NL8300059A - METHOD FOR MANUFACTURING MOLDED FOOD PRODUCTS - Google Patents

Description

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Method for manufacturing shaped food products.

The preparation of food products by reconstitution of finely divided materials by forming the finely divided materials using gums and gelling materials by mechanical methods such as extrusion and molding as well as by thermal treatment such as heating and cooling are common practices in the food industry . Various methods are known for the manufacture of such shaped food products. Many of these methods are based on the use of a gelling system comprising an alginate and a divalent cation such as the calcium ion.

One type of method using these materials produces a molded product enclosed in a skin, such as a sausage.

For example, U.S. Pat. Nos. 3,650,765 and 3,650,766 disclose food products made in any shape or size according to a method comprising the steps of forming an extrudable slurry from a food material, extruding the slurry, and forming of a gel-like skin around the extruded product. The skin is formed by subjecting gellable materials such as alginates to the action of gelling agents such as alkaline earth ions on the surface of the extruded product. U.S. Pat. Nos. 3,891,776, 3,922,360, U,117,172, and 3,676,158 disclose similar processes in which a molded food product enclosed in a skin is formed. Some of these methods produce a peelable self-supporting skin. When the skin is peeled off and the product obtained is again subjected to the action of a divalent cation solution, a skin is again formed.

Other methods based on the use of alginates and calcium enzymes produce a stabilized food product whereby the alginate present in the suspension used for the preparation is converted into a fully advanced gel. Thus, e.g. US 8300059 i-* - 2 - patent 2,791 * 508 a "method for preparing reconstituted food products comprising initially forming a thixotropic semi-gel-like substance by dispersing a finely divided, powdery, granular or planed food product in a solution 5 of water of an edible hydrophilic colloid in which the dispersed food is present as discrete particles more or less completely enclosed in a matrix of the colloid gel Alginates have been disclosed as more suitable hydrophilic colloids In addition, gelling agent such as calcium carbonate must be added to the dispersed food. 10 part and hydrophilic colloid are added to cause gelling The time at which the gelling agent is added to the dispersion of the food and the hydrophilic colloid is critical since when the gelling agent is added it releases calcium ions which react rapidly with the colloid under form g of a gel.

Since this gelation takes place quickly, it is necessary to quickly transfer the substance into an extrusion feed pipe in which the finished advanced gel structure is formed. The feed pipe should be such that the resulting mixture becomes an advanced gel substantially simultaneously with the exit. This is a significant drawback since if the gelling agent is added too quickly, the mixture will form an advanced gel before exiting the extruder, causing a blockage in the extruder mechanism. On the other hand, if the gelling agent is added too late, the mixture will not become advanced gel as it exits the extruder, thereby preventing the formation of a molded food product.

Therefore, the known methods described above can result in both production and product difficulties such as undesirable skin formation, undesired texture of the finished product and difficulties during extrusion.

Accordingly, one of the objects of the present invention is to provide an improved method of manufacturing molded food products in which both production is smooth and a control of the desired properties of the finished product is possible.

According to the invention it has been found that prepared food products of any desired size or shape 83 0 0 0 5 9 ---------------- * '-I * - 3 - can be formed from a suspension of finely divided food particles and additives comprising a binder and a time-reaction system comprising a digestion agent such as an alginate and a material releasing a divalent ion. The slurry used in the process of the invention has the required theological properties for molding and retaining shape allowing a continuous production process based on either extrusion, molding or the like. The consistency of the suspension is such that the molded product can be easily released from the former.

The method according to the invention can be applied to a wide variety of foods, including vegetables, fruits, protein-like substances such as meat and fish products, shrimp products and the like, and is not dependent on the acidity of the foods or on the temperature. According to the invention, the suspension may be formed from one or more of the above-mentioned finely divided food materials, including a binder, e.g. a cellulose ether alone or together with a gum such as guar gum, an alginate, a bivalent ion-releasing material such as calcium carbonate, which reacts with the alginate to form a gel, a stretching agent such as flour and / or starch and optionally a pH adjusting agent such as citric acid or any other weak physiologically acceptable acid, a suitable sequestrant such as a metaphosphate and other additives such as salt, sweeteners and colorants.

The binder used in the suspension maintains a certain degree of rigidity and shape of the product and the gradual gelation of the alginate results in a certain fixation of the product.

The pH adjusting agent in combination with the sequestrant results in a predetermined rate of release of the calcium ions, resulting in a controlled gelation of the alginate.

