Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G9/00—Frozen sweets, e.g. ice confectionery, ice-cream; Mixtures therefor
  • A23G9/52—Liquid products; Solid products in the form of powders, flakes or granules for making liquid products ; Finished or semi-finished solid products, frozen granules
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
  • A21D13/00—Finished or partly finished bakery products
  • A21D13/80—Pastry not otherwise provided for elsewhere, e.g. cakes, biscuits or cookies
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
  • A21D2/00—Treatment of flour or dough by adding materials thereto before or during baking
  • A21D2/08—Treatment of flour or dough by adding materials thereto before or during baking by adding organic substances
  • A21D2/14—Organic oxygen compounds
  • A21D2/16—Fatty acid esters
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
  • A21D2/00—Treatment of flour or dough by adding materials thereto before or during baking
  • A21D2/08—Treatment of flour or dough by adding materials thereto before or during baking by adding organic substances
  • A21D2/14—Organic oxygen compounds
  • A21D2/18—Carbohydrates
  • A21D2/186—Starches; Derivatives thereof
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23D—EDIBLE OILS OR FATS, e.g. MARGARINES, SHORTENINGS OR COOKING OILS
  • A23D7/00—Edible oil or fat compositions containing an aqueous phase, e.g. margarines
  • A23D7/005—Edible oil or fat compositions containing an aqueous phase, e.g. margarines characterised by ingredients other than fatty acid triglycerides
  • A23D7/0053—Compositions other than spreads
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23D—EDIBLE OILS OR FATS, e.g. MARGARINES, SHORTENINGS OR COOKING OILS
  • A23D7/00—Edible oil or fat compositions containing an aqueous phase, e.g. margarines
  • A23D7/005—Edible oil or fat compositions containing an aqueous phase, e.g. margarines characterised by ingredients other than fatty acid triglycerides
  • A23D7/0056—Spread compositions
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23D—EDIBLE OILS OR FATS, e.g. MARGARINES, SHORTENINGS OR COOKING OILS
  • A23D7/00—Edible oil or fat compositions containing an aqueous phase, e.g. margarines
  • A23D7/02—Edible oil or fat compositions containing an aqueous phase, e.g. margarines characterised by the production or working-up
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23D—EDIBLE OILS OR FATS, e.g. MARGARINES, SHORTENINGS OR COOKING OILS
  • A23D9/00—Other edible oils or fats, e.g. shortenings or cooking oils
  • A23D9/007—Other edible oils or fats, e.g. shortenings or cooking oils characterised by ingredients other than fatty acid triglycerides
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
  • A23L27/70—Fixation, conservation, or encapsulation of flavouring agents
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L27/00—Spices; Flavouring agents or condiments; Artificial sweetening agents; Table salts; Dietetic salt substitutes; Preparation or treatment thereof
  • A23L27/70—Fixation, conservation, or encapsulation of flavouring agents
  • A23L27/72—Encapsulation
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L29/00—Foods or foodstuffs containing additives; Preparation or treatment thereof
  • A23L29/20—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents
  • A23L29/206—Foods or foodstuffs containing additives; Preparation or treatment thereof containing gelling or thickening agents of vegetable origin
  • A23L29/212—Starch; Modified starch; Starch derivatives, e.g. esters or ethers
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
  • A23L7/10—Cereal-derived products
  • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
  • A23L7/191—After-treatment of puffed cereals, e.g. coating or salting
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
  • A23L7/10—Cereal-derived products
  • A23L7/198—Dry unshaped finely divided cereal products, not provided for in groups A23L7/117 - A23L7/196 and A23L29/00, e.g. meal, flour, powder, dried cereal creams or extracts
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/10—Coating with edible coatings, e.g. with oils or fats
  • A23P20/11—Coating with compositions containing a majority of oils, fats, mono/diglycerides, fatty acids, mineral oils, waxes or paraffins
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/10—Coating with edible coatings, e.g. with oils or fats
  • A23P20/12—Apparatus or processes for applying powders or particles to foodstuffs, e.g. for breading; Such apparatus combined with means for pre-moistening or battering
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
  • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
  • A61K47/30—Macromolecular organic or inorganic compounds, e.g. inorganic polyphosphates
  • A61K47/36—Polysaccharides; Derivatives thereof, e.g. gums, starch, alginate, dextrin, hyaluronic acid, chitosan, inulin, agar or pectin
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
  • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
  • A61K47/44—Oils, fats or waxes according to two or more groups of A61K47/02-A61K47/42; Natural or modified natural oils, fats or waxes, e.g. castor oil, polyethoxylated castor oil, montan wax, lignite, shellac, rosin, beeswax or lanolin
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08B—POLYSACCHARIDES; DERIVATIVES THEREOF
  • C08B30/00—Preparation of starch, degraded or non-chemically modified starch, amylose, or amylopectin
  • C08B30/12—Degraded, destructured or non-chemically modified starch, e.g. mechanically, enzymatically or by irradiation; Bleaching of starch
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
  • C08L3/02—Starch; Degradation products thereof, e.g. dextrin
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G2200/00—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents
  • A23G2200/06—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents containing beet sugar or cane sugar if specifically mentioned or containing other carbohydrates, e.g. starches, gums, alcohol sugar, polysaccharides, dextrin or containing high or low amount of carbohydrate

Definitions

• Starch is a high molecular weight polymer composed of repeating 1,4- ⁇ -D-glucopyranosyl units (anhydroglucose units, or AGU) and is typically a mixture of linear and branched components.
