PROCESS AND APPARATUS FOR PRODUCING DIETARY FIBER PRODUCTS
Cross-Reference This application claims the benefit of U.S. Application No.
08/696,614 filed August 14, 1996 and titled "Dietary Fiber Products and Process and Apparatus for Producing Same" by Bruce K. Redding, Jr. and Jerome Harden, and U.S. Application No. 08/988,758 filed December 1 1 , 1997 and titled "Process and Apparatus for Producing Dietary Fiber Products" by Bruce K. Redding, Jr. and Jerome Harden, both of which are incorporated by reference as if fully set forth herein . Background of the Invention
The invention relates to dietary fibers and more particularly to novel dietary fiber products and a process and apparatus for producing same. Dietary fibers are used in a variety of food applications as both a means to reduce overall fat and calorie content for the ultimate food product and as a bulking agent replacement for products with reduced sugar or sweeteners.
Used as a fat replacer, dietary fibers are employed as a fat mimic, approximating the mouth feel and texture of fat while affording a lower calorie alternative. As a bulking agent, dietary fibers are employed in efforts to reduce sugar and other sweeteners especially from baked goods such as snack food, cakes, pies and bread products. In such products having a reduced sugar content, a bulking agent is used to return the desired mass, texture and mouth feel to the product. Dietary fibers are usually fibers derived from corn, wheat, cellulose, oats, or other natural grains. Generally, a dietary fiber is high in insoluble (i.e., indigestible) fiber content, ideally low in calories and low in fat content. Most dietary fibers offer great promise as an improved dietary additive to food products, but there are also several drawbacks.
Dietary fibers tend to absorb many times their weight in moisture, requiring longer bake times for baked goods incorporating
such fiber ingredients. High water absorbing fibers require more machining time, i.e., time required for mixing and blending, and may produce a baked product which requires special packaging, standard packaging is usually not effective upon baked products incorporating dietary fibers because the fibers absorb a significantly high amount of moisture.
Many dietary fibers also exhibit high oil absorption and retention properties, making their use in breaded coatings and mixes which are applied to fried foods a main source of absorbed fat and calories. Newer dietary fibers derived from corn or starch also provide very high calories, much the same as found in various starches.
The uniformity of dietary fiber features and properties often varies significantly from batch to batch and they are therefore not reliable in many processed food products. Accordingly it is an object of the invention to provide improved dietary fibers in which at least some of these drawbacks are reduced .
It is an object of this invention to provide improved dietary fibers which exhibit reduced water absorption factors to improve the use of that fiber in baked goods, from machining, packaging and mouth perception factors.
It is an additional object of this invention to provide a means of reducing the oil, and fat, absorption and retention of bake mixes, batters and breaded coatings for fried foods through the use of modified dietary fibers. A further object is to improve the mouth feel of dietary fibers by in some cases increasing the water absorption of dietary fibers.
A further object includes the ability to increase the total dietary fiber content, essentially increasing the insoluble or indigestible component of treated dietary fiber, thereby also reducing the fat and caloric content of the treated dietary fiber.
A further object includes the improvement of baked and fried foods, by increasing their dietary functionality, through the addition of
treated dietary fibers.
It is another object to provide a process for producing the above- mentioned improved fibers.
It is still another object to provide apparatus for producing these improved fibers.
These and other objects which will appear are achieved in accordance with the invention as follows. Summary of the Invention
Briefly, we have discovered that the use of high pressure pulses, applied to dietary fibers, can have the result of converting the fibers to ones which exhibit either increased or reduced moisture absorption, reduced oil absorption, reduced oil retention, higher insoluble fiber content, reduced calories, reduced fat content and also provide a more uniform dietary fiber from batch to batch. This pressure pulse is applied to the original dietary fibers while they are in either a slurry of a given solvent containing dispersed dietary fiber particulates, or in a totally dissolved state, with the pressure being applied in the form of abrupt pressure pulses induced by mechanical means. The solvent may be water, alcohol or some other liquid media or organic solvent.
In this document, these abrupt pressure increases will sometimes be referred to as "pressure shock waves". However, it is recognized that they may not really fit the theoretical definition of "shock waves".
Such abrupt pressure increases, or pressure shock waves, are believed to transmit energy in three basic forms: high compression forces; heat via friction; and cavitation.
Studies of cavitation show that the heat produced during a cavitation effect can be very high, if only for a short period of time. Without intending to be bound by this explanation, Applicants theorize that pressure shock waves applied to a dispersion (e.g., slurry containing dietary fibers) can produce a modified form of dietary fibers through the effects of the heat energy caused by cavitation and the
compressive forces produced by the pressure shock wave application.
Experiments described below have clearly demonstrated that such modified dietary fibers are indeed produced in accordance with the present invention and that these exhibit the following modified properties:
• Immediate and permanent reduction of calories.
• Reduction in moisture absorption properties.
• Increase in moisture absorption properties to improve mouth feel, texture and taste perception. • Increase in the proportion of insoluble fibers.
• Decrease of fat content within the fiber.
• Greater uniformity between production batches. An apparatus that improves the cavitation effects includes a pressure treatment apparatus (similar to the one described in the related Application No. 08/696,614 filed August 14, 1996) modified by cavitation enhancers. The cavitation enhancers are preferably ring- shaped members positioned proximate to the inlet and outlets of the pressure treatment apparatus. Tabs projecting radially inward from the perimeter of the ring disrupt the flow of the dispersion. A second type of cavitation enhancer resembles a plate having a substantially flat bottom surface and a top surface that has projections and indentations. This second type of cavitation enhancer is positioned over the strike plate of a "normal" pressure treatment apparatus in alignment with the pressure inducing piston. Description of the Drawings
For further details, reference is made to the discussion which follows, in light of the accompanying drawings, wherein:
Figure 1 is a diagrammatic illustration of the process for modifying dietary fibers in accordance with the invention involving the use of filtration;
Figure 2 is an overall illustration of apparatus for carrying out the process of dietary fiber modification through pulse pressure treatment;
Figure 3 is a more detailed illustration of the piston component of the pressure treatment apparatus of Figure 2, showing the use of cavitation enhancers within the compression chamber;
Figure 4 is a diagram of the baffled chamber component of the pressure treatment apparatus; and
Figure 5 is a diagram of a baffle ring used in the baffled chamber component of the pressure treatment apparatus.
