NZ550924A - Dairy product and process - Google Patents

Abstract

Disclosed is an imitation cheese composition comprising: a) moisture in an amount that is at least 45% by weight of the composition; b) farinaceous material in an amount that is at least 5% by weight of the composition; c) a proteolysed casein containing source in an amount of at least 5% by weight of the composition; d) a fat source that is at least 10% by weight of the composition; e) a complex phosphate emulsification salt that is at least 0.01% by weight of the composition; and f) optionally one or more GRAS ingredients selected from one or more flavour ingredients that are natural or artificial, one or more natural or artificial colours, one or more preservatives, one or more acidulants and one or more bulking or texturising agents; wherein the composition is sufficiently firm that it can be comminuted, formed into a bar, or formed into a slice (IWS) that is peelable from a plastic backing film. Also disclosed is a method for preparing an imitation cheese composition comprising: a) combining a source of casein, farinaceous material, fat, water, at least one emulsification salt, and optionally one or more GRAS ingredients; b) adding a proteolytic enzyme; c) heating to about 50 deg C to melt the fat and to allow the proteolytic enzyme to react; d) cooking the mixture of step c) at between about 86 deg C and 100 deg C for between 2 minutes and 30 minutes; and e) cooling the cooked mixture of step d).

Description

550924 NEW ZEALAND PATENTS ACT, 1953 No: 550924 Date: 30 October 2006 COMPLETE SPECIFICATION DAIRY PRODUCT AND PROCESS We, FONTERRA CO-OPERATIVE GROUP LIMITED, of 9 Princes Street, Auckknd, New Zealand, do hereby declare the invention for which we pray that a patent may be granted us, and the method by which it is to be performed, to be particularly described in and by the following statement: (followed by page la) » 5509^ DAIRY PRODUCT AND PROCESS FIELD OF THE INVENTION The present invention is directed to an imitation cheese product and a method of making same 10 particularly although by no means exclusively to an imitation cheese that can be formed into a bar or an individually wrapped slice (IWS), or can be comminuted and used as an ingredient in a food product such as a nutritional bar or snack bar.

BACKGROUND OF THE INVENTION Imitation cheeses are made with a reduced amount of butterfat and/or casein protein but supposedly resemble natural or processed cheese in appearance, taste, texture and nutrition. The cost savings involved in replaced expensive butterfat and/or casein protein with less expensive substitutes such as starch, gum, vegetable, oil etc, provides the incentive to industry to produce 20 such imitation cheeses. A growing market is in the fast food industry, for example in the productions of an imitation cheese slice product for use in the burger industry, and in the production of nutrition bars as a healthy snack option or targeted at the sports market.

However, to date no suitable imitation cheese product has been produced which has the 25 necessary functionality to be useful across such a wide range of food applications. For example, for a cheese slice, the imitation cheese requires specific functionality in terms of texture (including hardness) (to enable the cheese to be formed into a slice that is peelable from a plastic film) whilst retaining the required melt characteristics. Replacement of butterfat and/or casein protein with starch, gum or vegetable oil etc has resulted in imitation cheese products that have 30 the desired hardness (usually achieved by adding starch) to be able to be formed into a sliced (IWS) but which have no or poor melt, or which have the desired melt characteristics (usually achieved by increasing moisture content) but which have decreased hardness and cannot be formed into a slice (IWS).

An imitation cheese useful as a snack bar does not have such stringent functionality requirements such as melt, but must be sufficiently bland in texture and flavour so as not to make the final nutritional bar product unpalatable. It is highly desirable that such a snack type product peels cleanly from its wrapper. The snack product contains relatively few calories (per standard 550924 2 serve) compared to other known art snacks but has good flavour and gives the consumer satiation from its protein content.

It is an object of the present invention to provide an imitation cheese product that has the combination of desirable hardness and melt properties to make an IWS and is of suitable texture 10 and flavour for use in a nutritional bar and/or to provide the public with a useful choice.

SUMMARY OF THE INVENTION In a first aspect, the present invention provides an imitation cheese composition comprising: 15 a) moisture in an amount that is at least 45% by weight of the composition; b) farinaceous material in an amount that is at least 5% by weight of the composition; c) a proteolysed casein containing source in an amount of at least 5% by weight of the composition; d) a fat source that is at least 10% by weight of the composition; e) a complex phosphate emulsification salt that is at least 0.01% by weight of the composition; and f) optionally one or more GRAS ingredients selected from one or more flavour ingredients that are natural or artificial, one or more natural or artificial colours, one or more preservatives, one or more acidulants and one or more bulking or texturising agents; wherein the composition is sufficiently firm that it can be comminuted, formed into a bar or formed into a slice (IWS) that is peelable from a plastic backing film.

The composition may be useful as a food product such as a nutritional bar or a snack bar.

The moisture content of the composition may be at least 50%, preferably at least 55% and more preferably at least 60% by weight of the composition.

The farinaceous material may be selected from native starch or flour containing native starch.

The farinaceous material may be present in an amount calculated to replace at least 20% of the casein or caseinate that would be present in an equivalent non-imitation cheese product. 550924 3 Preferably the farinaceous material may be present in an amount to replace at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% of casein or caseinate that would be present in an equivalent non-imitation cheese product.

