A PROCESS FOR THE REDUCΗON OF FAT IN FOOD AND AN APPARATUS FOR PRESSURE TREAΗNG DIETARY FIBERS
Background of the Invention
Efforts to improve the food features of processed foods are 5 concentrated in two categories, namely fat reduction and the use of inherently low calorie food ingredient substitutes. The first category, fat reduction, includes the replacement of certain food compounds for fat. These food compounds that are used as fat replacers mimic the mouth feel and flavor retention of fat. 0 In the second category, low calorie compounds are used to replace common high caloric (but usually low fat) compounds in recipes for baked goods, microwave and frozen foods, beverages and soft drinks. For example, aspartame is used to replace sugar in beverages to reduce overall calories. Also, dietary fibers are used as a bulking 5 agent to lower the calories in baked goods, including cookies, snack foods and bread products. Generally, dietary fibers are highly indigestible, low in calories and low in fat content.
Although less common, semi-artificial compounds have been developed to act as both a fat replacer and as low calorie ingredient 0 substitutes. Such semi-artificial compounds have inherent problems in marketability, and regulatory acceptance. Many such semi-artificial compounds have no historical background in recipe incorporation, leading to long term market introduction problems.
There have been several attempts to develop low calorie and low 5 fat food ingredients and food products. For example: US Patent No. 5,693,350 to Fernandez et al. and US Patent No. 5,232,722 refer to the preparation of a meat pate which exhibits low fat content by first preparing a meat emulsion by combining meat, water, salt and a fat substitute. The emulsion is then cooked and subjected to a hydrostatic 0 pressure greater than 400,000 kPa. In the aforementioned two patents pressure is applied to force the emulsion against an orifice plate, generating a shearing effect, which assists in the homogenization of
the original meat emulsion and the fat substitute. Pressure is used merely as a propulsion device to move the emulsion and to maintain homogenization.
US Patent No. 5,518,755 employs the use of a pressure homogenizer to form smaller particles in a nut spread, thereby improving mouth feel of the homogenized nut spread. An improved mouth feel can translate into less fat being incorporated into the nut spread as the small particle size acts to mimic the overall texture, flavor and perception of a higher fat product. In this instance pressure is used to force a peanut paste against an orifice plate, developing high shear, and creating a homogenous emulsion.
In the above referenced patents, pressure is used in a hydrostatic means to force a target food compound against an orifice plate for the purpose of forming a homogenous mixture with a certain particle size that will enable less fat to be incorporated into the product, but still provide the taste and mouth sensation of a higher fat content product. In most instances fat mimics or fat replacers are employed in the homogenous mixture to lower the fat yet enhance taste and texture perception. Pressure is not used tangentially, as a. means of directly eliminating or reducing fat, or for the purpose of calorie reduction. Summary of the Invention
This invention provides a means of improving the functionality of food compounds, in terms of reduced fat and reduced calories, wherein a food compound is caused to have a lower fat or reduced calorie feature by means of a high pressure treatment process, wherein the pressure is used directly as the mechanism for fat reduction and calorie reduction, in most instances the targeted food compound is a natural food substance, not a blend of homogenized fat substitutes that mimic fat perception.
Pressure is applied directly to a food substance to modify the properties of the food substance. The direct pressure application
causes a lowered fat content, and a lowered caloric content, and is not used as a primary propulsion means to move the food substance.
This invention relates to a means of reducing calories in food compounds via a direct pressure treatment process. This invention also relates to a means of reducing the fat content of targeted food compounds, also by utilization of a pressure treatment process.
It is an object of this invention to provide a means of reducing the fat content in treated food compounds by means of a direct pressure treatment process which may be in the form of a abrupt pressure change, a pressure shock wave, or an impact or shearing effect caused by high pressure forces.
Forces which may accompany the subject pressure treatment may also be utilized in the effort to reduce calories or fat. Said accompanying forces include friction, heat, cavitation, or electrostatic charges build up by the pressure treatment.
It is an object of this invention to provide an apparatus, which will effect the reduction of the caloric content and or fat content in treated food compounds by means of a directed pressure treatment process. Said apparatus can include means of generating a directed pressure shock wave, pulse or other pressure treatment by use of a piston, series of pistons, ultrasonic, explosive, grinding, homogenization or other mechanical device which will impart pressure to a targeted food compound.
It is an object of this invention to provide specialty low calorie and or low fat food compounds, which have been modified as to their fat or caloric content via a method involving the use of direct pressure treatments.
A further object of this invention is to provide a means of fat reduction in treated food compounds wherein the food compound has been subjected to Pressure treatments including pressure shock waves, or abrupt pressure treatments, ultrasound, friction, heat, cavitation, or electrostatic charges build up by the pressure treatment or an impact or
shearing effect caused by high pressure forces, wherein the fat component of the treated food compound has been liquified or otherwise dissolved by the forces applied.
A additional object of this invention is to provide a means of calorie and fat reduction wherein the crystalline structure of a treated food compound has been altered, or wherein the carbohydrate structure has been altered, by directed pressure treatment and its accompanying forces.
It is an object of this invention to provide an apparatus which will effect the reduction of the caloric content and or fat content in treated food compounds by means of a directed pressure treatment process. Said apparatus can include means of generating a directed pressure shock wave, pulse or other pressure treatment by use of a piston, series of pistons, ultrasonic, explosive, grinding, homogenization or other mechanical device which will impart pressure to a targeted food compound.
Description of the Drawings
FIGURE 1 is a flow diagram of the process according to the present invention, wherein directed pressure, and its accompanying effects, are used to reduce the fat content and caloric value of targeted food compounds.
FIGURE 2 is a perspective view of a direct pressure application apparatus in accordance with the present invention.
FIGURE 3A is a top plan view of a cavitation enhancer component, which is added to the pressure applicator device for the purpose of increasing the effect of cavitation.
