FR2705534A1 - Method for manufacturing dairy products with fibrous texture by means of extrusion cooking, and products obtained - Google Patents

Abstract

The method for manufacturing dairy products with a fibrous texture comprises blending and thermomechanically processing a pulverulent mixture of proteins, carbohydrates, an agent making it possible to slow down the agglomeration of the fibres, and water, and the extrusion of the mixture formed through a cooling die.

Description

PROCESS FOR MANUFACTURING TEXTURED DAIRY PRODUCTS
FIBERATED BY EXTRUSION COOKING AND PRODUCTS OBTAINED
The subject of the invention is a process for manufacturing dairy products with a fiber texture by cooking-extrusion, as well as the textured products obtained. It is more particularly aimed at the manufacture of analogs of fiber-textured cheeses.

 We know string type cheeses with peelable texture. These cheeses are most generally prepared from mozzarella which is the typical example of spun cheese. However, these cheeses, made from traditional mozzarella cheese technology, have a shredded texture, in the sense that the product cylinders tear preferentially along the length of the cylinder, revealing fine and fragile fibers. during the tearing.

 Various processes for texturing food products and in particular cheese have also been proposed.

Thus, in US patent 4,288,465 (in the name of
Meyer), the preparation of a cheese with a longitudinal fibrous structure is described by elongation and application of tensions to ribbons or cylinders of cheese by means of a gear system. The cheeses used are preferably of the pasta filata type, because of their natural extensibility properties. The cheese is introduced at 70 ° C. at the entry of an endless screw which makes it possible to form the cheese by pressure through a rectangular or circular orifice. A circulation of water in a double envelope, at 70 C, keeps the temperature constant. At the outlet of this apparatus, a first series of cylinders stretches the cheese, and gives it a fibrous structure, by elongation in a bath of cold water which simultaneously ensures the cooling of the cheese. The latter then passes between several pairs of cylinders, to prolong the elongation tensions and maintain the fibrous structure.

The ribbon is then cut into sections and wrapped.

 It is therefore a physical fibration process applied to an existing cheese, which consists of stretching the cheese leaving an endless screw, by means of cogs and by dipping.

Application EP 0 225 770, in the name of Minaminihon
Rakuno Kyodo Kabushiki Kaisha, concerns the preparation of a food product with a fibrous texture, by extrusion of a mixture formed of a milk protein having undergone a treatment making it resistant to acids and bases, of a material to which the fibrous structure must be imparted, and calcium and magnesium ions.

 To give the milk protein the desired resistance properties, the following treatment is carried out: an aqueous mixture of a milk protein, for example casein, and an acid polysaccharide is prepared, the acid polysaccharide being used to 25% (w / w) of the protein. The mixture is subjected to a heat treatment at 700C or more, for 3 to 90 min, in the presence of an alkali, to adjust the pH of the preparation between 7.3 and 10.5. The water content is adjusted between 20 and 86 t.

 This protein preparation is added to the material on which it is desired to impart a fibrous structure: fat, low molecular weight polysaccharides, proteins, peptides, etc., at a rate of 5 to 400% by weight of protein resistant to acids and bases. 0.13 to 2% (w / w protein) of calcium ion and 1% (w / w protein) of magnesium ion are required. The premix is then extruded, at 600C for example, using a twin-screw extruder. The feed rate is 100 kg / h, the screw rotation speed of 200 rpm. The water content of the products is adjusted between 20 and 86% (w / w) by adding water before or during extrusion. The extrudates have a fibrous structure, containing fibers of 100 Rm in length, and sometimes comprising a membranous part. These fibers are observable under a microscope.

 In this patent, the milk proteins must undergo chemical and heat treatments in the presence of calcium and / or magnesium ions, in order to acquire specific properties. In addition, the baking-extrusion treatment of this patent is carried out with two zones of kneading elements and the fibers described are microscopic and measure only a few microns to a hundred microns.

US Patent 4,430,356, in the name of Kuraray Co
Ltd, describes the preparation of food products based on microfibrillated proteins. An aqueous gel of 35% protein is formed, for example by adding calcium chloride and another calcium salt to a casein solution at 55 ° C. A protease is then added. After 1 h, a aqueous gel consisting essentially of calcium caseinate. To this protein gel are added a dehydrating agent, for example sodium chloride, and a dispersing agent, for example dextrins or sodium caseinate, in order to distribute the microfibrils of milk proteins and ensuring the plasticity of the products obtained. Fat can optionally be added. Cheese powder, meat extracts, etc., can be incorporated into the aqueous protein gel, in a mixer, at 550 C. The resulting homogeneous product is extruded at a temperature between 55 and 900C, to form product cylinders The microfibrils present in the product can be observed under a microscope.

