GB2229077A - Process for the production of margarine with a reduced fat content - Google Patents

Description

k PROCESS FOR THE PRODUCTION OF MARGARIXE WITH A REDUCED FAT CONTENT The

present invention is concerned with a process tor the production of margarine with a reduced fat content, as well as with a product obtained thereby.

The number of diseases and fatalities which are to be attributed to excessive or faulty nutrition due to a high consumption of fat is very great in the highly developed industrial countries and constitutes a health problem. Therefore, for nutritional- scienrific and physiological reasons, it is desired to make available calory-reduced and fat-reduced spreads as a replacement for butter or margarine. Thus, for many years, the socalled half fat margarines and half fat milk have been commercially available. However, these still have a fat content of 40%. Further reducing the fat content comes up against many problems. Butter and margarine are spreadable fats, the consistency of which is due to the fact that they are water-in-oil emulsions. In the case of reducing the fat content to less than 40%, obtaining water-in-oil emulsions which are satisfactory with regard to consistency, appearance and spreadability, as well as with regard to flavour characteristics, becomes problematical. Furthermore, in the case of increasing the proportion of water, hygiene problems arise since the growth of bacteria is favoured by a high content of water.

The previously known products have an insufficient emulsion stability so that heating subsequent to J production was not possible. Therefore, in order to make the previously known products storage stable, either the addition of preserving agents was necessary or laborious processes had to be carried out, i.e. the starting materials had to be sterilised or pasteurised and the process as a whole had to be carried out in surroundings which were as free as possible from microorganisms.

Therefore, it is an object of the present invention to provide a fat-reduced margarine which has aEat content in the range of 20 to 30%, diSDlays a good emulsion stabilicy and remains bacteriologically satisfactory even when stored for a comparatively long time.

Thus, according to the present invention, there is provided a process for the production of margarine with a reduced fat content, wherein a stable emulsion is prepared with 5 to 30% by weight of fat and 80 to 55% by weight of water, as well as 10 to 30% by weight of additives, by melting the fat and dispersing an emulsifier and a hydrocolloid in a part of the molten fat; dissolving maltodextrin with a DU-value of <- 6, possibly together with conventional additives, in warm water or aqueous medium and heating this mixture to the temperature of the fat phase, subsequently mixing the molten fat phase and the aqueous phase with vigorous -stirring, adding the second part of the molten fat 0 thereto and stirring until an emulsion has formed, homogenising the emulsified mixture at a Dressure of at least 80 bar, heating the homogenised mixture to QICC. and subsequently transferring it into containers at a temDerature of at least 72'C. and then allowing it to cool slowly.

Surprisingly, we have ascertained that, when maintaining the process steps defined according to the present invention, a stable oil-in-water emulsion can be obtained with a fat content in the range of 5 to 30% which combines an excellent consistency with appropriate organcleptic properties.and displays an increased heat stability so that the product can be pasteurised and thus can be kept -for a long time in cold storage. By means of the process according to the present invention, a spreadable fat is produced in which a phase reversal into a water-in-oil emulsion has not taken place and, nevertheless, displays advantageoUs properties.

In the present invention, the fat is first melted and a part thereof is mixed with fat soluble additives, then the aqueous phase is mixed with the water-soluble additives and this mixture heated to the same temperature as the fat phase. Subsequently, both phases are mixed together with vigorous stirring. The remainder of the fat phase is added to the emulsified mixture and the emulsion obtained is t stabilised in a hi_h_pressure homogeniser. The emulsion which thereby results is so stable that it can be heated to comparatively high temperatures in order to destroy all pathogenic and undesirable micro- organisms and can then be transferred into containers in a hot state. Thereafter, the product is slowly cooled and can then be kept in cold storage.