Figure 6 is an enlarged view of the compression chamber illustrated in Figure 3. Figure 7 is a top plan view of the flow cavitation enhancers according to the present invention.
Figure 8 is a side view of the reflecting cavitation enhancer according to the present invention.
Figure 9 illustrates the effects of varying pressure and time or exposure to pressure and water holding capacity for pressure treated cellulose fiber.
Figure 10 depicts the flour replacement value of pressure treated cellulose fiber compared to conventional fibers in baked applications. Detailed Description of the Invention Referring to Figure 1 , this shows the process of the invention, in a flow-diagram format. In this Figure, a treatment vessel 101 contains a fluid carrier material 103 (e.g., water or an organic solvent), to which are added raw dietary fibers 102. Agitation provided by a mixer 104 turns this mixture into a slurry 105. Depending on the fluid carrier chosen and the type of row dietary fibers added, the dietary fibers are either dispersed throughout or dissolved into the slurry 105. Once properly mixed, the fiber slurry 105 is delivered to pressure treatment device 106. The slurry may be applied in a heated, ambient or chilled state. In a preferred embodiment, the pressure treatment device 106 applies a single pressure treatment to the fiber slurry. If desired, the slurry 105 may be subjected to multiple cycles of pressure treatment through a repetition of the single treatment process. Such repetition is
indicated by arrow 107.
The pressure treatment consists of the application of a single, or continuously recurring pressure shock waves to the slurry 105. The pressure treatment is measured in applied or compressive pressure as a function of the time period the pressure is applied to the slurry 105.
The pressure levels can be as low as 1 psi to over 90,000 psi from the equipment provided for test purposes. Time duration's range from 0.001 to 1 full second, with most treatment time periods being in the range of 0.1 to 0.25 seconds. Pressure is applied in the preferred embodiment via a piston pressure applicator as shown in Figures 2 and 3. However other designs are possible for the application of the pressure treatment, such as ones using multiple pistons for pressure application.
Referring again to Figure 1 , pressure-treated fiber slurry 108 exits the pressure treatment device 106. A pump can be used to move the slurry through the present process. If desired, the slurry 108 may be pumped back into the pressure treatment device 106 where it is subjected to additional pressure treatments as illustrated in the re-cycle loop 107. After the pressure treatment process, the slurry 108 is directed to a filtration device 109 which acts to remove the solid, pressure-treated particulates from the slurry, generally producing a "wet cake" 1 10. The "wet cake" 1 10 is then delivered to the appropriate drying mechanism 1 1 1 which usually yields a pressure- treated dietary fiber product 1 1 2 in the form of a powder. The wet cakes 1 10 may be delivered to the drying device manually or by an automatic conveying device.
The drying device 1 1 1 may be an oven, spray drier, vacuum dryer, fluid bed dryer, freeze dryer, flash dryer or any other mechanism which will remove the residual moisture 103 from the pressure treated fiber, resulting in a dry powder form 1 1 2.
Depending on the application, the pressure-treated fiber slurry 108 may be delivered directly to the drying device 1 1 1 without
filtering. Also, the pressure-treated slurry may be suitable for commercial application as a pressure treated fiber remaining in a slurry or suspension form.
The present invention converts conventional (commercially available) dietary fiber, subjects it to a shock treatment, and produces a modified dietary fiber, exhibiting properties not previously obtainable.
A preferred embodiment of an apparatus for modifying dietary fibers in accordance with the invention is shown in Figures 2, 3, 4 and 5. Referring now to Figure 2, the pressure treatment device 1 6 includes a pump 2 that drives a reciprocating piston 20 for exerting a pressure pulse on the material which is pumped through the apparatus. A reservoir 5 is placed at the input of the pressure treatment device 106. The reservoir 5 is usually not heated but may be in some cases by heating coils, not shown. The reservoir 5 may also be stirred to allow the dietary fibers to be dispersed prior to passing through the apparatus. In the illustrated embodiment, the slurry is gravity-fed into the pressure treatment device 106, but can easily be pumped from a large, remotely-located reservoir.
The dietary fibers can be provided to the reservoir 5 in any of the following states: a) A heated, mixture, or slurry; b) A mixture, or slurry at ambient conditions; c) A mixture, or slurry at chilled conditions; d) A mixture, or slurry containing dispersed particulates which are undissolved in a liquid carrier; e) A heated solution containing dissolved fiber; f) A solution containing dissolved fiber at ambient conditions; or g) A solution containing dissolved fiber at chilled conditions.
For purposes of identification all of these various states in which the fiber slurry may be introduced into the device are hereinafter
collectively called the pre-mix 40 (Figure 2) .
Referring again to Figure 2, a transfer conduit 6 leads to the pressure actuation or compression chamber 1 of the pressure treatment device 106. Transfer conduit 6 may be heated with heating coils to maintain the temperature of the pre-mix 40 as it passes to and from the pressure applicator assembly 2. At opposite ends of the pressure treatment device 106 (i.e., entry into and egress from the compression chamber 1 ) are placed valves 3 and 4. These valves 3 and 4 may be solenoid valves, manually operated valves or an automatic check valves. First or input valve 3 is connected to the fluid flow conduit channel 6. Second or output valve 4 is connected to an output transfer conduit 7.
Referring now to Figure 3, the compressed air pump 2 drives a reciprocating piston 20 within housing 42, as seen in Figure 3. Movable piston 20 is displaced within housing 42 by motor 22. The motor 22 may be powered by hydraulics, compressed air, electricity or combustion.
The output transfer conduit 7 is connected between exit valve 4 and a baffled chamber 23. The output transfer conduit 7 has a significantly smaller inner diameter than the input transfer conduit 6. This smaller inner diameter acts to develop a back pressure within the fluid flow which helps output valve 4 to stay closed longer. This helps to maintain the elevated pressure created within the compression chamber 1 for a longer period of time. Pressure-treated materials exit the compression chamber 1 , travel through the output valve 4 and transfer conduit 7 in route to the baffled chamber 23.
