Note: Descriptions are shown in the official language in which they were submitted.
` 215610~
Case 21098-1
FAT SYSTEMS AND PROCESSES FOR THE PRODUCTION OF NO
TRANS FATTY ACID CONTAINING STICR-TYPE MARGARINES AND
SPREADS
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to unique stick-type
margarines and spreads which do not contain trans fatty
acids but which possess the desired margarine
characteristics of butter-like flavor, color and physical
properties equivalent to stick-type margarines which do
contain trans fatty acids. More particularly, the unique
fat or oil system(s) of the present invention, which also
do not include any tropical oils, are chemically
interesterified to achieve both physical and functional
characteristics comparable to hydrogenated oils.
Additionally, the final margarine blends require specific
emulsifiers and preferably are manufactured according to
specific processing parameters in order to achieve the
desired stick-type margarine or spread products.
DESCRIPTION OF THE PRIOR ART
Margarine is a fatty food manufactured in semblance
of butter in flavor, color, physical properties and
composition except that the fat is not principally
milkfat. More specifically, margarine is generally a
water-in-oil emulsion, i.e. a suspension of one liquid
within a second immiscible liquid. In margarine, the fat
component is known as the continuous or oil phase while
~- 2~ ~6103
the dispersed or aqueous phase consists of water and/or
water dispersible components. Margarine is generally
defined as a composition containing at least 80~ fat (or
oil) by weight and about 20% by weight aqueous phase. In
contrast, emulsions containing less than 80~ by weight
fat are spreads. Both are manufactured in several forms
including stick, tub, whipped and liquid forms.
The fat in margarine is primarily completely
processed (i.e. refined, bleached, hydrogenated and
deodorized) mixed triglycerides (also known as
triacylglycerols) of vegetable or animal carcass origin.
Triglycerides are triesters of glycerol and various
saturated and unsaturated fatty acids. The physical
properties of fats are determined by the characteristics
of the individual fatty acid moieties and by their
distribution within the triglyceride molecule. For
purposes of making a suitable stick-type margarine, the
fat must have a plastic consistency at refrigeration or
ambient temperatures and yet have the essential
characteristic of melting readily and with substantial
completeness in the mouth of the consumer. Such a melting
characteristic normally requires a solid fat index (SFI),
which has specific values over a temperature range
established by accepted methodology [American Oil
Chemists' Society (AOCS) Official Method Cd 10-57]. In
addition, plastic margarine fats must have a crystal
habit which provides a smooth organoleptic consistency
without graininess or similar mouthfeel defects in
homogeneity.
The physical properties of the margarine are derived
predominantly from the composition of the fat, as well as
the processing technique in making the margarine.
Margarine is generally prepared from edible fats which
are physically modified by hydrogenation and/or
~156103
interesterification. In the United States, hydrogenation
has been the principal means of oil modification.
Hydrogenation is the chemical reaction of fats and
oils with hydrogen gas in the presence of a catalyst
which results in the addition of hydrogen to the fat,
thus transforming unsaturated bonds into saturated bonds
along with other reactions. The process of hydrogenation
of fats results in the raising of the melting point of
edible fats and improving the resistance of the fat to
oxidative deterioration. Hydrogenation also generates
positional and geometrical isomers.
Tropical oils, such as coconut, palm and palm kernal
have been conventionally utilized as a component of
margarine fats as they have acceptable melting and
solidification properties resulting from their higher
levels of intermediate carbon chain saturated fatty
acids. However, consumers have been increasingly
concerned in recent years about the saturated fat content
in the foods they eat and the effect of such foods on
their health. In fact, saturated fat has been shown in
numerous studies to increase levels of cholesterol in the
blood and has been linked to increased risk of heart
disease. Consequently, it is no surprise that consumers
conscientiously look for foods low in saturated fat
content. Accordingly, in order to reduce the saturated
fat, it is desirable to find suitable replacements for
tropical oils in margarine formulas with alternatives
that maintain the same flavor, color and physical
properties provided by tropical oils.
