Classifications

• • A—HUMAN NECESSITIES
  • A21—BAKING; EDIBLE DOUGHS
  • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
  • A21D13/00—Finished or partly finished bakery products
  • A21D13/30—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
  • 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
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
  • A23G3/34—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof
  • A23G3/50—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof characterised by shape, structure or physical form, e.g. products with supported structure
  • A23G3/54—Composite products, e.g. layered, coated, filled
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
• • A—HUMAN NECESSITIES
  • 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

Definitions

• the present Invention relates to the production of muitilayered food products and more particularly to a method for the production of a muitilayered food product where expansion of the muitilayered: food products is controlled, 0
• Muitilayered products are found In many different food industries such as cereals, puff pastry sugar wafer sticks, and snacks, Many prior art processes have been developed to address the complexities of layering each of these products.
• extrusion One technology which is found to be very suitable In the production of such muitilayered products is extrusion. Traditionally, extruded muitilayered products are produced by extruding separate layers in a side-by-side flow path and then subsequently the layers are combined when necessary to form the final product.0
• 2008/0199569 disclose a method and an apparatus for producing a rolled snack piece using an extruder having a plurality of spiral shaped orifices through which art extrudate exits the extruder.
• a desired length of extrudate stream or5 rope protrudes from an orifice, it is cut at. its base, thus producing individual snack pieces that appear to have been roiled after being sheeted.
• the snack pieces is then cooked, typically by frying, and are then seasoned and packaged by methods previously known in the art.
• the uncooked mix must go through several process steps (extrusion, cutting, cooking0 and seasoning) to form the final product.
• the multiple process steps and the post extrusion cooking makes it difficult to control the expansion of the rolled snack piece, and the method results in expansion of the. rolled snack piece, which changes the shape of the product and makes the shape of the product less reproducible.
• US 4,569,848 describes a snack-type confectionary product which comprises a hollow, substantially tubular body, mad of extruded cooked biscuit with particular .characteristics of lightness, crispness and digestibility, with the ends closed or open, The biscuit is stuffed with more or less fluid cream wit or without grains and fruit, possibly covered with chocolate and grains of various kinds.
• the process described for providing the snack-type confectionary product involves high temperature cooking extrusion of said biscuit, as well as subsequent operational phases for completing the product.
• the high pressure difference between th inside and the outside of the extruder di brings the expanded hollow body of the confectionary product.
• the snack-type confectionary produc Is highly expanded the shape of the product is changed compared to the shape of the extruder orifice which cause the shape of the product becomes less
• one aspect of the present invention relates to a method for providing a cooked multllayered food product, the method comprises the steps of:
• Another aspect of the present invention relates to a cooked multiiayered food product comprising substantia! individual layers of the cooked multiiayered food product,
• figure: 1 shows different shapes of the orifice (figure la-id)
• figure 2 shows examples of an extrusion die.
• Figure 3 shows examples of the final products.
• a product produced by the present Invention may be improved with respect to crispiness, texture, such as a improved flaky texture, and mouth feel.
• the present invention describes a single step operation that creates a cooked multiiayered food product with a wide variety of cross sectional geometries. Some examples are given in Figure I.
• Figure 1(a) represents a spiral shape with a closed centre section.
• Figure 1(b) represents a spiral shape with an open centre section.
• Figure 1(c) represents a layer-by-layer shape
• Figure 1(d) represents a shell shape
• a representation of such a final product can be seen in Figure 3(a)
• Figure 2(a) Is a representation of an extruder die with a multilayer shaped spiral type orifice providing a final product as illustrated in figure 3(b).
• Figure 2(b) is a representation of an extruder die with a multilayer shaped leaves type orifice providing a final product as illustrated in figure 3(a)
• Control and restrictio of expansion can be achieved by combinations of several features, such as making the orifice in th extruder die thinner, reduce the energy supplied to the food base product by low screw speed, use of higher levels of extrusion water and/or oil, and use of expansion restricting- ingredients in the food base product, such as fibres, lecithin, protein and sugar.
• the inventors of the present invention have surprisingly found that by controlling the expansion of the extrudate using the methods above combined with cooking extrusion, the food base product can be passed through complex extruder die shapes to form complex cooked multi-layered shapes of food products, in one processing step.
• Forming cooked multilayer food products of this format has until now been a more complex process involving roiling, folding or combining of several layers.
