JPH0851968A - Manufacturing process of food - Google Patents

Abstract

PURPOSE: To maintain flavor by mixing food materials to carbohydrate matrix material, extruding it and powdering it so as to process a food material spreadable at a room temperature at a comparatively low temperature. CONSTITUTION: The food material spreadable at room temperature (beef tallow, chicken fat, etc.), is mixed with carbohydrate matrix material (starch, etc.), extruded by a biaxial screw extruder, etc. and this extruded matter is powered. A wet viscous paste is converted to easily flowable powder.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a food manufacturing method and a food manufactured by this manufacturing method.

[0002]

It is known that by melt-spinning a food material with a carrier material, a product can be produced in which the food material is distributed on and / or in the matrix of the carrier. The product obtained is
It is easier to handle than the original ingredients themselves.

EP-A-054060 discloses a process for melt-filtrating a mixture of maltodextrin with various foodstuffs including peanut butter and dried soup. This technique requires the conditions of the melt filamentation process to feed the feedstock in the form of a flash stream, and is generally carried out at temperatures of 130-180 ° C. However, this method condition must be carefully controlled,
If operated outside this limit, the food will carbonize and the matrix material will become unprocessable. Yet another drawback of this melt filamentation process is that it is inherently inadequate in terms of final product yield. A large proportion of foodstuffs cannot be incorporated into the matrix material during the melt filamentation stage and therefore have to be recovered or simply discarded for reuse.

International Patent WO 85/03414 discloses a method of encapsulating many materials in a matrix containing maltodextrin and hydrogen octenyl butanedioate amylodextrin. This document discloses a method of encapsulating flavourants and oil, but does not describe a method of encapsulating foodstuffs. Similarly, European Patent Application Publication No. 0158460 and US Pat. No. 5,009,900 disclose methods for encapsulating volatile flavors in an extruded glass matrix.

[0005]

It is an object of the present invention to provide an improved process for treating foodstuffs with a matrix material which is more effective than the above melt filamentation process and which can be operated at lower temperatures. .

[0006]

According to the present invention, a food product is provided which comprises mixing a foodstuff that is spreadable at room temperature with a matrix material consisting of carbohydrates, extruding the resulting mixture and converting the extrudate into a powder. A method for manufacturing is provided.

The method of the invention makes it possible to convert a moist, viscous paste into a free-flowing powder. Furthermore, the invention comprises a foodstuff which is spreadable at room temperature and which can be produced by the method according to the invention and on a matrix material
Alternatively, a food product distributed within the matrix is provided.

The foodstuffs used in the method of the invention are those that are spreadable at room temperature and can be sold as spreads for application to other food substrates. It will be apparent to those skilled in the art that the spreadable foodstuffs can generally be viscous liquids, solid / liquid mixtures, semi-solids and low melting point (ie below 50 ° C.) solids. It has been found that these foodstuffs can be extruded with a matrix of carbohydrates at temperatures well below those required for the melt filamentation process.

Such foodstuffs are animals and / or plants
-It may comprise fats or oils, such as beef fat or chicken fat. If the product of the invention contains fats or oils, an instant roux mixture can be prepared by adding up to 10% of starch to it, and hot water can be added to it to make roux. .

Other preferred foodstuffs used in the method of the present invention include chocolate spreads, yeast extracts, peanut butter and mixtures thereof. When these foodstuffs are incorporated into the product of the invention, the product can be converted into a spreadable paste by hydration. If desired, flavoring agents, preservatives, stabilizers and other conventional food additives can be included in the products of this invention.

The matrix material that can be used in the present invention consists of carbohydrates. For the invention to be effective, the carbohydrate should be at least partially soluble in or dispersible in water at temperatures in the range of 0 to 100 ° C., whereby the foodstuff is It can be released from the matrix by hydration.

The carbohydrate may be a single substance or a mixture of different carbohydrates and is used alone or in combination with other additives (preferably less than 50% by weight based on the amount of carbohydrate). be able to.