According to the present invention there is provided a process for the production of margarine with a r.educed fat content, wherein a stable emulsion is prepared with 5. to 30-170 weight of fat and 80 to 55% by weight of water, as well as 10 to 30% by weight of additives, bv melting:he fat and dispersing an is Z-0 Z5 emulsiú.':4I.er and a hydracolloid in a part of the molten fat; dissolving maltodextrin with a DU value of < 6 in warm water or an aqueous medium, optionally together with conventional addizives, and heating this mixture,o the temperature of:he fat phase; subsequently mixing the molten fat phase and the aqueous phase with vigorous stirring, adding the second part of the molten fat thereto and stirring until an emulsion has formed, homo-enisina the emulsified mixture at a pressure of at least 80 bar, heating:h.e homogenised mixture to 90'C. and subsequently transferring it into containers at a teirperature of at least 72'C. and then allowing the mixture to cool slow1V.

1 k For carrying out the process, the fat 4s f-frst 'neared to such an extent that it is present in a molten state. Depending UDon the fat used, temperatures in the range of from 50 to 7CC. are suit--Dle for this purpose. As -Eat, there is used a fat mixture with proportions of hardened fat. Suitable for this purpose are especially mixtures of vezerable and animal fats. The fat mixture is thereby dependent upon the desired consistency of the and product. A mixture of hardened palm nut oil and of pure butter has proved to be especially useful. A fat is preferably used in which the solid material components, measured at different temperatures with NMR, are as follows: N 10 80 - 25; N 20 50 - 10; N 25 30 - 5; N,o 20 - 0; N 10 - 0 and N 0 5 - 0. A fat mixture 4 which fulfils this criterion is, for example, a mixture of 30% hardened palm nut oil and 70% pure butter.

After the fat has been melted, the water-free part is mixed with the fat-soluble additives. The proportion is not critical but it has proved to be advantageous to use about one third of the fat employed for taking up n 5 zie --.,'at-soluble additives..s fat-soluble additives, =-mulsij.:iers and hydrocolloids are dispersed in the fat phase.

As emulsifiers, there can be used those substances which are known in this field. For example, there can be used mono- or diglycerides or mixtures containing z,iem. According to the present invention, as emulsifier chera is preferably used the protein contained in whey and esDecially in the form. of a whey protein concentrate 10 since it forns the typical texture of margarine.

rurthermore, to obtain a margarinetexture, a hydrocolloid is used in combination with gelatine. There can here be used the hydrocolloids known n =he production of margarine, as well as mixtures,Mereof. Preferably carrageenin is used or a carrageenin fraction, kappacarrageenin being especially preferably used.

As hydrocolloids, there can also be used other vegetable Produces, for example alginates or xanthans.

However, we have found that in the case of the use of alginate or xanthan alone, admittedly the stabilising action is sufficient but the consistency of the end product is not optimal. Therefore, within the scope of the present invention, it is possible to use one of these known hydrocolloids in combination with carrageenin and possibly also in admixture with gelatine. The ratio of the individual components can then be varied, depending upon the desired consiscency.

The emulsiffer -'s added to the -',,iase:Dreger ablv in an amount of o m 5 L- o 3 % 'D v., 7 e h t -: n especially preferably of -Erom 6 to by referred to the weight of the fat phase. The concent rarion of the hvdrocolloid is dependent upon:'-a water content of the final product. Therefore, the ---oncenr- ration of the hydrocolloid is calculated reference to the water content of the mixture. The hydrocolloid is Dreferably used in such an amounr --hat 0._ t:o 1.070 by weight is present, referred to the amount jr- water in the final product, a concentration range of _from 0..

to.0.8% by weight being especially preferred.

The aqueous medium in the production of the mixture according to the present invenzion can be water. However, as aqueous medium, is prefer ably used. The aqueous medium is used in such an amounr that the water content of the end product is in che range of from 80 to 55% by weight. For dissolving:he water- soluble additives, the aqueous medium is warmed. preferably to a temperature in the range of from 30 to 4CC.

