IE41478B1 - Filled bread products - Google Patents

Abstract

The production of the novel foodstuff is carried out either by separate production and subsequent combination of core and case or by joint extrusion of the core and the outer layer.

Description

The present invention relates to a novel combination of two types of food, in which a mass of bread serves an an at-least partial covering for a core (whifeh core may, if desired, also contain a filling) of food other than bread, for example, a conventional (preferably sweet) spread. The mass of bread is bonded to the core.

Owing to the circumstances of modem life, such as long absences from home, travelling, car rides ^rtd school, the need for small, interim meals (snacks) is growing gener10 ally. There is a need for snack foods which require little preparation, which are convenient and which are easy to handle. Snack foods at present on the market include sweets, such as candy, chocolate (which may have a filling) and bars (with various, partly fatty fillings and chocolate covers).

Thesq products.suffer certain disadvantages for various reasons,, which mitigate against frequent consumption. The ingredients of these products, moreover, are not always considered to be appropriate substances to consume in the sense that they do not always provide the required degree of nourishment.

Chocolate and chocolate coatings are extremely - 2 41478 sensitive to temperature, as a result of which they melt and become soft when kept, for example in a warm car or in school. The molten or soft chocolate readily soils the hands and makes them sticky. This chocolate, particularly in the case of children, may be transferred to and soil clothes and furniture.

Moreover, although the sweet taste of the snack food initially attracts one to eat it, the desire for the sweet food rapidly wanes until the eater is satiated Iq and feels that he has eaten to excess. Moreover, the eater rapidly becomes (hirsty as a result of the sweetness of the snack food and this curbs further consumption of the snack food.

In an attempt to overcome the above disadvantages it has been suggested that chocolate should be eaten together with bread - a very palatable combination. This suggestion has been exploited by the advertising media with the recommendation that thin chocolate bars should be eaten on slices of bread, i.e. using the chocolate as a chocolate spread.

This latter-mentioned snack food also suffers disadvantages in that the stickiness of the chocolate and its characteristic of smearing is not avoided. Furthermore, no solid connection is formed between the chocolate and the bread, so that on biting the thin chocolate bar there is a risk that the bar will break and fall off the bread. Moreover there is the additional difficulty that bread must always be at one's disposal. Thus either the bread must be carried about or bread must be readily available at the place where it is desired to eat the bread/ chocolate mixture, if one wishes to eat this snack food outside the house. Moreover the bread must be cut in suitable shapes and sizes.

Filled waters are also known, but these contain another soft filling and the wafer consists of fine pastry, which does not possess the nourishing character of bread.

The present invention is based on the discovery of a snack food which combines the taste of bread with, for example, a sweet spread, while, at least in part, avoiding the described disadvantages.

According to one feature of the present invention there is provided a ready-to-eat food product in elongate form having a sheath/core construction the end portions of which product are either open with core material exposed or closed, the said product comprising a sheath of a bread mass bonded (as herein defined) to the core, the bread sheath having a water content of less than 15% by weight throughout its mass. 1 The term bonded as used throughout the complete specification means that the bond between the sheath and the core is sufficiently strong to prevent separation of the bread mass from the core during handling at ambient temperatures. 4147S The core material is preferably selected to have a good storage life, i.e. a life of at least 6 months when stored in hermetically sealed packs at a storage temperature not in excess of 25°C.

The bread sheath of the food products according to the invention is preferably produced by extrusion. In a particularly preferred embodiment the bread sheath is an extruded shell or casing with a continuous unbroken outer surface. The elongate food products of the present invention are preferably cylindrical in form with a square, half-round, round, oval or other cross-section with the core material extending in an axial direction therethrough.

The end portions of elongate food products according to the invention can be open with core material exposed, closed by bread or closed by other food substances as desired.

It is desirable to prepare food products according to the invention which have good storage life and it is thus preferred that the bread sheaths of the products should have a water content of less than 10 percent and more especially less than 5 percent by weight throughout their mass. In order to obtain the moisture levels necessary for good storage life a second baking step can be effected at a temperature and for a time necessary to give the desired moisture levels. Alternatively the conditions at which a single baking step are carried out can be adjusted to give the desired moisture levels.

