DE2342851C2 - Process for making a nutty food product - Google Patents

Description

In US Pat. No. 2,952,544, the manufacture nutty food products described that by drying dispersions made up of a continuous phase consisting of a dispersion of a hydratable film former wherein a water immiscible liquid is suspended, are built up. These products, although very good, do not always have a texture or structure, which can be regulated. For example, when using certain starting materials, this is The structure is nutty when chewed, but the product appears to have the desired smear effect instead of after the initial crunchy character occurs, to shatter into small pieces, which are in the collect the back of the throat. Other previous products also soften excessively when put in Moist foods, such as ice cream, are used, or they are too brittle at the low level Ice cream temperature. There are also flavors sometimes difficult to perceive. In addition, although desirable, there was less water in of the dispersion (in order to reduce drying times and costs), it is difficult to achieve this because too little water makes the dispersion viscous and it is difficult to extrude.

Another important disadvantage of previous methods is that they require extensive

to Drying Time Another disadvantage is the tendency for oil to sweat out of the finished product. this is of course undesirable. It has also been found that there is a tendency for oil to exude or that the product during transport, storage

t5 οάζτ if the pieces are rubbed against each other, it becomes oily. Another disadvantage of the prior art is the tendency of the mixed material to be attached to cutting knives which are used to divide into pieces or some other arrangement in which cutting is used at the end of the process to the cutting operation to cut the product into small pieces To break pieces or fine granules too small to be used to adhere.

It is in view of these and other disadvantages of the prior art that it is an object of the invention in a process for making an improved simulated nut product having the following properties and has advantages:

(a) the ability to work with a process that is effective and economical in technical Scale can be performed to consistently produce food products that closely simulate the texture of nut meat;

(b) creating a dense nut-like structure with

low tendency to excretion of fat;
(c) the creation of an effective means of controlling the texture, and particularly the brittleness of the finished product;

(d) the creation of an effective level of degradation the amount of water required in the dispersion;

(e) the creation of a food product that has the crunchy texture of nut meat; when used in wet or cold products such as ice cream;

(f) having a taste of satisfactory intensity no more than standard amounts of flavoring agents;

<%) Precautions to ensure the liability of

Salt on the finished product and
(h) the ability to extend the life span to one year or two up to six years in a polyethylene bag;

(i) an improvement in the drying time for simulated Nut meat for about 6 hours;

(j) the ability to reduce the amount of water contained in the dispersion prior to drying without substantially increasing the amount of bo oil lost in the finished product;

(k) precautions to prevent extruded Pieces stick to cutting knives and other surfaces and

(1) the reduction in the production of fines t> 3 during the cutting process.

The invention relates to a method for producing a nut-like food product,

being off

a) at least one edible, hydratable, film-forming Substance and

b) an edible, water-immiscible, oily substance containing 10 to 80% by weight of the The total of a) and b),

c) water and

O filler material, if necessary

a plastic dispersion is generated, which then is shaped and dried, characterized in that the dispersion takes place with exclusion of gas

The dispersion is expediently carried out using a vacuum. Preferably, a vacuum of at least 337 · 10 ^-3 bar (pressure 759 - 10- ⁵ bar) is applied

It is also beneficial to eliminate the gas bring about that the dispersion is placed in a mixing container until the container is completely filled with the Dispersion is filled

In the drawings there

F i g. 1 is a schematic flow diagram of a preferred one System for the production of simulated nuts according to the invention,

Fig.2 is a side view of the extruder, partly in Cut,

Figure 3 is a cross-sectional view taken along line 3-3 the fig. 2,

F i g. 4 is a partial plan view of the nozzle plate;

Fig. 5 is a graph showing the influence of vacuum on oil loss,

Fig. 6 is a graph showing the inflow of water on the oil loss;

F i g. 7 is a flow sheet showing a preferred method for making simulated nuts according to FIG Invention represents

FIG. 8 is an enlarged perspective view of a finished product and FIG

F i g. Figure 9 shows an ice cream product containing the simulated nuts made in accordance with the invention.

To initiate the process, oil or fat, water and a hydrophilic film former become one processed liquid dispersion, which consists of an edible film former as a continuous phase and a discontinuous phase containing an edible oleaginous substance, d. H. oil or a fat that is used to Time of preparation of the dispersion is liquid, is built up. Edible food particles, such as for example flour, sugar, starch or other flour-like materials in powder form can be in the oil dispersed, distributed between the encapsulated fat droplets or optionally in suspended in the film former. The first stage in the production of the composition according to the invention is the edible oily substance in a continuous phase of a polar material, namely the edible Film-forming agents homogeneously dispersed under conditions which exclude air, preferably under vacuum. the Dispersion has a shape-retaining, plastic consistency. The plastic product is then through Shaping, but preferably formed by extrusion as a band or strip with a defined shape. Water that is present in the continuous phase of the dispersion is carried out of the product Drying away. Since the moisture prevails in the continuous phase, the oil droplets become suspended and in the hydrophilic film former

ίο

encapsulated After drying, the oil droplets remain enclosed in the hydrophilic film former.

The edible oleaginous substance can be any edible vegetable or animal oil or fat or mixtures of these and include cottonseed oil, corn oil, wheat germ oil, bacon, peanut oil, Soybean oil, safflower oil, butter oil or margarine.

The prerequisite is that the oily substance is in a liquid state when it is dispersed.

So it is possible. Fats to use that at Room temperature are plastic, which, however, are made suitable for the purposes of the invention can be heated above the melting point, but not to a temperature at tier would denature, char or burn any accompanying constituents.