Bernoulli principles are employed to alter the fluid flow at the point where the flow channel diameters decrease in size. The speed of the fluid flow is increased at this point but back-pressure is built up within the fluid, which is used to keep the spring-loaded output check valve 4 closed longer than would normally be possible in a conventional hydraulic pump assembly.
Transfer conduit 7 may be heated by a heating coil (not shown) to maintain the temperature of the treated mix.
Attached to the output transfer conduit 7 is a baffled chamber 23, shown in more detail in Figure 4. Such a chamber consists of a number of baffles 55 placed directly in the fluid flow, for the purpose of inducing turbulence in the fluid and adding to the back pressure effect within the transfer conduit 7 against the output valve 4.
In the illustrated embodiment, the pump 2 is preferably activated by compressed air. Compressed air 30 is delivered though an air conduit 8 into the air motor 22, passing through an air filter 9, a regulator 10, an air flow oil reservoir 12, a 1 /4 turn air valve 1 3, and an air inflow port 1 6 to the air motor 22. The air filter 9 is used to drain water from the compressed air supply 30. The regulator 10 controls the air pressure, which is displayed on the pressure gauge 1 1 . Minute oil droplets are introduced into the compressed air supply 30 as the air flows over an oil reservoir 1 2. This is used to lubricate the air motor 22. The air motor cycles the piston 20 forward and backward as a result of the compressed air flow.
The number of strokes of a piston 20, as shown in Figure 3, is controlled by the 1 /4 turn air valve 13. A dial is placed on the 1 /4 turn air valve 13 at a 90 degree incremental basis. At setting zero, the valve is fully closed and no air flows to the air motor 22. At setting nine, which is at the 90 degree mark to the horizontal, the valve is fully open and the full volume and force of the compressed air 30 is delivered to the air motor 22. At setting zero the air motor is off. At setting nine the motor 22 is at full speed. The 1 /4 turn air valve 1 3 is therefore the speed controller of the pressure applying device 2, acting to cycle the piston 20 at its highest number of strokes.
In the case of this embodiment, the air motor 22 exhausts spent air though a muffler 1 5 which is connected to the outflow air port 17 of the air motor 22.
Pre-mix 40 is passed through the apparatus illustrated in Figure 2
and is pressure-treated as the piston 20 strikes downward during its up and down displacement cycle within the pressure applicator housing 2. The valves 3 and 4 may be closed while the piston 20 is in its "downstroke" or pressure stroke, thereby trapping the pre-mix 40 in the compression chamber 1 between valves 3 and 4.
Alternatively the valve action may be adjusted to provide a semi- continuous flow, wherein check valves are used in both the inlet valve 3 and the outlet valve 4. As the piston 20 is raised, in its negative pressure cycle, a quantity of pre-mix 40 is drawn into the compression chamber 1 , through inlet valve 3, while outlet valve 4 is closing up. As the piston 20 begins its pressure application or downward stroke both valves 3 and 4 may be closed for a period of time, allowing full pressure to build up within the compression chamber 1 . While the pre- mix 40 is still under pressure, valve 4 opens and the pressure within the chamber 1 causes the pressure treated pre-mix 40 to flow from the compression chamber 1 out of the device through the output transfer conduit 7, into the baffled chamber 23, finally exiting the system through exit conduit 24.
Figure 3 is a partial cut-away view of the piston pressure applying device 2. In this embodiment, both valves 3 and 4 are spring- loaded check valves. Compressed air 30 enters the pressure treatment device 106 at the air input port 1 6. Motor 22 moves the piston upwards, drawing pre-mix 40 through input valve 3 and into compression chamber 1 . Input valve 3 closes as motor 22 drives the piston 20 downward through the housing 42 into the compression chamber 1 . The pre-mix 40 is trapped at this point between input valve 3 and output valve 4. As the piston 20 is forced downward by the air motor 22 it strikes the surface of the pre-mix 40 and generates a shock wave through the pre-mix 40. As the motor 22 draws the piston upwards, valve 4 opens and the pressure-treated material 44 exits the machine into conduit 7, while substantially simultaneously drawing in untreated slurry through valve 3.
As illustrated in Figures 3 and 6, a series of inserts, 50, 51 , and 52 act to increase the effect of cavitation within the pre-mix 40 under pressure shock treatment. These inserts are referred to as cavitation enhancers and increase the generation of thermal and electrostatic effects within the treated pre-mix 40 as the piston 20 begins both its positive (forward ) and negative (withdrawing) application of pressure within compression chamber 1 . The number of inserts and their shape are mainly determined by the type of dietary fiber being treated the carrier fluid used, and the results desired. Inserts 50 and 51 are sometimes referred to as flow cavitation enhancers and insert 52 is sometimes referred to as a reflecting cavitation enhancer.
Applicants theorize that much of the altered states of the treated dietary fiber is due in part to the effect of cavitation, generated within the compression chamber 20. Insert 51 , shown in Figure 6 is positioned in the compression chamber 1 proximate to inlet valve 3. Referring to Figure 7, insert 51 is comprised of one or more ring-shaped members having tabs extending radially inward . Insert 50 is positioned in the compression chamber 1 proximate to outlet valve 4. As illustrated, insert 50 is similar in shape to insert 51 . Inserts 50 and 51 act to increase shear by forcing the pre-mix against a series of tabs 95 similar to that shown in the baffle of Figure 5. As pre-mix flows through the tabs 95, inserts 50 and 51 act to generate turbulence and high shear. The number, size, shape, length and position of the tabs determines the amount of turbulence produced.
Insert 52 is illustrated in Figure 8. In the preferred embodiment, the bottom surface of insert 52 is preferably flat. The insert 52 may be affixed to the bottom of the cavitation chamber or lie on the bottom depending on the orientation of the pressure treatment device 106. Insert 52 preferably has a regular pattern of baffles projecting upwards toward the piston. The preferred embodiment utilizes triangularly- shaped baffles although other designs are also effective. The insert 52
may be of any shape as long as a plurality of baffles are placed directly under the piston 20.
The inserts 50-52 are preferably made of stainless steel, although ceramic and polymer discs have also shown to increase cavitation within chamber 1 . Note that if all the inserts 52 have the same diameter as the compression chamber 1 the inserts can be easily replaced or exchanged for inserts having a different baffle or upper surface pattern.
