CA1170498A

CA1170498A - Low-fat, spread and process

Info

Publication number: CA1170498A
Application number: CA000365956A
Authority: CA
Inventors: Peter M. Bosco; William L. Sledzieski
Original assignee: Standard Brands Inc
Current assignee: Standard Brands Inc
Priority date: 1979-11-19
Filing date: 1980-12-02
Publication date: 1984-07-10
Also published as: FI69952B; DK492780A; IT8026048A0; AU538723B2; ES496983A0; IT1134321B; SE8007996L; FR2469877B1; ES8205256A1; CA1151466A; SE450451B; GB2066039B; FR2469877A1; FI803591L; AU6448680A; WO1981001354A1; DE3043655A1; FI69952C; MX6378E; GB2066039A

Abstract

ABSTRACT OF THE DISCLOSURE
A low-fat spread comprises a dispersed phase comprising from 5 to 40% fat, based on the weight of the spread; a continuous aqueous phase including a stabilizer; and an emulsifier system comprising a combination of a lipophilic emulsifier and a hydrophilic emulsifier; the relative and total amounts of the emulsifiers and the stabilizer being effective to provide a stable emulsion and a product which is solid at 40°F. A process for preparing the spread is also taught.
The product has a wide range of applications due to its texture, mouthfeel, appearance, and stability. It provides a rich tasting product with a caloric density which is preferably about 25 calories per 14 gram serving.

Description

~1704 ~ ~

The present invention relates to low-fat content spreads. More particularly, the present invention relates to diet products of this type having low caloric densities and to processes for preparing them.
In our Canadian Patent Application No. 365,992 filed concurrently with this application, there is described a low-fat-content, butter-flavored spread and a process for preparing it. That spread can have fat contents of from 5 to 40% based on total weight and is solid at 400F. That product is surprising in a number of respects for its close simulation of butter, and is especially surprising because of its low fat content.
It has now been found that this new product and the process for making it have application to the production of a wide variety of spreads using flavors other than butter.
It is an object of the present invention to provide a low-fat spread and a process for preparing it.
According to an aspect of the present invention there is provided a low-fat spread comprising a dispersed phase comprising from 5 to 40~ fat, based on the weight of the spread, a continuous aqueous phase including a stabilizer and an emulsifier system comprising a combination of a lipophilic emulsifier and a hydrophilic emulsifier, the relative and total amounts of the emulsifiers and the stabilizer being effective to provide a stable emulsion and a product which is solid a-t ~0F.
According to a further aspect of the present invention there is provided a process for preparing a low-fat spread which comprises preparing an oil-in-water emulsion comprising a dispersed phase comprising from 5 to 40~ fat, based on the weight of the emulsion, a continuous aqueous phase including a stabilizer, and an emulsiEier system comprising a combination of , _ L _ ~.
,.~. ) : \~

1~704~

a lipophilic emulsifier, and a hydrophilic emulsifier, the relative and total amounts of -the emulsifiers and the stabilizer being effective to provide a stable emulsion and a product which is solid at 40F, and cooling the emulsion under conditions effective to solidify it to form a product which is solid at Embodiments of the invention will now be described by way of example with reference to the following drawings in which:-Figure 1 is a photomicrograph, taken at 225 times magnification, of an emulsion sample as described herein after solidification;
Figure 2 is a photomicrograph of the sample of Figure1, taken at S00 times magnification; and Figure 3 is a flow diagram showing a preferred process scheme according to the invention.
The products described herein, which are prepared by the process described herein have a smooth, spreadable texture;
a rich, creamy mouthfeel; and excellent stability; yet have ~0 caloric densities of less than 50, and preferably about 10 to 35, calories per 14 gram serving. The spreads are solid at refrigerator temperature and remain so even after standing for at least 2, and preferably 5, hours at a room temperature of 70F. The spreads, which are based on stable oil-in-water emulsions, remain spreadable at normal refrigerator temperature, and melt quickly in -the mouth to release flavor without imparting a waxy texture or mouthfeel.
The products can be flavored as desired to simulate dairy products such as butter, sour cream or cheese dips or spreads, cream cheese, processed cheese and the like; spreadable ~ 1 .

1 ~ 7049~

salad dressings such as mayonnaise; nutritious spreads such as margarine and peanut butter; and a wide variety of other spreadable products. Moreover, the process described herein enables the production of a wide varie-ty of novel spreads, which have desirable new characteristics and are not simulations of known products.
The term "stable emulsion" identifies those emulsions which do not undergo any noticeable change in stability, due to water separation or otherwise, during storage in mois-ture-proof containers at a temperature of 40F or below for 6 months,and which will also remain stable when stored at a room tempera-ture of 70 F for a period of at least one day. Preferably,the emulsions described herein remain stable after melting, even at elevated temperatures of 180 F or more.
The term "solid" is used in its normal sense, to mean the product does not flow under its own weight. Included within the scope of this term are plastic, spreadable compositions which, while not susceptible to flow under their own weight in small quantities, are easily spread with a knife. The products described herein will exhibit penetrometer readings at 40F
within the range of about 25 to 400 units, using a standard penetrometer cone, having a 2.5 inch diameter and a 45 angle, with 47.5 grams added weight at a 5-second interval. Preferably, the penetrometer readings will be wlthin the range of from 60 to 250 units, and most preferably 100 to 200 units.
The products described herein can be aerated if desired, however, it is an advantage of the products that they do not have to contain any significant quantity of air or inert gas to stiffen their structures and provide a firmer consistency~
Thus, unlike many prior art products, the produc-t itself, i~ i 1 ~ 70~

