AU2005315984A1

AU2005315984A1 - Process for making bouillon or seasoning cubes

Info

Publication number: AU2005315984A1
Application number: AU2005315984A
Authority: AU
Inventors: Vivyan Yan Ying
Original assignee: Unilever PLC
Current assignee: Unilever PLC
Priority date: 2004-12-14
Filing date: 2005-11-24
Publication date: 2006-06-22
Anticipated expiration: 2025-11-24
Also published as: WO2006063690A1; AU2005315984B2; AR051718A1

Description

WO 2006/063690 PCT/EP2005/012837 PROCESS FOR MAKING BOUILLON OR SEASONING CUBES Field of the invention The present invention relates to a process for making bouillon or seasoning cubes, wherein at least part of the fat is powdered fat. Background of the invention Bouillon cubes are well known articles in the western and non-western cooking. Conventionally, bouillon cubes comprise solid, more or less dry ingredients such as one or more of salt, sugar, flavour enhancers (like e.g. monosodium glutamate MSG), herbs, spices, vegetable particulates, colourants and flavourants, next to e.g. 1-30% fat or oil. The industry distinguishes between so-called hard bouillon cubes and soft (or pasty) bouillon cubes. Soft or pasty bouillon cubes can usually be deformed by squeezing between two fingers before they break up into lumpy crumbles, and usually leave a pasty/oily feel on the fingers. Hard cubes tend to crumble into powder, lumps or small particulates upon squeezing between fingers. Crumbling between fingers is relevant for seasoning cubes, or for bouillon cubes used as seasoning cubes, as such cubes are usually crumbled between two fingers above food (e.g. in a cooking pot) or a dish. Even though some processed cubes crumble fairly well, a lot of cubes are still too hard to be easy to crumble, or, if they can be crumbled reasonably well they crumble to lumpy matter, rather than fine particulates or powders, as may be desired for good dispersion of flavouring ingredients. Also, the hardness of most (pressed) bouillon cubes tends to increase over time, but it is desired that over time, the cubes stay easy to crumble. Hence, there is a need for bouillon and seasoning cubes, tablets and the like (including all geometric forms, including ball shape, ecetera) that are easy to crumble, and preferable stay easy to crumble over time. It is also preferred that the cubes crumble to powdery matter, and not to lumpy matter (as lumpy matter still hinders good dispersion of flavouring ingredients). Seasoning cubes can be prepared in a similar way as bouillon cubes and often contain similar ingredients, but can contain (depending upon use) more fat, e.g. 10-98%.