 In this patent, the dairy proteins also undergo an enzymatic and heat treatment in this case, to make them suitable for fibration. In addition, the enzymatic treatment undergone could lead to a certain degree of hydrolysis in the protein preparation.

 It is further noted that the extruder mentioned in the examples of this patent is used only for modeling purposes. In fact, the ingredients are mixed and cooked during a stage preceding passage through the extruder for the purpose of shaping the product.

 In general, these methods do not make it possible to obtain products with long fibers visible on the macroscopic scale, having a given orientation and being able to separate under the effect of tearing.

In accordance with the invention, this object is achieved by means of a process characterized in that it comprises - the kneading of a mixture consisting essentially of (proportion by weight),
. 40 to 80% of water, preferably 50 to 75%,
. 20 to 45% protein, preferably 25 to
35%,
5 to 20% carbohydrates, preferably 10 to
15%,
2.5% at most of an agent participating in slowing down the agglomeration of the fibers, such as sodium chloride, the heat treatment of this mixture at a temperature of approximately 50 to 1000C, preferably from 70 to 950C, - Extruding the kneaded mixture through a die and simultaneously cooling it so as to give the product leaving the die a temperature of the order of 20 to 600C.

 The implementation of these provisions advantageously leads to a product whose texture has fibers that are clearly identifiable and easily identifiable from one another. The fibers, with a more or less parallel orientation, can reach several centimeters in length. The orientation of the fibers is visible on the surface of the product. These fibers are individualized during the tearing of the product.

 The proteins of the mixture advantageously consist essentially of milk proteins.

 As proteins of this type, mention will be made of caseinates, in particular calcium caseinate, where appropriate mixtures of caseinates, rennet casein, acid casein, native casein micelles, B casein, concentrates or protein isolates. milk or whey.

 When using calcium caseinate, use is more especially made of a caseinate having the following properties: viscosity <1200 mPa.s, calcium content> 0.95% (w / w), low water absorption.

 Alternatively, the proteins in the mixture also contain non-dairy proteins. These non-dairy proteins are advantageously present at a rate of approximately 5 to 30% relative to the total proteins.

 These are in particular egg white proteins, soy protein concentrates or isolates, wheat gluten proteins.

 Dairy proteins such as calcium caseinate will then be used for example at a rate of 15 to 43% (w / w), in particular from 18 to 33% (w / w).

 The carbohydrates entering the mixture are preferably maltodextrins or modified starches.

 The maltodextrins advantageously have a dextrose equivalent (D.E.) of 4 to 20.

 As indicated above, the carbohydrates are present in an amount of 5 to 20% by weight in the mixture, which corresponds to a carbohydrate / milk protein ratio of 0.1 to 1 (dry basis).

 Preferably, the proportion of carbohydrates in the mixture is from 10 to 15% by weight, ie a protein / carbohydrate ratio of 0.28 to 0.6 (dry base).

 It will be noted that the foregoing provisions lead to a dairy product of the type of light products in so far as no fat is present.

 However, if desired, according to another provision of the invention, the mixture of ingredients above also contains fat, and this in particular at a rate of approximately 30% (w / w) at most, preferably up to at 10% (w / w). It is one or more products of vegetable origin such as oils or solid vegetable fats, or of dairy origin such as butter, butter oil, anhydrous fat, fresh cream.

 The fat is added in a proportion less than or equal to 30% by weight, in particular to 10% by weight.

 In another variant of the invention, cheese curds are used as a source of milk proteins and fat. A cheese dough such as cagliata, pressed curd with spinning skills, allows a finely fiberized structure to be obtained.

 According to another arrangement of the invention, used where appropriate in combination with the above, the mixture is flavored, for example by incorporating cheese, herbs, spices, various flavors, flavor ingredients sweet or savory, such as cheeses, meat, poultry, crustacean, crab extracts, or even sweet or fruity flavors.

 The pH of the starting mixture, in these various arrangements, is of the order of 5.2 to 8, preferably from 6 to 7.

 The preparation of fiber-textured cheese analogs requires mechanical processing to ensure the intimate mixing of ingredients and heat treatment.

 These treatments are advantageously carried out using a cooker-extruder, which makes it possible to carry out the operations of mixing, cooking and texturing of the ingredients continuously.

 On the one hand, a mixture consisting of powdered protein and carbohydrate ingredients is introduced into the cooker-extruder and, on the other hand, an aqueous solution containing sodium chloride, more optionally fat in the fluid or molten state. If necessary, cheese curd is used as a source of milk protein and fat.

