GB2293828A - Tub-type margarines and spreads containing no trans fatty acid - Google Patents

Abstract

The present invention relates to tub-type margarines and spreads which do not contain trans fatty acids or tropical oils and which possess the desired margarine characteristics of butter-like flavor, color and physical properties equivalent to tub-type margarines which do contain trans fatty acids or tropical oils. The tub-type margarine products of the present invention comprise specific blends of co-interesterified liquid unsaturated vegetable oils and hardstocks and an unsaturated vegetable oil and hydrogenated cottonseed oil with the incorporation if a fully hydrogenated mono-glyceride emulsifier.

Description

FAT SYSTEMS AND PROCESSES FOR THE PRODUCTION OF NO TRANS FATTY ACID CONTAINING TUB-TYPE MARGARINES AND SPREADS BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates to unique tub-type margarines and spreads which do not contain trans fatty acids but which possess the desired margarine characteristics of butter-like flavor, color and physical properties equivalent to tub-type margarines which do contain trans fatty acids. More particularly, the unique fat or oil system(s) of the present invention, which also do not include any tropical oils, are chemically interesterified to achieve both physical and functional characteristics comparable to hydrogenated oils.

Additionally, the final margarine blends require specific emulsifiers and preferably are manufactured in accordance with processing parameters in order to achieve the desired tub-type margarine or spread products.

DESCRIPTION OF THE PRIOR ART Margarine is a fatty food manufactured in semblance of butter in flavor, color, physical properties and composition except that the fat is not principally milkfat. More specifically, margarine is generally a water-in-oil emulsion, i.e. a suspension of one liquid within a second immiscible liquid. In margarine, the fat component is known as the continuous or oil phase while the dispersed or aqueous phase consists of water and/or water dispersible components. Margarine is generally defined as a composition containing at least 80% fat (or oil) by weight and about 20% by weight aqueous phase. In contrast, emulsions containing less than 80% by weight fat are spreads. Both are manufactured in several forms including stick, tub, whipped and liquid forms.

The fat in margarine is primarily completely processed (i.e. refined, bleached, hydrogenated and deodorized) mixed triglycerides (also known as triacylglycerols) of vegetable or animal carcass origin.

Triglycerides are triesters of glycerol and various saturated and unsaturated fatty acids. The physical properties of fats are determined by the characteristics of the individual fatty acid moieties and by their distribution within the triglyceride molecule. For purposes of making a suitable stick-type margarine, the fat must have a plastic consistency at refrigeration or ambient temperatures and yet have the essential characteristic of melting readily and with substantial completeness in the mouth of the consumer. Such a melting characteristic normally requires a solid fat index (SFI), which has specific values over a temperature range established by accepted methodology [American Oil Chemists' Society (AOCS) Official Method Cd 10-57].In addition, plastic margarine fats must have a crystal habit which provides a smooth organoleptic consistency without graininess or similar mouthfeel defects in homogeneity.

The physical properties of the margarine are derivetl predominantly from the composition of the fat, as well a the processing technique in making the margarine.

Margarine is generally prepared from edible fats which are physically modified by hydrogenation and/or interesterification. In the United States, hydrogenation has been the principal means of oil modification.

Hydrogenation is the chemical reaction of fats and oils with hydrogen gas in the presence of a catalyst which results in the addition of hydrogen to the fat, thus transforming unsaturated bonds into saturated bonds along with other reactions. The process of hydrogenation of fats results in the raising of the melting point of edible fats and improving the resistance of the fat to oxidative deterioration. Hydrogenation also generates positional and geometrical isomers.

Tropical oils, such as coconut, palm and palm kernal have been conventionally utilized as a component of margarine fats as they have acceptable melting and solidification properties resulting from their higher levels of intermediate carbon chain saturated fatty acids. However, consumers have been increasingly concerned in recent years about the saturated fat content in the foods they eat and the effect of such foods on their health. In fact, saturated fat has been shown in numerous studies to increase levels of cholesterol in the blood and has been linked to increased risk of heart disease. Consequently, it is no surprise that consumers conscientiously look for foods low in saturated fat content.Accordingly, in order to reduce the saturated fat, it is desirable to find suitable replacements for tropical oils in margarine formulas with alternatives that maintain the same flavor, color and physical properties provided by tropical oils.

Vegetable oils or domestic oils, i.e. non-tropical oils, such as soybean, corn, cottonseed, peanut, sesame, and the like, may be partially hydrogenated in order to achieve margarine oils of the requisite physical characteristics which tropical oils provide. Usually, selectively hydrogenated oils are blended in order to achieve the required physical characteristics for margarine. More particularly, the desired consistency has been typically obtained by blending two or more partially hydrogenated vegetable oils, or blending liquid (unhydrogenated) vegetable oil with a partially hydrogenated vegetable oil.Conventional partial hydrogenation of vegetable oils containing unsaturated acids, depending on catalyst selectivity, degree of hydrogenation and other processing variables, produce substantial amounts of unsaturated fatty acids of the trans-configuration rather than the naturally occurring cis-configuration.