probably due to its unique microstructure, provides the solid consistency and there is no dependence upon the use of a gas to distend the emulsion structure to effect s~iffening or solidification. To provide the smoothest overall texture, the degree of gas incorporation .LS preferably kept to less than 40%, and more preferably to less than 20%, by volume.
Similarly, in distinction with some of the prior art compositions, those described herein do not depend upon the presence of protein to obtain the solid texture or the superior mouthfeel; however, they can contain proteins if desired.
Figures 1 and 2 are microphotographs taken of a representative emulsion prepared in Example I. Figure 1 was made at 225 times magnification and Figure 2 was made at 500 times. Both show the unique microstructure of the product. It is believed that the chains of small bead-like oil droplets entangle, or coalesce or fuse at points, to form small inte~stices wherein the aqueous phase is physically trapped as well as being bound to some extent by the attraction for the oil due to the presence of the emulsifiers and stabilizers. The thickened state of the aqueous phase contributed by the stabilizers is also believed to aid in maintaining the unique solid structure of the products described herein, even though the degree of thickening would not itself be sufficient to prevent it from flowing were it not for the other effects of the composition described herein. These products are so stable that the emulsions do not separate even after standing for 24 hours or more at room temperature.
The ingredients which are essential to the formation of the product are: (1) fat which is suitably selected to have a Solids Fat Index (SFI) which enables the formation o~ a solid -- 4 ~
`~ i ll7n4s~

product at 40F, (2) a water-soluble emulsion stabilizer, and (3) an effective emulsifier system comprising both lipophilic and hydrophilic eMulsifiers.
The fat can be present in amounts within the range of from 5 to 40 percent based on the weight of the spread, but is preferably present in an amount of from 10 to 30 percent by weight oF the spread.
The term "fat" as used herein is intended to include all edible, fatty acid -triglycerides regardless of origin or whether they are solid or liquid at room temperature. Thus, the term "fat" includes normally liquid and normally solid vegetable oils and animal fats. Typical of the vegetable oils which are included are the usual vegetable oils such as soybean oil, corn oil, coconut oil, cottonseed oil, peanut oil, safflower oil, palm kernel oil, sunflower oil, palm oil, and rapeseed oil.
The preferred fats for use herein will comprise partially-hydrogenated vegetable oils, and will most preferably be selected from the group consisting of soybean oil, corn oil, coconut oil, cottonseed oil, peanut oil, palm oil, palm kernel oil, safflower oil, sunflower oil, rapeseed oil, and mixtures of these. Preferred among these are those partially-hydrogenated vegetable oils which have an SFI profile within the following ranges:
Temp. BroadPreferred 50 F ~0 - 80%50 - 70~
70 F 25 - 50~30 - 40%
92 F ~10~ <5~
Particular, suitable fats are 92 F Wiley melting point partially-hydrogenated coconut oils sold under the trade marks PURF,CO 92 by Capitol City Products; HYDROL 92 by SCM Corporation;

Q

'`D' i ~ ~1 7û Ag t~

VICTORY 9 2 by Humko DiV . Kra~-t Inc.; and COBEE 92 by PVO
International, Inc.
The fat will preferably be selected -to provide a solid product at 70E, but will substantially completely melt in the mouth. Where necessary to increase the solids content at 40F
or 70F, an amount of a fat having a higher solids content can be added. Fats like hard stock stearin and cottonseed or soybean flakes have this ability, however, they remain solid and impart a waxy mouthfeel at eating temperature. Thus, while they can be employed to provide a desirable effect on texture, they should not be employed in large amounts.
The use of water-soluble emulsion stabilizers is essential to provide the necessary stability. These can be any of those known to the art for this purpose and will preferably be hydrophilic colloids, and can be selected from the group consisting of microcrystalline cellulose, carageenin, guar gum, alginate, xanthan gum, methyl cellulose, carboxymethyl cellulose, ethyl cellulose, hydroxypropylmethyl cellulose, dextrins, starch, gelatin, locust bean gum, soy protein isolate, pectin and the like and mixtures of these. Commercial stabilizers available from Polak's Frutal Works, Inc. and identified by the manufacturer under the trade marks FRI~lULSION Q8 and FRIMULSION 10 have been found effective, especially when used in combination. The Q8 product is a blend oE modified food starch, locust bean gum, - guar gum, gelatin and pectin, and is preEerably employed at a weight ratio within the range of from about 1:1 to 3:1 to the FRIMULSION 10 which is a blend of locust bean gum and guar gum.
The stabilizer can be employed in any amount effective under the conditions of processing and with the particular ingredients. It has been found, however, that levels of about ~ B
`
,.^ .

1 1 7f)~9~

0.1 to 3.0 percen-t, based on the total weight of the composition, are particularly effec-tive. In addition to their emulsion stabilizing function, these materials also have a viscosity-increasing effect on the emulsion. However, this effect is not sufficient in and of itself to control the large amounts of water present in these emulsions. Thus, the compositions described herein, unlike the approach taken by Bodor et al in U. S. Patent 4,103,037, do not depend upon a gelling agent to solidify the aqueous phase.
The compositions described herein further comprise an emulsifier system employing both lipophilic and hydrophilic emulsifiers. The relative and total amounts of the emulsifiers are selected to be effective to provide a stable emulsion and a product which is solid at 40F. Typical of effective levels will be levels of from 0.3~ to 4.0~, based on the weight of the total composition of the total emulsifier system which employs each of the hydrophilic and lipophilic emulsifiers at levels of at least 0.05%, on the same basis. The lipophilic emulsifier will -typically have an HLB (hydrophile-lipophile balance) of less than 7, and the hydrophilic emulsifier will typically have an HLB of from 10 to 20, preferably from 11 to 17.
The emulsifier system is preferably present at a level of from 0.5~ to 2%, and the lipophilic and hydrophilic emulsifiers are preferably each present at levels of at least 0.10%, all percentages on a formula weight basis.
The hydrophilic emulsifier will preferably comprise a member selected from the group consisting of polyoxyethylene (20) sorbitan monostearate, polyoxyethylene (20) sorbitan monooleate, and mixtures of these.
These emulsifiers, commonly known as polysorbate 60, ~ '' i ... .

