Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
  • A23J1/20—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from milk, e.g. casein; from whey
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
  • A23J1/20—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from milk, e.g. casein; from whey
  • A23J1/205—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from milk, e.g. casein; from whey from whey, e.g. lactalbumine
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
  • A23J1/08—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from eggs
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/04—Animal proteins
  • A23J3/08—Dairy proteins
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/14—Vegetable proteins
  • A23J3/16—Vegetable proteins from soybean
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
  • A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs

Definitions

• the present invention relates generally to a dry microparticulated protein product which is useful as a substitute for fat in food products, and more particularly to a spray dried, free-flowing microparticulated protein product which is readily rehydrated to give a fat substitute having desirable physical and organoleptic characteristics.
• microparticulated protein product which has been described by Singer et al., U.S. Patents 4,734,287 and 4,961,953. The disclosure of both of these patents is incorporated by reference herein for the purpose of generally describing the desired physical and organoleptic characteristics of microparticulated protein.
• the microparticulated protein product described by Singer et al. is characterized as a macrocolloid of properly sized spheroidal protein particles formed by heating soluble proteins under high shear conditions. Controlled heat and shear processes are used to form an aqueous dispersion of denatured protein particles having a range of sizes providing organoleptic characteristics that closely mimic the characteristics and properties of fat.
• This aqueous solution contains a mixture of protein microparticles, other solubilized proteins, sugars and starches as well as various salts, minerals and small amounts of insoluble materials.
• aqueous microparticulated protein product has been found to be an excellent substitute for the unwanted fat in a variety of food products (such as salad dressings, baked goods, coffee whitener, natural and processed cheeses, cream cheese, yogurt, puddings, soups, sauces, frostings, spreads, whipped toppings, ice cream and frozen desserts and related cultured dairy products)
• aqueous or liquid food ingredients typically have some undesirable attributes.
• aqueous protein or other nutrient- containing ingredients are very susceptible to microbial contamination and extensive efforts may be needed to prevent undesired microbial contamination.
• aqueous proteinaceous products may have a shortened shelf-live unless proper precautions and measures are taken in packaging or storage.
• some food processors are simply better adapted to using dry product formulations and processes and cannot readily use liquid products. Other food processors may not be willing or able to deal with the special handling and storage requirements of liquid products.
• aqueous whey protein solutions may be freeze-dried according to the procedures reported by Chang and Chang et al., U.S. Patents 4,029,825, 4,089,987, 4267,100 and 4,362,761 as well as by Concilion-Nolan et al. , U.S. Patent 4,058,510.
• different types of protein solutions may be dried using various spray drying processes. Specifically, spray dried protein products are reported in the following patents: Callewaert, U.S. Patent 4,486,345; Kajs, U.S. Patent
• a need in the food industry exists for an acceptable fat substitute in a dry form that is stable, has a long shelf-life and is readily adapted for use with existing food formulations and processing equipment.
• a fat substitute would be a microparticulated protein product that is an easy-to- handle, free-flowing powder that readily rehydrates without any appreciable loss of the desired organoleptic characteristics.
• the present invention provides a spray dried microparticulated protein product characterized as an agglomerate of rehydratable proteinaceous microparticles surrounded by a soluble matrix.
• a dry, free-flowing protein product of this invention includes a spheroidal agglomerate of a soluble proteinaceous matrix and microparticulated protein.
• substantially nonaggregated, spheroidal particles of denatured protein having substantially smooth, emulsion-like organoleptic character are obtained.
• the nonaggregated spheroidal particles of denatured protein have a mean diameter greater than about 0.1 micron and less than about 3 microns.