 As it is a question of cooking-extruding products with a high water content (40 to 80% (w / w), a twin-screw cooker-extruder with a long sheath, that is to say, is advantageously used. at least about 1.5 m.

 Part of the barrel of the extruder, for example the first third, ensures the mixing of the ingredients, essentially using kneading discs.

 The rest of the barrel, in this example, the last two thirds, comprises screw elements having increasingly tight pitches, ensuring compression of the ingredients in the barrel of the cooker-extruder, and making it possible to generate the pressure necessary to allow the passage of the mixture formed through the die located at the outlet of the cooker-extruder.

 The use of modular heating sections of the sheath allows partial heating of the latter, for example of the single end part, in particular the last two thirds, and the temperature adjustment with precision. An appropriate temperature is thus adapted according to the screw elements present in the barrel of the cooker-extruder.

 These temperatures are thus advantageously of the order of 20 to 250C in the first third, then from 50 to 1000C in the other two thirds, in particular from 60 to 800C.

Such temperatures are especially suitable for screw elements whose pitch ranges from 50 to 35, 25, then 15 mm. temperatures
The cooker-extruder is provided with a die through which the mixture is extruded. It is a sector at least 25 cm long, in particular at least 50 cm, and even at least lm to 1.5 m and up to 2 m or more.

 Advantageously, a die having a diameter of the order of 10 to 25 mm is used.

 This die has a geometry suitable for the desired modeling of a product and in particular a circular, rectangular or annular section.

 The use of a cooling system not only ensures the shaping, but also participates in the fiberization texturing of the food product.

 The cooling of this die is ensured for example by water or by a water-glycol mixture.

 Appropriate cooling temperatures are of the order of -10 to + 200C, which gives the product leaving a temperature of + 20 to + 600C approximately.

 The use of diffusion plates at the entrance to the die makes it possible to modify the fiber texture of the product and to obtain, for example, shorter fibers arranged in chevrons.

 The invention therefore provides the means of obtaining, using appropriate dies, textures with fibers of variable length, of parallel arrangement or with a given orientation.

 The product obtained at the end of the supply chain, with a fiber structure, is ready to be directly packaged and eaten as it is, for example in snacks, salads, or cooked in various cooked dishes such as pizzas, cheeseburger or croque-monsieur .

 The invention also relates, as new products, to dairy products with fiber texture as obtained by the process defined above.

These products are more particularly characterized in that they are analogues of cheese having fibers visible on the macroscopic scale, individualizable during tearing, separable from each other,
The length of these fibers and their orientation may be different depending on the method of manufacture. It is thus possible to obtain fibers several centimeters long, their variable diameter, which can range for example from 0.1 to 1 mm, or shorter fibers of the order of 5 to 10 mm, these fibers being arranged in parallel or not, for example in chevrons.

 In order to illustrate the invention, several examples of the manufacture of fiber-like cheese analogs are reported below.

 In these examples, reference is made to the single figure which represents the photos a, b and c of a cheese analog with fiber structure as obtained by the method of the invention.

 Raw materials used in the examples.

 Calcium caseinate: Ingredia.

 Malto dextrin 4 <D.E. <20: Roquette frères.

 Dehydrated egg white: Ovifrance.

 Sodium chloride: Les Salins du Midi.

 Fresh cream: Yoplait.

 Butter: Candia.

 Emmenthal aroma: Haarmann & Reimer.

 Mozzarella, type cagliata: Prodiaal.

Cooker-extruder
A cooker-extruder is used, preferably twin-barrel with a length of 1.5 m, L / D ratio = 25, with five modular heating sections, for example the cooker-extruder BC 45, CLEXTRAL (Firminy).

 The salt is dissolved in water, while the powdery ingredients are mixed together, by means of a rotary drum of the concrete mixer type. All the ingredients are introduced into the first section of the cooker-extruder (which is not heated), by means of a volumetric dispenser for powder mixtures and pumps for liquid ingredients (salt water, and possibly fluid fat or fondue). In the case of cheese curds, a pump ensures the supply at the level of the first section of the cooker-extruder. The feed rate can vary from 20 to 100 kg / h, preferably between 30 and 60 kg / h, with a screw rotation speed of 50 to 150 rpm, preferably 80 to 120 rpm.

 The screw configuration is made up of two parts: the first third of the sheath, which ensures the transport and the intimate mixing of the ingredients, includes elements of double thread screw conjugated with pitch of 50 mm, then mixing discs in one area of the sleeve, the last two thirds of the sleeve being constituted by elements of single thread screw with respective decreasing pitch of 50, 35, 25 and 15 mm.

