Note: Descriptions are shown in the official language in which they were submitted.
s
TTRll SYNTHETIC FOOD PRCDUCT
This invention relates generally to a process for
manufacturing an edible food product, and the product
so manufactured. In a particular application of this
invention, the edible food product can be used to
replace the well-known potato skin shells which are
typically stuffed with mashed or pre-garnished potato,
frozen, and sold as quick prepared stuffed potato.
Background of thls Invention
I~ is known to use certain kinds of thin casings
for sausages and the like, these being normally made
from extruded tubes of film plastics, or cleaned animal
intestines. Other casings are the thick shells or
casings normally made from flour, starch and/or
colloidal materials which are molded and dried or
baked. An example would be ice-cream cones.
However, the baked potato shells currently
available on the market are made from real baked
potatoes from which the content has been removed. The
shells are then refilled with pre-garnished mashed
potatoes, frozen and marketed as frozen baked stuffed
potatoes.
The main problem with the natural baked potato
shell has to do with the tediousness and expense of
preparing them. Further, there is no guarantee of
consistent quality or complete safety, because it often
happens that bits of grit and dirt remain on the skin,
despite rigorous cleaning.
Prior Patents
Applicants are aware of the following prior U.S.
patents of general interest to this area:
Patent Issued Applicant(s)
2802744 Aug. 13, 1957 Weingand
2813034 Nov. 12, 1957 Weingand et al
35 3494772 Feb. 10, 1970 Bradshaw et al
2897547 Aug. 4, 1959 Weingand
2965498 Dec. 20, 1960 Hartwig et al
2973274 Feb. 28, 1961 Langmaack
3362831 Jan. 9, 1968 Szczesniak
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Patent Issued ~licant(s)
3~93382 Feb. 3, 1970 Ryan et al
3687688 Aug. 2q, 1972 Stapley et al
3925566 Dec. 9, 1975 ~einhart
5 3962482 June 8, 1976 Comer et al
~089981 May 16, 1978 Richardson
4348418 Sept. 7, 1982 Smith et al
The foregoing patents generally disclose the use
of certain known organic materials in the manufacture
of edible casings for sausages, and the like.
Some of the patents refer to the use of an
alginate to make artificial food products, for example
U.S. Patent 3362831. Other patents refer to the
preparation of an edible synthetic product
incorporating glycerine, carrageenan and tapioca
starch. An example is U.S. Patent 3493382. The
material caseinate, and specifically sodium caseinate,
is disclosed in U.S. Patent 3925566 in terms of its use
in the preparation of a simulated meat product.
Some of the above-listed patents also discuss a
process by which sodium atoms can be replaced by
calcium atoms, by contacting the sodium alginate with a
calcium chloride solution. An example is U.S. Patent
2802744.
However, the applicants have gone beyond the
various processes and formulations set forth in the
prior patents, and have produced an edible food product
which, though obviously adaptable to other uses in the
food field, has shown itself to be ideal to provide a
synthetic potato skin which has a taste and consistency
very closely approximating the natural item.
General Description of the Invention
Although this invention will be described in the
context of producing an edible film especially adapted
when molded to resemble natural materials such as baked
potato shell, it will be understood from what follows
that the essence of the invention is not so restricted.
In essence, this invention provides a process for
manufacturing an edible food product, comprising the
steps:
~g~
a) making a mixture of
- a monovalent alginate salt
- a monovalent caseinate salt
- carrageenan
b) ad~ing the mixture to water at a temperatùre
high enough to brlng about substantially complete
dissolution, the amount of water being sufficient to
create with the mixture a thick, smooth slurry,
c) spreading the slurry as a film on a surface and
heating it to a temperature elevated above room
temperature to cause partial drying thereof, and
d) contacting the film with a solution of CaC12.
This inven~ion also includes the product itself,
when manufactured by the above process.
Detailed Descri~tion of the Invention
A satisfactory formula for producing an edible
food product suitable for molding as instant baked
potato shell is the following. Preferred weight
proportions are given in the middle column. The
right-hand column gives acceptable ranges for the main
ingredients. Ranges in parentheses are for ingredients
of secondary importance and are not critical.
Ingredient Parts by Preferred
Weight Range
A monovalent alginate salt,
25 preferably sodium alginate 1.5 0.6-2.9
A monovalent caseinate salt,
preferably sodium caseinate 3.0 1.0-5.5
Carrageenan 0.9 0.6-3.0
Wheat bran 1.5
30 Cooking oil 1.0 (0.5-~ 0)
Coloring (caramel) 0.25
Glycerine 1.0 (0.5-2.0)
The three primary and preferred materials are the
first three listed, namely sodium alginate, sodium
3S caseinate and carrageenan. All three of these
materials are gelling agents which are capahle of
forming an aqueous slurry with water, provided the
temperature of the water is high enough to cause
dissolution. These three materials exhibit different
degrees of crispiness and elasticity upon drying. For
example, the sodium caseinate tends to have a
substantial degree o- elastici~y, and thus resis~s
cracking upon being bent. However, from the viewpoint
of edibility, the sodium caseinate tends to be rather
tough, chewy and leathery if used alone. At the other
end of the scale is carrageenan, which tends to produce
a rather crisp and brittle material upon drying. If
used alone, it would tend to be too brittle to hold a
proper shape. The sodium alginate falls somewhere
between the sodium caseinate and the carrageenan in
terms of these properties.
All three of these primary materials are readiiy
available in powdered form, and it is in this form chat
the present invention contemplates their use.