• a dry, agglomerated microparticulated protein product of this invention is preferably derived from undenatured substantially soluble protein. Suitable proteins include proteins derived from the group consisting of whey, bovine serum albumin, egg white albumin, soy and mixtures thereof. A highly preferred protein is derived from whey.
• Suitable processes for drying a microparticulated protein product include employing conventional spray drying techniques with a solution of denatured protein microparticles formed by heat and high shear.
• a preferred microparticulated protein solution which is well suited to being spray dried is described in U.S. patent application Ser. No. 07/524,598 filed May 17, 1990. The disclosure of that application is incorporated by reference herein for the purpose of describing preferred processes and apparatus, useful for the preparation of microparticulated protein solutions.
• the dry microparticulated protein product of the invention may be used to provide a variety of food products prepared from formulations providing replacement of part or all of the fat content of the food.
• a variety of food products having part or all of the fat content of the food replaced with a hydrated agglomerate of this invention are also considered to be within the scope of the present invention.
• Figure 1 is a photomicrograph of a liquid microparticulated protein product.
• Figure 2 is a photomicrograph (environmental SEM) of a spray dried microparticulated protein product.
• Figure 3 is a photomicrograph of a rehydrated spray dried microparticulated protein product.
• the present invention provides microparticulated protein as an agglomerated, free- flowing powder which readily rehydrates without loss of desired physical or organoleptic characteristics.
• the dried powder is characterized as an essentially spheroidal agglomerate of protein microparticles that are reversibly held in a soluble or solubilizable matrix.
• the matrix readily dissolves or disperses and provides a suspension of nonaggregated microparticles useful as a fat substitute. Microscopic examination of the rehydrated protein microparticles indicates that the spray drying process has no apparent irreversible effect on the microstructurre of the microparticles.
• the dried product has an extended shelf-live compared to the liquid product.
• the dried product is stable for at least fourteen weeks when stored at room temperature.
• the water activity level is less than about 0.4, and preferably less than about 0.3, no flavor deterioration or clumping of the powder is evident.
• Example 1 describes a preferred process for producing a liquid solution of protein microparticles.
• Example 2 describes a process of drying such a solution of protein microparticles.
• a sweet whey protein solution is subjected to both ultrafiltration and low heat evaporation to provide a liquid whey protein concentrate which has a mild cooked flavor and a minimum protein solubility of 93%.
• a suitable liquid whey protein concentrate is WPC-54 whey protein concentrate which is available from First District Association, Litchfield, Minnesota. The characteristics of this whey protein concentrate are listed in Table 1.
• the liquid whey protein concentrate is deaerated in a VERSATOR deaerater (Cornell Machine Company, Springfield, New Jersey) and bottom fed into a sanitary tank equipped for non-aerating agitation.
• VERSATOR deaerater Cornell Machine Company, Springfield, New Jersey
• the deaerted concentrate is then pumped at a rate of 1200 lbs/hr by a positive displacement pump through an in-line strainer (300 micron cheesecloth) , a mass flow meter and plate heat exchanger which raises the temperature of the concentrate to about 145-150 °F.
• the heated concentrate is then pumped through a recirculating holding tube at a flow rate of approximately 15 ft/sec or at a flow rate sufficiently high enough to prevent fouling of the holding tube. As the concentrate is recirculated through the holding tube, the temperature is increased to about
• the average residence time of the concentrate in the recirculating holding tube is approximately six minutes.
• the concentrate is then sent from the recirculating holding tube into a plate surface heat exchanger which cools the concentrate to a temperature . of about 150 °F, a temperature lower than the target peak temperature inside a heat and high shear generating ("Microcooker") apparatus.
• the cooled concentrate flows from the recirculating holding tube and heat exchanger into a microcooker apparatus which is described in U.S. Patent 4,828,396 with the exception that the inlet and outlet ports have been interconverted, i.e., the inlet port is disposed where the outlet port is shown in Figures 1 and 2 of U.S. Patent 4,828,396 and the outlet port is located at the bottom of the bowl shaped vessel.
• the temperature of the concentrate in the microcooker apparatus is raised to 200 °F within about 5 seconds under high shear conditions. Rigorous control of the concentrate temperature is maintained in the microcooker apparatus at 200 °F by a cascade control loop.