The food product according to the invention consists, for example, of a product in the shape of a bar or in a similar elongate shape, consisting of an exterior, preferably closed cover of bread e.g. wholemeal bread and an interior, preferably sweet, for example cocoa- or chocolate-containing core. With regard to physiological nutrition the product may be enriched with protein, vitamins and trace elements.

A filler of fruit pulp, (e.g. maracuja (passion-fruit) or apricot) may also be employed in the core as a refreshing, thirst-quenching component enriched with vitamins.

The hollow bread covering may be filled not only with chocolate, but with for example yoghourt, yoghourt-containing masses, nougat, marzipan, caramel, toffee and similar substan ces. The invention is not restricted to the combination of a bread cover with a core of sweet material; thus meat such as hard sausage, or cheese may be considered as suitable fillings. In this case, a filler of fruit-pulp is preferably not used since this would, in general, have an adverse affect on the taste Of the product.

According to a further feature of the present invention there is provided a process for the preparation of a food product according to the invention as herein defined, wherein the core and the bread sheath are produced separately and subsequently united.

According to a still further feature of the present invention, there is provided a process for the preparation of a food product according to the invention as herein defined, which comprises co-extruding the core and a bread dough or bread mass and thereafter if necessary baking and/or drying to provide a product with a bread sheath having a water content of less than 15% by weight throughout its mass.

The mass of bread is preferably made of conventional rye and/or wheat dough. The preparation of the bread covering may either be effected together with or separately from the preparation of the core. When prepared separately, the dough may either be pressed directly through an extruder as a hollow body and subsequently baked by heat or microwaves; or the formless dough may be baked first, then crushed and the moist, or dried and subsequently remoistened, crumbs of bread formed into a hollow body. It is also possible to prepare half-shells of bread which may subsequently be filled with sweet material, the half-shells being joined together by heat, or by spreading or spraying a connecting edge with a viscous food, such as syrup. The preparation of the products of the invention may also be effected in such a way, that the half-shells are joined or sealed together ; before filling,, the filling being effected from the exterior, θ·9· by injection.

The production of the hollow bread bodies may also be effected by extrusion and subsequent wrapping of a strip of dough around a form e.g. a rod, baking being effected either simultaneously or subsequently. It is useful, to proceed in such a way that the strip of dough leaves the extruder about 20 to 25 nm wide and 3 nm thick. The strip of dough is subsequently wrapped continuously e.g. slanting y around a rotating rod of for example glass or metal of the desired shape (round, square) and baked. The dough may also be brought into contact with the rod in a fermentation room first (for development of the dough) and then put into the oven.

It is also advantageous to bake the dough first until it is partially baked e.g. half done, then to wrap it helically over a suitable form and subsequently to finish baking, or to grill and/or dry the helix of dough. Then, after dividing the product into portions and cooling as well as removing the interior form, the hollow bread may be filled.

In order to increase the binding property of the bread mass, other foodstuffs, for example native or coldswelling starch, glucose, sorbitol, protein or legally permitted food additives may, if required, be employed.

To increase durability, preservatives, such as calcium propionate may, if desired, be added. Moreover the bread may be enriched with vitamins and trace elements.

The sweet material preferably used for the core (e.g. chocolate, caramel or toffee) may be produced in any manner known per se (e.g. by 25 mixing, kneading or foaming) from protein, fat, sugar, sugar substitutes and/or cocoa and may also be enriched with vitamins and trace elements. Other possible starting materials for the core filling, such as yoghuort, cheese or meat are also produced in a manner known per se.

If desired, a sweet core may itself be filled in a manner known per se, e.g. by means of a pump, with a highly aromatic, preferably sourish fruit mass (e.g. as pulp, paste or gel). Pieces of whole fruit may also be incorporated in the core.

