WO2021151982A1 - Process of infusion – use of freeze drying as process step - Google Patents
Process of infusion – use of freeze drying as process step Download PDFInfo
- Publication number
- WO2021151982A1 WO2021151982A1 PCT/EP2021/051935 EP2021051935W WO2021151982A1 WO 2021151982 A1 WO2021151982 A1 WO 2021151982A1 EP 2021051935 W EP2021051935 W EP 2021051935W WO 2021151982 A1 WO2021151982 A1 WO 2021151982A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- infusion
- water
- soluble
- oil
- slices
- Prior art date
Links
- 238000001802 infusion Methods 0.000 title claims abstract description 45
- 238000000034 method Methods 0.000 title claims abstract description 28
- 230000008569 process Effects 0.000 title claims abstract description 19
- 238000004108 freeze drying Methods 0.000 title description 10
- 239000000463 material Substances 0.000 claims abstract description 27
- 229930003231 vitamin Natural products 0.000 claims abstract description 16
- 235000013343 vitamin Nutrition 0.000 claims abstract description 16
- 239000011782 vitamin Substances 0.000 claims abstract description 16
- 229940088594 vitamin Drugs 0.000 claims abstract description 16
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 14
- 239000011707 mineral Substances 0.000 claims abstract description 14
- 239000007764 o/w emulsion Substances 0.000 claims abstract description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 27
- 238000001035 drying Methods 0.000 claims description 18
- 239000007788 liquid Substances 0.000 claims description 15
- 238000007710 freezing Methods 0.000 claims description 3
- 230000008014 freezing Effects 0.000 claims description 3
- 238000009755 vacuum infusion Methods 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 2
- 150000003722 vitamin derivatives Chemical class 0.000 claims 6
- 239000000725 suspension Substances 0.000 claims 1
- 239000003978 infusion fluid Substances 0.000 abstract description 9
- 235000011888 snacks Nutrition 0.000 abstract description 6
- 238000009792 diffusion process Methods 0.000 abstract description 5
- 235000013305 food Nutrition 0.000 abstract description 4
- 235000010675 chips/crisps Nutrition 0.000 abstract description 2
- 239000011785 micronutrient Substances 0.000 abstract description 2
- 235000013369 micronutrients Nutrition 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 10
- 238000005470 impregnation Methods 0.000 description 7
- 244000061456 Solanum tuberosum Species 0.000 description 6
- 235000002595 Solanum tuberosum Nutrition 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 5
- 230000006872 improvement Effects 0.000 description 5
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 238000007781 pre-processing Methods 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- ZZZCUOFIHGPKAK-UHFFFAOYSA-N D-erythro-ascorbic acid Natural products OCC1OC(=O)C(O)=C1O ZZZCUOFIHGPKAK-UHFFFAOYSA-N 0.000 description 2
- 244000000626 Daucus carota Species 0.000 description 2
- 235000002767 Daucus carota Nutrition 0.000 description 2
- 244000017020 Ipomoea batatas Species 0.000 description 2
- 235000002678 Ipomoea batatas Nutrition 0.000 description 2
- 229930003268 Vitamin C Natural products 0.000 description 2
- 210000004027 cell Anatomy 0.000 description 2
- 210000002421 cell wall Anatomy 0.000 description 2
- 239000000839 emulsion Substances 0.000 description 2
- 238000000265 homogenisation Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 235000019154 vitamin C Nutrition 0.000 description 2
- 239000011718 vitamin C Substances 0.000 description 2
- FPIPGXGPPPQFEQ-UHFFFAOYSA-N 13-cis retinol Natural products OCC=C(C)C=CC=C(C)C=CC1=C(C)CCCC1(C)C FPIPGXGPPPQFEQ-UHFFFAOYSA-N 0.000 description 1
- 235000021537 Beetroot Nutrition 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 240000003183 Manihot esculenta Species 0.000 description 1
- 235000016735 Manihot esculenta subsp esculenta Nutrition 0.000 description 1
- 206010033546 Pallor Diseases 0.000 description 1
- 229920001213 Polysorbate 20 Polymers 0.000 description 1
- FPIPGXGPPPQFEQ-BOOMUCAASA-N Vitamin A Natural products OC/C=C(/C)\C=C\C=C(\C)/C=C/C1=C(C)CCCC1(C)C FPIPGXGPPPQFEQ-BOOMUCAASA-N 0.000 description 1
- 229930003316 Vitamin D Natural products 0.000 description 1
- QYSXJUFSXHHAJI-XFEUOLMDSA-N Vitamin D3 Natural products C1(/[C@@H]2CC[C@@H]([C@]2(CCC1)C)[C@H](C)CCCC(C)C)=C/C=C1\C[C@@H](O)CCC1=C QYSXJUFSXHHAJI-XFEUOLMDSA-N 0.000 description 1
