Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
  • C09K23/34—Higher-molecular-weight carboxylic acid esters
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
  • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
  • A23L19/18—Roasted or fried products, e.g. snacks or chips
  • A23L19/19—Roasted or fried products, e.g. snacks or chips from powdered or mashed potato products
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
  • A21D13/00—Finished or partly finished bakery products
  • A21D13/20—Partially or completely coated products
  • A21D13/28—Partially or completely coated products characterised by the coating composition
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
  • A21D2/00—Treatment of flour or dough by adding materials thereto before or during baking
  • A21D2/08—Treatment of flour or dough by adding materials thereto before or during baking by adding organic substances
  • A21D2/14—Organic oxygen compounds
  • A21D2/16—Fatty acid esters
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
  • A23G3/34—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof
  • A23G3/343—Products for covering, coating, finishing, decorating
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
  • A23G3/34—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof
  • A23G3/36—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof characterised by the composition containing organic or inorganic compounds
  • A23G3/42—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof characterised by the composition containing organic or inorganic compounds characterised by the carbohydrates used, e.g. polysaccharides
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G9/00—Frozen sweets, e.g. ice confectionery, ice-cream; Mixtures therefor
  • A23G9/32—Frozen sweets, e.g. ice confectionery, ice-cream; Mixtures therefor characterised by the composition containing organic or inorganic compounds
  • A23G9/34—Frozen sweets, e.g. ice confectionery, ice-cream; Mixtures therefor characterised by the composition containing organic or inorganic compounds characterised by carbohydrates used, e.g. polysaccharides
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
  • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
  • A23L19/13—Mashed potato products
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
  • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
  • A23L19/15—Unshaped dry products, e.g. powders, flakes, granules or agglomerates
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
  • A23L29/00—Foods or foodstuffs containing additives; Preparation or treatment thereof
  • A23L29/10—Foods or foodstuffs containing additives; Preparation or treatment thereof containing emulsifiers
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/10—Coating with edible coatings, e.g. with oils or fats
  • A23P20/11—Coating with compositions containing a majority of oils, fats, mono/diglycerides, fatty acids, mineral oils, waxes or paraffins
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
  • C09K23/017—Mixtures of compounds
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
  • C09K23/017—Mixtures of compounds
  • C09K23/018—Mixtures of two or more different organic oxygen-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
  • C11D1/66—Non-ionic compounds
  • C11D1/667—Neutral esters, e.g. sorbitan esters
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G2200/00—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents
  • A23G2200/06—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents containing beet sugar or cane sugar if specifically mentioned or containing other carbohydrates, e.g. starches, gums, alcohol sugar, polysaccharides, dextrin or containing high or low amount of carbohydrate

Definitions

• the present invention relates to emulsifier compositions containing relatively high levels of sorbitan monoesters. These sorbitan monoester-containing compositions are useful for a variety of applications.
• sorbitan esters are used as emulsifiers in a wide range of applications including but not limited to cosmetics, hard surface cleaners, shampoos and other personal cleaning products, industrial manufacturing, and the like. Sorbitan esters also have a variety of food and beverage applications including ice cream, whip cream, whipped toppings, confectionaries, frostings, breads, baked goods, sauces, salad dressings, and the like.
• sorbitan esters results in a number of materials, including sorbitan mono-, di- tri-, and tetraesters, isosorbide mono- and diesters, unesterified sorbitan and isosorbide, and sorbitol and esters thereof. While such combinations have utility in the aforementioned applications, Applicants have now discovered that sorbitan-containing compositions comprising relatively high levels of sorbitan monoesters are particularly useful emulsifier systems having numerous applications. Commercially available sorbitan ester compositions are commonly referred to by the industry as "sorbitan monoesters.” However, these compositions typically contain only from 25 to 35% sorbitan monoester. As discussed below, Applicants' use of the term "sorbitan monoester” refers to compositions containing sorbitan monoesters at levels greater than those described in the prior .art.
• compositions of the present invention also preferably contain relatively low levels of the deleterious isosorbide esters (which .are ⁇ -tending).
• the improved emulsifier system of the present invention can be used to reduce the level of emulsifier needed in the dehydration process, in particular, the amount of emulsifier needed as a processing aid in the drum drying operation. This reduces the cost of raw materials, as well as the potential for formation of off-flavors due to oxidation.
• the level of emulsifier in the dehydrated starch ingredients may be decreased. This allows the formulator to increase the level of other sources of triglycerides and still provide the reduced level of fat in the finished product necessary in most territories to make the fat-free claim.
• compositions of the present invention are useful in any application where an emulsifier is employed.
• emulsifiers include, by way of example only, cosmetics, hard surface cleaners, shampoos and other personal cleaning products, lotions, fabric softeners, and pharmaceuticals.
• the present invention is directed to emulsifier compositions comprising a sorbitan component containing relatively high levels of sorbitan monoesters and relatively low levels of isosorbide esters.
• the compositions comprise a sorbitan component, wherein the sorbitan component comprises at least about 50%, by weight, sorbitan monoesters and no more than about 10%, by weight, isosorbide esters.
• reference to the weight percent of a given sorbitan entity e.g., sorbitan monoester, sorbitan diester, isosorbide
• the total weight of the sorbitan component which is defined below
• the present invention is directed to compositions comprising a sorbitan component, wherein the sorbitan component comprises at least about 50%, by weight, of sorbitan monoesters and wherein not more than about 50% of the sorbitan positional isomers is the 1,4 positional isomer.
• the present invention is directed to an improved emulsifier system for making various food products including, but not limited to, dehydrated starch ingredients, wherein the emulsifier system comprises a sorbitan component, wherein the sorbitan component comprises at least about 50%, by weight, of sorbitan monoesters.
• Other applications include baked goods, confectionaries, sauces, cereals, etc.
• the present invention is directed to a process for making dehydrated starch ingredients. In one particul.ar embodiment, the process is directed to the production of dehydrated potato ingredients. The process comprises the steps of:
• step (e) adding an emulsifier system anytime prior to formation of the dehydrated potato ingredients in step (c); wherein the emulsifier system comprises a sorbitan monoester or a mixture of sorbitan monoesters.
