CH657251A5 - METHOD FOR PRODUCING MOLDED FOOD PRODUCTS AND MOLDED FOOD PRODUCT. - Google Patents

Description

The present invention relates to a process for producing shaped food products from ground, granulated or cut food products, and to a shaped food product produced by the process.

The production of food products by reconstituting shredded materials and shaping the 40 shredded materials with the help of rubbers and gel-forming materials by mechanical processes, such as extrusion and shaping, as well as by thermal treatment, e.g. B. heating or cooling are common methods in the food industry. Various processes are known for producing sol-45 shaped food products. Many of these methods rely on the use of a gel-producing system that contains an alginate and a divalent cation, such as the calcium ion.

Thus, in one type of this process using these materials, a molded product is obtained which is covered by a skin, such as a sausage. For example, U.S. Patents 3,650,765 and 3,650,766 describe food products made in any shape or size by a process in which an extrudable slurry is made from a food material, the slurry extrudes and a gel-like one Skin is formed around the extruded product. The skin is formed by exposing the gellable materials, such as alginates, to the influence of gelling agents, such as alkaline earth metal ions, on the surface of the extrusion product. In U.S. Patents 3,891,776,3,922,360,4,117,172 and 3,676,158, similar processes are also described in which a molded food product, which is wrapped in a skin, is produced. Some of these processes result in peelable, self-supporting skins or wrappings. If the skin is peeled off and the resulting pro

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product is exposed again to a solution of a divalent cation, a skin forms again.

Other methods based on the use of alginates and calcium ions result in a stabilized food product when the alginate contained in the slurry used for the preparation is completely converted into a complete «advanced» gel. For example, US Pat. No. 2,791,508 describes a process for the production of reconstituted food products, in which a thixotropic, semi-gel-like substance is first produced by preparing a chopped, powdered, granulated or chopped food in water solution from an edible, hydrophilic Colloid dispersed, wherein the dispersed food is in the form of discrete particles, which are more or less completely encased by the matrix of the colloidal gel. Alginates are described as common hydrophilic colloids. In addition, a gelatinizing agent such as calcium carbonate can be added to the dispersed food and the hydrophilic colloid to initiate gelatinization. The timing at which the gelatinizing agent is added to the food and hydrophilic colloid dispersion is critical because

when the gelatinizing agent is added, calcium ions are released which react rapidly with the colloid to form the gel. Since this gelatinization takes place very quickly, it is necessary to quickly feed the substance into a feed tube for extrusion, in which the last advanced gel structure is created. The length of the feed tube must be such that the mixture in question is essentially an advanced gel when it leaves the exit. This is a major disadvantage because

if the gelatinizing agent is added too quickly, the mixture will become an advanced gel before it leaves the extruder, thus clogging the extruder mechanism. On the other hand, if the gelatinizing agent is added too late, the mixture will not become an advanced gel when it exits the extruder, and this will prevent the formation of a molded food product.

The known processes described above thus result in difficulties, such as undesirable skin formation, an undesirable texture of the finished product, both in the production and in the product produced, and furthermore there are difficulties in extrusion.

The present invention is therefore based on the object of providing an improved process for producing shaped food products, according to which the production runs smoothly and according to which the desired properties of the finished product can be checked.

The process according to the invention for the production of shaped food products is characterized in that

1) prepares a slurry of one or more food products with a binder, a gelling agent and a divalent ion-releasing material, the amount of binder, gelling agent and divalent ion-releasing material being sufficient to post-react between the gelling agent and the divalent ion-releasing material a predetermined time after making the slurry;

2) produces the molded food product from the slurry by means of a shaping and shaping device.

It has now been found that food products of any desired size or

A form can be made from a slurry of comminuted food particles and additives including a binder and a time response system comprising a gelling agent such as an alginate and a divalent ion releasing material. The slurry used in the process according to the invention has the theological properties required for shape and shape retention, which enables a continuous production process by means of extrusion, molding or a similar process. The consistency of the slurry is chosen so that the molded product can be easily removed from the molding device.

The method of the present invention can be applied to a variety of foods including vegetables, fruits, proteinaceous substances such as meat and fresh products, shrimp products and the like, and does not depend on the acidity of the food products or their temperature. According to the invention, the slurry can consist of one or more comminuted foods as mentioned above, a binder which, for example, a cellulose ether alone or together with a rubber such as guar gum, an alignment, a divalent ion-releasing material such as calcium carbonate, which with reacting with the alginate to form a gel, an extender or extender such as flour and / or starch, and optionally a pH control agent such as citric acid or some other physiologically acceptable weak acid, a suitable sequestering agent such as a Metaphos-phit, and contains other additives such as salt, sweeteners and colorants.