The term "trans-acid" or "trans fatty acid" as used herein refers to an unsaturated fatty acid having a carbon chain length of from generally 16 to 24 carbon atoms and having at least one unsaturated carbon-carbon bond which is in the trans-configuration. In conventional margarine fat prepared from partially hydrogenated vegetable oil, the trans acid content may exceed 25% by weight or more of the margarine fat composition. This is a result of the partial hydrogenation conditions which are required to provide an acceptable solid fat index for a margarine fat. Unfortunately, the presence of such trans isomers of fatty acids in the diet have also become the target of concern in relation to the consumers' dietary health.Accordingly, margarine fat systems are desired which contain no detectable amounts of such trans acid moieties, or are present at levels which are nutritionally insignificant, yet have the flavor, color and physical properties of margarines which contain trans fatty acids.

Apart from vegetable oils being hydrogenated to achieve desired results, vegetable oils intended to be used for any food preparation purposes are also processed by first subjecting them to the well known techniques of alkali or physical refining, bleaching and steam deodorization. See Bailey's Industrial Oil And Fat Products, Wiley-Interscience Publishers (1982), Chapter 4 of Volume 2 for a detailed description of refining and bleaching, and Chapter 3 of Volume 3 for a detailed description of deodorization, both of which are incorporated by reference herein.

The alternate method of chemically modifying edible fats mentioned earlier is the process of interesterification and the related process of transesterification. This is a technique which may also be used to alter the triglycerides profile and therefore ultimately the physical properties of the resulting triglyceride mixtures. Both chemical and enzymatic interesterification are well known for modifying the triglyceride profile of fats and oils.

Chemical interesterification is based on the use of a chemical catalyst, such as sodium methoxide or sodium metal, to promote the migration of the fatty acid moieties between triglyceride molecules and to produce a random redistribution of the fatty acid moieties.

Enzymatic transesterification may be used for selective interchange under relatively mild reaction conditions.

As stated earlier, in addition to the composition of the fat, the physical properties of the margarine are also influenced by the processing parameters. In standard margarine manufacture, the aqueous phase is dispersed in the oil phase and the resulting emulsion is then sent through a scraped surface heat exchanger such as a Votator A-Unit. The A-Unit supercools the emulsion with a relatively short residence time. The supercooled emulsion is then sent to a crystallizer known as a static B-Unit, in the form of a jacketed hollow tube or "resting tube", normally used to provide firm stick-type margarine. By comparison, "working B-Units", for example in the form of picker units, serve to break up larger crystals, which affects solidification properties.

SUMMARY OF THE INVENTION The present invention relates to tub-type margarines and spreads which are essentially free of trans fatty acids or tropical oils but yet possess the butter-like attributes of margarines which contain and are dependent upon the existence of trans fatty acids or tropical oils.

More specifically, the butter-like characteristics of the tub-type margarines and spreads made in accordance with the present invention are obtained by the use of specific oil blends which are to be used as the base oil in the emulsion, the use of specific emulsifiers and the preferred implementation of specific processing parameters. By essentially free of trans fatty acids is meant that the level of trans fatty acids is negligible, typically below 2% by weight of the margarine oil.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram illustrating the process of making tub-type margarines and spreads in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to tub-type margarines and spreads which not only possess all of the desired butter-like characteristics such as flavor, color and physical properties, but which also meet growing health concerns. That is, the tub-type margarines and spreads made in accordance with the present invention are essentially free of trans fatty acids, the isomeric form of unsaturated fatty acids which have been linked to health risks such as heart disease. In addition, the tub-type margarines and spreads of the present invention do not contain any tropical oils which contain relatively high levels of saturated fatty acids. Certain saturated fatty acids have been identified as having potential health risks.

It has surprisingly been found that tub-type margarines and spreads can be made essentially free of trans fatty acids or tropical oils and yet maintain the desired qualities of a superior margarine or spread product. The tub-type products made in accordance with the present invention can be obtained by the implementation of a combination of factors, namely a unique oil blend to be used as the base oil in formulating the margarine or spread emulsion, specific emulsifiers and preferably specific processing conditions which deviate from the conventional processes involved in making margarines and spreads but which enable comparable products of the present invention to be made.

As stated above, the oil blends to be used in formulating the base oil of the margarine or spread emulsion is the first important factor critical to the present invention. The base oil of the present invention is comprised of only domestic oil, i.e. no tropical oils are present.