• the immediate cooking is crucial for fixing the geometry before it collapses and/or expand uncontrolled when exiting the extruder die,
• ⁇ controlled expansion relates to a process where the process parameters are set to obtain the desired expansion of the cooked multilayered food product.
• the expansion of the cooked multilayered food product Is controlled in a manner which results in a restricted expansion or substantially no expansion,
• the product can be filled, preferably centre filled-, with an appropriate filling.
• the center filled products can be achieved by co-extrusion of the cooked multilayered food product with the appropriate filling.
• the present invention relates to a method for providing a cooked muitilayered food product, the method comprises the steps of:
• the method according to the present Invention Is very effective, .quick, the products may be immediately ready to eat or immediately ready for distribution, and the method involves less- handling steps compared to traditionally used methods (or eve a minimum of handling),
• the multilayer shaped orifice of the extrusion die and the cooked muitilayered food product Is one continuous phase.
• th screw speed, feed rate and pressure before exiting the extruder die may be controlled and adjusted to control, avoid or reduce expansion of the cooked muitilayered food product.
• expansion of the muitilayered food product may be controlled by controlling or adjusting one or more of;
• th cooking extrusion process Is conducted at a speed providing a feed flow rat in the range of 5-100 m/min, such as 10-75 m/min, e.g. 12-60 m/min.
• the cooking extrusion process is conducted at a speed providing a feed flow rate in th range of 80-600 kg food base product/hour, such as 80-300 kg food base product/hour, e.g. 80-150 kg food base product/hour, such as 100-130 kg food base product/hour, e.g. 200- 550 kg food base product/hour, such as 300-500 kg food base product /hour.
• the feed flow rate may differ dependent on the type of food product to be produced.
• a confectionary product in particular a sweet confectionary product, may have a feed flow rate in the range of 100-140 kg food base product /hour, such as in the range of 110-130 kg food base product hour.
• the feed flow rate may preferably be 90-110 kg food base product /hour, such as about 100 kg food base product /hour,
• the food base product When providing food products by extrusion / the food base product may be subjected to larg pressures when the food base product is forced through the orifice of the extruder die.
• the pressure on the food base product before exiting the extruder die is in the range of 50-150 bar, such as In the range of 70-140 bar, e.g. 75-125 bar, such as 90- 100 bar, e.g. 75-90 bar.
• the cooking extrusion process Is conducted at a temperature above 75 e C, such as above iOO°Q e.g. above 125°C f such as above 150°C, Preferably the cooking extrusion process is conducted at a temperature in the range of 75-20O°C, such as in the range of 100-180°C, e.g. in the range of 125-175°C, such as In the range of 15G-175°C «
• the cooked multilayered food product has a controlled expansion relative to the multilayer shaped orifice of the extrusion die. This control may be obtained by adjusting and setting the parameters described above, In an embodiment of the present invention, expansion (and even extensive expansion) may be acceptable, however, only within restricted and controlled conditions whereb uniform shapes may be provided end reproduced.
• the cooked multilayered food product comprises substantial individual layers
• the cooked multilayered food product has a restricted expansion relative to the multilayer shaped orifice of the extrusion die.
• the present invention is less than 10% relative to the multilayer shaped orifice of the extrusion die, such as less than 5% relative to the multilayer shaped orifice of the extrusion die, e.g. less than i% relative to the multilayer shaped orifice of the extrusion die.
• the expansion relative to the multilayer shaped orifice of the extrusion die relates to the difference in shape, such as product shape, product volume and wail size, between the extruder orifice and the extruded food product.
• the food base product before reaching the extruder die has a base product temperature below 75°C, such as a temperature below 5Q°C, e.g. a temperature below 25*C, such as a temperature betow 15°C
• the food base product before reaching the extruder die has a base product temperature In the range of 5-75° €, such as in th range of 15- 60°C, e.g. in the range of 2Q 5G ?s € r such as in the range of 30 ⁇ 4Q°C, e.g. in the range of 50-75°C.
• the term w food base product relates to the dough mixture before any cooking Is performed in the extruder.
• the extruder and/or the extruder die may have a temperature of at feast 75°C, such as at least 100 C, e.g. at least 125°G f such as at least 150°C, Preferably the temperature of the extruder and/or the extruder die in the range of 75-200°C, such as in the range of 100 ⁇ I80 e C ; e.g. in the range of 125 ⁇ i75°G f such as in the range of 15Q ⁇ 175°C,
• the product temperature before die exit or orifice exit may have a temperature of at least 75°C, such as at least 100°C, e.g. at least 125°C, such as at least 150°C.