An important component which is necessary in order to produce a satisfactory product is maltodextrin which is added as stabiliser. Maltodextrins are products which are obtained by the breakdown of starch, in which the maltodextrins, depending upon the manner of processing the starch', have differant chain lengths and, therefore, 1 4.

have different properties. For the process according to tie present invencion, a maltodextrin is used, the DU value of which is --6. Preferably, there is used a ialtodext-,in a DU value of 4 to 6. Especially preferred for the process according to the present invention is a maltodext_= which has been obtained from Dorato scare;.-. or tapioca starch since it- has a texture similar to thaz of the foar and a corresponding flavour.

Maltodex=rin is dissolved in the aqueous phase and '-s used in a concentration of 8 to 15% and preferably of -from 10 to 13% by weight, referred to the weight of the aqueous phase. A combination of maltodextrin with 7elatine and starch has proved to be especially suitable. A Tn4---.cture of these three components gives rise to a Qroduct with a texture and spreadability which is cc-iDarable wich that of full-fat margarine. Gelatine and starch are used in comparatively low concent- \ rations. The gelatine can, for example, be admixed with the maltodextrin in a range of from 0.6 to 1.3% and preferably of from 0.8 to 1.1% by weight, referred to C the weight of the aqueous phase. As starches, there can be used not only native but also modified starches. Mixtures of native and modified starches can also be used. Modified wax maize starch is preferably -used.

The starch is used in a concentration of from 0 to 4% and preferably of from 0.7 to 1.5% by weight, referred to the weight of the aqueous phase.

Furthermore, conventional additives can also be -ldded to -the mixture, for examDle salt, _lroma materials, colouring materials and/or ant-4-,lxidants.

71 nese components are used in known manner and in =he 5 usual amounts.

For further processing, the aqueous phase is heated to the temperature of the fat phase.

For the -,D-oduc--4-on of the Droduc= acc--rd.Ln-- to the present invention, the molten fat, which. contains the emulsifier and hydrocolloid, as well as the acueous phase, which contains the other additives, are mi.xed together. For this purpose, the two phases are vigorously stirred until an emulsion has formed. Preferably, in L-he resultant emulsion, the pH value is so adjusted that it lies in the slightly acidic range, i.e. in the range of from 4.8 to 5.8. Especially preferably, the pH value is adjusted to a range of from 5.0 to 5.2. The adjustment of the pH value is carried our with an edible acid. Since most edible acids have a taste of their own, it is especially preferred to use lactic acid in order that the resulting product does not have a taste differin- from that which is usual for butter or marearine. The remainin. amount of the molten fat is then added thereto with viyorous stirring and the mixture is subsequently homogenised at a pressure of at least 80 bar. F or the homogenisation, there is used a high pressure homogeniser such as is commercially 4 available from various companies. There can be used -PDara-us with a one- suage or multi-stage manual or.nvdraulic hinh z)ressure svstem. For example, there can be used a high pressure homogeniser Model Lab. Standard Type 12.50, obtainable from the _firm Rannie, with a capacity of 200 litres which is equipped with a manual one-stage homogenising system.

During homogenisation, the fat globules are broken down to a size of from 1 to 5 pm. This small fat globule size is also responsible for the good heat stability of the emulsion.

The emulsion obtained in the case of the homogenisation is so stable that it can be heated to temDeratures of uD to 9CC. without loss of stability. In this temDerature range, all pathogenic and undesired micro- orzanisms are killed. The mixture is heated to temperature in the range of from 80 to 90'C. until all undesired micro-organisms are killed. As a rule, this is the case after 3 to 10 minutes.

In order to avoid a contam: ina tion when being transferred into containers, the product is transferred while still hot, into vessels which are free of micro organisms or have a very low content of micro-organisms.

The transfer should take place at a temperature which is above 72'C. The vessels are subsequently sealed and the product then slowly cooled to ambient temperature. The cooling should take place in such a manner that the A producc, only reaches a temperature in, the region of 2CC. after 6 to 10 hours. E-Especially prefera- 1,1, the cooli.ng should ta.',--e 18 to _4 hours. During cooling, the produc= crystallises in the desir-ad consistency. 1'he final Droducc can then be cold scored in L-he usual way and can be il-leD7- _for at leas= 6 -,.on--!-is.