• the cascade control loop monitors the temperature of the microparticulated product exiting the microcooker apparatus and holds the temperature constant by regulating the temperature of the mixture leaving the plate surface heat exchanger downstream from the recirculating holding tube.
• the speed of the rotor in the microcooker apparatus is held constant at about 6000 rpm. At this rpm, the shear rate is about 46,000 reciprocal seconds at the tips of the rotor which has a diameter of approximately 7 inches.
• the product flows directly into an recirculating product cooling loop and is pumped through a plate heat exchanger at a rate of about 6,000 lbs/hr in order to lower the temperature of the concentrate to less than about 100 °F.
• the cooled product is removed from the product cooling loop at an outlet when the final product is at a temperature of less than 45 °F.
• Control of the final microparticulated product viscosity may be achieved by varying the temperature of the concentrate in the recirculating holding tube loop. A reduction in the concentrate temperature in the holding tube decreases the viscosity of the final product.
• a preferred viscosity range for the final product is about 2400-3300 cps (Brookfield, 5 °C, 50 rpm, spindle #27) .
• the cooled, microparticulated liquid product is finally sent to a gently agitated blend tank or, if desired, to an on-line filler.
• a whey protein concentrate having the characteristics listed in Table 2 was processed using the processing parameters listed in Table 3 to give a final product having the characteristics listed in Table 4.
• Viscosity of Product 2340-3960 cps at Outlet (Brookfield, 5 °C, 50 rpm, spindle #27) Microcooker rotor speed 6000 rpm Temperature of Product 38-43 °F at Outlet
• Microparticulated Protein (no oversized
• a spray dried protein product was prepared from the liquid product having the characteristics listed in Table 4 of Example 1.
• the liquid microparticulated product is added to a refrigerated feed tank (temperature ⁇ 45 °F) and the product is pumped from the feed tank through a recirculating shell and tube heat exchanger to provide a temperature of about 120-130 °F.
• the recirculation flow rate must be sufficiently high enough to prevent fouling of the heat exchanger.
• the heated product is supplied to a high pressure pump which feeds the spray drying apparatus.
• the pressure of the product leaving the pump is typically about 3500-4000 psi when the product is sprayed through nozzle such as a SPRAY SYSTEMS 7A (50/28) Nozzle (orifice/insert) (Spraying Systems Company, Wheaton, IL) .
• the pumped product is then fed into a NIRO bustled dryer (Hudson, WI) having a three nozzle product inlet at a flow rate of about 4,000 - 5,500 lbs/hr.
• NIRO bustled dryer Hudson, WI
• the spray dryer is fed with concurrent, heated, filtered air at a temperature of about 400-450 °F (depending on the ambient humidity) which provides an air outlet stream temperature of approximately 180-210 °F.
• the dried microparticulated product is conveyed from the drier using filtered, dry air at about room temperature. Contact with the conveying air rapidly cools the dried microparticulated product to ambient temperatures.
• the cooled, dried product is collected from primary and secondary cyclones, passed through a sifter screen, and collected in powder collection silos.
• the final moisture content of the dried product is between about 3-4 wt. %.
• the final moisture content is conventional controlled by adjusting the air outlet temperature which in turn establishes the air inlet temperature and drying time.
• a dried microparticulated protein prepared according to the above process has the characteristics listed in Table 5. Table 5 Dried Microparticulated Protein

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• Life Sciences & Earth Sciences (AREA)
• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Polymers & Plastics (AREA)
• Food Science & Technology (AREA)
• Biochemistry (AREA)
• Nutrition Science (AREA)
• Health & Medical Sciences (AREA)
• Zoology (AREA)
• Dairy Products (AREA)
• Medicinal Preparation (AREA)
• Immobilizing And Processing Of Enzymes And Microorganisms (AREA)
• Peptides Or Proteins (AREA)

Applications Claiming Priority (2)

Publications (2)

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• 1992
  • 1992-10-23 CA CA002097316A patent/CA2097316A1/en not_active Abandoned
  • 1992-10-23 JP JP5507958A patent/JPH06509475A/ja active Pending
  • 1992-10-23 KR KR1019930701645A patent/KR930702905A/ko not_active Application Discontinuation
  • 1992-10-23 WO PCT/US1992/009180 patent/WO1993007761A1/en not_active Application Discontinuation
  • 1992-10-23 AU AU29001/92A patent/AU2900192A/en not_active Abandoned
  • 1992-10-23 EP EP92923192A patent/EP0564640A1/en not_active Withdrawn

Patent Citations (4)

Non-Patent Citations (1)

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