• the invention relates to dehydrated potato ingredients comprising a sorbitan monoester or a mixture of sorbit.an monoesters.
• the invention relates to a dough composition
• a dough composition comprising:
• the invention relates to a food product comprising these dehydrated starch ingredients.
• the invention relates to a composition
• a composition comprising an emulsifier system comprising a sorbitan component, wherein the sorbitan component comprises at least about 50%, by weight, sorbitan monoesters and no more than about 10%, by weight, isosorbide esters.
• the term "added water” refers to water that has been added to the composition being discussed. Thus, for example, water that is inherently present in the dry dough ingredients, such as in the case of the sources of flour and starches, is not included in the term added water.
• alpha-stable or " ⁇ -stable” means a material such as an emulsifier having the ability to remain in the ⁇ crystalline polymorph. It is common for emulsifiers to transition from to ⁇ ' and subsequently to the ⁇ crystalline polymorph. Alpha-stable emulsifiers are desirable herein because of their higher emulsification functionality.
• centipoise centipoise
• dehydrated starch ingredient refers to dehydrated potato products, dehydrated wheat product, dehydrated rice products, dehydrated corn products, and dehydrated tapioca products. These ingredients may be in the form of flakes, flanules, granules, slivers, nubbins, powder, flour, particles, or other pieces.
• diacetylated tartaric acid esters of monoglycerides and “DATEM” each refer to the mixture of products resulting from the reaction of diacetylated tartaric acid anhydride with monoglycerides. ' This reaction forms a complex mixture of various components, the most prevalent being diacetyl tartaric acid esters of monoglycerides (DATEM I), di-(diacetyl tartaric acid) esters of monoglycerides (DATEM II), diacetyl tartaric acid esters of diglycerides (DATEM HI) and monoacetyl mono (diacetyl tartaric acid) esters of monoglycerides (DATEM TV). See Danisco Ingredients Technical Paper TP2-le, available fromDanisco Cultor (New Century, KS).
• diglycerol monoesters and "DGME” each refers to a preferred type of polyglycerol monoester that may be used in the present invention.
• DGMEs are polymers of two glycerol units having one fatty acid esterified on the diglycerol backbone.
• Particularly preferred diglycerols are those esterified with palmitic, oleic, or stearic fatty acids, or a mixture of intermediate melting fatty acids.
• dispersion refers to an emulsifier system that exists as a colloidal system in water. These systems include dilute lamella liquid crystal, hexagonal, crystalline and mixed crystalline phases.
• stable dispersion refers to a dispersion that exists for at least 5 minutes at the temperature in question. The method for determining whether an emulsifier system exists as a stable dispersion is described in the Analytical Methods section of co-pending U.S. Application Serial No. 09/965,113, filed September 26, 2001 by P. Lin et al.
• the term “dough emulsifier” means an emulsifier or emulsifiers that are added during the dough making process in addition to the emulsifier(s) present in the dehydrated starch ingredients utilized.
• the term “flour blend” refers to a mixture of all dough ingredients, excluding the water. The “flour blend” includes all dry ingredients, as well as any other ingredients such as liquid emulsifier.
• free polyol refers to the portion of unesterified sorbitol, sorbitan and isosorbide in a given composition.
• intermediate melting and "IM" each mean esters formed from a mixture of fatty acids that are liquid and fatty acids that are solid at room temperature.
• fatty acid mixtures include, for example, mixtures of palmitic, oleic, linoleic, linolenic, stearic and other Ci 8 trans fatty acids. Partial hydrogenation is one way to produce IM fatty acid esters.
• lecithin includes conventional acetylated lecithins, hydroxylated lecithins, hydrogenated and partially hydrogenated lecithins and other suitable lecithin or lecithin-like compounds such as de-oiled lecithin, lysolecithins, egg lecithins, egg yolk powder, phosphotidyl choline enriched lecithin, phosphatidic acid and its salts, lysophosphatidic acid and its salts, and phospholated monoglycerides and any mixture thereof. Also suitable are lecithins blended with other emulsifiers, e.g., CentroMix®E from Central Soya, Ft. Wayne, IN, which is a blend of lecithin and Tween.
• emulsifiers e.g., CentroMix®E from Central Soya, Ft. Wayne, IN, which is a blend of lecithin and Tween.
• moisture means the total amount of water present in the material being discussed. With respect to doughs, “moisture” includes the water inherently present as well as any water that is added to the dough ingredients.
• monoglyceride refers to a mixture of glycerides (mono-, di-, and triglycerides) where at least 80% of the glycerol backbones are esterified with one fatty acid.
• Monoglyceride can be made by the reaction of glycerin with triglyceride (i.e., glycerolysis) to produce mono-, di- and triglycerides.
• the desired monoglyceride content is typically achieved by molecular distillation of the above described reaction mixture.
• monoglyceride can be made by an enzymatic process.
• mono-diglyceride refers to a mixture of glycerides where from about 30% to about 60% of the glycerol backbones are esterified with one fatty acid.
• Mono-diglyceride can be made by the reaction of glycerine with triglyceride (i.e., glycerolysis) to produce mono-, di- and triglycerides.
• polyglycerol ester and “PGE” are used interchangeably and each mean a polyglycerol ester having a polyglycerol backbone comprising from 2 to about 10 glycerol units, wherein not more than about 40% of the hydroxyl groups of the polyglycerol ester are esterified with fatty acids.
• PGEs PGEs
• psig pounds per square inch gauge
• sheetable dough means a dough capable of being placed on a smooth surface and rolled to the desired final thickness without tearing or forming holes.
• sorbitan refers to the various positional isomers of etherified sorbitol having one ring. There are several sorbitan positional isomers, including the most commonly occurring isomers l,4-.anhydro-D-glucitol, 1,5-anhydro-D-glucitol, 2,5-anhydro-D-mannitol, 2,5-anhydro- D-iditol, and 3,6-anhydro-D-glucitol.