- FPIPGXGPPPQFEQ-OVSJKPMPSA-N all-trans-retinol Chemical compound OC\C=C(/C)\C=C\C=C(/C)\C=C\C1=C(C)CCCC1(C)C FPIPGXGPPPQFEQ-OVSJKPMPSA-N 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- MKJXYGKVIBWPFZ-UHFFFAOYSA-L calcium lactate Chemical compound [Ca+2].CC(O)C([O-])=O.CC(O)C([O-])=O MKJXYGKVIBWPFZ-UHFFFAOYSA-L 0.000 description 1
- 235000014633 carbohydrates Nutrition 0.000 description 1
- 150000001720 carbohydrates Chemical class 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 235000008504 concentrate Nutrition 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000002354 daily effect Effects 0.000 description 1
- 235000013325 dietary fiber Nutrition 0.000 description 1
- 235000015872 dietary supplement Nutrition 0.000 description 1
- XPPKVPWEQAFLFU-UHFFFAOYSA-J diphosphate(4-) Chemical compound [O-]P([O-])(=O)OP([O-])([O-])=O XPPKVPWEQAFLFU-UHFFFAOYSA-J 0.000 description 1
- 235000011180 diphosphates Nutrition 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 235000020628 food by component Nutrition 0.000 description 1
- 235000014106 fortified food Nutrition 0.000 description 1
- 235000011389 fruit/vegetable juice Nutrition 0.000 description 1
- 229940050410 gluconate Drugs 0.000 description 1
- 238000005213 imbibition Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 235000021073 macronutrients Nutrition 0.000 description 1
- 239000003550 marker Substances 0.000 description 1
- 235000012054 meals Nutrition 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 235000016709 nutrition Nutrition 0.000 description 1
- 230000035764 nutrition Effects 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 235000010486 polyoxyethylene sorbitan monolaurate Nutrition 0.000 description 1
- 239000000256 polyoxyethylene sorbitan monolaurate Substances 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 235000013599 spices Nutrition 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000002910 structure generation Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
- 235000019155 vitamin A Nutrition 0.000 description 1
- 239000011719 vitamin A Substances 0.000 description 1
- -1 vitamin A and D Natural products 0.000 description 1
- 235000019166 vitamin D Nutrition 0.000 description 1
- 239000011710 vitamin D Substances 0.000 description 1
- 150000003710 vitamin D derivatives Chemical class 0.000 description 1
- 229940045997 vitamin a Drugs 0.000 description 1
- 229940046008 vitamin d Drugs 0.000 description 1
Classifications
-
- 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
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
-
- 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
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
- A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
-
- 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
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
- A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
- A23L19/18—Roasted or fried products, e.g. snacks or chips
-
- 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
- A23L33/155—Vitamins A or D
-
- 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
Definitions
- Typical components for fortification could be, without limiting it to, these examples, are vitamins like vitamin A and D, as well as minerals like Iron (Fe) and Zinc (Zn).
- Base materials of the snack could be, without limiting it to, roots and tubers like potato, sweet potato or carrots.
- the standard process is described for example in [1 and 2] and can be summarised as follows:
- the base material for example a root or tuber is sliced into thin slices.
- the root or tuber may be, for example, potato, sweet potato, carrot, beet root or cassava without limiting the choice to these materials.
- the material may be blanched (temperature treatment by steam or hot water) before- or after slicing.
- the slicing may be performed using any type of slicing apparatus, e.g. apparatus of Urschel CC Slicer type, Urschel Lab Inc. Chesterton, IN USA: Preferred slice thickness for infusion in the standard infusion process should be low. Preferred thickness is below as 5 mm, or more preferred below 2 mm, or more preferred below 1 mm, more preferred below 0.5 mm, or even more preferred 0.2 mm. [005] The invention is however not limited to thin slices as the diffusion is effectively enhanced, so that also thick slices up are possible. Limited to a preference of below 30 mm, or more preferred below 20 mm, or more preferred below 10 mm, or even more preferred 5 mm
- the slices are then either blanched or directly submitted to the infusion bath.
