Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTIQN
DELIVERY SYSTEM BASED ON A DISPERSION OF AN EMULSIFIER IN AN AQUEOUS SOLUTION
OF SUGAR
~~FI D OF THE INVENTION
The present invention relates to a delivery system for emulsifiers, emulsifier
dispersions
employing the delivery system, and methods for making and using and uses of
the
delivery system and the emulsifier dispersions.
The present invention also relates to an aqueous sugar or sugar alcohol, e.g.,
mono-
and/or disaccharide delivery system for emulsifiers, emulsifier dispersions
employing
the delivery system, and methods for making and using and uses of the delivery
system
and the emulsifier dispersions.
In addition, the present invention relates to an alpha gel emulsifier
dispersion obtainable
from combining at least one emulsifier, at least one sugar or sugar alcohol
such as at
least one mono- and/or disaccharide, and water.
2 0 The invention further relates to stabilizing the emulsifier dispersion,
preferably alpha gel
emulsifier dispersion, obtainable from combining at least one emulsifier, at
least one
sugar or sugar alcohol such as at least one mono- and/or disaccharide, and
water, that is,
to maintain longer interplanar spacing of the emulsifier bi-layer (in the
alpha gel), to
thus obtain a hydrated emulsifier system having longer shelf life or greater
storage.
The hydrophilic groups of the emulsifier or emulsifiers are exposed in the
dispersion.
That is, the stabilization provides for greater exposure of the hydrophilic
groups than in
shortening and conventional emulsifier dispersions. The inventive dispersion
is
homogenous, not heterogeneous or lumpy, and provides surprising benefits
including
3 0 any or all of: allowing a food manufacturer to use liquid or non-crystal
shortening;
allowing the use of a wider range of emulsifiers in food preparation, allowing
the use of
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an emulsifier system with dry ingredients, improved functionality of known
emulsifiers
cost reduction in the preparation of foodstuff, and stability both
functionally (the phase
remains stable for increased periods, including in certain applications at
least eight(8)
months to a year or longer) and microbially (no microbial growth, and no need
to
acidify food to prevent mold or microbial growth).
Various documents are cited in the following text. Each of the documents cited
herein,
and each of the references cited in each of those various documents, is hereby
incorporated herein by reference. None of the documents cited in the following
text is
admitted to be prior art with respect to the present invention.
Amphiphilic emulsifiers, i.e., having both lipophilic and hydrophilic
properties such as
food emulsifiers, for instance, polar lipids based on partial esters of
glycerides or
alcohol with fatty acid and/or organic acids such as edible organic acids,
e.g., lactic,
diacetylated tartaric, acetic and the like, possess some degree of surface
activity
depending on factors such as chemical composition, e.g., esterification of
monoglycerides with organic acids, changes in fatty acid radicals with respect
to chain
2 0 length or degree of unsaturation (See generally J. Birk Lauridsen, "Food
Surfactants,
Their Structure And Polymorphism," Technical Paper TP 2-le, Danisco
Ingredients,
Brabrand Denmark, and references cited therein; N. Krog, "Interactions of
Surface-
Active Lipids With Water, Protein and Starch Components In Food Systems,"
Technical
Paper TP 3-le, Danisco Ingredients, Brabrand, Denmark, and references cited
therein;
2 5 N. M. Barford, "The Influence of Emulsifiers and Hydrocolloids on Fat
Crystallisation
and Water Binding in Various Food Systems," Technical Paper TP 4-le, Danisco
Ingredients, Brabrand, Denmark, and references cited therein; N. Krog,
"Dynamic and
Unique Monoglycerides," Technical Paper TP 8-1 e, Danisco Ingredients,
Brabrand,
Denmark, and references cited therein).
A molecule in an emulsifier may be visualized as a hydrophobic tail ending in
a
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3
hydrophilic head. It can be further visualized that in the emulsifier, the
molecules
arrange themselves such that hydrophobic tails of different molecules tend
towards
being proximate to each other, and hydrophilic heads towards being proximate
to each
other, with the distance between proximate heads known as the short spacing
and the
distance between distal heads (going head of first molecule through tail of
first molecule
and tail of further molecule to head of further molecule known as the long
spacing (See
Lauridsen, Technical Paper TP 2-1 e, supra).
Emulsifiers are generally more lipophilic, i.e., more soluble in lipids than
water, and
1 o thus, cannot dissolve in water or are only sparingly soluble in water,
i.e., emulsifiers
have limited dispersion properties in water. Accordingly, emulsifiers have
been used by
providing them in powder form or dissolving them into a fat (shortening)
The provision of emulsifiers in powder form is disadvantageous at least
because of the
problems of shipping and handling. Powders produce dust which must be
contained.
Furthermore, powders are more difficult to dose than liquids and for this
reason are not
favoured by users.
Dissolution of emulsifiers into a fat (shortening) is disclosed in e.g.,
Hirschey et al.,
2o U.S. Patent No. 5,154,942 relating to shortening mixed with an emulsifier,
e.g.,
polyglycol ester/alkali stearoyl lactylate, and sugar, which is then blended
with sugar,
starch and water to make a creme; Cooper, U.S. Patent No. 3,533,802 providing
a
mixture of shortening, sugar and emulsifier; WO 70/73692.
2 5 A problem in the art is that it can takes an extended period of time for
emulsifiers
delivered by shortening to become hydrated. For instance, an emulsifier in a
shortening
delivery system must be mechanically and/or thermally randomized to expose
hydrophilic groups, e.g., by stirring and/or elevating temperature of the
shortening
emulsifier delivery system. It would be desirable to have an aqueous
emulsifier
3 o dispersion system.
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A further problem with shortening emulsifier delivery systems is that there
are only a
limited variety of emulsifiers provided in such delivery systems due to
limitations in the
manufacture thereof. For instance, such systems must be prepared in large
batches to be
economically feasible; and therefore, variety in the emulsifiers provided by
such
systems is limited. It would be desirable to provide an aqueous emulsifier
dispersion
system which allows it to be economically feasible for different emulsifiers
to be
incorporated therein.
Emulsifiers, such as food emulsifiers, can form, under certain conditions,
e.g., ion
concentration, electrolyte concentration, and temperature, liquid crystalline
mesophases
(lipid-water phases or lamella dispersions) (See generally Lauridsen,
Technical Paper
TP 2-le, supra; N. krog, Technical Paper TP 3-le, supra).
In the presence of water, there is a tendency to hydrate polar heads of the
emulsifier
molecule while hydrocarbon chains are kept together in bi-layer regions
separated by
the water, until the KRAFFT temperature is achieved. When achieved, fatty
hydrocarbon chains begin to get liquidity; they rotate; and, allow water
molecules to
penetrate (See generally N. Krog, Technical Paper TP 3-le, supra). Mesophases
can be
readily dispersed when used.
Emulsifiers delivered by shortening cannot readily form mesophases because of
the fat
environment, thus presenting a further problem in the art with respect to
shortening
delivery systems.
2 5 Thus, heretofore the use of sugar, especially at least one mono- and/or
disaccharide as a
delivery system for at least one emulsifier, as herein, has not been taught or
suggested.
In certain applications such as in bakery applications it is also desirable to
use
emulsifiers which are solidified into an alpha crystal form. Upon cooling,
lamella
3 0 dispersions form alpha gel wherein the lipid bilayers are still separated
by water layers
but the fatty acid hydrocarbon chains are now solidified into an alpha crystal
form.
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These alpha gels are typically metastable and must be used shortly after their
manufacture because after a short period of time they restructure, causing a
decrease in
functionality. Accordingly, a further problem in the art is that alpha gels
have only
5 short term storage stability or a low shelf life. 1t would be desirable to
have hydrated
emulsifier systems with a longer shelf life.
A related problem is that these gels cannot form when emulsifiers are
incorporated
within food applications. It would be desirable therefore to provide an
emulsifier
1 o system in a food application that is hydrated and is in the alpha gel. It
would then be
possible to maintain the alpha gel within the food application and provide
enhanced
emulsification and aeration properties.
A crystal composition (see, e.g., JP 56032955) which is not a hydrated
emulsifier
system involving the alpha gel does not address the problems in the art by way
of an
alpha gel as herein. Emulsifier systems which involve polysaccharides (see,
e.g., El-
Nokaly, U.S. Patent No. 5,215,757) or an oligosaccharide such as
maltitoligosaccharide
(also known as maltitol; see, e.g., JP 61249992) suffer from deficiencies or
do not
address the problems in the art as herein since the polysaccharides or
oligosaccharides
2 0 affect the alpha gel structure; for example the long and short spacing is
affected from
such bulky molecules moving with into spacings between emulsifier molecules.
Polysaccharides or oligosaccharides cannot reduce the activity of water with
respect to
the emulsifier; for instance, due to the size of the polysaccharides or
oligosaccharides.
2 5 The use of sugar or sugar alcohols in foodstuff compositions (see, e.g.,
WO 89/038455,
WO 79/44621, Food Product Development 1979, 13(10), 60, 62, 64 (Hartnett, D.L;
ICI
Americas)), for instance as a sweetener (see, e.g., EP 558523) does not
address the
problems in the art by way of an alpha gel as herein; for instance, such
compositions do
not teach or suggest employing sugar and the delivery system as herein, e.g.,
fails to
3 o recognize using sugar to form and/or stabilize the alpha gel. Furthermore,
the use of
polyols as a humectant (see, e.g., EP218277) fails to address the problems in
the art by
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way of an alpha gel as herein; for example, there is no teaching, suggestion
or
recognition of any preference or superiority of mono- and/or disaccharides for
use in
forming and/or stabilizing the alpha gel over other polyols, e.g.,
polydextrose, propylene
glycol, glycerol..
S
Thus, heretofore the use of sugar, especially at least one mono- and/or
disaccharide as a
delivery system for at least one emulsifier in an alpha gel, i.e., to form
and/or stabilize at
least one emulsifier in an alpha gel, as herein, has not been taught or
suggested.
1 o OBJECTS AND SUMMARY OF TH TNVENTION
It is an object of the invention to provide any or all of: a delivery system
for at least one
emulsifier, emulsifier dispersions employing the delivery system, and methods
for
making and using and uses of the delivery system and the emulsifier
dispersion, such as
15 those which address one or more of the problems in the art; for instance,
to provide an
aqueous sugar, e.g., mono- and/or disaccharide, delivery system for at least
one
emulsifier, an aqueous dispersion of at least one emulsifier, and methods for
making and
using and uses of the delivery system and the dispersion, especially such
dispersions
which exhibit stability both fimctionally (remain stable for of the order of 1-
2 weeks)
2 0 and microbially (no microbial growth, and no need to acidify food to
prevent mold or
microbial growth).
Accordingly, the present invention provides a delivery system for at least one
emulsifier
comprising an aqueous solution of at least one sugar, advantageously a sugar
which
2 5 reduces water activity or has strong water-binding properties, preferably
a mono- and/or
disaccharide, more preferably at least one monosaccharide, e.g., dextrose
(glucose),
sucrose, fructose, mannose, galactose, maltose, lactose, and the like.
Dextrose and high
fructose corn syrup are presently considered advantageous to use in the
practice of the
invention.
30 w
Instead of a mono- and/or disaccharide, a derivative thereof, such as a sugar
alcohol,
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e.g., an alditol, a pyranose or an ester or ether, e.g., a Ci-C6 alkyl ester
or ether, may be
used in the practice of the invention; but, the derivation should not
substantially increase
the size of the mono- and/or disaccharide or decrease its ability to reduce
water activity.
Further, edible mono- and/or disaccharides or derivatives thereof are
preferred in the
practice of the invention.
The sugar can be present in an amount of about 20 to 80 weight percent, e.g.,
about 30
to 70 weight percent, such as about 40 to 6~ weight percent, e.g., about 42 to
about 65
weight percent, such as about 40 to about 55 weight percent, e.g., about 45 to
about 55
weight percent. such as about 50 to about 54 or 55 weight percent.
Further, the emulsifier is advantageously an emulsifier which is an alpha
tending
emulsifier such as polyglycerol esters, propylene glycol esters or sorbitan
monostearate.
Preferred emulsifiers consist essentially of monoglycerides or mono-
diglycerides such
as distilled monoglycerides or mono-diglycerides (e.g., total monoglyceride
content of
90% minimum such as DIMODAN~ manufactured and distributed by DANISCO
INGREDIENTS, e.g., DIMODAN LS~ which are monoglycerides from sunflower oil).
The emulsifier can be present in an amount of about 15 to about 40 weight
percent, e.g.,
about 25 to about 40 weight percent, such as about 2~ to about 3~ weight
percent, e.g.,
about 25 or 26 weight percent to about 30 weight percent.
Water in the inventive delivery system can be present in an amount of about 10
to about
20 weight percent (the balance between the amounts of emulsifiers) and sugars)
to be
2 5 100 weight percent).
Thus, the invention comprehends the use of a sugar as a delivery system for an
emulsifier, wherein the sugar is any one or more of a monosaccharide, a
disaccharide, a
derivative of a monosaccharide, or a derivative of a disaccharide.
The delivery system may be for at least one emulsifier in hydrated form having
an alpha
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gel structure. The invention thus provides the use of an aqueous solution of
at least one
mono- and/or disaccharide for delivery of at least one emulsifier in hydrated
form
having an alpha gel structure.
The present invention further provides an aqueous dispersion of at least one
emulsifier
comprising the at least one emulsifier, water and at least one mono- and/or
disaccharide.
The inventive dispersion is homogeneous, not heterogeneous or lumpy.
The present invention even further provides a foodstuff obtainable from or
prepared
1 o with the inventive emulsifier delivery system or emulsifier dispersion.
The invention
thus provides the use of the inventive emulsifier delivery system or
emulsifier
dispersion in the preparation of a foodstuff.