FIGURE 3B is a side view of a flow cavitation enhancer according to the present invention.
FIGURE 4A depicts the Alpha state crystalline polymorph of many food compounds.
FIGURE 4B depicts the Alpha Prime state crystalline polymorph of many food compounds.
FIGURE 4C depicts the Beta state crystalline polymorph of many food compounds.
FIGURE 5 is a cut-away view of the pressure treatment apparatus of
Figure 2. FIGURE 6 is an enlarged view of the compression chamber and the piston component illustrated in Figure 5, showing the use of cavitation enhancers within the compression chamber.
FIGURE 7 is a photograph of a scanning electron microscope analysis of untreated powdered cellulose. FIGURE 8 is a photograph of a scanning electron microscope analysis of powdered cellulose which has been subjected to 90,000 psi/0.10 seconds of directed pressure treatment, showing the formation of fused fiber strands and the formation of microcrystalline cellulose nodules as a result of the pressure treatment. Detailed Description of the Invention
In describing a preferred embodiment of the invention, specific terminology will be selected for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
This invention involves the treatment of food compounds by directed pressure application, together with its accompanying effects.
The food compound's physical properties are modified by the direct pressure, producing a reduced calorie content and a reduced fat content in the treated food compound.
For purposes of this invention the term"food compound" shall include any ingestible product for human, fish or animal application wherein such product may also be classified as a food ingredient, food compound, food substance, food, or feed product.
Figure 1 illustrates the process for reducing calories and fat in food compounds using directed pressure treatments and their
accompanying effects. In a preferred embodiment, the food compound is an ingredient to be used in making another product. A food compound 1 is added to a solvent 4 in a mixing vessel 2 and agitated by a mixing element 3 into either a slurry state with dispersed particulates or into a dispersion whereupon the food compound 1 has dissolved or partially dissolved into a homogenous dispersion or emulsion. The mixing element 3 may be a standard agitator, a homogenizer mixer, a pressure homogenizer or a static mixer. The resultant dispersion, known as the pre-mix 5, is delivered to a pressure applicator device 6.
The pressure applicator 6 is preferably a Delta Processor Unit, supplied by Encapsulation Systems Inc., of Philadelphia, PA., USA, model number D-1001 . The unit delivers a directed pressure treatment to the pre-mix 5. The pressure treatment is in the form of an intense pressure pulse, variable in force from 0 to 300,000 psi. The time the pressure is present upon the target food compound may be varied from 0.001 to 1 .0 seconds, with a preferred treatment time period being between 0.10 and 0.25 seconds.
The pressure treated dispersion or slurry is called the post-mix 8, and may be directed out of the process to remain in a dispersion or slurry form or may be directed to re-cycle through the process for additional pressure treatment cycles (as indicated by arrow 7). Additionally the post-mix 8 may be reduced to a filter cake form 10 after entering a filtering device 9. In some instances, where a dry powder form 12 is desired, the filter cake 10 may then be delivered to a drier 1 1 . Alternatively, if a full dispersion form of the post-mix 8 is developed it can be delivered directly to the drier 1 1 for reduction into a dry powder 12.
Drier 1 1 may be any of a number of commercial driers depending on the type of food compound and quality of the final dry powder 12. For example, drier 1 1 may be a flash drier, fluid bed drier, convection drier or similar drying apparatus.
Examples of the final product variations include the use of starch as the target food compound 1 , when added to water as the solvent 4, will act to form a full dispersion. Such dispersion requires the use of a spray drier 1 1 after pressure treatment to produce a dry powder 12. In another example, soy fiber may be a target food compound 1 used in water 4 (i.e., the solvent), forming a slurry post-mix 8 which must be filtered 9 into a wet filter cake 10.
A further example would be the use of wheat fiber as the target food compound 1 , dispersed into a slurry form in water and then used as a slurry post-mix 8 directly into an extruded snack food, without first drying the slurry into a dry powder.
The above-described process employs the use of a directed pressure pulse treatment to cause physical property changes in treated food compounds. Applicants have observed that an intense pressure pulse generated by the pressure applicator device 6 causes food compounds to have a lowered fat and calorie content after exposure to the pressure treatment. The pressure generated in the apparatus 6 is developed in the form of an abrupt pressure change, pressure pulse or pressure shock wave. The intensity of pressure delivery can be greater than 300,000 psi. Accompanying effects which are also generated by the abrupt pressure change, also may play a role in the reduction of calories and fat in food. These accompanying effects include: Cavitation; Friction; Heat; and
Impact Compression The abrupt pressure change liberates gases trapped within the food compound 1 , thereby generating heat, through a process called cavitation. Various studies on cavitation show that the heat produced immediately upon cavitation can be very intense (5,000 degrees K or greater), even if only for a short period of time. The heat energy released is thought to be a major cause in the alteration of the physical
properties of food compounds. Reference is made to the article, "The Temperature of Cavitation", by Flint and Suslick, American Association for the Advancement of Science, September 20, 1991 , volume 253, pp. 1397-1398, wherein the heat energy caused by ordinary cavitation is discussed.
Cavitation within the pressure applicator device 6 assists in the dissolution of fat in targeted food compounds by melting the fat component into a liquid form. Heat generated by the cavitation effect acts not only to melt fat but also to re-form the carbohydrate branching of targeted food compounds, also resulting in reduced caloric and fat content.
The application of an abrupt pressure change may change the chemical structure in certain instances. Treated food compounds could be converted from an ionic to an anionic charge. Referring now to Figures 2, 5 and 6, the pressure treatment device 6 includes a pump 72 that drives a reciprocating piston 20 for exerting a pressure pulse on the pre-mix 5. The pre-mix 5 is stored in a reservoir 55 and connected to the input of the pressure treatment device 6 via input conduit 60. The input conduit 60 connects to an inlet valve 23 which leads into a compression/cavitation chamber 21 of the pressure treatment device 6. Input conduit 60 may be heated with heating coils (not shown) to maintain the temperature of the pre-mix 5.