As the piston 20 strikes the pre-mix 40 within the compression chamber 1 the pressure shock wave travels through the pre-mix 40 hitting the cavitation insert 52. There the pressure shock wave is reflected back upwards through the pre-mix. The shock wave hitting the cavitation insert 52 also generates an intense, instantaneous thermal effect which induces cavitation within the pre-mix 40, even as the piston 20 withdraws upward on its return stroke through the channel 19.
An alternative means of enhancing the cavitation effect is to utilize a vibrating plate 18 within the compression chamber 1 . The vibrating plate 18 can be an ultrasonic transducer which acts to generate a ultrasonic transmission through the pre-mix 40 as the piston 20 is completing its downward stroke. The combination of an intense mechanically induced pressure shock wave against the pre-mix 40 with a ultrasonic action significantly increases the cavitation effect within the pre-mix. Although the vibrating plate 1 8 has a flat upper surface, it is believed that a contoured or baffled surface similar to insert 52 will have a similar effect.
A series of seals and gaskets are placed along the compression chamber to provide isolation of the pre-mix from the rest of the pressure applicator's assemblage. These are illustrated at 21 and 50 in Figure 3.
In a conventional hydraulic pump, as the piston 20 drove downward, the output valve 4 would immediately open and allow the
flow to move onward . In this case, the output valve 4 is designed to have higher tension on its check valve springs so that more pressure is required to force its opening. The result is that as the piston 20 comes downward into the compression chamber 1 , both the input 3 and output 4 valves are kept in a closed position. This allows the piston 20 to generate the shock wave as it hits the pre-mix 40. If solenoid valves are used, the timing of the opening and the closing of the valves, especially the output valve 4, is adjusted to maximize the generation of the pressure shock wave generated by the piston 20 action against the pre-mix 40. The time during which the pre-mix 40 is exposed to the pressure build up within the compression chamber 1 is determined by the opening of output valve 4 and this is tied to the stroke rate determined by the 1 /4 turn air valve 13.
From the output channel 7, the treated material, now called the "post-mix" 44, flows into a baffled chamber 23 and finally out of the system through an exit channel 24. The baffled chamber 23 impedes the fluid flow enough for back pressure to build up against the output valve 4, keeping it closed even longer with just a step down in fluid flow channel diameters. Figure 4 shows an embodiment of the baffled chamber 23. The housing 54 of the chamber 23 is sufficiently long to allow turbulence to build up in the post-mix 44. The length of the chamber may be varied to accommodate various treatment effects. Pressure treated fluid (post-mix) 44 enters the chamber 23 through inflow nozzle 57 which is contained within the inner diameter 56 of the hollow chamber housing 54. A series of baffles 55 are placed along the interior length of the chamber 23 to further create turbulence as the pressure treated fluid passes through the chamber. In the preferred embodiment, the baffles are actually a series of rings with projecting tabs as shown in the cross- section of Figure 5. These tabs stick from the rings into the fluid flow, acting like baffles, and creating enhanced turbulence and shear within the pressure treated fluid 44.
While not wishing to be bound to this explanation, Applicants
theorize that piston 20 acts to generate cavitation within the compression chamber 1 as the piston 20 generates its pressure shock wave effect. The shock wave acts to liberate trapped gases within the pre-mix, thereby generating heat. The heat energy so released is thought to be a major factor in the modification of the physical properties of the fiber material within the pre-mix 40. Applicants further theorize that the pressure shock wave generated within the compression chamber 1 by the action of the piston 20 has the effect of compressing the material into a tighter space. The so-compacted material would exhibit altered physical properties.
The turbulence in chamber 23 also causes a back pressure effect upon the output check valve 4 shown in Figures 2 and 3. This back pressure effect causes a delay in the opening of the output check valve 4 and thereby enhances the length of time that pressure is applied to the target sample.
After encountering the turbulence caused by the baffles, the pressure treated fluid 59 exits the chamber 23 through outflow nozzle 58. In Figure 2 the inflow tubing leading to the chamber 23 is of smaller diameter than the outflow of the compression chamber 1 of the pressure applicator device 2. This step down in flow diameters helps to create the pressure shock wave effect within the compression chamber 1 by keeping output check valve 4 closed for a longer period of time. The outflow from the baffled chamber 23 is carried from the apparatus through outflow channel 24, and can then be delivered to a collection tank, or directly to a drying apparatus.
Below are reports of experiments performed on dietary fiber using the apparatus described above, in order to show the effects of proceeding in accordance with the present invention. Also included are comparisons with such fiber which has not been treated in accordance with the invention.
EXPERIMENT 1 :
PRESSURE TREATED FIBERS VS. CONTROL SAMPLES
WATER HOLDING CAPACITY AFTER ONE TREATMENT CYCLE
A slurry containing raw untreated fiber, was made using 1 7% dietary fiber in 83% ambient tap water. The slurry was agitated for several minutes using an air stirrer until the fiber was totally dispersed. The slurry was then filtered using a buchner funnel attached to a vacuum pump, producing a wet cake of dietary fiber. The wet cake was then freeze dried until a dried, fine, white, free flowing powder resulted. This produced a control sample.
A second slurry containing raw untreated fiber, was made using 1 7% dietary fiber in 83% ambient tap water. The slurry was agitated for several minutes using an air stirrer until the fiber was totally dispersed.
The slurry was then fed to a machine known as the Delta Processor Unit Model No. D-001 , supplied by Encapsulation Systems Inc., of Darby, Pennsylvania, which corresponds to the apparatus shown in Figures 2, 3, 4 and 5 and the above technical description of that apparatus.
The unit was set for various inlet feed pressure settings from 60 to 90 psi. The effective pressure is multiplied 1 ,000 times to produce lbs. of compressive pressure. The slurry was treated for one or five treatment cycles or passes through the machine. The treated slurry was then filtered using a buchner funnel attached to a vacuum pump, producing a wet cake of dietary fiber. The wet cake was then freeze dried until a dried, fine, white, free flowing powder resulted. This produced the sample identified as the Pressure Treated Fiber. Next the samples were analyzed using prescribed procedures, by
Medallion Laboratories, of Minneapolis, Minnesota, an independent
laboratory, to determine the properties of the pressure treated fiber vs. the control fiber.