The invention advantageously allows for use of the delivery system with a
foodstuff,
such as a flour-containing foodstuff, as the water does not migrate to the
constituents of
the foodstuff, such as the flour, and make it go bad (spoil). The foodstuff
also can be a
frosting, a creme filling, a dressing, Bechamel sauce or the like.
The invention allows the manufacturer of a foodstuff to use liquid or non-
crystal
2 o shortening, and a wider range of emulsifiers in the preparation of a
foodstuff. Further,
the invention may reduce the cost of the foodstuff.
For instance, in the preparation of flour-containing products such as breads,
cakes, and
the like, it has been observed that the invention provides a foodstuff which
has softer
2 5 crumbs, greater volume, and greater air cell stability, such that less
emulsifier and flour
are needed to prepare the foodstuff. Also, the foodstuff stays fresh longer,
i.e., does not
get firm or stale as quickly as control foodstuffs prepared without the
invention. Indeed,
an increase in freshness of three (3) to five (5) days or more has been
observed in flour-
containing foodstuff prepared with the instant invention. It is believed,
without
3 0 necessarily wishing to be bound by any one particular theory, that this
observation is
due to the alpha gel remaining intact, or otherwise advantageously interacting
with
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ingredients, e.g., protein, starches, etc. in the foodstuff.
Additionally. the invention allows the food manufacturer to not have to use
the
emulsifier system immediately or shortly after preparation or to acidify to
prevent mold
or microbial growth, as the invention has functional stability (stability of
the order of 1-
2 weeks or in one embodiment stability of at least eight (8) months to a year
or longer
without loss of the alpha gel) and microbial stability (no observed mold or
growth after
eight (8) months to a year or longer).
l0 In certain embodiments the invention provides a hydrated emulsifier system
comprising
or consisting essentially of: 15 to 60 weight percent of at least one
emulsifier, 42 to 65
weight percent of at least one sugar, wherein the sugar is predominantly
comprised of
mono and/or disaccharides, and 10 to 20 weight percent of water.
The sugar of the system of the present invention is preferably dextrose or
high fructose
corn syrup.
The emulsifier is preferably comprised predominantly of or consists
essentially of
monoglycerides or mono-diglycerides. The sugar is preferably dextrose or high
fructose
2 0 com syrup. In certain embodiments the at least one emulsifier can comprise
or consist
essentially of an ionic co-emulsifier and an emulsifier, preferably an alpha-
tending
emulsifier. A preferred ionic co-emulsifier is DATEM, DIMODAN~, GRINDSTEDTM
or sodium stearoyl ~lactylate, and the (alpha tending) emulsifier is
preferably polyglycol
ester(s), propylene glycol ester(s), or sorbitan monostearate. The emulsifier
can be
present in an amount of about 25 to about 40 weight percent, e.g., about 25 to
about 35
weight percent, such as about 25 or about 26 weight percent to about 30 weight
percent.
The invention also comprehends a method for preparing an emulsifier system or
a
hydrated emulsifier, advantageously a hydrated emulsifier having an alpha gel
structure,
3 0 comprising admixing the at least one emulsifier, the at least one sugar
and, optionally,
water at a suitable temperature for formation of the lamella mesophase. The
suitable
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temperature may chosen depending on the melting properites of the emulsifier,
for
example an emulsifier which is liquid at room temperature may be admixed at
room
temperature. In one alternative, the admixture may be prepared at for example,
about
5~° to about 80°C. The method can comprise blending the
emulsifier at about 55° to
5 about 80°C, preferably about 60° to about 80°C and
adding the sugar and water with
mixing at a temperature of about 5~ to about 80°C. The sugar and water
are added in an
amount to establish an emulsifier content of about 2~ to about 40 weight
percent, e.g.,
about 25 or 26 to about 30 weight percent. The mixture is then cooled to a
suitable
temperature, for instance to about room temperature (e.g., about 20° to
about 25°C), for
1 o alpha gel formation.
Given that water and a mono- and/or disaccharide are the vehicle for
delivering the
emulsifier, and the elegant simplicity in the preparation of the system, the
invention
provides an opportunity for a variety of different emulsifiers to be used in
the emulsifier
1 S system, providing foodstuff manufacturers with emulsifier options not
heretofore
provided by shortening delivery systems.
Accordingly, the invention further comprehends methods for making a foodstuff
comprising using the inventive dispersion system. For instance, in preparing a
foodstuff
2 0 the inventive emulsifier can be plated onto dry ingredients, and
thereafter the additional
ingredients of the foodstuff can be added, and the foodstuff prepared as is
typical for the
preparation of the particular foodstuff.
These and other embodiments are disclosed or are obvious from and encompassed
by,
2 5 the following Detailed Description.
Emulsifiers are typically delivered into food systems (e.g., cakes, fillings,
icings etc.)
3 o via shortening systems. This is done because emulsifiers are typically
more lypophilic
(fat loving) than hydrophilic (water loving) and therefore are soluble or at
least partially
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soluble in fats and oils. Unfortunately, as discussed herein, emulsifiers
delivered in via
a shortening system do not always function optimally as their activity as a
surfactant or
as an aerator is suppressed due to the time required for the emulsifier to
become
hydrated in such a fat medium. In addition, this mode of delivery can be quite
limiting
in applications requiring greatly reduced fat or no fat levels. Thus, there
are problems
with shortening systems for delivery of emulsifiers.
There are also spray congealed emulsifiers. In this mode, an emulsifier or an
integrated
blend of emulsifiers can be manufactured into a powdered bead form by a
process
known as spray congealing. That is, the emulsifier system in a molten state is
atomized
into small droplets which are then passed through a cooling tower initiating
crystallization when the necessary temperature is achieved. Generally, such
emulsifier
systems consist of non-ionic emulsifiers such as distilled monoglycerides in
combination with so-called co-emulsifiers which are ionic (e.g., DATEM, sodium
stearoyl lactylate, citric acid esters of monoglycerides) to improve wetting
properties.
In addition, other emulsifiers referred to as alpha tenders are included.
These
emulsifiers crystallize from the melt in an alpha crystal form with a single
chain packing
(SCL) where the fatty acids penetrate each other in the hydrocarbon region.
Such
crystal formations can be characterized by an x-ray diffraction with a short
spacing of
2 0 4.1 Angstroms. Such emulsifiers have generally large polar head groups and
include
propylene glycol esters of fatty acids, polyglycerol esters of monoglycerides,
sorbitan
esters of fatty acids. Emulsifiers demonstrating this behavior provide
aerating
properties upon hydrating. These crystallized (spray congealed) emulsifiers
can then be
dry blended with the other ingredients (e.g., flour, sugar, leavening agents)
before
2 5 processing in an industrial preparation or as in a prepackaged mix.
Although designed to hydrate readily in these applications, these spray
congealed
emulsifier systems must compete with the other components of the blend such as
starches, proteins, gums, sugars, etc. for the available water. This
competition can
3 0 reduce the activity of the system as it extends the time required for
hydration. This is a
problem as extending the time for hydration extends the time for the
emulsifiers) to
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complex with starches, to interact with proteins, to interact with other
lipids or to
reinforce foam structures. Also these systems have shown to be unstable in the
alpha
crystal form during storage. And, as transition occurs from the alpha crystal
to the beta
crystal, the emulsifier system will provide less functionality and less
aerating. It is
somewhat possible for the processor to improve the hydration tendency of these
emulsifier systems by first combining with water from the foodstuff recipe
with heat to
recrystallize back to the alpha crystal form. However this solution requires
the food
processor to incorporate an additional step in the processing scheme, causing
additional
time and/or equipment. And, this option to improve hydration is not available
for such
applications as in retail and food service prepared mixes (i.e. cakes,
muffins, brownies)
where the water addition is made by the consumer directly to a mix including
the
emulsifier system. Thus, there are problems with spray congealed emulsifiers.
There are also spray dried emulsifiers on carriers (i.e. bulking agents, milk
solids). In
this mode, an emulsifier or an integrated emulsifier blend is dispersed in an
aqueous
solution of, for instance, milk solids in a very controlled environment. This
dispersion
is then atomized into small droplets which pass through a tower of heated air
where the
water is removed by evaporation. This process results in a fine powder
composed of a
carrier encapsulated with the desired emulsifier system. Unfortunately, the
processing
2 o for the emulsifiers into this form is very energy intensive due to the
removal of the
water; and this, of course, can be quite expensive. For this reason, the
application of
emulsifiers in this form is often Quite limited; and thus, spray dried
emulsifiers on
carriers have problems.
2 5 There are also hydrated emulsifier systems. In this process, emulsifiers)
in a molten
form are dispersed into water using a high intensity mixer (i.e. homogenizer).
When the
dispersion is cooled below 40 - 45°C an alpha crystalline gel will be
formed. In this gel
form, the liquid bilayers are still separated by water layers, but the fatty
acid
hydrocarbon chains are solidified in an alpha crystal form (x-ray short
spacing of 4.1
3 0 Angstroms). The gel is then treated with an organic or inorganic acid to
reduce the pH
around 2 or 3 to prevent microorganism growth. In addition, small levels of
humectants
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(i.e. glycerol, sorbitol, etc.) can also be added to reduce water activity.
This
crystallized dispersion is then delivered to the food processor where it is
first plated
onto the dry ingredients. Unfortunately, this mode of delivery also has
several
disadvantages. For one, a high level of water is being transferred from the
manufacturer
to the end user which can be quite expensive. Also the incorporation of the
acids for pH
reduction can greatly hamper the dispersion characteristics of the emulsifiers
as the free
acid form will exist and this in turn inhibits the desired activity or
functionality. In
addition, the stability of the alpha crystals in this hydrated dispersion is
limited and with
time will transform into beta crystals, resulting in a collapse of the water
layer
l0 separating the lipid bilayers. This transformation will vary depending on
storage
conditions but generally occurs after at most only a few months. When this
occurs, the
hydrophilic polar groups on the emulsifiers are no longer as exposed or as
accessible,
and as a result the functionality is greatly reduced. Thus, previous hydrated
emulsifier
systems suffered from problems.
Accordingly, it would be desirable to overcome or address the problems of
prior
emulsifier delivery systems.
This invention allows an alternate delivery of emulsifiers to food
applications other than
2 0 via shortening or the other delivery systems; and, the invention delivers
the emulsifier in
a highly functional form.
The emulsifiers) in the inventive delivery system may be stabilized in the
alpha
crystalline spacing without any degradation for a prolonged period, for
example 1-2
2 5 weeks or at least eight (8) months. This was analysed by an X-ray
diffraction study of
the inventive dispersions. With such analysis the short spacing was believed
to
maintain at 4.1 Angstroms which correlates with the alpha crystalline gel. In
addition,
analysis of the long spacing was believed to maintain at 50 - 60 Angstroms,
which
suggests that a minimum 20 - 30% of the bilayer region may be occupied by the
liquid
3 o sugar (water and sugar molecules). By microscopic evaluation, the invenfne
dispersions were characterized as being as the alpha crystalline gel dispersed
with an
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14
aqueous sugar solution.
Subsequent evaluation of the invention demonstrated that the emulsifiers may
be alpha
crystalline stable in the gel form as the aqueous sugar solution expands into
the bilayer
and is maintained. These sugars (e.g., dextrose, fructose, sucrose) provide
strong water
binding properties, reducing the water activity and thereby stabilizing the
system against
microorganisms such as mold, yeast growth. In addition, the continuous sugar
matrix in
the inventive delivery system complements the wetting behavior of the
emulsifier,
acting very similarly to a protein carrier.
l0
The invention therefore provides the stabilization of the highly functional
alpha
crystalline phase promoting activity for an extended period of time.
Accordingly, as discussed, the invention pertains to a delivery system for an
emulsifier,
emulsifier dispersions employing the delivery system, and methods for making
and
using and uses of the delivery system and the emulsifier dispersions.
More particularly, the invention is the use of at least one mono- and/or
disaccharide as a
delivery system for at least one emulsifier, preferably in hydrated form
having an alpha
2 0 gel structure.
The delivery system contains an aqueous solution of at least one sugar,
advantageously
a sugar which reduces water activity or has strong water-binding properties,
preferably a
mono- and/or disaccharide, more preferably at least one monosaccharide, e.g.,
dextrose
2 5 (glucose), sucrose, fructose, mannose, galactose, maltose, lactose, and
the like.
Dextrose and high fructose corn syrup are presently considered advantageous to
use in
the practice of the invention.
3 0 Advantageously, the delivery system may contain 60-70 weight % high
fructose corn
syrup.
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WO 99/25207 PCT/IB98/01882
Instead of a mono- and/or disaccharide, a derivative thereof, such as a sugar
alcohol,
e.g., an alditol, a pyranose or an ester or ether, e.g., a C~-C6 alkyl ester
or ether, may be
used in the practice of the invention. In a preferred embodiment, the
derivation should
5 not substantially increase the size of the mono- and/or disaccharide or
decrease its
ability to reduce water activity. Further, edible mono- and/or disaccharides
or
derivatives thereof are preferred in the practice of the invention. As to
typical
derivatives of mono- and/or disaccharides and the distinction between (i) mono-
and/or
disaccharides and (ii) polysaccharides and oligosaccharides, reference is made
to
1 o Streitweiser and Heathcock, Introduction to Organic Chemistry Chapter 25
(Macmillan
Pub. Co. Inc. 1976). Other suitable derivatives of mono- and/or disaccharides
useful in
the practice of this invention can be ascertained by the skilled artisan
without undue
experimentation from this disclosure and knowledge of the art of food grade
derivatives
of mono- and/or disaccharides.
The sugar can be present in an amount of about 20 to 80 weight percent, e.g.,
about 30
to 70 weight percent, such as about 40 to 65 weight percent, e.g., about 42 to
about 65
weight percent, such as about 40 to about 55 weight percent, e.g., about 45 to
about 55
weight percent, such as about 50 to about 54 or 55 weight percent.
The present invention is particularly advantageous because it allows for the
delivery of a
further deliverable substance, i.e a deliverable substance other than the
emulsifier.