Vegetable oils or domestic oils, i.e. non-tropical
oils, such as soybean, corn, cottonseed, peanut, sesame,
and the like, may be partially hydrogenated in order to
achieve margarine oils of the requisite physical
characteristics which tropical oils provide. Usually,
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selectively hydrogenated oils are blended in order to
achieve the required physical characteristics for
margarine. More particularly, the desired consistency has
been typically obtained by blending two or more partially
hydrogenated vegetable oils, or blending liquid
(unhydrogenated) vegetable oil with a partially
hydrogenated vegetable oil. Conventional partial
hydrogenation of vegetable oils containing unsaturated
acids, depending on catalyst selectivity, degree of
hydrogenation and other processing variables, produce
substantial amounts of unsaturated fatty acids of the
trans-configuration rather than the naturally occurring
cis-configuration.
The term "trans-acid" or "trans fatty acid" as used
lS herein refers to an unsaturated fatty acid having a
carbon chain length of from generally 16 to 24 carbon
atoms and having at least one unsaturated carbon-carbon
bond which is in the trans-configuration. In conventional
margarine fat prepared from partially hydrogenated
vegetable oil, the trans acid content may exceed 25% by
weight or more of the margarine fat composition. This is
a result of the partial hydrogenation conditions which
are required to provide an acceptable solid fat index for
a margarine fat. Unfortunately, the presence of such
trans isomers of fatty acids in the diet have also become
the target of concern in relation to the consumers'
dietary health. Accordingly, margarine fat systems are
desired which contain no detectable amounts of such trans
acid moieties, or are present at levels which are
nutritionally insignificant, yet have the flavor, color
and physical properties of margarines which contain trans
fatty acids.
Apart from vegetable oils being hydrogenated to
achieve desired results, vegetable oils intended to be
2t5610~
-- 5
used for any food preparation purposes are also processed
by first subjecting them to the well known techniques of
alkali or physical refining, bleaching and steam
deodorization. See BaileY's Industrial Oil And Fat
Products, Wiley-Interscience Publishers (1982), Chapter 4
of Volume 2 for a detailed description of refining and
bleaching, and Chapter 3 of Volume 3 for a detailed
description of deodorization, both of which are
incorporated by reference herein.
The alternate method of chemically modifying edible
fats mentioned earlier is the process of
interesterification and the related process of
transesterification. This is a technique which may also
be used to alter the triglycerides profile and therefore
lS ultimately the physical properties of the resulting
triglyceride mixtures. Both chemical and enzymatic
interesterification are well known for modifying the
triglyceride profile of fats and oils.
Chemical interesterification is based on the use of
a chemical catalyst, such as sodium methoxide or sodium
metal, to promote the migration of the fatty acid
moieties between triglyceride molecules and to produce a
random redistribution of the fatty acid moieties.
Enzymatic transesterification may be used for selective
interchange under relatively mild reaction conditions.
As stated earlier, in addition to the composition of
- the fat, the physical properties of the margarine are
also influenced by the processing parameters. In standard
margarine manufacture, the aqueous phase is dispersed in
the oil phase and the resulting emulsion is then sent
through a scraped surface heat exchanger such as a
Votator A-Unit. The A-Unit supercools the emulsion with ~l
relatively short residence time. The supercooled emulsion
is then sent to a crystallizer known as a static B-Unit,
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6 --
in the form of a jacketed hollow tube or "resting tube",
normally used to provide firm stick-type margarine. By
comparison, "working B-Units", for example in the form of
picker units, serve to break up larger crystals, which
affects solidification properties.
8UMMARY OF THE INVENTION
The present invention relates to stick-type
margarines and spreads which are essentially free of
trans fatty acids or tropical oils but yet possess the
butter-like attributes of margarines which contain and
are dependent upon the existence of trans fatty acids or
tropical oils. More specifically, the butter-like
characteristics of the stick-type margarines and spreads
made in accordance with the present invention are
obtained by the use of specific oil blends which are to
be used as the base oil in the emulsion, the use of
specific emulsifiers and the preferred implementation of
specific processing parameters. By essentially free of
trans fatty acids is meant that the level of trans fatty
acids is negligible, typically below 2% by weight of the
margarine oil.