At the opposite end of the pressure treatment device 6 (i.e., egress from the compression chamber 21 ) an exit valve 24 leads to exit conduit 70. Valves 23 and 24 may be solenoid valves, manually operated valves, or automatic check valves.
In a preferred embodiment, the output transfer 70 has a smaller inner diameter than the input transfer conduit 60. This smaller inner diameter acts to develop a back-pressure within the fluid flow which helps output valve 24 to stay closed longer. This maintains an elevated pressure within the compression chamber 21 for a longer
period of time. Pressure treated post-mix 8- exits the compression chamber 21 , travels through output valve 24 and transfer conduit 70.
Referring still to Figures 2 and 5, a motor 82 drives a compressed air pump 72 which ultimately moves reciprocating piston 20 within housing 42. The motor 82 may be a hydraulic, compressed air, electric or combustion type.
As illustrated in Figure 2, the motor 82 is preferably activated by compressed air 30. The air motor 82 powers pump 72 which in turn cycles the piston 20 forward and backward as a result of the compressed air flow.
The compressed air 30 is delivered to the motor 82 through an air conduit 80. The compressed air 30 may pass through an air filter 90, a regulator 91 , an air flow oil reservoir 92, a quarter-turn air valve 93, an air inflow port 96 and finally to the air-driven motor 82 via air conduit 80. The air filter 90 is used to remove all water and water vapor from the compressed air supply 30. The regulator 91 controls the air pressure, which is displayed on the pressure gauge 99. Minute oil droplets are introduced into the compressed air supply 30 as the air flows over an oil reservoir 92. This is used to lubricate the air motor 22.
The number of strokes of the piston 20 is controlled by the quarter-turn air valve 93. The air valve 93 generally has ten settings from 0 to 9. When the air valve 93 is at its fully open setting of 9, the full volume and force of the compressed air 30 is delivered to the air motor 82.
The air motor 82 exhausts spent air through a muffler 95 which is connected to the outflow air port 97 of the air motor 82.
Pre-mix 5 is passed through the apparatus 6 illustrated in Figures 5 and 6 and is pressure treated as the piston 20 strikes downward during its up and down displacement cycle within the compression chamber 21 and channel 19. The valves 23 and 24 may be closed while the piston is in its down stroke or pressure stroke, thereby
trapping the pre-mix 5 in the compression chamber 21 between valves 23 and 24.
Alternatively, the valve action may be adjusted to provide a semicontinuous flow, wherein check valves are used in both the inlet valve 23 and the outlet valve 24. As the piston 20 is raised within channel 19, in its negative pressure cycle, a quantity of pre-mix 5 is drawn into the compression chamber 21 , through inlet valve 23, while outlet valve 24 is closing up. As the piston 20 begins its pressure application of a downward stroke, both valves 23 and 24 are closed for a period of time allowing full pressure to build up within the compression chamber 21 .
Valves or other control equipment can be used to control the cycle of piston 20. The same control equipment can coordinate the cycling of a piston 20 with the opening and closing of valves 23, 24. As piston 20 is forced downward through channel 19 and the compression chamber 21 by the air pump 72, it strikes the surface of the pre-mix 5 and generates a shock wave through the pre-mix 5. As the pump 72 draws the piston upwards, valve 24 opens and the pressure treated dispersion of post-mix 8 exits the machine into conduit 70, while substantially simultaneously drawing in new pre-mix 5 through valve 23.
As illustrated in Figure 6, one or more inserts act to increase the effect of cavitation within the pre-mix 5 during the pressure shock treatment. These inserts are referred to as cavitation enhancers 28 and increase the generation of thermal and electrostatic effects within the pre-mix 5. As the piston 20 begins both its positive (forward) and negative (withdrawing) application of pressure within compression chamber 21 it works with the cavitation enhancers 28 to generate thermal and electrostatic effects within the pre-mix 5. The number of Cavitation enhancers 28 and their shape are mainly determined by the type of food component being treated, the carrier fluid used, the size of the compression chamber 21 and the
results desired. Cavitation enhancers 28 preferably lie on the bottom surface of the compression chamber 21 . The cavitation enhancers 28 may be placed or affixed to the bottom on the cavitation chamber 21 . Each cavitation enhancer 28 preferably has a regular pattern of baffles projecting upwards towards the piston.
The preferred embodiment utilizes triangular-shaped baffles although other designs are also effective. The cavitation enhancer 28 may be of any shape as long as baffles are projected directly under the piston 20. In the preferred embodiment, the cavitation enhancer 28 is made of stainless steel, although ceramic and polymer disks have also shown increased cavitation within chamber 21 .
As the piston 20 strikes the pre-mix 5 within the compression chamber 21 , the pressure shock wave travels through the pre-mix 5 hitting the cavitation enhancers 28. There the pressure shock wave is reflected back upwards through the pre-mix 5. The shock wave hitting the cavitation enhancers 28 also generates an intense, instantaneous thermal effect which induces cavitation within the pre-mix 5, even as the piston 20 withdraws upward on its return stoke through the channel 19.
Reference is now made to Figure 6 wherein a cut-away view of a preferred embodiment of the apparatus 6 that can apply an abrupt pressure change to food compounds is illustrated. The apparatus 6 is comprised of a converted hydraulic pump with piston means 20 for generating an abrupt pressure change to a target food compound, which is pumped through the apparatus. A reservoir 55 is provided as a receptacle for the pre-mix 5, containing a target food compound 1 and may be adapted with a stirrer and heating coils (not shown) where necessary to maintain homogeneity and flow properties. Reservoir 55 is mounted to transfer conduit 60, which leads to pressure application assembly 22. Transfer conduit 60 may also be heated with heating coils to maintain the temperature of the food compound 1 pressure
application assembly 22, the terminal end of-which is disposed between inlet valve 23 and exit valve 24, and piston housing 44 which has within it a reciprocating piston 20.
