Note: Descriptions are shown in the official language in which they were submitted.
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Case 20241
PROTEIN BATTER PRODUCTS HAVING DISCRETE FLAVOR DOMAINS
Description
Background of the Invention
The present invention generally relates to
protein batters or emulsions having discrete flavor
domains, shaped food products containing the discrete
flavor domains, and processes for preparing the protein-
containing batters and the shaped food products. Moreparticularly, the discrete flavor domains are flavored
stabilized gel pieces which remain identifiable when
within the protein-containing emulsion and/or within the
shaped food product. These stabilized gel pieces include
any one of a variety of flavoring components. The
invention is especially well-suited for relatively high
moisture flavoring components, for example sauces, flavor
extracts, syrups, condiments, beverages, and the like.
In the past, emulsion-type products having
flavor components therewithin have been proposed and
commercially available. These include shaped food
products which combine two different foods. For example,
sausage and cheese products have been provided wherein a
ribbon of cheese is within a wiener or hot dog. Such
products can be prepared by coextrusion of the sausage
emulsion and a relatively flowable cheese composition.
Multiple cheese portions can be incorporated. By other
approaches, a flavor composition is spread into a
longitudinal, radial or spiral slit formed along the outer
surface or skin of a formed sausage.
Another previously proposed and/or practiced
approach for flavoring sausage products or other protein-
containing batter-originating or emulsion-originating
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products is to add flavor components directly into the
batter or emulsion. This approach is practiced, for
example, in adding liquid smoke or similar flowable
flavorings into the batter before it is shaped into a
sausage, meat patty, vegetable protein patty, and the
like.
In accordance with a somewhat different, but
related approach, the flavoring is incorporated into the
shaped food products after they are initially formed.
Exemplary in this regard are the traditional approaches by
which sausages and the like are stored within a smoke room
for a time long enough to have a flavoring atmosphere
permeate the food product. Less-traditional approaches
may inject flavorings into finished food products,
typically as a liquid component.
For products prepared by these latter types of
approaches, wherein the flavoring is incorporated in
liquid, gaseous or fluid form into the batter, emulsion or
initially shaped food product, the result is simply a
flavored food product. The taste experience for the
consumer is that of a blended flavor. It may be difficult
to discern separate flavor notes, and the consumer does
not have the experience of, for example, a separate
sausage flavor and a separate cheese flavor, which is
characteristic of the coextrusion approach and the like
first discussed above. While this approach is viable for
very viscous or solid-like food products such as cheeses,
same typically is not viable for a highly liquid or
relatively low viscosity flavoring component. Often,
components of this latter type are added separately by the
consumer or food preparer, such as after or during cooking
or heating. For some flavor components, this necessitates
separately heating the protein-containing food product and
the flowable flavoring component.
At times, convenience is a very important
consideration with respect to these types of food
products. Important considerations in this regard can
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include ease of purchase and storage so that the consumer
needs to acquire, store, handle, prepare and typically
cook or heat only a single component for each entre. With
prior approaches, for example, the consumer separately
purchases, stores, handles and prepares a sausage and a
high-moisture food enhancement such a sauce. These then
are combined shortly prior to consumption.
Another consideration in this regard is that
high moisture flavoring components such as sauces are not
particularly susceptible to single-serving packaging,
storage, delivery and use. Typically, these products are
marketed, stored and used in multiple-serving containers
such as jars, squeeze bottles, cans, and the like. One
approach which generally provides a single-serving sauce
source is Kratochvil U.S. Patent No. 5,009,867,
incorporated hereinto by reference. This relates to snack
kits which include a slice of a thermoreversable
carrageenan-gelatin sauce composite product. This sauce
composite product is said to be readily melted when
heated, such as with other pizza components prepackaged
within the snack kit. While the kit is self-contained,
this approach still requires the handling of separate
components, and the carrageenan-gelatin sauce composite
product slice must still be separately handled and
assembled with the other components, such as cheese
topping and a baked pizza crust.