• the linear component, amylose has a molecular weight of several hundred thousand; while the molecular weight of the branched amylopectin is on the order of several million.
• cornstarch contains about 25% amylose, cornstarch varieties are available commercially that range in amylose content from 0% (waxy cornstarch) to about 70% (high-amylose cornstarch).
• Starch occurs in living plants in the form of discrete granules ranging from about 5 to 40 microns in diameter, depending on the plant source. It is well known that starch, as isolated from the plant in its native state, is insoluble in water at room temperature because of strong hydrogen bonding between polysaccharide macromolecules. Areas of crystallinity within starch granules also inhibit water solubility. When a water suspension of granular starch is heated, granules at first slowly and reversibly take up water with limited swelling. Then, at a definite temperature, which is typically about 70o C, granules swell rapidly and irreversibly; and areas of crystallinity within the granule are lost. The temperature at which this occurs is commonly referred to as the gelatinization temperature.
• Jet cooking has been used commercially for decades to prepare starch solutions for non-food applications, for example, in the paper industry.
• the method involves pumping an aqueous starch slurry through an orifice where it contacts a jet of high pressure steam.
• steam jet cooking dissolves amylopectin as well as amylose.
• Jet cooked starch solutions that have been dried are often difficult to redisperse in water and generally do not yield lump-free pastes having the smooth consistency required for food applications.
• Starch monoesters of hydrophobic substituted succinates have been used to stabilize emulsions of oil and water, as taught by P. C. Trubiano, in “Modified Starches: Properties and Uses,” CRC Press, Boca Raton, FL, 1986, p. 131; and by O. B. Wurzburg, in Cereal Foods World, Vol. 31, 1986, p. 897.
• These starch derivatives are prepared by esterifying the hydroxyl substituents of starch through reaction with alkyl, alkenyl, aralkyl or aralkenyl succinic anhydrides.
• High-solids dispersions of these low-viscosity starch derivatives can be spray-dried to produce a powder containing up to 40-50% encapsulated oil. It has been generally recognized that underivatized starches do not function as oil-water emulsifiers. In this regard, Trubiano, supra, comments on page 139 that in salad dressing, "emulsions made with untreated starch, but having the same viscosity, show very large oil droplets, which may coalesce and separate with time.”
• Bracco (U.S. Pat. No. 4,088,792) describes a process for the preparation of an edible cream, in which an aqueous mixture comprising 10-35% by weight of starch, at least 5% by weight of proteins and at least 5% by weight of fat (of which at least 1% consists of emulsifying fat) is homogenized at a temperature of 70-90o C, and preferably not exceeding 120o C.
• the presence of proteins and emulsifying fats, such as monoglycerides and lecithins, are essential, suggesting that without the beneficial emulsifying effects of these substituents, starch alone would not be able to maintain the fat constituent in an emulsified state.
• Hermansson describes modified starch products prepared by binding starch with proteins, specifically a casein or caseinate, to form complexes. Complexes are prepared by heating starch with an aqueous dispersion of protein at a temperature exceeding the starch gelatinization temperature. The resulting modified starch does not have the sticky, gummy properties of unmodified starch and also functions as an emulsion stabilizer. The presence of protein in the composition is essential for the emulsion stabilization of lipids, suggesting that starch alone would not function in this capacity.