The oily fraction of the nut product consists of 10 to 80% by weight of the mass, with the remainder The fraction that contains the film-forming agent on a dry weight basis consists exclusively of fillers and Extenders. Water should be in the / itigen product in an amount of about 10% or less, and preferably less than 5% by weight in terms of a appropriate structure and conservation are available.

The film former can be any edible substance that forms a film around an edible oil using any known method. Examples are non-fat milk solids, sodium caseinate, Soy protein, egg albumin, egg yolk, film-forming substances that differ from wheat germ, gelatin, Peanut flour, bean flour, corn germ, dried whey, gelatinized starch, fish protein, bran protein, Derive gum arabic and other hydrophilic colloids, such as carboxymethyl cellulose, Agar agar, alginates, guar gum, carboxypropyl cellulose, carrageenin, and combinations thereof.

Fillers can be used at any stage of the mixing process to change the taste and taste added to the texture of the final product without affecting the character of the physical structure or change the process by which this structure is obtained. In some cases it can be a hydratable Film former, of course, with a filler content that does not interfere with the protein-containing part, can be used to produce a plastic dispersion but at the same time deliver a nutty taste. An example of such a film former is crushed wheat germ material. Other solid and liquid fillers and modifiers, such as sugar and glycerin, can be used without disturbing the basic process.

Smaller amounts of modifiers can optionally be added to the film former. Among such modifiers are salts, Polyaccharides, for example glucose, sucrose or lactose, polyhydric alcohols such as, for example Glycerin or other edible food substances such as starch and the like.

When wheat germ are used, sometimes resulting bad taste due to the present in the wheat germ material enzymes when the dispersion at lower temperatures, for example, is dried 6O ⁰ C or lower. However, these lower temperatures are desirable in order to prevent volatilization of the added flavors during the drying period. The taste-impairing enzymes can be inactivated,

if the dispersion is dried at temperatures between 76 and 88 ^° C., however, many of the added flavorings are lost if this temperature is maintained for a substantial period of time.

It has been found that have been added by heating the dispersion to the volatile flavors, at 82 ⁰ C for 2 to 20 minutes depending on the thickness of the piece and then cutting with continuous drying at 76 ± 5 ° C for 5 to 8 hours a number of essential advantages are obtained. The elimination of surface tack prevents the cutting blades from becoming coated. The exudation of oil on the cutting ends is also reduced. In addition, the generation of fines, which occurs when the tapes are cut after being completely dry, is reduced. Furthermore, the enzyme activity is destroyed and many flavors, which UiC would previously have VcidäiVipfi, are kept in your synthetic nut product. If the dispersion with the added volatile flavors initially at 82 ° C for about 20 heat treated to 60 minutes (depending on the strength of the piece) and then reduced the temperature to 6O ⁰ C for the final drying, so the enzyme activity is destroyed and many flavors which have so far been volatilized can be kept in the synthetic nut.

The dispersion favorably contains about 3 parts of vegetable oil and 1 part of wheat germ flour.

In trials leading to the development of the invention it was found that the loss of fat from the finished product was influenced by various factors in the process. The main ingredients used in these experiments were 24.5% by weight heat stabilized wheat germ flour; 75% by weight vegetable oil; 2% by weight sugar and 0.5% by weight flavor. Using this formulation, experiments were carried out in which a number of process variables were changed in order to determine their influence. The most important factors have been found, in order of decreasing importance, to (1) keep the vacuum pump running continuously during machining rather than turning off the pump after the appropriate vacuum has been achieved; (2) the extension of the mixing time (with improved effects being achieved with mixing times up to 40 minutes): (3) maintaining the temperature of the slurry during mixing at about 27 ° C instead of a higher temperature such as 38 ° C . Other factors considered besides those mentioned above are also important. It has been found that lower absolute pressures, that is, higher vacuums, reduce fat loss. As can be seen from FIG. 5, the fat loss in the finished product at a vacuum of 912 · 10 ^-3 bar (pressure ^{101-10 "3} bar) is 036% by weight. It is reduced to 0.15% by weight. ° / o lowered when the applied gauge pressure to 937 - 10- ³ bar (pressure 76 ■ 10- ³ bar) is reduced Further, the loss is reduced to 0 when the vacuum about 948 · 10 ^-3 bar (pressure 65th - ΙΟ " ³ bar) or more

The amount of water used to prepare the dispersion also influences the fat loss optimal amount of water is about 1 or 2% above that for forming an extensible dispersion required minimum amount of water. However, amounts of water outside of this point will increase the amount of the observed fat loss. Referring to FIG. 6 it can be seen that although the fat loss is about 0.1% with both 27.5 and 30.5% water, a minimum fat loss of about 0.025% by weight was found when the water value is between 28 and 29.5% by weight.

It has been found that the amount of water present should be between about 27 and 30% by weight. the Mixing time is just the time necessary to form a dispersion. At a percent stop Water above about 28.5% can usually do this in less than! 2 minutes using a mixer operating at a speed of 1600 rpm can be achieved.