The casein source may be present in the composition in an amount of at least 10%, at least 15% 10 or at least 20% by weight of the composition. The casein source may be selected from caseinate, rennet casein, MPC, or retentate. The MPC or retentate may contain at least 50% protein (on a dry basis), preferably at least 70% protein and more preferably at least 80% protein. The protein is proteolysed by addition of a proteolytic enzyme during the cheese making process.

The fat source may be selected from the group comprising of cream, double cream, butter, anhydrous milk fat (AMF), liquefied fresh frozen milk fat or recombining (FFMR), and a non dairy fat such as vegetable oil.

The complex phosphate emulsiflcation salt may be selected from a mono, di or polyvalent 20 cationic phosphate salt including metaphosphate, hexametaphosphace, pyrophosphate, polyphosphate and disodium phosphate (DSP).

Optionally one or more additional GRAS (Generally Regarded as Safe) ingredients may be present in the composition. A list of GRAS ingredients is available in Food Chemical Codex (4th 25 edition) or from the FDA or WHO.

When the composition is to be formed into a cheese slice, a preferred flavour ingredient is a cheese flavour that may be selected from the group consisting of enzyme modified cheese (EMC), enzyme modified lactile products, synthetic or artificial cheese flavourings, lipolysed 30 dairy flavours, dairy/cheese top notes and dairy/cheese push notes depending on the type of cheese that the imitation cheese slice is intended to mimic. The imitation cheese is preferably a mozzarella, Cheddar, parmesan or Colby cheese.

When the composition is to be formed into a nutritional bar, the flavour may be sweet or savoury 35 and may be selected from the group consisting of vanilla, chocolate, coconut, cinnamon, apricot, cherry, or any other fruit flavour, salt, spice, beef, chicken or any other meat flavour, cheese, including the preferred cheese flavours listed above, and so forth. The bar may comprise one or INTELLECTUAL PROPERTY OFFIUil OF N L. « r-?-« • ->9 b uJJwO R E C : '1V E D 550|24 more layers of the flavoured imitation cheese composition of the invention and may be coated with nuts, seeds, icing, chocolate or any other suitable coating.

When the composition is to be comminuted for use as an ingredient in a food product, it may be flavoured with a cheese flavour as for the cheese slice, or it may be flavoured in a variety of 10 ways as described for the nutritional bar, above.

The composition of the invention has equivalent melting characteristics as a processed cheese slice (IWS), which corresponds to a Schreiber melt value of between about 0.5 to about 2.0, preferably between about 1.0 to 1.5. When the composition is to be made into a cheese slice, the 15 slice itself will have these melt characteristics. When the composition is to be made into a bar or comminuted for use as an ingredient to be added to other food products, because additional ingredients will be present in the bar or other food product, these melt characteristics will be lost.

In a second aspect, the present invention provides a method for preparing an imitation cheese 20 composition comprising the steps: a) combining a source of casein, farinaceous material, fat, water, at least one emulsification salt, and optionally one or more GRAS ingredients; b) adding a proteolytic enzyme; c) heating to about 50°C to melt the fat and to allow the proteolytic enzyme to react; d) cooking the mixture of step c) at between about 86°C and 100°C for between 3 minutes and 30 minutes; and e) cooling the cooked mixture of step d).

When a cheese slice is to be made, the method may further comprise the steps of 30 f) forming the cooled composition of step e) into a sheet or film on a plastic backing film; and g) cutting the plastic backed sheet or film into individually wrapped cheese slices (IWS).

When a nutritional bar is to be made, the method may comprise the step f) forming the cooled 35 composition of step e) into individual bars of a desirable shape and size. The nutritional bar may further comprise additional ingredients such as fruit, meat, nuts, seeds etc to increase the nutritional value of the bar, and may be optionally coated with a suitable coating.

INTELLECTU ATPROPERTY OFFICE OF N.Z.

- S DEC 2038 RECEIVED Alternatively, the composition of step e) may be cooled and comminuted. The comminuted imitation cheese composition is useful as a food topping or as an ingredient in food products, such as nutritional bars.

Preferably step a) comprises combining at least 5% by weight of a casein or caseinate source; at 10 least 5% by weight farinaceous material; at least 45% by weight water; at least 10% by weight fat; at least 0.01% by weight of a complex phosphate of emulsification salt; and optionally one or more GRAS ingredients.

In step b), the proteolytic enzyme may be selected from the class of enzymes that are able to 15 convert kappa casein to para-kappa casein and is most preferably rennet (chymosin).

Step c) may be carried out at between about 90°C and 98°C for between 2 and 5 minutes, preferably between 92°C and 97°C for between 5 and 15 minutes and more preferably at 95°C for 10 minutes.

The present invention is also directed to a bar, an imitation cheese slice (IWS) or a comminuted imitation cheese product produced by the process of the invention.

In a third aspect, the present invention provides a method of preparing a nutritional bar product 25 comprising the steps: a) combining 1 to 90% by weight of comminuted imitation cheese composition of the invention with one or more ingredients selected from the group consisting of 0.1-40% by weight of carbohydrate; 0-40% by weight of protein, 0.1-5.0% by weight of vitamins and minerals, 0.1-40% by weight of water, 0.1-10% by weight of soluble and/or insoluble fibre, 0.1-10% by weight of fat, 0.1 -5% by weight of preservatives and 0-10% by weight of binder; b) mixing to form a homogenous mass; and c) forming the mixture of step b) into bars of a desirable shape and size.