• sorbitan component refers collectively to sorbitol and esters thereof (mono-, di-, tri-, tetra-, penta- and hexaesters), sorbitan and esters thereof (mono-, di-, tri-, and tetraesters) and isosorbide and esters thereof (mono- and diesters).
• a method for determining the sorbitan component of a sample is described in the Analytical Methods section below.
• sorbitan monoester refers collectively to any sorbitan positional isomer with one fatty acid esterified to one free hydroxyl group. It is understood that there are numerous ester isomers for a given sorbitan positional isomer (dictated by which free hydroxyl group is esterified). A method for determining the sorbitan monoester content of a sorbitan component is described in the Analytical Methods section below.
• starch and "modified starch” have the meanings set forth in co-pending U.S. Application Serial No. 09/965,113, filed September 26, 2001 by P. Lin et al.
• sorbitan monoesters are typically not obtainable in pure form (i.e., are not a single sorbitan ester), and are usually mixtures of different esters. This results from the manner in which the sorbitan monoesters are prepared. For that reason, when types of molecules are mentioned herein, it is meant that the material referred to is "predominantly" that material.
• an emulsifier referred to as sorbitan monooleate will include that material as a significant component, but will often also include other sorbitan esters with higher degrees of esterification (e.g., di- to tetra esters), esters with other fatty acid residues (e.g., stearate), as well as unesterified sorbitan. Further, there will be unreacted sorbitol (CH 2 OH)-(CHOH) CH 2 OH, the linear precursor to sorbitan), isosorbide (bicyclic side product) and esters thereof, and other "impurities" as well, as will be understood and appreciated by one of skill in the art.
• sorbitan monooleate will include that material as a significant component, but will often also include other sorbitan esters with higher degrees of esterification (e.g., di- to tetra esters), esters with other fatty acid residues (e.g., stearate), as well as unesterified
• compositions of the present invention will comprise a sorbitan component wherein at least about 50%, by total weight of the sorbitan component, is sorbitan monoester(s). As indicated above, this level of sorbitan monoester is greater than the levels in current sorbitan compositions.
• the compositions of the present invention can be made by either further purifying commercial sorbitan compositions, or by controlling the synthesis of the sorbitan starting with sorbitol.
• the composition will comprise a sorbitan component wherein at least about 60%, by total weight, of the component is sorbitan monoester(s).
• the composition will comprise a sorbitan component wherein at least about 70%, by weight, of the component is sorbitan monoester(s).
• the composition will comprise a sorbitan component comprising from about 50% to about 98%, by total weight, sorbitan monoester(s).
• the composition's sorbitan component will comprise not more than about 10%, by weight, isosorbide esters.
• the sorbitan component will comprise not more than about 7%, still more typically not more than about 4%, isosorbide esters.
• the sorbitan component contains a mixture of the monoesters of the various sorbitan positional isomers.
• monoesters of a mixture of sorbitan positional isomers leads to polymorphic behavior that is alpha-tending and perhaps alpha-stable. Alpha-tendency and alpha-stability result in more highly functional emulsifiers, particularly at relatively high temperatures.
• the sorbitan component will comprise not more than about 50%, by total weight, of a particular sorbitan positional isomer (e.g., the 1,4 positional isomer).
• the sorbitan component will comprise not more than about 40%, by total weight, of a particular sorbitan positional isomer.
• compositions useful herein will typically comprise relatively low levels of free polyol.
• the free polyol component e.g., sorbitol, sorbitan and isosorbide
• the free polyol component will constitute not more than about 20%, more typically not more than about 15%, still more typically not more than about 10%, by total weight of the sorbitan component.
• the sorbitan component of the present compositions will typically comprise not more than about 20%, more typically not more than about 12%, by weight, sorbitol esters.
• the sorbitan component of the composition will typically contain not more than about 30% sorbitan diesters. In another aspect, the sorbitan component will contain not more than about 20% sorbitan diesters. In yet another aspect, the sorbitan component will contain not more than about 10% sorbitan diesters. In another aspect, the sorbitan component will contain not more than about 30% sorbitan tri- and tetraesters. In another aspect, the sorbitan component will contain not more than about 20% sorbitan tri- and tetraesters. In yet another aspect, the sorbitan component will comprise not more than about 10% sorbitan tri- and tetraesters.
• the nature of the fatty acid moieties esterified to a hydi'oxyl group of a given sorbitan will depend in part on the end use of the composition.
• the sorbitan monoester containing composition will be utilized in making dehydrated ingredients
• the sorbitan monoester will typically be esterified with at least about 80%, more typically at least about 90%, and most typically at least about 95%, saturated fatty acids.
• the sorbitan monoester will typically comprise less than about 20%, more typically less than about 10%, and most typically less than about 5%, by weight, unsaturated cis and trans fatty acids.
• Preferred fatty acids include C 12 , C ⁇ 4 , Ci6, C 18 , C 2 o, and C22 fatty acids. It is preferred that the sorbitan monoesters used herein be esterified with fatty acids chosen from oleic, palmitic and stearic acids; however, fatty acids may range from C12-C22, and may be saturated or unsaturated. In general, in order to avoid any oxidation issues, in certain applications it may be desirable to minimize the level of unsaturated fatty acid esters.
• preferred fatty acids include C 1 0, C 12 , C ⁇ 4) Ci ⁇ , C ⁇ 8 , C 2 o, and C 22 fatty acids. It is preferred that the sorbitan monoesters used herein be esterified with fatty acids chosen from oleic, palmitic and stearic acids; however, fatty acids may range from C 10 -C 22 , and may be saturated or unsaturated.
• sorbitan monoesters for use in the emulsifier system described herein: sorbitan monopalmitate, sorbitan monostearate, sorbitan monooleate, sorbitan monomyristate, sorbitan monolaurate, and sorbitan monocaprylate.
• the present invention is directed to an improved emulsifier system for making various food products including but not limited to dehydrated starch ingredients, wherein the emulsifier system comprises at least about 50%, by weight, of sorbitan monoesters.
• Other applications include baked goods, confectionaries, sauces, cereals, etc.
