code: NCF) | 0.75 | 0.666 |
| Masa Flour Coarse grade (Batch Code: NCC) | 0.25 | 0.333 | |
| Water | 80% of total masa flour weight, + or - 5% based on usage | 80% of total masa flour weight, + or - 5% based on usage | |
| Mixing time (minutes) | 5-8 | 5-8 | |
| Masa moisture (%) | 46-50 | 46-50 | |
| Process and Quality Parameters | SCREW FEEDER/HOG PUMP SPEED | Based on VFD feeding setting per client basis | Based on VFD feeding setting per client basis |
| Sheet weight in gm for 10 pieces (But this is based on die-cut as well) | 28-30 | 28-30 | |
| Sheet thickness(mm) | 0.8-1 | 0.8-1 | |
| Oven temp (°C) | 275 | 275 | |
| Dwell time in sec | 50-55 | 50-55 | |
| moisture at baked chips oven exit (%) | 28-30 | 28-30 | |
| Cooling/Proofing time (minutes) | 3 | 3 | |
| Frying temp (°C) | 180°C | 180°C | |
| Frying time sec | 50-70 | 50-70 | |
| After frying weight in gm for 10 pieces (But this is based on chips die-cut as well) | 17-19 | 17-19 | |
| Fried chips moisture % | 1.5-2 | 1.5-2 | |
| Color | Taste yellow corn taste | Taste yellow corn taste | |
| Additives(Optional) | 0.2-0.4% Gaur gum or combination of 0.2-0.4% xanthan gum and 0.2-0.4% cmc or Modified 2-4% corn starch | 0.2-0.4% Gaur gum or combination of 0.2-0.4% xanthan gum and 0.2-0.4% cmc or Modified 2-4% corn starch |
| Kasat Masa Flour Characteristics | |
|---|---|
| Parameter | Standard |
| Moisture (%) | 13.0% max |
| Appearance | Yellow crystal free flowing |
| Foreign matter | Free from any foreign matter and non-edible matter |
| Extraneous matter | Free from any extraneous matter |
| color | Yellow with brown and black spots |
| flavour | Free from any objectionable matter |
| taste | Characteristic |
| dough formation | standard dough form |
| Quality Challenges | Photo | Solutions |
|---|---|---|
| Sheeting issue |  |
Use gums 0.2-0.4% Gaur gum or combination of 0.2-0.4% xanthan gum and 0.2-0.4% cmc or Modified 2-4% corn starch |
| Chips Puffing |  |
1. Not properly baked, Need to increase oven temperature and dwell time 2. Adjust thickness of masa sheet |
| Chips Flat |  |
Adjust the thickness of masa sheet or Masa flour has more coarse material, Increase masa fine material |
| Chips Curle |  |
1. Over baked, Need to decrease oven temperature and dwell time 2. Adjust thickness of masa sheet |
| Chips Breakage |  |
Increase thickness of masa sheet |