The binder used in the slurry causes a certain rigidity and shape of the product and the gradual gelling of the alginate causes a certain setting of the product.

The means for controlling the pH value, together with the sequestering agent, releases the calcium ions at a predetermined rate, as a result of which a controlled gel formation of the alginate takes place. In some cases the pH of the minced food product will be such that either the acid or the acid and sequestering agent need not be added. For example, in the case of chopped food products that release acid, such as onions, the pH control agent and sequestering agent need not be added to the slurry.

In any case, the slurry must be adjusted so that gel formation takes place within a predetermined time interval. Generally, the slurry is allowed to stand for a predetermined period of time, from about 5 to about 30 minutes, before actual deformation and further processing are started. This is sufficient time for gel formation. The ratio and amount of the various ingredients in the slurry determine the consistency and properties of the finished product.

The actual deformation takes place with an extruder, cutter or a deformation device. As mentioned above, the easy and rapid delivery of the molded products from the extruder, cutter or deforming device is important for an effective, continuous production process. Such delivery can be facilitated by continuously rinsing the extrusion head, cutter or mold with a liquid broth, water or with an aqueous solution of divalent ions such as calcium ions, whereby s

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the molded product is prevented from sticking to the molding apparatus. When a solution such as calcium chloride solution is used for rinsing, a smooth, sliding surface is obtained which has a very low coefficient of friction and which is easily released from the molding device. This rinsing solution is used in small amounts and concentrations and is only intended to facilitate the easy delivery of the product and not to cause the shape-retaining or self-supporting film or skin to form.

The molded product can be further processed either by treating it with a flour-like material or a normal dough or by coating it with dough. If the dough used to coat the product is to have better adhesion, a small amount of a gelling agent which reacts with the alginate in the top layer of the product can be added to the dough.

The molded product can also be coated, cooked, fried or fried in fat, frozen and packaged. When such frozen products are heated, they retain their shape, texture and eating qualities.

The components used for the process according to the invention are acceptable in terms of their price and the product can thus be manufactured economically.

As previously stated, the shaped foods of the present invention are made by first preparing a slurry from the minced food product and other additives. The slurry is then shaped by extrusion, shaping or a similar process, and then the finishing or processing follows, which involves boiling, for example in the use of a dough, in particular a thin batter, such as a pancake batter, the coating with bread dough or breadcrumbs such as heating in liquid oil, freezing and packaging. According to the invention, the slurry contains one or more comminuted food products, a binder, a gelling agent, a compound which releases divalent ions for the reaction with the gelling agent, extenders or extenders and optionally a pH control agent, a sequestering agent and Additives such as salt, spices, sweeteners and colorants.

Suitable binders that can be used in the present invention are edible cellulose ethers that are non-toxic and water-soluble. Examples of suitable cellulose ethers are alkyl, hydroxyalkyl and carboxyalkyl ethers in which the alkyl group contains 1 to 3 carbon atoms. Specific examples of the cellulose ethers are sodium carboxymethyl cellulose, methyl cellulose, ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose and combinations thereof. These cellulose ethers can be used together with gums such as guar gum, gum tragacanth, gum caraya, xanthan gum, carrageen gum, fur cellaran gum, locust bean gum, gum arabic or their mixtures. Although any suitable binder can be used, it is preferred to use hydroxypropylmethyl cellulose together with guar gum as the binder. A particularly preferred hydroxymethylpropyl cellulose is hydroxypropyl methocel K100M with a viscosity of 100,000 cP manufactured by Dow Chemical.

The binder is generally used in an amount from about 0.10 to about 6.0% by weight based on the weight of the minced food product. If the binder is both a cellulose ether and a

Including rubber, the cellulose ether is present, for example, in an amount of about 20 to about 30% by weight, based on the binder, and the rubber, for example in an amount of about 70 to about 80% by weight, based on the binder .

Although any suitable gelling or gelling agent can be used, it is preferred to use an alginate such as sodium alginate or potassium alginate. A particularly preferred alginate is a sodium alginate with the trademark Protanal SF-120, which is available from Multi-Kem Corp. distributed and manufactured by Protan and Fagertun of Norway. The alginate is generally present in the slurry in an amount from about 0.1 to about 1.0% by weight based on the weight of the minced food product.