Accordingly, the present invention recognizes
the need for an approach which allows for a unitary food
product which combines a protein-containing emulsion or
batter-originating food with a relatively high-moisture,
low-viscosity flavored food component. These protein food
and flavor components, in order to achieve the objectives
of the present invention, must be combined into a single
product which is sold, stored and prepared as a single,
complete entre. Also recognized by the present invention
as an advantageous possibility is the incorporation of
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less traditional flavoring components with protein-
containing foods.
Summary of the Invention
In accordance with the present invention, a
flavoring component and a source of gelatin are combined
into a flavored mixture which is then formed, typically by
heating, dispersing and cooling, into stabilized gel
pieces. In the preferred embodiment, the pieces are
formed from a stabilized gel block which is broken up into
a plurality of pieces after the block has set or
stabilized. These flavored stabilized gel pieces are
mixed with a protein-containing emulsion in order to form
a protein-containing emulsion having discrete flavor
lS domains composed of the flavored stabilized gel pieces.
This mixture is suitable for then shaping into finished
food products, such as sausages, patties, and the like,
typically by proceeding with conventional extrusion or
forming techniques and procedures.
It is accordingly a general object of the
present invention to provide a new and improved food
product which combines a protein-containing food and
discrete flavored pieces contained within the protein
product.
Another object of this invention is to provide
improved processes and products which embody flavored
stabilized gel pieces dispersed within a protein-
containing, emulsion-originating product such that the
protein-containing product and the flavored pieces are
contained within the same product during distribution,
storage, and preparation for consumption.
Another object of the present invention is to
provide an improved protein-containing emulsion having
discrete, relatively high moisture flavored domains
dispersed therewithout, wherein the respective flavor
notes of the protein-containing product and the flavor
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pieces remain in separately identifiable locations within
the food product.
Another object of the present invention is to
provide an improved protein-containing emulsion product
and process for producing same which incorporates gelatin-
based matrix pieces.
Another object of the present invention is to
provide improved sausage products, whether coarse ground
or finely comminuted, which incorporate therewithin
discrete flavor pockets of otherwise uncontainable flavor
components such as sauces, flavor extracts, syrups,
condiments, flavored drinks, and the like.
Another object of this invention is to provide a
means for stabilizing a highly liquid flavor product so
same provides a flowable but discrete flavor domain within
a batter-formed product, while also protecting that batter
product from deleterious properties of the flavor product,
such as low pH.
Another object of the present invention is to
provide improved sausage products which are of a low-fat
or no-fat variety and which are made especially highly
palatable.
Another object of this invention is to provide
improvements in low-fat and no-fat sausage making by
providing palatable and effective diluents useful in
reducing overall fat content of the sausage products.
These and other objects, features and advantages
of the present invention will be apparent from and clearly
understood through a consideration of the following
detailed description.
Description of the Preferred Embodiments
The present invention is particularly suitable
for making and providing food products which disperse
3S discrete flavor-laden pieces within a food emulsion or
food batter. This emulsion or batter containing the
flavor pieces is shaped into products traditionally made
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by such emulsions or batters which do not contain the
flavor pieces. Typically, the emulsion or batter will be
of the protein-containing variety. Included in this
regard are sausage emulsions and batters, patty batters,
vegetable protein emulsions and batters, seafood protein
batters and emulsions, low-fat protein emulsions and
batters and no-fat emulsions and batters.
Batters in this regard are formulated in
accordance with generally known procedures and with
generally accepted ingredients. Exemplary ingredients
include ground meat, ground byproducts, water, salts,
sweeteners, food-grade acids, preservatives, flavorings,
vegetable protein sources, isolates, and the like.