BRIEF DESCRIPTION OF THB DRAWINGS
FIG. 1 is a schematic diagram illustrating the
process of making stick-type margarines and spreads in
accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to stick-type
margarines and spreads which not only possess all of the
desired butter-like characteristics such as flavor, color
and physical properties, but which also meet growing
health concerns. That is, the stick-type margarines and
2~56103
spreads made in accordance with the present invention are
essentially free of trans fatty acids, the isomeric form
of unsaturated fatty acids which have been linked to
health risks such as heart disease. In addition, the
stick-type margarines and spreads of the present
invention do not incorporate tropical oils which contain
relatively high levels of saturated fatty acids. Certain
saturated fatty acids have been identified as having
potential health risks.
It has surprisingly been found that stick-type
margarines and spreads can be made essentially free of
trans fatty acids or tropical oils and yet maintain the
desired qualities of a superior margarine or spread
product. The stick-type products made in accordance with
the present invention can be obtained by the
implementation of a combination of factors, namely a
unique oil blend to be used as the base oil in
formulating the margarine or spread emulsion, specific
emulsifiers and preferably specific processing conditions
which deviate from the conventional processes involved in
making margarines and spreads but which enable comparable
products of the present invention to be made.
As stated above, the oil blends to be used in
formulating the base oil fat blend of the margarine or
spread emulsion is the first important factor critical to
the present invention. The base oil of the present
invention is comprised of only domestic oils, i.e. no
tropical oils are present.
More particularly, the base oil, which is utilized
in the present invention, is a blend of refined domestic
vegetable oil (i.e. liquid oil) and refined and bleached
fully hydrogenated vegetable oil (hereinafter referred to
as "hardstock~'). This specific blend is subjected to the
interesterification reaction which may be random,
2 1 ~ 6 1 0 3
8 --
directed or enzymatic. In the case of random
interesterification, the reaction is generally carried
out with about 0.1~ to about 0.5~ by wt. (usually based
on starting free fatty acids (FFA)) of a suitable
catalyst, for example, preferably sodium methoxide
(methylate) at temperatures from about 60C to about
100C for a period of about 3 to about 120 minutes with
agitation while under vacuum or inert atmosphere. After
the reaction achieves equilibrium, the reaction is
terminated through catalyst inactivation with eitner 1~
to 3% by wt. of water or a dilute acid solution such as
citric or phosphoric acid. The subsequent removal of
residues, such as metallic soaps and mono-diglycerides,
is carried out by traditional edible oil processing
methods which include, but is not limited to, water
washing, centrifugation, vacuum drying, bleaching with
acid activated or neutral bleaching/filtering media and
deodorization.
The base oil to be used in the present invention is
an co-interesterified blend of a domestic oil, preferably
a refined and bleached domestic oil and a refined,
bleached and deodorized hardstock in proportions by
weight of about 85:15 to about 60:40, preferably from
about 80:20 to about 70:30. It is again noted that it is
important that the vegetable oil hardstock be fully
hydrogenated, and thus fully saturated in order that no
trans fatty acids are formed. It is further noted that
the hardstock have an Iodine Value (IV) of less than or
e~ual to 5.
The IV of a fat or oil measures the number of grams
of Iodine absorbed by 100 grams of sample as determined
by A.O.C.S. Method Cd 1-25, also known as the Wijs
method. Iodine is absorbed by double bonds within the
fatty acids comprising an oil or fat molecule
~1~6103
g
(triglyceride) which is given to be an indication of an
oil or fat's relative unsaturation. The amount of solid
fat present at a given temperature for unhydrogenated
fats or oils relates to the amount of saturated fatty
acids found in the array or triglycerides unique to the
fat or oil. Therefore, the lower the IV of a given fat
or oil, the greater the saturation and solid content will
be at a given temperature. For example, cocoa butter and
cocoa butter substitutes and extenders usually have an IV
of about 35 or less.
Although refined and bleached, soybean oil and
canola oil are preferred as the domestic vegetable oil to
be used in the base oil of the present invention, other
domestic vegetable oils can be used. They include, but
are not limited to, cottonseed oil, corn oil, peanut oil,
sunflower oil, safflower oil, high erucic acid rapeseed
oil (HEAR) and the like, as well as genetically altered
varieties of these oils.
Similarly, the hardstock to be used in the oil blend
of the present invention, together with the domestic
vegetable oil, may be chosen from a wide variety of
edible liquid vegetable oils or domestic oils, including
soybean oil, cottonseed oil, corn oil, canola, peanut
oil, sunflower oil, safflower oil, high erucic acid
rapeseed oil (HEAR) and the like. Cottonseed oil,
soybean oil and mixtures thereof are most preferred as
the hardstock, as well as genetically altered varieties
of these oils.