• compositions of the present invention can include sorbitan monoesters as the key emulsifier component
• the compositions can include other known, functional emulsifiers.
• DATEM diacetyl tartaric acid ester monoglyceride
• DATEM is a monoglyceride (having an esterified fatty acid ranging from 12 to about 22 carbon atoms) that is esterified with diacetyl tartaric acid.
• compositions can also include polyglycerol esters such as those described in U.S. Serial No. 09/965,113, filed September 26, 2001; lactic acid esters of mono and diglycerides, (e.g., Grinsted® Lactam, available from Danisco (Kansas City, KS)); acetic acid esters of mono and diglycerides (e.g., Grinsted® Lactam, available from Danisco); or ethoxylated esters of mono and diglycerides.
• the compositions can comprise mixtures of one or more of these materials together with the sorbitan monoester.
• the emulsifier system of the present invention may include only one or a combination of sorbitan monoesters, it is possible to replace some portion of those emulsifiers with one or more other emulsifiers (including those having relatively lower functionality) and still provide an overall system that exhibits the desired functionality under relevant conditions. This is important because certain emulsifiers are relatively expensive. Accordingly, it may be desirable to have a portion of the emulsifier system comprised of other emulsifiers, so long as the desired functionality of the emulsifier system is maintained.
• the ability to use other emulsifiers with the sorbitan monoester(s) and the relative amount of that use will be dictated by several factors, including the functionality of the other emulsifier(s) used.
• a 'highly functional' sorbitan monoester e.g. a sorbitan monopalmitate
• the sorbitan monoester(s) can be blended with monoglyceride or mono-diglyceride that is currently used (at relatively high levels) in the dehydration process.
• the monoglyceride is derived from, for example, hydrogenated or partially hydrogenated soybean oil, rapeseed oil, cottonseed oil, sunflower seed oil, palm oil, palm olein, safflower oil, corn oil, peanut oil, palm stearin, tallow, lard and mixtures thereof.
• hydrogenated or partially hydrogenated monoglycerides ensures oxidative stability.
• preferred emulsifier systems comprise from about 40% to about 99% sorbitan monoester(s) and from about 60% to about 1% monoglyceride; typically, such a blend will comprise from about 40% to about 60% sorbitan monoester(s) and from about 60% to about 40% monoglyceride.
• the sorbitan monoester(s) can be blended with a lecithin to provide an emulsifier system useful herein.
• a preferred emulsifier system comprises not more than about 75%, and most preferably from about 1% to about 25%, of a lecithin, and at least about 25%, most preferably from about 75% to about 99%, of the sorbtian ester component.
• the sorbitan monoester(s) can be blended with a polysorbate (polyoxyethylene sorbitan esters) to provide an emulsifier system useful herein, hi this regard, a preferred emulsifier system comprises not more than about 75%, and most preferably from about 1% to about 25%, of a polysorbate, and at least about 25%, most preferably from about 75% to about 99%, of the sorbitan component.
• a polysorbate polyoxyethylene sorbitan esters
• the invention relates to an improved emulsifier system useful in making dehydrated starch ingredients, wherein the emulsifier system exists as a stable dispersion at a temperature of at least about 80°C.
• the emulsifier system exists as a stable dispersion at a temperature of at least about 80°C.
• saturated monoglycerides exist predominantly in the cubic plus water phase, which is a relatively low functional phase.
• conventional emulsifier systems do not exist as a stable dispersion at temperatures of about 80°C or higher.
• emulsifier systems that provide the desired dispersibility under dehydration conditions (i.e., exist as a stable dispersion at a temperature of at least about 80°C). These emulsifier systems will typically contain at least one emulsifier that itself exists as a stable dispersion. While a given emulsifier system may contain only an emulsifier (or combination of emulsifiers) having those physical properties, it is possible to combine one or more such emulsifiers with other emulsifiers that themselves do not exhibit the desired dispersed phase at a temperature of about 80°C. In general, based on Applicants' discovery and the present disclosure, one can readily select useful emulsifiers based on their ability to form the desired dispersion (as measured according to the Analytical Method section of co-pending U.S.
• Sorbitan ester (commercial quality) is typically obtained by simultaneous anhydration (also referred to as etherification) .and esterification of sorbitol directly with fatty acids. By simultaneously etherifying and esterifying, it is possible to avoid undesirably high concentrations of the 1,4 positional isomer.
• Such a method of sorbitan ester preparation is described more fully in MacDonald, "Emulsifiers: Processing and Quality Control", Journal of the American Oil Chemists' Society, Volume 45, October, 1968.
• the commercial sorbitan ester prepared by the above process is molecular distilled to enrich the sorbitan monoester content.
• isosorbide esters it is preferred that the process of esterification and anhydration be monitored to determine when the sorbitol has been converted to sorbitan such that the reaction can be terminated (neutralization of the catalyst) prior to formation of the bicyclic isosorbide. Additionally, isosorbide ester levels can be further reduced by steam stripping under reduced pressure or molecular distillation
• Sorbitan monoesters according to this invention can be prepared using Glycomul®-S, a commercial sorbitan monoester obtained from Lonza Group, Fairlawn, NJ. (this emulsifier comprises 25% sorbitan monoester and less than 15% isosorbide esters; less than 40% 1,4 sorbitan isomers), as a starting material.
• the predominant portion of the isosorbide esters, along with the free fatty acids, are removed by steam stripping using conventional shortening/oil deodorization equipment.
• the level of free fatty acid is typically less than 0.5% and the isosorbide ester content is typically less than 3%.
• the deodorized sorbitan ester (reduced isosorbide content) can be fractionally distilled, for example using a CMS -15A centrifugal molecular still (CVC Products, Inc., Rochester, NY) using multiple passes.
• CMS -15A centrifugal molecular still CVC Products, Inc., Rochester, NY
• the following conditions are suitable for sorbitan esters containing palmitic, stearic and oleic fatty acids:
• Rotor feed Gradually increased from 130 - 190°C during the consecutive passes Rotor Residue temperature 140-220°C
• distillate fractions are collected on the surface of the bell jar that is heated to facilitate removal. Distillate and residue are continuously removed by transfer pumps. The fractionation process is monitored by differential scanning calorimetry (DSC), HPLC, and refractive index determinations.