Generally speaking, traditionally prepared emulsions and
batters can be utilized in the products and processes
according to the invention. For example, a typical source
of vegetable protein originates from soybeans. These
emulsions and/or batters are prepared so as to be
generally flowable so that they can be pumped, extruded,
molded, stuffed, rolled or otherwise shaped and
subsequently set, typically in conjunction with the
application of energy, such as heating, smoking,
acidification, and the like. Typical thus shaped protein-
containing products take the form of sausages, patties,
analogs, simulated meat cuts, novelty shapes, and the
like. In perhaps their simplest form, the products are
shaped as sausages having a traditional generally
cylindrical shape with semi-spherical ends. Overall, the
advantages of the invention are most valuable for food
products which are reheated and served warm.
With reference to the discrete flavor pieces or
domains which are incorporated into these types of
emulsions or batters, they take the form of a plurality of
non-liquid pieces, chunks, cubes, dices, coarse grinds and
the like. Often, they can be characterized as flavored
stabilized gel pieces composed of a flavoring component
set within a three-dimensional protein matrix, typically a
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gel matrix or a gelatin-containing matrix. In a
particularly illustrated embodiment, these discrete flavor
domains are prepared by breaking up a stabilized gel
block, such as by dicing, grinding, cutting and the like.
Alternatively, the pieces could be prepared directly as,
in essence, smaller blocks which are already sized and
shaped as desired. For example, a multiple-compartment
mold could be used to prepare a plurality of these pieces
directly, thereby reducing the need for breaking into
pieces.
In an important aspect of the invention, the
discrete flavor domains or pieces are made from a mixture
incorporating gelatin. Preferably, the gelatin is of the
type which is approved for food use. Suitable gelatin in
this regard can be characterized as hydrolyzed gelatin.
Based on the total weight of the mixture from which the
discrete flavor domains are prepared, this gelatin
component comprises at least about 4 weight percent
thereof. A typical gelatin content is between about 4%
and about 15% by weight, preferably between 8% and about
12% by weight. Gelatins of various Bloom levels can be
incorporated, such as between 50 Bloom and 250 Bloom.
Generally speaking, the quantity of gelatin needed for the
higher Bloom versions is less than that needed for the
lower Bloom versions.
The mixture from which the discrete flavor
domains are prepared also includes substantial quantities
of the flavoring component. Flavoring components
typically include relatively high quantities of water.
Adequate water must be present in the overall mixture
system in order to dissolve the gelatin and permit the
mixture to stabilize and/or set and/or gel into the
discrete flavor pieces. A typical water content level for
the total mixture is at least about 30 weight percent,
typically between about 50 and about 95 weight percent.
Flavoring components having water contents of 75 weight
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percent and above can be accommodated by the present
invention.
Examples of flavoring components which are
suitable for use in accordance with the present invention
are sauces, flavor extracts, syrups, condiments,
beverages, and the like, and combinations thereof, whether
in the same or different pieces within a particular food
product.
Sauces include sauces or gravies of various
flavors and contents. These can be tomato-based, meat-
based, fish-based, vegetable-based, oil-based, water-based
and can include particulates, grindings, choppings of
vegetables, fruits, meats, fish, flavor nuggets and the
like. Exemplary sauces are barbecue sauces, pizza sauces,
lS marinara sauces, vinaigrette dressing, gravies, and other
traditionally pourable sauces and blends.
Exemplary flavor extracts are those containing
flavor particles and essences, such as clove extract and
essences or extracts of any number of differing flavoring
components. The syrup category includes maple syrup and
other flavored table syrups and baking syrups and the
like. Condiments include catsup, mustard, pickle relish,
finely diced onions, pepper purees and the like.
Beverages can include soft drinks, fruit juices, vegetable
juices, beer, wine, and the like.
With more particular reference to the option of
incorporating water into the flavoring mixture, when the
flavoring component is relatively low in moisture content
or is viscous, added water quantities should be greater
than for other types of flavoring components. An
exemplary flavoring component in this regard is honey.