• the product temperature before exit is in the range of 75-2G0 o C, such as in the range of 100- 180°C, e.g. in the range of 12S-175°C, such as in the range of 15Q-175°C.
• the method may be a continuous process
• the cooked mul til aye red food product emerging from the multilayer shaped orifice of the extrusion di are cut into uniform pieces, preferabiy the cutting Is performed continuously.
• the water present in the food base product may upon heating/cooking evaporate and thus, cause expansion of the food base product and/or the cooked
• the cooked ' multiiayered food product has a water content in the range of 2-15%
• the cooked multilayered food product may be a confectionary product, such as a sweet confectionary product, or a savoury product.
• the cooked multilayered food product preferably a sweet confectionary cooked multilayered food product, having a water content of about 5% and is produced by applying a feed rate of 105-115 kg/hr (preferably about 110 kg/hr), a screw speed of 250-270 rpm (preferably about 260 rpm), a temperature of the food base product of i7G-175°C (preferably about 172°C) and/or a pressure of the food base product of 77-82 bar (preferably about 79 bar).
• the cooked multilayered food product preferably a sweet confectionary cooked multilayered food product, having a water content of about 5% and Is produced by applying a feed rate of 105-115 kg/hr (preferably about 110 kg/hr), a screw speed of 250-270 rpm
• the cooked multilayered food product preferabl a sweet confectionary cooked multilayered food product, having a water content of about 7.5% and is produced by applying a feed rate of 120-140 kg/hr (preferably about 130 kg/hr),. a screw speed of 390-410 rpm (preferably about 400 rpm), a temperature of the food base product of 185-190° € (preferably about 187°C) and/or a pressure of the food base product of 67-71 bar (preferably about 69 bar).
• the cooked multilayered food product preferably a savoury cooked multilayered food product, having a water content of about 12.5% and is produced by applying a feed rate of 90-110 kg/hr (preferably about 100 kg/hr), a screw speed of 310-330 rpm (preferably about 320 rpm), a temperature of the food base product of 110-120°C (preferably about li5°G) and/or a pressure of the food base product of 135-145 bar (preferably about 139 bar).
• the cooked multilayered food product preferably a savoury cooked multilayered food product, having a water content of about il.5% and is produced by applying a feed rate of 90-110 kg/ r (preferably about 100 kg/hr), a screw speed of 340-360 rpm (preferably -about 350 rpm), a temperature of the food base product of-120-13-0°C (preferably about 124°C) and/or a pressure of the food base product of 87-91 bar (preferably about 89 bar),
• the method does not involve separate actions for forming the cooked multilayered food product.
• Such actions may be olding; roiling, assembling etc
• the cooked multilayered food product ma be subjected to cooling to maintain and quickly fix the shape of the cooked multilayered food product.
• cooking relates the process of preparing a food product by applying heat to the base food product to obtain the cooked
• drying relates to removal of excessive water from the cooked multilayered food product.
• One aspect of the present invention relates to a cooked multilayered food product comprising substantial individual layers of the cooked multilayered food product.
• Figure 3(a) represents an example of a leaves type product with a centre filling.
• Figure 3(b) represents an example of a spiral type product without a centre filling.
• Figure 3(c) represents an example of a spiral type product with a centre filling.
• Figure 3(d) shows a cut through a 3-dimensional tomography image of a circular type product,, where the centre of the circular type product could be filled. The image shows well the porosity and the layered structure of the cooked product.
• Individual layers' 1' relates to continuous layers of the same piece without any contact between, the individual layers.
• the cooked multilayer food product comprises substantial individual layers,
• substantially individual layers relates to two or more continuous layers of the same piece being partly attached in a limited manner.
• This "partly attached in a limited manner” relates to a part of the surface area of one individual layer may be attached to the surface area of another individual layer of the same piece.
• less than 50% of the surface area of one individual layer ma be attached to at least one of the other individual layers of the same piece, such as less than 40%, such as less than 30%, such as less than 20%, preferably less than 15%, such as less than 10%, preferably less than 9%, such as less than 5% of the surface area of one individual layer may be attached to at least one of the other Individual layers of the same piece.