• DSC differential scanning calorimetry
• sorbitan components having high levels of sorbitan monoester can be synthesized from sorbitol and fatty acids using esterification followed by etherification. This synthesis results in low levels of isosorbide and their esters and low levels of 1,4 sorbitan positional isomers.
• This process is conducted in a stainless steel reactor equipped with a mechanical agitator, heating and cooling coils, a condenser, and an electric heating jacket.
• the reactor is charged with sorbitol (e.g., 70%), oleic acid (e.g., Panmolyn 100, Hercules), and NaOH (e.g., 50%) as the esterification catalyst.
• sorbitol e.g., 70%
• oleic acid e.g., Panmolyn 100, Hercules
• NaOH e.g. 50%
• the temperature is reduced to 170°C and phosphoric acid (e.g., 70%) is added to the reactor to initiate the etherification process. A slight amount of water is used to wash all phosphoric acid into the reactor. The temperature is gradually increased to 220°C for the etherification process. Etherification is conducted until most of the sorbitol esters are converted to sorbitan esters and no significant level of isosorbide esters are formed.
• phosphoric acid e.g. 70%
• the free fatty acid level in the reaction mixture is determined by titration with base.
• the etherification endpoint is determined by HPLC according to the Test Methods section below.
• the reaction mixture is molecule distilled (according to Section IIIA, above) to produce a sorbitan component with greater than 50% sorbitan monoesters. Because deodorization has already been carried out during synthesis, distillation can be carried out without additional deodorization.
• sorbitan monoester enrichment may be accomplished using solvent crystal fractionation procedures on crude mixtures.
• a crude mixture containing sorbitan, sorbitol and isosorbide mixed esters of fatty acids is added to polar solvents, such as methanol or ethanol, at a temperature above the final melting point of the mixture.
• polar solvents such as methanol or ethanol
• the mixture is cooled (e.g., to 0-10°C) and filtered.
• the filtrate will contain relatively higher concentrations of sorbitan monoester.
• the crystals or filter cake will contain higher levels of isosorbide esters, sorbitan diesters, and sorbitan triesters. This process can be repeated to further enhance the concentration of sorbitan monoester.
• sorbitan monoesters are highly functional and therefore compositions containing relatively high levels of these monoesters are useful in emulsifier systems for various purposes.
• the present invention is directed in one respect to a process for making dehydrated starch ingredients.
• the process is particularly suitable for making dehydrated potato ingredients.
• saturated monoglycerides are currently used exclusively in the starch dehydration industry. Under the high temperature (typically between 80 and 95°C) and high moisture (greater than 50% moisture) dehydration conditions generally utilized, saturated monoglycerides exist predominantly in the cubic plus water phase, which is a relatively low functional phase. To compensate for their relatively low functionality under typical dehydration conditions, saturated monoglycerides are typically used at levels of approximately 0.3 to 0.5%, by weight of the resulting dehydrated starch ingredients normalized to 0% moisture content.
• compositions containing relatively high levels of the sorbitan monoesters described herein are sufficiently functional in the range of from about 0.005 to about 0.2%, by weight of the resulting dehydrated starch ingredients normalized to 0% moisture content, in the dehydration process. Accordingly, a benefit of utilizing emulsifiers having relatively high levels of sorbitan monoesters is the ability of a formulator of raw materials to reduce the level of the emulsifier needed as a processing aid in the drum drying operation. This reduces the cost of raw materials and also reduces the potential for the formation of off- flavors due to oxidation.
• the end producer can use other sources of triglycerides while still providing a low-fat food and while meeting the regulatory requirements in many geographies to label the food as "fat free.”
• the process of the present invention will be described emphasizing the preparation of dehydrated potato flakes. This is by way of illustration and not limitation.
• the process of the present invention is generally applicable to the preparation of dehydrated vegetables (e.g., potatoes, sweet potatoes, beets, spinach, onion, carrots, celery, pumpkin, tomatoes, zucchini, broccoli, mushrooms, peas); grains such as corn products (e.g., masa), barley, oats, rye, wheat, rice, amaranth, sago and cassava; and the like.
• the present invention is also applicable in producing flakes that can be used in baby foods.
• the process of the present invention can also be applied for other starch containing materials such as glues and pharmaceutical materials.
• any commercially available potatoes used to prepare conventional potato ingredients such as flakes, flanules or granules can be used to prepare the dehydrated potato ingredients of the present invention.
• the dehydrated ingredients are prepared from potatoes such as, but not limited to, Norchip, Norgold, Russet Burbank, Lady Russeta, Norkota, Sebago, Bentgie, Aurora, Saturna, Kinnebec, Idaho Russet, and Mentor.
• potatoes such as, but not limited to, Norchip, Norgold, Russet Burbank, Lady Russeta, Norkota, Sebago, Bentgie, Aurora, Saturna, Kinnebec, Idaho Russet, and Mentor.
• Any of a variety of potato pieces includes potato by-products, e.g. slivers, slices nubbins, or slabs) can be used in the practice of the present invention.
• the potato pieces are pre-conditioned.
• preconditioned refers to treatments such as blanching and cooling, which causes the potato cells to toughen.
• Co-pending U.S. Application Serial No. 09/965,113 filed September 26, 2001 by P. Lin et al., describes the production of dehydrated potato ingredients using polyglycerol esters. The conditions described therein (see in particular page 13, line 5 to page 17, line 8) are also useful in preparing dehydrated potato ingredients in accordance with the present invention.
• the emulsifier system of the present invention can be added during or between the cooking, mashing and drying steps, or any combination thereof.
• the emulsifier system is combined with the cooked potatoes just prior to or during the mashing step. Additionally, the potato ingredient will exhibit the other properties set forth in U.S.S.N. 09/965,113 (see page 17, lines 9-30), other than their possessing sorbitan monoesters as a result of their preparation.