1171)49~

and polysorbate 80, respec-tively, are preferred, however, it is believed that other hydrophilic emulsifiers with an HLB o between 10 and 20, and mos-t preferably 13 and 16, will be operable. Among other suitable emulsifiers are salts of fatty acid lactylates such as sodium and calcium stearoyl-2-lactylate;
and the polyglycerol esters of fatty acids, such as octaglycerol monooleate. Also suitable are other polysorbates, such as polysorbate 65 which is otherwise known as polyoxyethylene (20) sorbitan tristearate. Various factors such as off-flavor, off-color and ~enerally less desirable qualities of these othermaterials for use in foods make the aforementioned hydrophilic emulsifiers the most desirable choice. Polysorbate 60 and 80 are the most preferred because they provide a stiffness and spreading quality, especially a cold fracture quality, most like butter and margarine.
Polysorbate 60, polyoxyethylene (20) sorbitan mono-stearate, is a mixture of stearate and palmitate partial esters of sorbitol and sorbitol anhydrides condensed with approximately 20 moles of ethylene oxide (C2H~O) for each mole of sorbitol and its mono- and dianhydrides. It is a lemon to orange colored, oily liquid or semi-gel having a faint characteristic odor and a warm, somewhat bitter taste~ It is soluble in water, aniline, ethyl acetate, toluene, and is soluble at low levels in mineral and vegetable oils. Polysorbate ~0 is commercially available under the trade marks TWEEN 60 from ICI-Atlas, SVS-18 from Hodag, Inc., DREWPONE 60 from PVO International Inc., and DU~F~X 60 from SCM Corporation, and GYSPS-20 from Glyco, Inc.
Polysorbate 80, polyoxyethylene (20) sorbitan mono-oleate, is a mixture of oleate partial esters of sorbitol and sorbitol anhydrides condensed with approximately 20 moles of 1 1 7n~

ethylene oxlde (C2~I~O) for each mole of sorbitol and its mono-and dianhydrides. It is a yellow to orange colored, oil~ liquid having a faint, characteristic odor and a warm, somewhat bi-tter taste. It is very soluble in water, producing an odorless, nearly colorless solution, and is soluble in ethanol, fixed oils, ethyl acetate and toluene. Polysorbate 80 is commercially available under the trade marks TWEEN 80 from ICI-Atlas, SVO-9 from Hodag, Inc., DRhWPONE 80 from PVO International, Inc. and ~URFAX 80 from SCM Corporation, and GYSPO-20 from Glyco, Inc.
Polysorbate 65, polyoxyethylene (20) sorbitan tristearate, is not as preferred as polysorbate 60 or polysorbate 80, but still provides an acceptable product. It is a mixture of stearate and palmitate partial esters of sorbitol and its anhydrides condensed with approximately 20 moles of ethylene oxide (C2H4O) for each mole of sorbitol and its mono- and dianhydrides. I-t is a tan, waxy solid having a faintt character-istic odor and a waxy, somewhat bitter taste. It is soluble at low levels in mineral and vegetable oils; at higher levels in mineral spirits, acetone, ether, dioxane and methanol; and is dispersible in water and carbon tetrachloride. Polysorbate 65 is commercially available under the trade marks TWEEN 65 from ICI-Atlas, DREWPONE 65 from PVO International, Inc., DURFAX 65 from SCM Corporation, and GYSPTS-20 from Glyco, Inc.
The lipophilic emulsifier of the emulsifier system will preferably comprise a member selected from the group consis~
ting of mixed fatty acid monoglycerides; mixed fatty acid diglycerides; mixtures of fatty acid mono- and diglycerides;
lipophilic polyglycerol esters; glycerol esters, such as glyceryl monooleate, glyceryl dioleate, glyceryl monostearate, glyceryl distearate, glyceryl monopalmitate and glyceryl dipalmitate;

9 _ 1 1 7049~

lactylated esters such as glyceryl-lacto esters of fatty acids;
propylene glycol esters such as propylene glycol monopalmitate, propylene glycol monostearate, and propylene glycol monooleate;
sorbitan esters such as sorbitan monostearate, sorbitan trioleate, sorbitan tripalmitate, sorbitan tristearate and sorbitan sesquioleate; fatty acids or their soaps such as stearic acid, palmitic acid, and oleic acid; and mixtures thereof. Here, as in the case of the hydrophilic emulsifier, there is no known criticality in the use of any particular lipophilic emulsifier.
Thus, it is fully intended that other equivalent materials can be employed with satisfactory results. However, those specifically identified above, especially those selected from the group consisting of lipophilic polyglycerol esters, mono- and diglycerides, propylene glycol esters, lactylated esters and mixtures of these, are preferred from the standpoint of taste and effectiveness.
The products described herein are suitably colored and flavored to obtain the desired taste and appearance. Examples of coloring agents are beta carotene, annatto, turmeric, caramel color, paprika and FD&C dyes. Typically, the colors will be dissolved or dispersed in oil or the water phase to expedite blending. Representative of the flavors and/or flavor enhancers will be sodium chloride, butter flavors, fruit flavors, spices, nut flavors, vegetable flavors, herbs, dairy flavors, distilled beverage flavors, cheese flavors, seafood flavors, meat flavors, candy flavors, essential oils, botanical extracts, oleo resins and other natural and synthetic flavors. Among the flavors suitable where a butter flavor is desired are lactones, lipolyæed butter oils and starter distill&tes; diacetyl, 2-octanone and other ketones; bu-tyric acid, hexanoic acid, and other free fatty 9 ?9 acids; esters of butyric acid; delta-hydroxy acids and their glycerol esters; and mixtures of any of these wi-th other known dairy, buttery, or like flavors or flavor no-tes. Among the fruit flavors are: apricot, apple, banana, blackberry, black currant, blueberry, cantaloupe, cherry, currant, grape, grape-fruit, guava, honeydew, passion fruit, orangej peach, pear, pineapple, plum, prune, raspberry, raisin, strawberry, water-melon, and the like. Among the vegetables are red and green peppers, tomato, carrot, celery, garlic, squash, pumpkin~ onion, beet, pimento, turnip, parsley, chive and the like. Among -the dairy and cheese flavors other than bu-tter are sour cream, yogurt, cheddar cheese, cream cheese, swiss cheese, blue cheese, parmesan cheese, romano cheese and the like. Among the meat flavors are pork, bacon, ham, beef, turkey, chicken, sausage, pepperoni, hot dog, barbequed meat, veal, lamb and the like. The flavors can be artificial, natural extracts, concentrates or a fresh or dried natural ingredient in whole or chopped form. It is an advantage of the products that flavors have a very pronounced impact.
In addition to emulsion stability, the products described herein are preferably stable against microbiological and oxidative deterioration. To control mold and yeast growth, the products preferably contain one or more preservatives such as benzoic acid, sorbic acid, phosphoric acid, lactic acid and the soluble salts of these and other like materials. Preferred as antimicrobials are potassium sorbate, sodium sorbate, potassium benzoate, sodium benzoate and phosphoric acid. The pll of the aqueous phase is desirably maintained at a value below 6.0, and preferably within the range of 5.0 to 5.9~ to provide effective microbial control and good flavor with the lowest necessary levels r~3 i 1~0~9~

