DE3248692A1 - METHOD FOR PRODUCING MOLDED FOODSTUFFS AND PRODUCTS OBTAINED BY THE METHOD - Google Patents

Description

3560 AW / My

· Yechiel SMADAR

Ramat-Hasharon, Israel

Process for the production of shaped »foods and the products obtained in the process

The manufacture of food products by reconstituting shredded materials and deforming the crushed materials with the help of rubbers and gel-forming materials by mechanical methods, such as Extrusion and deformation, as well as thermal treatment, e.g. heating or cooling, are used in the food industry usual procedures. There are various methods of making such molded food products Procedure known. Many of these methods rely on the use of a gel producing system, which is a Contains alginate and a divalent cation such as calcium ion.

-, I »Mt Λ Ρ> 1

One type of this process that involves these materials are used, a shaped product is obtained which is wrapped in a skin, like a sausage. For example are described in U.S. Patents 3,650,765 and 3,650,766, which are disclosed in any of any shape or size can be made by a process in which an extrudable slurry is made from a food material, the slurry is extruded and a gel-like skin around the extruded product is formed. The skin is formed by using gellable materials such as alginates Exposure to the influence of gelling agents such as alkaline earth ions on the surface of the extrusion product. In the U.S. Patents 3,891,776, 3,922,360, 4,117,172, and 3,676,158 are also described similar processes in which a "molded food product encased by a skin is produced. Some of these processes result peelable, self-supporting skins or coatings. When the skin is peeled off and the resulting If the product is re-exposed to a solution of a divalent cation, skin will form again.

Other processes based on the use of alginates and calcium ions result in a stabilized food product, when the alginate contained in the slurry used for manufacture is complete is converted into a complete "advanced" gel. For example, in U.S. Patent 2,791,508, a Process for making reconstituted food products described, in which a thixotropic, semi-gel-like substance is first produced by a crushed, powdery, granulated or cr ^ chopped food in water solution from an edible, hydrophilic colloid dispersed, the dispersed food being in the form of discrete particles that

are more or less completely enveloped by the matrix of the colloidal gel, is present. Alginates are used as usual hydrophilic colloids described. In addition, a gelling agent such as calcium carbonate can be added to the dispersed Food and the hydrophilic colloid are added to start gelatinization. Point of time, to which the gelling agent is added to the dispersion of food and hydrophilic colloid, is critical because when the gelling agent is added it releases calcium ions, which are rapidly released with the Colloid react to form the gel. Because this gelatinization runs very quickly, it is necessary to quickly feed the substance into a feed pipe for extrusion to guide what the last advanced GEL structure is produced. The feed pipe must be of such a length that the mixture in question is substantially an advanced gel is when it leaves the exit. This is a major disadvantage since if that Gelling agent is added too quickly, the mixture becomes an advanced gel before it enters the extruder leaves, thus causing clogging of the extruder mechanism. On the other hand, if the gelling agent is added too late, the mixture will not become an advanced gel when it exits the extruder and this prevents the formation of a shaped food product.

The known methods described above thus result in both the production and the production Product difficulties such as undesirable skinning, undesirable texture of the finished product, and beyond Difficulty eytruding occurs.

The present invention is therefore based on the object of an improved method for producing shaped To provide food products according to the

production runs smoothly and according to which the desired properties of the finished product are controlled can be.

It has now been found that according to the invention food products with any desired size or shape from one A slurry of comminuted food particles and additives including a binder and a time response system which includes a gel agent, like an alginate, and a divalent ion-releasing one Material includes, can be produced. The slurry used in the process of the present invention has the necessary rheological properties for shape generation and shape retention, creating a continuous Manufacturing processes by means of extrusion, va molding or a similar process process are possible will. The consistency of the slurry is chosen so that the molded product is easily removed from the molding machine can be removed or withdrawn.

The method according to the invention can be used for a large number of of foods including vegetables, fruits, proteinaceous substances such as meat and fish products, Shrimp products and the like, are applied, and it does not depend on the acidity of the food products or on their temperature. According to the invention, the slurry can consist of one or more comminuted Foodstuffs, as mentioned above, a binder, for example a cellulose ether alone or together with a gum such as guar gum, an alginate, a divalent ion releasing agent Material like calcium carbonate which with the alginate reacts to form a gel, an extender such as flour and / or starch, and optionally a means of controlling the pH, such as citric acid or any other physiologically different

acceptable, weak acid, a suitable sequestering agent, such as a metaphosphite, and contains other additives such as salt, sweeteners and colorings.