More particularly, the base oil which is utilized in making tub-type margarines in accordance with the present invention, comprises (1) a co-interestified blend of a domestic vegetable oil and refined, bleached, fully hydrogenated and deodorized domestic vegetable oil hereinafter referred to as hardstock; (2) a refined, bleached, and deodorized (RBD) domestic oil; and (3) a small amount of cottonseed oil hardstock.

The domestic vegetable oil and hardstock of the cointerestified blend and the RBD liquid domestic oil may be chosen from a wide variety of oils, including soybean oil, cottonseed oil, corn oil, canola, peanut oil, sunflower oil, safflower oil and the like. Soybean oil and canola oil are preferred to be used as the RBD domestic oil, the soybean oil being most preferred. The RBD domestic oil is generally present in the base oil for the tub formula in an amount of from about 50% to about 90% by weight of the base oil, with an amount of about 75% to about 85% being preferred.

The co-interesterified blend of the domestic vegetable oil and hardstock is generally present in the tub formula of the present invention in an amount from about 10% to about 50% by weight based upon the weight of the base oil, with an amount from about 15% to about 25% being preferred. The proportion of vegetable oil to the hardstock generally ranges from about 90:10 to about 60:40, with about a 70:30 to about 85:15 ratio being preferred. The preferred vegetable oils to be used in the co-interestified blend are soybean oil and canola, while cottonseed oil hardstock and soybean oil hardstock are the preferred fully hydrogenated oils to be used. In addition, the hardstock can also be a mixture of cottonseed oil hardstock and soybean oil hardstock.

The third oil component in the base oil tub formula in accordance with the present invention is cottonseed oil hardstock. It is important that the cottonseed oil hardstock have an Iodine Value (IV) of less than or equal to 5. The cottonseed oil hardstock is generally present in the base oil tub formula in an amount of about 0.1% to about 6% by weight based upon the weight of the base oil with an amount of about 2% to about 5% by weight being preferred.

The IV of a fat or oil measures the number of grams of Iodine absorbed by 100 grams of sample as determined by A.O.C.S. Method. Cd 1-25, also known as the Wijs method. Iodine is absorbed by double bonds within the fatty acids comprising an oil or fat molecule (triglyceride) which is given to be an indication of an oil or fat's relative unsaturation. The amount of solid fat present at a given temperature for unhydrogenated fats or oils relates to the amount of saturated fatty acids found in the array or triglycerides unique to the fat or oil. Therefore, the lower the IV of a given fat or oil, the greater the saturation and solid content will be at a given temperature. For example, cocoa butter and cocoa butter substitutes and extenders usually have an IV of about 35 or less.

The specific oil blend to be interesterified, that is the combination of domestic vegetable oil and hardstock, is subjected to the interestification reaction which may be random, directed or enzymatic. In the case of random interestification, the reaction is generally carried out with about 0.1% to about 0.5% by weight (usually based on starting free fatty acid content) of a suitable catalyst, for example, preferably sodium methoxide (methylate) at temperatures from about 600C to about 1000C. for a period of about 3 to about 120 minutes with agitation under vacuum or inert atmosphere. After the reaction achieves equilibrium, the reaction is terminated through catalyst inactivation with either 1% to 3% by wt. of water or dilute acid solution such as citric or phosphoric acid. The subsequent removal of residues, such as metallic soaps and mono-diglycerides, is carried out by traditional edible oil processing means which include, but is not limited to, water washing, centrifugation, vacuum drying, drying under inert atmosphere, bleaching with acid activated or neutral bleaching/filtering media and deodorization. The interesterified oils or fats. to be used in the tub base oil formulas of the present invention may be interesterified, in admixture or separately, and surprisingly achieve physical and functional characteristics comparable to hydrogenated oils, essentially free of trans fatty acids which are normally found in partially hydrogenated oils.

The base oil compositions described above are to be used in making tub-type products. In the market place, margarines are generally sold as one of two principal types, print or stick-type margarine and soft or tub-type margarine with minor amounts sold as whipped or liquids.

Print or stick-type margarine must generally have a firmness consistent with a penetration range of from 35 to 120, said measurement being in units of 0.1 mm using an ASTM grease cone at 45 Fy Soft on tub-type margarine, on the other hand, as one would expect, does not have to be as hard as stick-type margarine and generally has a firmness consistent with a penetration range of from 130 to 250. Fluid margarine is sold in a form squeezable from a flexible container. Accordingly, it can be seen that depending upon the desired product type, both composition of the oil phase, as well as the processing parameters, plays an important role.

The tub-type margarine oil phase formulas in accordance with the present invention further include emulsifiers which will be discussed below. It is noted here, however, that without the addition of the RBD oil and cottonseed oil hardstock to the specific interesterified oil blend of the present invention, the emulsion products would not have the necessary plasticity, i.e. spreadability and mouthfeel, or the thermal stability (cycling from refrigerated to room temperatures) necessary for acceptable tub products.