The resulting bars may be coated on the top and/or bottom and/or sides with a suitable coating 35 before packaging.

The present invention is also directed to a nutritional bar product produced by the process of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described with reference to the figures of the accompanying drawings in which: Figure 1 shows the shear stress (firmness) of a cheese slice (IWS) made with MPC85(*) and casein (■) and containing rice starch at a level of 30% substitution; and Figure 2 shows the melt of imitation cheese slices of the invention containing MPC 85 or rennet 15 casein (RC), and rice starch (RS) at a level of 30% substitution.

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to an imitation cheese composition that can be formed into a 20 cheese slice, a cheese snack bar, a flavoured bar or can be comminuted and used as an ingredient in another food product. Preferably the imitation cheese composition of the invention is formed into a nutritional bar. Where the nutritional bar comprises a high percentage of the imitation cheese composition of the invention, so that it is high in protein, it is particularly useful as a protein supplement aimed at the sports market.

The imitation cheese composition of the present invention is also useful when in the form of a slice (IWS) as it is high in moisture and has a high casein substitution level yet has similar hardness and melt characteristics as an equivalent pasteurized processed cheese slice (IWS). The composition of the present invention is particularly useful as it has sufficient hardness that it can 30 be formed into a cheese slice product that is peelable from a plastic film. The resultant imitation cheese slice products resemble a processed cheese slice in term of gloss, low stickiness, elasticity, peelability, "break' and melt. The cheese slices the present invention are particularly useful in the fast food industry. For example, an individually wrapped cheese slice product having the necessary melt characteristics is particularly useful for burger toppings. Cheese with 35 limited melt is particularly useful in the preparation of barbecued food.

The imitation cheese product of the present invention may comprise additional ingredients such as fruit, meat, nuts, seeds etc to increase the nutritional value of the nutritional bar or cheese slice made from the composition of the invention.

To date imitation cheeses have not been successfully commercially produced. This is because 10 the replacement of casein and/or butterfat with starch, gum and/or vegetable oil in an imitation cheese results in a loss of important functional characteristics, specifically with respect to melt and texture (or firmness). Usually, the better the melt, the poorer the texture so that an imitation cheese with good melt is unable to be formed into a cheese slice that is peelable from a plastic film because of its poor texture (or firmness). Conversely, an imitation cheese with a good 15 texture (or firmness) which is able to be formed into a slice has no melt. This problem appears to be due to the composition of the imitation cheese. For example, it is known that melt characteristics of an imitation cheese may be improved by increasing the moisture content of the composition, however, an increase in moisture content is usually associated with a decrease in hardness (Hennelly et al, 2005 Journal of European Food Research and Technology 220 (3-4), 20 pp415-420). The hardness of an imitation cheese can be increased by increasing the starch content, however, an increase in starch content is usually associated with a decrease in melt Mounsey and O'Riordan, Journal of Food Science 64: 4, 701-703, 1999).

It has surprisingly been found that an imitation cheese which has a high moisture content (and 25 therefore desired melt characteristics) and is firm enough to be formed into a slice that is peelable from a plastic film may be produced by replacing at least 20% of casein with a farinaceous material and by carrying out the cooking step under relatively narrow conditions. To produce a suitable cheese slice (IWS), the cooking conditions are carried out at a relatively "high" temperature range (86-100°C) for a relatively "long" period of time (3 to 30 minutes).

Without being bound by theory, it is thought that the combination of the specific composition (high moisture and high substitution with a farinaceous material) together with the specific processing conditions (high temperature for long duration) that is responsible for producing the imitation cheese products of the invention. The imitation cheese products of the present 35 invention are superior over the prior art imitation cheese products as they have the desirable melt and firmness characteristics and are peelable from a plastic film are therefore suitable for large scale production and commercialisation of a number of products such as individually wrapped cheese slices and bars. 550924 8 Specifically, the present invention provides an imitation cheese composition comprising: a) moisture in an amount that is at least 45% by weight of the composition; b) farinaceous material in an amount of at least 5% by weight of the composition; c) a proteolysed casein source in an amount of at least 5% by weight of the composition; d) a fat source that is at least 10% by weight of the composition; e) at least one complex phosphate emulsification salt that is at least 0.01% by weight of the composition; and f) optionally one or more GRAS ingredients; wherein the composition is sufficiently firm that it can be comminuted, formed into a bar, or formed into a slice (IWS) that is peelable from a plastic backing film.

The amount of casein that can be substituted by a farinaceous material is from about 20-45%, 20 preferably from 20-50%, more preferably from 20-35%) and most preferably from 20-30%. As a result, the imitation cheese composition of the invention is low in protein leading to reduced manufacturing costs. Manufacturing costs are further reduced by the high moisture content of the imitation cheese composition of the invention.

The imitation cheese compositions of the present invention possess a smooth, creamy and dairy-like mouthfeel with a texture, firmness and melt similar to that of pasteurised processed cheese slice (IWS).

More specifically, the imitation cheese compositions of the invention have a textural character 30 such that the average sheer stress (Pa) of a formed IWS using a frequency sweep on paar physica rheometer, UDS 200 Universal Dynamic Spectrometer, is between 200 and 500 from 0.1 to 10 Hz. In addition, the imitation cheese compositions of the invention have a low melt profile up to 40°C, corresponding to a Schreiber melt value of between 0.5 to 2.0.

