WO2015171906A1 - Composition nutritionnelle à base de poudre extrudée et procédés de production associés - Google Patents
Composition nutritionnelle à base de poudre extrudée et procédés de production associés Download PDFInfo
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- WO2015171906A1 WO2015171906A1 PCT/US2015/029706 US2015029706W WO2015171906A1 WO 2015171906 A1 WO2015171906 A1 WO 2015171906A1 US 2015029706 W US2015029706 W US 2015029706W WO 2015171906 A1 WO2015171906 A1 WO 2015171906A1
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- WIPO (PCT)
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- protein
- nutritional composition
- extruder
- oil
- heat labile
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Classifications
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
- A23L33/17—Amino acids, peptides or proteins
- A23L33/19—Dairy proteins
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
- A23L33/115—Fatty acids or derivatives thereof; Fats or oils
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
- A23L33/15—Vitamins
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
- A23L33/16—Inorganic salts, minerals or trace elements
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
- A23L33/17—Amino acids, peptides or proteins
-
- 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
- A23P10/00—Shaping or working of foodstuffs characterised by the products
- A23P10/20—Agglomerating; Granulating; Tabletting
- A23P10/22—Agglomeration or granulation with pulverisation of solid particles, e.g. in a free-falling curtain
-
- 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
- A23P10/00—Shaping or working of foodstuffs characterised by the products
- A23P10/40—Shaping or working of foodstuffs characterised by the products free-flowing powder or instant powder, i.e. powder which is reconstituted rapidly when liquid is added
-
- 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
Definitions
- the present disclosure relates to extruded powder nutritional compositions and methods of producing extruded powder nutritional compositions. More particularly, the present disclosure relates to methods of producing an extruded powder nutritional composition that includes a heat labile protein and a significant portion of the heat labile protein retains its native, undenatured form.
- a number of heat sensitive ingredients are desirable for incorporating into nutritional compositions.
- exposure to high temperatures such as those encountered during a sterilization process or spray drying, can irreversibly denature the heat sensitive ingredient.
- the heat sensitive ingredient can lose a substantial amount of its biological activity or overall effectiveness.
- techniques such as dry blending have been used to incorporate heat sensitive ingredients.
- the extended mixing required to achieve a homogenous powder with dry blending generates a substantial amount of fines, which makes the powder difficult to reconstitute into a liquid.
- Extruded powder nutritional compositions and methods of producing extruded powder nutritional compositions are provided.
- the exemplary extruded powder nutritional compositions described herein include a carbohydrate, a fat, and a protein. A portion of the total protein is a heat labile protein and a significant portion of the heat labile protein retains its native, undenatured form.
- several exemplary embodiments of extruded powder nutritional compositions and methods of producing the compositions are provided herein.
- a method of producing an extruded powder nutritional composition includes introducing a first dry blend comprising a first protein into an initial port of an extruder.
- An aqueous solvent is introduced into the extruder to hydrate the first dry blend, and an oil blend comprising fat is introduced into the extruder.
- the hydrated first dry blend and the oil blend are mixed to form an emulsified mixture within the extruder.
- a second dry blend comprising a carbohydrate and a heat labile protein are introduced into an end port of the extruder.
- the emulsified mixture and the second dry blend are extruded to form a nutritional composition extrudate.
- a powder nutritional composition is formed from a dried form of the nutritional composition extrudate.
- an extruded powder nutritional composition comprises from 20 wt% to 70 wt% carbohydrate, from 10 wt% to 40 wt% fat, and from 5 wt% to 40 wt% total protein.
- a heat labile protein comprises from 0.25 wt% to 60 wt% of the total protein, and from 40% to 90% of the heat labile protein is in its native, undenatured form in the extruded powder nutritional composition.
- FIG. 1 is a schematic diagram of a method of producing an extruded powder nutritional composition according to an embodiment of the present disclosure.
- extruded powder nutritional composition refers to a nutritional composition in a solid flowable or scoopable form that can be reconstituted with water or another liquid prior to consumption, and is formed, manufactured, or produced utilizing an extruder as described herein.
- extruded powder nutritional composition includes powdered infant nutritional formulas, pediatric and follow-on nutritional powders, adult nutritional powders, and nutritional powders generally that are formed, manufactured, or produced utilizing an extruder as described herein.
- the presently disclosed extruded powder nutritional compositions and methods of producing the same include a heat labile protein, and in certain embodiments include an additional heat labile component.
- Conventional processes for producing nutritional compositions may utilize heat labile components, but the high processing temperatures of such conventional processes (e.g., retort sterilization, spray drying) result in the heat labile component losing a substantial amount of its biological activity or nutritional effectiveness often requiring overfortification to result in a sufficient quantity of the heat labile component in the end product.
- the presently disclosed methods permit heat sensitive components to be included in a powder nutritional composition while ensuring that a significant portion of their biological activity and nutritional effectiveness is retained.
- the presently disclosed methods promote homogenous distribution of the heat sensitive components in the powder nutritional composition while also providing effective reconstitution characteristics when the powder nutritional composition is reconstituted with an aqueous liquid.
- a method of producing an extruded powder nutritional composition includes introducing a first dry blend comprising a first protein into an initial port of an extruder.
- An aqueous solvent is introduced into the extruder to hydrate the first dry blend, and an oil blend comprising fat is introduced into the extruder.