WO 2006/063690 PCT/EP2005/012837 2 As the fats used in bouillon cubes or seasoning cubes should not stain the packaging and/or melt upon storage, partially or fully hardened vegetable oils are frequently used as fat in such cubes, optionally together with liquid oil. 5 Conventional manufacturing of pressed -bouillon cubes involves melting fat, mixing with dry solid ingredients (salt, MSG, herbs, spices, etc), leaving the mixture to mature for e.g. 24 hoursfollowed by pressing into cubes. Seasoning cubes can be prepared in much the same way. EP 1419699 discloses bouillon cubes using a specific fat blend. The fat used is solid at room temperature, and processing is reported to be in the conventional way for bouillon 10 cubes, which is along the lines as disclosed above. EP 594152 discloses a process for manufacturing granules comprising fat and particulate matter (e.g. flour), in which the fat is first melted and then mixed with the particulates matter and processed further. 15 EP 780058 relates to processes for producing flowable powdered foodproducts. To this end, fat is melted, when melted mixed with particulate ingredients, thus coating the particulate ingredients with melted fat. The so-obtained mixture is reported to be flowable. The introduction of this patent application refers to a process for producing stock cubes via a 20 process which is referred to as the "hard" process. Such "hard" process is reported to comprise the steps of melting and mixing solid fats, cool such melted fats on a roller to produce fat flakes. Such fat flakes are then mixed with the other ingredients of the stock products and the mixture pressed to cubes. 25 US 2002/0168450 discloses melting bodies comprising a filling and an outer wall. The filling is reported to be pulverulent, liquid or semi-liquid. EP 888723 discloses a process for preparing solid savoury seasoning articles which are prepared by melting fat at e.g. 50-60*C, followed by mixing the melted fat with the other 30 ingredients, conditioning this mixture at 5-25*C, shaping, covering with a sticking agent followed by covering with visual elements. Summary of the invention A process for preparing bouillon or seasoning cubes has now been developed, the process 35 comprising the steps of: WO 2006/063690 PCT/EP2005/012837 3 (a) mixing 2-99% of particulate ingredients comprising one or more of salt, flavour enhancers, spices, herbs, flavourants, sugar, yeast extract, or hydrolysed vegetable protein with 1 98% of fat solid at 20 0 C in the form of a powdered fat, (b) pressing to cubes, 5 wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 2 mm, and wherein the powdered fat is prepared by one or more of spray-cooling, spray-chilling, spray freezing, prilling, grinding, cryo-grinding, or milling. 10 In the process as given above wide ranges of the amount of ingredients are given. The actual amount depends e.g. on the intended use. For bouillon (incl. broth and stock and the like) cubes the amount of fat is preferably 1-30%, more preferably 2-25%. For seasonings (incl. melting) cubes the amount of fat is preferably 10-99%, more preferably 20-70%. Cubes e.g. for soups and sauces can have fat contents of 5-60%, preferably 10-50%. All percentages are 15 percentages by weight of the total cube. For very low amounts of fat (e.g. 1-5%) it may be needed to include ingredients of which it is known that they aid compressing into a tablet, like maltodextrin and/or moist ingredients. In the above, the powdered fat has preferably such a particle size that in a sieve analysis: 20 at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 2 mm, and more preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 1.5 mm, and even more preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 1 mm, and most preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a 25 mesh size of 0.5 mm. Preferably, the powdered fat is not micronised fat or granulated micronised fat. Detailed description of the invention It was surprisingly found that cubes prepared in this way are, under otherwise identical 30 processing conditions (e.g. compression pressure, moisture, temperature) can be easier to crumble between fingers, can stay easier to crumble over time, and can yield non-lumpy matter upon crumbling. In this case, crumbling was easier and more complete than cubes prepared in a process in which the solid fat is in a different physical format.