Moisture is present in the imitation cheese composition in an amount greater than 45% by weight, preferably greater than 50% by weight, greater than 55% by weight or greater than 60% by weight. The moisture may be added to the composition as water, diluted acidulant, whey or any other suitable potable liquid.

INTELLECTUAL PROPERTY OFFICE OF n.2, - 9 DEC 2MB Farinaceous material for use in the imitation cheese composition of the present invention includes any native starch or flour containing native starch, or a mixture thereof. The native starch may be derived from cereal or tuber crops such as rice, tapioca, potato, wheat, maize and pea starch or flour. A particularly preferred farinaceous material for use in the present invention is a native rice starch or flour containing native rice starch. Examples of rice flours include 10 M01080, M01120 and GM00080 (available from Sage V Food, Treeport, Texas, USA); 2281 (medium ground), 3500 (fine ground) (both available from Sun Rice - Leeton, NSW 2705, Australia). Examples of native rice starch includes Remy DR7-111 and Remy AX-DR (both available from Remy Industries NV - Remylaan 4, Leuven-Wijgmaal, Belgium).

The farinaceous material may be present in an amount of up to about 10% of the composition, preferably between about 5% and 7.5% of the composition.

The casein source material may be present in the imitation cheese composition of the invention in an amount from about 5% to about 30%, preferably from about 10.% to about 25% and most 20 preferably from about 15 to 20%. Preferably the casein is caseinate, rennet casein, MPC or retentate. Suitable commercially available sources of rennet casein include ALAREN 711, ALACO 6804, DSE 5275, and DSE 5267 (all available from Fonterra Cooperative Group Ltd, Auckland, New Zealand). A suitable commercially available source of MPC is ALAPR04850, (available from Fonterra Cooperative Group Ltd, Auckland, New Zealand). The casein is 25 proteolysed by the addition of a proteolytic enzyme during cheese manufacture.

The fat source may be selected from an animal or vegetable origin, or mixtures thereof and may be liquid or solid at room temperature (21°C). The fat source may be selected from the group consisting of lard, butter, cream, double cream, anhydrous milk fat (AMF), liquified fresh frozen 30 milk fat for recombining (FFMR), fully saturated vegetable oils, partially hydrogenated vegetable oils, non-hydrogenated vegetable oils, soybean oil, sunflower oil, olive oil, canola (rapeseed) oil, cottonseed oil, coconut oil, palm kernel oil, corn oil, butterfat, safflower oil and mixture thereof. Examples of preferred fats include butter and partially hydrogenated vegetable oil, soybean oil or a mixture thereof. In some embodiments, the fat source may include butterfat 35 to improve the flavour of the imitation cheese composition.

In general, the fat is present in an amount sufficient to create a desired texture and consistency of the imitation cheese composition. Generally, the fat is present in an amount of at least 10% by INTELLECTUAL PROPFRTY OFFICE OF M.2. - 8 DEC 2008 550^ weight of the composition, preferably from between about 15% and about 25% by weight, more preferably between about 20% and 25% by weight.

The one or more complex phosphate emulsification salts are preferably selected from mono, di or polyvalent cationic phosphate salts including metaphasphate, hexametaphosphate, 10 pyrophosphate, polyphosphate . Preferred salts are disodium phosphate (DSP) and sodium hexametaphosphate (SHMP).

In general, the emulsification salts are present in an amount sufficient to disperse the fat evenly throughout the composition in an emulsified form. The emulsification salts are present in the 15 imitation cheese composition in an amount that is at least 0.01% by weight of the composition, preferably between at least 0.05% and 2.5% by weight, preferably around 0.1% by weight.

Optionally, the imitation cheese composition of the invention may comprise one or more GRAS ingredients selected from one or more flavours, colours, preservatives, texturising agents, 20 bulking agents, acidulants, etc as would be appreciated by a skilled worker.

Particularly preferred GRAS ingredients include a cheese flavour which imparts a characteristic savoury cheesy taste to the composition. Suitable cheese flavours are known in the art and include enzyme modified cheese (EMC), enzyme modified lactile products, synthetic or artificial 25 cheese flavourings; synthetic or artificial cheese flavourings, lipolysed dairy flavours, dairy/cheese top notes and dairy cheese push notes.

Additional flavouring agents such as salt and citric or lactic acid (which also acts as an acidulant) may also be added.

The final imitation cheese flavour will depend upon the type of cheese that the imitation cheese composition is intended to mimic. Preferably the imitation cheese of the present invention corresponds to a mozzarella, parmesan, cheddar or colby cheese.

The imitation cheese composition of the present invention is preferably in the form of a bar such as a flavoured snack bar or high protein bar, or an individually wrapped cheese slice (ISW) which is useful as a topping for burgers.

When the imitation cheese composition of the present invention is formed into a bar, the composition may comprise additional ingredients such as nuts, seeds or pieces of fruit to increase the nutritional content of the imitation cheese bar. The bar may also comprise more than one layer of imitation cheese and may be coated with a suitable coating.

Alternatively, the bar may be flavoured by a non-cheese savoury or sweet flavour selected from the group consisting of vanilla, chocolate, coconut, cinnamon, apricot, cherry, or any other fruit flavour, salt, spice, beef, chicken, pork or any other meat flavour as would be appreciated in a skilled worker.