It has also been found that the drying time is significantly influenced by the speed of the mixer and that high mixing speeds, for example an orbital blade speed of about 83 rpm, increases the drying time considerably compared to an orbital mixing speed of about 67 rpm. It has also been found that mixing speeds significantly less than 67 rpm require more time to form a dispersion.
With regard to the mixing time required to form the dispersion, it has been found that higher amounts of water decrease the time required to form a dispersion. In a special approach with a water content of 273% by weight, based on ®.J the constituents other than water, 13 minutes are required to form the dispersion, while only 10.5 minutes are required if the water content is 29 .5% (all percentages here being based on the weight of the constituents other than water) and only requires about 7.25 minutes if the amount of water is increased to 32.5%. However, as noted above, the loss of oil in the finished product makes it desirable to use about 28-30% water.
With reference to FIG. 1, in which the invention is explained as an example, oil 10 stored in container 5 is passed by means of pump 6 through heat exchanger 7 for heating to the desired temperature. It is then introduced into the mixer 16 through the metering device 8 at a regulated speed. The remaining ingredients are water, wheat germ flour, sodium caseinate. Sugar and flavorings 18 are then added. Vigorous mixing is initiated in container 16 to form the aqueous dispersion. Good results have been obtained by first mixing the oil 10 and a dry powdery film-forming substance 12 as a slurry. Moisture 14 is preferably added last. Vigorous beating continues in mixer 16 until the film-forming substances hydrate and coalesce into a continuous cellular phase which separates and traps the oil droplets. The oil components 10 can also be mixed with the previously hydrated film-forming substances. Any other method of combining the film-forming and oil components which causes dispersion of the oil component through a continuous phase of the hydrated film-forming agent is also satisfactory.

A signal generated by pump 20 vacuum of about 813 - ΙΟ- ³ bar to 986 · ³ bar ΙΟ- (pressure 200 · ³ to 27 · ΙΟ- 10- ³ bar) is preferred to the mixer 16 close to the mixing process at the start, the vacuum is applied should continue until the end of the mixing process

to prevent air entrainment and reduce oil loss.

The container 16 is equipped with a stirrer motor 16a, which by suitable gear with the Agitator blades 166 and 16c, which sweep the inner side walls of the mixing container 16, is connected. Mixing is carried out until a homogeneous dispersion is achieved. Mixing time is about OK to 30 min usually sufficient. From the container 16, the dispersion is turned into one by a high pressure pump 24 Extruder 26 transferred, which produces a band 28 of a defined cross-sectional shape.

The extruder 26 will now be described with specific reference to FIG. 2 and 3. As can be seen from the figures, the extruder 26 comprises a feed hopper 100 made up of four mutually perpendicular walls which are designed to receive a feed 101 of the dispersion. A cover 102 is attached to the upper part of the filling funnel and is rotatably attached to the upper part of a .Seitwand riss filling funnel at 103. At each end of the funnel there are two horizontally and laterally aligned vertically arranged peg plates 104 and 106, of which only the two at the end closest to the observer in FIG. 2 are shown. Each of the laterally aligned plates 104 is provided with a lower extension 104a which is hinged for rotatable movement about a stationary trunnion shaft 105 which extends from one side of the extruder to the other. A drive device 137 fixedly mounted on the extruder 26 by means of a bracket 138 is provided with a ¹ · reciprocating drive shaft 137 which engages with the upper part of the plate 104 and thereby the plate 104 to the left or right, as shown in the figure can be seen, about the shaft 105 rotates.

For rotation in the laterally aligned plates 104, a drive roller 112 is rotatably mounted, the itself is attached to a roller shaft 112a, which extends therethrough and is rotatably supported for rotation within each support plate 104. Firmly associated with the roller shaft 112a is a drive gear 108, the in driving engagement with a chain of sprockets including a sprocket 116 (which is on the trunnion shaft 105), gears 118 and 120, both for rotation on a suitable support frame are mounted, and a gear 122 which is rotatable about a pivot shaft 106a that is fixed to the two Plates 106 is attached, is rotatably mounted, is. The gear 122 is in turn in driving engagement with a Drive gear 110 connected, which is fixed to the roller shaft 114a one parallel to the roller 112 mounted drive roller 114 is attached. In a typical application, the roller 114 is off the roller 112 apart by about 0.25 mm. The distance between the rollers is adjusted by an adjusting screw 131 which is screwed through the top of the plate 106 closest to the observer and the end of which in abutting engagement at 131 a with a stop 134 which is attached to the upper part of the plate 104 is arranged.

A sprocket 124 is also disposed on shaft 105 and is fixed with respect to gear 116 attached. A drive chain 126, which is driven via the sprocket 124, is more suitable Way connected to a drive motor (not shown). Engaged with the lower surfaces of the rollers 112 and 114 are arranged laterally extending, vertically arranged, parallel scraper blades 130 and 132. The blades or knives 130 and 132 are expediently in the position shown mounted so that material carried down by rollers 112 and 114 from their surfaces is scraped off when the rollers rotate, causing the accumulated material to move down between the Knife is brought. The dispersion, which at this point is a shape retaining plastic mass, becomes through rollers 112 and 114 down in contact with and pressed through a nozzle plate 127. The nozzle plate 127 is arranged horizontally and extends on the side of the device between the knives 130 and 132. The nozzle plate 127 has a plurality circular nozzles 128, each having an opening 128a with a cross-sectional shape that somewhat resembles the cross-sectional shape of a natural nut, as best seen in FIG. 4 can be seen.

As can best be seen from FIG. 3, the rollers 112 and 114 are provided with longitudinally extending helically oriented teeth. The teeth may be inclined at a small angle with respect to a tangent to the edge of the roller that intersects an edge of one of the teeth. In one embodiment suitable for delivering 181 kg of dispersion per hour to the dryer, the rollers were 21.6 cm in diameter and 95.8 cm in length. Rollers 112 and 114 were ^{rotated at I 3} AU / min. The surface of each tooth is set at an angle of about 72 ° with respect to a radius extending through its edge.

