WO2011117641A1

WO2011117641A1 - Consumables and methods of production thereof

Info

Publication number: WO2011117641A1
Application number: PCT/GB2011/050594
Authority: WO
Inventors: Peter Clarke; Sarah Marshall; Clive Richard Thomas Norton
Original assignee: Cadbury Uk Limited
Priority date: 2010-03-23
Filing date: 2011-03-23
Publication date: 2011-09-29
Also published as: GB201004902D0

Abstract

The present invention relates to savoury consumable products comprising an extruded body portion, the body portion being formed with two or more channels disposed therein, wherein the channels contain a substance which is different from the substance of the body portion. The present invention also relates to a method of production of the same.

Description

. l -

CONSUMABLES AND METHODS OF PRODUCTION THEREOF

Technical Field of the Invention

The present invention relates to savoury consumable products and also to a method of production thereof. In particular, the invention relates to savoury consumable products comprising at least one channel, wherein the channel may be filled with a substance.

Background to the Invention

It is desirable to produce consumable products (i.e. edible items such as foodstuffs, toothpaste, etc) formed of different components, so as to increase sensory pleasure. A number of consumable products exist, which have a flavoured liquid or syrup centre which is released upon chewing. For example, WO 2007/056685 discloses an apparatus and method for the continuous production of centre-filled confectionery products in the format of a continuous extrudate having a plurality of centre-filled confectionery ropes. Whilst a product formed from such an apparatus does increase sensory pleasure, the period of pleasure is often short lived as the centre is released quickly and/or degraded. It is therefore desirable to provide a consumable product which can release a capillary centre over an extended period of time.

There is also a demand for providing consumable products having a reduced fat or sugar content. It is desirable to provide a consumable product which can be produced having a lowered fat or sugar content, whilst still maintaining an excellent sensory pleasure.

Further, there is demand for consumable products having improved visual appearance whilst maintaining flavour. It is desirable to provide a consumable product which is eye-catching whilst still providing a desirable flavour.

Yet further there is demand for consumable products having improved convenience whilst maintaining or improving flavour. It is thus desirable to provide a consumable product which increases convenience whilst still maintaining, or even improving, flavour.

It is also preferable to provide a consumable product having an improved or novel sensory experience.

Summary of the Invention

According to a first aspect of the present invention, there is provided a savoury consumable product comprising an extruded body portion, the body portion being formed with two or more channels disposed therein, wherein the channels contain a substance which is different from the substance of the body portion.

Preferably the channels comprise a substance that belongs to a different food group to the substance of the body portion. Examples of different food groups are (i) protein rich matter such as meats and fish; (ii) fat. rich matter, such as oils, butters and emulsions; and

(iii) carbohydrate rich matter such as pasta, pastry, rice or bread.

According to another aspect of the present invention there is provided a process for manufacturing a savoury consumable product comprising a body portion having two or more channels disposed therein, the process comprising the step of extruding a material with two or more channels disposed therein, wherein the channels contain a substance that is different from the substance of body portion. A yet further aspect of the invention provides an apparatus adapted for producing a savoury consumable product according to this process.

By the term "savoury" it is meant herein that the consumable product would not typically be regarded as sweet (such as a confectionery product). It should be understood that the term "channel" generally refers to a conduit or space created by an extrusion or other forming process within the body of the product. The capillary typically contains matter, and that matter can be in the form of a gas, a liquid, a solid, or a mixture thereof. The channels may be formed in different locations within the body portion - these different locations may be ordered or random. Alternatively, the channels may be located concentrically within the body portion (that is to say one channel is located within a larger channel.) The embodiment of the invention includes two or more channels, and the channels can have the same or different shapes. The channels can be capillaries but could alternatively be wide channels exhibiting a variety of cross sectional shapes. The cross-sectional shape of some or all channels may be at least partially frusto- conical, wherein the channels increase or decrease in diameter depending upon which end of the product the channel is viewed from. Alternatively, the one or more of the cross-sections of the channels may have an 'oscillating' shape, such that it has alternating sections having narrower diameters followed by sections having wider diameters. This is discussed further hereinbelow.