• the dehydrated potato products can be rehydrated and used to produce food products such as mashed potatoes, potato patties, potato pancakes, potato soup, and other potato snacks such as extruded French fries and potato sticks.
• food products such as mashed potatoes, potato patties, potato pancakes, potato soup, and other potato snacks such as extruded French fries and potato sticks.
• potato flakes may be coarsely ground to about 0.1-1 cm 2 .
• seasonings such as salt, pepper, onion powder, garlic powder, MSG, butter flavors, or cheese powder, may be added to the ground flakes before packaging.
• various stabilizers may be added, for example BHT and citric acid.
• the consumer prepares the mashed potatoes by adding the potato flakes to hot water containing salt, margarine and milk. The product is mixed and is ready for consumption in a few minutes.
• dehydrated starch ingredients can be used to produce extruded French fried potato products such as those described in U.S. Patent No. 3,085,020, issued April 9, 1963 to Backinger et al., and U.S. Patent No. 3,987,210, issued October 18, 1976 to Cremer.
• the dehydrated potato products can also be used in breads, gravies, sauces, or any other suitable food product.
• an especially preferred use of the dehydrated potato ingredients is in the production of fabricated chips made from a dough.
• fabricated chips include those described in U.S. Patent No. 3,998,975 issued December 21, 1976 to Liepa, U.S. Patent No. 5,464,642 issued November 7, 1995 to Villagran et al., U.S. Patent No. 5,464,643 issued November 7, 1995 to Lodge, PCT Application No. PCT/US95/07610 published January 25, 1996 as WO 96/01572 by Dawes et al., and U.S. Patent No. 5,928,700 issued July 27, 1999 to Zimmerman et al.
• U.S.S.N. 09/965,113 describes the preparation of farinaceous products from a dough.
• the application describes the dough compositions themselves, the preparation of the dough, sheeting of the dough, preparation of dough pieces and frying of the dough pieces to provide the end product.
• the skilled artisan can refer to the teachings of the '113 application, including relevant materials and ranges of incorporation, in using the dehydrated starch ingredients of the present invention.
• the sorbitan component is converted to sorbitan by saponification.
• the sorbitan is analyzed for its sorbitan isomer distribution using gas chromatography with a flame ionization detector.
• Heating stir plate CMS #267-914 capable of 160°C, or equivalent
• Sodium methoxide solution Dilute 2 mL sodium methoxide to 100 mL with methanol
• Steps 11 through 13 as many times as is necessary to obtain a clear residue. Normally this is three times.
• This residue may then be treated as a sorbitan sample and prepared for GC analysis in the same manner.
• FID flame ionization detector
• Applicants have identified, by gas chromatography/mass spectrometry (GC/MS), 11 peaks with a molecular weight of 452 (chemical ionization m/z 453), that corresponds to the molecular weight of fully silylated sorbitan.
• GC/MS gas chromatography/mass spectrometry
• the FID areas of these peaks are integrated and the results are normalized to the total area of the 11 peaks.
• Table 1 below shows retention times and normalized area % for a composition of the present invention.
• NMR data are used along with MS data to identify 1,4-anhydro-D- glucitol, a peak of primary interest.
• Two other peaks (2,5-anhydro-D-mannitol and 1,5-anhydro- D-glucitol) are confirmed with commercially available standards from the electron ionization (El) fragmentation patterns and GC retention times.
• Two other peaks (3,6-anhydro-D-glucitol and 2,5-anhydro-L-iditol) are tentatively identified from their El mass spectra and from MS/MS spectra of protonated sorbitans. The remaining relevant peaks are not typically identified. (It will be recognized that there will be additional, non-sorbitan peaks in the chromatogram that are not relevant to this analysis.)
• Free polyol and fatty acid esters of sorbitol, sorbitan and isosorbide are separated by gradient elution (water: acetone:methylene chloride) on two Beckman ODS columns.
• An evaporative light scattering detector is used for eluent detection.
• Elution order is first by class with unesterified polyols eluting first followed by sorbitol monoesters, sorbitan monoesters and isosorbide monoesters. Analytes with a higher degree of esterification elute after the monoesters and in the same backbone order. Within classes, analytes elute in order of increasing carbon number (acyl chain length).
• the detector response for unesterified polyols is lower than the detector response for sorbitan esters. Therefore, to compensate for these differences, percent free polyol per sample is determined using an external sorbitol calibration curve.
• step 4 to prepare a 3:50, 5:50, 7:50, and 9:50 dilution of sorbitol stock.
• Reservoir A contains water
• reservoir B contains methylene chloride
• reservoir C contains acetone.
• the sorbitol peak is integrated to provide the total sorbitol peak area. Peak areas (dependent variable) are then plotted against the total amounts of sorbitol injected in grains (independent variable) to create the external sorbitol calibration curve.
• Percent free polyol free polyol peaks are integrated and summed to provide the total free polyol peak area. The total free polyol peak area is then used to determine the total amount of free polyol injected based on the external sorbitol calibration curve.
• the total amount of sample injected is calculated by multiplying the concentration of the sample solution (in g/lOOmL) by the injection volume (in mL).
• Percent free polyol (% free polyol) is then determined by dividing the amount of free polyol injected by the total amount of sample injected, and multiplying the quotient by 100.
• Percent sorbitan monoesters all sorbitol ester, sorbitan ester and isosorbide ester component peaks in the resulting LC chromatogram are integrated and summed to provide the total ester component peak area. (Ester component peaks are identified by LC/MS or by LC retention time of standards.) Sorbitan monoester peaks are integrated and summed to provide the total sorbitan monoester peak area.
• Percent sorbitan monoester is dete ⁇ nined by dividing the total sorbitan monoester peak area by the total ester component peak area and multiplying by the difference between 100 and the percent free polyol. See equation below:
• Percent isosorbide esters isosorbide ester peaks are integrated and summed to provide the total isosorbide ester peak area. Percent isosorbide esters (%ISE) is dete ⁇ nined by dividing the total isosorbide ester peak area by the total ester component peak area and multiplying by the difference between 100 and the Percent free polyol. See equation below.