Within the compression chamber 21 is a series of inserts called "cavitation enhancers" 28, placed directly under the path of the piston 20. Figures 3A and 3B illustrate two possible designs for a cavitation enhancers 28. As the piston 20 drives into and away from the compression chamber 21 it generates a positive and negative application of pressure, leading to cavitation within the compression chamber 21 . The cavitation enhancers 28 within the compression chamber 21 act to increase friction as the piston drives through the center hole 40 of the cavitation enhancer 28. Tabs 42 extend into the center hole 40 from the housing 44 of the cavitation enhancer 28. As the piston moves through and upward from the cavitation enhancer, through the center hole 40 the pressure shock wave generated by the piston striking a liquid within the compression chamber 21 acts to generate a cavitation effect, accompanying the compressive pressure generated by the movement of the piston 20. The cavitation effect includes friction and intense instantaneous heat energy. The cavitation enhancer 28 within the compression chamber acts to enhance the effect, intensity, and duration of the cavitation effect as pressure is generated within the compression chamber.
The output transfer conduit 70 is connected to exit valve 24 for directing the post-mix 8. Two modifications of the subject apparatus may be employed to regulate the closing of exit valve 24. First, the diameter of the output transfer conduit 70 is smaller than the diameter of either output conduit 60 or compression chamber 21 thereby creating a back pressure upon the exit valve 24, helping to the opening of that valve for a sufficient period of time as to effect pressure to build up within the compression chamber 21 upon downward strokes of the piston 26. This delay in opening exit valve 24 controls the time of compression
applied to the pre-mix 5 within the compression chamber 21 . This lower diameter acts to develop a back pressure within the system thereby causing exit valve 24 to remain closed for a longer period. More particularly, Bernoulli principles are employed to interrupt the fluid flow at the point where the flow channel diameter decreases in size. While the velocity of fluid increases at this point, a back pressure is created which maintains the spring loaded exit valve 24 in the closed position longer than would normally be experienced in a conventional hydraulic pump assembly. This function thus extends the pressure application period within compression chamber 21 , which in turn facilitates physical modification of pre-mix 5 and its properties. Second, the valves may be controlled via electronic, pneumatic or other means to operate the opening and closing timing, and therefore the time in which pressure is present within the compression chamber. The actual operation of the apparatus will now be described with reference to Figure 1 . A desired or target food compound 1 is charged to the mixing vessel 2 in any state capable of flow through the system such as a pure liquid or carried by another liquid in the form of a mixture, solution, dispersion, suspension, emulsion, slurry or otherwise. Food compound 1 may be processed in heated, cooled or ambient temperature depending upon its flow properties. A wide variety of food compounds may be employed either alone or in combination with the method and apparatus of this invention, including but not limited to those listed in Table - 1 . The solvent 4 used in the process can be water or an organic solvent or supercritical fluid. Its primary purpose is usually to dissolve the target food compound into a solution or to provide a liquid media for slurry. The untreated solution or slurry 5, called the pre-mix exits the mixing vessell 2 and enters the pressure applicator apparatus 6. Referring to Figure 2, the pre-mix 5 is stored temporarily in a reservoir 55. The food compound within the reservoir 55 remains in either a suspended or dissolved state.
As the piston 20 is drawn upward into the housing 44 within channel 19, a vacuum can be created in the compression chamber 21 , opening inlet valve 23, and drawing the pre-mix 5 into the compression chamber 21 between the outlet valve 24 and inlet valve 23. Depending on the type of valves 23, 24 and system used, the pre-mix 5 may be gravity-fed into the compression chamber 21 .
Normally, the pre-mix would be pushed from the compression chamber 21 as the piston begins its downward action. In such instance the inlet valve 23 would close while the outlet valve 24 would open. In this embodiment of the invention the action is radically different. When the piston 20 begins its downward cycle both valves, 23 and 24 close, entrapping the pre-mix between them. The piston 20 is forced at high velocity into the compression chamber 21 and strikes the pre-mix 5, generating an intense pressure pulse, or shock wave, through the liquid media into which the target food compound is placed. The target food compound 1 is pressure treated as the piston 20 strikes the pre-mix 5 on its positive and negative displacement cycle within the pressure applicator housing 44.
Valves 23 and 24 are both partially locked in the closed position while piston 20 is applying pressure to the food compound 1 trapped between the valves in the compression chamber 21 . As the piston 20 drives into the compression chamber it passes through the cavitation enhancer 28, as shown in Figure 3. The positive and negative displacement cycle of the piston 20 acts to generate an intense cavitation, and heat effect. Food compounds 1 within the compression chamber come into contact with the elements within the compression chamber and against the tabs 42 of the insert 28, generating intense immediate friction, shearing and heat effects, which also act to de-gas the fluid used as the solvent 4 support for the food compound 1 . Eventually the pressure built up within the compression chamber
21 is sufficient to force open the exit valve 24, which has either been kept closed intentionally (through control circuitry) or through back
pressure exerted upon the outflow side of the exit valve 24. Pressure- treated food compounds 1 B within the post-mix 8 exit the apparatus 6 through the outflow conduit 70. At this point the piston 20 begins another cycle, moving upward within the channel 19, forcing exit valve 24 totally closed, while opening input valve 23 to draw another quantity of pre-mix 5 into the compression chamber 21 for another treatment.