 The configuration of the screws can vary in so far as the number of reduced pitch screw segments can be increased at the expense of the larger pitch screw segments, thereby providing a more efficient pressure build-up area.

 The heating of the food mixture to temperatures between 50 and 1000C, preferably between 70 and 950C, is ensured by magnetic induction in the last four modular heating sections of the sheath, which corresponds to the last two thirds, or 1 m section heated.

 More specifically, the first third of the sheath is maintained at a temperature of 20 to 25pu, the second and third thirds at around 700C, the temperature of the last modular section can be lowered if necessary, before passing through the die, for example at around 500C.

 The pressure measured upstream of the cooling system is between 0 and 20.105 Pa, preferably between 1.105 and 10.105 Pa. The residence time in the barrel of the cooker-extruder is between 1 and 5 min, depending on the industry used. out of the scabbard.

 A die of circular section makes it possible to reduce the residence time compared to a die of rectangular section of the same length.

The channels used can be of various sections
- rectangular: 4 mm x 3 to 6 mm x 400 to 800 mm,
- annular: 27 mm internal diameter x 35 mm external diameter x 570 mm,
- circular: 21 mm diameter, 260 to 1560 mm long.

Examples of Preparation of the Cheese Analogs of the Invention
Example 1
Calcium caseinate 32.0% (w / w)
Malto-dextrin DE = 11 - 14 13.3 9s (w / w)
Dehydrated egg white 3.5% (w / w)
Sodium chloride 1.5% (w / w)
Water added 49.7% (w / w)
Water content: 47.5% (w / w), protein content: 31% (w / w).

 A cooker-extruder is used as described above at 700C, provided with a cooling die of circular section 21 mm in diameter and 560 mm long, cooled to -50C, by glycol water.

The analog of extruded cheese leaves the die at a temperature of 550C. The pressure upstream of the die is 2.105 Pa.

 The single figure represents photos a, b and c showing the fiber structure of the cheese analog obtained. Cylindrical in shape, cream in color, the analog of extruded cheese is torn into fibers several centimeters in length, easily individualized. The product can be peeled lengthwise.

 The use of a diffusion plate with 14 holes of 2 mm in diameter, located at the entrance of the die, makes it possible to obtain a particular fiber texture, consisting of short fibers of 5 mm long, arranged in chevrons on cylinders of 3 to 4 mm in diameter, the association of these cylinders constituting the cheese analog cylinder of 21 mm in diameter.

Example 2
Calcium caseinate 26.3% (w / w)
Malto dextrin DE = 11 - 14 .. 10.9% (w / w)
Dehydrated egg white 2.9% (w / w)
Sodium chloride 1.5% (w / w)
Butter 10.0% (w / w)
Water added 48.4% (w / w)
Water content: 47.5% (w / w), protein content: 26% (w / w), fat content: 8% (w / w)
The cooker-extruder of Example 1 is used, heated to 700C, provided with a cooling die of circular section 21 mm in diameter and 1060 mm long, cooled to -50C, with glycol water. The analog of extruded cheese leaves the die at a temperature of 550C. The pressure upstream of the die is 2 bars
The cheese analog obtained has a fiber texture of the type of that of the single figure. Cylindrical in shape, cream-yellow in color, the analog of extruded cheese tears into fibers 1 to 2 cm in length. The product can be peeled lengthwise. It has a characteristic buttery flavor.

Example 3
Calcium caseinate 29.6% (w / w)
Malto dextrin DE = 11 -14 12.3% (w / w)
Dehydrated egg white 3.3% (w / w)
Sodium chloride 1.5% (w / w)
Fresh cream 10.0% (w / w)
Water added 46.5% (w / w)
Water content: 47.5% (w / w), protein content: 29% (w / w), fat content: 3.5% (w / w)
The cooker-extruder of example 1 is used at 70 ° C., and the cooling die of example 2 but cooled to 5 ° C. by glycol water. The analog of extruded cheese leaves the die to a temperature of 550 C. The pressure upstream of the die is 2 bars. The cheese analog has, like the preceding products, a fiber texture as illustrated in the single figure. Cylindrical in shape, creamy yellow in color, the analog of extruded cheese tears into fibers 1 to 2 cm in length, allowing the product to peel lengthwise.