Compounds that release divalent ions for reaction with the alginate to form a gel are calcium carbonate, calcium phosphate and the like. Calcium carbonate is particularly preferred. The calcium ions release the compounds react with the alginate to form a calcium alginate gel. The ion releasing compound is generally present in an amount from about 0.001 to about 0.004% by weight based on the weight of the minced food product.

25 Suitable agents for pH control are weak organic acids such as citric acid, maleic acid and tartaric acid.

The pH control agent can be omitted from the slurry when the comminuted food product used releases a weak acid. Onions are an example of such a food product. When the pH control agent is used, it is generally present in an amount from about 0.001 to about 0.05% by weight based on the weight of the chopped food product.

Although any suitable sequestering agent can be used with the pH control agent, it is preferred in the present invention to use a metaphosphate such as sodium hexametaphosphate. The sequestering agent is generally used only when a pH control agent is used. Generally, the sequestering agent, if used, will be present in an amount from about 0.001 to about 0.05% by weight based on the weight of the chopped food product.

Suitable extenders or extenders which can be used in the slurry according to the invention are starch and flour, which are normally used together. Generally, the starch is present in an amount from about 3 to about 12 percent by weight based on the weight of the chopped food product. However, it is preferred to use starch in an amount from about 5.5 to about 6.5 percent by weight. The flour is generally present in an amount from about 3 to about 12% by weight based on the weight of the chopped food product. A preferred amount is about 7.5 to about 8.5 percent by weight.

The slurry may also contain one or more additives such as salt, spices, sweeteners and so on colorants. When such materials are present in the slurry, they are generally present in an amount from about 0.01 to about 1.0 percent by weight based on the weight of the chopped food product.

As indicated above, the food products 65 which can be used in the present invention are, for example, vegetables, fruits, proteinaceous substances such as meat and fish products, shrimp products and the like. The method according to the invention is special

Suitable for shredded or cut or grated food products, such as fresh onions, rehydrated onions, cauliflower, mushrooms, pepper or. Peppers, apples, poultry, meat, fish,

Shrimp and calamari. A preferred product is onion rings, which require a very well-defined consistency so that they are in acceptable form as a salable product. The food products are chopped, planed or chopped according to methods known per se.

The slurry is made by mixing all of these materials that make up the slurry except for the chopped or shredded food product. After the dry mixture of these materials is mixed, the chopped or shredded food product is added and mixed for 2 to 5 minutes at room temperature to form a slurry. The resulting slurry, which has a very high viscosity, can then stand for a period of about 5 to about 30 minutes, so that the release of the ions, such as the calcium ions from calcium carbonate, is possible and a calcium alginate gel is generated. The slurry is then placed in a molding machine, such as an extruder or a molding machine. Although any suitable device can be used, it is preferred to pump the slurry through an extruder with cutting heads. In the manufacture of onion rings, an autoprod / food extruder manufactured by Autoprod, Inc. with cutting heads can be used to produce annular products weighing approximately 10 to 12 grams. The same extruder can be used with different cutting heads to extrude other shapes such as spheres, crescents, croissants, chopsticks, etc.

Preferably, a rinse solution containing divalent ions is used to wash the extruder cutter or mold plate to facilitate easy dispensing of the molded product from the cutter or mold plate. It is preferred to use an aqueous calcium chloride solution (0.2 to 5.0%).

The extruder-shaped products then fall individually onto a wire mesh conveyor belt, which transports the products to a dough unit (pancake dough unit), where the dough is applied. If the dough is to adhere better to the product, a small amount of a suitable alginate, e.g. Add sodium alginate to the thin batter, which then reacts with the calcium ions on the surface of the product. The breading unit in which the products are breaded usually follows this process stage. The breaded products are then usually cooked and, in the case of onion rings, frozen for a short period of time, for example about 30 seconds, at -10 ° C (or 400 ° F) and then individually frozen and packaged quickly.

Before use of the liquid dough and breadcrumbs according to the invention, the finished, shaped product contains, for example, a cellulose ether in an amount of about 0.10 to about 2.5% by weight, a gum in an amount of about 0 to about 2%. 5% by weight, alginate salt in an amount of about 0.05 to about 0.80% by weight, an extender in an amount of about 6.0 to about 15.0% by weight, and a food in an amount of about 80 up to about 90% by weight. A preferred example includes 0.2% cellulose ether, 0.9% guar gum, 0.36% alginate salt, 12.0% extender and 86.0% food (onions).