In certain cases, the pH of the finely divided food product is such that it is not necessary to add either the acid or the acid and the sequestrant. For example, e.g. in the case of finely divided food products that release acid such as onions, the pH 35 control agent and the sequestrant not to be added to the suspension 83 0 0 0 5 9 ........... ~

V

- k - den added.

In each case, the slurry must be adjusted in such a way that the gelation takes place at a predetermined period of time. Generally, the slurry is allowed to stand for a predetermined period of time ranging from about 5 to about 30 minutes before actually forming. and further treatment is started. This allows sufficient time for the gelling to take place. The ratio and amount of the different ingredients in the slurry determines the consistency and properties of the final product.

The actual molding is performed with an extruder, cutter or molding device. As mentioned earlier, easy and quick release of the molded food product from the extruder, cutter or molding device is important for efficient continuous production process. Such release can be assisted by continuous rinsing of the extrusion head, cutter, or mold with a liquid, water, or with an aqueous solution of divalent ions, such as calcium ions, to prevent the molded product from sticking to the former. When a solution such as a calcium chloride solution is used for rinsing, a smooth surface is created which has a very small coefficient of friction and which will easily release from the molding machine. This rinse solution is used in a small amount and concentration and is only intended to promote easy release of the product and does not result in the formation of a shape-retaining or self-supporting film or skin.

The molded product can be further processed by contacting it with a flour-like material or a normal batter and breading. If increased adhesion of the batter coating to the product is desired, a small amount of gelling agent can be added to the batter, which will react with alginate in the top layer of the product.

The food products formed can also be coated, heated, baked, frozen and packaged. When heated, such frozen products retain their shape, texture, and edible qualities.

8300059 4Γ> - 5 -

The components used for the method of the present invention are reasonably priced and therefore the product can be manufactured on an economical basis.

As indicated above, the shaped food products of the invention may be prepared by first forming a slurry of a finely divided food product and other additives, then forming the slurry by extrusion, molding or the like, followed by a final treatment which may include applying batter, breading, heating, such as baking, freezing and packaging. According to the present invention, the suspension contains one or more finely divided food products, a binder, a gelling agent, a compound which releases bivalent ions for reaction with the gelling agent, extenders and optionally a pH adjusting agent, a sequestrant and additives such as salt, spices, sweeteners and colorants.

Suitable binders for use in the invention include edible cellulose ethers, which are non-toxic and water-soluble. Examples of such cellulose ethers are alkyl, hydroxyalkyl and carhoxyalkyl ethers, in which the alkyl group contains 1 to 3 carbon atoms. Specific examples of the cellulose ethers are sodium carboxymethyl cellulose, methyl cellulose, ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethyl cellulose and combinations thereof. These cellulose ethers can be used in combination with gums such as a guar gum, gum tragacanth, gcankaraya, xanthan gum, cargenan gum, furcellar gum, locust bean gum, gum arabic or combinations thereof. Although any suitable binder can be used, it is now recommended to use hydroxypropylmethyl cellulose together with guar gum as a binder. A particularly preferred hydroxymethylpropyl cellulose is hydroxypropylmethocel 30 K1QQM 100,000 cps viscosity grade prepared by Dow Chemical.

Generally, the binder is used in an amount of about 0.105? to about 6.0 wt.% based on the weight of the finely divided food product. When the binder consists of both a cellulose ether and a gum, the cellulose ether is e.g. present in an amount from about 20% to about 30% by weight of the 8300059. -ί - 6 - binder and the gum is e.g. present in an amount from about 70 to about 80% by weight of the binder.

Although any suitable gelling agent can be used, it is now recommended to use an alginate such as sodium alginate or potassium alginate. A particularly preferred alginate is a sodium alginate with the trade name Protanal SP-120 sold by Multi-Kem Corp. and prepared by Protan and Fagertun (Hoorwegen). The alginate is generally present in the suspension in an amount of about 0.1 to 1.0% by weight based on the weight of the finely divided food product.

Compounds that release bivalent ions for reaction with the alginate to yield a gel include calcium carbonate, calcium phosphate and the like. However, calcium carbonate is now preferred. The calcium ion. releasing compounds react with the alginate to produce a calcium alginate gel. The ion-releasing compound is generally present in an amount from about 0.001 to about 0.00% by weight based on the weight of the finely divided food product.

Suitable pH control agents include weak organic acids such as citric, maleic and tartaric acids. The pH adjusting agent can be omitted from the suspension if the finely divided food product used releases a weak acid. Onions are an example of such a food product. When the pH adjusting agent is used, it is generally present in an amount from about 0.001 to about 0.05% by weight based on the weight of the finely divided food product.

