Note: Descriptions are shown in the official language in which they were submitted.
l~S146~
The present invention relates to low-fat content, butter-
flavored spreads which simulate the flavor, texture, mouthfeel,
appearance, and stability of butter and margarine. More particu-
larly, the present invention relates to diet products of this
type having a reduction in caloric density of from 50 to 90%,
and to processes for preparing them.
The art is replete with prior art attemptS to provide
low-fat butter or margarine substitutes. Among these is U.S.
3,457,086 to Josefowicz, et al. which teaches the production
of a protein-free spread which can contain as low as 35% fat.
The patent states that observance of specified conditions is
necessary to maintain the emulsion in the water-in-oil form.
Unfortunately, products of this type tend to have a watery flavor
because of their high water contents and the absence of milk
proteins which help impart the desirable butter-like taste of
margarine or butter, but which cannot be tolerated in the product
because of their emulsion de-stabilizing effect. Moreover, the
high water contents tend to make emulsions of this type rapidly
break down on hot foods, tending to make foods like toast become
soggy and unappetizing. Also, while some consumers have found
it convenient to buy large quantities of margarine or butter
at sale prices and then freeze them, low-fat spreads based on
water-in-oil emulsions cannot tolerate freezing. Upon thawing,
the emulsion breaks down with consequential release of its water
phase.
Some recent patents suggest that water-in-oil emulsions
can be formed with fat contents as low as 25 or 30% to success-
fully simulate butter or margarine. This has always presented~
severe problems because the external fat phase tends to become -
stretched out and the aqueous phase becomes more predominant.
A ~
SlSl~i~i
For example, U.S. 4,103,037, to Bodor et al. discloses a processfor preparing a proteinaceous low-fat spread which is stabilized
by a gelling agent, such as gelatin, having ~ melting point
sufficiently high to withstand room temperature yet low enough
to allow it to melt in the mouth. This gelling agent ties up
all available water into minute solid particles which are
dispersed throughout a continuous fat phase. These meltable
particles contain the water soluble flavors and salt, and further
diminish the flavor impact of these components which are already
diminished due to the nature of the water-in-oil emulsion.
The adverse effect of water-in-oil emulsions on flavor
impact is so pronounced that this is the problem which was dealt
with by Moran in U.S. 4,115,598. Therein, flavor impact for
a low-fat spread comprising 35 to 65% by weight of a continuous
fat phase and dispersed aqueous phase is said to be improved
by specially formulating the water-in-oil emulsion to destabilize
in the mouth to release the water-soluble flavors.
Further representative of the state of the art of low-
fat spreads is U.S. 4,071,634 to Wilton et al. This patent
states that low-fat spreads are generally emulsions of the water-
in-oil type and cap have fat contents reduced to as low as 30%,
as compared to 80% for margarine~ It is indicated that problems
related to inferior organoleptic properties or emulsion stability
are often encountered in these types of products. Apparently,
products of this type which are sufficiently stable, have flavor
release problems; while those with good flavor release, are in-
sufficiently stable to keep the aqueous phase adequately dis-
persed under storage conditions. To remedy this problem, Wilton
et al. propose a complex emulsion wherein a discontinuous aqueous
li5~gSlI
phase contains phosphatides and a discontinous, second fatty
phase dispersed therein.
Among other attempts to provide low-fat spreads is
the approach described by Nijhoff in U.S. 3,418,133. Therein,
edible spreads are described wherein a portion of a fat content
is replaced by an aqueous solution of carboxyme~hyl-ceLlulose.
In Example 2, a margarine substitute is described which is pre-
pared from a 50/50 mixture of margarine and aqueous solution.
This product presumably has a fat content of about 40% (i.e.,
one half that of margarine~; however, the type of emulsion is
not identified and the emulsions do not remain stable and solid
at room temperature.
U.S. 3,809,764 to Gabby et al. discloses essentially
fat-free products which are characterized as "emulsions" of poly-
glycerol fatty est,ers with an aqueous hydrophilic colloid. Among
the products, are those which are said to simulate margarine
yet contain fat contents of less then 5%. These products, while
fairly flavorful and fat mimetic, are significantly different
in overall flavor, texture, mouthfeel, and appearance from either
margarine or butter.
Richardson, in U.S. 4,156,021, also discloses low-
fat compositions said to simulate margarine. Example III of
this patent employs about 7% corn oil. The emulsions are said
to be of the oil-in-water type but obtain much of their body
from high levels of cellulose fiber, which also adds its characte-
ristic impact on mouthfeel which is significantly different from
that of fat.
Other workers have disclosed stable emulsified products
containing oil-in-water emulsions, wherein sugars where employed;
however, the necessity for sugar made them sweet and clearly
115~,46d
distinct from butter or margarine. Among these is U.S. 3,958,033
to Sims et al. which relates to shelf-stable, clear, liquid emul-
sions. The sugar was essential in these formulations to supply
the desired sweetness, adjust the refractive index of the aqueous
phase to improve product clarity, and enhance shelf stability.