• Bosco et al. (U.S. Pat. No. 4,468,408) describe a stable butter flavored oil-in-water emulsion, useful as a low-fat liquid spread.
• the composition of Bosco et al. comprises a dispersed phase, containing less than 40% fat, based on the weight of the spread, and a continuous aqueous phase containing 0.1-4% of an emulsifier system comprised of both lipophilic and hydrophilic emulsifiers.
• the components of the composition are mixed in water, homogenized and cooled to yield the final composition.
• Morehouse et al. describe dried compositions prepared from oil-in-water emulsions.
• Fung U.S. Pat. No. 5,082,684 describes a low-calorie fat substitute prepared by combining an oil or fat with an aqueous phase which is rendered non-flowable by addition of a gel-forming composition, such as a natural gum. Water-binding compositions such as soluble carbohydrates may also be added. Unlike the compositions of the invention described herein, an emulsifier is an essential ingredient of these prior art compositions.
• Fung et al teach a carbohydrate fat extender that is added to the composition of Fung, supra; and a portion of the fat is replaced with an incompletely digestible fat mimetic.
• Rubens U.S. Pat. No. 5,149,799 describes an apparatus and method for preparing a spray-dried, pregelatinized starch, in which the resulting starch contains a greater degree of whole, unbroken granules than a starch prepared by conventional spray-drying or drum drying processes.
• other ingredients such as emulsifiers, flavors, colors, or fats may be added to the starch slurry prior to drying, presumably in minor amounts, the patent teaches that total disruption and solubility of starch granules, such as would be encountered during steam jet-cooking, yields inferior products for food applications.
• Doane et al. (U.S. Pat. No. 4,911,952) describe a method for encapsulating various agents, such as agricultural chemicals and food constituents within a starch matrix. After the starch is jet cooked, any of several additives, including vegetable oils, may be blended into the cooked dispersion by slow mixing, such as in a sigma blade mixer.
• Kasica et al. teach the preparation of pregelatinized starches by a process utilizing thermal jet cooking. This process produces a pregelatinized starch having a molecular weight, as determined by intrinsic viscosity, that is not substantially less than that of native, uncooked starch.
• the split second drying time coupled with the fact that the superheated starch solution is not vented to the atmosphere or cooled prior to spray-drying, minimizes the association of starch molecules (i.e., retrogradation) and yields a starch that readily dissolves or disperses in water.
• aqueous dispersions of the pregelatinized starch form firm gels on standing. These gels exhibit gel strengths higher than those observed when drum drying is used, suggesting that drum drying should be avoided if pregelatinized starches with maximum water solubility or dispersibility are sought.
• Our invention is based on the discovery that stable and non-separable compositions comprised of microscopic droplets of oil uniformly distributed throughout a starch phase can be prepared in the absence of emulsifying or dispersing agents by gelatinizing starch in the presence of water under conditions which will completely solubilize the starch and then intimately mixing oil into the starch-water solution under conditions of high turbulence before the starch has a chance to retrograde.
• the resulting emulsions are characterized by the following properties: (1) they are stable and do not phase separate into their oil and water components on prolonged standing; (2) on prolonged standing, they form soft gels that can be easily converted back to pourable fluids by the application of heat; (3) they may be dried, for example by use of a drum drier, to yield solid compositions that are not oily to the touch; and (4) dried compositions hydrate rapidly and are easily redispersed in water to form smooth, stable, and lump-free dispersions that are similar in properties to aqueous compositions that have never been dried.
• the smoothness and lubricity of the starch-water-oil compositions of this invention make them suitable for use in foods as thickening agents, suspending agents and fat substitutes.
• the presence of the oil component in these compositions causes them to function as emulsifying and dispersing agents and makes them receptive to the addition of a variety of water-immiscible materials, for example, additional lipid, volatile and essential oils and food flavoring materials, antioxidants, medicinal agents, agricultural chemicals, etc.
• the compositions are also useful as seed coatings, since the oil component provides a significant level of compatibility between the dried composition and the waxy coating found on many seed varieties.
• compositions of the invention have oil uniformly and stably dispersed throughout at levels up to at least 65% of the starch-oil composition.
• these compositions are essentially nonoily to the touch, particularly those which are loaded with less than about 29% oil by weight of the combined starch and oil.
• the compositions of the invention have a nongreasy, yet slippery, texture.
• FIG. 2 shows hexane-extracted fracture surfaces of films prepared from compositions containing approximately 40 parts oil per 100 parts starch as described in Example 30.