When consumed, the savoury consumable product of the present invention has an extended release of any material inserted into the channels. Further the savoury consumable product may have a more diverse cross section such that it is more eye catching, and with the convenience of any material inserted into the channels being integral with the consumable product and leakage from the ends of the product minimised.

It should be understood that the term "liquid" is intended to mean that the material is capable of or has a readiness to flow, including gels, pastes and plasticized material. Furthermore, this term is intended to include (but is not limited to) those materials which may be "molten" during extrusion. The skilled addressee will understand that the term "molten" means that the material has been reduced to a liquid form or a form which exhibits the properties of a liquid. The body portion may be at least partially or substantially solid, so that it can no longer be considered to flow in a liquid form. It will be apparent that the body portion may be liquid during extrusion and solidify shortly thereafter. Furthermore, if desired, extrusion may assist in solidifying the material (by cooking for example).

The material used to produce the body portion may comprise a number of materials commonly used in the production of consumable products - for example foodstuffs such as meat, cereal, cheese, potato, pastry, fruit, spreads or pate, or indeed consumable products such as pet food or toothpaste.

The channels may extend along substantially the entire length of the body portion, but may in some embodiments extend no less than 75%, 80%, 90%, 95% or 99% along the length of the body portion (for example, when it is desired to seal the ends of the body portion). If the channels extend along the entire length of body portion, typically the ends of the channels are visible at one or more ends of the body portion. Different channels may incorporate different materials if desired, and/or any one channel can be filled with different substances along its length. The channels may be filled with a material which is solid at a room temperature and fluid at a temperature greater than room temperature. It will be apparent to the skilled addressee that room temperature is commonly regarded as around 20°C. Alternatively, the channels may be filled with a material which is deposited as a liquid and which subsequently solidifies. In such embodiments, the solidification may be dependent or independent of heat. It will be apparent that solidification of a liquid filled channel may be achieved in a number of ways. For example solidification may take place due to one or more of the following:

Cooling - the filling may be molten when deposited which then cools to a solid at room temperature;

Heating - the filling may be liquid when deposited, and the heat of the extruded body portion sets the filling (e.g. pumping egg albumen into a hot extruded body portion will set the egg on contact);

Drying - the filling may be a solution that dries into a solid (e.g. the moisture from the solution is absorbed into the extruded body portion);

Solvent loss - the filling may be in a solvent, whereby the solvent is absorbed into the extruded body portion, leaving a solid;

Chemical reaction - the filling may be deposited as a liquid but reacts or

"goes off into a solid;

Cross-linking - the filling may form a constituents for a cross-linked material due to mixing and/or heating; and

Time - the filling may simply set with time (e.g. a solution of sugars and gelatin will eventually set over time).

If the channels are filled, suitable filling materials for the channels include, but are not limited to, aqueous media, fats, fruit or vegetable purees, medications, sauces such as ketchup, cream, or any combination or mixture thereof. If desired, the product may further comprise a coating portion to envelop or enrobe the body portion. The skilled addressee will appreciate that a number of coatings could be employed - for example flour, fat, batter, breadcrumbs, pastry etc.

The body portion may be connected to one or more further portions. In some embodiments, the body portion is sandwiched between materials or may be connected or laminated to one or more layers. The further portion or portions may or may not contain inclusions. Suitable inclusions will be apparent to the skilled addressee and include a wide range of granular or powdered material, liquid-filled beads and encapsulated materials. Inclusions may include nut pieces, breadcrumbs, salt crystals, sugar crystals etc. In some embodiments, multiple channels are distributed substantially uniformly throughout the body portion, and may be spaced evenly apart from adjacent channels. In other embodiments, channels may be distributed in pre-defined configurations withi the body portion, such as around the periphery of the body portion, or in groups at one or more locations within the body. In some embodiments the body portion has a circular, elliptical, regular polygonal or semicircular cross-section. The body portion may be shaped in the form of a cylinder, a rope, a filament, a strip, a ribbon or the like, or may be shaped in the form of a standard consumable product such a slab, pellet, ball, stick or ribbon, for example. The exterior of the body portion may be irregular or regular in shape. Furthermore, the body portion may be formed in potentially any shape, for example in the shape of an object, cartoon character or an animal to name a few.