In some instances the post-mix 8, after only one application of the pressure apparatus 6, may be the desired end product. Referring again to Figure 1 , the post-mix 8, containing pressure treated food compounds, may be recycled through the apparatus 6 for exposure to additional pressure treatments, through the re-cycle pathway 7, or may be directed to one or more similar systems connected in series or parallel for additional treatments. In other instances, particularly if a slurry is employed, the desired end product may be a filter cake 10. In this instance the post- mix 8 may be filtered of water to reduce the moisture content, producing a wet cake 10 through means of a vacuum filter, centrifuge, pressure filter or similar de-watering apparatus or filter 9. If a dry powder 12 is desired as the end product the wet cake
10 could be delivered to an appropriate drier 1 1 to produce a dry powder form 12. Alternatively, the post-mix 8 itself could be delivered directly to a drier 12, such as a flash drier, spray drier or fluid bed drier, to generate a final dry powder form 12. There are several effects generated within the pressure treated food compounds, but notably the reduction in fat content and caloric value is often the result. A series of experiments were conducted to illustrate the effect of pressure treatments upon food compounds. In each case a device known as the Delta Processor, model number D-1001 , developed by Encapsulation Systems Inc. was employed. The Delta Processor device corresponds to the apparatus illustrated in Figs. 2, 5 and 6. The pressure applicator employed was a modified
hydraulic pump supplied by S.C. Hydraulics Company, model number 10-600-8-SS-SI, modified to increase the force the piston strikes into the compression chamber. Cavitation enhancers were also installed within the compression chamber 21 of the pump as depicted in Figure 6. The tension on the output check valve 24 was adjusted to open far slowly than would normally be the case for this model's capabilities using distilled water to test the flow rate of the modified pump assemblage and the number of strokes per minute.
The quarter-turn valve 93 employed in all of the following experiments has ten settings labeled from 0 to 9 and is used to regulate the speed of motore 82 and ultimately the cycle speed of piston 20. The quarter-turn valve was set at speed dial 9 and at either 60- or 90 psi on the regulator gauge. The pump system, however, multiplies the effective force of compression by 1 ,000 x. The pressure applied in the compression chamber is effectively 60,000 lbs. at the 60 psi regulator position. At the 90 psi regulator position, the effective pressure in the compression chamber is 90,000 lbs.
The timing of the opening of the output check valve 24 controls how long the piston is in a downward or positive pressure position, i.e. how long the target food compound is under pressure. In the experiments described below, the machine was set for speed dial setting 9 at either 60 or 90 psi. At the 60 psi setting, speed level 9, the transition time, the time by which the food compound was under direct positive compression was measured at 0.12 seconds. At the 90 psi setting, speed level 9, the transition time was measured at 0.10 seconds. The difference between the two pressure settings alters the transition time by only 0.02 seconds, but the effective pressure differential was 30,000 psi.
In the following group of experiments the solvent used was water. A number of target food compounds were selected from the general list provided in LIST - 1 to provide a cross section of differing food compounds which exhibited reduced caloric or fat content after
directed pressure treatment according to this invention.
LIST - 1 PARTIAL LIST OF FOOD COMPOUNDS THAT CAN BE MODIFIED
And any other food compound, or combination of food compounds, identified for human or animal ingestion, or useable as a chewing gum or tooth paste additive, by the Food and Drug Administration of the United States, including those food or feed compounds listed in the Food Chemical Codex, National Academy Press, 1996 edition, 2101
Constitution Ave., Washington, DC 20418, And by the Code of Federal Regulations, Food and Drugs, Federal Register, National Archives and Records Administration of the United States, OR any other food ingredients, food substance or food additive, food product. A number of experiments were conducted to demonstrate the effectiveness of this invention in the reduction of calories and fat content in food compounds:
EXPERIMENT 1 300 grams of Perma-flow starch supplied by AE Staley Company are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The starch forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at either of two main settings, 60 or 90 psi, inlet pressure and the samples are treated by a single or multiple passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce either 60,000 lbs. or 90,000 lbs. respectively. The treated food compound dispersion is then delivered to a settlement tank whereupon the food compound settles to the bottom. The excess water is decanted from the tank and the treated wet starch is then placed into a pan and delivered to a oven for drying into a fine powder, similar in appearance to the original starch.
The resultant treated starch is then tested using a Bomb calorimeter to determine its caloric content.
TABLE - 1
CALORIC COMPARISON OF PRESSURE TREATED FOOD COMPOUND
MATERIAL.PERMA-FLOW STARCH
NT = Not Tested
Experiment No. 1 . clearly shows a significant reduction in calories after pressure treatment. A reduction of 27.82%. There is no increase in calorie reduction when the pressure treatment is increased above 60,000 psi. Calories are determined by several methods, the most significant is the bomb calorimeter method. A further method employs the extraction of fat from the food compound, followed by a calorie analysis of the fat component. This indicates the amount of calories derived from fat, which is considered often the most significant contributor to weight gain. In Experiment No. 1 , 21 calories/100 grams were detected in the fat component. After 60,000 psi and 90,000 psi the caloric content of the fat component was nearly non-existent. This suggests that the pressure treatment dissolved the fat, liquifying the fat component possibly through cavitation energies developed in the process. Such liquified fat would be left in the filtrate before the treated food compound was dried. Figure 2 illustrates the final drying step. Applicants theorize that the fat component is
extracted from the food compound first via the pressure shock treatment, and then liquified via cavitation and thermal energies developed resultant to the application of both the positive and negative application of the pressure treatment. The liquified fat is then extracted via filtration and drying steps, 66 in Figure 2, to produce a low fat, low calories resultant product, 67.
EXPERIMENT 2 300 grams of Consista™ Starch supplied by AE Staley Company are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The Food compound forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at either of two main settings, 60 or 90 psi, inlet pressure and the samples are treated by a single or multiple passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce either 60,000 lbs. or 90,000 lbs. respectively. The treated food compound dispersion is then delivered to a settlement tank whereupon the food compound settles to the bottom. The excess water is decanted from the tank and the treated wet food compound is then placed into a pan and delivered to a oven for drying into a fine powder, similar in appearance to the original food compound.
The food compound is then tested using a Bomb calorimeter to determine its caloric content.