of preservatives. Additional stability against oxidative deterioration at higher ternperatures may be obtained by the use of the usual antioxidants, typical among which are normal propyl gallate, the several tocopherols, butylated hydroxanisole (B~IA), butylated hydroxytoluene (BHT), nordihydroguaiaretic acid (NDGA), tertiary-butylhydroquinon (TBHQ) and citric acid.
While the products described herein do not require proteins to obtain the proper texture or mouthfeel, they are sometimes desired for nutritional reasons as well as their positive contribution to the flavor and physical properties of the product. Additionally, protein can enhance freeze/thaw stability. Among the suitable protein materials are any of those known to the art for similar uses in spreads. These can include those derived from vegetable as well as animal sources.
Thus, vegetable protein isolates such as those derived from soy, peanut, cottonseed, alfalfa, pea and the like; milk protein containing materials such as non-fat dry milkj whey, caseinates, casein and delactosed whey; and other nutritional proteins, can be employed in desired amounts. One suitable type of protein is that sold under the MELOTEIN MP-14P trade mark by Dairyland, Inc. These products are spray dried blends of milk proteins such as sweet dairy whey and caseinates. Typically, they are added in amounts of up to 10% based on the total weight of the spread.
Preferred levels will be from 1 to 8% on this basis.
Also added can be any of the vitamins and minerals desired. Preferred among -these are vitamins A and D which are normally associated wi-th dairy products. I~ desired, these can be added in amounts approximating those in butter or margarine.
Also where desired, a chelating agent such as ethylene diaminetetraacetic acid (EDTA), its salts, such as calcium -~l7n~

disodium EDTA, or the like can be employed to tie up metal ions which may otherwise detrimentally interact with one or more of the ingredients.
All of the above ingredients can be formed into -the low-fat spread described herein by following the preferred process scheme set out in Figure 3, or otherwise preparing an oil-in-water emulsion comprising the essential ingredients, and then cooling the emulsion under conditions effective to solidify it and form a spread which is solid at 40F, preferably at 70F
and most preferably at 75F.
The flow diagram of Figure 3 shows the separate prepara-tion of fat and aqueous phases prior to blending and emulsifying them. The water and water-soluble ingredients, such as milk protein solids, salt and preservatives, are added to mixing vessel 10 by lines 12 and 14, respectively. The vessel may be equipped with a suitable heater 16 which can be an electrical resistance heater, a water or steam jacket, or the like.
Alternatively, the water from line 12 can be supplied hot.
Typically, the water will be heated to a temperature of about 190F to assure complete hydration of the water soluble materials added. Agitation is supplied by mixing device 17.
Where the stabilizers, which are water soluble, are mixed with the water at this stage in processing, the shear supplied by the mixing must be intense enough to overcome the normal tendency of these materials to clump together and prevent complete hydration and dispersion. I-t is preferred, however, to predis-perse the stabilizers in a portion of the fa-t phase prior to contact with water. This can be accomplished by blending with mixing device 18 in vessel 19, and then passing to vessel 10 by line 20.

n 1 1 7n4gp, The fat phase is prepared in a separate vessel 21 which can also be equipped with a sui-table heating device 22 and mixing device 24. The fat-soluble materials such as the color, flavor, vitamins and emulsifiers, if desired, are added at 26 to the fat which is added at 28. The hydrophilic emulsifier can be added to the water phase instead of the fat phase. The fat is maintained at a temperature high enough to assure its liquid character. Temperatures of from about 120 to 190F, preferably about 130 to 150F, are effective to provide good solubility of additives and a suitably low viscosity.
The fat phase can be drawn from mixing vessel 21 by line 30 and passed to vessel 35 wherein it is mixed with the water phase which is supplied by line 36 and may have been cooled to approximately the same temperature as the fat phase by means of heat exchanger 38. Adequate mixing is provided by device 40 which supplies sufficient shear to begin the emulsification of the fat into the water. At the completion of mixing, an emulsion will have been formed which uniformly disperses the fat into droplets within the aqueous phase;
however, the droplets are not broken down finely enough to permit emulsion stability.
The rough emulsion prepared in vessel 35 is then passed via line 42 to homogenizer 44 wherein the final emulsion is formed. The emulsion will, a-t this point, still be at a temperature sufficiently high to maintain the fat in the liquid state. Homogenization will typically be accomplished at a pressure of from 100 to 500, and preferably about 250, atmospheres. Any of the typical homogenizers or colloid mills effective for dairy purposes can be employed in this process.
Thus, the Manton-Gaulin 2-s-tage homogenizer or the Cherry ` B