Various fibers were treated including cellulose, wheat, wheat bran, oat and soy. Analytical tests were then conducted on various features of the control sample to the pressure treated sample, including water holding capacity, oil retention capacity, reproducibility, caloric content, insoluble fiber content, fat content and other features. The tables listed below detail the analytical results and attest to the changes effected in the pressure treated fibers. LIST OF TABLES
Table 1 illustrates the analytical results found for water holding capacity, after one treatment cycle.
Table 2 illustrates the analytical results found for water holding capacity using multiple treatment cycles. Table 3 compares reproducibility data with regard to moisture holding capacity over 5 different samples of pressure treated cellulose fiber vs. untreated control samples of raw cellulose fiber.
Table 4 illustrates the analytical results found for water holding capacity, after one treatment cycle, wherein ethanol was used instead of water as the solvent or liquid media.
Table 5 compares raw control cellulose fiber to pressure treated cellulose fiber in terms of dietary analytical results.
Table 6 illustrates the analytical results found for oil retention and holding capacity, after one treatment cycle. Table 7 is a listing of the many food products which can be utilized by this invention, either already classified as a dietary fiber or which can be so classified after pressurization treatment.
Fig. 9 is a graph illustrating the effects of altering pressure and time of exposure upon the water holding capacity of pressure treated cellulose fiber.
Fig. 10 is a graph depicting the increased amount of fiber which can be added to a baked food formulation as a result of pressure treatment.
TABLE - 1
COMPARISON OF PRESSURE TREATED FIBERS
WITH CONTROL FIBERS
WATER HOLDING CAPACITY
LEGEND:
BH 200 = Powdered Cellulose supplied by International Filler Corp, Untreated control sample
BH 200/60K = Powdered Cellulose supplied by International Filler Corp, treated at 60,000 Psi.
BH 200/90K = Powdered Cellulose supplied by International Filler Corp, treated at 90,000 Psi.
OAT OPTA = Oat fiber supplied by OPTA Food Ingredients Corp., Untreated control sample
DELTA OAT/90K = Oat fiber supplied by OPTA Food Ingredients Corp., treated at 90,000 Psi.
SOY = Soy fiber supplied by Fibred Corp., Untreated control sample
DELTA SOY/90K = Soy fiber supplied by Fibred Corp., treated at 90,000 Psi.
WHEAT 1000 = Wheat fiber supplied by Watson foods Corp., model no 1 ,000, Untreated control sample.
DELTA WHEAT 1000/90K = Wheat fiber supplied by Watson foods Corp., model no 1 ,000, treated at 90,000 Psi.
WHEAT 3000 = Wheat fiber supplied by Watson foods Corp., model no 3,000, Untreated control sample.
DELTA WHEAT 3000/90K = Wheat fiber supplied by Watson foods Corp., model no 3,000, treated at 90,000 Psi.
WHEAT BRAN = Wheat bran flake supplied by ADM Corp. and micronized, Untreated control sample.
DELTA WHEAT BRAN/90K = Wheat bran flake supplied by ADM Corp. and micronized, treated at 90,000 Psi.
OAT HULL CH. = Fiber derived from oat hulls , supplied by Canadian Harvest Corp. and known as model no. Sno-White, Untreated control sample.
DELTA OAT HULL/90K CH. = Fiber derived from oat hulls , supplied by Canadian Harvest Corp. and known as model no. Sno-White, treated at 90,000 Psi.
A size comparison was made to provide equivalent sized particulates for the water holding study. This eliminated a difference in particle size as the explanation of the cause in such a dramatic reduction in water holding capacity.
In each instance a freeze dryer was utilized as the drying method, to rule out the chance that the drying method could be a causal factor in the resultant effects in the treated fibers.
All studies used just one treatment cycle through the apparatus, the
treated fibers were all in a slurry form, using water as the liquid carrier, under ambient temperature conditions.
From this data it can be clearly seen that the pressure treatment caused a significant reduction in water holding capacity in most instances. However the water holding capacity for treated wheat bran exhibited an increase.
EXPERIMENT #2 MULTIPLE PRESSURE TREATMENT CYCLES
The procedure described in experiment # 1 is repeated for various cellulose fibers, but instead of one treatment cycle the material is treated for a total of five passes through the apparatus. The results are indicated in Table 2, wherein it can be seen that in most cases the benefits of multiple pressure treatment cycles tends to obtain a lower water holding capacity than can be achieved with just a single cycle. These tests were conducted using different cellulose sources, soft and hard woods and cellulose derived from plants, i.e. cottonseed cellulose.
TABLE - 2
COMPARISON OF PRESSURE TREATED FIBERS
SUBJECTED TO MULTIPLE TREATMENT PASSES WITH RAW FIBERS
WATER HOLDING CAPACITY
BH 200 = Cellulose fiber derived from soft woods, supplied by International Filler Corp.
BH 200/901 = Cellulose fiber derived from soft woods, supplied by International Filler Corp., treated at 90,000 psi at one treatment cycle.
BH 200/905 = Cellulose fiber derived from soft woods, supplied by International Filler Corp., treated at 90,000 psi at five treatment cycles.
B-600 = Cellulose fiber derived from Hard woods, supplied by International Filler Corp.
B-600/901 = Cellulose fiber derived from Hard woods, supplied by
International Filler Corp., treated at 90,000 psi at one treatment cycle.
B-600/905 = Cellulose fiber derived from Hard woods, supplied by International Filler Corp., treated at 90,000 psi at five treatment cycles.
HKB-300 = Cellulose fiber derived from cottonseed pulp, supplied by International Filler Corp.
HKB-300/901 = Cellulose fiber derived from cottonseed pulp, supplied by International Filler Corp ., treated at 90,000 psi at one treatment cycle.
HKB-300/905 = Cellulose fiber derived from cottonseed pulp, supplied by International Filler Corp., treated at 90,000 psi at five treatment cycles.
Generally it is noted that multiple pressure treatments do not achieve as high a reduction in water holding capacity but the multiple treatments may lead to other features desirable in a particular fiber.