- the hydrated first dry blend and the oil blend are mixed to form an emulsified mixture within the extruder.
- a second dry blend comprising a carbohydrate and a heat labile protein are introduced into an end port of the extruder.
- the emulsified mixture and the second dry blend are extruded to form a nutritional composition extrudate.
- a powder nutritional composition is formed from a dried form of the nutritional composition extrudate.
- an extruded powder nutritional composition comprises from 20 wt% to 70 wt% carbohydrate, from 10 wt% to 40 wt% fat, and from 5 wt% to 40 wt% total protein.
- a heat labile protein comprises from 0.25 wt% to 60 wt% of the total protein, and from 40% to 90% of the heat labile protein is in its native, undenatured form in the extruded powder nutritional composition. It should be understood that the extruded powder nutritional composition according to the second embodiment may be, but is not necessarily, prepared by the methods of the first embodiment, as disclosed herein.
- the methods of the present disclosure utilize an extruder apparatus to produce the extruded powder nutritional compositions.
- the extruder apparatus may be used to produce the extruded powder nutritional composition in batch format, or in a continuous process. Any suitable extruder known for use in the nutritional art may be used with the methods of the present disclosure.
- the extruder may be a single screw extruder, multi screw extruder, ring screw extruder, planetary gear extruder, and the like.
- the extruder is a co-rotating, twin screw extruder that may be used to continuously produce the extruded powder nutritional compositions.
- twin screw extruders comprise a barrel having one or more ports for adding ingredients, two screws, and a die.
- the extruder screws are positioned inside of the barrel and may comprise a wide variety of functional elements including, but not limited to, shear elements, mixing elements, conveying elements, kneading elements, emulsifying elements, disc elements, or any combination of the foregoing in any interchangeable order.
- the barrel of the extruder may comprise a number of segments that are bolted, clamped, or otherwise joined together.
- the barrel or barrel segments may be jacketed to permit indirect, controlled heating or cooling of the material being processed within the extruder.
- the barrel or barrel segments include one or more ports for adding ingredients into the extruder.
- the die comprises one or more openings which shape the product (i.e., the extrudate) as it flows out of the extruder.
- producing an extruded powder nutritional composition includes introducing a first dry blend comprising a first protein into an initial port of an extruder.
- the term "initial port of the extruder” as used herein refers to a port that is located within the first 25% of the length of the extruder.
- the first dry blend may be introduced into the initial port of the extruder by a variety of techniques including, but not limited to, gravity feeding from a hopper, pumping from a storage tank, and the like.
- the first dry blend may comprise, in addition to the first protein, a carbohydrate, water soluble vitamins, water soluble minerals, or a combination thereof. It should be understood that the first dry blend is a flowable powder that may contain some amount of residual moisture (e.g., less than 5 wt% water).
- an aqueous solvent is introduced into the extruder to hydrate the first dry blend.
- the aqueous solvent is water.
- the aqueous solvent is added in an amount sufficient to result in 5 wt% to 30 wt % weight aqueous solvent in the nutritional composition extrudate, including in an amount sufficient to result in 15 wt% to 25 wt% aqueous solvent in the nutritional composition extrudate.
- the aqueous solvent includes water in combination with one or more water soluble components (e.g., water soluble vitamins and water soluble minerals).
- the aqueous solvent is introduced into the extruder at an initial port of the extruder.
- the aqueous solvent may be introduced into the extruder by a variety of methods such as by pumping the aqueous solvent from a storage tank into the extruder.
- the aqueous solvent is introduced into the extruder at a point upstream of where the first dry blend is introduced into the extruder. Introducing the aqueous solvent upstream of the point where the first dry blend is introduced helps ensure proper hydration of the first dry blend, which permits the components of the first dry blend to adequately mix so that they do not stick as readily to the inside of the extruder.
- the aqueous solvent is introduced into the extruder at the same point (i.e., the same barrel of the extruder) where the first dry blend is introduced into the extruder. In yet other embodiments, the aqueous solvent is introduced into the extruder at a point downstream of where the first dry blend is introduced into the extruder. Water soluble vitamins and minerals may optionally be introduced into the extruder upstream, downstream, or at the point where the aqueous solvent is introduced.
- the method of the first embodiment also includes introducing an oil blend comprising a fat into the extruder.
- the oil blend may be introduced into the extruder by a variety of methods such as by pumping the oil blend from a storage tank into the extruder.
- the oil blend is introduced into the extruder as a liquid having a temperature of about 23°C to about 80°C and a pumpable viscosity.
- the oil blend in addition to containing one or more oils (also referred to as "fats" herein), may comprise oil soluble vitamins or other oil soluble ingredients such as carotenoids.
- the oil blend is introduced into the extruder downstream of where the first dry blend and the aqueous solvent are introduced into the extruder.
- the oil blend is introduced into the extruder at a point at which the hydrated first blend has already been formed.
- a portion of the oil blend e.g., from 1% to 5%
- the oil blend is introduced into the extruder at the same point (i.e., the same barrel of the extruder) where the aqueous solvent is introduced into the extruder, and the remainder of the oil blend is introduced into the extruder downstream of where the first dry blend and the aqueous solvent are introduced into the extruder.
- the hydrated first dry blend and the oil blend are mixed together within the extruder to form an emulsified mixture.
- an additional liquid feed may be introduced into the extruder upstream or downstream (i.e., before or after) of where the oil blend is introduced into the extruder.