Having an adequate water level also improves handling and
cleanup, and the water-reduced viscosity typically assists
in transferring the mixture out of the blender and the
like. In this respect, the water content functions more
as a processing aid, in addition to its function in
assisting in dispersing and dissolving the gelatin for
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purposes of forming the three-dimensional protein matrix.
An adequate amount of free moisture is needed for properly
setting the mixture and stabilizing the sauce component
within the matrix of the flavor domains.
It will be appreciated that several of the
flavor components have a pH which is significantly acidic
for food products. If an acidic sauce, such as a typical
barbecue sauce, is simply added to a protein emulsion such
as a hot dog batter, and in quantities which are adequate
to flavor the finished product, the meat emulsion is
stressed to the extent that the emulsion does not remain
together as otherwise expected, resulting in a poor
finished product. Acid stressing of a batter causes
batter break down. The batter will not properly set up or
hold together when cooked, and the product will not have
the proper texture.
Thus, according to the present invention, these
concerns due to acid stressing and the like are alleviated
by providing the ability to stabilize sauces or other wet
ingredients for inclusion into batters and finished
products, even when the fluid sauces and the like
themselves are detrimental to emulsion stability, such as
due to their pH or other characteristics which could
otherwise, for example, bring the pH to or near the
isoelectric point of the batter. The invention is useful
in protecting salt-soluble components during a
reassociation of the salt-soluble protein upon heating of
a meat batter in order to set the shape of the meat batter
into a sausage during processing within the plant.
Concerning the process aspects of the invention,
the liquid-containing flavor component is stirred while
the hydrolyzed gelatin and, when needed, water quantities
are added. This mixture is heated until the gelatin fully
dissolves and all of the components are thoroughly blended
together. Typically, the mixture will be heated to
between about 130~ F. and about 160~ F. (about 54~ C. and
about 72~ C.).
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Next, the mixture of flavoring component and
gelatin is cooled or allowed to cool. In some instances,
freezing may be desired in order to facilitate handling.
In any event, it will be appreciated that, without the
gelatin component, it is not possible to stabilize or set
the flavor component so as to form the gel dices and the
like, even if subjected to freezing conditions at this
stage. Typically, this cooling can be to a temperature of
between about -20~ F. to about 20~ F. ~between about
-29~ C. and about -7~ C.) when the cooling step is to
include freezing. A typical cooling step temperature in
this regard is about 0~ F. (about -18~ C.)
After the cooling has been accomplished as
desired, the mixture is in the form of a stabilized gel
block. If, for ease of handling, the gel block is of a
relatively large size, it will next be broken up into
pieces of an average size which will allow same to be
readily combined with the protein-containing emulsion or
batter. A typical operation in this regard introduces the
block of material into conventional dicing, cutting or
coarse grinding equipment. The pieces can be symmetrical
or non-symmetrical, and they can be shaped as uniform or
elongated cubes, wafers, spheres, slivers, and the like.
It is especially preferred that dicing or thick slicing
action be accomplished because the pieces resulting from
such actions are generally six-sided in configuration and
are especially useful for good dispersion and flavor
release in the mouth of the consumer upon mastication. An
especially preferred embodiment has the flavored
stabilized gel pieces in the shape of a cube having a side
dimension of between about 3 mm and about 10 mm.
It is important to appreciate that, with the
present invention, a dicing, cutting or grinding operation
is successfully performed without substantial damage to
the gel matrix. The resultant pieces generally remain
intact to provide a plurality of reduced size gel
matrices. Most particularly, the flavor component or
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sauce remains adequately stabilized within the flavor
pieces or domains and does not leak out to any detrimental
extent until consumption.
By whatever manner the pieces of gel-stabilized
flavoring component are shaped and sized, a plurality of
these pieces are mixed into the protein-containing batter
or emulsion, such as a fully chopped meat batter. This
blend is then shaped, such as by stuffing, molding and the
like, into the final product shape. Often, these forming
activities heat the batter. It has been found that, when
subjected to such processing, the protein-containing
batter sets up and forms cavities which are filled with
flavoring component pieces dispersed within the shaped
product. Because of this effect, the flavoring component
pieces remain within the food product, even if their gel
structure should liquify during product processing.