Similarly, in U.S. 4,146 652, Xahn et al. describe stable oil-
in-water emulsions containing high sugar levels to obtain micro-
biological stability. In U.S. 4,107,343 to Petricca the sugar
was required for sweetness demanded of the whipped products invol-
ved. Thus, despite the disclosure by these patents of stableoil-in-water emulsions with fat contents in the 10 to 30% range,
and the disclosure by Sims et al. in Example XXII of a maple-
flavored spread, and a confectionary butter cream in Example
I of Kahn et al., there is no solution afforded the skilled worker
in the low-fat margarine or butter substitute art seeking a pro-
duct which can successfully reproduce the flavor, texture, mouth-
feel, stability and appearance of butter or margarine at a calo-
ric density of 10-45 colories per 14 gram serving, as compared
to the 50 or more calories per similar serving for the best low-
fat, butter-flavored spreads commercially available to date.
It is an object of the present invention to provide
an improved low-fat, butter-flavored spread and a process for
preparing it.
According to an aspect of the present invention there
is provided a low-fat, butter-flavored spread comprising, a dis-
persed phase comprising from 5 to 40% fat, based on the weight
of the spread, a continuous aqueous phase including a stabilizer,
and an emulsifier system comprising a combination of a lipophilic
emulsifier and a hydrophilic emulsifier, the relative and total
amounts of the emulsifiers and the stabilizer being effective
llS14~;~
to provide a stable emulsion and a product which is solid at
40F.
According to a further aspect of the present invention
there is provided a process for preparing a low-fat, butter-
flavored spread, which comprises, preparing an oil-in-water emul-
sion comprising a dispersed phase comprising from 5 to 40~ fat,
based on the weight of the emulsion, a continuous aqueous phase
including a stabilizer, and an emulsifier system comprising a
combination of a lipophilic emulsifier, and a hydrophilic emulsi-
fier, the relative and total amounts of the emulsifiers and thestabilizer being effective to provide a stable emulsion and a
product which is solid at 40F, and cooling the emulsion under
conditions effective to solidify it to form a product which is
solid at 40F.
Embodiments of the invention will now be described
by way of example with reference to the accompanying drawings
in which:
Figure 1 is a photomicrograph, taken at 225 times magni-
fication, of an emulsion sample as described herein after solidi-
fication;
Figure 2 is a photomicrograph of the sample of Figure1, taken at 500 times magnification; and
Figure 3 is a flow diagram showing a preferred process
scheme according to the invention.
The products described herein, which are prepared by
the process described herein, effectively simulate natural butter
and good quality margarine in flavor, texture, appearance, mouth-
feel and stability, yet have caloric densities of less than 50,
and preferably about 10 to 35, colories per 14 gram serving com-
pared to about 100 for margarine and butter. The spreads are
.'
~`
~151~*0
solid at refrigerator temperature and remain so even after stand-
ing for at least 2, and preferably 5, hours at a room temperature
of 70F. The spreads, which are based on stable oil-in-water
emulsions, remain spreadable at normal refrigerator temperature,
and melt quickly in the mouth to release flavor without imparting
a waxy texture or mouthfeel.
The term "butter-flavored" is meant to include composi-
tions flavored to simulate butter by both naturally-derived and
simulated butter flavors. This term is used in its literal
sense and is not meant to be otherwise restricted. A composition
is considered "butter-flavored" when an expert panel trained
to evaluate flavors of this type characterizes the product as
"buttery" or "butter-like" in flavor.
The term "stable emulsion" identifies those emulsions
which do not undergo any noticeable change in stability, due
to water or fat separation or otherwise, during storage in mois-
tureproof containers at a temperature of 40F or below for 6
months, and which will also remain stable when stored at a room
temperature of 70F for a period of at least one day. Preferably,
the emu~sions described herein remain stable after melting, even
at elevated temperatures of 180F or more.
The term "solid" is used in its normal sense, to mean
the product does not flow under its own weight. Included within
the scope of this term are plastic, spreadable compositions which,
while not susceptible to flow under their own weight in small
quantities, are easily spread with a knife. The more realistic-
appearing products described herein will exhibit penetrometer
readings at 40F within the range of about 60 to 250 units, using
a standard penetrometer cone, having a 2.5 inch diameter and
a 45 angle, with 47.5 grams added weight at a S-second interval.
-- 6
: -
~S~.466
Preferably, the penetrometer readings will be within the rangeof from 100 to 200 units.
The products described herein can be aerated if desired;
however, it is an advantage that the products do not have to
contain any significant quantity of air or inert gas to stiffen
their structures and provide a firmer consistency. Thus, unlike
many prior art products, the product itself, probably due to
its unique microstructure, provides the solid consistency and
there is no dependence upon the use of a gas to distend the emul-
sion structure to effect stiffening or solidification. To provide
the best overall texture, the degree of gas incorporation is
preferably kept to less than 40%, and more preferably less than
20~, by volume.
Similarly, in distinction with some of the prior art
compositions, those described herein do not depend upon the pre-
sence of protein to obtain the solid texture or the superior
mouthfeel; however, they can contain proteins if aesired.