- a carbohydrate solution or carbohydrate-containing slurry is introduced into the extruder downstream of where the oil blend is introduced.
- the carbohydrate solution or slurry comprises galactooligosaccharide.
- a second dry blend comprising a carbohydrate and a heat labile protein are introduced into an end port of the extruder.
- the second dry blend comprises from 85 wt% to 95 wt% carbohydrate and from 5 wt% to 15 wt% heat labile protein. It should be understood that one or more than one carbohydrate and one or more than one heat labile protein may be introduced.
- end port of the extruder refers to a port that is located within the last 25% of the length of the extruder.
- the second dry blend may be introduced into the end port of the extruder by a variety of techniques including, but not limited to, gravity feeding from a hopper, pumping from a storage tank, and the like. It should be understood that the second dry blend is a flowable powder that may contain some amount of residual moisture (e.g., less than 5 wt% water). In certain embodiments of the first embodiment, the second dry blend is added to the extruder in an amount sufficient to result in 30 wt% to 60 wt% of the second dry blend in the nutritional composition extrudate, including in an amount sufficient to result in 40 wt% to 60 wt% of the second dry blend in the nutritional composition extrudate. The emulsified mixture and the second dry blend are mixed within the extruder and then extruded (i.e., mixed together and conveyed out of the extruder) to form a nutritional composition extrudate.
- extrudate i.e., mixed together and conveyed out of the extruder
- the nutritional composition extrudate comprises from 15 wt% to 25 wt% first dry blend, from 5 wt% to 30 wt% aqueous solvent, 15 wt% to 30 wt% oil blend, and 30 wt% to 60 wt% second dry blend.
- the nutritional composition extrudate will have a thick, paste-like consistency.
- the nutritional composition extrudate has a water activity ranging from 0.5 to 0.9, including from 0.65 to 0.85.
- the nutritional composition extrudate may be cut into a desired size upon exiting the extruder. After formation of the nutritional composition extrudate in accordance with the first embodiment, a powder nutritional composition is formed from a dried form of the nutritional composition extrudate.
- the configuration of the extruder and the operating conditions thereof are such that the extruded powder nutritional composition includes the heat labile protein and a significant portion (e.g., from 40% to 90%) of the heat labile protein retains its native, undenatured form.
- controlling the temperature of the material at various areas within the extruder when carrying out the method, as well as controlling the residence time of the heat labile components within the extruder has been found to result in significantly less denaturation or degradation of the heat labile components.
- the extruder is configured such that an end port of the extruder is spaced from an initial port of the extruder by a distance of 1.5 to 2.5 meters.
- one or more than one port may be located in the end portion of the extruder such that the extruder has one or more than one end port.
- one or more than one port may be located in the initial portion of the extruder such that the extruder has one or more than one initial port.
- the temperature of the material within the extruder may be controlled throughout the extruder.
- the temperature at various areas of the extruder may be controlled depending on the materials being added and the function of the extruder (e.g., mixing, emulsifying, extruding) at any given area within the extruder.
- the mixing and extruding processes are carried out at a temperature from 60°C to 95°C, from 60°C to 90°C, from 65°C to 85°C, from 65°C to 80°C, from 65°C to 75°C, or at a temperature of about 70°C.
- the pressure within the extruder may be adjusted accordingly from above atmospheric pressure (e.g., during mixing and emulsification) up to between 200 kPa and 10 MPa (e.g., during dispersive mixing, plasticizing, and extruding).
- the materials introduced into the extruder may be mixed and emulsified within the extruder for a time period ranging up to 300 seconds, including from 55 seconds to 180 seconds, including from 75 seconds to 120 seconds, and including from 90 seconds to 1 10 seconds.
- the heat labile protein as well as any additional heat labile components are introduced into the extruder at an end port of the extruder.
- the heat labile components are further protected from denaturing or degradation by being introduced into an extruder at an end port.
- Introduction of the heat labile components at an end port of the extruder reduces the residence time of the heat labile components and subjects the heat labile components to less shear force, while ensuring that the heat labile components are homogenously dispersed in the emulsified mixture.
- the heat labile protein (and any additional heat labile components introduced into an end port) has a residence time in the extruder of 10 seconds to 60 seconds, including 15 seconds to 55 seconds, including 20 seconds to 50 seconds, and including 25 seconds to 45 seconds.
- the extruder is a twin screw extruder having 14 barrels, each of which may have one or more than one port for introducing ingredients into the extruder.
- a first dry blend comprising a first protein (e.g., nonfat dry milk (at ⁇ 4.8 kg/hr)) is introduced into the first barrel along with the aqueous solvent (e.g., water (at ⁇ 3.9 kg/hr)) to form a hydrated first blend within the extruder.
- a first protein e.g., nonfat dry milk (at ⁇ 4.8 kg/hr
- aqueous solvent e.g., water (at ⁇ 3.9 kg/hr
- An oil blend (at ⁇ 6.4 kg/hr) is introduced at the fifth barrel and is mixed with the hydrated first dry blend to form an emulsified mixture within the extruder.
- An additional liquid feed e.g., a galactooligosaccharide (GOS) solution or syrup (at - 1.6 kg/hr)
- GOS galactooligosaccharide
- syrup at - 1.6 kg/hr
- a second dry blend comprising a carbohydrate (e.g., lactose (at ⁇ 9.5 kg/hr)) and a heat labile protein (e.g., whey protein concentrate (at - 1.2 kg/hr)) is introduced into the extruder at the eleventh barrel.