~ 1 7n49~

,~
serrell 2-stage homogenizer can be employed effectively~
From the homogenizer 44, the homogenized emulsion is passed via line 46 to a suitable heat exchanger 48 where it is cooled. The heat exchanger 48 will preferably be of a kind capable of rapidly cooling the emulsion. Typical of the suitable devices are scraped-wall heat exchangers ~"A" units), such as those sold under the VOTATOR trade mark. Typically, the heat exchanger coolant will be maintained a-t a temperature of about -200F to cool the emulsion rapidly from about 140 to 1~0~' to below about 700F, and preferably below about 40F.
The cooled emulsion is then preferably passed from the heat exchanger 48 via line 50 to a mixing chamber 52 wherein gentle agitation is maintained internally by a suitable rotating mixing device 54 for a period of time effective to initiate crystallization of the fat and the propagation of the unique physical structure of the product described herein. The agitation promotes crystallization and enhances solidification.
According to the most preferred mode of operation, a series, preferably about three, "A" units cool the emulsion; and a blender ("B" unit) is positioned at the end of the series, or between two of the "A" units in the series, to aid in promoting crystallization.
The spreads described herein can be printed into sticks, formed in-to pats or filled into tubs. Thus, these spreads, despite their low fat contents and high water contents, can have any desired physical appearance.
The following examples are presented for the purpose of further illustrating and explaining the present invention and are not to be taken as limiting in any regard. Unless otherwise indicated, all parts and percentages will be by weight.

-- , . .

~ 1 7nA9~

EXAMPLE
This example describes the preparation of a butter-flavored spread as described above, and details the procedure for obtaining the microphotographs shown in Figures 1 and 2.
The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Coconut oil, 92 F Wiley melting point 19.0000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.5000 Beta carotene (30~ in oil) and vitamins 0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0.4000 Water 76.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 _________________________ ( ) DUREM* 114 (b) DURFAX* 60 (c) FRIMULSION* Q8 (d) FRIMULSION* 10 * a trade mark 1~7n~9~

An aqueous phase was prepared by heating the water to 190 F and adding the dry ingredients, an~ -the FRIMULSION* Q8 and 10 stabilizers predispersed in a portion of the melted fat, to it with agitation~ Mixing was continued until the stabilizers were uniformly dispersed and hydrated.
A separate fa-t phase was prepared by melting the fat and the emulsifiers at a temperature of about 150F. The color and flavor were then admixed with the melt to obtain a uniform blend.
The aqueous and fat phases were then blended at about 160F to provide an emulsion. The emulsion was then homogenized in a Gaulin Laboratory homogenizer, Model 15M, set at 150 atm.
first stage and 100 atm. second stage.
The emulsion was then cooled to 40F in about 15 minutes by slowly agitating with a Hobart Model N50 mixer fitted with a wire whip and a jacketed (water/alcohol coolant at approximately -200F) 5-quart mixing bowl. The resulting product was transferred to a tub and refrigerated for 24 hours. The resulting solidified spread exhibited a penetrometer reading of 130 units when measured by a Krebs Penetrometer with a standard penetrometer cone having a 2.5 inch diameter and a 45 angle, with 47.5 grams added weight at a 5-second interval. (Penetro-meter procedures according to ANS/ASTM D217-68).
The spread was prepared for microphotography by placing a very small amount of product on a glass slide and carefully covering with a cover glass. Photographs at 225 and 500 times magnification were prepared and are reproduced in Figures 1 and 2.
The final product was heated to determine the stability a trade mark . . _: ..

- ~17049~

and viscosity oE the emulsion at various temperatures. Using a Brookfield RVT Viscometer fitted with a number 1 spindle, the emulsion exhibited the following viscosities at 10 rpm:
100 F - 880 centipoises 150 F - 500 centipoises 200 F - 310 centipoises The emulsion is stable at all of these temperatures.
The product was tested to determine the type of emulsion by microscopic and colorimetric analysis. Under the microscopic test, a small amount of the product was placed on a microscope slide. A drop of water was then placed near the outer edge of the product. The interface between the product and the water was -then observed. If the emulsion was diluted, i.e., water from the droplet entered the emulsion, the emulsion was of the oil-in-water type, with the water being the continuous phase. Under the colorimetric test, an intensely colored fruit juice, such as grape, elderberry, raspberry, or the like, was dropped on the surface of the product. If the color was absorbed by the product, the emulsion was of the oil-in-water type. If no color was absorbed, the emulsion was of the water-in-oil type. Under both tests, the emulsion of this example was found to be oil-in-water.

EXAMæLE II
-This example describes the preparation of another buttèr-flavored spread. The details of the procedure were the same as in Example I. The only difference was that dairy solids were added and the proportions of the other ingredients were adjusted accordingly.

The spread was made from the following materials .~ 1 1 1 7()~

which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) - Coconut oil, 92 F Wiley melting point 18.5000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.5000 Beta carotene (30% in oil) and vitamins 0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0,4000 Water 73.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Whey/caseinate blend(e) 3,5000 Calcium disodium EDTA 0,0057 :-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (a), (b), (c) and (d): See Example I.
(e) MELOTEIN* MP-14P.

The solidified spread exhibited a penetrometer reading of 166 units when measured as in Example I.

EXAMPLE III
- This example describes the preparation of another butter-flavored spread, but this time containlng about 30% fat.
The procedure was the same as in Example I. The spread was made from the following materials which were employed in the amounts listed:

* a trade mark 1 1 704~ Ps Amount Ingredient (Parts b~ wt.) Coconut oil, 92 F Wiley melting point 29.0000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0~5000 Beta carotene (30% in oil) and vitamins 0.0050 Salt 1.6500 But-ter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0-4000 Water 66.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 _______________________ (a), (b), (c) and (d): see Example I.
The solidi~ied spread exhibited a penetrometer reading of 175 units when measured as in Example I.