Thus, in an advantageous aspect the delivery system of the present invention
comprises
an emulsifier and a further deliverable substance.
This aspect is particularly advantageous because one may provide a delivery
system
comprising an emulsifier and one or more further deliverable substances. Thus
a single
aqueous system may be provided containing each of the components required for
delivery. This is further advantageous in the food industry where a single
system may
3 0 be provided containing each of the required ingredients, preferably
functional
ingredients, for a recipe. This single system may be dosed into the recipe.
Yet further,
CA 02308294 2000-04-28
WO 99/25207 PCT/I898/01882
16
one may incorporate powders and liquids in the delivery system. Thus, separate
delivery to, storage by and dosage of the power and liquid by the end user is
not
required.
The further deliverable substance and/or the emulsifier may be in the form of
a
particulate substance, such as a powder, granulate, pellet or bead.
Preferably, the
particulate substance has an average particle size of no greater than 800 ~,m.
When the further deliverable substance is a particulate substance the present
invention is
particularly advantageous. Many particulate substances such as powders need to
be
readily dispersible in liquids such as water or milk. In the food industry
this is the case
in, for example, powdered isotonic sport drinks, instant cocoa powder and
protein
powders such as Na-caseinates.
Typically, particulate substances such as powders can be rendered dispersible
by an
agglomeration process or by coating them with a surface active agent. For
example,
instant cocoa powders are very often coated with high amounts of lecithin
(approx. 5%
of an ordinary lecithin containing approx. 50% soy bean oil) to render the
dispersible.
However, this coating may cause off flavour problems due to the oxidation of
the soy
2 0 bean oil {often referred to as the reversion flavour typically for soy
bean oil). Moreover,
most of the lecithin used worldwide are derived from soy beans. Many supplies
of soy
beans comprise beans from genetically modified plants. Consumer pressure and
legislation renders the use of such beans undesirable or unacceptable. Thus,
there is a
desire in industries such as the cocoa industry to replace lecithin with other
emulsifiers.
The inventive delivery system comprising a particulate substance such as
powder is
advantageous in that it is readily dispersed. The delivery system provides
improved
wetting of the particulate substance and therefore more rapid dispersion.
3 o Preferably, the further deliverable substance is selected from the group
consisting o~
hydrocolloids, flavourings, food ingredients, enzymes, gums, starch, vitamins,
CA 02308294 2000-04-28
- WO 99125207 PCT/IB98/01882
17
sweeteners, functional proteins, salts, stimulants, including caffeine,
pharmaceuticals,
nutrients, food supplements, lecithin, including purified lecithin, clours,
preservative,
antioxidants and mixtures thereof.
Preferably, the pharmaceutical is administerable orally.
Food ingredients may be selected from cocoa, herbs, mustard powder, egg powder
and
mixtures thereof.
1 o Sweeteners may be selected from artificial sweeteners, including
saccharin, aspartame
(NutrasweetTM), acesulfame-K, thaumatin (TalinTM), glycyrrhizin, alitame,
dihydrochalcone, miraculin (miracle fruit), morellin (serendipity fruit),
steriside, MDs
aryl sweetener and mixtures thereof.
The emulsifier is advantageously an amphiphilic emulsifier, preferably a food
emulsifier. For instance, the emulsifier can be a polar lipids) based on
partial esters)
of glyceride(s) or alcohol with fatty acid and/or organic acids) such as
edible organic
acid(s), e.g., lactic acid, diacetylated tartaric acid, acetic acid and the
like.
Advantageous emulsifiers include CREMODAN~ (manufactured and distributed by
2 o DANISCO INGREDIENTS) including CREMODAN~ DC, CREMODAN~
MOUSSE, CREMODAN~ SE, CREMODAN~ SI, CREMODAN~ SIM,
CREMODAN~ SL, CREMODAN~ TEF; GRINDSTEDTM (manufactured and
distributed by DANISCO INGREDIENTS), including GRINDSTEDTM BK,
GRINDSTEDTM CITREM, GRINDSTEDTM ES, GRINDSTEDTM FF, GRINDSTEDTM
GA, GRINDSTEDTM PS such as GRINDSTEDTM PS 100, GRINDSTEDTM PS 200,
GRINDSTEDTM PS 300, GRINDSTEDTM PS 400, GRINDSTEDTM WP; RECODANTM
(manufactured and distributed by DANISCO INGREDIENTS); RYLOTM (manufactured
and distributed by DANISCO INGREDIENTS), including RYLOTM AC, RYLOTM CI,
RYLOTM LA, RYLOTM MD, RYLOTM MG, RYLOTM PG, RYLOTM PR, RYLOTM SL,
3 o RYLOTM SO, RYLOTM TG; DATEM (diacetyl tartaric acid esters of mono=
diglycerides), e.g., PANODAN~ (manufactured and distributed by DANISCO
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18
INGREDIENTS), CITREM (citric acid esters of monoglycerides) and/or sodium
stearoyl lactylate. Thus, the emulsifier can be an ionic emulsifier.
The emulsifier may also be selected from E 420, E 421, E 481-482, E 473, E
474, (5 g/
kg) and mixtures thereof.
Further, the emulsifier is advantageously an emulsifier which is an alpha
tending
emulsifier such as polyglycerol esters, propylene glycol esters or sorbitan
monostearate.
Preferred emulsifiers consist essentially of monoglycerides or mono-
diglycerides such
1 o as distilled monoglycerides or mono-diglycerides (e.g., total
monoglyceride content of
90% minimum such as DIMODAN~ manufactured and distributed by DANISCO
INGREDIENTS, e.g., DIMODAN LS~ which are monoglycerides from sunflower oil).
Other emulsifiers which can be used in the practice of the invention include
lecithin,
acetic acid esters of mono-diglycerides, lactic acid esters of mono-
diglycerides, citric
acid esters of mono-diglycerides, succinic acid esters of mono-diglycerides,
salts of
fatty acids, polyglycerol esters of fatty acids, propylene glycol esters of
fatty acids,
calcium stearoyl lactate, sucrose esters of fatty acids, polysorbate 60, 65,
and 80.
2 o For suitable emulsifiers in the practice of the invention, reference is
made to J. Birk
Lauridsen, "Food Surfactants, Their Structure And Polymorphism," Technical
Paper TP
2-1 e, Danisco Ingredients, Brabrand Denmark, and references cited therein; N.
Krog,
"Interactions of Surface-Active Lipids With Water, Protein and Starch
Components In
Food Systems," Technical Paper TP 3-le, Danisco Ingredients, Brabrand,
Denmark, and
2 5 references cited therein; N. M. Barford, "The Influence of Emulsifiers and
Hydrocolloids on Fat Crystallisation and Water Binding in Various Food
Systems,"
Technical Paper TP 4-le, Danisco Ingredients, Brabrand, Denmark, and
references cited
therein; N. Krog, "Dynamic and Unique Monoglycerides," Technical Paper TP 8-
le,
Danisco Ingredients, Brabrand, Denmark, and references cited therein. Other
3 0 emulsifiers commercially available include SOFT TOUCH #640, and KAKE MA'I
E
SPECIAL #21.
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19
The emulsifier can be present in an amount of about 15 to about 60 weight
percent, such
as about 2~ to about 40 weight percent, e.g., about 2~ to about 35 weight
percent, such
as about 25 or about 26 to about 30 weight percent.
Water in the inventive delivery system can be present in an amount of about 10
to about
20 weight percent (the balance between the amounts of emulsifiers) and sugars)
to be
100 weight percent).
l0 The preferred inventive delivery system is for at least one emulsifier in
hydrated form
having an alpha gel structure. The invention thus provides the use of an
aqueous
solution of at least one mono- and/or disaccharide for delivery of at least
one emulsifier
in hydrated form having an alpha gel structure.
The interplanar spacing of the emulsifier bilayer in the alpha gel formed in
the delivery
system of the present invention may be characterized by low angle diffraction.
The
emulsifier dispersions of the invention have demonstrated stability in this
spacing for
eight (8) months to a year, and longer.
2 0 Without wishing to necessarily be bound by any one particular theory, it
is believed that
the mono- and/or disaccharide molecules become oriented in between the bilayer
of the
emulsifier molecules. This in turn is believed to prevent the bilayer from
collapsing
and also allows for better and improved wetting properties of the alpha gel.
In this
regard, monosaccharides are especially preferred, as monosaccharides provide
water
2 5 management for the emulsifier dispersion which holds the water activity
very low.
Accordingly, the inventive emulsifier dispersion is also microbially stable,
allowing it to
be incorporated into dry mixes such as retail cake mixes, without adversely
impacting
upon the proteins or leavening agents. Thus, foodstuff manufacturing benefits
from the
inventive emulsifier dispersion.
3 0 -"
Thus, the invention entails an aqueous dispersion of at least one emulsifier
comprising
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the at least one emulsifier, water and at least one mono- and/or disaccharide.
The
emulsifier is in hydrated form and has an alpha gel structure. The invention
accordingly
further entails an alpha gel dispersion wherein hydrophilic groups are
exposed. The
inventive dispersion is homogeneous, not heterogeneous or lumpy.
5
Furthermore, the invention provides a foodstuff obtainable from or prepared
with the
inventive emulsifier delivery system or emulsifier dispersion. The invention
thus
provides the use of the inventive emulsifier delivery system or emulsifier
dispersion in
the preparation of a foodstuff.
The foodstuff may be selected from baked goods, such as cakes including low
fat cakes,
bread, sweet dough products, laminated doughs, biscuits and liquid batters;
caramels,
halawa; ice creams, mousses, whipped dairy creams. whipped vegetable creams,
sorbets,
aerated and non-aerated whippable products, fillings, oil-in-water emulsions,
water-in
oil emulsions, spreads including chocolate spreads, low fat and very low fat
spreads,
cream margarine, cake margarine, low fat cake margarine; dressings,
mayonnaise, dips,
emulsified sauces, cream based sauces, emulsified soups, cream based soups,
beverages,
spice emulsions, meat products including processed meats, emulsified type
sausages or
combinations thereof.
A particular foodstuff of the invention is a flour-containing foodstuff, such
as a dried
cake mix, e.g., for preparation of pound cake, or bread. The invention
advantageously
allows use with flour so that water does not migrate to the flour and make it
spoil.
Other foodstuffs which can be prepared using the invention include frostings,
creme
2 5 fillings, and the like.
The invention allows the manufacturer of a foodstuff to use liquid or non-
crystal
shortening, and a wider range of emulsifiers in the preparation of a
foodstuff.
3 0 The invention allows one to provide an emulsifier without the need to
homogenise tFe
emulsifier. Typically, emulsifiers must be melted and homogenised together
with a fat
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WO 99/25207 PCT/IB98101882
21
phase in a product to be completely distributed onto the fat globules and
thereby
become functional. This is ofren achieved by heating the emulsifier to
65°C to render it
functional. The emulsifier of the delivery system of the present invention may
be
functional at room temperature. Homogenisation, for example by heating, may
not be
essential. This is particularly advantageous if the emulsifier is to be
delivered to a
system comprising starch. Starch may be spoilt by homogenisation treatments
such as
heating.
In a further preferred aspect the emulsifier of the inventive delivery system
may be
l0 homogenised. In this aspect, the homogenised emulsifier has increased
funtionality than
a homogenised emulsifier which has been delivered in accordance with the prior
art.
Moreover, the known advantages of homogenisation by heating such as
destruction of
bacteria may also be achieved.
1 S The improved functionality of emulsifiers when delivered by the system of
the present
invention not only provides for enhanced functional behaviour of typically
used
emulsifiers but also provides for the use of emulsifiers not usually
considered active
enough for the desired application and for the use of emulsifiers which are
usually only
active enough for the desired application when at an elevated temperature.
The applicant has found that the delivery system of the present invention may
provide:
i) a pumpable delivery system as an alternative to the prior art systems of
dry-blended
mixtures of emulsifiers and further deliverable substances such as
hydrocolloids and
integrated functional systems (fiu~ther deliverable substances such as
hydrocolloids
2 5 melted into the emulsifier phase).
ii) the use of many/all emulsifier types in combination with further
deliverable
substances such as hydrocolloids in one pumpable system. This contrasts with
the prior
art in which soft emulsifiers cannot be used in dry-blended mixes of further
deliverable
substances such as hydrocolloids and emulsifiers and cannot be used in
integrated
3 0 functional systems.
iii) the integration of further deliverable substances such as gums or other
ingredients
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22
e.g. flavours in a single delivery system
iv) improved emulsifying properties. The system of the present invention
provides a
good dispersion of emulsifiers. Thus the emulsifiers are directly functional
and can be
used in a hot system without homogenisation or in a cold system without heat
treatment
and homogenisation.
Further, the invention may reduce the cost of the foodstuff. For instance, in
the
preparation of flour-containing products such as breads, cakes, and the like,
it has been
observed that the invention provides a foodstuff which has softer crumbs,
greater
l0 volume, and greater air cell stability. Thus, less emulsifier and flour
than without the
invention are needed to prepare the foodstuff including the invention. The
skilled
artisan can adjust recipes without undue experimentation, using the knowledge
in the
art.
Also, foodstuff, such as flour-containing foodstuff, e.g., cake, bread,
prepared with the
present invention, stays fresh longer, i.e., does not get firm or stale as
quickly as control
foodstuffs prepared without the invention. Indeed, an increase in freshness of
three (3)
to five (5) days or more has been observed in flour-containing foodstuff
prepared with
the instant invention.
It is believed, without necessarily wishing to be bound by any one particular
theory, that
this observation is due to the alpha gel remaining intact, or otherwise
advantageously
interacting with ingredients, e.g., protein, starches, etc. in the foodstuff.
2 5 Furthermore, the inventive emulsifier system can be used in the
preparation of a
foodstuff in conjunction with or in addition to other emulsifier systems.