The wheat bran suggested in the above formula is
provided for its nutritional value, and for the food
fiber which it contains. It is not powdered, and does
not mix homogeneously with the other ingredients. It
lends chewability and an attractive appearance to the
final product. However, it should be considered merely
as an optional additive, depending upon the degree of
nutrition and fiber that is desired, and the required
final appearance of the product. For these reasons, no
range of parts by weight need be given.
Cooking oil is added mainly as a lubricant, since
it facilitates removal from a mold, and release from a
surface upon which the slurry is spread as a thin film.
Any suitable edible lubricant could be utilized.
The purpose of the coloring material is
self-evident. Caramel is the preferred coloring since
it is a natural substance rather than an artificial
one, and it does tend to give a shade of coloring
similar to that of a baked potato skin. No range of
parts by weight need be given.
Glycerine is added to increase the flexibility of
the final product, although it may not be necessary
depending upon the proportions of the first three
ingredients.
~21~L65
The first step in the process is to mix the above
ingredients thoroughly. Then, a suitable quantity of
water is added with constant stirring at ~ temperature
between about 40C and about 60C, until a smooth
slurry is obtained. We have found that a satisfactory
slurry can be made by mixing 10 parts of the mix with
90 parts of water.
The resultant slurry is then spread or coated on a
suitable surface. In the experimental work which we
have carried out, the surface was provided by a glass
plate, although on a production scale installation, the
slurry could be coated on a moving stainless s'_eel belt
as a continuous procedure.
The material must then be heated to a t~nperature
elevated above room temperature, to cause partial
drying. We have found that heating the film on the
plate to a temperature between about 90C and 100C for
a period of between 35 minutes and 45 minutes is
sufficient to remove most of the water added ~o make
the slurry, and results in a unitary film which can be
removed from the plate without disintegration.
However, one further step is necessary in order to
ensure that the film will retain its integrity when
contacted with a moist filling material. This step is
to contact the film with a solution of calcium chloride
(CaC12), so that some of the sodium atoms in the film
are replaced by calcium atoms from the calcium chloride
solution. The calcium bond tends to be stronger than
the sodium bond, and thus this step adds strength to
the film. In particular, it has been noted that the
step of contacting the film with the solution of
calcium chloride allows the film to retain its
integrity even when later contacted with a moist
filling material.
The contact with the calcium chloride solution can
be done either by dipping the film in a water bath for
a given period of time, or by spraying a suitable
amount of calcium chloride solution onto the film. We
have found, however, that by spraying a specific weight
165
of calcium chloride solution of a given percentage, the
result ~f the atomic displacement process is to give a
quantity of released ~aCl (table sa]t) that is able to
provide a complimentary salt taste. If there is too
great a degree of atomic displacement, with a resultant
large quantity of NaC1 being released the excessive
salty taste may require an extra water spray for its
removal. Because the degree of saltiness is dependent
upon the degree of atomic displacement of sodium atoms
by calcium atoms, this subsequent rinse in a water bath
or a spray is regarded as optional. Where the optional
additional water rinse is employed, a fu;ther drying
step may also be necessary.
The next primary step is that of irolding, where
the film is intended to provide an article like a baked
potato skin. Molding can be carried out in a mold made
of aluminum or other suitable material, having a male
and female part.
The molding can be done either wi~h a room
temperature mold or with a mold operated at an elevated
temperature, for example 110C. If the mold is
operated at room temperature, then a subsequent drying
step is required, in which the molded product can be
subjected to a stream of hot alr in the region of 60C
to 80C for from 10 to 30 minutes. However, by the use
of a mold heated to the region of 110C, the molding
and drying can take place simultaneously, and a time
saving can be effected.
The intended filling material for the manufactured
potato skin can be obtained by first peeling, slicing,
washing and cooking potatoes that have a high dry
matter content. The cooked potatoes are then mashed
hot and whipped for about 2 minutes. During mashing, a
small quantity of potato granules or flakes or other
suitable dry material such as milk powder may be added
to make the mash drier and mealier. Other materials
such as salt, butter, cheese, flavorings (e.g. baked or
mashed potato flavor) may be added at this stage as
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well. Short whipping of the mash will make its texture
lighter and fluffier.
The shell is then filled with the mash, and the
filling should be substantially complete so as to
reduce possible shrinkage during freezing and
reheating. The product may be frozen cryogenically or
in a batch or continuous air-b]ast freezer. It is
worth remarking that the freezing should be as quick as
possible. Slow freezing is undesirable because it
tends to create ice crystals that are too large. Then,
when these crystals thaw they create sogginess in the
product.
Typically, the product may ~e reheated in a
microwave oven at a high power ~etting requiring about
5~7 minutes. In a regular oven at 180C, about 15-~0
minutes is required.
We have found that the reheated product has an
appearance, texture and taste closely resembling those
of superior haked potatoes. The present invention thus
allows "baked potatoes" of a consistent quality, safety
and nutrition to be produced and marketed all year
round.
Our examination of the resultant product shows
that it is an edible film of desirable thickness, with
adequate tear-strength and elastic-strength. These tWQ
qualities may be manipulated by the length of time the
film is dipped in a CaC12 solution, or by the amount of
the solution sprayed on it. The film is easily molded,
and its texture on chewing is very similar to the
natural skin of many fruits and vegetables. It is
nutritious as it contains a considerable amount of high
quality protein (caseinate). It is also capable of
incorporating dietary fiber, such as that provided by
wheat bran. The film is useful for any products which
require this type of shell for wrapping, for example
cabbage rolls, egg rolls, and potato skins. Further,
it could be molded into an artificial skin for other
fruits or vegetables.
i5
While one embodiment of this invention has been
described hereinabove, it will be evident to those
skilled in the art that changes and modifications may
be made thereto, without departing from the essence of
this invention as set forth in the appended claims.