The base oil compositions described above are to be
used in making stick-type margarine or spreads. In the
market place, margarine is generally sold as one of two
principal types, print or stick, and soft or tub
margarine with minor amounts sold as whipped or liquid.
Print or stick-type margarine generally have a firmness
2156103
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consistent with a penetration range of from 35 to 120,
said measurement being in units of 0.1 mm using an ASTM
grease cone at 45F. Soft or tub margarine, on the other
hand, as one would expect, does not have to be as hard as
stick-type margarine and generally has a firmness
consistent with a penetration range of from 130 to 250.
Lesser amounts of ~argarine are sold in a form so soft
that it is fluid, being at least capable of being
squeezed from a flexible container. Accordingly, it can
be seen that depending upon the desired product type,
both composition of the oil phase, as well as the
processing parameters, play an important role.
The stick-type margarine base oil formulas in
accordance with the present invention further include
emulsifiers which will be discussed below. It is noted
here, however, that without the addition of the specific
base oil and specific emulsifiers, the emulsion products
would not have the necessary plasticity, i.e.
spreadability, mouthfeel, or the thermal stability
(cycling from refrigerated to room temperatures)
necessary for acceptable stick-type products.
The mixtures of oils or fats to be used in the stick
base oil formulas of the present invention are
interesterified, in admixture or separately, and
surprisingly achieve physical and functional
characteristics comparable to hydrogenated oils, without
the presence of trans fatty acids which are normally
found in partially hydrogenated oils.
For the purpose of making margarines, the oil phas~
described above must make up at least 80~ by weight of
the margarine to meet the fat requirement set forth by
the Standards of Identity for margarine. Still, the
present invention is further directed to the use of thr
oil blends described above in the preparation of calori~
2156103
reduced margarines (diet margarines), bulk food processor
margarine and spreads, blends with dairy products and
other spreads containing less than 80~ by weight fat by
weight. For purposes of making emulsified products,
which include margarine and spreads, the oil phase may
range from about 25% to 90~ by weight.
It is important to note that the percentages of said
oil phases given above include, in addition to the
indicated base oil, emulsifiers, and optional colorings,
oil-soluble flavors, vitamins and antioxidants.
Of the additional components which may be added to
the oil phase in addition to the base oil, the second
critical factor for the purposes of making the products
in accordance with the present invention is the presence
of specific emulsifiers. The specific emulsifiers to be
used in the oil phase of the present invention are non-
plastic fully hydrogenated distilled monoglycerides such
as Myverol 1807~ (Eastman Chemical, Kingsport, TN).
Lecithin is also used in the oil phase of the emulsions
in accordance with the present invention. The non-
plastic distilled monoglycerides act to help formulate
the water-in-oil emulsion and, in addition, provides
necessary physical integrity and plasticity to allow
machinability (forces inherent in forming and packaging).
Lecithin, to a lesser extent, has the same function as
conventional emulsifiers. However, lecithin also
functions to impart the primary salt perception to the
product as well as being a known anti-spattering
additive. The non-plastic distilled monoglycerides may
be present in the oil phases of the present invention in
an amount from about 0.2% to about 3.0~ by weight based
upon the total weight of the margarine or spread.
Preferably, the non-plastic distilled monoglycerides are
~156103
.
- 12 -
present in an amount of from about 0.3% to about 1.0~ by
weight.
With respect to the optional components of the oil
phase, examples of typical coloring agents which may be
added include beta-carotene, annatto, turmeric, paprika,
FD & C dyes and the like. Various oil-soluble flavors
which may be added to the oil phase of the fat blends of
the present invention include lipolyzed butter oils,
diacetyl, 2-octanone, butyric acid, hexanoic acid and the
like. Examples of vitamins which may be added to the oil
phase include Vitamin A and its derivatives. In
addition, antioxidants, such as TBHQ (or other approved
phenolic-type antioxidants), can also be added into the
oil phase mix.