• FIG. 2A shows the product prepared by standard excess steam jet cooking; and
• FIG. 2B shows the product prepared by the add-back procedure described in Example 30.
• Lipid is a comprehensive term referring to substances which are found in living cells and which are comprised of only a nonpolar hydrocarbon moiety or a hydrocarbon moiety with polar functional groups (see the Encyclopedia of Chemistry, 3rd Edition, C. A. Hampel and G. G. Hawley, eds., 1973, p. 632). Most lipids are insoluble in water and are soluble in fat solvents such as ether and chloroform. Fats constitute a major division of the lipid family. Fats are glycerol esters of fatty acids, which are chiefly palmitic, stearic, oleic and linoleic; although many other fatty acids are found in nature. Most fats exist as triesters of glycerol.
• Oils are classified into three categories: (1) fatty substances of vegetable and animal organisms; (2) volatile or essential oils, i.e., the odorous principles of vegetable organisms; and (3) mineral oils, fuel oils and lubricants, i.e., hydrocarbons derived from petroleum and its products.
• any lipid is suitable for the preparation of the compositions of this invention, preferred are: the fluid and edible vegetable oils, for example, soybean oil, canola oil and olive oil and the semi-solid hydrogenated vegetable oils, for example, the material commonly marketed under the trademark "Crisco”; the fats of animal origin, such as butter, lard or tallow; and the refined and non-toxic mineral oils commonly referred to as paraffin oil.
• the term “oil” is often used herein interchangeably with the terms "lipid” and “fat”, and that other lipids (i.e. fats and hydrocarbons) could be substituted therefore.
• volatile or essential oils are limited only by their volatility; since they tend to escape as volatile vapors during the preparative process rather than being retained within the composition.
• volatile or essential oils and flavorings may be added as "additional oil" to the compositions of this invention after the cooking process but prior to drying, provided that drying of the composition is carried out at a sufficiently low temperature.
• Compositions of starch, non-volatile oil and water that are prepared according to this invention readily absorb volatile or essential oils and flavorings when they are added in such a manner.
• the added agent remains entrapped for prolonged periods of time within the substantially dry starch matrix and is stable with respect to loss via evaporation. The added agent is immediately released when the starch matrix is either scratched or broken.
• compositions of the invention are prepared from starch and oil in amounts ranging from about 5 parts of oil to about 900 parts of oil, by weight, per 100 parts of starch (about 5-90% of the combined starch-oil composition on a dry weight basis). Although it is obvious that fewer than 5 parts of oil per 100 parts of starch can also be used, it is questionable whether, for most applications, the presence of oil in such small quantities will lead to sufficient improvements in the properties of the starch-containing composition to justify the costs associated with processing.
• the upper limit for the oil content of the final composite composition is dictated by the point at which oil begins to separate from the recovered product. A dried composition having an outwardly oily character would be objectionable for many applications since it would be difficult to grind or mill such a product to a small particle size.
• a particulate composition having an outwardly oily character would tend to cake and be resistant to flow.
• a level of oil approaching 90% (based on the combined weight of starch and oil) can be obtained, for most applications the upper limit of oil would not exceed 65 parts oil per 100 parts by weight of the starch (40%).
• Preferred compositions are comprised of about 20 parts to 40 parts of oil per 100 parts by weight of starch (17-29%).
• the usual, and perhaps the most expeditious, method for preparing the compositions of this invention is to first prepare a blend of starch, oil and water by rapidly stirring the components of the mixture together at or near room temperature. When the stirrer is stopped, these mixtures tend to separate almost immediately into an upper phase, that consists substantially of oil, and a lower phase that consists substantially of starch and water. Therefore, it is desireable to quickly feed the dispersion into the cooker in order to minimize such separation.
• the pH of the dispersion is typically in the 5-7 range and may be optionally adjusted to any range desired b ⁇ the addition of an acid or base, typically hydrochloric acid or sodium hydroxide.
• the starch concentration in water is typically in the range of about 10-15% by weight, although concentrations as high as about 35% by weight may be used.
• the upper limit for the concentration of starch in water is dictated only by the high viscosity of the cooked dispersion of starch, oil and water. Starch concentrations lower than about 10-15% may also be used; however, with lower solids levels, greater amounts of water must be removed during product recovery, and the expense associated with the drying process will thus be increased.