The binder used in the slurry gives the product a certain rigidity and shape, and that Gradual gelling of the alginate causes the product to set in a certain way.

The pH control agent, together with the sequestering agent, releases the calcium ions at a predetermined speed, whereby a controlled gel formation of the alginate takes place. In In some cases the pH of the comminuted food product will be such that either the acid or the acid and sequestering agent do not have to be added. For example, in the case of crushed Food products that release acid such as bipods, pH control agents and the sequestering agent cannot be added to the slurry.

In either case, the slurry must be adjusted so that gelation occurs within a predetermined time interval takes place. Generally, the slurry is left for a predetermined period of time of about Stand for 5 to about 30 minutes before actual deformation and further processing commence. this is sufficient time for gelation. The ratio and amount of the various ingredients in of the slurry determine the consistency and properties of the finished product.

The actual deformation is done with an extruder, cutter or deforming device. As mentioned above, is the easy and quick dispensing of the shaped

Products from the extruder, the cutting device or the deformation device for an efficient, continuous Production process important. Such a discharge can be achieved by continuously flushing the extrusion head, the cutting device or the form with a liquid brew, water or with an aqueous solution divalent ions such as calcium ions, thereby preventing the molded product from adhering to the Forming device sticks. When a solution such as calcium chloride solution is used for rinsing, one obtains a smooth, gliding surface that has a very low coefficient of friction and is easily exposed to the molding device is dispensed. This rinsing solution is used in a small amount and concentration and should only facilitate the easy delivery of the product "and not the formation of the shape-retaining or self-supporting Effect film or skin.

The molded product can be further processed by it is either treated with a flour-like material or normal dough, or it is covered with dough. if the dough that is used to coat the product is supposed to have better adhesion, one can add to the Add a small amount of a gelling agent to the dough that will work with the alginate in the top layer of the product reacted.

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

The stock used for the method according to the invention ' parts are acceptable in terms of price and thus the product can be manufactured in an economical manner will.

As previously indicated, those of the present invention are molded Food is made by first making a slurry of the shredded food product and other additives. Thereafter, the slurry is extruded, molded, or the like Process deforms, and then follows the finishing or processing, for example in the application of a Dough, especially a thin dough such as a pancake dough, the coating with bread dough or Breadcrumbs, cooking such as heating in liquid oil, freezing and packaging. According to the invention contains the slurry is one or more comminuted food products, a binder, a gelling agent, a compound that reacts divalent ions releases with the gelling agent, extender or extender and, if necessary, an agent for pH control, a sequestering agent and additives such as salt, spices, sweeteners and colors.

Suitable binders that can be used in the present invention are edible cellulose ethers, which are non-toxic and soluble in water. Examples of suitable cellulose ethers are alkyl, hydroxyalkyl and Carboxyalkyl ethers in which the alkyl group has 1 to 3 carbon atoms contains. Specific examples of the cellulose ethers are sodium carboxymethyl cellulose, methyl cellulose, Ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethyl cellulose and combinations thereof. These cellulose ethers can be used together with gums such as guar gum, gum tragant, gum caraya, Xanthan gum, carraghe gum, furcellaran gum, Locust bean gum, gum arabic or their mixtures, be used. Although any suitable binder can be used, it is preferred, hydroxypropylmethyl cellulose to be used together with guar gum as a binding agent. 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 of from about 0.10 to about 6.0 wt.%, Based on the weight of the shredded food product may be used. When the binder comprises both a cellulose ether and a gum, the cellulose ether is, for example, in an amount of about 20 to about 30 % by weight, based on the binder, and the gum is, for example, in an amount of about 70 to about 80% by weight .%, based on the binder, present.

Although any suitable gelling or gel forming agent can be used, it is preferred to use an alginate such as sodium alginate or potassium algirate use. A particularly preferred alginate is sodium alginate under the trademark Protanal SF-120, which is available from Multi-Kem Corp. distributed by Protan and Fagtun of Norway is made. The alginate is generally in the slurry in an amount of about 0.1 to about 1.0% by weight, based on the weight of the comminuted Food product, available.