For the purpose of making margarines, the oil phase described above must make up at least 80% by weight of the margarine to meet the fat requirement set forth by the Standards of Identity for margarine. Still, the present invention is further directed to the use of the oil phase described above in the preparation of calorie reduced margarines (diet margarines), bulk food processor margarines and spreads, blends with dairy products and other spreads containing less than 80% by weight fat.

For purposes of making emulsified products including margarine and spreads, the oil phase may range from about 25% to about 90% by weight and the aqueous phase may range from about 10% to about 75%.

It is important to note that the percentages of said oil phases given above include, in addition to the indicated base oil, emulsifiers, optional colorings, oilsoluble flavors, vitamins and antioxidants.

Of the additional components which may be added to the oil phase in addition to the oils, the second critical factor for the purposes of making the products in accordance with the present invention is the presence of specific emulsifiers. The specific emulsifiers to be used in the oil phase of the present invention are nonplastic fully hydrogenated distilled monoglycerides, such as Myverol 1807tom (Eastman Chemical, Kingsport, TN).

Lecithin is also used in the oil phase of the emulsions in accordance with the present invention. The nonplastic fully hydrogenated distilled monoglycerides act to help formulate the emulsion and, in addition, provides necessary physical integrity and plasticity to allow machinability (forces inherent during filling and packaging). Lecithin, to a lesser extent, has the same function as conventional emulsifiers. However, lecithin also functions to impart the primary salt perception to the product as well as being a known anti-spattering additive. The non-plastic distilled monoglycerides may be present in the oil phases of the present invention in an amount from about 0.2% to about 3.0% by weight based upon the total weight of the margarine or spread.

Preferably, the non-plastic distilled monoglycerides are present in an amount of from about 0.3% to about 1.0% by weight.

With respect to the other components of the oil phase, examples of typical coloring agents which may be added include beta-carotene, annatto, turmeric, paprika, FD & C dyes and the like. Various oil-soluble flavors which may be added to the oil phase of the fat blends of the present invention include lipolyzed hydrolyzed butter oils, diacetyl, 2-octanone, butyric acid, hexanoic acid and the like. Examples of vitamins which may be added to the oil phase include Vitamin A and its derivatives. In addition, antioxidants, such as TBHQ (or other approved phenolic-type antioxidants), can also be added into the oil phase mix.

In addition to the oil phase, the emulsions used to make the products of the present invention must also contain an aqueous phase. The aqueous or water phase of the emulsions in accordance with the present invention 1 comprised of conventionally known components and may include water-soluble flavors, milk or milk solids, whey solids, salt, preservatives, casein, caseinates, albumin, water and other suitable margarine ingredients. The milk component can be derived from whole milk, low-fat milk ( < 2% butter fat content), skim milk or nonfat dry milk solids. The amount of milk and/or milk solids (in terms of % by weight solids) usually ranges from about 0.5% to about 5% by weight of the emulsified product and more typically from about 1% to about 3% by weight.

Particularly where milk solids are used, potable water is included as part of the aqueous phase. Salt may also be included in an amount of from about 0.5% to about 3.5% by weight of the emulsified product and more typically in an amount of from about 1% to about 2.5% by weight. The amount of other water soluble flavors depends upon the particular flavor characteristics desired. Examples of preservatives which are added in amounts to prevent or retard bacterial sorbate, EDTA, sodium bensoate, sorbic acid and the like.

The aqueous phase, thus comprising preferably potable water, a suitable protein source, salt and appropriate preservatives, is slowly added and blended with the oil phase at a temperature from about 40C to about 630C to form an emulsion. The ingredients may be formulated in separate mix tanks from which they are metered out into another tank where the aqueous phase is dispersed in the melted oil phase. The emulsion is then processed preferably under specific processing conditions to produce the final product.

Figure 1 is a schematic diagram of the processing steps and conditions which result in the tub-type margarine and other spreads of the present invention.

With reference to Figure 1, the melted dispersion (2), i.e. the combined oil and aqueous phases, is fed from a storage tank (4) via a supply pump (6) and a positive displacement pump (8) to a scraped surface heat exchanger (10). An example of a scraped surface heat exchanger is the Votator A-Unit. The A-Unit (10) usually consists ot a stainless steel shaft (mutator shaft) rotating eccentrically inside a shell which is jacketed and cooled externally by liquid ammonia or brine solution or other refrigerant. The rotating mutator shaft is fitted with scraper blades which at high rotation speeds are pressed against the cooled inner surface. The rotation speed of the scraper blades by definition is proportional to the extent of supercooling the emulsion. The internal pressures and chilling action supercools the emulsion in the A-Unit (10).