• the term "attached to” relates to two individual layers from; the same piece which are connected and joined together, In an embodiment of the present invention the term “attached to” does not Imply that the individual layers cannot be lying above each other touching, In the context of the present invention, the term “piece” relates to the cooked multilayer food product comprising at least 2 individual or at least 2 substantial individual layers.
• the cooked multilayer food product may be filled with an appropriate filling.
• the product may be centre filled with an appropriate filling.
• at least 3% of the cross sectional area of the middle zone, taken perpendicular to the longitudinal axis of the cooked multilayered food product and limited by the outer iayer(s) may be filled with the appropriate filling, such as at least 10%, preferably 25%, such as at least 50%, preferably 60% , , such as at least 70%, preferably 80%, such as at least 90%, of the cross sectional area of the middle zone may be filled with the appropriate filling,
• the cooked multilayered food product may comprise alternating layers of cooked multilayered food product and air.
• the cooked multilayered food product may have a center filling surrounded by alternating layers of cooked multilayered food product and air. It has been found that the cooked multilayered food product produced by
• conventional cooking extrusion methods (such as a product as described in. US 5 2008/0199569) are not always suitable for being filled with a filling, because of the expansion that occurs with conventional produced cooked multilayered food products does not provide a continuous internal cavity for holding the filling., however, a network of walls and cavities are formed which are difficult to fill .
• the extruded cooked 10 multilayered food product has a controlled expansion which leaves a continuous internal cavity suitable for holding the filling.
• the cooked multilayered food product may be one single continuous piece
• the cooked multilayered food product has:
• multilayered food product is in the range of 55-70%, such as in the range of 60- 25 70% . , e.g. in the range of 55-60%,
• cooked multilayered Food products like sugar wafers have a porosity according to the present invention which is in the range of 60-70%.
• 3 ⁇ 4 porosity relates to is a measure 30 of the void spaces in a material, and is presented as a fraction of the volume of voids over the total volume as a percentage between 0-100%.
• the mean wall thickness of the cooked multilayered food product Is i the range of 60-110 pm, such as in the 35 range of 65-100 urn,, e.g. In the range of 95-105 pro, such as in the range of 65- 85 pm.
• cooked multilayered food products like sugar wafers have a mean wall thickness according to the present Invention which is in the range of 65-85 pm
• the cooked multiiayered food product has a porosity in the range of 55-70%, such as in the range of 60-70%, e.g. n the range of 55-60% and a mean wail thickness in the range of 60-110 ⁇ , such as in the range of 65-100 pm, e.g. in the range of 95-105 pm, such as in the range of 65-85 pm.
• the food base product may hav a water content in the range of 5-25% (w/w), such as in. the range of 7-20% (w/w), e.g. in the range of 10-15% (w/w). It should be noted that embodiments and features described in the context of one of the aspects or one of the embodiments of the present Invention also apply to the other aspects or other embodiments of the present invention,
• a filled confectionery cooked multilayered food product is produced in the shape of tub with 3 wings (a starfish type shape), like cereal layers surrounding the cereal tu e.
• the extrusion die shape is demonstrated in Figures 2b, Method
• the resulting filled confectionery cooked muitiiayered food product had the shape as depitched in Figure 3(a) and the following composition: ⁇

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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)
• General Preparation And Processing Of Foods (AREA)
• Formation And Processing Of Food Products (AREA)
• Confectionery (AREA)

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• 2010
  • 2010-06-29 EP EP10167692A patent/EP2401926A1/en not_active Withdrawn
• 2011
  • 2011-06-28 MX MX2012015077A patent/MX2012015077A/es unknown
  • 2011-06-28 BR BR112012033676A patent/BR112012033676A2/pt not_active Application Discontinuation
  • 2011-06-28 MY MYPI2012701138A patent/MY160993A/en unknown
  • 2011-06-28 EP EP11727982.8A patent/EP2587947A1/en not_active Withdrawn
  • 2011-06-28 RU RU2013103691/13A patent/RU2013103691A/ru not_active Application Discontinuation
  • 2011-06-28 AU AU2011273577A patent/AU2011273577B2/en not_active Ceased
  • 2011-06-28 US US13/806,286 patent/US20130202744A1/en not_active Abandoned
  • 2011-06-28 WO PCT/EP2011/060758 patent/WO2012000953A1/en active Application Filing
  • 2011-06-28 CN CN201180032602.XA patent/CN102958392B/zh not_active Expired - Fee Related
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