As previously indicated, the ingredients, when dry blended, contain the following Ma5 657 251 before adding the minced or cut food product

materials (based on the weight of the materials in the slurry prior to adding the food, with a wide range that can be used for the material and preferred amounts given).

Materials Preferred (%) Range (%)

10 starch, especially corn

Strength

37

30-60

wheat flour

49

30-60

Hydroxypropylmethylcellu

loose

1.5

1-15

15 guar gum

6.0

0-15

Sodium alginate

2.5

0.5-5

Calcium carbonate

0.012

0.006-0.02

Sugar (if any)

4.4

0-10

Salt (if applicable)

0.9

0-5

20 citric acid (if necessary

derly)

0

0-0.02

Sodium hexametaphosphate,

(if necessary)

0

0-0.02

The ratio of the cut, fresh and / or re-hydrated onions to the dry mixture system is preferably 6.0 to 1, but can be in the range from about 5: 1 to about 10: 1.

30 Specific examples of some preferred recipes are given in the following examples.

Example 1 Production of onion rings 3s A dry mixture is produced from the following materials.

Parts by weight

Corn starch 16

40 wheat flour 25

Sodium alginate (Keltone from Kelco Co.) 0.8

Calcium carbonate 0.003 hydroxypropylmethyl cellulose with a viscosity of 100,000 cP (hydroxy

45 propyl-methocel K-1000M from Dow Chemical) 3.2

This mixture is added to 250 parts of V3 "cut fresh onions on a ribbon mixer and then mixed for 3 minutes at room temperature to form a slurry.

The resulting slurry has a paste-like viscosity. The mixture is left to stand for 5 to 15 minutes, so that calcium ions are released from the calcium carbonate, due to the acidic pH which is produced by the onion exudate 55, and for the subsequent reaction of the calcium ions with the algin molecules to form a calcium alginate gel.

The slurry is then pumped through a dairy pump through an autoprod food extruder with 60 heads to form annular products weighing approximately 10 to 12 grams. The cutting heads are washed with an aqueous solution of calcium chloride of 5 parts per 100 parts water, expressed by weight. This washing solution facilitates the release of the ring-shaped products formed from the cutting heads.

The extruded onion rings fall individually onto a mesh conveyor belt, which turns the product into a dough unit

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(for thin dough), which is followed by a breading unit. The breaded product is deep-frozen at - IOC (400 ° F) for 30 seconds and then quickly frozen and packaged individually.

After reconstitution in the heat, the finished product has the desired juiciness and mouthfeel.

EXAMPLE 2 Production of Onion Rings Extruded onion rings are produced according to Example 1, dried pieces of onion rehydrated with water being used, which after reconstitution with water are about 0.63 cm CU ") in size.

The inside texture of the finished, cooked product is similar to that of Example 1.

Example 3 Production of onion rings A dry mixture is produced from the following materials.

Parts by weight

Corn starch 15.2

Wheat flour 20.0 sodium alginate 1.0 calcium carbonate 0.004 hydroxypropylmethylcellulose 0.6 guar gum 2.5 salt 0.4 sugar 1.8

This mixture is added to 250 parts of cut (0.63 cm or 1 "), fresh onions. The process for producing the onion rings is carried out according to Example 1.

Example 4 Preparation of Apple Rings A dry mix is made from the following materials.

Parts by weight

Corn starch 25

white flour 16

Sodium alginate 0.6

Calcium carbonate 0.003

Hydroxypropylmethylcellulose 2.3 guar gum 1.1

Sugar 5 salt 1

This mixture is added to 250 parts of cut (0.63 cm or 1U ") fresh apples. The procedure is then as in Example 1.

Example 5 Preparation of a Shrimp Product A mixture of the following ingredients is prepared.

Parts by weight of shredded shrimp 85

Salt 1.0

H VP 1.5

Garlic powder 0.02

Onion powder 0.3

Corn starch 1.2

Water up to 100

TÜÖ

250 parts of the above mixture are mixed with the dry mixture from Example 1, then the procedure is as in Example 1. The product is given a crescent or shrimp shape.

Example 6 Zucchini Rings or Pieces A mixture of the following ingredients is prepared.