- a carbohydrate e.g., lactose (at ⁇ 9.5 kg/hr)
- a heat labile protein e.g., whey protein concentrate (at - 1.2 kg/hr)
- the second dry blend and the emulsified mixture are mixed and extruded to form a nutritional composition extrudate.
- the temperatures of the various barrels may be controlled such that the various mixing, emulsifying, and extruding processes within the extruder are carried out at a temperature of 60°C to 95°C.
- the feed rates for the various components introduced into the extruder, as well as the flow rate for the nutritional composition extrudate and sizes of the entry points to the various barrels will depend on the size of the extruder.
- the powder nutritional composition is prepared from a dried form of the nutritional composition extrudate.
- the nutritional composition extrudate comprises from 70 wt% to 95 wt% total solids, including from 75 wt% to 95 wt%, from 80 wt% to 95 wt%, from 85 wt% to 95 wt%, and from 90 wt% to 95 wt% total solids, with the remainder being all, or essentially all, water.
- the nutritional composition extrudate comprises 5 wt% to 30 wt% water, including 10 wt% to 25 wt%, and also including 15 wt% to 25 wt% water.
- a wide variety of conventional drying methods are suitable for drying the nutritional composition extrudate to a desired water content for the extruded powder nutritional composition.
- the extrudate may be dried using a vacuum belt dryer, an air dryer, a continuous microwave dryer, or a vacuum drum dryer.
- Other drying processes including, but not limited to, infrared drying, radiant drying, and conduction drying may also be used to prepare a suitably dried form of the nutritional composition extrudate.
- the nutritional composition extrudate is dried at a temperature of from 25°C to 170°C, including from 50°C to 125°C, and including from 70°C to 100°C. In certain embodiments of the first embodiment, drying of the nutritional composition extrudate is carried out under vacuum, such as 20 millibar (mbar) to 50 mbar, or 30 mbar. A combination of heat and vacuum may also be utilized.
- a vacuum belt dryer is used to dry the nutritional composition extrudate.
- the drying time will typically depend on the amount of aqueous solvent that was introduced into the extruder and remains in the nutritional composition extrudate. For example, about 1.0 kg/hr to about 1.6 kg/hr of water may require about 5 to about 45 minutes of drying time, such as about 25 minutes.
- the vacuum pressure may be about 20 mbar to about 50 mbar, such as about 30 mbar.
- the vacuum drying temperature may be about 100°C to about 170°C.
- the nutritional composition extrudate may be dried using a continuous microwave dryer.
- the nutritional composition extrudate may be transported through the microwave dryer via a conveyor passing through the microwave dryer.
- the nutritional composition extrudate may be deposited across the conveyor at a uniform density and a uniform thickness for optimum product characteristics.
- the desired depth of the nutritional composition extrudate may vary depending on the penetration depth of the microwave emitter.
- the microwave dryer may optionally use air flow in the interior of the microwave dryer to further aid in drying the nutritional composition extrudate.
- the air flow may be heated, dried, or both, prior to entering the microwave dryer, or the air may be ambient air as it exists near the process site.
- the nutritional composition extrudate may be dried in the microwave dryer for a period of about 5 to about 20 minutes.
- the microwave dryer may operate at a vacuum pressure of about 20 mbar to about 30 mbar and a power of about 0.3 kW to about 1.0 kW.
- the nutritional composition extrudate may be dried using a vacuum drum dryer.
- the drum dryer may include a pair of drums positioned substantially parallel with each other. Although the present example includes two drums, any other suitable number of drums may be used.
- the drums may be spaced apart to form a gap having a distance of about 0.1 mm to about 2 mm between the drums.
- the drums may rotate in opposing directions.
- the drums may be made of carbon or stainless steel and coated in a hard chrome-plated metal.
- the drums may be positioned within a housing.
- the nutritional composition extrudate may be distributed between the drums such that the extrudate adheres to the drums as the extrudate passes through the gap between the drums.
- the nutritional composition extrudate may be applied such that the extrudate is distributed substantially evenly onto the drums.
- the nutritional composition extrudate is gravity fed to the drums.
- a belt system or other suitable system may be used to feed the nutritional composition extrudate through the drums.
- the drums may be heated, such as with steam or thermal oil, to dry the nutritional composition extrudate applied to the drums. As the nutritional composition extrudate is applied to and rotates on the heated drums, the water in the nutritional composition extrudate evaporates.
- a scraper may be positioned adjacent to each drum such that the scrapers remove the dried nutritional composition extrudate adhered to the drum as the drum rotates against the scraper.
- the scrapers may be positioned about 270° around the circumference of the drum from the entry point of the extrudate such that the extrudate is applied to the drums for about a 3 ⁇ 4 turn. For instance, the drums may rotate between about 0.5 rpm to about 3 rpm, such as about 2 rpm.
- the nutritional composition extrudate may be dried in the drum dryer for a period of about 15 to about 90 seconds at a temperature of about 90°C to about 140°C.
- the rotary drum dryer may have a vacuum pressure of about 50 mbar.
- the dried form of the nutritional composition extrudate comprises no more than about 5 wt% water.