Compounds that release divalent ions to react with the alginate to form a gel Calcium carbonate, calcium phosphate and the like. Calcium carbonate is particularly preferred. The compounds releasing calcium ions react with the alginate to form a calcium alginate gel. The ion releasing compound is generally in an amount of about 0.001 to about 0.004 wt.%, Based on the weight of the shredded food product.

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

The pH control agent can be obtained from the slurry be omitted if the comminuted food product that is used emits a weak acid. Onions are an example of such a food product. If the agent is used for pH control, it is it generally in an amount of from about 0.001 to about 0.05% by weight, based on the weight of the comminuted food product, before.

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

Suitable extenders or diluents that are used in the invention Slurry that can be used are starch and flour, which are usually used together. Generally, the starch is in an amount of from about 3 to about 12 weight percent based on the weight of the comminuted Food product, available. However, it is preferred to use starch in an amount from about 5.5 to about 6.5% by weight to be used. The flour is generally in an amount of about 3 to about 12 wt. 96 based on the Weight of the shredded food product, available. A preferred amount is from about 7.5 to about 8.5 wt%.

The slurry can further contain one or more additives contain, such as salt, spices, sweeteners and colorings. If such materials are present in the slurry

They are generally in an amount of from about 0.01 to about 1.0 percent by weight, based on the weight of the comminuted Food product, available.

Vie stated above are the food products that can be used in the present invention, for example vegetables, fruits, protein-containing substances, such as meat and fish products, shrimp products and the like. The method according to the invention is particularly suitable rehydrated on shredded, sliced or shredded food products such as fresh onions Onions, cauliflower, mushrooms, pepper or. Peppers, apples, poultry, meat, fish, Shrimp and Kalamari. A preferred product are double rings, which require a very well-defined consistency, so that they are in acceptable form as a salable product are present. The food products are chopped, planed or by methods known per se crushed.

The slurry is made by doing all of these Materials making up the slurry mixed with the exception of the shredded or shredded food product. After the dry mixture of these materials has been mixed, it is crushed with the crushed one or shredded food product for 2 to 5 minutes at room temperature to form a slurry offset and mixed. The resulting slurry, which has a very high viscosity, can then during a Stand for about 5 to about 30 minutes so that the release of the ions, such as the calcium ions from calcium carbonate, possible and a calcium alginate gel is produced. The slurry is then transferred to a molding machine, such as an extruder or a shaping device. While any suitable device can be used, it is preferred to pass the slurry through an explosion hazard

pump truder with cutting heads. When making onion rings, you can use an autoprod / food extruder, manufactured by Autoprod, Inc., use with cutting heads, being annular products weighing approximately 10 to 12 g can be produced. The same extruder can be used with different cutting heads for extrusion other shapes such as spheres, crescents, croissants, chopsticks, etc. can be used.

A rinsing solution containing divalent ions is preferred for washing the extruder cutting device or the molding plate used to facilitate the discharge of the molded product from the cutting device or the Mold plate to facilitate. It is preferred to use an aqueous calcium chloride solution (0.2 to 5.0%).

The extruder formed products then individually fall onto a wire mesh conveyor belt that 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, for example sodium alginate, can be added to the thin dough, which then reacts with the calcium ions on the surface of the product. This process stage is usually followed by the breading unit in which the products are breaded. The breaded products are then usually cooked and in the case of onion rings during a short period of time, for example, about 30 seconds at -10 ⁰ C (or 400 ⁰ F) frozen and then frozen individually quickly and packaged.

The finished molded product contains prior to application the liquid dough and breadcrumbs according to the invention for example a cellulose ether in an amount of about 0.10 to about 2.5% by weight, a gum in an amount from about 0 to about 2.5 wt.%, alginate salt in one

Amount from about 0.05 "to about 0.80 weight percent, an extender in an amount of about 6.0 to about 15.0% by weight and a food in an amount of about 80 to about 90% by weight. A preferred example comprises 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 contain when dry Mix the following materials together prior to adding the shredded or sliced food product (based on the weight of the materials in the slurry prior to the addition of the food, where for the particular material, a wide range that can be used, and preferred amounts are given).