The carbohydrate is selected from monosaccharides, oligosaccharides, polysaccharides and mixtures thereof. Preferably, the carbohydrate is starch (the term "starch" as used herein includes all types of starch, including modified starch) or a product obtained from starch (described as a derivative of starch). Is. Suitable starch derivatives are starch derivatives having a reduced molecular weight and / or altered structure compared to starch. Derivatives are obtained, for example, by heat treating or hydrolyzing starch, which may be enzymatic or acid catalyzed, for example, and these techniques are well known to those skilled in the art.

The carbohydrates are therefore preferably starch or products obtained from starch with a DE (dextrose equivalent) of 0-100, such as dextrins, maltodextrins and glucose solids.

Carbohydrates not derived from starch can also be used in the present invention. These include sucrose, fructose and dextran. The most preferred carbohydrate in the method of the present invention is starch, glucose solids or maltodextrin, with maltodextrin being particularly preferred. Of particular suitability are maltodextrins having a DE in the range of 30 to 60, as these impart a slight sweetness to the product, thereby enhancing its taste.

The product obtained according to the present invention comprises 20 to 70% of food materials,
It may preferably consist of 50-70%. The presence of the food material in a relatively high proportion allows the taste of the product to more closely resemble the taste characteristics of the food material itself, avoiding the cost and volume problems associated with the use of large amounts of matrix material.

The matrix material and the food material are mixed to form a substantially homogeneously distributed mixture of the food material and the matrix material. This can be achieved by using a high shear mixer. The resulting raw material may contain other additives such as flavorings or preservatives. It has been found that the addition of up to 2% water to this feed aids the extrusion process.

The extrusion step of the process of the present invention is carried out using a conventional extruder (preferably a twin screw extruder). It is an important advantage of the present invention that the extrusion process can be carried out under conditions that are less detrimental as compared to the conditions imposed on the matrix material and the foodstuff in the conventional method. This process can be operated using an extruder with a barrel temperature of 20-90 ° C. It has been found to be particularly preferred to carry out the process under barrel temperatures of 30-70 ° C. The products obtained under these conditions maintain a high level of food flavor.

The extrusion step can be carried out by using an extruder having any suitable die, the die is sized extrudates can have a cross-sectional area of 1mm ² ~400mm ² of Is preferred. By maintaining the size of the extrudate in this range, the extrudate can easily be converted into a powder. Obviously, there is no need to reduce the size of the extrudate if the size of the extrudate has a suitably small cross-sectional area and fragments when leaving the die by the action of gravity or mechanical means such as a cutter. Ah However, in many cases the extrudate requires further processing to convert it into a powder, which is usually done by a mill. In the present invention, it is preferred that the extrudate has a cross-sectional area of about 50 mm ² , which is then ground to produce free-flowing granules.

[0020]

EXAMPLES The ingredients used in the following examples were obtained from the following suppliers: Smooth Peanut Butter-CPC International Inc., PO Box 8000, Alternative Plaza, Englewood Cliffs, New Jersey. 07632, USA Maltodextrin 1940 ── Casco Inc., CPC International I (Glucose solids) nc. Split company Nussani Chocolate ── Dohler (UK) Ltd., 4 Vincent (30) Have a fat content of Avenue, Crownhill Business Centre, Chocolate Hazelnut Milten Keynes, Buckinghamshire MK8 0AB paste) Peppermint Essence ── Rayner & Co Ltd., London N18 1TQ Orange Essence ─ ─ Rayner & Co Ltd ., London N18 1TQ Banana Flavor ── EF Langdale Ltd., Chase Road, Northern Way, Bury St Edmunds, Suffolk IP32 6NT Chicken Fat ── Nortech Food ( Nortech Food) Ltd., 172 Wak efield Road, Rothwell, Leeds Beef Fat ── British American Products, 400 Cleveland Street, Bir kenhead, Merseyside Tomato Serum ── Makhteshim Chemic al Works ) Ltd., POB 60, Beer-Sheva 84100, Is rael Tomato Starch ── Deltown Special ities, 1712 Deltown Place, Fraser, New York 13753. USA Modified Starch ── National Starch and Chemical, Prestbury Court , Greencourts Business Park, 333 Styal Road, Manchester M22 5LW Corn oil ── CPC UK Ltd., Claygate House, Esher, Surrey Sugar ── British Sugar plc, Colney, Norwich, Norfolk Vinegar ─ ─ Nestle ) UK Ltd., St Georges House, Croydon, Surrey CR9 1NR Maltodextrin 01921 ── Cerestar UK Ltd, Trafford Park, Manchester M17 1PA Example 1 Smooth Peanut butter and maltodextrin 1940
1: 1 mixture was made by blending the two components for 5 minutes in a high shear Hobart® mixer equipped with a dough hook. This mixture was introduced into an MPF50D twin screw cocker extruder (manufacturer: APV-Baker) equipped with a 25: 1 L: D barrel. This solids feed was introduced at a preset speed of 15 kg per hour by a variable speed twin screw K-Tron® solids feed hopper with a variable stroke of a single head to feed the liquid. A displacement pump was used for the product. The extrusion barrel was heated with an electric cartridge heater and cooled with Tricool® water circulating in a cooling system. The temperature in the barrel region was controlled by the West Octet microprocessor temperature controller. The extruder control panel displays torque and screw speed as percentages of maximum. The screw arrangement used consists initially of a transport screw for carrying the mixture from the feed port to the mixing section. The mixture was then passed through two 30 ° reversing zones divided by multiple mixing sections. A further mixing section was placed in the last section of the extruder barrel at the point before the product exiting the die.

