Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
  • A23P30/20—Extruding
  • A23P30/25—Co-extrusion of different foodstuffs
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
  • A21C11/00—Other machines for forming the dough into its final shape before cooking or baking
  • A21C11/16—Extruding machines
  • A21C11/163—Applying co-extrusion, i.e. extruding two or more plastic substances simultaneously, e.g. for making filled dough products; Making products from two or more different substances supplied to the extruder
• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
  • A21D13/00—Finished or partly finished bakery products
  • A21D13/30—Filled, to be filled or stuffed products
  • A21D13/37—Co-extruded products, i.e. products obtained by simultaneous extrusion of the dough and the filling
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers

Definitions

• the present invention concerns a co-extruded product comprising a filling and an outside shell. More particularly, the present invention concerns a co- extruded product comprising a filling and an outside cereal and/or starch based shell.
• the filling fat must be chosen to have a melting point between 30-35 0 C such that it sets between the die head (where it must be liquid to be pumped into the extrusion die) and the cutting station.
• the filling fats with lower melting points it is explained that it is necessary to crimp the ends of the cereal shell to retain the filling.
• the products obtained with the processes known in the art are found in practice to have a rather high density. This is due to the limitation that when a highly expanded product exits from the extruder die it shoots forward at high speed.
• cut the extrudate for example with a guillotine
• Lower density products comprising a filling and an outside cereal and/or starch based shell.
• Lower density products maximize the size impression for the consumer while at the same time delivering fewer calories and being able to be sold at a lower price by volume.
• the creation of low densities in combination with soft fillings provides new and desirable products.
• the fact that the filling does not flow out means in the present specification that the possibility of flowing out is so minimized that it does not spoil the product and does not block the process.
• the present invention concerns a co-extruded product comprising a filling (second substance) and an outside open or closed cereal and/or starch based material (first substance ) shell, wherein the amount of filling is comprised between 10 and 80 % in weight, the density of the product in the case of an open shell is comprised between 40 and 400 g/1 and the density of the product in the case of a closed shell is comprised between 40 and 190 g/1.
• the density (texture-range) described above allows a very mouth-melting texture, therefore a very indulgent product.
• the density of the product can be measured by determining the volume of a single product (for example by measuring the external dimensions) , weighing the product and then calculating the density as the ratio of the mass in grams to the volume in litres. An average of the density of 50 products should be taken.
• the density of the outside shell can be calculated in a similar way to the overall product density, except that the volume and weight of the filling are subtracted from those of the overall product.
• the density of the outside shell is between 30 and 200 g/1.
• the filling is pasty or liquid at room temperature.
• the product of the invention has a density comprised between 40 and 300 g/1 : this is already considered as an expanded outside shell product, giving a very mouth-melting texture.
• the product of the invention has a density comprised between 40 and 260 g/1.
• the density of the product is comprised between 40 and 190 g/1 : in this case, this product is considered as a super expanded outside shell, with maximum melting charactreristic and apparent volume .
• the coating can be any type of coating known in the art. More specifically, the coating is taken from the group consisting of peanut coating, chocolate coating, panned sugar coating and others known in the art.
• the product of the invention has a density, which is from 40 to 80 g/1 higher, in the most preferred embodiment. This increase depends on the type of coating and on the thickness thereof.
• the composition of the outside cereal and/or starch based material shell is not critical and can be of any type.
• the outside shell can be an expanded starch based material, for example using potato starch, or an expanded cereal material: Any type of cereal can be taken in consideration, for example corn, wheat, rice, barley and oat. It is also possible to have other types of outside cereal shell, like those used in confectionary, for example biscuit, no- or low-sugar wafer, or sugar wafer.
• the product of the invention can be considered for human food, but also for petfood.
• the filling of the product of the invention can be of any type.
• the filling is pasty or liquid and does not flow out of the outside cereal shell at room temperature, at the cutting stage nor during subsequent processing. It is possible to have a jam filling which is non-aerated or aerated.
• the jam can be any type of fruit jam known per se.
• a chocolate filling can be taken into consideration.
• the filling is a fat-cream filling, which is non-aerated or aerated. Under fat-cream filling, we understand in the present specification a filling comprising a continuous fat phase and a suspension of solid materials.
• the solid materials can be for example sugar, cocoa powder, milk powder, ground cereal shell material or fruit powder.
• the filling fat blend used in the fat-cream filling has a melting point below 30 °C, most preferably the filling fat blend is completely liquid at 20 °C.
• the melting point of the filling fat blend can be determined by extracting the fat from the filling, for example by Soxhlet extraction, and then performing a slip melting point determination. To characterise the rheological characteristics of suitable fillings extrusion measurements can be performed using a Texture Analyser HDplus from Stable Micro Systems (Godalming, Surrey, UK) , equipped with a 250 kg load cell and an extrusion assembly.
• the extrusion assembly consists of a cylindrical perspex barrel of internal diameter 48 mm and internal depth 103 mm, at the bottom of which is a countersunk circular aperture, i.e. a die, of internal diameter 14 mm and external diameter 10 mm. The depth of the aperture is 4 mm.
• the filling is transferred to this barrel and the filled barrel is placed in an air oven for 20 minutes at 80 degrees Celsius. At the end of this time, the barrel is quickly placed in the testing machine, and the filling forced through the die by the movement of a plunger downward into the barrel. At its point of contact with the filling the plunger has a horzontal disk of thickness 5 mm and diameter 40 mm. The applied rate of movement is 10 mm /s.
• the filling has a yield point at 80 °C of between 0.2N and 4ON, preferably between 0.5N and ION.
• a temperature around 80 °C is used for the analysis because it is about the temperature at the cutting step.
• the specified yield point values shows that the product is flowing but not as liquid as water.
• the amount of filling is preferably comprised between 40 and 70 %. All percentages in the present specification are given in weight. The above-mentioned range allows a very high product-indulgence and processability .
• the co-extruded product of the invention has a diameter around 8 to 30 mm and a length between 5 and 200 mm. In a preferred embodiment of the invention, the product has a diameter around 15 to 20 mm and a length between 10 and 50 mm.