Parts by weight of cut (0.63 cm or l / 4 ") zucchini 56

Tomato paste 42

Onion powder 0.15

Garlic powder 0.15

Oregano 0.4

Salt 1,3

100

250 parts by weight of this mixture are mixed with the dry mixture from Example 1 and the procedure is as in Example 1, giving a ring-shaped or bar-shaped product.

Example 7 Poultry Rings or Crescent Moons A mixture of the following ingredients is prepared.

Parts by weight cut (0.63 cm or 1/4 ")

Poultry cuts 76.6

Poultry flavor 3.0

Parsley 0.1

Water 17.7

100

250 parts by weight of this mixture are mixed with the dry mixture of Example 1 and then small cakes with a diameter of approximately 5.08 cm (2 ") are produced. These are then processed according to Example 1.

The above examples are repeated with different binders and rubbers as well as with different proportions of extenders and with the addition of further rubbers. Different ratios of alginates with other poorly soluble calcium compounds are tried. Satisfactory products are obtained in all cases by suitable selection of the components.

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Claims (17)

657 251 2nd PATENT CLAIMS 1. A method for producing shaped food products from comminuted, granulated or cut food products, characterized in that (1) prepares a slurry of one or more food products with a binder, a gelling agent and a divalent ion releasing material, the amount of binder, gelling agent and divalent ion releasing material being sufficient to cause a reaction between the gelling agent and the divalent ion releasing material after a predetermined time after preparation of the slurry; (2) produces the molded food product from the slurry using a forming and shaping device 2. The method according to claim 1, characterized in that a cellulose ether is used as the binder as follows: carboxymethyl cellulose, carboxyethyl cellulose, carboxypropyl cellulose, methyl cellulose, ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose or a mixture thereof, and that the binder additionally contains a rubber . 3. The method according to claim 2, characterized in that guar gum, gum tragacanth, gum caraya, xanthan gum, carragheen, fur cellaran gum, locust bean gum, gum arabic or mixtures thereof are used as gum. 4. The method according to any one of claims 1 to 3, characterized in that an alkali metal alginate is used as the gelling agent and a compound with low solubility containing calcium ions is used as the divalent ion-releasing compound. 5. The method according to claim 4, characterized in that one uses sodium alginate as alkali metal alginate and calcium carbonate as calcium compound. 6. The method according to any one of claims 1 to 5, characterized in that the slurry additionally contains, as a pH control agent, a weak, organic acid, selected from citric acid, tartaric acid and maleic acid. 7. The method according to any one of claims 1 to 6, characterized in that the slurry additionally contains a sequestering agent. 8. The method according to any one of claims 1 to 7, characterized in that the molded food product is rinsed with an aqueous solution containing calcium chloride, while it is removed from the shaping and shaping device. 9. The method according to any one of claims 1 to 8, characterized in that the slurry additionally contains an extender. 10. The method according to any one of claims 4 to 9, characterized in that the components are used in such proportions that the slurry can be left for a period of 5 to 30 minutes, so that the reaction of the alginate with the calcium ion-releasing compound enables which increases the viscosity of the slurry before the deformation step. 11. The method according to any one of claims 1 to 10, characterized in that the binder in an amount of 0.10 to 6.0 wt.%, That the alginate in an amount of 0.10 to 1.0 wt.%, that the divalent ion-releasing compound in an amount of 0.001 to 0.02% by weight, based on the weight of the comminuted food product, is present. 12. The method according to any one of claims 1-11, characterized in that the shaped food product is either treated with a floury material or normal dough, in particular low-viscosity dough, and 5 finally breaded. 13. Shaped food product produced by the method according to claim 1. 14. A molded food product according to claim 13, characterized in that the food product is in gel form and a cellulose ether selected from hydroxyalkyl and carboxyalkyl cellulose, the alkyl groups of which contain 1 to 3 carbon atoms, in an amount of 0.1 to 2.5% by weight; Alginate salt in an amount of 0.05 to 0.80% by weight; contains a chopped, granulated or cut food, selected from vegetables, fruits, meat, fish and fish products and mixtures thereof, in an amount of 80 to 90% by weight and an extender in an amount of 6 to 15% by weight. 15. Shaped food product according to claim 20 14, characterized in that it additionally contains a gum in an amount of 0.1 to 2.5 wt.%. 16. A molded food product according to claim 14, characterized in that it contains 25 onions or apples as food. 17. Shaped food product according to claim 16, characterized in that it is in the form of a ring. 30th