The at least one channel of the invention can have a non-uniform cross section along its length. Suitable examples of such non-uniform cross section include variations in shape and/or area along the channel length. For instance, a channel could exhibit a maximum cross-sectional area that is at least 10% greater than the minimum cross-sectional area of that channel, typically at least 20% greater, more typically at least 50% greater, most typically at least 100% greater.

By way of example of variation of cross-sectional area with length, the channels may be roughly circular in cross section, with a diameter that oscillates from a small to a large diameter along the length of the channel. In the limit, the arrangement would give rise to discrete 'bubbles' being present laterally along the length of the consumable product, wherein the 'bubbles' are separated by areas formed of the same material as the body portion and/or channels having a negligible or no cross-sectional area. The oscillations can be sinusoidal or regularly spaced in any manner, such that all 'bubbles' are of equal size, or irregular such that differently sized 'bubbles' are created. The 'bubbles' can also have non-circular cross sections, such as triangles, squares, ovals, stars, and the like.

Variation in cross-sectional diameter such that at least a portion of the at least one channel has a somewhat narrower diameter enables the problem of leakage of the centre-fill from the channels to be addressed. If the channel is of a substantially consistent and wide diameter, there may be issues of premature leakage of the centre-fill both when a consumer bites into the product and also when the product has been extruded and is then being cut to create the discrete product items. However, if at least part of the diameter of the at least one channel is narrower than the rest, there is significantly reduced scope for the leakage to occur. Indeed, in the embodiments of the invention comprising the 'bubbles' channels, or where the narrow part of the channels are on a micrometre scale, the arrangement of the channels and the cutting process can be set up such that the extruded product is cut precisely in the sections of the product where the at least one channel is at it narrowest, thus removing premature leakage.

By way of example of variation of shape with length, the cross section of the channel can oscillate, along the length of the channel, between a shape which is oriented vertically and the same shape which is oriented horizontally. Other suitable shapes include rectangles, ovals, stars, etc.

Variations in cross-sectional area with respect to length can be achieved by varying the rate of extrusion of the body portion in relation to the rate of channel formation. For example, if the rate of extrusion of the body portion is slowed, but the rate of channel formation (by virtue of pumping gas or liquid into the extrudate via a die) is maintained or sped up, then a bigger channel cross section will result. Conversely if the rate of extrusion of the body portion is sped up (or maintained), and the rate of chaimel formation is maintained (or slowed), then a smaller channel cross section will result.

Further variations in cross-sectional area with respect to length can be achieved by extruding the body portion onto a convenor belt and varying the speed of extrusion relative to the speed of the belt or visa versa.

A range of effects can be formed in the extrudate by rotating the die head whilst extruding onto a planar convenor belt, or rotating the extrudate after extrusion from a static die head, so as to produce channels in the format of swirls or helices.

The nozzles of the die may or may not be located centrally in the die head. If it is located centrally in the extrudate, a sinusoidal channel or line of bubbles can be produced. Alternatively, if the nozzle is not located centrally in the die head, different channel profiles can easily be produced and further formats can be produced by rotating the extrudate relative to the die head. For example, a channel forming a 'ring, 'swirl', 'loop', or part helical-shaped pathway through the body portion, can be produced if the die is rotated slowly and continuously; or, if the fluid expulsion from the die is sufficiently rapid and/or discrete to 'nip' the channel into bubbles, a pattern of bubbles can be created where the bubbles are alternately located at the top or bottom of the body portion.