A circular die with a diameter of 3 mm was used. Water was pumped into the extruder to aid the initial movement of the mixture as it moved through the barrel. Once the barrel was filled with the mixture, the water supply was stopped.

The extruded sample was collected on a metal plate coated with aluminum foil. Once this sample was cured, the sample was placed on a Retsch ZML mixer (Retsch Mill ZM
l) crushed in. This grinder was chosen because it does not generate much heat during use and can be comminuted by passing the extrudate through a 2 mm grill at its highest setting.

The temperature profile and screw speed used are listed in Table 1. Table 1 Processing parameters for Example 1 Temperature range profile (° C) Screw speed Feed rate 1 2 3 4 5 6 7 8 9 (rev / min) (kg / h) 20 20 20 40 40 50 50 60 70 350 15 A pale brown / yellow product of mild consistency slowly emerged from the extruder without aeration. Example 2 Example 1 is repeated, but with a maximum temperature in the barrel of 50
Lowered to ℃. The temperature profile and screw speed used are shown in Table 2. Table 2 Processing parameters for Example 2 Temperature profile (° C) Screw speed Feed rate 1 2 3 4 5 6 7 8 9 (rev / min) (kg / h) 20 20 20 20 30 30 40 40 50 350 15 A pale brown / yellow thin string of samples showing no oil separation was obtained. The string sample cured within about 10 minutes.

The extruded products of both Examples 1 and 2 were easy to grind and no problems such as plugging or oil separation occurred during this grinding process. The sample was passed through a grill to obtain a fine powder that was slightly lighter in color than the extruded product. Comparative Example for Examples 1 and 2 A 1: 1 sample of peanut butter and maltodextrin 1940 used in Examples 1 and 2 was processed using the method of EP 0540460 at 3600 rpm. This material easily passed through the sample head with minimal ribbon deposition. The processed sample was obtained as fine needles, but material accumulated along the annulus of the collection bottle.

The products obtained in Examples 1 and 2 were evaluated by their expert panel for their organoleptic qualities, the panel commenting on the peanut flavor of the products and these and the European patents. The product obtained according to published application 0540460 was compared. The prior art product was extremely sweet and the peanut flavor was very strong, but with a slight lack of freshness.

The sample of Example 1 initially felt less sweet than the prior art product and had a very tasty flavor similar to raw peanuts. A slight malt flavor was also felt.