TABLE - 2
CALORIC COMPARISON OF PRESSURE TREATED FOOD COMPOUND
MATERIAL:CONSISTA™ STARCH
NT = Not Tested
In Experiment 2 the Bomb calorimeter indicated a reduction in overall calories for this particular grade of starch, averaging - 25.21 % over five tested samples. Calories derived from fat indicates, first that fat was originally present in the material, and since the caloric content derived from fat was reduced to zero, it can be surmised that the fat content was likewise reduced to zero. The particular starch chosen was a modified starch.
EXPERIMENT 3 300 grams of Capsul starch supplied by International Food compound Co. are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The Food compound forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at either of two main settings, 60 or 90 psi, inlet pressure and the samples are treated by a single or multiple passes through the apparatus. The effective
pressure is multiplied 1 ,000 times to produce either 60,000 lbs. or 90,000 lbs. respectively. The treated food compound dispersion is then delivered to a settlement tank whereupon the food compound settles to the bottom. The excess water is decanted from the tank and the treated wet food compound is then placed into a pan and delivered to a oven for drying into a fine powder, similar in appearance to the original food compound.
The food compound is then tested using a Bomb calorimeter to determine its caloric content.
TABLE - 3 CALORIC COMPARISON OF PRESSURE TREATED FOOD COMPOUND
MATERIAL: CAPSUL STARCH
NT = Not Tested
In Experiment 3 the Bomb calorimeter indicated a reduction in overall calories for this particular grade of starch, averaging - 26.77% over five tested samples. Calories derived from fat indicates, first that fat was originally present in the material, and since the caloric content derived from fat was reduced to zero, it can be surmised that the fat content was likewise reduced to zero. The particular starch chosen was a chemically modified dextrin.
EXPERIMENT 4
1 50 grams of powdered cellulose, model no BH-300, supplied by International Filler are dispersed in 1 ,500 ml of tap water and agitated for 30 minutes at ambient temperature. The cellulose powder forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at either of two main settings, 60 or 90 psi, inlet pressure and the samples are treated by a single or multiple passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce either 60,000 lbs. or 90,000 lbs. respectively. The treated cellulose dispersion is then delivered to a buchner funnel whereupon the cellulose is filtered into a wet cake. The treated wet cellulose is then placed into a pan and delivered to a oven for drying into a fine powder, similar in appearance to the original powdered cellulose. The cellulose is then tested to determine its caloric content.
TABLE - 4A CALORIC COMPARISON OF PRESSURE TREATED CELLULOSE MATERIAL: CELLULOSE POWDER
TABLE 4-B INSOLUBLE FIBER CONTENT
Applicants theorize that the polymorphic crystal structure of powdered cellulose was altered via exposure to the directed pressure treatment present in this invention, converting the cellulose into a form of microcrystalline cellulose. Figure 4 illustrates the process of converting crystal structures form an un-aligned polymorphic structure shown in Figure. 4A, known as the alpha state, through conversion to a partial aligned state, shown in Figure 4B to a fully aligned polymorphic structure as shown in Figure 4C.
Applicants theorize that food compounds when in a fully aligned polymorphic state exhibit reduced caloric and fat content properties. Photograph-1 is a scanning electron microphotograph of powdered cellulose, model no BH-300, supplied by International Filler Corporation, in its normal untreated and raw state. Examination of this microphotograph illustrates that the cellulose fiber is thin and lengthy. Photograph-2 is a scanning electron microphotograph of the same powdered cellulose material after exposure to 90,000 psi/0.10 seconds of directed pressure treatment . The microphotograph shows the formation of several spherical nodules, which are highlighted in the photograph to draw attention. The nodules were tested using standard, accepted identification procedures as listed in the U.S. Pharmacopeia, National Formulary, Volume USP XXII, NF - XVII, 1 990 methodology that identifies the presence of powdered cellulose vs. microcrystalline cellulose. Using these standard procedures the raw cellulose shown in Photograph-1 tested as "Powdered Cellulose". The nodules shown in Photograph-2 were filtered from the surrounding matrix and tested as
"Microcrystalline Cellulose" according to the methodology listed in the U.S. Pharmacopia. Further examination of Photograph-2 shows that the same magnification, 100 x, was used in both Photograph-analysis studies. However the fiber strands in Photograph-2 appeared thicker, longer, and fused together. Applicants theorize the conversion of the cellulose into a microcrystalline form may account for the reduction in the caloric content listed in TABLE - 4A, wherein the caloric content dropped from 20/100 g to just 2/100 g after pressure treatment. Applicants also theorize the dietary fiber content, which raised from 89.72% to 95.08%, after directed pressure treatment, may also account for the reduction in tested calories in the treated cellulose.
EXPERIMENT 5 300 grams of Cocoa Powder supplied by Hershey Foods are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The Cocoa Powder forms a solution, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet pressure and the samples are treated by a single or multiple passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs. The treated solution is then delivered to a spray dryer for drying into a fine powder, similar in appearance to the original cocoa powder.
The cocoa powder is then tested to determine its caloric and fat content.
TABLE - 5
CALORIC COMPARISON OF PRESSURE TREATED COCOA POWDER
MATERIAL: HERSHEY COCOA POWDER
In the above example the directed pressure treatment of cocoa powder resulted in a reduction in calories of 14%, while the fat content dropped by 7.40%. Applicants theorize that the directed pressure treatment of cocoa powders results in a reduction of the fat content and this results in a accompanying drop in related calories.
EXPERIMENT 6
300 grams of dent starch supplied by AE Staley Company are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The Food compound forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet pressure and the samples are treated by a single or a total of five passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs.. The treated food compound dispersion is then delivered to a settlement tank whereupon the food compound settles to the bottom. The excess water is decanted from the tank and the treated wet food
compound is then placed into a pan and delivered to a oven for drying into a fine powder, similar in appearance to the original food compound.