EXPERIMENT #3 REPRODUCIBILITY AND RELIABILITY
The procedure described in experiment # 1 is repeated several times using a standard cellulose fiber, to determine reliability and reproducibility. Standard fiber values vary from batch to batch. The use if pressure treatments has been found to make for a more reliable and reproducible result. Table 3 lists the results of a comparison to raw
untreated cellulose fibers from several batches compared to the pressure treated counterparts from the same production batches. All of the pressure treated batches used water as the carrier and the pressure level was 90,000 psi.
TABLE - 3
COMPARISON OF PRESSURE TREATED CELLULOSE FIBER
TO RAW CELLULOSE FIBER
WATER HOLDING CAPACITY
REPRODUCIBILITY STUDY
From this data it can be seen that the Pressure Treated Cellulose Fiber sample holds far less moisture than the raw control fiber and is more consistent and reproducible from batch to batch.
EXPERIMENT #4 USE OF A SOLVENT DURING PRESSURE
PROCESSING
The procedure of Experiment 1 is followed using cellulose fiber, but ethanol is replaced as the liquid carrier or solvent, the test was to demonstrate that the Pressure treatment effect is also manifested in an organic solvent. Table 4 shows the results of pressure treated cellulose processed in ethanol.
TABLE - 4
CHANGE IN WATER HOLDING CAPACITY
ETHANOL PROCESSING
Pressure setting at 90,000, for one treatment cycle
BH-200 and BH-300 are both cellulose fibers supplied by International Filler Corp., with BH-300 being of smaller particle size.
In both instances pressure applications used in conjunction with a
organic solvent also resulted in altered physical properties for the
treated fiber.
EXPERIMENT #5
FULL DIETARY ANALYSIS OF RAW CELLULOSE VS. PRESSURE
TREATED CELLULOSE TREATED AT 90,000 PSI
The procedure of Experiment # 1 is conducted using water as the carrier and BH-200 Cellulose fiber supplied by International Filler Corp.. The fiber was subjected to 90,000 psi for one treatment cycle. A
comparison of dietary features was conducted on the raw untreated original material vs. the pressure treated cellulose. The results are listed in Table 5.
TABLE 5
COMPARISON OF PRESSURE TREATED CELLULOSE FIBER
WITH RAW CELLULOSE FIBER
Tests conducted by Medallion Laboratories, Minneapolis, MN
The pressure treated sample is both extremely high in insoluble dietary fiber and extremely low in calorie content, (only 2 calories/100 grams) and high in insoluble fiber content (95.08%), while it also has a low water (moisture) holding capacity (360%), compared to conventional cellulose fibers which hold as much as 526% water (see Table 1 ).
A key feature of the pressure treated dietary fiber is its extremely low calorie content for cellulose fiber: 2.0 calories vs. 20 calories per gram for the raw untreated cellulose fiber. This effect of the pressure
processing is also reflected in the Carbohydrates Available number, which was 4.8% for the raw untreated cellulose fiber and 0% for the pressure treated sample. This is an indicator that the fat content of the fiber has been reduced via the pressure processing treatment. The insoluble fiber content has increased in the pressure treated dietary fiber from 89.72% to 95.08%.
A key discovery of the pressure treatment is that a reduction in calories is possible depending upon the amount of pressurization employed. In the instance of the cellulose fibers, the calories dropped from 20 calories/100 grams to just 2 calories/100 grams. While
Applicants do not wish to be bound by the following explanation, this reduction may be due to the following effects within the fiber created by the pressure treatment.
1 ) An increase in the insoluble (i.e. indigestible) fiber component of the fiber, essentially making more of the material indigestible, and thereby reducing absorbed calories. In the instance of the cellulose fiber, the insoluble fiber was originally 89.72%, but after pressure treatment the insoluble fiber component was raised to 95.5%, a 6 percentage point increase in indigestible fiber content (refer to Table 1 ). This reorganization of the structure and functionality of the material after pressure treatment into a more indigestible form could account for the reduction in calories.
2) As further evidence of the effects of digestible component reorganization, the "carbohydrates available" test revealed a reduction in carbohydrates from 4.8% in the raw sample to 0.0% for the pressure treated sample. This indicates that a significant portion of the material was reorganized into a more indigestible form.
3) The reduction in carbohydrates also exhibits lower calories derived from fat content from 2.0 calories/gram to 0.02 calories/gram in the instance of the cellulose fiber. This suggests that the fat component of the material can be destructured as a result of the pressure treatment, resulting in lower calories.
4) The carbohydrate branching structure may have been altered, possibly through a process of pressure induced cross-linking of the polymer chains or base sugars composing the carbohydrate molecule, thereby resulting in less bio-available fat content, and therefore in lower tested calories.
EXPERIMENT #6 TEST FOR OIL ABSORPTION AND RETENTION
PROPERTIES
The samples made form experiment # 1 are analyzed for oil absorption and retention properties. A fiber or flour will tend to absorb vegetable oil during a frying process, and along with it absorb fat and calories. The use of pressure treatments applied to dietary fibers and to flour will tend to reduce the absorption and retention ability for oil, resulting in fried batters and fried breading which exhibit reduced overall fat content and lower overall calories. A typical example of a fried batter would be a pancake mix. Examples of a fried breaded coating would be breaded chicken, shrimp, fish, or certain fried or extruded snack foods. In the fibers listed in Table 6 the pressure setting for the pressure treated versions was 90,000 psi.
TABLE - 6
COMPARISON OF PRESSURE TREATED FIBERS
WITH CONTROL FIBERS
OIL RETENTION CAPACITY
LEGEND:
BH 200 = Powdered Cellulose supplied by International Filler Corp, Untreated control sample
BH 200/90K = Powdered Cellulose supplied by International Filler Corp, treated at 90,000 psi.
SOY = Soy fiber supplied by Fibred Corp., Untreated control sample
DELTA SOY/90K = Soy fiber supplied by Fibred Corp., treated at 90,000 Psi.
WHEAT 1000 = Wheat fiber supplied by Watson foods Corp., model no 1 ,000, Untreated control sample.
DELTA WHEAT 1000/90K = Wheat fiber supplied by Watson foods Corp., model no 1 ,000, treated at 90,000 psi.