- the slices are submerged into an infusion liquid, which is a baseliquid which contains the material that shall be infused.
- Typical infusion material in standard infusion processes are calcium, for texture improvement, or vitamin C, for chemical stabilisation or taste improvement.
- the infusion liquid may be stagnant or moving, for example flowing in a duct or in a mixer vessel by use of a stirrer. Flowing liquid would show an enhanced mass transport from the liquid to the slices [3] This infusion step will be characterised by its duration and the liquid temperature.
- the snacks are produced by the standard production process similar to the process for non-fortified products.
- the process may be adapted to take the sensitivity of the fortification material into account, for example lower temperatures.
- this particularly involves, but is not limiting to, a drying- or a frying step to reduce product moisture and generate a crispy structure.
- a cooling step is followed by any kind of finishing step, for example flavouring, surface coating or any other finishing step.
- the target is to enrich snack base material with a sufficient quantity of the fortification material, i.e. 5% of the daily recommended allowance (RDA), even preferred more than 10% of the RDA, or even preferred more than 30% RDA, even preferred more than 50% RDA or more than 100% of the RDA within a standard portion size.
- RDA daily recommended allowance
- the optimum level may depend on the risk of overdosing of the fortification material.
- the infusion typically work on the basis imbibing the fortification material into the product by diffusion. This may take a long time especially if slices are thick.
- the maximum amount of fortification material that can be added economically is limited. This is particularly true for cell material like slices of roots and tubers.
- the cell wall poses a diffusion barrier that reduces the diffusion efficiency significantly. This has led to the invention of vacuum impregnation techniques as descripted for example by Tiwari et al. [2]
- the presented process provides a significant improvement over this state of art technology in food infusion or so called imp
- the impregnation efficiency has been improved by adding an additional process step to the impregnation- or infusion procedure.
- the product Before impregnation, the product is freeze dried to generate a preferred structure for infusion. Freeze drying is a process whereby the product is dried while maintaining its solid form. The water is not in liquid form, so that no or only little shrinkage occurs during drying. Voids remain at places where ice crystals had been before drying.
- the process comprises a freezing step, followed by a drying or evaporation step to remove the solidified water. This drying step is performed at conditions avoiding a melting of generated ice crystals, which is given at drying conditions below the triple point of water.
- the triple point of water is defined by a water vapour pressure of 611 Pa (Pascal) and a temperature of 273 K. Often the drying is divided in a main drying step, as described, and a final drying step at a higher temperature, to remove so-called "bound" water. More details can be found, for example, in [4, 5]
- the freeze drying can, for example, be performed in a two chamber freeze dryer, like the Zirbus Sublimator 15, Zirbus technology GmbH, Bad Grund Germany, or any other freeze dryer installation, including so-called atmospheric freeze dryers.
- the structure generation proceeds from the outside of the dried product into the material. Therefore, also an incomplete drying will generate structures well- suited for impregnation, as long as the generated porosity has a higher or equal volume than the volume of the infusion liquid, containing the intended amount of infusion material.
- the dried material will then be exposed to the known infusion- and production process as already described.
- the process comprising specifically, but is not limited to: infusion, drying or frying, plus optional steps like layering or finishing.
- a particularly efficient variant of the technique is the combination of the described pre processing with a so-called vacuum impregnation [2] as an infusion technique.
- This process comprises the following steps: placing the product in a vacuum impregnation room, removing parts of the atmosphere by drawing an appropriate vacuum given as a pressure difference to the starting pressure of more than 100 hPa (10000 Pa) or more preferred more than 200 hPa, or more preferred more than 500 hPa, or more preferred more than 700 hPa.
- This pressure difference stands for a removed volume of gas i.e.
- air from the pore space he above data should be read in the case of starting gas pressures higher than the standard atmospheric pressure of 0.1 MPa as pressure ratios (ratio of reduced pressure to starting pressure) of 0.9, 0.8, 0.5 and 0.3 respectively.
- the infusion liquid is injected into the infusion room and is imbibing into the dried slices. This imbibition can be enhanced by increasing the gas pressure in the room i.e. breaking the vacuum. The higher pressure on the outside of the slice, compared to the inner gas pressure, pushes the infusion liquid into the slices.
- Fresh potato was cut into slices of 1.5 mm thickness using a manual slice cutter "Allesschnieder Master M90 Graef, Arnsberg, Germany" .