If the production of the core and sheath is effected simultaneously, the materials to form the core and sheath are fed separately into a co-extruder. The co-extruder may form the product into any desired cross-sectional shape e.g. square, half-round, round or oval or similar shape e.g. having a cross-section of approximately 5 to 30 mm.

The bread dough or bread mass to form the sheath is extruded from the co-extrusion device as a cylinder and the core is simultaneously extruded so that it is situated within the said cylinder. The bread sheath and the core (including any pulp filling) are conveniently used in a weight ratio of 1 to 5 to 5 to 1, preferably 1 to 3 to 3 to 1 , and advantageously in a weight ratio of about 1 to 1. However, it is also possible to produce smaller products the bread sheath of which for example completely encloses the core e.g. in the size and shape of conventional sweets or chocolates.

If desired, when the core comprises chocolate, it is possible to inject fat crystals in known manner into the chocolate. This modifies the consistency of the chocolate and in particular alters the bite characteristics thereof.

The final product is preferably provided with an airtight wrapping.

If the bread dough is baked only after is leaves the nozzle of the extruder, the interior mouthpiece must be extended beyond the heating zone, so that the filling only enters the bread sheath after it has been baked.

It is also possible to prepare the core by known techniques in the form of a hollow chocolate body. The aa It is useful to prefabricate the wrapping for the production of the invention in such a way, that it can be opened with one hand (one-hand wrapping).

An embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings: Fig. 1 shows a cross section through an extruder indicating the production of a snack food according to the present invention.

Fig. 2, 3 and U each show various forms of foods 15 of the present invention.

Figure 1 shows various ingredients of a food product of the present invention issuing from an extruder consisting of three concentric cylinders. The extruder is provided with a nozzle adapted to supply three separate components simultaneously in extruded form.

The bread or bread-dough mass (1) is extruded between the outer surface of the nozzle (5) and the inner surface of the nozzle (6). The sweet material (e.g. chocolate) (2) is extruded between the inner surface of the nozzle (5) and the outer surface of the nozzle (4). The fruit 3 filling (e.g. a passion fruit gel) (3) is extruded through the nozzle (4). The nozzle (6) terminates prior to termination of the nozzle (4) and (5). Thus in use the bread or bread-dough mass (1) exits from the extruder to form a coating or layer around the nozzle (5). This coating or layer passes through the baking zone (7), baking being effected by microwaves or by conventional heating in an oven. After the coating or layer of bread has issued from the baking zone (7) it passes into the cooling zone (8) and thereafter the sweet material (2) and fruit filling (3) issue from the inner nozzles (4) and (5) to be enclosed by an outer coating or layer of bread (1).

Figures 2, 3 and 4 illustrate various forms which the food products of the present invention may take. The reference numerals employed in Figure 1 have the same meanings in Figures 2, 3 and 4.

The following Examples illustrate the invention without restricting same: <3 Example 1 a) Bread ingredients 70.0 kg of rye-flour (type 1150 as marketed in West Germany) 30.0 kg of wheat-flour (type 1050 as marketed in West Germany) 3.0 kg of yeast 0.8 kg of a standard commercial leavening agent (corresponding to approximately 0.7 kg of citric acid) 2.0 kg of common salt to 70 litres of water The dough prepared from the above-mentioned ingredients is allowed to stand for approximately 45 minutes at a dough temperature of approximately 27°C and subsequently processed in the conventional manner.

The pieces of dough thus formed are baked at a decreasing temperature of 240/220°C.

When the lpaves of bread have cooled, they are crushed in a mixer or with a grater. The crumbs are mixed with 0.05 to 0.1% of calcium propionate and adjusted to the desired moisture content of less than 10% by weight throughout their mass. b) Composition of sweet material:800 g of cocoa butter (or other fat) 1200 g of cocoa mass 1100 g of milk powder (or skimmed milk) 6900 g of sugar (or other sweet material) The bread crumb and sweet material are extruded through an extruder as illustrated in Figure 1 of the accompanying drawings. A thin thread of maracuja-pulp (passion fruit pulp) is simultaneously 10 extruded in the middle of the core. The product is cut into portions and sealed in airtight wrappers.