• the cooking is preferably carried out with an excess-steam jet cooker [see R. E. Klem and D. A. Brogly, Pulp & Paper, Vol. 55, pages 98-103 (May 1981)] under conditions necessary to attain complete disruption of starch granules and complete solution in water of both the amylose and amylopectin components of starch.
• an excess-steam jet cooker see R. E. Klem and D. A. Brogly, Pulp & Paper, Vol. 55, pages 98-103 (May 1981)
• emulsion in the context of this invention refers to micron-sized droplets of oil uniformly entrapped within a starch or starch-water matrix. It is surprising that stable emulsions of this nature, wherein domains of the oil as the discontinuous phase are substantially uniformly dispersed throughout the continuous aqueous starch phase, can be obtained without the addition of an external emulsifying agent.
• jet cooking conditions may be varied by one skilled in the art according to the particular starch variety and the particular oil used, preferred cooking conditions for these compositions are in the range of about 130-150o C with a steam pressure of about 20-50 psig within the cooker and a pumping rate of about 0.75-2.0 liters per min. Typical conditions are 140o C with a steam pressure of 40 psig and a pumping rate of 1.1 1/min. Line pressure steam entering the cooker to achieve such conditions would be 65-70 psig. Thus the excess steam flowing through the cooker, over and above that needed to maintain the desired cook temperature, should be at least about 15 psig, and preferably between about 25 and 30 psig.
• the products within the ambit of this invention will be characterized by oil droplets having a maximum diameter on the order of about 100 microns.
• oil droplet sizes ranging from under one micron to about 25 microns, with preferably 95% of the oil droplets, and most preferably 95% by weight of the oil droplets, being under 10 microns in size.
• These oil droplet sizes can be achieved by appropriate control of the conditions of emulsification and product recovery. Smaller oil droplets have a lowered tendency to coalesce, and thus the formation of these smaller oil droplet sizes is preferred.
• oil droplets under 10 microns in diameter will be considered as being "micron-size".
• the amount of oil used relative to starch, the solids concentration in water and the conditions of cooking are all selected so that the hot, jet cooked dispersion is in the form of a pourable, free-flowing fluid, but having a viscosity significantly higher than that of water itself.
• Higher line pressures and higher steam pressures within the cooker than those described above will cause a higher level of molecular breakdown of the starch and will thus reduce the ultimate viscosity of the jet cooked dispersion. Steam pressure may thus be varied to alter the physical properties of the final product.
• the products of this invention are recovered under conditions which will stabilize the distribution of the oil droplets in the starch phase. Allowing the emulsion to cool below 100o C or lower, preferably to about 95" C, prior to drying promotes retrogradation and concomitant viscosity increase in the final product. After the material exits the excess steam jet cooker, this cooling occurs very rapidly under atmospheric conditions as previously described. The cooling step also provides favorable conditions for molecular complexation between starch and the components of the lipid. While not desiring to be bound to any particular theory of operation, it is believed that helical inclusion complexes form in the products of the invention.
• the oil has a tendency to separate from the starch and water in the precooked dispersion.
• This recycle, or "add-back" stream can be material which is either obtained directly from the exit of the steam jet cooker, or recovered as ground, dried product.
• the amount of recyle material in this preferred embodiment should be in excess of about 1% of the dispersion on a dry weight basis in order to have a noticeable effect on the stability of the blend.
• the add-back material would constitute 10-25% of the dispersion.
• the oil is not added until after the aqueous starch dispersion exits from the jet cooker.
• a "Waring" blender provides a sufficient amount of mechanical shear on a laboratory scale to intimately mix the oil with the hot starch dispersion. It is envisioned that a colloid mill could also be used for this purpose.
• drum drying is the preferred method.
• Typical drum drying conditions for starch-oil compositions are 20-60 psig within the drums with a drum rotation of 2-6 rpm. Preferred conditions are about 30 psig steam pressure within the drums and a drum rotation rate of 4 rpm.
• a composition is considered to be dry when its moisture (free water) level is less than about 20%.
• the recovered products will be dried to about 5-12% moisture. Dry compositions may then be ground, milled, or pulverized to any desired particle size.
• the dried compositions of this invention have unique properties which can be tailored to specific end uses by appropriate selection of the ingredients, proportions, and procession conditions. For the most part, these compositions hydrate rapidly and yield dispersions that are not only smooth and viscous, but also possess considerable lubricity. Exceptions are the highly retrograded products prepared from high amylose starch, which are not as readily redispersible and tend to remain as grainy particles. Dispersions having a sufficiently high solids content to yield viscous pastes at room temperature will become thin enough to pour when heat is applied. Heated dispersions will then resolidify when cooled. These properties are analogous to those of a typical meltable fat or shortening.