The nozzle opening in nozzle 128 creates a ribbed pattern on both the top and bottom Area of the simulated nut meat. The distributed pieces obtained were almost indistinguishable from real split nut kernels. The tape 28, which has a thickness of about 3.2 mm, is through with paint Spray nozzles 30 are coated and migrate to drying oven 32, where it is preferably at about 82 ± 5 ° C heating for about 5 to 10 minutes to reduce surface tack. The tape will then cut across the knife 33 at intervals of about 3.2 mm to 5 cm as desired. The ribbon then migrates to a large conveyorized dryer 34 for about 5 to 10 and in typically about 6 hours at 76 ± 5 ° C, reducing the moisture content to below about 10% and preferred is reduced below about 3% and the product becomes brittle.

Other forms of drying can be used, such as microwave drying. In general, the pieces expand when they are exposed to temperature conditions above the boiling point subjected to water, and are no longer similar to nut meat in terms of structure.

During the preliminary drying in the pre-dryer 32, the surface tack is reduced and the tapes can be cut without dirtying the cutting device the plastic pieces 28 by the final drying in the dryer 34 in hard, dry, crunching pieces 35 transferred, which the desired nutty bite properties and then the greasy feel of real nut meat and practically exactly the texture and chewing properties of Simulate nuts.

The dispersion of the oil component through the continuous phase of the hydrated film former leads to a plastic dispersion that slowly dries with the oil droplets in situ, causing the

hydrated film formers become increasingly dehydrated without displacing any oil. If Water vapor or oil vapor pressure due to the application of too high a temperature during the Drying is produced, the cellular structure is broken up and the oil particles coalesce and bleed from the product. Therefore, the drying is carried out over a relatively long period of time, for example in ClWa 5 or 6 hours up to 20 hours.

When the ingredients are applied selectively, the finished product resembles nut kernels and even special types of nut kernels.

If necessary, the pieces migrate from the dryer 34 via the conveying device 36 to a Slicer 37 when pieces of very small size are required. You then migrate through Rotary screen 38 where undersized particles are removed or flavor added. the Pieces can also be placed in a rotating metal cylinder 40, which is sufficiently heated by the heating device 41 is to bring the cylinder 40 to a temperature above the solidification temperature of the coating fat 42, for example to bring about 52 ° C, occur. The moisture retardant coating 42 is through a Line 44 is fed to nozzle 48 by means of pump 46. The coating device 40 bathes in this way Surface of each piece with a molten coating 42 of any type, such as Beeswax, melted shortening, zein, mono- or diglycerides or edible shellac or the like. This coating is applied over the entire surface of each cut piece, creating chunks or Pieces are produced that have color on all sides except those where the cuts were made have and a moisture-retardant coating on all surfaces including the cut ends exhibit. In this way, the cut pieces 35 are made to be cut Resemble nut kernel pieces very closely.

Any suitable commercially available nut flavoring agent or certain other flavoring agents such as for example chocolate. Fruit and the like can be stored in the mixing drum 38 in the required quantity can be added to impart the desired taste and aroma.

If it is necessary to classify the pieces, the drum 38 is passed through a cylindrical classifying screen replaced. The taste is very beneficial after drying and before coating 42 instead of being applied in the dispersion itself. Optionally, the flavoring agents can both can be used in the coating as well as in the dispersion.

The edible coating 42 protects the pieces from becoming moist or softened, particularly when that Nut meat is intended to be used in other food products such as ice cream. Of the Coating 42 is then dried in a conventional manner if necessary, such as salt or other seasoning is to be added, it is dosed onto the pieces at 50 The pieces then move into a salt coating device, which has another cylinder 40, to which heat is supplied by a second heating system 41 that is sufficient to exceed the temperature of the cylinder to increase the solidification temperature of the coating fat 42 (for example above 52 ° C).

It has been found that mixing the dispersion in a vacuum of 813 x 10 ^-3 to 986 x 10 ^-3 bar (pressure 200 x 10 ^-3 to 27 x 10 -4 bar) produces a product that is equivalent to a given amount of water can be made less sensitive to oil exudation in the dispersion.

Conversely, a satisfactory product can be obtained by using less water in the dispersion when a vacuum is created.

A big improvement is made in terms of

Intensity and quality of the taste sensation

in obtained when volatile flavors are used when the taste on the Surface of each piece is brought directly under the coating 42.

In the same way, a number of oils and fats have been experimentally made along with applied different combinations of film formers. In each case the plastic dispersion was in stable form and then dried again to produce the nutty product.

Furthermore, the proportions of the components were varied widely. It should be noted that gums and certain types of starch, if hydrated, can serve as film formers. When in particulate form remain, they act as a filler.

In Figure 7, which illustrates another example of the invention, the method is illustrated by vigorous mixing the aqueous dispersion introduced into a heated vessel 216. Good results will come through Mixing the oil ingredients 210 and a dry, powdered, film-forming substance 212 as one Obtain slurry. Moisture 214 is then added to mixer 216 with vigorous beating, until the particles of the film-forming substance hydrate and form a plastic dispersion

3) a continuous cellular phase that coalesces isolates itself and traps droplets of the oil component. The oil components 210 can also be used with the previously hydrated 'reforming substance 212 are mixed, the mixture then vigorously is moved and a dispersion of the oil component throughout the hydrated film-forming substance is obtained, in which the droplets of the ölkort.ponente are included. Optionally, dry Ingredients 218 such as sugar, flavorings and the like added Any other Process for combining the film-forming and the oil components, that the dispersion of the oil component caused by a continuous phase of the hydrated film former is also satisfactory.