Thus, for
example, the inventive emulsifier system can be used in concert with
emulsified
shortenings to improve functionality. In this way, the invention allows the
foodstuff
manufacturer several advantages, such as the ability to reduce shortening
inventory or
3 0 shortening use, as well as the ability to employ a greater variety of
emulsifiers in tTie
preparation of a foodstuff.
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23
Also, it is noted that the inventive emulsifier system is useful in ordinary
doughs, i.e.,
doughs intended for ordinary (not especially sweetened) breads (in contrast to
especially
sweetened breads such as Irish Soda Bread or cakes). That is, it is noted that
the
inventive emulsifier system is useful for delivery of the emulsifier in
foodstuffs wherein
sweetening of the foodstuff is either not necessary or not desired. And thus,
the
invention is distinguished from previous uses of sugar or sugar solutions in
that
previous uses of sugar were for sweetening whereas the sugar in the present
invention is
used for stabilizing the alpha gel, as sugar molecules replace water molecules
in the
alpha gel.
Additionally, the invention allows the food manufacturer to not have to use
the
emulsifier system immediately or shortly after preparation or to acidify to
prevent mold
or microbial growth, as the invention has functional stability and microbial
stability. A
I5 stability of eight (8) months to a year or longer without loss of the alpha
gel has been
observed with the emulsifier dispersion of the present invention with no
observed mold
or growth after that eight (8) months to a year or longer.
In certain embodiments the invention provides a hydrated emulsifier system
comprising
2 0 or consisting essentially of: 15 to 40 weight percent of at least one
emulsifier, 42 to 65
weight percent of at least one sugar, wherein the sugar is predominantly
comprised of
mono and/or disaccharides, and 10 to 20 weight percent of water. The
emulsifier is
preferably comprised predominantly of or consists essentially of
monoglycerides or
mono-diglycerides. This emulsifier composition is particularly preferred when
the
25 system is used in the preparation of a bakery product such as bread. The
sugar is
preferably dextrose or high fructose corn syrup. The emulsifier can be present
in an
amount of about 26 to 30 weight percent. Thus, inventive dispersions contain
about 15
to about 40 weight % emulsifier, preferably about 26 to about 30 weight %
emulsifier,
about 42 to about 65 weight % sugar, and about 10 to about 20 weight % water.
The method for preparing an emulsifier system or a hydrated emulsifier,
advantageously
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24
a hydrated emulsifier having an alpha gel can comprise admixing the at least
one
emulsifier, the at least one sugar and the water at a suitable temperature for
formation of
the lamella mesophase, e.g., about 55° to about 80°C. The method
can comprise
blending the emulsifier at about 55° to about 80° preferably
about 60° to about 80°C,
S and adding the sugar and water with mixing at a temperature of about 55 to
about 80°C.
The sugar and water can be added in an amount to establish an emulsifier
content of
about 25 to 40 weight percent, e.g., about 25 or about 26 to about 30 weight
percent.
The resultant mixture is then cooled to a suitable temperature such as about
20° to about
25°C (e.g., room temperature) for alpha gel formation.
to
The invention provides an opportunity for a variety of different emulsifiers
to be used in
the emulsifier system, providing foodstuff manufacturers with emulsifier
options not
heretofore provided by shortening delivery systems.
15 The invention accordingly further comprehends methods for making a
foodstuff
comprising using the inventive dispersion system. For instance, in preparing a
foodstuff
the inventive emulsifier can be plated onto dry ingredients, and thereafter
the additional
ingredients of the foodstuff can be added, and the foodstuff prepared as is
typical for the
preparation of the particular foodstuff.
We have also found that the delivery system of the present invention may
deliver the
further deliverable substance in such a manner that, if the substance is
unstable, it may
be protected from degradation. This has particularly found with artificial
sweeteners
such as aspartame.
Therefore, by this disclosure, the skilled artisan is provided with an
advantageous
alternative to previous dispersion systems.
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The present invention will now be described by way of examples.
5 EXAMPLE 1
PHASE PROPERTIES AND STRUCTURE OF
~ONOGLYCERIDE-SUCROSE-WATER SYSTEM
This Example is adapted from Soderberg, I. (Department of Food Technology,
l0 University of Lund, Box 124, S-221 00 Lund, Sweden) and Ljusberg-Wahren, H.
(Swedish Sugar Company, Box 32, S-232 21 Arlov, Sweden), "Phase Properties and
Structure of a Monoglyceride-Sucrose-Water System" (in press).
The phase behavior of a sunflower oil, monoglyceride-sucrose-water system was
15 studied at 30°C. The different phases were identified by low-angle X-
ray diffraction
and polarization microscopy. The main feature of the phase diagram is the
transition
from a cubic phase to a reversed hexagonal phase (HIi) when sucrose is added
to the
monoglyceride-water mixture. A similar phase behavior was also shown to occur
for
monoolein-sucrose-water, as well as in the corresponding systems when sucrose
was
2 0 replaced by trehalose, fructose and glucose, respectively.
The phase transition from a cubic phase to a H" phase, when sugar is
introduced to a
monoglyceride-water system, corresponds to an increased average wedge shape of
the
lipid molecule. One explanation for this phenomenon is a structural change of
the lipid
2 5 caused by interaction between the sugar and they hydrated polar head
group, thus
reducing the interfacial area of the polar region at the contact zone with
water.
Monoglycerides are "swelling" amphiphiles with low monomer concentration in
water.
During "swelling" considerable amounts of water are incorporated when the
3 0 monoglycerides form various liquid crystalline phases.
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26
This Example considers the phase properties and structure of liquid-
crystalline phase in
the system of sucrose, sunflower oil, monoglycerides and water. Interactions
between
sugars and monoglycerides in liquid crystalline phases are discussed in
relation to the
well-known properties of aqueous sucrose solutions and binary monogIyceride-
water
systems. Monoglycerides are extensively used in the food industry as
emulsifiers.
Monoglycerides from sunflower oil (DIMODAN LSO) were supplied by A/S
Grindsted, Brabrand, Denmark (DANISCO INGREDIENTS). The sample contained
66% C 18:2, 19% C 18:1 C 16:0 and 5% C 18:0. The content of other fatty acids
was
below 1 %. Monoolein ( I -Monooleoyl-rac-Glycerol), 99% purity, was purchased
from
Sigma.
Sucrose (0.013% (w/w) ash content) was supplied by the Swedish Sugar Company.
D(+)-Glucose p.a. and D(-)-Fructose p.a. were obtained from Fluka and D(+)-
Trehalose
p.a. was obtained from Sigma.
The experimental samples were obtained by mixing appropriate amounts of the
technical monoglyceride and sugar solution in 10 ml test tubes with screw
caps. The
samples were heated in a waterbath (90°C) for I min and centrifuged.
They were then
2 o stored at 50°C for 2 h and finally repeated to 90°C for
another minute. The samples
were equilibrated for at least 1 week at 30°C. The initial high
temperature used was
needed in order to melt the most saturated monoglyceride homologues. No
increase in
monosaccharide content or acid number was detected after the thermal
treatment.
2 5 Samples of the system containing pure monoolein were obtained by weighing
appropriate amounts of monoolein and mixing it with water to form a La phase.
The
samples were stored at 40°C (to melt the monoolein) and subsequently
centrifuged (in
order to ensure good mixing). Sugar solution was added to the La phase. The
samples
were then allowed to equilibrate at room temperature for 1 week.
All the samples were examined between crossed polarizers for birefringence and
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27
homogeneity. The centrifuge step was repeated during storage until no further
change
in macroscopic behavior could be seen. When the samples had reached
equilibrium, the
structure of the different phases was investigated by low angle X-ray
diffraction and
polarization microscopy.
For the X-ray measurements a DPT camera (Stenhagen) and a Guiner camera after
Luzzati (Luzzati et al.), with a quartz monochromater were used. The
measurements
were performed at 30°C and before the samples had been in equilibrium
for one month.
An Olympus Vanox microscope was used for polarization microscopy.
There are three liquid crystalline phases with lamellar (L~, cubic (C) and
reversed
hexagonal (H,~) structure. In addition there are two liquid phases: an oil
continuous
solution (L2), in the monoglyceride corner, and the aqueous sucrose solution
(when
plotted in a ternary phase diagram from the results). The Hip phase and the L2
phase
exist over a larger range of sucrose concentrations than the cubic and the
lamellar
phases, which exist only with low amounts of sucrose. At a monogiyceride to
water
ratio of about 85:15% (w/w), a maximum amount of sucrose is incorporated in
the HI~
phase.
2 o The different phases were identified according to their X-ray diffraction
characteristics
and texture in polarized light. In Table 1 X-ray diffraction data are listed.
The Hll phase
was rather stiff, showing a fan-like texture in the polarization microscope
(Rosevear, J.
Am. Oil. Chem. Soc.; Rosevear, J. Soc. Cosmetic Chemists).
2 5 For samples in the H,I one-phase region with constant monoglyceride: water
ratio, an
approximate "wedge-shape" factor was derived. The hydrophilic components,
water
and sugar, were regarded as a momogeneous ideal solution. The minimum lipid
bilayer
thickness was assumed to be constant and the water channels were considered to
be
cylindrical. The wedge shape factor was defined as the ratio between the cross-
section
3 0 at the end of the hydrocarbon chain and the cross sectional area at the
polar head group.
The wedge-shape factor, thus defined, had a value of 1.3 at maximum sucrose
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WO 99/25207 PCT/IB98/01882
28
concentration.
This behavior of the monoglyceride-sucrose-water system shows that the
replacement of
water with sucrose produces a transition from a cubic phase to a HI, phase.
This should
be compared with a reduction of water content by dehydration of the cubic
phase which
produces a transition from a cubic phase to a La phase.
For a binary monglyceride-water system an increase in temperature results in a
transition from a cubic phase to a HjI phase (Lutton et al.; Larsson et al.),
which is
l0 consistent with an increased average wedge-shape of the amphiphilic
molecules from
the polar group towards the methyl end group. This is thought to provide a
driving
force for the transition C ~ H,I (Israelachvili et al.), which is thus related
to an
increased disorder of the hydrocarbon chains towards the methyl end group
plane. In
the phase transition of aqueous monoglycerides induced by sucrose, C ~ HI,,
the
increased wedge-shape is probably due to a reduction in the area of the polar
groups at
the interface between the sucrose solution and the hydrocarbon region. Sucrose
is a
hydrophilic molecule and is therefore assumed not to interfere with the
hydrophobic part
of the lipid.
2 o Monoolein is one homologue of the technical monoglyceride mixture used in
the ternary
diagram reported above. To samples of monoolein, aqueous solutions of sucrose,
trehalose, fructose and glucose were added. The results are summarized in
Table 2.
The binary system monoolein-water was in agreement with the same system
investigated by Hyde et al. This Example shows that monoolein swelled in sugar
2 5 solutions of both mono- and disaccharides has a different phase behavior
than
monoolein swelled in the same amount of water. Substitution of some water by
sucrose
is shown to have a greater effect on the phase properties of hydrated
monoolein than
when the same amount of water is replaced by fructose.
3 o Water can dissolve 68.2% (w/w) of sucrose at 30°C (Charles) and
sucrose
crystallization only occurs in supersaturated solutions. In samples with both
H,i phase
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WO 99/25207 PCT/IB98/01882
29
and aqueous sucrose solution, the sucrose will crystallize at lower sucrose
concentrations, assuming that the added water and sugar form a homogeneous
mixture.
Relatively little has been reported on such interactions between aqueous
carbohydrate
solutions and liquid crystalline phases. Two alternatives, which both promote
sugar
crystallization, are mentioned in the literature. One is an asymmetrical
distribution of
sugar between the liquid crystalline phase and the solution (Koymova et al.),
and the
other is a type of surface association of sucrose molecules in the vicinity of
the
aggregated amphiphile molecules (Tyrell et al.). Both of these suggestions may
have
relevance for sucrose crystallization in the presence of monoglycerides.
Within the liquid crystalline phases, formed by water and monglycerides, the
acyl
chains are in a disordered state, while the hydrated polar groups are anchored
by an
ordered hydrogen bond system. The phase behavior of a monglyceride-sucrose-
water
system indicates that the sucrose alters the hydrogen bond system in such a
way that the
polar head groups become more close-packed laterally. For any change in
physical
properties, which is related to the amount of dissolved molecules,
monosaccharides such
as fructose are expected to be more effective than disaccharides such as
sucrose on a
weight basis. The results in this Example show that sucrose has a greater
effect than
fructose, concerning the phase properties of hydrated monooleins. This
illustrates the
2 0 interaction between sugars and hydrated monoglycerides is related to the
structure of the
carbohydrate.
Thus, the inventive delivery system is structurally different than systems
employing
polysaccharides. Further, this Example demonstrates that the sugar used in the
present
2 5 invention indeed stabilizes the alpha gel.
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TABLE 1. Experimental low-angle X-ray diffraction data for the system
monoglyceride-water-sucrose at 30°C (The phase were identified by X-ray
diffraction,
ratio of spacings, 1:3:4, and polarization microscopy).
Composition (%) (w/w) a Phase
Monoglyceride Sucrose Water
75.2 16.1 8.7 47.5 L2+H,~
84.8 3.0 12.2 47.0 L2+HII
79.4 4.1 16.5 51.6 H~,
70.2 19.4 10.4 47.7 HII
80.1 7 12.4 46.2 HIS
79.9 2.0 18.0 51.2 H"
75 2.5 22.5 49.2 H,I
76 1.7 22.1 45.0 HIS
54.9 29.3 15.8 47.7 H~i+liq.
49.9 32.6 17.5 46.2 HMI+liq.
40.3 38.8 20.9 46.3 H"+liq.
65 12.3 22.8 52.7 HI,+liq.
50 17.5 32.5 51.8 H"+liq.
59.9 20.1 20.I 51.4 HI,+liq.
51 25 24 50.8 H"+liq.
40.2 29.9 29.9 54.4 Htl+Iiq.
74.6 12.7 12.7 45.3 HII+liq.
