Ratio of mixing masa flour grades- NCC (Coarse grade):NCF (Fine grade) is 20%:80% Note:If required, please increase the fine grade by 5-10% to get the softer bite or increase the coarse grade by 5-10% for crunchier bite chips.
Add 80% water. If needed, adjust water by 5-10% to get the perfect dough Ex: In 100gms of corn masa flour add 80ml of water. Pinch of salt can be added for taste Adjust water to get the perfect dough as shown in below photo.
Perfect Dough
Excess Water In Dough
Less Water In Dough
Mixing Time- 5 minutes.
If there is a sheeting issue, then add 0.1-0.3% Guar gum while making dough to increase sheeting strength and rollability. Please see below photos
Sheeting issue (low strength)
Perfect sheeting (Good Strength)
Baking has to be adjusted if the chips are getting puffed or complete flat.
Please see below photos :
Flat Chips
Puffed chips
Perfect chips
| 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 |