!he present invention also provides a margarine with a reduced content, wherein it contains 80 to c51 by wei-ht of water, D- to 101 by wei-Lit of /0 t _j /0 - mixture containing hardened fat, S to 15,1, by weight of maltodextrin, optionally 0.5 - 3'110 by wei-nt modifled starch, 1 to 1_% by weight of whey protein, 0.4 to 0.6% by weight of carrageenin and 0.4 to 0.6% by we4- -h-, of aelatine, as well as ontionally aroma and colou-.:'.,"1:7 15 materials.

In a preferred embodiment, the margarine additionally contains starch and gelatine. The pr"oduct according to the present invention is characterised by a good taste and good spreadability, as well as by an appropriate consistency. Even in the case of long storage, the product is very stable without having to use preserving agents.

The following Examples are given for the purpose of illustrating the present invention: ExaMD1e 1.

The SFI (solids content) of a fat was determined at a definite temperature by the relationship of the - 12 magneric signals of the hydrogen nuclei in the solid phase to the signals of the whole fat. The solids content is given in weight-.7. at the temperature in question. For the determination, after a suitable tempering at which the temperature of the sample is adiusted to a stable state of crystallisation, the sam,Dle is introduced into a homogeneous magnetic field. By use of a second magnetic field which is at -rightan,-., les to the first one, protons are disDlaced. The orientation thereby deDends upon whether it belongs to tl.-le solid or the liquid phase of the -fat. Via a receiver coil, a signal is produced which can be measured and is a criterion for the solids content of a sample. By comparison with fats of known solids content, the solids content of the fat can then be calculated.

In the present case, for the determination of the solids content, there was used a pulse NMR apparatus which is commercially available under the name Bruker Minispek pc 20. As reference substances for the calibration, there were used fats with a solids content of 0%, 35% and 70%. The test substances can be measured at ambient temperature without pretreatment.

A waterbath is necessary for each desired measure- ment temperature. The waterbath can be thermostatically regulated between 10 and 80'C. with an error of 0.1C. It is equipped with a stirrer and thermometer. Further- 1.

used which 's -,::41led more, a O'C. bar-h. with cr-7osr-az with a solution of -90% ethylene c,1, 7col 4n wa-r and 's adjusted to O'C. = 0.1'C.

For the measurement, samD!e tubes made of 7.1ass and provided with Dlastic caDs are used, the external diameter of which is 10.00 0.25 mm., the '-'enzti of which is 150 n=. and the wall --.'i4.c'L\-ness of 0.9 = 0. 05 mm. In each case, the samDles are -.e-lted at SO'C. in a..jazer:)ath, homogenised and, if necessar- -filtered in order to ensure that they are clear.

For the measurement, the _fat to be 4-nvesz---,.--,,azed is melted in a waterbath at 800C. and transferred into the sample tubes to a height of at least 3 cm. and the plastic cap put on. Weighing is not necessary. For each desired measurement temperature, a samD!e tube is filled. The sample tubes, which contain the completely melted fat, are then placed in a waterbath at SO'G. Subsequently, for stabilisation, the samples are placed in a waterbath at O'C. The tubes are dried and rapidly, without warming up, placed in the provided hollow spaces of the metal blocks in the waterbaths with the desired measurement temperatures. The tubes are left for 60 to 65 minutes in the waterbath -at the desired temperature. Subsequently, the sample tubes are placed as quickly as possible in the test head of the NMR spectrometer and the measurement carried out. The outsides of the sample tubes must be clean and dry. The solids content in % is - 1A - indicated after 6 seconds. All the tubes are measured in this way.

For a mixture of 30% hardened palm nut oil and 70%. pure butter, the _followin- SFI values were 0 determined: N, 65.4%; W70 51.5%; N 32.6%.

30 ExamDle 2.

4arzar4-ne with 10% far.

For this Example, there was used a fat mixture consisting of 6 kg. hardened palm nut oil and 16.9 kg.

butter. The --'ar had the following SFI values: N 10 80%.