Alternatively, the imitation cheese composition of the invention may be comminuted for use as a food topping (eg pizza topping) or for use as an ingredient in foodstuffs. Particularly preferred is a comminuted imitation cheese composition as an ingredient in a nutritional bar as an alternative snack or as a high protein bar aimed at the sports market.

The imitation cheese composition of the present invention may be manufactured by mixing together all of the ingredients and heating under shear to a first temperature of about 50°C to ensure that the fat is melted. A proteolytic enzyme capable of converting kappa casein to para-kappa casein is added to the mixture and held at about 50°C until the enzyme has reacted with the protein component. Alternatively, the dry ingredients may be added to a pre-heated water and pre-melted fat. Once the fat is melted, the proteolytic enzyme can be added and once it has reacted and all of the ingredients have been mixed together under shear, the mixture is heated to a cooking temperature of between 86°C and 100°C for between 3 minutes and 30 minutes and cooled and formed into a peelable slice. The hot cooked mixture is formed into a peelable slice by pouring or extruding onto a sheet of plastic film, covered with a second sheet and rolled with a rolling pin between 2.4mm high rails.

Preferably the hot cooked mixture is cooled to at least about 15°C, preferably less than 10°C before it is poured or extruded into the plastic sheet.

The cheese slices can also be formed in casts by known methods.

Alternatively, the hot cooked mixture is formed or cast into bars of desired shape and size.

The hot cooked mixture may also be formed into blocks or sheets and the blocks or sheets comminuted for use as a food ingredient or food topping.

Any type of process cheese type cooker may be used in the process of the present invention. For example, a lay-down Blentech type or a higher sheer vertical axis Stephan type. Heating may be 10 conducted using indirect means (e.g. convection) or directly via steam injection, or a combination of both. The cooking devices may be operated at above atmospheric pressure.

The imitation cheese bars and slices, or the comminuted imitation cheese product of the present invention may be packaged and stored in chilled conditions, preferably below 5°C, and 15 preferably in an atmosphere that will minimise spoilage. A snack type bar product may be packaged aseptically using known high temperature processing systems (UHT) into a sealed wrapper to give an ambient stable food product.

In a third aspect, the present invention provides a method of preparing a nutritional bar 20 comprising the steps: a) combining 1 to 90% by weight of comminuted imitation cheese composition of the invention with one or more ingredients selected from the group consisting of 0.1-40% by weight carbohydrate; 0-40% by weight protein, 0.1-5.0% by weight vitamins and minerals, 0.1-40% by weight water, 0.1-10% by weight soluble and/or insoluble fibre, 0.1-10% by weight fat, 0.1-5% by weight preservatives and 0-10% by weight binder; b) mixing to form a homogenous mass; c) forming the mixture of step b) into bars of a desirable shape and size; and d) packaging the nutritional bars of step c).

A wide variety of carbohydrates can be used in the nutritional bars of the invention such as monosaccharides or disaccharides and mixtures thereof including dextrose (glucose), sucrose, fructose, lactose, maltose, galactose, sugar alcohols, invert sugar syrups, brown sugar, corn syrup, honey, molasses, maple syrup and the like.

A wide variety of additional protein may be used in the nutritional bars of the invention, for example cereal proteins, milk proteins, egg protein, animal protein, vegetable proteins, and mixtures thereof.

A wide variety of fats can be used in the nutritional bars of the invention including the fats listed above used in the imitation cheese composition of the invention, such as olive oil, canola oil, palm oil, coconut oil, sunflower oil, peanut oil, fish oil, lard, butter, margarine and other animal, vegetable and marine fats which are commercially available.

A wide variety of vitamins and minerals may be used in the nutritional bars of the invention including, for example, Vitamin A, Vitamin B group, Vitamin C, Vitamin D, Vitamin E, Vitamin K, calcium, iron, phosphorous, iodine, magnesium, selenium, zinc, copper, chromium, molybdenum, choline, fluoride, chlorine, potassium, sodium and mixtures thereof. Such vitamins and minerals are commercially available from sources known in the art.

A wide variety of sources of soluble and non-soluble fibre may be used in the nutritious bars of the invention, for example, dried beans, oats, barley, fruits such as apples and citrus, vegetables such as potatoes, wheat bran, whole grains, cereals, seeds, nuts and the skin of many fruits and vegetables.

One or more preservatives, such as sodium benzolate, ascorbyl palmitrate, sorbic acid, or BHT may optionally be used in the nutritional bars of the present invention to increase the shelf life of the products.

Binders may also be used to ensure uniform consistency of the nutritional bars, such as polyvinyl alcohol, glycerol or methylcellulose.

A number of other edible natural or artificial flavours and ingredients may optionally be used depending on the desired colour, flavour, nutritional content or other benefit of the nutritional 30 bar being produced as would be appreciated by a skilled worker.

The nutritional bars comprising the comminuted imitation cheese of the invention may be made by any known method in the art, but generally comprises mixing together the ingredients to a homogenous mass and forming the mixture into bars of a desired shape and size.

The bars may be coated on the top and/or bottom and/or sides with any desirable coating before packaging. 550^ The bars are preferably packaged aseptically using known high temperature processing systems (UHT) into a sealed wrapper to give an ambient stable food product.