In addition to the oil phase, the emulsions used to
make the products of the present invention must also
contain an aqueous phase which ranges from 10% to 75% by
weight of the emulsion. The aqueous or water phase of
the emulsions in accordance with the present invention is
comprised of conventionally known components and may
include water-soluble flavors, milk or milk solids, whey
solids, salt, preservatives, casein, caseinates, albumin,
water and other suitable margarine ingredients. The milk
component can be derived from whole milk, low-fat milk
(<2% butter fat content), skim milk or nonfat dry milk
solids. The amount of milk and/or milk solids (in terms
of % by weight solids) usually ranges from about 0.5% to
about 5% by weight of the emulsified product and more
typically from about 1% to about 3% by weight.
Particularly where milk solids are incorporated as a
protein source, potable water is included as part of the
aqueous phase. Salt may also be included in an amount of
from about 0.5% to about 3.5% by weight of the emulsified
spread and more typically in an amount of from about 1%
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to about 2.5% by weight. The amount of other water
soluble flavors depends upon the particular flavor
characteristics desired. Examples of preservatives which
are added in amounts to prevent or retard bacterial and
mold growth, include citric acid, potassium sorbate,
EDTA, sodium benzoate, sorbic acid and the like.
The aqueous phase, thus comprising preferably
potable water, a suitable protein source, salt, and
appropriate preservatives, is slowly added and blended
with the oil phase at a temperature from about 4OC to
about 63C to form an emulsion. The ingredients may be
formulated in separate mix tanks from which they are
metered out into another tank where the aqueous phase is
dispersed in the melted oil phase. The emulsion is then
processed under processing conditions to produce the
final product.
Figure 1 is a schematic diagram of the processing
steps and conditions which result in the stick-type
margarine and spreads of the present invention. With
reference to Figure 1, the emulsion (2), i.e. the
combined oil and aqueous phases, is fed from a storage
tank (4) via a supply pump (6) and a positive
displacement pump (8) to a scraped surface heat exchanger
(10). An example of a scraped surface heat exchanger is
the Votator A-Unit. The A-Unit (10) usually consists of
a stainless steel shaft (mutator shaft) rotating
accentically inside a shell which is cooled externally by
liquid ammonia or brine solution or other refrigerant.
The rotating mutator shaft is fitted with scraper blades
which at high rotation speeds are pressed against the
cooled inner surface. The rotation speed of the scraper
blades by definition is proportional to the extent of
supercooling the emulsion. The internal pressures and
21S610~
- 14 -
chilling action supercools the emulsion in the A-Unit
( 10 ) .
It has surprisingly been found that given the
specific oil base in accordance with the present
invention, there exists a unique relationship between
improved machinability of the products produced and the
degree of supercooling in the A-Unit (10), as well as the
incorporation of an extrusion valve (16) between the exit
of the A-Unit and the entrance of the crystallization
tube (18), which will provide the necessary shear to
enhance solidification properties.
The invention will be described, in relation to
experiments, and pilot plant runs conducted on a pilot
scale Votator Model No. S3/41A manufactured by Cherry-
Burrell Process Equipment (Louisville, Kentucky) whichwas fitted with an extrusion valve Part No. 201848 also
manufactured by Cherry-Burrell. The back pressures,
extrusion pressures, rpms and pump pressures set forth,
hereinafter, relate specifically the aforementioned
equipment. One skilled in the art would be able to
utilize this information, in arriving at suitable
processing conditions for other equipment. However, it
is preferred in all cases, with all equipment, to
incorporate an extrusion valve located between the exit
of the A-Unit and the entrance of the crystallization
tube. The extrusion valve will produce a smaller crystal
size, which will in turn enhance the formability of the
margarine or spread product, thereby facilitating
crystallization rate and making the product more
machinable. The extrusion valve, in this application,
produces a different function than the more commonly
utilized back pressure valve. The extrusion valve
produces high shear, in that it provides a constant flow
and maintains a constant pressure and
2156103
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shearing/homogenization action as a consequence of its
design. This is in direct contrast with a back pressure
valve, which has a primary function of regulating and
maintaining proper volume in the A-Unit to insure
efficient, uniform chilling.