It has surprisingly been found that given the specific fat blends in accordance with the present invention, there exists a unique relationship between improved machinability of the products produced and the degree of supercooling in the A-Unit (10), as well as the incorporation of an extrusion valve between the exit of the B-Unit and the filler.

The invention will be described, in relation to experiments, and pilot plant runs conducted on a pilot scale Votator Model No. S3/41A manufactured by Cherry Burrell Process Equipment (Louisville, Kentucky) which was fitted with an extrusion valve Part No. 201848 also manufactured by Cherry-Burrell. The back pressures, extrusion pressures, rpms and pump pressures set forth, hereinafter, relate specifically the aforementioned equipment. One skilled in the art would be able to utilize this information, in arriving at suitable processing conditions for other equipment. However, it is preferred in all cases, with all equipment, to incorporate an extrusion valve located between the exit of the B-Unit and the filler.The extrusion valve will produce a smaller crystal size, which will in turn enhance the formability of the margarine or spread product, thereby facilitating crystallization rate and making the product more machinable. The extrusion valve, in this application, serves a different function than the more commonly utilized back pressure valve. The extrusion valve produces high shear, in that it provides a constant flow and maintains a constant pressure and shearing/ homogenization action as a consequence of its design. This is in direct contrast with a back pressure valve, which has a primary function of regulating and maintaining proper volume in the A-Unit thus providing uniform chilling.

More specifically, in conventional processing, the mutator shaft speed of the A-Unit (10) is usually about 180220 rpms while both the pump pressure (12) and system pressure (14) range from about 50 to about 75 psi (about 3.45 to about 5.17 bar). In accordance with the present invention, the mutator shaft speed of the A-Unit (10) can be set somewhat higher than that used in conventional processing. Optimum integrity of the final products is obtained when the A-Unit operates from about 200 to about 275 rpms, with a range of 210 to 230 rpms being preferred.

The pump pressure (12) is significantly higher in the process of the present invention at a pressure of from about 225 to about 425 psi (about 15.51 to about 29.30 bar), with a pressure of about 250 to about 350 psi (about 17.24 to about 24.13 bar) being preferred. The process of the present invention also employs an extrusion valve (16) positioned between the exit of the B-Unit (18) and the filler (20) in order to maintain a system pressure (14) between the A-Unit (10) and the B-Unit (18) of from about 225 to about 425 psi (about 15.51 to about 29.30 bar), which is also significantly greater than conventional processing conditions. The preferred extrusion pressure to be maintained in the method of the present invention is between about 250 to about 350 psi (about 17.24 to about 24.13 bar).

Pressures below 225 psi (15.51 bar) result in a product too soft to form while pressures of 425 psi (29.30 bar) or greater result in a product exhibiting signs of emulsion stress (i.e.

weeping). However, modern equipment for high speed (82,74 bar).

processing allows pressures up to 1200 psi/ It has been found that with the increased system pressure and extrusion pressures employed by the process of the present invent ion, the formability of the product is improved greatly and a superior product is obtained.

The temperature within the A-Unit (10) ranges from about 40C to about 100C. The emulsion is discharged from the A-Unit (10) to the B-Unit (18) at a temperature of from about 10"C to about 130 C. The total residence time within the A-Unit (10) ranges from about 2.5 to about 3.5 seconds.

The chilled emulsion from the A-Unit (10) is then fed to a working B-Unit (18). The working B-Unit (18), is usually a picker unit which typically consists of a large diameter tube having stator pins on the inner cylinder wall and a rotating shaft fitted with the rotor pins. The combination of the stator and rotor pins mechanically work the fat as it passes through the B-Unit (18) to form homogeneous crystals. The residence time of the emulsion in the B-Unit (18) is typically from about 10 to about 15 seconds. The temperature in the B-Unit generally ranges from about .70C to about 13 C.

The crystallized emulsion leaves the B-Unit (18) and is fed through the extrusion valve (16) before the filler (20) where it is packed in tub form as the final tub-type margarine product. The packed margarine is usually tempered at a temperature of from about 300F (-10C) to about 500F (1000) for at least a period of about 24 hours, or until crystal stability is achieved.

Thus, it has been found by employing the specific blends of co-interesterified oils, domestic vegetable oil and cottonseed oil hardstock of the present invention which include the incorporation of specific emulsifiers identified above, and by preferably adjusting the processing conditions, i.e. the supercooling and working parameters of the A and B-Units, as well as system pressures provided by an extrusion valve before the filler, a tub-type margarine product essentially free of trans fatty acids or tropical oils is obtained which has all the functional benefits and physical characteristics of margarines which have trans fatty acids (i.e.

partially hydrogenated oils) or tropical oils. These butter-like characteristics of the products of the present invention including flavor, color and physical properties.