69.7 6.1 24.2 58.1 H"+liq.
65 7 28 51.4 HII+Iiq.
59.9 8.0 32.1 57.2 HMI+liq.
44.9 11.2 43.9 59.1 H"+Iiq.
5
a: hexagonal lattice parameter calculated from the diffraction Lines.
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31
TABLE 2. Phase behaviour of some monoolein (1-Monooleoyl-rac-Glycerol)-water-
sugar samples at 25°C. The different phases were detected by
polarization microscopy.
Type of Composition (w/w), % Phases
sugar
Monoolein Sugar Water
Sucrose 81.9 0.9 17.2 C
Sucrose 80.4 8.6 11 HI,
Fructose79.7 8.6 11.7 C
Trehalose87.4 2.9 9.8 C
Glucose 83.1 3.I 13.8 C
Additionally, this Example demonstrates that in the foregoing text, amounts
specified
for the emulsifier, sugar and water in the inventive delivery system are
preferred
amounts, and that these amounts can be varied to still obtain a stabilized
alpha gel of the
1 o invention. For instance, Table 1 shows that the amount of emulsifier can
be as high as
about 80 % (w/w) and in the range of about 40 to 80 % (w/w), the amount of the
sugar
can be from about 4 % (w/w) to about 40 % (w/w), and the amount of water can
be in
the range of about 10 to about 44 % (w/w). Thus, from this Example the skilled
artisan
can obtain additional embodiments of the invention, e.g., with respect to
amounts of
emulsifier, sugar and water for particular formulations.
EXAMPLE 2
AN INVENTIVE DELIVERY SYSTEM
2 0 An integrated emulsifier blend consisting of 65 parts polyglycerol esters
of fatty acids
(GRINDSTEDTMPGE 55 KOSHER mfg. by DANISCO INGREDIENTS), 25 parts
distilled monoglyceride (DIMODAN~ O KOSHER mfg. by DANISCO
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32
INGREDIENTS) and 10 parts sodium stearoyl lactylate (EMPLEX mfg. by American
Ingredients) at a temperature of 65°C was dispersed into a high
fructose corn syrup
(Isosweet 180 mfg. by A.E.Staley) with intense agitation at a loading of 30%
on a total
weight basis. The dispersion was then cooled to 42°C under continued
agitation and
then allowed to temper at ambient temperature for 2 days.
EXAMPLE 3
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
An integrated emulsifier blend consisting of 65 parts distilled monoglyceride
(DIMODAN~ O KOSHER mfg. by DANISCO INGREDIENTS), 25 parts polysorbate
60 (TWEEN 60 mfg. by ICI) and 10 parts sodium stearoyl lactylate (EMPLEX mfg.
by
American Ingredients) at a temperature of 65°C was dispersed into a
high fructose corn
syrup (Isosweet 180 mfg. by A.E. Staley) with intense agitation at a loading
of 35% on a
total weight basis. The dispersion was then cooled to 40°C under
continued agitation
and then allowed to temper at ambient temperature for 2 days.
2 0 Prepared bakery mixes for cakes, muffins, brownies and the like represents
a very large
segment of the baking industry and serves a very important role for homes,
store
bakeries, institutional kitchens and restaurants. A large variety and forms of
such mixes
are manufactured to provide high eating quality and convenience for the end
consumer.
Although there are many types, the standard yellow layer cake is one of the
most
2 5 common. The basis ingredients of a prepackaged mix for yellow cake is as
follows:
I,agnts weight % total mix basis
granulated sugar 39.9
3 o cake flour 3 3.5
non-fat dry milk 3.1
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33
salt 0.9
modified starch 1.5
baking powder 2.3
powdered egg whites 8.8
emulsified cake shortening 10.0
TOTAL 100.0
These basic ingredients can be augmented with various optional ingredients
such as
flavoring spices, nuts, etc. In addition, the level and ratio of the
ingredients can vary
somewhat depending on the application of the mix. As an example, if the mix is
designed for a layer cake as opposed to a loaf pan, the ratio of sugar to
flour can be
higher since a layer cake requires less structural strength than a loaf cake.
Also the
ratios of the sugar to flour can be increased if a higher absorption cake is
desired.
The type of the emulsifiers that are applied to these mixes can vary but
typically are a
combination of mono- and diglyceride with either propylene glycol esters of
fatty acids
or polysorbate 60. In addition, emulsifiers such as lecithin, polyglycerol
esters of fatty
acids, sorbitan esters of fatty acids, ethoxylated monoglycerides may be
incorporated as
2 0 a replacement for or as an addition to the before mentioned. The
shortening system
provides a variety of functions during the preparation of the cake and for the
eating
quality of the finished product including:
~ lubrication for the batter;
~ adding structure to the batter;
2 5 ~ enhancing air incorporation to the batter; and
~ shortening the texture in the baked product.
In addition, the shortening serves to deliver the emulsifiers to the mix. The
shortening is
generally based on a blend of partially hydrogenated soybean oil with either
fully
3 0 hydrogenated cottonseed oil or fully hydrogenated palm oil. To insure that
the resulting
mix will be free flowing and to reduce lumping, the shortening system selected
must
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34
provide a level of solids for a sufficient degree of crystallization on the
dry solids.
Depending on the solid fat content and/or level of the emulsifiers in the
shortening, the
loading can vary from ~ - 15%. In most cases this loading represents only a
fraction of
the total fat content in the finished cake as the consumer will add additional
plastic
shortening or liquid oil during preparation.
Generally, preparation of the mix involves first weighing the ingredients
individually
and then transferring all to a high efficiency blender. The shortening system
would then
be added to the mixer and creamed or plated onto the dry blend. If necessary,
the mix
may be passed through several sieves and additional mixers to insure a uniform
and free
flowing blend before packaging.
Application of the invention, e.g., either of the formulations of this Example
or of
Example 2 allows the delivery of the emulsifiers into the mix without a
shortening as
the processor would plate the dry ingredients with the invention. As a result,
all of the
fat in the finished cake would be incorporated during the processing of the
mix. This
invention thus provides very effective emulsifying and aerating capabilities
for the
batter. It can also offer other advantages such as:
~ The removal of less nutritious hydrogenated fats which contain low ratios of
2 0 polyunsaturated fatty acids to saturated fatty acids. In addition, these
partially
hydrogenated fats contain high levels of positional and geometrically isomers.
The
consumer could simply add a salad oil found commonly in the home such as
soybean,
corn, canola, or sunflower oil instead of the fat of the shortening.
~ Reduction in the production cost of the mix.
As an example of the invention's effectiveness, the following formulation
provided a
yellow layer cake:
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YELLOW CAKE FORMULATION
~~edients grams
a a
5
granulated sugar 120.0
cake flour 100.0
non fat dry milk g.g
salt 2.7
10 modified starch 4.4
baking powder 6.5
powdered egg whites 25.0
stage 2:
emulsifier dispersion (from Example 2) 15.5
2 o water 120.0
whole eggs 60.0
liquid vegetable oil 50.0
processing:
( 1 ) The ingredients from stage 1 were weighed and dry blended in a Hobart
bowl.
(2) The emulsifier dispersion was weighed and then applied by creaming onto
the
dry blend. Mixing or sieving was continued until the dispersion was uniformly
applied
to the entire surface of the dry mix ingredients.
3 0 (3) With continued mixing in the Hobart bowl, the eggs and water listed in
stage 3
were added. After the addition was complete, the mixing speed was raised to 2
for 2
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36
minutes. Finally, oil was added with additional mixing of 2 minutes.
(4) The batter was placed into a greased pan and baked at 350°F for 1 ~
minutes.
(5) The cakes were then removed from the pan and placed on a rack to cool for
1
hour before evaluating.
The cakes prepared with the inventive emulsifier dispersion had excellent
volume and a
tight crumb structure. in addition the cakes had excellent uniformity in
dimensions and
crown coloration. The surface of the crown was free from any significant
defects such
as blistering or bubbles. The crumb was quite soft with excellent mouthfeel.
Snack cakes:
A snack cake may be defined as a wrapped unit of soft cake weighing between 1
to 3
ounces, usually filled and topped with an icing or compound coating.
Production and
consumption of this type of cake have rapidly grown because of numerous
advantages
for the producer and the consumer. For the consumer, these snack cakes
represent a
convenient food for eating between meals or to be included with meals (e.g.,
sack
2 0 lunches, picnics, etc.). For the producer, these cakes which are designed
for a single
serving are smaller and thus maintain greater structural stability during
baking.
Preparing cakes with liquid oil on an industrial level is generally more
demanding since
liquid oiI can depress the foam production from the egg proteins whereas
plastic
2 5 shortening seems to support foam.
A typical formulation for a snack-type cake is as follows:
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37
INGREDIENTS % (flour basisl
sta 1:
Flour, cake 100.00
Sugar, granular 59.00
Dextrose 23.00
Nonfat dry milk 2.00
Dairy blend 4.30
Soy flour 8.00
1 o Yellow coloring 2.00
Vanilla Flavoring 1.00
Salt 2.50
Baking powder 5.00
st~~;.
Whole eggs 13.00
Water 55.20
Corn syrup 33.00
Emulsified shortening 11.50
2 5 stage 4:
Water 36.00
Again, as in the Yellow Cake Formulation according to this invention, an
inventive
emulsifier system can be employed as a replacement or as a compliment for the
3 0 emulsified shortening. In the case of this invention being applied as a
replacement for
the emulsified shortening, an all purpose or non-emulsified shortening may be
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38
employed instead of the emulsified shortening. As such, the following snack
cake was
prepared:
IN . FDIENTS % ~(~lour basisl
S t~g~:
Flour, cake 100.00
Sugar, granular 59.00
Dextrose 23.00
Nonfat dry milk 2.00
1 o Dairy blend - 4.30
Soy flour 8.00
Yellow coloring 2.00
Vanilla Flavoring 1.00
Salt 2.50
15 Baking powder 5.00
stake 2:
Emulsifier dispersion
(from Example 3) 2.70
2 o Whole eggs 13.00
Water 55.20
Corn syrup 33.00
~ta~;e 3:
2 5 AlI purpose shortening 11.50
,~~e 4:
Water 36.00
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39
PROCESSING:
( I ) The stage I ingredients were dry blended for 2 minutes on low speed.
{2) The emulsifier dispersion (from Example 3) was added and blended an low
speed for 2 minutes. The remaining stage 2 ingredients (eggs, water, corn
syrup) were
added with mixing continued until smooth; I minute on Iow and 2 minutes on
medium
speed.
(3) The stage 3 ingredients were added and mixed for 1 minute on low speed.
(4) The mixing was continued for 2 minutes on medium speed until lumps
1 o disappear. The bowl was scraped.
(S) The stage 4 ingredients were added and mixed in for 1 minute on low speed
and
3 minutes on medium or until smooth and desired specific gravity was achieved
(batter
temperature app. 76-78°F)
(6) The batter was scaled into greased cups and baked at 375°F for I 1
minutes.
(7) The cakes were allowed to cool for 1 hour before evaluating.
The batter ingredients wetted and aerated very quickly. The finished snack
cakes were
2 0 characterized as having a very tight, soft grain in the crumb with a
uniform crown.
Overall the cakes had excellent eating quality.
This Example demonstrates that the invention comprehends finished foodstuff,
and that
the invention is useful in the preparation of foodstuff.
EXAMPLE 4
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
The following ingredients were added to an ordinary pot and were mixed while
being
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heated on a hot plate.:
318.6 g glucose syrup 42 DE
220.0 g sugar
5 15.4 g emulsifier delivery system*
250.0 g condensed milk
80.0 g water
* The emulsifier delivery system contained 26% mono-diglycerides (GRINDSTEDT""
l0 TOFFAN 60) and 74% glucose syrup 42DE.
After mixing of the above ingredients, 110.0 g fat (hydrogenated palm kernel
oil), and
5.0 g salt were mixed by agitation while being heated to 127°C. To
adjust the
consistency, the water content was adjusted to the desired level by weighing
before and
15 after heating to 127°C.
The caramel was cooled to a temperature below 60°C and the caramel
flavour was
added. After addition of flavour, the caramel was cut into small pieces.
2 0 The use of the emulsifier delivery system provided caramel having
stickiness, cutting,
and improved shelf life properties comparable to that of caramel prepared by
the
addition of emulsifier by itself.
The emulsifier delivery system in accordance with the present invention can be
2 5 modified by replacing the mono-diglycerides (GRINDSTEDT"' TOFFAN 60) with
distilled monoglycerides (DIMODAN~ PM).
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41
EXAMPLE S
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
~a(awa
The following ingredients were mixed in a pot:
347.0 g sugar
141.76 g glucose syrup
19.24 g emulsifier delivery system*
0.7 g citric acid
80.0 g water
* The emulsifier delivery system contained 26% sorbitan monostearates
(GRINDSTEDT"" SMS) and 74% glucose syrup 42DE.
After mixing, the sugar solution was heated on a ordinary hot plate to
128°C while
being stirred continuously. The boiled sugar mass was filled into a Hobart
mixer
connected to a 100°C hot oil bath and whipped for 4 minutes with the
flat whisk at
2 0 speed 2. 485.0 g tahina was heated in a water bath to 40°C and 10.0
g distilled
monoglycerides (DIMODAN° PV) were added to the 40°C warm tahina
and mixed well
to prevent oil separation. The whipped sugar mass and tahina were then mixed
manually. First, it was folded gently with a rubber spatula and then the
layers of tahina
and sugar mass were folded by hand over and over again with a pulling
movement.
2 5 Finally, the halawa was filled into a tin.
The emulsifier delivery sytem acted as a delivery system for sorbitan
monostearates
(GRINDSTEDT"" SMS). This emulsifier functions as a whipping agent in the sugar
mass, providing halawa having good colour and texture.