WO 2006/063690 PCT/EP2005/012837 4 Herein, the powdered fat (or fat in pwodered form) which is prepared by spray-cooling, spray chilling, spray freezing, prilling, grinding,cryo-grinding, or milling, as in use in the present invention, is for brevity referred to as "powdered fat". 5 It was furthermore found that (when working at temperatures less than 20*C) in the process according to the invention the fat.(when in such small particulates as indicated) could be mixed with the other particulate ingredients in a fairly easy way using equipment as known in the art, e.g. using a ribbon, paddle or Nauta mixer. It can be preferred, e.g. when working at higher temperatures than 20*C) that the fat in the process according to this invention is solid 10 at 30*C, in powdered form. More preferred can be wherein the fat in the process according to this invention is solid at 40*C, in powdered form. Powdered form is herein to be understood as each individual particulate is solid, and (due to e.g. size of the particulates) the whole mass of fat is preferably free-flowing. 15 At reasonable environmental and processing conditions, the fat as specified above is free flowing at temperatures below 20*C (prior to mixing with the other ingredients). To take into account slightly higher processing or environmental temperatures, it can be preferred to -use powdered fat of which the particulates are free flowing at temperatures below 30*C, more preferably free flowing at temperatures below 400C. 20 Such fat (in particular specified by the small particles and the temperature at which they are solid: 200C, preferably 30*C, more preferably 400C) can be free flowing. The bulk density (as a bed) of the powdered fat as used in the process according to the invention is preferably 400 700 g/l, more preferably 500-600 g/l. The free-flowing nature of the fat can enhance efficiency, 25 which is an additional benefit of the process according to this invention. Preferred fats for the application as set out herein are fully hardened vegetable fats. It is preferred to use powdered fat which comprises 10-100% fully hardened palm oil. 30 Although the mixing stage can last almost infinitively long, it is preferred for that mixing is sufficiently long to obtain a homogeneous mixture for all particulate ingredients. Actual mixing times needed will depend e.g. on the type of mixer chosen, and the mixing times needed can be determined by the skilled person in the art, taking into account a minimum time of mixing needed. From a practical point of view preferred that the first mixing stage takes 10 seconds 35 to 60 minutes, preferably 1 - 20 minutes (as long as a homogeneous mixture is obtained by WO 2006/063690 PCT/EP2005/012837 5 the mixing operation). The mixing itself can be performed with any mixer as known in the art of making bouillon cubes, such as a ribbon, paddle mixer or Nauta mixer. It is preferred that the powdered fat according to the present invention comprises less than 3% 5 (wt % based on total fat) of triglycerides of trans-fatty acids. Contrary to the prior art, the presently claimed process does not require the bulk ingredients (apart from the fat) to be milled. Hence, preferably they are not milled. Also, it is preferred that the cubes according to the invention do not comprise a filler (e.g. material of the carbohydrate 10 group like (corn)starch, flour, cassava powder, and/or maltodextrin) and/or sticking agent. In the process and product according to the invention the flavour enhancers preferably comprise monosodium glutamate or other particulate flavour enhancers. 15 At least part of the fat solid at 20 0 C should be powdered fat. Preferably all of the fat solid at 20 0 C used in the present formulation is powdered fat (particles sizes as indicated before). The powdered fat can be a fat already solid at 200C as it is, or by fully hardening a vegetable oil. Although fats that become liquid at e.g. 250C may work under processing temperatures which are lower, it may be preferred to use fats (for fraction (a) above) that are still solid at 300C, or 20 more preferably still solid at temperatures above 40 0 C. This will widen the margin for operating conditions. The fat fraction (a) should be solid at processing (mixing) temperature, and preferably still contain enough solid matter under storage conditions. Preferably, no liquid oil is included in the formulations and processes according to the invention. 25 Depending upon the recipe, the mixing stage may include one or more of herbs, spices, nucleotide flavour enhancers, vegetable particulates, meat powder, flavourants, colourants in the mixture. The pressing preferably comprises pressing in a mould. The cubes may be pressed by 30 conventional pressing equipment for (hard) bouillon or seasoning cubes, such as Fette presses. Although it is referred to herein as "bouillon cubes or seasoning cubes", the present invention of course does not just encompass cube-shaped objects, but also other solid particulates of 1 35 25 gram weight (preferably 2-20g, more preferably 3-20g), preferably of regular shape, and of WO 2006/063690 PCT/EP2005/012837 6 other geometric form, such as tablets, triangles, balls, cones, and also briquettes, pellets etcetera. Likewise, the invention does not just relate to cubes for making bouillon, but also to cubes for preparing a broth or stock, use as seasoning, as or for use in soup, sauce, etcetera. The apparent bulk density of the pressed cubes according to the invention is preferably above 5 650 g/l, more preferably above 700 g/l. Depending upon the exact compositions and auxiliary components, either hard or soft cubes can be obtained. 10 EXAMPLES Example 1 Hard bouillon cubes were made according to the following composition: Ingredients Amounts (weight % on total cube) Bulk ingredients (salt, sugar, MSG) 62 % Yeast extract 15% Sett P55 (powdered hydrogenated palm 15 % oil, melting point 55-60*C) Herbs and spices 3 % Meat extract powder 2.5 % Flavours 2% Colours 0.5 % In the above, Sett P55 is a powdered fat having a bulk density range of 500-600g/L. The sieve 15 analysis is as follows. - approx. 50%, with mesh size 0.2 mm - approx. 100%, mesh size 0.5 mm - 100%, mesh size 1.0 mm. 20 The processing involved mixing all dry ingredients including the solid fat (Sett P55) in a paddle mixer for 5 minutes. Then the mixture was fed to a cubing machine (W. Fette, Rotary Tabletting Machine Hanseate Perfecta 4B). No maturation time was needed between mixing and pressing. The resulting cubes were dry, still fairly hard, but upon pressure by hand crumbled apart. 25 WO 2006/063690 PCT/EP2005/012837 7 Example 2 Bouillon cubes were made according to the following composition: Ingredients Amounts (weight % on total cube) Salt 47% Monosodium glutamate 15 % Sugar 7% Garlic powder 12% Fat (palm stearin, mp 51-55*C) 9 % Corn starch 6% Maltodextrin 2% Citric acid 1 % Garlic flavour 1 % With the above base recipe three different trials were made, differing in the physical format of 5 the fat employed. The physical formats were: - melted, liquid fat - fat flakes - spray-cooled fat powder 10 The spray cooled powdered fat was obtained from the firm Juchem. The fat flakes were produced between rollers and breaking it up. Particle sizes as estimated by microscopy: Fat flakes: at least 70% by weight has a diameter of 350-500 microns, and a thickness of 200 400 microns. Powdered fat: at least 70% by weight has a diameter of 2-6 microns. 15 The processing involved mixing all non-fat ingredients in a small, lab-bench Kenwood mixer for 2 minutes. The fat was added and mixed for another 5 minutes (melted liquid fat was added whilst in melted state, at 60*C). Thereafter, the mixture was fed to a lab-bench, simple cubing equipment. The powder was compressed by applying 5 kN pressure. The resulting 20 cubes were tested for hardness I ease of crumbling, as well as the type of crumbles formed, by crumbling by hand, on two moments: immediately after pressing and 5 days later.