- the nutritional composition extrudate may be dried to a water content of from about 0.5 wt% to about 5 wt%, including from about 0.75 wt% to about 5 wt%, including from about 1 wt% to about 4 wt%, including about 2 wt% to about 3 wt%, and also including about 2.5 wt% to about 3 wt%. It should be understood that prior to drying, the nutritional composition extrudate will have relatively more water, generally 5 wt% to 30 wt%, including 15 wt% to 25 wt%.
- an extruded powder nutritional composition is formed from the dried form of the nutritional composition extrudate.
- the extruded powder nutritional composition is formed by milling, or otherwise grinding, the dried nutritional composition extrudate.
- high impact milling is used to grind the dried nutritional composition extrudate to form the extruded powder nutritional composition.
- other conventional grinding processes may be utilized in accordance with the method of the first embodiment to form the extruded powder nutritional composition from the dried form of the nutritional composition extrudate.
- the extruded powder nutritional composition may be formed with a desired particle size.
- the powder nutritional composition may have a particle size range of 50 microns to 750 microns, including 100 microns to 500 microns, and also including 100 microns to 250 microns.
- the extruded powder nutritional composition may be produced to have a particle size distribution such that at least 1 wt% of the composition comprises particles that are 500 microns and larger, at least 1 wt% of the composition comprises particles that are 100 microns and smaller, and at least 90 wt% of the composition comprises particles that are between 100 microns and 500 microns.
- the extruded powder nutritional composition may be an extruded infant nutritional powder, an extruded pediatric nutritional powder, an extruded follow on formula nutritional powder, or an extruded adult nutritional powder.
- an extruded powder nutritional composition is provided. It should be understood that the method according to the first embodiment may be utilized to produce the extruded powder nutritional composition of the second embodiment. However, the extruded powder nutritional composition may also be produced by methods that vary in one or more ways from the methods of the first embodiment. In addition, it should be understood that the various components and ingredients described with respect to the extruded powder nutritional composition of the second embodiment apply equally to the various components and ingredients that may be utilized in connection with the method according to the first embodiment.
- the extruded powder nutritional composition according to the second embodiment comprises from 20 wt% to 70 wt% carbohydrate, from 10 wt% to 40 wt% fat, and from 5 wt% to 40 wt% total protein, on a dry weight basis.
- a heat labile protein comprises from 0.25 wt% to 60 wt% of the total protein.
- from 40% to 90% of the heat labile protein is in its native, undenatured form in the extruded powder nutritional composition.
- the weight percentages of the various macronutrients (i.e., protein, carbohydrates, and fats) contained in the extruded powder nutritional composition are presented herein on a dry weight basis.
- the various embodiments of the extruded powder nutritional composition disclosed herein will generally contain some amount of residual moisture (e.g., no more than about 5 wt% water in the dried form of the nutritional composition extrudate).
- a first dry blend comprising a first protein is utilized to produce the extruded powder nutritional composition.
- the first dry blend can include at least one of a carbohydrate, one or more vitamins, and one or more minerals, in addition to the first protein.
- the first protein is selected from the group consisting of nonfat dry milk, milk protein isolate, milk protein concentrate, calcium caseinate, sodium caseinate, soy protein isolate, soy protein concentrate, pea protein, corn protein, potato protein, and combinations thereof.
- the extruded powder nutritional composition according to certain embodiments of the second embodiment can include at least one protein selected from the group consisting of nonfat dry milk, milk protein isolate, milk protein concentrate, calcium caseinate, sodium caseinate, soy protein isolate, soy protein concentrate, pea protein, corn protein, potato protein, and combinations thereof as a portion of the total protein present in the powder nutritional composition.
- the extruded powder nutritional composition according to the second embodiment, and certain embodiments of the first embodiment comprises 5 wt% to 40 wt% of total protein.
- the extruded powder nutritional composition comprises 5 wt% to 35 wt% of total protein, including 5 wt% to 30 wt%, 5 wt% to 25 wt%, and also including 10 wt% to 20 wt% of total protein.
- the total protein comprises soluble protein in an amount such that the extruded powder nutritional composition when reconstituted with water at 13% (w/w) contains no more than 20% of the soluble protein as aggregated protein.
- soluble protein in an amount such that the extruded powder nutritional composition when reconstituted with water at 13% (w/w) contains no more than 20% of the soluble protein as aggregated protein.
- Such characteristics help ensure that the powder nutritional composition adequately disperses and dissolves upon reconstitution.
- One of ordinary skill in the art can readily determine the amount of soluble protein and aggregated protein in a powder.
- the soluble protein concentration of the powder may be determined by: (a) creating an aqueous suspension (e.g., a 13% (w/w) preparation of the powder in Milli-Q Plus water stirred at 300 rpm for one hour at room temperature); (b) centrifuging the aqueous suspension (e.g., 14,000 x g for 5 minutes at room temperature); (c) diluting the supernatant obtained from centrifuging the aqueous suspension (e.g., ⁇ 2 grams of supernatant to 10 mL of HPLC mobile phase solution); and (d) performing size exclusion HPLC to determine the soluble protein.
- an aqueous suspension e.g., a 13% (w/w) preparation of the powder in Milli-Q Plus water stirred at 300 rpm for one hour at room temperature
- centrifuging the aqueous suspension e.g., 14,000 x g for 5 minutes at room temperature
- the extruded powder nutritional composition comprises a heat labile protein. It should be understood that one or more than one heat labile protein can be used. According to the second embodiment and certain embodiments of the first embodiment, from 0.25 wt% to 60 wt% of the total protein in the extruded powder nutritional composition is a heat labile protein.