A further manner of obtaining the non-uniform channel cross-sectional diameter is by employing the use of a moveable belt on the extruder which is able to tilt in different directions to move the extrudate relative to the injection of fluid from the die while the die remains stationary. The extrudate may be expelled from the extruder onto a conveyor belt and the speed of the belt may be varied so as to move at a faster or slower rate relative to the speed of extrusion.

Any two or more channels may have different cross-sectional areas from one another. Such an arrangement will allow, if desired, for different quantities of different fill materials to be incorporated into different channels. Furthermore, the two or more channels may have different cross-sectional shapes or the same cross- sectional shapes but present in a staggered format. For example, the consumable product may have channels having a cross-sectional shapes including stars and triangles, or different shapes of animals etc.

In one embodiment, the channels in the body portion result in a voidage in the range of about 1 - 99% of the extrudate, or in the range of 5 - 99% of the extrudate. The voidage may be in the range of about 10 - 60%, 20 - 50%, 30 - 45%, or 35 - 40%. The voidage may also be in intermediate points in these ranges, for example, about 5 - 40%, 5 - 45%, 5 - 50%, 5 - 60%, 10 - 40%, 10 - 45%, 10 - 50%, 10 - 99%, 20 - 60%, 20 - 45%, 20 - 40%, 20 - 60%, 20 - 99%», 30 - 40 %, 30 - 50%, 30 - 60 % or 30 - 99%. The voidage may be up to about 99%, 95%, 90%, 80%, 60%, 50%, 45%, 35%, 30%, 20%, 10%, or 5%. The voidage may be over about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% or 95%. It should be understood that the term "voidage" generally refers to the volume percent of the channel volume relative to the sum of the channel volume and the extruded body portion volume. That is voidage (%) = 100 x channel volume / (channel volume + extruded body portion volume). In some embodiments, the extruded body portion volume does not include any central region volume created by certain dies, such as an annular die.

The incorporation of channels of a small cross-sectional width or diameter enables the channels in the body portion to be- filled with contrasting or complementary consumable materials whilst avoiding the need to incorporate large centre-fill areas which may be prone to leakage through,, or out of, the consumable product. The use of a plurality of channels also enables two or more materials to be incorporated into the consumable product to give multiple textures, tastes, colours and/or mouth-feel sensations, throughout the whole consumable product.

It should be understood that the term "plurality" is intended to mean two or more. In some embodiments, a plurality is 3 or more, or 4 or more, or 5 or more, or 6 or more, or 7 or more. There is no particular upper limit on the number associated with "plurality". In the context of the phrase "plurality of channels", numbers up to 50 and higher are contemplated.

The channels may be filled by entrainment processes, or alternatively may be filled by using pump to provide the contrasting or complementary consumable materials. ϊη some embodiments, the chamiels have a diameter or width of no more than about 2 mm, 1 mm, 0.5 mm, 0.25 mm, or even less. It is possible to have channels having a diameter or width of no more than about ΙΟΟμτη, 50μη or ΙΟμηι.

Alternatively, wide channels may have a diameter or width of more than 2mm, more than 5 mm, more than 1cm, more than 2cm or even more than 3 cm. The channels of each portion may be formed substantially parallel to one another. In one embodiment, the first and second portions are in a stacked configuration, such that the channels of the first and second portions are substantially parallel to each other. In an alternative embodiment, the first and second portions are in a folded configuration. In yet another alternative embodiment, the first and second portions are discontinuous and the channels are oriented in a random configuration in relation to one another. In some embodiments, the channels of the first and/or second portions have a diameter or width of no more than about 3 mm, 2 mm, 1 mm, 0.5 mm, 0.25 mm, or less. It is possible to have channels having a diameter or width as low as about 100 μηι 50 μηι or 10 μηι. The channels of the first and/or second portions may have different widths or diameters.

Alternatively, wide channels may have a diameter or width of more than 2mm, more than 5mm, more than 1cm, more than 2cm or even more than 3 cm. The skilled addressee will of course realise that these subsequent embodiments may incorporate features which have already been discussed with reference to the initial embodiment. As mentioned above, the invention provides a process for manufacturing a savoury consumable product comprising a body portion, having two or more channels disposed therein, the process comprising the step of:

a) extruding a consumable material with two or more channels disposed therein, wherein the at least one channel contains a substance that is different from the substance of the body portion.