Although any suitable sequestrant may be used in conjunction with the pH controlling agent, it is preferred in the present invention to use a metaphosphate such as sodium hexametaphosphate. The sequestrant is usually used only when a pH control agent is used. Generally, when using a sequestrant, it is present in an amount of from about 0.001 to about 0.05% by weight, based on the weight of the finely divided food product. Suitable extenders contained in the suspension of the invention are 83 0 0 0 5 9 ..........................- ------------ + i - 7 - can be applied starch and flour commonly used together. In general, the starch is present in an amount from about 3 to about 12 weight percent based on the weight of the finely divided food product. However, it is currently recommended to use starch in an amount from about 5 * 5 to about 6.5 weight percent. The flour is generally present in an amount of from about 3 to about 12% by weight based on the weight of the finely divided food product. A preferred amount ranges from about 7.5 to about 8.5 wt.

The suspension may also contain one or more additives of choice such as salt, spices, sweeteners and colorants. When such materials are present in the slurry, they are generally present in an amount of from about 0.01 to 1.0 weight percent based on the weight of the particulate food particles.

As mentioned above, the food product suitable for use in the present invention include vegetables, fruits, proteinaceous substances such as meat and fish products, shrimp products and the like. The method according to the invention is particularly suitable for use with finely divided or grated food products such as fresh onions, rehydrated onions, cauliflower, mushrooms, peppers, apples, poultry meat, meat, fish, shrimps and calamari. A preferred product is onion rings, which require a very well-defined consistency to yield an acceptable and salable product. The food products are grated, diced or finely divided by known conventional means.

The slurry is prepared by mixing together all the materials that make up the slurry except for the finely divided or grated food product. When the dry mixture of these materials is mixed together, they are then added and mixed with the finely divided or grated food product for 2-5 minutes at room temperature to form a slurry. The resulting suspension, which has a very high viscosity, is allowed to stand for a period of about 5 to about 30 minutes to allow the ions, such as calcium ions, to be released from the calcium carbonate to form a calcium alginate gel. The slurry is then placed in an 8 3 0 0 0 5 9 "- 8 - mold such as an extruder or molding machine. Although any suitable equipment can be used, it is currently recommended to pump the slurry through an extruder with cutting heads. When making onion rings, an Autoprod / food extruder manufactured by Autoprod, Ine., Can be used with cutting heads that provide an annular product of about 10-12 g. The same extruder can be used with other cutting heads for extruding other shapes such as balls, crescents, sticks, etc.

It is desirable to use a divalent ion-containing rinsing solution 10 for washing the extrusion cutters or molding plate to facilitate easy release of the molded product from the cutter or molding plate. It is currently recommended to use an aqueous calcium chloride solution (0.2-5.0%).

The products formed with the extruder then fall individually onto a mesh-shaped conveyor belt which transports the products to a batter unit, in which batter is applied. If better adhesion of the batter to the product is desired, a small amount of a suitable alginate, e.g. sodium alginate is added to the batter which will then react with the calcium ions on the surface of the product. This process step is normally followed by a breading unit in which the products are breaded. The breaded product is then usually heated and, in the case of onion rings, deep fried for a short period of time e.g. 30 seconds at 20 ° C and then quickly frozen and packaged individually.

The final molded product for batter application and breading contains e.g. a cellulose ether in an amount from about 0.10% to about 2.5% by weight, a gum in an amount from about 0 to about 2.5% by weight, alginate salt in an amount from about 0.05 to about 0.80 wt%, a stretching agent in an amount of from about 6.0 to about 15 wt%, and a foodstuff in an amount from about 80 to about 90 wt%. Preferred example is 0.2 $ cellulose ether, 0.9 $ guar gum, 0.36 $ alginate salt, 12.0 $ stretching agent and 86.0 $ food (onion).

As mentioned previously, ingredients in the dry mixture 35 for the addition of the finely divided or grated food product include the 8 TO 0 0 5 9 ..... ...... ............. ..

- 9 - Subsequent materials where the weight percentage (based on the weight of materials in the slurry before addition of the food) is indicated for each material and represents the wide range that can be used with preferred ranges.