More specifically, in conventional processing, when
utilizing the previously-identified equipment the mutator
shaft speed of the A-Unit (10) is usually about 200+20
rpms while both the pump pressure (12) and back pressure
(14) range from about 50 to about 75 psi. In accordance
with the present invention, the mutator shaft speed of
the A-Unit (10) can be set somewhat higher than that used
in conventional processing. Optimum integrity of the
final product is obtained when the A-Unit operates from
about 200 to about 275 rpms. The pump pressure (12) is
significantly higher in the process of the present
invention at a pressure of from about 250 to about 350
psi, with a pressure of about 300 psi being preferred.
The process of the present invention also employs an
extrusion valve (16) positioned near the entrance to the
crystallization tube (1~) in order to maintain a system
pressure (14) of from about 225 to about 425 psi, which
is also significantly greater than conventional
processing conditions. The preferred extrusion pressure
to be maintained in the method of the present invention
is between about 250 to about 350 psi. Pressures below
225 psi results in a product too soft to form while a
pressure of 425 psi or greater results in a product
exhibiting signs of emulsion stress (i.e. weeping).
However, modern equipment for high speed processing
allows pressures up to 1200 psi. It has been found that
with the increased pump pressure and extrusion pressure~;
employed by the process of the present invention, the
21561~3
- 16 -
formability of the product is improved greatly and a
superior product is obtained.
The temperature within the A-Unit (10) ranges from
about 4C to about 10C. The emulsion is discharged from
the A-Unit (10) and through the extrusion valve (16) at a
temperature of from about 10C to about 13C. The total
residence time within the A-Unit (10) ranges from about
2.5 seconds to about 3.5 seconds.
The chilled emulsion from the A-Unit (10) is then
supercooled without further working by being pumped to a
static crystallization tube (18). Residence time in the
resting tube is a function of the rate which best
achieves the integrity necessary for filling or forming
and wrapping.
The residence time of the emulsion in the
crystallization tube (18) is at least about 1.6 minutes
and is more typically from about 1.6 to about 5 minutes.
The temperature in the static crystallization tube (18)
generally ranges from about 10C to about 13C.
The crystallized emulsion leaves the resting tube
(18) and is fed into the former (20) where it is packed
as the final stick-type margarine product. For the
stick-type products of the present invention, the former
(20) is a square die which either extrudes or molds the
margarine product into sticks by techniques well known in
the margarine art. The packed margarine is usually
tempered at a temperature of from about -1C to about
10C for at least a period of about 24 hours or until
crystal stability is achieved.
Thus, it has been found by employing the specific
blends of co-interesterified liquid oils and hardstocks
of the present invention which include the incorporation
of the specific emulsifiers identified above, and
preferably by adjusting the processing conditions, i.e.
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- 17 -
the supercooling rate in the A-Unit as well as the
incorporation of an extrusion valve which produces
elevated pressures and sufficient shear, a stick-type
margarine product essentially free of trans fatty acids
or tropical oils is obtained which has all the functional
benefits and physical characteristics of stick-type
margarines which have trans fatty acids (i.e. partially
hydrogenated oils) or tropical oils.
The following examples are provided to further
illustrate the present invention.
EXAMPLE 1
A stick-type margarine was made with an emulsion
having the following ingredients:
15 Oil Phase Wt. ~
Co-interesterified soybean oil: 79.727
Cottonseed oil hardstock (75:25)
Myverol 1807T~ 0.399
Lecithin 0.100
Flavor 0.052
Carotene/Vitamin A mix 0.004
Aqueous Phase
Potable Water 13.452
Salted Whey 4.884
Salt 1.333
Preservative 0.049
More specifically, a blend of completely dry,
refined soybean oil and refined, bleached and deodorized
cottonseed oil hardstock (75:25) was co-interesterified
in the presence of 0.3% sodium methylate for a period of
about 30 minutes under an inert atmosphere. After
achieving equilibrium, as determined by melting point,
the reaction was terminated by adding 2% by wt. of a
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citric acid solution. The oil was then washed to remove
residual by-products of the interesterification reaction
and then dried under an inert atmosphere at a temperature
of about 104C.
After achieving a moisture level of <0.1% by wt, the
interesterified blend was treated with 1~ acid activated
bleaching earth at a temperature of about 82C. The
temperature was then raised and held at a temperature of
about 104C for a period of about 20 minutes. The
interesterified blend was then cooled and filtered to
remove the spent bleaching earth. Following filtering,
the oil was deodorized using standard well-known
conditions to remove compounds that promote unacceptable
flavor and oxidative characteristics in a finished edible
oil product.