Example 2 Example 1 is repeated except that the bread is baked in a microwave hearth in order to avoid the formation of a crust.

Example 3 Example 1 is repeated except that the bread is baked in pumpernickel boxes (water-bath) (so-called Wulbern baking boxes).

Example 4 Bread crumbs prepared as described in any one of Examples dad1?© ls 2 or 3 are mixed with 5% of crystallized chicken protein, 5% of water and 5% of coconut fat (melting point 27 - 30°C). The sweet material is prepared as described in Example 1 and the products are then produced as described in Example 1.

Example 5 ( Bread crumbs are prepared as described in any one of Examples 1, 2 or 3.

The crumbs are spread on trays and dried and/or roasted 10 with 30% of sorbitol (70% solution in water), and % of water fortified with the following vitamins: vitamin B^ vitamin 3% vitamin Βθ vitamin vitamin C vitamin E nicotinic acid amide calcium-D-pantothenate The product obtained is co-extruded using the composition b) of sweet material as described in Example 1, and the final product is cut into portions and sealed in airtight wrappers again as described in Example 1.

Example 6 Bread dough, prepared as described in Example 1, is baked on baking sheets, equipped with convex moulds, e.g. of the size 22 x 90 x 11 mm (width x length x height) - similar to chocolate-covered sweets in ball-shape - or on bakingsheets with concave moulds e.g. measuring 30 x 100 x 15 mm (width x length x depth) with an upper mould of the size 22 x 90 x 11 mm as half-shells.

Rounded shapes e.g. 22 x 90 mm. are prepared from the 10 following ingredients :2200 g of cocoa butter 1000 g of cocoa mass 1300 g of milk powder 5500 g of sugar (or substance replacing sugdr) if desired together with a fruit-pulp. The rounded shapes are placed into two of the above described half-shells. Bonding of the half-shells to the rounded shape is attained by heat or by previous spraying of the interior surface of the half-shell with a viscous food, such as sugar syrup.

Example 7 A mass of crushed bread, to which may be added a raising agent (air, carbon dioxide, nitrogen, baking powder, ammonium carbonate), is extruded through the exterior part of a nozzle, the nozzle consisting of a plurality of internal cylinders as illustrated in Figure 1 of the accompanying drawings, with a sweet material and fruit pulp being simultaneously extruded as described in Example 1. The product is cut into portions and wrapped. This example may be repeated using a bread dough instead of a bread mass.

Example 8 a) Dough: kg of rye-flour (type 1150 as marketed in West Germany) kg of wheat-flour (type 550 as marketed in West Germany) kg of yeast kg of fat kg of salt kg of malt extract or sugar 55-60 kg of water and/or milk The dough is prepared from the above-mentioned ingredients is allowed to stand for 45 minutes at a dough temperature of approximately 27°C, and is then processed in the conventional way. The dough is then rolled out until it is 2 to 3 mm thick, cut into strips 15 to 25 mm, preferably 20 mm, in width or produced in a similar shape by any extruder. The strips are wrapped helically around rods, 6 mm in diameter, and set on sheets. After passing through a fermentation zone the material is baked as follows: A) By placing in an oven at 240°C and then baking at about 200°C until the desired moisture content of less than 10% by weight is obtained and the material is light-brown to brown in colour. or B) By conventional baking to give bread with a moisture content of about 50% by weight. The rods are removed and the bread shells are then subsequently subjected to a second baking step at about 180°C until they have the desired moisture content of less than 10% by weight and are light-brown to brown in colour.

The rods are removed and the bread-cover, after drying and cooling is filled with the filling detailed below, b) Filling: 16.00 kg of sugar, ground 4.70 kg of skimmed milk powder 12.50 kg of coconut fat 0.20 kg of lecithin 1.05 kg of yoghourt powder 0.03 kg of citric acid 0.15 kg of strawberry powder (or of another fruit) fruit essence beetroot powder.

As described above, the filling contains an inner core, in this case strawberry jam. The jam may be separated from the bread cover by a chocolate layer.