In some embodiments, the process may include an extra step selected from:

b) cutting the extrudate into two or more pieces having a plurality of channels disposed therein and forming a consumable product incorporating the pieces; and/or

c) folding the extrudate and forming a consumable product incorporating the folded extrudate.

Any of the above processes may further comprise the step of depositing a filling in at least part of one or more of the channels. The deposition of the filling may be during the step of extrusion - but could also take place after extrusion. In an embodiment, the filling comprises a fluid. The fluid may comprises a liquid, or a material which is liquid at a temperature greater than room temperature. The fluid may solidify after deposition if desired. Any of the processes may further comprise the step of quench cooling the extrudate after extrusion. The quench cooling may utilise a fluid, such as air, an oil or liquid nitrogen - but other methods of quench cooling will also be apparent to the skilled addressee.

Any of the processes may further comprise the step of, immediately after extrusion, stretching or rotating the extrudate. Stretching or rotating the extrudate may be undertaken by a number of means, for example passing the extrudate over, or through conveyor belts or rollers operating at different speeds, so as to stretch the extrudate. By employing this additional step, extrusions having channels of a larger diameter can be undertaken, which can be reduced in diameter gradually over time so as to produce an extrudate with smaller channels which would have been more difficult to produce. Commonly, channels having a bore size of about 2 mm or more will be produced during extrusion and these channels will be reduced significantly by stretching the extrudate. In some embodiments the channels may be reduced to no more than about 1 mm, 0.5 mm or 0.25 mm.

Any of the processes may further comprise the step of enveloping the consumable product in a coating. Such a coating will be apparent to the skilled addressee and was discussed previously hereinabove.

The extrudable consumable material will at least partially or substantially solidify after extrusion. If desired, two or more channels may be formed having different maximum widths or diameters. Furthermore, two or more of the channels may be formed having different cross-sectional profiles. The processes may be used for producing a consumable product as herein above described.

As mentioned above, the invention also provides apparatus which is adapted for producing a consumable product according to the processes as herein above described. WO 2005/056272 discloses an apparatus for producing an extrudated product including a plurality of channels. WO 2008/044122 discloses a related apparatus, which additionally includes means for quench cooling an extrudate as it exits the die. Both of these apparatus may be employ ed/adapted for use in producing the consumable product in accordance with the present invention.

Detailed Description of the Invention and examples

Specific examples of the present invention will now be described, by way of illustration only, with reference to the accompanying drawings, in which: Figure 1 shows a cross-section of a sausage roll in accordance with the present invention;

Figure 2 shows a cross-section of a pasta product in accordance with the present invention; Figure 3 shows a cross- section of a blue cheese product in accordance with the present invention; Figure 4 shows a cross-section of a cereal product in accordance with the present invention;

Figure 5 shows a cross-section of a potato product in accordance with the present invention;

Figure 6 shows a cross-section of a burger product in accordance with the present invention; and

In detail, Figure 1 shows a cross section through a sausage roll product, wherein a channel containing sauce 1 runs through the sausage meat core 2, and the sausage meat core is encased within pastry 3. The sausage meat and pastry are extruded concurrently, and the sauce is also deposited into a channel during the extrusion process by use of a narrow nozzle located within a larger nozzle which dispenses the sausage meat. The pastry and the sausage meat are at least partially cooked during extrusion by virtue of the high temperature and pressure used during the process. If desired, or required, the sausage roll can be finished off in an oven if the extruder only partially cooks the product. Figure 2 shows a pasta snack comprising a central meat filling 2 surrounded by a pasta tube 4. The meat and pasta are extruded concurrently, and the pasta has a number of channels running tliroughout the channels and containing a tomato sauce 1 , wherein the sauce is deposited via a narrow die.