The co-interesterified soybean oil: cottonseed oil
hardstock blend was mixed with the other oil phase
components identified above, i.e. the emulsifier (i.e.
Myverol 1807~), lecithin, coloring (beta carotene),
Vitamin A, and natural and/or artificial butter flavor,
in proportions to achieve the >80% fat requirement set
forth by the Standards of Identity for margarine. The
water or aqueous phase, comprising potable water, salted
whey (i.e. a suitable protein source), salt and
preservatives, was then mixed with the oil phase at a
temperature of 52C+2C to achieve an emulsion.
The emulsion was then pumped through the A-Unit of
the previously described Votator equipment. The supply
pump (6) maintained approximately 30 psi to the A-Unit
feed pump. The extrusion pressure valve was adjusted to
achieve 300 psi. The system pressure of 300 psi was
achieved with an extrusion valve positioned between the
A-Unit and the entrance of the crystallization tube.
Exit temperature out of the A-Unit was 9C.
2156103
-- 19 --
The rate was adjusted to maintain minimal
temperature differential, i.e. 1C, between the A-Unit
discharge and the exit temperature of the crystallization
tube which provided a residence time of about 1.6 minutes
in the crystallization tube.
The resulting plasticity relative to mouthfeel,
flavor release (i.e. sharpness of melting at body
temperature), spreadability after 24 and 48 hrs. was
determined by an expert panel to be comparable to
hydrogenated stick-type margarine even though the product
has more solids at lower SFI temperatures. In addition
to the aforementioned characteristics of the stick-type
margarine, it is noted that trans fatty acids were
undetected in the margarine as was the presence of any
tropical oils.
COMPARATIVE EXAMPLE 1
An emulsion was prepared as in Example 1 with the
exception of the emulsifier. The Myverol 1807~ was
replaced with approximately 43% type mono-diglyceride at
the same level.
This resulted in a product having a significant drop
in plasticity. The resulting product was too soft to
endure the forces involved in extruding, forming, and
wrapping stick-type margarine.
COMPARATIVE EXAMPLE 2
An emulsion was prepared as in Example 1 with the
exception of the processing configuration and conditions.
The extrusion valve used in the present invention was
replaced with a conventional back pressure valve
positioned near the exit of the A-Unit. Exit temperature
out of the A-Unit was 9C. Residence time in the
crystallization tube was 2 minutes.
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Again, the resulting product was too soft and lacked
the integrity to withstand the forces involved in
extruding, forming and wrapping stick-type margarine.
EXAMPLES 2-6
Stick-type margarines were prepared in accordance
with Example 1 with the exception that the co-
interesterified soybean oil: cottonseed oil hardstock
(75:25) was replaced with the following co-
interesterified domestic vegetable oil: hardstock blends:
EXAMPLE CO-INTERESTERIFIED BLEND
2 soybean oil: cottonseed oil hardstock
(80:20)
3 soybean oil: soybean oil hardstock (80:20)
4 soybean oil: soybean oil hardstock:
cottonseed hardstock (80:19:1)
soybean oil: soybean oil hardstock:
cottonseed hardstock (75:24:1)
6 canola: cottonseed oil hardstock (75:25)
The stick-type margarines produced in Examples 2 to
6 were comparative to the final product as described in
Example 1.
COMPARATIVE EXAMPLES 3 AND 4
A co-interesterified soybean oil and cottonseed oil
hardstock (90:10) blend was prepared as was a co-
interesterified soybean oil and cottonseed oil hardstock(50:50) blend and were substituted into the stick-type
margarine formula described in Example 1.
The (90:10) blend (Comparative Example 3) was
obviously too soft to form a stick-type margarine and an
emulsion was not even attempted.
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Similarly, the (50:50) blend (Comparative Example 4)
was obviously too hard and too brittle to form an
acceptable stick-type margarine and an emulsion was not
even attempted.
The above preferred embodiments and examples are
given to illustrate the scope and spirit of the present
invention. The embodiments and examples described herein
will make apparent, to those skilled in the art, other
embodiments and examples. These other embodiments and
examples are within the contemplation of the present
invention. Therefore, the present invention should be
limited only by the appended claims.