WHEAT Flour = Wheat flour supplied by the Snavely Mill Co. Untreated control sample.
DELTA WHEAT FLOUR /90K = Wheat flour supplied by Snavely Mil Co., treated at 90,000 psi.
WHEAT BRAN = Wheat bran flake supplied by ADM Corp. and micronized, Untreated control sample.
DELTA WHEAT BRAN/90K = Wheat bran flake supplied by ADM Corp. and micronized, treated at 90,000 psi.
In most instances the use of pressure treatment effects a lowering of the oil absorption and retention properties in the resultant fiber, however it is possible to effect an increase in oil retention in certain fibers as well.
EXPERIMENT #7
EFFECTS OF VARIOUS PRESSURE LEVELS VS. TIME OF
PRESSURIZATION EXPOSURE FOR CELLULOSE FIBER
The procedure of Experiment #1 was followed for cellulose fiber but the pressure level applied to the cellulose was varied along with the time during which the pressure was present upon the sample. The test was used to determine the effect of pressure/time upon a given material. Pressure in the apparatus shown in Figure 2 is a function of the inlet pressure and the geometry of the design of the piston and compression chamber.
On average the inlet pressure in the apparatus can be multiplied by more than 1 ,000 X. The 1 /4 turn valve 1 3, in Figure 2, also regulates the positive and negative application of pressure, and therefore the timing of each pressure application, by regulation the quantity of compressed air 30 allowed into the air motor at a given instant. By adjusting the 1 /4 turn valve it possible to achieve a 0.10 second to as much as a 0.25 second time of pressure exposure upon a target pre- mix 40. Pressure exposure time is calculate to include both the positive application of pressure and the negative application, both contributing factors to the pressure or cavitation effect. The Positive application of pressure occurs when the piston shown in Figure 3 is forward into the compression chamber 1 . The negative application of pressure occurs
when the piston 20 is withdrawing away from the compression chamber 1 .
The results were indicated in a reduction of water holding capacity. Fig. 9 illustrates the results. At 60,000 psi, applied for 0.10 seconds the water holding capacity of pressure treated cellulose was reduced by 24%.
At 90,000 psi, applied for 0.10 seconds the water holding capacity of pressure treated cellulose was reduced by 37%.
At 44,000 psi, applied for 0.20 seconds the water holding capacity of pressure treated cellulose was reduced by 32%.
At 1 20,000 psi, applied for 0.20 seconds the water holding capacity of pressure treated cellulose was reduced by 60%.
By varying both the pressure level and time of exposure differing resultant features can be achieved in the treated fiber. While but a few examples of dietary fibers have been discussed in this invention it should be obvious that there are several food stuffs or grains which are now classified as dietary fibers or which may be so classified after pressure treatment, including but not limited to the list provided in Table 7. TABLE - 7
PARTIAL LISTING OF VARIOUS DIETARY FIBER PRODUCTS SUITABLE FOR ENHANCEMENT VIA PRESSURE PROCESSING TECHNIQUES IN ACCORDANCE WITH THE PRESENT INVENTION
APPLE FIBER BARLEY FLOUR, HIGH PROTEIN
BRAN FIBER BARLEY FIBER
BARLEY BRAN FLOUR BREWER'S SPENT GRAINS
FLOUR BARLEY'S BEST HIGH PROTEIN
FLOUR FIG POWDER
BARLEY RICE CORNSTARCH GUAR GUM MALTED GERM
BLEACHED CORN FIBER GUM ARABIC
CARRAGEEN GUM LOCUST BEAN GUM
CELLULOSE GUM OAT BRAN
CITRUS FIBER OAT FIBER
COCOA PEA FIBER
CORN BRAN POWDERED CELLULOSE
CORN FIBER PECTIN
SODIUM PRUNES, DRIED
CARBOXYMETHYL
CELLULOSE RICE BRAN, DE-FATTED
CORN FLOUR RICE BRAN, STABILIZED
CORN HUSKS RICE FIBER
DRIED CRANBERRIES CELLULOSE FIBERS
DE-FATTED WHEAT SUCROSE GERM
SOY FIBER
FIBERS DERIVED FROM OAT HUSKS SUGAR BEET FIBER
PEANUT FLOUR WHEAT BRAN
MICROCRYSTALLINE WHEAT FIBER CELLULOSE
WHEAT FLOUR
TARA GUM
WHEAT GERM, DE-FATTED
XANTHAN GUM
COMBINATIONS OF ANY NUMBER OF THE ABOVE FIBERS
BLENDS OF ABOVE FIBERS IN A RAW STATE WITH THEIR PRESSURE TREATED VERSIONS
ANY OTHER SUBSTANCE USED AS A DIETARY FIBER
EXPERIMENT 8
USING PRESSURE TREATED FIBER (CELLULOSE) IN VARIOUS
BAKED FOOD FORMULATIONS
Cellulose fiber, BH-200, which is pressure treated according to the parameters set forth in Experiment #1 is used in various baked food recipe's. It was discovered that the pressure treated fiber can replace more of the flour used in the recipe as opposed to the raw untreated fiber. Fig. 10 illustrates the findings. The Flour Replacement value is a based upon the machining stress or torque generated by a hobart planetary mixer in a standard recipe. Since the raw fiber tended to absorb a great deal of water it required more water and thereby placed more strain on the mixing machinery. This also required more time to bake to remove the absorbed moisture. Since the pressure treated version enjoyed a far lower water holding capacity the torque was less, and the bake out time was less. By replacing more flour with a dietary fiber a corresponding lowering of the calories in the final baked product resulted.
Recipes 1 through 5 illustrate the features and procedures for making an improved dietary product incorporating pressure treated fiber.
RECIPE 1
PRESSURE TREATED CELLULOSE IN
APPLE MUFFINS
CALORIES/SERVING
ORIGINAL RECIPE 190
PRESSURE TREATED VERSION 155
SERVES: 12 Preparation Time: 30 Minutes Elapsed Time: 1 Hour Bake Time: 20 to 25 Minutes Oven Temp: 400° (F)
* If using self-rising flour, omit baking powder and salt.