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EXAMPLE 6
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
Ice Cream and Dairv Products
The structure of aerated emulsions such as ice cream, and other aerated
desserts such as
mousse, whipped dairy, and vegetable cream consists of air cells distributed
uniformly
in a frozen or liquid continuous phase containing carbohydrates, proteins, and
fat
globules. The texture and stability of the whipped product is related to the
air cell
l0 structure which is built up by shells of fat globules or crystals arranged
at the interface
between air and water.
The driving force for this structure to be built is a partial destabilisation
of the fat
globules during the whipping process.
The destabilisation involves both a desorption of protein from the fat globule
surface
and a crystallisation of the fat phase taking place e.g. during the aging
period of an ice
cream mix before freezing.
2 0 Both these processes are essential for the whippability of emulsions and
are enhanced
by emulsifiers such as monoglycerides and lactic acid esters of mono- and
diglycerides.
The following recipes were prepared
i Recipes
Ice cream Reference1 2
Composition
Dairy cream, 38% fat 23.65 23.65 23.65
Skimmed milk 53.50 53.39 53.44
Skimmed milk powder 4.90 4.90 4.90
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Sugar 7.60 7.60 7.60
HFCS 4.40 3.95 3.95
Glycose syrup, DE 42, 75% 5.35 5.35 5.35
TS
Hydrocolloid blend 0.18 0.18 0.18
Flavour 0.05 0.05 -
CR.EMODAN~ SUPER 0.37 - -
Delivery Systems
40% CREMODAN~ SUPER, - 0.93 -
60% HFCS*
40% CREMODAN~ SUPER, - - 0.93
5% Flavour, 55% HFCS
Total 100.00 100.00 100.00
* High Fructose Corn Syrup (HFCS)
The recipes were prepared in accordance with the following process
1. Pre-heat milk to 40°C
2. Add all ingredients.
3. Mix continuously until all ingredients are fully dissolved
4. Pasteurise at 80°C/20 sec.
5. Homogenise at 80°C/190bar.
6. Cool to 1-3°C
7. Age overnight
8. Freeze in continuous freezer to 100% overrun
9. Harden in tunnel at -40°C
lO.Store below -25°C
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44
Dairy whippinb cream
Reference
Composition
Dairy cream, 38% fat 79.00 79.00
Skimmed milk 13.99 13.99
Sugar 6.00 6.00
GRINDSTEDTM Carregeenan CL 110 0.012 0.012
HFCS 0.60 0.00
GRINDSTEDTM LACTEM P22 0.40 0.00
40% GRINDSTEDTM LACTEM P22, 0.00 1.00
60% HFCS
Total 100.00 100.00
Process:
1. Pre-heat milk to 40° C
2. Add all ingredients to cold liquids
3. Mix continuously until all ingredients are fully dissolved
4. UHT-treat at 142°C/3 sec.
5. Homogenise at 80°C/30bar
6. Cool to 5°C
7. Store at 5°C
The above recipe in accordance with the present invention was comparable in
appearance, texture and flavour with the reference product.
The above recipe clearly showed that the delivery system of the present
invention may
be used to obtain results as good as the application of an ordinary emulsifier
or an
emulsifier stabiliser blend. Furthermore, the applicant found that the
incorporation of
the flavour via the delivery system worked as well as an ordinary applied
flavour.
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EXAMPLE 7
ANOTHER INVENTIV i D,~LIVERY SYSTEM AND THEREOF
5 Wetting~gents
As discussed above, many powders need to be readily dispersible in liquids
such as
water or milk. In the food industry this is the case in, for example, powdered
isotonic
sport drinks, instant cocoa powder and protein powders such as Na-caseinates.
Typically, powders can be rendered dispersible by an agglomeration process or
by
coating them with a surface active agent. For example, instant cocoa powders
are very
often coated with high amounts of lecithin (approx. 5% of an ordinary lecithin
containing approx. 50% soy bean oil) to render the dispersible. However, this
coating
may cause off flavour problems due to the oxidation of the soy bean oil (often
referred
to as the reversion flavour typically for soy bean oil). Moreover, most of the
lecithin
used worldwide are derived from soy beans. Many supplies of soy beans comprise
beans
from genetically modified plants. Consumer pressure and legislation renders
the use of
such beans undesirable or unacceptable. Thus, there is a desire in industries
such as the
2 0 cocoa industry to replace lecithin with other emulsifiers.
The following experiments were performed using the following powders
1. Untreated defatted (10-12% fat) cocoa powder - Reference sample
2 5 2. Defatted cocoa powder coated with an ordinary lecithin (~ 50% oil).
This powder
was coated in the manner described below - Reference sample
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46
Sample Powder Delivery system Delivery system
conc. on cocoa
powder
1 1 DIMODAN LS + PANODANT"" AB 3.84%
100b
2 1 None
3 2 Lecithin
a: The delivery system is 26% emulsifier and 74% high fructose corn syrup
b: DIMODAN LS and PANODANTM AB 100 were added in a ratio of 3:1
c: The delivery system is 2.6% emulsifier and 97.4% high fructose corn syrup
Coatins ~ro~edure
The cocoa powder was placed in a food processor/blender. The motor was started
at
maximum speed. The emulsifier/delivery system was added to the blender/tood
processor and mixed onto the cocoa powder for at least 3 min. The delivery
system may
be added either at room temperature or heated carefully until melted.
Test procedure
Wettability: I g of cocoa powder was mixed with 3 g of finely powdered sugar.
The
mixture was sieved onto a surface (either water or milk) and the time for the
last cocoa
powder to disappear underneath the surface is measured.
2 o By the use of this invention it was possible to decrease the wetting time
up to 50-75% as
compared to the untreated reference sample of defatted coca powder. The coated
and
defatted cocoa powder in accordance with the present invention exhibited
proper
wetting properties and dispersability i.e. it sank faster than the untreated
reference
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47
sample.
EXAMPLE 8
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THER_FOF
Fat Based Products
It was found that the delivery system in the production of margarine and fat
based
products allows for the simplification of the production process of fat
containing
l0 products, particularly cake and cream margarine, fillings, chocolate
spreads and low fat
spreads. That is possible due to incorporation of the most important
ingredients
(advantageously emulsifier(s), stabiliser system, sugars and flavourings) in
the delivery
system.
The fat based products below were prepared in accordance with the following
procedure:
Heat the water and blend the water phase ingredients, (pasteurise if
necessary).
Adjust pH. Temper to approx. 50-60°C.
2 o 2. Melt and blend the fat phase. Add the ~3-carotene and flavourings, if
necessary.
3. Make the emulsion at 50-60°C, while agitating vigorously. Add the
emulsifier
delivery system.
4. Crystallise and knead in a tube chiller. Outlet temperature is 10-14
°C.
2 5 8 1 Cake margarine /cream mara,arine (full-fat and 60% fats
Full-fat 60°/
Water p ase Water 16.0% 38.4%
Salt 1.5% 1.5%
K-sorbate 0.1 % 0.1
GRINDSTEDTM Alginate LFS 200* 1.0%
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48
pH 5.5
a a Fat blend 80.9% 55.0%
3~ parts soya 41 °C
20 parts Soya 35 °C
20 parts soya oil
25 parts coconut oil
Emulsifier deliver system (in emulsion tankl 3.3% 5.0%
* Is added when there is no GRINDSTEDTM Alginate LFS 200 in the Emulsifier
Delivery System.
Emulsifier delivery s sy tem
for full-fat for 60% fat
GR11VDSTEDT~''~ PGE 20 VEG 30.0% - 30.0%
Polyglycerol Ester
ISOSWEET** 70.0% - 70.0% -
DIMODAN~ PVP Distilled - 10.0% - 10.0%
Monoglyceride
GRI1~TDSTEDTM PGE 55 - 20.0% - 50.0%
Polyglycerol Ester
ISOSWEET** - 70.0% - 20.0%
GRINDSTEDTM Alginate LFS - - - 20.0%
200
* * a High Fructose Corn Syrup
Results
The emulsifier delivery system for the addition of the emulsifier and
stabiliser system in
cake/ 'cream margarine resulted in stable products with good whipping and
baking
properties. The baked pound cakes had excellent uniformity and coloration. The
top of
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49
the cakes was free from any significant defects. The crumbs were quite soft
with
excellent mouthfeel.
8.2 Filling
Filling was made in a ice cream freezer with mono-pump (capacity 27 kg/hr).
Nitrogen
blown in after the pump and before the cooling cylinder. Outlet temperature:
15-17 °C.
Water phase Water 12.5%
GRINDSTEDTM Pectin LFS 100 0.5%
SMP 8.0%
Sucrose 9.9%
Invert sugar 9.0%
Sorbitol 70% 8.0%
Glucose syrup 14.0%
Glycerol 7.0%
K-sorbat 0.1
fat ~ha~ Lecithin 0.4%
Fat blend (100% coconut 31 C) 26.6%
Butter flavouring 2598 0.03%
Emulsifier deliver, to in emulsion 4.0%
tank)
Emulsifier delivery s, s
DIMODAN~ PVP Distilled Monoglyceride 25.0%
70% Glucose syrup 65.0%
Water 10%
Results
The filling cream was smooth with good flavour release. Specific gravity of
the cream:
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0.71 g/ml.
$.3 Snack cakes cream filling
High fructose corn syrup 49.7%
Powdered sugar 19.0%
Shortening 21.5
Salt 1.0%
Sorbic acid 0.2%
Water 5.0%
HPMC K-100 0.1%
Na-caseinate 0.5%
GRINDSTEDTM LACTEM P 22 Lactic Acid 1.0%
Ester
PANODANTM 150 DATEM 0.1
GA 1738* 2.8%
5
* Emulsifier delivery system GA 1738 is 26% monoglyceride with high fructose
corn
syrup.
Results
The snack cakes cream filling was smooth with good flavour release. Specific
gravity
of the cream filling: 0.66 g/ml
8.4 Chocolate s rn ead
Water phase Water 25.0%
Cocoa powder 5.0%
SMP 3.0%
Hazelnut paste 1.0%
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S1
Salt 0.2%
GRINDSTEDTM Alginate LFS 0.7%
200
Sugar 23.8%
Potassium sorbate 0.1
pH 5.0-5.5
Fat a a Fat blend: 39.1%
2 parts GRINDSTEDTM PS 101
18 parts Soya 41
30 parts Soya 35
parts coconut oil
40 parts liquid oils
Emulsifier delivery system (in emt 2.1
1 ion tan )
Emulsifier delivery system:
DIMODAN~ CP Distilled Monoglyceride 24.1
GRINDSTEDTM PGPR 90 Polyglycerol Polyricinoleate 4.8%
Glucose Syrup 67.3%
Chocolate Flavouring 3031 1.9%
Hazelnut Flavouring 3433 1.9%
5 Results
The finished chocolate spread was characterised as a nice, stable product with
fine
mouthfeei and good flavour release with hazelnut note.
10 8.5 Low fat spread & 8.6 very low fat s rn ead
The delivery system of the present invention was also is useful in the
production o~-a
low fat spread with and without protein (in accordance with example 8.5 given
below)
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and a very low fat spread (in accordance with formulations 8.6 given below).
The
delivery system was used for the delivery of flavourings and/or stabilising
systems.
The spreads were prepared in accordance with the method given above.
8 ~ - 40% Fat Spread with and without Protein
With protein Protein free
Water Water 42.3% 57.2%
Salt 1.2% 1.2%
K-sorbate 0.1 % 0.1
Whey powder 1.0%
GRINDSTEDTM Pectin LFS 100 1.0%
pH 5.5
Fat phase Fat blend 39.5% 39.5%
25 parts Soya 41
75 parts liquid oil
Emulsifier delivery system (in emulsion1.7% 2.0%
tank)
F__r_r~ulsifier deliverv,~ystem for spread with rn otein
DIMODAN~ OT Distilled Monoglyceride 29.2%
(3-carotene 1.2%
Butter Flavouring 2873 0.6%
Butter Flavouring 3507 0.6%
ISOSWEET 68.4%
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FmmlcifiPr deliver system for spread without rn otein
DIMODAN~ CP Distilled Monoglyceride24.5%
(3-carotene 1.0%
Butter Flavouring 3385 0.5%
Butter Flavouring 2807 0.5%
GRINDSTEDTM Pectin LFS 100 24.5%
ISOSWEET 48.0%
8 6 - 20% Fat Spread with and without r~ otein
Protein-free With Protein
Water phase Water 73.0% 74.0%
Salt 1.0% 1.0%
Whey powder - 1
K-sorbate 0.1 % 0.1
pH 5.5
GRINDSTEDTU LFS 560 2.0%
Stabilising System
F~ phase Fat blend 19.2% 19.2%
75 parts soya oiI
25 parts Soya 41 C
GRINDOXTM TOCO 50 0.01 % 0.01
Antioxidant
~,mulsifier delivery system (in 4.7% 4.7%
emulsion tank)
emulsifier delivery system
DIMODAN~ LS Distilled Monoglyceride 21.2%
GRINDSTEDTM PGPR 90 8.5% _ _
ISOSWEET 69.3%
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~3-carotene 0.4%
Butter Flavouring 3195 0.4%
Butter Flavouring 3399 0.2%
Results of 8.~ and 8.6
The low-fat spreads and very low-fat spreads containing the new delivery
system were
stable and had good water dispersion. Sensory evaluation of the samples showed
that they
had a very good flavour release and colour.
EXAMPLE 9
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
Fine Foods
The following recipes were prepared and tested:
30% Bechamel Sauce, with a pH of S.5
30% Dressing with a pH of 4.0
50% Mayonnaise with a pH of 4.0
Bechame! Sauce Dressing Mayonnaise
Composition % Composition % Composition
Veg.0i1 30.0 Veg.0i1 30.0 Veg.Oil 50.0
Bouillon 2.0 Sugar 1.0 Sugar I.0
Wheat flour 1.0 Salt 1.0 Salt 0.3
K-benzoate 0.1 K-benzoate 0.1 K-benzoate 0.1
Modified Starch2.0 Vinegar 10% 4.0 Vinegar 10% 4.0
Salt 0.3 Modified Starch1.0 Modified Starch1.0
GRINDSTEDT" 0.2 GRINDSTEDT"" 0.3 GRINDSTEDT"" 0.2
FF FF
5101 5101 Stab. FF 5101 stab.