- the slice thickness was determined using an eddy-current thickness measurement device. Freeze drying was performed in a Zirbus Sublimator 15, Zirbus technology GmbFI, Bad Grund Germany. The infusion was performed with water-based mineral solutions. The concentrations of fortifying minerals in the infusion liquid are given in the table below.
- the sample marked "blank” were infused with water. Vacuum infusion as well as standard infusion at ambient gas pressure were conducted. Infusion time was set to 3 min.
- the final drying was conducted in a Philips Airfryer XXL Results are shown in figure 1 and figure 2. A clear improvement can be seen when freeze drying was used as a pre-processing step.
- Infusion Pressure ambient pressure, 300 mbar
- Fresh potato was cut into slices of 1.5 mm thickness using a manual slice cutter "Allesschnieder Master M90 Graef, Arnsberg, Germany” .
- the slice thickness was determined using an eddy-current thickness measurement device. Freeze drying was performed in a Zirbus Sublimator 15, Zirbus technology GmbFI, Bad Grund Germany.
- the infusion was performed with an oil-in-water emulsion. Said emulsion contained 12,5% oil and was prepared using a high-pressure homogenisator type HL 1.3- 400KX, FIST Maschinenbau GmbFI, Dassow, Germany, at a homogenisation pressure of 30 MPa.
- the sample marked "blank” were infused with water.
- Vacuum infusion as well as standard infusion at ambient gas pressure were conducted.
- the final drying was conducted in a Philips Airfryer XXL Infusion time was set to 3 min.
- Oil is the carrier of oil-soluble fortification material, like oil-soluble vitamins. Oil load is used as a marker for successful fortification with oil-soluble fortification material. Results are shown in figure 3, showing a clear improvement when using freeze drying as a pre-processing step.
- Infusion Pressure ambient pressure and 300 mbar
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- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Nutrition Science (AREA)
- Engineering & Computer Science (AREA)
- Food Science & Technology (AREA)
- Polymers & Plastics (AREA)
- Mycology (AREA)
- Inorganic Chemistry (AREA)
- Preparation Of Fruits And Vegetables (AREA)
Abstract
1. Title: Process of infusion of vitamins and/or minerals 2. Short Description: 2.1 Technical problem of the invention: Infusion into plant-based slices is ineffective, as the diffusion into the cell structure is limiting both the speed of the infusion process and the amount of material infused in a given infusion time. The new process is meant to improve the process efficiency. 2.2 Solving the problem or technical task: Using an oil-in-water emulsion as infusion liquid, instead of two subsequent infusion steps. 2.3 Field of application: Fortification of food material especially crisps or other snacks with oil- and /or water-soluble micronutrients
Description
Description of Invention
Process of infusion - use of freeze drying as process step
Background
[001] Human nutrition is highly complex. Beside the macronutrients: fat, protein and carbohydrates, that mainly provide energy, also micronutrients have to be supplied to the human body in sufficient quantities. On a more detailed level beside vitamins and minerals, also dietary fibres and antioxidants need to be considered. A high number of people do not manage to meet all requirements adequately. Fortification is a way to complement everyday food by components that are not supplied by the standard meals. The complemented material may be natural occurring foods like juices or spices or concentrates or a specially produced material like vitamin C. In this context, the question of bioavailability is also of importance. A fortified food has the advantage over a food supplement, like a tablet or liquid dose, as it does not need specific acceptance, but will be consumed with the regular food. Fortifying snacks is of particular interest, as snacks are often supplied in a dried- and storage- stable form. Therefore, these products are well-suited for fortification with temperature-instable components.
[002] Typical components for fortification could be, without limiting it to, these examples, are vitamins like vitamin A and D, as well as minerals like Iron (Fe) and Zinc (Zn). Base materials of the snack could be, without limiting it to, roots and tubers like potato, sweet potato or carrots.
State of art
[003] The standard process is described for example in [1 and 2] and can be summarised as follows: The base material for example a root or tuber is sliced into thin slices. The root or tuber may be, for example, potato, sweet potato, carrot, beet root or cassava without limiting the choice to these materials. The material may be blanched (temperature treatment by steam or hot water) before- or after slicing.
[004] The slicing may be performed using any type of slicing apparatus, e.g. apparatus of Urschel CC Slicer type, Urschel Lab Inc. Chesterton, IN USA: Preferred slice thickness for infusion in the standard infusion process should be low. Preferred thickness is below as 5 mm, or more preferred below 2 mm, or more preferred below 1 mm, more preferred below 0.5 mm, or even more preferred 0.2 mm.