- the total protein of the extruded powder nutritional composition comprises 1 wt% to 55 wt% heat labile protein, including 5 wt% to 50 wt%, 10 wt% to 40 wt%, and also including 20 wt% to 30 wt% heat labile protein.
- the total protein of the extruded powder nutritional composition comprises 0.25 wt% to 15 wt% heat labile protein, including 1 wt% to 10 wt%, 1 wt% to 8 wt%, and also including 1 wt% to 5 wt% heat labile protein.
- heat labile proteins that may be utilized in connection with the first and second embodiments include whey protein, glutathione, lactoferrin, serum albumin, immunoglobulin, bioactive peptides, and combinations thereof.
- a significant portion of the heat labile protein in the extruded powder nutritional composition according to the second embodiment, and in certain embodiments of the first embodiment, is in its native, undenatured form.
- from 40% to 90%, including from 55% to 75%>, 55%> to 70%>, and also including 60%> to 65%> of the heat labile protein is in its native, undenatured form in the extruded powder nutritional composition.
- the heat labile protein comprises whey protein comprising ⁇ -lactoglobulin and a-lactalbumin.
- from 40% to 90% of the ⁇ -lactoglobulin and the a- lactalbumin (combined total) are in their native, undenatured form in the extruded powder nutritional composition.
- from 45% to 85%, 50% to 80%, 55% to 75%, 55% to 70%, and also including 60% to 65% of the ⁇ -lactoglobulin and the a-lactalbumin are in their native, undenatured form in the extruded powder nutritional composition.
- an oil blend comprising fat is utilized to produce the extruded powder nutritional compositions disclosed herein.
- the oil blend comprises at least one fat selected from corn oil, soy oil, canola oil, high oleic sunflower oil, high oleic safflower oil, fish oil, algal oil, and a polyunsaturated fatty acid.
- the polyunsaturated fatty acid (PUFA) comprises an omega-3 PUFA, an omega-6 PUFA, or both an omega-3 PUFA and an omega-6 PUFA.
- Exemplary omega-3 PUFAs include, but are not limited to, alpha-linolenic acid (ALA), eicosapentaenoic acid (EPA), and docosahexaenoic acid (DHA).
- Exemplary omega-6 PUFAs include, but are not limited to, linoleic acid (LA), gamma-linolenic acid (GLA), dihomo-gamma-linolenic acid (DGLA), and arachidonic acid (AA).
- the oil blend in addition to the fat, comprises one or more of an emulsifier, an oil soluble bioactive (e.g., a carotenoid), and one or more oil-soluble vitamins.
- Emulsifiers that may be used include, but are not limited to, lecithin, mono- and diglycerides of fatty acids, and combinations thereof.
- Suitable oil soluble bioactives that may be used include, but are not limited to, beta-carotene, lutein, lycopene, and zeaxanthin.
- a non-limiting list of oil-soluble vitamins that may be incorporated into the oil blend include vitamin A, vitamin D, vitamin E, vitamin K, and combinations thereof.
- the extruded powder nutritional composition according to the second embodiment, and certain embodiments of the first embodiment comprises from 10 wt% to 40 wt% fat, including from 10 wt%> to 35 wt%>, from 15 wt%> to 30 wt%>, and also including from 15 wt%> to 25 wt%> fat.
- the fat comprises at least one of corn oil, soy oil, canola oil, high oleic sunflower oil, high oleic safflower oil, fish oil, algal oil, and a polyunsaturated fatty acid.
- the polyunsaturated fatty acid comprises an omega-3 PUFA, an omega-6 PUFA, or both an omega-3 PUFA and an omega-6 PUFA.
- omega-3 PUFAs include, but are not limited to, alpha-linolenic acid (ALA), eicosapentaenoic acid (EPA), and docosahexaenoic acid (DHA).
- omega-6 PUFAs include, but are not limited to, linoleic acid (LA), gamma-linolenic acid (GLA), dihomo-gamma- linolenic acid (DGLA), and arachidonic acid (AA).
- the extruded powder nutritional composition comprises one or more of an emulsifier, an oil soluble bioactive (e.g., a carotenoid), and one or more oil-soluble vitamins.
- Emulsifiers that may be used include, but are not limited to, lecithin, mono- and diglycerides of fatty acids, and combinations thereof.
- Exemplary oil soluble bioactives that may be used in the oil blend include, but are not limited to, beta-carotene, lutein, lycopene, zeaxanthin, and combinations thereof.
- a non-limiting list of oil- soluble vitamins that may be incorporated into the oil blend include vitamin A, vitamin D, vitamin E, vitamin K, and combinations thereof.
- a second dry blend comprising a carbohydrate and the heat labile protein is utilized to produce the extruded powder nutritional compositions disclosed herein.
- the second dry blend comprises at least one carbohydrate selected from lactose, sucrose, fructose, maltodextrin, digestion resistant maltodextrin, galactooligosaccharide, fructooligosaccharide, starch, dietary fiber, and stabilizers (e.g., carboxymethyl cellulose, microcrystalline cellulose, carrageenan, alginates, gums). Any one or more of the foregoing carbohydrates may also be suitably used in the first dry blend.