Figures 1 and 2 are photomicrographs taken of a repre-
sentative emulsion prepared in Example 1. Figure 1 was made
20 at 225 times magnification and Figure 2 was made at 500 times.
Both show the unique microstructure of the product. It is
believed that the chains of small bead-like oil droplets entangle,
or coalesce or fuse at points, to form small interstices wherein
the aqueous phase is physically trapped as well as being bound
to some extent by the attraction for the oil due to the presence
of the emulsifiers and stabilizers. The thickened state of the
aqueous phase contributed by the stabilizers is also believed
to aid in maintaining the unique solid structure of the products
described herein, even though the degree of thickening would
not itself be sufficient to prevent it from flowing were it not
r~
~lS14~i6
for the other effects of the composition described herein. These
products are so stable that the emulsions do not separate even
after standing for 24 hours or more at room temperature.
The ingredients which are essential to the formation
of the product are: (1) fat which is suitably selected to have
a Solids Fat Index (SFI~ which enables the formation of solid
product at 40F, ~2~ a water-soluble emulsion stabilizer, and
(3) an effective emulsifier system comprising both lipophilic
and hydrophilic emulsifiers.
The fat can be present in amounts within the range
of from 5 to 40 percent based on the weight of the spread, but
is preferably present in an amount of from 10 to 30 percent by
weight of the spread.
The term "fat" as used herein is intended to include
all edible, fatty acid triglycerides regardless of origin or
whether they are solid or liquid at room temperature. Thus,
the term "fat" includes normally liquid and normally solid vege-
table oils and animal fats. Typical of the vegetable oils which
are included are the usual vegetable oils such as soybean oil,
corn oil, coconut oil, cottonseed oil, peanu$ oil, safflower
oil, palm kernel oil, sunflower oil, palm oil, and rapeseed oil.
The preferred fats for use herein will comprise partially hydro-
genated vegetable oils, and will most preferably be selected
from the group consisting of soybean oil, corn oil, coconut oil,
cottonseed oil, peanut oil, palm oil, palm kernel oil, safflower
oil, sunflower oil, rapeseed oil, and mixtures of these. Pre-
ferred among these are thosepartially-hydrogenated vegetable
oils which have an SFI profile within the following ranges.
-- 8 --
'~
11S~466
.
Temp. BroadPreferred
50F 40-80% 50-70~
70F 25-50% 30-40%
92F <10~ ~5~
Particular, suitable fats are 92F Wiley melting point
partially-hydrogenated coconut oils sold under the trade marks
PURECO 92 by Capitol City Products; HYDROL 92 by SCM Corporation;
VICTORY 92 by Humko Div. Kraft Inc.; and COBEE 92 by PVO Inter-
national, Inc.
The fat will preferably be selected to provide a solid
product at 70F, but will substantially completely melt in the
mouth. Where necessary to increase the solids content at 40F
or 70F, an amount of a fat having a higher solids content can
be added. Fats like hard stock stearin and cottonseed or soybean
flakes have this ability, however, they remain solid and impart
a waxy mouthfeel at eating temperature. Thus, while they can
be employed to provide a desirable effect on texture, they should
not be employed in large amounts.
The use of water-soluble emulsion stabilizers is essen-
tial to provide the necessary stability. These can be any of
, those known to the art for this purpose and will preferably behydrophilic colloids, and can be selected from the group consis-
ting of microcrystalline cellulose, carageenin,. guar gum, algi-
nate, xanthan gum, methyl cellulose, carboxy-methyl cellulose,
ethyl cellulose, hydroxypropolymethyl cellulose, dextrins, starch,
gelatin, locust bean gum, soy protein isolate, pectin and the
like, and mixtures of these. Commercial stabilizers available
from Polak's Frutal Works, Inc. and identified by the manufac-
turer under the trade marks FRIMULSION Q8 and FRIMULSION 10 have
been found effective, especially when used in combination. The
g _
11514~
Q8 product is a blend of modified food starch, locust bean gum,
guar gum, gelatin and pectin, and is preferably employed at a
weight ratio within the range of from about 1:1 to 3:1 to the
FRIMULSION 10 which is a blend of locust bean gum and guar gum.
The stabilizer can be employed in any amount effective
under the conditions of processing and with the particular ingre-
dients. It has been found, however, that levels of abou-t 0.1
to 3.0 percent, based on the total weight of the cbmposition,
are particularly effective. In addition to their emulsion sta-
bilizing function, these materials also,have a viscosity-
increasing effect on the emulsion. However, this effect is not
sufficient in and of itself to con~rol the large amounts of water
present in these emulsions. Thus, the compositions described
herein, unlike the approach taken by Bodor et al. in U.S.
4,103,037, do not depend upon a gelling agent to solidify the
aqueous phase.
The compositions described herein further comprise
an emulsifier system employing both lipophilic and hydrophilic
emulsifiers. The relative and total amounts of the emulsifiers
are selected to be effective to provide a stable emulsion and
a product which is solid at 40F. Typical of effective levels
will be levels of from 0.3% to 4.0~, based on the weight of the
total composition of the total emulsifier system which employs
each of the hydrophilic and lipophilic emulsifiers at levels
of at least 0.05%, on the same basis. The lipophilic emulsifier
will typically have an HLB (hydrophile-lipophile balance), of
less than 7, and the hydrophilic emulsifier will typically have
an HLB of from 10 to 20, preferably from 11 to 17.