Materials Preferred (%) "Range (%)

Starch, especially corn starch, wheat flour
Hydroxypropyl methyl cellulose

20 guar gum

Sodium alginate
Calcium carbonate
Sugar (if applicable) salt (if applicable)

25 citric acid (if necessary) sodium hexametaphosphate, (if necessary)

The ratio of cut, fresh and / or rehydrated The ratio to the dry mix system is preferably 6.0 to 1, but can range from about 5: 1 up to about 10: 1.

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

37 30-60 49 30-60 1.5 1 - 15 6.0 0-15 2.5 0.5 - 5 0.012 0.006-0.02 4.4 0-10 0.9 0-5 0 0-0.02 0 0-0.02

example 1 Manufacture of onion rings

Prepare a dry mix of the following materials.

Parts by weight

Corn starch 16

Wheat flour 25

Sodium alginate (Keltone from Kelco Co.) 0.8 Calcium carbonate 0.003

Hydroxypropylmethylcellulose with a viscosity of 100,000 cP (hydroxypropyl-methocel

K-1000M from Dow Chemical) 3.2

This mixture is added to 250 parts of 0.63 cm (1/4 ") cut fresh onions on a ribbon blender and then mix for 3 minutes at room temperature to form a slurry.

The resulting slurry is pasty Viscosity. The mixture is left to stand for 5 to 15 minutes so that calcium ions from the calcium carbonate are conditional due to the acidic pH created by the onion exudate and the subsequent reaction of the calcium ions are released with the algin molecules to form a calcium alginate gel.

The slurry is then pumped using a dairy pump pumped through an autoprod food extruder with cutting heads, taking annular products weighing about 10 to 12 g are formed. The cutting heads are treated with an aqueous solution of calcium chloride 5 parts to 100 parts of water in terms of weight. This washing solution facilitates the release of the formed ring-shaped products from the cutting heads.

ff .) *

The extruded onion rings fall individually onto a mesh conveyor belt, which transports the product into a dough unit (for thin dough), which is followed by a breading unit. The breaded product is ^{deep-frozen for 30 seconds at -10 0} C (400 ⁰ F) and then quickly frozen and packaged individually.

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

Example 2 Manufacture of onion rings

Extruded onion rings are produced according to Example 1, with water rehydrated and dried Use pieces of onion that are approximately 1/4 "(0.63 cm) in size when reconstituted with water.

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

Example 3 Manufacture of onion rings

Prepare a dry mix of the following materials.

Parts by weight

Corn starch 15.2

Wheat flour 20.0

Sodium alginate 1.0

Calcium carbonate 0.004

Hydroxypropyl methyl cellulose 0.6

Guar gum .2.5

Salt 0.4

Sugar 1.8

zcr

This mixture is cut into 250 parts (0.63 cm or 1/4 ") ι given fresh onions. The procedure for The onion rings are produced according to the example

Example 4 Manufacture of apple rings

Prepare a dry mix of the following materials en her.

Parts by weight

Corn starch 25

white flour 16

Sodium alginate 0.6

Calcium carbonate 0.003

Hydroxypropyl methyl cellulose 2,3

Guar gum 1.1

Sugar 5

Salt 1

This mixture is added to 250 parts of cut (0.63 cm, or 1/4 "), fresh apples. One then operates as in Example 1 ^u.

Example 5 Manufacture of a shrimp product

Prepare a mixture of the following ingredients.

Parts by weight

shredded shrimp 85

Salt 1.0

HVP 1.5

Garlic powder 0.02

Onion powder 0.3

Corn starch 1,2

Water up to 100

100

Room

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.
5

Example 6 Zincchini rings or pieces

A mixture is made from the following ingredients here.

Parts by weight of cut (0.63 cm or 1/4 ") 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 of Example 1 and works according to Example 1, using a ring-shaped or piece-shaped product receives.

Example 7
Poultry rings or crescents

Prepare a mixture of the following ingredients.

Parts by weight

cut (0.63 cm or 1/4 ") poultry pieces 76.6

Poultry flavor 3.0

Parsley 0.1

Water 17.7

100 35

250 parts by weight of this mixture are mixed with the dry mix of Example 1 are mixed and then cupcakes about 5.08 cm (2 ") in diameter are made. These are then processed according to Example 1. 5

The above examples are made with different binders and gums as well as with different proportions Extenders and repeated with the addition of more rubbers. There will be different ratios of alginates with others tried little soluble calcium compounds. In all cases, a suitable selection of the Components of satisfactory products.