• compositions of this invention When the starch/oil emulsions are prepared at solids contents exceeding about 30%, the resulting products tend to be thick and sticky, suggesting utility as adhesives.
• the properties of the compositions of this invention thus make them suitable for incorporation into a variety of food formulations.
• formulations into which compositions of the invention can be incorporated as a fat replacer include sour cream, yogurt, ice cream, cheese, cheese spreads, cake mixes, cookies, dry roasted peanut coatings, salad dressings, meats, margarine, powdered shortening, instant gravies, confectioneries and the like.
• the compositions can be formulated with from about 5% to about 70% fat by weight of the starch.
• Other food uses for the compositions of this invention are as carriers for volatile flavors and aromas and as low-fat coatings to enhance the flavor and ease of popping of popcorn in a microwave oven.
• compositions of the invention are useful as carriers or vehicles in pharmaceutical, cosmetic and personal care product formulations.
• examples of such formulations include hand and body lotions and creams, bath oils, shampoos and conditioners, sun tan lotions, lip sticks, eye shadows, dusting powders, foot powders, medicinal oils, vitamins, antibiotics, antifungal agents and the like.
• compositions are useful as carriers for antifungal agents, herbicides, nematocides, growth regulators, hormones, nutrients, germination stimulators, and other active agents as known in the art.
• the starch-oil products processed with or without a protein additive would be useful in the food industry to emulsify additional oils or volatile agents, flavors, odors, fresh fruit extracts, and the like.
• These emulsified materials would also find application in agriculture, such as for coatings of fruit and vegetables for spoilage retardation or oxidation inhibition, and for bud and bulb protection. They could also be used in the production of scratch and sniff pads.
• compositions of the invention include formulation of adhesives, as thickeners of paints, inks, polishes, paint removers, lubricants, toners, and drilling muds, and as starch fillers in plastic formulations with increased compatibility for hydrophobic additives and plastics.
• adhesives as thickeners of paints, inks, polishes, paint removers, lubricants, toners, and drilling muds
• starch fillers in plastic formulations with increased compatibility for hydrophobic additives and plastics.
• This example describes a preferred embodiment of the invention wherein 20 parts by weight of soybean oil per 100 parts of cornstarch are co-cooked and then evaluated as both an aqueous dispersion and a dried product.
• a portion of the hot, jet cooked dispersion was poured into a beaker and allowed to stand and cool with no agitation. After standing for 22 hrs at room temperature, the dispersion had a pH of 5.2.
• the Brookfield viscosity measured at 30 rpm with the standard No. 3 spindle, was 600 cp. Cornstarch alone, when jet cooked in the absence of oil and allowed to cool under the same conditions, produced a Brookfield viscosity of 1150 cp. There was no separation of oil on standing.
• Another portion of the hot dispersion was poured onto a polyethylene sheet and allowed to dry at room temperature to form a continuous, brittle film. No free oil was observed on the film surface. A portion of the film was broken to expose a fresh fracture surface, and the specimen was soaked in absolute ethanol for 15 min to extract the entrapped oil. The fracture surface, with oil extracted, was then examined by scanning electron microscopy (SEM) to reveal holes or voids in the continuous starch phase that were previously occupied by entrapped oil (see FIG. 1A).
• SEM scanning electron microscopy
• the remaining hot dispersion was dried on an 18 X 12 inch diameter double-drum drier heated with 30 psig steam and rotating at 4 rpm.
• the solid came off the drums in the form of large, brittle flakes and sheets; and the dried solid was not oily to the touch.
• the product was then coarsely ground by passing it through a "Retsch" mill, and the product was observed not to be oily to the touch.
• the moisture content of the milled product was 6.2%, as determined by weight loss after vacuum drying for 4 hrs at 100o C over P 2 O 5 .
• the milled product was sieved to obtain a fraction passing through a 12 mesh sieve but retained by 20 mesh. The moisture content of this fraction was 8.0%.
• Example 2 After the mixture had stood in a covered beaker for 18 hr at room temperature, the viscosity was 1460 cp. Refrigeration of the dispersion at 5o C for an additional 26 hr increased the Brookfield viscosity to 2970 cp. The dispersion remained smooth and creamy, and there was no apparent separation of oil from the aqueous phase.