- the extruded powder nutritional composition according to the second embodiment comprises from 20 wt% to 70 wt% carbohydrate, including from 25 wt% to 65 wt%, from 30 wt% to 60 wt%, from 40 wt% to 60 wt%, from 50 wt% to 60 wt%, and also including from 60 wt% to 70 wt% carbohydrate.
- the carbohydrate comprises at least one of lactose, sucrose, fructose, maltodextrin, digestion resistant maltodextrin, galactooligosaccharide, fructooligosaccharide, starch, dietary fiber, and stabilizers (e.g., carboxymethyl cellulose, microcrystalline cellulose, carrageenan, alginates, gums).
- stabilizers e.g., carboxymethyl cellulose, microcrystalline cellulose, carrageenan, alginates, gums.
- the method according to the first embodiment and the composition according to the second embodiment include the use of a heat labile component in addition to the heat labile protein.
- Other heat labile components that may be utilized in certain embodiments according to the first and second embodiments include a heat labile enzyme, a heat labile vitamin, a heat labile phytonutrient, a probiotic, a reactive mineral, and combinations thereof.
- any additional heat labile components may be advantageously introduced into an end port of the extruder.
- a heat labile enzyme is introduced into an end port of the extruder.
- the heat labile enzyme is one or more of a hydrolase (e.g., phytase, lactase), a protease, a carboxylase, and an isomerase.
- the heat labile enzyme is introduced into an end port of the extruder separate from (e.g., later in time or at a separate end port) the second dry blend.
- the extruded powder nutritional composition comprises at least one heat labile enzyme selected from a hydrolase (e.g., phytase, lactase), a protease, a carboxylase, and an isomerase.
- a heat labile vitamin is introduced into an end port of the extruder.
- the heat labile vitamin comprises one or more of vitamin A, vitamin I1 ⁇ 2, vitamin C, vitamin D, vitamin E, thiamin, riboflavin, folic acid, and pantothenic acid.
- at least about 80%, or at least about 85%, or at least about 90%, or at least about 95% of the heat labile vitamins are retained in the extruded powder nutritional composition.
- the heat labile vitamin is introduced into an end port of the extruder as part of the second dry blend.
- the heat labile vitamin is introduced into an end port of the extruder separate from (e.g., later in time or at a separate end port) the second dry blend.
- the extruded powder nutritional composition comprises at least one heat labile vitamin selected from vitamin A, vitamin Bi 2 , vitamin C, vitamin D, vitamin E, thiamin, riboflavin, folic acid, and pantothenic acid.
- a heat labile phytonutrient is introduced into an end port of the extruder.
- the heat labile phytonutrient comprises at least one of green tea polyphenols, fruit extracts, and vegetable extracts.
- introducing the heat labile phytonutrient into the extruder at an end port reduces the amount of shear force to which the heat labile phytonutrient is exposed.
- the heat labile phytonutrient is introduced into an end port of the extruder as part of the second dry blend.
- the heat labile phytonutrient is introduced into an end port of the extruder separate from (e.g., later in time or at a separate end port) the second dry blend.
- the extruded powder nutritional composition comprises at least one heat labile phytonutrient selected from green tea polyphenols, fruit extracts, and vegetable extracts.
- the extruded powder nutritional composition may comprise a probiotic.
- a probiotic is introduced into an end port of the extruder.
- Suitable probiotics for use in the extruded powder nutritional composition include various strains of Bifidobacterium and Lactobacillus, which may be either active or inactive.
- the probiotic is introduced into an end port of the extruder as part of the second dry blend.
- the probiotic is introduced into an end port of the extruder separate from (e.g., later in time or at a separate end port) the second dry blend.
- a reactive mineral is introduced into an end port of the extruder.
- the term "reactive mineral” as used herein refers to a mineral or ions thereof that react with proteins, oxidize oils, or both.
- the reactive mineral comprises one or more of iron, soluble calcium, magnesium, zinc, manganese, chromium, copper, phosphates, citrates, and sulfates.
- the reactive mineral is introduced into an end port of the extruder as part of the second dry blend.
- the reactive mineral is introduced into an end port of the extruder separate from (e.g., later in time or at a separate end port) the second dry blend.
- the extruded powder nutritional composition comprises at least one reactive mineral selected from iron, soluble calcium, magnesium, zinc, manganese, chromium, copper, phosphates, citrates, and sulfates.
- the methods and extruded powder nutritional compositions described herein may further comprise other optional components that may modify the physical, chemical, aesthetic, or processing characteristics of the compositions or serve as pharmaceutical or additional nutritional components when used in a targeted population.
- optional ingredients are known or otherwise suitable for use in nutritional products, medical foods, or pharmaceutical dosage forms and may also be used in the extruded powder nutritional compositions described herein, provided that such optional ingredients are safe and effective for oral administration and are compatible with the essential and other ingredients in the extruded powder nutritional compositions.
- Non-limiting examples of such optional ingredients include one or more of: preservatives, anti-oxidants, emulsifying agents, buffers, pharmaceutical actives, additional nutrients as described herein, vitamins, minerals, sweeteners including artificial sweeteners (e.g., saccharine, aspartame, acesulfame K, Stevia extract, and sucralose), colorants, flavorants, thickening agents and stabilizers, emulsifying agents, lubricants, prebiotics, and amino acids.