EXAMPLE IV
This example describes the preparation of yet another butter-flavored spread, again employing the procedure of Example I, but this time utilizing only 10% fat. The spread was made from the following materials which were employecl in the amounts listed:

` ~? i 4~s Amount Ingredient (Parts by wt.) Coconut oilt 92 F Wiley melting point 9.0000 Mono- and diglycerides(a) 0.5000 Polysorbate 60~b) 0.5000 Beta carotene (30% in oil) 0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0-4000 Water 86.6791 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 ____________________ _ (a), (b), (c) and (d): See Example I.
The penetrometer reading for the final produc-t was 227 units when measured as in Example I.

EXAMPLE V
This example describes the preparation of another butter-~lavored spread, but this time utilizing different stabilizers. The spread was made from the following materials which were employed in the amounts listed:

.~) i 1~70~9P~

Amount Ingredient (Parts by wt.) Coconut oil, 92 F Wiley melting point 20~0000 Mono- and diglycerides(a) 0.5000 Polysorbate 60( ) 0.5000 Beta carotene (30% ln oil) and vitamins 0.0035 Salt 1.6500 Butter flavor 0.0320 Stabilizer (89% micro-crystalline cellulose and 11% sodium carboxymethyl cellulose)(f) 2.1000 Water 74.9613 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0250 _____________________ (a) and (b): see Example I.
(f) AVICEL* 581, FMC, Inc.
The procedure was essentially the same as that of Example I, but differing in that: the water was heated to only 160F; and the oil was heated to only 130F.
The penetrometer reading for the final product was 82 units when measured as in Example I.

* a trade mark 1~

. .

117~9~

EXAMPL~ VI
This example describes the preparation of another butter-flavored spread, but -this time em~loying a different emulsifier system. Except for the change in formulation, the process was the same as in Example I. The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt~) Coconut oil, 92 F Wiley meltin~ point 17.5000 Glyceryl-lacto esters o)f fatty acid, lipophilic emulsifier(g 0.5000 Octaglycerol monooleate, hydrophilic emulsifier (HLB=13.0) 2.0000 Beta carotene (30% in oil)0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0.4000 2Q Water 76.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 --_ _ (c) and (d): see Example I
(g) DURLAC* 100 WK

* a trade mark '' 'lB i `` 1~70~9Q

The resulting solidified spread exhibited a penetrometer reading of 117 units when measured as in ~xample I.

EXAMPLE VII
This example describes the preparation of another butter-flavored spread, but this time employing soybean oil and employing a lower level of polysorbate 60 than in Example I.
The process was the same as in Example I. The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Soybean oil, partially hydrogenated(h) 19.2500 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.2500 Beta carotene (30~ in oil) and vitamins 0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) 1.0000 Stabilizer(d) 0,4000 Water 76.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 _________________ ___ (a), (b), (c) and (d): see Example I

(h) TEM*-Plus 95, Swift, Inc.

* a trade mark B

117û49~

The resulting spread exhibited a penetrometer reading of l99 units when measured as described in Example I.

EXAMPLE VIII
This example describes the preparation of another butter-flavored spread, but this time employing polysorbate 80 in place of the low level of polysorbate 60 in Example VII.
The process was the same as in Example VII. The spread was made Erom the following materials which were employed in the amounts listed:

Amount Ingredients (Parts by wt.) Coconut oil, 92F Wiley melting point 19.2500 Mono- and diglycerides(a) 0.5000 Polysorbate 80(i) 0.2500 Beta carotene (30% in oil) and vitamins 0.0050 Salt 1.6500 Butter flavor 0.0200 Stabilizer(C) l.0000 Stabilizer(d) 0,4000 Water 76.6743 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phospho~ic acid 0.0150 Calcium disodium EDTA 0.0057 ________ :
~a), (c) and (d): see Example I
(i) DURFAX* 80.

The resulting spread exhibited a penetrometer reading of 182 units when measured as in Example I.

* a trade mark 7n4~

EXAMPLE IX
-This example describes the preparation of a mushroom-flavored spread. The details of the procedure were the same as in Example I. The principal differences were that flavors other than butter were added and the level of polysorbate 60 was reduced.
The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Coconut oil, 92F Wiley melting point 19.4000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.2500 Caramel color 1.0000 Salt 2.0000 Mushroom powder~i) 2.0000 Onion powder( ) 0.5000 White pepper(l) o 5000 Stabilizer(C) 1.0000 Stabilizer(d) 4000 Water 72~1993 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 .______________________ (a), (b), (c) and (d): see Example I
- (j) Beatrice Nature Tone (k) McCormick (1) McCormick ~r ~ - 26 -~). i ~ 1 ~04~P~

EXAMPLE X
This example describes the preparation of a garlic-flavored spread. The details of the procedure were the same as in Example I. The main differences were tha-t flavors other than butter were added and the level of polysorbate 60 was reduced.
The spread was made from the following materials which were employed in the amounts listed:

Amount _gredient (Parts by wt.) Coconut oil, 92 F Wiley melting point 19.4000 Mono- and diglycerides( ) 0O5000 Polysorbate 60(b) 0.2500 Beta carotene (30% in oil) and vitamins 0.0050 Salt 2.0000 -Garlic powder( ) 4.5000 Garlic flavor(n) 0.5000 Stabilizer(C) 1.0000 Stabilizer(d) 0.4000 Water 71.1943 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 _ _ _ _ _ _ (a), (b), (c) and (d): see Example I
(m) McCormick (n) D & O Spisoseal .?,?

1 1 7(~

EXAMPLE XI
-This example describes the preparation of a blue-cheese flavored spread. The details of the proce~ure were the same as in Example I. The main differences were that flavors other than butter were added and the level of polysorbate 60 was reduced~
The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.
Coconut oil, 92F Wiley melting point 19.4000 ~lono- and diglycerides(a) 0.5000 Polysorba-te 60(b) 0.2500 Titanium dioxide 0.0300 Salt 2.0000 Blue Cheese spice mix( ) 3.8400 Stabilizer(C) 1.0000 Stabilizer(d) 4000 Water 72.3293 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 ___________ ___________ - (a), (b), (c) and (d): see Example I.
(o) Hidden Valley Ranch Style, The H.R.V. Company.