WO 2006/063690 PCT/EP2005/012837 8 The resulting cubes were tested on easy of crumbling, and it was monitored how it crumbled. The results are set out in the table below: Spray-cooled Fat flakes Melted fat powdered fat Ease of crumbling (1) Very easy crumbling Good crumbling (+) Hard, not easy to (++) crumble (0) Appearance after crumbling Powder Powder Lumpy powder 1) Ease of crumbling (2) Very easy crumbling Good crumbling (+) Hard, not easy to (++) crumble (0) Appearance after crumbling Powder Powder and small Lumpy powder (2) lumps (1): directly after pressing. (2): 5 days after pressing 5 It shows that cubes prepared with fat flakes and spray cooled fat are immediately after pressing far easier to crumble than processes in which melted fat is included (using otherwise the same recipe and processing, e.g. compression force), with the cubes with powdered fat being easiest to crumble. The resulting crumbled product was similar for flakes and powdered fat (immediately after pressing). 10 After 5 days there is a difference between cubes which contain (spray-cooled) powdered fat vs. flakes: the cubes that contain powdered fat still break down to powder, whereas the cubes that contain fat flakes now break down in more lumpy material. This breaking down in powder is a desired result. It is expected that the difference between recipes in which (spray-cooled) 15 powdered fat is used when compared with recipes with fat flakes become bigger when there is more time between testing and pressing. Such is relevant as such cubes are usually stored by the consumer for a long to very long time.

Claims

1. Process for preparing bouillon or seasoning cubes, the process comprising the steps of: 5 (a) mixing 2-99% of particulate ingredients comprising one or more of salt, flavour enhancers, spices, herbs, flavourants, sugar, yeast extract, or hydrolysed vegetable protein with 1-98% of fat solid at 20*C in the form of a powdered fat, (b) pressing to cubes, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% 10 by weight of the individual powdered fat particles passes a sieve with a mesh size of 2 mm, and wherein the powdered fat is prepared by one or more of spray-cooling, spray chilling, spray-freezing, prilling, grinding, cryo-grinding, or milling.

2. Process according to claim 1, wherein the powdered fat has such a particle size that in 15 a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 1.5 mm.

3. Process according to claim 1-2, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles 20 passes a sieve with a mesh size of 1 mm.

4. Process according to claim 1-3, wherein the formulation comprises 1-30% of fat solid at 30'C in particulate form. 25

5. Process according to claim 1-4, wherein the formulation comprises 1-30% of fat solid at 40*C in particulate form.

6. Process according to claim 1-5, wherein the fat prior to mixing is free flowing at temperatures below 20*C, preferably below 30'C, more preferably below 40*C. 30

7. Process according to claim 1-6, wherein the bulk density of the powdered fat used in the process is 400-700 g/l, preferably 500-600 g/l.

8. Process according to claim 1-7, wherein the fat solid at 200C in particulate form 35 comprises 10-100% fully hardened palm oil. WO 2006/063690 PCT/EP2005/012837 10

9. Process according to claim 1-8, wherein the mixing stage takes 10 seconds to 120 minutes, preferably 30 seconds to 60 minutes. 5

10. Process according to claim 1-9, wherein pressing comprises pressing in a mould.

11. Process according to claim 1-10, wherein the amount of fat solid at 20*C in particulate form is 5-20%. 10

12. Process according to claim 1-11, wherein fat solid at 20*C contains less than 3% (wt % based on total fat) of triglycerides of trans-fatty acids.

13. Process according to claim 1-12, wherein one or more of herbs, spices, nucleotide flavour enhancers, vegetable particulates, meat powder, flavourants, colourants are 15 included in the mixing step.