Example 4
Calcium caseinate 31.4% (w / w)
Malto dextrin DE = 11 - 14 13.0% (w / w)
Dehydrated egg white 3.4% (w / w)
Sodium chloride 1.5% (w / w) Emmenthal flavor ...... 1.0% (w / w)
Water added 49.7% (w / w)
Water content: 47.5% (w / w), protein content: 29% (w / w)
The cooker-extruder of Example 1 at 700C is used, provided with a cooling die of circular section 21 mm in diameter and 1560 mm long, cooled to 100C, with glycol water. The analog of extruded cheese leaves the die at a temperature of 550C. The pressure upstream of the die is 2 bars.

The cheese analog presents, like the products of the preceding examples, a fiber texture. Cylindrical in shape, cream in color, the analog of extruded cheese tears into fibers several centimeters in length. The product can be peeled lengthwise. It has a characteristic odor and flavor of emmenthal.

Example 5
Calcium caseinate 11.0% (w / w)
Malto dextrin DE = 11 - 14 4.6% (w / w)
Dehydrated egg white 1.2% (w / w)
Mozzarella (ES 54.6%, MG 48%) 58.1% (w / w)
Water added 25.1% (w / w)
Water content: 47.5% (w / w), protein content: 26% (w / w), fat content: 28% (w / w)
The cooker-extruder at 700C is used, provided with the cooling die according to Example 1, this die being cooled to 10 ° C., by glycol water.

The analog of extruded cheese leaves the die at a temperature of 600C. The pressure upstream of the die is 2 bars. The cheese analog has the fiber texture of Figure 1. The cylindrical shape, yellow-cream in color, the extruded cheese analog tears into fibers 1 to 2 cm in length. The product can be "peeled" along its length. It has the light flavor and smell of mozzarella.

Claims (12)

 1 / Process for manufacturing dairy products with a fiber texture, characterized in that it comprises - the kneading of a mixture essentially consisting of (proportion by weight),  . 40 to 80% of water preferably 50 to 75%,  20 to 45% protein, preferably 25 to  35%,  5 to 20% carbohydrates, preferably 10 to  15%,  2.5% at most of an agent making it possible to slow the agglomeration of the fibers, such as sodium chloride, - the heat treatment of this mixture at a temperature of approximately 50 to 1000C, preferably from 70 to 950C, - extruding the kneaded mixture through a die and simultaneously cooling it so as to give the product leaving the die a temperature of the order of 20 to 600C.  2 / A method according to claim 1, characterized in that the proteins are dairy proteins, in particular caseinates, in particular calcium caseinate, if necessary mixtures of caseinates, rennet casein, acid casein, native micelles caseins, ss casein, concentrates or protein isolates from milk or whey.  3 / A method according to claim 1 or 2, characterized in that the proteins also contain non-dairy proteins in an amount of 5 to 30% relative to the total proteins, these non-dairy proteins being chosen in particular from egg white proteins , soy protein concentrates or isolates, wheat gluten proteins.  4 / Method according to one of claims 1 to 3, characterized in that the carbohydrates are maltodextrins or modified starches, the maltodextrins advantageously having a dextrose equivalent of 4 to 20.  5 / A method according to any one of the preceding claims, characterized in that the fatty mixture of vegetable origin such as oils, vegetable solid fats, or of dairy origin, butter, is added to the starting powder mixture. butter oil, anhydrous fat or crème fraîche, this addition of fat being carried out at a rate of 30% (w / w) at most, preferably up to 10% (w / w) .  6 / A method according to claim 5, characterized in that cheese curds are used as a source of protein and fat.  7 / A method according to any one of the preceding claims, characterized in that the starting mixture is flavored, for example by incorporation of cheese, herbs, spices, various flavors, ingredients of sweet flavor or salty such as cheeses, meat, poultry, crustacean, crab extracts, or even sweet or fruity flavors.  8 / A method according to any one of the preceding claims, characterized in that the pH of the starting mixture is 5.2 to 8, in particular 6 to 7.  9 / A method according to any one of claims 1 to 8, characterized in that the kneading and the heat treatment of the mixture of ingredients are carried out in a cooker-extruder, of the twin-screw type with a long barrel of at least 1 , 5 m, in which the screw elements have increasingly tight pitches, to generate the pressure necessary for the passage of the product through the cooling die at the outlet of the cooker-extruder.  10 / A method according to claim 8 or 9, characterized in that the cooker-extruder is provided with modular heating sections allowing partial heating of the sheath and the application of different temperatures depending on the screw elements present in the sheath of the cooker- extruder.  11 / Textured dairy products, such as cheese analogs with fiber structure, characterized in that they have fibers visible on the macroscopic scale, from 1 to several cm in length, individualizable during tearing, separable from each other .  12 / Use of the products according to claim 11 as such, for example in snacks, salads, or cooked, in ready meals such as pizzas, cheeseburger or croque-monsieur.