BAKING INSTRUCTIONS
Heat oven to 400 degrees. Prepare Streusel Topping. Grease bottoms only of 1 2 medium muffin cups, 2-1 /2 X 1 -1 /4 inches, or line with paper baking cups. Beat milk, oil vanilla and egg. Stir in flour, sugar, baking powder, salt and cinnamon all at once until flour is moistened (batter will be lumpy). Fold in apples. Divide batter evenly among muffin cups. Sprinkle each with about 2 teaspoons Streusel Topping. Bake 20 to 25 minutes or until golden brown. Immediately remove from pan.
STREUSEL TOPPING:
Mix all ingredients until crumbly.
Copyright 1996 Delta Food Group Darby, PA
RECIPE 2
PRESSURE TREATED CELLULOSE IN
BROWNIES
CALORIES/SERVING
ORIGINAL RECIPE 37
PRESSURE TREATED VERSION 21
SERVES: 72 Preparation Time: 15 Minutes Elapsed Time: 45 Minutes
Bake Time: 23 Minutes/convection Oven Time: 350°(F)
Heat Oven to temperature. Cream Mono & Diglycerides and bakers sugar together on medium speed. Dry Blend with other ingredients at low speed for 5 minutes. Add water. Mix 2 minutes. Scrape down after 1 minute. Bake in convection oven for 23 minutes at 350(f).
Copyright 1996 Delta Food Group Darby, PA
RECIPE 3
PRESSURE TREATED CELLULOSE IN
WHOLE WHEAT BATTER BREAD
CALORIES/SERVING
ORIGINAL RECIPE 85
PRESSURE TREATED VERSION 67
SERVES: 2 Loaves/16 slices ea. Preparation Time: 15 minutes
Elapsed Time: 1 Hour 1 5 Minutes Bake Time: 25 Minutes Oven Temp: 400° (F)
If using self-rising flour, omit baking powder and sale
BAKING INSTRUCTIONS
Mix 3-1 /2 cups all-purpose flour, the sugar, salt, baking soda and yeast in large bowl. Add warm milk and warm water. Beat on low speed until moistened. Beat 3 minutes on medium speed, scraping bowl occasionally. Stir in whole wheat flour, raisins and enough remaining all-purpose flour to make a stiff batter.
Grease 2 loaf pans, 8-12X4-1 /2X2-1 /2 inches and sprinkle with cornmeal. Divide batter evenly between pans. Round tops of loaves by patting with floured hands. Sprinkle with cornmeal. Cover and let rise in warm place about 30 minutes or until batter is about 1 inch below top of pan.
Heat oven to 400 degrees. Bake about 25 minutes or until loaves are light brown; remove from pans. Cool on wire rack.
Copyright 1996 Delta Food Group Darby, PA
RECIPE 4
PRESSURE TREATED CELLULOSE IN
CHOCOLATE CHIP COOKIES
CALORIES/SERVING
ORIGINAL RECIPE 90
PRESSURE TREATED VERSION 67.5
SERVES: 72 Cookies Preparation Time: 15 Minutes Elapsed Time: 45 Minutes Bake Time: 8-10 Minutes Oven Temp: 375° (F)
* If using self-rising flour, omit baking powder and salt
BAKING INSTRUCTIONS Heat Oven to temperature. Mix sugars, margarine and egg. Stir in flour, baking soda, and salt
(dough will be stiff). Stir in nuts and chocolate chips. Drop dough by rounding teaspoonfuls about 2 inches apart onto ungreased cookie sheet. Bake 8-10 minutes until light brown. Centers will be soft. Cool slightly; remove from cookie sheet. Copyright 1996 Delta Food Group
Darby, PA
RECIPE 5
PRESSURE TREATED CELLULOSE IN
BASIC YELLOW CAKE
CALORIES/SERVING
ORIGINAL RECIPE 95
PRESSURE TREATED VERSION 63
SERVES: One 3-layer cake Preparation Time: 15 Minutes Elapsed Time: 1 Hours 30 Minutes Bake Time: 20 to 25 Minutes Oven Temp: 375° (F)
BAKING INSTRUCTIONS
Cream shortening; gradually add sugar, beating well at medium speed of an electric mixer. Add eggs, one at a time, beating well after each addition.
Combine flour, baking powder, and salt; add to creamed mixture alternately with milk, beginning and ending with flour mixture. Mix after each addition. Stir in flavorings. Pour batter into 3 greased and floured 9-inch round cakepans. Bake at 375 degrees for 20 to 25 minutes or until a wooden pick inserted in center comes out clean. Cool in pans 10 minutes; remove from pans, and let cool completely on wire racks. Frost as desired. Copyright 1996 Delta Food Group
Darby, PA
In the above recipes the original recipe, made without the pressure treated dietary ingredient has a significantly higher caloric content. By substituting part of the flour or sugar content with pressure treated fiber the overall caloric content for the baked product can be significantly reduced.
The use of Pressure treated fibers in various baked or fried foods results in improved dietary functionality for the final end product by producing several key improvements:
• Reduced caloric content for the end product due to increased loading of a dietary fiber ingredient , with lowered calorie content within the fiber. • Increased total dietary fiber content in the end product due to increased loading of a improved dietary fiber, possessing increased insoluble fiber values.
• Reduced ability to absorb moisture in the end product,due to the incorporation of dietary fiber ingredients which exhibit lowered water holding capacity, leading to longer shelf life.
• Improved mouth feel, texture and taste perception. Usually a product highly loaded with dietary fiber tends to absorb far too much mouth moisture, leading to negative impressions in mouth feel and taste profile. The use of a low moisture absorbing fiber, effected via pressure processing techniques, helps to improve mouth sensation features in the end product.
• Reduced oil absorption and retention properties in breaded coatings or fried batters means less fat absorbed, and therefore less calories for the end product. These and other improvements are possible through the use of dietary fiber ingredients which are pressure modified.
While it is obvious to anyone skilled in the art that there are several means of generating a pressure shock wave or abrupt pressure change the preferred embodiment of the apparatus is disclosed as merely the forerunner of similar devices. While only a few fibers have been listed it should be obvious to one skilled in the art of food science that several dietary fibers are possible, from non-currently classified food stuffs, after pressure treatment.