The emulsifier system is preferably present at a level
of from 0.5% to 2~, and the lipophilic and hydrophilic emulsifiers
-- 10 --
Al
i
llS1466
are preferably each present at levels of at least 0.10%, all
percentages on a formula weight basis.
The hydrophilic emulsifier will preferably comprise
a member selected from the group consisting of polyoxyethylene
(20) sorbitan monostearate, polyoxyethylene (20) sorbitan monoo-
leate, and mixtures of these.
These emulsifiers, commonly known as polysorbate 60
and polysorbate 80, respectively, are preferred, however, it
is believed that other hydrophilic emulsifiers with an HLB of
between 10 and 20, preferably between 11 and 17, and most prefer-
ably 13 and 16, will be operable. Among other suitable emulsi-
fiers are the polyglycerol esters of fatty acids, such as octa-
glycerol monooleate. Also suitable are other polysorbates, such
as polysorbate 65 which is otherwise known as polyoxyethylene
(20) sorbitan tristearate. Various factors such as off-flavor,
off-color and generally less desirable qualities of these other
materials for use in foods make the aforementioned hydrophilic
emulsifiers the most desirable choice. Polysorbate 60 and 80
are the most preferred because they provide a stiffness and
spreading quality, especially a cold fracture quality, most like
butter and margarine.
Polysorbate 60, polyoxyethylene (20) sorbitan mono-
stearate, is a mixture of stearate and palmitate partial esters
of sorbitol and sorbitol anhydrides condensed with approximately
20 moles of ethylene oxide (C2H4O) for each mole of sorbitol
and its mono- and dianhydrides. It is a lemon to orange colored,
oily liquid or semi-gell having a faint characteristic odor and
a warm, somewhat bitter taste. It is soluble in water, aniline,
ethyl acetate, toluene, and is soluble at low levels in mineral
and vegetable oils. Polysorbate 60 is commercially available
li5146~
under the trade marks TWEEN 60 from ICI-Atlas, SVS-18 from Hodag,
Inc., DREWPONE 60 from PVO International Inc., DURFAX 60 from
SCM Corporation, and GYSPS-20 from Glyco, Inc.
Polysorbate 80, polyoxyethylene (20) sorbitan mono-
oleate, is a mixture of oleate partial esters of sorbitol and
sorbitol anhydrides condensed with approximately 20 moles of
ethylene oxide (C2H4O) for each mole of sorbitol and its mono-
and dianhydrides. It is a yellow to orange colored, oily liquid
having a faint, characteristic odor and a warm, somewhat bitter
taste. It is very soluble in water, producing an odorless, nearly
colorless solution, and is soluble in ethanol, fixed oils, ethyl
acetate and toluene. Polysorbate 80 is commercially available
under the trade marks TWEEN 80 from ICI-Atlas, SVO-9 from Hodag,
Inc., DREWPONE 80 from PVO Internatlonal Inc., DURFAX 80 from
SCM Corporation and GYSPO-20 from Glyco, Inc.
Polysorbate 65, polyoxyethylene (20) sorbitan tristear-
ate, is not as preferred as polysorbate 60 or polysorbate 80,
but still provides an acceptable product. It is a mixture of
steareate and palmitate partial esters of sorbitol and its anhy-
drides condensed with approximately 20 moles of ethylene oxide
(C2H4OI for each mole of sorbitol and its mono- and dianhydr~ides.
It is a tan, waxy solid having a faint, characteristic odor and
a waxy, somewhat bitter taste. It is soluble at low levels in
mineral and vegetable oils; at higher levels in mineral spirits,
acetone, ether, dioxane and methanol; and is dispersible in water
and carbon tetrachloride. Polysorbate 65 is commercially avail-
able under the trade marks TWEEN 65 from ICI-Atlas, DREWPONE
65 from PVO International, Inc., DURFAX 65 from SCM Corporation,
and GYSPTS-20 from Glycol, Inc.
The lipophilic emulsifier of the emulsifier system
~1
lS14fi6
will preferably comprise a member selected from the group consist-
ing of mixed fatty acid monoglycerides; mixed fatty acid digly-
cerides; mixtures of fatty acid mono- and diglycerides; lipo-
philic polyglycerol esters; glycerol esters, such as glyceryl
monooleate, glyceryl dioleate, glyceryl monostearate, glyceryl
distearate, glyceryl monopalmitate and glyceryl dipalmitate;
lactylated esters such as glyceryl-lacto esters of fatty acids;
propylene glycol esters such as propylene glycol monopalmitate,
propylene glycol monostearate and propylene glycol monooleate;
sorbitan esters such as sorbitan monostearate, sorbitan trioleate,
sorbitan tripalmitate, sorbtian tristearate and sorbitan sesqui-
oleate; fatty acids or their soaps such as stearic acid, palmitic
acid and oleic acid; and mixtures thereof. Here, as in the case
of the hydrophilic emulsifier, there is no known criticality
in the use of any particular lipophilic emulsifier. Thus, it
is fully intended that other equivalent materials can be employed
with statisfactory results. However, those specifically identi-
fied above, especially those selected from the group consisting
of lipophilic polyglycerol esters, mono- and diglycerides, propy-
lene glycol esters, lactylated esters, and mixtures of these,are preferred from the stand point of taste and effectiveness.