[005] The invention is however not limited to thin slices as the diffusion is effectively enhanced, so that also thick slices up are possible. Limited to a preference of below 30 mm, or more preferred below 20 mm, or more preferred below 10 mm, or even more preferred 5 mm
[006] The slices are then either blanched or directly submitted to the infusion bath. The slices are submerged into an infusion liquid, which is a baseliquid which contains the material that shall be infused. Typical infusion material in standard infusion processes are calcium, for texture improvement, or vitamin C, for chemical stabilisation or taste improvement. The infusion liquid may be stagnant or moving, for example flowing in a duct or in a mixer vessel by use of a stirrer. Flowing liquid would show an enhanced mass transport from the liquid to the slices [3] This infusion step will be characterised by its duration and the liquid temperature. After infusion, the snacks are produced by the standard production process similar to the process for non-fortified products. The process may be adapted to take the sensitivity of the fortification material into account, for example lower temperatures. In the case of crisps, this particularly involves, but is not limiting to, a drying- or a frying step to reduce product moisture and generate a crispy structure. A cooling step is followed by any kind of finishing step, for example flavouring, surface coating or any other finishing step.
Problem to be solved
[07] The target is to enrich snack base material with a sufficient quantity of the fortification material, i.e. 5% of the daily recommended allowance (RDA), even preferred more than 10% of the RDA, or even preferred more than 30% RDA, even preferred more than 50% RDA or more than 100% of the RDA within a standard portion size. The optimum level may depend on the risk of overdosing of the fortification material. The infusion typically work on the basis imbibing the fortification material into the product by diffusion. This may take a long time especially if slices are thick. In addition, the maximum amount of fortification material that can be added economically is limited. This is particularly true for cell material like slices of roots and tubers. The cell wall poses a diffusion barrier that reduces the diffusion efficiency significantly. This has led to the invention of vacuum impregnation techniques as descripted for example by Tiwari et al. [2] The presented process provides a significant improvement over this state of art technology in food infusion or so called impregnation.
Description of invention
[008] The impregnation efficiency has been improved by adding an additional process step to the impregnation- or infusion procedure. Before impregnation, the product is freeze dried to generate a preferred structure for infusion. Freeze drying is a process whereby the product is dried while maintaining its solid form. The water is not in liquid form, so that no or only little shrinkage occurs during drying. Voids remain at places where ice crystals had been before drying. The process comprises a freezing step, followed by a drying or evaporation step to remove the solidified water. This drying step is performed at conditions avoiding a melting of generated ice crystals, which is given at drying conditions below the triple point of water. The triple point of water is defined by a water vapour pressure of 611 Pa (Pascal) and a temperature of 273 K. Often the drying is divided in a main drying step, as described, and a final drying step at a higher temperature, to remove so-called "bound" water. More details can be found, for example, in [4, 5] The freeze drying can, for example, be performed in a two chamber freeze dryer, like the Zirbus Sublimator 15, Zirbus technology GmbH, Bad Grund Germany, or any other freeze dryer installation, including so-called atmospheric freeze dryers.
[009] In drying technology it is known that the drying speed in freeze drying of plant material can be accelerated by freezing the product slowly. This is explained by stronger growth of the crystals that consequently break the cell wall, allowing water to leave the cell more easily [4] The basic concept of this invention is to use this mechanism to generate a pathway for the infusion liquid in the specific task. As the ice crystals are of considerable size (several pm) this should also allow oil drops to penetrate the structure that is generated by freeze drying. Typically, the product will be dried completely, i.e. most frozen water being evaporated or even dried to a standard dried material, having a water activity aw (at 25°() of below 0.6, or more preferred of below 0.4, or even more preferred of below 0.3 or most preferred below 0.2. The structure generation proceeds from the outside of the dried product into the material. Therefore, also an incomplete drying will generate structures well- suited for impregnation, as long as the generated porosity has a higher or equal volume than the volume of the infusion liquid, containing the intended amount of infusion material.
[010] The dried material will then be exposed to the known infusion- and production process as already described. The process comprising specifically, but is not limited to: infusion, drying or frying, plus optional steps like layering or finishing.