Stabiliser
System
Emulsifier A) Emulsifier B) Emulsifier B)
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Water up to 100°,o Water up to 100°~o Water up to I OU%
Total 100.0 Total 100.0 Total 100.0
Dispersed Emulsifier and reference emulsifiers which has been tested
Emulsifiers Dosage of sugar
dispersion or
emulsifier in
the recipes
A) B)
40% PANODANT"" AB 100 DATEM, 60% HFCS1.10 % I .25%
26% GRINDSTEDT"" CITREM NI2, 74% HFCSl. % 0.00%
PANODANT"" AB 100 0.44 % ~ 0.50%
GRINDSTEDT"" CITREM N I 2 0.40 % 0.00%
The samples were made on a Koruma mixer (Colloid mill)
Process:
1. Mix water. and all dry ingredients except Emulsifier &: Stabiliser system
2. Blend the sugar dispersed Emulsifier &: Stabiliser system with part of
1 o the oil and add it to the water phase
3. Mix continuously until all ingredients have been fully dissolved
4. Emulsify the rest of the oil into the water phase
5. Alternatively
a) Pack
1 S b) Homogenise at 150 bar and pack
c) Heat to ~0°C for 1 minute before step 4) and pack
d) Heat to ~0°C for 1 minute before step 4) and homogenise at 150 bar
and pack
Results - Bechamel Sauce:
Particle size measurement together with visual evaluation in microscope was
used as a
indication of the stability of the emulsion.
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Mean diameter D[4,3J (~ a) cold b) Cold c) Hot d) Hot
m) + +
150 bar 150 bar
PANODANT"' AB 100 17 7 23 6
Delivery system containing 17 4 18 5
PANODANT"" AB 100
GRINDSTEDT"' CITREM N 12 40 28 90 32
Delivery system containing 33 7 50 19
GRINDSTEDT"" CITREM N12
When looking at the performance of PANODANTM AB 100, one can see a slight
improvement by adding the vegtable emulsifier through the present delivery
system.
S The mean particle size diameter goes from 7 ~.m to 4 p.m. The performance of
T~t
GRINDSTED CITREM N12 is considerably improved, from the mean particle size
diameter of 28 ~.m to 7 ~,m .
Results - 30% dressing and 50% mayonnaise:
pH 4.0, cold process and homogenisation at 150 bar
Emulsifier Dosage Fat D[4.3] p.m
% %
PANODANT"" AB 100 0.50 30 29
40 % PANODANT"" AB 100 1.25 30 8
PANODANT"' AB 100 0.50 50 70
40 % PANODANT"" AB 100 1.25 50 19
X(Mastersizer - Particle diameter measurements)
It was not possible, in a cold process, to make a stable emulsion with the
recipe with a
ordinary applied emulsifier. In contrast using the dispersed emulsifier in
accordance
with the present invention, the emulsion was stable. The differences between
the two
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emulsion was even greater at higher fat level. The 50% mayonnaise made with
ordinary
applied emulsifier was unstable and transparent, whereas the dispersed
emulsifier was
stable with a white appearance.
Conclusion:
The experiment clearly showed that the emulsifier delivery system of the
present
invention worked better than an ordinary applied emulsifier. To obtain
sufficient
emulsifying power with the ordinary applied emulsifier it is necessary to
homogenise
l0 before packing.
In contrast to normal behaviour of CITREM emulsifier, the present delivery
system
used in a cold process made a stable emulsion ( D < 20 ~ m). Thus, with the
system of
the present invention not only is it possible to use a vegetable emulsifier as
a dispersed
emulsifier in a cold system, but the stability of the emulsion is improved.
The system of the present invention may also be used in the preparation of:
~ Mayonnaise and similar products (low-fat, fat-free etc.)
2 0 ~ Dressings and dips
~ Emulsified sauces
~ Cream-based sauces
~ Emulsified soups
~ Cream based soups
2 5 ~ Spice emulsions
The delivery system of the present invention may also be used in the following
processes and equipment:
3 0 ~ Stephan Cooker (or similar)
~ Schroder Combinator (or similar)
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~ Fryma Mixer
~ Herbort Mixer
~ Other high shear mixers
EXAMPLE 10
ANOTHER INVENTI DEL1VERY YSTEM AND U la , THEREOF
Flavourings
In the production of low-fat spread it is often necessary to use two
flavourings: one for the
oil phase and one for the water phase.
An emulsifier delivery system in accordance with the present invention may be
prepared
to deliver two such flavourings. The delivery system consists of emulsifier,
sugar and
flavourings. The delivery system should be added to the emulsion, while
agitating
continuously.
2 o A delivery system having the following recipe was incorporated in a 40%
fat spread in
accordance with example 8.~.
Delivery system
Butter Flavouring 3385 5.0%
Butter Flavouring 2807 5.0%
DIMODAN~ CP Distilled Monoglyceride20.0%
ISOS WEET 70.0%
Concentration of the delivery system in the low-fat spread was 0.2%.
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Results
Evaluation of the test sample and the control sample to which the flavourings
were added
via the fat and oil phases showed that both samples had a creamy, fresh and
fermented
taste, and that there was no difference between them.
The present invention is advantageous because the two flavourings may be added
in a
simple manner as a single system, integrated with the emulsifier(s).
1 o EXAMPLE 11
ANOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
Baked Goods
The delivery system of the present invention can successfully be used as a
delivery
system for functional ingredients for baked goods, such as cakes, sweet dough
system,
laminated doughs, biscuits and liquid batters.
The delivery system of the present invention is advantageous for the
preparation of
2 o bakery and cereal products (such as like sponge cakes, Swiss rolls, tea
buns, hamburger
buns, crackers, biscuits, and wafers) because:
~ the emulsifier is kept stable in its active form
~ it is possible to integrate different functional ingredients such as
emulsifiers,
2 5 enzymes, flavours, hydrocolloids, starch, salts, proteins
~ a pumpable delivery system is provided, as an alternative to bakery
functional
ingredients which can be a mixture of powdered, beads, flakes, or liquid
ingredients.
~ an integrated product may be prepared containing emulsifier in combination
with
different types of further deliverable substances, for example different types
of
3 o emulsifiers (saturated with unsaturated), different types of food grade
enzymes,
different types of flavourings (oil as well as water soluble) and/or
hydrocoiloids.
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~ functional ingredients are easier distributed in the system.
The following baked goods were prepared
5 11.1 Low fat and No fat Cakes
Sponge cakes and low to no fat cakes are produced from egg, sugar, flour,
baking
powder and eventually some fat e.g. butter, margarine and/or oil. In small
scale
production e. j. household, egg and sugar are whipped together in order to
provide an
10 aerated and light cake, afterwards, flour, baking powder, a little water is
added. This is
however a time consuming process as the preparation of the cake batter include
several
mixing steps. In industrial scale it is much more convenient if all the
ingredients are
added in a 'all in one' process meaning that all ingredients are added and
mixed
together, this process however does not give sufficiently aeration to the cake
batter and
15 the result will be a very flat and dense cake. Emulsifiers like mono-di
glycerides, lactic
acid esters of monoglycerides, polyglycerol esters, polyglycerol monostearate,
sorbitan
monostearate, can when they are dispersed in water or on an active alpha form
provide
both aeration and batter stability.
2 0 Ll .~ oon a cake
A sponge cake is typically prepared as an all in one procedure where all the
ingredients
are added at the same time and immediately whipped. Emulsifiers must be added
to the
mixture of ingredients. Preparing a cake as an all in one procedure without
using
2 5 emulsifiers results in a collapse of the cake as the air incorporation is
not stabilised. The
use of emulsifiers is essential in preparation of these cakes in an "all in
one" procedure.
When emulsifiers are used they can be added in different ways: hydrated as in
a gel,
spray crystallised, or spray dried on a powdered carrier system, however the
main thing
3 0 is that the emulsifier is in an active a-form when used.
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The following recipes were prepared wherein the emulsifier is either added as
a
powdered sponge improver or as a gel.
Ingredients A) with B) with C) with D) with
powdered GRINDSTED GRINDSTED present
improver T"" GA 505 T"" GA 504 delivery
gel gel sys.
Sugar 3/20 208 200 200 190
Flour 188 160 160 160
Corn Starch 60 75 75 75
Baking powder 14 4 4 4
Egg 200 23~ 235 235
Water 1 ~0 100 100 100
Delivery system0 0 0 20
Powdered sponge30 0 0 0
cake improver
GRINDSTEDT"" 0 18 0 0
GA 505 Gel
GRINDSTEDT"" 0 0 18 0
GA 504 Gel
* a delivery system in accordance with Example 2
Procedure:
A: Mix all the ingredients for 6 min. on a Hobart N50.
Scale 2 x 350 g into round sponge cake tins.
Bake for 35 min. at 180°C.
If softness measurements are required:
scale 350 g into a round sponge cake tin and 3 x 175 into softness tins.
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B,C&D: Mix all the ingredients for 3 min. on a Hobart N50 at 3'd speed.
Scale 2 x 350 g into round sponge cake tins.
Bake for 35 min. at 180°C.
By the use of the present delivery system it is possible to produce low fat
cakes as an all
in one procedure with similar properties regarding surface smooth and even,
volume.
The crumb structure is however finer and the reliance is improved -
sensorically tested
the cake is much more moist even after 14 days and thus the performance of
this
delivery system compared to a powdered sponge cake improver or an emulsifier -
in a
gel system is improved.
Baking trials were performed. The results are as follows:
A (powdered)B (GA SOS) C (GA X04) D (delivery
sys.)
Litre weight 350 345 340 342
Specific volume5.58 5.35 5.54 x.63
All cakes were homogeneous with good and even crumb structures. The cake
prepared
with the delivery system had improved bite and resilience and a slightly
darker surface.
The above examples were repeated to prepare Swiss rolls of a similar recipe.
Swiss
2 o rolls had similar properties to rolls made in accordance with typical
prior art procedures.
11.3 Sweet dough ~ystem~
Sweet doughs are characterised by the presence of sugar in the recipe,
eventually also
2 5 fat and/or eggs. In sweet doughs emulsifiers, enzymes and flavourings are
often used as
functional ingredients. The delivery system of the present invention can be
successfully
be used as a delivery system of functional ingredients such as emulsifiers
(e.g. DATEM,
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CITREM, ethoxylated monoglycerides, polysorbate, monoglycerides, sodium
stearoyl
lactylate [SSL] and calcium stearoyl lactylate [CSL]) and enzymes found in a
sweet
dough or any other dough system. Commonly found enzymes include amylolytic
enzymes and other enzymes capable of modifying starch, non-starch
polysaccharides,
protein or lipids and enzymes capable of oxidising or reducing components.
Other
functional ingredients often used in such doughs include flavourings (butter,
citrus,
panetone, bread) in for example tea buns, hamburger buns, brioche (French
product),
panetone (Italian product). The present delivery system can be used in both
straight
dough procedure, chorleywood procedure as well as the more labourious US
sponge and
dough type of bread.
The following recipes were prepared in accordance with the usual procedure of
making
a bread or a sweet dough bread or roll, namely mixing, t resting, scaling,
resting,
moulding, shaping, proofing and baking.
I5
Ingredients Tea Hamburger Brioche
buns buns
Flour 1500 1500 1500 1500 1725 1725
Egg 0 0 0 0 450 450
Salt 15 15 30 30 15 15
Sugar 150 125 190 165 360 330
Compressed yeast 150 I SO 90 90 75 75
Fat 150 150 75 75 0 0
Butter 0 0 0 0 330 330
Gluten 0 0 45 45 0 0
Ascorbic acid 0 0 0 0 60 60
Water 870 870 900 900 450 450
Cystein 0 0 20ppm 20ppm 0 0
PANODANT"" 4.5 0 4.5 0 5.18 0
DATEM
DIMODAN~ 4.5 0 4.5 0 5.18 0
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GRINDAMYLT"" 200ppm 0 200ppm 0 200ppm 0
S
100
Delivery system*0 3~ 0 3~ 0 40
*The delivery system contains 12.5% PANODANT""AB 100, 12.5% DIMODAN~
SDM-T, I .0% GRINDAMYLT"" S 100, and 74% High Fructose Corn Syrup.
~'rocedures
Tea buns: mixing 2+10 min on a Hobart mixer with hook. dough temperature
approx.
26°C. Scale 1350 g, moulding (Fortuna 3-17-7). Proofing 50 min at
35°C, 85% RH.
Baking 10 min at 220°C.
Hamburger buns: mixing on a Hobart mixer 2+15 min. (Dough temp approx.
26°C).
Scaling (1800 g). resting 5 min. Moulding (Fortuna 6-27-~). Rolling out 3.Smm.
Proofing 50 min at 40°C, 85% RH. Baking 12 min at 195°C.
Brioche: Flour and sugar are dry blended, if functional ingredients (enzymes,
emulsifiers, flavourings) are used they are also added at this step. Eggs,
water and butter
is added, mixing 3+5 min. Add yeast, mix for another 5 min (2"d speed), salt
is added,
mix for 10 min (2"d speed). Resting 30 min at 30°C, 80% RH. Scaling
(400 g). proofing
150 min at 30°C, 80% RH. Baking approx. 30 min. at 180°C.
Baking trials in sweet dough systems e.g. tea buns, hamburger buns, or brioche
comparing the effect of using single ingredients PANODANT"" AB 100, DIMODAN~
SDM-T and GRINDAMYLT"" S 100 and the delivery system of the present invention
(containing a combination of PANODANT"" AB 100, DIMODAN~ SDM-T and
2 5 GRINDAMYLT"" S 100) have proven that the use of the present delivery
system
provides desirable properties to the baked goods e.g. improved volume and
tolerance, as
the conventional systems. Better softness and a more homogenous crumb
structure was
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also provided by the present delivery system. Moreover, by using the present
delivery
system easier dosing was possible as only one and not three ingredients had to
be
scaled.