The following examples are provided to further illustrate the present invention.

EXAMPLE 1 A tub-type margarine was made with an emulsion having the following ingredients: Oil Phase Wt.% Co-interestified soybean oil: 12.0756 Cottonseed oil hardstock (75:25) RBD soybean oil 65.4572 Cottonseed oil hardstock (IV < 5) 2.1942 Myverol 1807 0.399 Lecithin 0.100 Flavor 0.052 Carotene/Vitamin A mix 0.004 Aqueous Phase Wt.

Potable Water 13.452 Salted Whey 4.884 Salt 1.333 Preservative 0.049 More specifically, a blend of completely dry, refined soybean oil and refined, bleached and deodorized cottonseed oil hardstock (75:25) was co-interestified in the presence of 0.3% sodium methylate for a period of about 30 minutes under an inert atmosphere. After achieving equilibrium, as determined by melting point, the reaction was terminated by adding 2% by weight of a citric acid solution. The oil was then washed to removed residual by-products of the interestification reaction and then dried under an inert atmosphere at a temperature of about 1040C.

After achieving a moisture level of < 0.1% by weight, the interestified blend was treated by adding 1% acid activated bleaching earth at a temperature of about 820C.

The temperature was then raised and held at a temperature of about 1040C for about 20 minutes. The interestified blend was then cooled and filtered to remove the spent bleaching earth. Following filtering, the oil was deodorized using standard well-known conditions to remove compounds that promote unacceptable flavor and oxidative characteristics in a finished edible oil product.

The co-interestified soybean oil, cottonseed oil hardstock blend was mixed with the other oil phase components identified above, i.e., RBD soybean oil, cottonseed oil hardstock, the emulsifiers (Myverol 1807 and lecithin), flavor, coloring (beta carotene) and Vitamin A, in proportions to achieve the > 80% fat requirement set forth by the Standards of Identity for Margarine. The water or aqueous phase, comprising potable water, salted whey (i.e., a suitable protein source), salt and preservatives, was then mixed with the oil phase at a temperature of about 520C. to achieve an emulsion.

The emulsion was then pumped through a scraped surface heat exchanger of the previously described Votator equipment. The emulsion was fed from the A-Unit with an exit temperature of 9 C, to a B-Unit where optimum crystal formation was achieved. The residence time of the emulsion in said B-Unit was approximately 6 seconds. Additionally, 6% nitrogen was injected into the emulsion prior to the A-Unit for optimum plasticity, density, and appearance. The system pressure was (about 14.13 bari.

maintained at about 350 psi / The system pressures were achieved with an extrusion valve positioned between the exit of the B-Unit and before the filler.

The product obtained had the physical characteristics of conventional tub-type margarine relative to spreadability, at both refrigerated and room temperature, emulsion stability (from temperature cycling) and flavor release. In addition to the aforementioned characteristics of the tub-type margarine, it is noted that trans fatty acids were undetected in the margarine product as was the presence of any tropical oils.

COMPARATIVE EXAMPLE 1 An emulsion was prepared as in Example 1 with the following ingredients: Oil Phase Wt.% Co-interestified soybean oil: 79.727 Cottonseed oil hardstock (75:25) Mono-diglyceride (approx. 43% monoglyceride) 0.399 Lecithin 0.100 Flavor 0.052 Carotene/Vitamin A mix 0.004 Aqueous Phase Wt.% Potable Water 13.452 Salted Whey 4.884 Salt 1.333 Preservative 0.049 As will be noted, the emulsion differs from that in Example 1 in that Myverol 1807 was replaced with approximately 43% type mono-diglyceride at the same level and the oil phase components of RBD soybean oil and cottonseed oil hardstock were replaced with the equivalent amount of the co-interestified blend of soybean oil and cottonseed oil hardstock.

The emulsion was then pumped through the scraped surface heat exchanger or A-Unit rotating at approximately 200 rpm and at pump and back pressures of (11.03 bar).

160 psi / The system pressures were achieved with a conventional back pressure valve positioned after the B Unit. Exit temperature out of the A-Unit was 90C.

One working B-Unit was used resulting in a product that was hard and brittle. Additionally, 6% nitrogen had been injected into the mix for optimum plasticity.

The resulting product was brittle and unspreadable.

COMPARATIVE EXAMPLE 2 An emulsion was prepared as in Example 1 with the following ingredients: Oil Phase Wt.t Co-interestified soybean oil: 39.8635 Cottonseed oil hardstock (75:25) RBD soybean oil 39.8635 Myverol 1807tom 0.399 Lecithin 0.100 Flavor 0.052 Carotene/Vitamin A mix 0.004 Aqueous Phase Wt.% Potable Water 13.452 Salted Whey 4.884 Salt 1.333 Preservative 0.049 Like Example 1, the emulsion in this example contained the special emulsifier, Myverol 1807tom, and the additional RBD soybean oil. The oil phase, unlike Example 1, did not contain the additional cottonseed hardstock. The product was prepared in accordance with the procedure set forth in Comparative Example 1.