[Oil] A particularly efficient variant of the technique is the combination of the described pre processing with a so-called vacuum impregnation [2] as an infusion technique. This process comprises the following steps: placing the product in a vacuum impregnation room, removing parts of the atmosphere by drawing an appropriate vacuum given as a pressure difference to the starting pressure
of more than 100 hPa (10000 Pa) or more preferred more than 200 hPa, or more preferred more than 500 hPa, or more preferred more than 700 hPa. This pressure difference stands for a removed volume of gas i.e. air from the pore space he above data should be read in the case of starting gas pressures higher than the standard atmospheric pressure of 0.1 MPa as pressure ratios (ratio of reduced pressure to starting pressure) of 0.9, 0.8, 0.5 and 0.3 respectively. The infusion liquid is injected into the infusion room and is imbibing into the dried slices. This imbibition can be enhanced by increasing the gas pressure in the room i.e. breaking the vacuum. The higher pressure on the outside of the slice, compared to the inner gas pressure, pushes the infusion liquid into the slices.
Example 1
[012] Fresh potato was cut into slices of 1.5 mm thickness using a manual slice cutter "Allesschnieder Master M90 Graef, Arnsberg, Germany" . The slice thickness was determined using an eddy-current thickness measurement device. Freeze drying was performed in a Zirbus Sublimator 15, Zirbus technology GmbFI, Bad Grund Germany. The infusion was performed with water-based mineral solutions. The concentrations of fortifying minerals in the infusion liquid are given in the table below. The sample marked "blank" were infused with water. Vacuum infusion as well as standard infusion at ambient gas pressure were conducted. Infusion time was set to 3 min. The final drying was conducted in a Philips Airfryer XXL Results are shown in figure 1 and figure 2. A clear improvement can be seen when freeze drying was used as a pre-processing step.
Slices · Raw material: potato
• Thickness: 1.5 mm
• Pretreatment: no treatment, freeze dried
Infusion Liquid · Ca-solution (1 %(w/w) Ca-lactate in distilled water)
Fe/Zn-solution (0.1 %(w/w) Fe(lll)pyrophosphate + 0.1 %(w/w) Zn-gluconate)
Infusion Pressure: ambient pressure, 300 mbar
Process Temperature: ambient Time: 3 min
Drying · Device: Air fryer
• Temperature: 100 °C
• Time: 15 min
Example 2
[013] Fresh potato was cut into slices of 1.5 mm thickness using a manual slice cutter "Allesschnieder Master M90 Graef, Arnsberg, Germany" . The slice thickness was determined using an eddy-current thickness measurement device. Freeze drying was performed in a Zirbus Sublimator 15, Zirbus technology GmbFI, Bad Grund Germany. The infusion was performed with an oil-in-water emulsion. Said emulsion contained 12,5% oil and was prepared using a high-pressure homogenisator type HL 1.3- 400KX, FIST Maschinenbau GmbFI, Dassow, Germany, at a homogenisation pressure of 30 MPa. The sample marked "blank" were infused with water. Vacuum infusion as well as standard infusion at ambient gas pressure were conducted. The final drying was conducted in a Philips Airfryer XXL Infusion time was set to 3 min. Oil is the carrier of oil-soluble fortification material, like oil-soluble vitamins. Oil load is used as a marker for successful fortification with oil-soluble fortification material. Results are shown in figure 3, showing a clear improvement when using freeze drying as a pre-processing step.
Slices · Raw material: potato
• Thickness: 1.5 mm
• Pretreatment: o no treatment o blanching - 75 °C, 2 min o pre-dried - 75 °C, 10 min o pre-dried - 75 °C, 30 min o freeze dried
Infusion · O/W Emulsion:
Liquid o Oil concentration: 12.5 %(w/w) o Tween 20 per oil: 0.15 (w/w) o Homogenization pressure: 30 MPa
Infusion Pressure: ambient pressure and 300 mbar
Process Temperature: ambient Time: 2 min
Drying · Device: Air fryer
• Temperature: 100 °C
• Time: 15 min
Cited non Patent Literature
1 Lusas, E. W.; Rooney, L. W.; Snack Food Processing 2001, CRC Press, ISBN 1-56676-932-9
2 Tiwari, P., Joshi, A., Varghese, E., Thakur, M., 2018. Process standardization and storability of calcium fortified potato chips through vacuum impregnation. J. Food Sci. Technol. 55, 3221- 3231. https://doi.org/10.1007/sl3197-018-3254-3
3 Mersmann, A.; Thermische Verfahrenstechnik, 1980, Springer Verlag, ISBN 3-540-09903-4
Claims
1. a procedure to promote the infusion into plant-based slices, said procedure comprising the steps of: a. freezing said slice of plant-based material b. drying the frozen slices at conditions below the triple point of water i.e. temperatures below 0°C and water vapour pressures below 6,11 hPa. c. infusing the resulting porous material with a liquid d. drying or frying the slices e. finishing the slices by a coating- or layering step, whereby the steps d and e are optional. The infusion step may be a vacuum infusion or atmospheric infusion.
