CA2068494A1 - Method of adhering food toppings - Google Patents

Abstract

Abstract Particulates are adhered to each other and retained on food using up to 3% cold water soluble starch by weight of particulate.

Description

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MET~OD OF AD~ERING ~OO~ T~PPINGS

The present invention related to foods having particulate or powdered toppings and more particularly to a method of adhering such toppings to the food with starch.

BacXground o~ Invention Foods prepared having particulate or powdered toppings such as seasonings, decorations or food particulates often suffer when the topping ~ecomes separated from the bulk portion of the food. Such separation may occur during preparation of the product, during handling by factory workers or equipment, during packaging, during shipment and during use by the consumer.
This problem is particularly difficult during high speed manufacturing of foods such as pizza or bakery products where large particulate of expensive ingredients such as cheese, ground, and sliced meats, nuts and the like are involved. Conveying of such products through to packaging causes some of the particulate topping to be lost reducing product flavor, quality, appearance and resulting in loss of valuable food ingredients. The consumer is often faced with an undesirable looking danish with much of the topping lying loosely in the packages. Pizza must often be overtopped to compensate for loss of particulates during manufacturing.
The prior art has attempted to reduce separation of toppings and coatings and to further protect them from loss of flavor, oiling, moisture transfer and the like. Budd, et al , U.S. Patent No. 4,910,0~1 discloses a snack food wherein a concentrated sugar solution and a sweetness suppressor are used to bind or adhere one or more toppings to a base during production, packaging and shipping. McKee, U.S. Patent No.
4,06~,796 uses two algin films on a pizza product, one on the 1 crust to prevent migration of moisture and one that holds the food ingredients physically in place on the pizza crust while it is subjected to processing. Kielsmeier, et al., U.S.
Patent No. 4,997,670 discloses a method of baking pizza involving free-flowing cheese granules. Palmlin, et al., U.S.
Patent No. 4,919,953 discloses a process for coating food with root vegetable particles using a heat-settable adhesive film, such as a tempura batter, on which the particulate material is placed. The food is then deep fried and frozen. Rispoli, et al., U.S. Patent No. 4,260,637 discloses a self-sticking bread crumb composition of bread crumbs mixed with 1-35%, preferably 5-15%, protein which may also contain starch and/or gum and sprayed with oil to adhere the material to the crumbs. The self-sticking crumbs will then adhere, without use of a batter, to a food product during coo~ing. In example II, Rispoli, et al., employ 10% egg white solids, 5~
pregelatinized modified waxy maize starch, seasoning and oil on 63.1% bread crumbs.
"Purity Gum 59" a starch used in this invention, is a low viscosity, cold water-soluble, modified food starch derived from waxy maize supplied by National Starch and Chemical Corporation. "Purity Gum 59" was developed for use as a clear, film-forming agent to replace gum arabic in pan coating confections and tablets and as a glaze for bakery items or to serve as a replacement for egg wash on baked goods. It also can be used as a coating for adhesion of seasonings and seeds, to cxackers and nut meats.
The prior art has yet to find a method ~or adhering large particulates to food stuffs in a simple and innocuous manner. The above prior art either uses high levels of material which contribute to flavor and appearance, employing heavy films which are usually apparent or treats powdery small materials.

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-~umma~ of the Invention We have found that particulate and/Dr powdery toppings can be stabilized and adhered to the bulk portion of a food by using a cold water~soluble starch which binds the topping to the food without being noticeable or sticky. The starch is introduced to the topping using a fine spray of an aqueous solution of the starch or as a powder which is thereafter moistened with a mist of water. The starch quicXly drys to a clean, smooth, non-sticky, pliable film. Cold water-soluble starch is particularly useful for adhering large particulates of protein material, such as cheese and meat, to carbohydrate-based foods such as pizza-flavored breads as well as pizza itself. The starch incorporated into a conventional egg wash is particularly useful for bindin~ nuts and other large particulates to bakery products. Of course small particles are egually bound to each other.

Detailed DescriPticn of the Invention The application of the cold water-soluble starch of this invention to adhere particulates or powders of meat, vegetable, seasoning or nuts to a carbohydrate-based food minimizes the loss of such food toppings in the manufacturing process where high line speeds are required, ensures proper topping weight on the food and eliminates the need to collect dropped topping. The invention also affords higher line speeds and improved productivity.
By carbohydrate-based products we mean typical bakery items such as breads, buns and rolls, including pizza-sauced products made from bread, buns or rolls, or pizza crust, pies, cakes and pastries, particularly danish and snack items of all kinds.