• the product according to the invention has a circular cross section. But, it is also in the scope of the invention to have a product with a square, rectangular, triangular, or other cross section.
• the product of the invention, in its length can be either linear or shaped (for example corrugated or dented) .
• the above- mentioned dimensions provide appropriate range for the product according to the invention, notably the snack- format sizes, from sticks or long snacks to nibbles.
• the present invention concerns further a process for the preparation of a co-extruded product as described above, wherein
• both substances are co-extruded to form a rope at the exit of said extruder, - the rope is travelling on a conveying device,
• a moving knife cuts said rope at the exit of this hole into pieces, - said pieces are transported into means for preventing their random dispersion by the knife ,
• a powder or a powder with liquid or a paste can be from cereal origin.
• the liquid used is normally water with or without additives or oil.
• the conditions of the extrusion are well known from the man skilled in the art. It is in the scope of the invention to have either a cooking extrusion or a cold extrusion depending on the manufactured product.
• the product Before the product is packaged, it is normally dried to reach a water content comprised between 1 and 8 %. However, processes without drying are also feasible.
• a coating can be also applied on the product of the invention.
• the rope Before the cutting of the rope, it is necessary to stabilise during a certain period of time said rope : the rope is travelling on a conveying device, like a belt for example, at room temperature and at atmospheric pressure.
• the distance of conveying is comprised between 0.5 and 20m, which gives a duration of around 1 to 20 seconds. It is also possible according to the invention to minimize the belt transportation : the less soft, chewy or sticky the rope at cutting process step, the shorter the conveying.
• the important feature of the invention is to have after the conveying the cutting of the rope. This cutting is carried out after the passage of said rope in the hole of the plate or the tube.
• a knife is disposed directly after said plate or tube to carry out said cutting.
• Means for preventing random dispersion of the pieces by the knife, placed downstream of the knife can be for example a tube, a cone, a flat cone or another equivalent device, like a thick plate.
• the length of the tube, cone or thick plate is comprised between 2 and 30 cm.
• the diameter of the tube or of its entry if it is a cone is about 1.05 and 2 times the diameter of the rope.
• the type of movement of the knife is not critical : it can be for example either a rotating movement, or an oscillating movement or an alternating movement.
• the rope is travelling at a speed comprised between 10 and 100 m/minute. This speed is depending on the type of product which is prepared according to the invention. In the case of a super expanded product, it is more a higher speed. In the case of a breakfast cereal, it is more a lower speed.
• the drying is normally carried out at a temperature around 100 to 200 °C. Drying the cut pieces in bulk, which is the most efficient method, is possible because the moving knife, coupled with the means for preventing the random dispersion of the pieces by the knife, can cut the rope and deposit the pieces gently on the belt of the dryer such that the hot filling does not flow out.
• the present invention concerns finally a device for carrying out the process of the invention.
• the device comprises - a extrusion apparatus for the formation of the rope,
• first plate or a tube with a hole for receiving said rope means at the exit of said hole for preventing the cut pieces to be randomly dispersed by the knife, a second plate for supporting the said means and a knife fixed on the second plate to cut the rope at the exit of the hole of the first plate.
• the distance between the first plate or tube and the second plate is not critical, but is normally or around the length of the tube or cone.
• Figure 2 is a perspective view of the cutting part of the device
• Figure 3 is a perspective view of the product according to the invention.
• Figure 4 is a perspective view of the product of figure 3 cut along the length.
• Figure 5 is a plot of force against distance showing the yield point measurement of the filling of the example.
• a cereal base is cooked in (2), a cream filling is added from (1) through a pipe (9) into the extruder (3), so that a co-extrusion is carried out through the die (10) .
• a rope (11) of co-extruded product is travelled on the conveyor (4) .
• Said rope is then fed into the cutting apparatus (5) and the small pieces (12) travelled in a dryer (6) .
• these small pieces are coated in the device (7) and packaged in (8) .
• the product is now ready to be stored or transported to the retailer. It is possible with the device of the invention to prepare open-ended product with a pasty or liquid filling at room temperature and at cutting process step without any dropping of the filling of the outside shell at said step in such a way that it would incapacitate the process.
• FIG 2 shows more closely the cutting apparatus (5) of the invention.
• the direction of movement of the rope is given by arrow A.
• the first plate or entry tube of the cutting apparatus is not shown on the figure, but is just before the knife (16) .
• the rope (11) enters in the hole of the first plate and then in the tube (18) .
• the rotating knife (16) cuts the rope (11) to obtain small pieces of the product (12) according to the invention. These pieces are travelling in the tube and are exiting in (17) .
• the motor (13) and the knife hub (15) rotate the knife at the desired speed.
• the second plate (14) supports the tube (18) .
• the pieces (17) are then transported to the dryer (6) shown on figure 1.
• a corn based cereal is cooked at a temperature of 150 0 C and a cream filling comprising vegetable oil (fully liquid at 20°C), cocoa powder, sugar, starch and vanilla flavour is fed into the cooking-extruder.
• a circular super expanded rope is co-extruded and travels on the conveyor belt at a speed of 80 m/min. The rope is cut and passed through a tube having a length of 10 cm.
• the piece (12) has a diameter of 18 mm and a length of 35 mm.
• the filling represents 60 % of the whole product and the filling diameter is 6.5 mm.
• the density of this product is of 75 g/1.
• the product is then dried to a moisture of 2.5 % and coated. This product is stored and sent to the packaging process step.
• Example 2 The yield point of a sample of the filling from example 1 was measured using a Texture Analyser HDplus from Stable Micro Systems (Godalming, Surrey, UK) , equipped with a 250 kg load cell and extrusion assembly.
• the extrusion assembly comprised a cylindrical perspex barrel of internal diameter 48 mm and internal depth 103 mm, at the bottom of which was a countersunk circular aperture, i.e. a die, of internal diameter 14 mm and external diameter 10 mm. The depth of the aperture was 4 mm.
• the filling was transferred to this barrel and the filled barrel was placed in an air oven for 20 minutes at 80 degrees Celsius.
• the barrel was quickly emplaced in the testing machine, and the filling forced through the die by the movement of a plunger downward into the barrel.
• the plunger featured a horzontal disk of thickness 5 mm and diameter 40 mm.
• the applied rate of movement was 10 mm /s.
• the measured yield point for the filling of example 1 was 4 ⁇ 1 N.