-r,~ - 28 -1 ~ 7n~

EXAMPLE XII
This example describes the preparation of a sour cream flavored spread. The details of the procedure were the same as in Example I. The main differences were that flavors other than butter were added and the level of polysorbate 60 was reduced.
The spread was made from the foll.owing materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Coconut oil, 92F Wi.ley melting point 19.4000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.2500 Titanium dioxide 0.1300 Salt 2.0000 Sour cream powder (P) 1.2000 Stabilizer(C) 1.0000 Stabilizer(d) 0.4000 Water 75.2193 Potassium sorbate 0.1300 Sodium benzoate o,]ooo Phosphoric acid 0.0150 Calcium disodium EDTA o,oo57 ____________ _ _______ .(a), (b), (c), and (d): See Example I.
(p) Borden sour cream powder #66.

. - 29 -~ ~n~

EXAMPLE XIII
This example describes the preparation of a bacon-flavored spread. The details of the procedure were the same as in Example I. The main differences were that bacon flavor was employed and the level of polysorbate 60 was reduced.
The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Coconut oil, 92F Wiley melting point 19.4000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.2500 Caramel color 1.5000 Salt 2.0000 Artificial bacon flavor(q)l.0000 Stabilizer(C) l.0000 Stabilizer(d) 0.4000 Water 73.6993 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0.0057 ______________________ (a), (b), (c), and (d): see Example I
(q) Alex Fries #2300.

~'\~) i ~117n4 EXAMPLE XIV
This example describes the prepara-tion of a yogurt-flavored spread. The de-tails of the procedure were the same as in Example I. The principal differences were that a different flavor was employed and the level of polysorbate 60 was reduced.
The spread was made from the following materials which were employed in the amounts listed:

Amount Ingredient (Parts by wt.) Coconut oil, 92F Wiley melting point 19.4000 Mono- and diglycerides(a) 0.5000 Polysorbate 60(b) 0.2500 Titanium dioxide 0.0300 Salt 1.6500 Artificial yogurt flavor( )1.0000 Stabilizer(C) 1.0000 Stabilizer(d) 4000 Water 73.67~3 Potassium sorbate 0.1300 Sodium benzoate 0.1000 Phosphoric acid 0.0150 Calcium disodium EDTA 0,0057 ________________________ (a), (b), (c) and (d): see Example I
(r) Alex Fries #800.

. .,

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A low-fat spread comprising:
a dispersed phase comprising from 5 to 40% fat, based on the weight of said spread;
a continuous aqueous phase including a stabilizer; and an emulsifier system comprising a combination of a lipophilic emulsifier and a hydrophilic emulsifier;
the relative and total amounts of said emulsifiers and said stabilizer being effective to provide a stable emulsion and a product which is solid at 40°F.

2. A low-fat spread according to claim 1, wherein said fat comprises from 10 to 30% of the total weight of said spread.

3. A low-fat spread according to claim 1, wherein said fat comprises a partially hydrogenated vegetable oil having a solids profile effective, when employed in the total system, to provide a product which remains solid at 40°F, remains spreadable at normal refrigerator temperature, and melts quickly in the mouth to release flavor without imparting a waxy texture or mouthfeel.

4. A low-fat spread according to claim 3, wherein said fat comprises a par-tially-hydrogenated vegetable oil having an SFI profile with the following ranges:
50°E - 40-80%
70°F - 25-50%
92°F - <10%

5. A low-fat spread according to claim 4, wherein said fat comprises a partially-hydrogenated vegetable oil having an SFI profile with the following ranges:
50°F - 50-70%
70°F - 30-40%
92°F - <5%

6. A low-fat spread according to claim 1, 3 or 4, wherein said fat is selected from the group consisting of:
soybean oil, corn oil, coconut oil, cottonseed oil, peanut oil, palm oil, palm kernel oil, safflower oil, sunflower oil, rapeseed oil, and mixtures thereof.

7. A low-fat spread according to claim 3, 4 or 5, wherein said fat is selected from the group consisting of: 92°F
Wiley melting point partially-hydrogenated coconut oils identified by the trade marks: PURECO 92, HYDROL 92, VICTORY 92 and COBEE 92.

8. A low-fat spread accordlny to claim 1, which exhibits a penetrometer reading at 40°F within the range of 60 to 250 units using a standard penetrometer cone, having a 2.5 inch diameter and a 45° angle, with 47.5 grams added weight at a 5-second interval.

9. A low-fat spread according to claim 8, which exhibits a penetrometer reading within the range of 100 to 200 units under the same conditions.

10. A low-fat spread according to claim 1, wherein said emulsifier system is present in an amount of from 0.3 to 4.0%, based on the total weight of said spread, and each of said lipophilic and hydrophilic emulsifiers are present at levels of at least 0.05% on the same basis.

11. A low-fat spread according to claim 1, wherein said emulsifier system is present in an amount of from 0.5 to 2%, based on the total weight of said spread, and each of said lipophilic and hydrophilic emulsifiers are present at levels of at least 0.10% on the same basis.

12. A low-fat spread according to claim 10, wherein said hydrophilic emulsifier has an HLB of from 11 to 17.

13. A low-fat spread according to claim 10 or 11, wherein said hydrophilic emulsifier has an HLB of from 10 to 20.

14. A low-fat spread according to claim 11, wherein said hydrophilic emulsifier has an HLB of from 13 to 16.

15. A low-fat spread according to claim 11, 12 or 14, wherein said hydrophilic emulsifier comprises a member selected from the group consisting of: polyoxyethylene (20) sorbitan monostearate, polyoxyethylene (20) sorbitan monooleate, and mixtures thereof.

16. A low-fat spread according to claim 11, 12 or 14, wherein said hydrophilic emulsifier comprises polyoxyethylene (20) sorbitan tristearate.