It will be appreciated that the baking processes described in Example 8 can be employed in cases where the bread mass is produced from the dough by methods other than that described in Example 8, e.g. by extrusion.

Claims (30)

1. A ready-to-eat product in elongate form having a sheath/core type construction the end portions of which product are either open with core material exposed or closed, the said product comprising a sheath of a bread mass bonded (as herein defined) to the core, the bread sheath having a water content of less than 15% by weight throughout its mass.

2. A food product as claimed i n claim 1 wherein the core has a good storage life (as herein defined) •

3. A food product as claimed in claim 1 or claim 2 wherein J the core comprises a sweet material.

4. A food product as claimed in claim 3 wherein the core of sweet material is hollow and is filled ’ with a highly aromatic fruit pulp.

5. A food product as claimed in claim 1 wherein the core comprises chocolate.

6. A food product as claimed in claim 1 wherein the core comprises meat and/or cheese.

7. A food product as claimed in any of the preceding claims wherein the bread sheath is an extruded shell or casing with a continuous unbroken outer surface.

8. A food product as claimed in claim 7, in cylindrical form, having a square, half-round, round or oval cross-section and having the core material extending in an axial direction therethrough.

9. A food product as claimed in claim 7 or claim 8 the end portions of which are closed by bread.

10. A food product as claimed in claim 7 or claim 8 the end portions of which are closed by a food substance other than bread.

11. A food product as claimed in any of the preceding claims wherein the bread sheath has a water content of less than 10% by weight throughout its mass.

12. A food product as claimed in claim 11 wherein the bread sheath has a water content of less than 5% by weight throughout its mass.

13. A food product as claimed in any of the preceding claims wherein the bread mass comprises rye bread.

14. A food product as claimed in any of the preceding claims in an air-tight pack.

15. A food product as claimed in claim 1 substantially as herein described.

16. A food product as claimed in claim 1, substantially as herein described in any of the Examples.

17. A process for the preparation of a food product as claimed in claim 1, wherein the core and the bread sheath are produced separately and subsequently united.

18. A process for the preparation of a food product as claimed in claim 1 which comprises co-extruding the core and a bread dough or bread mass and thereafter the necessary baking and/or drying to provide a product with a bread sheath having a water content of less than 15% by weight throughout its mass.

19. A process as claimed in claim 17, which comprises first preparing a hollow body of bread mass and subsequently filling said hollow body with a core of sweet material.

20. A process as claimed in claim 19, wherein (a) the hollow body of bread mass is produced by extruding a strip of dough, (b) the said strip of dough is subsequently wrapped around a foam and (c) baking is effected either simultaneously with or subsequently 5 to (b).

21. A process as claimed in claim 19, wherein the dough is initially only partially baked and is then wrapped helically around a foam after which baking is completed.

22. A process as claimed in claim 17, which comprises 10 producing two half-shells of the bread mass, filling the said half-shells with a core of sweet material and subsequently uniting the half-shells by heat or by means of a syrupy food.

23. A process as claimed in claim 18 wherein the bread dough or bread mass is extruded from a co-extrusion device 15 as a cylinder and the core is simultaneously extruded so that it is situated within the said cylinder.

24. A process as claimed in either claim 17 or claim 18 wherein the core of sweet material is produced as a hollow body and filled with a high aromatic fruit mass. 20

25. A process as claimed in any of claims 17 to 24 wherein the bread mass is baked a second time before or after contact with the core.

26. A process as claimed in claim 25 wherein the second baking step reduces the water content of the bread to less 25 than 10% by weight throughout its mass.

27. A process as claimed in claim 26 wherein the second baking step reduces the water content of the bread to less than 5% by weight throughout its mass.

28. A process as claimed in any of claims 17 to 27 substantially as herein described.

29. A process for the production of a food product as claimed in claim 1 substantially as herein described in any 5 of the Examples.

30. A food product as claimed in claim 1, when prepared by a process as claimed in any of claims 17 to 29. Dated this 13th day of June 1975, TOMKINS