As contrasted with Comparative Example 1, the use of Myverol 1807tom and the replacement of 50% by weight of the co-interestified blend of liquid soybean oil and fully hydrogenated cottonseed oil hardstock with refined, bleached and deodorized soybean oil, improved the plasticity of the product markedly. Although significant improvement resulted, the product was not optimal.

COMPARATIVE EXAMPLE 3 An emulsion was prepared as in Example 1 with the following ingredients: Oil Phase Wt.t Co-interestified soybean oil: 14.3509 Cottonseed oil hardstock (75:25) RBD soybean oil 65.3761 Myverol 1807tom 0.399 Lecithin 0.100 Flavor 0.052 Carotene/Vitamin A mix 0.004 Aqueous Phase Wt.% Potable Water 13.452 Salted Whey 4.884 Salt 1.333 Preservative 0.049 The oil phase composition differs from Comparative Example 2 in that in the present example, 822 by weight of the co-interestified blend was replaced with the refined bleached and deodorized soybean oil. The product was prepared in accordance with the procedure set forth in Comparative Example 1. The resulting margarine was improved, but slightly soft.

EXAMPLE 2 A tub-type margarine was prepared in accordance with the procedures as set forth in Example 1 and using the emulsion composition as set forth in Example 1 with the exception that the 75:25 co-interestified soybean oil: cottonseed oil hardstock was replaced with an equal amount of 80:20 co-interestified soybean oil:soybean oil hardstock.

The tub-type margarine product was comparable to the product described in Example 1.

EXAMPLE 3 A tub-type margarine was prepared in accordance with the procedure set forth in Example 1 and using the emulsion composition as set forth in Example 1 with the exception that the 80:20 co-interestified soybean oil:cottonseed oil hardstock was replaced with an equal amount of 75:25 co-interesterified canola oil:cottonseed oil hardstock. In addition, the RBD soybean oil was replaced with an equivalent amount of RBD canola oil.

The tub-type margarine product was slightly soft but otherwise comparable to the product of Example 1 and suitable as a tub-type margarine product.

COMPARATIVE EXAMPLES 4 AND 5 A co-interestified soybean oil and cottonseed oil hardstock (90:10) blend was prepared as was a cointerestified soybean oil and cottonseed oil hardstock (50:50) blend as described in Example 1.

The 90:10 blend (Comparative Example 4) was obviously too soft to form a tub-type margarine and an emulsion was not even attempted. However, it is conceivable that this proportion would produce an acceptable product if the base oil incorporated additional cottonseed oil hardstock.

Similarly, the 50:50 blend (Comparative Example 5) was obviously too hard and too brittle to form an acceptable tub-type margarine and an emulsion was not even attempted.

The above preferred embodiments and examples are given to illustrate the scope and spirit of the present invention. The embodiments and examples described herein will make apparent, to those skilled in the art, other embodiments and examples. These other embodiments and examples are within the contemplation of the present invention. Therefore, the present invention should be limited only by the appended claims.

Claims (23)

1. A tub-type margarine or spread comprising an emulsion of from about 25% to about 90% by weight of an oil phase and from about 10% to about 75% by weight of an aqueous phase, wherein said oil phase comprises a base oil which comprises from about 10% to about 50% by weight based upon the weight of the base oil of a co-interesterified blend of domestic vegetable oil and vegetable oil hardstock wherein the proportion of domestic vegetable oil to hardstock ranges from about 90:10 to about 60:40, from about 50 to about 90% by weight based upon the weight of the base oil of a refined, bleached and deodorized vegetable oil, from about 0.1% to about 6% by weight of cottonseed oil hardstock and from about 0.2% to about 3.0% by weight based upon the total weight of the margarine or spread of a nonplastic fully hydrogenated, distilled monoglyceride emulsifier.

2. A tub-type margarine or spread according to claim 1, wherein said domestic oil is selected from soybean oil, cottonseed oil, peanut oil, sesame oil, corn oil, sunflower oil, canola, safflower oil and mixtures thereof.

3. A tub-type margarine or spread according to claim 2, wherein said domestic vegetable oil is soybean oil or canola oil.

4. A tub-type margarine or spread according to any one of claims 1 to 3, wherein said hardstock is selected from soybean oil, cottonseed oil, corn oil, canola, peanut oil, sunflower oil, safflower oil, high erucic acid rapeseed oil (HEAR) and mixtures thereof.

5. A tub-type margarine or spread according to claim 4, wherein said hardstock is cottonseed oil, soybean oil or a mixture thereof.