The term "comprising" as used in this specification and claims means "consisting at least in part of'; that is to say when interpreting statements in this specification and claims which include 10 "comprising", the features prefaced by this term in each statement all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in similar manner.

This invention may also be said broadly to consist in the parts, elements and features referred to 15 or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

EXAMPLES Example 1 IWS made from MPC85 or rennet casein using 3 different types of native starch: 1. Rice flour, Sage V M01080, (Sage V Foods, Freeport, Texas, USA). 2. Rice starch, Remy DR7-111, (Remy Industries N.V., Belgium). 3. Potato starch, Avebe 5001/5900/5903/5904/06 BU-IFP (Chemiplas NZ Ltd, Auckland, 30 New Zealand).

Table 1 shows the formulation used.

Table 1 ISW using starch, protein, oil/fat and emulsification salts Ingredients Composition (w/w %) Quantity (g) Water 55 16.5 ALAREN 711 or MPC85 16.45 4.94 550^2^ Rice flour (RF)/ rice starch (RS)/ potato starch (PS) 7.05 2.12 Fat (Soya oil) 6.0 Emulsifying salts (JSC, DSP or SHMP) 1 0.3 Common Salt 0.5 0.15 Total 100 % 30g MPC85 (ALAPR04850) and rennet casein (ALAREN 711) were supplied by Fonterra Cooperative Group Limited, Auckland, New Zealand.

RVA-temperature and shear profile Method 1. emulsification salts and NaCl were dissolved in water mix for 5 minutes; 2. oil was added and mixed for 2 minutes; 3. the rest of the dry powders (i.e. RS/ RF/PS, rennet casein or MPC), were added and hand stirred for 2 minutes; 4. the canister on a RVA, Rapid Visco Analyzer (RVA) [RVA-4, Newport Scientific, Warriewood, Australia], was loaded with the mixture and heated at 4°C/min to 95°C and cooked for 10 minutes at constant temperature. The RVA was operated at 400rpm; . at the end of cooking, the sample was poured onto a sheet of plastic film, covered with a second sheet and rolled with a rolling pin between 2.4 mm high rails to form a cheese-like film (cheese slice). This film of cheese was stored in a refrigerator overnight to set and for sampling and analysis.

Sample evaluation Samples were evaluated for firmness (shear), melt, texture and moisture content.

The shear and melt of the cheese slices (IWS) were measured using standard techniques in the art as follows: • Frequency Sweep on Paar Physica rheometer, UDS 200 Universal Dynamic Spectrometer, (Paar Physica Messtechnik GmbH, Stuttgart, Germany) (Figure 1) • Melting test (G' and G") on Paar Physica rheometer (Figure 2) 550^ Results and Discussion The imitation cheese compositions made with TSC as emulsification salt did not give an acceptable slice.

The imitation cheese compositions made with DSP or SHMP as emulsification salts produce 10 acceptable slices. SHMP produced the best slice. The shear and melt characteristics of the slices made using SHMP are shown in figures 1 and 2. Slices made with 30% substitution of rice starch and either MPC or rennet casein produced excellent slices which were firm and had a texture which showed fracture (or "break") similar to a processed cheese slice. The slices of the invention also had a similar melt profile to a processed cheese slice.

Conclusion An imitation cheese composition with 30% casein substituted by rice starch had acceptable melt and firmness characteristics for an IWS when the remaining casein source was rennet casein or MPC.

Example 2: Production of IWS using 15kg batches in a blentech cooker/mixer.

Scaled up runs using 15kg batches in Blentech The formulation used in the Blentech experiments is shown in Table 2.

Table 2 Formulation for the preparation of imitation cheese slices (IWS) Ingredient Mass (kg) Composition (%) MPC85 (ALAPR04850) 2.47 16.45 Remy DR7111 rice starch 1.06 7.06 Anhydrous milk fat 3.0 19.96 Steam (condensate) 2.25 14.98 Added water 6.0 39.95 Common salt 0.075 0.50 Sodium hexametaphosphate (Europhos) 0.15 1.0 Potassium sorbate 0.015 0.1 Total 100.00 550^ The fat (pre-melted) and dry ingredients were added to a Blentech horizontal twin-screw blender-cooker (Model CC45, Blentech Corporation, Rohnert Park, Calif. USA.) and stirred at low speed (50rpm) for 5 minutes at ambient temperature (about 25°C). The water was added and stirring continued at ambient temperature for another 40 minutes. Direct steam (DSI) was applied (over about 12 minutes) to the mixture to raise the temperature to 95°C and this was held 10 for 15 minutes (all at 120rpm). The homogenous molten product was then poured onto plastic film covering a chilled table , covered with a second plastic film and rolled to form a sheet about 2.5 mm thick. Once cooled, the mass was cut into approx. 75x75mm squares.

The slices were stored in a fridge at about 5°C.

The first batch was found to stick to the plastic film and was unacceptable as a peelable slice.

A second run was performed using the same base recipe and procedure except that 0.01kg of a 20 proteolytic enzyme, Renco® liquid natural calf rennet, Dairy Meats N.Z. Ltd., Enzyme Division, Eltham, New Zealand, was added along with the water into the cooker (Blentech).

A third run was performed similar to the second but only half the quantity of rennet (0.005kg) was added.