The sample obtained in Example 2 had a salty peanut taste, which could be felt immediately upon eating. This product was rated as having an excellent peanut flavor, and had a salty and "peanut butter-type" creaminess felt during the assessment, resulting in a material processed by the method of EP 0540460. Were different. Example 3 The method of Example 1 was repeated using the following compositions (i)-(v) as raw materials for the extrusion process. Ingredients (i) (ii) (iii) (iv) (v) Peanut Butter 45 15 50 50-Marmite® Yeast Extract 15----Nusani Haselnuts-45--60 Cholate Paste Banana Flavor ----0.8 Peppermint Essence--0.8--Orange Essence---0.8-Maltodextrin 1940 40 40 49.2 49.2 39.2 All ingredients were easily combined in a Hobart® blender and extruded smoothly from the barrel Formed a soft lump. All samples emerged from the extrusion die as thin cords with the color characteristics of each component. Samples containing peanut butter at a level of 50% ((iii) and (i
v)) showed some signs of slight oil separation at the beginning of the process, but this only occurred for a very short time and did not interfere with the successful production of the product.

These samples were crushed to make a fine powder. This powder was found to have good flavor and "texture" properties when rehydrated with water at a level of 17.5%. Example 4 Chicken fat and beef fat were separately combined with maltodextrin 1940 at a level of 20% each.

Each fat was melted before blending to achieve a more homogenous mix. This raw material had a wet and brittle consistency, which was easy to feed. Both samples were easily processed and emerged from the extruder as a deep gray glossy mass.

Fat content measurements were made on both raw and processed materials. This result was compared with the result obtained from the analysis of the corresponding sample produced using the method disclosed in EP-A-0540460. Table 3 shows the results. Table 3 Comparison of fat content of the invention and samples produced according to EP 0540460 European patent application EP 0540460 The present invention Beef fat raw sample 20.5 18.2 Beef fat raw processed sample 10.4 15.8 Chicken fat raw Sample 20.0 21.2 Processed samples using chicken fat 9.6 14.5 Using the method of EP-A-540460 up to 50% of the fat in the original material is lost during this process and up to 10% fat in the carrier Was taken in.

In comparison, according to the method of the invention, 75% of the fat in the raw extruded sample was taken up and
15% was encapsulated. Example 5 At least 20% tomato serum (5-15)
%) And tomato starch (10-20%), and corn oil (2%), vinegar (2%), sugar (4%), modified starch (5-15%), maltodextrin 01921 (40-60%) And a pizza topping composition consisting of a small amount of the flavor component (4-6%). This raw material had a damp and brittle consistency, which hardened immediately upon standing and was very cumbersome to use. This material was processed at a slightly higher temperature than in the above examples to remove excess water that hardens the mass. The processing conditions used in this example are as follows: Temperature range profile (° C) Screw speed Feed rate 1 2 3 4 5 6 7 8 9 (rev / h) (kg / h) 20 30 40 50 80 90 110 130 150 350 15 The molten product coming out of the die has a bright red color,
Upon cooling, it hardened immediately and was crushed into a fine powder. Rehydration with water at a level of 3: 1 gave a smooth paste.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Olive Cey Burke England, London, Es D'Abri, 19, 7 El Y, Wimbledon, Alexandra Road, 99

Claims (13)

[Claims] 1. A process for producing a food product, which comprises mixing a foodstuff which is spreadable at room temperature with a matrix material consisting of carbohydrates, extruding the mixture obtained and converting the extrudate into a powder. 2. The method of claim 1 wherein the mixture is extruded using an extruder at a barrel temperature of 20-90 ° C. 3. The method of claim 2 wherein the barrel temperature is 30-70 ° C. 4. The method according to claim 1, wherein the extrudate is crushed to form free-flowing granules. 5. The method according to claim 1, wherein the matrix material is starch, maltodextrin or glucose solids. 6. The method according to claim 1, wherein the foodstuff comprises animal and / or vegetable fats or oils. 7. A product comprising up to 10% starch.
Any one of 6 methods. 8. The method according to claim 1, wherein the food material is selected from chocolate spread, yeast extract, peanut butter and mixtures thereof. 9. extrudate The method of any one of claims 1-8 having a cross sectional area of 1mm ² ~400mm ^2. 10. The product comprises 20-70% foodstuff.
~ Any one of 9 methods. 11. The product comprises 50-70% food material.
the method of. 12. A foodstuff which can be produced by the method according to any one of claims 1 to 11 and which is spreadable at room temperature,
Food products distributed on and / or in a matrix material consisting of carbohydrates. 13. The food product of claim 12, wherein the matrix material is starch, glucose solids or maltodextrin.