The food compound is then tested using a Bomb calorimeter to determine its caloric content.
TABLE - 6 CALORIC AND FAT COMPARISON OF PRESSURE TREATED
FOOD COMPOUND MATERIAL: DENT STARCH
Dent starch is a natural starch material, also showing a caloric reduction after pressure treatment. In this instance multiple treatment passes produced a slightly higher caloric reduction in the treated sample.
EXPERIMENT 7
300 grams of milk powder supplied by Hershey Foods Corp. are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The milk powder forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet pressure and the samples are treated by a single or five passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs. The
treated milk powder dispersion is then delivered to a spray drier for drying into a fine powder, similar in appearance to the original powdered milk.
The treated milk powder is then tested to determine its caloric and fat content.
TABLE - 7 CALORIC AND FAT COMPARISON OF PRESSURE TREATED
MILK POWDER MATERIAL: MILK POWDER FROM HERSHEY FOODS
Table - 7A
In this experiment the lower pressure treatment resulted in a greater caloric and fat content reduction value. In Table -7A the results of exposure to 90,000 psi/0.10 seconds of pressure exposure
produced a virtually insignificant change in either the calorie or fat content values. However at 60,000 psi, also applied at 0.10 seconds of exposure the caloric drop was - 8.68% while the fat content drop was -34.91 %. EXPERIMENT 8
300 grams of wheat flour supplied by Hershey Foods Corp. are dispersed in 1 ,000 ml of tap water and agitated for 30 minutes at ambient temperature. The wheat flour forms a dispersion, which is then pumped through the pressure apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet pressure and the samples are treated by a single or five passes through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs. The treated wheat flour dispersion is then delivered to a spray drier for drying into a fine powder, similar in appearance to the original wheat flour.
The treated wheat flour is then tested to determine its nutritional values at a standard serving size, as well as its caloric and fat content.
TABLE - 8A . WHEAT FLOUR is pressure modified exhibiting Reduced Fat and a Lowered Caloric content, while maintaining the normal gluten levels in the flour and the proper taste profile. NUTRITIONAL VALUES
Table 8A shows the data for a standard serving size in nutritional values for the wheat flour, which is treated at 90,000 psi at 0.10 seconds of pressure exposure.
Table 8B compares the label required in the United States, for untreated wheat flour vs. pressure treated wheat flour wherein the pressure treated flour was subjected to 90,000 psi/0.10 seconds, for one treatment cycle. This table clearly indicates a major difference between the pressure treated wheat flour and the untreated sample, in particular the lowering of the caloric content associated with fat, the dropping of the fat content to zero and an indication of the alteration of the carbohydrate structure after pressure treatment. This experiment illustrates that the NLEA method for calculating calories and fat content, leading to label declarations for the product, likewise show a caloric and fat content reduction. EXPERIMENT 9
13 lbs. of wheat bran fiber, supplied by Arthur Daniel's Midland Company, are first micronized into a powder form with 100% passing through a 60-mesh screen. The powdered wheat bran is then suspended in 50 gallons of tap water, agitated without heating, for 30 minutes to form homogeneous slurry. No other chemicals are added to the slurry. The slurry is then delivered to a pressure treatment apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet pressure and the samples are treated by a single pass through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs. The timing of pressure exposure is maintained at 0.10 seconds. The treated wheat bran slurry is then delivered to a filter, vacuum filtered into a wet cake and then dried using a flash drier into a fine powder, similar in appearance to the original wheat bran powder.
The treated wheat bran is then tested to determine its caloric
and fat content.
TABLE - 9
The pressure treated wheat bran sample indicated significant changes in total carbohydrates, and in the production of additional dietary fiber, which accounts for the reduction of the total calories from 216.8 to 156.4/100 grams. Applicants note that a significant portion of the wheat bran was a starch component, which appears to have been converted to a resistant starch, into a dietary fiber component as evidenced by the increase of 49.3% of total dietary fiber. This increase in Total dietary fiber content drives the calorie content downward, even though in this instance there was little effect of the directed pressure treatment upon the fat component of the bran.
EXPERIMENT 10
13 lbs. of soy fiber, supplied by Fibred Company, are suspended in 50 gallons of tap water, agitated without heating, for 30 minutes to form a homogeneous slurry. No other chemicals are added to the slurry. The slurry is then delivered to a pressure treatment apparatus known as a delta processor Unit Model no. D-005, supplied by Encapsulation Systems Inc., a system corresponding to the apparatus disclosed herein. The unit is set to treat the material at 90 psi, inlet
pressure and the samples are treated by a single pass through the apparatus. The effective pressure is multiplied 1 ,000 times to produce 90,000 lbs. The timing of pressure exposure is maintained at 0.10 seconds. The treated soy fiber slurry is then delivered to a filter, vacuum filtered into a wet cake and then dried using a flash drier into a fine powder, similar in appearance to the original soy fiber powder.
The treated soy fiber is then tested to determine its caloric and fat content.
TABLE - 10
The pressure treated soy sample indicated significant changes in the production of additional dietary fiber, which accounts for the reduction of the total calories from 28.4 to 0/100 grams. The increase in Total dietary fiber (by + 7.70%) content drives the calorie content downward . Added by a reduction in the fat content (-12.2%) the final calorie content is reduced to zero.
The above experiments show that the pressure treatment affects both a caloric and fat content reduction in food compounds. The caloric reduction is theorized to be due to the reformation of the carbohydrate composition of the food compound. US Patent No. 5,209,879 to Redding, disclosed that high-pressure pulses applied to
molten waxes could have the effect of adjusting the resultant wax from a disorganized polymorphic state to an aligned more stable "beta" state. With many food compounds the crystal structure of said food compound could likewise be adjusted to produce an alignment effect, thereby altering the physical properties of the food compound. One resultant effect could the crystallization of fat composites within the treated food compound. Experiment # 4 illustrates a significant reduction of the fat component and a re-alignment of the carbohydrates. The re-alignment of the crystal polymorph of a target food compound the fat composition can be either reduced or converted into a form, which no longer tests as "fat", by established testing procedures.