Conventional stuffing, shaping, processing, and packaging
procedures and equipment can be used in order to prepare
the product for distribution.
Exemplary illustrations of the disclosure herein
are provided in the following examples.
ExamPle 1
A quantity of commercially sold BULLSEYE~
barbecue sauce was placed into a mixer. Thereafter, a
quantity of 8% hydrolyzed gelatin and a quantity of 8%
water, both percentages being based upon the total weight
of the thus-formed mixture, were added to the sauce. The
sauce was heated to 160~ F. (about 71~ C.), and mixing
continued until full dispersion was achieved. The mixture
was then cooled to 0~ F. (minus 17.8~ C.), resulting in
gel-stabilized barbecue sauce blocks having an approximate
size of 2 inches (5 cm) high, 3 inches (7.6 cm) wide and 6
inches (15.2 cm) long.
The blocks were reduced in particle size to
dices or cubes of about 1/4 inch (6.4 mm) on a side. The
resulting gel-stabilized barbecue sauce pieces or domains
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were blended with fully chopped hot dog meat batter. This
batter was stuffed and processed through a stuffing horn
and into hot dog making equipment in order to provide hot
dogs having a conventional appearance but with dices of
barbecue sauce domains dispersed therethroughout. Upon
thermal processing, the hot dog batter was observed to set
up and form generally cube-shaped pockets or cavities
which surrounded and effectively encapsulated the barbecue
sauce domains. Upon subsequent heating for consumption,
even though some or all of the barbecue sauce domains
liquified, the sauce remained within these internal
pockets of the hot dog.
Example 2
The procedure of Example 1 was generally
followed for use in preparing pieces of gel-stabilized
pizza sauce. In this instance, the heating step was 140~
F. (60~ C.). Again, hot dogs were prepared. These
products had cubes of pizza sauce dispersed throughout
set-up pockets within the shaped hot dog. The gel-
stabilized pizza sauce had an overall consistency and
general appearance of diced cooked beets. At random
locations on the surface of the hot dog, darker
colorations were visible where the pizza sauce pieces were
relatively close to the surface of the hot dog.
Example 3
Soy protein analog hot dogs are prepared
substantially in accordance with Example 1, except the
batter within which the sauce pieces are distributed
incorporates soy protein rather than meat protein as a
primary component of the product batter.
ExamPle 4
A very low fat wiener type product was prepared
generally in accordance with Example 1. The meat batter
had a fat percentage of about 0.9 weight percent, and the
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finished product was a "no-fat" hot dog with enhanced
juiciness provided by the barbecue sauce pieces
distributed therethroughout.
ExamPle 5
A meat patty product is prepared generally in
accordance with Example 1. In this instance, the
flavoring component is a clove extract, and the product is
shaped within patty-forming equipment to provide a product
having the characteristic disc shape of a patty. A
stabilized gel matrix containing the clove extract was
successfully set up, and this matrix was readily diced to
provide the clove extract pieces. The clove extract
pieces are distributed throughout the patty during
shaping.
ExamPle 6
A course-ground sausage product was prepared
generally in accordance with Example 1, except the
flavoring component was maple syrup. A stabilized gel
block of maple syrup was successfully set up and
subsequently diced in conventional dicing equipment to
provide the pieces of gel-stabilized maple syrup.
Example 7
A sausage product is prepared generally in
accordance with Example 1, except the flavoring component
is Coca-Cola0. A stabilized gel block of this beverage
was successfully set up and subsequently diced by hand to
provide the pieces of gel-stabilized Coca-Cola0.
It will be understood that the embodiments of
the present invention which have been described are
illustrative of some of the applications of the principles
of the present invention. Various modifications may be
made by those skilled in the art without departing from
the true spirit and scope of the invention.