So the vacuum 220 is applied to the mixer 216 preferably near the start of mixing given up. The vacuum should continue until mixing is complete to avoid entrainment To prevent air. It can be seen that the components of the dispersion in a round bottom provided, heated mixing container 216 are brought, which has a stirring motor 216a, which by a suitable gearbox (not shown) is connected to a scraper arm agitator (not shown) which controls the The mixing is carried out until homogeneous Dispersion is achieved; mixing time is about 10 to 30 minutes usually sufficient. The dispersion is evacuated from the container 216 through valve 217 by means of high pressure pump 24 conveyed to an extruder 226, which produces a band 228 of a defined cross-sectional shape

In this case, parallel bumps and furrows result in a ribbed pattern on both the top and the top

the lower surface of the simulated nut meat ·: especially when the nut kernels are to be split into small pieces. The crushed pieces obtained, as shown in Fig. 8, are practically indistinguishable from real crushed must-meat. The ribbon is coated with paint 229 (Fig. 8) through spray nozzles 230 and travels to conveyor oven 232. Edible paint material 229 is applied to the surface to simulate the nut skin. The belt then travels to conveyor oven 232 where the moisture content is reduced to below about 10%, making the product brittle. If salting, the salt is applied to the tape before it is heat set to create a strong bond between the salt and the product.

By drying the product is converted into hard, dry, crunchy pieces, which the e desired crunch and then a smeary feeling of real nut meat and practically i. * nau the texture and the chewing properties simulate nuts.

The now hardened shaped material moves into a chopping machine 234, which cuts the tape at 235 transversely into pieces 236 (FIG. 8). The pieces are then fed via conveyor 238 to any type of coating device 240 where an edible coating such as beeswax, zein, mono- and di-lycerides, or edible shellac or the like 241 is applied over the entire surface of each cut piece thereby creating chunks or pieces of paint 229 on the sides, tops and bottoms and a moisture-proof coating on all surfaces including both ends 239 . In this way the cut pieces are made similar to cut nut kernels.

The edible coating 241 protects the pieces from becoming moist or softened, particularly if the nut meat is to be used in other food products such as ice cream. The coating 241 is then dried in a conventional manner, if necessary.

As shown in FIG. 9, an important effect of the invention is that the simulated

ίο Nut meat 205 can be used with success in ice cream 252 . The simulated nut texture is a function of both temperature and composition. The texture in ice cream depends on the type of nut that is simulated.

It has been found that by mixing the dispersion without gas contact, a product is produced, that is less prone to oil exudation for a given amount of water in the dispersion can be made. Conversely, an Product can be made using less water in the dispersion, if none Gas contact is allowed. It also enables the application of a vacuum during locking a consistent creation of a finished product that has the desired crunchy texture subsequent smeary sensation when chewing, which closely resembles the texture of real nut meat simulates without the tendency of certain products to break in such a way that small pieces in the rear part

ίο the throat being caught.

There is a significant improvement in the intensity of the taste sensation perceived when the flavoring agent is placed in coating 229 or 238 or both.

The illustrative examples show the wide application of the invention.

Examples 1 and

Simulated nut meat preparation
(Components other than water in% by weight)

Components

example 1

Product for
direct consumption

Example 2

Approach for
Ice cream

Wheat germ flour (heated) *)

Partially hydrogenated vegetable oil (clears at 18 to 21 ⁰ C) sugar

Flavor

Sodium caseinate

water

Dye (0.75% solution)

*) Manufactured according to the process of US patent application 760,745.

22% 24.5% 68 73 2.5 2 1.5 0.5 6th - 100% 100% 38% 29% 0.6 0.6

The process conditions for Example 2 are as follows: The temperature of the oil at the time it is added to the mixer is 35 ° C. The water temperature is 13 ° C. The mixer is operated at an orbital speed of 48 rev / min and a vacuum of 946 · 10 ^-3 bar (pressure 67 · 10- ³ bar) is abandoned. Mixing is continued for about 10 to 15 minutes until a dispersion forms. After the dispersion is formed, mixing is continued for 20 minutes. The dispersion is then fed into the extruder 26 and at a rate of about 3 kg / min through nozzles of suitable shape having a width of 15.8 mm

and a thickness of 32 mm Preliminary drying takes place over a period of about 7> / 2 min at 82 ° C to allow the on the surface the strip of sprayed dye 30 to dry. The material is then transverse at intervals of 63 mm crushed and then dried for 6 hours at 7 ° C. It is then cooled to about 32 ° C by blowing chilled air onto the product added and in an upper pulling device 40 with coated with a continuous coating of hydrogenated vegetable oil 42 at a temperature of 65 ° C.

The procedure of Example 1 is the same as Example 2 with the following changes. Half of the Water is added to the other components, and mixing is continued for 15 minutes. The other half of the water is added while the Mixing is continued until a dispersion is formed (about 2 to 10 minX the remainder of the The procedure is the same with the exception that the drying is carried out for 8 hours and no top coat is used.

The approach for the finished pieces from Example 2 is shown in the following table.

Components 42 Example 3A
(Comparative example) Wt% Dried finished pieces
(simple, not overdone) Pecan flavor imitation Air mixing 90.90 coating salt approach 4.55 Stabilized soybean oil
dried egg albumin
dried ground wheat germ
Sucrose
Black walnut flavoring agents
water 0.91 procedure 3.64 100.00 39.7%
4.6%
23.2%
6.0%
0.23%
26.27%

The dried ingredients were placed in a mixing ball and the oil was added. The slurry was mixed at low speed using a paddle mixer until the oil had coated all of the dry ingredients and the slurry was smooth. All of the water (with the flavor dissolved therein) was added and mixing continued for 1 minute. The sides of the mixing container were scraped down and the mixer set at its highest speed. Mixing was continued for 5 minutes during which time a stable dispersion formed. The mixer was stopped again and the mixing container scraped down. Mixing was continued for an additional 5 minutes. This product was then placed on a polyethylene film and spread to a thickness of 3.2 mm and then placed in a set at 82 ⁰ C air circulating oven for 45 min.