Applicants further theorize that the pressure treatment of food compounds in the manner prescribed herein leads to a reduction of fat, and therefore to an overall lowering of calories derived from that fat component's presence. In some case the reorganization of the carbohydrates crystalline structure leads directly to a resistant form which inherently possess lower caloric content. US Patent No. 5,455,342 to Redding, discloses that the physical properties of starch and other natural polymers including gum products may be altered significantly via the pressure treatment process. On further investigation it was discovered that many food compound compounds exhibited lower overall calories after pressure treatment. This may be due to the alteration of the crystal structure of the treated food compound.
Applicants also proposed that intense cavitation effects the resultant caloric and fat content of treated food compounds. The apparatus disclosed delivers an intense cavitation effect within a treated food compound, containing cavitation degassing and high instantaneous friction generated thermal energies. Applicants theorize that such cavitation treatment crystallizes or breaks down fat compositions in much the same manner as ultrasound does directly to
fat. liquifying the fat composition. Reference is made to the article " The Temperature of Cavitation ", by Flint & Suslick, previously mentioned, which demonstrated that an ultrasonic pulse produced a pressure wave and cavitation effect capable of generating 5,075 (°K). {4,802°C} Applicants theorize the cavitation effect created by a positive and displacement action of a pressure applicator device generates an intense thermal effect, which can be used to:
Liquify fat
Re-structure a carbohydrate form Alter the polymorphic structure
Reduce the protein content Such physical property changes result in lowered fat or calorie content for any directed pressure treated food compound.
Two of the more common methods used to determine calories in foods are, the Bomb Calorimeter and the Nutrition Labeling and
Education Act (NLEA). The bomb calorimeter essentially heats the test sample and measure the physical energies, often reported as joules/gram, emitted during the heating process. This method however did not fully translate the term "calories" as used in food or nutritional applications. That terminology applied to either increasing "energy" in the body or producing fat in the body. Accordingly the United States adopted a more reflective analytical procedure to determine if a food product can be used by the body to generate energy or fat buildup.
The NLEA method was developed by the United States Food and Drug Administration as a quick reference guide to consumers to determine the fat, and caloric content of food products sold in the united states. The methodology for determining calories is based upon calculation, after analyzing the fat, protein and carbohydrate composition of a given food compound. The analytical procedures used are for:
AOAC = AMERICAN Organization of Analytical Chemists
Note; the above procedures for the NLEA are also referred to as the
Prosky Method.
Applicants observe that the NLEA methodology will yield a lower calculated caloric content in a particular food compound if the following occurs: 1 . The Total Dietary Fiber Value increases.
Possibly caused by conversion of the crystal polymorph to a more stable, aligned form, example the conversion of cellulose to microcrystalline cellulose
Increase in Total Dietary Fiber or Insoluble fiber content via the alignment of the polymorphic structure or the re-alignment of the
carbohydrate branching.
2. Total Carbohydrate-Less Fiber Value decreases due to Total Dietary Fiber content increasing
During the test methodology employed the crystalline form of the food compound created after directed pressure treatment may act to inhibit digestion by enzymes, resulting in a higher total dietary fiber content value.
3. Fat Content is reduced decreasing the Calories derived from Fat Value Applicants theorize that the Intense pressure shock wave developed during the directed pressure treatment may act to forcibly separate fat from the food compound .
Alternatively it has been observed that the Intense pressure shock wave developed during the directed pressure treatment, generates a significantly high cavitation and resultant heating effect which could act to liquify the fat content.
4. Protein Content is reduced decreasing the Calories derived from Protein Value
Applicants theorize that the Intense pressure shock wave developed during the directed pressure treatment may act to forcibly separate or dissolve protein from the food compound .
Alternatively it has been observed that the Intense pressure shock wave developed during the directed pressure treatment, generates a significantly high cavitation and resultant heating effect which could act to liquify the protein content.
This invention describes the use of a directed pressure treatment for the reduction of calories and fat in treated food compounds. While a pressure application employing a single piston device as the generator of the pressure treatment effect is shown other variations are possible: a) A system employing one or more pistons to apply the directed pressure treatment b) A system employing explosives to generate the pressure
treatment c) A system employing an ultrasonic generator to produce the pressure treatment d) A system employing a mechanically driven cam or other mechanical device, which imparts a significant, pressure treatment to target food compounds e) A pressure homogenizer wherein the pressure is not just used to increase the flow of a dispersion but is directed against a food compound within the mix for the purpose of effecting caloric or fat reduction f) A grinding or pulverization device, including a mechanical mill g) A jet mill or air classifier, which imparts a directed pressure force, via impact, against food, compounds, resulting in the lowering of the caloric or fat content. h) An Extrusion, screw pressure applicator, centrifugal extruder, fluid energy injector, gyratory crusher, jaw crusher or energy imparters, impact breakers, roll crushers, roll mills, dual rotor impact, cage mills, rotary knife, pan crusher, tumbling mills, Ball mills or tumbling mills, non-rotary ball or bead mills, vibratory mills, hydrocyclones, hammer -mills, i) pressure autoclaves, pressure cookers, j) Any other apparatus, device or process which generates either a cavitation effect or a directed pressure effect upon a targeted food compound, mixture, blend or combination of food compounds for the purpose or effect of reduction in calories or fat content in such treated food compound. While but only one method is described in the specification of this patent application, it should be obvious to anyone skilled in the art that other methods may exist for generating a pressure treatment sufficient in intensity and magnitude to effect calorie and fat reduction in treated food compounds.
Although this invention has been described and illustrated by
reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of this invention. The present invention is intended to be protected broadly within the spirit and scope of the appended claims.