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By toppings we mean any powdered, particulate or sliced ~opping normally added to the above carbohydrate-based products but particularly large particles of protein-based toppings such as cheese and meats. Toppings c~n include nuts of all kinds, candy confections, coconut, fruit and simulated fruit, powdered Elavoranls as well as the preferred cheeses and meat toppings in any form which requires assistance in adhering the topping to the carbohydrate base.
The invention is particularly useful for adhering large particles to the carbohydrate base. By large particles we mean shreds, pieces, slices of foods, especially cheese or meat or nuts such that at least one dimension of ~he particle is greater than 1/8 inch preferably greater than 0.25 inches.
The cold water-soluble starch is employed either in - up to 40% starch solution in water, preferably 10-35%, or is dry blended up to 3% with the topping and later acti~ated with a fine mist of water before the product is packagcd and/or frozen.
The cold water-soluble starch can be any pregelatinized starch which will be tacky long enough to adhere the particulate and/or powder to the food and/or to itself but will rapidly dry during subsequent processing of the food to a clear, smooth, non-sticky, pliable film.
Chemically or otherwise modified pregelatinized starches can be employed such as a cold water-soluble modified waxy maize starch like "Purity Gum 59" and the like.
We employ up to 3.0% of the topping of cold water soluble modified starch preferably 0.5-2.5% and most prefexably 1-2%. About 1.25% to about 1.5% starch has been found sufficicnt to adhere cheese to prebaked, sauced pizza and to adhere nuts to danish dough prior to baking. We employ from 0.005 to 0.15 g of starch per square inch of topping surface area preferably 0.0075 to 0.10 g/in2. Amounts of other food materials may be made part of the cold water-1soluble starch coating system. The coating system can include emulsifiers effective to promote adhesion, acidulants, flavoring materials, antioxidants, colors and the like.
Sugars and g~s and proteins can also be included.
5~or bakery items we have found it particularly useful to prepare a mixture of conventional egg wash with the water soluble starch and 'o apply the mixture for convenience and efficiency, just as the egg wash is applied. Starch is used from at a ievel of 15 to 50, preferably 25 to 30, parts of 10starch per 100 parts of the whole egg and starch is dissolved in water to give a soluble mi~ture (usually 20-35~ solids~, refrigerated and sprayed on the bakery dough just as with conventional egg wash prior to adding the topping. The dough is usually lightly flattened with a roller after adding the 15staxch, the nuts or other toppings are then added and the - toppings lightly rolled onto the dough. The egg and starch wash can be employed either before or after adding the topping to the dough. The dough is then placed in pans and baked. We have found the amount of topping that falls from the topped 20product during handling of the dough, baking, packaging and distribution is reduced by at least ~0%, typically at least 50% due to use of the cold water-soluble starch in the egg wash.
Except for use of egg when binding bakery coatings 25we usually prefer to employ the binder without additives. For example, the cold water-soluble starch can be dry blended with cheese and/or other particulates and the mixture deposited on the surface of a raw dough or baked carbohydrate base. A
typical base would be a prebaked, sauced pizza crust or bread.
30 The substrate containing the applied starch-coated particulates is then subjected to a moist environment followed by drying, such as in an oven or by exposure to ambient air, during processing to fix the topping to itself so as to retain -the topping on the carbohydrate substrate. Typically, the 35 topped substrate would then be packaged and frozen. Another 2~8~

1 embodmear of the invention involves the application of a 10-35% solution of the cold water-soluble starch to the already topped carbohydrate substrate. This solution can be sprayed over the applied topping and will quickly dry. Again, we have found that at least 40% of the topping which is normally shaken from the substrate during manufacturing and shipping is retained as a result of using the starch to adhere the topping to the carbohydrate substrate. It would, of course, be possible to combine more of the various embodiments of this invention in order to further minimi~e loss of topping material.

Exam~le 1 Twenty-eight lbs. of "Purity Gum 59'` starch was added, a little at a time, into 100 lbs of warm water (12~
degrees F), agitating in a kettle equipped with a Lightenin~M
mixer. The starch-water dispersion was agitated employing high speed mixing for about lO minutes to complctely dissolve the starch in water. The temperature of this solution was 86 degrees F. Then 100 lbs of blended whole cggs and 6 lbs. of salt were added to the kettle and mlxed with medium speed agitation for about two minutes to achieve a uniform egg wash-starch blend. The kettle with its contents was rolled into a chilling room to lower the temperature of the contents. Egg wash-starch ~lend was used within two hours of preparatlon and final temperature was 46 degrees F.
The starch was completely solubilized in water and mixed very well with the egg wash and salt and was very homogenous. This egg wash-starch blend was then sprayed onto the surface of danish dough rings. These rings were formed from strips of laminated, sweet dough containing a fruit and nut-based filling. The strips are cut, rolled and formed into a ring. A few seconds after spraying the ring passes under a roller which flattens the top surface a little bit. The nutmeats are then dispersed onto the coatcd, dough ring by a 2 & ~