6. A tub-type margarine or spread according to any one of claims 1 to 5, wherein said oil phase comprises at least 80% by weight of the emulsion.

7. A tub-type margarine or spread according to any one of claims 1 to 6, wherein said refined, bleached and deodorized vegetable oil is selected from soybean oil, cottonseed oil, corn oil, canola, peanut oil, sunflower oil, safflower oil, high erucic acid rapeseed oil (HEAR) and mixtures thereof.

8. A tub-type margarine or spread according to claim 7, wherein said refined, bleached and deodorized vegetable oil is soybean oil or canola oil.

9. A tub-type margarine or spread according to any one of claims 1 to 8, wherein said non-plastic fully hydrogenated distilled monoglyceride emulsifier is present in an amount of from about 0.3% to 1%.

10. A tub-type margarine or spread according to any one of claims 1 to 9, wherein said base oil comprises refined, bleached and deodorized vegetable oil in an amount of from about 75% to about 85%.

11. A tub-type margarine or spread according to any one of claims 1 to 10, wherein said oil phase comprises a base oil which comprises from about 15% to about 25% by weight of a co-interesterified blend comprising domestic vegetable oil and vegetable oil hardstock in a proportion ranging from about 70:30 to about 85:15, from about 75% to about 85% by weight refined, bleached and deodorized vegetable oil, from about 2.0% to about 5% by weight cottonseed oil hardstock and from about 0.3% to about 1% by weight non-plastic fully hydrogenated distilled monoglyceride emulsifier.

12. A process for making an emulsified spread comprising the steps of: (a) forming an emulsion of from about 25% to about 90% by weight of an oil phase and from about 10% to about 75% of an aqueous phase, wherein said oil phase comprises a base oil comprising from about 10% to about 50k by weight of the total weight of the base oil of a co-interesterified blend of a domestic vegetable oil and a vegetable oil hardstock wherein the proportion of domestic vegetable oil to hardstock ranges from about 90:10 to about 60::40, from about 50 to about 90% by weight of a refined, bleached and deodorized vegetable oil, from about 0.1k to about 6% by weight of cottonseed oil hardstock and from about 0.2k to about 3% by weight of the final margarine or spread of a non-plastic fully hydrogenated, distilled monoglyceride emulsifier; (b) feeding to and supercooling the emulsion in an A-Unit; (c) discharging the supercooled emulsion from the A-Unit and feeding the emulsion into a B-Unit and working said emulsion to form homogeneous crystals; (d) discharging the emulsion from the B-Unit through an extrusion valve which functions to maintain sufficient pressure and shear; (e) feeding the emulsion to a filler; and (f) packing the emulsion.

13. A process according to claim 12, wherein said extrusion valve is positioned between the exit of the B-Unit and the filler.

14. A process according to claim 12 or claim 13, wherein said domestic oil is selected from soybean oil, cottonseed oil, peanut oil, sesame oil, corn oil, sunflower oil, canola, safflower oil and mixtures thereof.

15. A process according to claim 14, wherein said domestic vegetable oil is soybean oil or canola.

16. A process according to any one of claims 12 to 15, wherein said hardstock is selected from soybean oil, cottonseed oil, corn oil, canola, peanut oil, sunflower oil, safflower oil, high erucic acid rapeseed oil (HEAR) and mixtures thereof.

17. A process according to claim 16, wherein said hardstock is cottonseed oil, soybean oil or a mixture thereof.

18. A process according to any one of claims 12 to 17, wherein said refined, bleached and deodorized vegetable oil is selected from soybean oil, cottonseed oil, corn oil, canola, peanut oil, sunflower oil, safflower oil, high erucic acid rapeseed oil (HEAR) and mixtures thereof.

19. A process according to claim 18, wherein said refined, bleached and deodorized vegetable oil is soybean oil or canola.

20. A process according to any one of claims 12 to 19, wherein said non-plastic fully hydrogenated distilled monoglyceride emulsifier is present in an amount of from about 0.3% to about 1.0%.

21. A process according to any one of claims 12 to 20, wherein said base oil comprises refined, bleached and deodorized vegetable oil in an amount from about 75% to about 85%.

22. A process according to any one of claims 12 to 21, wherein said oil phase comprises a base oil which comprises from about 15% to about 25% by weight of the cointeresterified oil blend comprising domestic vegetable oil and vegetable oil hardstock in a proportion ranging from about 70:30 to about 85:15, from about 75% to about 85% by weight refined, bleached and deodorized vegetable oil, from about 2.0% to about 5% by weight cottonseed oil hardstock and from about 0.3% to about 1% by weight non-plastic fully hydrogenated distilled monoglyceride emulsifier.

23. A process according to any one of claims 12 to 22, wherein said oil phase comprises at least 80% by weight of the emulsion.