• Aqueous dispersion characterization is performed in accordance with the method described in Section V-Analytical Methods of co-pending U.S. Application Serial No. 09/965,113, filed September 26, 2001 by P. Lin et al.
• An improved emulsifier containing a sorbitan component having a high level of sorbitan monoester (hereafter referred to as ' ⁇ mulsifier-1”) has the following composition: Ester Composition 82% Sorbitan Monoester 2% Sorbitan diester 14% Sorbitan 1% Isosorbide monoester
• Fatty Acid Composition 88% Palmitic Acid 11% Stearic Acid 1% Other fatty acids
• the material is prepared by taking Glycomul®-P and applying the following two enrichment steps.
• the predominant portion of the isosorbide esters, along with the free fatty acids, are removed by steam stripping using conventional shortening/oil deodorization equipment and the following conditions:
• the level of free fatty acid is less than 0.3% and the isosorbide ester content is less than 1%.
• the deodorized sorbitan ester is fractionally distilled using a CMS -15 A centrifugal molecular still (CVC Products, Inc., Rochester, N.Y.) using 5 passes. The following conditions are used:
• distillate fractions are collected on the surface of the bell jar that is heated to facilitate removal. Distillate and residue are continuously removed by transfer pumps. The fractionation process is monitored by differential scanning calorimetry (DSC), HPLC, and refractive index determinations.
• DSC differential scanning calorimetry
• Example 2 An improved emulsifier containing a sorbitan component having a high level of sorbitan monoester (hereafter referred to as "Emulsifier-2”) has the following composition: Ester Composition 70% Sorbitan Monoester 9% Sorbitan diester 1% Sorbitan triester 15% Sorbitan 5% Isosorbide monoester
• Fatty Acid Composition 86% Palmitic Acid 13% Stearic Acid 1% Other fatty acids
• the material is prepared according to the enrichment procedure described in Example 1.
• An improved emulsifier containing a sorbitan component having a high level of sorbitan monoester has the following composition: Ester Composition 60% Sorbitan monoester 15% Sorbitan diester 17% Free polyol (2% Isosorbide) Fatty Acid Composition 90% Palmitic Acid 8% Stearic Acid 2% Other fatty acids The material is prepared according to the enrichment procedure described in Example 1.
• Example 4 An improved emulsifier containing a sorbitan component having a high level of sorbitan monoester (hereafter referred to as "Emulsifier-4”) has the following composition:
• the temperature is reduced to 170°C and 70g of phosphoric acid (70%) is added to the reactor to initiate the etherification process. A slight .amount of water is used to wash all phosphoric acid into the reactor. The temperature is gradually increased to 220°C for the etherification process. Etherification is conducted until most of the sorbitol esters are converted to sorbitan esters and no significant level of isosorbide esters are formed.
• the free fatty acid level in the reaction mixture is dete ⁇ nined by titration with base.
• the etherification endpoint is determined by HPLC according to the Test Methods section.
• reaction mixture is molecular distilled (according to Section JJIA) to produce sorbitan component with greater than 50% sorbitan monoesters. Because deodorization has already been carried out during synthesis, distillation can occur without additional deodorization. Examples 5-7
• a mixture of 66% Russet Burbank and 34% Norkota potatoes having an overall solids level of about 20% and reducing sugars of about 1.6% are washed in room temperature water to remove dirt and any foreign materials.
• the potatoes are then steam-peeled and cut into 0.625 in. (1.59 cm) thick slices.
• the slices are then cooked for 30 minutes at a steam pressure of 38-40 psig.
• the cooked potato slices are then shredded and mashed as they are forced through a die plate.
• Emulsifier is added to the potato mash in the form of a 5% aqueous dispersion as outlined in the table below.
• the potato mash is mixed with the dispersion as it is fed through an augur and distributed to two single drum dryers.
• the potato mash is spread onto the drying drum with four applicator rolls, forming a thin sheet layer of 0.005-0.008 in. (0.013 to 0.020 cm).
• the drum is rotated at approximately 14-16 s/rev. This results in a dehydrated potato sheet having a moisture content of 7-8%, which is removed from the drum by a doctor knife.
• DATEM PanodanTM 205, a commercially available DATEM made by Danisco Cultor (New Century, KS). It has the following fatty acid composition:
• Dimodan® PVP a commercial distilled monoglyceride available from Danisco
• UltraLec®F is a deoiled, ultrafiltered soybean lecithin available from ADM, Decatur,
• Example A A dough composition is prepared that comprises 35% water, 3% dough emulsifier*, and 62% of the following mixture of ingredients:
• Aldo® DO The dough emulsifier used in the preparation of the dough is Aldo® DO, which is available from Lonza Group, Fairlawn, NJ.
• Aldo® DO comprises monoglycerides, diglycerides, and triglycerides with the following composition:
• the potato flakes, potato flanules, corn meal, wheat starch, and maltodextrin are mixed together in a blender. (Alternatively, the maltodextrin may be dissolved in the water before being added to the dough.)
• the emulsifier is heated to produce a homogeneous liquid. Using a dough mixer the emulsifier is added to the dry mixture followed by water (or water plus maltodextrin) to form a loose, dry dough.
• the dough is sheeted by continuously feeding it through a pair of sheeting rolls, forming an elastic continuous sheet without pinholes. Sheet thickness is controlled to about 0.02 in. (0.051 cm).
• the dough sheet is then cut into oval shaped pieces and fried in a constrained frying mold at 375°F (191°C) for about 6 seconds to make a finished product.
• the frying oil is NuSunTM oil.
• NuSunTM oil is a mid-oleic sunflower oil that is commercially available from ADM (Decatur, IL).
• Example B A dough composition is prepared as in Example A, wherein the dough emulsifier is a di- triglycerol monoester.
• This dough PGE referred to as 2,3-1-0, is a developmental sample from Lonza Group (Fairlawn, NJ).