Surprisingly, the products of the second and third runs peeled cleanly from the film, had good gloss and shine and had a texture (fracture [know in the art as 'break']) similar to processed cheese individually wrapped cheese slice.

Typically, processed cheese slices alter their physical properties over time when stored. Often the texture deteriorates. The changes to the texture may range from insignificant to severe.

After storage in a fridge for 3 months and once warmed to ambient temperature, a sample of the second run was examined. Any change in texture was considered insignificant. Surprisingly the 35 sample had retained its low stickiness, peelability, elasticity and gloss and its processed cheese slice 'break' characteristic. In contrast, the texture of the sample of the third run had deteriorated considerably and was crumbly.

Example 3: A nutritional bar can be made according to the following recipe (per lOOg serving): An imitation cheese composition prepared according to example 1: Sucralose: Citric acid: Apricot pieces: Apricot flavour: It is expected that this bar will have a soft chewy texture and sweet fruity flavour. 79.3g 0.8g 1-lg 18.2g 0.6g It is not the intention to limit the scope of the invention to the abovementioned examples only. As would be appreciated by a skilled person in the art, many variations are possible without departing from the scope of the appended claims.

Claims (46)

55p^24 5 What We Claim Is:

1. An imitation cheese composition comprising: a) moisture in an amount that is at least 45% by weight of the composition; b) farinaceous material in an amount that is at least 5% by weight of the composition; 10 c) a proteolysed casein containing source in an amount of at least 5% by weight of the composition; d) a fat source that is at least 10% by weight of the composition; e) a complex phosphate emulsification salt that is at least 0.01% by weight of the composition; and 15 f) optionally one or more GRAS ingredients selected from one or more flavour ingredients that are natural or artificial, one or more natural or artificial colours, one or more preservatives, one or more acidulants and one or more bulking or texturising agents; wherein the composition is sufficiently firm that it can be comminuted, formed into a bar, or formed into a slice (IWS) that is peelable from a plastic backing film. 20

2. An imitation cheese composition as claimed in claim 1, wherein the moisture content of the composition is at least 50% by weight of the composition.

3. An imitation cheese as claimed in claim 2, wherein the moisture content of the 25 composition is at least 55% by weight of the composition.

4. An imitation cheese composition as claimed in claim 3, wherein the moisture content of the composition is at least 60% by weight of the composition. 30

5. An imitation cheese composition as claimed in claim 1, wherein the farinaceous material is selected from native starch or flour containing native starch.

6. An imitation cheese composition as claimed in claim 5, wherein the farinaceous material is present in an amount calculated to replace at least 20% of the casein or caseinate that would be 35 present in an equivalent non-imitation cheese product.

7. An imitation cheese composition as claimed in claim 6, wherein the farinaceous material is present in an amount to replace at least 25% of casein or caseinate that would be present in an equivalent non-imitation cheese product. INTELLECTUAL PROPERTY OFFICE OF f\i.Z. - S LX 2008 r f r. p i \/ f n 55W 5

8. An imitation cheese composition as claimed in claim 7, wherein the farinaceous material is present in an amount to replace at least 30% of casein or caseinate that would be present in an equivalent non-imitation cheese product. 10

9. An imitation cheese composition as claimed in claim 8, wherein the farinaceous material is present in an amount to replace at least 35% of casein or caseinate that would be present in an equivalent non-imitation cheese product.

10. An imitation cheese composition as claimed in claim 9, wherein the farinaceous material 15 is present in an amount to replace at least 40% of casein or caseinate that would be present in an equivalent non-imitation cheese product.

11. An imitation cheese composition as claimed in claim 10, wherein the farinaceous material is present in an amount to replace at least 45% of casein or caseinate that would be 20 present in an equivalent non-imitation cheese product.

12. An imitation cheese composition as claimed in claim 11, wherein the farinaceous material is present in an amount to replace at least 50% of casein or caseinate that would be present in an equivalent non-imitation cheese product. 25

13. An imitation cheese composition as claimed in claim 1, wherein the casein source is present in the composition in an amount of at least 10% by weight of the composition.

14. An imitation cheese composition as claimed in claim 13, wherein the casein source is 30 present in the composition in an amount of at least 15% by weight of the composition.

15. An imitation cheese composition as claimed in claim 14, wherein the casein source is present in the composition in an amount of at least 20% by weight of the composition. 35 16. An imitation cheese composition as claimed in any one of claims 13-15, wherein the casein source is selected from caseinate, rennet casein, MPC, or retentate. intellectual property office of n.z. 11 AU6 2008

RECElVFnj 550g|4 5

17. An imitation cheese composition as claimed in claim 1, wherein the fat source is selected from the group comprising of cream, double cream, butter, anhydrous milk fat (AMF), liquefied fresh frozen milk fat or recombining (FFMR), and a non dairy fat such as vegetable oil.

18. An imitation cheese composition as claimed in claim 1, wherein the complex phosphate 10 emulsification salt is selected from a mono, di or polyvalent cationic phosphate salt including metaphosphate, hexametaphosphace, pyrophosphate, polyphosphate and disodium phosphate

19. An imitation cheese composition as claimed in claim 1, wherein when the composition is 15 formed into a cheese slice, the flavour ingredient is a cheese flavour selected from the group consisting of enzyme modified cheese (EMC), enzyme modified lactile products, synthetic or artificial cheese flavourings, lipolysed dairy flavours, dairy/cheese top notes and dairy/cheese push notes depending on the type of cheese that the imitation cheese slice is intended to mimic.