This "solidified" the stable dispersion and denatured all of the enzymes that may be present in the wheat germ product. The product was then cut out of the furnace and removed in pieces of 22x13x3,2mm and air dried on stainless steel screens at 60 ⁰ C for 18 hrs. In the air circulating oven. This enables the incorporation of flavors that would volatilize at 82 ° C.

The product obtained was nutty and crunchy with the taste of black walnuts, tended however, to break at air pockets after an initial bite, with small sandy particles in the rear Part of the throat remained.

Example 3B (Invention)

Vacuum mixing

The same dried ingredients used in Example! 3A were used in one with was placed in a stainless steel mixer equipped with a Sigma blade and the oil was added The slurry became at low speed blended until it became smooth. At this time the mixer was turned off and all of the water (with the flavorant dissolved in it) was turned off admitted. The lid of the mixer was then placed on the mixer, and a vacuum of 946 · 10- ³ bar (pressure 67 · 10 ^J bar) was applied and the product at high speed for 15 min mixed While mixing a stabHe dispersion which showed a darker appearance due to the removal of air formed. This product was then placed on a polyethylene sheet and closed 3.2 mm thick and then placed in a forced air oven at 82 "C for 45 minutes. This "Solidified" the stable dispersion and denatured all of the enzymes in the wheat germ material may exist. The product was then removed from the oven and cut into 22x13x3.2 mm pieces cut and in the air on stainless steel sieves for 18 hours at 60 ° C in the air circulation oven dried. This enables the incorporation of Flavors that evaporate at 82 ° C would.

The product obtained was nutty and had the bite and taste of a black walnut. Your bite and the lubricating properties were the same as

so with a natural black walnut.

Example 4

In the absence of air or other gas produced synthetic nut

approach

3934% Stabilized Soybean Oil

9.87% dried egg albumin 15.51% sucrose

4.73% sodium caseinate 12.40% corn starch 18.12% water

0.03% hazelnut flavor 100.00%

procedure

The dry ingredients mix together in the oil to form a smooth slurry

mixed using a mixer.This slurry is then pumped into a basin into which at the same time the water (with the flavoring substance dissolved in it) is pumped. This mixture will then pumped into a mixer in such a way that no air can be incorporated into the mixture. The mixer forms then a stable dispersion which is then extruded into ribbons. These ribbons are cut into pieces of 13 mm cut, placed on stainless steel sieves and air-dried at 77 ° C. for 12 hours. The product obtained was white in color, possessed the hazelnuts smooth nutty texture when eating and had a pleasant taste of toasted hazelnuts. No gas voids occurred in this product in appearance.

Example 5

Method using a vacuum mixer approach

33.6% stabilized cottonseed oil

5.1% dried egg albumin

25.5% ground dried wheat germ

6.7% sucrose

0.6% imitation nut flavor

284% water

procedure

All dry ingredients plus oil are placed in the mixer and ^{mixed under a vacuum of 846 - ΙΟ - 3} bat (pressure 167 * K) - ³ bar) until the slurry was smooth. The vacuum was removed, the mixing process stopped and the water (with the flavoring substance dissolved in it) added in one portion. A vacuum of 846 · H) ^-3 bar (pressure 167 · 10 ^-3 bar) was applied and the mixture was mixed at high speed for 10 minutes, during which a stable dispersion was formed. The product obtained was extruded into star-shaped rods (with a diameter of about 9.5 mm), placed on polyethylene films and heat-cured in an air circulation oven at 77 ° C. for 1 hour. These rods were cut into pieces of 25 mm, placed on stainless steel screens and dried at 6O ⁰ C in an air circulating oven for 24 hours.

Results

The product obtained had a nutty bite with a gentle crunch and a smear effect without small pieces resulting from gas voids. The taste was nutty but did not indicate one certain type of nut.

Example 6 Vacuum mixing method using

a cutter mixer, using

Torula yeast for flavoring and under Adding salt before drying

approach

553% stabilized cottonseed oil!

16.6% ground dried wheat germ

2.0% Torula yeast

3.6% dried egg albumin

2.0% sucrose

20.5% water

procedure

All dry ingredients plus oil were in brought the cutter mixer and put it under a vacuum

von846 - IO ³ bar (pressure 167 - bar 10- ^) blended was obtained until a smooth slurry. The mixer was opened and the water added in one portion. Again vacuum from 846 - 10-? bar (pressure 167 - 10 ~ ³ bar) is applied, and the material was mixed for 10 minutes, during which time a stable dispersion formed. The material obtained was then extruded into shapes resembling cashews, placed on polyethylene sheets and heat-cured in a fan oven for 1 hour at 82 ° C. The pieces were then in a forced air oven for 18 hours on the Air dried

Results

The product obtained had a cashew bite and taste and had the appearance of cashew halves. The addition of the Torula yeast gave the effect that could not be added by adding artificial flavors. There were no gas voids before.

Also, some of the material had sprayed onto the surface prior to heat setting Grains of salt. The salt tended to dissolve on the surface but not completely dissolve, and after heat-setting and subsequent drying, the salt dried and remained on the surface of the Stick nut, resulting in a uniformly salted nut.