Figure 3 shows a cheese string comprised mainly of low fat cheese emulsion 6. Additional flavour and colouring is however provided by a number of channels containing blue cheese flavouring 5. Such products provide the taste benefits and look of blue cheese whilst largely maintaining the low fat characteristics of the low fat cheese. If desired, the low fat cheese 6 could be in the form of a paste which is inserted into a tube so that it can be dispensed onto sandwiches etc.

Figure 4 shows an extruded cereal bar 7, comprising an elongate channel of strawberry puree 8 and a parallel elongate channel of cream flavoured paste 8b which are introduced during extrusion by way of a rectangular die.

Figure 5 shows an extruded meat product which incorporates features of a face. The product is generally circular in shape and is formed of a reformed meat portion 20. Two circular eyes and nose 21 are formed of a tomato emulsion and mouth 22 formed of a gherkin emulsion.

Figure 6 shows an extruded potato chip material 9 having tomato ketchup 10 running through a central channel. The exterior of the chip 9 is covered by breadcrumbs. The product can be cooked by the consumer so as to provide a novel taste and texture sensation. As the tomato ketchup 10 is located in the centre of the product, it is less liable to heat damage during cooking. Additionally, products such as this exhibit increased convenience for the consumer since the potato chip need not be dipped in ketchup by the consumer.

Although the body portion and channels may be depicted as uniform in shape and pattern in some embodiments described herein, it should be understood that the body portion and/or the channels may be non-uniform in some embodiments. There may be variations in the overall dimensions of the product, such as, for instance, the dimensions of the body portion, the channels, the wall thicknesses between each channels and the outer wall thickness of the product. For example, in some embodiments, the mechanical process of extrusion and optional further manipulation of the extrudate, such as stretching, may create non-uniformities in the dimensions of the product. Such processes also may create random variations in the positioning of the channels. The channels accordingly may be irregularly positioned in some embodiments. In addition, the channels may be symmetrically disposed in the body portion or asymmetrically disposed in the body portion. In some embodiments, one group of channels may be symmetrically disposed and another group of channels may be asymmetrically di sposed in the body portion.

The invention is not restricted to the details of the foregoing embodiment and the skilled addressee will appreciate that a number of other embodiments could also be employed.

Claims

1. A savoury consumable product comprising an extruded body portion, the body portion being formed with two or more channels disposed therein, wherein the channels contain a substance which is different from the substance of the body portion material.

2. A savoury consumable product according to claim 1, wherein the channels are formed in different locations and/or concentrically within the body portion.

3. A savoury consumable product according to any preceding claim wherein one channel has a diameter of less than 5mm, and another channel has a diameter of greater than 1cm.

4. A savoury consumable product according to any preceding claim, wherein different channels contain different materials.

5. A savour consumable product according to any preceding claim, wherein the body material comprises a carbohydrate food material.

6. A savour consumable product according to any preceding claim, wherein the channels are at least partially filled with a protein and/or fat rich food material.

7. A savoury consumable product according to any one or claims 1-6, wherein the channels are at least partially filled with a liquid material.

8. A process for manufacturing a savoury consumable product comprising a body portion having two or more channels disposed therein, the process comprising the step of: a) extruding an extrudable consumable material with two or more channels disposed therein, wherein the two or more channels contain a substance which is different from the body portion material.

The process as claimed in claim 8, wherein the substance is deposited during the step of extrusion.

The process as claimed in either claim 8 or 9, wherein the channels are formed in different locations and/or concentrically within the body portion during extrusion.

The process as claimed in any one of claims 8-10, wherein the body portion and/or the material in the channels is at least partially cooked during extrusion.

The process as described in any one of claims 8-11, wherein the body portion is shaped or cut after extrusion.

An apparatus adapted for producing a savoury consumable product according to the process claimed in any of claims 8-12.

A savoury consumable product substantially as described herein and with reference to the accompanying drawings.

A process for producing a savoury consumable product substantially as described herein and with reference to the accompanying drawings.