• Example 2
• Example 2 describes a variation of the method of Example 1, wherein the composition, having about the same 20:100 oil to starch ratio used in Example 1, was prepared by first dissolving starch in water by jet cooking and then later blending soybean oil into the resulting starch solution.
• Example 1 Twenty grams, dry basis, of the milled but unsieved product containing 5.8% moisture was blended with 200 ml of water and heated to boiling in a microwave oven, as described in Example 1. The dispersion was smooth and creamy, and there was no apparent separation of oil from the aqueous phase. Brookfield viscosities, measured at 80, 50, and 30o C, were 56, 104, and 192 cp, respectively. As in Example 1, Brookfield viscosities were then measured after 18 hr at room temperature (1900 cp) and after an additional 26 hr at 5o C (3660 cp). It is apparent that the Brookfield viscosities of the compositions produced by the method of Example 2 were generally higher than those produced by the co-cook method of Example 1.
• compositions of this invention demonstrate the ability of the compositions of this invention to encapsulate volatile oils and flavorings and to stabilize them against evaporation until they are used.
• This example illustrates the use of the compositions of this invention in the preparation of low-fat cakes.
• test cakes were similar in taste to the control, cakes containing high levels (25 g) of the compositions of this invention tended to be coarse and gummy. All formulations having the shortening substitute yielded cakes which were more breadlike than the control cake.
• Loaf volumes of test cakes ranged from 73% of the full-fat control (for a recipe containing starch:butter, 100:50) to 86% of the full-fat control (for a recipe containing starch:soy protein:canola oil in a 100:20:20 ratio).
• the specific formulations and relative cake volumes are given in Table V.
• compositions of this invention to prepare spreadable formulations having properties similar to butter or margarine.
• the resulting dispersion was then heated in a microwave oven to about 94o C, and the hot mixture was returned to the blender and stirred at full power for 5 min.
• the dispersion was finally poured into a plastic container and allowed to cool to room temperature.
• the cooled dispersion was creamy in texture and had good spreading properties. These properties were retained after refrigeration and for periods of up to six weeks.
• This experiment illustrates an embodiment for loading a high percentage of oil into products prepared in accordance with the invention.
• a starch:soy protein:canola oil (100:20:20) product was prepared as in Example 27.
• the drum dried powder was resuspended in water at 10% solids and 50 ml of the suspension was added to 25 ml of soy oil in a "Waring" blender. After blending for one minute, the emulsion was heated in a microwave oven to 90o C and then reblended in the "Waring" blender for two minutes at high speed. An emulsion formed upon cooling that was stable for at least 6 weeks. Based on the total weight of solids (oil, starch and protein), the amount of oil in the system was 89%.
• a mixture of 280.7g of dextran (moisture content 12%) and 106.9g of soybean oil was slowly added to 2 liters of water with rapid stirring.
• the amount of oil used corresponds to 43 parts of oil per 100 parts of dextran on a dry weight basis.
• the resulting dispersion was jet cooked under the conditions used in Example 1.
• Example 1 The remaining hot, jet cooked dispersion was drum dried as in Example 1. Unlike analogous compositions prepared from starch, the dispersion did not drum dry well and contained some areas that were only partially dried. These areas were separated from the majority of the material, which was then pulverized by stirring dry in a Waring blender. When the dried and pulverized product was extracted with hexane using the same procedure described in Example 30, the results were quite different than those observed for the starch-containing products shown in Table IV. The fraction of oil that was "loosely bound", i.e.
• compositions of this invention having viscoelastic properties not obtainable from a single starch variety.
• a dispersion of 180g of soybean oil and 0.2g of ⁇ -tocopherol in 3 liters of water was prepared using the technique described in Example 1. This amount of oil was calculated to equal 20 parts of oil per 100 parts of total starch in the formulation.
• a jet cooked dispersion was prepared from 40 parts of soybean oil per 100 parts of starch using the technique described in Example 3. The hot, jet cooked dispersion was divided into two portions.
• Example 2 The first portion was drum dried and coarsely ground as described in Example 1.
• "loosely bound” oil constituted 15.0% of the original sample weight (starch + oil); whereas "tightly bound” oil constituted 5.7 % of the original sample weight.
• Total oil recovery (loosely bound + tightly bound) amounted to 72.6% of the oil added prior to jet cooking.