- preservatives e.g., saccharine, aspartame, acesulfame K, Stevia extract, and sucralose
- sweeteners including artificial sweeteners (e.g., saccharine, aspartame, acesulfame K, Stevia extract, and sucralose), colorants, flavorants, thickening agents and stabilizers, emulsifying agents, lubricants, prebiotics, and amino acids.
- sweeteners e.g., sacchar
- Example 1 illustrates an extruded powder nutritional composition according to the second embodiment described herein. All ingredient amounts listed in Example 1 are listed as kilogram per 1000 kg batch of the extruded powder nutritional composition, unless otherwise indicated.
- the extruder utilized was a twin-screw extruder with 14 barrels and a capacity of 60- 80 pounds/hour. The ingredients were added to the extruder as follows. To barrel 1 was added the nonfat dry milk and whey protein concentrate (at a rate of 13.2 pounds/hour). Also added to barrel 1 was water (at a rate of 8.5 pounds/hour) and part of the oil blend (at a rate of 0.3 pounds/hour).
- Example 2 illustrates the soluble protein concentration of extruded nutritional compositions prepared according to the embodiments disclosed herein (and utilizing the ingredients provided in Table 1 of Example 1) compared to a conventional spray dried nutritional composition containing identical ingredients and pasteurized fat free milk as controls.
- the soluble protein concentrations of the samples were estimated by: (a) creating an aqueous suspension (a 13% (w/w) preparation in Milli-Q Plus water was stirred at 300 rpm for one hour at room temperature); (b) centrifugation of the aqueous suspension (14,000 x g for 5 minutes at room temperature); (c) dilution of the supernatant ( ⁇ 2 grams of supernatant to 10 mL of HPLC mobile phase solution); and (d) performing size exclusion HPLC to determine the soluble protein.
- the HPLC system setup is described in Table 2 below, and the soluble protein concentrations along with the aggregated protein (high MW protein) as a percentage of the soluble protein is shown in Table 3 below.
- the extruded powder nutritional compositions contained more soluble protein compared to the similarly formulated spray dried nutritional powder. Moreover, the extruded powders included substantially less aggregated protein as compared to the spray dried powder. The lower amount of aggregated protein indicates that less of the protein was denatured, and thus, more of the protein was in its native state.
- Example 3 illustrates the native whey protein concentrations of extruded nutritional compositions prepared according to the embodiments disclosed herein compared to conventional spray dried nutritional compositions with an identical formulation.
- the concentrations of native ⁇ -lactoglobulin and native a-lactalbumin in the samples were determined as follows: 1) reconstitution of the powder with water followed by centrifugation (e.g., 31 ,000 x g, at 20°C for 3 hours); 2) determine amount of soluble protein by performing size exclusion chromatography (pH 7.5) of the supernatant; and 3) determine amount of native protein by reversed phase liquid chromatography (pH 2.5) of the supernatant.
- the native whey protein concentrations (which were estimated from the response of a pasteurized, fat free milk sample) for each sample is presented in Table 4 below.
- each extruded powder composition contained more native whey protein (as ⁇ -lactoglobulin + a-lactalbumin) as compared to the each similarly formulated spray dried powder composition. Moreover, each extruded powder sample contained at least three times as much native ⁇ -lactoglobulin as compared to each corresponding spray dried powder sample. In addition, the extruded powder samples, with the exception of Extruded Powder D, contained more native a-lactalbumin compared to the corresponding spray dried powder samples. It should be noted that all of the protein utilized to produce Extruded Powder B and Extruded Powder D was introduced into the extruder at an initial port of the extruder.
- the protein including the heat labile protein, experienced a longer residence time in the extruder at an elevated temperature, which may explain the reduced amount of native a- lactalbumin in Extruded Powder D as compared to Spray Dried Powder D.
- the procedure used to produce Extruded Powder A and Extruded Powder C was a modification of the procedure described in Example 1 in that the whey protein was added in an end port of the extruder, specifically barrel 1 1 of the 14 barrel twin-screw extruder. Accordingly, the data indicates that extruded powder nutritional compositions produced in accordance with the methods described herein result in less denaturation of heat labile components (e.g., whey protein) as compared to similarly formulated spray dried powder compositions.
- heat labile components e.g., whey protein
- the data also shows that the introduction of heat labile protein at an end port of the extruder (Extruded Powder A and Extruded Powder C) results in a relatively higher percentage of the protein being retained in the native state as compared to introduction of all proteins (including the heat labile protein) at an initial port of the extruder.
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Abstract
L'invention concerne une composition nutritionnelle à base de poudre extrudée et des procédés de production associés. La composition nutritionnelle à base de poudre extrudée comprend une protéine thermolabile et une partie significative de la protéine thermolabile conserve sa forme native non dénaturée.
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CN106418104A (zh) * | 2016-11-08 | 2017-02-22 | 安徽省纽斯康生物工程有限公司 | 一种有助身体调理的营养冲剂及其制备方法 |
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WO2020089032A1 (fr) * | 2018-10-30 | 2020-05-07 | Dsm Ip Assets B.V. | Extrudats comprenant de la vitamine b9 |
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CN108294302A (zh) * | 2018-01-30 | 2018-07-20 | 贵州中科金玖生物技术有限公司 | 一种全营养配方粉、其制备方法以及其制品 |
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