Example 7 Vacuum mixing method using

of a sigma mixer, using roasted

Rye as a flavor component and use

of vacuum drying for pieces of thick

cross-section

approach

32336% Stabilized Soybean Oil 8.08% dried egg albumin 6.11% sucrose 330% sodium caseinate

16.86% ground, roasted, crushed rye 0394% imitation taste of roasted hazelnuts 31.72% water

procedure

Ground rye is processed through a stainless steel micropulverizer ground a sieve of 0.3 mm. The ground Rye is then roasted for 25 minutes at 163 "C. All dry ingredients plus oil are placed in a sigma blender and blended at low speed until smooth. The water (with in it dissolved flavor) is in a portion added (bar pressure 67 · 10 ^-3), a vacuum of 946 · IO ³ bar is applied to the product, and the mixing takes place at a maximum speed for 15 minutes (a vacuum of only about 337 · 10- ³ bar (pressure can) 676 · 10- ³ bar used will). A stable dispersion forms during this time. This product then becomes hazelnuts shaped like balls and placed on a polyethylene film and heated for 1 hour in one

Air circulation oven set at 71 ° C solidified

The balls (diameter of about 9.5 mm) are then placed on stainless steel sieves and air-dried at 71 ^° C. for a further 3 hours. This product is then placed in a 71 ° C and a vacuum of 946 - ΙΟ- ³ bar (pressure 67 - 10-3 bar) transferred vacuum oven set, it wa further 16 hours is dried.. The products obtained have the bite and taste of a roasted hazelnut and, after being immersed in a 2% caramel color for 3 minutes and then air-dried, have the appearance of hazelnuts. There are no gas voids. If vacuum drying is not used, even after 96 hours of drying in a forced air oven, the product will not dry in the center and will discolor and lose its taste in the center of the piece. By using the roasted, ground rye, it is possible to achieve the roasted hare-nut flavor that could not be achieved using wheat germ as a base.

As mentioned above, masses tend to involve air or other gas with the dispersion in their manufacture may come in contact during their formation, becoming nutty in character if, however, chewed they often had a tendency to form small pieces that were placed in the back of the throat Catch a swallow. However, if vacuum is applied during formation of the dispersion or that Mixing is carried out with no gas present as described herein, this problem is eliminated and the simulated nut kernels obtained are characterized by having a crunchy texture and then have the natural lubricating properties of a real nut kernel.

The improved eating qualities of the nut kernels produced using the invention agree physical tests carried out on the nut kernels. Thus, the eating qualities a nut can be described in various ways as hard or soft, tough or tender, crunchy, greasy, chewable, limp, etc. It has been found that by compressing simulated standard nut kernel pieces in evenly using a fixed amount of compression and a fixed one Degree of movement of the compression device, the resistance to compression can be recorded on a measuring strip as a puncture of time or displacement.

Simulated nut kernels, which were produced according to Examples 3A (comparison) and 3B (invention) and had dimensions of 22 13 χ 3.2 mm, were tested on an Instron tester to a total deformation of 5 mm at a speed of 2JS mm / min compressed. After a deformation of 2.59 mm was reached, the compression was reversed until the original position was reached, the jaws being moved at the same speed of 21 mm / min. A second complete cycle (compression and subsequent decompression of the deformation at the same speed) was of the same piece then performed this test showed that the nut kernels according to Example 3A (Air-treated) were made, a total compression force F in deformation of 0 _r 5mm of Reached an average value of about 2500 g. On the other hand, those made according to Example 3B (vacuum-treated) achieved a total compressive force F of about 5800 g. The strength fern at the end of the first compression was taken as the strength or hardness of the nut. The distance that the clamping jaws moved against each other during compression is rated as elastic recovery E. The area under the curve from the beginning of the compression to the end of the relaxation gives the compression work in the first cycle. Similarly, the area under the curve during the second compression is the work of compression in the second cycle. The ratio of work during the second cycle to the work done during the first cycle is taken as the cohesiveness (C) of the sample. Two other physical parameters are derived from those mentioned above.

/ = internal strength = Fx C

and
S or greasiness = Fx Cx £

Typical values obtained during these tests are shown in the table below reproduced. The three columns on the left relate to three samples prepared according to Example 3B while the three right-hand columns relate to three different samples, which are according to Example 3A were manufactured.

Table I. Samples according to Example 3B Samples according to Example 3 A

F. 6190 g 7140 g E. 0.172 mm 0.162 mm C. 0.284 0.230 1 1760 g 1640 g S. 12.0 g 10.5 g X 2.5 cm x 2.5 cm

8550g 0.157mm 0.198 1693g 10.5g X 2.5cm 2680g
0.101 mm
0.350
938 g
3.75 g
x 2.5 cm

5700 g
0.086 mm
0.180
1025 g
3.49 g
X 2.5 cm

6050 g
0.178 mm
0.173
1048 g
7.33 g
X 2.5 em

Referring to the table, it can be seen that the value S is also more than double the the internal strength / in the case of the vacuum-treated 65 value of the old mass.

It can thus be seen that the invention provides a new simulated nut kernel product which does significantly

Nut kernels is much larger than that prepared according to Example 3A and that the nut kernels are made in this way are more crunchy or chewable. In addition, improved structural properties and eating qualities

compared to similar products in the present of a gas such as air. These structural properties are reflected in the physical properties. It should therefore be made clear that physical tests alone simulated those Cannot characterize nuts because their texture varies considerably from one type of nut to another, for example, from cashews, which are soft, to almonds, which are much harder, vary. The improved product can be done either by vacuum mixing or by mixing in the absence of added gases, such as for example air can be obtained. While gas can be excluded in numerous ways, A preferred method other than vacuum is to use it a mixer that is completely filled with the material to be mixed

The drying phase of the invention has a further advantage when using wheat germ for flavoring be used. It was found that drying at elevated temperatures reduced wheat germ enzyme activity prevents that can cause bad taste. At the same time, however, the loss prevents volatile flavors, which is of course desirable

Another advantage of the invention is that Flavor materials, such as salt, reliably adheres to the surface of the simulated Nut kernels can be bonded by applying the salt before removing moisture. It therefore happens that the moisture present in the simulated nut kernels affects the surface of the Moisturizes the salt and promotes the formation of a bond between the nut kernel and the salt and that this bond is later strengthened, when the last traces of moisture are removed.