• This PGE (2,3-1-0) has the following composition:
• a dough composition is prepared as in Example A, where the flakes and dough emulsifier blend are specified in the following table:
• NuSunTM oil is a mid-oleic sunflower oil that is commercially available from ADM (Decatur, IL).
• UltraLec® F is a deoiled, ultrafiltered soybean lecithin that is commercially available from ADM (Decatur, IL). Examples K-R
• a dough composition is prepared as in Example A, where the flakes and dough emulsifier blend are specified in the following table:
• Span 80TM is a commercial sorbitan ester available fromUniqema (Wilmington, DE).
• PanodanTM SD is a DATEM available from Danisco Cultor, New Century, KS and has the following composition:
• Example S-Z A dough composition is prepared as in Example A, where the flakes and dough emulsifier blend are specified in the following table:
• dough emulsifier blends are used to prepare fat-free fabricated chips.
• the lecithin component is a commercial lecithin, UltraLec® P, available from ADM, Decatur, IL.
• the PGE a mixture of di- and triglycerol mono- and diesters of IM fatty acids, is a developmental sample from Lonza Group, Fairlawn, NJ. This PGE has the following composition:
• Dough compositions are prepared using the potato flakes prepared in Example 5. Each dough composition comprises 35% water, 3% dough emulsifier, and 62% of the following mixture of ingredients:
• the potato flakes, potato flanules, modified starches, and maltodextrin are mixed together in a blender. (Alternatively, the maltodextrin may be dissolved in the water before being added to the dough.)
• the emulsifier is heated to produce a homogeneous liquid. Using a dough mixer the emulsifier is added to the dry mixture followed by water (or water plus maltodextrin) to form a loose, dry dough.
• the dough is sheeted by continuously feeding it through a pair of sheeting rolls, forming an elastic continuous sheet without pinholes. Sheet thickness is controlled to about 0.02 in. (0.051 cm).
• the dough sheet is then cut into oval shaped pieces and fried in a constrained frying mold in Olean® at 375°F (191°C) for about 6 seconds to make a finished product.
• a dough composition is prepared as in Example A, wherein the dough emulsifier is a 50:50 mixture of triglyceride oil (NuSunTM oil, described above) and 2-1-O, a DGME available from Danisco Cultor (New Century, KS) having the following composition:
• a dough composition is prepared that comprises 35% water, 3% dough emulsifier*, and 62% of the following mixture of ingredients:
• the dough emulsifier used in the preparation of the dough comprises Emulsifier 4.
• the potato flakes, potato flanules, corn meal, wheat starch, and maltodextrin are mixed together in a blender. (Alternatively, the maltodextrin may be dissolved in the water before being added to the dough.)
• the emulsifier is heated to produce a homogeneous liquid. Using a dough mixer the emulsifier is added to the dry mixture followed by water (or water plus maltodextrin) to form a loose, dry dough.
• the dough is sheeted by continuously feeding it through a pair of sheeting rolls, forming an elastic continuous sheet without pinholes. Sheet thickness is controlled to about 0.02 in. (0.051 cm).
• the dough sheet is then cut into oval shaped pieces and fried in a constrained frying mold at 375°F (191°C) for about 6 seconds to make a finished product.
• the frying oil is NuSunTM oil.
• NuSunTM oil is a mid-oleic sunflower oil that is commercially available from ADM (Decatur, IL).
• Example AE A mashed potato is made with the following composition:
• a decorative frosting for cakes and pastries is made with the following ingredients.
• the dry ingredients (sucrose, corn syrup solids, salt, sodium carboxymethyl cellulose, and sodium citrate) are mixed and added to a solution of methyl ethyl cellulose and water.
• the temperature is raised to 50°C.
• the fat and the emulsifier system (Tween 60 plus sorbitan monoester) are melted together and the homogeneous mixture is blended with the aqueous mixture with stirring.
• the final composition is pasteurized, homogenized at a total of 1,500 psi and frozen.
• a microwave cake mix is prepared as follows.
• An emulsifier-shortening blend is prepared by warming soybean oil to a temperature of about 79°C.
• An emulsifier blend (monoglyceride, propylene glycol monoesters of palm oil, lactic acid esters of monoglyceride and sorbitan ester) is added to the heated oil.
• a cake mix is prepared by combining the following ingredients.
• the sugar and flour are co-milled as described in U.S. Patent No. 3,694,230, to Cooke.
• the co-milled sugar and flour are then added with the shortening and the remaining ingredients in a ribbon blender.
• the dry mix (460 g) is then mixed with 144 g eggs, 55 g oil, and 320 g water to make a batter.
• the mixing time is for 2 minutes at 850 rpm with a portable mixer.
• the batter has a density of 0.85 g/cc and a viscosity of 5800 cp (at 21°C).
• the batter is then baked in a microwave oven (preferably with a carousel) in a Pyrex bowl for 11.5 minutes using 500 watts power.
• a cake having a good grain and texture is prepared.
• 109.4 g of the emulsion is blended in a home mixer running at high speed with 278.7 g of ice water, 93.9 g nonfat milk solids, and 105.0 g of sucrose for about 2 minutes.
• the resulting aerated mixture has an overrun of about 75%.
• the aerated mixture is then placed in a freezing compartment at a temperature of about -18°C for about 5 hours.
• the resulting product is a frozen dessert that has a density of about 0.62 g/cc and had good texture and appearance.
• a cake mix is prepared as follows:
• the shortening composition is:
• the sugar and flour are co-milled together using the method described in U.S. Pat. No. 3,694,230.
• the shortening is prepared by mixing the propylene glycol monoester and the sorbitan component at a temperature of about 71°C. This mixture is then added to the remaining ingredients in the shortening. The polyol is allowed to settle out and is separated. The shortening and co-milled sugar/flour are mixed together. To this mix is then added the remaining ingredients.
• Cake batters are prepared by using the following formulation:
• Batters are prepared by mixing the above ingredients for two minutes using a standard home mixer at a medium speed. The batter is weighed into two 20 cm round pans. The layers are baked to doneness; about 37 minutes at 177°C.
• a moist, light tasting cake is produced.

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