17. A low-fat spread according to claim 11, 12 or 14, wherein said hydrophilic emulsifier comprises octaglycerol monooleate.

18. A low-fat spread according to claim 1, wherein said lipophilic emulsifier has an HLB of less than 7.

19. A low-fat spread according to claim 18, wherein said lipophilic emulsifier comprises a member selected from the group consisting of: mixed fatty acid monoglycerides; mixed fatty acid diglycerides; mixtures of fatty acid mono- and diglycerides; lipophilic polyglycerol esters; glycerol esters including glyceryl monooleate, glyceryl dioleate, glyceryl monostearate, glyceryl distearatel glyceryl monopalmitate and glyceryl dipalmitate; lactylated esters including glyceryl-lacto esters of fatty acids; propylene glycol esters including propylene glycol monopalmitate, propylene glycol monostearate, and propylene glycol monooleate; sorbitan esters including sorbitan monostearate, sorbitan trioleate, sorbitan tripalmitate, sorbitan tristearate. and sorbitan sesquioleate; fatty acids and their soaps including stearic acid, palmitic acid, and oleic acid; and mixtures thereof.

20. A low-fat spread according to claim 18, wherein said lipophilic emulsifier comprises a member selected from the group consisting of: lipophilic polyglycerol esters, mono-and diglycerides, propylene glycol esters, lactylated esters and mixtures thereof.

21. A low-fat spread according to claim 1, having less than 40% by volume of gas incorporated therein.

22. A low-fat spread according to claim 12, 14 or 18, having less than 20% by volume of gas incorporated therein.

23. A low-fat spread according to claim l, wherein said stabilizer is a hydrophilic colloid selected from the group consisting of locust bean gum, gelatin, pectin, micro-crystalline cellulose, carageenin, guar gum, alginate, xanthan gum, soy protein isolate, methyl cellulose, carboxymethyl cellulose, ethyl cellulose, hydroxypropylmethyl cellulose, dextrins, soluble starch and mixtures thereof.

24. A low-fat spread according to claim 1, wherein said stabilizer comprises from 0.1 to 3.0% of the total weight of said spread.

25. A low-fat spread according to claim 1, 11 or 24, which is solid at 70°F.

26. A low-fat spread according to claim 1, wherein said hydrophilic emulsifier comprises a member selected from the group consisting of: polyoxyethylene (20) sorbitan monostearate, polyoxyethylene (20) sorbitan monooleate, and mixtures thereof and said spread is solid at 70 C.

27. A low-fat spread according to claim 1, wherein the composition further comprises an effective amount of an antimicrobial agent to prevent microbiological spoilage of said spread.

28. A low-fat spread according to claim 27, wherein the pH of the aqueous phase is below 6.

29. A low-fat spread according to claim 28, wherein the pH of said aqueous phase is in the range from 5.0 to 5.9.

30. A low-fat spread according to claim 29, further comprising an additive selected from the group consisting of:
a coloring agent, a flavoring agent, a flavor enhancing agent, an antioxidant, a protein, a vitamin, a mineral, a chelating agent and mixtures thereof.

31. A low fat spread according to claim 30, wherein said spread has about 25 calories per 14 gram serving and remains solid after standing for 5 hours at 70°F.

32. A low-fat spread according to claim 31, wherein the emulsion is stable for 6 months when stored in a moisture-proof container at a temperature up to 40°F and is stable for at least one day at a temperature of 70°F.

33. A low-fat spread according to claim 32, wherein said emulsion is stable, after melting, at a temperature of 180°F.

34. A low-fat spread according to claim 33, which is solid at 75°F.

35. A process for preparing a low-fat spread, which comprises:
preparing an oil-in-water emulsion comprising a dispersed phase comprising from 5 to 40% fat, based on the weight of said emulsion, a continuous aqueous phase including a stabilizer, and an emulsifier system comprising a combination of a lipophilic emulsifier, and a hydrophilic emulsifier, the relative and total amounts of said emulsifiers and said stabilizer being effective to provide a stable emulsion and a product which is solid at 40°F; and cooling said emulsion under conditions effective to solidify it to form a product which is solid at 40°F.

36. A process according to claim 35, wherein said lipophilic emulsifier and other fat soluble components are blended with said fat at a temperature effective to provide a uniform blend, prior to preparing said emulsion.

37. A process according to claim 35 or 36, wherein said stabilizer is blended with said fat prior to preparing said emulsion.

38. A process according to claim 35, wherein said stabilizer is blended with water at a temperature and with sufficient agitation to provide a uniform suspension, prior to preparing said emulsion.

39. A process according to claim 35, 36 or 38, wherein said hydrophilic emulsifier is blended with water prior to preparing said emulsion.

40. A process according to claim 35 or 36, wherein said hydrophilic emulsifier is blended with said fat prior to preparing said emulsion.

41. A process according to claim 35, 36 or 38, wherein said emulsion is agitated after cooling to promote crystallization and enhance solidification.

42. A process according to claim 35, wherein all of the ingredients are thoroughly blended, at a temperature sufficient to maintain said fat in a liquid state, prior to homogenization.

43. A process according to claim 42, wherein the blended ingredients are homogenized at a temperature of from 120 to 190°F.

44. A process according to claim 43, wherein a temperature of from 130 to 150°F is used.

45. A process according to claim 43 or 44, wherein said blended ingredients are homogenized at a pressure of from 100 to 500 atmospheres.

46. A process according to claim 43 or 44, wherein said blended ingredients are homogenized at a pressure of 250 atmospheres.

47. A process according to claim 43, wherein said emulsion is rapidly cooled to a temperature below 70°F after emulsification.

48. A process according to claim 47, wherein the rapid cooling is effected by a series of 3 "A" units.

49. A process according to claim 47, wherein said emulsion is agitated after cooling to a maximum temperature of 50°F.

50. A process according to claim 35, 36 or 42, wherein said emulsion is cooled and then agitated in a "B" unit blender.