The products described herein will most closely simulate
butter and margarine when they are suitably colored and flavored
with those materials known to the art for these purposes. Exam-
pleas of coloring agents are beta carotene, annatto, turmeric,
paprika and FD~C dyes. Typically, the colors will be dissolved
or dispersed in oil or the water phase to expedite blending.
Representative of the flavors and/or flavorenhancers will be
sodium chloride; lactones; lipolyzed butter oils and starter
distillates; diacetyl, 2-octanone, and other ketones; butyric
~ 13 -
~1
11514~fi
acid; hexanoic acid and other free fatty acids; esters of butyric
acid; delta-hydroxy acids and their glycerol esters; and mixtures
of any of these with other known dairy, buttery, or like flavors
or flavor notes. It is an advantage of the products described
herein that flavors have a very pronounced impact as compared
to prior art water-in-oii compositions.
In addition to emulsion stability, the products describ-
ed herein are preferably stable against microbiological and oxi-
dative deterioration. To control mold and yeast growth, the
products preferably contain one or more preservatives such as
benzoic acid, sorbic acid, phosphoric acid, lactic acid and the
soluble salts of these and other like materials. Preferred as
antimicrobiais are potassium sorbate, sodium sorbate, potassium
benzoate, sodium benzoate and phosphoric acid. The pH of the
aqueous phase is preferably maintained at a value below 6.0,
and more preferably within the range of 5.0 to 5.9, to provide
effective microbial control and good flavor with the lowest neces-
sary levels of preservatives. Addtional stability against oxida-
tive deterioration at higher temperatures may be obtained by
the use of the usual antioxidants, typical among which are normal
propyl gallate, the several tocopherols, butylated hydroxyanisole
(BHA), butylated hydroxytoluene (BHT), nordihydroguaiaretic acid
(NDGA), tertiary-butylhydroquinon (TBHQ) and citric acid.
While the products described herein do not require
proteins to obtain the proper texture or mouthfeel, they are
sometimes desired for nutritional reasons as well as their posi-
tive contribution to the flavor and physical properties of the
product. Additionally, protein can enhance freeze/thaw stability.
Among the suitable protein materials are any of those known to
the art for similar uses in margarine and margarine substitutes.
These can include those derived from vegetable as well as animal
- 14 -
~l
" 115~46~
-
sources. Thus, vegetable protein isolates such as ~hose derived
from soy, peanut, cottonseed, alfalfa, pea and the like; milk-
protein containing materials such as non-fat dry milk, whey,
caseinates, casein and delactosed whey; and other proteins, can
be employed in desired amounts. One suitable type of protein
is that sold under the MELOTEIN MP-14P trade mark by Dairyland,
Inc. These products are spray dried blends of milk proteins
such assweet dairy whey and caseinates. Typically, they are
added in amounts of up to 10~ based on the total weight of the
spread. Preferred levels will be from 1 to 8~ on this basis.
Also added can be any of the vitamins and minerals
desired. Preferred among these are vitamins A and D which are
normally associated with butter or margarine products. If desir-
ed, these can be added in amounts approximating those in butter
or margarine.
Also where desired, a chelating agent such as ethylene-
diaminetetraacetic acid (EDTA), its salts, such as calcium diso-
dium EDTA or the like can be employed to tie up metal ions which
may otherwise detrimentally interact with one or more of the ingre-
dients.
All of the above ingredients can be formed into the
low-fat, butter-flavored spread described herein by following
the preferred processscheme set out in Figure 3, or otherwise
preparing an oil-in-water emulsion comprising the essential ingre-
dients, and then cooling the emulsion under conditions effective
to solidify it and forma spread which is solid at 40F, prefera-
bly at 70F, and most preferably at 75F.
The flow diagram of Figure 3 shows the separate prepa-
ration of fat and aqueous phases prior to blending and emulsi-
fying them. The water and water-soluble ingredients, such as
- 15 -
,~1
11514~6
milk protein solids, salt and preservatives, are added to mixing
vessel 10 by lines 12 and 14, respectively. The vessel may be
equipped with a suitable heater 16 which can be an electrical
resistance heater, a water or steam jacket or the like. Alter-
natively, the water from line 12 can be supplied hot. Typically,
the water will be heated to a temperature of about 190F to
assure complete hydration of the water soluble materials added.
Agitation is supplied by mixing device 17. Where the stabilizers,
which are water soluble, are mixed with the water at this stage
ln processing, the shear supplied by the mixing must be intense
enough to overcome the normal tendency of these materials to
clump together and prevent complete hydration and dispersion.
It is preferred, however, to predisperse the stabilizers in a
portion of the fat phase prior to contact with water. This can
be accomplished by blending with mixing device 18 in vessel 19,
and then passing to vessel 10 by line 20.