5 Materials Preferred Area corn starch 37% 30 - 60% wheat flour U9 30 - 60 hydroxypropylmethylcellulose 1.5 1 - 15 guar gum 6.0 0-15 10 sodium alginate 2.6 0.5-5 calcium carbonate 0.012 0.006-0.02 sugar (to optional) 0-10 salt (optional) 0.9 0-5

Citric acid (as required) 0 0 - 0.02 15 sodium hexametaphosphate (as required) 0 0 - 0.02

The ratio of fresh and / or rehydrated onion cut to dice to the dry mixed system is preferably 6.0 to 1, but may range from about 5: 1 to about 10: 1.

Specific examples of some preferred compositions 20 are illustrated in the examples below.

Example I: Preparation of onion rings.

A dry mixture of the following ingredients was prepared (parts): 166 parts corn starch 25 parts wheat flour 0.8 parts sodium alginate (KELTONE, Kelco Co.) 0.003 parts calcium carbonate 3.2 parts hydroxypropyl methyl cellulose, HO,000 cps viscosity quality (Hydroxypropylmethocel K-1000M, Dow Chemical) This mixture was added to 250 parts of diced fresh onions (6 mm rib) in a belt mixer and mixed for 3 minutes at room temperature to form a slurry.

The suspension obtained had a very high pasty viscosity. The mixture was allowed to stand for 5 to 15 minutes to allow the release of calcium ions from the calcium carbonate due to the acid ... 83 0 0 0 5 9 ---------- ---------------------------------- - 10 - pH created by allowing the onion exudate and for the subsequent reaction of the calcium ions with the algin molecules with the addition of a calcium alginate gel.

The suspension was then pumped with a cream pump through an Autoprod Food ex-truder with cutting heads to form an annular product of about 10-12 g. The cutters were washed with an aqueous solution of calcium chloride of 5 parts by weight to 100 parts by weight of water. This washing solution promoted the release of the formed annular product from the cutters. The extruded rings fell individually onto a woven conveyor belt which transported the product to a batter unit followed by a breading unit. The breaded product was deep fried at 2Dk ° C for 30 seconds and then quickly frozen and packaged separately.

The finished product had after. before serving, reconstitute the desired juiciness and mouthfeel.

Example II: Preparation of onion rings.

Extruded onion rings were prepared according to Example 1, substituting water-rehydrated dried pieces which were approximately 6 mm in size when reconstituted with water.

The internal texture of the finished heated product was similar to that of Example I.

Example III; Preparation of onion rings.

A dried mixture of the following ingredients was prepared (parts by weight): 25 parts of corn starch 20.0 parts of wheat flour 1.0 parts of sodium alginate 0.00 parts of calcium carbonate 0.6 parts of hydroxypropyl methyl cellulose 30 2.5 parts of guar gum Q, parts salt 1.8 parts sugar.

This mixture was added to 250 parts of 6 onions diced fresh onions. The method of preparing the onion rings was as in Example I.

...... 8300059 - 11 -

Example IV; Preparation of apple rings.

A dry mixture of the following ingredients was prepared (parts by weight): 25 parts corn starch 5 16 parts white flour 0.6 parts sodium malginate 0.003 parts calcium carbonate 2.3 parts hydroxypropyl methyl cellulose 1.1 parts guar gum 10 parts sugar 1 part salt.

This mixture was added to 250 parts of fresh apples cut to dice with a 6 mm rib. The rest of the process is as described in Example IV. Example V: Preparation of a gamma product.

A mixture was prepared from the following components (parts by weight): shredded shrimp 85 salt 1.0 20 HVP 1.5 garlic powder 0.02 onion powder 0.3 corn starch t, 2 water to 100 25 250 parts of the above mixture mixed with the dry mixture of Example I and processed as described in Example I to give a crescent or shrimp shape.

Example VI: Zucchini rings or nuggets.

A mixture was prepared comprising parts by weight: 30 zucchini (dice, 6 mm rib) 56 tomato paste h2 onion powder 0.15 garlic powder 0.15

oregano 0, U

Salt 1.3 100 '8300059 - 12 - 250 parts by weight of this mixture were mixed with the dry mixture of example I and processed as mentioned in example I into ring or lump form.

Example VU: Chicken rings or half-moons.

A mixture was prepared comprising parts by weight: chicken roll (dice, rib 6 mm) 76.6 chicken flavor 3.0 parsley 0.1 water 17.7 10 100 250 parts by weight of this mixture were mixed with the dry mixture described in example I and processed on patties of about 5 cm in diameter. These were further processed as mentioned in example I.