N..)o 25.7, 'N l-'.4, N'20 7.0, N 2.0, N < 0.5.

35 40 The hardened far was melted at 6CC., mixed with 1.2 kg. 60% whey protein concentrate, 0.5 kg. kappacarrageenin and fat-soluble colouring and aroma materials and a fat dispersion produced.

8 kg. maltodextrin (spray-dried starch sacctiarification product obtained by the hydrolysis of starch) with a DU value of 4 to 6, which is commercially available under the name Snowflake 01906 (CPC), were dispersed in 59 kg. of water at a temperature of 3CC., toaether with 0.5 kg. gelatine, 0.5 kg. starch, 1.3 kg. salt and, as flavour-imparting components, 5 kg. cream (10%) and a small amount of butter aroma. Furthermore, 0.2 kg. lactic acid was added thereto so as to adjust thepH value to about 5.0.

The mixture was heated to 600C. The warm fat dispersion was then added to this aqueous phase at WC. with vigorous stirring and emulsified for 3 minutes.

- is-- Subseauently, the remainder of the molten fat was added to this emulsion with gentle stirring. TIL-Le emulsion was then stabilised at 100 bar with a high pressure homogeniser and then heated to 90'G. for 5 minutes. The homogeneous mixture 6btained was allowed to cool to about 8CC. and transferred at this temperature into containers. The final product transferred into the containers was -then cooled to ambient temperature in the course of 24 hours. Subsequently, the product was kept at 5'C. in cold storage. The product so obtained could be kept for 6 months. Examnle 3. Marzarine with 5% fat.

For this Example, there was used a fat mixture consisting of 4.2 kg. hardened palm nut oil and 1 kg. butter. The fat had the following SFI values: N 10 80, N 20 54.9, N 25 33.8, N 30 13.5, N 35 4.9, N 40 1.3. ', The hardened fat was melted at 6CC., mixed with 0.65 kg. 60% whey protein concentrate, 0.8 kg. kappa- carrageenin and fat-soluble colouring and aroma materials and a fat dispersion produced.

11 kg. maltodextrin with a DU value of 4 to 6, which is commercially available under the name Snowflake 01906 (CPC), were dispersed in 77 kg. of water at JCC., together with 1 kg. gelatine, 3 kg. starch, 1.3 kg. salt and, as flavouring imparting components, small amounts.of butter aroma. Furthermore, 0.2 kg. lactic acid was 1.4.

16 added thereto so as to adjust the:pH value to about 5.0. This mixture was heated to 60'C. The at disDersion was then added with vigorous stirring to:..,iis aqueous phase at 60'C. and emulsified for 3 minutes.

Subsequentlv, the remainder of the molten _at was added to this emulsion with gentle stirring. The emulsion was c-hen stabilised at 100 bar in a high pressure homogeniser and then heated to 9CC. for 5.ninutes. The homogeneous mixture obtained was allowed to cool to about SOOC. transferred at this trature into containers. The final product in the containers was then allowed to cool to ambient temperature in the course of 24 hours. Subsecuently, it was kept in cold storage at 5'C. The product so obtained could be kept for 6 months. ExaMD1e 4. marzarine with 30% fat.

For this Example, there was used a fat mixture consisting of 6 kg. hardened palm nut oil and 26 kg.

butter, as well as 3.2 kg. soya oil. The fat has the following SFI values: N 10 46.9, N 20 18.1, N 25 10.31 N 30 5.3, N 35 1.4.

The hardened fat was melted at 600C., mixed with 1.75 kg. 60% whey protein concentrate, 0.4 kg. kappa- carrageenin and fat-soluble colouring and aroma materials and a fat dispersion produced.

6.3 kg. maltodextrin with a DU value of 4 to 6, whizh is commercially available under the name N-Oil (National Starch), were dispersed in _13 kg. or water at 30'C., together with 0.6 kg. gelatine, 0,4. kg. starch, 1. 3) kg. salt and, as jlavour-imDar-.4--.ig COMDonents, small amounts of butter aroma. Furthermore, 0.2 ka. lactic acid was added thereto so as to adjust the pH value to about 5.0. The mixture was heated to 60'C. The -., 7a---fat disDersion was then added with vigourous stirring to this aqueous phase at 60'C. and emulsified for 3 minutes.