• the second portion of hot, jet cooked dispersion was spray dried at 145-150o C in a Yamato Pulvis Mini-Spray drier, Model GA-31.
• "loosely bound” oil constituted 9.1% of the original sample weight (starch + oil); whereas "tightly bound” oil constituted 7.0% of the original sample weight.
• Total oil recovery (loosely bound + tightly bound) amounted to 56.4% of the oil added prior to jet cooking.
• Example 3 describes a variation of the method of Example 3, wherein an aqueous composition, having the same 40:100 oil to starch ratio used in Example 3, was prepared by first dispersing jet cooked and drum dried starch in water at room temperature and then blending soybean oil into the resulting dispersion using high-shear mixing. Procedures similar to this are useful for preparing compositions of this invention in which the oil is either volatile or unstable at high temperatures.
• a suspension of 400g, dry basis, of food grade cornstarch from A.E. Staley in 3 liters of water was jet cooked, drum dried and coarsely ground under the conditions used in Example 1.
• Ten grams of this dry product was then added to 90ml of water in a Waring blender bowl, and the mixture was stirred at the highest speed for 1 min.
• Four grams of soybean oil was then added, and the mixture was stirred at the highest speed for 2 min.
• the final temperature of the dispersion was 43o C.
• a portion of the dispersion was poured onto a sheet of polyethylene and allowed to evaporate to dryness.
• the resulting brittle film showed no trace of oil on the surface.
• the film was broken to expose a fresh fracture surface, which was then extracted with hexane to remove oil. Examination of this hexane-extracted fracture surface by SEM showed micron-sized voids, indicating that the oil was intimately dispersed within the starch matrix in the form of micron-sized droplets.
• the remaining dispersion was poured into a beaker and allowed to stand for 4 days at room temperature with no agitation. There was no apparent separation of oil from the aqueous phase, and the dispersion had a Brookfield viscosity of 1930 cp (No. 3 spindle, 30 rpm).
• This example describes the preparation of solutions of taxol in aqueous dispersions of starch-soybean oil compositions.
• Procedure A A solution of 25 mg of taxol in 0.3 ml of warm ethanol was prepared, and 0.7 ml of alpha-tocolperol (vitamin E) was added with stirring in a homogenizer.
• vitamins E alpha-tocolperol
• the composite was prepared by: 1) jet cooking an aqueous mixture containing 100 parts of cornstarch and 5 parts of soybean oil, by weight; and 2) drum drying the resulting jet cooked dispersion. The final mixture was vigorously stirred in a homogenizer for 5 min under high shear and was then transferred to a glass vial. This dispersion could be either dried to a film or diluted with additional starch-oil composite.
• Procedure B A solution of 500 mg of taxol in 5 ml of warm ethanol was prepared, and 8.0 ml of alpha-tocopherol (Vitamin E) was added with stirring in a homogenizer. Eighty milliliters of a hot ( 80-90"C) 20% aqueous dispersion of twice-cooked starch-soybean oil composite was added, followed by 7 ml of a 10% aqueous dispersion of once-cooked starch-soybean oil composite.
• Vitamin E alpha-tocopherol
• the starch-soybean oil composites were prepared by: 1) jet cooking an aqueous mixture containing 100 parts of cornstarch and 20 parts of soybean oil, by weight (either one or two passes through a jet cooker); and 2) drum drying the resulting jet cooked dispersions. The final mixture was vigorously stirred in a homogenizer for 5 min under high shear and was then transferred to a glass containere for storage. Scanning electron micrographs of dried films showed a honeycomb-like structure composed of taxol-containing oil droplets surrounded by thin starch walls.
• This example describes the preparation of plywood adhesives from urea, formaldehyde and starch-lipid composites.
• a solution of 74 g of urea in 100 ml of water was prepared, and 100 ml of 37% formaldehyde solution was added.
• 50 g of a dry cornstarch-lipid composite prepared by: 1) jet cooking an aqueous mixture containing 100 parts of cornstarch and 40 parts of either boiled linseed oil or lanolin by weight; and 2) drum drying the resulting jet cooked dispersion. The mixture was stirred in a Warring blender until smooth and was then let stand for 1-2 hr.
• the resulting dispersion was coated onto both sides of a 3/32-inch pine sheet, typically used for the preparation of plywood. This coated sheet was then placed between two uncoated wooden sheets, and the composite board was pressed for 10 min at about 121oC. The resulting plywood sheet was well bonded and was resistant to water when soaked overnight at room temperature.

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