2. Process of nfusion with a water-based solution into slices of plant-based material using claim 1
3. Infusion with an oil-based liquid into slices of plant-based material using claim 1
4. Infusion with a water-based solution into slices of tubers or roots using claim 1
5. Infusion with an oil-based liquid into tuber slices using claim 1
6. Infusion based on claim 1 with a water-based liquid containing a water-soluble mineral or a combination of water-soluble minerals
7. Infusion based on claim 1 with a water-based suspension containing a non-water-soluble mineral or a combination of non-water-soluble minerals
8. Infusion based on claim 1 with a water-based liquid containing vitamins, i.e. either a single vitamin or a combination thereof, where the vitamin is water soluble
9. Infusion based on claim 1 with a water-based liquid containing vitamins, i.e. either a single vitamin or a combination thereof, where the vitamin is not water soluble
10. Infusion based on claim 1 of a liquid fat containing a mineral or a combination of minerals
11. Infusion based on claim 1 of a liquid fat containing an oil-soluble vitamin or a combination of oil- soluble vitamins
12. Infusion based on claim 1 of a liquid fat containing a combination of one or more of the following components: oil-soluble vitamins, non-oil-soluble vitamins and minerals
13. Infusion based on claim 1 of an oil-in-water emulsion containing any combination of the following components: an oil-soluble vitamin, non-oil-soluble vitamins, water-soluble mineral or non-water-soluble mineral in either of the phases.
14. Any combination of claim 5 to 12.
15. Any combination of claim 2 and 3.
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6440449B1 (en) * | 1998-01-15 | 2002-08-27 | Edward Hirschberg | Methods of infusing phytochemicals, nutraceuticals, and other compositions into food products |
US20090297671A1 (en) * | 2008-06-02 | 2009-12-03 | Frito-Lay North America, Inc. | Infusion Method for Vacuum Fried Fruit Leveraging |
US20160095329A1 (en) * | 2014-10-01 | 2016-04-07 | University College Cork, National University Of Ireland, Cork | Edible snack food product having a low water content and a high solids content, and a method for the production thereof |
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Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6440449B1 (en) * | 1998-01-15 | 2002-08-27 | Edward Hirschberg | Methods of infusing phytochemicals, nutraceuticals, and other compositions into food products |
US20090297671A1 (en) * | 2008-06-02 | 2009-12-03 | Frito-Lay North America, Inc. | Infusion Method for Vacuum Fried Fruit Leveraging |
US20160095329A1 (en) * | 2014-10-01 | 2016-04-07 | University College Cork, National University Of Ireland, Cork | Edible snack food product having a low water content and a high solids content, and a method for the production thereof |
Non-Patent Citations (4)
Title |
---|
LUSAS, E.W.ROONEY, L. W.: "Snack Food Processing", 2001, CRC PRESS |
MERSMANN, A.: "Thermische Verfahrenstechnik", 1980, SPRINGER VERLAG |
TIWARI PRATIBHA ET AL: "Process standardization and storability of calcium fortified potato chips through vacuum impregnation", JOURNAL OF FOOD SCIENCE AND TECHNOLOGY, SPRINGER (INDIA) PRIVATE LTD, INDIA, vol. 55, no. 8, 10 July 2018 (2018-07-10), pages 3221 - 3231, XP036547856, ISSN: 0022-1155, [retrieved on 20180710], DOI: 10.1007/S13197-018-3254-3 * |
TIWARI, P.JOSHI, A.VARGHESE, E.THAKUR, M.: "Process standardization and storability of calcium fortified potato chips through vacuum impregnation", J. FOOD SCI. TECHNOL., vol. 55, 2018, pages 3221 - 3231, XP036547856, Retrieved from the Internet <URL:https://doi.org/10.1007/s13197-018-3254-3> DOI: 10.1007/s13197-018-3254-3 |
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