Claims (27)

Claims 1. Process for making shaped food products from crushed, granulated or cut up Food products, characterized in that one (1) a slurry of one or more food products with a binder, a gelling agent and a divalent ion releasing material, wherein the amount of binder, gelling agent and divalent ion releasing material sufficient to cause a reaction between the gelling agent and the divalent ion releasing material a predetermined time after preparing the slurry to surrender; (2) the molded food product from the slurry by means of a deforming and shaping device manufactures; and (3) processing the molded food product into the final product. 2. The method according to claim 1-, characterized in that that a cellulose ether is used as a binder. 3. The method according to claim 2, characterized in that the cellulose ether is carboxymethyl cellulose, carboxyethyl cellulose, Carboxypropy cellulose, methyl cellulose, Ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, Hydroxypropylmethyl cellulose or a mixture same used. 4. The method according to any one of claims 1 to 3 »thereby characterized ,, that the binder is a cellulose ether and contains another gum. 35 BATH ORIGINAL " ζ 5. The method according to claim 4, characterized in that another gum is guar gum, gum tragant, gummikaraya, Xanthan gum, carragheen, furcellaran gum, carob gum, gum arabic or mixtures thereof are used. 6. The method according to any one of claims 1 to 5, characterized in that there is a gel forming agent Alkali metal alginate and, as a compound releasing divalent ions, a compound containing calcium ions low solubility used. 7. The method according to claim 6, characterized in that the alkali metal alginate is sodium alginate and the calcium compound is calcium Calcium carbonate used. 8. The method according to any one of claims 1 to 7, characterized in that the slurry is additionally contains a pH control agent. 9. The method according to claim 8, characterized in that the means for pH control is a weak, organic Acid is selected from citric acid, tartaric acid and maleic acid.
.25 10. The method according to any one of claims 1 to 9, characterized in that the slurry additionally contains a sequestering agent. 11. The method according to claim 10, characterized in that that metaphosphate is used as a sequestering agent. 12. The method according to claim 11, characterized in that that sodium hexametaphosphate is used as the metaphosphate. 13. The method according to any one of claims 1 to 12, characterized in that the shaped food product is rinsed with an aqueous solution containing a calcium compound, while it is from the shaping and deforming device is removed. 14. The method according to claim 13, characterized in that there is a solution of a calcium compound aqueous calcium chloride solution used. 15. The method according to any one of claims 1 to 1.4, characterized in that the slurry additionally contains an extender. 16. The method according to claim 15, characterized in that that one uses starch, flour or a mixture thereof as an extender. 17. The method according to any one of claims 6 to 16, characterized characterized in that the components are used in proportions that the slurry during a time of about 5 "to about 30 minutes, so that the reaction of the alginate with the Calcium ion releasing compound is enabled, thereby increasing the viscosity of the slurry prior to the deformation stage is increased. 18. The method according to any one of claims 1 to 17? through this characterized in that the binder in an amount of about 0.10 to about 6.0 wt.%, Based on the weight of the shredded food product. 19. The method according to any one of claims 1 to 18, characterized in that the alginate in an amount of from about 0.10 to about 1.0 weight percent based on the weight of the comminuted food product. 20. The method according to any one of claims 1 to 19, characterized in that the divalent ion-releasing compound is present in an amount of about 0.001 to about 0.02 percent by weight, based on the weight of the comminuted food product. 21. The method according to any one of claims 1 to 20, characterized in that the further processing stage (3) is carried out by molding the molded food product treated with either a floury material or normal dough, especially thin dough and then breaded. 22. Shaped food product, 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 about 0.1 to about 2.5 wt.96 ; Alginate salt in an amount from about 0.05 to about 0.80 weight percent; a pulverized, granulated or shredded foodstuff selected from vegetables, fruits, meat, fish and fish products and mixtures thereof, in an amount of about 80 to 90 wt.% and containing an extender in an amount of about 6 to 15 wt.%. 23. Shaped food product according to claim 22, characterized in that it is a. another rubber in Contains an amount of about 0.1 to 2.5% by weight. 24. Food product according to claim 22, characterized in that it contains onions as food. 1 25. Food product according to claim 22, characterized in that it contains apples as food. 26. Product according to claim 24, characterized in that it is in the form of a ring. 27. Product according to claim 25, characterized in that that it is in the form of a ring.