The fat phase is prepared in a separate vessel 21 which
can also be equipped with a suitable heating device 22 and mixing
device 24. The fat-soluble materials such as the color, flavor,
vitamins and emulsifiers, if desired, are added at 26 to the
fat which is added at 28. The hydrophilic emulsifier will prefer-
ably be added to the water phase instead of the fat phase. The
fat is maintained at a temperature high enough to assure its
liquid character. Temperatures of from about 120 to 190F, pre-
ferably about 130 to 150F, are effective to provide good solubi-
lity of additives and a suitably low viscosity.
The fat phase can be drawn from mixing vessel 21 by
line 30 and then passed to vessel 35 wherein it i3 mixed with
the water phase which is supplied by line 36 and may have been
cooled to approximately the same temperature as the fat phase
- 16 -
- 1151466
by means of heat exchanger 38. Adequate mixing is provided by
device 40 which supplies sufficient shear to begin the emulsifi-
cation of the fat lnto the water. At the completion of mixing,
an emulsion will have been formed which uniformly disperses the
fat into droplets within the aqueous phase; however, the droplets
are not broken down finely enough to permit emulsion stability.
The rough emulsion prepared in vessel 35 is then passed
via line 42 to homogenizer 44 wherein the final emulsion is form
ed. The emulsion will, at this point, still be at a temperature
sufficiently high to maintain the fat in the liquid state. Homo-
genization will typically be accomplished at a pressure of from
100 to 500, and preferably about 250, atmospheres. Any of the
typical homogenizers or colloid mills effective for dairy purposes
can be employed in this process. Thus, the Manton-Gaulin 2-
stage homogenizer or the Cherry Burrell 2-stage homogenizer can
be employed effectively.
From the homogenizer 44, the homogenized emulsion is
passed via line 46 to a suitable heat exchanger 48 where it is
cooled. The heat exchanger 48 will preferably be of a kind capa-
ble of rapidly cooling the emulsion. Typical of the suitable
devices are scraped-wall heat exchangers ("A" units), such as
those sold under the VOTATOR trade mark. Typically, the heat
exchange~ coolant will be maintained at a temperature of about
-20F to cool the emulsion rapidly from about 140 to 160F to
below about 70F, and preferably below about 40F.
The cooled emulsion is then preferably passed from
the heat exchanger 48 via line 50 to a mixing chamber 52 wherein
gentle agitation is maintained internally by a suitable rotating
mixing device 54 for a period of time effective to initiate crys-
tallization of the fat and the propagation of the unique physical
- 17 -
A
" ~lSi46i~
structure of the product described herein. The agitation promotes
crystalli~ation and enhances solidification. According to the
most preferred mode of operation, a series, preferably about
three, "A" units cool the emulsion, and a blender ~"B" unit)
is positioned at the end of the series, or between two of the
"A" units in the series, to aid in promoting crystallation.
The spreads described herein can be printed into sticks,
formed into pats or filled into tubs. Thus, these spreads, des-
pite their low fat contents and high water contents, have the
physical appearance, as well as other characteristics, of high
quality margarine or butter.
The following examples are presented for the purpose
of further illustrating and explaining the present invention
and are not to be taken as limiting in any regard. ~nless other-
wise indicated, all parts and percentages will be by weight.
Example I
This example describes the preparation of a preferred
spread as described above and details the procedure for obtaining
the microphotographs shown in Figures 1 and 2.
The spread was made from the following materials which
were employed in the amounts listed:
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Amount
Ingredients Iparts by wt.)
Coconut oil, 92F Wiley melting point l9.0000
Mono- and diglycerides(a) 0.5000
Polyso~bate 60(b) 0-5000
Beta carotene (30% in oil) and vitamins 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer(C) 1.0000
Stabilizer(d) 0~4000
Water 76.6743
Potassium sorbate 0.1300
Sodium Benzoate 0.1000
Phosphoric acid 0.0150
Calcium disodium EDTA 0.0057
(a) DUREN 114
(b) DURFAX 60
(c) FRIMULSION Q8
(d) FRIMULSION 10
An aqueous phase was prepared by heating the water
to 190F and adding the dry ingredients, and the FRIMULSION
Q8 and 10 stabilizers predispersed in a portion of the melted
fat, to it with agitation. Mixing was continued until the stabi-
lizers were uniformly dispersed and hydrated.
A separate fat phase was prepared by melting the remain-
ing portion of the fat and the emulsifiers at a temperature of
about 150F. The color and flavor were then admixed with the
melt to obtain a uniform blend.
The aqueous and fat phases were then blended at about
* A trade mark - 19 -
i~S1466
;
160F to provide an emulsion. The emulsion was then homogenized
in a Gaulin Laboratory homogenizer, Model 15M, set at 150 atm.
first stage and 100 atm. second stage.