20 20. An imitation cheese composition as claimed in claim 19, comprising imitation mozzarella, imitation cheddar, imitation parmesan or imitation Colby cheese.

21. An imitation cheese composition as claimed in claim 1, wherein when the composition is formed into a bar, the flavour is sweet or savoury selected from the group consisting of vanilla, 25 chocolate, coconut, cinnamon, apricot, cherry, or any other fruit flavour, salt, spice, beef, chicken or any other meat flavour, or a cheese flavour as defined in claim 19.

22. An imitation cheese composition as claimed in claim 1, when the bar comprises additional ingredients selected from nuts, seeds, fruit, meat and the like, to increase its nutritional 30 value.

23. An imitation cheese composition as claimed in claim 21 or 22, wherein the bar comprises one or more layers of the flavoured imitation cheese composition, and is optionally coated with nuts, seeds, icing, chocolate or any other suitable coating.

24. An imitation cheese composition as claimed in claim 1, wherein the composition has melting characteristics corresponding to a Schreiber melt value of between about 0.5 to about (DSP). 35 2.0. office of N.z 2 2 AUG im 55gg>4 5

25. An imitation cheese composition as claimed in claim 24, wherein the composition has melting characteristics corresponding to a Schreiber melt value of between about 1.0 to about 1.5. 10

26. A method for preparing an imitation cheese composition comprising the steps: a) combining a source of casein, farinaceous material, fat, water, at least one emulsification salt, and optionally one or more GRAS ingredients; b) adding a proteolytic enzyme; c) heating to about 50°C to melt the fat and to allow the proteolytic enzyme to react; 15 d) cooking the mixture of step c) at between about 86°C and 100°C for between 2 minutes and 30 minutes; and e) cooling the cooked mixture of step d).

27. A method as claimed in claim 26, comprising the further steps of 20 f) forming the cooled composition of step e) into a sheet or film on a plastic backing film; and g) cutting the plastic backed sheet or film into individually wrapped cheese slices (IWS).

28. A method as claimed in claim 26, comprising the further step of f) forming the cooled 25 composition of step e) into individual bars of a desirable shape and size.

29. A method as claimed in claim 26, further comprising the step of comminuting the cooled composition of step e).

30 30. A method as claimed in claim 26, wherein step a) comprises combining at least 5% by weight of a casein or caseinate source; at least 5% by weight farinaceous material; at least 45% by weight water; at least 10% by weight fat; at least 0.01% by weight of a complex phosphate of emulsification salt; and optionally one or more GRAS ingredients. 35

31. A method as claimed in claim 26, wherein in step b), the proteolytic enzyme is selected from the class of enzymes that are able to convert kappa casein to para-kappa casein.

32. A method as claimed in claim 31, wherein the enzyme is rennet (chymosin). INTELLECTUAL PROPERTY OFFiCE OF N.Z. - S DEC ■ a r l \ l c n 5529)24 5

33. A method as claimed in claim 26, wherein step d) is carried out at between about 90°C and 98°C for between 2 and 5 minutes.

34. A method as claimed in claim 26, wherein step d) is carried out between 92°C and 97°C 10 for between 5 and 15 minutes.

35. A method as claimed in claim 26, wherein step d) is carried out at 95°C for 10 minutes.

36. An imitation cheese slice (IWS) produced by the method of claim 27. 15

37. A bar produced by the method of claim 28.

38. A comminuted imitation cheese product produced by the method of claim 29. 20

39. A method of preparing a nutritional bar product comprising the steps: a) combining 1 to 90% by weight of comminuted imitation cheese composition of claim 36 with one or more ingredients selected from the group consisting of 0.1-40% by weight of carbohydrate; 0-40% by weight of protein, 0.1-5.0% by weight of vitamins and minerals, 0.1-40% by weight of water, 0.1-10% by weight of soluble and/or insoluble fibre, 0.1-10% by 25 weight of fat, 0.1-5% by weight of preservatives and 0-10% by weight of binder; b) mixing to form a homogenous mass; and c) forming the mixture of step b) into bars of a desirable shape and size.

40. A method as claimed in claim 39, wherein the bar is coated on the top and/or bottom 30 and/or sides with a suitable coating before packaging.

41. A nutritional bar product produced by the method of claim 39.

42. An imitation cheese composition as claimed in claim 1 substantially as herein described 35 with reference to any example thereof and/or the accompanying drawings.

43. A method as claimed in claims 26 or 39 substantially as herein described with reference to any example thereof and/or the accompanying drawings. INTELLECTUAL PROPERTY OFFICE OF N.Z. ■ - S DEC 2C;3 !-* r- /-* i- i \ # e: r* 55£24 5

44. An imitation cheese slice as claimed in claim 36 substantially as herein described with reference to any example thereof and/or the accompanying drawings.

45. A bar as claimed in claim 37 or 41 substantially as herein described with reference to any 10 example thereof and/or the accompanying drawings.

46. A comminuted imitation cheese product as claimed in claim 39 substantially as herein described with reference to any example thereof and/or the accompanying drawings. 15 INTELLECTUAL PROPERTY OFFICE OF N.Z. - e DEC 2008