The above examples were repeated with different binders and gums as well as different amounts of extenders and with the addition of further gums. Different amounts of alginates and other sparingly soluble calcium compounds were tested. Satisfactory products were always obtained by an appropriate adjustment of the components.

83 0 0 0 5 9 “.....- - .....“ ............................. ...... -

Claims (22)

A method for manufacturing molded food products from finely divided, granulated or chopped food materials comprising (1) preparing a suspension of one or more foodstuffs with a binder, a gelling agent and a bivalent ion releasing material, wherein the amounts of binder, gelling agent and said divalent ion-releasing material is sufficient to allow a degree of reaction between the gelling agent and the divalent ion-releasing material after a predetermined period of time after the slurry has been prepared; (2) preparing a molded food product by molding the slurry with the help of a molding machine; and (3) processing the formed food product into. an end product. A method according to claim 1, characterized in that the binder is a cellulose ether. A method according to claim 2, characterized in that the cellulose ether is csrboxymethyl cellulose, carboxyethyl cellulose, carboxypropyl cellulose, methyl cellulose, ethyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose or a mixture thereof. h. Process according to claims 1-3 », characterized in that the binder contains a cellulose ether and another gum. Process according to claim 4, characterized in that the other gum is guar gum, tragacanth gum, karaya gum, xanthan gum, caragenan, vurcella rangom, locust bean gum, gum arabic or a mixture thereof. 6. A process according to claims 1 to 5, characterized in that the gelling agent is an alkali metal alginate and the divalent ion-releasing compound is a low-solubility calcium ion-containing compound. 7. Process according to claim 6, characterized in that the alkali metal alginate is sodium alginate and the calcium compound calcium carbonate. Method according to claims 1-9, characterized in that the suspension additionally contains a pH-regulating agent. 8300059 a - V - I - A method according to claim 8, characterized in that the pH controlling agent is a weak organic acid selected from citric acid, tartaric acid, and maleic acid. Method according to claims 1-9, characterized in that the suspension additionally contains a sequestrant. A method according to claim 10, characterized in that the sequestrant is a metaphosphate. A method according to claim 11, characterized in that the metaphosphate is sodium hexametaphosphate. Process according to claims 1 to 12, characterized in that the shaped food product is washed with an aqueous solution of a calcium compound while it is unloaded from the molding machine. 1½. Process according to claim 13, characterized in that the aqueous solution of the calcium compound is an aqueous calcium chloride solution. Method according to claims 1 - 1, characterized in that the suspension additionally contains a stretching agent. A method according to claim 15, characterized in that the stretching agent is starch, flour or a mixture thereof. 17. Process according to claims 6 - 16, characterized in that the components are used in such proportions that, when the suspension is left to stand for a period of 5-30 minutes, the reaction of the alginate with the calcium ion gives off compound occurs while increasing the viscosity of the suspension 25 to form it. 18. A method according to claims 1-17, characterized in that the binder is present in an amount from about 0.10 to about 6.0% by weight, based on the weight of the finely divided food material. A method according to claims 1-18, characterized in that the alginate is present in an amount from about 0.10 to about 1.0 wt based on the weight of the finely divided food product. 20. Method according to claims 1-19, characterized in that the divalent ion-emitting compound is present in an amount of ----------- 8 3 0 0 0 5 9 .....- - -------------------------------------------------- .................-.............- - 15 - from about 0.001 to about 0.02 wt. # Based on bet weight of the finely divided food product. 21. Method according to claims 1 - 20, characterized in that the processing step (3) is carried out by contacting the formed food product with a flour material or normal batter and then breading. 22. Shaped food product, which is in the form of a gel and comprises a cellulose ether selected from the group consisting of hydroxyalkyl and carboxyalkyl celluloses, the alkyl groups of which contain 1 to 3 carbon atoms, which cellulose ether is present in an amount from about 0.1 to about 2.5 wt%; alginate salt in an amount from about 0.05 to about 0.80 wt. 3%; a finely divided, granulated or baked food material selected from vegetables, fruits, meat, fish and seafood and mixtures thereof, in an amount of from about 80 to 90% by weight and a stretching agent in an amount of from about 6 to 15% by weight. %. Shaped food product according to claim 22, characterized in that it still contains another gum in an amount of about 0.1 to 2.5 wt.%. 20 2k. Food product according to claim 22, characterized in that onions are used as said food material. Food product according to claim 22, characterized in that apples are used as said food material. 26. The product of claim 2U in the form of a ring. 27. The product of claim 25 in the form of a ring. -------- 330 0 0 5 9 --------------- - - —................... ........