The emulsion was then cooled to 40F in about 15 min-
utes by slowly agitating with a Hobart Modei N50 mixer fitted
with a wire whip and a jacketed (water/alcohol coolant at appro-
ximately -20F) 5-quart mixing bowl. The resulting product was
transferred to a tub and refrigerated for 24 hours. The result-
ing solidified spread exhibited a penetrometer reading of 130
10 units when measured by a Krebs Penetrometer with a standard pene-
trometer cone having a 2.5 inch diameter and a 45 angle, with
47.5 grams added weight at a 5-second interval. ~Penetrometer
procedures according to ANS/ASTM D217-68).
The spread was prepared for microphotography by placing
a very small amount of product on a glass slide and carefully
covering with a cover glass. Photographs at 225 and 500 times
magnification were prepared and are reproduced in Figures 1 and
2.
The final product was then heated to determine the
20 stability and viscosity of the emulsion at various temperatures.
Using a Brookfield RVT Viscometer fitted with a number 1 spindle,
the emulsion exhibited the following viscosities at 10 rpm:
100F - 880 centipoises
150F - 500 centipoises
200F - 310 centipoises
The emulsion was stable at all of these temperatures.
The product was tested to determine the type of emul-
sion by microscopic and colorimetric analysis. Under the micro-
scopic test, a small amount of the product was placed on a micro-
30 scope slide. A drop of water was then placed near the outer
-- 20 --
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edge of the product. The interface between the product and thewater was then observed. If the emulsion was diluted, i.e.,
water from the droplet entered the emulsion, the emulsion was
of the oil-in-water type, with the water being the continuous
phase. Under the colorimetric test, an intensely colored fruit
juice, such as grape, elderberry, raspberry or the like, was drop-
ped on the surface of the product. If the color was absorbed
by the product, the emulsion was of the oil-in-water type. If
no color was absorbed, the emulsion was of the water-in-oil type.
Under both tests, the emulsion of this example was found to be
oil-in-water.
Example II
This example describes the preparation of another
spread. The details of the procedure were the same as in Example
I. The only difference was that dairy solids were added and
the proportions of the other ingredients were adjusted according-
ly .
The spread was made from the following materials which
were employed in the amounts listed.
~1
1~514~;
Amount
Ingredient ~parts by wt.)
Coconut oil, 92F Wiley melting point18.5000
Mono- and diglycerides(a) 0.5000
Polysorbate 60 (b) 0.5000
Beta carotene (3096 in oil) and vitamins 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer(C) 1.0000
Stabilizer(d) 0,4000
Water 73.6743
Potassium sorbate 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0150
Whey/caseinate blend(e) 3.5000
Calcium disodium EDTA 0.0057
_
(a), (b), (c) and (d): see Example I.
(e) MELOTEIN MP-14P.
The solidified spread exhibited a penetrometer reading of 175
units when measured as in Example I.
Example III
This example describes the preparation of another
spread, but this time containing about 30% fat. The procedure
was the same as in Example I. The spread was made from the fol-
lowing materials which were employed in the amounts listed:
* A trade mark
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:11514~6
Amount
Ingredient (parts by wt.)
Coconut oil, 92F Wiley melting point 29.0000
Mono- and diglycerides(a) 0.5000
Polysorbate 60(b) 0.5000
Beta carotene (30% in oil) and vitamins 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer(C) 1.0000
Stabilizer(d) 0.4000
Water 66.6743
Potassium sorbate 0.1300
Sodium bensoate 0.1000
Phosphoric acid 0.0150
Calcium disodium EDTA 0.0057
(a), (b), (c) and (d): see Example I.
The resulting solidified spread exhibited a penetrometer reading
of 166 units when measured as in Example I.
Exam~ e IV
This example describes the preparation of yet another
spread, again employing the procedure of Example I, but this
time utilizing only 10% fat. The spread was made from the follow-
ing materials which were employed in the amounts listed:
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il51~
Amount
Ingredient (parts by wt.)
Coconut oil,, 92F Wiley melting point 9.0000
Mono- and diglycerides(a) 0.5000
Polysorbate 60(b) . 0.5000
Beta carotene (30% in oil) 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer (c) 1.0000
Stabilizer~d) 0.4000
Water 86.6791
Potassium sorbate , 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0150
Calcium disodium EDTA 0.0057
(a), (b), (c) and (d): see Example I
The penetrometer reading for the final product was 227 when
measured as in Example I.
Example V
This example describes the preparation of another
spread, but this time utilizing different stabilizers. The
spread was made from the following materials which were employed
in the amounts listed:
-- 24 --
~ !
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:`
Amount
Ingredient (parts by wt.)
Coconut oil 92F Wiley melting point 20.0000
Mono- and diglycerides(a) 0.5000
Polysorbate 60(b) . 0.5000
Beta carotene (30% in oil) and vitamins 0.0035
Salt 1.6500
Butter flavor 0.0320
Stabilizer (89% micro-crystalline2.1000
cellulose and 11% sodium carboxy-
methyl cellulose)(f)
Water 74.9613
Potassium sorbate 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0250 ~-
_
(a) and (b): see Example I
(f) AVICEL 581, FMC, Inc.
The procedure was essentially the same as that of
Example I, but differing in that: the water was heated to only
160F; and the oil was heated to only 130F.
The penetrometer reading for the final product was
82 units when measured as in Example I.