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• Engineering & Computer Science (AREA)
• Life Sciences & Earth Sciences (AREA)
• Food Science & Technology (AREA)
• Chemical & Material Sciences (AREA)
• Polymers & Plastics (AREA)
• Manufacturing & Machinery (AREA)
• Grain Derivatives (AREA)
• Confectionery (AREA)
• Formation And Processing Of Food Products (AREA)
• General Preparation And Processing Of Foods (AREA)
• Cereal-Derived Products (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Cited By (4)

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Citations (5)

Family Cites Families (3)

• 2007
  • 2007-01-10 UA UAA200904461A patent/UA100368C2/ru unknown
  • 2007-10-01 RU RU2009116426/13A patent/RU2449632C2/ru not_active IP Right Cessation
  • 2007-10-01 CN CNA200780037206XA patent/CN101522060A/zh active Pending
  • 2007-10-01 WO PCT/EP2007/060394 patent/WO2008040705A1/en active Application Filing
  • 2007-10-01 MX MX2009003485A patent/MX2009003485A/es active IP Right Grant
  • 2007-10-01 BR BRPI0719964-3A patent/BRPI0719964B1/pt active IP Right Grant
  • 2007-10-04 CL CL200702874A patent/CL2007002874A1/es unknown
• 2009
  • 2009-03-17 IL IL197631A patent/IL197631A/en active IP Right Grant
  • 2009-04-06 CO CO09035423A patent/CO6170412A2/es active IP Right Grant

Patent Citations (5)

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