5 The results of trials performed in respect of tea buns in accordance with
the above recipe
are as follows:
Standard recipe Delivery system
Specific volumne 7.89 7.85
Comments Capping in some of Good and homogenous
the rolls rolls
due to lack of stability
No differences were observed regarding dough handling. The overall best
appearance
10 was seen in rolls prepared with the delivery system.
11.4 Laminated doqghs
In laminated dough systems emulsifiers (e.g. PANODANT"" DATEM, polysorbate,
15 CITREM, SSL, CSL) and enzymes are often used in order to improve the dough
handling, ease the lamination process and improve the baking performance and
texture
of the final product. Baked products where laminations are commonly used are
products
like crackers, puffed biscuits (Japanese style), croissants and puff pastry.
2 0 The delivery system of the present invention provided an eased delivery
system as well
as an improved distribution of functional ingredients like emulsifiers,
enzymes and
flavourings.
The following recipes for crackers, croissants and biscuits were followed.
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~ 1.4.1 Crackers
Ingredient Standard with delivery
Amount system
(g)
Wheat flour 640 640
Shortening 120 120
Whey powder 12 12
Ammonium bicarbonate 10 10
Salt 8 8
Water 200 200
PANODAN'"' AB 100 1.3 0
Delivery system * 0 3.2~
Sodium metasulphite based 400 ppm 400 ppm
on total
recipe
* containing 40 % PANODANT"" AB 100 and 60 % HFCS
ocr edurg
1. Sodium meta-bisulphite (SMS) was added as a 2% solution. The addition is
12.8 g
which corresponds to 400 ppm calculated on the total amount of dough.
2. All-in-one procedure.
l0 3. Kneading time: Until a dough temperature of 35°C is reached.
After mixing the
dough rest for 10 min.
4. The dough is rolled down to 3 mm. and the dusting powder is placed on the
center of
the dough piece.
1 S Dusting powder
Wheat flour 83.0 g --
Shortening 18.0 g
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Salt 0.6 g
1. Mixed as all-in-one procedure and kneaded for 15 min.
2. Laminating: 3 x 3 without turning. Roll down to 1.0 mm. After laminating
the dough
rests for ~ min.
3. Baking: ?00 °C - 6 min. in Werner Pfleider (WP) oven.
Similar results were obtained by adding the emulsifier (PANODANT"" AB 100)
using
the present delivery system as if it were added as a single ingredient. An
advantage of
using the delivery system of the present invention is that when more than one
functional
ingredients is used, all the functional ingredients may be incorporated in the
delivery
system e.g. flavours, enzymes. Then only one product (the delivery system) has
to be
scaled instead of several minor ingredients.
1 I .4.2 French croissants
Ingredients g
Flour 1000 1000
Yeast 30 30
Salt 20 20
Sugar 100 95
Egg 60 60
Water 600 600
PANODANT"' AB 100 4 0
delivery system 0 10
consisting of 40%
PANODANT"" AB 100
and 60% HFCS
Puff pastry margarine~ 400 400
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Proce
1. Mixing on a Mahot mixer 4+2 min
2. Resting covered for 90 min. laminated 2x3 + 1 x4
3. Proofing for 90 min at 25-27°C, 70% RH
4. Baking 1 ~ min at 230°C.
The baking performance of the two different recipes performed identically. An
advantage of using the delivery system of the present invention is that when
more than
one functional ingredients is used, all the functional ingredients may be
incorporated in
Io the delivery system e.g. flavours, enzymes. Then only one product (the
delivery system)
has to be scaled instead of several minor ingredients.
~ 1.4.3 Biscuits
The production of biscuits starts with creaming up the fat and sugar. The
flour is added
as the last ingredient in the recipe and will be (if the recipe is close to
balanced) covered
by the fat. Emulsifiers such as PANODANT"" DATEM, SSL and/or lecithin may be
added in such a system. Other emulsifiers (e.g. GRINDSTEDT"" CITREM and
GRINDSTEDT"" LACTEM) which improve the dough handling, improve the fat
2 o distribution (specially if and fat reduced recipe is used) or the texture
of the biscuits may
also be used. Often biscuits like Lincoln or Marie (laminated) type also
contain
flavourings (which may be both oil and water soluble) e.g. butter, vanilla,
cacao, red
berries, citn~ ; types. In order to prevent the gluten development enzymes
e.g. proteolytic
types can be used to degrade or reduce the protein structure.
The following recipe was followed to prepare rotary moulded or wire cut
biscuits. In
this manner a delivery system in accordance with the present invention
containing
emulsifier, enzymes and flavourings was successfully used in the production of
biscuits.
Ingredients, g ~ Control I Present Invention
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Flour 588 588
Fat 146 124
Caster sugar 173 167
Water 62 62
Skimmed milk powder (SMP)10 10
Salt 6 6
NaHC03 2 2
NH4HC03 1 1
PANODANTM AB 100 DATEM 4 0
Delivery system * 0 10
* 40 % PANODANT"" AB 100, 60 % HFCS
Pr c a
~ Ammonium bicarbonate is dissolved in water to avoid black spots on the
biscuits.
~ All ingredients, except flour and water/NH4HC03 is creamed up on a Hobart
N50 for
1 min. at 1 st speed. If a flavouring is to be added, it should be added at
this stage.
~ Water and NH4HC03 are added next and mixed for 3 min. in 2nd speed.
~ The flour is added and the batter is mixed for 7 min. at 1 st speed.
~ The biscuits are baked at 180°C for approx. 6 min. or program 9 in
the Werner
Pfleider oven.
Similar results were obtained by adding the emulsifier (PANODANT"" AB 100)
through
the inventive delivery system as if it were added as a single ingredient.
During trials the
consistency of the biscuit doughs and the appearance of the biscuits were
comparable
between two recipes. An advantage of using the delivery system of the present
invention is that when more than one functional ingredients is used, all the
functional
ingredients may be incorporated in the delivery system e.g. flavours, enzymes.
Then
2 0 only one product (the delivery system) has to be scaled instead of several
minor
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ingredients.
11 ~ Liauid dou ~h systems
5 Wafers and waffles
For baked products like wafers and waffles where flowability of the batter is
an
important issue, like a cold hydrophilic system like a wafer batter, with a
slow mixing
and where gluten development is not desired, a homogenous distribution of
emulsifier
1 o can be difficult to obtain. By the use of the delivery system of the
present invention as
an emulsifier delivery system the homogenous distribution of emulsifier in the
batter is
facilitated/eased, and the temperature for the wafer batter can be decreased.
eci
Ingredient g
Wheat flour 374.0 374
Sugar 142.0 124
Whey powder -. 5.~ S.5
Salt 1.5 l.~
Sodium bicarbonate 0.5 0.5
Water 441.5 441.5
Vegetable oil 22.5 22.5
GRINDSTEDTM CITREM LR 10 Citric Acid 6.0 0
Ester
Delivery system * 0 24
* 26% GRINDSTEDT"" CITREM LR 10 and 74% HFCS
procedure _ _
2 0 ~ Heat oil and Soya lecithin or GRINDSTEDT"' CITREM LR 10 to 40°C.
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WO 99/25207 PCT/IB98/41882
71
~ Mix with the other ingredients at 2°'' speed for 3 min.
~ Bake in a machine for ice cone wafers for 20 sec.
The performance of two different recipes was identical. An advantage of using
the
delivery system is that all the ingredient can be added at once, meaning that
step 1 in the
process can be left out due to the facilitated distribution of the emulsifier
when
incorporated in this delivery system. A further advantage of using the
delivery system of
the present invention is that when more than one functional ingredients is
used, all the
functional ingredients may be incorporated in the delivery system e.g.
flavours,
enzymes. Then only one product (the delivery system) has to be scaled instead
of
several minor ingredients.
EXAMPLE 12
~NOTHER INVENTIVE DELIVERY SYSTEM AND USES THEREOF
Meat Products
The delivery system of the present invention allows one to upgrade high-fat
meat
products.
Meat with a high fat content has a poor emulsifying capacity due to its low
content of
lean meat or to imbalances between salt soluble protein (mainly myosin) and
collagen
(known as short-meat). This also applies to meat batter that has been over-
chopped, as
the surface of the fat is increased to such an extent that the protein
solution is unable to
2 5 coat all of the fat particles. Even if the amount of salt soluble protein
in the batter is
sufficient to coat all fat particles with myosin, the reaction may only remain
stable for a
few hours unless it is heated.
The present emulsifier delivery system is capable of stabilising the batter or
chunks
3 0 over time, allowing the batter to be cooled or frozen for later heat
treatment. Tlie
emulsif er prevents the meat from rendering before and during heating, which
may
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72
result in fat caps or fat pocketing.
In hot emulsified meat batter, an advantage of using a cold emulsifier
delivery system in
accordance with the present invention may be found in the processing step of
cutting in
the bowl chopper. The cold emulsifier system can be used instantly without any
preceding processing steps contrary to traditional emulsifiers which have to
be added to
hot water the day before use to form a dispersed and homogeneous creamy mass.
Products
The present emulsifier system is suitable for various meat products, e.g. hot
emulsified
products, e.g. liver sausage and liver pate, and cold emulsifed products, e.g.
emulsion-
type sausages such as ham sausage, bologna, mortadella, frankfurters,
bockwurst and
meat loaf. Furthermore, the emulsifier system can be used as a fat replacer
for low-fat
meat products to improve their emulsifying properties and to improve
mouthfeel. The
cold emulsifier system is particularly suitable for fresh meat, which is not
heat treated
prior to sale, e.g. reformed chicken, pork and beef for chops, steaks and
burgers, etc.
Materials and methods
The below formulations are all based on traditional products commonly used
within the
meat industry.
1) Hot emulsified product: Liver Sausage (German style)
Ingredients:
Liver, Pork 20.00
Belly Fat 2.00
Belly Meat, bone-out 40.00
3 o Nitrite, salt 0.36
Seasoning 0.38
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73
Emulsifier delivery system * 1.15
Water (Soup) to 100.00
* 26% GRINDSTEDT"" CITREM M 12 and 74 % High Fructose Corn Syrup (HFCS}.
Eqz~ipment.~ Mincer, bowl steam chopper (high speed), cooker.
Procedure:
Fat and meat are preheated in a cooker for 30 minutes at 95°C. The
liver is minced
through a 3 mm plate, and chopped in a bowl chopper at high speed. While
chopping,
salt is added and the blend is chopped until air bubbles are formed. The
chopped liver is
removed from the bowl chopper, and the bowl chopper is reset (0 (zero)
rotations). The
preheated belly fat and belly meat are added to the bowl chopper and chopped
with the
emulsifier at 65°C. After 80 rotations and at the temperature of
52°C, liver and
seasoning are added. After 100 rotations the final temperature of 42°C
is reached. The
batter is filled into sterile artificial casings, and cooked at 75°C to
an internal
temperature of 72°C. The liver sausage is cooled by means of water and
stored at 5°C.
2 o A trial with the present delivery system has been conducted in a hot
emulsified product,
namely liver sausage (German Style), in accordance to the fomulation and
procedure
given above.
The results indicate that liver sausage made with the present delivery system
is equal in
2 5 texture and sensory appearance to that of a commercial liver sausage made
with a
traditional emulsifier such as GRINDSTEADT"" CITREM N12.
The use of the present invention is advantageous because easier technical
handling
during the production of the liver sausage is time saving, compared to the
production of
3 0 liver sausage with a traditional emulsifier such as GRINDSTEADT"" CITREM
N12.
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74
2) Cold emulsified product: Frankfurter
Ingredients:
Beef, Whole-carcass 20.00
Belly meat 20.00
Fat, pork 30.00
Nitrite, salt 1.00
Salt 0.90
Seasoning 0.80
Phosphate 0.25
Emulsifier delivery 1.92
system *
Water/ice to 100.00
* 26% emulsifier and 74 % High Fructose Corn Syrup (HFCS).
Equipment: Mincer, bowl chopper (high speed), cooker/smoker.
Procedure:
Beef, pork and fat are minced through a 3 mm plate. Half the phosphate and
half the salt
are added to the beef and chopped in a bowl chopper. While chopping, half of
the ice-
water is slowly added. The chopping is continued until a good emulsion and the
desired
texture is obtained. The beef batter is removed from the bowl chopper and the
pork is
2 5 chopped according to the same procedure as the beef, i.e. the remaining
phosphate and
salt are added to the pork followed by the remaining ice-water, chopping
continuously.
When the desired texture of the pork mass is achieved, the beef mass is added.
Fat,
emulsifier and seasoning are added and the mass is chopped until it becomes
glossy.
The batter is filled into cellulosic or lamb casings linked in the desired
sizes. The linked
3 o casings are placed around smoke sticks in loops. The smoke sticks are
placed in a
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WO 99/25207 PCT/IB98/01882
cooking/smoking oven with sufficient space around them to allow a good air
flow.
The procedure for the cooking and smoking is as follows:
Drying: 20 minutes at 70°C
5 Smoking: 60 minutes at 70°C
Cooking: 10 minutes at 78°C
Cooling: 10 minutes at 5°C by means of water.
Store at S°C.
l0 Meat products produced with the present emulsifier delivery system are
equal in texture
and sensory appearance to meat products produced with a traditional
emulsifier.
The advantages of using the present delivery system is in the processing step
of cutting
the meat in the bowl chopper, as it is easier to apply to the meat batter than
a traditional
15 emulsifier and thus saves time in the production of emulsified meat
products.
***
Having thus described in detail preferred embodiments of the present
invention, it is to
2 o be understood that the invention defined by the appended claims is not to
be limited by
particular details set forth in the above description as many apparent
variations thereof
are possible without departing from the spirit or scope thereof.
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76
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