Subsequently, the remainder of the molten fat was added to this emulsion with gentle stirring. The emulsion was then stabilised at 100 bar with a high pressure homogeniser and heated to 90'C. for 5 minutes.

The homogeneous mixture obtained was allowed to cool to about SO'C. and transferredinto containers at this temperature. The final product in the containers was thlen allowed to cool to ambient temperature in the course of 24 hours.. Subsequently, it was kept in cold storage at 50C. The product so obtained could be kept 6 months.

z

Claims (1)

1. CLAIMS: 1. Aprocess for the production of margarine with a reduced fat

   content, wherein a stable emulsion is DreDared with 5 to 3070 weiaht of fat and 80 to 55% by weight of water, as well as 10 to 30% by weight of additives, by melting the fat and dispersing an emulsifier and a hydrocolloid in a part of the molten fat; dissolving maltodexcr-in with a DU value of < 6 in warm water or anaqueous medium, optionally together

   LO with conventional additives, and heating this mixture to the temperature of the fat phase; subsequently mixing the molten fat phase and the aqueous phase with vigorous stirring, adding the second part of the molten fat thereto and stirring until an emulsion has formed, homogenising the emulsified mixture at a pressure of at least 80 bar, heating the homogenised mixture to 90'C. and subsequently transferring it- into containers at a teirperature of at least 72'C. and then allowing the mixture to cool slowly.

   2. A process as claimed in Claim 1 wherein a mixture of vegetable and animal fats is used as hardened fat.

   3. A process as claimed in Claim 1 or CL-dn 2 wherein as fat there is used a fat with the following solids content, as determined by the NMR spectrum: N 10 80 - 25; N 20 50 10; N 25 30 - 5; N 30 20 - 0; N 35 10 - 0; N 40 5 0.

   7.

   is ) 5 4. A process as claimed in any one of the preceding claims, wherein a mixture of 30% hardened palm nut oil and 70% pure butter is used as fat. 5. A process as claimed in any one of the preceding claims, wherein whey protein concentrate is used as emulsifier. 6. A process as claimed in any one of the preceding claims, wherein carrageenin is used as hydrocolloid.

   A process as claimed in any one of the preceding claims, wherein milk is used as the aqueous medium. 8. A process as claimed in any one of the preceding claims, wherein colouring materials, vitamins, antioxidants and/or emulsifiers are additionally added to the aqueous medium. 9. A process as claimed in any one of the preceding claims, wherein the pH value of the product is adjusted to a value of from 4.8 to 5.8 by the addition of an edible acid. 10. A process as claimed in Claim 9, wherein the pH value is adjusted by the addition of lactic acid. 11. A process as claimed in any one of the preceding claims, wherein a mixture of gelatine, maltodextrin and starch is used for stabilisation. 12. A process as claimed in Claim 1 for the production of a margarine with a reduced fat content, substantially as hereinbefore described and as exemplified in any one of the Examples 1 to 4.

   - 20 13. Margarine with a reduced fat content, whenever produced by a process as claimed in any one of claims 1 to 12. 14. Margarine with a reduced fat content containing 80 - 55% by weight of an aqueous medium, 5 30% by weight of a fat mixture containing hardened fat, 8 15% by weight maltodextrin, optionally 0.5 3% by weight modified starch, 1 - 2% by weight whey protein concentrate, 0.4 - 0.6% carrageenin and 0.4 - 0.6% by weight gelatine, as well as, optionally, aroma and colouring materials.

   1 Published 1990 atThe Patent Office, State House.66 ?1 Iligh Holborn. London WC1R 4TP. Purther copies maybe obtained from The Patent 0 11ce 2Wes Branch, St Mary Cray. Orpington, Kent BU 3RD. Printed by W2Uplex techniques ltd. St Mary Cray, Kent, Con. V87