1 cascade applicator and then lightly pressed by another roller.
The rings are then placed in oiled aluminum pans, proofed for about two hours and baked at 380 to 400 degrees F for about 20 minutes.
Extended plant runs were made for a period of about two hours. Subsequently, testing was done for one entire shift of about seven hours which did not create any operational problem. Based upon the test conducted in the example it is seen that 1.5% pregelatinized starch based on the weight of topplng, reduces by at least 40 the loss of nutmeats from danish rings without any operational difficulty.
Sensory evaluations conducted in the laboratory revealed no adverse effect on the quality of the danishes when "Purity Gum 59" was incorporated into the egg wash at the level tested above.
Example 2 296.25 lbs of mozzarella shredded cheese and 3.75 lbs of "Purity Gum S9" brand cold water-soluble starch were preweighed and placed in a GlobusTM z-vane rotary tumbler and mixed for four minutes. The mixture (1.25~ starch) was added using a RaqueTM Cascade dispenser as a top layer onto prebaked, pizza bread a bottom layer of cheese shreds and a coating of pizza sauce. The topped bread was passed through a mist chamber giving a total moisture addition of 0.1 to 0.3 grams for 20 grams of cheese topping. Adherence was excellent and the amount of topping fell from the pizza bread during packaging, freezing and handling was reduced by at least 50%
compared to pizza bread prepared in the same way without using the starch binder.
Example 3 An aqueous solution of 35% by weight cold water-soluble starch was prepared in a jacketed-kettle using a LighteninTM mixer till homogenous. The solution was sprayed on top of fully assembled pizza which resulted in an increase 0.~-0.5 gms solution per pizza. The starch solution (1.5%

2 ~ ~ 3 4 ?~ 4 1 starch based on topping) dried quickly at ambient conditions to form a film on the topping which significantly improved the adhesion of the ingredients so as not to fall off the bread base.

Claims (18)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A baked, carbohyclrate-based product selected from the group consisting of breads, pizza, buns, rolls, pie, cakes, danish and pastries having a minor amount of a powdered or particulate topping there on and a fat-free coating comprising, as applied, of up to 3% of said topping of a cold water-soluble starch effective to retain at least 40% of the topping that is normally shaken from the carbohydrate-based product.

2. The product of claim 1 in which the topping is nuts and the product is danish and the starch is present in 0.5-2.5% of the topping.

3. The product of claim 2 in which the starch is present from 1-2% of the topping.

4. The product of claim 3 in which the starch is present at about 1.25 to 1.5% of the topping.

5. The product of claim 1 in which the topping is protein-based particulates, the product is pizza or pizza-styled bread and the starch is present in 0.5-2.5% of the topping.

6. The product of claim 5 in which the starch is present in form 1-2% of the topping and the protein is meat or cheese.

7. The product of claim 6 in which the starch is present in about 1.5% of the topping.

8. A method of treating topped, carbohydrate-based products comprising incorporating up to 3% of a cold water-soluble starch with said topping effective to retain at least 40% of the topping that is normally shaken from the carbohydrate-based product.

5. The method of claim 8 in which the starch and topping are dry-blended, a minor amount of the blend placed on the top of a sauced-pizza, carbohydrate-based product, the topping exposed to a mist of water sufficient to add up to 3%
by weight moisture and thereafter allowing the starch to dry into a clear, smooth, non-sticky, pliable film.

10. The method of claim 9 in which from 0.005 to 0.15 grams of starch is present on every square inch of surface area of topping.

11. The method of claim 8 in which a minor amount of topping is placed on the top of a prebaked, sauced-pizza, carbohydrate-based product and the topped product thereafter sprayed with an up to 40% aqueous solution of a cold water-soluble starch sufficient to add up to 3% by weight moisture and thereafter allowing the starch to dry to a clear, smooth, non-sticking, pliable film.

12. The method of claim 11 in which from 0.005 to 0.15 grams of starch is present for every square inch of surface area of the topping.

13. The method of claim 8 in which an unbaked dough is rolled, sprayed with an egg wash containing 15-50 parts starch by weight of 100 parts whole egg, a minor amount of particulates are placed thereon and lightly rolled on the dough which is thereafter baked.

14. The method of claim 13 in which from 0.005 to 0.15 grams of starch is present for every square inch of surface area of the topping.

15. A process for preparing bread-based, pizza-type product comprising:

a. forming and baking a dough to form a carbohydrate base product;
b. coating the base product with a pizza sauce;
c. adding a topping of particulate or sliced material selected from a group consisting of cheese and meat;
d. incorporating up to 3% of a cold water-soluble starch with the topping;

e. moistening said topping and starch by adding from 0.5 to 3% water sufficient for the starch to stick particulates of the topping together;
f. drying the topping to form a clear, non-sticky, pliable starch film, adhering pieces of the topping to each other; and g. freezing and packaging the pizza product.

16. The process of claim 15 in which from 0.005 to 0.15 grams of starch is added per square inch of surface area of the topping.

17. A process for preparing danish products comprising:

a. forming a layered danish pastry dough;
b. spraying the dough with an egg wash containing 15-50 parts cold water-soluble starch to 100 parts whole egg to incorporate up to 3% starch by weight of the subsequent added topping;
c. rolling the dough to flatten the top surface;
d. adding a surface layer of danish topping particulates selected from nuts, candies, coconut, fruit and simulated fruit, chocolate;
e. lightly rolling the topped surface;
f. baking the dough; and g. packaging.

18. The process of claim 18 in which from 0.005 to 0.15 grams of starch is added per square inch of surface area of the topping.