Another advantage in one embodiment of the invention is the use of Torula yeast for Achievement of a cashew nut flavor as described in Example 6. The Torula yeast can be used in a simple manner treated at a reasonable cost and delivers excellent cashew nut flavor.

Another advantage of the invention is described in Example 7, in which roasted ground rye is used as Nut base is used. The roasted rye can be easily obtained, and it was made found that it provides a very palatable foundation, due to the lack of a maple note that sometimes undesirable especially in the production of simulated hazelnuts.

Another aspect of the invention is the effectiveness of vacuum drying to provide a uniform and effective drying of relatively thick simulated nut pieces, for example those with a Thickness of over about 4.7 mm as described in Example 7 to be obtained. It has thus been found that, although even thick pieces were dried, the moisture distribution through each was very even Piece could be retained. This made these pieces resistant to deterioration and could be given the same texture throughout.

It can be seen that the invention provides other important advantages and improvements. Among these results the improvement in color obtained by applying spray paint 30 to the outside of the piece was made possible. In addition, water-soluble paint can be used, and the paint will be in effective from bleeding or dissolving when the kernels are in a water-containing food product can be used by subsequent application of the moisture-impermeable top layer 42 protected

The pre-drying carried out in the pre-dryer 32 conditions the tape in such a way that it does not adhere to the Cutter 33 to glue and without breaking into many fine pieces, which would be the case if it were

ίο would be cut after complete drying, can be cut. In this way the amount of fines is reduced. It has been found that preliminary drying in a satisfactory manner with a typical batch and a tape gauge of for example 3.2 mm in about 20 to 30 minutes at 82 "C can be achieved using a hot air oven.

It is further noted that the invention a reduction in total drying time of about 12 hours to about 6 hours causes. Depth reduction of the drying time is based on a number of factors, of which the most pressing a reduction in the amount of water used for the application of vacuum and the Speed of the mixer. Decreasing the amount of water can only be achieved by understanding its relationship to fat loss.

The application of a moisture resistant coating 42 by tumbling the pieces in a molten plastic fat was found to be highly effective in reducing moisture absorption and bleeding of the sprayed paint coating.
A very effective medium for protecting taste has also been found. A good deal of versatility is also provided by the method with respect to the coating grease that can be used. It should be noted that if the melting point is too low, the pieces will become sticky after storage and will fail

is high, the coating has a tendency to peel and the products have a waxy feel in the It has also been found that the coating 42 is highly effective in binding the salt to the pieces after a long period of storage

If a nut flavor is to be used, it is applied below the coating fat 42, with an oil soluble nut flavor imitation being preferred. It should be pointed out that the flavors applied in this way are not exposed to the heat prevailing during several hours of drying and thus a loss of the desired volatile components is fraternized in this way.
The method is can also be used highly versatile with regard to the uses for the e & lertige product. Excellent results can be obtained, for example, by making simulated nut kernels that are used in ice cream. In this application it was surprising to find that finished pieces with a moisture content of about 1.5% have a different texture when cooled to the temperature of the ice cream (about -18 to -26 ° C). It has been found, however, that the texture of the nut kernels becomes much harder and tougher at this temperature than at room temperature. It was then found that it could be done by creating a relatively soft or fragile texture at room temperature.

the right chewing properties at the temperature of the Reach ice cream. Optionally, the dried product can be roasted sufficiently to changing its taste while maintaining its structure.

For the production of simulated nut kernels to be used in ice cream, it was found that less Protein and more fat should be used. the end

a comparison of Examples 1 and 2 shows that by reducing the proleine content by about 6% and increasing the fat content by about 5%, a change in texture can be achieved, wherein particularly good results are obtained when the pieces are used in ice cream at a temperature which is usually about -26 ° C.

For this purpose 4 sheets of drawings

Claims (6)

Patent claims: 1. A process for the manufacture of a nut-like food product, wherein from a) at least one edible, hydratable, (Reshaping substance and b) an edible, water-immiscible, oily substance containing 10 to 80% by weight of the The total of a) and b), c) water and d) if necessary, filler material a plastic dispersion is generated, which then is shaped and dried, characterized in that the dispersing under Gas exclusion takes place 2. The method according to claim 1, characterized in that that the dispersion is carried out using a vacuum. 3. The method according to claim 1 or 2, characterized in that the plastic dispersion is first heated at a temperature of at least 76 ° C for at least about 20 minutes and then dried at a lower temperature. 4. The method according to any one of claims 1 to 3, characterized in that a before drying solid, granulated flavor material applied to the surface of the plastic dispersion will. 5. The method according to claim 7, characterized in that 27 to 30% by weight of water, based on the constituents other than water, are used, the dispersion takes place at a pressure of 946 · 10 " ³ bar or less and the The resulting plastic dispersion is heated to a temperature of at least 76 ° C. for at least 2 minutes, cut into pieces, dried and then a moisture-insoluble, edible coating is applied. 6. The method according to claim 5, characterized in that the coating is a plastic fat coating and salt are applied and the fat is allowed to harden.