Example VI
This example describes the preparation of another
spread, but this time employing a different emulsifier system.
Except for the change in formulation, the process was the same
as in Example I. The spread was made from the following mate-
rials which were employed in the amounts listed:
* A trade mark
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1~51q~
Amount
Ingredient (parts by wt.)
Coconut oil, 92F Wiley melting point 17.5000
Glyceryl-lacto esters of fatty 0.5000
acid, lipophilic emulsifier(g~
Octaglycerol monooleate, hydro- - . 2.0000
philic emulsifier (HLB=13.0)
Beta carotene (30% in oil) 0.0050
Salt 1.6500
Butter flavor . 0.0200
Stabilizer (c) 1.0000
Stabilizer(d) 0.4000
Water 76.6743
Potassium sorbate 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0150
Calcium disodium EDTA 0.0057
(c) and (d): see Example I
(g) DURLAC 100 WK
20 The resulting solidified spread exhibited a penetrometer reading
of 117 units when measured as in Example I.
* A trade mark - 26 -
~ '
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Example VII
This example describes the preparation of anotherspread, but this time employing soybean oil and employing a lower
level of polysorbate 60 than in Example I. The process was the
same as in Example I. The spread was made from the following
materials which were employed in the amounts listed:
Amount
Ingredient (parts by wt.)
Soybean oil, partially hydrogenated(h) 19.2500
Mono- and diglycerides(a~ 0.5000
Polysorbate 80(b) 0.2500
Beta carotene (30% in oil) and vitamins 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer(C) 1.0000
Stabilizer(d) 0.4000
Water 76.6743
Potassium sorbate 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0150
: Calcium disodium EDTA 0.0057
_
(a), (b), (c) and (d): see Example I
(h) TEM-Plus 95, Swift, Inc.
The resulting spread exhibited a penetrometer reading of
199 units when measured as described in Example I.
* A trade mark 27 _
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Exam~le VIII
This example describes the preparation of another
spread, but this time employin~ polysorbate 80 in place of the
low level of polysorbate 60 in Example VII. The process was
the same as in Example VII. The spread was made from the follow-
ing materials which were employed in the amounts listed:
Amount
Ingredient (parts by wt.)
Coconut oil, 92F Wiley melting point 19.2500
Mono- and diglycerides( ) 0.5000
Polysorbate 80(i) 0.2500
Beta carotene (30% in oil) and vitamins 0.0050
Salt 1.6500
Butter flavor 0.0200
Stabilizer(C) 1.0000
Stabilizer~d) 0.4000
Water 76.6743
Potassium sorbate 0.1300
Sodium benzoate 0.1000
Phosphoric acid 0.0150
Calcium disodium EDTA 0.0057
_
(a), (c) and (d): see Example I
(i) DURFAX 80
The resulting spread exhibited a penetrometer reading of
182 units when measured as in Example I.
* A trade mark _ 28 _
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Example IX
A comparison was made between the product prepared
according to Example I, conventional margarine products (both
soft and stick) and a commercial diet margarine substitute.
Margarine will typically contain:
Amount
Inqredient Iparts by wt.)
Partially Hydrogenated Vegetable Oil 80.000
Lecithin 0.100
Mono- & Diglycerides 0.150
Color, Flavor, Vitamins 0.020
Dairy Solids 1.600
Salt 2.000
Water 16.130
To prepare the margarine it will typically be processed
by blending oil (130F) and water (50F) phases either in-line
or in an emulsion tank. The emulsion ls pumped through a series
of coollng scraped surface heat exchangers (usually 3). A blend-
er ("B" unit) is usually positioned between the second and third
heat exchanger or after the third heat exchanger, to aid in pro-
moting crystallization. The product is normally filled ln the
40-50F range.
The margarines made in this manner are available in two
general types - soft, which is sold in small plastic dishes
called tubs; and stick, which is sold in sticks like butter.
A diet margarine substitute will typically contain:
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-- . ...
115146:~;
Amount
Ingredient (parts by wt.)
Partially hydrogenated vegetable oil 39.40
Monoglycerides 0.50
Lecithin 0.10
Vitamin, Color and Flavor Mix 0.01
Water 57.78
Salt 2.00
Preservatives 0.21
To prepare the diet margarine substitute a water-in-
oil emulsion is prepared by blending the oil phase (120F) with
the water phase (95F~ in an emulsion tank. The emulsion is
pumped through a series of cooling, scraped-surface heat exchang-
ers (usually 3). A blender ("B" unit) is usually positioned
between the second and third heat exchanger or after the third
heat exchanger, to aid in promoting crystalliæation. The product
is normally filled in the 70 - 75F range. Diet products proces-
sed in this manner are normally available only in the soft form,
which is sold in small plastic dishes called tubs. Taking the
product produced in Example I, a commercial soft margarine, a
commercial stick margarine and a commercial diet margarine sub-
stitute, the penetrometer readings were taken as discussed in
Example I.
Penetrometer Data (40F)
Ran~e Average
Example I 117-143 130
Soft Margarine 103-174 131
Stick Margarine 80-133 113
Diet Margarine substitute 135-180 155
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